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In the field of modern industry and construction, cranes are used as important material handling equipment, and their performance and design are directly related to productivity and safety. This design manual focuses on the comprehensive analysis of 15-ton trolley, aiming to present readers with a lifting equipment design that integrates high efficiency, safety and durability. Through the design background, structural features, material selection, performance testing and maintenance, etc., aims to help users fully understand the design concept and practical application of the trolley. Whether for professionals engaged in the design and manufacture of cranes, or for the use of the equipment operators and maintenance personnel, this manual will become an indispensable technical reference to help improve work efficiency and ensure operational safety.
trolley for vietnam customer
Design Overview
15-ton trolley design background and purpose
With the increasing scale and complexity of industrial production, the demand for material handling equipment is also growing. As the core equipment for material handling, the performance and efficiency of cranes directly affect the smoothness of production lines and the economic benefits of enterprises. In order to meet the needs of medium and large-scale workpiece handling, improve operational efficiency and reduce labor costs, we designed this 15-ton trolley. This trolley not only has a compact structure and stable performance, but also integrates the concepts of intelligence and automation, which makes it adapt to the development trend of the modern industry 4.0 and at the same time has the advanced nature of the future industry. In order to ensure the stability and safety of the trolley under severe working conditions, we have fully optimized the structural design and material selection. This 15-ton trolley is designed to meet the needs of diverse operating scenarios, improve operational efficiency and reduce labor costs.
Design Principles and Requirements
In the design process, we strictly follow the following principles: firstly, to ensure that the load capacity of the trolley reaches 15 tons and has a stable lifting performance within the working range; secondly, to focus on the compactness and lightweight of the structure in order to improve the operating efficiency and reduce energy consumption; furthermore, to strengthen the safety protection measures to ensure the safety of the operators; finally, to consider the intelligence and ease of operation of the electrical control system to improve the user experience. At the same time, the design should also meet the requirements of relevant national standards and regulations to ensure the legality and compliance of the product.
Main technical parameters and performance indicators
The main technical parameters of the 15-ton trolley include: rated lifting capacity of 15 tons, working class A3, lifting height of 12 meters, and span can be customized according to user requirements. In terms of performance indicators, the trolley has excellent lifting speed, running speed and positioning accuracy, and at the same time ensures low noise, low vibration and good environmental adaptability. These parameters and indexes ensure that the trolley can operate stably and efficiently under various working conditions.
Trolley overall structure design
The overall structure design of the trolley is an important part of engineering and industrial applications, which integrates the knowledge of many fields such as mechanical design, material science, safety engineering and electrical control. The design adopts the modularization idea, dividing the trolley into several functional modules, such as drive module, steering module, load-bearing module, etc. Each module has a clear function and interface, which is easy to assemble and maintain. This design method not only improves the production efficiency, but also reduces the maintenance cost.
The main frame is the core part of the overall structure of the trolley, which is welded with high-strength steel to ensure the stability and load-bearing capacity of the structure. High-strength steel has high tensile strength and yield strength, and can withstand a variety of complex loads and stresses. Welding process is also a key factor to ensure the quality of the main frame, which requires the use of advanced welding technology and equipment to ensure the welding quality and strength.
In addition to the main frame, the overall structural design of the trolley also focuses on the optimization of the design to achieve the goal of compact structure and light weight. Through finite element analysis and simulation, the structure was optimized and designed to reduce redundancy and unnecessary weight and improve the energy efficiency ratio of the entire vehicle. Lightweight materials and technologies are also used to further reduce the weight of the entire vehicle and improve mobility and energy efficiency.
Crane Construction and Layout
Crane construction and layout is an important part of engineering and industrial applications, which integrates knowledge from a number of fields such as mechanical design, materials science, safety engineering and electrical control. Crane construction includes key components such as winches, wire ropes, pulley blocks and so on. The selection and design of these components are directly related to the performance and safety of the crane.
Winch is one of the core components of the crane, adopting frequency conversion speed control technology to realize smooth lifting and landing. The speed of the motor is controlled by the frequency converter, which regulates the linear speed of the winch, realizing smooth and precise control of the lifting process. This technology improves the efficiency and safety of the crane and reduces mechanical wear and energy consumption.
Wire rope is one of the key components of the crane, which directly affects the carrying capacity and service life of the crane. The design process requires careful calculation and selection of wire rope to ensure that its strength, wear resistance and corrosion resistance and other properties meet the requirements. Pulley block is also an important part of the crane, which can change the traction direction of the wire rope and the size of the force. In the design of the crane, it is necessary to reasonably select the number of pulleys and layout to ensure that it can meet the requirements of use and improve lifting efficiency.
In terms of layout, the crane components need to be reasonably distributed to avoid mutual interference and improve operational efficiency. For example: winches, wire ropes and pulley blocks and other components need to be rationally arranged position and connection to avoid interference and vibration and other problems. It is also necessary to adopt advanced manufacturing process and technology to ensure the manufacturing quality and precision of the crane.
