Counterweight self-loading and self-unloading control method, control system and crane

Abstract

A balance weight self-loading and unloading control method comprises the steps that the pressure of hydraulic oil in a rod cavity of a balance weight oil cylinder is detected, the pressure value of the rod cavity of the balance weight oil cylinder is generated, the flow of hydraulic oil on a rod cavity connecting pipeline of the balance weight oil cylinder is detected, and the flow value of the rod cavity of the balance weight oil cylinder is generated; and when the pressure value of the rod cavity of the counterweight oil cylinder is smaller than a second pressure preset value P2 and the flow value of the rod cavity of the counterweight oil cylinder is smaller than a flow preset value Q1, the rotary table is controlled to rotate, so that the counterweight oil cylinder is connected with or separated from the counterweight assembly in a hanging mode. And the piston rod of the counterweight oil cylinder is controlled again to rise till the pressure value of the rod cavity of the counterweight oil cylinder is larger than the first pressure preset value P1 and the flow value of the rod cavity of the counterweight oil cylinder is smaller than the flow preset value Q1. The invention further relates to a counterweight self-loading and self-unloading control system and a crane.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, and in particular to a counterweight self-loading and unloading control method, control system and crane. Background Technology

[0002] Counterweight, also known as counterbalance, is an additional mass used to balance the weight of an object, adjust its center of gravity, or increase its stability. On cranes, counterweight is usually placed at the rear of the turntable and is mainly used to maintain the stability of the entire machine during lifting operations and prevent the crane from tipping over.

[0003] Currently, to adapt to more lifting conditions and carry greater weights, medium and large tonnage truck cranes typically add counterweights to the rear section of the crane's turntable during operation to maintain overall stability. For ease of movement, part of the counterweight is removed from the rear section of the turntable. The most common method for disassembling and assembling counterweights is to use a remote control to rotate the crane's turntable, causing the counterweight cylinders mounted at the rear of the turntable to rotate to a specific position. This, combined with the remote control's control of the counterweight cylinders' lifting and lowering movements, achieves the purpose of disassembling and assembling the counterweight. During the disassembly and assembly process, one person usually needs to hold the remote control, constantly observing the mechanism's movement and continuously adjusting the mechanism's position to ensure the structural components fit together properly. Alternatively, a rotary encoder can be used to detect the rotation angle, thereby enabling automatic disassembly and assembly of the counterweight.

[0004] Existing technical solutions require constant monitoring of the mechanism's position, which is difficult to accurately determine visually. This necessitates frequent remote control adjustments, making the counterweight assembly and disassembly process inconvenient and time-consuming. Automatic assembly and disassembly solutions rely on rotary encoders for positioning. However, these encoders may accumulate errors over time, affecting positioning accuracy. Furthermore, deviations in zero-position calibration or counterweight assembly / disassembly calibration can lead to assembly / disassembly anomalies, structural component collisions, damage, or other unknown risks. Summary of the Invention

[0005] In view of this, the present invention provides a counterweight self-loading and unloading control method, a control system and a crane, which adopt a fully automatic control method to realize the automatic loading and unloading of counterweight.

[0006] The counterweight self-loading and unloading control method provided in this embodiment of the invention includes: detecting the hydraulic oil pressure in the rod chamber of the counterweight cylinder and generating a pressure value for the rod chamber of the counterweight cylinder; detecting the hydraulic oil flow rate in the rod chamber of the counterweight cylinder and generating a flow rate value for the rod chamber of the counterweight cylinder; controlling the piston rod of the counterweight cylinder to descend; when the pressure value in the rod chamber of the counterweight cylinder is less than a second preset pressure value P2 and the flow rate value in the rod chamber of the counterweight cylinder is less than a preset flow rate value Q1; controlling the turntable to rotate so that the counterweight cylinder is engaged or disengaged from the counterweight assembly; and controlling the piston rod of the counterweight cylinder to rise again until the pressure value in the rod chamber of the counterweight cylinder is greater than a first preset pressure value P1 and the flow rate value in the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1.

[0007] Furthermore, during the self-installation of the counterweight, after controlling the turntable to rotate to the first preset rotation position, the piston rod of the counterweight cylinder is lowered. When the pressure value in the rod chamber of the counterweight cylinder is less than the second preset pressure value P2 and the flow rate value in the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, the turntable is controlled to rotate to the second preset rotation position to engage the counterweight cylinder with the counterweight assembly. The piston rod of the counterweight cylinder is then raised again until the pressure value in the rod chamber of the counterweight cylinder is greater than the first preset pressure value P1 and the flow rate value in the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1. Q1; During the self-disassembly of the counterweight, after controlling the turntable to rotate to the second preset rotation position, control the piston rod of the counterweight cylinder to descend. When the pressure value of the rod chamber of the counterweight cylinder is less than the second preset pressure value P2 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, control the turntable to rotate to the first preset rotation position to separate the counterweight cylinder from the counterweight assembly. Then control the piston rod of the counterweight cylinder to rise again until the pressure value of the rod chamber of the counterweight cylinder is greater than the first preset pressure value P1 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1.

