Procedures for operating a crane and crane

Abstract

Method for operating a crane (50) with a movable undercarriage (10), a superstructure (12) rotatably mounted on it with a luffing boom system (54) and derrick boom (55) arranged thereon, wherein an auxiliary crane (1) is used as derrick ballast, characterized in that, in particular for erecting the boom system (54), the auxiliary crane (1) drives onto a ballast base plate (3) attached to the derrick boom (55) in order to form at least a large part of the counterweight (100).

Description

[0001] The invention relates to a method for operating a crane with a movable undercarriage, a rotatably mounted superstructure thereon with a luffing boom system arranged thereon and a derrick boom according to the preamble of claim 1.

[0002] Large cranes, especially large crawler cranes, require a substantial counterweight to counteract the lifted payload and prevent the crane from tipping over. This counterweight can be provided by a central ballast, a superstructure ballast, and / or a ballast on the derrick boom. A ballast plate supported against the ground by appropriate means is commonly suggested as a derrick ballast. Alternatively, a completely suspended ballast or a derrick ballast carried by a ballast wagon are also possible.

[0003] Against this background, special ballast wagons were developed that are designed as self-propelled vehicles and can therefore be moved together with the crane to ensure largely unrestricted crane operation. However, such solutions always require the complex in-house development of a suitable ballast wagon used exclusively for ballasting. Furthermore, such a ballast wagon must be transported separately to the construction site for crane operation, which negatively impacts the operating costs, as these generally depend on the required ballast mass.

[0004] On the other hand, German patent DE 10 2011 105 960 A1 already discloses the use of an auxiliary crane with a telescopic boom as derrick ballast for the crane. This ballasting option can be used, for example, during regular crane operation or even during the crane setup process, specifically during the erection of the luffing jib system. A relatively small crane required for the setup of the large crawler crane could be used as the auxiliary vehicle.

[0005] Furthermore, in the unpublished DE 10 2014 012 661 A1 it has already been proposed to use an auxiliary crane as a ballast wagon with an additional suspended ballast.

[0006] However, it should be noted that a lattice crane with a suspended ballast must comply with several failure criteria. It is obvious that the entire crane must be prevented from tipping backward over the tipping edge, i.e., over the end of its base on the ground. This can be achieved by monitoring the overall center of gravity.

[0007] Another important feature is preventing the uncontrolled rearward swing of a boom section around its luffing axis. Boom sections can be the main boom, i.e., the boom system, or the derrick boom. While fall-back devices counteract this effect, their effectiveness is limited. The crane's structural integrity must also be considered in the event of "load breakage" as defined by EN 13000. In this case, the crane must not tip backward.

[0008] Another aspect to consider when designing a crane is minimizing its footprint on the construction site. Construction sites, especially those for the installation of wind turbines, are often crowded with transport trucks. These trucks must maneuver very close to the crane to keep its reach short when lifting loads. Several solutions have already been developed to address these challenges. For example, German patent DE 296 07 257 U1 describes a crane with a gate-shaped undercarriage. A truck can pass through this undercarriage. Furthermore, German patent DE 10 2007 028 778 A1 describes a crane with a raised connection between the superstructure and the ballast wagon, which also allows a truck to pass through.

[0009] Finally, to prevent a situation in which the crane tips backward or is pulled backward by the suspended ballast, it was already proposed in EP 2 308 792 A1 that a triangular derrick significantly reduces the distance along the longitudinal axis of the superstructure between the axis of the superstructure and the suspended ballast. In this solution, a very large derrick ballast is applied in order to reduce the derrick ballast radius.

[0010] A crane similar to this invention is also known from US Patent 3,955,684 A.

[0011] The aforementioned solutions each have different advantages and disadvantages.

[0012] The solution according to DE 10 2011 105 960 A1 has the advantage that a small crane already present on the construction site can be used as derrick ballast, thus eliminating the need for a separate ballast wagon. On the other hand, the coupling mechanism of this auxiliary crane to the crane being ballasted is comparatively complex, meaning that any other use of the auxiliary crane would involve considerable dismantling effort. This is where the present invention comes in.

