20-5噸雙梁橋式起重機設計【含4張CAD圖紙+文檔全套】
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未來中國起重機的發(fā)展方向
隨著中國經(jīng)濟的不斷發(fā)展,現(xiàn)代科學技術不斷更新，工業(yè)生產(chǎn)規(guī)模的擴大和自動化程度的提高，起重機在現(xiàn)代化生產(chǎn)過程中應用越來越廣，作用愈來愈大，對起重機的要求也越來越高。尤其是電子計算機技術的廣泛應用，促使了許多跨學科的先進設計方法出現(xiàn)，推動了現(xiàn)代制造技術和檢測技術的提高。激烈的國際市場競爭也越來越依賴于技術的競爭。這些都促使起重機的技術性能進入嶄新的發(fā)展階段，起重機正經(jīng)歷著一場巨大的變革。
我國正以前所未有的速度進入全球化國際競爭市場，中國的起重機制造業(yè)面臨著機遇與挑戰(zhàn)并存的新形勢。因此中國起重機要不斷發(fā)展和創(chuàng)新。現(xiàn)根據(jù)國內(nèi)外起重機的新理論、新技術和新動向，結合實例，簡要論述現(xiàn)代起重機的特征和未來中國起重機的發(fā)展方向。
1.重點產(chǎn)品大型化、高速化
由于工業(yè)生產(chǎn)規(guī)模不斷擴大，生產(chǎn)效率日益提高，以及產(chǎn)品生產(chǎn)過程中物料裝卸搬運費用所占比例逐漸增加，促使大型或高速起重機的需求量不斷增長。起重量越來越大，工作越來越頻繁，并對能耗和可靠性提出更高的要求。起重機已成為自動化生產(chǎn)流程中的重要環(huán)節(jié)。起重機不但要好用，容易維護，操作方便，而且安全性要好，故障要少，平均無故障工作時間要長?？煽啃允菄H市場產(chǎn)品競爭的焦點，國外許多大公司都制定了可靠性內(nèi)控標準。我國起重機的性能要趕超世界先進水平，最關鍵的是要改變傳統(tǒng)的思維理念,提高可靠性，使起重機具有優(yōu)異的耐久性、無故障性、維修性和使用經(jīng)濟性。
2、系列產(chǎn)品模塊化、標準化、組合化和實用化
許多起重機是成系列成批量的產(chǎn)品，采用系統(tǒng)多目標整體優(yōu)化方法進行起重機系列設計已成為發(fā)展重點，通過全面考慮性能、成本、工藝、生產(chǎn)管理、制造批量和使用維護等多種因素對系列主參數(shù)進行合理匹配，以達到改善整機性能．降低制造成本，提高通用化程度，用較少規(guī)格數(shù)的零部件組成多品種、多規(guī)格的系列產(chǎn)品，充分滿足用戶需求。
用模塊化設計代替?zhèn)鹘y(tǒng)的整機設計方法，將起重機上功能基本相同的構件、部件和零件 制成有多種用途，有相同聯(lián)接要素和可互換的標準模塊，通過不同模塊的組合，形成不同類型和規(guī)格的起重機。對起重機進行改進，只需針對某幾個模塊。設計新型起重機，只需選用不同模塊重新進行組合。由于提高了通用化程度，可使單件小批生產(chǎn)的產(chǎn)品改換成具有相當批量的模塊生產(chǎn)，實現(xiàn)高效率的專業(yè)化生產(chǎn)，降低制造成本。能以較少的模塊形式，組合成多品種多規(guī)格的起重機，滿足市場需求，增加競爭能力。
3、通用產(chǎn)品輕型化、小型化和多樣化
有相當批量的起重機是在一般的車間倉庫使用，要求并不很高，工作并不十分繁重。如何提高這些起重機的適用性，降低制造成本，是市場競爭能否獲勝的關鍵。考慮綜合效益，要求起重機盡量降低外形高度，簡化結構，減小自重和輪壓，也可使整個建筑物高度下降，建筑結構輕型化，降低造價和使用維護費用。因此電動葫蘆橋式起重機和輕型梁式起重機會有更快的發(fā)展，并將大部分取代中小噸位一般用途橋式起重機。
用戶的需求性促進了起重機的多樣性。起重機的系列參數(shù)范圍進一步擴大，功能選擇進一步增加，一機多用產(chǎn)品進一步得到發(fā)展，以增強應變能力。在一般使用場合采用無線遙控操作的比例也將逐步增多。
芬蘭科尼起重機公司經(jīng)過長期的開發(fā)和創(chuàng)新，已形成一個輕型組合式標準起重機系列。整個系列由組合式工字形單梁、箱形單梁、懸掛箱形單梁、角形小車箱形單梁、偏軌箱形雙梁和UKA流動工作站多個品種組成。主梁與端梁相接共有20多種形式，可適合不同建筑物和不同起吊物的要求。每種規(guī)格起重機都有三種單速及三種雙速可供任意選擇，并且大小車運行采用變頻控制作為標準配置，還能根據(jù)客戶要求、使用工況做針對性的設計。操縱方式有地面手電門自行移動、手電門隨小車移動、手電門固定、遠紅外或無線電遙控、司機室固定、司機室隨小車移動、司機室自行移動、PLC編程控制等多種選擇，外加不同的導電形式，不同的電控形式，通過不同的組合，可搭配成百上千種起重機，充分滿足用戶不同的需求。
