Suspension energy recovery system of hybrid power crane

Abstract

The utility model discloses a suspension energy recovery system of a hybrid power crane, and aims to improve the energy utilization rate of the crane in the using process and reduce the energy consumption. The system mainly comprises key components such as a suspension hydraulic oil cylinder, a first hydraulic valve, a second hydraulic valve, a hydraulic motor, a generator, an alternating-current and direct-current converter and an electric energy storage unit. When the crane carries out lifting operation, the suspension hydraulic oil cylinder can be stretched and retracted, hydraulic oil is guided to flow to the hydraulic motor by controlling the opening and closing state and the opening proportion of the hydraulic valve, and then the generator is driven to generate electric energy. And the generated electric energy is stored in the electric energy storage unit after being subjected to AC-DC conversion by the AC-DC converter, so that the electric energy can be subsequently used by the crane or fed to a power grid. Compared with the prior art, the system has the characteristics of high efficiency, flexibility and intellectualization, the utilization rate of energy can be remarkably improved, the energy consumption is reduced, and a new technical support and a new solution are provided for green development of the engineering machinery industry.

Description

Technical Field

[0001] This utility model relates to the field of engineering machinery technology, specifically to a hybrid power crane suspension energy recovery system. Background Technology

[0002] Hybrid cranes are a new type of product in the construction machinery industry. Their basic principle is similar to that of hybrid vehicles, combining internal combustion engines and electric motors to achieve complementary and optimized energy utilization. However, because cranes are much longer and heavier than trucks, they generate a significant amount of inertial and gravitational potential energy during operation. This energy is often wasted in traditional cranes, resulting in low energy utilization and high energy consumption.

[0003] Specifically, when a crane performs lifting operations, the suspension system moves up and down with the load. During this process, the suspension hydraulic cylinders extend and retract, containing a significant amount of gravitational potential energy. Traditional cranes do not effectively recover and utilize this energy, instead allowing it to dissipate as heat or other forms of energy. This not only wastes energy but also increases the crane's operating costs and environmental burden.

[0004] Therefore, there is an urgent need for a new method for energy recovery in crane suspension systems to effectively recover and utilize this wasted energy, improve the energy efficiency of cranes, reduce energy consumption, and promote the green development of the construction machinery industry. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the above-mentioned technical defects and provide a hybrid power crane suspension energy recovery system.

[0006] To solve the above-mentioned technical problems, the technical solution provided by this utility model is: a hybrid power crane suspension energy recovery system, comprising:

[0007] The suspension hydraulic cylinder has its internal cavity divided into a rod-side chamber and a rodless chamber by a piston.

[0008] The main oil circuit is connected to the oil outlet of the rodless chamber of the oil cylinder, and is provided with a first oil outlet branch and a second oil outlet branch respectively. A first hydraulic valve and a second hydraulic valve are respectively provided on the first oil outlet branch and the second oil outlet branch.

[0009] The oil tank is connected to the output end of the first oil outlet branch, and its oil supply end is connected to the rodless chamber of the oil cylinder through the oil supply pipeline.

[0010] A hydraulic motor is connected to the outlet end of the second oil outlet branch;

[0011] The generator is connected to the output end of the hydraulic motor;

[0012] AC / DC converter unit, connected to the output terminal of generator;

[0013] An energy storage unit is connected to the output terminal of the AC / DC converter unit;

[0014] The controller is connected to the first hydraulic valve and the second hydraulic valve via two first signal lines, and is connected to the generator and the energy storage unit via control lines and transmission lines, respectively.

[0015] Furthermore, the suspension hydraulic cylinder is also equipped with a displacement sensor and a pressure sensor, both of which are connected to the controller via a second signal line.

[0016] Furthermore, the controller includes:

[0017] The data acquisition module is used to acquire the extension and retraction length data of the suspension hydraulic cylinder output by the displacement sensor and the pressure data of the hydraulic oil inside the suspension hydraulic cylinder output by the pressure sensor.

[0018] The hydraulic valve control module controls the opening and closing status and opening ratio of the first and second hydraulic valves in real time based on the data acquired by the data acquisition module, so as to adjust the flow direction and flow rate of hydraulic oil in the rodless chamber of the cylinder.