Safety guard design
The design of safety guards is an important part of the overall structural design of the trolley, which is intended to protect the operator and equipment from injury or damage. These devices include limit switches, overload protection, emergency stop buttons, etc. Limit switches are protective devices that are used to prevent the trolley from exceeding its operating range. By installing limit switches, you can ensure that the trolley automatically stops or switches to a safe mode when it reaches a preset position, avoiding damage or danger due to overdriving or impact. The overload protection device is a safety protection device that can automatically cut off the power supply or sound an alarm when the lifting capacity exceeds the rated value. By installing an overload protection device, you can ensure that the trolley will not cause structural damage or safety accidents due to overloading during transportation. The emergency stop button is a protective device used in emergency situations. By installing an emergency stop button, it is possible to quickly stop the trolley in the event of an emergency and avoid further risk or damage. Together, these devices form a complete safety protection system.
Trolley Safety Guard Design Ideas
Electrical control system design
The electrical control system of the trolley is an important part of it, and PLC control technology is used to realize intelligent and automated operation.PLC (Programmable Logic Controller) is a kind of digital arithmetic operation electronic system specially designed for the application of the industrial environment, which adopts the programmable memory for its internal storage program to perform logical operation, sequential control, It uses programmable memory to store programs internally to perform logical operations, sequential control, timing, counting and arithmetic operations, and other user-oriented commands, and to control various types of mechanical equipment or production processes through digital or analog inputs/outputs.
In an electrical control system, the operator can easily control the various functions of the trolley through the touch screen interface. The touch screen serves as an intuitive and easy-to-use input device that allows the operator to interact with the system in a simple and quick manner. It can also display the running status and key parameters of the trolley in real time, which makes it easy for the operator to understand and monitor the operation of the equipment. The system is also equipped with fault diagnosis and alarm functions, which improve the reliability and maintainability of the equipment. The fault diagnosis function can monitor the operation status of each part of the system in real time, and once abnormalities are found, the system will immediately issue an alarm and display the corresponding fault information. This allows maintenance personnel to quickly locate and solve problems, reducing equipment downtime and maintenance costs.
Material Selection and Manufacturing Process
Material Selection Principles and Criteria
Material selection plays a crucial role in product design, which directly affects the performance, life, cost and safety of the product. When selecting materials, we follow a series of strict principles and standards to ensure that the selected materials can meet the needs of the product. Among them, the principles of high strength, light weight, corrosion resistance and easy processing are the core concepts of material selection. High-strength materials can withstand greater loads and stresses, lightweight materials can reduce the weight of the product, corrosion-resistant materials can extend the service life of the product, and easy-to-process materials can improve production efficiency. For the main frame and key components, high strength steel and low alloy steel are used. High-strength steel has high tensile strength and yield strength, and can withstand larger loads and stresses to ensure the stability and safety of the product. Low-alloy steel has good plasticity and toughness, which can improve the fatigue resistance and durability of the product. For electrical components and control systems, well-known brands are used to ensure performance and reliability. Famous brand products have been strictly tested and verified, with high reliability and stability, which can ensure the normal operation and service life of the products.
Material analysis of key components
Key components, such as winches and pulley sets, are manufactured with high-quality alloy steel and wear-resistant materials to improve wear resistance and service life. High-quality alloy steel has high strength and toughness, which can ensure the stability and safety of key components. Wear-resistant materials have better wear resistance and corrosion resistance, which can improve the service life and reliability of key components. At the same time, strict inspection and testing of materials to ensure compliance with design requirements. Inspection and testing of materials is an important means to ensure product quality. Through strict inspection and testing of materials, it can ensure that the performance and quality of materials meet the design requirements and provide reliable data support for product design and production.
Manufacturing process and quality control
The manufacturing process includes raw material preparation, cutting, welding, assembly, debugging and other links. Each link strictly follows the quality control standards to ensure product quality. Raw material preparation is the starting point of the manufacturing process, to ensure the quality and stability of raw materials. In the raw material preparation stage, the raw materials should be strictly inspected and tested to ensure that the raw materials meet the design requirements and quality standards. The cutting process is an important part of the manufacturing process, to ensure the precision and efficiency of cutting. In the cutting process, advanced cutting technology and equipment should be used to ensure the quality and efficiency of cutting. Welding link is a key link in the manufacturing process, to ensure the quality and stability of welding. In the welding process, advanced welding technology and equipment should be used to ensure the quality and efficiency of welding. At the same time, it is also necessary to carry out strict inspection and testing of welding to ensure that the welding meets the design requirements and quality standards. The assembly link is an important part of the manufacturing process, to ensure the precision and efficiency of assembly. In the assembly process, advanced assembly technology and equipment should be used to ensure the quality and efficiency of assembly. Debugging is a key link in the manufacturing process, to ensure the accuracy and stability of debugging. In the debugging process, advanced debugging technology and equipment should be used to ensure the quality and efficiency of debugging. At the same time, it is also necessary to carry out strict inspection and testing of the commissioning to ensure that the commissioning meets the design requirements and quality standards. By adopting advanced welding technology and testing equipment, the welding quality and overall performance of the product are improved. Advanced welding technology can improve the quality and efficiency of welding and reduce welding defects and problems; while advanced testing equipment can timely detect and correct problems and defects in the product to improve the quality and reliability of the product
Key component manufacturing process flow
Key component manufacturing process flow
Design Manual for Crane 15 ton Trolley (https://www.craneyt.com/design-manual-for-crane-15-ton-trolley.html)