Electric actuator ram change hanger, system, and method

Abstract

The present application belongs to the field of device replacement, and particularly relates to an electric actuating cylinder replacement lifting ring, system and method, aiming at solving the problems of inconvenient operation, difficult posture adjustment and prominent safety hazards in the prior art. The present application comprises an outer ring, an inner ring and a lifting ring beam. The outer ring is composed of two groups of sickle-shaped circular ring hubs, and the inner ring is fixedly connected by two semicircular hub groups to clamp and fix the electric actuating cylinder. The outer ring is connected with the outer periphery of the inner ring through an inner bearing, so that the inner ring can be manually rotated relative to the outer ring, thereby conveniently adjusting the orientation of the motor junction box of the actuating cylinder during hoisting. This structure solves the problems of difficult orientation adjustment and high risk during hoisting of heavy parts, and significantly improves the safety and efficiency of replacement operation.

Description

Technical Field

[0001] This invention belongs to the field of intelligent manufacturing equipment and component replacement, specifically relating to an electric actuator for replacing lifting rings, a system, and a method. Background Technology

[0002] As the core drive and execution component of a six-degree-of-freedom platform, the electric actuator is widely used in intelligent manufacturing equipment such as industrial robots, special-purpose robots, and high-precision motion simulation platforms. Its performance and reliability directly affect the accuracy and stability of the entire motion system. To ensure long-term stable operation of the platform, the electric actuator needs to be replaced and maintained regularly.

[0003] Currently, the industry generally uses a combination of traditional hoisting and manual labor to replace the electric actuators of six-degree-of-freedom platforms. The typical process includes: first, backing up the system configuration and dismantling the electrical wiring; then, using a traditional forklift or crane to transport the actuator, which weighs several hundred kilograms (usually about 400 kg), to the replacement area; during installation and dismantling, workers need to use simple lifting rings to lift the actuator with a crane, and mainly rely on manual methods to adjust its spatial orientation, especially to precisely adjust its motor junction box to a specific orientation; finally, it is connected and installed with the platform's lower bearing and other structures.

[0004] However, the aforementioned existing technologies have several significant drawbacks: First, in the transportation phase, relying on traditional forklifts to move the heavy and bulky actuator cylinder within a narrow platform space is extremely inconvenient, resulting in poor maneuverability and a risk of collision. Second, in the attitude adjustment phase, due to the actuator cylinder's enormous mass, adjusting its spatial angle using traditional lifting rings and methods, especially when rotating it around its axis to align with the junction box, is not only extremely time-consuming and labor-intensive, but also makes it difficult to guarantee adjustment accuracy. More seriously, operators often need to manually assist in rotating the massive load at close range, a process posing a high safety risk and easily leading to personal injury or equipment damage. Finally, in the final installation and positioning phase, precisely aligning the bottom of the actuator cylinder with the slot in the Lower Bearing relies entirely on the crane operator's manual control and ground personnel's visual guidance, resulting in high coordination difficulty, low positioning efficiency, and the fine-tuning process also carries safety hazards.

[0005] Based on this, the present invention proposes an electric actuator for changing the lifting ring, system and method. Summary of the Invention

[0006] To address the aforementioned problems in the prior art, namely the inconvenience of the electric actuator cylinder replacement process, the difficulty in adjusting its posture, and the significant safety hazards, this invention provides an electric actuator cylinder replacement ring, system, and method.

[0007] In a first aspect, the present invention provides an electric actuator for changing lifting rings, comprising:

[0008] The outer ring is composed of two fixedly connected sickle-shaped circular hub groups. Each sickle-shaped circular hub group is composed of two semi-circular sickle hub groups connected together. Each semi-circular sickle hub group is composed of two sickle-shaped hubs connected by multiple bearings.

[0009] The inner ring is formed by two semi-circular hub assemblies fixedly connected together, and each semi-circular hub assembly is formed by two semi-circular hubs fixedly connected together. The inner ring is used to clamp and fix the electric actuator cylinder.

[0010] The outer ring is connected to the outer circumferential surface of the inner ring via a bearing disposed on its inner side, so that the inner ring can rotate relative to the outer ring to achieve adjustment of the orientation of the electric actuator cylinder during hoisting.

[0011] The lifting ring beam is fixedly installed between two sickle-shaped circular hub assemblies and is used to connect the hook or lifting equipment.

[0012] Furthermore, the two sets of semi-circular sickle wheel hubs of the outer ring are fixedly connected by the first fixing block and bolts, thereby forming a complete ring structure.

[0013] Furthermore, the semi-circular hub of the inner ring is fixedly connected by a fixed stem block and a second fixed block to form a complete annular structure for clamping the electric actuator cylinder.

[0014] The fixing block is fixed on the inner circumferential surface of the semi-circular hub and is used to clamp the electric actuator cylinder, while the second fixing block is fixed on the inner surface of the semi-circular hub.

[0015] Furthermore, the two sickle-shaped circular hub assemblies are fixedly connected by a third fixing block and a lifting ring beam.

[0016] Furthermore, the two semi-circular sickle wheel hubs are rotatably connected by a rotating shaft.

