Electric control device and equipment for electric compact cranes

Abstract

This application provides an electrical control device and equipment for a compact electric crane, belonging to the field of crane electrical control technology. The electrical control device includes a control console for receiving operating commands; a compact engineering-type drive, including a rectifier unit and at least one inverter unit. The rectifier unit converts AC power into DC power and distributes it to each inverter unit via a DC bus. The inverter unit converts the DC power into controllable AC power output; a permanent magnet synchronous motor connected to the output terminal of the inverter unit; an integrated electrical control cabinet communicatively connected to the control console, including an incoming power supply cabinet and a control cabinet. The incoming power supply cabinet receives and distributes multiple power sources from the hull, and the control cabinet integrates a whole-machine control logic processing unit and hardware control loops; and a liquid cooling heat dissipation device thermally coupled to the drive and the permanent magnet synchronous motor for heat dissipation. The entire electrical control device has a compact and integrated structure, and features efficient energy conversion and precise drive control.

Description

Technical Field

[0001] This application relates to the field of crane electrical control technology, specifically to an electrical control device and equipment for an electric compact crane. Background Technology

[0002] With the development of marine engineering, multi-functional heavy-lift vessels and bulk carriers have placed higher demands on the compactness, efficiency, and environmental friendliness of their cranes.

[0003] However, heavy-duty and bulk cranes generally rely on hydraulic drive systems. Their working principle involves an engine driving a hydraulic pump to generate high-pressure hydraulic fluid, which is then transmitted through complex piping and valve control systems to hydraulic motors or cylinders, ultimately driving the drum and boom. Compared to electric drive systems, hydraulic systems allow for a more compact actuator design due to the smaller size of hydraulic cylinders and motors. This system also boasts relatively low initial costs and provides immense power. However, as operating environments become increasingly complex and environmental requirements become more stringent, the shortcomings of hydraulic systems are becoming increasingly apparent. For example, lengthy piping and multiple energy conversions lead to inefficiency; the presence of large amounts of hydraulic oil poses a continuous risk of leakage and contamination; and system maintenance is extensive, with complex fault diagnosis.

[0004] Today, electric drive systems have become the mainstream trend for heavy-duty and bulk cargo cranes. Their working principle involves directly driving the motor via the crane's frequency converter drive system through the ship's electrical grid. The entire electric drive system is highly efficient, enabling extremely precise speed and position control, with fast response and high repeatability. Furthermore, the motors and electrical components are essentially maintenance-free or have very long service life. There are no hydraulic oil leaks, the system is clean, highly reliable, and fault diagnosis is more intuitive. However, current electric drive systems are relatively large and cannot meet the current demand for a more compact and efficient overall system. Summary of the Invention

[0005] In view of this, this application provides an electrical control device and equipment for a compact electric crane, which solves the problem that the electric drive system is too large and cannot meet the current demand for a compact and efficient whole system.

[0006] To solve the above-mentioned technical problems, this application adopts the following technical solution:

[0007] In a first aspect, this application provides an electrical control device for an electric compact crane, comprising:

[0008] A compact engineering driver includes a rectifier unit and at least one inverter unit, the rectifier unit for converting AC power to DC power and distributing it to each of the inverter units via a DC bus, the inverter units for converting the DC power to a controllable AC power output, and the braking unit for resistor braking.

[0009] A permanent magnet synchronous motor is connected to the output terminal of the inverter unit;

[0010] The control panel is used to receive operation commands;

[0011] An integrated electrical control cabinet, which is communicatively connected to the control console, includes an incoming power supply cabinet and a control cabinet. The incoming power supply cabinet is used to receive and distribute multiple power sources from the hull. The control cabinet integrates a whole-machine control logic processing unit and a hardware control loop, which is used to receive and process the operation commands and control the driver to output the corresponding power supply frequency and voltage value to the corresponding synchronous motor to drive the operation of each mechanism of the crane.

[0012] A liquid cooling heat dissipation device is thermally coupled to the driver and the permanent magnet synchronous motor for heat dissipation.

[0013] As one embodiment of this application, the inverter unit has a one-piece molded housing and an integrated liquid cooling unit inside.

[0014] As an embodiment of this application, the inverter unit integrates a vector control algorithm module, which is used to output corresponding alternating current values ​​based on the start and stop of the crane and load fluctuations, so as to control the torque of the permanent magnet synchronous motor.

[0015] As an embodiment of this application, the rectifier unit is an active front-end rectifier module; the electronic control device further includes a braking resistor and / or an energy storage device disposed on the hull side; the braking resistor is used to consume the regenerative electrical energy generated by the crane, and the energy storage device is used to store the regenerative electrical energy fed back by the crane.

