32-5t 26m A型双梁门式起重机门架结构设计【6张PDF图纸+CAD制图+文档】
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A型双梁门式起重机门架结构设计【6张PDF图纸+CAD制图+文档
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Thus facings of rockfill and blast-formed dams of rock covered with poured asphalt are simple, are easily programmed with respect to properties and design, and are easily made by commercial equipment, which opens broad opportunities for their use. LITERATURE CITED i. S.N. Popchenko, Yu. N. Kasatkin, and G. V. Borisov, Asphaltic Concrete Facings of HYdraulic Structures in Russian, Energiya, Leningrad (1970). 2. I.V. Korolev, Ways to Save Bitumen in Road Construction in Russian, Transport, Moscow (1986). 3. Recommendations on the Design of Reversed Filters of Hydraulic Structures: II-92-80/ VNIIG in Russian, Leningrad (1984). 4. Yu. N. Kasatkin, Design of the composition of transition layers of asphalt concrete diaphragms in earth dams, Gidrotekh. Stroit., No. 6 (1981). 5. V.F. Van Asbek, Use of Bitumens in Hydrotechnical Construction in Russian, Energiya, Leningrad (1975). DESIGN OF CRANES FOR OPERATING GATES I. Kh. Kaplan As is known, when lifting a gate its wedging in the guideways of the groove is possible, as a result of which both overloading of the hoisting device and transmission of an increased pulling force from the hoisting device to the gate, trash rack, grab, etc., being raised oc- cur. During lowering of the gate its jamming in the guideways of the groove is possible. In this case, the hoisting device continues to operate and unwinds the cable from the drum, i.e. slackening and sagging of the cable occur. After this a sudden spontaneous movement (drop) of the gate occurs and a dynamic load (jerk) considerably exceeding the design load often Occurs. To limit overloading of the crane during lifting and to limit slackening of the cables during lowering of a gate, load relays are installed on cranes, which should provide during lifting an overload of not more than 25% of the rated load and during lowering should provide a maximum slackening of the cables equal to the tension in the cable from half of the mass of the suspension. At the same time, one and the same crane can operate different gates or racks. In this case, different pulling forces are required for raising each of the gates or racks. In the case of wedging of the gate or rack in the grooves, the rated pulling force of the crane plus 25% of the overload is transmitted to the restrained load (gate, rack, etc.). As a result of the large difference in the required pulling forces for operating different gates, the pulling force of the crane in the event of wedging of a restrained load can damage or destroy it. Often in such cases there are different hoisting mechanisms on the crane carriage for different restrained loads, which leads to an increase of the overall dimensions both of the crane carriage and of the crane itself. It is clear from the aforesaid that a crane and the restrained load which it operates are a single system and a device performing functions of protection both of the crane and of the restrained load under various necessary pulling forces is needed for such systems. In order not to install additional mechanisms of different capacity on the crane, it was nec- essary to create a special device which could change (or assign) the required nominal capacity of the crane and protect the crane and restrained load from overload and slackening of the cables for various capacities. Furthermore, there has long been the need to replace the un- reliably operating spring and eccentric type load limiters. The Moscow Special Design Department for Steel Hydraulic Structures (Mosgidrostal) de- veloped a device for controlling the hoisting mechanism I for a gantry crane of the water intake and outlets of the Kambarata No. 2 hydroelectric station. The device for controlling Translated from Gidrotekhnicheskoe Stroitelstvo, No. i0, pp. 37-38, October, 1989. 0018-8220/89/2310-0605512.50 ?9 1990 Plenum Publishing Corporation 605 ili II 8 Fig. i. Hydromechanical diagram of the device for controlling the hoisting mechanism: i) hydraulic cylinder; 2) frame of the crane carriage; 3) rod; 4) equalizing tackle block; 5) block and tackle; 6) load-lifting drum; 7) limit switch; 8) pressure relay; 9) choke with check valve; i0) distributor; Ii) supporting valve; 12) manom- eter; 13) safety valve; 14) filter; 15) check valve; 16) electric motor; 17) pump; 18) tank; 19) rule. the hoisting mechanism of the crane is located on the crane carriage, which makes it possible to change (in the given case, toward a decrease) of its capacity from i00 to 30 tons and to protect the crane and restrained load from overloading and slackening of the cables for each capacity, respectively. The developed design of the device for controlling the hoisting mechanism has as the main actuators of hydraulic cylinder, hydraulic apparatus, and electrical apparatus, which make it possible to easily determine the extent of overloading of the crane or the value of slckening of the cables, as well as to hack-up the control system (pressure relays and limit switches). Furthermore, it became possible to select (assign) the capacity of the crane, and it is accomplished by the crane operator directly from the operating cabin. The device (Fig. I) consists of: a hydraulic piston cylinder, on the rod of which is fastened an equalizing tackle block. The hydraulic cylinder is made in the body of a crossbeam installed in rolling contact bearings, which makes it possible to arrange the hydraulic cylinder at the required angle and thereby to eliminate the transmission to the rod of the horizontal forces occurring from tension of the cables at an angle to the equalizing block; an oil-pressure system for delivering the working fluid under pressure to the hydrau- lic cylinder in order to create the necessary force. The oil-pressure system consists of a welded tank, pumping plant with a gear pump submerged in oil, pipelines, panel with hydraulic apparatus, electric heaters heating the system at negative temperatures, thermal relay check- ing the temperature of the oil in the tank; housing with a jacket for heat-insulating and waterproofing the system. The device can be adjusted for a capacity of i00 and 30 tons (other capacities were not required). During raising or lowering of the restrained load (gate, racks), the crane operator sets the switch of the capacity to the position corresponding to a capacity of 30 or 100 tons. The oil-pressure system is turned on and the oil goes to the lower cavity of the hydraulic cylinder under pressure; the piston moves upward, moving the equalizing block with the rule. The rule closes the limit switch. The piston continues to move up to the stop in the cover, the pressure increases in the hydraulic system and operates the pressure relay The load hoisting mechanism is turned on. When an overload occurs on the crane suspension the piston tries to descend, in which case the pressure begins to increase in the lower cavity. As soon as the increase of pressure becomes equivalent to the prescribed overload of the mech- anism, the pressure relay operates and the hoisting mechanism and electric motor of the pump are turned off. During lowering of the restrained load the oil-pressure system is also turned on and the oil goes from the pump into the upper cavity of the hydraulic cylinder. The piston 606 with the equalizing block and rule descend. The rule closes the contacts of the limit switch. The direction of the oil flow changes. The oil begins to enter the lower cavity of the hydraulic cylinder. The pressure in the lower Cavity begins to increase, the pressure relay operates, and the hoisting mechanism is turned on for lowering the load. A rise of the piston does not occur, since the oil under a pressure equivalent to the force on the rod, equal to 0.5 of the mass of the suspension, drains through the supporting valve into the tank. When the load on the rod decreases (owing to the fact that slackening of the cable occurs), the piston begins to rise and the pressure in the system falls. Opening of the contacts of the pressure relay and then of the limit switch occurs. The crane hoisting mechanism and electric motor of the pump are switched off. Heating of the oil in the tank is provided for in the device. At an air temperature below 5 heating of the device is turned on. The electric heaters begin to heat the oil and upon reaching an air temperature of 5 under the housing, heating is turned off. The temperature regime of the oil in the tank is regulated by a thermal relay. To check the performance of the device, Mosgidrostal developed and manufactured a device for controlling the hoisting mechanism. The device is made on the basis of hydraulic and electrical apparatus being produced by industry and in design is anal- ogous to the