通用橋式起重機說明書

1、一、概述本說明書適用于各類橋式起重機（包括吊鉤、抓斗、電磁、防爆、絕緣、兩用、三用、鑄造等）的安裝、維修，供安裝、操作和維修人員使用。（一）起重機的主要用途電動橋式起重機用于工廠、電站、庫房、料場等固定跨間內(nèi)搬運物料，安裝維修設備按用途及取物裝置可以分以下幾種類型：1.吊鉤橋式起重機適用于廠礦、企業(yè)車間、倉庫等在室內(nèi)或室外的固定跨間作一般裝卸及起重運輸工作，常用工作級別一般為A3A6。A3A4適用于設備安裝維修用，A5適用于機械加工、金屬結(jié)構(gòu)、裝配，A6適用于工作繁忙或經(jīng)常滿負荷工作的工況。該起重機不適用于吊運易燃、易爆危險物品或高溫液體金屬。2.抓斗橋式起重機適用于冶金、化工、水泥及其他企業(yè)

2、的倉庫和車間，在室內(nèi)或露天的固定跨間從事礦石、石灰石、煤、砂等散粒物料的搬運工作。抓取裝置為雙卷筒的四繩平口抓斗。抓斗可在任意高度張開和閉合，當抓取物料塊大于60mm以上需選用帶齒抓斗。3.電磁橋式起重機1）電磁橋式起重機電磁橋式起重機電磁橋式起重機帶有可卸的電磁盤，適用于冶金工廠較繁忙地裝卸及搬運具有磁性的黑色金屬制品和材料，電磁盤由小車上的電纜卷筒直接供電。電磁橋式起重機的額定起重量是指電磁盤的重量和被起升物品重量的總和。2）電磁掛梁橋式起重機電磁掛梁橋式起重機帶有可拆卸或不可拆卸的掛梁及電磁盤，主要適用于造船、鋼鐵等行業(yè)吊運超長形鋼鐵物料，電磁掛梁下可設有多個電磁盤，電磁盤由小車上的電纜

3、卷筒直接供電或在掛梁上安裝電纜筐。電磁掛梁方向按用戶要求可平行于或垂直于主梁。3）上旋轉(zhuǎn)電磁掛梁橋式起重機上旋轉(zhuǎn)電磁掛梁橋式起重機是由上部可旋轉(zhuǎn)的小車帶動掛梁及電磁盤旋轉(zhuǎn)的起重機，主要適用于鋼鐵企業(yè)成品跨車間。4）下旋轉(zhuǎn)電磁橋式起重機下旋轉(zhuǎn)電磁橋式起重機是由掛梁上的旋轉(zhuǎn)機構(gòu)帶動吊具及被吊物旋轉(zhuǎn)的起重機。4.兩用橋式起重機分為抓斗-電磁兩用和抓斗-吊鉤兩用，為了提高生產(chǎn)效率，在同一臺小車上同時安裝有吊鉤和抓斗或者電磁盤和抓斗，但每一工作循環(huán)只能使用其中一種取物裝置。5.三用橋式起重機帶有可卸電磁盤、馬達抓斗或重力抓斗、吊鉤的起重機，稱為三用起重機，三用取物裝置可以互換使用，可運送成品件、散粒物品

4、或帶磁性的金屬材料，但每次只能使用其中的一種吊具。6.防爆吊鉤橋式起重機防爆起重機適用于具有易燃、易爆混合氣體的車間、倉庫等，作一般運輸作業(yè)。防爆等級根據(jù)JB5897-1991標準的規(guī)定有兩大類，類為礦用起重機，類為工廠用起重機。該起重機電氣設備均具有防爆性能，機械部分也采取相應的防爆措施，防止起重機在運行過程中可能產(chǎn)生的火花而引起燃燒或爆炸事故的發(fā)生。各類防爆電器均有“EX”標識。起重機的防爆級別，應根據(jù)危險物質(zhì)的分級來選擇，按、A、B、C表示四個級別（類用電壓660V-1140V，類用電壓380V）。工廠常用B、C級ONE GeneralThe manual is applicable f

5、or different overhead cranes（including those with hook，crab，electric magnet，explosion-proof，isolation，two functions,three functions,casting,etc.）as a guidance of erection,operation and maintenance for erection,operation and maintenance persons.1.Chief uses of cranesElectric Overhead Cranes are usual

6、ly used to move materials or install and maintain equipments in fixed span at factories,power station,stories,power station,storehouse abd goods yard.According to different purposes and objects lifted,they are divided into following types:1.1 OVERHEAD CRANE WITH HOOKIt is applicable in workshop,ware