[0016] As one embodiment of this application, the energy storage device is one or more combinations of a supercapacitor, a battery pack, or a flywheel energy storage device.

[0017] As one embodiment of this application, the liquid cooling heat dissipation system includes a coolant circulation unit, which circulates coolant through a liquid cooling heat dissipation plate that is in close contact with the driver and the permanent magnet synchronous motor.

[0018] As an embodiment of this application, the multi-source power supply includes a main power supply, an auxiliary power supply, and an emergency power supply; the incoming power supply cabinet is equipped with a multi-level protection circuit breaker, which is connected to the main power supply and the auxiliary power supply respectively. The incoming power supply cabinet is used to distribute the main power supply to the driver and the control cabinet, distribute the auxiliary power supply to the lighting equipment and the heating auxiliary equipment, and distribute one branch of the emergency power supply to the emergency lighting equipment and the crane uninterruptible power supply, and another branch to the communication equipment between the crane and the ship hull.

[0019] As an embodiment of this application, the integrated electrical control cabinet is a cabinet in which the incoming line cabinet and the control cabinet are connected; the main back panel inside the incoming line cabinet is provided with at least a molded case switch, a miniature circuit breaker and a contactor, and the two sides of the incoming line cabinet are provided with branch terminals and terminal blocks to facilitate internal branching and external incoming lines;

[0020] The main back panel inside the control cabinet is equipped with at least an industrial-grade programmable logic controller, signal module, multi-channel electronic circuit breaker, power module, relay and control circuit. Terminal blocks for external wiring are provided on both sides of the inside of the control cabinet.

[0021] Secondly, this application also provides a lifting device, including the electrical control device of the electric compact crane described in the first aspect embodiment.

[0022] The above-mentioned technical solution of this application has at least one of the following beneficial effects:

[0023] The electric control device of the compact electric crane according to an embodiment of this application achieves compact integration, efficient energy conversion, and precise drive control of the electric control system through the synergistic action of the control panel, driver, permanent magnet synchronous motor, and integrated electrical control cabinet. Therefore, this device effectively solves the problems of low efficiency and complex maintenance of traditional hydraulic systems, as well as the size limitations faced by electric drive systems in heavy-duty and bulk cargo lifting applications. Furthermore, this integrated control cabinet design optimizes space utilization and improves the overall compactness of the system. Attached Figure Description

[0024] Figure 1 This is a structural block diagram of the electrical control device of the electric compact crane according to an embodiment of this application;

[0025] Figure 2 This is another structural block diagram of the electrical control device of the electric compact crane according to an embodiment of this application;

[0026] Figure 3A This is a schematic diagram of the linkage table according to an embodiment of this application;

[0027] Figure 3B This is a structural schematic diagram of the linkage table from another angle according to an embodiment of this application;

[0028] Figure 4 This is a schematic diagram of the power distribution system of the electronic control device according to an embodiment of this application;

[0029] Figure 5 This is a single-line schematic diagram corresponding to the driver in an embodiment of this application.

[0030] Figure label:

[0031] Electrical control device 100;

[0032] Linkage unit 110; Left linkage unit 111; Right linkage unit 112; Seat 113; Inclined surface 114;

[0033] Driver 120; Rectifier unit 121; Inverter unit 122;

[0034] 130 permanent magnet synchronous motor;

[0035] Integrated electrical control cabinet 140; incoming power supply cabinet 141; control cabinet 142;

[0036] Liquid cooling heat dissipation device 150. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the described embodiments of this application are within the scope of protection of this application.

[0038] To facilitate understanding of the technical solution of this application, the technical problems of this application will be further explained below.

[0039] As described in the background above, traditional heavy-duty and bulk cargo cranes generally rely on hydraulic drive systems. These systems have complex operating principles, low energy conversion efficiency, and high operating costs. Furthermore, the presence of hydraulic oil poses a continuous risk of leakage and pollution, and system maintenance is extensive and fault diagnosis is complex. With increasingly complex operating scenarios and stringent environmental requirements, the shortcomings of these hydraulic systems are becoming increasingly apparent. Although electric drive systems have become the mainstream trend, and the entire system offers advantages such as precise speed and position control and high repeatability, the compact design of the electrical control system is particularly crucial due to the overall size limitations of heavy-duty and bulk cargo cranes. The overall architecture of the electrical control system directly affects the overall size of the crane.

