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 stations1.1 电池房 Battery-Rooms12 电池充电站 Battery charging stations2. 建筑结构 Building construction2.1 充电站内的车辆空间 Truck pla

2、ce in charging stations2.2 电池房的空间 Place in battery rooms2.3 地板条件 Floor condition3. 电气安装 Electrical installation3.1 视在功率 Apparent Power3.2 取暧 Heating4. 充电机 Charger5. 通风 Ventilation5.1 总贝 ij General5.2 根据 DIN VDE 0510 i 十算 Calculation according DIN VDE 05105.3 必要的空闲房屋空间计算 Calculation of the necessary

3、free room space5.4 必要的空气流量计算 Calculation of the necessary volume of airflow5.5 通风纟吉构 Construction of a ventilation6. 房屋和气候 Room temperature and climate7. 加i水 Water topping8. 搬运电池 Battery changing arrangements8.1 起巫设备和货车 Crane Equipments and changing lorries9. 维护和维修地方 Maintenance and repair places10.

4、 和规定 Labels and regulations11. 急救措施First aid12. 重要的规范和规定 Important norms and regulations1 充电站的定义和说明Definitions and regulations of charging stations1.1电池房Battery-Rooms:电池房於一种专门给电池充电和储存电池的谢屋.也可以将充电机安装在电池沟内。A battery room is a special room for charging and storing batteries, in these rooms also the cha

5、rgers could be in stalle d.12电池充电站Battery charging stations:电池充电站是一种专门房屋.在屋内，可以给裝在车辆匕的电池充电也可以给所述的电池充电.A battery chargi ng stati on is a special room for chargi ng batteries which are in stalled in the trucks and also charg ing batteries according 1 1 总之先要决定圧否应该建立电池功或充电站，大多数借况下两班或三班工作制运行应该有电池房，充电机前放有

6、正常充 好电和正在充电的电池。在充电站里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1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 charg

7、er. In battery charging stations normally trucks with installed batteries are connected to the chargers Also both different versions could be in stalled in one room.朿要的於房屋圧否肚一个冇人负责对电池管理 维护和充电的工作场所.这样必须冇专门规定，如：灯光 噪音、温 度气体释放等等出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

8、are in charge to optain and maintain and change batter ies. 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 constr

9、uctions2.1 充电站里的车辆空间Truck place in charging stations总则Gen eral充电站的平ifii空间取决于充电站规模和车辆种类而冃根据VDI 2197, 2198和2199或国家特殊标准计算车辆进、岀 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

10、and turn around with the trucks must be calculated according the regulation VDI 2197, 2198 and 2199 or special national norms.实际可以用15rp2计算，重耍的足：车辆的种类和外形尺寸毎个车型的车辆数虽车辆总数虽充电机的数試和种类车辆占据的而积（宽和深）车辆髙In practice you can calculate with 15 m2 square meters, important are: kind and largeness of the trucks quan

11、tity of 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，必须将车辆周闱空间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 meter

12、s and a dis- tance 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 goods充电机A charger A充电机B charger B屐少 0,6 meter最!少 1 meter屐少 2,5 metera）车辆周围必备空间necessary space around the truckb）电池和充电机间必备距离necessary distance between battery and

13、charger C）到易燃品的必备距离necessary distance to inflammable stored goods d）到易爆品的必备距离 necessary distanee to explosive material必备髙度（取决于车辆）necessary high of the place （depends of the trucks）最!少 5 meter屐少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)0.6m(B = Wa + 0,6ni)necess

14、ary distance between the opposite placed truck should be the half of the turn around 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祇设备或运输充放电电池的车辆的种类数戢和大小.In battery charging rooms the necessary square meters depends of the quantity and the

15、largeness of the batteries and 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毎个充电机前必须计算出必备空间，以放宣两个电池加上电池Z间協少0.2m的通风空间。In front of each charger the necessary place must be calculated fo

16、r two batteries plus a distanee of minimum 0,2 meter between the batteries to have a good ventilation during charge 放电池的托架必须以粧重的电池考虑计算，并R与地隔离。Battery banks must be calculated for the heaviest battery and must be isolated against the ground.充电机前而板到电池的啟短距离(a)为0.5m 电池到遛度超过200 C的加热装置屐短距离为2.5mcThe minimu