4、產(chǎn)品性能自動化、智能化和集成化
起重機的更新和發(fā)展，很大程度上取決于電氣傳動與控制的改進。將自動化技術和機械傳動技術相結合，將先進的微電子技術、電力電子技術、光纜通訊技術、液壓技術、模糊控制技術應用到機械的驅(qū)動和控制系統(tǒng)，實現(xiàn)自動化和半自動化。使起重機組成的物料搬運系統(tǒng)具有更高的柔性，以適應未來多批次少批量的柔性生產(chǎn)模式。
大型高效起重機的新一代電氣控制裝置已發(fā)展為全電子數(shù)字化控制系統(tǒng)。主要由全數(shù)字化控制驅(qū)動裝置、可編程序控制器PLC、故障診斷及數(shù)據(jù)管理系統(tǒng)、數(shù)字化操縱給定檢測等設備組成。它賦于起重機以信息功能，可進行信息傳遞、處理及動力控制，大大提高了綜合自動化水平。目前控制方面重點發(fā)展吊具防偏防搖技術，取物裝置自動取、卸物技術，位置檢測及自動位置控制技術，故障自診斷監(jiān)控技術等。
電氣傳動方面重點開發(fā)以微處理機為核心的高性能電氣傳動裝置，使起重機具有優(yōu)良的調(diào)速和靜動特性，可進行操作的自動控制、自動顯示與記錄，起重機運行的自動保護與自動檢測，復雜條件下的遠距離遙控等，以適應自動化生產(chǎn)的需要。
科尼起重機針對一些特殊行業(yè)，采用激光裝置查找起吊物的重心位置，依靠超聲波傳感器引導取物裝置抓取貨物。大車和小車運行采用編碼軌系統(tǒng)測定路徑，起升高度采用恒定張緊的測量索和角度發(fā)生器測定。起重機采用磁場變換器或激光達到高精度定位。起重機上安裝了近場感應系統(tǒng)，可避免起重機之間的互相碰撞。采用無線遙控時載重稱量也能在遠控發(fā)射機上顯示。起重機上還裝有微機自診斷監(jiān)控系統(tǒng)，該系統(tǒng)能提供大部分常規(guī)維護檢查內(nèi)容，如鋼絲繩狀況，減速器油溫油位，車輪軸承溫度，起重機載荷、應力和振動情況，制動器摩擦襯片的壽命及溫度狀況等。
5、產(chǎn)品設計微機化、精確化和快速化
隨著電子計算機技術的廣泛應用和系統(tǒng)工程、優(yōu)化工程、價值工程、可靠性工程、創(chuàng)造工程和人機工程等現(xiàn)代設計理論的不斷發(fā)展，促使許多跨學科的現(xiàn)代設計方法出現(xiàn)，使起重機的設計進入創(chuàng)新、高質(zhì)量、高效率的新階段。目前，計算機輔助設計(CAD)已逐步深入到設計的各個階段和設計工作所涉及的各個領域。不僅能利用計算機運算速度快、計算精度高、存儲信息量大和邏輯推理能力強等優(yōu)點代替人工進行方案選擇、計算分析與繪圖，而且還能通過人機交互，最大限度地發(fā)揮設計人員的創(chuàng)造力和經(jīng)驗。國際上一些大型的起重機公司都廣泛應用CAD徹底拋棄了傳統(tǒng)的圖板。并且還與計算機輔助工藝規(guī)劃(CAPP)和計算機輔助制造(CAM)相銜接，做到了無圖化生產(chǎn)。
芬蘭科尼起重機公司對其所有產(chǎn)品采用三維模擬仿真設計，對每個受力點進行模擬計算，使每個配件都能發(fā)揮理想的效用；并且科尼起重機公司以預先編制程序和設計標準為基礎開發(fā)了高質(zhì)，高效和先進的設計軟件以確保起重機的安全性和可靠性。采用相同和標準的方法設計起重機和選擇科尼的標準零部件，遍布全球的科尼工程師均可采用公司集中開發(fā)的軟件，方便而先進的工程軟件使得起重機設計更便捷和可靠。鋼結構的優(yōu)化設計和零部件正確選擇確保起重機在其整個壽命內(nèi)安全可靠，級別適宜，性能穩(wěn)定。
隨著起重機的高速化和大型化，還需進一步深入開展對起重機載荷變化規(guī)律、動態(tài)特性和疲勞特性的研究。進一步開展對起重機整機及零部件的可靠性試驗研究，提供起重機新的設計方法和數(shù)據(jù)。極限狀態(tài)設計、優(yōu)化設計、可靠性設計、有限元法、模塊化設計、疲勞設計將會更深入全面地得到應用。
6、產(chǎn)品構造新型化、美觀化和綜合化
結構方面采用薄壁型材和異型鋼，減少結構的拼接焊縫，提高抗疲勞性能。采用各種高強度低合金鋼新材料，提高承載能力，改善受力條件，減輕自重和增加外形美觀。橋式類型起重機橋架大多采用箱形四梁結構(兩根端梁,兩根主梁)，主梁與端梁采用高強度螺栓聯(lián)接，便于加工、運輸與安裝。
