WO2016086872A1 - 一种轮胎式龙门起重机双动力节能系统 - Google Patents

一种轮胎式龙门起重机双动力节能系统 Download PDF

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WO2016086872A1
WO2016086872A1 PCT/CN2015/096279 CN2015096279W WO2016086872A1 WO 2016086872 A1 WO2016086872 A1 WO 2016086872A1 CN 2015096279 W CN2015096279 W CN 2015096279W WO 2016086872 A1 WO2016086872 A1 WO 2016086872A1
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power
rtg
battery pack
energy
power supply
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PCT/CN2015/096279
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English (en)
French (fr)
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安同会
贾凯
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深圳市安顺节能科技发展有限公司
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Priority claimed from CN201410736525.1A external-priority patent/CN104444806B/zh
Priority claimed from CN201520790156.4U external-priority patent/CN205114884U/zh
Application filed by 深圳市安顺节能科技发展有限公司 filed Critical 深圳市安顺节能科技发展有限公司
Priority to SG11201704533YA priority Critical patent/SG11201704533YA/en
Publication of WO2016086872A1 publication Critical patent/WO2016086872A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
    • B66C13/00—Other constructional features or details
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/14—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/34—Parallel operation in networks using both storage and other dc sources, e.g. providing buffering

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  • 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).
  • RTG tire type gantry crane
  • 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:
  • the diesel engine's characteristic curve A area the engine has the lowest fuel consumption when the output power is about 240kW at 1200-1300 rpm, and 186g/kWh is called the “best economic fuel consumption zone”.
  • 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.
  • the RTG heavy load is accelerated, the engine fuel is poorly burned, often black. Smoke, serious pollution;
  • 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 energy utilization efficiency of RTG and reducing overall energy consumption of 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.
  • 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.
  • the generator set is started to provide power. Once the generator set is put into operation, it is controlled to operate in the optimal 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.
  • the battery pack reaches the set high level, Turn off the 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 generator set and the battery pack can independently support the RTG operation to form the “dual power” power supply of the RTG.
  • the battery pack fails, it can be switched to the genset mode operation to improve the reliability of the RTG;
  • the generator set runs intermittently. 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 provide the RTG. Power while the surplus energy charges 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;
  • the system is mainly composed of battery pack, inverter power supply, 24V DC power supply and system controller.
  • 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 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.
  • Figure 1 Schematic diagram of the dual power system of the present invention
  • Figure 2 Typical characteristics of diesel fuel.
  • the present invention is an RTG dual-power energy-saving system with 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.
  • connection modes 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 supply and the DC control power supply, and the recovered energy; the input end of the inverter power supply 4 is connected in parallel with the DC bus, the output terminal is connected to the auxiliary transformer 6, and the auxiliary transformer 6 is output AC380V.
  • auxiliary electric equipment such as lighting and air conditioning is used; the input end of the 24V DC power supply is connected in parallel with the DC bus, the output end is the RTG control power supply; the generator set is divided into two outputs, one of which is connected to the RTG lifting mechanism inverter 7
  • the AC input terminal is rectified and connected to the DC bus to supply power to the RTG working mechanism or to charge the battery pack; the other is connected to the input terminal of the auxiliary transformer 6 and directly supply power to the auxiliary mechanism when the generator set is put into normal operation.
  • 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 .
  • the generator set 3 When the battery pack 2 is in the set working range, the power requirement of the whole machine is provided by the battery pack 2 through the DC bus; when the power of the battery pack 2 falls to the set low value, the generator set 3 is started; the generator set 3 is put into normal After the operation, all the power equipment of the RTG is supplied with power, and the surplus energy charges the battery pack 2; as the power of the battery pack 2 increases, the voltage gradually increases, and when the voltage of the battery pack 2 rises to the set high value, the system controller 1 After the genset 3 is controlled to idle for a period of time, the flame is turned off and the genset 3 is turned off.
  • 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 optimal.
  • the system controller 1 controls the output power of the generator set 3. 200kW to 300kW.
  • 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 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 is continuously increased, the charging current Gradually, when the sum of the charging power and the power demand of the RTG system deviates from the economical 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.
  • 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; since there is a certain loss in each charge and discharge, the theoretically recovered energy can be recycled in an infinite loop until it is close to “0” but never returns to “0”. Realize energy recycling.
  • the present invention proposes an RTG dual-power energy-saving system for a working condition of a tire-type gantry crane, which uses a battery pack as a main power source, and the battery pack can satisfy the full-electric operation of the RTG for a period of time.
  • the power source output power and the equipment power demand are fully matched to improve energy efficiency; the RTG brake energy recovery is realized and recycled; the generator set controls the output power under the optimal energy efficiency once the work is performed, and the energy efficiency is the highest; the engine is not overloaded, Do not emit black smoke; shorten the running time of the generator set and extend the maintenance cycle.
  • the power of generator set 3 and battery pack 2 can meet the maximum power requirement of RTG. It can independently support the normal operation of RTG and improve the reliability of equipment.
  • battery pack 2 is the main power source, and the output power of battery pack 2 is RTG power requirements are fully matched throughout the process to improve energy efficiency;
  • 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 running time and extend the maintenance cycle.
  • 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.
  • the generator set and battery pack can be accurately calculated. Parameters, higher energy saving rate.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Control Of Eletrric Generators (AREA)
  • Supply And Distribution Of Alternating Current (AREA)
  • Secondary Cells (AREA)

