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Mechanical Industry Standard of the People's Republic of China
Electric hoist gantry crane
1Theme content and application scope
Technical conditions
JB 5663.2—91
This standard specifies the technical requirements, test methods and inspection regulations for electric hoist gantry cranes (hereinafter referred to as cranes). This standard is applicable to cranes with a hoisting mechanism (electric hoist) trolley running on the lower flange of the main beam, a hook, a grab bucket or an electromagnetic suction cup as the retrieval device, and its type and basic parameters comply with JB/T5663.1. This standard does not apply to cranes that have flammable, explosive, corrosive gases in the working environment and lift molten metal and hot and dangerous goods above 300C.
2 Reference standards
GB146.1
GB 191
GB699
GB700
GB985
GB 986|| tt||GB1031
GB 1591
GB3323
GB 3811
GB 4628
Standard gauge railway rolling stock limits
Packaging and storage Transportation graphic mark
Technical conditions for high-quality carbon structural steel
Carbon structural steel
The basic form and size of weld grooves for gas welding, manual arc welding and gas shielded welding Basic form and size of solitary weld groove surface roughness parameters and their numerical values
Low alloy structural steel
Code for radiography and quality grading of steel fusion welded butt joints Crane design
Bridge crane cylindrical wheel
GB 4942. 2
GB 5117
GB5118
GB5837
GB 5905
Low-voltage electrical enclosure protection level
Carbon steel electrodes
Low alloy steel electrodes
Fluid coupling types and basic parameters
Crane test specifications and procedures
GB 6164. 2| |tt||Crane rubber buffer
GB6333
: electro-hydraulic block brake
GB 8923
GB9286
GB10095
GB 10183
GB11352
Cross-hatch test of steel surface corrosion grade and rust removal grade paint and varnish film before painting
Involute cylindrical gear accuracy
Bridge General engineering casting carbon steel parts for manufacturing and track installation tolerances of gantry cranes
GB/T13306
Signs
JB1152
JB2299
Boilers and Steel pressure vessel butt weld ultrasonic flaw detection mining engineering, lifting and transportation machinery product painting colors and safety signs The Ministry of Machinery and Electronics Industry of the People's Republic of China approved 1991-08-14 and was implemented on 1992-07-01
495|| tt | Conditions ZBK26007YZ series three-phase asynchronous motors for hoisting and metallurgy Technical conditions ZBK26008YZR series wound rotor three-phase asynchronous motors for hoisting and metallurgy Technical conditions JB/ZQ4000.3 General technical conditions for welding parts 3 Technical requirements
of cranes Design and manufacturing should comply with the relevant provisions of GB3811 and this standard. 3.1 Environmental conditions
3.1.1 The power supply of the crane is three-phase AC, frequency 50Hz, voltage 380V. 3.1.2 The altitude where the crane is installed and used shall not exceed 2000m (when it exceeds 1000m, the motor capacity shall be checked). 3.1.3 The working environment temperature of the crane is -25~~1040C. 3.1.4 The working wind pressure of the crane in inland areas shall not be greater than 150Pa (equivalent to level 6 wind). 3.1.5 The working wind pressure of the crane in coastal areas shall not be greater than 250Pa (equivalent to level 7 wind). 3.7.6 The maximum wind pressure of the crane in non-working state is 800Pa (equivalent to level 11 wind). Note: If the above range is exceeded, the supplier and the buyer must negotiate and order. 3.2 Performance
3.2.1 For a crane operated by the cab, the electric hoist lifts the rated load at the cantilever end (or within the span). When the trolley starts (or brakes) at maximum speed, the crane moves in the direction of the electric hoist. The vibration amplitude shall not be greater than /1000 (H- is the height between the rail surface and the measured point, see Figure 5).
3.2.2 The static rigidity of the crane is specified as: the vertical static deflection caused by the rated lifting capacity and the self-weight of the electric hoist at the mid-span of the main beam. For A2 and A3, it should not be greater than S/700. A4 and A5 should not be greater than S/700. Greater than 5/800; the vertical static deflection caused at the effective cantilever should not be greater than L (or L2)/350.