[0008] Furthermore, the flow rate of hydraulic oil at the inlet of the rotary motor is detected and a rotary motor inlet flow rate value is generated. The rotary speed of the turntable is calculated using the rotary motor inlet flow rate value, and the rotary speed of the turntable is adjusted in real time to keep the rotary speed of the turntable within a preset speed range.

[0009] Furthermore, before the counterweight is self-installed, it is confirmed that the counterweight assembly is not attached to the piston rod of the counterweight cylinder and that the piston rod of the counterweight cylinder has risen into position.

[0010] This invention also relates to a counterweight self-loading and unloading control system, including a PLC controller, and a counterweight cylinder rod chamber pressure sensor, a counterweight cylinder rod chamber flow sensor, a rotation position detection component, a rotation control valve group, and a counterweight cylinder lifting control valve group connected to the PLC controller via signals; the counterweight cylinder rod chamber pressure sensor is used to detect the hydraulic oil pressure in the rod chamber of the counterweight cylinder and generate a counterweight cylinder rod chamber pressure value which is transmitted to the PLC controller; the counterweight cylinder rod chamber flow sensor is used to detect the hydraulic oil flow in the rod chamber of the counterweight cylinder and generate a counterweight cylinder rod chamber flow value which is transmitted to the PLC controller; the rotation position detection component is used to generate a rotation position signal which is transmitted to the PLC controller when the turntable rotates to a preset position; the rotation control valve group is used to control the rotation of the turntable; the counterweight cylinder lifting control valve group is used to control the rise or fall of the counterweight cylinder; the PLC controller has a built-in counterweight self-loading and unloading control method as described in claim 1 or 2.

[0011] Furthermore, the rotation position detection component includes a first rotation position detection component and a second rotation position detection component. The first rotation position detection component generates a first rotation position signal and transmits it to the PLC controller when the turntable rotates to a first preset rotation position. The second rotation position detection component generates a second rotation position signal and transmits it to the PLC controller when the turntable rotates to a second preset rotation position. The rotation control valve group includes a left rotation control valve and a right rotation control valve. The left rotation control valve controls the turntable to rotate to the left, and the right rotation control valve controls the turntable to rotate to the right. The counterweight cylinder lifting control valve group includes a counterweight cylinder lifting control valve and a counterweight cylinder lowering control valve. The counterweight cylinder lifting control valve controls the piston rod of the counterweight cylinder to rise, and the counterweight cylinder lowering control valve controls the piston rod of the counterweight cylinder to fall.

[0012] Furthermore, it also includes a rotary motor inlet flow sensor connected to the PLC controller. The rotary motor inlet flow sensor is used to detect the flow rate of hydraulic oil at the inlet of the rotary motor and generate a rotary motor inlet flow rate value, which is then transmitted to the PLC controller. The PLC controller is also used to calculate the rotation speed of the turntable using the rotary motor inlet flow rate value and to adjust the rotation speed of the turntable in real time to keep the rotation speed of the turntable within a preset speed range.

[0013] Furthermore, it also includes an interactive device connected to the PLC controller. The interactive device is used to issue commands to start or stop the counterweight installation and to start or stop the counterweight disassembly. It is also used to display the pressure value of the rod chamber of the counterweight cylinder, the flow value of the rod chamber of the counterweight cylinder, the first rotation position signal, the second rotation position signal, the inlet flow value of the rotation motor, and the rotation speed of the turntable.

[0014] Furthermore, it also includes a sensor, wherein the first rotation position detection component cooperates with the sensor to confirm that the turntable has rotated to the first rotation preset position, and the second rotation position detection component cooperates with the sensor to confirm that the turntable has rotated to the second rotation preset position.

[0015] The present invention also relates to a crane, including the above-described counterweight self-loading and unloading control system.

[0016] In summary, the counterweight self-loading and unloading control system and crane of the present invention have the following beneficial effects: the present invention realizes self-installation and self-disassembly of the counterweight without human intervention, which greatly improves the convenience of counterweight operation and reduces the intensity of manual labor. At the same time, it avoids the structural component interference and collision problems caused by possible deviations in the zero-position calibration of the slewing or the cumulative error of the slewing encoder in the prior art.

[0017] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0018] Figure 1 This is a schematic diagram showing the disassembly and assembly positions of the counterweight component in a crane according to a preferred embodiment of the present invention.

[0019] Figure 2 This is a schematic diagram of the counterweight assembly in a crane according to a preferred embodiment of the present invention.

[0020] Figure 3 This is a schematic diagram showing the connection between the counterweight assembly and the counterweight cylinder in a crane according to a preferred embodiment of the present invention.

[0021] Figure 4 This is a schematic diagram of the bottom counterweight block, the hanging column, and the counterweight cylinder in the counterweight assembly of the crane according to a preferred embodiment of the present invention.