[0017] In a second aspect, the present invention provides an electric actuator cylinder replacement system, based on an electric actuator cylinder replacement lifting ring, the system comprising:

[0018] An electric actuator replacement lifting ring is used to fix the electric actuator at its center of gravity. The electric actuator replacement lifting ring is configured to allow the operator to manually rotate the electric actuator in the lifting state so that the inner ring rotates relative to the outer ring, switching the orientation of the motor junction box between upward and downward.

[0019] Lifting equipment is used to connect and lift electric actuators equipped with electric actuator replacement rings, enabling them to be lifted vertically and moved horizontally.

[0020] Ground transport vehicles for transporting the electrically operated cylinder within the installation or dismantling area;

[0021] The system is configured such that: during the disassembly process, the disassembled actuator motor junction box is adjusted to face upwards by manually rotating the lifting ring before being packed into a box; during the installation process, the actuator motor junction box to be installed is adjusted to face downwards by manually rotating the lifting ring before being installed in the designated position on the platform.

[0022] Furthermore, the system also includes:

[0023] A status monitoring module is installed on the hoisting equipment or the electric actuator replacement ring to collect the dynamic status data of the electric actuator in real time during the hoisting process.

[0024] The processing control unit is communicatively connected to the status monitoring module and the hoisting equipment, and is configured as follows:

[0025] Based on the dynamic state data, determine whether the swing state of the electric actuator cylinder exceeds the safety threshold;

[0026] When the determination is yes, a control command is generated and sent to the hoisting equipment to control the hoisting equipment to perform compensating motion and actively suppress the swing of the electric actuator cylinder.

[0027] Furthermore, based on the aforementioned dynamic state data, the method for determining whether the oscillation state of the electrically driven actuator exceeds a safety threshold is as follows:

[0028] The raw dynamic state data continuously collected by the state monitoring module is serialized to obtain a dynamic data sequence that reflects its changes over time.

[0029] Based on the dynamic data sequence, the swing angle and swing angular velocity of the electric actuator at the current and next moments are estimated by the state estimation algorithm.

[0030] The absolute value of the obtained swing angle estimation value is compared with the preset angle safety range extreme value, and the absolute value of the swing angular velocity estimation value is compared with the preset angular velocity safety range extreme value.

[0031] If the absolute value of the estimated swing angle exceeds the extreme value of its corresponding safe angle range, or the absolute value of the estimated swing angular velocity exceeds the extreme value of its corresponding safe angular velocity range, then the swing state is determined to have exceeded the safe threshold.

[0032] Furthermore, control commands are generated and sent to the hoisting equipment to control the hoisting equipment to perform compensating movements and actively suppress the swaying of the electrically driven cylinder. The method is as follows:

[0033] Based on the determined oscillation state exceeding the safety threshold, the vector direction and required momentum of the suppressive force to be applied to suppress the oscillation are calculated.

[0034] The vector direction and the desired momentum are mapped to specific vector parameters that the hoisting equipment drive mechanism should follow. These specific vector parameters are used to instruct the hoisting equipment to generate a reverse smooth displacement that is opposite to the current swing trend.

[0035] Based on the specific vector parameters, a corresponding digital control command is generated and sent to the underlying drive controller of the hoisting equipment.

[0036] The underlying drive controller executes the digital control instructions to drive the hoisting equipment to generate displacement movement according to the specific vector parameters. The displacement movement is transmitted to the electric actuator through the sling, thereby generating a suppressive force opposite to the swing direction, actively canceling and attenuating its swing kinetic energy.

[0037] A third aspect of the present invention provides a method for replacing an electrically operated actuator cylinder, based on an electrically operated actuator cylinder replacement system, the method comprising the following steps:

[0038] At the disassembly station, the electric actuator replacement lifting ring is fixedly installed at the center of gravity of the electric actuator to be disassembled, and then connected to the lifting equipment;

[0039] Disconnect the electric actuator from the platform and operate the hoisting equipment to lift the electric actuator to a suspended state;

[0040] Manually rotate the suspended electric actuator cylinder to drive the inner ring of the electric actuator cylinder to rotate relative to the outer ring until the orientation of its motor junction box is adjusted to face upwards.

[0041] The hoisting equipment is used to transfer the electrically driven cylinder, which has been positioned and placed on a ground transport vehicle, and then transport it away from the dismantling station.

[0042] At the installation station, the replacement lifting ring of the electric actuator cylinder is fixedly installed at the center of gravity of the electric actuator cylinder to be installed, and then connected to the lifting equipment;

[0043] Operate the hoisting equipment to lift the electrically driven cylinder to a suspended state;

[0044] Manually rotate the suspended electric actuator cylinder to drive the inner ring of the electric actuator cylinder to rotate relative to the outer ring until the orientation of its motor junction box is adjusted to face downwards;

[0045] Operate the hoisting equipment and move the electric actuator cylinder, after its orientation adjustment, to the installation area. Use ground transportation vehicles to accurately position it and finally install it at the designated location on the platform.

[0046] The beneficial effects of this invention are:

[0047] This invention, through the structural design of a rotatable lifting ring, allows operators to conveniently and manually adjust the position of the actuator cylinder from a position away from the load, completely avoiding the safety risks such as squeezing and collision caused by personnel directly contacting and pushing and pulling heavy objects in traditional operations.