[0040] Based on the aforementioned technical problems, this application proposes an electrical control device for a compact electric crane. This device employs a pure electric drive system, transmitting power from the ship's electrical grid via a central current collector to the drive unit and integrated electrical control cabinet to achieve frequency conversion and directly drive the motor. Furthermore, this electric drive system can work in conjunction with a water-cooled permanent magnet synchronous motor to reduce size, enabling precise speed and position control of the actuator. Moreover, the overall device is not limited by the space constraints of heavy-duty and bulk cargo cranes, allowing for a more compact overall electrical control device structure.

[0041] The electrical control device of the electric compact crane according to an embodiment of this application is described below with reference to the accompanying drawings.

[0042] refer to Figure 1 and Figure 2 , Figure 1 A structural block diagram of the electrical control device (hereinafter referred to as the electrical control device) of the electric compact crane according to an embodiment of this application is shown. Figure 2 Another structural block diagram of the electrical control device of the electric compact crane according to an embodiment of this application is shown.

[0043] like Figure 1 As shown, the electrical control device 100 includes a control panel 110, a driver 120, a permanent magnet synchronous motor 130, and an integrated electrical control cabinet 140.

[0044] The integrated electrical control cabinet 140 is communicatively connected to the control panel 110. The control panel 110 can receive user operation commands, such as starting the crane via the function buttons and master handle of the control panel 110. The integrated electrical control cabinet 140 then identifies the operation commands and controls the AC power output of the driver 120 to drive the permanent magnet synchronous motor 130 to operate the crane.

[0045] like Figure 2 As shown, the integrated electrical control cabinet 140 includes an incoming power supply cabinet 141 and a control cabinet 142. The incoming power supply cabinet 141 is used to receive and distribute multiple power sources from the hull. For example, the multiple power sources are the power grid of the hull and may include multiple circuits with different voltage values. These circuits can provide power to the electrical control device and use the power to drive the permanent magnet synchronous motor 130 to realize the operation of equipment such as cranes at the execution end.

[0046] The control cabinet 142 integrates a whole-machine control logic processing unit and hardware control loop to receive operation commands issued by the control console 110. For example, the control cabinet 142 may contain an industrial-grade programmable logic controller or embedded controller, which runs a preset control algorithm to parse operation commands and generate corresponding control signals according to the current state and operation requirements of the crane. Thus, the control cabinet 142 controls the driver 120 to output the corresponding output power frequency and voltage value to the corresponding permanent magnet synchronous motor 130 to drive the crane's various mechanisms. For example, when a lifting command is received, the control cabinet 142 receives and processes the master control handle signal from the control console 110, sends a command to the driver 120, and calculates the required speed and torque of the permanent magnet synchronous motor 130. This causes the inverter unit 122 to output AC power of the corresponding frequency and voltage, thereby driving the permanent magnet synchronous motor 130 to drive the drum mechanism to lift the load, etc., enabling precise control of the torque of the permanent magnet synchronous motor 130 and achieving precise control of the crane and other equipment.

[0047] Furthermore, the driver 120 shares a main power supply with the integrated electrical control cabinet 140, and the driver 120 may include a rectifier unit 121 and an inverter unit 122. The rectifier unit 121 is used to convert AC power to DC power. For example, an uncontrolled rectifier bridge composed of diodes or a controllable element such as an IGBT can be used to convert the input AC power from the hull into DC power. This DC power is then distributed to each inverter unit 122 via a DC bus. The inverter unit 122 is used to convert the DC power into controllable AC power output to the permanent magnet synchronous motor 130. For example, a voltage-source inverter composed of insulated gate bipolar transistors can be used to convert the DC power into AC power with adjustable frequency and voltage through pulse width modulation technology. The permanent magnet synchronous motor 130 is configured to receive the controllable AC power from the inverter unit 122 and convert it into mechanical energy to drive the operation of the crane's various mechanisms. For example, the permanent magnet synchronous motor 130 can be directly connected to the hoisting mechanism, luffing mechanism, or slewing mechanism of the crane. Through its precise speed and torque control, it enables smooth lifting and lowering of the crane load. This design structure not only achieves efficient energy conversion and precise drive of the entire electrical control device, but also achieves compact integration of the entire electrical control system, thereby overcoming the shortcomings of traditional hydraulic systems such as low efficiency, complex maintenance, and size limitations.

[0048] Furthermore, the driver or permanent magnet synchronous motor may generate a large amount of heat during operation, leading to insufficient heat dissipation and affecting the performance and stability of the device. Therefore, in the embodiments of this application, the electronic control device also includes a liquid cooling heat dissipation device, which is thermally coupled to the driver and / or permanent magnet synchronous motor. The coupling through the liquid cooling heat dissipation device can not only solve the heat dissipation problem of the entire device, but also greatly reduce the overall space of the electronic control device.

