叉车充电站设计

'液态铅酸电池充电站计划PlaningofchargingstationsforliquidacidPb-batteries厦门叉车有限公司Linde-XiamenForkLiftTruckCo.,Ltd2002.11 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划2目录Content1.充电站的定义和说明Definitionsanddescriptionsofchargingstations..................1.1电池房Battery-Rooms.....................................................................................................1.2电池充电站Batterychargingstations..............................................................................2.建筑结构Buildingconstruction....................................................................................2.1充电站内的车辆空间Truckplaceinchargingstations...................................................2.2电池房的空间Placeinbatteryrooms.............................................................................2.3地板条件Floorcondition................................................................................................3.电气安装Electricalinstallation.....................................................................................3.1视在功率ApparentPower...........................................................................................3.2取暖Heating....................................................................................................................4.充电机Charger...............................................................................................................5.通风Ventilation..............................................................................................................5.1总则General....................................................................................................................5.2根据DINVDE0510计算CalculationaccordingDINVDE0510....................................5.3必要的空闲房屋空间计算Calculationofthenecessaryfreeroomspace......................5.4必要的空气流量计算Calculationofthenecessaryvolumeofairflow............................5.5通风结构Constructionofaventilation.............................................................................6.房屋温度和气候Roomtemperatureandclimate.........................................................7.加水Watertopping........................................................................................................8.搬运电池Batterychangingarrangements...................................................................8.1起重设备和货车CraneEquipmentsandchanginglorries...............................................9.维护和维修地方Maintenanceandrepairplaces..........................................................10.标记和规定Labelsandregulations..............................................................................11.急救措施Firstaid...........................................................................................................12.重要的规范和规定Importantnormsandregulations..................................................2/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划31.充电站的定义和说明Definitionsandregulationsofchargingstations1.1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。Abatteryroomisaspecialroomforchargingandstoringbatteries,intheseroomsalsothechargerscouldbeinstalled.1.2电池充电站Batterychargingstations: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。Abatterychargingstationisaspecialroomforchargingbatterieswhichareinstalledinthetrucksandalsocharg-ingbatteriesaccording1.1.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，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。Generalistodecideifabatteryroomorabatterychargingstationshouldbesetup.Mostlyabatteryroomisnecessaryatatwoorthreeshiftoperation,normallyrechargedbatteriesandbatteriesunderchargestandinfrontofonecharger.Inbatterychargingstationsnormallytruckswithinstalledbatteriesareconnectedtothechargers.Alsobothdifferentversionscouldbeinstalledinoneroom.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。Importantisiftheroomisaworkingplacewherepersonsareinchargetooptainandmaintainandchangebatter-ies.Inthiscasespecialregulationsforworkingplacesarenecessary,forexamplequestionsaboutlight,noise,temperature,gas-emissionandsoon,additionalwaitingrooms,washroomsandrestroomshadtobeinstalled.2.