Design Manual for Crane 15 ton Trolley

In the field of modern industry and construction, cranes are used as important material handling equipment, and their performance and design are directly related to productivity and safety. This design manual focuses on the comprehensive analysis of 15-ton trolley, aiming to present readers with a lifting equipment design that integrates high efficiency, safety and durability. Through the design background, structural features, material selection, performance testing and maintenance, etc., aims to help users fully understand the design concept and practical application of the trolley. Whether for professionals engaged in the design and manufacture of cranes, or for the use of the equipment operators and maintenance personnel, this manual will become an indispensable technical reference to help improve work efficiency and ensure operational safety.

Design Overview

15-ton trolley design background and purpose

With the increasing scale and complexity of industrial production, the demand for material handling equipment is also growing. As the core equipment for material handling, the performance and efficiency of cranes directly affect the smoothness of production lines and the economic benefits of enterprises. In order to meet the needs of medium and large-scale workpiece handling, improve operational efficiency and reduce labor costs, we designed this 15-ton trolley. This trolley not only has a compact structure and stable performance, but also integrates the concepts of intelligence and automation, which makes it adapt to the development trend of the modern industry 4.0 and at the same time has the advanced nature of the future industry. In order to ensure the stability and safety of the trolley under severe working conditions, we have fully optimized the structural design and material selection. This 15-ton trolley is designed to meet the needs of diverse operating scenarios, improve operational efficiency and reduce labor costs.

Design Principles and Requirements

In the design process, we strictly follow the following principles: firstly, to ensure that the load capacity of the trolley reaches 15 tons and has a stable lifting performance within the working range; secondly, to focus on the compactness and lightweight of the structure in order to improve the operating efficiency and reduce energy consumption; furthermore, to strengthen the safety protection measures to ensure the safety of the operators; finally, to consider the intelligence and ease of operation of the electrical control system to improve the user experience. At the same time, the design should also meet the requirements of relevant national standards and regulations to ensure the legality and compliance of the product.

Main technical parameters and performance indicators

The main technical parameters of the 15-ton trolley include: rated lifting capacity of 15 tons, working class A3, lifting height of 12 meters, and span can be customized according to user requirements. In terms of performance indicators, the trolley has excellent lifting speed, running speed and positioning accuracy, and at the same time ensures low noise, low vibration and good environmental adaptability. These parameters and indexes ensure that the trolley can operate stably and efficiently under various working conditions.

Trolley overall structure design

The overall structure design of the trolley is an important part of engineering and industrial applications, which integrates the knowledge of many fields such as mechanical design, material science, safety engineering and electrical control. The design adopts the modularization idea, dividing the trolley into several functional modules, such as drive module, steering module, load-bearing module, etc. Each module has a clear function and interface, which is easy to assemble and maintain. This design method not only improves the production efficiency, but also reduces the maintenance cost.

The main frame is the core part of the overall structure of the trolley, which is welded with high-strength steel to ensure the stability and load-bearing capacity of the structure. High-strength steel has high tensile strength and yield strength, and can withstand a variety of complex loads and stresses. Welding process is also a key factor to ensure the quality of the main frame, which requires the use of advanced welding technology and equipment to ensure the welding quality and strength.

In addition to the main frame, the overall structural design of the trolley also focuses on the optimization of the design to achieve the goal of compact structure and light weight. Through finite element analysis and simulation, the structure was optimized and designed to reduce redundancy and unnecessary weight and improve the energy efficiency ratio of the entire vehicle. Lightweight materials and technologies are also used to further reduce the weight of the entire vehicle and improve mobility and energy efficiency.

Crane Construction and Layout

Crane construction and layout is an important part of engineering and industrial applications, which integrates knowledge from a number of fields such as mechanical design, materials science, safety engineering and electrical control. Crane construction includes key components such as winches, wire ropes, pulley blocks and so on. The selection and design of these components are directly related to the performance and safety of the crane.

Winch is one of the core components of the crane, adopting frequency conversion speed control technology to realize smooth lifting and landing. The speed of the motor is controlled by the frequency converter, which regulates the linear speed of the winch, realizing smooth and precise control of the lifting process. This technology improves the efficiency and safety of the crane and reduces mechanical wear and energy consumption.

