Safe assembly method for crawler crane

Abstract

The invention relates to the technical field of wind generating sets, and discloses a crawler crane safe assembly method which comprises the following steps: according to wind field information, whole vehicle parameters and assembly types of a target crawler crane, formulating a safe assembly process of each assembly of the target crawler crane and process matters needing attention corresponding to the safe assembly process; planning the specification, land flatness, land bearing capacity, approach roads and auxiliary equipment of a target site according to the safe assembly process and the process matters needing attention, and establishing an assembly area meeting construction requirements according to the plan; and in the assembly area, safe assembly of the target crawler crane is completed according to the safe assembly process and the process matters needing attention. According to the invention, the crawler crane of the large fan can be efficiently and safely assembled in a wind field.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine generators, and specifically, to a safe assembly method for a crawler crane. Background Art

[0002] A large wind turbine generator, hereinafter referred to as a large wind turbine, generally refers to a wind turbine generator with a power greater than 600 kW, and its tower barrel height is usually between 80 and 150 meters. Due to the increase in height, when hoisting a large wind turbine, a crawler crane matching the tower barrel height and weight will be used. The self-weight and boom length of this crawler crane are also relatively large. It is necessary to disassemble the crawler crane and transport it to the wind farm for assembly, and after assembly, further hoist the large wind turbine.

[0003] At the same time, since the wind farms of large wind turbines are usually located in mountainous areas, in order to adapt to relatively poor construction environments and transportation conditions, the crawler cranes corresponding to large wind turbines are usually further disassembled to facilitate loading and transportation. This will increase the assembly process and the matters needing attention in the process when assembling the crawler crane, resulting in an increase in assembly difficulty and a decrease in assembly efficiency. In the prior art, there is also a lack of a safe and efficient assembly method for the crawler crane of a large wind turbine. Summary of the Invention

[0004] The purpose of the present invention is to provide a safe assembly method for a crawler crane. By combining the information of the target crawler crane and the relevant information of the wind farm, formulating the key processes for assembling the target crawler crane and reasonably planning the assembly area, and then assembling the target crawler crane, it is possible to achieve the efficient and safe assembly of the crawler crane of a large wind turbine in the wind farm.

[0005] The present invention is achieved by the following technical solutions: A safe assembly method for a crawler crane, applied to a crawler crane for hoisting a large wind turbine, includes the following steps: Step S1, according to the wind farm information, the vehicle parameters and component types of the target crawler crane, formulate the safe assembly processes for each component of the target crawler crane and the matters needing attention corresponding to the safe assembly processes. The safe assembly processes include the target crawler crane transportation and main machine unloading processes, the installation, assembly or debugging processes of the target components, and the target crawler crane trial operation and trial hoisting processes; Step S2, according to the safe assembly processes and the matters needing attention, plan the specifications, land flatness, land bearing capacity, access roads and auxiliary equipment of the target site, and establish an assembly area that meets the construction requirements according to the plan; Step S3, within the assembly area, complete the safe assembly of the target crawler crane according to the safe assembly processes and the matters needing attention.

[0006] To better implement the present invention, further, the target components include an upper vehicle component, a mast, crawlers, vehicle body ballast, rear counterweight, auxiliary outriggers, a boom, a moment limiter, and a safety device; The safety assembly process includes the installation processes of the upper vehicle component, the mast, the vehicle body ballast, the rear counterweight, and the auxiliary outriggers, the assembly processes of the crawlers and the boom, and the commissioning processes of the moment limiter and the safety device.

[0007] To better implement the present invention, further, the installation process of the upper vehicle component includes: According to the type of the target upper vehicle component, match a corresponding plug-in quick connector or threaded quick connector for the target upper vehicle component; According to the matching relationship of the quick connectors, install the quick connectors inside the turntable and the quick connectors of the hoist. When installing quick connectors for adjacent oil pipes with the same pipe diameter on the hoist, the male quick connectors and the female quick connectors are installed alternately; Install the hoist onto the turntable through a fixing member and complete the connection between the turntable oil circuit and the hoist oil circuit through the quick connectors.

[0008] To better implement the present invention, further, the installation process of the mast includes: Connect the mast to the turntable, raise the mast, and lower the mast to the slewing platform; The mast raising includes: Check the luffing hoist wire rope and the wire rope pulley to determine that the luffing hoist wire rope and the corresponding wire rope pulley are properly matched; While jacking up the mast, pay out the wire rope using the luffing hoist until the mast flips forward by more than 90° to form an angle of 105° with the horizontal plane in the transportation state, then stop jacking up and let the mast naturally drop to the specified angle range.