建筑结构Buildingconstructions2.1充电站里的车辆空间Truckplaceinchargingstations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VDI2197,2198和2199或国家特殊标准计算车辆进、出和转弯的必备空间。Thenecessarysquaremetersofchargingstationsdependsinthemainpartofthekindofchargingstationandthetrucks,alsothenecessaryspacefordriveinandoutandturnaroundwiththetrucksmustbecalculatedac-cordingtheregulationVDI2197,2198and2199orspecialnationalnorms.2实际可以用15m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2Inpracticeyoucancalculatewith15msquaremeters,importantare:3/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划4-kindandlargenessofthetrucks-quantityoftrucksofeachtrucktype-totalquantityoftrucks-quantityandtypeofchargers-thestandsquaremetersofthetruck(wideanddeep)-highofthetruck车辆附加的占地面积，必须将车辆周围空间0.6m和充电机到电池间1m的距离计算在内。Additionaltothestandsquaremetersofthetrucksanecessaryspacearoundthetruckof0,6metersandadis-tancechargertobatteryof1metermustbecalculated.车辆到充电机和存储的货物之间最小距离：Minimumdistancesoftruckstochargersandstoredgoods充电机A充电机BchargerchargerABbbrennbareGegenstände,易燃品inflammablegoodsz.B.eingelagerteWarec车辆A车辆BtruckAtruckBStellplatzAStellplatzBaaafeuer-,adexplosions易爆品-oderexplosivegoodsexplosivstoff-gefährdeteBereichea)车辆周围必备空间necessaryspacearoundthetruck最少0,6meterb)电池和充电机间必备距离necessarydistancebetweenbatteryandcharger最少1meterc)到易燃品的必备距离necessarydistancetoinflammablestoredgoods最少2,5meterd)到易爆品的必备距离necessarydistancetoexplosivematerial最少5meter必备高度(取决于车辆)necessaryhighoftheplace(dependsofthetrucks)最少2meter充电站的房屋布局4/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划5Roomarrangementatachargingstation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)necessarydistancebetweentheoppositeplacedtruckshouldbethehalfoftheturnaroundspace(Wa)ofthetruckplus0,6meter(B=Wa+0,6m)B2.2电池房的空间Placeinbatteryrooms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。Inbatterychargingroomsthenecessarysquaremetersdependsofthequantityandthelargenessofthebatteriesandthechargersandofthekindofcraneorthechange-wagontohandletherechargedandthedischargedbat-teries2实际上，可以用7m计算2Inpracticeyoucancalculatewith7m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。Infrontofeachchargerthenecessaryplacemustbecalculatedfortwobatteriesplusadistanceofminimum0,2meterbetweenthebatteriestohaveagoodventilationduringcharge.放电池的托架必须以最重的电池考虑计算，并且与地隔离。Batterybanksmustbecalculatedfortheheaviestbatteryandmustbeisolatedagainsttheground.a5/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划6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200°C的加热装置最短距离为2.5m。Theminimumdistance(a)ofthechargerfrontpaneltothebatteryis0,5meterandminimum2,5meterbe-tweenbatteryandheatingsystemswithatemperaturemorethan200°C2.3地板要求Floorconditions地板上应该盖有一层防酸材料压强>8N/mm²抗酸腐蚀抗硫酸H2SO4(50%)8泄漏电阻<10ohm绝缘阻抗>100kohm墙8泄漏电阻<10ohm(电池周围1.5m。)绝缘阻抗>100kohm(电池周围1.5m。)屋顶抗酸腐蚀抗硫酸tH2SO4(50%)3地板必须有一个最小0.25m坑，其周围斜度为1%。Thefloorshouldbecoveredwithanacidresistantmaterial:Pressuresolidity>8N/mm²AcidsolidityagainstH2SO4(50%)8Divertresistance<10ohmIsolationresistance>100kohmWalls8Divertresistance<10ohm(onlyaroundtheplaceofthebatteries(1,5m)Isolationresistance>100kohm(onlyaroundtheplaceofthebatteries(1,5m)RoofsAcidsolidityagainstH2SO4(50%)3ThefloormusthaveaGradientof1%toapitofminimum0,25m3.电气安装Electricalinstallation总则General按照DINVDE0100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。TheelectricalinstallationistobedoneaccordingDINVDE0100orspecialnationalnormswithamainswitchpowerbreakerandeachchargerwithapowerbreakerwithslowactingfusesorautomaticbreakersformotor-ratedcircuitsaccordingthetechnicalinstructionsofthesupplierofthechargers.Withaventilationitshouldbeinstalledaregulationthatonlywithaworkingventilationachargeispossible3.1视在功率Apparentpower视在功率计算必须包括下列项目：-充电机-加热系统-通风-照明6/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划7Forthecalculationoftheapparentpowerthefollowingcomponentsmustbeincluded:-chargers-heatingsystems-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)xaa=因数，所有充电机都工作(一般为0,8)Calculationoftheapparentpowerofthechargers1ton:PoweraccordingtheinformationofthesupplierP1,P2,....PnP(total)=(P1+P2+...Pn)xaa=factorifallchargersareinfunction(typical0,8)对于充电机，效率和功率因数cosphi同样重要，典型计算：充电机技术/曲线效率cosphi50Hz-充电机/Wa,WoWa75%0,750Hz-充电机/IUIa85%0,7HF-充电机/IUIa90%0,95Forthechargersalsotheefficiencyetaandthepowerfactorcosphiareimportanttypicalcalculationchargetechnique/curveetacosphi50Hz-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。