[0013] The object of the invention is therefore to provide a method for operating a crane and a corresponding crane which, in particular for the different load conditions during the erection of the crane on the one hand, but also during the operation of the crane, provides the necessary counterweight quickly and in a simple manner using the simplest possible means.

[0014] According to the invention, this problem is initially solved by combining the features of claim 1. Accordingly, a crane with a movable undercarriage, a superstructure rotatably mounted thereon, a luffing boom system arranged thereon, and a derrick boom in which an auxiliary crane is used as derrick ballast, is further developed in such a way that, particularly when erecting the boom system, during which a very large counter-moment must be applied, the auxiliary crane is driven onto a ballast base plate attached to the derrick boom in order to form at least a large part of the counterweight.

[0015] This allows the derrick ballast to be quickly and easily loaded. Instead of laboriously stacking ballast plates to the height of the auxiliary crane's mass, the auxiliary crane can simply and quickly drive onto the ballast base plate to form the necessary derrick ballast. The auxiliary crane no longer needs to be attached to the superstructure of the crane being ballasted using a separate adapter. This significantly simplifies assembly and disassembly and allows for much more flexible use of the auxiliary crane. This substantial derrick weight is often only required during the erection of the boom system, as a particularly high counter-moment must be applied at this stage. Once the boom system is erected, the auxiliary crane can then be driven back down from the ballast base plate.

[0016] Further advantageous embodiments of the invention are set out in the dependent claims following the main claim.

[0017] Therefore, at least one additional stack of counterweight plates can be placed on the ballast base plate. The counterweight plates can be divided into different weight stacks to achieve an even distribution of weight across the counterweight plate.

[0018] At least one bracing system can be arranged between the derrick boom and the ballast base plate such that bracing rods are led from the derrick boom, preferably via variable-length cylinder arrangements, to a crossbeam which, together with lateral connecting blocks that serve to connect the crossbeam to the ballast base plate, forms a kind of gate into which the auxiliary crane can enter.

[0019] Furthermore, the inclination of the ballast base plate can be detected via at least one inclination sensor, whereby the recorded inclination values ​​are recorded and monitored via a control system of the crane, so that if necessary the inclination of the ballast base plate is returned to a desired range via the cylinder arrangement.

[0020] Furthermore, a sensor system can determine whether the ballast base plate is completely lifted from the ground. This measured status value is advantageously also transmitted to the control system.

[0021] To generate a comparatively larger ballast moment, the distance between the ballast base plate and the upper structure of the crane can advantageously be determined by means of a guide frame arranged between them.

[0022] It is particularly advantageous that, after the boom system has been erected or other crane operations requiring a very large counterweight have been carried out, the ballast, which consists at least of a ballast base plate with the ballast on it, is detached from the crane via detachable connections, preferably via bolted connections arranged between the spreader beam and the connecting brackets, for subsequent movement or rotation of the crane. After the ballast base plate and the ballast on it have been detached, the crane can be moved or rotated without difficulty. This is possible because the crane no longer requires such a high counter-moment during movement and rotation. The ballasting provided by the central ballast is often sufficient for this condition.

[0023] The method is advantageously further developed by the fact that, after uncoupling the ballast attached to the derrick boom, which consists at least of the ballast base plate with the ballast located on it, counter-stack plates are attached to the crossbeam still attached to the derrick boom or directly via appropriate connecting means, if necessary, in order to form a constant ballast attached to the derrick boom. Such a constant ballast is sufficient, for example, to achieve the necessary lifting capacity for the assembly of components of systems, such as wind turbines, when the maximum ballasting of the main crane with central ballast and superstructure ballast is insufficient.

[0024] This constant ballast can advantageously be directly attached to the decoupled ballast base plate via the connecting elements of the counterweight plates, if required. In this alternative design, the attached crossbeam of the previously described variant is therefore no longer necessary.