[0009] To better implement the present invention, further, the installation process of the crawlers includes: Raise the mast to the specified angle and connect the hook using a flexible sling to complete the installation of the self-installing spreader; Install the crawlers using the self-installing spreader and connect the corresponding pipelines.

[0010] To better implement the present invention, further, the installation process of the vehicle body ballast includes, when counterweighting the vehicle body ballast frame, dividing the vehicle body ballast into two parts and symmetrically arranging them in front of and behind the target crawler crane body, and installing them after completing the installation of the crawler assembly; The installation process of the rear counterweight includes, when counterweighting the counterweight frame, placing one standard counterweight block each time and placing them alternately.

[0011] To better implement the present invention, further, the precautions for the auxiliary outriggers include: When raising the boom, the deviation angle between the boom and the auxiliary outriggers shall not be greater than 2°; After raising the boom, the adjusting screw shall be rotated counterclockwise to lift the sole plate of the auxiliary outrigger off the ground.

[0012] To better implement the present invention, further, the precautions for the lifting boom include: Connect the tension plates of the lifting boom in the order from the boom tip to the bottom boom section.

[0013] To better implement the present invention, further, step S1 further includes establishing an assembly monitoring model according to the safety assembly process and the precautions for the process. The assembly monitoring model is configured to identify whether an abnormality occurs in the target process according to the assembly data generated during the assembly process; Step S2 further includes setting data acquisition devices in the assembly area according to the data acquisition requirements of the assembly monitoring model; Step S3 further includes using the assembly monitoring model for monitoring during the assembly process, and giving an early warning when an abnormality in the target process is identified.

[0014] To better implement the present invention, further, abnormalities in the target process include abnormal process sequence and abnormal component installation; Step S3 further includes using the assembly monitoring model for monitoring during the assembly process, and intercepting the wrong control signal when an abnormal process sequence is identified.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects: By combining the information of the target crawler crane and the relevant information of the wind farm, the key processes for assembling the target crawler crane are formulated to improve the efficiency and safety during assembly; By reasonably planning the assembly area, the efficiency and safety during assembly are further improved; By installing reasonable safety assembly processes and process precautions and performing assembly in an assembly area that meets the requirements, efficient and safe assembly of large wind turbine crawler cranes in the wind farm can be achieved. Description of the Drawings

[0016] The present invention will be further described in conjunction with the following drawings and embodiments. All the creative concepts of the present invention should be regarded as the disclosed content and the protection scope of the present invention.

[0017] Figure 1 It is a schematic flowchart of Embodiment 1 of a method for safe assembly of a crawler crane in this application.

[0018] Figure 2This is a schematic flow chart of Embodiment 3 of a safety assembly method for a crawler crane in this application. Specific Embodiment

[0019] Embodiment 1: A safety assembly method for a crawler crane in this embodiment is applied to a crawler crane for hoisting large wind turbines. As Figure 1 shown, it includes the following steps: Step S1: According to the wind farm information, the vehicle parameters of the target crawler crane, and the component types, formulate the safety assembly processes for each component of the target crawler crane and the process precautions corresponding to the safety assembly processes. The safety assembly processes include the target crawler crane transportation and main machine unloading processes, the installation, assembly, or commissioning processes of target components, and the target crawler crane trial operation and trial hoisting processes; In this embodiment, the target crawler crane is the crawler crane that needs to be assembled, and the target component is the component that needs to plan the installation, assembly, or commissioning process after combining the actual situation of the wind farm, the vehicle parameters, and the component types. For example, the mast and turntable transported separately. The wind farm information is the relevant information of the site where the wind turbine is hoisted after the target crawler crane is assembled, which may include the road information, carrying capacity information, weather information, etc. of the wind farm. The vehicle parameters include the external dimensions and weights of each component of the target crawler crane; The target crawler crane transportation process may include allocating each component to the corresponding vehicle according to the bearing capacity of the wind farm road, the carrying capacity of the construction party's vehicle, the external dimensions and weights of each component of the target crawler crane, and formulating relevant transportation protection measures, etc. as process precautions.

[0020] Adopting this implementation method, by combining the target crawler crane information and the relevant information of the wind farm, the key processes for assembling the target crawler crane are formulated to improve the efficiency and safety during assembly.

[0021] Step S2: According to the safety assembly processes and process precautions, plan the specifications, land flatness, land bearing capacity, access roads, and auxiliary equipment of the target site, and establish an assembly area that meets the construction requirements according to the plan; In this embodiment, the assembly area can be divided into two parts: the main machine assembly area and the boom assembly area. For the 100t crawler crane with a main boom length of 126m and a jib length of 7m in this embodiment, the main machine assembly area is greater than or equal to 30m × 25m, and the boom assembly area utilizes the access road to facilitate meeting the positioning requirements of the auxiliary crane; the land bearing capacity needs to match its total weight. If there are holes underground in the assembly area, reinforcement is required; remove the obstacles in the assembly area that affect the crane's positioning and turning, and arrange lighting equipment to ensure sufficient lighting for night construction.

