Describe the installation procedures and technical requirements of manual and electric single-beam suspension cranes (not including track installation, only the track is reviewed) to ensure that the installation quality of single-beam suspension cranes meets the requirements of standards or design specifications, and is suitable for the projects undertaken by our company The installation of the single-beam suspension crane involved in.
GB50278-98 Specification for construction and acceptance of lifting equipment installation engineering.
Trolley: For manual single-beam suspension cranes, it refers to hand-drawn trolleys; for electric single-beam suspension cranes, it refers to electric hoists .
5.1 Track review
5.1.1 The position deviation between the actual centerline of the track and the actual centerline of the crane girder should not be greater than 10mm; and should not be greater than half the thickness of the crane girder web (if the crane girder is a steel structure).
5.1.2 The deviation of the actual center line of the track from the horizontal position of the installation reference line shall not be more than 3 mm.
5.1.3 The allowable deviation of track span shall meet the following requirements:
(1) The jalur derek span is ≤10 m, and the allowable span deviation is ±3 mm.
(2) The crane track span is more than 10 m, and the allowable span deviation is calculated as follows, but the maximum does not exceed ±15 mm.
△S=±[3+0.25×(S-10)] mm
△S----allowable deviation of crane span (mm)
S---- Crane track span (m)
5.1.4 The longitudinal inclination of the top surface of the track at its design position should not be greater than 1/1000; measure one point every 2 m, and the height difference within the full stroke should not be greater than 10 mm.
5.1.5 The allowable deviation of the elevation of the datum point on the top surface of the track relative to the design elevation is ±5 mm.
5.1.6 The relative elevation difference between two parallel tracks in the same section shall not be greater than 5 mm.
5.1.7 For cranes guided by horizontal guide wheels, the track bends in the horizontal plane along the length direction, and the allowable deviation is ±1 mm for every 2 m measured length.
5.1.8 The lateral inclination of the I-beam track should not be greater than 1/100 of the track width.
5.1.9 The joint positions of the two parallel tracks should be staggered, and the staggered distance should not be equal to the base distance of the front and rear wheels of the crane.
5.1.10 Track joints shall meet the following requirements:
(1) When the joint is butt welded, the top and side welds of the joint should be polished smooth.
(2) When the joints are connected by fishplates, the height difference and lateral misalignment of the track joints should not be greater than 1 mm, and the gap should not be greater than 2 mm.
(3) The gap at the expansion joint should meet the design regulations, and the allowable deviation is ±1 mm.
(4) For square steel rails supported by backing plates, the width of the backing plates at the joints (along the length of the track) should be doubled compared to other places.
5.1.11 When the elastic pad is used as the cushion layer under the rail, the specifications and material of the elastic pad shall meet the design requirements. Before tightening the bolts, the rail should be tightly attached to the elastic backing plate; when there is a gap, a backing plate should be added under the elastic backing plate to be firm, and the length and width of the backing plate should be 10-20 mm larger than the elastic backing plate.
5.1.12 Check that there should be no loosening of each bolt.
5.1.13 The gears on the track should be installed before the crane is hoisted, and the gears on the two tracks at the end of the same span should be in contact with the crane buffer.
5.1.14 If the recheck result meets the requirements, the result shall be filled in the track recheck record form and received, before the installation of the single-beam suspension crane can be carried out.
5.2 Equipment unpacking inspection (record according to table SPI-QZ-03)
5.2.1 The equipment technical documents should be complete.
5.2.2 Before unpacking the equipment, you should be familiar with the packing list and check whether the equipment name, model, specification and quantity are consistent with the equipment to be installed.
5.2.3 Check the types, specifications and quantities of equipment, materials and accessories according to the equipment packing list, and should meet the requirements of the design and equipment technical documents, and should have a factory certificate and necessary factory test records.
5.2.4 Machinery and electrical equipment should be free of deformation, damage and rust, and the steel wire ropes should not be rusted, damaged, bent, looped, kinked, split or loose.
5.3 The bridge assembly is in place
The pairing of the bridge frame can determine whether the crane is paired on the ground or on the track according to the lifting capacity of the crane, the structure of the factory building, and the time of the topping.
5.3.1 Use a crane to hoist the main beam and place it flat on the pile of wood, and then lift one end beam for assembly.
5.3.2 Use a crowbar to adjust the upper connecting plate to align the eye position, and put on the connecting bolts to assemble the other end beam with the main beam.
5.3.3 Measure the span of the crane, the relative difference of the span (the difference in the distance between the connecting plates), the camber of the main girder, the curvature of the main girder and the deviation of the relative difference of the diagonal line.
5.3.4 Re-inspect the manual single-beam suspension crane and make a re-inspection record.
(1) Crane span S----allowable deviation ±6 mm.
(2) Relatively poor span ---- allowable deviation 6 mm.
(3) The relative difference of the diagonal line-the allowable deviation is 8 mm.
(4) The camber of the main beam F (F=S/1000) ---- allowable deviation ± 2 mm
(5) Curvature next to the main beam ---- allowable deviation S/2000 mm.
5.3.5 Re-examine the electric single-beam suspension crane and keep a record of the re-examination.
(1) Crane span S
Main and end beam hinged: allowable deviation ±4 mm
Main and end beams are just connected
S≤10 m: Allowable deviation ±2 mm
S>10 m: Allowable deviation ±[2+0.1×(S-10)] mm
(2) The camber of the main beam F (F=S/1000) ---- allowable deviation 0.3F mm.