prototype. Tests confirmed the performance of the device and the results were published for adjusting and regulating the device after its insulation on the crane for the Kambarata No. 2 hydrostation. The technical and economic indices of the device are: the possibility of changing (assigning) the capacity of the hoisting mechanism makes it possible to reduce the number of hoisting mechanisms on the crane, which in turn made it possible to reduce the size and weight of the crane carriage and crane itself; the accuracy of limiting overloading of the crane increases, i.e., overloading of the crane decreases due to using electrical and hydraulic apparatus instead of mechanical compo- nents used in the spring or eccentric type load limiters; operating safety on the crane increases, since the control apparatus is backed up in the device; the possibility of changing the capacity makes it possible to protect the tzash racks, gates, grabs, etc., from damage as a result of wedging. Thus the operating reliabil- ity of the mechanical equipment increases and the probability of failures decreases; if necessary, the device can be made as an independent drive of increased capacity with a small stroke for lifting the gate from the sill and with a reduced load lifting or lowering speed. LITERATURE CITED i. I. Kh. Kaplan, Device for controlling the hoisting mechanism of cranes, Inventors Certificate No. 1428681 in Russian. 607 门式起重机设计I. Kh. Kaplan众所周知，当升降闸门的楔形槽的导轨是活动的，由于这两超载吊装设备和传输牵引力的增加，起重设备闸门、拦物栅、抓斗等。在门槽的导轨干扰降低是可能的。在这种情况下，吊装设备继续运行，然后从吊索，即松弛下垂的电缆发生突然的自发运动后（下降）的门时，动态负载（工件）大大超过设计负荷的情况也是时有发生的。限制超载的起重机在吊装和限制放松电缆在栅降低，负载继电器安装在起重机在起吊过程中，应提供不超过25%的额定负载的过载和下降时应提供最大松弛的电缆相当于吊索的张力。同时，同一个起重机操作不同的门架。在这种情况下，不同的牵引力提高门架要求。在楔形门或架在槽内的情况下，额定拉力的起重机加上超载25%发送到约束载荷（门架，等）。由于所需拉力操作不同的门的差异较大，在楔形约束加载工作的起重机的拉力可以导致其受到破坏。在这种情况下，在不同的约束荷载作用下，起重机的起升机构有不同的起升机构，从而导致起重机车架和起重机的整体尺寸增大。从上述两种装置中，可以清楚地表明，它所操作的起重机和受约束的负载是一个单一的系统和一个装置，该装置执行功能的保护，这两个起重机和约束的负载下的各种必要的拉力是必要的，这样的系统。为了不在起重机上安装不同容量的额外的机制，有必要创建一个特殊的装置，可以改变（或转移）所需的标称容量的起重机和起重机过载保护和约束载荷，减少电缆的各种能力。此外，长期以来一直有需要更换不可靠操作弹簧和偏心型载荷限制器。莫斯科式特别设计部钢液压结构（mosgidrostal”）开发一种用于对kambarata 2号水电站进水口和出口门式起重机起升机构控制的I。用于控制起重机起升机构装置位于起重机运输，这使得它有可能改变（在给定的情况下，对减少其容量从30100吨和保护起重机和约束载荷过载和放缓的电缆每能力。开发设计的控制装置起升机构液压缸的主要执行机构，液压装置，电气装置，这使得它可以容易地确定该起重机或slckening电缆的价值超载程度，以及黑客的控制系统（压力继电器和限开关）。此外，它成为可能选择（分配）的能力的起重机，它是由起重机操作员直接从操作舱。装置（图1）：图一、水力机械图的控制装置起升机构：I）液压缸；2）起重机的车架；3）杆；4）平衡滑车；5）滑轮；6）起吊滚筒；7）限位开关；8）压力继电器；9）节流止回阀；I0）配电盘；11）配套阀门；12）压力计；13）安全阀；14）滤波器；15）止回阀；16）电动机；17）泵；18）油箱；19）尺液压活塞缸，上杆系平衡滑车。液压缸在横梁安装在滚动接触轴承体，这使得它可以安排液压油缸所需的角度，从而消除传递的水平力而产生的电缆张力在一个角度的平衡块的杆；提供工作流体压力的液压缸下为了创造必要的力油压系统。油压系统由一个焊接罐、一个齿轮泵抽油机、管道、面板、液压装置、加热系统、负温度、热继电器、检查油箱内的油温度组成；有保温和防水系统外罩。活塞试着下降，在这种情况下压力开始增加在较低的空腔。随着压力的增加变得相当于规定的过载的机制，压力继电器动作，起升机构和电机泵的关闭。在约束载荷的降低时，油压力系统也被打开，油从泵进入液压缸的上腔。活塞与平衡块和规则下。规则闭合限位开关触点。油流变化方向。油开始进入液压缸的下腔。在较低的腔压力开始增加，压力继电器工作，和起升机构被打开，以降低负载。活塞的上升不会发生，因为油在压力下相当于杆上的力，等于0.5的悬浮液，通过支护阀进入罐中。当杆上的负载减少（由于减少电缆发生），活塞开始上升，系统中的压力降。开触点的压力继电器，然后发生限位开关。该泵的起重机构和电动机被切断。装置中的油的加热装置。在低于5的空气温度下，设备的加热被打开。电热水器开始加热油，并在外壳下到达5的空气温度下，加热被关闭。罐中的油的温度制度是由一个热继电器调节。检查设备的性能，mosgidrostal的开发和制造的控制起升机构的装置。该装置是基于液压和电气设备产生的工业设计是类似的原型。试验证实该装置和业绩公布调整和规范设备的kambarata 2号水电站起重机绝缘后。设备的技术和经济指标改造（指派）的可能性，使起升机构的能力，使得有可能减少起重机的起升机构的数量，这反过来又使有可能减少起重机运输和起重机本身的尺寸和重量；限制超载起重机的增加，即准确性、起重机的超载降低由于使用代替机械部件采用弹簧或偏心型载荷限制器的电气和液压装置；在起重机的增加操作的安全性、自控制装置中备份设备；改变能力的可能性，使得它可以保护支架，箱盖，抓斗，等，因此，机械设备增加了操作可靠性和失效的概率降低；如果有必要，该设备可以作为一个独立的驱动器的能力增加一个小动力，以起升并与减少负载提升或降低速度。参 考 文 献1. I. Kh. Kaplan, Device for controlling the hoisting mechanism of cranes, Inventors Certificate No. 1428681 in Russian.2. S . N . Popchenko, Yu. N. Kasatkin, and G. V. Borisov, Asphaltic Concrete Facings of HYdraulic Structures in Russian, Energiya, Leningrad (1970).3. Recommendations on the Design of Reversed Filters of Hydraulic Structures: II-92-80/ VNIIG in Russian, Leningrad (1984).4. Yu. N. Kasatkin, Design of the composition of transition layers of asphalt concrete diaphragms in earth dams, Gidrotekh. Stroit., No. 6 (1981).5. V . F . Van Asbek, Use of Bitumens in Hydrotechnical Construction in Russian, Energiya, Leningrad (1975).32/5t/ 26m A型双梁门式起重机门架结构设计摘 要进入21世纪以来,我国的铁路、造船工业进入了快速发展的轨道,门式起重机因其在露天作业环境中有其它类型起重机无法替代的优势,因此对其进行研究、创新,使其结构更合理,使用更方便,具有重要的战略和现实意义。本次设计为32/5tA型双梁门式起重机结构设计；门式起重机实现港口货场装卸作业效率，减轻工人劳动强度，改善工人操作条件；是货场重要的起重运输机械。A型双梁门式起重机主要由双主梁 两刚支腿 两柔支腿以及马鞍 刚性立柱 下横梁组成门式起重机的主要金属结构。关键字：A型门式起重机；结构；跨中；悬臂。32/5t / 26m A-type double-girder gantry cranegantry structure designAbstract：Since entering the 21st century, the railway and shipbuilding industry of our country has entered the track of rapid development.There are advantages that can not be replaced by other types of cranes in open-air working environment, so the structure of crane is studied and innovated.More reasonable, more convenient to use, has important strategic and practical significance.This design is the structure design of 32/5tA type double girder gantry crane, which can realize the loading and unloading operation of port freight yard.Efficiency, reduce the labor intensity of workers, improve the working conditions of workers; is an important lifting and transportation machinery in the yard. Type A double beamGantry crane mainly consists of double main girder, two rigid legs, two flexible legs and saddle rigid column under the crossbeamThe main metal structure of a heavy machine.Keyword： A dual-beam gantry crane；Metal structure；Middle of span；Cantilever目 录摘 要Abstract：1 绪论11.1 起重机概述及结构简介11.2 国内外研究动态31.2.1 国内发展现状31.2.2 国外发展现状51.3 完成本题的目的和意义61.4 主要研究目标和内容71.5 准备工作情况和主要工作措施82 总体方案设计92.1 基本参数和已知条件92.2 材料选择及许用应力92.3 门架的载荷计算102.3.1 箱形结构门架自重102.3.2 惯性力（一根主梁）102.3.3 风载荷113 主梁的计算133.1 主梁的几何尺寸和特性133.1.1 主梁几何尺寸133.1.2 主梁几何特性143.2 主梁的内力计算143.2.1 垂直载荷引起的主梁内力153.2.2 水平载荷引起的主梁内力183.3 主梁的强度验算203.3.1 主梁弯曲应力的验算203.3.2 主梁剪应力的验算203.3.3 主梁扭转剪应力的验算213.4 主梁稳定性的计算214 支腿的计算234.1 刚支腿的几何尺寸和特性234.2 支腿的内力计算254.2.1 门架平面内的支腿内力计算254.2.2 支腿平面内的支腿内力计算284.3 支腿的强度验算294.4 支腿稳定性的计算305 下横梁和马鞍的计算345.1 下横梁的几何尺寸和特性345.2 马鞍的几何尺寸和特性355.3 下横梁的内力计算355.4 下横梁的强度验算355.5 下横梁稳定性的计算366 门机的抗倾覆稳定性校核377 门架的刚度计算407.1 主梁静刚度校核407.2 主梁动刚度校核417.3 门架水平静位移418 主梁的翘度和拱度449 连接部分计算449.1 刚性支腿与主梁连接处的螺栓强度验算449.2 刚性支腿与下横梁连接处的螺栓强度演算46参考文献48英文原文49中文对照67致 谢801 绪论1.1 起重机概述及结构简介起重机是以反复短暂的工作循环方式完成货物装卸或设备安装作业的。一个工作循环包括：取物、货物上升、水平运动、下降、卸载，然后空吊具返回原地。一个工作循环时间一般从几分钟到二三十分钟，其间各机构在不同时刻有短暂的停息时间，中国古代灌溉农田用的桔是臂架型起重机的雏形。14世纪，西欧出现了人力和畜力驱动的转动臂架型起重机。19世纪前期，出现了桥式起重机；起重机的重要磨损件如轴、齿轮和吊具等开始采用金属材料制造，并开始采用水力驱动。19世纪后期，蒸汽驱动的起重机逐渐取代了水力驱动的起重机。20世纪20年代开始，由于电气工业和内燃机工业迅速发展，以电动机或内燃机为动力装置的各种起重机基本形成。起重机主要包括起升机构、运行机构、变幅机构、回转机构和金属结构等。起升机构是起重机的基本工作机构，大多是由吊挂系统和绞车组成，也有通过液压系统升降重物的。运行机构用以纵向水平运移重物或调整起重机的工作位置，一般是由电动机、减速器、制动器和车轮组成。变幅机构只配备在臂架型起重机上，臂架仰起时幅度减小，俯下时幅度增大，分平衡变幅和非平衡变幅两种。回转机构用以使臂架回转，是由驱动装置和回转支承装置组成。金属结构是起重机的骨架，主要承载件如桥架、臂架和门架可为箱形结构或桁架结构，也可为腹板结构，有的可用型钢作为支承梁。起重机根据结构的不同分类1、梁式型起重机可在长方形场地及其上空作业，多用于车间、仓库、露天堆场等处的物品装卸，有梁式起重机、桥式起重机、龙门起重机、缆索起重机、运载桥等。梁式起重机：梁式起重机主要包括单梁桥式起重机和双梁桥式起重机单梁桥式起重机桥架的主梁多采用工字型钢或钢型与钢板的组合截面。起重小车常为手拉葫芦、电动葫芦或用葫芦作为起升机构部件装配而成。按桥架支承式和悬挂式两种。前者桥架沿车梁上的起重机轨道运行；后者的桥架沿悬挂在厂房屋架下的起重机轨道运行。单梁桥式起重机分手动、电动两种。手动单梁桥式起重机各机构的工作速度较低，起重量也较小，但自身质量小，便于组织生产，成本低，时候用于无电源后搬运量不大，对速度与生产率要求不高的场合。手动单梁桥式起重机采用手动单轨小车作为运行小车，用手拉葫芦作为起升机构，桥架由主梁和端梁组成。主梁一般采用单根工字钢，端梁则用型钢或压弯成型的钢板焊成。电动单梁桥式起重机工作速度、生产率较手动的高，起重量也较大。电动单梁桥式起重机由桥架、大车运行机构、电动葫芦及电气设备等部分组成。桥式起重机：桥式起重机是桥架在高架轨道上运行的一种桥架型起重机，又称天车。桥式起重机的桥架沿铺设在两侧高架上的轨道纵向运行，起重小车沿铺设在桥架上的轨道横向运行，构成一矩形的工作范围，就可以充分利用桥架下面的空间吊运物料，不受地面设备的阻碍。桥式起重机广泛地应用在室内外仓库、厂房、码头和露天贮料场等处。桥式起重机可分为普通桥式起重机、简易梁桥式起重机和冶金专用桥式起重机三种。普通桥式起重机一般由起重小车、桥架运行机构、桥架金属结构组成。起重小车又由起升机构、小车运行机构和小车架三部分组成。起升机构包括电动机、制动器、减速器、卷筒和滑轮组。电动机通过减速器，带动卷筒转动，使钢丝绳绕上卷筒或从卷筒放下，以升降重物。小车架是支托和安装起升机构和小车运行机构等部件的机架，通常为焊接结构。2、悬臂起重机（旋臂起重机）悬臂起重机有立柱式、壁挂式、平衡起重机三种形式.柱式悬臂起重机是悬臂可绕固定于基座上的定柱回转，或者是悬臂与转柱刚接，在基座支承内一起相对于垂直中心线转动的由立柱和悬臂组成的悬臂起重机。它适用于起重量不大，作业服务范围为圆形或扇形的场合。一般用于机床等的工件装卡和搬运。 壁上起重机是固定在墙壁上的悬臂起重机，或者可沿墙上或其他支承结构上的高架轨道运行的悬臂起重机。平衡起重机俗称平衡吊，它是运用四连杆机构原理使载荷与平衡配重构成一平衡系统，可以采用多种吊具灵活而轻松地在三维空间吊运载荷。平衡起重机轻巧灵活，是一种理想的吊运小件物品的起重设备，被广泛用于工厂车间的机床上下料，工序间、自动线、生产线的工件、砂箱吊运、零部件装配，以及车站、码头、仓库等各种场合.本课题设计的门式起重机就是桥式起重机的一种，常见的又分为桁架式和箱梁式两种 从结构上来说起重机(crane)运行机构一般只用四个主动和从动车轮，如果起重量很大，常用增加车轮的办法来降低轮压。当车轮超过四个时，必须采用铰接均衡车架装置，使起重机的载荷均匀地分布在各车轮上，桥架的金属结构由主梁和端梁组成，分为单主梁桥架和双梁桥架两类。单主梁桥架由单根主梁和位于跨度两边的端梁组成，双梁桥架由两根主梁和端梁组成。 主梁与端梁刚性连接，端梁两端装有车轮，用以支承桥架在高架上运行。主梁上焊有轨道，供起重小车运行。桥架主梁的结构类型较多比较典型的有箱形结构、四桁架结构和空腹桁架结构。 箱形结构又可分为正轨箱形双梁、偏轨箱形双梁、偏轨箱形单主梁等几种。正轨箱形双梁是广泛采用的一种基本形式，主梁由上、下翼缘板和两侧的垂直腹板组成，小车钢轨布置在上翼缘板的中心线上，它的结构简单，制造方便，适于成批生产，但自重较大。偏轨箱形双梁和偏轨箱形单主梁的截面都是由上、下翼缘板和不等厚的主副腹板组成，小车钢轨布置在主腹板上方，箱体内的短加劲板可以省去，其中偏轨箱形单主梁是由一根宽翼缘箱形主梁代替两根主梁，自重较小，但制造较复杂。 1.2 国内外研究动态1.2.1 国内发展现状经过半个多世纪的发展，我国起重机设计经历了早期直觉设计阶段、传统设计阶段和现代设计阶段。近年来，随着我国重工业的发展，已有一千多家起重机生产单位得到国家质检局的许可2。其中最具代表性的起重机生产厂家有徐州重工、三一重工、中联重科和抚挖等公司，这些单位生产的起重机种类齐全，市场占有率高。在前不久bauma China的展会上，我国的起重机生产厂商纷纷亮相了不少新产品，有些还创了国际记录。其中，以“千亿元、国际化、世界级”为战略的徐州重工在展会上首次推出XCA5000型1600t全地面起重机，该款起重机具备双动力驱动及9轴分时驱动重载转场的技术，可在升起110m高度的情况吊重140t的重量;三一重工推出了自己的新产品SCC36000A型履带起重机，该起重机底部采用车架与回转支撑结合、上部为双臂的结构形式，起重量高达3600t，可广泛用于煤化工、石化、核电等工程领域，是国际同类起重机产品中最大的之一;中联重科推出的2000t级全地面起重机，为目前世界最大的全地面起重机，可实现3MW风机安装，主臂起升高度可达106m，兼并世界上臂架长度第一、起升重量第一等多个世界纪录;抚挖采用多元化配置，模块化设计思想，推出了自己最新的Fwx系列的液压履带起重机产品。除上述公司的产品之外，其他一些起重机生产企业也纷纷克服技术难题，实现技术创新，研制出了自己新的产品。