[0022] Adopting this embodiment, through the reasonable planning of the assembly area, the efficiency and safety during assembly can be further improved.

[0023] Step S3: Within the assembly area, complete the safe assembly of the target crawler crane according to the safe assembly process and process precautions.

[0024] Adopting this embodiment, by installing a reasonable safe assembly process and process precautions for assembly within a qualified assembly area, the efficient and safe assembly of the crawler crane for large wind turbines in the wind farm can be achieved.

[0025] Embodiment 2: This embodiment is further optimized on the basis of Embodiment 1. In this embodiment, the target components include the upper vehicle part, mast, crawler, body counterweight, rear counterweight, auxiliary outrigger, boom, moment limiter, and safety device; The safe assembly process includes the installation processes of the upper vehicle part, mast, body counterweight, rear counterweight, and auxiliary outrigger, the assembly processes of the crawler and boom, and the commissioning processes of the moment limiter and safety device.

[0026] Adopting this embodiment, specific target components are planned for the target crawler crane, so that during assembly, the assembly can be carried out in an orderly manner according to the processes corresponding to the target components, further improving the efficiency and safety during assembly; The upper vehicle part includes components such as the turntable, various winches, anti-back-tipping oil cylinders for superlift, self-loading and unloading oil cylinders, and superlift counterweight oil cylinders. These components need to be connected by hydraulic pipelines during use, so they need to be disassembled for transportation. The corresponding assembly process needs to ensure assembly efficiency and safety. The assembly efficiency can be ensured through quick connectors and the assembly can be carried out according to the corresponding anti-misconnection settings; To improve the assembly efficiency, the mast assembly process can include using the cooperation of the mast jacking mechanism and the main luffing winch to jack up the mast to a specified angle, and then allowing it to fall forward by its own weight to achieve self-installation; The crawler assembly process can include spreader installation, crawler hoisting, and pipeline connection; When planning the body counterweight installation process and the rear counterweight installation process, sufficient consideration needs to be given to preventing the counterweight blocks from tipping over; To increase the self-erecting stability, the installation process of the auxiliary outrigger needs to be planned for the crawler crane equipped with a wind power boom; The boom assembly process can include connecting the tension plates in the order from the boom tip to the bottom boom section to make the assembly easier and improve the assembly efficiency; The commissioning processes of the moment limiter and safety device can include the inspection of key moment limiters such as the main boom large-angle limit switch and the main hook height limit switch, and keeping the error between the span displayed by the moment limiter and the actual lifting weight within 3%.

[0027] Furthermore, the installation process of the upper vehicle components includes: According to the type of the target upper vehicle component, match the corresponding plug-in quick connector or threaded quick connector for the target upper vehicle component; According to the matching relationship of the quick connectors, install the quick connectors inside the turntable and the quick connectors of the winch. When installing quick connectors for adjacent oil pipes with the same pipe diameter on the winch, male quick connectors and female quick connectors are installed alternately; Install the winch on the turntable through the fixing parts and complete the connection between the turntable oil circuit and the winch oil circuit through the quick connectors.

[0028] Adopting this embodiment, by matching a suitable quick connector for the target upper vehicle component, the quick installation of the upper vehicle component is realized, and the assembly accuracy is further improved through the anti-misconnection setting of the connector.

[0029] Specifically, the installation process of the upper vehicle components includes: Installation of the quick connectors inside the turntable. Connect the hydraulic pipelines to the luffing winch of the auxiliary boom, the hoisting winch of the goose head, the luffing winch of the superlift, the anti-backward tilting cylinder of the superlift, the self-loading and unloading cylinder, and the counterweight cylinder of the superlift through the quick connectors; Connection of the quick connectors of the main and auxiliary hoists and the main luffing winch. Due to the limitation of the transportation weight, the winches inside the turntable need to be disassembled for transportation when the machine is transferred. To improve the assembly efficiency and facilitate disassembly and assembly, the connection form adopts quick connector installation at the places where there are rubber hoses connecting the winch and the turntable. For the luffing winch, to avoid the situation of reverse connection, the quick connectors of the two oil pipes on the same side are respectively set as a male and a female. When connecting, they are butt-connected to avoid reverse connection. The installation of the quick connectors of the hoisting winch also adopts a similar anti-misconnection method; Installation of the main and auxiliary winches. Install the main and auxiliary winches on the turntable with pins and spring pins. The two winches can be interchanged, and the pins play a positioning role; The corresponding matters needing attention in the process include: Before connecting or disconnecting the hydraulic pipeline with the quick connector, the pressure of the entire hydraulic system circuit must be zero, and the engine must stop working for more than 5 minutes; For joint parts, such as the pipe socket and the pipe head, after installation, the nut needs to be tightened by hand to the fixed dead point position. Tools are not allowed for the connection operation to prevent damage to the joint.

