A key project of the National Science and Technology Support Plan, "Research and Application of Key Technologies for Lightweight Bridge Crane Machinery", which spans the 12th and 13th Five Year Plans, was initiated by the Ministry of Science and Technology of the People's Republic of China and organized and implemented by the China Machinery Industry Federation. After three years of joint promotion by the project organizer and co organizers, breakthrough progress has been made. Recently, the China Machinery Industry Federation organized a strong project acceptance team to conduct a comprehensive acceptance of the lightweight core transmission equipment reducer of lifting machinery by listening to the project work report and organizing on-site technical certification. The acceptance expert group fully affirmed the timely progress of the project and achieved multiple technological breakthroughs, providing a complete set of technical support system for deepening the transformation and upgrading of China's lifting machinery towards precision, lightweight, green and energy-saving directions, and catching up with and surpassing international advanced levels.

The national science and technology support project spanning two five-year plans has passed authoritative acceptance

Recently, the China Machinery Industry Federation organized a comprehensive acceptance of the "Twelfth Five Year Plan" National Science and Technology Support Plan "Research and Application of Key Technologies for Lightweight Reducers in Bridge Crane Machinery" undertaken by Jiangsu Tailong Reducer Co., Ltd. and other units in Jiangsu. The expert group carefully listened to the project work report, conducted on-site inspection, technical demonstration, and combined acceptance, After inquiry and discussion, it was confirmed that the project focuses on the key technical requirements of lightweight reducers in bridge crane machinery. Key technical research has been carried out, including structural optimization of lightweight lifting mechanisms, optimization design and dynamic analysis of lightweight reducers, manufacturing and quality control of key components of lightweight reducers, and testing and application of lightweight reducers. A series of lightweight reducers with 13 three-level and 12 four-level specifications have been developed, We have developed a comprehensive performance testing device for lightweight reducers, completed various research contents and assessment indicators specified in the project task book, and achieved the expected goals.

The project recognizes that Tailong Reducer Company has optimized the structure and transmission system of the lifting mechanism of lightweight bridge cranes, and proposed a structural form of single side support for lightweight reducers; Based on the concept of generalization and combination diversity, parameterization and modularization technology are used to form a series of models for bridge crane reducers; The precision heat treatment technology for hard tooth surface gears based on the optimal design of hardened layer depth, residual stress and deformation control has formed a production process for high-power density gears, improving the load-bearing capacity of gears and reducers; The use of dynamic and static combination sealing technology has solved the problem of oil leakage in the reducer; Completed the lightweight design and manufacturing of 10 prototypes. We have independently designed and manufactured the reducer for the lifting mechanism of lightweight bridge cranes.

This project has established a corresponding production demonstration base at Tailong Reducer Company, which meets the annual production capacity of 5000 sets of lightweight reducers for the lifting mechanism of bridge cranes; Apply for 10 patents, including 4 invention patents and 1 computer software copyright; Published 15 academic papers; We have formulated one enterprise standard and trained a group of technical backbone, including 9 graduate students, 1 doctoral student, and 8 master's students.

This project is based on the development ideas and important tasks proposed in the "National Medium and Long Term Science and Technology Development Plan Outline (2006-2020)" and the "12th Five Year Plan" for the development of green manufacturing technology in the manufacturing industry, I have undertaken the development and research project of "Research and Application of Lightweight Key Technologies for Bridge Cranes", a technology support project spanning the "12th Five Year Plan" and "13th Five Year Plan" issued by the Ministry of Science and Technology of the People's Republic of China. The core equipment and independent project "Research and Application of Key Technologies for Lightweight Reducers of Bridge Cranes" in this project are clearly led and undertaken by Jiangsu Tailong Reducer Co., Ltd., in collaboration with Beijing Crane Transport Machinery Design and Research Institute, Zhengzhou Machinery Research Institute, Chongqing University, and Jiangsu University of Science and Technology to form an industry university research consortium. From January 2015 to the end of April 2018, it was divided into different levels Implement the research and project promotion work of this topic jointly by topic.