随着国内对现代设计理论和材料研究的进展，使得我国起重机不断取得新的成果4，如将H型钢和T型钢应用于起重机的钢结构中，将MC尼龙材料替换起重机钢丝滑轮，降低了起重机的生产成本、延长零部件的使用寿命;将起重机的金属结构和机械分级，为不同工作强度和频率的起重机提供系列化的产品;应用三合-减速器、立式减速器等- -些新型装置;利用结构优化技术手段实现起重机的轻量化等。尽管我国生产起重机的技术相比之前已有 所突破， 但是与国外技术相比，但仍存在一定的差距，主要表现在以下几个方面215(1)制造工艺水平低我国国内的加工制造工艺还不成熟，工艺技术水平发展相对比较滞后，对先进和特殊的工艺缺乏研究和经验，生产出的起重机零部件性能差，使用寿命短，使整机水平难以提高。另外，国内设计的起重机只注重功能要求而忽略了 细节设计，往往急于投向市场，其研发和调试周期较短，使其在工作过程中容易出现很多问题。(2)产品技术标准更新滞后技术标准作为科技成果转化为生产力的重要条件，是指导企业生产的依据，对企业开发新产品有着重要推动作用。科技先进的制造企业会根据市场和技术发展的需要来指定符合自身的技术标准。而我国国内起重机械的一-些关键的技术标准仍然以采用发达国家和地区的标准为主，其关键技术标准的滞后和缺失严重阻碍了我国起重机新产品、新技术的开发、推广和应用。(3)核心部件技术水平欠缺目前，像发动机、液压件等- -些起重机关键部件，其主要技术仍然掌握在外国人手里，我国国内自主研发和生产能力较弱，在一定程度上还是必须依靠进口。另外，像薄型钢材、异性钢材和起重机轨道型材等结构材料紧缺，规格品种较少，造成配套件的供应不足，从而导致整机结构的匹配程度不高。这不仅大大制约了我国起重机的发展和竞争力也进一步降低国内起重机的利润和市场占有率。为弥补核心技术部件的不足，我们应该不断积累设计经验，弥补技术上的不足，提高整机的匹配水平，提供更实用、更安全和更经济的设计方案。(4)产品研发能力差我国国内起重机行业起步较晚、技术资料陈旧、缺乏，使得整体科技实力较弱、自主开发能力不足，产品更新换代缓慢，在-一些重要的使用场合还要依靠国外生产制造的起重机。同时由于管理水平、科研经费和科技人员素质等因素的制约也阻碍了我国起重机的开发。另外，国内设计人员对计算机辅助设计、可靠性设计、模块化设计和制造等方面的应用还需要很大的提高。1.2.2 国外发展现状目前，国外起重机的生产厂家较多，其中以欧美的利勃海尔、马克托瓦克和特克雷斯一德马格为代表的起重机制造企业，其技术先进、 品类齐全、拥有较高的市场占有率6。利勃海尔采用创新理念推出的LTM 1160-5.2 机型， 它摈弃了这种大吨位起重机一-贯使用的双发动机概念，只需一台发动机来带动整个上部结构，即使用单一发动机加一根机械轴来带动160 吨重的上盖，从而减少了整机设备的重量和维修作业量，增加了设备的负载能力。马克托瓦克采用先进的变频技术设计的MC120B型起重机，在起升作业中可实现五倍变速平稳，发展起着至关重要的作用。它需要依靠液压技术、电力电子技术、电子技术、机械技术、计算机技术、模糊控制技术和微电子技术的相互结合，将它们应用到起重机上的驱动系统和控制系统中，推动其电气元件和控制系统的升级和改进， 从而达到起重机自动化、智能化的目的。 目前， 新一代的起重机电气控制装置已经发展成为全电子数字化的控制系统，其中包括数字化操纵给定检测、故障诊断及数据管理系统、可编程序控制器和全数字化控制驱动装置等设备。另外，三维条形码技术、无接触供电、载波通讯及控制、近场感应防碰撞技术、高效速度的控制，适用于施工强度大、对塔机生产效率要求高、吊重定位精准的超高层建筑工地。特克雷斯推出的QuaymateM50移动式港口起重机最大负载能力达50吨，工作半径高达36米，其用途广泛，能够处理大多数的类型货物。该起重机最大的特点是可以连接外部电源，在工作过程中可以实现零污染气体的排放。随着科学技术的进步和工业自动化水平的提高，起重机的发展也越来越呈现出以下几种发展趋势78。(1)模块化、组合化模块化的设计思想是将起重机上功能基本相同的零部件制成具有相同连接要素且用途多样可互换的标准化模块。通过模块不同的组合形式，形成具有不同规格和型号的起重机类型。在对新型起重机设计和修改时，无需再对整机进行重新设计，只需将模块化的产品修改和重新组合即可实现新产品的修改和更新换代。模块化设计思路使传统小批量生产的起重机转变为大批量模块化生产，降低了企业的生产成本、提高了企业的生产效率和产品的通用化程度，增强了企业在市场的竞争力。目前，日本和一些欧美国家的大型生产企业已经开始采用模块化的设计思想，并取得了十分可观的经济效益。例如:德国的德马格公司采用模块化的设计思想设计的葫芦双梁起重机使设计费用降低12%，相比国内起重机的自重减轻了35%左右，取得了明显经济效益。(2)大型化和高速化随着目前工业发展水平和劳动生产率的提高，产品的物料搬运费用也逐渐的增加，这就促使起重机不断向更大起重量和更高速度转变。目前，全球最大的履带起重机起重量为3600t,浮游起重机为6500t。大型化和高速化的起重机产品正在顺应市场潮流，成为今后起重机的一个发展趋势。(3)自动化和智能化起重机上的电气元件和控制系统的升级和改进对起重机的自动化和智能化激光查找起吊物重心、吊具防摇的模糊控制、故障自诊监控、射频数据通讯、变压变频调速及现场总线等都得到了广泛应用。(4)轻型化和多样化为达到节省耗材、提高整机的承载能力，适应不同的工作场合，起重机的发展也越来越趋于向轻量化和多样化的发展。相比国外的起重机，国内生产的起重机整机尺寸偏大，结构笨重。起重机的轻量化发展也正在引起国内起重机生产厂家的关注。国外一些起重机企业应用铝合金材料和高强度钢等新型轻量化材料，大大减轻了起重机金属结构的质量。另外，随着优化技术的广泛应用、新型切割工艺和焊接工艺的发展也为起重机轻型化发展带来了便利条件。1.3 完成本题的目的和意义通过对双梁 A 型门式起重机的研究和创新设计，能够让我很好的掌握 结构力学、材料力学在金属结构件和起重机运输中的运用。作为1设计 的一大课题，在融合贯通机械专业的同时，更能很好的使自己所学专业知 识全面化、系统化。本次设计的结构较复杂，特别是支腿、马鞍部分，设计难度较大，计算量也较多。不光是对专业知识的考察，更体现在自己对 待生活和学习的态度上。通过这一环节的训练，更能很好的提高了以下方面的能力： 1、综合运用所学知识和技能，独立分析和解决设计问题；2、熟练运用基本技能，包括绘图、计算机应用、翻译、查阅文献等；实验研究，撰写科技论文和技术报告，正确运用国家标 准和技术语言阐述理论和技术问题； 3、收集加工各种信息的能力，获取知识； 4、多角度的培养我们综合运用和扩大所学知识面，以提高理论联系实际； 5、通过依据数据、准确的制图，培养了我们收集、整理、分析及运用资料；6、另外它不仅仅局限在机械基础知识上更涉及了有关材料学、力学等多学科知识，使我们对交叉学科有了一定的涉足，拓宽了我们的知识面，更激发了进行本专业工作、学习的激情与兴趣。1.4 主要研究目标和内容本设计为 32t 双梁A型门式起重机结构设计，根据给出的设计参数，设计出符合要求满足使用性能的起重机结构，所用到的研究方法主要有经验总结法、比较研究法、文献资料法等。比较研究法可以理解为是根据一定的标准，对两个或两个以上有联系的事物进行考察，寻找其异同，探求普遍规律与特殊规律的方法。本次设计主要是借鉴前人对起重机结构设计的成熟经验，结合目前双梁 A 型门式起重机所存在的缺点和不足，对设计出来的结构进行轻量化处理。通过翻阅相关文献书籍进行主梁、支腿、马鞍、下横梁等设计计算，特别是载荷计算及载荷组合，螺栓的连接计算；包括（1材料选择及许用应力；门架的载荷计算；2主梁的几何尺寸和特性；主梁的内力计算；主梁的强度验算主梁稳定性的计算；3刚支腿的几何尺寸和特性；支腿的内力计算支腿的强度验算；支腿稳定性的计算；4马鞍的几何尺寸和特性；下横梁的几何尺寸和特性；下横梁的内力计算；下横梁的强度验算；下横梁稳定性的计算；5门机的抗倾覆稳定性校核；5主梁静刚度校核；主梁动刚度校核；主梁的翘度和拱度；6刚性支腿与主梁连接处的螺栓强度验算；刚性支腿与下横梁连接处的螺栓强度演算。）最后绘制总图、主梁图、下横梁图、支腿图、马鞍图等，进行说明书撰写。1.5 准备工作情况和主要工作措施本设计采用规范的设计计算对A型双梁门式起重机各机构进行了分析。首先，通过查阅相关书籍和资料，学习门式起重机的相关知识，了解门式起重机的发展和应用现状，掌握门式起重机金属结构的设计方法，学习并掌握AutoCAD软件的使用，掌握一般的绘图方法和计算分析步骤;其次，根据现今国内外生产门式起重机采用的各种结构类型，结合课本知识和参考文献信息，设计符合使用要求的结构，门式起重机的受力情况，计算门式起重机的自重载荷、起升载荷、水平惯性载荷，并对门式起重机进行轻量化处理，在可控范围内尽可能节省材料2 总体方案设计2.1 基本参数和已知条件起重量Q：32/5t 跨度L：26m工作级别：A5 起升高度（主/副）：10.5/11.5m大车车轮直径：700mm 小车重量：10.7t起升速度（主/副）：9.0/18.7m/min 运行速度（大/小）：43.2/38.6m/min轮距（大/小）：9000/2700mm 小车轨距：2500mm左悬臂长=右悬臂长：7500mm 有效悬臂长度：5000mm2.2 材料选择及许用应力根据总体结构采用箱形梁，主要采用板材及型材。主梁、端梁均采用Q235-A钢，二者的联接采用螺栓连接。材料许用应力及性质： 取= 取= 取=2.3 门架的载荷计算2.3.1 箱形结构门架自重箱形结构主梁自重 t式中：额定起重量 ：主梁全长 ：起升高度2.3.2 惯性力（一根主梁）(1) 大车制动时引起的水平惯性力=N 式中：大车运行速度 ：制动时间，取3.5s 大车制动惯性力应受到主动轮打滑的限制，即N 式中：粘着系数，取0.15 ：大车主动轮轮压，N (2) 小车制动时引起的水平惯性力=N 为了防止小车制动时打滑也应满足N 式中：小车主动轮轮压N2.3.3 风载荷 (1) 作用于货物的风载荷 式中：风力系数，取1.5 ：工作状态最大风压，取 ：货物迎风面积，当时，N (2) 作用于小车上的风载荷 式中：小车的迎风面积，由小车防雨罩的尺寸确定，N (3) 作用于主梁上的风载荷 式中：主梁长度方向迎风面积，N 将主梁上的风载荷化为均布载荷 (4) 作用在支腿上的风力 式中：支腿迎风面积， 将支腿上的风载荷化为均布载荷 由于上述的各种载荷不可能同时作用于门架结构上，因此要根据门机的使用情况来确定这些载荷的组合。3 主梁的计算3.1 主梁的几何尺寸和特性3.1.1 主梁几何尺寸图1主梁几何尺寸 高度mm , 取腹板高度mm , 翼缘板厚度mm , 腹板厚度mm ; mm , 主梁总高度mm主梁宽度mm , 腹板外侧间距取mm , 上下翼缘板不同,分别为及.主梁端部变截面长取3.1.2 主梁几何特性面 积 形 心 mm mmmm mm惯性矩 截面模数 3.2 主梁的内力计算3.2.1 垂直载荷引起的主梁内力 (1) 移动载荷引起的主梁内力 一个偏轨箱形主梁上总的小车轮压，按下式计算N 式中：起重机小车自重 ：起升载荷 ，：冲击系数 ：桥架主梁的根数 因此：N 现分别计算小车位于跨中和悬臂端时的主梁内力：小车位于跨中 图2 弯矩图 最大弯矩作用位置m 求得支反力=N 剪力 ：小车位于悬臂端 图3悬臂端弯矩图支反力=剪力 弯矩=(2) 均布固定载荷引起的主梁内力 图4 主梁内力图双梁门机半个桥架的单位长度重量载荷 式中：双梁门机半个桥架质量 ：主梁的总长度 支反力 剪力 弯矩=(3) 小车制动惯性力引起的主梁内力图5 主梁内力图 支反力 剪力 弯矩3.2.2 水平载荷引起的主梁内力 当大车制动时，由惯性力和风载荷引起的主梁内力。在主梁水平面内，大车制动时产生的惯性力顺大车轨道方向，其中由主梁自重引起的和由满载小车自重引起的的计算值已于前述，顺大车轨道方向的风载荷为，（其值也列在前面）。他们引起的主梁内力见下图图6 水平载荷主梁内力图 小车在跨中 弯矩式中= 小车在悬臂端 弯矩=3098.83N.m3.3 主梁的强度验算3.3.1 主梁弯曲应力的验算由上表可知，主梁在垂直面和水平面内的合成弯矩：小车在跨中时，跨中弯矩最大。小车在悬臂端时，支承处弯矩最大。现分别验算主梁跨中和支腿D处的弯曲应力。 跨中弯曲应力：= 支承处弯曲应力=3.3.2 主梁剪应力的验算根据上述计算，小车在悬臂端时，主梁支承处剪力最大。主梁支承处垂直面内的剪应力由下式计算：小车在跨中：小车在悬臂端 剪应力 主梁在水平面内受水平惯性力和风力引起的剪应力一般较小，可忽略不计3.3.3 主梁扭转剪应力的验算对于偏轨箱形主梁受扭的影响，按纯扭转计算。主梁截面弯心的位置如下图所示。 (1) 外扭矩式中 (2) 主腹板上的剪应力 (3) 副腹板上的剪应力 (4) 盖板上的剪应力 3.4 主梁稳定性的计算主梁整体稳定性的计算 主梁高宽比： 稳定主梁局部稳定性的计算翼缘板 需设置一条纵向加劲肋，不再验算。 翼缘板最大外伸部分 稳定 主腹板 副腹板 故需设置横隔板及两条纵向加劲肋，主腹板，副腹板相同，布置见下图 。隔板间距，纵向加劲肋位置，主腹板外侧设置短加劲肋与上翼缘板顶紧以支承小车轨道，间距 加劲肋的确定：横隔板厚度，板中开孔尺寸为。翼缘板纵向加劲肋选用角钢， 纵向加劲肋对翼缘板厚度中线（1-1）的惯性矩为：= 合格主，副腹板采用相同的纵向加劲肋， 纵向加劲肋对主腹板厚度中线的惯性矩为： 合格4 支腿的计算 因为跨度只有26m，没有超过35m，所以采用支腿均为刚性。4.1 刚支腿的几何尺寸和特性 对于带马鞍的门机,在支腿两个平面都制成上宽下窄,通常其尺寸宽差率为；;mm ,mm因此 mm , mm图7 截面图8 II-II截面刚性支腿几何特性I-I截面 II-II截面 折算惯性矩 4.2 支腿的内力计算4.2.1 门架平面内的支腿内力计算 (1) 由主梁均布自重产生的内力图9 主梁均布内力图有悬臂时的侧推力为： 式中 其中 ：主梁绕x轴的惯性矩 ：支腿折算惯性矩， 为了安全起见，现将有悬臂门架当作无悬臂门架计算，即 弯矩： (2) 由移动载荷产生的内力 ：小车在跨中图10移动载荷内力图当，时，侧推力为： 弯矩： B：小车在悬臂端，主钩在左极限位置， 侧推力为：= 弯矩： 图11极限位置弯矩图 (3) 作用在支腿上的风载荷产生的支腿内力图12支腿内力弯矩图 侧推力： 弯矩： (4) 由顺小车轨道方向的小车制动惯性力和风载荷产生的支腿内力图13支腿内力图 侧推力： 弯矩：4.2.2 支腿平面内的支腿内力计算 由起升载荷，自重载荷引起的支腿垂直载荷及引起的内力图14 垂直载荷内力图 =弯矩：=4.3 支腿的强度验算由上述支腿的内力计算可知：在门架平面内，支腿上部弯矩较大向下逐渐减小。在支腿平面内，支腿上部弯矩较大向下逐渐减小。所以双主梁门机的支腿在两个方向的宽度可变化为变截面形状，见支腿截面图。对于支腿上部截面，当小车位于跨中时，可按门架平面的合成弯矩：和支腿平面弯矩：验算弯曲应力。刚性支腿：柔性支腿：4.4 支腿稳定性的计算 刚性支腿整体稳定性的计算 支腿的整体稳定性按下式验算式中，：门架平面和支腿平面的计算弯矩（常取距支腿小端处截面弯矩） ：支腿承受的轴力 ，：距支腿小端处截面的截面积和截面模数 ：压杆的许用应力折减系数，由支腿的长细比确定 其中： 图15 轴向力查表得：187查表得：回转半径 刚性支腿局部稳定性的计算 为了防止支腿的翼缘板和腹板发生波浪变形，应对支腿进行局部稳定性校核，否则可能导致结构过早损坏。 对于箱形截面支腿，其两腹板间的翼缘板宽度与厚度之比和腹板的计算高度与厚度之比应满足下式：由支腿截面可得： ，因此： 故需要设置纵向加劲肋（通常由钢板或扁钢制成），纵向加劲肋应成队布置，同时，为了增加支腿的抗扭刚度，必须设置横隔板。 劲肋的确定： 纵向加劲肋的宽度： 式中 = 8mm 纵向加劲肋的厚度： 横隔板的宽度：取 横隔板的间距： 横隔板的厚度：，取5 下横梁和马鞍的计算5.1 下横梁的几何尺寸和特性下横梁是支腿架的基础梁，其截面主要由大车车轮的安装尺寸决定，今选用大车车轮D700，轨道型号QU70，车轮组宽度520mm。下横梁截面的几何尺寸如下图所示，截面的几何特性为： 图16 截面几何特性5.2 马鞍的几何尺寸和特性小车最高点到轨面，导电架高，护栏高取，综上所述去马鞍高度。马鞍截面的几何尺寸如下图所示，截面几何特性为： 图17马鞍的几何尺寸5.3 下横梁的内力计算下横梁承受支腿传来的垂直力和水平力（通过下法兰）以及自重和压重，在支腿法兰面和跨中截面都产生弯矩，但后者较大。在跨中由支腿水平力对下横梁引起的反向力矩将起减载作用，下横梁的跨中弯矩计算：图18 跨中弯矩=式中5.4 下横梁的强度验算下横梁强度按下式验算：5.5 下横梁稳定性的计算下横梁整体稳定性的计算 高宽比：，则不需要验算下横梁的整体稳定性，一般均可满足。下横梁局部稳定性的计算翼缘板：，满足要求腹板：,因故需要设置横隔板，其间距布置通常为：，且不大于，因此：，不需要设置纵向加劲肋。6 门机的抗倾覆稳定性校核起重机抗倾覆稳定性是指起重机在自重和外载荷作用下抵抗翻倒的能力。保证起重机具有足够的抗倾覆稳定性，是起重机设计中最基本的要求之一。对带悬臂的门机，需验算纵向（悬臂平面）工况1（无风静载）和工况2（有风动载）的稳定性，以及横向工况4（暴风侵袭）的稳定性。图19（悬臂平面）工况1图20 工况2（有风动载）(一)纵向工况1（悬臂平面，无风静载） 小车位于悬臂端，起吊额定载荷。其抗倾覆稳定性校和计算公式为： 式中，：自重和起升载荷的载荷系数； ，：桥架重心和小车重心到倾覆边的水平距离； (二)纵向工况2（悬臂平面，有风动载） 满载小车在悬臂端起（制）动，工作状态下的最大风力向不利于稳定 的方向吹。其抗稳定性校核计算公式为： 式中，：水平惯性力和风载荷的载荷系数； ：起重机轨道面至小车轨道面的距离； ，：起重机所受风载荷及其重心至起重机轨道的距离； ：作用在小车和货物上的风载荷； (三)横向工况（大车走行方向，暴风侵袭） 非工作状态的起重机受沿大车轨道方向的暴风侵袭。其抗倾覆稳定性 校核计算公式为： 式中：轴距或前后支腿间的距离； ，：非工作状态下，起重机所受风载荷及其重心至起重 机轨道的距离； 其中： 式中：风压高度变化系数；取 ：非工作状态计算风压；取 7 门架的刚度计算7.1 主梁静刚度校核取超静定门架简图计算 (1) 小车位于跨中时。图21跨中门架简图 主梁在跨中的垂直下挠度按下式计算：=(2) 小车位于悬臂端时。图22悬臂端简图主梁在悬臂端的垂直下挠度按下式计算：=7.2 主梁动刚度校核主梁的动刚度，可以按下式验算主梁满载自振频率来控制式中：满载自振频率（HZ） ：主梁结构在跨中的刚度系数 ：主梁结构在跨中的换算集中质量与小车质量之和 ：与额定起升载荷的质量之比，即 ：与钢丝绳绕组的刚度系数之比，即 (1) 小车在跨中时=因此：= 式中：绕组的分支数 ：钢丝绳的纵向弹性模量 ：单根钢丝绳的横截面积 ：钢丝绳绕组在相当于额定起升高度时平均下放长度因此： (2) 小车在悬臂端时=因此：= =因此：所以：皆大于2HZ，满足要求7.3 门架水平静位移 满载小车位于悬臂端时，超静定门架水平静位移按下图模型计算 图23 超静定门架水平静位移 式中：主梁截面对横轴的惯性矩 ：静载荷， ：门架许用水平静位移，推荐8 主梁的翘度和拱度 为了使小车正常运行，门机的主梁也需要在跨间设置拱度，在悬臂设置翘度。主梁跨中央上拱度可取为：，即 悬臂端的翘度可取为：，即 其它部分按二次抛物线变化，考虑制造误差和可能引起的变化，允许将拱度和翘度值增大（减小）。9 连接部分计算9.1 刚性支腿与主梁连接处的螺栓强度验算此次设计所用的螺栓均采用高强度螺栓，高强度螺栓连接是靠连接板之间的摩擦来传力的，连接时连接板件（构件）的表面需要清污喷丸处理，以提高其摩擦力，螺栓直径与孔径的间隙不大于，高强度螺栓用力矩扳手拧紧，能使每个螺栓达到均匀的预紧力值。每个高强度螺栓抗剪切许用承载力为： 式中：安全储备系数 ：传力摩擦面数； ：摩擦因数；（喷丸钢） ：高强度螺栓预紧力； 螺栓布置如下图所示：图24 螺栓布置门架平面内的弯矩： 支腿平面内的弯矩： 支腿轴向力： 距轴最远处的一个螺栓的拉力为： 式中：轴向力至轴的距离； ：左边列至轴的距离； ：各螺栓至轴距离的平方和； 距轴最远处的一个螺栓的拉力为： 该螺栓所受合力： 对于高强度螺栓： 合格9.2 刚性支腿与下横梁连接处的螺栓强度演算 螺栓布置如下图所示： 图25 螺栓布置 门式起重机支腿与下横梁连接，同时受压，弯，剪的栓接。 剪切力由精制螺栓平均承受，如水平扭矩由精制螺栓承受，螺栓最大内力的计算如前面所述。 所有螺栓均受拉力，假设法兰板足够刚度，在弯矩M作用下，法兰板绕右边螺栓线x轴旋转，使左边列螺栓受压最大拉力。 距x轴最远的一个螺栓的拉力为： Pl= 2（M-Ne）y1/ yi2 Pl 式中：M ,N -连接所受弯矩和压缩力。 e-压缩力至x轴的距离。 