[0030] Adopting this embodiment, corresponding matters needing attention in the process are further set for the specific upper vehicle components to prevent errors during the assembly process.

[0031] Furthermore, the installation process of the mast includes: The mast is connected to the slewing platform, raised and lowered to the slewing platform. The raising of the mast includes: Inspect the luffing hoist wire rope and the wire rope pulley to ensure the normal cooperation between the luffing hoist wire rope and the corresponding wire rope pulley. While jacking up the mast, pay out the wire rope using the luffing hoist until the mast flips forward by more than 90° to form an angle of 105° with the horizontal plane in the transportation state, then stop jacking up and let the mast naturally drop to the specified angle range.

[0032] Adopting this embodiment can realize the self-installation of the mast, further improve the installation efficiency of the mast, and at the same time set the corresponding safety angle range to improve the safety during installation.

[0033] Specifically, the installation process of the mast includes: Connect the mast to the slewing platform. Use an auxiliary crane to lift the mast until the installation hinge ear holes at the front of the slewing platform are aligned. Operate the mast pin telescopic switch on the right control panel of the operator's cab or the on-board auxiliary control box. Extend the pin cylinder to the specified position to connect the mast to the slewing platform and fix it with a pin. Connect the luffing pulley block to the slewing platform with a pin and fix it. Remove the pin and fixed pin at the connection between the mast and the luffing pulley block. Fix the main luffing hoist to the slewing platform with a pin and a spring pin. Remove the chain on the main luffing hoist. Lay the mast flat on the tail bracket of the slewing platform. Raise the mast. Visually inspect that the luffing hoist wire rope must be correctly threaded through its respective wire rope pulley. Operate the mast jacking mechanism to raise the mast and pay out the wire rope of the main luffing hoist. Use the mast jacking cylinder to jack up the mast until the mast flips forward by more than 90° and forms an angle of about 105° with the horizontal plane in the transportation state, and then let it drop forward by its own weight. Before the mast is at an angle of 20° with the horizontal, interrupt the wire rope paying-out operation of the luffing hoist. Lower the mast to the slewing platform. Take in the luffing hoist wire rope. Rely on the gravity of the mast to press the mast jacking cylinder back. When the mast is at an angle of 5° with the rear horizontal, interrupt the wire rope taking-in operation of the luffing hoist. The corresponding precautions for the process include: The operation must be slow. During the mast jacking process, pay attention to observing the deformation of the mast, the synchronization of the jacking cylinders, and the slack of the luffing wire rope, etc., and make the wire rope paying-out speed of the luffing wire rope synchronize with the speed of the mast jacking cylinder. Otherwise, there is a risk of the wire rope getting tangled or the mast being damaged. When the mast is jacked up by more than 90°, slow down the wire rope paying-out of the luffing and the mast jacking speed. When operating the self-installation of the mast without the crawler installed, the angle between the mast and the front horizontal direction must be greater than 60°. In any state, the angle between the mast and the front horizontal direction shall not be less than 20°. Rotation and other operations can only be carried out after the mast is jacked over 90°.

[0034] With this embodiment, specific mast installation procedures and precautions for the procedures are set, enabling the self-installation of the mast, further improving the efficiency during mast installation, and setting corresponding safety angles to enhance the safety during installation.