Wire rope is one of the key components of the crane, which directly affects the carrying capacity and service life of the crane. The design process requires careful calculation and selection of wire rope to ensure that its strength, wear resistance and corrosion resistance and other properties meet the requirements. Pulley block is also an important part of the crane, which can change the traction direction of the wire rope and the size of the force. In the design of the crane, it is necessary to reasonably select the number of pulleys and layout to ensure that it can meet the requirements of use and improve lifting efficiency.

In terms of layout, the crane components need to be reasonably distributed to avoid mutual interference and improve operational efficiency. For example: winches, wire ropes and pulley blocks and other components need to be rationally arranged position and connection to avoid interference and vibration and other problems. It is also necessary to adopt advanced manufacturing process and technology to ensure the manufacturing quality and precision of the crane.

Safety guard design

The design of safety guards is an important part of the overall structural design of the trolley, which is intended to protect the operator and equipment from injury or damage. These devices include limit switches, overload protection, emergency stop buttons, etc. Limit switches are protective devices that are used to prevent the trolley from exceeding its operating range. By installing limit switches, you can ensure that the trolley automatically stops or switches to a safe mode when it reaches a preset position, avoiding damage or danger due to overdriving or impact. The overload protection device is a safety protection device that can automatically cut off the power supply or sound an alarm when the lifting capacity exceeds the rated value. By installing an overload protection device, you can ensure that the trolley will not cause structural damage or safety accidents due to overloading during transportation. The emergency stop button is a protective device used in emergency situations. By installing an emergency stop button, it is possible to quickly stop the trolley in the event of an emergency and avoid further risk or damage. Together, these devices form a complete safety protection system.

Electrical control system design

The electrical control system of the trolley is an important part of it, and PLC control technology is used to realize intelligent and automated operation.PLC (Programmable Logic Controller) is a kind of digital arithmetic operation electronic system specially designed for the application of the industrial environment, which adopts the programmable memory for its internal storage program to perform logical operation, sequential control, It uses programmable memory to store programs internally to perform logical operations, sequential control, timing, counting and arithmetic operations, and other user-oriented commands, and to control various types of mechanical equipment or production processes through digital or analog inputs/outputs.

In an electrical control system, the operator can easily control the various functions of the trolley through the touch screen interface. The touch screen serves as an intuitive and easy-to-use input device that allows the operator to interact with the system in a simple and quick manner. It can also display the running status and key parameters of the trolley in real time, which makes it easy for the operator to understand and monitor the operation of the equipment. The system is also equipped with fault diagnosis and alarm functions, which improve the reliability and maintainability of the equipment. The fault diagnosis function can monitor the operation status of each part of the system in real time, and once abnormalities are found, the system will immediately issue an alarm and display the corresponding fault information. This allows maintenance personnel to quickly locate and solve problems, reducing equipment downtime and maintenance costs.

Material Selection and Manufacturing Process

Material Selection Principles and Criteria

Material selection plays a crucial role in product design, which directly affects the performance, life, cost and safety of the product. When selecting materials, we follow a series of strict principles and standards to ensure that the selected materials can meet the needs of the product. Among them, the principles of high strength, light weight, corrosion resistance and easy processing are the core concepts of material selection. High-strength materials can withstand greater loads and stresses, lightweight materials can reduce the weight of the product, corrosion-resistant materials can extend the service life of the product, and easy-to-process materials can improve production efficiency. For the main frame and key components, high strength steel and low alloy steel are used. High-strength steel has high tensile strength and yield strength, and can withstand larger loads and stresses to ensure the stability and safety of the product. Low-alloy steel has good plasticity and toughness, which can improve the fatigue resistance and durability of the product. For electrical components and control systems, well-known brands are used to ensure performance and reliability. Famous brand products have been strictly tested and verified, with high reliability and stability, which can ensure the normal operation and service life of the products.