[0025] Advantageously, special load tables are integrated into the crane control system, which can be selected in the case of the attached constant ballast, ensuring that the crane does not tip backwards when the boom system is advantageously tilted.

[0026] The method is particularly advantageous for erecting the boom system because, to increase the moment, counterweight plates are taken directly from the superstructure ballast and stacked on the ballast base plate. This means the counterweight plates no longer act as superstructure ballast but as derrick ballast, increasing the moment without the need to transport additional counterweight plates to or from the derrick.

[0027] A crane according to the invention for carrying out the aforementioned method is defined in claim 12 and the dependent claims. Such a crane comprises a movable undercarriage, a superstructure rotatably mounted on the undercarriage with a luffing boom system and derrick boom arranged thereon, and a crane control system. It is characterized in that it has a ballast device as derrick ballast, which consists at least of a ballast base plate for receiving an auxiliary crane, wherein this is connected to a crossbeam via lateral connecting brackets in such a way that a gate is formed into which the auxiliary crane can move, the crossbeam in turn being connected to the derrick boom via guy rods.

[0028] Advantageously, longitudinally variable elements in the form of hydraulic cylinder arrangements can be provided between the derrick boom and the crossbeam.

[0029] At least one additional counterweight stack consisting of counterweight plates can be stacked on the ballast base plate.

[0030] Advantageously, detachable connections can be arranged between the crossbeam and the connecting brackets. This allows the entire ballast base plate and the ballast on it to be easily decoupled.

[0031] According to a particular embodiment of the invention, connecting means for the direct attachment of counterweight plates to form a counterweight assembly suspended from the derrick boom can be additionally fastened to the crossbeam. These connecting means can be mandrels, such as those known, for example, from DE 20 2004 009 497 U1. Advantageously, just enough counterweight plates are installed in the counterweight assembly so that the crane, when the boom system is raised sufficiently for the travel position, is just barely stable and does not tip backward.

[0032] According to another advantageous aspect of the invention, support feet are arranged on the traverse, onto which the traverse can be placed, particularly during transport.

[0033] To increase the ballast, the auxiliary crane standing on the ballast base plate can also take on additional ballast itself and, if necessary, can also take on a load on the crane hook that also acts as ballast.

[0034] Further features, details and advantages of the invention are explained in more detail with reference to exemplary embodiments shown in the figure.

[0035] They show: Fig. 1: A side view of the crane according to the invention in a representation with the boom system largely erected, Fig. 2 and Fig. 3: Side views of the crane according to the invention, only partially shown, with attached auxiliary crane in different versions, the boom system to be erected not shown, Fig. 4: a perspective view of a design variant of the derrick ballast, Fig. 5: another perspective view of the derrick ballast according to Fig. 4, Fig. 6: A side view of the derrick ballast according to the Fig. 4 and Fig. 5, Fig. 7 to 9: Details of the derrick ballast, and the Fig. 10 and Fig. 11: Different configurations of the derrick ballast according to alternative embodiments of the invention.

[0036] The crane 50 according to the invention is characterized in its construction by the illustration shown. Fig. 1. The crane 50 has an undercarriage 10 with a chassis, which in the illustrated embodiment is designed as a crawler chassis and comprises two crawler tracks arranged on the right and left. A superstructure 12, rotatably mounted about an upright pivot axis, is arranged on the undercarriage 10. The superstructure 12 carries a main boom 54, which, within the scope of the invention, is referred to as the boom system and can thus encompass all conventional boom configurations. This boom 54 is articulated to the superstructure 12 about a horizontal luffing axis and has a hoist cable (not shown) in the usual manner.

[0037] On the rear side of the superstructure 12 opposite the pivot point of the boom 54, it carries an operating ballast 58, which counteracts the tipping moment induced by the boom 54 or a load suspended from it.

[0038] Behind the boom system 54, the rearward-oriented derrick boom 55 is mounted, wherein the boom system 54 or the main boom head is braced in a manner known per se via the adjustable bracing 14 on the derrick boom 55.