[0035] Specifically, the installation procedures for the crawler include: Install the sling, operate the lower vehicle auxiliary remote control box, slowly retract the vertical outriggers until the distance between the frame bottom plane and the ground is about 800 mm, operate the upper vehicle auxiliary control box or the control panel in the operator's cab, extend the elevation cylinder at the bottom of the operator's cab, adjust the operator's cab to tilt up to an angle of about 20° with the horizontal plane, lift the mast to an angle of about 25° with the front horizontal, extend the self-unloading cylinder to the maximum stroke, hang the three equipped flexible slings on the two hooks, and then retract the luffing wire rope to lift the mast to an angle of about 65° with the front horizontal; Install the first crawler. Drive the crawler transporter as close as possible to the main machine. Adjust the main machine hoist hydraulic cylinder, operate the hoist control valve of the cylinder to lift the cylinder, first lift one side of the crawler assembly, pass it through the cross beam of the main machine, when the crawler is pushed to be in contact with the limit stop, connect the fixed pull plate of the crawler, and push out the fixed pin of the crawler to fix the crawler. Then, reliably connect the hydraulic pipeline and control pipeline of the crawler travel motor in sequence; Install the second crawler. Retract the outrigger on the side where the crawler has been installed, lower the crawler to the ground, rotate the slewing platform to the other side, and complete the installation in the same way as installing the first crawler; Complete the installation of the crawler frame hydraulic pipeline. Similarly, to prevent incorrect connection, for two adjacent pipelines with the same diameter, one end of the quick connector is set as male and the other as female; The corresponding precautions for the procedures include: Before rotating the slewing platform, the first installed crawler must firmly touch the ground. Otherwise, the crane is at risk of tipping over; After installing the second crawler, retract the vertical outrigger cylinder and lower the crawler to the ground; Lay the mast forward and remove the flexible sling and sling; Fully retract the vertical outrigger cylinder, remove the outrigger foot plate and fix it to the crawler frame; Remove the outrigger strut, fix it to the frame, swing the outrigger back, and fix it with a pin; Pull out the fixed pin of the crawler installation plate, lower the crawler installation plate, and fix it with a pin.

[0036] With this embodiment, specific crawler assembly procedures and precautions for the procedures are set, further improving the safety and efficiency during crawler assembly.

[0037] Further, the installation process of the body counterweight includes, when counterweighting the body counterweight frame, dividing the body counterweight into two parts and symmetrically arranging them in front of and behind the target crawler crane body, and installing them after the installation of the track assembly is completed; The installation process of the rear counterweight includes, when counterweighting the counterweight frame, placing one standard counterweight block each time and placing them alternately.

[0038] Specifically, the installation process of the body counterweight includes: Dividing the body counterweight into two parts, each part including 1 body counterweight frame and 3 standard counterweight blocks, symmetrically arranging them in front of and behind the crane, after the main machine installs the left and right track assemblies, using an auxiliary crane to lift the body counterweight frame and hook it on the vehicle frame, and placing 3 standard counterweight blocks on each body counterweight frame respectively; The installation process of the rear counterweight includes: Inserting a pin into the upper pin hole of the counterweight frame and fixing it with a spring cotter pin; Using an auxiliary crane to lift the counterweight frame; aligning the pin of the counterweight frame with the hanger ear on the rear side of the turntable and completely falling into the hanger ear groove.

[0039] Rotating the counterweight frame around the pin until it contacts the turntable bottom plate, positioning the counterweight frame on the installation ear plates on both sides of the turntable with pins respectively, and fixing it with spring cotter pins; Installing the other side counterweight frame in the same way; Using an auxiliary crane to stack standard counterweight blocks on the counterweight frame, one block each time, placing them alternately left and right. Before the main boom is not installed or the main boom is off the ground, the total counterweight on the left and right shall not exceed the bearing capacity of the auxiliary crane; After the head of the main boom is off the ground, set the counterweight according to the selected working conditions. Tighten the lifting chain with bolt assemblies, bases, lower baffles, pin tubes, pins, plates, round bars, baffles, bolts, and washers as shown in the figure to fix the counterweight blocks.

[0040] Adopting this embodiment, specific installation processes and process precautions for the body counterweight and the rear counterweight are set, further improving the safety and efficiency when installing counterweight blocks.

[0041] Further, the process precautions for the auxiliary outriggers include: When raising the boom, the deviation angle between the boom and the auxiliary outriggers shall not be greater than 2°; After raising the boom, the adjusting screw must be rotated counterclockwise to lift the sole plate of the auxiliary outrigger off the ground.

[0042] Specifically, the installation process of the auxiliary outriggers includes: Using an auxiliary crane to lift the auxiliary outriggers to the front and side of the main machine, aligning them with the large pin holes below the outside of the tracks, and fixing them with pins and spring cotter pins; Use an auxiliary crane to lift the front end of the auxiliary outrigger leg upward and rotate it to align with the upper small pin hole, and fix it with a pin shaft and a spring cotter pin; Remove the foot plate from the crawler assembly and install it on the adjusting screw of the auxiliary outrigger leg, and fix it with a bent pin; Remove the side assist lever of the auxiliary outrigger leg, insert it into the large hole above the adjusting screw, and rotate the assist lever clockwise to firmly land the foot plate until the assist lever cannot be rotated; Install the other auxiliary outrigger leg in the same steps.