[0048] This invention significantly optimizes the efficiency and convenience of the replacement process. Operators no longer need to rely on repeated crane lifting and lowering or multiple people working together; they can quickly and accurately adjust the motor junction box of the heavy electric actuator to the required orientation simply by rotating the lifting ring. This simplifies the operation, reduces labor intensity, and shortens the operation time.

[0049] From a structural and functional perspective, the specialized lifting ring achieves controllability and stability in the adjustment process. Its inner and outer rings are connected by bearings, ensuring smooth and reliable rotation. This makes adjusting the position of heavy objects weighing hundreds of kilograms easier and more precise, effectively overcoming the shortcomings of traditional lifting rings, such as limited functionality, difficulty in adjustment, and susceptibility to wobbling. Attached Figure Description

[0050] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0051] Figure 1 This is a schematic diagram of the overall structure of an electric actuator cylinder replacement ring according to the present invention;

[0052] Figure 2 This is a schematic diagram of the outer ring structure of a replacement lifting ring for an electrically operated cylinder according to the present invention;

[0053] Figure 3 This is a schematic diagram of the structure of a sickle-shaped annular hub assembly in an electric actuator cylinder replacement ring according to the present invention;

[0054] Figure 4 This is a schematic diagram of the semi-circular sickle hub assembly in the electric actuator cylinder replacement ring according to the present invention;

[0055] Figure 5 This is a schematic diagram of the sickle-shaped hub in the electric actuator cylinder replacement ring of the present invention;

[0056] Figure 6 This is a schematic diagram of the inner ring structure of an electric actuator for changing the lifting ring of the present invention;

[0057] Figure 7 This is a schematic diagram of the structure of a semi-circular hub assembly for replacing the lifting ring of an electrically operated cylinder according to the present invention;

[0058] Figure 8 This is a schematic diagram of the structure of a semi-circular hub for replacing the lifting ring of an electric actuator cylinder according to the present invention. Detailed Implementation

[0059] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0060] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0061] like Figures 1-8 As shown, in the first embodiment of the present invention, an electric actuator cylinder replacement ring is provided, comprising:

[0062] The outer ring 1 is composed of two fixedly connected sickle-shaped circular hub groups 2. Each sickle-shaped circular hub group 2 is composed of two semi-circular sickle hub groups 3 connected together. Each semi-circular sickle hub group 3 is composed of two sickle-shaped hubs 4 connected by multiple bearings.

[0063] The inner ring 5 is formed by two semi-circular hub assemblies 6 fixedly connected together. Each semi-circular hub assembly 6 is formed by two semi-circular hubs 7. The inner ring 5 is used to clamp and fix the electric actuator cylinder. The two semi-circular hub assemblies 6 are fixed by bolts.

[0064] The outer ring 1 is connected to the outer peripheral surface of the inner ring 5 through a bearing disposed on its inner side, so that the inner ring 5 can rotate relative to the outer ring 1 to realize the adjustment of the orientation of the electric actuator cylinder during the hoisting process;

[0065] The lifting ring beam 8 is fixedly installed between two sickle-shaped circular wheel hubs 2 and is used to connect the hook or lifting equipment.

[0066] like Figure 4 and Figure 5 As shown, each of the semi-circular sickle hub groups 3 consists of two sickle-shaped hubs 4 connected by multiple bearings, specifically, by three roller bearings.

[0067] As a further explanation of the present invention, such as Figure 2 and Figure 3As shown, the two sets of semi-circular sickle wheel hubs 3 of the outer ring 1 are fixedly connected by the first fixing block 9 and bolts, thereby forming a complete ring structure.

[0068] This invention securely connects two sets of semi-circular sickle hub assemblies 3 into a single, rigid, complete ring structure using a first fixing block 9 and bolts. This connection method significantly enhances the integrity and structural stability of the outer ring, enabling it to distribute stress evenly and avoid localized deformation when subjected to the load of a heavy-duty electric actuator. Simultaneously, the bolted connection provides reliable bonding strength, ensuring safety during hoisting and facilitating equipment disassembly and maintenance. This design effectively improves the durability and reliability of the lifting ring under heavy-load, high-frequency operating conditions.

[0069] As a further explanation of the present invention, such as Figure 6 and Figure 7 As shown, the two sets of semi-circular hubs 7 of the inner ring 5 are fixedly connected by the fixed stem block 10 and the second fixed block 11 to form a semi-circular hub group 6. The two sets of semi-circular hub groups 6 form a complete ring structure for clamping the electric actuator cylinder.

[0070] The fixing block 10 is fixed on the inner circumferential surface of the semi-circular hub 7 and is used to clamp the electric actuator cylinder, while the second fixing block 11 is fixed on the inner surface of the semi-circular hub 7.

[0071] This invention distributes the clamping force evenly on the surface of the actuator cylinder by fixing the stem block 10, which not only ensures the reliability of load transmission but also protects the surface of the equipment. This modular, split design overcomes the drawback of the integrated ring structure, which cannot be installed, and ultimately forms a complete ring-shaped load-bearing structure that can tightly cover and safely support the heavy actuator cylinder, fundamentally improving the safety and convenience of hoisting operations.