Abstract

公开了一种轮胎式龙门起重机（RTG）双动力节能系统，包括系统控制器（1）、电池组及管理系统（2）、发电机组（3）单向DC/AC逆变电源（4）、单向DC/DC直流电源（5）和辅助变压器（6）。电池组和发电机组均可独立支持RTG作业，形成双动力系统，提高设备可靠性。RTG以电池组为主动力源，输出功率与需求功率高度匹配，提高能源效率；电池组电量高时，关闭发电机组由电池组供电，电池组电量低时启动发电机组给RTG直接供电，富余能量给电池组充电。

Description

一种轮胎式龙门起重机双动力节能系统 [技术领域]
本发明涉及一种码头设备动力系统，属于新能源应用领域，主要应用于轮胎式龙门起重机(Rubber Tyre Gantry，以下简称RTG)。
[背景技术]
伴随着世界经济的发展，工业生产及交通运输等对石油的依赖程度越来越高，随之而来的温室效应、生态恶化等环境问题日益突出，如何保持经济与环境和谐发展成为全球关注的焦点。码头的常规轮胎式龙门起重机(RTG)采用单一发电机组为动力，燃油效率不足30％。主要原因如下：
a)装机容量大：由于必须满足RTG短时最高负荷需求，发电机组功率必须按RTG最高需求设计，比RTG实际作业平均功率约大8倍；
b)燃油效率低：发电机组在最佳经济油耗区运转时，其能源效率是最佳的，轮胎式龙门起重机(RTG)工作时，为了确保控制系统及工作机构的正常供电，发电机组的输出功率必须高于RTG的动力需求，发电机组要不间断地在额定转速下运行，因为RTG不同工况的功率需求不同，发电机组需要实时调整输出功率使之与RTG的功率需求匹配，大部分时间都偏离最佳经济油耗区运转，能源效率低下。如图2柴油机万有特性曲线图A区，发动机在1200-1300转/分钟的转速下输出功率为240kW左右时油耗率最低，186g/kWh——称之为“最佳经济油耗区”。当系统功率需求降至40kW以下时，耗油率高达426g/kWh(图2的B区)，是最佳经济油耗的2.3倍；RTG重载起升加速时，发动机燃料燃烧不良，经常冒黑烟，污染严重；
c)无制动能量回收功能：RTG的起升机构下降、小车运行和大车行走机构减速制动时，因无储能装置，导致回馈的能量无法存储，必须通过能耗电阻实时消耗掉。
[发明内容]
针对RTG上述缺陷，本发明公开了一种轮胎式龙门起重机(RTG)的双动力节能系统，旨在实现动力输出功率与需求功率高度匹配，从而提高RTG的能源利用效率，降低RTG的整体能耗，节能减排。
本发明改变传统RTG以单一发电机组供电或以“发电机组+电池组”功率叠加式供电方式，采用发电机组和电池组双动力源，两个动力源均可独立满足RTG的正常作业功率需求。
电池组电量在设定范围时，RTG作业以电池组为动力源，实现动力源输出功率与RTG功率需求全程高度匹配；当电池组电量不足时启动发电机组提供动力。发电机组一旦投入运行，便控制在最佳经济油耗区运行，令发电机组以最高效率运行；发电机组给RTG直接供电时，富余能量给电池组充电，当电池组电量达到设定高位值时，关闭发电机组。
电池组充电功率大于RTG最大回馈能量功率，实现回馈能量全回收。
该系统详细说明如下：
a)发电机组和电池组均可独立支持RTG作业，形成RTG的“双动力”电源，当电池组故障时，可切换为发电机组模式作业，提高RTG的可靠性；
b)发电机组间歇性运行，当电池组电量达到系统设定高位值时关闭发动机，RTG动力完全由电池组提供；当电池组电量降至设定低位值时，启动发电机组，直接为RTG提供动力的同时富余能量为电池组充电。发电机组一旦投入运行，便始终运行在最佳经济油耗区，确保以最高效率运行；
c)RTG起升机构下降、小车运行和大车行走等机构制动减速时的回馈能量回收至电池组并实现循环利用。
本发明的目的可通过以下技术方案来实现：
在不改变RTG原有设备性能参数和结构的前提下，增加一组电池动力电 源系统，系统主要由电池组、逆变电源、24V直流电源以及系统控制器等组成。
逆变电源输入端与直流母线并联，输出端经过辅助变压器给RTG的照明、空调等辅助用电设备供电；24V直流电源输入端与直流母线并联，输出端为RTG控制系统提供直流电源。
本发明对旧RTG设备进行节能改造时，不需更换RTG原动力系统、不需要改动原设备任何参数和结构，仅需增加一组动力电池电源及控制系统，即可完成节能改造；对新制造的RTG设备，通过精确计算配置发电机组与电池组参数，节能效果更佳。
[附图说明]
图1：本发明双动力系统原理图；
