20T行车节能系统应用案例

20T行车节能系统应用案例 | 20T Crane Energy-Saving System Case

项目简介 | Project Introduction

本项目为20吨桥式起重机（行车）势能回收节能系统，由稳利达电力电子提供整套超级电容储能与DCDC变换解决方案。设备由1台17.15kW双向DCDC模块与5串48V187.5F超级电容模组构成，接入行车变频器直流母线，实现主钩下降势能的高效回收与释放。行车下放重物时，势能通过DCDC转换为电能储存于超级电容（120-240Vdc）；提升或重载作业时，超容能量经DCDC回馈至直流母线，辅助电机做功，显著降低行车电能消耗与电网冲击。系统配置10寸触摸屏、RS485（Modbus RTU）与以太网（Modbus TCP）双通道通讯，具备完备的过压、欠压、过流、过温及通讯保护，故障解除后自动恢复运行，自然冷却、IP20防护，适用于各类工业厂房桥式起重机、门式起重机、冶金铸造起重机的节能改造。

This project is a potential-energy-recovery energy-saving system for a 20-ton bridge crane (overhead travelling crane), delivered by Wenlida Power Electronics as a complete super-capacitor storage and DC-DC conversion solution. The unit consists of one 17.15kW bidirectional DC-DC module and five 48V187.5F super-capacitor modules in series, connected to the crane inverter DC bus to efficiently recover and release the potential energy of the main hook. When the crane lowers a load, potential energy is converted via the DC-DC module into electricity stored in the super-capacitors (120-240Vdc); during lifting or heavy-load operation, the stored energy is fed back to the DC bus to assist the motor, significantly reducing energy consumption and grid impact. The system features a 10-inch touch screen, dual-channel RS485 (Modbus RTU) and Ethernet (Modbus TCP) communication, comprehensive over-/under-voltage, over-current, over-temperature and communication protections, and auto-recovery after fault clearance. It is naturally cooled with IP20 protection, and is suitable for energy-saving retrofit of bridge cranes, gantry cranes and metallurgical casting cranes in industrial plants.

系统拓扑说明 | System Topology Description

图2：20T行车节能系统应用场景 | Figure 2: 20T crane energy-saving system application scenario

整套系统配置10寸本地触摸屏，供客户监控数据和触摸操作；提供一路RS485接口，支持遥控、遥测、遥调功能。超级电容组经DCDC低压侧接入（120-240Vdc），DCDC高压侧接入行车变频器直流母线（450-750Vdc）。行车下降时超容充电储能，提升时超容放电回馈母线，形成"势能—电能—机械能"的闭环能量利用。

The system is equipped with a 10-inch local touch screen for on-site data monitoring and touch operation, and one RS485 port for remote telecontrol, telemetry and tele-adjustment. The super-capacitor bank connects to the low-voltage side of the DC-DC module (120-240Vdc), while the high-voltage side connects to the crane inverter DC bus (450-750Vdc). During lowering, the super-capacitors charge and store energy; during lifting, they discharge back to the bus, forming a closed-loop "potential energy – electrical energy – mechanical energy" utilization.

势能回收计算 | Potential-Energy Recovery Calculation

完整全套参数表 | Complete Parameter Tables

表1 17.15kW DCDC模块电气参数 | Table 1 Electrical Parameters of 17.15kW DC-DC Module

表2 整机规格参数 | Table 2 Complete Unit Specifications

设备搬运说明 | Equipment Handling Instruction

机柜底座开有两个方形孔，搬运时叉车两根货叉通过方形孔叉入机柜底部，移动过程中需保证缓慢、平稳，避免设备磕碰倾倒。

Two square holes are reserved at the cabinet base. Insert two forklift forks through the square holes to the cabinet bottom during handling. Move slowly and steadily to prevent collision or tipping-over.

应用场景 | Application Scenarios

典型应用 | Typical Applications

? 工业厂房20T及以下桥式起重机（行车）势能回收

? 冶金铸造起重机、门式起重机节能改造

? 港口门座起重机、料场抓斗起重机下放势能回收

? 电梯、提升机、立体车库重力势能回收

? 冲击性负载电网缓冲与功率平抑

? Potential-energy recovery for industrial-plant bridge cranes up to 20T

? Energy-saving retrofit of metallurgical casting cranes and gantry cranes

? Lowering-energy recovery for port portal cranes and grab cranes

? Gravitational-potential recovery for elevators, hoists and automated parking systems

? Grid buffering and power smoothing for surge loads