[0022] Figure 5 This is a schematic diagram of the electrical connection of the controller in the counterweight self-loading and unloading control system of a crane according to a preferred embodiment of the present invention.

[0023] Figure 6 This is a schematic diagram showing the connection of the slewing motor, slewing reducer, and slewing gear ring in a crane according to a preferred embodiment of the present invention.

[0024] Figure 7 This is a schematic diagram of the slewing motor and slewing reducer in a crane according to a preferred embodiment of the present invention.

[0025] Figure 8 This is a schematic diagram of the arrangement of the slewing position detection proximity switch in the counterweight self-loading and unloading control system of a crane according to a preferred embodiment of the present invention.

[0026] Figure 9 This is a flowchart of the counterweight self-installation control process.

[0027] Figure 10 This is a flowchart of the counterweight self-disassembly control process. Detailed Implementation

[0028] To further illustrate the technical means and effects adopted by the present invention in order to achieve the intended purpose, the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments.

[0029] Figure 1 This is a schematic diagram showing the disassembly and assembly positions of the counterweight assembly in a crane according to a preferred embodiment of the present invention. Please refer to... Figure 1 The crane, for example, is a truck crane. The crane includes a frame (not shown), a slewing mechanism 20, and a turntable 30, with the turntable 30 mounted on the frame via the slewing mechanism 20. The counterweight self-loading and unloading control system of the present invention is mainly used to automatically install the counterweight component 40 from a designated position onto the counterweight cylinder 110 (i.e., counterweight self-installation), and to automatically disassemble the counterweight component 40, already attached to the counterweight cylinder 110, to a designated position (i.e., counterweight self-disassembly). This designated position can be located on the frame, on the turntable 30, or on other transport vehicles; any designated position can be preset as needed. The counterweight self-installation and self-disassembly actions can lift and lower the counterweight component 40 at the same designated position; or, combining the counterweight self-installation, self-disassembly, and slewing actions can transfer the counterweight component 40 from one designated position to another. When the counterweight assembly 40 is installed on the turntable 30, the center of gravity of the counterweight assembly 40 and the center of gravity of the boom 10 are located on opposite sides of the slewing mechanism 20 to adjust the center of gravity of the entire machine during lifting operations. Figure 1 The boom 10 shown in the illustration faces the rear of the vehicle, while the counterweight assembly 40 is positioned closer to the front of the vehicle.

[0030] Figure 2 This is a schematic diagram of the counterweight assembly in a crane according to a preferred embodiment of the present invention. Figure 3 This is a schematic diagram of the bottom counterweight block and counterweight cylinder of a crane according to a preferred embodiment of the present invention. Figure 4This is a schematic diagram of the bottom counterweight block, the hanging column, and the counterweight cylinder in the counterweight assembly of the crane according to a preferred embodiment of the present invention. Please refer to it as well. Figure 2 , Figure 3 and Figure 4 The counterweight assembly 40 includes a bottom counterweight block 41 and two hanging columns 42 fixed on the bottom counterweight block 41. These hanging columns 42 are spaced apart on the same side surface of the bottom counterweight block 41 and extend upwards. Each hanging column 42 has a hanging hole 421 at its top (the end furthest from the bottom counterweight block 41). The counterweight assembly 40 may also include a movable counterweight block 43 with a through hole. The movable counterweight block 43 is fitted onto the hanging column 42 through the through hole, and the hanging hole 421 at the top of the hanging column 42 protrudes from the upper surface of the movable counterweight block 43. In this embodiment, the movable counterweight block 43 includes a middle counterweight block 431 and an upper counterweight block 432. The middle counterweight block 431 and the upper counterweight block 432 are stacked sequentially on the bottom counterweight block 41. The middle counterweight block 431 may be multiple or absent, used to adjust the total weight of the counterweight assembly 40 to adapt to cranes of different tonnages. When the counterweight assembly 40 is not self-installed on the turntable 30, it is generally placed on the frame. The movement of the counterweight assembly 40 on the plane is restricted by the clearance fit between the positioning pin on the frame and the positioning hole at the bottom of the bottom counterweight block 41, so that the crane can safely carry the counterweight assembly 40 and it is also easy to self-install on the turntable or remove it.

[0031] In this embodiment, the bottom counterweight 41, the middle counterweight 431 and the top counterweight 432 have different shapes, and these counterweights can be made into a whole block through structural fitting.

[0032] The counterweight cylinder 110 is mounted on the turntable 30. The counterweight cylinder 110 has a piston rod 111, and the end 1111 of the piston rod 111 is used to engage with the mounting hole 421 of the counterweight assembly 40 (e.g., ...). Figure 3 (As shown) The mounting hole 421 on the mounting column 42, through cooperation with the piston rod 111 of the counterweight cylinder 110, can be mounted on the rear of the turntable 30 to achieve the function of balancing torque and maintaining the stability of the entire vehicle during the lifting operation. The upper surface of the counterweight assembly 40 is also provided with a guide hole (not shown in the figure) for inserting the end 1111 of the piston rod 111 into the guide hole of the counterweight cylinder 110. The guide hole communicates with the mounting hole 421, and the end 1111 of the piston rod 111 connects to the counterweight assembly 40 by entering the mounting hole 421.