[0072] As a further explanation of the present invention, such as Figure 2 As shown, the two sickle-shaped circular hub assemblies 2 are fixedly connected by a third fixing block 12 and a lifting ring beam 8.

[0073] The third fixing block 12 enhances the overall structural rigidity and stability of the outer ring. Its core effect is to firmly connect and integrate the two independent sickle-shaped annular hub assemblies 2 into a unified load-bearing unit, effectively preventing relative displacement or deformation caused by uneven stress on the two hub assemblies during heavy lifting. This design ensures that the load can be smoothly and evenly transferred between the two sickle-shaped annular hub assemblies through the third fixing block, avoiding stress concentration.

[0074] As a further explanation of the present invention, such as Figure 1 and Figure 2As shown, the two semi-circular sickle wheel hubs 3 are rotatably connected by a rotating shaft 13.

[0075] The rotating shaft connection structure allows the two semi-circular sickle hub assemblies 3 to rotate relative to each other around a common axis, which enhances the adaptability and flexibility of the entire lifting ring. This enables it to better adapt to slight deflections or angle changes that may occur during the lifting process, thereby effectively alleviating the internal stress concentration problem that may be caused by rigid connection and improving the reliability and service life of the lifting ring under complex stress conditions.

[0076] A second embodiment of the present invention proposes an electric actuator cylinder replacement system, based on an electric actuator cylinder replacement lifting ring, the system comprising:

[0077] The electric actuator replacement lifting ring is used to fix the electric actuator at its center of gravity. The electric actuator replacement lifting ring is configured to allow the operator to manually rotate the electric actuator in the hoisting state so that the inner ring 5 rotates relative to the outer ring 1, switching the orientation of the motor junction box between upward and downward.

[0078] Lifting equipment is used to connect and lift electric actuators equipped with electric actuator replacement rings, enabling them to be lifted vertically and moved horizontally.

[0079] Ground transport vehicles for transporting the electrically operated cylinder within the installation or dismantling area;

[0080] The system is configured such that: during the disassembly process, the disassembled actuator motor junction box is adjusted to face upwards by manually rotating the lifting ring before being packed into a box; during the installation process, the actuator motor junction box to be installed is adjusted to face downwards by manually rotating the lifting ring before being installed in the designated position on the platform.

[0081] In its implementation, the system first involves pre-operational preparation at the disassembly station for the electric actuator to be replaced. Operators back up the system configuration file and disconnect its associated electrical wiring, including the motor power line, pressure switch, and HomeSwitch signal line. They also remove the wiring channel and deflate the actuator's airbag. Subsequently, jacks and prosthetics are installed at appropriate locations on the platform to provide reliable support, preparing for subsequent disassembly. Operators then install the electric actuator replacement lifting ring at the center of gravity of the actuator to be disassembled and connect the lifting ring beam using the hook of the hoisting equipment. The actuator is then slowly lifted into a suspended state using the hoisting equipment, and the mechanical connection between its upper and lower ends is disengaged using specialized tools.

[0082] At this point, the actuator cylinder motor junction box is facing downwards. The operator holds the actuator cylinder body and manually applies rotational force, driving the inner ring 5 of the lifting ring to rotate 180 degrees relative to the outer ring 1, turning the motor junction box upwards. This orientation facilitates subsequent packing, storage, and transportation. The hoisting equipment then lifts the aligned actuator cylinder into a packaging box placed on sleepers, completing the sealing process. During the installation phase, the new actuator cylinder to be installed is pre-packed and transported to the site. The operator uses ground transportation to move it horizontally to the installation area next to the six-degree-of-freedom platform, with its motor junction box facing upwards. The replacement lifting ring is used to reliably secure it, and the hoisting equipment lifts it appropriately off the ground. Then, the actuator cylinder airbag is deflated, and the cylinder is compressed using a telescopic rope.

[0083] Afterwards, the operator manually rotates the actuator cylinder again, driving the inner ring 5 of the lifting ring to rotate 180 degrees in the opposite direction, precisely adjusting its motor junction box to the required downward orientation for installation. The hoisting equipment then places it back onto the ground transport vehicle, which carries it directly beneath the platform. Installation begins at the bottom of the actuator cylinder. The operator installs the shims onto the Lower Bearing, then manipulates the leveling mechanism on the ground transport vehicle to finely adjust the actuator cylinder's spatial angle and horizontal position, slowly aligning its bottom with and smoothly pushing it into the Lower Bearing's slot, completing the bottom installation. Following this, the upper part of the actuator cylinder is connected and installed sequentially. The prosthetic limbs and jacks used for support are removed. Nitrogen is then introduced into the new actuator cylinder, all electrical wiring is restored, lubrication is added, and a series of other operations are performed. Finally, the system configuration file is restored, and the equipment is started for functional testing to verify the new actuator cylinder's performance. The entire process, through the coordinated operation of the lifting ring, hoisting equipment, and ground transport vehicle, achieves a safe, efficient, and convenient replacement operation.