y1=左边列出至x轴的距离。 yi =某个螺栓至x轴的距离。 yi2 =各螺栓至x轴的距离平方和。 2-个螺栓预紧力不均匀系数。(1)刚性支腿：1：M取为：300KNN=955KN采用M30的螺栓，按其扳手间距布置螺栓分布： 刚支腿下截面尺寸长900mm 宽600mm所以：再向其截面外扩张80mm。共采用22个M30螺栓连接。2：连接计算校核：y1=1080mm=1.08m e=540mm=0.54myi2 =51.08+2(1.08-0.15)+(1.08-0.3)+(1.08-0.45)+(1.08-0.6)+(1.08-0.75)+(1.08-0.9)=10.3所以：Pmax= Pl= =171KNPl=176.4KN 刚支腿与下横梁连接计算结束，同时，在刚支腿与下横梁法兰连接处的法兰上，每个螺栓连接之间加上小的劲肋-增强其连接可靠性（必须在保证扳手空间距离的前提下）-适当加劲肋。参考文献1 胡宗武汪西应汪春生，起重机设计与实例M，北京机械工业出版社，2009.6；2 刘鸿文，材料力学，高等教育出版社，2004；3 起重机设计手册编写组，起重机设计手册M，北京机械工业出版社1980；4 成大先，机械设计手册，北京，机械工业出版社，2004；5 林贵瑜，史勇.关于起重机发展的几个技术问题J，建设机械技术与理,2006,12；6 徐格宁.等，起重机设计规范：中国标准出版社，2008；7 司徒忠,李璨，机械工程专业英语，武汉武汉理工大学出版社，2001；8 张质文,包起帆等，起重机设计手册，北京中国铁道出版社，2001；9 陈道南,盛汉中，起重机设计课程设计，北京机械工业出版社,1993；10 任金泉,机械设计课程设计，西安交通大学出版社，2005；11倪庆兴，王焕勇，起重机械M，上海：上海交通大学出版社，1990；12 张质文.等，起重机设计手册M，北京：中国铁道出版社,1998；13 朱小海，大型门式起重机结构特性与系统虚拟仿真研究，西南交通大学，2013；14 徐格宁，机械装备金属结构设计（第2版），北京机械工业出版社，2016；15 王存，双梁桥式起重机钢结构优化及交互式设计，郑州大学，2016；16 刘跃昆. 起重机金属结构件的结构优化及轻量化研究D，郑州大学,2017；17 罗彦华.起重机械安全管理注意事项J.建筑机械，2017；18 谭云波. 大跨度双梁桥式起重机动刚度分析及优化D.中南林业科技大学,2017；19 从言言，基于知识重用的门式起重机适应性设计及应用，华东交通大学，2017；20 姜峰，履带起重机桁架臂标准节稳定性分析与试验研究，吉林大学2016-06-01；21 秦静;赵恒博，力学中求解约束力的方法解析，焦作大学学报，2018-03-15；22 Auwalu M. Abdullahi,Z. Mohamed,H. Selamat,Hemanshu R. Pota,M.S. Zainal Abidin,F.S. Ismail,A. Haruna. Adaptive output-based command shaping for sway control of a 3D overhead crane with payload hoisting and wind disturbanceJ. Mechanical Systems and Signal Processing,2018,98；23 Mihee Nam,Jinbeom Kim,Jae Chang Lee,Daekyung Kim,Donghyuk Lee,Jangmyung Lee. Cooperative control system of the floating cranes for the dual liftingJ. International Journal of Naval Architecture and Ocean Engineering,2017。24 SangHyeok Han,Shafiul Hasan,Ahmed Bouferguene,Mohamed Al-Hussein,Joe Kosa. An integrated decision support model for selecting the most feasible crane at heavy construction sitesJ. Automation in Construction,2018,87.25 Przemysaw Busse. Some aspects of the occurrence and behaviour of the crane Grus grus in Poland in light of pre-investment wind-farm monitoringJ. The Ring,2016,38(1).26Jozef Kulka,Martin Mantic,Gabriel Fedorko,Vieroslav Molnar. Failure analysis of increased rail wear of 200tons foundry crane trackJ. Engineering Failure Analysis,2016,67.27 NAKAMURA Ryutaro,SATO Hiroki,OSUMI Hisasi. Obstacle avoidance of overhead crane by hoistingJ. The Proceedings of JSME annual Conference on Robotics and Mechatronics (Robomec),2017,2017(0).英文原文CraneThe concept ofCrane is a crane, for recycling is an intermittent mechanical movement. A working cycle including: extracts from the plant extract to bring the items, and then move to the designated location standard items down and then reverse campaign to extract device back to the original position for the next cycle.Usually by the crane hoisting mechanism (up and down movement of goods), run the institutions (so that the mobile crane), luffing and slewing mechanism (so that the level of articles for Mobile), together with the metal body, power unit, control control and the necessary combination of assistive devices.TypeIn the bridge used in the lifting machinery, in accordance with its structure and performance vary, but generally can be divided into small light lifting equipment, bridge-type crane and jib crane type three categories. Light a small lifting equipment such as: jack, hoist, winch, etc. Such as the type of crane bridge girder cranes, gantry cranes and so on. Jib cranes, such as fixed type slewing crane, tower crane, truck crane, tires, crawler cranes.A certain extent the level of vertical lifting and carrying heavy loads of lifting appliances and more action. Also known as the cable car. Are material handling machinery. Cranes work is characterized by intermittent movement so that the work cycle in a Reclaimer, transport, unloading, etc. The corresponding action is the turn of the work.The embryonic form of a craneAncient Chinese irrigation used orange is the embryonic form of boom-type cranes. The 14th century, Western Europe appeared in human and animal-driven boom-type crane rotation. The early 19th century, a bridge crane; crane important items such as shaft wear, gear and began to use metals such as spreader materials, and introducing the hydraulic drive. The late 19th century, steam-driven crane gradually replaced the hydraulic-powered crane. 20 the beginning of the 20th century era, as the electrical industry and the rapid development of the internal combustion engine industry to electric motors or internal combustion engine power unit for the basic formation of a variety of cranes.Crane main lifting mechanism, operating agencies, luffing mechanism, slewing mechanism and metal structure. Crane hoisting mechanism is the basic work of agencies, mostly by hanging winch system and the composition, but also through the hydraulic system of the heavy lifting. Run institutions for the vertical adjustment of the level of migration of heavy cranes or location, is normally provided by electric motors, reducers, brakes and wheel components. Only equipped with luffing jib cranes in, the arm looked up and when the rate of decrease, the rate increased when leaned over, sub-balance variation and variation in two non-equilibrium. Slewing mechanism to enable the rotary arm,By the drive device and the composition of slewing devices. Metal structure of the skeleton is a crane, main bearing parts such as bridge, jib and gantry for the box structure or truss structure, but also for the web structure, and some can be used as the supporting steel beams.Crane in accordance with the structure of the different classificationType of crane beam 1, beam-type cranes. Venues in rectangle and above the operation, used for workshops, warehouses, open storage space for loading and unloading of goods, etc., beam cranes, bridge cranes, gantry cranes, cable cranes, carrying bridges. crane beam: beam cranes include single girder bridge crane and two-beam bridge craneSingle-girder bridge crane girder bridge use the I-beam or steel plate-type with a combination of cross-section. Often lifting trolley hand chain hoist, electric hoist or hoist hoisting mechanism as assembled from components.Supported by the bridge and hanging two. Cars along the former bridge crane beam orbit; latter suspension bridge along the roof at the plant under the orbit of the crane. Single-girder overhead traveling crane at hand, the electric two. Manual single-girder overhead traveling crane with the various agencies have a lower speed, since the weight is also smaller, but the quality of its small, easy production, low cost, the time for no little amount of power after the removal of the speed and productivity requirements high occasions. Manual single-girder overhead traveling crane manually run the car as a single-track car, with his hands as a lifting hoist pulling bodies from the main bridge beams and beam-end components.Main beam of the general use of a single I-beam, side beam bending using steel or steel plate welded into shape.Electric single-girder overhead traveling crane speed, high productivity over manually, since the weight as well. Electric single-girder bridge crane from the bridge, carts run institutions, electric hoist and electrical equipment components. bridge crane:Bridge crane is a bridge in an elevated running track as a bridge-type crane, also known as Crane. Bridge crane installed in the bridge along the track on both sides of the elevated vertical run, lifting trolley along the bridge on the laying of the track in the horizontal run, which constitute the scope of work of a rectangle, you can take full advantage of the space bridge was being lifted the following materials, the hindered from ground equipment.Bridge crane widely used in indoor and outdoor warehouses, factories, docks and outdoor storage yard, etc. Bridge crane bridge crane can be divided into ordinary, simple beam bridge crane and metallurgical three special bridge crane.General by the general bridge crane lifting trolley, bridge run institutions, the structure of the composition of the metal bridge. Car lifting and lifting by the agencies, institutions and small car running frame is composed of three parts.Lifting bodies, including the motor, brake, reducer, drum and pulley blocks. Motor through reducer, driven rotating drum so that the wire rope around the drum or from the reel down to take-off and landing weights. Small frame is a child care support and installation of lifting mechanism and operation of institutions such as car chassis components, usually welded structure.2, cantilever cranes (crane Arm)There are立柱式cantilever crane, wall-mounted, three forms of balance crane. cantilever crane is a cantilever column can be fixed around the base of the column will be rotating, or cantilever rigid with the column switch, with the base support in relation to the centerline of rotation from the vertical column and the composition of