在機構方面進一步開發(fā)新型傳動零部件，簡化機構。“三合一”運行機構由于結構緊湊。拆裝方便、調(diào)整簡單并運行平穩(wěn)，將成為起重機運行機構的主流，減速器殼體、卷筒及滑輪等的制造都以焊代鑄，能減輕自重、增加承載能力和改善加工制造條件。減速器齒輪采用硬齒面，以減小體積，提高承載能力，增加使用壽命。
7、售后服務快捷化、專業(yè)化和人性化
公司的發(fā)展很大程度來自于售后服務是否完善，對客戶來說自己所購買的產(chǎn)品售后是否有保障，設備出現(xiàn)故障時能否即時處理，減少對生產(chǎn)的影響。
芬蘭科尼起重機公司在電氣系統(tǒng)方面采用了接插件設計，每部分控制電路都采用對號入座，大大提高了安裝與維修的效率；在電氣系統(tǒng)中加入了監(jiān)控單元，對電氣系統(tǒng)進行故障自檢，電子顯示屏顯示錯誤信息，并對使用過程中的違規(guī)操作進行數(shù)據(jù)儲存，這些數(shù)據(jù)都可以導入PC設備，從而很快的分析出原因，排出故障。科尼的培訓中心，不僅僅只為科尼公司的技術人員和檢測人員提供培訓，同時也為客戶的服務人員，起重機操作人員提供系統(tǒng)全面的設備培訓?？颇帷耙钥蛻魹楸尽钡淖谥迹瑸榭蛻艚獬箢欀畱n，使客戶能把更多的關注投入到生產(chǎn)發(fā)展上。
總結過去，中國的起重機應吸取國內(nèi)外起重機的新理論、新技術和新動向，提高產(chǎn)品的可靠性，走現(xiàn)代化起重機之路，以強大的技術實力，融入國際化市場的大舞臺！
China's future development direction of crane
Along with China's economic development, modern science and technology constantly updated, the expansion of the scale of industrial production and automation degree rise, crane in modern production process used more and more widely, and more and more big role, to the requirements of the crane more and more is also high. Especially the wide application of electronic computer technology, prompted many interdisciplinary advanced design method appears, promote the modern manufacturing technology and detection technology improvement. The fierce international competition in the market also rely more and more on technology competition. These have prompted the crane technical performance into a new stage of development, crane is experiencing a big changes.
country is in an unprecedented speed into the global international competition market, China's crane manufacturing are facing opportunities and challenges of the new situation. Thus China's development and innovation to crane. Now according to the domestic and foreign crane of new theories, new technology and new trends, combined with examples, briefly discusses the modern crane characteristics and the future development direction of Chinese crane.
