機床安裝用起重機的設計(梁與小車)
機床安裝用起重機的設計(梁與小車),機床安裝用起重機的設計(梁與小車),機床,安裝,起重機,設計,小車
國內工程起重機發(fā)展趨勢與市場前景
一、 行業(yè)市場狀況
改革開放20多年來，國民經濟突飛猛進，國家基礎建設蓬勃發(fā)展，帶動著國內工程機械的 需求，推動著工程機械的發(fā)展。工程起重機行業(yè)也同其它工程機械一樣得到長足的發(fā)展。目前從行業(yè)2003年13家企業(yè)報表來看，1-6月份銷售量4600臺，比去年同期增長50%以上，估計全年 將超過8000臺市場規(guī)模，各個企業(yè)都有不同程度的增長。從起重機行業(yè)歷年來的銷售數據分析，以下四個特點十分明顯：
一是市場規(guī)模具有顯著的地域性，經濟發(fā)達的地區(qū)持續(xù)熱銷，落后地區(qū)的購買力則相對較 弱；二是中大噸位產品增長迅速，16噸以上產品均有較大幅度增長，今年上半年20噸級以上產 品增幅更是高達100%以上；三是行業(yè)發(fā)展與國家投資政策關聯(lián)率較大，周期變化受國民經濟發(fā) 展影響明顯；四是用戶的不確定性和分散性，據統(tǒng)計，目前私人用戶占整體用戶的70%以上， 而且還有不斷增加的趨勢。可以預見在2002年大發(fā)展的基礎上，今年又將取得突破性發(fā)展，體 現(xiàn)著國民經濟發(fā)展的強大動力和潛力。隨著國家發(fā)展戰(zhàn)略調整，各項措施的到位和落實及全民 共謀發(fā)展奔小康的強烈愿望，經濟建設必將走向快速健康發(fā)展之路，工程起重機及配套行業(yè)， 通過市場競爭的洗禮，也必將擺脫前幾年徘徊局面，進入健康穩(wěn)步發(fā)展的新時期。 我國工程起重機行業(yè)面對新一輪挑戰(zhàn)
二、行業(yè)產品發(fā)展情況
工程起重機行業(yè)在94~99年是發(fā)展低谷，5年中行業(yè)幾個主要的生產廠家，苦練內功，積極 組織產品變型和換代，在產品外觀上下功夫。從99年以來，隨經濟建設新一輪啟動，工程起重 機市場競爭格局發(fā)生巨大變化，各企業(yè)不斷調整思路、更新觀念、轉換機制、提高核心競爭 力，努力開發(fā)產品，開拓市場。產品重心也從8t、12t向16t、25t、50t中大噸位發(fā)展，25t增 速最快，產量不斷翻新，基本占據主導地位。50t產品由于需求面較廣，技術逐漸成熟，也大 批量進入市場。目前國內主要產品系列，汽車起重機為8t、12t、16t、20t、25t、35t、50t、 65t、80t、l00t，全地面起重機為25t、50t、125t、160t和履帶起重機為35t、50t、l00t、 150t。整體技術風格是： 下車有全頭和半頭兩種不同風格，多年來半頭車因總體布置的方便性及價格因素一直被廣 泛采用。但近年來隨著物質條件的改善，人們的生活條件和質量提高，操作方便、舒適、可靠 逐漸成為用戶關注的焦點，中大噸位向全頭方向發(fā)展。 上車操縱從傳統(tǒng)的機械操作向液比例和電液比例方向發(fā)展，起重吊臂也從傳統(tǒng)的三節(jié)向四節(jié)、五節(jié)方向發(fā)展，產品的起重性能和起重高度有了較大提高，產品的外觀和可靠性有了較大 幅度提高。 我國工程起重機市場趨勢與對策分析
三、工程起重機行業(yè)技術發(fā)展趨勢
國內工程機械產品近十年來隨著技術的引進、消化、吸收，有了長足的進步，產品性能、
可靠性、外觀都有較大幅度的提高，但同國外工程機械比較來看，還存在較大差距，就工程起 重機而言，今后的發(fā)展主要表現(xiàn)在如下幾個方面：
l、整機性能：由于先進技術和新材料的應用，同種型號的產品，整機重量要輕20%左右。 隨著結構分析應用和先進設備的使用，結構形式更加合理：
2、高性能、高可靠性的配套件，選擇余地大、適應性好,性能得到充分發(fā)揮；
3、電液比例控制系統(tǒng)和智能控制顯示系統(tǒng)的推廣應用；
4、操作更方便、舒適、安全，保護裝置更加完善：
5、向吊重量大、起升高度、幅度更大的大噸位方向發(fā)展。加入世貿組織后，雖然國內市場(特別是配套件)將受到較大沖擊，但同時也給我們帶來新技術的應用，使國內主機和配套件企業(yè)更清晰認識到差距，更多地了解國產產品存在的致命問題，必將引導主機和配套件企業(yè)的技術創(chuàng)新和技術進步。徐工集團重型廠和其他競爭廠家一樣準備用3-5年時間進行產品創(chuàng)新，更新?lián)Q代，緊跟世界先進技術，將自身發(fā)展和帶動汽車起重
機整個制造行業(yè)的技術進步放在同等位置上，力求把起重機行業(yè)從低價格惡性競爭的狀態(tài)，帶 向高技術含量、高附加值的良性品牌競爭的新時代，從而帶動配套行業(yè)的健康發(fā)展。起重機電氣控制技術未來的發(fā)展趨勢
四、國外工程起重機配套件發(fā)展趨勢及應用情況
國外工程起重機從整體情況分析，領先國內10~20年(不同類型產品有所不同)。隨著國外 經濟發(fā)展速度趨于平穩(wěn)，工程起重機向智能、高性能、靈活、適應性強、多功能方向發(fā)展。 25t以下基本上不生產，產品向高附加值、大噸位發(fā)展，如利勃海爾公司汽車起重機基本退出 市場，目前市場主導產品為全地面起重機，最小噸位是35t，而80t和160t是主導產品；格魯夫 公司：主導產品是全地面起重機和輪胎起重機，最小噸位是25t；多田野公司：汽車起重機只 占20%，主導產品是全地面起重機和輪胎起重機，最小噸位16t。因此行業(yè)配套也與國內有所不同：
1、下車主要是300kW以上柴油大功率發(fā)動機，與之配套的液力變矩器和自動換檔變速箱、12噸級驅動轉向橋及越野輪胎。
2、上車：高強度材料、大扭矩的起升機構、回轉機構、回轉支承。
3、液壓系統(tǒng)：變量泵、變量馬達、電磁換向先導閥及主閥、平衡閥、懸掛系統(tǒng)閥、液壓
鎖、液壓缸及管路標準配套件。
4、智能控制系統(tǒng)：力限器顯示控制、記憶通訊及單缸順序伸縮自動控制。由于國外工程機械起步較早，形成了成熟的配套件體系。如力士樂的泵馬達、閥、起升、回轉、行走機構；貝林格的主閥、先導閥、平衡閥；哈威的主閥、先導閥、平衡閥；ZF的變速箱、分動箱；凱斯蘭的橋；PAT的力限器等等。配套廠能與主機廠協(xié)作密切，聯(lián)合開發(fā)，再加上主機廠家的專有技術，能形成很強的核心競爭優(yōu)勢，能夠保證主機性能的發(fā)揮和可靠性的提高。多家外國廠商看好中國塔式起重機市場全球起重機巨頭力圖搶占中國市場份額國內外隨車起重機現(xiàn)狀及發(fā)展趨勢
五、主機產品開發(fā)對配套產品的總體要求及關鍵零部件的發(fā)展
(一)產品開發(fā)對配套產品總體要求
主機廠家產品技術水平和檔次的提高，一方面依賴主機廠產品開發(fā)、技術進步，另一個重要方面就是配套行業(yè)整體水平的提高和質量的保證?？己四骋划a品兩項最重要的指標就是性能和可靠性，性能的高低是以可靠性作基礎的，沒有可靠性的保證，高性能是不能成立的。因此產品的開發(fā)首當其中的要考慮產品可靠性，在滿足可靠性的前提下，不斷提高產品性能，不斷使產品升級換代，這就要求配套廠家時刻與主機廠保持同步，隨時了解企業(yè)產品的質量可靠情況，多聽最終用戶呼聲和要求，加強產品質量控制，及時掌握主機廠家產品性能的總體要求，加強溝通和服務，這樣才能適應市場和用戶，才能與主機廠一起開發(fā)新品，開拓市場，以達到共贏的目的。縱觀世界工程機械行業(yè)發(fā)展狀況，可以明顯感覺到目前歐美配套的液壓件、傳動件等零部件大公司，其產品開發(fā)不僅僅局限于零部件的研究，而是注重整機系統(tǒng)的匹配。在推銷產品的同時，給主機廠匹配系統(tǒng)，非常了解行業(yè)的發(fā)展動態(tài)，能與主機廠一起研究用戶的需求，不僅功能上滿足要求，還在系統(tǒng)的微動性和平順性上給主機廠提供保證，使產品發(fā)展能夠實現(xiàn)自動化平穩(wěn)操作，極大地提高產品性能和舒適性，提高產品的競爭能力。目前，國內大部分配套廠家只注意主機廠功能要求，對性能和可靠性關注較少，雖然主機廠積極引導，在新品開發(fā)和老品改進上仍難滿足要求，高技術含量、高附加值的產品仍主要依賴進口，這就要求配套廠家加大新產品開發(fā)力度，加大投入，加強產品質量攻關，提高產品可靠性，及時研究市場需求的變化，使企業(yè)與市場同步，這樣才能贏得客戶，企業(yè)才能健康持續(xù)發(fā)展。近幾年起重機行業(yè)液壓控制技術的發(fā)展已從單一的機械操作方式向液壓先導、電液比例控制、自動控制集成顯示的方向發(fā)展，配套廠家應積極研究這種變化，努力開發(fā)出適合中國國情 的產品，使企業(yè)與整個行業(yè)發(fā)展同步。