Theheatingpowerdependsofthekindandlargenessoftheroomitwillbedecreasedbytheheatingofthechargersandthebatteries.KnxQexLFxnxUmE=-----------------------------------etax1000E视在功率apparentpower[kWh]Kn额定容量nominalcapacity[AhK5]Qe放电等级dischargegrade[%]LF充电系数chargefactorn单体电池数量numberofcellsU中负载电压middleloadvoltage[V/Z]eta充电机效率efficiencyofthecharger1000kWh转换Whcalculationof[Wh]in[kWh]充电能量计算例如电池48V750Ah,放电等级80%充电机输出曲线WoWa,负载系数1,2中负载电压2,4V/Z效率80%总能量：64,8kWh(所有充电机有功功率)消耗的负载能量51,8kWh损失能量13,0kWh(可用于加热)Calculationofthechargeenergy7/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划8ExampleBattery48V750Ah,dischargegrade80%ChargeroutputcurveWoWa,loadfactor1,2middleloadvoltage2,4V/Zefficiency80%Totalenergy:64,8kWh(apparentpowerofallchargers)consumedloadenergy51,8kWhLostenergy13,0kWh(usableforheating)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。Toselectthecorrectchargersitisnecessarytoknowthebatterytype,thekindofbattery,thenominalvoltage,thenominalcapacityandthechargingtimedependingofthekindofworking,singleshiftortwo,threeshiftopera-tion.Thechargersareeitherwallmountedorfloormounteddependingofthelargenessofthechargers.Importantisalsoadistancebetweenthechargersofminimum0,2metertogetagoodventilationoftheair.Themountinghighshouldbeselectedthatagoodoperationwiththechargersispossible.Anyinstallationofwatermustbebelowthechargers.Exampleforwallmountedchargers例如，墙上安装充电机：Kabelkanal电线槽cablecanalCEE32CEE1669LG-Typ1SchukoLG0Typ2mm1800553mmmm>500mm100mm保护斜坡protectionramp8/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划95.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。Abatterycabformagasmixtureofhydrogenandoxygenduetotheelectrolyticdecompositionofwater.Thisgasdevelopsparticularlytowardstheendofbatterychargingorifthebatteryisovercharged.Itisatitgreatestabovethevoltageatwhichgassingstarts.Batterychargingroomsandbatterychargingstationsshallwherepossiblebedesignedsothatthenaturalventila-tionissufficient.Ifartificialventilationisnecessary,itshallbeensuredthattheventilationisswitchedonwhilstchargingistakenplace.Theinletairshallenterascloseaspossibletotheground,passoverthebatteriesandescapeashighaspossi-bleontheoppositeside.5.2根据DINVDE0510第三部分计算CalculationaccordingDINVDE0510part3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量Q,Q由以下公式决定：TheventilationofbatteryroomsandchargingstationsisregardedasadequateifduringchargingatleastthevolumeofairflowQ,determinedaccordingtothefollowingequation,isguaranteed.Q[m³/h]=vxqxsxnxI这里where:3Q空气流量m/h3isavolumeofairflowinm/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)isthedilutionfactorwhichisequaltotheratiooftheamountbyvolumeofairandhydrogenattheatthelowerexplosionlimitofthehydrogen/airmixture(96%Luft/4%H2=24)q氢气体积流量，与一个单体电池在0°C和1013Pa时电解液Ah每A每h的电流强度有关isthevolumetricflowofhydrogenrelativetothestrengthofthecurrentwhichat0°Cand1013hPadevelopsinonecellperAandperhduetoelectrolysisAh(0,42E-3m³/h)s安全系数=5（船舶核潜艇=10）safetyfactor=5(shipsandsubmarines=10)n单体电池数量isthenumberofcellsI产生氢气的电流安培数isthecurrentlevelinAwhichcausesthedevelopmentofhydrogen电流I的指导数GuidevaluesforcurrentIChargingcharacteristiccurvecurrentlevelIper100Ahnominalcapacity充电特性曲线每100Ah额定容量电流IWa-特性characteristic(4A/100Ah)Wsa-特性characteristic(6A/100Ah)WoWa-特性characteristic(4A/100Ah)IU-到2.4V/Z的特性(2A/100Ah)IU-characteristicupto2,4V/ZIUI-特性characteristic(5A/100Ah)IU-到2.25V/Z的特性1AIU-characteristicupto2,25V/Z9/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划10Q[m³/h]=0,05xnxI[A](vxqxs=0,05共计together)5.3必备的空闲房屋空间计算*Calculationofthenecessaryfreeroomspace*: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：Normallyatbatteryroomsandchargingstationsnospecialventilationisnecessaryifthehallsarelargeenough,theformulais:V=Qx2,5m³宽wideL:.........m伸deepB:........m高highH:........m体积volumeV:........m³(LxBxH)*不包含充电机体积、电池体积和其他*brut,withoutcharger-volume,battery-volumeandothers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。