the cantilever cantilever crane . It is suitable for the weight of not starting, operating services to round or fan-shaped range of occasions. Generally used for machine tool equipment such as cards and handling the workpiece.Cantilever crane column used as a chain electric hoist lifting mechanism and operation of institutions, less use of wire rope electric hoist and hand chain hoist. The level of rotation and the use of mobile operating manual, only larger in weight fromWhen the use of electric. crane wall is fixed in the wall of the cantilever crane, or can be wall or other supporting structure on the orbit of the cantilever overhead crane.Cranes line the wall of occasions for the use of large-span, height larger workshop or warehouse, close to the wall near the Department lifting operations have become more frequent in the most suitable. Wall line with the top of a crane or bridge crane beam with the use of services in close proximity to the walls in a rectangular space, light is responsible for lifting small objects, large or by the bridge crane beam to bear. balance hoist crane, commonly known as the balance, it is the principle of the use of four-bar linkage so that the load weight and balance form a balanced system, using a variety of spreader can be flexible and easy to load in three-dimensional space was being lifted. Lightweight and flexible balance crane, lifting is an ideal small items of lifting equipment, is widely used in the machine tool factory floor up and down material, processes, the automatic line, production line of the workpiece, lifting sandbox, parts assembly, as well as stations, terminals, warehouses, etc., on various occasions.1.2 status of cranes at elevated levels1.2.1 current status of the national exhibitionDuring the period of more than half a century, the craneOne of the big: the 2000t all-ground crane introduced by Zhonglian heavy department is the largest all-ground crane in the world at present. The installation of 3MW fan can be realized. The hoisting height of the main arm can reach 106m, merging the world records of the first length of the arm and the first in the lifting weight, etc. By adopting the diversified configuration and modular design idea, the author has launched his latest Ew series hydraulic crawler crane products. In addition to the products of the above companies, some other crane manufacturing enterprises have overcome technical problems, to achieve technological innovation, and developed their own new products. With the development of modern design theory and material research in our country, the crane in our country has made new achievements , such as applying H-section steel and I-section steel to the steel structure of crane, replacing the steel wire pulley of crane with MC nylon material. Reduces the production cost of the crane, prolongs the service life of the parts, classifies the metal structure and machinery of the crane, It provides series of products for cranes with different working intensity and frequency: applying triple-reducer, vertical reducer, etc. Some new devices, using structural optimization technology to realize cranes light internalization, etc. Although some breakthroughs have been made in the production of cranes in our country, there is still a certain gap compared with foreign technology, mainly in the following aspects （1）Low level of manufacturing processChinas domestic processing and manufacturing technology is still immature, the level of technological development is relatively lagging behind, lack of research and experience on advanced and special processes, the crane parts produced poor performance, short service life, Make the whole machine difficult to improve the level. In addition, the domestic design of cranes only pay attention to functional requirements and ignore the details of the design, often rush to the market, its research and development and debugging cycle is relatively short, so it is easy to appear a lot of problems in the process of work.（2）Product technical standard update lagAs an important condition for the transformation of scientific and technological achievements into productive forces, technical standards are the basis for guiding the production of enterprises and play an important role in promoting enterprises to develop new products. Scientific and technological advanced manufacturing enterprises will be in accordance with the needs of the market and technological development to designate their own technical standards. However, some key technical standards of lifting machinery in China are still mainly adopted in developed countries and regions, and the key technical standards are lagging behind and lacking.Full and more economical design.（3）LackoftechnicallevelofcorecomponentsAtpresent,suchasengines,hydrauliccomponentsandsoon-somekeypartsofthecrane,itsmaintechnologyisstilloutofhandInthehandsoftheChinesepeople,ourdomesticindependentR&Dandproductioncapacityarerelativelyweak,andwestillhavetorelyonimportstoacertainextent.Inaddition,structuralmaterialssuchasthinsteel,heterosexualsteelandcranerailprofilesareinshortsupplyandhavefewerspecifications.Asaresultofthelackofsupplyofaccessories,resultingintheoverallstructureofthematchingdegreeisnothigh.Itsnotjustabigconstraint.ThedevelopmentandcompetitivenessofChinesecranesalsofurtherreducetheprofitandmarketshareofdomesticcranes.ForindemnityTomakeupfortheshortageofthecoretechnicalcomponents,weshouldaccumulatethedesignexperiencecontinuously,makeupfortheshortageofthetechnology,improveThematchinglevelofthewholemachineprovidesamorepractical,saferandmoreeconomicaldesignscheme.（4）Poor product R & D capabilityChinas domestic crane industry started late, technical data is old, lack of, make the overall scientific and technological strength is weak, independentPoor development capacity, slow product upgrading, and cranes that depend on foreign production in some important use situations. At the same time, because of the management level, scientific research funds and the quality of scientific and technological personnel and other factors also hindered the development of cranes in China. In addition, domestic designers are involved in computer aided design, reliability design, modular design and manufacturing, etc.The application of this method needs to be greatly improved.1.2.2 current situation of foreign developmentAt present, there are many crane manufacturers abroad. Among them, the crane manufacturing enterprises represented by Liebherr, Maktovak and Tekrez-Demag in Europe and America have advanced technology, complete category and high market share 6. Liebherrs innovative LM1160-5.2 model, which rejects the concept of a one-to-one dual engine for large tonnage cranes, requires only one engine to drive the entire. Superstructure. Even with a single engine and a mechanical shaft to drive the 160 tons of H cover, thus reducing the heavy and maintenance of the whole machine equipment in the operation, increased the equipment load capacity. The MC120B crane designed by using the advanced frequency conversion technology in Maktovak can realize five times speed change stably in the lifting operation and play an important role in the development of the crane. It relies on the combination of hydraulic technology, power electronics technology, mechanical technology, computer technology, fuzzy control technology and microelectronic technology to apply them to the drive and control systems on the crane, To promote the upgrade and improvement of its electrical components and control system, so as to achieve the purpose of crane automation and intelligence. At present, the new generation of crane electrical control device has been developed into a full electronic digital control system, including digital manipulation of given detection, fault diagnosisAnd data management system, programmable controller and fully digital control drive device and other equipment. In addition, 3D barcode technology, contactless power supply, carrier communication and control, near-field induction anti-collision technology, and high speed control are suitable for high construction intensity, high efficiency of tower crane production and lifting load.（1）ModularandcombinationalType of heavy machine. In the design and modification of the new crane, there is no need to redesign the whole machine, only modularized product modification and recombination can realize the modification and replacement of the new product. The idea of modularization design makes the traditional small batch crane turn into a large quantity of modular production, which reduces the production cost of the enterprise and raises the production of the enterprise.Efficiency and the degree of generalizability of products enhance the competitiveness of enterprises in the market. At present, Japan and some European and American countriesLarge production enterprises have begun to adopt modular design ideas, and have achieved considerable economic benefits. For example: the German Demag company adopts the modular design idea to design the hoist double beam crane to reduce the design cost 12%, compared with the domestic crane weight reduction about 35%, has obtained the obvious economic benefit.