By the national Ministry of science and technology, a key project of the national science and technology support program across the "12th Five-Year" and "13th Five-Year" - "the key technology research and application of bridge crane light weight", carried out by the China Machinery Industry Federation, has been carried out by the contractors and the co sponsors for three years. To achieve breakthrough progress. Recently, the China Machinery Industry Federation organized the intensive project acceptance team. By listening to the report of the work of the project and the field organization technical certification, a comprehensive acceptance of the lifting gear reducer for the lifting machinery and lightweight core transmission was carried out. The acceptance expert group fully affirms the advance of the project, and has made many technical breakthroughs. It provides a complete set of technical support system for the deepening of China's lifting machinery in the direction of precision, light quantification and green energy saving, and overtaking the advanced international level.
National Science and technology support projects across the two five year plan passed authoritative acceptance.
Recently, the China Machinery Industry Federation held a comprehensive acceptance of the "12th Five-Year" National Science and technology support program "key technology research and application of the bridge type lifting machinery lightweight reducer" in Jiangsu, which was undertaken by the Jiangsu Tai Long reducer Limited by Share Ltd and other units. The expert group listened to the report of the project and entered into the project. On the basis of field investigation, technical demonstration and combination acceptance, the key technical requirements of the lightweight reducer for bridge crane are confirmed by inquiry and discussion. The structure optimization of lightweight lifting mechanism, the optimization design and dynamic analysis of the lightweight reducer, the manufacturing of the key parts and the quality control of the lightweight reducer, and the quality control are carried out. The research on the test and application of the lightweight reducer, 13 kinds of lightweight reducer series three and 12 kinds of light weight reducer are developed. The comprehensive performance test device of the lightweight reducer is developed, and the research content and evaluation index are completed, and the expected target has been achieved.
The project determines that the structure and transmission system of the lifting mechanism of the lightweight bridge crane are optimized by the Tai Long reducer company, and the structure form of the single side support of the lightweight reducer is put forward. Based on the parameterization and modularization technology of the concept of universal and combinatorial diversity, the series spectrum of the decelerator of the bridge crane is formed; based on the optimum. The depth design of the hardened layer and the precision heat treatment technology of hard tooth gear controlled by residual stress and deformation have formed the production process of high power density gear, improved the bearing capacity of gear and reducer, and solved the leakage problem of the reducer by using the static and static combination seal technology, and completed the lightweight design and manufacture of 10 prototype machines. . The independent design and manufacture of light-weight bridge crane lifting mechanism is realized.
This project has built a corresponding production demonstration base in Tai Long reducer company, which meets the annual production capacity of 5000 sets of lightweight reducer for lifting mechanism of bridge crane; 10 patents are applied, including 4 patents of invention, 1 Copyright of computer software, 15 articles published in academic literature, 1 items of enterprise standards, and cultivated for training. A group of technical backbone, including 9 graduate students, 1 doctorate and 8 master's degree.
According to the development ideas and important tasks of the manufacturing industry in the national medium and long term science and technology development plan (2006~2020) and the "green manufacturing technology development" 12th Five-Year "special plan", the project undertook the two five year plan of "12th Five-Year" and "13th Five-Year" under the Ministry of science and technology of the state. Science and technology support project - development and research topic of research and application of lightweight technology for overhead cranes. The key equipment in the project and the independent subject, "key technology research and application of bridge type crane lightweight reducer", is clearly led by Jiangsu Tai Long reducer Limited by Share Ltd, combined with Beijing heavy transport machinery design institute, Zhengzhou Institute of machinery research, Chongqing University and Jiangsu University of Science and Technology. From January 2015 to the end of April 2018, the Research Institute jointly implemented the research and project promotion work at different levels and sub themes.
According to the requirements of the national Ministry of science and technology and the acceptance group of the project acceptance group, the light weight reducer is compared with the JB/T10817 type reducer with the traditional lifting machinery, the power density is increased by 41%, the bearing capacity is raised by 30%, the weight is reduced by 10%, the noise is reduced by 3dB (decibels), and the material node is about 10%, reaching the leading domestic products. Level. The bridge crane with this mechanical equipment can reduce the weight of 15%~20% and reduce the use of energy consumption by more than 10%. It lays a solid technical foundation for China's lifting machinery to climb the international advanced level and realize light quantification, intelligence and green manufacturing.