(二)配套產品主要存在的問題
從目前產品配套情況和市場反饋信息表明，外配套件存在大量問題其中質量和可靠性問題
占問題反饋的比例非常高，而且廠家反應慢，整改效果不明顯，對整機銷售的服務造成巨大壓力，也為主機廠技術服務出很多難題，嚴重制約著市場的開拓和新產品快速成長的步伐。
主要存在的問題是：
液壓缸、閥，鎖類：漏油、內泄、異響；
機構類：漏油、異響、操作不便、不可靠；
橋箱類：漏油、漏氣、斷齒、操作不靈；
電器元件：接觸不良、易燒、失靈；
兩室及外觀件：漏水、焊縫開裂、密封老化脫落等。
主要原因分析：
1、技術水平落后，設備不能滿足加工要求，突出表現(xiàn)在零件的平面度、光潔度及軸線的
垂直度達不到設計要求；
2、產品開發(fā)滯后，不能迅速形成換代產品；
3、觀念落后，指導思想不能滿足市場的強烈需求；
4、服務意識淡薄，不能直接面對用戶，不能完全進入市場；
5、控制手段不全，責任意識不強，質保體系不能有效發(fā)揮。
(三)配套廠家應采取的措施和方法
根據多年新產品試制經驗和市場反饋分析表明，絕大多數問題是配套件引起的，主機廠自制件突出的是外觀問題，性能基本可以滿足要求。因此在以后的工作中，主機廠在加強產品細 化設計，提高制造裝配技術水平的同時，要求配套廠應重視以下幾個方面的工作，以便降低反 饋率，大力提高產品的性能和實物質量。
1、轉變觀念，把傳統(tǒng)的滿足功能要求轉變?yōu)榫o隨主機廠，提高可靠性和性能方面來：
2、加快技術創(chuàng)新和產品進步，不要有依賴主機廠的思想，積極引進人才，不斷開發(fā)出市
場需求的、質量可靠的產品，推動起重機行業(yè)的良性發(fā)展，在這方面可以進行合作開發(fā)，提供一些專有配套技術產品；
3、加快技術改造，提升自身的制造能力，新產品開發(fā)不能直接整機裝配試驗，問題不能
在整機上暴露，這樣會降低產品開發(fā)成功率，延誤進入市場的良機，這些工作應在試驗臺完
成，批量產品的試驗、調整應在試驗臺嚴格調試、嚴格控制、嚴格把關，不能寄希望主機廠發(fā)現(xiàn)問題后再改；
4、提高零部件加工精度和光潔度，嚴格裝配工藝規(guī)范，加強責任意識和質量意識教育。
關鍵的零部件采用進口件，提高產品的清潔度；
5、加強產品技術售后服務(不能只限于主機廠，還要到產品最終用戶去服務)，了解最終
用戶要求，滿足用戶需求，只有直接面對用戶，才能了解真實信息，才能有壓力和動力，產品性能和實物質量才能提高。
總之，行業(yè)和發(fā)展要靠大家的共同努力，堅持創(chuàng)新發(fā)展主題，本著誠信共贏的原則，實現(xiàn)我們參與國際競爭的美好遠景。
翻譯：
China Construction Crane and the development trend of the pre-market
First, industry market conditions
Reform and opening up over the past 20 years, the national economy by leaps and bounds, national infrastructure development boom, driven in domestic demand for construction machinery, engineering machinery to promote the development. Crane also works with other industries, like construction machinery have developed by leaps and bounds. Currently industry in 2003 from 13 enterprises statements of the 1-June sales of 4,600 units over the same period last year more than 50 per cent, it is estimated that more than 8,000 Taiwan will be the year the size of the market, various companies have different degrees of growth. Crane industry over the years from sales of data analysis, the following four characteristics is very clear:
???? First, the size of the market with significant regional, economic developed areas continued hot, backward areas of purchasing power is relatively weak; second is the rapid growth of large-tonnage products, 16 tons or more products have a big increase, the first half of this year 20-ton increase over product is as high as 100 percent above the third is the development of industries associated with the national rate of greater investment policy, periodic changes affect significantly the development of the national economy; Fourth, users of uncertainty and dispersion According to statistics, At present private users total more than 70 percent of users, but also the increasing trend. It can be foreseen in the 2002 large-scale development on the basis of this year will achieve a breakthrough development, reflects the strong driving force for national economic development and potential. With the adjustment of national development strategies, the measures in place and implement all the people and seek common development and the strong desire of fairly well-off, economic construction is bound to rapid and healthy development, engineering cranes and supporting industries, through the baptism of market competition, will also A few years ago to shake off lingering situation, access to health steady development of the new era. China Construction Crane industry faced a new round of challenges