According to the requirements of the supported project of the Ministry of Science and Technology of the People's Republic of China and the evaluation and confirmation of the project acceptance team, compared with the JB/T10817 reducer matched with traditional lifting machinery, the lightweight reducer has a power density increase of 41%, a load capacity increase of 30%, a weight reduction of 10%, a noise reduction of 3dB (decibels), and a material saving of about 10%, reaching the leading level of similar products in China. The bridge crane equipped with this transmission mechanical equipment can reduce the overall weight by 15% to 20%, reduce energy consumption by more than 10%, and lay a solid technical foundation for China's lifting machinery to climb the international advanced level and achieve lightweight, intelligent, and green manufacturing.

Technological Innovation of Lightweight Decelerator Transformation

Lifting machinery is an important infrastructure required for the start-up process of production, transportation, lifting, and storage in various industries of the national economy, and is widely used in warehouses, ports, docks, factories, and storage sites. For a long time, with the vigorous development of the national economy, the demand and driving force for lifting machinery in fields such as steel, metallurgy, electricity, building materials, petroleum, chemical industry, new energy industry, river and sea tunnels, and road and bridge construction in China have led to a high growth rate of over 30% in the crane industry every year. At present, the annual production of domestic lifting machinery and equipment reaches over 40000 units, with an output value of over 17 billion yuan, and an annual consumption of over 1.7 million tons of high-grade steel. In the components of lifting machinery, reducers are the core equipment of various components. The performance and structure of reducers not only affect and determine the speed, efficiency, and stability of the lifting machinery, but also are closely related and complementary to the structural connections of the main components such as the crane box, transmission system, motor, coupling, brake, and drum.

According to Yin Aiguo, the general manager of Tailong Reducer Company, the commonly used bridge crane in China is the Q developed in the 1980s

Through the research of this project, a series of types of lightweight reducers for bridge cranes have been formed; Implemented modular design of lightweight reducers; Established a series of design schemes for lightweight reducers; Completed the trial production and comprehensive performance testing of five types of reducer prototypes; A new type of three-point support lifting mechanism transmission system suitable for 5~100t bridge cranes and 125~200t bridge cranes has been proposed. Based on the complete theoretical research and comprehensive performance testing of the prototype, it is proven that the research results of this project have all the conditions for promoting the application of lightweight bridge cranes. Through the research of this project, it has promoted the improvement of the enterprise's technological innovation ability and the cultivation of talent teams, adapted to the market demand of lightweight cranes, and added new economic growth points for the enterprise. The successful development of lightweight reducers is of great significance for promoting the development of China's lifting machinery towards international advanced technologies such as lightweight, energy-saving, safety and reliability. It will also play an important supporting role in improving China's independent innovation ability and technological level, and enhancing the core competitiveness of domestic manufacturing industry.

Docking with "Made in China 2025" to Improve International Modernization Level

The reducer is a core component that ensures the safety and reliability of lifting machinery operations. Its overall structure must adapt to the linkage operation of the crane under both no-load and load conditions. The operating system is designed with intelligence and can strictly follow the given lifting speed, greatly improving work efficiency, saving work time, and reducing energy consumption. The supporting project of this project is the lightweight research and development and manufacturing of 5~200t bridge cranes, and the necessary economic and social benefits have been given. This project belongs to a multidisciplinary and interdisciplinary project that closely combines technical research and engineering applications. Currently, the project has made overall breakthroughs in the possession of independent intellectual property rights, the cultivation of scientific and technological talents, and the construction of industrial bases. We have studied and formulated the "Enterprise Standard for Crane Two Point Reducers", drafted the "Industry Standard for Crane Two Point Reducers" submission plan, published 3 international papers and 1 domestic paper, and obtained two national patents. The organizer of this project and four co sponsoring units have all participated in 58 people, including 9 doctoral and graduate students. The research and manufacturing time invested in this project has reached 408 people/month, cultivating a large number of professional research and design personnel. We have established a research and development team in parameter modular design and structural modular manufacturing, laying a solid talent and technical foundation for the design and manufacturing of modular series products in China, The cultivation has created an industrial development base.

Yin Genzhang, Chairman of the China Transmission Industry Association and Chairman of Jiangsu Tailong Machinery Group, introduced to our reporter that lightweight bridge cranes are the future development direction of China. Currently, the traditional crane market in China has a total of 100000 units, with a huge industrial scale and broad application prospects. The development and development of lightweight reducers can reduce the weight of bridge cranes by 15% to 20%, and save 100000 to 150000 tons of high-grade steel annually. With the promotion of the "Made in China 2025" strategy and the current technological development and national economic construction needs of China, the application of lightweight cranes can increase the height of major buildings