Material analysis of key components

Key components, such as winches and pulley sets, are manufactured with high-quality alloy steel and wear-resistant materials to improve wear resistance and service life. High-quality alloy steel has high strength and toughness, which can ensure the stability and safety of key components. Wear-resistant materials have better wear resistance and corrosion resistance, which can improve the service life and reliability of key components. At the same time, strict inspection and testing of materials to ensure compliance with design requirements. Inspection and testing of materials is an important means to ensure product quality. Through strict inspection and testing of materials, it can ensure that the performance and quality of materials meet the design requirements and provide reliable data support for product design and production.

Manufacturing process and quality control

The manufacturing process includes raw material preparation, cutting, welding, assembly, debugging and other links. Each link strictly follows the quality control standards to ensure product quality. Raw material preparation is the starting point of the manufacturing process, to ensure the quality and stability of raw materials. In the raw material preparation stage, the raw materials should be strictly inspected and tested to ensure that the raw materials meet the design requirements and quality standards. The cutting process is an important part of the manufacturing process, to ensure the precision and efficiency of cutting. In the cutting process, advanced cutting technology and equipment should be used to ensure the quality and efficiency of cutting. Welding link is a key link in the manufacturing process, to ensure the quality and stability of welding. In the welding process, advanced welding technology and equipment should be used to ensure the quality and efficiency of welding. At the same time, it is also necessary to carry out strict inspection and testing of welding to ensure that the welding meets the design requirements and quality standards. The assembly link is an important part of the manufacturing process, to ensure the precision and efficiency of assembly. In the assembly process, advanced assembly technology and equipment should be used to ensure the quality and efficiency of assembly. Debugging is a key link in the manufacturing process, to ensure the accuracy and stability of debugging. In the debugging process, advanced debugging technology and equipment should be used to ensure the quality and efficiency of debugging. At the same time, it is also necessary to carry out strict inspection and testing of the commissioning to ensure that the commissioning meets the design requirements and quality standards. By adopting advanced welding technology and testing equipment, the welding quality and overall performance of the product are improved. Advanced welding technology can improve the quality and efficiency of welding and reduce welding defects and problems; while advanced testing equipment can timely detect and correct problems and defects in the product to improve the quality and reliability of the product

Performance Testing and Evaluation

Load Capacity Test

Load capacity test is the key link to verify the carrying capacity of the trolley. In order to ensure that the trolley can safely and efficiently carry heavy objects in practical applications, we have conducted rigorous load capacity tests. The testers observed and recorded the lifting performance and stability of the trolley by loading different weights of objects under different working conditions. The test results show that the trolley can maintain stable operation under the rated lifting capacity without obvious deformation or damage. This shows that the trolley has excellent loading capacity and stability, and can meet the needs of various complex working conditions.

Operation Stability and Safety Test

Operational stability test is an important part of evaluating the performance of the trolley. In the test, we simulate the actual working conditions of the operation, the trolley’s speed, acceleration, positioning accuracy and other key parameters were measured accurately. The accuracy of these parameters directly affects the stability and efficiency of the trolley. At the same time, we conducted detailed functional tests on the trolley’s safety guards to ensure that it can respond quickly and effectively protect the operator’s safety in an emergency. The results of these tests show that the trolley has excellent operational stability and safety, and is capable of meeting the demands of a variety of complex working conditions.

Durability Testing and Evaluation

Durability testing is an important part of evaluating the long-term operational reliability and service life of the trolley. In order to ensure that the trolley can maintain good performance and stability during long-term use, we have conducted continuous operation and cyclic loading tests. During the tests, we closely observed the trolley’s wear and tear, performance changes, and failure rates and other indicators. Through these tests, we evaluated the durability and reliability level of the trolley, which provided an important basis for subsequent improvement and refinement. The test results show that the trolley has good durability and reliability and can meet the needs of long-term use.

Environmental Adaptability Test

Environmental adaptability test is the key link to evaluate the working performance and stability of the trolley in different environments. In order to ensure that the trolley can work normally in various harsh environments, we have conducted tests in harsh environments such as high temperature, low temperature, humidity and dust. During the tests, we focused on the electrical performance, mechanical performance, and the effectiveness of the safety guards. Through these tests, we evaluated the adaptability of the trolley in different environments, which provided an important basis for subsequent improvement and refinement. The test results show that the trolley has strong environmental adaptability and is able to maintain stable operation under harsh working conditions.