[0039] When lifting very heavy loads, it is necessary to brace the derrick boom 55 using an additional derrick ballast. Typically, a derrick ballast suspended above the ground, shown here as constant ballast 200, is used for this purpose. In contrast to the prior art, the crane 50 according to the invention provides a novel approach to ballasting the derrick boom 55, particularly during the assembly of the boom system 54, where especially high counter-moments must be generated.

[0040] This novel approach to ballasting, particularly during the erection of the boom system 54, results in particular from the Fig. 2 and Fig. 3. For reasons of space, the outrigger system 54, which is still lying on the ground and still needs to be erected, is not shown in these two illustrations.

[0041] In the Fig. 2 and Fig. 3. Each of these features includes a ballast device 100 with a high counterweight as derrick ballast. The design of the ballast device 100 is determined in particular by the following: Fig. 4 to 6 and additionally from the detailed illustrations 7 to 9. A key element of this ballast device 100 is the auxiliary crane 1, which, with its entire weight, forms part of the derrick ballast. An auxiliary crane 1, such as can be used in the present invention, has, for example, a mass of approximately 180 t. Thus, when using the auxiliary crane, the transport of 180 t of counterweight to the construction site can be saved. In order to make the mass quickly available, the auxiliary crane 1 can advantageously be accessed via a ramp 2 (see Figure 4 to 6). Fig. 6) Drive independently onto the ballast base plate 3. Contrary to previous state-of-the-art solutions, a further connection between the auxiliary crane 1 itself and the crane 15 is not provided here.

[0042] In addition to the auxiliary crane 1, further space can be provided on the ballast base plate to stack additional ballast, in particular further counterweight plates 4. The counterweight plates 4 can be arranged as shown in Fig. 4, shown, are divided into four counterweight stacks 5, 5', 5", 5"'. A sensor device 6 can be provided on the ballast base plate 3 to detect when the ballast base plate has completely lifted off the ground and to transmit this information to the control system of the crane 50, which is not shown in detail here.

[0043] The ballast device 100 is connected to the derrick boom 55 via parallel guy wires 51, 51'. The spacing of the guy wires is predetermined within certain limits by the width of the derrick boom 55. This spacing is significantly smaller than the width of the auxiliary crane 1. A crossbeam 52 is provided to ensure a secure connection. This crossbeam connects the guy wires 51, 51' and corresponding connecting brackets 53, which connect the crossbeam 52 to the ballast base plate 3. The connecting brackets 53 and the crossbeam 52 form, as shown in Fig. Figure 4 shows a gate into which the auxiliary crane 1 can drive.

[0044] Close the guy wires 51, 51' as shown in Fig. Figure 2 shows variable-length cylinder arrangements 61 that transmit the force into the derrick boom 55. If these cylinders 61 do not rotate synchronously, the crossbeam 52 will be jammed, as is the case, for example, in the Fig. Figure 9 shows that if the difference in synchronization is greater than, for example, 1000 mm, which is detected by a tilt sensor (not shown in detail here), the crane control system can compensate accordingly by controlling the cylinders 61. Bolted connections 56 are provided between the crossbeam 52 and the connecting brackets 53 that support the ballast base plate 3. This allows for a certain degree of pivoting. However, the ballast base plate 3 is generally aligned parallel to the crossbeam 52.

[0045] To increase the mass of auxiliary crane 1, it can be equipped with a central ballast. An additional ballast is also possible. Furthermore, an additional load can be attached to the hook of auxiliary crane 1, as not shown here, to increase the counter-moment. Even without additional ballast or an additional load on the hook, the total mass of, for example, 480 t can be achieved. This can therefore be increased even further by adding more ballast and a hook load.

[0046] With the sufficiently large mass of the ballast device 100, the crane 50 can erect its long boom system 54. The erection process is monitored by the crane control system and a suitable erection load table. Once the boom is erected, the crane can operate with a significantly smaller counterweight arrangement 200 and, for example, perform the lifts necessary for erecting a wind turbine. Several wind turbines often need to be erected on a construction site. The crane could also travel from one assembly site to another with the boom system 54 erected.