1. The key product large-scale, quick running
With the industrial production scale unceasingly expands, the production efficiency is increasing day by day, and the product manufacturing process materials handling fee increase gradually proportion, prompting the large or high-speed crane growing demand. The weight is more and more big, the work is more and more frequent, and the energy consumption and demand higher reliability. Crane has become an important link in the automatic production process. Crane is not only to use, easy maintenance, convenient operation, and better safety, failure to less, the average trouble-free time should be long. Reliability is the focus of the products in the international market competition, the overseas many big companies have formulated reliability internal control standards. The performance of the crane to catch up in the advanced world level, the most important thing is to change the traditional thinking principle, improve reliability to make excellent durability, crane sex, maintainability and use without efficiency.
2.series product modularization, standardization, combination, and practical
Many crane is a series of batch into product, the whole system multiobjective optimization methods for crane series design has become the focus of development, through the overall consideration performance, cost and process, production management, manufacturing batch and maintenance of the many factors such as parameters for reasonable matching series, in order to improve the comprehensive performance. Reduce manufacturing cost, improve generalization degree, with a relatively small number of parts specifications many varieties and specifications of products, fully meet user requirements.
Use the modular design of the whole machine instead of traditional design method, the crane function basically the same components, components and parts are made from a variety of purposes, with the same connection elements and interchangeable standard module, through the combination of different modules, form different types and specifications of the crane. In crane was improved, just for one several modules. A new design crane, need to choose different modules combination again. Due to improve the generalization degree, can make mini-batch production of products with a batch convert the module production, achieve high efficiency specialized production, reduce the production cost. To less module form, a combination of many specifications varieties of crane, meet the market demand, increasing competition ability.
3. general product light-duty, miniaturization, and diversification
There are quite a batch of crane is in general use workshop warehouses, the requirement is not very high, work is not very heavy. How to improve the applicability of the crane, reduce manufacturing cost, is the market competition can the keys of success. Consider benefit, and requirements to minimize appearance crane height, simplified structure, reduce weight and wheel pressure, also can make the whole building highly drop, light-duty architecture structure, reduce the costs and maintenance costs. So the electric hoist bridge crane and light beam type faster development opportunity lifting, and will replace most of medium and small tonnage general purpose bridge crane.
The user needs of promoting the diversity of crane. The crane series parameters range further expand, function selection to further increase, multi-use further develop products, in order to improve capability. In general use occasions the remote proportion also will gradually increase.
Finland coney crane companies after long-term development and innovation, and has formed a light combined standard crane series. The whole series single by combined i-section box single-girder, hanging box single-girder, Angle form small trunk form, partial rail single box beam and flow workstation double UKA of varieties. The main girder beams with various forms of 20 connect, suitable for different buildings and different lifted the requirement of content. Each specification cranes have three single speed and three double speed for any choice, and the big car running USES frequency conversion control as standard equipment, can also according to the customer request, do the design of specific aim operating conditions. Control have ground flashlight door to mobile, flashlight door with the small car mobile, flashlight door fixed, far infrared remote control, the driver or radio fixed, driver, with room room car mobile, the driver room to move, PLC program control and so on many kinds of choices, and different conducting form, the application of different forms, through the different combination, can match hundreds or thousands of kind of crane, fully meet the needs of different users.
4. product performance automation, intelligent and integration
Crane update and development, to a great extent, depends on the electric drive and control improvement. Will automation technology and mechanical transmission technologies, advanced microelectronics technology, will power electronic technology, fiber optic cable communication technology, the hydraulic pressure technology, the fuzzy control technology is applied to mechanical drive and control system, and realize the automatic and semi-automatic. Make up of crane materials handling system has higher flexible, to meet the future batches of small quantity flexible production mode.
Large efficient crane of a new generation of electrical control equipment has been developed as the electronic digital control system. Mainly by the digital control drive device, PLC programmable controller, fault diagnosis and data management system, digital manipulation of a given detection equipment. It with the information function of the crane fu, information transmission, processing and power control, greatly improving the integrated automation level. Currently control key development sling anti-eccentrically the wave technology, take content device to be automatic take things, unloading technology, position detection and automatic position control technology, fault diagnosis monitoring technology, etc.
Electric drive in microprocessor key development as the core of the high-performance electric transmission device, make the crane with excellent speed and static dynamic characteristics, can undertake operating automatic control, automatic shows and records, crane operation of the automatic protection and automatic detection, under complicated conditions such as long distance remote, in order to adapt to the needs of the production of the automation.