(2) Large-scale and high-speedWith the development of industry and the improvement of labor productivity, the material handling cost of products is increasing gradually.The crane is constantly shifting to larger hoists and higher speeds. At present, the worlds largest crawler crane lifting capacity is 3600t, floating crane is 6500t. Large-scale and high-speed crane products are following the trend of the market and become a development trend of crane in the future.（3）Automation and intelligenceUpgrading and improvement of Electrical components and Control system on Crane the automatic and Intelligent Laser search of Crane for lifting object Center of Gravity, Fuzzy Control for Anti-rolling of lifting equipment, Fault Self-diagnosis Monitoring, RF data Communication, variable Voltage Frequency conversion. Speed regulation and field bus are widely used.(4) lightness and diversificationIn order to save consumables, improve the load capacity of the whole machine and adapt to different working conditions, the development of crane tends to be more and more light and diversified. Compared with foreign cranes, the size of the whole crane produced in China is on the large side and the structure is heavy. Crane light development is also attracting the attention of domestic crane manufacturers. Foreign crane enterprises use aluminum alloy materials and high strength steel and other new lightweight materials, greatly reduce the quality of crane metal structure. In addition, with the wide application of optimization technology, the development of new cutting technology and welding technology has also brought convenience to the light development of crane.2 SignificanceoflightweightDesign2.1 InternationaltrendsCranelightweightproductsarealreadyquitecommonabroad,suchasGermanysDemag,Steele,Amber,FinnKonyofLan,SumitomoofJapan,Hitachi,KobeSteel,IshikawaIsland,KoreanPeninsula,Gaobo,USA,FranceFrantekofSpain,Linden-Co-mofSpain-manCranemanufacturers,allincranes.w.Themechanism,structure,electricalandotheraspectshavebeenimprovedtomakethecraneproductslight,energysavingandbeautiful.With the acceleration of the process of internationalization, the proportion of imported cranes in China is increasing year by year, and the number of cranes exported by our country is also increasing year by year. Foreign light crane in the domestic market has been good, our own brand of Lianlihua products have also been successful.From the point of view of the present situation at home and abroad, crane light internalization has already possessed the technical and market conditions, and is gradually being popularized. At present, our country from the country to the enterprise are paying attention to the crane light internalization, for example, the 12th Five-Year Plan of National Science and Technology support Project: the general bridge crane light design technology and its application, Nantong Runbang low clearance bridge crane A series of research topics, such as Hangzhou Huaxins New Bridge Crane with low clearance , are in progress in an orderly manner. PartialIt has been applied.2.2 heavy crane in ChinaCompared with foreign countries, Chinas crane deadweight is generally 20% heavier than foreign advanced cranes, some even more.7-9 for example, a common two-beam bridge crane with a lifting capacity of 10 t and a span of 22.5 m in China has a self-weight of 24 t, while the Dermarger crane has a deadweight of only 8.7 t, which reduces 63.8%: the domestic double-beam bridge crane of 32t in crane and 25.5 m in span.The weight of the hoist is 46. 4 t, while the weight of the Dermarger electric hoist bridge crane is only 18. 5 t and the mass is 60% lighter. The whole machine weight of the Kony electric hoist bridge crane is 17. 9 t, which is 62% lighter than the domestic product respectively: the domestic QD32-22.5 double-beam bridge crane. The weight of the crane is about 33.8t, while the weight of the crane is only about 18t. The weight of the double-beam bridge crane of QD50-22.5 in china is about 43 t, the whole machine of Kony is about 20 t, and the weight of quality is 53. 5%. 2.3 need for energy conservationThe newly revised regulations on Safety Supervision of Special equipment and the Law on Energy Saving all emphasize the energy saving of special equipment.At present, we are about to enter the era of low-carbon economy, energy conservation is the main body, crane energy-saving contribution is extraordinary. Metal structures account for about 40% of the quality of the whole machine, 70%, giant cranes can reach more than 90%. The crane is moving, so reducing the weight can not only save the raw materials, but also reduce the load of the mechanism and the cost of the supporting structure.Light-in-place design is one of the effective, direct and feasible ways to save energy and improve economy of crane, and it is the key research direction of energy saving of crane in recent stage in our country. Light3 Progressinlightweightdesign3.1lightweightdesignmethodology1）thelimitstatedesignmethodhasbeenusedintheengineeringstructuredesignsincethe1970s.Thetendencyofthispaperistoadoptthelimitstatedesignmethodbasedonprobabilitytheory,whichisreferredtoasprobabilisticdesignmethod.Thiscalculation.Methodsthecalculationresultsareaccurateandaccordwiththeactualworkingconditionsofmetalstructures.Andthusmorefully.Makeuseofthepropertiesofsteeltosavematerials.2) applying modern design methods, these methods correctly consider the effect of load on the properties of steel and its structure.As a characteristic.For example: finite element method, equal strength design, crane dynamics, boundary element method, sensitivity analysis, fuzzy optimization design andModular design to reduce the weight of the maximum, large-scale equipment can also consider computer simulation and dynamic simulation methods. 3) at present, all countries in the world are making full use of the scientific and technological achievements of other countries to digest, absorb and innovate, and further develop their own new technologies and products. Reverse engineering design is a combination of a series of methods and application techniques for digestion and absorption of advanced technology. Reverse engineering design analyses, studies, dissects and tests existing advanced products through physical or technical data, understands its parameters, properties, structures and functions, and grasps its key technologies, working principles and technological principles. A method of creating new products by copying, improving, or developing. 2.2 Li-li Chemical ResearchResearch development1)National Science and Technology support Plan Project General Bridge Crane lightweight Design Technology and Application. The projectOne of the evaluation indexes is that the crane can reduce the weight by 15% or 20% on average.2) the project of QQD bridge crane lightweight product development aims to carry out the light internalization design of metal structure of QQD5 32t bridge crane, use Ansye software to carry out finite element optimization analysis, adopt end beam flexible support system, and study the corresponding manufacturing technology. In order to ensure the performance of the whole machine, the single equipment can be reduced by 20% / 25% and the manufacturing cost will be reduced by 20% / 25%.Energy consumption was reduced by 15%.3) the R & D design of low clearance bridge crane is about 30% in the vehicle and 20% in the whole vehicle. 