[0047] In the case of the crane 50 presented here, the moment of the erected boom system 54 is insufficient to lift the large mass of the ballast device 100 from the ground. To nevertheless enable the main crane 50 to be moved or rotated, detachable connections, in particular bolted connections 56, are provided between the crossbeams 52 and the connecting supports 53. After the boom system 54 has been erected, the bolted connections 56 can be released. Thus, the main crane 50 is free and can be moved or rotated.

[0048] To achieve the necessary lifting capacity, for example for the assembly of the components of a wind turbine, even maximum ballasting of the main crane 50 with central ballast 57 and superstructure ballast 58 is insufficient. Therefore, an additional derrick ballast is required. This derrick ballast can be provided by a counterweight arrangement 200, as described in Fig. 1 or in the Fig. 10 and Fig. As shown in 11, it should be provided.

[0049] A first embodiment of this counterweight arrangement 200, also referred to as constant ballast, results from the Fig. 10. Here, a known mandrel 60 is inserted directly onto the crossbeam 52, from which the ballast device 100 has been detached, via appropriate connecting means 59. This mandrel is known from German utility model DE 20 2004 009 497 U1 of the same applicant and has been used for many years to hold counterweight plates. Each mandrel 60 can support one or more counterweight plates 4. Advantageously, precisely the number of counterweight plates 4 are installed in the counterweight plate arrangement 200 so that the crane, with the boom system 54 raised sufficiently for the travel position, is just barely able to tip backward. For this purpose, a special load table BC can be selected in the crane control system to ensure a safe condition at all times. The system increases the load capacities without rebalancing the suspended ballast pallet.For example, the main crane 50, after the mandrels 50 are attached, could move them via the ballast device 100, and each of these requires two counterweight plates 4, as shown in the . Fig. The ballast device 100, as shown in the illustrations, can be picked up independently. According to the invention, no complex restacking of the ballast device 100 would be necessary for this purpose.

[0050] According to an alternative version, as it appears in Fig. 11 is shown, and how they also emerge from the Fig. As can be seen from Figure 1, the traverse 52 with the ballast device 100 can be removed. The pins 60 are then attached directly to the guy rods 51, 51' using the corresponding connecting elements 59.

[0051] It is advantageous that monitoring of the counterweight assembly 200 when it is "lifted off the ground" is unnecessary. Its relatively low weight prevents damage to the crane during travel or rotation, even when placed on the ground. Furthermore, in the USA, for example, ballast that is not placed on the ground is not considered suspended ballast and therefore does not fall under the relevant regulations. According to load capacity table BC, only those luffing positions of the boom system 54 are permissible that ensure the counterweight assembly remains constantly lifted off the ground.

[0052] Another key aspect of the invention is that the variable effective radius of the counterweight plates 4 is modified as follows. This allows the upper carriage ballast 58, necessary for the operation of the crane 50, to be removed during erection and used in the ballast device 100. This significantly increases the counter-moment, and fewer counterweight plates 4 are required. Consequently, the transport costs for delivering the counterweight plates to and from the construction site can be reduced.

[0053] At traverse 52, as in Fig. Figure 8 shows support feet 63. The crossbeam 52 can be placed on these.

[0054] In the Fig.In the embodiment shown in Figure 3, a spacer device in the form of a guide frame 62 is additionally used to enable a larger ballast moment. This is arranged between the ballast base plate 3 and the superstructure 12 of the crane 50.