[0084] In this embodiment, the ground transport vehicle is specifically a ground tank, capable of carrying an electrically driven actuator weighing several hundred kilograms and achieving horizontal movement and precise positioning within the installation area. Furthermore, the ground transport vehicle of this invention also features a lifting and fine-tuning function. The ground tank has an integrated leveling mechanism, specifically a jack. Operators can easily adjust the height and pitch angle of the actuator placed on its platform by manipulating this jack, ensuring its bottom is precisely aligned and smoothly pushed into the slot of the six-degree-of-freedom platform's Lower Bearing, thus completing the installation.

[0085] In this embodiment, the system further includes:

[0086] A status monitoring module is installed on the hoisting equipment or the electric actuator replacement ring to collect the dynamic status data of the electric actuator in real time during the hoisting process.

[0087] The processing control unit is communicatively connected to the status monitoring module and the hoisting equipment, and is configured as follows:

[0088] Based on the dynamic state data, determine whether the swing state of the electric actuator cylinder exceeds the safety threshold;

[0089] When the determination is yes, a control command is generated and sent to the hoisting equipment to control the hoisting equipment to perform compensating motion and actively suppress the swing of the electric actuator cylinder.

[0090] Specifically, the condition monitoring module is typically implemented using a combination of an inertial measurement unit (IMU) and a force sensor. The IMU is securely mounted on the lifting ring beam 8 of the electric actuator cylinder or the hook structure of the lifting equipment, and is used to collect high-frequency data on the angular velocity and linear acceleration of the electric actuator cylinder in three axes during lifting and rotation adjustment. The force sensor is installed in series between the hook and the sling to monitor the tension changes of the lifting load in real time. These sensor elements together constitute the data sensing layer of the condition monitoring module. They continuously convert the collected raw dynamic state data into electrical signals and perform analog-to-digital conversion, ultimately transmitting the data to the processing and control unit via wired or wireless communication.

[0091] In practice, the processing and control unit is typically an embedded industrial computer or a high-performance programmable logic controller (PLC), pre-installed with proprietary anti-sway control algorithm software. This unit continuously receives real-time data streams from the status monitoring module via its communication interface. Its internal processor first preprocesses this data, including using digital filtering algorithms to remove measurement noise and using data fusion algorithms to estimate the current swing angle, angular velocity, and swing trend of the actuator. Subsequently, the core algorithm performs real-time logical operations to compare the absolute values ​​of the calculated swing angle and angular velocity with pre-stored angle and angular velocity safety threshold parameters in memory. If either value is determined to exceed the safety tolerance, the algorithm immediately triggers the control command generation program.

[0092] The program calculates the magnitude and direction of the optimal compensating force required to suppress the sway based on the sway state vector, and converts this mechanical objective into a displacement command vector that the hoisting equipment drive mechanism can directly execute. This command vector includes the direction of displacement, a small displacement amount, and a smooth velocity curve parameter. Its core feature is instructing the hoisting equipment to generate a smooth, reverse displacement opposite to the current sway direction. Finally, this digital control command is sent in real-time to the hoisting equipment's underlying drive controller via an industrial fieldbus or Ethernet protocol. The underlying drive executes this command, precisely controlling the motor or hydraulic mechanism to generate the compensating motion. This motion applies a suppressive force opposite to the sway direction through the sling system, thereby actively and smoothly counteracting and attenuating the sway kinetic energy of the electric actuator until it returns to a stable, safe state.

[0093] In this embodiment, the method for determining whether the swing state of the electrically actuated cylinder exceeds the safety threshold is as follows:

[0094] The raw dynamic state data continuously collected by the state monitoring module is serialized to obtain a dynamic data sequence that reflects its changes over time.

[0095] Based on the dynamic data sequence, the swing angle and swing angular velocity of the electric actuator at the current and next moments are estimated by the state estimation algorithm.

[0096] The absolute value of the obtained swing angle estimation value is compared with the preset angle safety range extreme value, and the absolute value of the swing angular velocity estimation value is compared with the preset angular velocity safety range extreme value.

[0097] If the absolute value of the estimated swing angle exceeds the extreme value of its corresponding safe angle range, or the absolute value of the estimated swing angular velocity exceeds the extreme value of its corresponding safe angular velocity range, then the swing state is determined to have exceeded the safe threshold.

[0098] In this embodiment, the processing control unit first continuously receives raw dynamic state data streams from the state monitoring module through its data acquisition interface. These data streams contain real-time angular velocity, linear acceleration, and tension information of the actuator cylinder. The microprocessor inside the unit immediately serializes these raw data streams arriving in chronological order, timestamping them and organizing them into a continuous dynamic data sequence reflecting their changes over time, laying the foundation for subsequent time-series analysis.

[0099] Subsequently, the processing control unit invokes its internally pre-set state estimation algorithm to further process the dynamic data sequence. This algorithm is essentially a data fusion and prediction algorithm that combines a system dynamics model with real-time observation data. Through comprehensive analysis of historical and current data, it can accurately estimate the swing angle and swing angular velocity of the electric actuator at the current moment and at a short predicted future moment. This estimation process effectively filters out interference from measurement noise, providing a more accurate and stable basis for judging the true state of the system.

