TWI592358B - Double power energy saving system of rubber tyre gantry crane (rtg) - Google Patents

Description

Tire type gantry crane (RTG) dual power energy saving system

The invention relates to a dock equipment power system, belonging to the field of new energy applications, and mainly applied to a tire type gantry crane (Rubber Tyre Gantry, hereinafter referred to as RTG).

With the development of the world economy, industrial production and transportation are becoming more and more dependent on oil. The environmental problems such as greenhouse effect and ecological deterioration are becoming more and more prominent. How to maintain the harmonious development of economy and environment has become a global concern. focus. The conventional tire-type gantry crane (RTG) at the terminal is powered by a single generator set with less than 30% fuel efficiency. The main reasons are as follows: a) Large installed capacity: Since the RTG short-time maximum load demand must be met, the generator set power must be designed according to the highest RTG demand, which is about 8 times larger than the RTG actual operating average power; b) the fuel efficiency is low: the generator set is When the best economic fuel consumption area is running, its energy efficiency is the best. When the tire type gantry crane (RTG) is working, in order to ensure the normal supply of the control system and the working mechanism, the output power of the generator set must be higher than the power demand of the RTG. The generator set must be operated continuously at the rated speed. Because the power requirements of the RTG under different working conditions are different, the generator set needs to adjust the output power immediately to match the power demand of the RTG, and most of the time deviates from the optimal economic fuel consumption area. Energy efficiency is low. Figure 2 shows the diesel engine's characteristic curve A area, the engine is at 1200-1300 At the speed of revolutions per minute, the output power is about 240kW, the fuel consumption rate is the lowest, and 186g/kWh is called the “best economic fuel consumption zone”. When the system power demand drops below 40kW, the fuel consumption rate is as high as 426g/kWh (B area in Figure 2), which is 2.3 times the optimal economic fuel consumption. When the RTG heavy load is accelerated, the engine fuel is poorly burned, often black. Smoke, serious pollution; c) No brake energy recovery function: When the RTG's hoisting mechanism is lowered, the trolley is running, and the trolley's traveling mechanism is decelerating and braking, the energy of the feedback cannot be stored because there is no energy storage device, and the energy consumption resistance must be passed. Instant consumption.

In view of the above defects of RTG, the present invention discloses a dual-power energy-saving system for a tire-type gantry crane (RTG), which aims to achieve a high matching of power output power and demand power, thereby improving the energy utilization efficiency of the RTG and reducing the overall energy consumption of the RTG. Energy conservation.

The invention changes the traditional RTG to supply power by a single generator set or the power supply mode of "generator + battery pack" power, adopts a dual power source of the generator set and the battery pack, and both power sources can independently meet the normal working power requirement of the RTG.

When the battery pack is in the set range, the RTG operation uses the battery pack as the power source to achieve a high matching of the power source output power and the RTG power demand. When the battery pack is low, the generator set is started to provide power. Once the generator set is put into operation, it is controlled to operate in the best economic fuel consumption area, so that the generator set runs at the highest efficiency; when the generator set supplies power directly to the RTG, the surplus energy charges the battery pack, and when the battery pack reaches the set high level, the battery pack is turned off. Generator set.

The charging power of the battery pack is greater than the maximum return energy of the RTG, and the full recovery of the feedback energy is realized.

The system is described in detail as follows: a) The generator set and the battery pack can independently support the RTG operation to form the “dual-power” power supply of the RTG. When the battery pack fails, it can be switched to the genset mode operation to improve the reliability of the RTG. b) The intermittent operation of the generator set When the battery pack reaches the system set high value, the engine is turned off, and the RTG power is completely provided by the battery pack; when the battery pack power drops to the set low value, the generator set is started to directly power the RTG while the surplus energy is used to charge the battery pack. . Once the generator set is put into operation, it will always operate in the best economic fuel consumption area to ensure the highest efficiency; c) The return energy of the RTG lifting mechanism, trolley operation and cart walking, etc., will be recovered to the battery pack. Achieve recycling.

The object of the present invention can be achieved by the following technical solutions: adding a battery power supply system without changing the performance parameters and structure of the original equipment of the RTG, the system mainly consists of a battery pack, an inverter power supply, a 24V DC power supply, and a system. Controller and other components.

The input end of the inverter power supply is connected in parallel with the DC bus, and the output end supplies power to the auxiliary power equipment such as lighting and air conditioning of the RTG through the auxiliary transformer; the input terminal of the 24V DC power supply is connected in parallel with the DC bus, and the output terminal provides DC power for the RTG control system.

The input end of the inverter power supply is connected in parallel with the DC bus, and the output end supplies power to the auxiliary power equipment such as lighting and air conditioning of the RTG through the auxiliary transformer; the input terminal of the 24V DC power supply is connected in parallel with the DC bus, and the output terminal provides DC power for the RTG control system.