[0033] Figure 5 This is a schematic diagram of the electrical connection of the controller in the counterweight self-loading and unloading control system of the crane according to a preferred embodiment of the present invention. Please refer to... Figure 5 The counterweight self-loading and unloading control system provided by the present invention includes a counterweight cylinder 110 (e.g., Figure 3 , 4(As shown), the system includes an interactive device 120, a PLC controller 130, a counterweight cylinder rod chamber pressure sensor 141, a counterweight cylinder rod chamber flow sensor 142, a rotation position detection assembly, a rotation control valve assembly, a counterweight cylinder lifting control valve assembly, a rotation motor inlet flow sensor 150, and a rotation brake valve 180. The rotation position detection assembly includes a first rotation position detection assembly 161. The second rotation position detection component 162, the rotation control valve group including the left rotation control valve 171 and the right rotation control valve 172, the counterweight cylinder lifting control valve group including the counterweight cylinder lifting control valve 191 and the counterweight cylinder lowering control valve 192; the counterweight cylinder 110, the interaction device 120, the counterweight cylinder rod chamber pressure sensor 141, the counterweight cylinder rod chamber flow sensor 142, the rotation motor inlet flow sensor 150, the first rotation position detection component 161, the second rotation position detection component 162, the left rotation control valve 171, the right rotation control valve 172, the rotation brake valve 180, the counterweight cylinder lifting control valve 191 and the counterweight cylinder lowering control valve 192 are all connected to the PLC controller 130 via signals.

[0034] The interactive device 120 is primarily responsible for human-machine interaction, used to issue commands to start or stop the automatic installation of the counterweight, and to issue commands to start or stop the automatic disassembly of the counterweight. It also displays the inlet flow rate of the rotary motor, the pressure value of the rod chamber of the counterweight cylinder, the flow rate of the rod chamber of the counterweight cylinder, the first rotation position signal, the second rotation position signal, and the rotation speed of the turntable 30, and communicates with the PLC controller 130 via a bus. The interactive device 120, for example, is a torque limiter, mainly including operation buttons for inputting commands, a display screen, and other components.

[0035] The PLC controller 130, as the main control unit, is installed in the crane's electrical control box. It is used to receive input signals and bus signals, perform logic calculations, and output control signals to control the operation of the slewing mechanism 20 and the counterweight cylinder 110. It also communicates with the interactive device 120 via bus, receives bus commands from the interactive device 120, and sends relevant information to be displayed on the interactive device 120.

[0036] The rod chamber pressure sensor 141 of the counterweight cylinder is installed in the rod chamber of the counterweight cylinder 110. The rod chamber pressure sensor 141 is used to detect the hydraulic oil pressure in the rod chamber of the counterweight cylinder 110 and generate the rod chamber pressure value data of the counterweight cylinder and transmit it to the PLC controller 130.

[0037] The flow sensor 142 of the rod chamber of the counterweight cylinder can be installed on the connecting pipe of the rod chamber of the counterweight cylinder 110. The flow sensor 142 of the rod chamber of the counterweight cylinder is used to detect the hydraulic oil flow in the rod chamber of the counterweight cylinder 110 and generate the flow value data of the rod chamber of the counterweight cylinder to be transmitted to the PLC controller 130.

[0038] When the pressure of the hydraulic oil in the rod chamber of the counterweight cylinder 110 reaches a certain high pressure value and the hydraulic oil flow rate in the connecting pipe of the rod chamber of the counterweight cylinder 110 is very small, it indicates that the piston rod 111 of the counterweight cylinder 110 has retracted to the highest point; when the pressure of the hydraulic oil in the rod chamber of the counterweight cylinder 110 is very small and lower than a certain low pressure value and the hydraulic oil flow rate in the connecting pipe of the rod chamber of the counterweight cylinder 110 is very small, it indicates that the piston rod 111 of the counterweight cylinder 10 has fully extended to the lowest point.

[0039] In this embodiment, the extension and retraction of the piston rod 111 of the counterweight cylinder 110 can be determined by detecting the pressure and flow rate in the rod chamber of the counterweight cylinder. In other embodiments, a length sensor can be used to detect and determine the extension length of the piston rod 111, or image recognition and other methods can be used for determination.

[0040] Figure 6 This is a schematic diagram showing the connection between the slewing motor, slewing reducer, and slewing gear ring in a crane according to a preferred embodiment of the present invention. Figure 7 This is a schematic diagram of the slewing motor and slewing reducer in a crane according to a preferred embodiment of the present invention. Please refer to it as well. Figure 6 and Figure 7 The slewing mechanism 20 includes a slewing motor 21, a slewing reducer 22, and a slewing gear ring 23. The slewing motor 21 has an oil inlet 211 and an oil outlet 212, which are respectively connected to hydraulic oil pipes. The slewing motor 21 and the slewing reducer 22, as well as the slewing reducer 22 and the slewing gear ring 23, transmit power through gear meshing.