[0019] The generator control module is used to control the torque and speed of the generator, thereby adjusting the speed of the variable hydraulic motor connected to it, so as to limit the pressure and flow generated by the hydraulic system in the second oil outlet branch, and thus achieve the purpose of adjusting the extension and retraction speed of the suspension hydraulic cylinder.

[0020] The energy management module monitors the charging status of the energy storage unit and coordinates the operation of the hydraulic valve control module and the generator control module based on the charging status and current energy recovery requirements.

[0021] Furthermore, a filter is installed on the oil supply line.

[0022] The advantages of this invention compared to existing technologies are as follows: This application achieves high efficiency, flexibility, and intelligence in energy recovery of the hybrid crane suspension system. By designing an integrated system comprising a suspension hydraulic cylinder, precision hydraulic valve group, hydraulic motor, generator, AC / DC converter, and energy storage unit, this application successfully converts the gravitational potential energy released by the crane during operation into electrical energy and stores it efficiently. This process not only significantly improves energy utilization but also effectively reduces energy consumption problems caused by energy waste in traditional cranes.

[0023] More importantly, the present application realizes flexible adjustment of the energy recovery process through the precise control of the hydraulic valve by the controller. According to the real-time collected displacement and pressure data and the preset control strategy, the controller can dynamically adjust the opening and closing state and the opening proportion of the hydraulic valve, so as to maximize the energy recovery efficiency while ensuring the stability of the system. This intelligent control method not only improves the response speed and accuracy of the system, but also makes the energy recovery process more in line with the actual demand, further enhancing the practicability and reliability of the system.

[0024] In summary, the present application realizes efficient, flexible and intelligent energy recovery of the suspension system of the hybrid crane through integrated design, precise control and intelligent management, and provides new technical support and solutions for the green development of the engineering machinery industry. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 is a block diagram of the energy recovery system of the hybrid crane according to the present application.

[0026] Figure 2 is a structural schematic diagram of the controller according to the present application.

[0027] Figure 3 is a flow chart of the energy recovery process according to the present application.

[0028] As shown in the figure: 1, suspension hydraulic cylinder, 2, rod cavity of the hydraulic cylinder, 3, rodless cavity of the hydraulic cylinder, 4, main oil circuit, 5, first oil outlet branch, 6, second oil outlet branch, 7, first hydraulic valve, 8, second hydraulic valve, 9, oil tank, 10, hydraulic motor, 11, generator, 12, AC-DC converter unit, 13, electric energy storage unit, 14, oil supply pipeline, 15, controller, 151, data acquisition module, 152, hydraulic valve control module, 153, generator control module, 154, energy management module, 16, control line, 17, transmission line, 18, displacement sensor, 19, pressure sensor, 20, first signal line, 21, second signal line, 22, filter. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0030] It should be noted that all directional indications (such as up, down, left, right, front, rear, etc.) in the embodiments of the present application are only used to explain the relative position relationship, movement condition, etc. between components in a certain specific posture (as shown in the drawings), and if the specific posture changes, the directional indications will also change accordingly.

[0031] In addition, the description such as "first", "second" and the like in the present application is only for the purpose of description, and cannot be understood as indicating or implying the relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise specifically limited.

[0032] Furthermore, the technical solutions of each embodiment of the present application can be combined with each other, but it must be based on the realization of the ordinary skilled in the art, and when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, nor within the protection scope required by the present application.

[0033] Referring to the drawings Figure 1 - the drawings Figure 3 A kind of hybrid crane suspension energy recovery system, comprising: suspension hydraulic cylinder 1, its inner cavity is divided into cylinder rod cavity 2 and cylinder rodless cavity 3 by piston;Main oil circuit 4, it is connected to the oil outlet of cylinder rodless cavity 3, first oil outlet branch 5 and second oil outlet branch 6 are respectively arranged on it, first hydraulic valve 7 and second hydraulic valve 8 are respectively arranged on the first oil outlet branch 5 and the second oil outlet branch 6;Oil tank 9, the output end of first oil outlet branch 5 is communicated with it, and its oil supply end is communicated with cylinder rodless cavity 3 by oil supply pipeline 14;Hydraulic motor 10, it is connected to the oil outlet end of second oil outlet branch 6;Generator 11, it is connected to the output end of hydraulic motor 10;AC-DC converter unit 12, it is connected to the output end of generator 11;Electric energy storage unit 13, it is connected to the output end of AC-DC converter unit 12;Controller 15, it is connected with first hydraulic valve 7 and second hydraulic valve 8 by two first signal lines 20 respectively, and is connected with generator 11 and electric energy storage unit 13 by control line 16 and transmission line 17 respectively.