图2：柴油万有特性曲线图。
[具体实施方式]
下面结合附图对本发明的具体实施方式做详细阐述。
如图1所示，本发明是一种工作时以电池组为主电源的RTG双动力节能系统，整套系统主要包含：系统控制器1、电池组及管理系统2、发电机组3、单向DC/AC逆变电源4、单向DC/DC直流电源5和辅助变压器6等组成，RTG与本系统关联的用电设备主要包括：起升机构变频器7、小车运行机构变频器8和大车行走机构变频器9以及辅助用电设备和控制电源等。
其中所述各部件连接方式及主要功能如下：
电池组2与RTG的直流母线连接，为工作机构提供动力、辅助电源和直流控制电源以及回收能量；逆变电源4的输入端与直流母线并联，输出端连接辅助变压器6，辅助变压器6输出AC380V/220V50Hz三相四线电源，给RTG 的照明、空调等辅助用电设备使用；24V直流电源的输入端与直流母线并联，输出端为提供RTG控制电源；发电机组3分二路输出，其中一路连接到RTG起升机构变频器7的交流输入端，经整流后与直流母线连接，为RTG工作机构供电或给电池组充电；另一路连接到辅助变压器6输入端，发电机组投入正常工作时，直接为辅助机构供电。
本系统的能量管理控制及工作原理详细说明如下：
根据电池的电量-电压特性设定电池组2的电压工作范围(或通过DC/DC)使之与变频器的电压工作范围匹配，确保RTG整机控制系统的稳定。
系统控制器1监控动力电池组2的电压、电量等状态；并控制发电机组3启动、怠速、全速或熄火。
当电池组2电量在设定工作范围内时，整机功率需求由电池组2通过直流母线提供；当电池组2的电量降至设定低位值时，启动发电机组3；发电机组3投入正常运转后，给RTG所有用电设备供电，富余能量给电池组2充电；随着电池组2的电量增加电压逐步升高，当电池组2的电压升至设定高位值时，系统控制器1控制发电机组3怠速运转一段时间后熄火，关闭发电机组3。
发电机组3输出功率控制：如图2柴油机万有特性曲线图，柴油机转速在1500转/分钟时输出为200～300kW之间时燃油效率最佳，系统控制器1控制发电机组3的输出功率在200kW～300kW。当电池组2电量较低启动时，由于电池组2的电压较低，充电电流较大，充电功率会大于发电机组3的额定输出功率，此时系统控制器1通过控制，限制电池组2的最大充电电流，确保充电功率与RTG正常工作的功率需求之和不大于发电机组3的额定功率——即控制发电机组3的输出功率小于300kW；随着电池组2的电压不断升高，充电电流逐步减小，当充电功率与RTG系统功率需求之和偏离发电机组3的经济油耗时——即低于200kW时，关闭发电机组3。发电机组3一旦投入工作，便始终在经济油耗区运行，燃油效率最高。
能量回收与控制：RTG每个工作循环均有一定比例的回馈能量，当回馈能量产生时，母线电压升高，回馈能量优先给逆变电源4和24V直流电源5供电，富余能量回收至电池组2；所回收的能量在RTG下一工作循环时使用；由于每次充放电均存在一定损耗，理论上所回收的能量可无限循环回收再利用直至接近“0”但永不归“0”，实现能量循环回收利用。
综上所述，本发明针对轮胎式龙门起重机的工作特性，提出了一种RTG双动力节能系统，采用一套电池组作为主动力电源，电池组可满足RTG在一段时间内的全电作业，实现动力源输出功率与设备功率需求全程完全匹配，提高能源效率；实现RTG制动能量回收并循环利用；发电机组一旦工作便控制在最佳能效下输出功率，能源效率最高；实现发动机不过载、不冒黑烟；缩短发电机组运行时间、延长维护保养周期。
本发明轮胎式龙门起重机双动力节能系统具备以下特点：
1、发电机组3和电池组2功率均可满足RTG的最大功率需求，可独立支持RTG正常工作，提高设备可靠性；RTG作业时以电池组2为主动力电源，电池组2的输出功率与RTG功率需求全程完全匹配，提高能源效率；
2、发电机组3间歇性工作，机组一旦投入工作，便控制在经济油耗区运转，燃油效率高，并确保发动机不过载、不冒黑烟；缩短发动机运行时间，延长维护保养周期。
3、实现RTG回馈能量的全回收并循环利用。
4、本系统应用于旧RTG改造时，可不更换原发电机动力系统和不改变原设备的性能参数及结构，降低改造成本；应用于新造RTG设备时，通过精确计算配置的发电机组和电池组参数，节能率更高。
以上所述的本发明实施方式，并不构成对本发明保护范围的限定。任何在本发明的精神和原则之内所作的修改、等同替换和改进等，均应包含在本发明的权利要求保护范围之内。