[0049] According to the embodiments of this application, the electrical control device 100, through the synergistic action of the linkage 110, the driver 120, the permanent magnet synchronous motor 130, the liquid cooling heat dissipation device, and the integrated electrical control cabinet 140, achieves compact integration, efficient energy conversion, and precise drive control of the electrical control system. Thus, this device effectively solves the problems of low efficiency and complex maintenance of traditional hydraulic systems, as well as the size limitations faced by electric drive systems in heavy-duty and bulk cargo lifting applications. Its integrated control cabinet design optimizes space utilization and improves the overall compactness of the system; the efficient energy conversion mechanism reduces energy loss; and the precise motor drive control ensures the response speed and positioning accuracy of the crane operation, thereby improving the operational efficiency and reliability of heavy-duty and bulk cargo lifting.

[0050] In some embodiments, this liquid cooling device utilizes a liquid, such as a water-glycol mixture, as a heat transfer medium to absorb and remove heat. The thermal coupling method ensures that heat can be efficiently transferred from the heat-generating component to the liquid cooling device. This cooling method effectively absorbs the heat generated by the heat-generating component.

[0051] In some embodiments, the liquid cooling heat dissipation device can adopt an indirect liquid cooling method, that is, by installing a metal plate with good thermal conductivity on the surface of the heat-generating component, and then allowing the coolant to flow through the flow channel inside the metal plate, thereby transferring heat from the heat-generating component to the coolant; or, it can adopt an immersion liquid cooling method, that is, directly immersing the heat-generating component in an insulating coolant, with the coolant in direct contact with the heat-generating component, absorbing heat through convection and phase change.

[0052] In some embodiments, the compact engineered driver 120 may also include a braking unit for resistive braking, which can effectively dissipate excess energy during deceleration and braking.

[0053] In some embodiments, the integrated electrical control cabinet 140 is a combined cabinet of incoming power supply cabinet 141 and control cabinet 142, eliminating the need for cross-cabinet cable connections. The main backplane of the incoming power supply cabinet 141 primarily houses molded case switches, miniature circuit breakers, and contactors. In actual operation, power distribution can be planned according to requirements. Branch terminals and terminal blocks on both sides of the incoming power supply cabinet 141 facilitate internal branching and external wiring. The main backplane of the control cabinet 142 is equipped with at least an industrial-grade programmable logic controller, signal modules, multi-channel electronic circuit breakers, power modules, relays, and control circuits. Terminal blocks for external wiring are located on both sides of the interior of the control cabinet 142. This structure further reduces the overall space occupied by the device.

[0054] In some embodiments, the control panel 110 can integrate multiple components. For example, the control panel 110 can be configured as an operation panel consisting of a series of physical buttons and switches, allowing the operator to issue operational commands such as lifting and lowering by pressing buttons or toggling switches. For instance, a handle for controlling lifting or lowering can be provided, along with multiple buttons for auxiliary functions such as lighting and alarms. In another implementation, the control panel can employ a touchscreen interface, allowing the operator to input operational commands by tapping or swiping on the screen.

[0055] refer to Figure 3A and 3B , Figure 3A A schematic diagram of the linkage table 110 according to an embodiment of this application is shown. Figure 3B This paper presents a structural schematic diagram of the linkage table 110 from another angle according to an embodiment of this application.

[0056] like Figure 3A and 3BAs shown, the linkage table 110 may include an integrated left linkage table 111 and a right linkage table 112. The table surface of the left linkage table 111 is an inclined surface 114. This inclined surface 114 can be achieved by the left linkage table itself having a preset tilt angle, for example, by integral molding or welding, or by connecting it to the base through an adjustable support structure, allowing the tilt angle to be adjusted within a certain range. Auxiliary function operating components are arranged on the inclined surface 114. For example, the linkage table may integrate function buttons, selection switches, operating handles, and indicator lights, and the switches and buttons related to the auxiliary functions are arranged on the inclined surface 114, while the operating handles can be arranged on the main table surfaces of the left and right linkage tables respectively, for operating the mechanism.

[0057] Furthermore, the right linkage platform 112 can be configured to be rotatable and height-adjustable, facilitating operator access and providing ample space for personnel passage. In some feasible implementations, this rotating structure can be achieved by incorporating a rotary bearing or turntable mechanism at the bottom of the right linkage platform, enabling 360-degree rotation or rotation within a specific angle range on the horizontal plane; alternatively, a rotating base with a locking mechanism can be used, allowing the operator to fix the right linkage platform at a selected angle. Simultaneously, height adjustment is possible through embedded bearings and the locking device. This integration of structures facilitates operator control of the crane via the linkage platform and further integrates the overall device.

