How to reduce energy consumption when using a single-beam bridge crane

1. Equipment selection optimization: Reduce energy consumption from the source

Efficient drive system configuration

Variable frequency speed regulation technology: It employs a frequency converter to control the speed of the motor, achieving soft start and smooth speed regulation for the hoisting, crane, and trolley mechanisms. Compared to traditional wound-type motors, variable frequency drives can reduce energy consumption by 20%-30%, while also reducing mechanical impact and extending equipment life.

Case: After a certain automobile manufacturing plant converted the hoisting mechanism of a single-beam bridge crane to a variable frequency drive, the annual electricity consumption decreased from 120,000 kWh to 85,000 kWh, achieving an energy-saving rate of 29.2%.

Permanent magnet synchronous motor: Under heavy-load conditions, permanent magnet motors exhibit a 3%-5% higher efficiency compared to asynchronous motors, and their power factor approaches 1, which can reduce reactive power loss.

Applicable scenarios: Suitable for working conditions with frequent start-stop operations and significant load variations (such as steel lifting).

Lightweight structural design

Application of high-strength steel: The main beam is constructed using Q345B or Q420B high-strength structural steel. While ensuring the load-bearing capacity, the self-weight is reduced by 10%-15%, thereby reducing the inertial load during operation.

Optimize the section shape: Change the main beam section from rectangular to I-shaped or box-shaped to improve the bending stiffness and reduce material usage.

Data support: Through structural optimization, the self-weight of a single-beam bridge crane at a certain port has been reduced by 12%, and its annual energy consumption has been decreased by 8%.

II. Operation control strategy: dynamically matching load demands

Intelligent speed control

Load adaptive speed regulation: Real-time monitoring of lifting load through a torque sensor, automatically adjusting the motor speed. For example:

When operating under no load or light load conditions (≤30% of rated load), run at 1.5 times the rated speed;

When operating under heavy load (≥80% of rated load), switch to low gear (0.5 times rated speed) to avoid motor overload.

Multi-mechanism linkage optimization: When the cart, trolley, and lifting mechanism operate simultaneously, PLC coordination control is employed to ensure that the accelerations of each mechanism are matched, thereby reducing energy waste.

Effect: After adopting intelligent speed regulation, the average daily energy consumption of a single crane in a certain logistics center has been reduced from 45 kWh to 32 kWh.

Regenerative braking energy recovery

Configure supercapacitors or battery packs: During the descent or braking of the lifting mechanism, store the regenerative electric energy generated by the motor in the supercapacitors for subsequent lifting actions.

Energy saving rate: Under frequent start-stop conditions, 15%-20% of the braking energy can be recovered.

Common DC bus technology: The DC buses of frequency converters of multiple cranes are connected in parallel to achieve energy sharing. When one crane brakes, the regenerated electric energy can be absorbed and utilized by other cranes.

Application case: After adopting a common DC bus system, the total electricity consumption in the plant area of a certain steel factory decreased by 12%.