[0041] A rotary motor inlet flow sensor 150 is installed at the inlet (i.e., oil inlet 211) of the rotary motor 21 to detect the flow rate of hydraulic oil at the inlet end of the rotary motor 21 and generate rotary motor inlet flow rate data, which is then transmitted to the PLC controller 130. Based on the rotary motor inlet flow rate and relevant structural parameters, the rotation speed of the turntable 30 can be calculated, as follows: Rotary motor speed

[0042] speed reducer

[0043] Rotation speed

[0044] Rotation speed

[0045] In the above formula: q represents the inlet flow rate of the rotary motor, in mL / min; V0 represents the displacement of the rotary motor, in mL; This represents the volumetric efficiency of the rotary motor. This represents the speed ratio of the rotary reducer; This represents the number of teeth on the gear that meshes with the gear ring in the rotary reducer; Represents the number of teeth on the gear ring; , , The unit is r / min. The unit is ° / s.

[0046] Left rotation control valve 171, right rotation control valve 172, and rotation brake valve 180 are all mounted on the turntable 30 and electrically connected to the output port of the PLC controller 130. The rotation control valve group is used to control the rotation of the turntable 30. Specifically, left rotation control valve 171 mainly controls the left rotation of the turntable 30, right rotation control valve 172 mainly controls the right rotation of the turntable 30, and rotation brake valve 180 is used to brake the turntable 30 to stop its rotation. Specifically, when left rotation control valve 171 and rotation brake valve 180 are energized, the turntable 30 rotates to the left; when right rotation control valve 172 and rotation brake valve 180 are energized, the turntable 30 rotates to the right. In this embodiment, left rotation control valve 171 and right rotation control valve 172 are both electro-proportional valves. The rotation speed can be controlled by PID regulation. The PLC controller 130 can adjust the output current of the left rotation control valve 171 and the right rotation control valve 172 in real time according to the calculated rotation speed value, so as to maintain the rotation speed of the turntable 30 within a preset stable low speed range, so that it can stop in time when it reaches the preset position, without exceeding the deviation value, and ensuring the normal operation of counterweight self-installation and self-disassembly.

[0047] Please refer again. Figure 1 The boom 10 is fixed to the turntable 30 and connected to the turntable 30 by a pin. When the turntable 30 rotates, the boom 10 also rotates. The counterweight cylinder 110 is installed at the rear of the turntable 30 and is also connected to the turntable 30 by a pin. The counterweight cylinder lifting control valve group is used to control the rise or fall of the counterweight cylinder 110. The rise and fall of the end 1111 of the piston rod 111 of the counterweight cylinder 110 are controlled by the counterweight cylinder lifting control valve 191 and the counterweight cylinder falling control valve 192, respectively. The counterweight cylinder lifting control valve 191 and the counterweight cylinder falling control valve 192 are both solenoid valves, installed on the turntable 30, and electrically connected to the output port of the PLC controller 130. The end 1111 of the piston rod 111 is used to attach the counterweight assembly 40. The rising and falling of the end 1111 of the piston rod 111 drives the lifting and lowering of the counterweight assembly 40. This is exactly what is used for the installation and removal of the counterweight assembly 40.

[0048] Figure 8 This is a schematic diagram of the arrangement of the slewing position detection proximity switches in the counterweight self-loading and unloading control system of the crane according to a preferred embodiment of the present invention. Please refer to... Figure 8 The rotation position detection component generates a rotation position signal and transmits it to the PLC controller 130 when the turntable 30 rotates to a preset position. The first rotation position detection component 161 and the second rotation position detection component 162 are both mounted on the frame, spaced apart around the outer periphery of the rotation gear ring 23, and higher than the rotation gear ring 23. A sensor 163 is arranged circumferentially on the turntable 30 along the rotation gear ring 23. In this embodiment, the first rotation position detection component 161, the second rotation position detection component 162, and the sensor 163 cooperate to detect whether the turntable 30 has rotated to the preset position. However, this is not a limitation; if the first rotation position detection component 161 and the second rotation position detection component 162 can directly identify the preset position, the sensor 163 may not be required. For example, the first rotation position detection component 161 and the second rotation position detection component 162 can be angle sensors. By detecting the angle of the turntable 30 relative to the frame, the current position of the turntable 30 can be identified. It is understood that other components with the same function can also be used.