[0058] In some embodiments, the left control console 111 can be designed as a box-type structure, integrating a power distribution module and a signal acquisition module. The power distribution module distributes power to the various electronic components and operating devices within the control console and may include overload protection and short-circuit protection functions. It can be a compact box design integrating circuit breakers, fuses, relays, and terminals, or it can adopt a modular design. The signal acquisition module receives electrical signals from operating devices such as buttons, handles, and sensors, and converts them into digital signals recognizable by the integrated electrical control cabinet. It can be an interface module, flexibly configurable with digital input / output modules and analog signal modules, and communicates with the integrated electrical control cabinet using a fieldbus interface. In some embodiments, the console surface can be designed as a hinged opening structure, facilitating the installation of the overall components and subsequent equipment maintenance, and providing support for the compact design of the electrical control device.

[0059] By adopting the left linkage 111 and right linkage 112 as an integrated unit, the space waste caused by component separation is significantly reduced, and the operation functions are centrally integrated, thereby improving the overall compactness.

[0060] like Figure 3A As shown, the control panel 110 can also be equipped with an ergonomic seat 113, which can better improve the comfort of workers who operate for long periods of time.

[0061] refer to Figure 4 , Figure 4 A schematic diagram of the power distribution system of the electronic control device according to an embodiment of this application is shown.

[0062] like Figure 4 As shown, for more detailed management of the ship's power supply, the power supply can be divided into three lines to the crane, meaning multiple power supplies can include a main power supply of 440V, an auxiliary power supply of 230V, and an emergency power supply of 230V. The main power supply of 440V is split into two after passing through the central current collector. One line goes to the crane's frequency converter system as the driver power supply, providing power to the drive; the other line goes to the crane's control cabinet power supply, providing power to other equipment. The main power supply refers to the primary power supply during normal ship operation, such as the power from the ship's main generator set. Its characteristics are high power, stability, and reliability, and it is mainly used to drive core loads.

[0063] The 230V auxiliary power supply provides power to the crane's lighting, heaters, and other auxiliary equipment. Auxiliary power supply typically refers to the power supply used by the ship for non-core, auxiliary functions, such as power from the ship's auxiliary generators or shore power. It is characterized by relatively small power output and is used for support equipment.

[0064] A 230V emergency power supply provides emergency lighting power in the event of a crane power failure. An emergency power supply is an independent power source that can automatically or manually activate to provide short-term power to critical equipment when the main or auxiliary power supply fails. Examples include marine emergency generators and battery banks. Its characteristics include high independence and rapid response, ensuring safety and basic functionality in emergencies. For example, the main power supply can be the ship's three-phase AC grid, the auxiliary power supply can be the ship's low-voltage AC grid or DC power supply, and the emergency power supply can be an independent diesel generator set, marine battery bank, or uninterruptible power supply system.

[0065] To ensure the safety of power distribution, the incoming power cabinet 141 is equipped with multi-level protection circuit breakers. Multi-level protection circuit breakers refer to circuit breakers of different types, rated currents, and tripping characteristics installed in the power distribution system according to different protection objects and protection ranges, forming a hierarchical protection system to prevent damage to equipment and personnel caused by faults such as overload, short circuit, and leakage.

[0066] In some embodiments, the main 440V power supply can be supplied to the driver 120 and the incoming power cabinet 141 via a central current collector, providing stable and reliable power to the core power and control system of the crane. For example, the main power supply is led out to the power input terminal of the control cabinet 142 via the branch terminals or busbars inside the incoming power cabinet 141, through corresponding circuit breakers and contactors. Simultaneously, auxiliary power is distributed to lighting and heating auxiliary equipment to provide power for non-core but necessary auxiliary functions on the crane and to isolate auxiliary loads from core loads. For example, the auxiliary power supply is connected to the lighting fixtures and heating auxiliary equipment on the crane via the auxiliary power distribution circuit inside the incoming power cabinet 141, through their respective protective circuit breakers.

[0067] Furthermore, the emergency power supply is distributed in separate circuits. One circuit is allocated to the emergency lighting equipment and the crane's uninterruptible power supply (UPS), ensuring that the crane can maintain basic lighting and critical control system operation even in the event of a main power or auxiliary power failure. For example, the emergency power supply connects to the independent emergency lighting circuit and the crane's UPS input terminal via the emergency power distribution circuit inside the incoming power cabinet 141, through a protective circuit breaker. The other circuit is allocated to the communication equipment between the crane and the ship, ensuring uninterrupted communication between the crane and the ship in emergencies for fault reporting. For example, another circuit of the emergency power supply connects to the power input terminal of the communication module on the crane via an independent circuit inside the incoming power cabinet 141, through a protective circuit breaker.