ExampleforachargerwithWoWacharacteristic:Atthesecharacteristicthecalculationistobedonewithacurrentof4Aforeach100Ahbatterycapacity所充电池为：Batterieswhichwillberecharged:10个带有48V/400Ah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):1610batterieswith48V/400AhQuantityofbatteries10Nominalvoltage48Numberofcellsperbattery24Totalnumberofcells240Nominalcapacity400Gassingcurrent(A/100Ah):4Totalgassingcurrent(A/400Ah):16Q[m³/h]=0,05xnxI=0,05x240x16Q=192m³/h如果用2.5xQ计算不需要专门的通风，空闲房屋空间要足够大。10/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划11Afreenetroomspaceisenough,toworkwithoutventilation,ifthecalculationisdonewith2,5xQ2,5xQ=2,5x192=480m³33对于空闲房屋空间480m来说，550m充电房足够大。33Achargingroomwith550mislargeenoughifthefreenetspaceis480m.例如，房屋可以选用wxdxh:10x10x5.5mHallforexamplewxdxh:10x10x5,5m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：Thiscalculationhastobedoneforallbatteriesinachargingroom,thatmeansthesinglevolumesofairflowhadtobeadded.总的Q=Q1..Qn之和=VQtotal=sumQ1..Qn=V5.5空气通风的构成Constructionofaventilation专用电池充电房和充电站。Specialforbatteryroomsandchargingstations空气air空气air空气air空气air6.室温和气候Roomtemperatureandclimate(同样见3.2章“取暖”seealsochapter3.2heating)充电站应该具有+10°C到+25°C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。Achargingstationshouldhavearoomtemperaturebetween+10and+25°Candadryenvironmenttosolvethelifetimeofchargersandbatteries.Aretheseclimateconditionsnottorealisesotheusedequipmenthadtobefitoutforexampleairconditionforthechargersorheatingtablesforthebatteries.Forthisthesupplieroftheequipmentcangiveinformation’s.7.加水11/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划12Watertopping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DIN43530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0.2bar最大1bar、2到10米，询问电池供货商有关加水系统的正确计划。Batterieswithliquidelectrolytelostwatercauseofthegassingduringcharge,thismustberefilled.ThereforitmustbeuseddistilledwateraccordingDIN43530ornationalnorms,normalwaterdestroyedthebattery.Automaticallywatertoppingsystemswithoutanymaintainholdgoodcausecontrolledbythechargertherefillingofwatertakesplaceatthecorrecttimeshortlybeforethechargewillbefinished.Batteriesmusthavespecialself-closingcrams.Thepressureoftheautomaticallywatertoppingsystemshouldhaveminimum0,2andmaximum1bar,especially2to10meter.Askabatterysupplierforthecorrectplanningofawatertoppingsystem.8.搬运电池Batterychangingarrangements8.1起重设备，运输车辆CraneEquipments,changinglorries根据电池重量、数量和大小决定起重设备，运输车辆，相关计划询问专门供货商。Alsofortheplanningofacraneequipmentorchanginglorriesaspecialsupplierhadtobeasked,thisequipmentdependsofthequantityofbatteriesandthelargenessandweightofthebatteries.9.维护和维修场所Maintenanceandrepairplaces必须定期检查和清洁电池，同样根据DIN0510每年必须检查绝缘阻抗，如果阻抗太低，电池就要清洗。维护和维修场所必须用防酸材料与其他充电房隔离。见2.3项地板要求，同样大型充电站应该有专门的维修电池的场所，同时还有对电池充放电的充电机。Batteriesmustcleanedandcheckedperiodically,alsotheisolationresistantmustcheckedeachyearaccordingDIN0510,istheresistanttoolessthebatteryshouldbewashed.Thisplacemustbeseparatedoftherestcharg-ingroombyacidresistancematerial,seealsopoint2.3floorconditions.Atlargechargingstationsalsoaspecialplaceshouldbeinstalledtorepairbatteriesequippedwithaspecialchargertodischargeandrechargethebatter-ies.10.标识和规定Labelsandregulations单个充电场所应该有以下标识Singlechargingplacesshouldbelabelledwithfollowinglabels:电池危险警告严禁吸烟明火WarningofdangerofthebatteryProhibitionoffireopenlightandsmoking11.急救措施12/13 PlaningofchargingstationsforliquidacidPb-batteries液态铅酸电池充电站计划13Firstaid对于由硫酸引起的事故，下面设备必须放在充电场所易见、易拿的地方。Foraccidentswithacidthefollowingequipmentshouldbeplacedgoodvisibleandeasyreachablenearbythechargingplace.急救箱Firstaidcase紧急冲洗Emergencyshower洗眼站Eyewashingstation灭火器Fire-extinguisherAcidbindingagent12.重要标准和规定ImportantnormsandregulationsVDI2197,2198,2199DINVDE0100DINVDE0510part3AGIJ31part2andpart3VDI3616ZVEI-norms13/13'