When the energy saving retrofit of the old RTG equipment is carried out, the RTG prime power system does not need to be replaced, and any parameters and structures of the original equipment need not be changed, and only one set of power battery power supply and control system needs to be added to complete the energy-saving transformation; RTG equipment, through accurate calculation of the configuration of the generator set and battery pack parameters, energy saving effect is better.

1‧‧‧System Controller

2‧‧‧Battery pack and management system

3‧‧‧Generator

4‧‧‧Inverter power supply

5‧‧‧DC power supply

6‧‧‧Auxiliary transformer

7‧‧‧ Lifting mechanism inverter

8‧‧‧Trolley running mechanism inverter

9‧‧‧Large drive mechanism inverter

FIG. 1 is a schematic diagram of a dual power system of the present invention; and FIG. 2 is a graph showing a typical characteristic of a diesel engine.

The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

As shown in FIG. 1 , the present invention is an RTG dual-power energy-saving system that uses a battery pack as a main power source during operation. The whole system mainly includes: system controller 1, battery pack and management system 2, generator set 3, one-way DC/ AC inverter power supply 4, unidirectional DC/DC DC power supply 5 and auxiliary transformer 6 are composed of RTG and the related electrical equipment of the system mainly include: hoisting mechanism inverter 7, trolley running mechanism inverter 8 and cart The traveling mechanism inverter 9 and auxiliary electric equipment and control power supply.

The connection mode and main functions of the components are as follows: the battery pack 2 is connected with the DC bus of the RTG to provide power for the working mechanism, the auxiliary power source and the DC control power source, and the recovered energy; the input end of the inverter power source 4 is connected in parallel with the DC bus. The output terminal is connected to the auxiliary transformer 6, and the auxiliary transformer 6 outputs AC380V/220V50Hz three-phase four-wire power supply for use in auxiliary power equipment such as lighting and air conditioning of RTG; the input terminal of 24V DC power supply is connected in parallel with the DC bus, and the output terminal is provided with RTG control. Power supply; the generator set is divided into two outputs, one of which is connected to the AC input terminal of the inverter 7 of the RTG lifting mechanism. After rectification, it is connected with the DC bus to supply power to the RTG working mechanism or to charge the battery pack; the other is connected to the auxiliary. At the input end of the transformer 6, when the generator set is put into normal operation, it directly supplies power to the auxiliary mechanism.

The energy management control and working principle of the system are described in detail as follows: According to the battery's power-voltage characteristics, set the voltage working range of battery pack 2 (or through DC/DC) to match the voltage operating range of the inverter to ensure the stability of the RTG control system.

The system controller 1 monitors the state of the voltage, power, and the like of the power battery pack 2; and controls the start, idle, full speed, or flameout of the genset 3 .

When the battery pack 2 is in the set working range, the whole machine power demand is provided by the battery pack 2 through the DC bus; when the battery pack 2's power reaches the set low value, the generator set 3 is started; after the generator set 3 is put into normal operation , powering all the power equipment of the RTG, the surplus energy is charged to the battery pack 2; as the power of the battery pack 2 increases, the voltage is gradually increased, and when the voltage of the battery pack 2 rises to the set high value, the system controller 1 controls the generator set. 3 After the idle speed is turned off for a period of time, turn off the generator set 3.

Generator unit 3 output power control: as shown in Figure 2, the diesel engine has a characteristic curve. When the diesel engine speed is between 1500 rpm and the output is between 200 and 300 kW, the fuel efficiency is the best. The system controller 1 controls the output power of the generator set 3. 200kW~300kW. When the battery pack 2 is low in power, since the voltage of the battery pack 2 is low, the charging current is large, and the charging power is greater than the rated output power of the genset 3, at which time the system controller 1 limits the battery pack 2 by control. The maximum charging current ensures that the sum of the charging power and the power demand of the RTG operating normally is not greater than the rated power of the genset 3 - that is, the output power of the control genset 3 is less than 300 kW; as the voltage of the battery pack 2 continues to rise, the charging current is gradually Decrease, when the sum of the charging power and the RTG system power demand deviates from the economic fuel consumption of the genset 3 - that is, below 200 kW, the genset 3 is turned off. Once the generator set 3 is put into operation, it will always operate in the economic fuel consumption area with the highest fuel efficiency.

Energy recovery and control: RTG has a certain proportion of feedback energy per working cycle. When the feedback energy is generated, the bus voltage rises. The feedback energy is preferentially supplied to the inverter 4 and 24V DC power supply 5, and the surplus energy is recycled to the battery pack. 2; the recovered energy is used in the next working cycle of the RTG; There is a certain loss in each charge and discharge. In theory, the recovered energy can be recycled in an infinite loop until it is close to “0” but never returns to “0” to realize energy cycle recycling.