[0100] Next, the execution logic of the processing control unit enters the comparison and judgment stage. It takes the absolute value of the calculated estimated swing angle at the current moment and compares it with the angle safety range extreme value parameter pre-stored in non-volatile memory. At the same time, it also compares the absolute value of the estimated swing angular velocity with the same preset angular velocity safety range extreme value parameter in parallel. These two comparison processes are independent and performed simultaneously.

[0101] Ultimately, the decision-making logic within the unit makes a judgment based on the comparison results. If the logic operation finds that the absolute value of the estimated swing angle exceeds the extreme value of the safe angle range, or that the absolute value of the estimated swing angular velocity exceeds the extreme value of the safe angular velocity range, as long as either condition is met, the processing control unit will ultimately determine that the current swing state of the electric actuator has exceeded the safety threshold. This "OR" logic ensures that the system can respond promptly to any single-dimensional over-limit risk, thereby triggering subsequent suppression control commands.

[0102] More specifically, the processing control unit is configured to estimate the swing angle estimate and the swing angular velocity estimate based on the dynamic data sequence in the following manner:

[0103] Based on a pre-established discrete state-space model describing the swing characteristics of the hoisting system, the prior estimate of the state at the current moment is predicted using the state estimate of the previous moment.

[0104] Real-time acquisition of the latest observation data collected by the status monitoring module;

[0105] Calculate the optimal weighting coefficients for the reliability of the dynamic equilibrium model predictions and the latest observation data;

[0106] The prior predicted value and the latest observed data are fused with the optimal weighting coefficient to generate the optimal posterior estimate of the swing angle and swing angular velocity at the current moment, and to predict the state at the next moment.

[0107] This recursive algorithm effectively suppresses measurement noise interference and provides accurate and stable state estimation results through continuous prediction and update cycles.

[0108] In this embodiment, control commands are generated and sent to the hoisting equipment to control the hoisting equipment to perform compensating movements and actively suppress the swaying of the electrically driven cylinder. The method is as follows:

[0109] Based on the determined oscillation state exceeding the safety threshold, the vector direction and required momentum of the suppressive force to be applied to suppress the oscillation are calculated.

[0110] The vector direction and the desired momentum are mapped to specific vector parameters that the hoisting equipment drive mechanism should follow. These specific vector parameters are used to instruct the hoisting equipment to generate a reverse smooth displacement that is opposite to the current swing trend.

[0111] Based on the specific vector parameters, a corresponding digital control command is generated and sent to the underlying drive controller of the hoisting equipment.

[0112] The underlying drive controller executes the digital control instructions to drive the hoisting equipment to generate displacement movement according to the specific vector parameters. The displacement movement is transmitted to the electric actuator through the sling, thereby generating a suppressive force opposite to the swing direction, actively canceling and attenuating its swing kinetic energy.

[0113] Specifically, the processing control unit first performs calculations based on the specific swing state it determines exceeds the safety threshold. This calculation is based on a built-in inverted pendulum system dynamics model, which abstracts the swing of the hoisting system as a physical pendulum. By calculating the phase and amplitude of the current swing angle and angular velocity in real time, it calculates the vector direction and required momentum of the optimal damping force needed to counteract the swing and restore stability. This calculation process aims to determine a control target that can most effectively dampen the swing energy.

[0114] The processing control unit converts the abstract mechanical control objective—the calculated vector direction and momentum—into specific motion vector parameters that the lifting equipment's drive mechanism can directly recognize and execute. This mapping process takes into account factors such as the specific mechanical structure of the lifting equipment, the performance parameters of the drive motor, and the length of the slings. The generated specific vector parameters precisely instruct the lifting equipment to produce a smooth, reverse displacement that is completely opposite to the currently detected sway trend. This displacement is optimized in both amplitude and velocity to produce a counteracting effect rather than introducing new disturbances.

[0115] The processing control unit generates corresponding digital control commands based on these specific vector parameters. These commands are typically encapsulated according to a specific industrial fieldbus protocol standard and contain key information such as target position and speed curve. The encapsulated digital control commands are then transmitted in real time to the underlying drive controller of the hoisting equipment via a high-speed communication link.

[0116] Finally, the bottom-level drive controller of the hoisting equipment receives and parses the digital control command. Based on the parameters in the command, the controller drives actuators such as servo motors or proportional hydraulic valves through its internal closed-loop control algorithm to precisely generate the required displacement. This minute, precise, and smooth compensating displacement is transmitted to the electric actuator through the sling system, applying a suppressive force opposite to the current swing direction. The negative work done by this force actively cancels out and attenuates the kinetic energy of the swing, thereby causing the electric actuator to quickly converge and return to a stable and safe state, completing one full cycle of active suppression control.

[0117] More specifically, based on the determined oscillation state exceeding the safety threshold, the vector direction and required momentum of the suppressive force needed to suppress the oscillation are calculated. The method is as follows:

[0118] Based on the pre-established swing dynamics model of the hoisting system, the current swing state that exceeds the safety threshold is calculated in real time.

[0119] The calculation process determines the core swing mode and energy distribution by analyzing the phase and amplitude of the current swing angle and swing angular velocity.