17、m distari8 (a) of the charger front panel to the battery is 0t5 meter and minimum 2t5 meter be tween battery and heating systems with a temperature more than 200 C2.3地板要求Floor conditions地板匕应该盖有层助酸材料乐强抗酸腐蚀 泄混电阻 绝缘附抗 8 N/mm抗硫酸 H2SO4 (50%)100 kohm墙泄漏电阻绝缘阻抗100 kohm(电池周围 1.5m)屋顶一抗 酸腐辿抗硫酸 t H2SO4 (50%)地板必

18、须有一个昴小0.25亦坑！ 嗣鬧斜度为1%。The floor should be covered with an acid resista nt material:Pressure solidity 8 N/mmAcid solidity against H2SO4 (50%) 100 kohm100 kohm (only around the place of the batteriesRoofsAcid solidityagainst H2SO4 (50%)3. 电气安装Electrical installation总则Gen eral按照DIN VDE 0100或& 门国家标准或根据充

19、电机供货商的说明进行电安装，应具有市电电源断路器、为毎个充 电 机安装带慢动作熔丝的电源断路器或电机电路H动空气开矢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 breaker withslow acting fuses or automatic breakers for motor-rate

20、d 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卜列项冃:充电机加热系统通风照明For the calculati on of the appare nt power the following com

21、p onents must be in eluded: chargers heating systems ven tilatio n illuminatio n充电机1到n的视在功率计算：根据供货商的信息功率P1.P2PnP (总功率)二(P1 + P2 + . Pn) x aa二因数，所有充电机都工作(般为0,8)Calculation of the apparent power of the chargers 1 to n:Power according the information of the supplier Pit P2. Pn P (total) = (P1 +P2 + . P

22、n)xaa = factor if all chargers are in function(typical 0.8)对于充电札效率和功率因数COS phi同样重要典型计算脣充电机技术/曲线效率cos phi50Hz-充电机 /Wa, WoWa75%0.750Hn充电机/lUla85%07HF -充电机/lUla90%0,95For the chargers also the efficiency eta and the power factor cos phi are importard typical calculationcharge technique / curveetacos ph

23、i50Hz-charger / Wat WoWa75%D.750Hz-charger / lUla85%D.7HF-charger/ lUla90%0t953.2 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 by the heating of the chargers and the batteries.充电能呈计算例如 电池48 V 750 Ah,放电等级80%输出充电机曲线WoWa,负载系

24、数1.2中负载总能虽：电压2,4 V/Z效率80%64.8 kWh （所自充电机有功功，消耗的负载能戢51.8 kWh损失能虽13t0 kWh （可用于加热）Calculation of the charge energyKii x Qe x LF x n x Um 匸一eta x 1000E视在功率 appaient power kWhKii额定容磧 nonunal capacity All K5Qe放电等级 discliaige grade %LF充电系数 charge factorn单体电池数虽numbei of cellsI】中负载电压 middle load voltage V/Ze

25、ta允电机效率 efficiency of the chaigei1000 kWh 转换 wh calculation of Wh m kWhExampleBattery ChargerTotal energy:8nsumed load energy Lost en ergy48 V 750 Ah, discharge grade 80%output curve WoWa, load factorl ,2 middle load voltage 2.4 V/Z efficiency 80%64.8 kWh (apparent power of all chargers)51.8 kWh13t0

26、 kWh ( usable for heating )4. 充电机Chargers为了选择正确的充电机，必须要知道电池空号、电池种类、额定电乐额定容就和根据工种、单班、两班或三班决 定 的充电时间.充电机根括外形大小既町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间跑很朿要。为便丁方便操作，应该选择好安装充电机的高度。任何与水有矢的安載必须在充电机卜面。To select the correct chargers it is necessary to know the battery type, the kind of battery, the nominal voltage,

27、 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 chargers Important is also a distanee between the chargers of minimum 0.2 meter to get a go

28、od 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电线M cable canalExample for wall mounted chargers 例如.焙上安装充电机：通风 Ventilation5.1 总则 General 因为电解液的水分离在电池胶内形成氢氧混合气体这个过程是在接近电池充电结朿时即电池过充时

29、发生的，超过过 充电乐就开始放气阶段要设计电池充电功和充电站有足够的门然通风如果需契强迫通风就应该在始开充电时接通通凤装宣进风尽可能的接 近地面经过电池然后尽可能高的从对面排岀A battery cab form a gas mixture of hydrogen and oxygen due to the electrolytic decomposition of wa 怕 r. This gas develops particularly towards the end of battery chargi ng or if the battery is overcharged .It is

30、 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 ventila- tion is sufficie nt. If artificial ventilatio n is necessary .it shall be ensured that the ventilati on is switched on whilst c