7、house,stock ground or similar places where there is a fixed span for loading,unloading,lifting or transporting.Working grades generally used are A3A6.A3A4 is suitable for equipment installation and maintenance;A5 is suiable for machine processing,metal structure assembling;A6 is suitable for those b

8、usy job or frequent full-load job.This type of crane is not suitable for lifting those material flammable,explosive,dangerous or of high temperature liquid metals.1.2 OVERHEAD CRANE WITH GRABIt is applicable in the warehouse and workshop in the fields of metallurgies,chemistry and cement.It lifts an

9、d transports ores,limestone,coal,sand or such gtain materals in a fixed span either indoor or outdoor and closed an any height.Grab with teeth should be applied when the size of grain material is over 60mm.The grab is only applicable for natural heap of grain materials.Special announcement should be

10、 made in advance if it is used to grad grain materials from under water.The rating lifting capacity of the overhead crane with grab means the total weight of the grab and the material grabed.1.3 OVERHEAD CRANE WITH MAGNET1.3.1 Overhead Crane with Magnet This crane has a demountable electric magnet p

11、late.It is applied in metallurgic factory and can busily transit ferrous metal or such products.The power for the electric magnet plate is supplied from the cable drum on the trolley.The rating lifting capacity of the overhead crane with magnet means the total weight of the electric magnet plate and

12、 the material lifted.1.3.2 Overhead Crane with Magnet and Carrier-beam There is a demountable or fixed carrier-beam with electric magnet on the crane,which is suitable for lifting over long iron or steel objects in such plance as shipyard,iron and steel plant.More than one electric magnet plates can

13、 be set up under on the carrier-beam.The power for the magnet plates comes from the cable drum on the trolley or from the cable basket set up on the carrier-beam.The direction of the carrier-beam can be paraller or vertical with the direction of the main girection of the main girder at users option.

14、1.3.3 Overhead Crane with upper Rotating Carrier-beam and Electric MagnetA rotatable trolley on the crane can bring the carrier-beam and electric magnet plate rotaing.I is suitable for storage bay of steel plants.Overhead Crane with lower Rotating Carrier-beam and Electric MagnetThe rotating device

15、on the carrier-beam makes the magnet plate and the lifted objects rotate.1.3.4 TWO PURPOSES OVERHEAD CRANE There are two different matchings,grab/electric magnet plate and grab/hook.In order to increase efficiency, grab/electric magnet plate or grab/hook can be installed on one trolley,but only one

16、of them can be used in one working circle.1.3.5 THREE PIRPOSES OVERHEAD CRANEThere are three kinds of tools（demiuntable electric magnet plate,motor grab/gravity grab and hook）on this kind of overhead crane.The three tools are changeable for readymade products,grain materials or ferrous material but

17、only one of them can be used in one working circle.1.3.6 OVERHEAD EXPLSION-PROOF CRANE WITH HOOKThe explsion-proof crane is applied to transmit inflammable and explosive substances in workshops and warehouses.There are two grads according to Standard JB5897-1991.The Grabe I is applied in mines and G

18、rade is applied in factories.The electric equipments of the crane are all explosion-proof and the machines also adopt explosion-proof measures in order to prevent any possible sparkles in working,which may cause flame or explosion.There are marks“EX”on each explosion-proof electric equipment.The gra

19、des of explosion-proof should be chosen according to the grade of the dangerous substances.There are 4 grades-I,A,B,C（I Grade for 660-1140Volts, Grade for 380Volts）. B and C are usually applied in factories.Please read the Attachment A for detailed description.1.3.7 OVERHEAD ISOLATION CRANE WITH HOO

20、K This crane is suitable for aluminum or magnesium electrolytic workshop.Several isolation devices are set up in proper places in the crane（usually three）in order to prevent electricity,via the lifted material,passing to the crane and thus endangering the safety of the operator.The isolation value o

21、f each device is 1M.Please read Attachment B for detailed description.1.3.8 OVERHEAD CRANE WITH DOUBLE TROLLEYS OR EVEN MOREThere are two trolleys or even more on this kind of crane.The hoisting and moving mechanism of the trolleys can be linked or separated in operation.Total lifting weight is carr

22、ied out according to the contract.It may be the summation of all the lifting weight or the lifted weight of the main hoist.1.3.9 OVERHEAD CRANE FOR FOUNDRYThis crane is suitable for lifting high temperature liquid metal in smelting shop.The structure is commonly with four main girders and double tro

23、lley or double girder and one trolley（with main hook and auxiliary hook）.There are double driving devices on the main hoisting（for heavy crane）or single driving device（for light crane）.Please read the drawing attached to the crane and Attachment C for details.1.3.10 OVERHEAD CRANE WITH MOVABLE CABIN

24、For the purpose of accurate operation,the cabin of this crane is movable either together with the trolley or separately along with the main beam.The movable cabin is mainly applied on crane with super long span.2.Main parameter and structure of crane Parameters show the working ability of the crane.