Use and Maintenance Guide

Installation and Commissioning Steps

Installation and commissioning is a necessary step before the trolley is put into use, which is vital to ensure the normal operation and safety of the trolley. First of all, it needs to be assembled and commissioned according to the design drawings. In the assembly process, each component needs to be installed correctly to ensure the stability and safety of the trolley. In the debugging process, the functions of the trolley need to be tested to ensure its normal operation. Second, the electrical control system is programmed and debugged. This requires a professional electrical engineer to operate to ensure that the program is correct. In the programming process, various factors need to be considered, such as the types of input and output signals, communication protocols, etc. During the debugging process, the program needs to be tested and verified to ensure that it is able to perform the required functions. Finally, no-load and load tests are performed. In the no-load test, it is necessary to check the operation of the trolley without load, such as speed and stability. In the load test, it is necessary to check the operation of the trolley under load conditions, such as load carrying capacity, speed, etc. Through these tests, it can be ensured that the trolley can meet the design requirements.

Daily operation and maintenance requirements

Daily operation and maintenance are important measures to ensure the long-term stable operation of the trolley. In order to ensure the normal operation and prolong the service life of the trolley, the operator needs to be familiar with the structure and function of the trolley. The operator should receive professional training and learning, and understand the operating procedures and precautions of the trolley. During use, operators need to operate in strict accordance with the operating procedures. They should clean, lubricate and inspect the trolley regularly. Through these measures, potential faults and problems can be found and dealt with in time to avoid the expansion of faults and the aggravation of damage.

Trouble Diagnosis and Troubleshooting Methods

Troubleshooting and diagnosis is an important means of maintaining the normal operation of the trolley. When the trolley fails, the operator needs to analyze and judge according to the fault phenomenon and alarm information. By observing the operation of the trolley and the alarm information, the cause of the fault can be initially judged. Then, the troubleshooting and repair are carried out in accordance with the fault diagnosis process. In the process of troubleshooting, it is necessary to check and test the various components of the trolley to find the specific location of the fault. In the repair process, correct repair measures need to be taken, such as replacing damaged parts and adjusting loose screws. Finally, the repaired trolley is functionally tested and verified to ensure that it can operate normally. By taking these steps, it can be ensured that the trolley can resume operation in time and improve the efficiency of its use.

Common Problems and Troubleshooting Methods (Trolley)

Fault phenomenon	Possible reasons	Troubleshooting
The trolley won’t start.	Low battery level	Check the battery level and charge or replace the battery
_	Control board malfunction	Check the connection of the control board and replace the damaged control board
_	Motor fault	Check the connection of the motor and replace the damaged motor
The trolley runs unstably	Sensor fault	Check the connection of the sensor and replace the damaged sensor
_	Tire wear or insufficient air pressure	Check for tire wear and replace severely worn tires; Check the tire pressure and adjust it to the standard value
_	Overload	Check the load situation and reduce the load
The trolley deviates from the track	Uneven track	Check the smoothness of the track and make repairs
_	Insufficient sensitivity of sensor	Adjust the sensitivity of the sensor or replace it with a sensor with higher sensitivity
Control system alarm	Program error	Reprogram or update the control program
_	Abnormal input/output signal	Check the connection status of input/output signals and repair abnormal signals

Trolley Maintenance Recommendations

Maintain the project	Maintenance Cycle	Maintenance content
Battery Maintenance	Every month	Check battery level, charge or replace batteries; keep batteries dry and clean
Control board maintenance	Quarterly	Check the connection of the control board, clean the control board; avoid moisture, heat
Motor Maintenance	Quarterly	Check motor connections and clean motor; lubricate motor bearings
Sensor Maintenance	Every month	Check sensor connections and clean sensors; avoid impact or crushing of sensors
Tire Maintenance	Quarterly	Check tire wear and replace badly worn tires; check tire air pressure and adjust to standard values
Track maintenance	Every month	Check track leveling and repair uneven tracks; clean tracks to avoid debris on them
Control program maintenance	At any time	Update or optimize control procedures as required; perform regular program testing and validation

Safe Operation Regulations

Pre-operation Preparation and Inspection

Before starting to operate the trolley, a series of detailed and rigorous preparations and inspections must be carried out, which is the cornerstone to ensure that the entire operation process is safe and smooth. First of all, conduct a comprehensive inspection of the mechanical properties and functions of the trolley itself to make sure that it is in good working condition, including but not limited to tire wear, brake system efficiency, whether the hydraulic system is normal, whether the lighting and signaling devices are complete and effective.