31、harging is taken place The inlet air shall enter as close as possible to the ground, pass ever 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戢Q.Q由以下公式决定：The ventilation of battery rooms

32、and charging stations is regarded as adequate if during charging at least the volumeof airflow Q, determined according to the following equation, is guaranteed Q m /h = v x q x s x nxl 这里 where:Q空气流虽m3/his a volume of airflow in 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 facto

33、r which is equal to the ratio of the amount by volume of air and hydrogen at the at the lower explosion limit of the hydro gen/air mixture (96% Luft/4%H2 =24)q氢气体积流虽与一个单体电池ZF 0 C和1013 Pa时电解液Ah毎A毎h的电流強度育矢is the volumetric flow of hydroge n relative to the strength of the cur re nt which at 0 C and 10

34、13 hPa develops in one cell per A and per h due to electrolysis Ah (0,42E-3 m Zh)S安全系数=5 (船舶核潜f=10)safety factor = 5 (ships and submarines = 10)n单体电池数虽is the number of cellsI产生氢气的电流安培数is the current level in A which causes the development of hydrogen电流工的指导数Guide values for current ICharging characte

35、ristic curve 充电特性曲线current level 1 per 100 Ah nominal capacity 每 100Ah额定容量电流IWa特性 characteristic(4 A/100Ah)Wsa待性 characteristic(6A/100Ah)WoWa特,性 characteristic|(4 A/100Ah)IU到 2.4V/Z 的特性 lU-characteristic up to 2,4 V/Z(2 A/100Ah)IUI特性 characteristic(5A/100Ah)IU 到 2.25V/Z 的特性 lU-characteristic up to2,

36、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 *:正常请况下，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 chargi ng stations no special ventilation is necessary if the halls are large eno ugh, the formula is:V = Q x

37、2,5 m宽wideL:m m高 high H:.m体枳 volume V: m (L x B x协不包含充电机体积、电池体积和其他Prut, without charger-volume, battery-volume and others例如：对具WoWa特性曲线的充电机：对干这种特性已经计篦出毎100Ah的电流为4A。Example for a charger with WoWa characteristic:At these characteristic the calculation is to be done with a current of 4A for each 100Ah

38、battery capacity所充电池为：Batteries which will be recharged:10个带有48 V / 400 Ah的电池电池数虽10额定电压48每个电池所倉单休电池24总单体电池数240额定容虽400放气电流(A/100Ah):4总放气电流(AMOOAh):1610 batteries with 48 V / 400 AhQuantity of batteries10Nominal voltage48Number of cells per battery24Total number of cells240Nominal capacity400Gassing c

39、urrent (A/100Ah):4Total gassing current (A/400Ah):16Q m /h=0,05 x n x I=0,05 x 240 x 16=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 n et room space is eno ugh, to work without ventilation, if the calculati on is done with 2,5 x Q2.5x0 = 2,5x192 = 480 m对于空闲房屋空间480 m3来说，550 m3充电房足够大.A chargi ng room

40、 with 550 m3 is large eno ugh if the free net space is 480m3.例如，房屋可以选用wxd xh: 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，即必须加入单个流呈：This calculation has to be done for all batteries in a charging room, that means the single volumes of airflow had to be added.总的Q = Q1.Q

41、n之和二VQ total = sum Q1 .Qn = V5.5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空气6.室温和气候Room temperature and climate（同样见 3.2 说“取暧see also chapter 3.2 力eating）充电站应该具有TO C到+25 C的室温和F慄环境以保证充电机和电池与命。如果这些环境条件不能満足.就要配备 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矢信息。A c

42、harging station should have a room temperature between +10 and +25 C and a dry environment to solve the lifetime of chargers and batteries Are these climate conditions not to realise so the used equipment had to be fit out for example air condition for the chargers or heating tables for th batteries

43、 For this the supplier of th equipment can give informations.7.加水Water toppi ng带液态电解液的电池.山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或国标必须加蒸懾水，般 的水会破坏电池。由充电极控制的不需维护的门动加水系统对电池加水有益在充电结束前的适当时间进行短时加水电池必须有专门的 添满自矢闭装置门动加水系统的压力应该肚：最小0.2 bar大Ibar、2到10米，询问电池供货商有矢加水系统的正确计划。Batteries with liquid electrolyte lost water ca

44、use 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 the battery.Automatically water topping systems without any maintain hold good cause 8ntrolled 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