叉车充电站规划设计技术要求

1、液态铅酸电池充电站计划Planing of charging stationsfor liquid acid Pb-batteries林德-厦门叉车有限公司Linde-Xiamen Fork Lift Truck Co., Ltd2002. 11目录Content1.充电站的定义和说明Definitions and descriptions of charging stations 1.1电池房Battery-Rooms 1.2电池充电站Battery charging stations 2.建筑结构Building construction2.1充电站内的车辆空间Truck place in

2、 charging stations .2.2电池房的空间Place in battery rooms .2.3地板条件Floor condition.3.电气安装Electrical installation 3.1 视在功率Apparent Power .3.2 取暖Heating 4.充电机Charger 5.通风Ventilation 5.1总则General 5.2 根据DIN VDE 0510计算Calculation according DIN VDE 0510.5.3 必要的空闲房屋空间计算Calculation of the necessary free room space

3、.5.4 必要的空气流量计算Calculation of the necessary volume of airflow.5.5 通风结构Construction of a ventilation 6.房屋温度和气候Room temperature and climate 7.加水Water topping 8.搬运电池Battery changing arrangements 8.1起重设备和货车Crane Equipments and changing lorries 9.维护和维修地方Maintenance and repair places10.标记和规定Labels and regu

4、lations 11.急救措施First aid 12.重要的规范和规定Important norms and regulations 1. 充电站的定义和说明Definitions and regulations of charging stations1.1 电池房Battery-Rooms:电池房是一种专门给电池充电和储存电池的房屋，也可以将充电机安装在电池房内。A battery room is a special room for charging and storing batteries, in these rooms also the chargers could be ins

5、talled.1.2 电池充电站Battery charging stations:电池充电站是一种专门房屋，在屋内，可以给装在车辆上的电池充电也可以给1.1所述的电池充电。A battery charging station is a special room for charging batteries which are installed in the trucks and also charging batteries according 1.1.总之先要决定是否应该建立电池房或充电站，大多数情况下两班或三班工作制运行应该有电池房，充电机前放有正常充好电和正在充电的电池。在充电站里，

6、正常情况下装在车辆中的电池和充电机相接，以上两种充电方式都可以放在一间房中。General is to decide if a battery room or a battery charging station should be set up. Mostly a battery room is necessary at a two or three shift operation, normally recharged batteries and batteries under charge stand in front of one charger. In battery chargin

7、g stations normally trucks with installed batteries are connected to the chargers. Also both different versions could be installed in one room.重要的是房屋是否是一个有人负责对电池管理、维护和充电的工作场所。这样必须有专门规定，如：灯光、噪音、温度、气体释放等等，是否还要有附加等候室、清洗室和休息室。Important is if the room is a working place where persons are in charge to opt

8、ain and maintain and change batteries. In this case special regulations for working places are necessary, for example questions about light, noise, temperature, gas-emission and so on, additional waiting rooms, wash rooms and rest rooms had to be installed. 2. 建筑结构Building constructions2.1充电站里的车辆空间T

9、ruck place in charging stations 总则General充电站的平面空间取决于充电站规模和车辆种类，而且根据VDI 2197, 2198 和 2199或国家特殊标准计算车辆进、出和转弯的必备空间。The necessary square meters of charging stations depends in the main part of the kind of charging station and the trucks, also the necessary space for drive in and out and turn around with

10、the trucks must be calculated according the regulation VDI 2197, 2198 and 2199 or special national norms.实际可以用15 m2 计算，重要的是：- 车辆的种类和外形尺寸- 每个车型的车辆数量- 车辆总数量- 充电机的数量和种类- 车辆占据的面积（宽和深）- 车辆高In practice you can calculate with 15 m2 square meters, important are:- kind and largeness of the trucks- quantity o

11、f trucks of each truck type- total quantity of trucks- quantity and type of chargers- the stand square meters of the truck (wide and deep)- high of the truck车辆附加的占地面积，必须将车辆周围空间0.6 m 和充电机到电池间1m的距离计算在内。Additional to the stand square meters of the trucks a necessary space around the truck of 0,6 meters

12、 and a distance charger to battery of 1 meter must be calculated.车辆到充电机和存储的货物之间最小距离：Minimum distances of trucks to chargers and stored goodsa) 车辆周围必备空间necessary space around the truck最少 0,6 meterb) 电池和充电机间必备距离necessary distance between battery and charger最少1 meterc) 到易燃品的必备距离necessary distance to in