[0120] Based on the core oscillation mode and energy distribution, the optimal direction and magnitude of the damping force that can most effectively dampen the current oscillation kinetic energy are calculated.

[0121] The vector direction of the optimal restraining force is opposite to the current oscillation trend, and its momentum is positively correlated with the intensity of the current oscillation.

[0122] In practice, the processing control unit calls its internally preset hoisting system swing dynamics model, which simplifies the electric actuator, slings, and hook into an inverted pendulum or compound pendulum. Based on this model, real-time numerical calculations are performed on the current swing state that has been determined to exceed the safety threshold.

[0123] The calculation process first performs frequency and time domain analysis on the real-time estimated current oscillation angle and oscillation angular velocity signals. By analyzing the phase relationship, amplitude, and rate of change of these two signals, the algorithm can identify the dominant frequency, oscillation axis, and energy distribution in different directions, thereby accurately determining the core oscillation mode and the main spatial distribution characteristics of energy.

[0124] After clarifying the core oscillation mode and energy distribution, the algorithm performs calculations based on a suppression strategy designed using Lyapunov stability theory or optimal control theory. Its goal is to find a control force that dampens the current oscillation kinetic energy with the fastest speed and minimum energy consumption. The core of the calculation is to solve for an optimal function that makes the total energy of the system decrease over time; the solution to this function represents the required optimal suppression force's direction and momentum magnitude. The final output of this optimal suppression force has its vector direction set exactly opposite to the instantaneous trend direction of the current oscillation, while its momentum magnitude is positively correlated with the intensity of the current oscillation, i.e., the amplitude of the oscillation angle and angular velocity. The more intense the oscillation, the larger the suppression momentum required for calculation.

[0125] It should be noted that the electric actuator replacement system provided in the above embodiments is only an example of the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be further decomposed or combined. For example, the modules in the above embodiments can be merged into one module, or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the various modules or steps and are not considered as an improper limitation of the present invention.

[0126] The third embodiment of the present invention proposes a method for replacing an electrically operated actuator cylinder, based on an electrically operated actuator cylinder replacement system in the second embodiment. The method includes the following steps:

[0127] Step S10: At the disassembly station, the electric actuator replacement lifting ring is fixedly installed at the center of gravity of the electric actuator to be disassembled, and connected to the lifting equipment.

[0128] Step S20: Disconnect the mechanical connection between the electric actuator and the platform, and operate the hoisting equipment to lift the electric actuator to a suspended state;

[0129] Step S30: Manually rotate the electric actuator cylinder that is in a suspended state to drive the inner ring 5 of the electric actuator cylinder replacement ring to rotate relative to the outer ring 1 until the orientation of its motor junction box is adjusted to face upward.

[0130] Step S40: Operate the hoisting equipment to transfer the oriented electrically operated cylinder and place it on a ground transport vehicle to move it away from the dismantling station;

[0131] Step S50: At the installation station, the replacement lifting ring of the electric actuator cylinder is fixedly installed at the center of gravity of the electric actuator cylinder to be installed, and connected to the lifting equipment;

[0132] Step S60: Operate the hoisting equipment to lift the electrically driven cylinder to a suspended state;

[0133] Step S70: Manually rotate the electric actuator cylinder that is in a suspended state to drive the inner ring 5 of the electric actuator cylinder replacement ring to rotate relative to the outer ring 1 until the orientation of its motor junction box is adjusted to face downwards.

[0134] Step S80: Operate the hoisting equipment and move the electric actuator cylinder with adjusted orientation to the installation area. Use ground transportation vehicles to accurately position it and finally install it at the designated position on the platform.

[0135] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working process and related explanations of the methods described above can be found in the corresponding processes in the foregoing system embodiments, and will not be repeated here.

[0136] Although the steps in the above embodiments are described in the above order, those skilled in the art will understand that in order to achieve the effect of this embodiment, different steps do not need to be executed in such an order. They can be executed simultaneously (in parallel) or in a reverse order. These simple variations are all within the protection scope of this invention.