In summary, the present invention proposes an RTG dual-power energy-saving system for a working condition of a tire type gantry crane, which adopts a battery pack as a main power source, and the battery pack can satisfy the full power operation of the RTG in a period of time. The power source output power is fully matched with the equipment power demand to improve energy efficiency; RTG braking energy recovery and recycling are realized; once the generator set is working, the output power is controlled under the optimal energy efficiency, and the energy efficiency is the highest; the engine is not overloaded and does not take the risk. Black smoke; shorten the execution time of the generator set and extend the maintenance cycle.

The tire-type gantry crane dual-power energy-saving system of the invention has the following characteristics:

(1) The power of generator set 3 and battery pack 2 can meet the maximum power requirement of RTG, which can independently support RTG normal operation and improve equipment reliability; battery pack 2 is the main power source for RTG operation, and output power of battery pack 2 Fully match the RTG power requirements to improve energy efficiency;

(2) The generator set 3 works intermittently. Once the unit is put into operation, it is controlled to operate in the economic fuel consumption area, with high fuel efficiency, and ensures that the engine is not overloaded and does not emit black smoke; shorten the engine execution time and extend the maintenance cycle.

(3) Realize the full recovery and recycling of RTG feedback energy.

(4) When the system is applied to the old RTG transformation, the original generator power system can be replaced without changing the performance parameters and structure of the original equipment, and the transformation cost can be reduced; when it is applied to the newly-built RTG equipment, the generator set can be accurately calculated and configured. Battery pack parameters, higher energy saving rate.

The embodiments of the invention described above are not intended to limit the scope of the invention. Any modifications, equivalent substitutions and improvements made within the spirit and scope of the invention are intended to be included within the scope of the appended claims.

1‧‧‧System Controller

2‧‧‧Battery pack and management system

3‧‧‧Generator

4‧‧‧Inverter power supply

5‧‧‧DC power supply

6‧‧‧Auxiliary transformer

7‧‧‧ Lifting mechanism inverter

8‧‧‧Trolley running mechanism inverter

9‧‧‧Large drive mechanism inverter

Claims (4)

A tire-type gantry crane (RTG) dual-power energy-saving system, comprising: a system controller, a battery pack and a management system, a generator set, a unidirectional DC/AC inverter power supply, a unidirectional DC/DC DC power supply, and an auxiliary transformer The power equipment associated with the RTG and the system mainly includes: the hoisting mechanism inverter, the trolley operating mechanism inverter and the trolley traveling mechanism inverter, as well as the auxiliary power equipment and the control power supply; wherein the power modules are connected and mainly The function is as follows: Battery pack: Parallel to the DC bus of the variable frequency drive of the RTG working mechanism, to provide power for the working mechanism and auxiliary power supply, 24V DC power supply; In addition, when the working mechanism has inverter energy feedback, the inverter is powered by the DC bus. Power supply or recycling to the battery pack; Inverter power supply: The input terminal is connected in parallel with the DC bus, converting the DC power inverter into an AC power output, the output terminal is connected to the auxiliary transformer, and the auxiliary transformer output AC380V/220V50Hz three-phase four-wire power supply to the RTG lighting, Auxiliary electrical equipment such as air conditioner; 24V DC power supply: input terminal is connected to DC bus, output is R TG control power supply; generator set: two-way output, one of which is connected to the AC input end of the RTG hoisting mechanism inverter 7, after rectification and parallel with the DC bus, for RTG working mechanism, inverter power supply, 24V DC power supply or The battery pack is charged; the other is connected to the auxiliary transformer input terminal. When the generator set is put into normal operation, it directly supplies power to the auxiliary mechanism; the generator set and the battery pack can independently support the normal operation of the RTG, and the RTG uses the battery pack as the main power source and outputs The power is highly matched with the demand power; the generator set works intermittently, and once the generator set is put into operation, it is controlled to work in the economic fuel consumption area. The generator set is either working in the economic fuel consumption area, or idle or stalled, and the RPG power is improved while saving energy and reducing emissions. Sex. For example, the tire-type gantry crane (RTG) dual-power energy-saving system described in claim 1 wherein the battery pack voltage operating range of the system is completely matched with the RTG variable-frequency drive voltage operating range, and the battery pack can be free of DC/ The DC is directly connected in parallel with the DC bus of the variable frequency drive of the RTG working mechanism. For example, the tire-type gantry crane (RTG) dual-power energy-saving system described in claim 1 of the patent scope, wherein the system is applied to the RTG transformation, the RTG original generator set does not need to be replaced. For example, the tire-type gantry crane (RTG) dual-power energy-saving system described in claim 1 wherein the battery pack charging power is greater than the maximum return energy of the RTG, and the RTG feedback energy is fully recovered.