[0034] In one embodiment, in a preferred embodiment, the suspension hydraulic cylinder 1 is also provided with a displacement sensor 18 and a pressure sensor 19, which are connected to the controller 15 through the second signal line 21. The controller 15 internally contains a data acquisition module 151, a hydraulic valve control module 152, a generator control module 153, and an energy management module 154. The data acquisition module 151 is responsible for collecting data output by the displacement sensor 18 and the pressure sensor 19, providing real-time information for other control modules. The hydraulic valve control module 152 controls the opening and closing state and opening ratio of the first hydraulic valve 7 and the second hydraulic valve 8 in real time according to these data, to adjust the flow direction and flow rate of the hydraulic oil in the cylinder rod cavity 3. The generator control module 153 is used to control the torque and speed of the generator 11, thereby adjusting the speed of the variable hydraulic motor 10, limiting the pressure and flow generated by the hydraulic system, and achieving the purpose of adjusting the extension and retraction speed of the suspension hydraulic cylinder 1. The energy management module 154 is responsible for monitoring the charging state of the electric energy storage unit 13, and coordinating the work of the hydraulic valve control module 152 and the generator control module 153 according to the charging state and the current energy recovery demand.

[0035] In order to further improve the reliability and safety of the system, a filter 22 is provided on the oil supply pipeline 14. The filter 22 can effectively filter out impurities and particulate matter in the hydraulic oil, preventing them from entering the hydraulic system and causing damage or failure.

[0036] Working principle: When the suspension system of the hybrid crane is lowered due to load reduction or operation instructions, the suspension hydraulic cylinder 1 begins to retract. In this process, the volume of the cylinder rod cavity 3 decreases, causing the hydraulic oil in it to be compressed, thereby forming hydraulic energy. This part of hydraulic energy is converted from the gravitational potential energy during the crane's descent.

[0037] As the hydraulic oil in the cylinder rod cavity 3 is compressed, the high-pressure oil flows through the total oil line 4 to two oil outlet branches: the first oil outlet branch 5 and the second oil outlet branch 6. At this time, the controller 15 controls the first hydraulic valve 7 and the second hydraulic valve 8 according to the real-time data collected by the displacement sensor 18 and the pressure sensor 19, and the pre-set control strategy.

[0038] Specifically, in order to maximize energy recovery efficiency, the second hydraulic valve 8 will be fully opened (100% open), allowing as much hydraulic oil as possible to flow to the hydraulic motor 10. The hydraulic motor 10, as a key component of energy conversion, has its main shaft coaxially connected to the rotor of the generator 11. Therefore, when the hydraulic oil drives the hydraulic motor 10 to rotate, the rotor of the generator 11 will also rotate, thereby generating alternating current.

[0039] The generated alternating current is then sent to the AC-DC converter unit 12 for AC-DC conversion, i.e. converting alternating current to direct current. This step is necessary because the electrical energy storage unit 13 (such as a battery pack) can usually only store direct current. The converted direct current is finally stored in the electrical energy storage unit 13 for subsequent use by the crane or feeding to the power grid.

[0040] At the same time, in order to balance the pressure and flow of the hydraulic system and adjust the recovery rate according to the actual energy recovery demand, the first hydraulic valve 7 will be opened by a certain proportion R (R is a value between 0 and 100) according to the instruction of the controller 15. When R is small, it means that more hydraulic oil is directed to the hydraulic motor 10 for energy recovery, and only a small amount of hydraulic oil flows back to the oil tank 9. In this case, the energy recovery capability is strong, and the gravitational potential energy can be quickly converted into electrical energy. On the contrary, when R is large, only a small amount of hydraulic oil flows to the hydraulic motor 10, and most of the hydraulic oil flows back to the oil tank 9. At this time, the energy recovery capability is weak, but it helps to maintain the stability and safety of the hydraulic system.