4) 370t low clearance New Type Bridge Crane is 15% 30% lighter than that of General Bridge Crane.5) the low clearance light chemical series crane is 20% lighter than the similar general purpose product 35%.6) study on the lightweight design of large shipbuilding gantry crane. By means of finite element analysis and optimization, the weight of shipbuilding crane I is reduced7) the static and dynamic characteristics of the metal structure of the super large container crane and its lightweight characteristics; the mechanical properties and buckling characteristics of the metal structure of the quayside container crane under various working conditions; And the light internalization design method of the metal structure of quayside container crane.4 ShortcomingsoflightweightDesign4.1 Designcalculation4.1.1 InsufficientThe same safety factor is used for metal structures with different uses and different working properties, and the safety factor is often too large or too small. Therefore, the crane metal structure designed according to allowable stress calculation method, or consume more metal materials, or the degree of safety is low. In this calculation, the load coefficients in the load calculation refer to the recommended values of the design manual, and selected according to the experience, and are the static design concept. Because the selected load coefficient is not accurate, the load combination is wrong.Poor, resulting in the designers of the design results are not expected to be accurate, for safety, the current design most of the larger safetyFull coefficient of wealth, leading to a larger crane weight, so Chinas crane weight is generally more than the foreign advanced crane weight of 20% and 50%, geometric size is relatively large, the crane itself waste material. In manufacturing, transportation and installation, the waste of manpower and material resources in the use of electrical energy, and directly affect the height of the plant, the increase of wheel pressure also affects the design requirements of the plant structure and the design requirements for the ground foundation. And then affect the use of building materials and land resources.4.1.2 recommendations1) the limit state design method is widely used. The calculation results obtained by this method are more accurate and accord with the gold.It can make full use of the properties of steel and save materials. The design of crane metal structure by using prestressing force method can improve the stress state of the structure and save steel. Current Crane Design StandardsEn 130014: 2004 recognizes that the limit-state method is more advanced and applies to the design of all types of cranes. In addition, the standard also stipulates that the allowable stress method can only be used to verify the capability of a certain crane under special working conditions. The oEN 130014: 2004 standard also recognizes that the limit state method is more appropriate for crane design than the allowable stress method. The allowable stress method does not accord with the concept of risk. Because the allowable stress method can not meet the requirements of crane capacity verification at present, the allowable stress method should be replaced by the limit state method. The allowable stress method should be considered a secondary method and can only be used in the preliminary analysis of crane design.Can not be used for mandatory crane capability verification. Therefore, the latest version of the ISO 8686 crane standard should stipulate that crane capability verification can only be done using the limit state method.(2)checking according to the concept of Positioning Precisionassesstherigidityrequirementofcraneaccordingtopositioningprecisionconcept.3)reverseengineeringdesigntakesfulladvantageofforeignadvancedscientificandtechnologicalachievementstodigest,absorbandinnovate,anddevelopthesymbolNewtechnologiesandproductsinlinewithChinasnationalconditions.4)Moderndesignmethods:finiteelementmethod,equalstrengthdesign,cranedynamics,boundaryelementmethodandsensitivity.AnalysisandfuzzyoptimizationDesignandmodulardesign,tominimizeweight,largeequipmentcanalsobeconsideredcomputersimulationAnddynamicsimulationmethods.4.2 insufficient4.21 processAt present, most bridges and gantry cranes in our country adopt the steel plate welded box structure as the mechanical component, and the production process is semi-mechanized manual manufacture. Lead to long delivery time of crane products, heavy structure, ugly appearance.4.2.2 recommendationsLight crane and crane can use I-steel, channel steel, H-section steel, welding robot or manipulator, heat treatment of gears, pulleys, wheels and so on, to enhance the surface hardness, the light crane and crane can use I-steel, channel steel, H-section steel, welding robot, gear, pulley, wheel, etc., after heat treatment. The parts are welded instead of cast.4.3 insufficient material 4.3.1 deficienciesMost of the materials used on cranes in China are Q235 and Q345.The application of light alloy material, polymer material, section steel and high strength steel are few. In addition, due to the incomplete performance parameters of steel, negative deviation and little pretreatment, the crane designers tend to increase the thickness of plate, process reinforcement plate, reinforced plate and so on, which lead to waste of materials. 4.3.2 recommendations1) use light alloy or high strength structural steel to make crane, saving material and reducing weight. The jib of bridge crane, gantry crane and wheeled crane with aluminum alloy structure has been trial-produced abroad, and the deadweight has been reduced by 30% 60%. Germany made of aluminium alloy box type single girder bridge crane, the weight of the steel double beam bridge crane with the same parameters is reduced by 70%.It can reduce the load of plant structure and supporting structure and reduce the investment of the whole industrial enterprise.2) replace cast iron or steel with high strength nylon, not only prolonging life, but also saltiness and less noise.3) the roller bearing is replaced by silicon nitride and silicon carbide high ceramic bearing, which not only has better mechanical properties than steel bearing, but also has high temperature resistance, low friction coefficient and less energy consumption.4) using H-section steel instead of plate can save 10% 15% of structural material, and the flexural resistance can be improved by more than 30%.5) reasonable selection of plate thickness material and reasonable use of material. 4.4 inadequate structure 4.4.1 InsufficientThe metal structure of crane is based on the steel section rolled by metal material (such as angle steel, channel steel, I-beam, steel pipe etc.) and steel plate as the basic component, by welding, bolting and other methods, according to certain composition rules. According to the different structure, can be divided into truss type and box structure. After years of development, the metal structure of cranes in China has not changed obviously. For example, the most of bridge cranes are still box-shaped double-beam structures, and the trolleys are mostly box-type cranes.Stability and security, at the expense of economic waste, make the structure generally bulkier. 4.4.2 recommendations1) the thickness of web plate of thin-walled box beam is determined by technological factors or prevention of uplift, and the height is determined according to the flexural stiffness and strength of bridge frame, so the material is not fully utilized. The partial rail box bridge structure isDeveloped on the basis of the original box structure, its characteristic is that the car track is directly laid on the center line of the main web of the beam. In this way, the local bending caused by small wheel pressure can be avoided, the stress of the transverse diaphragm can be improved, and the main force can be alleviated.Liang self-weight. In addition, according to the requirements of using, pushing and repairing, mechanical arrangement and so on, the skewed rail beam adopts a larger beam width, so that the mechanical and electrical equipment can be installed in the interior of the beam belly, and the quality of the additional structure such as the platform can be reduced.2) in 1960s, single beam crane has been widely used in foreign countries, its weight is light, the ratio of payload to weight is larger, and the power consumption is relatively less. The single girder I crane can also simplify the leg of the I frame.Therefore, it is widely used and is developing to a large scale.3) in recent years, the empty web truss structure is used in the bridge structure of the large crane, which is also called the slantless bar system. In this kind of structure, the main beam is a closed section composed of steel plate, and from each plane it is a hollow truss without inclined bar. Unlike normal trusses, this kind of web truss is not formed by splicing steel bars, but by cutting many windows on the steel plate. In order to increase strength and rigidity, the frame with slabs or sections on the window side of the plane of the main and secondary truss is provided.Fight. This kind of structure has the advantages of both solid web box beam and truss beam, that is, the weight is light, the manufacture is convenient, and the rigidity is very good.4) using ground operation or remote control to cancel driver room, adopting ground operation or remote control not only lightens the quality of driver room, but also simplifies the quality of electric system and reduces the quality of the whole machine. Must use the drivers room operation may use the light weight aluminum alloy driver room.5) adopting the I type crane used outside the truss structure, especially the I portal crane used in the construction site, the use of the truss structure can reduce the wind load, reduce the weight of the body and save the basic cost.6) improving and popularizing the structure without small frame The simple section of beam