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新型单梁起重机轻量化设计节能技术
发布时间: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、技术名称:新型单梁起重机轻量化设计节能技术

二、技术所属领域及适用范围:通用机械行业 各种通用单梁起重机
三、与该技术相关的能耗及碳排放现状
通用单梁起重机是一种应用量大面广的机械设备之一。现有通用单梁起重机,受传统的设计理念局限,产品自重过大,制造成本过高,运行耗能较高。采用现代设计理论及科学设计方法对传统产品进行轻量化设计,可实现节能、节材、节电的目的,是通用单梁起重机产品升级的重点任务之一。目前应用该技术可实现节能量2万tce/a,CO2减排约5万t/a。
四、技术内容
1.技术原理
(1)采用模块设计,将起升机构的电动机+减速器+制动器设计组成一个模块,分设17kW、32kW和63kW三个机型,灵活组织批量生产;根据不同起重量组合成14个吨位的起升机构;将车轮设计成φ250mm、φ315mm、φ400mm、φ500mm四个模块,按不同的起重量和跨度、最大承载能力可设计成四轮、八轮和十六轮等结构;
(2)起重机的主梁采用全偏轨设计,小车运行轨道采用方钢;
(3)控制系统采用PLC变频调速技术,各机构采用变频调速、PLC可变控制程序、在线监控、故障显示及报警,机构互相连锁,实现调速和控制一体化。
2.关键技术
(1)起重小车的轻量化设计的研究;
(2)起重桥架的轻量化设计的研究;
(3)大小车行走机构的轻量化设计的研究;
(4)运行机构安全保护限位装置的设计研究;
(5)主梁自动焊接技术的研究与应用;
(6)起重机各机构采用变频调速、PLC可变控制程序、在线运行监控、故障显示及报警,机构互相连锁,实现调速和控制一体化。
(7)轻量化单梁起重机配套技术研究。
五、主要技术指标
1.起重量5-100t;
2.起重机每台平均节电率约37.9%;
3.起重机每台平均节约钢材率18.0%;
4.起重机每台平均自重减轻34.4%;
5.在不改变原厂房的结构基础上起重量可提升25%。
六、技术鉴定、获奖情况及应用现状
该技术已获得3项实用新型专利,并于2010年通过了浙江经信委组织的技术成果鉴定。目前全国总共有15台该类型的设备在使用。
七、推广前景及节能减排潜力
预计未来5年,该技术可在全国单梁起重机使用企业推广20%,形成的年节能能力可达35万tce,年减排能力92万tCO2。
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