Secondly, focus on checking the electrical control system to confirm that the control buttons, indicator lights, alarm devices and other functions are normal, the wiring is intact, the power supply is stable and reliable, to ensure that the electrical system can accurately and correctly execute the instructions in the operation process, and have an effective emergency cut-off function when necessary. For the verification of safety protection devices should not be ignored, such as guards, limit switches, emergency stop buttons, etc., these devices are designed to prevent accidents, so we must make sure that it is complete and in good working condition, can be quickly activated when necessary and play a due role in protection.

Finally, carefully check whether the working environment meets the safety requirements. Check whether the ground is flat and free of obstacles, whether the working area has enough space to avoid collision or overturning of the trolley running process; confirm that the operating area is well lit, no obstruction of vision, so as to facilitate the operator to clearly observe and judge; at the same time, we should also pay attention to the environment of the temperature, humidity, wind speed and other factors in the equipment within the scope of the allowable, as well as the existence of flammable, explosive, toxic and harmful and other hazardous

Through the above meticulous preparations and inspections, we can minimize the potential risks during the operation of the trolley and ensure the safety and stability of the whole operation process. This is not only a responsible performance for the equipment, but also a strong guarantee for the safety of the operators and the overall safety of the enterprise.

Safety precautions during operation

During operation, a series of detailed and rigorous safety regulations and precautions must be strictly observed to ensure the safety and stability of the entire process. First of all, the operator should maintain a high degree of concentration and pay attention to the running status of the trolley and changes in the working environment. They should not operate under fatigue, sleepiness or inattention, so as not to cause safety accidents due to carelessness.

Secondly, strictly follow the specific requirements of the operating procedures on lifting and handling. During lifting operation, it should ensure that the spreader is properly selected, and the lifting process is kept vertical and smooth to avoid equipment damage or safety accidents caused by overloading and illegal operation; during the handling process, it is necessary to follow the correct handling posture and techniques to avoid personal injury or equipment damage caused by improper force or improper operation.

In addition, pay close attention to the operation status of the trolley and environmental changes. Once abnormalities or potential safety hazards are found, measures should be taken immediately to deal with them and report to the relevant departments and personnel in a timely manner. For possible accidents or malfunctions, preventive measures should be taken in a predictable and anticipatory manner to prevent the accident from expanding or generating secondary accidents.

These safety precautions are the cornerstone of ensuring a safe and smooth operation process. Only by strictly adhering to these protocols and precautions can we effectively reduce the potential risks of the operation process and safeguard the lives of the operators and the integrity of the equipment.

Emergency measures

When facing an emergency, effective countermeasures are the key to protect the operator and equipment safety. First of all, the operator should press the emergency stop button quickly and accurately to immediately cut off the power supply and stop the operation of the trolley. This action must be rigorously trained and practiced to ensure that it can be implemented quickly and effectively in an emergency.

Secondly, in an emergency, the operator needs to remain calm and clear-headed, quickly assess the situation and take appropriate measures to control the trolley’s operating status. This may include manually operating the brakes, using specialized tools to intervene in the trajectory of the trolley, or taking other specialized emergency measures. Operating procedures and relevant safety standards must be strictly adhered to throughout the process in order to prevent further escalation or secondary accidents.

Finally, when faced with an emergency situation, you must report it to the relevant departments and personnel in a timely manner. The content of the report should include detailed information on the nature of the emergency, the location where it occurred, the possible scope of influence, and the countermeasures that have been taken. Through timely reporting and communication and coordination, the relevant departments can quickly activate the emergency plan and organize effective rescue forces to deal with the situation. At the same time, it also helps to follow up on the emergency and summarize and analyze the lessons learned and experience gained from the work to improve the ability to deal with similar emergencies in order to provide a strong guarantee for the future safety of production.