[0068] The embodiments of this application effectively solve the problems of chaotic power management and insufficient protection by clearly defining power types and optimizing allocation paths. On the one hand, multiple power supplies are clearly divided into main power, auxiliary power, and emergency power, clearly defining the specific classification of power supplies, distinguishing power supplies with different functional requirements, ensuring power isolation between core equipment and auxiliary equipment, avoiding mutual interference, thereby improving the efficiency of power management and the stability of the system. On the other hand, the incoming power cabinet is equipped with multi-level protection circuit breakers, and the multi-level protection circuit breakers are connected to at least the main power and auxiliary power supplies. This configuration provides hierarchical safety protection, which can effectively prevent overload or short circuit risks and significantly enhance the reliability of the system.

[0069] refer to Figure 5 , Figure 5 A single-line schematic diagram corresponding to the driver in an embodiment of this application is shown.

[0070] like Figure 5As shown, the driver 120 includes a rectifier unit 121 and multiple inverter units 122. In one embodiment of this application, the inverter unit corresponding to the higher power motor (the three inverter units on the left side of the figure) can use single-electric control output, while the inverter unit 122 corresponding to the lower power motor can be a dual-electric control output type, capable of driving two motors simultaneously. The inverter unit integrates a vector control algorithm module, which is used to output the corresponding alternating current value based on the start and stop of the crane and load fluctuations to control the torque of the permanent magnet synchronous motor.

[0071] Specifically, the inverter unit 122 is designed as a dual-electrically controlled output type and adopts an engineering-grade inverter module. Through a reinforced housing structure, it features high integration, uses high-reliability aviation connectors, has a small size, and simplifies installation and maintenance. It also boasts high power density, high efficiency, and an IP67 protection rating, effectively preventing dust and splashing liquids from entering and ensuring continuous and stable operation in harsh marine environments. Furthermore, it achieves this by integrating two sets of power output stages and control circuits within a single inverter. Each output stage connects to a separate motor and is driven by independent control logic. This design allows the inverter unit to simultaneously drive two synchronous motors, providing independent and controllable power output to both motors for synchronous or asynchronous operation.

[0072] In some embodiments, the inverter unit housing can be integrally molded from aluminum die casting molds, without a control cabinet metal housing. This independent structure has a small size, which is more conducive to the overall compactness of the electronic control device, and the installation position is flexible. In addition, it integrates a liquid cooling heat dissipation unit for timely heat dissipation.

[0073] Furthermore, the inverter unit 122 integrates a vector control algorithm module, which outputs corresponding alternating current values ​​based on the crane's start / stop and load fluctuations. Specifically, this module collects the speed, position, and current feedback signals of the permanent magnet synchronous motor in real time, and combines them with operating commands. Through algorithms such as coordinate transformation, flux linkage observation, current loop, and speed loop control, along with a 150% / 60s overload capacity, it generates precise current commands to ensure stable and efficient motor operation under various working conditions. For example, when the crane starts, the vector control algorithm module outputs a smoothly increasing current command to avoid impact. When the load suddenly increases, it quickly adjusts the current to provide sufficient torque support. When the load is unloaded, it reduces the current accordingly to avoid overspeed. Ultimately, this module aims to control the torque of the permanent magnet synchronous motor by precisely controlling the phase relationship between the motor's magnetic field and rotor current, achieving direct, rapid, and precise adjustment of the motor's output torque.

[0074] In this embodiment, the rectifier unit 121 is an active front-end rectifier module. The electronic control device 100 also includes a braking resistor and / or energy storage device disposed on the hull side, adaptable to a compact crane configuration, and can also be disposed on the crane side if space permits. The braking resistor is used to consume the regenerative energy generated by the crane, and the energy storage device is connected to the DC bus via the active front-end rectifier module to store the regenerative energy fed back by the crane. Unlike traditional passive rectifiers, the active front-end rectifier module typically employs controllable semiconductor devices (such as IGBTs) and pulse width modulation technology, which can not only efficiently convert AC power to DC power and supply power to the DC bus, but also invert the power on the DC bus back to AC power when the system generates regenerative energy, or perform other processing according to the control strategy.