25、The main parameters include lifting weight,lifting height,span,working grade,spead,etc.The structure of overhead crane mainly includes bridge,crane traveling mechanism and trolley with hoisting and traveling mechanism.The bridge is composed of weld-box main girder,end girder,platform and so on.Above

26、 the main girder there is the steel track for trolley and there are platforms outside the two main girders for installing the electric box for the crane travelling on one side and electric conductor device for the trolley on the other.The cabin is suspended under the main girder,in which linkage con

27、sole or cam controller is set.There is stairs between the canbin and the walking platform.The main girder is linked to the two end girders with connectors in the middle.Crane traveling mechanism adopts independent drive（Pic.1-1）.There are four or eight wheels（maybe more）on the bridge.The wheels and

28、angle bearing box（45° structure bearing box）are installed on the end girder or equalizing truck.Trolley is composed to hoisting mechanism traveling mechanism and the steel structure.The common structure can be seen in Pic.1-2 and Pic.3.Power supply of trolley is in the form of suspension electr

29、ic conduction and the track of the cable pulley is I-shaped steel track or channel steel track.Power supply for the crane traveling is in the form of 1 phase bus bar,multi-phase bus bar,shaped steel,soft cable,etc.There is a maintenance platform on the power lead of the crane.There are different ope

30、ration methods such as cabin,pendant,remote or combined.Electric heater,electric fan or conditioner may be attached into the cabin according to requirement.Fordetailed information of parameters and surcture of crane,refer to the drawings attached to it.For operation and maintenance of parts such as

31、reducer,motor,brake,conditioner,etc,please read the related instruction.TWO Erection and commission2.1 Preparation for erection and notes2.1.1 Accidents such as wresting,bending or striking should be especially avoided while unloading or transporting.When lifting the crane,two lifting points are nec

32、essary and there must be underlay in the enlacing point.The enlacing points are limited at the wheels or the main girder,and if possible,at the connection points of the main girder and end girders.2.1.2 Transition of crane should be on truck or flat trailer.Dragging on ground or rollers is forbidden

33、.2.1.3 If stoting,crane should be flatly and stably set on sleepers.The sleepers must be placed symmetrically and the ground must be massiness in order to prevent any transfiguration of the bridge,2.1.4 If storing long time outdoor,waterproof measures should be taken.Necessary measures should be tak

34、en for transmission parts and electric equipments to avoid water,rusr,erosion,bump and theft.2.1.5 Related erection persons should study the drawings carefully before erection and clear out the transfiguration or defects caused by unsuitable transportation or storage if any.If there is any transfigu

35、ration of the metal structure,it must be adjusted before erertion. 2.1.6 Before the erection,erection persons with the deputies of Erection Company and manufacturer should open the box to check the number of components and spare parts that listed on the packing list and attached documents,to see if

36、there is any shortage or damage,then read the erection drawing and rechnical requirement carefully to ensure the detailed erection procedure.2.1.7 Crane is large equipment which may be transported with separated parts.During long-haul transportation or storage,transfiguration or defect may be caused

37、.Therefore,it should be assembled and checked（see Drawing2-1）before erection.If there is any problem which is diffcult for user to solve,it is important to contact with the manufacturer at once.Otherwise,even the manufacturer may feel difficult to solve if the problems happen after erection.2.2 Cran

38、e installtion2.2.1 BridgeCrane can be wholly or separately erected according to the capacity of lifting equipment at site.When erecting,install the bridge first,bundle the trolley tightly on the bridge,lift it to the height of the cabin,fix the cabin onto the bridge,then lift and fix them to the tra

39、ck.When separately erecting,separate the end girders from the main girders,lift the main girders on to the track,lift and fix the end girders to the main girders,then lift the trolley onto the track on the main girders.In order to reduce work in the air,choose the fist way as priority if lifting cap

40、acity permit.A.Method and Requirement for ErectionWhen assembling on the ground,the crane should be put on the shelves built according to its span and thus make the main girder is above the ground.If steel track can be put on the shelves,the crane wheels can be put on the track.If not,the shelves sh

41、ould be put under the bottom plange plate near two ends of main girder.No matter which method is used,the gradienter must be used to make it plane.For the shelf with steel track,take the upper surface of the track as benchmark and find the plane;For the shelf under the main girder,measure the plane