, when required by the user and design, the dynamic rigidity of the crane is stipulated as follows: when the trolley is located in the middle of the span, the full-load natural vibration frequency of the main beam should not be lower than 3.2.3
below 2Hz.
3.2.4 The grab grab rate should not be less than 90%. 3.2.5 The weight suction capacity of the electromagnetic chuck should not be less than the rated value, and it should be able to reliably hold heavy objects. 3.3 Materials and heat treatment
3.3.1 The material of the metal structural parts of the crane, ordinary carbon structural steel according to GB700. Low alloy steel according to GB1591. The selection of grades should comply with the provisions of the table,
Table 1
Component types
Working environment temperature
Grade
Important components
Not less than -20℃bzxz.net
Q235-BF||tt ||Q235-Bb
Q235-B3
Note: 1) The important components refer to the main beam, outriggers, upper beam and lower beam. Less than 20
Q235-D
16Mn2
25c
general components
not less than--25C
Q235-AF| | tt | 3) When the plate thickness is >20mm, the steel grade should be no less than Q235-C3.3.2 The material of the brake wheel should be no less than 45 steel in GB699 or ZG340-640 in GB11352, and the surface heat treatment hardness should be 45~55HRC , the hardness at a depth of 2mm is not less than 40HRC. 496
n
\:
asiein
JB 5663.2—91
3.3.3 The material of shaft parts shall not be lower than 45 steel in GB699 . 3.3.4 The material of the gear should be no less than 45 steel in GB699 or ZG340-640 steel in GB11352. 3.3.5 Steel used in metal structures should undergo surface rust removal treatment. The surface rust removal quality level of the main beam, legs, upper beams and lower beams should not be lower than the Sa2 level in GB8923, and the remaining parts should reach the St2 or St3 level. 3.4 Main components
3.4.1 The wire rope electric hoist used as the lifting mechanism should comply with the regulations of ZBJ80013.2. 3.4.2 Brakes
The brakes of the crane operating mechanism should be able to ensure the crane's slow and steady deceleration and reliable braking. Priority should be given to electro-hydraulic block brakes that comply with the regulations of GB6333. If the diameter of the brake wheel is less than 160mm, other types of brakes can be used. 3.4.3 Buffer
The crane should be equipped with a rubber buffer whose performance is not lower than that specified in GB6164.2. The corresponding parts of the main beam of the mast should be equipped with trolley running stops with rubber buffers.
3.4.4 Reducer and open gear transmission device 3.4.4.1 The accuracy level of the gear pair of the reducer of the crane operating mechanism should not be lower than the 8-8-7 level specified in GB10095. If open gear transmission is used, the accuracy level of the gear pair should be no less than level 8. 3.4.4.2 The surface roughness of the gear working surface shall comply with the provisions of GB1031. When the normal module m ≤ 8 mm, the reducer gear must not be lower than next, and the split gear must not be lower than m.When 8mm, the reduction gear must not be lower than the split gear.