[0075] By introducing an active front-end rectifier module, combined with a braking resistor and / or energy storage device, this application effectively solves the problem of handling regenerative electrical energy generated during crane operation. The active front-end rectifier module enables bidirectional energy flow, not only efficiently converting AC to DC, but also, when the crane generates regenerative electrical energy, feeding it back to the grid, dissipating it through the braking resistor, or storing it in the energy storage device, depending on system requirements. For example, when the crane brakes or lowers a heavy object, the permanent magnet synchronous motor operates as a generator, producing regenerative electrical energy. At this time, the active front-end rectifier module can precisely control the DC bus voltage to avoid overvoltage. A portion of the regenerative electrical energy can be converted into heat energy and dissipated through the braking resistor, effectively preventing excessive DC bus voltage and ensuring the stable operation of the drive and other equipment. More preferably, another portion of the regenerative electrical energy can be stored in an energy storage device, such as a battery pack or supercapacitor. This stored energy can be released again during subsequent lifting or acceleration operations of the crane to power the permanent magnet synchronous motor, thereby significantly improving the energy utilization efficiency of the entire electronic control device and reducing energy waste. This solution not only ensures the stability and safety of the system, but also reduces operating energy consumption and improves the overall economy of the crane through energy recovery and utilization.

[0076] In some embodiments, the energy storage device is one or more combinations of supercapacitors, battery packs, or flywheel energy storage devices. These energy storage devices achieve a more optimized performance balance within a limited space.

[0077] In some embodiments, the liquid cooling system includes a coolant circulation unit that directs coolant through a liquid-cooled heat sink in close contact with the drive and / or permanent magnet synchronous motor. This constitutes the physical connection between the heat sink and these heat-generating components. The coolant circulation unit drives the flow of coolant. This unit can take various forms; for example, it can be an electric pump, such as a centrifugal pump or a positive displacement pump, that mechanically forces the coolant to circulate within the system. This minimizes thermal resistance and ensures efficient heat transfer from components to the coolant, thereby preventing performance degradation, operational instability, or even equipment failure due to overheating.

[0078] In some embodiments, compared to asynchronous motors, permanent magnet synchronous motors (PMSMs) provide their rotor magnetic field with permanent magnets, eliminating the need for external excitation and fundamentally eliminating rotor excitation losses. They maintain extremely high efficiency across a wide load and speed range. For crane operations involving frequent starts and stops and varying loads, the energy-saving effect is exceptionally significant. Furthermore, when combined with vector control or direct torque control technologies, extremely precise torque and speed control can be achieved. Additionally, for rotary motors, due to their ample upward space, they can be either asynchronous or permanent magnet synchronous motors, offering a high degree of flexibility in selection.

[0079] Preferably, the permanent magnet synchronous motor solution, by using high energy density permanent magnet materials, has high power density, smaller motor size and lighter weight, which perfectly meets the characteristics of the compact space of the crane tower body. The lighter motor also reduces the load on the metal structure, providing space for the lightweight design of the whole machine.

[0080] In summary, the electric control device of the compact electric crane according to the embodiments of this application integrates core components such as a linkage platform for receiving operation commands, a driver for driving the motor, and an integrated electrical control cabinet for implementing the overall control logic. Its compactness is reflected in the high integration and optimized layout of each functional module, minimizing space occupation. For example, modular design can be used to highly integrate electrical components with different functions, or the overall size can be reduced by optimizing internal wiring and heat dissipation structures. Furthermore, the compactness can be further improved by selecting miniaturized, high-performance electronic components. As the core control unit of the lifting equipment, this electric control device is responsible for receiving operation commands, processing control logic, and precisely driving the operation of various mechanisms of the crane, thus laying the foundation for efficient and precise operation of the lifting equipment. In addition, this application also provides a lifting device that integrates an electric control device, effectively solving the challenge of achieving efficient and reliable lifting operation within a limited space. Through this integration method, the electric control device is directly incorporated into the structural framework of the lifting equipment, avoiding additional installation space requirements and complex interface designs, thereby significantly optimizing the overall size of the equipment and ensuring its compactness. Meanwhile, due to its efficient and precise motor control capabilities, the compact design of this electronic control unit allows it to occupy minimal space within the lifting equipment while maintaining high performance and low maintenance requirements. This not only solves the shortcomings of traditional hydraulic systems in terms of size limitations and hydraulic oil leakage contamination, but also achieves faster response speeds and higher repeatability through electric drive, thereby improving the overall operating efficiency and reliability of the lifting equipment.