Claims

[1] Method for operating a crane (50) with a movable undercarriage (10), a superstructure (12) rotatably mounted on it with a luffing boom system (54) and derrick boom (55) arranged thereon, wherein an auxiliary crane (1) is used as derrick ballast, characterized by , that in particular for erecting the boom system (54) the auxiliary crane (1) drives onto a ballast base plate (3) attached to the derrick boom (55) in order to form at least a large part of the counterweight (100). [2] Method according to claim 1, characterized by , that at least one additional counterweight stack (5) made of counterweight plates (4) is stacked on the ballast base plate (3). [3] Method according to claim 1 or 2, characterized by, that at least one bracing (51) between derrick boom (55) and ballast base plate (3) is arranged such that bracing rods (51) are led from the derrick boom (3) preferably via variable-length cylinder arrangements (61) to a crossbeam (52), which together with lateral connecting blocks (53) that serve to connect the crossbeam (52) to the ballast base plate (3) form a kind of gate into which the auxiliary crane (1) can enter. [4] Method according to claim 3, characterized by , that the inclination of the ballast base plate (3) is detected via at least one inclination sensor, that the inclination values ​​are detected and monitored via a control system, and that, if necessary, the inclination of the ballast base plate (3) is returned to a desired range via the cylinder arrangement (61). [5] Method according to any one of the preceding claims, characterized by, that at least one sensor device (6) determines whether the ballast base plate (3) is completely lifted off the ground, and that this value is transmitted to the control system. [6] Method according to any one of the preceding claims, characterized by , that in order to generate a larger ballast moment the distance between the ballast base plate (3) and the superstructure (12) of the crane (50) can be determined via a guide frame (62) arranged between them. [7] Method according to any one of the preceding claims, characterized by , that for moving or rotating the crane (50) the ballast (100), at least consisting of ballast base plate (3) with the ballast located on it, is decoupled from the crane (50) via detachable connections, preferably bolt connections (56) arranged between the crossbeam (52) and the connecting blocks (53). [8] Method according to any one of the preceding claims, characterized by, that after uncoupling the ballast (100) attached to the derrick boom, which consists at least of the ballast base plate (3) with the ballast located on it, counterweight plates can be attached to the traverse (52) still attached to the derrick boom (55) or directly via appropriate connecting means (60) to form a constant ballast (200) attached to the derrick boom (55). [9] Method according to claim 8, characterized by , that the counterweight plates can be directly picked up from the decoupled ballast base plate of the ballast (100) via the connecting means (60) if required. [10] Method according to one of the preceding claims, wherein a special load table (BC) is integrated in the crane control which can be selected in the case of the attached constant ballast (200), which ensures that the crane (50) does not tip backwards when the boom system (54) is raised. [11] Method according to any of the preceding claims, characterized by , that in particular for erecting the boom system (54) to increase the moment, counterweight plates (4) are taken from the superstructure ballast (58) and stacked on the ballast base plate (3). [12] Crane for carrying out the method according to one of claims 1 to 11 comprising a movable undercarriage (10), a superstructure (12) rotatably mounted on it with a luffing boom system (54) and derrick boom (55) arranged thereon, and a crane control system, characterized by , that it has as derrick ballast a ballast device (100) which consists at least of a ballast base plate (3) for receiving an auxiliary crane (1), wherein these are connected via lateral connecting blocks (53) to a crossbeam (52) in such a way that a gate is formed into which the auxiliary crane (1) can drive, wherein the crossbeam (52) is in turn connected to the derrick boom (55) via guy rods (51). [13] Crane according to claim 12, characterized by that length-variable elements in the form of hydraulic cylinder arrangements are provided between the derrick boom and the crossbeam. [14] Crane according to one of claims 12 or 13, characterized by , that at least one additional counterweight stack (5) consisting of counterweight plates (4) can be stacked on the ballast base plate (3). [15] Crane according to any of the preceding claims, characterized by , that detachable connections (56) are arranged between the crossbeam and the connecting blocks (53). [16] Crane according to one of the preceding claims, characterized by , that connecting means (60) for the direct attachment of counterweight plates (4) to form a counterweight arrangement (200) suspended from the derrick boom (55) can be attached to the traverse (52). [17] Crane according to one of the preceding claims, characterized by, that support feet (63) are arranged on the traverse (52). [18] Crane according to one of the preceding claims, characterized by , that the auxiliary crane (1) standing on the ballast base plate (3) also takes on ballast and / or a load on the crane hook.

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