Second, industry product development
??? Construction Crane industry in the 94 to 99 is the development of low ebb, the five-year industry in several major manufacturers, bitter Liannei Gong, and actively organize and updating of product variations in product appearance on. From 99 since, with the launch a new round of economic construction, engineering crane market competition has seen tremendous changes, companies constantly adjust ideas, new concepts and mechanisms to enhance core competitiveness, product development efforts and open up the market. Product focus from 8 t, 12t to 16 t, 25t, 50t development of the Chinese University of tonnage, 25 t the fastest growth rate of output constant renovation, basic hold the leading position. 50t products due to demand broader, technology matured, but also in large quantities to enter the market. At present domestic product family, truck crane to 8 t, 12t, 16t, 20t, 25t, 35t, 50t, 65t, 80t, l00t, the whole ground crane for 25 t, 50t, 125t, 160t and cranes to 35 t, 50t, l00t, 150t. Overall technical style is: get off a full head and the first half of two different styles, semi-trucks over the years due to the overall layout of the convenience and price factor has been widely used. But in recent years with improvements in material conditions, people's living conditions and to improve the quality, convenient, comfortable, reliable gradually become the focus of attention of users, the first large-tonnage to the whole direction of development. On the train from the manipulation of the traditional mechanical operation of proportion to the ratio of electric and develop in the direction of lifting the crane from the traditional three to four, five direction of development, product performance and lifting the lifting height have been greatly improved , Product reliability and the appearance of a more substantial increase. China Construction Crane analysis of market trends and countermeasures
Third, engineering industries and technological development trend of cranes
???? Domestic construction machinery products over the past 10 years as the technology introduction, digestion and absorption, has made great progress in product performance,
Reliability, appearance has greatly increased, compared with foreign construction machinery, there are still a wide gap between the crane project, the future development mainly in the following areas:
???? l,performance: As advanced technology and the application of new materials, the same types of products with two light weight to about 20 percent. With the application of structural analysis and the use of advanced equipment, a more rational structure:
???? 2, high-performance, high reliability, the matching pieces, choice, adaptability, and performance are brought into full play;
3, the proportion of electro-hydraulic control systems and intelligent control system showed that the popularization and application;
4, operation more convenient, comfortable, safe and protective equipment more perfect:
5, to hoist the weight, lifting height, the greater rate of large tonnage direction. After joining the WTO, although the domestic market (especially the supporting pieces) will be larger impact, but also bring us new technology applications, mainframe and supporting domestic enterprises were more clearly aware of the gap, to learn more about China-made products there fatal problems, will guide the host of enterprises and supporting the technological innovation and technological progress. Xugong Group of heavy plant and other competitive manufacturers like to use three to five years to develop new products, upgrading, keeping up with the world's advanced technologies, will lead its own development and car lifting
For the entire manufacturing industries technological progress on the same location, to the crane industry in vicious competition from low-price state, with the high-tech content and high added value of healthy competition in the brand new era, thus supporting the healthy development of industry. Crane electrical control the future development trend of technology
Fourth, foreign works crane supporting the trend of development and application of
??? Crane foreign works from the overall situation analysis, the leading domestic 10 to 20 (different types of products vary). As foreign economic growth rate has stabilized, engineering crane to the smart, high-performance, flexible, adaptable, multi-functional direction. 25t following basically does not produce, to the high value-added products, development of large tonnage, such as company car Liebherr cranes basic withdraw from the market, the current market-driven products for the whole ground crane, the minimum tonnage is 35 t, and 80 t and 160 t is the dominant product; grid Lu Fu Company: leading products is the ground crane and tire cranes, the minimum tonnage is 25 t; TADANO Company: truck crane only 20 percent, leading products is the ground crane and tire cranes, the minimum tonnage of 16 t. And therefore also supporting the domestic industry is different:
??? 1, get off is more than 300 kW high-power diesel engines and its accompanying torque converter and automatic transmission gearbox, 12-ton drive to the bridge and cross-country tires.
??? 2, on the train: high-strength materials, high torque or from the agencies, Rotary, Rotary support.
??? 3, hydraulic system: the variable pump, variable motor, electromagnetic valve for the pilot and the main valve, balance valve, the suspension system valves, hydraulic
Lock, hydraulic cylinder and standard-parts pipeline.
??? 4, intelligent control system: control of the limited display, memory and communication order telescopic single-cylinder automatic control. As foreign construction machinery started earlier and formed a maturity of the matching system. Rexroth as the pump motors, valves, lifting, rotating, walking; Beling the main valve, the pilot valve, balance valve; Hawe the main valve, the pilot valve, balance valve; ZF's transmission, transfer case ; Kai Silan bridge; PAT force limiter, and so on. Ancillary works in close collaboration with Zhuji Chang, joint development, coupled with the manufacturers of proprietary mainframe technology, can form a strong core competitive edge, to ensure that a host of performance and reliability of the increase. Many foreign firms were optimistic about China tower crane market global giant crane trying to seize market share, domestic and foreign lorry crane status quo and development trend