[0049] Specifically, the length of the sensing element 163 is s=θR, where R is the radius from the sensing element to the center of the rotary gear ring 23, and θ is the allowable rotation angle deviation that ensures the positioning pin on the frame and the positioning hole at the bottom of the counterweight assembly 40 can cooperate. The sensing element 163 is used to cooperate with the first rotation position detection assembly 161 and the second rotation position detection assembly 162 for detection sensing. When the first rotation position detection component 161 is directly facing the middle position of the sensor 163, it is the first rotation preset position. The first rotation position detection component 161 generates a first rotation position signal and transmits it to the PLC controller 130. At this time, the counterweight cylinder 110 can pass through the guide hole at the top of the counterweight component 40 and extend and retract normally without interfering with the counterweight component 40. When the second rotation position detection component 162 is directly facing the middle position of the sensor 163, it is the second rotation preset position. The second rotation position detection component 162 generates a second rotation position signal and transmits it to the PLC controller 130. At this time, the end 1111 of the piston rod 111 of the counterweight cylinder 110 can be engaged with the hook hole 421 on the counterweight component 40. The counterweight cylinder 110 can be retracted to lift the counterweight component 40. Alternatively, the counterweight cylinder 110 can be extended, and the positioning hole at the bottom of the counterweight component 40 can also be engaged with the positioning pin on the frame.

[0050] The first rotation position detection component 161, the second rotation position detection component 162, and the sensor 163 can be configured into multiple groups, with each group of the first rotation position detection component 161, the second rotation position detection component 162, and the sensor 163 corresponding to different preset counterweight loading and unloading positions.

[0051] Counterweight self-installation refers to the process of lowering the piston rod 111 of the counterweight cylinder 110 and hooking it with the counterweight assembly 40 (i.e., connecting them to each other) and then raising the counterweight assembly 40. Figure 9 This is the flow chart for the counterweight self-installation control. Please refer to it. Figure 9 After clicking the counterweight self-installation button on the interactive device 120, a confirmation prompt box will pop up to confirm that the counterweight component 40 is not actually attached to the piston rod 111 of the current counterweight cylinder 110 and that the piston rod 111 of the counterweight cylinder 110 has risen to the correct position. After confirmation, the interactive device 120 sends the instruction to the PLC controller 130, and the PLC controller 130 starts running the counterweight self-installation control program to automatically install the counterweight.

[0052] Specifically, after receiving the counterweight self-installation command, the PLC controller 130 waits for 2 seconds and then determines whether the first rotation position detection component 161 has sensed a signal (i.e., whether the PLC controller 130 has received the first rotation position signal). If the first rotation position detection component 161 has not sensed a signal, the turntable 30 begins to rotate to the right until the first rotation position detection component 161 senses a signal (i.e., until the turntable 30 rotates to the first rotation preset position). If a signal is sensed (i.e., when the PLC controller 130 receives the first rotation position signal), it means that the turntable 30 has rotated to the first rotation preset position. At this time, the piston rod 111 of the counterweight cylinder 110 is in the descending position, the counterweight cylinder descending control valve 192 is energized, and the counterweight cylinder 10 and piston rod 111 extend and descend. When the pressure value of the rod chamber of the counterweight cylinder is less than the second preset pressure value P2 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, it is determined that the piston rod 111 of the counterweight cylinder 110 has descended to the bottom, and then the turntable 30 rotates to the right. When the second rotation position detection component 162 senses the signal, it indicates that the rotation position of the turntable 30 has reached the second preset rotation position, which is the calibrated counterweight installation and removal position. The end 1111 of the piston rod 111 of the counterweight cylinder 110 has rotated into the mounting hole 421 of the counterweight component 40. At this time, the counterweight cylinder lifting control valve 191 is energized, and the piston rod 111 of the counterweight cylinder 110 rises to the point where the pressure value of the rod chamber of the counterweight cylinder is greater than the first preset pressure value P1 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, thus completing the self-installation of the counterweight.

[0053] Counterweight self-disassembly refers to the process in which, when the counterweight component 40 is already attached to the counterweight cylinder 110, the counterweight component 40 is automatically lowered to a designated position and the counterweight cylinder 110 is separated from the counterweight component 40, and then the piston rod 111 of the counterweight cylinder 110 is raised. Figure 10 This is the flow chart for the counterweight self-disassembly control. Please refer to it. Figure 10 The counterweight self-disassembly command is also issued through the interactive device 120, and the operation process is similar to that of the counterweight self-installation.

[0054] Specifically, after receiving the counterweight self-disassembly command, the PLC controller 130 will wait for 2 seconds and then determine whether the second rotation position detection component 162 has sensed the signal. If no signal is sensed, the turntable 30 will start to rotate to the right until the second rotation position detection component 162 senses the signal. If the second rotation position detection component 162 senses the signal, it means that the rotation position of the turntable 30 has reached the second rotation preset position, which is the counterweight disassembly / assembly position. At this time, the counterweight cylinder descent control valve 192 is energized, and the piston rod 111 of the counterweight cylinder 110 extends and descends. When the pressure value of the rod chamber of the counterweight cylinder is less than the second preset pressure value P2 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, it is considered that the descent is in place, and the turntable 30 begins to rotate to the left. When the first rotation position detection component 161 senses the signal, it indicates that the turntable 30 has rotated to the first rotation preset position, and the piston rod 111 of the counterweight cylinder 110 has rotated out of the mounting hole 421 of the counterweight component 40. At this time, the counterweight cylinder elution control valve 191 can be energized, and the piston rod 111 of the counterweight cylinder 110 retracts and rises. When the pressure value of the rod chamber of the counterweight cylinder is greater than the first preset pressure value P1 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, the counterweight self-disassembly is completed.