[0043] The corresponding process precautions include: To make the foot plate firmly land and bear force, it is necessary to rotate the adjusting screw downward to the limit with the assist lever; After the boom is raised, the adjusting screw must be rotated counterclockwise to lift the foot plate off the ground; To ensure the force requirement, it is generally not allowed to travel with the auxiliary outrigger legs; When the boom is raised, the deviation angle between the boom and the auxiliary outrigger leg shall not be greater than 2°; When raising and lowering the boom, the boom length combination of the auxiliary outrigger legs needs to be used.

[0044] Furthermore, the process precautions of the boom include: Connect the tension plates of the boom in the order from the boom tip to the bottom boom section.

[0045] Specifically, the assembly process of the boom includes: Assemble the bottom boom section of the main boom, including rotating the turntable so that the turntable is placed directly in the crawler direction or on the positive side of the crawler; use an auxiliary crane to lift the bottom boom section of the main boom, transport it to the pin shaft connection position of the turntable; extend the main boom pin shaft oil cylinder, connect the turntable and the bottom boom section of the main boom, and fix the end plate of the main boom pin shaft oil cylinder with a pin shaft and a spring pin; connect the wires from the turntable to the bottom boom section of the main boom; lower the bottom boom section of the main boom to the ground cushion plate, and remove the auxiliary crane; raise the mast, luff forward, disconnect the limit switch circuit of the main boom anti-backward tilting oil cylinder, fully extend the oil cylinder and then connect the limit switch circuit; Connect the main boom and the drawplate, including lowering the mast forward to an angle of approximately 25° with the horizontal, removing the transportation fixing pins on the bottom section of the main boom, and connecting the drawplate on the mast to the clamping plate on the bottom section of the main boom through a hollow pin shaft and a spring cotter pin; use an auxiliary crane to hoist the intermediate section near the bottom section, align the single and double hinge ear holes on the upper part of the boom, use a hydraulic pump station and a pin-pulling cylinder to drive the pin into the pin hole, and fix it with a spring cotter pin; start the luffing winch, slightly lift the bottom section of the main boom off the ground until the lower hinge ear hole is aligned with the intermediate section, use a hydraulic pump station and a pin-pulling cylinder to drive the pin into the pin hole, and fix it with a spring cotter pin; sequentially connect the remaining intermediate boom sections, the top section of the main boom, and the boom head; after installing the boom head according to the above steps, release the main luffing wire rope, lay the mast forward, and disconnect the drawplate at the connection between the mast and the main boom; remove the transportation fixing shaft of the drawplate on the boom, and sequentially connect the drawplates from the boom head to the bottom section according to the drawplate connection requirements; retract the main luffing wire rope, raise the mast, and tighten the main boom drawplate; continue to retract the main luffing wire rope to tighten the main boom drawplate, slightly lift the boom head off the ground, fill the rear counterweight to the full according to the working conditions requirements, and fix it with a counterweight chain; according to the working conditions requirements, select a suitable hook and place it near the boom head, turn down the supporting rope roller at the bottom of the bottom section of the main boom, start the rope threading winch, pass the rope threading winch wire rope through the lower supporting rope roller of the bottom section respectively, and thread it through the hook pulley block, the main boom pulley block, and the main boom guiding pulley block in the reverse winding order of the hoisting wire rope, and pull it to the front of the turntable to connect with the end of the hoisting wire rope with a shackle and a swivel ring; start the hoisting winch and the rope threading winch, while retracting the rope threading winch wire rope, release the hoisting wire rope until the hoisting wire rope is fully wound with the required block ratio on the hook, and then pull out a certain length, stop the winch operation, and loosen the connection shackle of the two ropes; use a bag-type rope end to connect and fix the hoisting wire rope to the wedge socket seat at the boom head; repeat the above steps using a double hoisting winch; retract the rope threading winch wire rope; Complete the electrical connection and perform the main boom erection.

[0046] Specifically, the debugging procedures for the moment limiter and safety devices include: Check whether the limit switches such as the main boom large-angle limit switch and the main hook height limit switch, the winch monitor camera, and the angle sensors and tension sensors of each moment limiter are correctly installed and reliably fixed, and whether the connection cables of all these electrical components are reliably connected and reasonably and effectively fixed, to ensure that the connection cables of these electrical components will not become loose or even damaged during the working process; conduct on-line tests respectively before erecting the main boom to ensure that the electrical signals of each component are normal and the functions are effective before proceeding with the main boom erection operation; after the whole machine is installed, specifically test the safety devices to ensure that each safety device works normally, and the error between the span displayed by the moment limiter and the actual lifting weight is within 3%.

