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(shù)名稱：新型單梁起重機輕量化設(shè)計節(jié)能技術(shù)

二、技術(shù)所屬領(lǐng)域及適用范圍：通用機械行業(yè) 各種通用單梁起重機
三、與該技術(shù)相關(guān)的能耗及碳排放現(xiàn)狀
通用單梁起重機是一種應(yīng)用量大面廣的機械設(shè)備之一。現(xiàn)有通用單梁起重機，受傳統(tǒng)的設(shè)計理念局限，產(chǎn)品自重過大，制造成本過高，運行耗能較高。采用現(xiàn)代設(shè)計理論及科學(xué)設(shè)計方法對傳統(tǒng)杭州起重機產(chǎn)品進行輕量化設(shè)計，可實現(xiàn)節(jié)能、節(jié)材、節(jié)電的目的，是通用單梁起重機產(chǎn)品升級的重點任務(wù)之一。目前應(yīng)用該技術(shù)可實現(xiàn)節(jié)能量2萬tce/a，CO2減排約5萬t/a。
四、技術(shù)內(nèi)容
1.技術(shù)原理
(1)采用模塊設(shè)計，將起升機構(gòu)的電動機+減速器+制動器設(shè)計組成一個模塊，分設(shè)17kW、32kW和63kW三個機型，靈活組織批量生產(chǎn);根據(jù)不同起重量組合成14個噸位的起升機構(gòu);將車輪設(shè)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(shè)計成四輪、八輪和十六輪等結(jié)構(gòu);
(2)起重機的主梁采用全偏軌設(shè)計，小車運行軌道采用方鋼;
(3)控制系統(tǒng)采用PLC變頻調(diào)速技術(shù)，各機構(gòu)采用變頻調(diào)速、PLC可變控制程序、在線監(jiān)控、故障顯示及報警，機構(gòu)互相連鎖，實現(xiàn)調(diào)速和控制一體化。
2.關(guān)鍵技術(shù)
(1)起重小車的輕量化設(shè)計的研究;
(2)起重橋架的輕量化設(shè)計的研究;
(3)大小車行走機構(gòu)的輕量化設(shè)計的研究;
(4)運行機構(gòu)安全保護限位裝置的設(shè)計研究;
(5)主梁自動焊接技術(shù)的研究與應(yīng)用;
(6)起重機各機構(gòu)采用變頻調(diào)速、PLC可變控制程序、在線運行監(jiān)控、故障顯示及報警，機構(gòu)互相連鎖，實現(xiàn)調(diào)速和控制一體化。
(7)輕量化單梁起重機配套技術(shù)研究。
五、主要技術(shù)指標(biāo)
1.起重量5-100t;
2.起重機每臺平均節(jié)電率約37.9%;
3.起重機每臺平均節(jié)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(jié)構(gòu)基礎(chǔ)上起重量可提升25%。
六、技術(shù)鑒定、獲獎情況及應(yīng)用現(xiàn)狀
該技術(shù)已獲得3項實用新型專利，并于2010年通過了浙江經(jīng)信委組織的技術(shù)成果鑒定。目前全國總共有15臺該類型的設(shè)備在使用。
七、推廣前景及節(jié)能減排潛力
預(yù)計未來5年，該技術(shù)可在全國單梁起重機使用企業(yè)推廣20%，形成的年節(jié)能能力可達35萬tce，年減排能力92萬tCO2。