The heat treatment hardness of a pair of meshing tooth surfaces: the pinion gear is not less than 241HB, the large gear forging is not less than 190HB, the hardness difference between the small gear and the large 3.4.4.3
gear should be 25~ 90HB (except for gear pairs with hard tooth surfaces). 3.4.4.4 The gear teeth shall not have casting defects that affect the performance and shall not be repaired by welding. 3.4.4.5 The assembled reducer should ensure flexible rotation and no oil leakage. 3.4.4.6 When the reducer rotates without load at no less than the working speed, and without other external noise interference, the noise measured at a distance of 1m from the front, rear, left and right of the reducer on the contour line of the box split surface shall not be allowed. Greater than 85dB(A). 3.4.5 Hydraulic coupling
It is recommended to use a hydraulic coupling that complies with GB5837 regulations in the crane operating mechanism. 3.4.6 Wheels
Crane wheels should comply with the requirements of GB4628, and it should be ensured that the circular runout of the reference end face of the wheel after installation (marked by a circular groove about 1.5mm deep on the wheel) does not exceed the requirements of Table 2 . Table 2
Wheel diameter mm
End face circular runout
3.4.7 Brake wheel
≤250
100
After installation The brake wheel should ensure that the radial circular runout does not exceed the requirements in Table 3. Table 3
brake wheel diameter mm
radial circular runout μm
3.5 welding
125250
100
>250-500
120
>250～500
120
3.5.1 The form and size of welded joints shall comply with the provisions of GB985GB986. Welds with special requirements shall be shown in the drawings indicated in. 3.5.2 The butt welds in the tension zone of the main beam shall meet the Grade II quality requirements in GB3323 or the Grade II quality requirements in JB1152. 3.5.3 There shall be no obvious defects visible by visual inspection such as cracks, holes, solid slag inclusions, lack of fusion, and lack of penetration on the outside of the weld. Except for welds specified in 3.5.2 497
JB5663.2-91
, the quality assessment level shall comply with the provisions of JB/ZQ4000.3. Butt welds are BS grade and fillet welds are It is CK level. 3.5.4 The welding rods, welding wires and flux used for welding parts should comply with the regulations of GB5117 and GB5118, and be compatible with the materials to be welded. 3.6 Gantry
3.6.1 Main beam mid-span upper camber F= (0.9/1000~1.4/1000)S. And the maximum camber should be controlled within the range of S/10 in the middle of the span; the cantilever end camber is F, two (0.9/350~1.4/350)L, (or 1, (see Figure 1). This camber and The degree of upturn should be measured without the influence of sunlight temperature difference
Figure 1
2 The horizontal bending F of the main beam is ≤L3/2000 (see Figure 2). ||La | The remaining areas are not larger than 1.28 (see Figure 3)
upper flange plate of main beam
E/y
Figure 3
3.6.4 Truss beam chord and web member. Straightness of parts: Au0.0015a (see Figure 4). 498
JB5663.2
Figure 4
Note: The simplified diagram used in this standard is only used to indicate the dimension parameters and Deviation code is used. 91
3.6.5 The verticality of the rigid leg and the main beam in the span direction: A11. ≤H./2000 (see Figure 5). If the span of the crane can be guaranteed by other methods. This item is not required for examination. Figure 5
3.6.6 Outrigger straightness, Ar≤1.5H1/1000, △y≤1.5H/1000 (see Figure 6)
3.7. Assembly
3.7.1 The assembled mechanisms and devices should be flexible and work properly. When using a hydraulic coupling, they should comply with the assembly requirements of the hydraulic coupling.
3.7.2 Crane. The limit deviation AS of the span S (see Figure 7) shall comply with the following regulations: when a
S≤10m, As-±6mm, and the relative difference between the span S on both sides and S shall not be greater than 6mm: b. When S≤26 m, AS=±8mm, and the relative difference between the span S on both sides and S2 is not more than 8mm; when cS>26m, △S=±10mm, and the relative difference between the span S and S2 on both sides is not more than 8mm. Greater than 10mm. 499
JB5663.2--
91
The tension value and correction value used to measure the span are shown in Table 4. 3.7.3 Outrigger height difference