[0041] When it is necessary to interrupt the energy recovery process, the controller 15 will close the second hydraulic valve 8, thereby cutting off the passage of hydraulic oil to the hydraulic motor 10. In this way, the hydraulic system will return to the normal working state and no longer perform energy recovery.

[0042] In summary, the hybrid crane suspension energy recovery system provided by the present application realizes an efficient and stable energy recovery process by precisely controlling the opening and closing state and opening proportion of the hydraulic valve, as well as using intelligent algorithms for real-time monitoring and adjustment. At the same time, by setting safety measures such as filters, the reliability and safety of the system are further improved. This innovation not only helps to improve the energy efficiency of the crane, but also provides a new technical path for the green development of the engineering machinery industry.

[0043] The above describes the present application and its embodiments, which are not limiting. The embodiments shown in the drawings are only one of the embodiments of the present application, and the actual structure is not limited thereto. In summary, if a person skilled in the art is inspired by this, without departing from the spirit of the present application, without creative design, similar structural modes and embodiments of the technical solutions can be designed and belong to the protection scope of the present application.

Claims

1. A hybrid crane suspension energy recovery system, characterized by, The application relates to a suspension hydraulic cylinder (1) and a control system thereof. The suspension hydraulic cylinder (1) comprises an inner cavity which is divided into a cylinder rod cavity (2) and a cylinder rodless cavity (3) by a piston; a total oil circuit (4) is connected to an oil outlet of the cylinder rodless cavity (3) and is respectively provided with a first oil outlet branch (5) and a second oil outlet branch (6); the first oil outlet branch (5) and the second oil outlet branch (6) are respectively provided with a first hydraulic valve (7) and a second hydraulic valve (8); an oil tank (9) is communicated with an output end of the first oil outlet branch (5) and is communicated with the cylinder rodless cavity (3) through an oil supply pipeline (14); a hydraulic motor (10) is connected to an oil outlet end of the second oil outlet branch (6); a generator (11) is connected to an output end of the hydraulic motor (10); an AC / DC converter unit (12) is connected to an output end of the generator (11); an electric energy storage unit (13) is connected to an output end of the AC / DC converter unit (12); and a controller (15) is connected to the first hydraulic valve (7) and the second hydraulic valve (8) through two first signal lines (20) respectively, and is connected to the generator (11) and the electric energy storage unit (13) through a control line (16) and a transmission line (17) respectively. The suspension hydraulic cylinder (1) is further provided with a displacement sensor (18) and a pressure sensor (19), and the displacement sensor (18) and the pressure sensor (19) are connected to the controller (15) through a second signal line (21). The controller (15) comprises: a data acquisition module (151) for acquiring the extension length data of the suspension hydraulic cylinder (1) output by the displacement sensor (18) and the pressure data of the internal hydraulic oil of the suspension hydraulic cylinder (1) output by the pressure sensor (19); a hydraulic valve control module (152) for controlling the opening and closing states and opening ratios of the first hydraulic valve (7) and the second hydraulic valve (8) in real time according to the data acquired by the data acquisition module (151) so as to adjust the flow direction and flow rate of the hydraulic oil in the cylinder rodless cavity (3); a generator control module (153) for controlling the torque and rotating speed of the generator (11) so as to adjust the rotating speed of the variable hydraulic motor (10) connected to the generator (11), thereby limiting the pressure and flow rate generated by the hydraulic system in the second oil outlet branch (6) and achieving the purpose of adjusting the extension and retraction movement speed of the suspension hydraulic cylinder (1); an energy management module (154) for monitoring the charging state of the electric energy storage unit (13) and coordinating the work of the hydraulic valve control module (152) and the generator control module (153) according to the charging state and the current energy recovery demand. The oil supply pipeline (14) is provided with a filter (22).

2. A hybrid crane suspension energy recovery system according to claim 1, characterised in that, ​ 3. A hybrid crane suspension energy recovery system according to claim 2, characterised in that, ​ ​ ​ ​ ​ 4. A hybrid crane suspension energy recovery system according to claim 1, characterized in that, ​

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