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新型單梁起重機輕量化設計節能技術

發布時間:2015-06-02

Technology Name: new single beam crane lightweight design energy saving technology

Two. Technical field and applicable scope: general machine industry all kinds of general single girder crane

Three, and the technology related energy consumption and carbon emissions status quo

General purpose single girder crane is one of the mechanical equipments with wide application.. Existing general single girder crane, limited by the traditional design concept, product weight is too large, manufacturing costs are too high, running high energy consumption. Lightweight design for the traditional products with modern design theory and the scientific design method, to achieve the purpose of energy saving, material saving and power saving, general single beam crane product upgrades, one of the key tasks. At present, the technology can realize the energy of 20000 tce/a, CO2 emission reduction of about 50000 t/a.

Four, technical content

1 technical principle

(1) adopts modular design and the lift mechanism of motor + reducer + brake design consisting of a module, divided into 17kw, 32kw and 63kw three models, the flexible organization of mass production; according to the different weight combinations into 14 tonnage hoisting mechanism; the wheel design into four modules: 250mm, Phi 315 mm and the diameter of 400mm, 500mm, according to different lifting capacity and span, the maximum carrying capacity can be designed into four wheel, eight rounds and 16 wheel structure.

(2) the whole crane girder using partial rail design, car running track with square steel;

(3) the control system adopts PLC variable frequency speed adjusting technology, each institution adopts frequency conversion, PLC variable control program, on-line monitoring, malfunction and alarming, and the linkage of the mechanism to realize speed control and control.


Seven, promotion prospects and energy-saving emission reduction potential

Is expected in the next 5 years, the technology can be used in the national single girder crane promotion of 20%, the formation of energy-saving capacity of up to 350000 TCE, the annual emission reduction capacity of 920000 tCO2.


一、技術名稱:新型單梁起重機輕量化設計節能技術

二、技術所屬領域及適用范圍:通用機械行業 各種通用單梁起重機
三、與該技術相關的能耗及碳排放現狀
通用單梁起重機是一種應用量大面廣的機械設備之一?,F有通用單梁起重機,受傳統的設計理念局限,產品自重過大,制造成本過高,運行耗能較高。采用現代設計理論及科學設計方法對傳統杭州起重機產品進行輕量化設計,可實現節能、節材、節電的目的,是通用單梁起重機產品升級的重點任務之一。目前應用該技術可實現節能量2萬tce/a,CO2減排約5萬t/a。
四、技術內容
1.技術原理
(1)采用模塊設計,將起升機構的電動機+減速器+制動器設計組成一個模塊,分設17kW、32kW和63kW三個機型,靈活組織批量生產;根據不同起重量組合成14個噸位的起升機構;將車輪設計成φ250mm、φ315mm、φ400mm、φ500mm四個模塊,按不同的起重量和跨度、最大承載能力可設計成四輪、八輪和十六輪等結構;
(2)起重機的主梁采用全偏軌設計,小車運行軌道采用方鋼;
(3)控制系統采用PLC變頻調速技術,各機構采用變頻調速、PLC可變控制程序、在線監控、故障顯示及報警,機構互相連鎖,實現調速和控制一體化。
2.關鍵技術
(1)起重小車的輕量化設計的研究;
(2)起重橋架的輕量化設計的研究;
(3)大小車行走機構的輕量化設計的研究;
(4)運行機構安全保護限位裝置的設計研究;
(5)主梁自動焊接技術的研究與應用;
(6)起重機各機構采用變頻調速、PLC可變控制程序、在線運行監控、故障顯示及報警,機構互相連鎖,實現調速和控制一體化。
(7)輕量化單梁起重機配套技術研究。
五、主要技術指標
1.起重量5-100t;
2.起重機每臺平均節電率約37.9%;
3.起重機每臺平均節約鋼材率18.0%;
4.起重機每臺平均自重減輕34.4%;
5.在不改變原廠房的結構基礎上起重量可提升25%。
六、技術鑒定、獲獎情況及應用現狀
該技術已獲得3項實用新型專利,并于2010年通過了浙江經信委組織的技術成果鑒定。目前全國總共有15臺該類型的設備在使用。
七、推廣前景及節能減排潛力
預計未來5年,該技術可在全國單梁起重機使用企業推廣20%,形成的年節能能力可達35萬tce,年減排能力92萬tCO2。
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