5, host of ancillary product development products and the general requirements for the development of key parts and components
???? (A) product development to overall requirements for supporting products
???? Console manufacturers technical level and grades of products increased reliance on the one hand, Zhu Jichang product development, technological progress, is another important aspect of supporting industries and raise the overall level of quality assurance. Two appraisal of a product is the most important indicators of performance and reliability, performance, the level of reliability as a basis, with no guarantee of reliability, high-performance can not be established. So when the first product development to be considered one of reliability, to meet the reliability of the premise and continuously improve product performance, and constantly upgrading their products, which requires matching Zhuji Chang manufacturers to keep pace with the times, be kept informed of their products Reliable quality, end-users to listen to voices and demands, strengthen quality control, console manufacturers make the best of the general requirements for product performance, enhance communication and services, in order to adapt to the market and users can Zhuji Chang together with the development of new products, open up markets, To achieve the objective of a win-win situation. Throughout the construction machinery industry development, can clearly feel that the current Europe and the United States of supporting the hydraulic, transmission and other parts of large companies, their product development is not limited to parts of the study, but rather focus onthe match. At the same time in the marketing of products to Zhuji Chang matching system, is well aware of the development of the industry dynamics, together with Zhu Jichang on the user's needs, not only meet the functional requirements of the system is still fretting and ride on to provide Zhuji Chang Assurance that product development to achieve a smooth automated operation, greatly improve the performance and comfort, improve product competitiveness. Currently, most domestic manufacturers only supporting the attention of Zhuji Chang functional requirements, the performance and reliability of less concern, although Zhu Jichang positive guidance, in new product development and improvement of old goods on sentiment and meet the requirements of high-tech content, high value-added Products still rely mainly on imports, which requires supporting manufacturers intensify efforts to develop new products, increase investment, enhance product quality research, improve product reliability and timely study of changes in market demand, so that enterprises and the market simultaneously, in order to win customers, In a sound and sustainable development of enterprises. Hydraulic crane industry in recent years the development of control technology from a single hydraulic machinery operation to the pilot, electro-hydraulic proportional control, automatic control the direction of the development of integrated display, supporting manufacturers should actively explore such changes, efforts to develop suitable for China Conditions of products, enterprises and the development of the entire industry simultaneously.