42、at A,B,C,D-the 4 points which are the cross points of the track central lines and end girder central lines（Drawing2-1）.Before measuring the planeness,the end girders should be well-connected according to the drawing.If the wheels have taper surface,the side of track should contact with the flange of

43、 the wheels for fear of affecting the veravity of the planeness.B.Quality Requirement for the Aassembly of the Bridge.The assembly quality of bridge with support points under the wheel should be checked item by item according to the regulation of 2-1table.If the supporter is under the main girder,ev

44、ery item can be checked except upper arch of the main girder.The installation quality of the traveling system of the crane can be checked at the same time.2.2.2 TralleyMedium and small tonnage trolley has been assembled and commissioned in workshop before delivery.It can be installed on bridge after

45、 necessary checks and adjustment.When the bridge installation accord with related technical requirements,“three legs”condition should not exist（that is,only three wheels contact with the track and the other is susoending）.Otherwise,underlay should be put under the bearing box or the track of the sus

46、pending wheel.As for the large tonnage trolley needed disassembly,reassembly it according to the marks on the connecting drawing,and then lift and install it to the bridge as a whole.2.2.3 Traveling Mechanism of CraneCrane traveling mechanism has been assembled to the bridge and has passed commissio

47、n by the manufacturer.After assembled,crane traveling mechanism should be checked and installed according to following requirement（This procedure should be applied too after any maintenance）:A.Benchmark of the check:outer side of driving wheels should be as benchmark when checking the traveling mech

48、anism.B.The lecel defiexion of end surface of wheels is shown as Drawing 2-2.The level deflexion of end surface of each wheel is P1/1000L（L means length measured）.The direction of disalignment of each driving（or driven）wheel in a pair should be raverse.Any combination shown in the Drawing 2-3 is tal

49、led with requirement.C.Measuring of the span:See the drawing 2-1D.Rectify wheels:the rectification includes parallel,uprighness,coordination.a）Parallel:Draw two parallel 0.61.0mm nylon lines under the wheels to see if the parallel ines equally contact with the four wheels.If it is,it shows that the

50、four wheels are parallel and on the same lines.If there is certain clearance,check if it is in stand scope.If not,adjust it though loosening the bolts of fixed angle bearing box.If necessary,the base plate on which the angle bearing box is fixed can be shoveled off or cut off with gas cutting and th

51、en be welded again after the wheels are adjusted well.b）Uprightness:Ddflexion of wheel in vertical direction should be less than 1/400(L means the length mdasured)and the upper part should be forth(as drawing 2-4)c)Coordination between sheels under same end girder（drawing2-5）:less than 2mm while the

52、re are two wheels,less than 3mm while there are three wheels or more.Measuring method:Draw a steel line along the oueer flange of the end girder,paralleling with the central line of the end girder,measure the distance between the ling and measuring point of each wheel;choose one wheel as benchmark a

53、nd the coordination of other wheels can be calculated.THREE Principles of electric control and installation3.1 Principal of electric controlThe circuit of overhead crane consists of main circuit of each system,control circuit,light circuit,signal circuit and protective circuit(shown as drawing 3-1).

54、3.1.1 Light design QB1- QB 4 series protective cupboards are adopted as the protective device for electric overhead crane,which is widely applied in those places where requirements for speed,sart and brake are not strict.Take QB4E as example and illustrate as follows:The main circuit drawing and con

55、trol circuit are shown as Drawing 3-2and 3-3.Type symbol with prefix “-”shows the item does not exist in the protective cupboard.A. General short-circuit protective system adopts breaker or fuse.B. The main contactor KO can make option according to the current passing the machine.C. The wound-rotor

56、motor in every sytem is protected by current breaker.D. The protective cupboard,matching with cam controller or main order controller,is adoptedin protections of operational zero-position,door swich ,end limiter and controller zero-position.Safety switches(S90- S93)for gateway doors are connected in

57、 main contactor(KO)in series.In cawd of any one of the doors is not closed well,the whole crane can not get power supply and therefore ca not operate in order to prevent any accident(at users request,signal device can be designed on).The zero-position contact points for=10-S40(trolldy),-06-S40(auxil

58、iary hoist)and-12-S40(crane)can insure the main contactor(KO)being on only when all the lperational handles at zero-position.In shis way ,automatic-start is avoided shen power supply is resumed after a sudden break.=12-S90,=10-S90 are limit switches for the crane and trolley.When moving to the limit

59、 position in one direction,the crane/trolley will stop and at the same time the way to the converse direction is provided;= 06-S90 is the upper position limiter.When it comes to the limit position,the hoist will stop going up and at the same time the way to go down is provided.E. There are key switches-S11(only in linkage control type),startup button-S10,stop bu