(3) The gap between the connecting plates (the main and end beams are hinged)-the allowable deviation is 2 mm.
Wheel track <3 m: allowable deviation 5 mm
Wheel track ≥3 m: allowable deviation 6 mm
(4) Curvature next to the main beam f----allowable deviation S/2000 mm.
5.3.6 Remove the passive wheel of the cart, tie the chain hoist on the track, lift the bridge to the track installation position, reassemble the passive wheel, and adjust the gap between the inner side of the wheel flange and the rail flange, which should be 3 ~5 mm.
5.4 The car is in place
5.4.1 Lift the trolley to the bottom of the main beam, remove the passive wheels, tie the chain hoist on the main beam, and lift the trolley to the main beam assembly position.
5.4.2 Reassemble the passive wheel, adjust the gap between the inner side of the wheel flange and the rail flange, which should be 3 to 5 mm, and assemble the power control box.
5.4.3 The sprocket grooves of the chain electric hoist should be kept on the same vertical surface, and the chain should not be twisted, jammed or severely worn during operation.
5.5 Electrical installation and commissioning
According to the electrical installation and debugging procedures.
5.6 Inspection and adjustment
5.6.1 Adjust the gap between the two brake shoes and the brake wheel to be consistent. The requirements are as follows:
(1) The brake should be opened and closed flexibly, and the brake should be stable and reliable.
(2) The brake of the hoisting mechanism should be 1.25 times of the rated load, and 1.4 times for special requirements. There should be no slipping under static load.
(3) The brakes of the operating mechanism should not be adjusted too loosely or too tightly, so that the phenomenon of slipping and impact should not occur.
5.6.2 The elastic buffers in the same direction should contact and collide at the same time.
5.6.3 All limit switches should be adjusted to make their actions accurate and reliable, and not to malfunction.
5.6.4 The installation of electrical systems, safety interlocking devices, controllers, lighting and signal systems shall meet the requirements, and the actions shall be sensitive and accurate.
5.6.5 The fixing of the wire rope end and its winding on the hook, retrieval device, pulley block and reel should be correct and reliable.
5.6.6 The performance, specifications and quantity of the oil and grease added to each lubrication point and reducer shall meet the requirements of the equipment technical documents.
5.6.7 When turning the brake wheels of each motion mechanism, the last shaft in the rotating system should make one revolution without any blockage.
5.7 Trial run
5.7.1 No-load test run
(1) The operating direction of the control mechanism should be consistent with the operating direction of each mechanism of the crane.
(2) The motors of each mechanism should be turned on separately, and their operation should be normal, and the carriage and trolley should not be jammed when running; each brake can act accurately and timely, and the action of each limit switch and safety device should be accurate and reliable.
(3) When the hook is lowered to the lowest position, the number of loops of the wire rope on the drum shall not be less than 2 (except for the fixed loop).
(4) When the cable is used to conduct electricity, the speed of cable-rewinding and unwinding should be coordinated with the speed of each operating mechanism, and can meet the requirements of the working limit position.
(5) The anti-collision device, buffer and other devices of the crane should be able to work reliably.
(6) Except for item (5), which can be used for one or two tests, all other tests should be no less than 5 times, and the actions should be accurate.
5.7.2 Static load test run
(1) The crane should stop at the post of the factory building.
(2) For cranes with multiple lifting mechanisms, the static load test of each lifting mechanism shall be carried out separately; if required, the static load test of the combined lifting mechanism of the lifting mechanism shall be carried out; the lifting weight shall conform to the equipment technology Document regulations.
(3) The static load test is carried out according to the following procedures and requirements:
Start the lifting mechanism first, carry out the no-load lifting operation, and make the trolley run back and forth on the full stroke. This no-load test run should not be less than 3 times, and there should be no abnormal phenomena.
Stop the trolley in the middle of the main girder, gradually load the load and do a lifting test run until the rated load is added, so that the trolley runs back and forth on the full stroke of the main girder for several times. There should be no abnormal phenomena in each part. After the load is removed, the bridge structure should No abnormal phenomenon.
Park the trolley in the middle of the main beam and lift the load 1.25 times the rated lifting weight without impact. The suspension staying time should not be less than 10 minutes at a distance of 100-200 mm from the ground, and there should be no instability, and then unload it. Remove the load and drive the trolley to the end of the span or the outrigger, and check the metal structure of the crane bridge, and there should be no defects such as cracks, weld cracks, paint peeling, and other damage or looseness that affect safety.
The 1.25 times load test shall not exceed 3 times, and there shall be no permanent deformation for the third time. Measure the actual camber of the main beam and it should be greater than 0.7S/1000 mm.
Check the static stiffness of the crane (deflection under the main beam). Drive the trolley to the middle of the main girder, and lift the load with the rated lifting weight 200 mm above the ground. After the crane and the load are stationary, measure the camber value. The difference between this value and the previous result is the static stiffness of the crane. The allowable value is: electric S/700 mm.
5.7.3 Test run under dynamic load
(1) The dynamic load test operation of each mechanism shall be carried out separately, and when there is a requirement for joint operation test operation, it shall be carried out in accordance with the provisions of the equipment technical documents.
(2) The dynamic load trial operation of each mechanism should be carried out on the full stroke. The lifting capacity is 1.1 times of the rated lifting capacity, and the cumulative starting and running time should not be less than 1 hour for electric cranes; it should not be less than 10 minutes for manual cranes. The actions of each mechanism should be sensitive, stable and reliable, and the actions of safety protection, interlocking devices and limit switches should be accurate and reliable.
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