[0055] During the self-loading and unloading (i.e., self-installation and self-disassembly) of the counterweight, if the automatic loading and unloading is interrupted or stopped, it can be manually operated by remote control, or a manual operation interface can be set on the interactive device 120 to control the lifting and lowering of the piston rod 111 of the counterweight cylinder 110 and the rotation can be controlled by the action handle; or a relevant operation interface can be set on the mobile APP to control the lifting and lowering of the piston rod 111 of the counterweight cylinder 110 and the rotation of the turntable 30.

[0056] In this invention, the rotation direction of the turntable 30 is not limited to the directions described above. For example, when the position of the mounting hole 421 of the counterweight component 40 is opposite to the position of the guide hole when the counterweight cylinder 110 is inserted into the counterweight component 40, the rotation direction of the turntable 30 should also be reversed when the end 111 of the piston rod 111 of the counterweight cylinder 110 moves into / out of the mounting hole 42 from the guide hole. After the counterweight self-installation and counterweight self-disassembly commands are issued, the rotation direction of the turntable 30 when searching for the first and second preset rotation positions during the rotation process can also be optimized by the shortest path. For example, when the left rotation path is closer, left rotation is selected, and when the right rotation path is closer, right rotation is selected.

[0057] Compared with existing technologies, this invention achieves self-installation and self-disassembly of the counterweight without human intervention, greatly improving the convenience of counterweight operation and reducing manual labor intensity. It also avoids structural component interference and collision problems caused by potential deviations in the zero-position calibration or accumulated errors in the rotary encoder, as seen in existing technologies. Specifically, it employs a pressure sensor and a flow sensor in the rod chamber of the counterweight cylinder to determine whether the piston rod of the counterweight cylinder has reached its designated position. Furthermore, a flow sensor at the rotary motor inlet measures the flow rate of the hydraulic oil at the rotary motor inlet and calculates the rotary speed in real time based on relevant system parameters. The controller adjusts the valve openings of the left and right rotary control valves by controlling the output current of the left and right rotary control valves, thereby controlling the flow rate and adjusting the rotary speed. A proximity switch is used to locate and detect the rotational position during installation and disassembly. The fully automatic control method enables automatic loading and unloading of the counterweight.

[0058] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for controlling the self-loading and unloading of counterweights, characterized in that, include: The hydraulic oil pressure in the rod chamber of the counterweight cylinder (110) is detected and a pressure value of the rod chamber of the counterweight cylinder is generated. The hydraulic oil flow rate in the rod chamber of the counterweight cylinder (110) is detected and a flow rate value of the rod chamber of the counterweight cylinder is generated. The piston rod (111) of the counterweight cylinder (110) is controlled to descend. When the pressure value of the rod chamber of the counterweight cylinder is less than the second pressure preset value P2 and the flow rate value of the rod chamber of the counterweight cylinder is less than the flow rate preset value Q1, the turntable (30) is controlled to rotate so that the counterweight cylinder (110) is engaged or disengaged from the counterweight assembly (40). The piston rod (111) of the counterweight cylinder (110) is controlled to rise again until the pressure value of the rod chamber of the counterweight cylinder is greater than the first pressure preset value P1 and the flow rate value of the rod chamber of the counterweight cylinder is less than the flow rate preset value Q1.

2. The counterweight self-loading and unloading control method as described in claim 1, characterized in that, During the self-installation of the counterweight, the turntable (30) is controlled to rotate until the first preset rotation position, and then the piston rod (111) of the counterweight cylinder (110) is controlled to descend. When the pressure value of the rod chamber of the counterweight cylinder is less than the second preset pressure value P2 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, the turntable (30) is controlled to rotate until the second preset rotation position so that the counterweight cylinder (110) is connected to the counterweight assembly (40). Then the piston rod (111) of the counterweight cylinder (110) is controlled to rise again until the pressure value of the rod chamber of the counterweight cylinder is greater than the first preset pressure value P1 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1. During the self-disassembly of the counterweight, the turntable (30) is controlled to rotate until the second preset rotation position, and then the piston rod (111) of the counterweight cylinder (110) is controlled to descend. When the pressure value of the rod chamber of the counterweight cylinder is less than the second preset pressure value P2 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1, the turntable (30) is controlled to rotate until the first preset rotation position so that the counterweight cylinder (110) is separated from the counterweight assembly (40). Then the piston rod (111) of the counterweight cylinder (110) is controlled to rise again until the pressure value of the rod chamber of the counterweight cylinder is greater than the first preset pressure value P1 and the flow rate value of the rod chamber of the counterweight cylinder is less than the preset flow rate value Q1.

