Technical Background and Industry Positioning

The electrically controlled winch, as a core component of lifting equipment, directly affects both construction efficiency and safety. Zhengzhou Rongjing Machinery Equipment Co., Ltd. has accumulated more than ten years of technology, focusing on the research and development of all types of electronically controlled winches, covering multiple scenarios such as construction, mining, and water conservancy projects. Through the modular design concept, the company realizes the flexible configuration of pulling force range of 500kg-50t and speed of 0.5-20 m/min, supports vertical, horizontal, external and other installation forms to meet the space limitation requirements of different working conditions.

Technical Architecture and Core Parameter Analysis

1. Drive system: Three-phase asynchronous motor + frequency converter combination, support 0-1500rpm stepless speed regulation, motor protection level of IP55, adapt to -20 ℃ ~ 50 ℃ extreme environment. Inverter built-in overload protection module, when the load exceeds the rated value of 120, 0.5 seconds to trigger power-off protection.

2. Braking system: Configure dual-circuit hydraulic brake, the braking torque reaches 150 of the rated torque, and the braking distance ≤ 0.3m (full load condition). The brake pad is made of copper-based powder metallurgy material, and the wear-resistant life is more than 8000 cycles.

3. Powertrain system: The gear box adopts hard tooth surface carburizing and quenching process, the tooth surface hardness is HRC58-62, and the transmission efficiency is ≥ 95%. Support single-speed, two-speed, frequency conversion three transmission modes, speed ratio range 5-100 optional.

Customized technology implementation path

STEP1: Condition Analysis Phase: The technical team obtains on-site spatial data through 3D scanning, and establishes a mechanical model in combination with load characteristics (such as frequent start and stop, impact load). For example, in a mine project, in view of the limitation of the roadway height of only 3.2m, the traditional vertical structure is changed to horizontal installation, and the drum diameter and motor layout are redesigned.

STEP2: Parameter optimization phase: using ANSYS finite element analysis software, stress simulation of key components. In a water conservancy project case, by increasing the wall thickness of the drum by 2mm and optimizing the distribution of ribs, the anti-overturning capacity of the whole machine is improved by 40%, which is verified by ISO 898-1 standard.

STEP3: Production verification stage: CNC machining center shall be used to ensure the accuracy of parts of ± 0.05mm, and 24-hour full-load running-in test shall be carried out after the whole machine is assembled. After 1200 hours of continuous operation, the temperature rise of the gearbox is only 18 ℃, which is lower than the industry standard of 25 ℃.

Typical Application Case Review

In a subway construction project, the customer needs to hoist 20t shield machine parts in a 25m deep foundation pit. The technical solution provided by Zhengzhou Rongjing includes three innovations:

1. Equipped with a dual-motor synchronous drive system, the speed difference between the two motors is less than or equal to 0.5rpm through PLC control, so as to solve the synchronization problem when starting with heavy load;

2. The drum adopts a segmented structure, each segment is 1.2m long, and is connected by flanges to meet the needs of segmented transportation in the foundation pit;

3. Increase the wireless remote control module, the operating radius of 100m, to meet the needs of multi-angle operation in the foundation pit. After the implementation of the project, the hoisting efficiency is increased by 35%, and the failure rate is reduced to 0.2 times/month.

Technical maintenance and troubleshooting

FAQ1: How to deal with the difficulty of starting the electronically controlled winch?
Check whether the three-phase power supply voltage is balanced (allowable deviation ± 5%), and measure the insulation resistance of the motor to be ≥ 0.5 MΩ. If the inverter reports an overcurrent fault, it is necessary to detect whether the brake is completely released, which can be solved by adjusting the preload of the brake spring.

FAQ2: Why is the brake heating abnormal?
Common in the brake pad clearance is too small (standard value 1.5-2mm) or hydraulic oil viscosity is too high. It is recommended to check the brake clearance every 500 hours of operation, use 46# anti-wear hydraulic oil, and control the working temperature below 60°C.

FAQ3: Inverter Frequently Reports Overload Fault?
It is necessary to check whether the rated power of the motor matches the selection of the frequency converter. For example, 5.5kW motor should be equipped with 7.5kW frequency converter, leaving 20% power margin. At the same time, check whether the load is stuck, and monitor the operating current fluctuation value through the ammeter.