13、flammable stored goods最少2,5 meterd) 到易爆品的必备距离 necessary distance to explosive material最少5 meter必备高度(取决于车辆)necessary high of the place (depends of the trucks)最少2 meter充电站的房屋布局Room arrangement at a charging station相对放置的车辆间必备距离应该是车辆转动空间的一半（Wa）加上0.6m (B = Wa + 0,6m) necessary distance between the opposi

14、te placed truck should be the half of the turnBaround space (Wa) of the truck plus 0,6 meter(B = Wa + 0,6m)2.2电池房的空间Place in battery rooms电池充电房的必要面积取决于电池、充电机、起重设备或运输充放电电池的车辆的种类、数量和大小。In battery charging rooms the necessary square meters depends of the quantity and the largeness of the batteries and

15、the chargers and of the kind of crane or the change-wagon to handle the recharged and the discharged batteries实际上，可以用7 m2计算In practice you can calculate with 7 m2每个充电机前必须计算出必备空间， 以放置两个电池加上电池之间最少0.2m的通风空间。In front of each charger the necessary place must be calculated for two batteries plus a distanc

16、e of minimum 0,2 meter between the batteries to have a good ventilation during charge.放电池的托架必须以最重的电池考虑计算，并且与地隔离。Battery banks must be calculated for the heaviest battery and must be isolated against the ground.a充电机前面板到电池的最短距离(a)为0.5m，电池到温度超过200C的加热装置最短距离为2.5m。The minimum distance (a) of the charger

17、front panel to the battery is 0,5 meter and minimum 2,5 meter between battery and heating systems with a temperature more than 200C2.3地板要求Floor conditions地板上应该盖有一层防酸材料压强 8 N/mm抗酸腐蚀抗硫酸H2SO4 (50%)泄漏电阻100 kohm墙泄漏电阻100 kohm (电池周围1.5m。)屋顶抗酸腐蚀抗硫酸t H2SO4 (50%)地板必须有一个最小0.25 m3 坑，其周围斜度为1% 。The floor should b

18、e covered with an acid resistant material:Pressure solidity 8 N/mmAcid solidityagainst H2SO4 (50%)Divert resistance100 kohmWallsDivert resistance100 kohm (only around the place of the batteries (1,5m)RoofsAcid solidityagainst H2SO4 (50%)The floor must have a Gradient of 1% to a pit of minimum 0,25 m

19、33.电气安装Electrical installation总则General按照DIN VDE 0100或专门国家标准或根据充电机供货商的说明进行电气安装，应具有市电电源断路器、为每个充电机安装带慢动作熔丝的电源断路器或电机电路自动空气开关。应该具有通风并规定：只有工作通风时才能充电。The electrical installation is to be done according DIN VDE 0100 or special national norms with a main switch power breaker and each charger with a power br

20、eaker with slow acting fuses or automatic breakers for motor-rated circuits according the technical instructions of the supplier of the chargers. With a ventilation it should be installed a regulation that only with a working ventilation a charge is possible3.1视在功率Apparent power视在功率计算必须包括下列项目：- 充电机-

21、 加热系统- 通风- 照明For the calculation of the apparent power the following components must be included:- chargers- heating systems- ventilation- illumination充电机1到n的视在功率计算：根据供货商的信息，功率P1, P2, .PnP (总功率) = (P1 + P2 + . Pn) x aa = 因数，所有充电机都工作 (一般为 0,8)Calculation of the apparent power of the chargers 1 to n:P

22、ower according the information of the supplier P1, P2, .PnP (total) = (P1 + P2 + . Pn) x aa = factor if all chargers are in function (typical 0,8)对于充电机，效率和功率因数cos phi同样重要，典型计算：充电机技术 / 曲线效率cos phi50Hz-充电机 / Wa, WoWa75%0,750Hz-充电机 / IUIa85%0,7HF-充电机 / IUIa90%0,95For the chargers also the efficiency et

23、a and the power factor cos phi are importanttypical calculationcharge technique / curveetacos phi50Hz-charger / Wa, WoWa75%0,750Hz-charger / IUIa85%0,7HF-charger / IUIa90%0,953.2加热Heating加热功率取决于房屋种类和大小，与充电机和电池的发热成反比。The heating power depends of the kind and largeness of the room it will be decreased