[0137] In the description of this invention, terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," which indicate direction or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. These are used merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0138] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0139] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0140] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. An electrically operated actuator cylinder replacement system, characterized in that, The system includes: The electric actuator replacement lifting ring includes an inner ring (5) for clamping and fixing the electric actuator, and an outer ring (1) for rotatably supporting the inner ring (5) and for connecting to the lifting equipment. The electric actuator replacement lifting ring is used to fix the electric actuator at the center of gravity position. The electric actuator replacement lifting ring is configured to allow the operator to manually rotate the electric actuator in the lifting state so that the inner ring (5) rotates relative to the outer ring (1) to switch the orientation of the motor junction box between upward and downward. Lifting equipment is used to connect and lift electric actuators equipped with electric actuator replacement rings, enabling them to be lifted vertically and moved horizontally. Ground transport vehicles for transporting the electrically operated cylinder within the installation or dismantling area; The system is configured such that: during the disassembly process, the disassembled actuator motor junction box is adjusted to face upwards by manually rotating the lifting ring before being packed into a box; during the installation process, the actuator motor junction box to be installed is adjusted to face downwards by manually rotating the lifting ring before being installed in the designated position on the platform. The system also includes: A status monitoring module is installed on the hoisting equipment or the electric actuator replacement ring to collect the dynamic status data of the electric actuator in real time during the hoisting process. The processing control unit is communicatively connected to the status monitoring module and the hoisting equipment, and is configured as follows: Based on the dynamic state data, determine whether the swing state of the electric actuator cylinder exceeds the safety threshold; When the determination is yes, a control command is generated and sent to the hoisting equipment to control the hoisting equipment to perform compensating motion and actively suppress the swing of the electric actuator cylinder; Based on the aforementioned dynamic state data, the method for determining whether the oscillation state of the electrically driven actuator exceeds a safety threshold is as follows: The raw dynamic state data continuously collected by the state monitoring module is serialized to obtain a dynamic data sequence that reflects its changes over time. Based on the dynamic data sequence, the swing angle and swing angular velocity of the electric actuator at the current and next moments are estimated by the state estimation algorithm. The absolute value of the obtained swing angle estimation value is compared with the preset angle safety range extreme value, and the absolute value of the swing angular velocity estimation value is compared with the preset angular velocity safety range extreme value. If the absolute value of the estimated swing angle exceeds the extreme value of its corresponding safe angle range, or the absolute value of the estimated swing angular velocity exceeds the extreme value of its corresponding safe angular velocity range, then the swing state is determined to have exceeded the safe threshold.

2. The electric actuator cylinder replacement system according to claim 1, characterized in that, A control command is generated and sent to the hoisting equipment to control the hoisting equipment to perform compensating movements and actively suppress the swaying of the electrically driven cylinder. The method is as follows: Based on the determined oscillation state exceeding the safety threshold, the vector direction and required momentum of the suppressive force to be applied to suppress the oscillation are calculated. The vector direction and the desired momentum are mapped to specific vector parameters that the drive mechanism of the hoisting equipment should follow. These specific vector parameters are used to instruct the hoisting equipment to generate a reverse smooth displacement that is opposite to the current swing trend. Based on the specific vector parameters, a corresponding digital control command is generated and sent to the underlying drive controller of the hoisting equipment. The underlying drive controller executes the digital control instructions to drive the hoisting equipment to generate displacement movement according to the specific vector parameters. The displacement movement is transmitted to the electric actuator through the sling, thereby generating a suppressive force opposite to the swing direction, actively canceling and attenuating its swing kinetic energy.

3. The electric actuator cylinder replacement system according to claim 2, characterized in that, Based on the determined oscillation state exceeding the safety threshold, the vector direction and required momentum of the suppressive force needed to suppress the oscillation are calculated. The method is as follows: Based on a pre-established swing dynamics model of the hoisting system, the current swing state that exceeds the safety threshold is calculated in real time. The calculation process determines the core swing mode and energy distribution by analyzing the phase and amplitude of the current swing angle and swing angular velocity. Based on the core oscillation mode and energy distribution, the optimal direction and magnitude of the damping force that can most effectively dampen the current oscillation kinetic energy are calculated.

4. The electric actuator cylinder replacement system according to claim 1, characterized in that, The electric actuator cylinder replacement lifting ring includes: The outer ring (1) is composed of two fixedly connected sickle-shaped circular hub groups (2). Each sickle-shaped circular hub group (2) is composed of two semi-circular sickle hub groups (3) connected together. Each semi-circular sickle hub group (3) is composed of two sickle-shaped hubs (4) connected by multiple bearings. The inner ring (5) is formed by two semi-circular hub groups (6) fixedly connected. Each semi-circular hub group (6) is formed by two semi-circular hubs (7) fixedly connected. The inner ring (5) is used to clamp and fix the electric actuator cylinder. The outer ring (1) is connected to the outer circumferential surface of the inner ring (5) by a bearing disposed on its inner side, so that the inner ring (5) can rotate relative to the outer ring (1) to realize the adjustment of the orientation of the electric actuator cylinder during the hoisting process; The lifting ring beam (8) is fixedly installed between two sickle-shaped circular wheel hubs (2) and is used to connect the hook or lifting equipment.

5. The electric actuator cylinder replacement system according to claim 4, characterized in that, The two sets of semi-circular sickle wheel hubs (3) of the outer ring (1) are fixedly connected by the first fixing block (9) and bolts, thereby forming a complete ring structure.

6. The electric actuator cylinder replacement system according to claim 5, characterized in that, The semi-circular hub (7) of the inner ring (5) is fixedly connected by a fixed stem block (10) and a second fixed block (11) to form a complete annular structure for clamping the electric actuator cylinder. The fixing block (10) is fixed on the inner circumferential surface of the semi-circular hub (7) for clamping the electric actuator cylinder, and the second fixing block (11) is fixed on the inner surface of the semi-circular hub (7).

7. The electric actuator cylinder replacement system according to claim 4, characterized in that, The two sickle-shaped circular hub assemblies (2) are fixedly connected by a third fixing block (12) and a lifting ring beam (8).

8. The electric actuator cylinder replacement system according to claim 4, characterized in that, The two semi-circular sickle wheel hubs (3) are rotatably connected by a rotating shaft (13).

Images