The relative difference between the four outriggers, calculated from the crane wheel tread to the height H of the electric hoist trolley running track plane, in the span direction shall not be greater than 10mm (when S≤26) or 15mm (when s>26m) (see Figure 7 ). 3.7.4 The horizontal deflection of the wheels at the left (right) end of the crane: A/≤1/1000 (1 is the measured length), and the deflection direction of the opposite wheels on the same axis should be opposite (see Figure 7) | |tt||Trolley track surface
A inquiry
Span measurement part
Figure 7
3. 7. 5
Span
m
10
14
18
22
26
30
35
40| |tt|| The vertical deflection of the left (right) end wheel of the crane: △≤1/400 (see Figure 8), 1 is the measured length (see Figure 7). Table 4
Tensile force value
N
150
10X0.25
2.0
2.5
3.0||tt ||3.5
4.0
4.0
4. 0
3.5
Steel tape measure cross-section size
13×0.2||tt| |Correction value nm2
2.0
2.5
3.0
3.5
3.5
3.5
3.5||tt| |2.5
mrn
15×0.2
1.5
2.0
2.5
2.5
2.5||tt| |2.0
1.5
0
15X0. 25
1.0
1.5
1. 5
1.0|| tt | When the wind blows, the steel tape measure should droop naturally. The reading period on the measured steel tape measure is the correction value in the table above and the measurement correction value of the steel tape measure (must be verified by the provincial level metrology department and be within the validity period), which is the crane's actual span. 500 | Figure 8
3.8 Driver's Cabin
The driver's cabin should comply with the relevant standards. 3.9 Electrical equipment
The electrical equipment of the crane should comply with the requirements of JB4315 and the following regulations. 3.9.1 Principles for the selection of electrical equipment
s
Figure 9
3.9.1.1 The power supply of the crane is three-phase AC, with a frequency of 50Hz and a voltage of 380V. The upper limit of the allowable voltage fluctuation of motors and electrical appliances is 10% of the rated voltage, and the lower limit (at peak current) is -15% of the rated voltage. 3.9.1.2 The motor of the crane operating mechanism should be given priority to the motor specified in ZBK26008. If equipped with a hydraulic coupling, the motor specified in ZBK26007 or other types can also be used. 3.9.1.3 When using a complete set of crane resistors, priority should be given to standard products. If there are special needs, the manufacturer can also design it by itself, but it must comply with the requirements of Article 5.3 of GB3811. 3.9.1.4 Control equipment should adopt centralized control or handle control. 3.9.1.5 Outsourced electrical supporting products must have a production license or model use certificate and product certificate. If first-class products are used, priority shall be given. New products should have technical conditions, type test reports and identification certificates, and self-made equipment must meet relevant standards. 3.9.1.6. The minimum protection level of electrical equipment shall not be lower than IP30 in GB4942.2 in the cab, and not lower than IP33 in other parts (accessories shall comply with the corresponding standards. When accessories complying with the corresponding standards are used, the protection level shall be lower than this standard) When required, a protective cover should be added). 3.9.2 Feeding device
3.9.2.1 The design of the feeding device shall meet the requirements of Article 5.6 of GB3811. 3.9.2.2 Electric hoists should generally use cables to conduct electricity. 3.9.2.3 The power feed of the crane should be conducted by conductive cables. 3.9.3 Installation of electrical equipment
3.9.3.1 Electrical equipment should be installed firmly. During the operation of the host, there should be no horizontal movement or vertical jump relative to the host. Vertically installed control cabinets and control panels (when When the control panel is installed), its verticality should not exceed 12/1000. When the maximum vibration condition of the installation site is greater than 5~~13Hz, the displacement is 1.5mm; when it is greater than 13~150Hz, the vibration acceleration is 10m/s2. 3.9.3.2 The electrical equipment installed in various parts of the crane should be easy to maintain and safe. 3.9.3.3 Crane wires should be laid in wire troughs or metal tubes, and cables are allowed to be laid directly. However, protective measures should be taken in places with mechanical damage, chemical corrosion, and oil corrosion. Wires laid in trunking or metal conduits are not allowed to have joints. Wire connections must use cold-pressed connectors, and soldering is not allowed. When the cable is fixedly laid, the bending radius shall not be less than 5 times the cable diameter. When the cable is movable, the bending radius shall not be less than 8 times the cable diameter.