3. The counterweight self-loading and unloading control method as described in claim 1 or 2, characterized in that, The flow rate of hydraulic oil at the inlet of the rotary motor (21) is detected and the inlet flow rate of the rotary motor is generated. The rotary speed of the turntable (30) is calculated using the inlet flow rate of the rotary motor, and the rotary speed of the turntable (30) is adjusted in real time to keep the rotary speed of the turntable (30) within the preset speed range.

4. The counterweight self-loading and unloading control method as described in claim 3, characterized in that, Before the counterweight is installed, confirm that the counterweight assembly (40) is not attached to the piston rod (111) of the counterweight cylinder (110) and that the piston rod (111) of the counterweight cylinder (110) has risen into place.

5. A counterweight self-loading and unloading control system, characterized in that, The system includes a PLC controller (130), and a counterweight cylinder rod chamber pressure sensor (141), a counterweight cylinder rod chamber flow sensor (142), a rotation position detection assembly, a rotation control valve assembly, and a counterweight cylinder lifting control valve assembly, all connected to the PLC controller (130). The counterweight cylinder rod chamber pressure sensor (141) is used to detect the hydraulic oil pressure in the rod chamber of the counterweight cylinder (110) and generate a counterweight cylinder rod chamber pressure value, which is then transmitted to the PLC controller (130). The counterweight cylinder rod chamber flow sensor (142) is used to detect the pressure of the counterweight cylinder rod chamber. The flow rate of hydraulic oil in the rod chamber of the counterweight cylinder (110) is measured, and the flow rate value of the rod chamber of the counterweight cylinder is generated and transmitted to the PLC controller (130); the rotation position detection component is used to generate a rotation position signal and transmit it to the PLC controller (130) when the turntable (30) rotates to a preset position; the rotation control valve group is used to control the rotation of the turntable (30); the counterweight cylinder lifting control valve group is used to control the rise or fall of the counterweight cylinder (110); the PLC controller (130) has a built-in counterweight self-loading and unloading control method as described in claim 1 or 2.

6. The counterweight self-loading and unloading control system as described in claim 5, characterized in that, The rotation position detection component includes a first rotation position detection component (161) and a second rotation position detection component (162). The first rotation position detection component (161) is used to generate a first rotation position signal and transmit it to the PLC controller (130) when the turntable (30) rotates to a first preset rotation position. The second rotation position detection component (162) is used to generate a second rotation position signal and transmit it to the PLC controller (130) when the turntable (30) rotates to a second preset rotation position. The rotary control valve group includes a left rotary control valve (171) and a right rotary control valve (172). The left rotary control valve (171) is used to control the rotary table (30) to rotate to the left, and the right rotary control valve (172) is used to control the rotary table (30) to rotate to the right. The counterweight cylinder lifting control valve group includes a counterweight cylinder lifting control valve (191) and a counterweight cylinder lowering control valve (192). The counterweight cylinder lifting control valve (191) is used to control the piston rod (111) of the counterweight cylinder (110) to rise, and the counterweight cylinder lowering control valve (192) is used to control the piston rod (111) of the counterweight cylinder (110) to fall.

7. The counterweight self-loading and unloading control system as described in claim 6, characterized in that, It also includes a rotary motor inlet flow sensor (150) connected to the PLC controller (130) via signal. The rotary motor inlet flow sensor (150) is used to detect the flow rate of hydraulic oil at the inlet end of the rotary motor (21) and generate a rotary motor inlet flow rate value which is transmitted to the PLC controller (130). The PLC controller (130) is also used to calculate the rotation speed of the turntable (30) using the rotary motor inlet flow rate value and to adjust the rotation speed of the turntable (30) in real time so that the rotation speed of the turntable (30) is kept within a preset speed range.

8. The counterweight self-loading and unloading control system as described in claim 7, characterized in that, It also includes an interactive device (120) connected to the PLC controller (130) via signals. The interactive device (120) is used to issue commands to start or stop the counterweight installation and to start or stop the counterweight disassembly. It is also used to display the pressure value of the rod chamber of the counterweight cylinder, the flow value of the rod chamber of the counterweight cylinder, the first rotation position signal, the second rotation position signal, the inlet flow value of the rotation motor, and the rotation speed of the turntable (30).

9. The counterweight self-loading and unloading control system as described in claim 6, characterized in that, It also includes a sensor (163), the first rotation position detection component (161) cooperates with the sensor (163) to confirm that the turntable (30) has rotated to the first rotation preset position, and the second rotation position detection component (162) cooperates with the sensor (163) to confirm that the turntable (30) has rotated to the second rotation preset position.

10. A crane, characterized in that, Including the counterweight self-loading and unloading control system as described in any one of claims 5-9.

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