composed of plate and steel is usually operated on the lower flange of the I-beam by hand pulling hoist or electric hoist with a simple car as a lifting car. The bridge can run along the track on the elevated frame or along the track suspended under the elevated frame.7)inordertoreducetheweightofthemaingirder,thewingofboxsectionismainlyconsideredinthemaingirderofthegantrycranewithvariablecrosssection.Theplatewithdifferentthicknessisusedinthelengthandheightdirectionoftheplateandthewebplate,andthemainbeamisdividedintovariouscross-sectionsalongthelengthdirection,andthesoundisdistributedsymmetricallytobothsidesinthecenterofthespan.8)Acranewithasimplebeamusedasabridgeframeiscalledabeamcrane,andthemainbeamismadeofanI-shapedsteelorothertypeofcrane.Asimplesectionbeamofsectionsteelandplatesteelwithahand-drawnhoistorelectrichoistwithasimpletrolleyforsmallliftingThecarrunsonthelowerflangeoftheI-beam.Thebridgecanrunalongthetrackontheelevatedframe,oralongthetrackoftheviaduct.Thesuspensionofatrackunderanelevatedframe.4.5 Institutional and electrical 4.5.1 deficienciesOne of the key factors for the slow progress of crane lightening in China is the quality and process of lifting mechanism parts, the efficiency of transmission system, and the performance of electrical control system.4.5.2 recommendations1) adopt the compact lifting mechanism to integrate the motor, reducer, reel and brake on the traditional small frame to make a three-in-one or four-in-one hoisting mechanism. In this way, the space can be saved and the weight of the lifting mechanism can be reduced, thus the whole machine can be lightened Heavy.2) Frequency conversion speed regulation has the advantages of stable speed regulation, accurate position, low mechanical impact, eliminating resonance, improving dynamic stiffness and high precision of safety protection device. It provides the guarantee for the light design and energy saving design of crane. If the special frequency conversion speed regulation system for crane is developed, the energy saving effect will be better.3) the high speed motor is used in the high speed motor, and the motor adopted by each mechanism is developed to the high speed, which can reduce the base number of the motor, reduce the size of the quality and shape, and can match the brake with small braking torque.4) hard gear reducer is used to replace medium hard gear reducer.5) apply electric hoist as lifting mechanism to small and medium-sized cranes using hoist as lifting mechanism.The utility model can lighten the quality of the lifting mechanism and the quality of the lifting trolley so as to avoid too long reel. 4.6 PolicyAccording to the statistics in 2009, the number of registered cranes in China reached 1.3527 million, accounting for the proportion of all 8 kinds of special equipment as high as 22 kWh. The annual energy consumption exceeded 36.5 billion kWh. Therefore, the design of crane lightweight is of great significance.However, cranes are accident prone equipment. In machinery, metallurgy, construction, seaport and railway industries, crane accidents account for about 30% of accidents in these industries and 7% or 12% of total accidents Most crane accidents are caused by improper operation or illegal operation, but in fact the special equipment itself is caused by it.Less than 10% of the accidents occurred in the use, transportation, loading and unloading. It is therefore recommended that:1) perfect special4) improve crane safety assessment and safety monitoring technology:5)to formulate and implement the technological innovation policy of cranes to encourage the technological progress of crane energy conservation;6) untied crane manufacturing license. In the process of acceptance and use, the new products will also encounter difficulties of one kind or another due to the inconsistent understanding of national policies and new technologies between the regulatory authorities, inspection agencies and users:1) State-led. Because of historical reasons and the particularity of crane products, the reform of crane design and the promotion of new products can not be separated from the support of national policy and the promotion of relevant department 5 ConclusionLightweight design is a system engineering, with its technical and historical difficulties, it needs government departments, manufacturing enterprises, Researchers, regulatory authorities, inspection agencies, users and other members of the whole society to participate. In design, the allowable stress method is changed to the limit state method, and the reverse engineering method is used to learn from the advanced technology of foreign cranes. Modern design methods such as finite element method, equal strength design, crane dynamics, boundary element method, sensitivity analysis, fuzzy optimization design and modular design are widely used. Research and development of high-performance materials: do innovative structural design: improve the efficiency of institutions and electrical systems: improve the quality and performance of components: government support, scientific research promotion, enterprise cooperation, social participation.中文对照起重机 概念起重机属于起重机械的一种，是一种作循环、间歇运动的机械。一个工作循环包括：取物装置从取物地把物品提起，然后水平移动到指定地点降下物品，接着进行反向运动，使取物装置返回原位，以便进行下一次循环。通常起重机械由起升机构(使物品上下运动)、运行机构(使起重机械移动)、变幅机构和回转机构(使物品作水平移动)，再加上金属机构，动力装置，操纵控制及必要的辅助装置组合而成。类型 在建桥工程中所用的起重机械，根据其构造和性能的不同，一般可分为轻小型起重设备、桥式类型起重机械和臂架类型起重机三大类。轻小型起重设备如：千斤顶、葫芦、卷扬机等。桥架类型起重机械如梁式起重机、龙门起重机等。臂架类型起重机如固定式回转起重机、塔式起重机、汽车起重机、轮胎、履带起重机等。在一定范围内垂直提升和水平搬运重物的多动作起重机械。又称吊车。属于物料搬运机械。起重机的工作特点是做间歇性运动，即在一个工作循环中取料、运移、卸载等动作的相应机构是交替工作的。起重机的雏形中国古代灌溉农田用的桔是臂架型起重机的雏形。14世纪，西欧出现了人力和畜力驱动的转动臂架型起重机。19世纪前期，出现了桥式起重机；起重机的重要磨损件如轴、齿轮和吊具等开始采用金属材料制造，并开始采用水力驱动。19世纪后期，蒸汽驱动的起重机逐渐取代了水力驱动的起重机。20世纪20年代开始，由于电气工业和内燃机工业迅速发展，以电动机或内燃机为动力装置的各种起重机基本形成。起重机主要包括起升机构、运行机构、变幅机构、回转机构和金属结构等。起升机构是起重机的基本工作机构，大多是由吊挂系统和绞车组成，也有通过液压系统升降重物的。运行机构用以纵向水平运移重物或调整起重机的工作位置，一般是由电动机、减速器、制动器和车轮组成。变幅机构只配备在臂架型起重机上，臂架仰起时幅度减小，俯下时幅度增大，分平衡变幅和非平衡变幅两种。回转机构用以使臂架回转，是由驱动装置和回转支承装置组成。金属结构是起重机的骨架，主要承载件如桥架、臂架和门架可为箱形结构或桁架结构，也可为腹板结构，有的可用型钢作为支承梁。起重机根据结构的不同分类梁式型起重机1、梁式型起重机。可在长方形场地及其上空作业，多用于车间、仓库、露天堆场等处的物品装卸，有梁式起重机、桥式起重机、龙门起重机、缆索起重机、运载桥等。梁式起重机：梁式起重机主要包括单梁桥式起重机和双梁桥式起重机单梁桥式起重机桥架的主梁多采用工字型钢或钢型与钢板的组合截面。起重小车常为手拉葫芦、电动葫芦或用葫芦作为起升机构部件装配而成。按桥架支承式和悬挂式两种。前者桥架沿车梁上的起重机轨道运行；后者的桥架沿悬挂在厂房屋架下的起重机轨道运行。单梁桥式起重机分手动、电动两种。手动单梁桥式起重机各机构的工作速度较低，起重量也较小，但自身质量小，便于组织生产，成本低，时候用于无电源后搬运量不大，对速度与生产率要求不高的场合。手动单梁桥式起重机采用手动单轨小车作为运行小车，用手拉葫芦作为起升机构，桥架由主梁和端梁组成。主梁一般采用单根工字钢，端梁则用型钢或压弯成型的钢板焊成。电动单梁桥式起重机工作速度、生产率较手动的高，起重量也较大。电动单梁桥式起重机由桥架、大车运行机构、电动葫芦及电气设备等部分组成。桥式起重机：桥式起重机是桥架在高架轨道上运行的一种桥架型起重机，又称天车。桥式起重机的桥架沿铺设在两侧高架上的轨道纵向运行，起重小车沿铺设在桥架上的轨道横向运行，构成一矩形的工作范围，就可以充分利用桥架下面的空间吊运物料，不受地面设备的阻碍。桥式起重机广泛地应用在室内外仓库、厂房、码头和露天贮料场等处。桥式起重机可分为普通桥式起重机、简易梁桥式起重机和冶金专用桥式起重机三种。普通桥式起重机一般由起重小车、桥架运行机构、桥架金属结构组成。起重小车又由起升机构、小车运行机构和小车架三部分组成。起升机构包括电动机、制动器、减速器、卷筒和滑轮组。电动机通过减速器，带动卷筒转动，使钢丝绳绕上卷筒或从卷筒放下，以升降重物。小车架是支托和安装起升机构和小车运行机构等部件的机架，通常为焊接结构。2、悬臂起重机（旋臂起重机）悬臂起重机有立柱式、壁挂式、平衡起重机三种形式.柱式悬臂起重机是悬臂可绕固定于基座上的定柱回转，或者是悬臂与转柱刚接，在基座支承内一起相对于垂直中心线转动的由立柱和悬臂组成的悬臂起重机。它适用于起重量不大，作业服务范围为圆形或扇形的场合。一般用于机床等的工件装卡和搬运。柱式悬臂起重机多采用环链电动葫芦作为起升机构和运行机构，较少采用钢丝绳电动葫芦和手拉葫芦。旋转和水平移动作业多采用手动，只有在起重量较大时才采用电动。壁上起重机是固定在墙壁上的悬臂起重机，或者可沿墙上或其他支承结构上的高架轨道运行的悬臂起重机。壁行起重机的使用场合为跨度较大、建筑高度较大的车间或仓库，靠近墙壁附近处吊运作业较频繁时最适合。壁行起重机多与上方的梁式或桥式起重机配合使用，在靠近墙壁处服务于一长方体空间，负责吊运轻小物件，大件由梁式或桥式起重机承担。平衡起重机俗称平衡吊，它是运用四连杆机构原理使载荷与平衡配重构成一平衡系统，可以采用多种吊具灵活而轻松地在三维空间吊运载荷。平衡起重机轻巧灵活，是一种理想的吊运小件物品的起重设备，被广泛用于工厂车间的机床上下料，工序间、自动线、生产线的工件、砂箱吊运、零部件装配，以及车站、码头、仓库等各种场合.1.2 起重机发展现状1.2.1 国内发展现状 经过半个多世纪的发展，我国起重机设计经历了早期直觉设计阶段、传统设计阶段和现代设计阶段。近年来，随着我国重工业的发展，已有一千多家起重机生产单位得到国家质检局的许可2。其中最具代表性的起重机生产厂家有徐州重工、三一重工、中联重科和抚挖等公司，这些单位生产的起重机种类齐全，市场占有率高。在前不久bauma China的展会上，我国的起重机生产厂商纷纷亮相了不少新产品，有些还创了国际记录。其中，以“千亿元、国际化、世界级”为战略的徐州重工在展会上首次推出XCA5000型1600t全地面起重机，该款起重机具备双动力驱动及9轴分时驱动重载转场的技术，可在升起110m高度的情况吊重140t的重量;三一重工推出了自己的新产品SCC36000A型履带起重机，该起重机底部采用车架与回转支撑结合、上部为双臂的结构形式，起重量高达3600t，可广泛用于煤化工、石化、核电等工程领域，是国际同类起重机产品中最大的之一;中联重科推出的2000t级全地面起重机，为目前世界最大的全地面起重机，可实现3MW风机安装，主臂起升高度可达106m，兼并世界上臂架长度第一、起升重量第一等多个世界纪录;抚挖采用多元化配置，模块化设计思想，推出了自己最新的Fwx系列的液压履带起重机产品。除上述公司的产品之外，其他一些起重机生产企业也纷纷克服技术难题，实现技术创新，研制出了自己新的产品。随着国内对现代设计理论和材料研究的进展，使得我国起重机不断取得新的成果4，如将H型钢和T型钢应用于起重机的钢结构中，将MC尼龙材料替换起重机钢丝滑轮，降低了起重机的生产成本、延长零部件的使用寿命;将起重机的金属结构和机械分级，为不同工作强度和频率的起重机提供系列化的产品;应用三合-减速器、立式减速器等- -些新型装置;利用结构优化技术手段实现起重机的轻量化等。尽管我国生产起重机的技术相比之前已有所突破， 但是与国外技术相比，但仍存在一定的差距，主要表现在以下几个方面215 (1)制造工艺水平低 我国国内的加工制造工艺还不成熟，工艺技术水平发展相对比较滞后，对先进和特殊的工艺缺乏研究和经验，生产出的起重机零部件性能差，使用寿命短，使整机水平难以提高。另外，国内设计的起重机只注重功能要求而忽略了细节设计，往往急于投向市场，其研发和调试周期较短，使其在工作过程中容易出现很多问题。 (2)产品技术标准更新滞后 技术标准作为科技成果转化为生产力的重要条件，是指导企业生产的依据，对企业开发新产品有着重要推动作用。科技先进的制造企业会根据市场和技术发展的需要来指定符合自身的技术标准。而我国国内起重机械的一-些关键的技术标准仍然以采用发达国家和地区的标准为主，其关键技术标准的滞后和缺失严重阻碍了我国起重机新产品、新技术的开发、推广和应用。 (3)核心部件技术水平欠缺 目前，像发动机、液压件等- -些起重机关键部件，其主要技术仍然掌握在外国人手里，我国国内自主研发和生产能力较弱，在一定程度上还是必须依靠进口。另外，像薄型钢材、异性钢材和起重机轨道型材等结构材料紧缺，规格品种较少，造成配套件的供应不足，从而导致整机结构的匹配程度不高。这不仅大大制约了我国起重机的发展和竞争力也进一步降低国内起重机的利润和市场占有率。为弥补核心技术部件的不足，我们应该不断积累设计经验，弥补技术上的不足，提高整机的匹配水平，提供更实用、更安全和更经济的设计方案。 (4)产品研发能力差 我国国内起重机行业起步较晚、技术资料陈旧、缺乏，使得整体科技实力较弱、自主开发
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