3.9.3.4 Metal pipes for electric wires should be cleaned of rust stains and burrs on the inner wall and coated with anti-rust paint. The bending radius of the metal pipe shall not be less than 5 times the diameter of the metal pipe. The inlet and outlet of metal pipes and wire troughs must be protected by protective mouths or corresponding measures. Metal pipes and wire troughs should be able to prevent rainwater from soaking people. 3.9.4 Lighting
3.9.4.1 The crane should be equipped with under-bridge lighting to supplement the working surface lighting. The lighting should take into account thunderproof measures in three directions and facilitate inspection, repair and replacement. Light bulb.
JB5663.2—91
3.9.4.2 The voltage of fixed lighting devices should not exceed 220V, and metal structures are strictly prohibited as lighting circuit loops. The voltage of portable lighting devices should not exceed 36V.
3.9.4.3 Dedicated circuits should be installed for lighting. The power supply should be tapped from the incoming end of the main circuit breaker (or main switch). When the main circuit breaker (or main switch) is disconnected, the lighting and signal circuits should not be powered off. , lighting, signal circuits and their branch circuits should be equipped with short-circuit protection. 3.10 Safety and health
3.10.1 The grounding of the power supply part of the crane should be reliable. 3.10.2 When there are two or more cranes on the same track, a main isolation switch or other isolation measures should be installed. 3.10.3 The crane must be equipped with pressure loss protection and zero-position protection, and an emergency power-off switch should be installed where the driver can easily operate it. 3.10.4 Each mechanism must be provided with overcurrent protection separately, but exceptions can be made for mechanisms driven by squirrel cage motors. 3.10.5 The insulation resistance to ground of each circuit in the crane's electronic control equipment should be no less than 0.8M2 in a general environment and should be no less than 0.8M2 in a humid environment. Not less than 0.4MQ.
3.10.6 For electromagnetic cranes, the wiring of the power supply of the electromagnetic chuck on the AC side should ensure that when the power is cut off due to various accidents inside the crane (the conductor of the crane is not powered off), the power supply to the electromagnetic chuck is not cut off, that is, the objects to be sucked are not cut off. fall off. 3.10.7 For the cables that power the retrieval devices below the hook (such as electromagnetic suction cups and detachable grab buckets), the retracting and unwinding speed should be basically consistent with the lifting and lowering speed of the hook. During the lifting process, the cables should not touch the lifting wire rope. . 3.10.8 The operating mechanism of the crane should be equipped with rail sweeping plates and limiters. 3.10.9 The running mechanism of the trolley should be equipped with a bumping head. 3.10.10 The height of the railings on the walking platform (or platform) on the crane should be 1050mm, and there should be two horizontal bars with a spacing of 350mm. The bottom should be equipped with a guard plate with a height of not less than 70mm. Any part of the railings should be able to withstand 1kN load from any direction without permanent deformation.
3.10.11 Protective covers should be installed on exposed rotating parts on the crane that may cause injury, such as open gears, couplings, and drive shafts. 3.10.12 In the absence of other external noise interference, the noise generated by the crane during operation should not be greater than 82dB (A) when measured from the driver's cab seat. When measuring in the closed driver's cab, the openable window of the driver's cab should be opened. The correction values ??for background noise are shown in Table 5. Table 5
The difference between total noise minus background noise
Background noise impact value
3
3
2
2| |tt||6
1
8
1
9
0.5
10
0.5||tt ||dB(A)
>10
0
3.10.13 When the lifting height of the crane is greater than or equal to 12m, or the span S≥30m, a wind speed alarm device should be installed. When the crane span is S40 m, it is appropriate to install a deflection adjustment and display device. 3.10.14 For cranes working in the open air, the electrical equipment should be equipped with rain covers or other rain-proof measures should be taken. 3.10.15 The crane should be equipped with a reliable manual or motorized wind protection device that can prevent the wind force specified in 3.1.4~3.1.6. When a motorized rail clamp is used, it should be used both by machine and hand, or with an additional auxiliary manual wind protection device. 3.11 Appearance
3.11.1 The painting colors and safety signs of each part of the crane should comply with the regulations of JB2299. 3.11.2 The painted surface of the crane should be evenly painted, bright, complete and consistent in color, and should not have defects such as roughness, leakage, wrong paint, threads, pinholes and sagging.