[0047] Specifically, the trial hoisting procedures include: No-load test: within the limit position, perform the hook lifting and lowering actions to check whether the limit switch is sensitive and reliable, whether all moving parts of the hoisting mechanism are flexible, the arrangement of the wire rope on the drum, rotate the machine body 360° to the left and right, and move forward and backward for 15 m each. Only after confirmation of compliance can the next test be carried out; Static load test: With a safety factor of 5, after loading and lifting off the ground for the first height, maintain the preset test hoisting time. For a certain type of crawler crane in this embodiment, the corresponding lifting weight is 43.2 t × 1.25 = 54 t, the working radius is 20.5 m, use 2 pairs of Φ32 wire ropes and 4 pieces of 10 t shackles, with a safety factor of 5, hang 4 lifting points to lift 9 roadbed plates, lift off the ground by 200 - 300 mm after loading, and remain static for about 10 minutes. The distance between the heavy object and the ground should remain unchanged; Dynamic load test: With a safety factor of 7, after loading and lifting off the ground for the second height and complete the preset test hoisting actions. For a certain type of crawler crane in this embodiment, the corresponding lifting weight is 43.2 t × 1.1 = 47.52 t, the working radius is 20.75 m, use 2 pairs of Φ32 wire ropes and 4 pieces of 15 t shackles, with a safety factor of 7, hang 4 lifting points to lift 7 roadbed plates, lift off the ground by 300 - 500 mm after loading, and perform the following actions: lift the hook up and down 3 times each, walk back and forth for 15 m 2 times each, rotate the whole process 2 times each. When braking, check whether there is any phenomenon of the hook slipping, and verify the stability of the whole machine during braking.

[0048] Other parts of this embodiment are the same as those of Embodiment 1, so they will not be elaborated here.

[0049] In summary, this embodiment further improves the assembly efficiency and assembly safety by further setting specific installation procedures and precautions for the procedures.

[0050] Embodiment 3: On the basis of the above Embodiment 1 or 2, this embodiment is further optimized. In this embodiment, the step S1 further includes establishing an assembly monitoring model according to the safe assembly procedures and precautions for the procedures. The assembly monitoring model is configured to identify whether an abnormality occurs in the target procedure according to the assembly data generated during the assembly process; The step S2 further includes setting data acquisition devices in the assembly area according to the data acquisition requirements of the assembly monitoring model; The step S3 further includes using the assembly monitoring model for monitoring during the assembly process, and giving an alarm when an abnormality in the target procedure is identified.

[0051] Furthermore, the abnormality of the target procedure includes the abnormality of the procedure sequence and the abnormality of the component installation; The step S3 further includes using the assembly monitoring model for monitoring during the assembly process, and intercepting the incorrect control signal when the abnormality of the procedure sequence is identified.

[0052] Specifically, a safety assembly method for a crawler crane in this embodiment is applied to a crawler crane for hoisting large wind turbines, and includes the following steps: S201. According to the wind farm information, the vehicle parameters and component types of the target crawler crane, formulate the safety assembly processes for each component of the target crawler crane and the precautions corresponding to the safety assembly processes. Moreover, according to the safety assembly processes and the precautions, establish an assembly monitoring model, which is configured to identify whether an abnormality occurs in the target process based on the assembly data generated during the assembly process. The safety assembly processes include the target crawler crane transportation and main machine unloading processes, the installation, assembly or commissioning processes of the target components, and the target crawler crane trial operation and trial hoisting processes; S202. According to the safety assembly processes and the precautions, plan the specifications, land flatness, land bearing capacity, access roads and auxiliary equipment of the target site, establish an assembly area that meets the construction requirements according to the plan, and, according to the data acquisition requirements of the assembly monitoring model, set data acquisition devices in the assembly area; S203. In the assembly area, complete the safety assembly of the target crawler crane according to the safety assembly processes and the precautions. During the assembly process, use the assembly monitoring model for monitoring. When an abnormal component installation is identified, give an early warning. When an abnormal process sequence is identified, intercept the incorrect control signal and give an early warning.

[0053] Specifically, the data acquisition devices may include cameras installed in the site, sensors installed at relevant positions of the crawler crane, and cameras worn on the construction workers to obtain real-time data during construction, use image recognition technology to monitor the states of key components, such as whether the pins are removed and whether the fixed pin shafts are pulled out, etc. By collecting the data of the cameras and sensors, use machine learning algorithms for analysis to identify the key processes and abnormal behaviors in the assembly process. According to the assembly process of the crawler crane, set the sequence and conditions of the key processes. For example, before rotating the cab, it must be confirmed that the fixed pin shaft has been pulled out.

[0054] Other parts of this embodiment are the same as those in the above Embodiment 1 or 2, so they will not be described in detail.