Coney crane for some special industries, using laser device it the center of gravity of the search that position, rely on ultrasonic sensors guide take content device grab goods. And the car running the cart coding rail systems measure path, lifting height of the constant tensioning measurement cable and Angle generator determination. Crane used magnetic field or laser achieve high precision positioning converter. The crane installed near field induction system, can avoid the each other between crane collision. Using wireless remote control truck when weighing also can be in that remote control on the launch. The crane with microcomputer diagnosis monitoring system, this system can provide most of the routine maintenance and inspection content, such as wire rope status, reducer oil temperature oil level, wheel bearing temperature, crane load, stress and vibration, the brake friction burr and life expectancy of the temperature condition and so on.
5. the design of the product of computerization, precision and quickly
Along with the wide application of electronic computer technology and system engineering, optimizing the engineering, value engineering, reliability engineering, engineering and man-machine engineering to create the development of the modern design theory, prompting many interdisciplinary modern design method appears, make the design of the crane, high quality, and innovation in the new stage of high efficiency. At present, the computer aided design (CAD) has gradually into the design of each stage and design work involved in various fields. Don't
Can only use computer operation speed, high precision, store information and logical reasoning ability strong advantages to replace artificial scheme selection and calculation analysis and drawing, but also through the human-computer interaction, maximum design personnel's creativity and experience. Some large crane on international companies are widely used CAD thoroughly discards the traditional board. And still with computer aided process planning (CAPP) and computer aided manufacturing (CAM) link up, do no pictures of production.
Finland coney crane company on the product all the 3 d simulation design, each bearing point to simulate calculation, and that every accessories can play the ideal utility; And coney crane company with programmed procedures and design standards for the development foundation of high quality, high efficient and advanced design software to ensure the safety and reliability of the crane. Use the same standard method and design and choice of crane coney standard parts, all over the world's coney engineers are can use focuses on the development of software, convenient and advanced engineering software makes crane design more convenient and reliable. The steel structure of the optimization design and the parts to ensure the correct choice in the whole span crane safe, reliable, and suitable for level, stable performance.
Along with the fast pace and large crane, must have further research on crane load change rule, dynamic characteristic and fatigue property of research. Further research on the reliability of the machine parts and crane test research, a new design method and provide crane data. Limit state design, optimization design, design reliability, finite element method, the modular design, fatigue design will be more comprehensive, to get the application.
6. product structure, MeiGuanHua and integration of new type
The structure of a thin-walled profile and the special-shaped steel, reduce the joining together of weld structure, improve the anti-fatigue performance. With various kinds of high strength low alloy steel new materials, improve the bearing capacity, improve the stress condition, reduce weight and increase the beautiful appearance. Bridge type type crane bridge is used mostly box four beam structure (two of the girders, two of the main girder), the main girder beams with high strength bolt connection, and facilitate processing, transportation and installation.
Further development in institutions new transmission parts, simplifying the mechanism. "" operation organization because of compact structure. Disassembling convenient, easy adjustment and smooth operation, will become the mainstream of the crane operation organization, reducer, drum and pulley shell in the manufacturing welding generation cast, it can reduce weight, increase the bearing capacity and improving processing manufacturing conditions. Using a reduction gear tooth surface, in order to reduce the volume, improve the bearing capacity, increase the service life.
7. and after-sales service, professional and humanized high-speeding
The development of the company to a great degree from after-sales service is perfect to the customer to purchase the products for your after-sales if there is security, equipment failure can real-time processing, and to reduce the influence of the production.
Finland coney crane companies in the electrical system adopt the connector design, each part of the control circuit is adopted by the reserved seats, greatly improving the installation and maintenance of the efficiency; In the electrical system with the monitoring unit, to the electric breakdown self check system, electronic display screen display an error message, and the deregulation operation in the process of using data storage, these data are can import PC devices, and the analysis of the reason out soon, discharge fault. Coney training center, not only for coney corporate technicians and testing personnel to provide training, but also for the customer the service personnel, crane operatio personnel to provide comprehensive training system of the. Co equipment ney "customers foremost" purpose for the customer remove trouble back at home, so that customers can put more attention to production development in.
Learn from the past, China should learn from the domestic and foreign crane crane new theories, new technology and new trend, improve the reliability of products, go way of modern crane, with strong technical strength and into the international market big stage!
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