3.11.3 The thickness of each paint film layer is 25~35μm, and the total thickness of the paint layer is 75~105μm. 3.11.4 The paint film adhesion should comply with the Level 2 quality requirements in GB9286. 3.11.5 Before the crane leaves the factory, anti-rust measures should be taken on all exposed processed surfaces. 502 | 4.1 Visual inspection
The visual inspection should include whether the specifications and status of all important parts meet the requirements, such as: various mechanisms and devices, electrical equipment, safety devices, brakes, couplings, controllers, lighting and signaling systems; cranes Metal structures and their connecting parts, ladders, platforms, passages, driver's cabs; all protective devices; hooks or other retrieval devices and their connecting parts: wire ropes and their fixings; pulley blocks and their axial fixings. It is not necessary to disassemble any parts during inspection, but covers that should be opened during normal maintenance and inspection, such as limit switch covers, etc. Visual inspection should also include checking whether the necessary certificates are provided and audited. 4.2 Qualification test
4.2.1 After 2~~3 times of gradual loading, until the load is 1.0G. (G——- is the rated lifting capacity, the deviation shall not be greater than ±1%). Make movements in various directions. Test and test to verify that the items listed in Table 6 should meet the design and requirements of this standard. Table 6
Serial number
6
8
10
11
static
rigid
dynamic
rigidity
project name
lifting height
lifting speed
running trolley running speed
crane running speed||tt| |Main beam mid-span static deflection
Effective cantilever static deflection
Main beam mid-span natural vibration frequency
Vibration swing amplitude of the crane running along the electric hoist
direction|| tt||Ground insulation of each circuit in the electronic control equipment
Resistance
Noise from the crane
Reliability of the limiter
4.2.2 Grab grab full Rate test
Unit of measurement
m
m/min
mm
Hz
MQ
dB(A)
Required value
Nominal value of product performance parameters
(see design drawing)
Article 3.2.2 of this standard
Article 3.2.3 of this standard| |tt||Article 3.2.1 of this standard
Article 3.10.5 of this standard
Article 3.10.12 of this standard
Accurate parking
Permissible deviation| |tt||-5%
±5%
±15%
410%
E
say
Ming|| tt||Press ZBJ80013.2
Slow speed will not be assessed
Calculated after measuring the motor speed
Assessed only when the type test or user
makes a request
The grabbed material More than 90% of the particles have a particle size within 30mm2, and the largest particle size does not exceed 100mm. Grab 5 times on the newly stacked loose materials (the material surface is horizontal), and use the average value to evaluate the fullness rate, which should comply with Article 3.2.4 Provisions. When the stacking bulk density of the test material is less than the design data, the full rate is calculated by volume; when it is greater than the design data, the full rate is calculated by the weight picked up.
4.2.3 The weight suction capacity and power connection safety test of the electromagnetic chuck should adopt the same or similar weight suction capacity test method as that of the manufacturer. The test blocks must be connected together, and the adsorption area of ??the test block should be the size of the electromagnetic chuck. 1~~1.6 times the area. The flatness of the holding surface of the test block is not greater than 3mm, and the holding results comply with the provisions of Article 3.2.5. When the electromagnetic chuck holds a heavy object, cut off the internal power supply of the crane and verify whether the electromagnetic chuck of the crane is powered off. , requiring that the holding object should not fall off.
4.3 Load lifting capacity test
4.3.1 Static load test
Before the static load test, first determine the base section of the mid-span upturn and cantilever upturn. Lift 1.0G load. After running the entire length of the mast three times, remove the load, stop the electric hoist at the outriggers, and measure the original values ??of the upper camber in the span and the upwarp at the cantilever end. During the static load test, a test load of 1.25G should be lifted at the mid-span and cantilever end respectively. After each repetition 3 times, the inspection should be carried out. No more 503
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