24、 by the heating of the chargers and the batteries. Kn x Qe x LF x n x UmE = - eta x 1000E视在功率apparent power kWhKn额定容量nominal capacity Ah K5Qe放电等级discharge grade %LF充电系数charge factorn单体电池数量number of cellsU中负载电压middle load voltage V/Zeta充电机效率efficiency of the charger1000kWh转换Wh calculation of Wh in kW

25、h充电能量计算例如电池48 V 750 Ah,放电等级 80%充电机输出曲线 WoWa, 负载系数1,2中负载电压 2,4 V/Z效率 80%总能量：64,8 kWh (所有充电机有功功率)消耗的负载能量51,8 kWh损失能量13,0 kWh ( 可用于加热 )Calculation of the charge energyExampleBattery48 V 750 Ah,discharge grade 80%Chargeroutput curve WoWa, load factor1,2middle load voltage 2,4 V/Zefficiency 80%Total ener

26、gy:64,8 kWh (apparent power of all chargers)consumed load energy51,8 kWhLost energy13,0 kWh ( usable for heating )4.充电机Chargers为了选择正确的充电机，必须要知道电池型号、电池种类、额定电压、额定容量和根据工种、单班、两班或三班决定的充电时间。充电机根据外形大小既可以墙上安装也可以地面安装。为了良好通风充电机之间最小0.2m间距很重要。为便于方便操作，应该选择好安装充电机的高度。任何与水有关的安装必须在充电机下面。To select the correct charger

27、s it is necessary to know the battery type, the kind of battery, the nominal voltage, the nominal capacity and the charging time depending of the kind of working, single shift or two, three shift operation.The chargers are either wall mounted or floor mounted depending of the largeness of the charge

28、rs. Important is also a distance between the chargers of minimum 0,2 meter to get a good ventilation of the air. The mounting high should be selected that a good operation with the chargers is possible. Any installation of water must be below the chargers.Example for wall mounted chargers例如，墙上安装充电机：

29、5.通风Ventilation5.1总则 General因为电解液的水分离在电池腔内形成氢氧混合气体，这个过程是在接近电池充电结束时，即电池过充时发生 的，超过过充电压就开始放气阶段。要设计电池充电房和充电站有足够的自然通风，如果需要强迫通风，就应该在始开充电时接通通风装置，进风尽可能的接近地面，经过电池然后尽可能高的从对面排出。A battery cab form a gas mixture of hydrogen and oxygen due to the electrolytic decomposition of water. This gas develops particularly

30、 towards the end of battery charging or if the battery is overcharged. It is at it greatest above the voltage at which gassing starts.Battery charging rooms and battery charging stations shall where possible be designed so that the natural ventilation is sufficient. If artificial ventilation is nece

31、ssary, it shall be ensured that the ventilation is switched on whilst charging is taken place.The inlet air shall enter as close as possible to the ground, pass over the batteries and escape as high as possible on the opposite side.5.2根据DIN VDE 0510 第三部分计算Calculation according DIN VDE 0510 part 3电池充

32、电房和充电站的通风，在充电时要考虑到至少有足够的空气流量Q,Q由以下公式决定：The ventilation of battery rooms and charging stations is regarded as adequate if during charging at least the volume of airflow Q, determined according to the following equation, is guaranteed.Q m/h = v x q x s x n x I这里where:Q空气流量m3/h is a volume of airflow i

33、n m3/hv 稀释系数，氢/空气混合物在较低的爆炸限度时，空气和氢气体积之比(96% 空气/4%氢气 =24)is the dilution factor which is equal to the ratio of the amount by volume of air and hydrogen at the at the lower explosion limit of the hydrogen/air mixture (96% Luft/4%H2 =24)q 氢气体积流量，与一个单体电池在0C 和1013 Pa时电解液Ah每A每 h的电流强度有关is the volumetric fl

34、ow of hydrogen relative to the strength of the current which at 0C and 1013 hPa develops in one cell per A and per h due to electrolysis Ah (0,42E-3 m/h)s安全系数=5（船舶核潜艇=10）safety factor = 5 (ships and submarines = 10)n单体电池数量is the number of cellsI 产生氢气的电流安培数is the current level in A which causes the d