Claims (4)

  1. 一种轮胎式龙门起重机(RTG)双动力节能系统，其特征在于：包括系统控制器、电池组及管理系统、发电机组、单向DC/AC逆变电源、单向DC/DC直流电源和辅助变压器，RTG与本系统关联的用电设备主要包括：起升机构变频器、小车运行机构变频器和大车行走机构变频器以及辅助用电设备和控制电源；
    其中各功率模块连接方式与主要功能如下：
    电池组：与RTG工作机构变频驱动器的直流母线并联，为工作机构提供动力以及辅助电源、24V直流电源供电；另外，当工作机构有逆变能量回馈时，通过直流母线给逆变电源供电或回收至电池组；
    逆变电源：输入端与直流母线并联，将直流电逆变转换成交流电输出，输出端连接辅助变压器6，辅助变压器6输出AC380V/220V50Hz三相四线电源，给RTG的照明、空调等辅助用电设备使用；
    24V直流电源：输入端与直流母线联接，输出端为RTG控制电源供电；
    发电机组：二路输出，其中一路连接到RTG起升机构变频器7的交流输入端，经整流后与直流母线并联，为RTG工作机构、逆变电源、24V直流电源供电或给电池组充电；另一路连接到辅助变压器输入端，发电机组投入正常工作时，直接为辅助机构供电。
    发电机组和电池组均可独立支持RTG正常作业，RTG以电池组为主动力源，输出功率与需求功率高度匹配；发电机组间歇性工作，发电机组一旦投入运转便控制在经济油耗区工作，发电机组要么在经济油耗区工作，要么怠速或熄火停机，节能减排的同时提高RTG动力可靠性。
  2. 根据权利要求1所述的轮胎式龙门起重机(RTG)双动力节能系统，其特征在于：本系统的电池组电压工作范围与RTG变频驱动器电压工作范围完全匹配，电池组可以不加设DC/DC直接与RTG工作机构的变频驱动器直流母线并联，无论电池组是否经过DC/DC再并入直流母线均属于本发明权利要 求范围。
  3. 根据权利要求1所述的轮胎式龙门起重机(RTG)双动力节能系统，其特征在于：系统应用于RTG改造时，不需要更换RTG原有发电机组。
  4. 根据权利要求1所述的轮胎式龙门起重机(RTG)双动力节能系统，其特征在于：电池组充电功率大于RTG最大回馈能量功率，实现RTG回馈能量全回收。
PCT/CN2015/096279 2014-12-05 2015-12-03 一种轮胎式龙门起重机双动力节能系统 WO2016086872A1 (zh)

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