Complete set of transformation plan for overspeed protection of variable frequency bridge gantry crane lifting mechanism

1. Compliance basis for program preparation

2. The composition of the complete set of equipment: integrated sensor assembly for speed measurement and acquisition + overspeed protection

Core advantages of equipment adaptation to working conditions

1. Heavy-duty mechanical structure, impact and wear resistance

   The shaft of the equipment adopts a solid stainless steel keyed structure, which can withstand the radial and axial impact loads caused by frequent start and stop of the crane; the whole machine is made of all-metal sealed housing with a protection level of IP66, dustproof, waterproof, and oil-resistant. It is suitable for the harsh operating environment of high temperature radiation, high dust, and strong vibration in metallurgical workshops, and it is stable for a long time.run.

2. Strong electrical compatibility, anti-frequency conversion electromagnetic interference

   Support multiple types of signal output, and the mainstream lifting frequency converters and PLC control systems on the market can be directly matched; wide-voltage power supply design, internal integrated reverse connection and short-circuit protection circuits, effectively avoid harmonic interference of frequency conversion equipment; pulse resolution, multiple gears are optional, taking into account the needs of high-precision speed closed-loop control.

3. Dual-type overspeed protection structure, according to demand selection

(1) Mechanical centrifugal overspeed protection (the first choice for high-risk working conditions)

(2) Electronic intelligent overspeed protection (standard for new intelligent driving)

3. The operating principle of the equipment and the core safety protection functions

1. Uninterrupted real-time speed acquisition

   The integrated speed measuring and sensing components operate synchronously with the motor drive shaft, continuously collect pulse data of the motor and reel speed, and monitor the lifting speed of the lifting mechanism online 24 hours a day, without monitoring blind spots.

2. Intelligent graded overspeed threshold determination

   The control system stores the rated safe speed parameters of the equipment, compares the measured speed with the preset protection threshold in real time, and can flexibly adjust and adjust the parameters according to the on-site load and operating environment.

3. Extremely fast braking response to curb the hook from falling overspeed

   When the measured speed exceeds the critical range of 10% to 15% of the rated safety limit, the system outputs a passive shutdown signal within 0.5 seconds, connects to an independent safety circuit of the equipment, and drives the brake to brake urgently, so as to prevent the crane from losing control of the hook and falling accidents from the root cause.

4. Electromechanical dual redundancy pocket bottom protection

   The complete set of system is equipped with a dual protection structure of electrical overspeed monitoring + mechanical centrifugal overspeed; once the electrical control system fails and the site is accidentally powered off, the mechanical overspeed mechanism can act independently to forcibly cut off the safety circuit, which fully complies with the redundant safety design specifications of special equipment.

5. Local storage and traceability of fault data

   The electronic integrated model can automatically keep all overspeed alarms and equipment operation records. The data cannot be tampered with, and can be exported at any time as valid certificates for equipment maintenance, special equipment inspection, and safety accident traceability.

4, three types of implementation service plans

Solution 1: The new machine is shipped with a pre-installed solution

Option 2: Retrofit and renovation plan for old unprotected vehicles

Option 3: Replacement and rectification plan for the original overspeed device

5. Core highlights of the complete set of solutions

1. Worry-free compliance, successfully passed various safety inspections

   The design of the whole machine is fully benchmarked with the TSG 51-2023 lifting specification to solve the problems of unqualified annual inspection and administrative penalties for safety supervision caused by the lack of overspeed protection, and complete acceptance of technical data.

2. Integrated, cost-effective is better than split procurement

   A single set of equipment simultaneously realizes the dual functions of inverter speed feedback and independent overspeed shutdown. There is no need to purchase the encoder + independent overspeed switch separately, which reduces the comprehensive cost of equipment procurement and on-site installation.

3. Strong adaptability to harsh working conditions, reduce maintenance costs

   The heavy-duty industrial-grade protective structure is suitable for the complex environments of metallurgy, ports, and heavy-duty processing workshops. The equipment has a long service life and reduces the frequency of late troubleshooting and replacement of accessories.

4. Customized adaptation, suitable for various on-site working conditions

   Equipment shaft diameter, pulse specifications, signal output mode, and speed threshold of overspeed action can be customized and matched according to on-site driving tonnage, motor parameters, and operating requirements.

6. Supporting full-process technical services

1. Free on-site site survey, equipment technical selection, and calculation of overspeed action parameters；
2. Provide standardized electrical wiring drawings, online remote installation guidance, and electrical debugging of the whole machine；
3. Undertake batch on-site renovation services for multiple vehicles in the factory area, and complete a full set of technical files for supporting rectification.；