[0055] In summary, this embodiment further improves the safety of the assembly by using the assembly monitoring model to monitor the assembly process.

[0056] The above is only a preferred embodiment of the present invention, and does not impose any form of limitation on the present invention. Any simple modification or equivalent change made to the above embodiments based on the technical essence of the present invention falls within the protection scope of the present invention.

Claims

1. A crawler crane safe assembly method, characterized in that: The crawler crane used to hoist a large wind turbine includes the following steps: Step S1, formulating the safe assembly process of each component of the target crawler crane and the process precautions corresponding to the safe assembly process according to the wind farm information, the vehicle parameters and component types of the target crawler crane, wherein the safe assembly process includes the target crawler crane transportation and host unloading process, the target component installation, assembly or debugging process, and the target crawler crane test operation and test lifting process; Step S2: According to the safe assembly process and process precautions, the specifications, land flatness, land bearing capacity, access roads and auxiliary equipment of the target site are planned, and an assembly area that meets the construction requirements is established according to the plan; Step S3: In the assembly area, complete the safe assembly of the target crawler crane according to the safe assembly process and process precautions.

2. A crawler crane safe assembly method according to claim 1, characterized in that: The target assembly includes a superstructure, a mast, tracks, a body weight, a rear counterweight, auxiliary legs, a lifting arm, a torque limiter and a safety device; The safety assembly process includes the installation process of the upper vehicle parts, mast, vehicle body weight, rear counterweight and auxiliary legs, the assembly process of the crawler and the lifting arm, and the debugging process of the torque limiter and the safety device.

3. A crawler crane safe assembly method according to claim 2, characterized in that: The installation process of the vehicle upper component includes: According to the type of the target vehicle component, a corresponding plug-in quick connector or threaded quick connector is matched to the target vehicle component; According to the matching relationship of the quick connectors, install the quick connectors inside the turntable and the quick connectors for the winch. When installing the quick connectors for the adjacent oil pipes with the same diameter on the winch, the male quick connectors and the female quick connectors are installed alternately. The winch is installed on the turntable through the fixing parts and the connection between the turntable oil circuit and the winch oil circuit is completed through the quick connector.

4. A crawler crane safe assembly method according to claim 2, characterized in that: The mast installation process includes: Mast connection to turntable, mast hoisting and mast lowering to the turntable; The mast hoisting comprises: Check the luffing winch wire rope and wire rope pulley to ensure that the luffing winch wire rope and the corresponding wire rope pulley are properly matched; While lifting the mast, use the luffing winch to release the rope until the mast flips forward more than 90° to 105° with the horizontal plane in the transportation state. Then stop lifting and let the mast fall naturally to the specified angle range.

5. A crawler crane safe assembly method according to claim 4, characterized in that: The crawler installation process includes: Lift the mast to the specified angle and use the flexible sling to connect the hook to complete the installation of the self-installing sling; Use the self-installing sling to install the crawler and connect the corresponding pipelines.

6. A crawler crane safe assembly method according to claim 2, characterized in that: The installation process of the body weight includes: when balancing the body weight frame, dividing the body weight into two parts and symmetrically arranging them at the front and rear of the target crawler crane body, and installing them after the crawler assembly is installed; The installation process of the rear counterweight includes placing one standard counterweight block at a time and placing them alternately when counterweighting the counterweight frame.

7. A crawler crane safe assembly method according to claim 2, characterized in that: The process precautions for the auxiliary legs include: When raising the arm, the deviation angle between the arm and the auxiliary outrigger shall not exceed 2°; After raising the arm, the adjusting screw must be rotated counterclockwise to lift the foot plate of the auxiliary leg off the ground.

8. A crawler crane safe assembly method according to claim 2, characterized in that: The process precautions of the lifting arm include: The pull plates of the boom are connected in order from the boom head to the bottom boom.

9. A crawler crane safe assembly method according to claim 1, characterized in that: The step S1 further includes establishing an assembly monitoring model according to the safe assembly process and process precautions, wherein the assembly monitoring model is configured to identify whether an abnormality occurs in a target process according to assembly data generated during the assembly process; The step S2 further includes setting a data acquisition device in the assembly area according to the data acquisition requirements of the assembly monitoring model; The step S3 also includes monitoring the assembly process using the assembly monitoring model, and issuing an early warning when an abnormality is identified in the target process.

10. A crawler crane safe assembly method according to claim 9, characterized in that: Target process abnormalities include process sequence abnormalities and component installation abnormalities; The step S3 also includes monitoring the assembly process using the assembly monitoring model, and intercepting erroneous control signals when an abnormal process sequence is identified.

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