[0081] It should be noted that all units / modules mentioned in the device embodiments of this application are logical units / modules. Physically, a logical unit / module can be a physical unit / module, a part of a physical unit / module, or a combination of multiple physical units / modules. The physical implementation of these logical units / modules themselves is not the most important factor; the combination of functions implemented by these logical units / modules is the key to solving the technical problems proposed in this application. Furthermore, to highlight the innovative aspects of this application, the above-described device embodiments of this application have not introduced units / modules that are not closely related to solving the technical problems proposed in this application. This does not mean that the above-described device embodiments do not contain other units / modules.

[0082] It should be noted that in the examples and description of this patent, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0083] Although this application has been illustrated and described with reference to certain preferred embodiments thereof, those skilled in the art should understand that various changes in form and detail may be made thereto without departing from the spirit and scope of this application.

Claims

1. An electrical control device for a compact electric crane, characterized in that, include: A compact engineering driver includes a rectifier unit and at least one inverter unit, the rectifier unit for converting AC power into DC power and distributing it to each of the inverter units via a DC bus, the inverter units for converting the DC power into a controllable AC power output; A permanent magnet synchronous motor is connected to the output terminal of the inverter unit; The control panel is used to receive operation commands; An integrated electrical control cabinet, which is communicatively connected to the control console, includes an incoming power supply cabinet and a control cabinet. The incoming power supply cabinet is used to receive and distribute multiple power sources from the hull. The control cabinet integrates a whole-machine control logic processing unit and a hardware control loop, which is used to receive and process the operation commands and control the driver to output the corresponding power supply frequency and voltage value to the corresponding permanent magnet synchronous motor to drive the operation of each mechanism of the crane. A liquid cooling heat dissipation device is thermally coupled to the driver and the permanent magnet synchronous motor for heat dissipation.

2. The electronic control device according to claim 1, characterized in that, The inverter unit has a one-piece molded casing and an integrated liquid cooling heat dissipation unit inside.

3. The electronic control device according to claim 1 or 2, characterized in that, The inverter unit integrates a vector control algorithm module, which is used to output corresponding alternating current values ​​based on the start and stop of the crane and load fluctuations, so as to control the torque of the permanent magnet synchronous motor.

4. The electronic control device according to claim 1, characterized in that, The rectifier unit is an active front-end rectifier module; The electronic control device also includes a braking resistor and / or an energy storage device disposed on the hull side or the crane side. The braking resistor is used to consume the regenerative electrical energy generated by the crane, and the energy storage device is used to store the regenerative electrical energy fed back by the crane.

5. The electronic control device according to claim 4, characterized in that, The energy storage device is one or more of a supercapacitor, a battery pack, or a flywheel energy storage device.

6. The electronic control device according to claim 2, characterized in that, The liquid cooling heat dissipation device includes a coolant circulation unit, which circulates coolant through a liquid cooling heat dissipation plate that is in close contact with the driver and the permanent magnet synchronous motor.

7. The electronic control device according to claim 1, characterized in that, The multiple power supplies include a main power supply, an auxiliary power supply, and an emergency power supply; The incoming power cabinet is equipped with multi-level protection circuit breakers, which are connected to the main power supply and the auxiliary power supply respectively. The incoming power cabinet is used to distribute the main power supply to the driver and the control cabinet, distribute the auxiliary power supply to the lighting equipment and the heating auxiliary equipment, and distribute one emergency power supply to the emergency lighting equipment and the crane uninterruptible power supply, and another to the communication equipment between the crane and the ship.

8. The electronic control device according to claim 1, characterized in that, The integrated electrical control cabinet is a combination of the incoming power supply cabinet and the control cabinet; the main back panel inside the incoming power supply cabinet is equipped with at least a molded case switch, a miniature circuit breaker and a contactor, and the two sides of the incoming power supply cabinet are equipped with branch terminals and terminal blocks; The main back panel inside the control cabinet is equipped with at least an industrial-grade programmable logic controller, signal module, multi-channel electronic circuit breaker, power module, relay and control circuit. Terminal blocks for external wiring are provided on both sides of the inside of the control cabinet.

9. The electronic control device according to claim 1, characterized in that, The linkage unit includes an integrated left linkage unit and a right linkage unit; The left linkage console has a main table and an inclined surface integrated. The main table is equipped with a master control handle and main function operation components, while the inclined surface is equipped with auxiliary function operation components. The left linkage console also integrates a power distribution module and a signal acquisition module. The entire platform of the right linkage console can rotate and rise and fall. The main platform of the right linkage console is equipped with an operating handle. The linkage console communicates with the programmable logic controller in the integrated electrical control cabinet via industrial Ethernet communication to receive the operation signals from the operating handle and buttons in order to control the operation of various mechanisms of the crane.

10. A lifting device, characterized in that, Includes the electrical control device of the electric compact crane as described in any one of claims 1-9.

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