???? (B) products are supporting the existing problems
Judging from the current situation and market products supporting feedback shows that there are a lot of ancillary problems of quality and reliability of these issues
The proportion of the problem feedback is very high, and manufacturers respond slowly, rectification and reform ineffective, the sale of services tremendous pressure, but also Zhuji Chang technical services to many problems, seriously restricting the development of the market and the fast-growing new products Pace.
The main question is:
Hydraulic cylinders, valves, Locks: oil spills, within China, abnormal sound;
Agencies categories: oil spills, abnormal sound, operation inconvenience, not reliable;
Bridge me categories: oil spills, leakage, broken teeth, the operation failed;
Electrical components: connection is bad and easy to burn, failure;
Liang Shi and appearance of: water leakage, weld cracks, sealing the aging, such as shedding.
Analysis of main reasons:
1, backward technology, processing equipment can not meet the requirements highlighted in parts of the plane, and finish the axis
Vertical amount less than the design requirements;
2, product development lags behind, can not be quickly formed and updating of products;
3, the concept behind, guiding ideology can not meet the strong market demand;
4, have a weak sense of service, can not directly face the user, can not enter the market;
5, control means incomplete, sense of responsibility not strong, and can not play an effective quality assurance system.
(C) supporting measures to be taken by the manufacturers and methods
??? Preparation of new products based on years of experience and market feedback analysis shows that the vast majority of the problem is caused by matching pieces, Zhuji Chang made of prominent is the issue of appearance, performance, to meet the basic requirements. Therefore, in future work, Zhuji Chang refined products designed to strengthen and improve the technological level of manufacturing assembly at the same time, the plant should attach importance to supporting demands the following aspects of work, so as to reduce the response rate, greatly improve the performance and in-kind product quality.
??? 1, changing concepts, the traditional meet the functional requirements for the following changes in Zhuji Chang, improve reliability and performance to:
??? 2, to accelerate technological innovation and product improvement, without relying on the idea of Zhuji Chang, the positive introduction of talent, and continuously develop the city
Market demand, quality and reliable products, and promote the healthy development of a crane industry in this area can cooperate in the development, with some supporting proprietary technology products;
??? 3, speed up technological innovation, and enhance its own manufacturing capacity, the development of new products can not directly testassembly, the problem can not be
Inon the exposed, this will reduce the rate of successful product development, delays in market access opportunities, such work should be test-bed End
10% of the bulk product testing, adjustments should be strictly in the test bed debugging, strict control, strict control and can not pin hope Zhuji Chang later found to the problem;
??? 4, improving accuracy and finish processing components, the assembly process stri
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