Technological innovation of the rebirth of light weight reducer
Lifting machinery is an important infrastructure needed to start the process of production, transportation, hoisting and storage in all walks of life of the national economy. It is widely used in warehouses, ports, wharfs, factories and storage places. For a long time, with the vigorous development of the national economy, China's steel, metallurgy, electricity, building materials, petroleum, chemical, new energy industries, Jianghai tunnel and Luqiao construction and other fields of lifting machinery demand and drive, so that the crane industry in China has achieved more than 30% high growth every year. At present, the annual output of domestic lifting appliances is more than 40 thousand units, and the output value is more than 17 billion yuan, which consumes more than 1 million 700 thousand tons of medium and high grade steel products every year. In the lifting machinery component, the reducer is the core equipment of various components. The performance and structure of the reducer not only affects and determines the speed, efficiency and stability of the lifting machinery, but also is closely related to the structural connection of the crane box, transmission system, motor, shaft, brake, drum and other main components. Complement each other.
Yin Aiguo, general manager of Tai Long reducer company, said that the general use of bridge cranes in our country at present is the QG series products developed in 80s of last century. The reducer is ZQ series, QJ series, QY series and so on. Its structure generally exists in large size, low precision, single interface form and dumb model. Disadvantages such as heavy weight, poor gear accuracy, low power density and noise, seriously restrict the upgrading and modernization of lifting appliances in China. Through the renewal and replacement of the reducer, the light weight manufacturing of lifting machinery is the need of the contemporary industry development. It is also the inevitable choice of the special plan of "12th Five-Year" to "13th Five-Year" and the development of medium and long term science and technology in China.
Through the study, the series spectrum of the lightweight reducer of bridge crane is formed, the modular design of the lightweight reducer is realized, the series design scheme of the lightweight reducer is established, the trial production and the comprehensive performance test of the five reducer prototype are completed, and the suitable for 5~100t bridge crane and 12 are put forward. The three point support of 5~200t bridge crane is a new lifting mechanism transmission system. According to the complete theoretical research of the subject and the comprehensive performance test of the prototype, it is proved that the research results of this subject have all the conditions for the popularization and application of the lightweight bridge crane. Through the research of this project, it has promoted the upgrading of technological innovation ability of enterprises and the training of talent team, adapted to the market demand of lightweight crane and added new economic growth points for enterprises. The success of the lightweight reducer is of great significance for promoting the development of China's lifting machinery in the direction of light quantification, energy saving, safety and reliability. It will play an important supporting role in improving our independent innovation ability and technical level and improving the core competitiveness of domestic manufacturing industry.
Docking "made in China 2025" to raise the level of international modernization
The reducer is the core component to ensure the safety and reliability of the lifting machinery. Its overall structure must be adapted to the operation of the crane in the state of empty and load. The operation system can strictly follow the given lifting speed, greatly improve the working efficiency, save the working time and reduce the use of energy. This project is supported by the lightweight R & D of 5~200t grade bridge cranes, and the economic and social benefits that must be achieved are given. The project is a project which is intersecting with multidisciplinary and multidisciplinary, technical research and engineering application. At present, the project has made a whole breakthrough in the possession of independent intellectual property, the cultivation of scientific and technological talents and the construction of industrial base. We have studied and formulated "the enterprise standard for the two fulcrum reducer of the crane", drafted the "industry standard for the two pivot reducer of the crane", published 3 international papers, 1 domestic papers, and two national patents. The sponsor and the 4 co sponsored units participated in the total of 58 people, including doctoral students and 9 graduate students. The research and manufacturing time of this project was 408 times per month, and a large number of scientific research designers with professional quality have been trained. Modular product design and manufacturing has laid a solid foundation for talents and technology, and has created a base for industrial development.
Yin Genzhang, chairman of the China subtraction transmission industry association and chairman of Jiangsu Tai Long Machinery Group Co., Ltd., introduced to our newspaper reporters that the lightweight bridge crane is the direction of our country's future development. At present, China's traditional crane market has a total of 100 thousand units, huge industrial scale and wide application prospects. The development of lightweight reducer can reduce the weight of bridge crane by 15%~20%, and save 100 thousand ~15 million tons of medium and high-grade steel annually. With the development of "China made 2025" strategy and the demand for the development of science and technology and the construction of national economy at the present stage of our country, the application of crane can be reduced greatly, and the structure of the building will turn to the direction of light quantification, precision, energy saving and saving type, which will push the manufacturing of China from large to strong. Change, improve the core competitiveness of the equipment manufacturing industry, promote our equipment manufacturing industry to catch up with the international advanced level, will play an important supporting role, and have a positive and far-reaching impact!