35、evelopment of hydrogen电流I 的指导数Guide values for current ICharging characteristic curve充电特性曲线current level I per 100 Ah nominal capacity 每100Ah额定容量电流IWa- 特性 characteristic(4 A/100Ah)Wsa- 特性 characteristic(6 A/100Ah)WoWa- 特性characteristic(4 A/100Ah)IU- 到2.4V/Z的特性IU-characteristic up to 2,4 V/Z(2 A/100A

36、h)IUI- 特性characteristic(5A/100Ah)IU- 到2.25V/Z的特性IU-characteristic up to 2,25 V/Z1 AQ m/h = 0,05 x n x I A (v x q x s = 0,05 共计 together)5.3 必备的空闲房屋空间计算*Calculation of the necessary free room space *:正常情况下，如果房屋足够大，不必对充电房和充电站加专门通风，公式如下：Normally at battery rooms and charging stations no special ventila

37、tion is necessary if the halls are large enough, the formula is:V = Q x 2,5 m宽wideL:.m伸deep B:.m高high H:.m 体积volume V:.m (L x B x H)*不包含充电机体积、电池体积和其他*brut, without charger-volume, battery-volume and others例如：对具有WoWa特性曲线的充电机：对于这种特性已经计算出每100Ah的电流为4A。Example for a charger with WoWa characteristic:At th

38、ese characteristic the calculation is to be done with a current of 4A for each 100Ah battery capacity所充电池为：Batteries which will be recharged:10 个带有 48 V / 400 Ah的电池电池数量10额定电压48每个电池所含单体电池24总单体电池数240额定容量400放气电流(A/100Ah): 4总放气电流 (A/400Ah):1610 batteries with 48 V / 400 AhQuantity of batteries10Nominal

39、voltage48Number of cells per battery24Total number of cells240Nominal capacity400Gassing current (A/100Ah): 4Total gassing current (A/400Ah):16Q m/h = 0,05 x n x I = 0,05 x 240 x 16 Q= 192 m/h如果用2.5 x Q计算不需要专门的通风，空闲房屋空间要足够大。A free net room space is enough, to work without ventilation, if the calcula

40、tion is done with 2,5 x Q 2,5 x Q = 2,5 x 192 = 480 m对于空闲房屋空间480 m3来说，550 m3充电房足够大。A charging room with 550 m3 is large enough if the free net space is 480m3. 例如，房屋可以选用w x d x h: 10x10x5.5mHall for example w x d x h: 10 x 10 x 5,5 m对于一个充电房内所有电池都要进行这样的计算，即必须加入单个流量：This calculation has to be done for

41、all batteries in a charging room, that means the single volumes of airflow had to be added. 总的Q = Q1.Qn之和 = V Q total = sum Q1.Qn = V空气air空气air空气air空气air5.5空气通风的构成Construction of a ventilation专用电池充电房和充电站。Special for battery rooms and charging stations 6.室温和气候Room temperature and climate(同样见3.2章“取暖”s

42、ee also chapter 3.2 heating)充电站应该具有+10 C到 +25C的室温和干燥环境，以保证充电机和电池寿命。如果这些环境条件不能满足，就要配备一些设备如：对充电机用空调，对电池用加热电缆。设备的供货商可以提供相关信息。A charging station should have a room temperature between +10 and +25C and a dry environment to solve the lifetime of chargers and batteries. Are these climate conditions not to

43、realise so the used equipment had to be fit out for example air condition for the chargers or heating tables for the batteries. For this the supplier of the equipment can give informations.7. 加水Water topping带液态电解液的电池，由于充电时会引起放气过程而失去水分，必须再加水，根据DIN 43530或国标必须加蒸馏水，一般的水会破坏电池。由充电极控制的不需维护的自动加水系统对电池加水有益，在充

44、电结束前的适当时间进行短时加水，电池必须有专门的添满自关闭装置 。自动加水系统的压力应该是：最小 0.2 bar最大1 bar、 2到10米 ， 询问电池供货商有关加水系统的正确计划。Batteries with liquid electrolyte lost water cause of the gassing during charge, this must be refilled. Therefor it must be used distilled water according DIN 43530 or national norms, normal water destroyed t

45、he battery. Automatically water topping systems without any maintain hold good cause controlled by the charger the refilling of water takes place at the correct time shortly before the charge will be finished. Batteries must have special self-closing crams.The pressure of the automatically water topping system should have minimum 0,2 and maximum 1 bar, especially 2 to 10 meter. Ask a battery supplier for the correct planning of a water topping system.8. 搬运电池Battery