“Өү энд Өү Си Эйч” ХХК

CRANE BASIC
KNOWLEDGE

CRANE BASIS ENZHI LI 2008

 Contents

What is crane?
Crane type
Basic mechanics
theory
Crane components
Power supply
Electric controls
 What is crane?
Crane definition ：
Crane is one kind of facility which are used for lifting,
moving, load or unloading object or material.
Crane type (according utilization )
Crane type (according to form)
Process crane and standard crane
Standard crane Types

Crane : A machine for lifting and lowering a load and moving it horizontally, with
the hoisting mechanism as an integral part of the machine.

Pole jib crane

EOT double girder crane

EOT single girder crane XM

Properties

Crane general properties

Lifting height
 Properties

Crane general properties and terms

• EOT = Electronic Overhead Travelling

Cranes
• WRH = Wire Rope Hoist
• ECH = Electronic Chain Hoist
• Nominal capacity (tons)
• Crane span = dimension measured from
middle of a crane railway to another
railway
• Height of lift (HOL) = dimension from
floor to highest hook position
• C-dimension, dimension from hook to
hoist fixing point (travelling wheel
Main girder track
surface, or fixed fixing point) C C
Main girder
• Hoisting speed = m (ft)/min flange
• Cross travelling speed = m (ft)/min for
trolley on a main girder
• Long travelling speed = m (ft)/min
 Industrial Cranes

ndard crane is a predesigned crane, extended with options and predefined applications .

Konecranes Standard Lifting Konecranes Heavy Lifting

Condition
monitoring Outdoor use

Load display Steel warehouses

Remote controls Galvanizing plants

industrial crane options applications process crane

Duty
Environment
Industrial Cranes

Single girder crane is an overhead travelling crane with one main girder.

Top Running Single Girder Cranes

I-beam (profile) type main girder

 Spans up to 18 m (59 ft)
 Loads up to 10 Tons

Box type main girder

 Spans up to 30 m (98 ft)
 Loads up to 40 Tons

Under Running Single Girder Cranes

 Spans up to 22 m (72 ft) 1 main girder
 Loads up to 12,5 Tons
 Industrial Cranes

ouble girder crane is an overhead travelling crane with two

ain girders.

 Spans up to 30 m (98 ft)

 Loads up to 80 Tons

2 main girders
Gantry Cranes

Gantry crane is an overhead travelling crane,

where the track is on the ground and the main
girder is on top of legs!

 Hoist and hoist power supply are as in

standard cranes

 Maximum load 30 tons

 Maximum crane span 20 m (65 ft)

 Maximum height from ground to main

girder 8 m (59 ft)

 As a standard for indoor use, as a special

for outdoors main girder
hinge
joint leg solid leg

end carriage
runway
Gantry Cranes

Hinge joint
Gantry cranes have a hinge joint in the other
end of the main girder.

Purpose

 Deflection of the main girder causes torque

to the legs that is avoided with hinge joint. Maximum load

 This affects also to dimensioning of the leg

 Prevents wearing of drive mechanism

Main girder deflection

Hinge joint Torque
Semi Gantry Cranes

Semi gantry crane is an overhead travelling

crane, where one end carriage runs on a track
which is mounted on a wall while the other
one is on a track on the ground.

 Hoist and hoist power supply are as in

standard cranes

 Maximum load 30 tons

 Maximum crane span 20 m (65 ft)

 Maximum height from ground to main

girder 8 m
runway
leg
 As a standard for indoor use, as a
special for outdoors
runway
 Does not need hinge joint
 Workstation Cranes

Workstation cranes are chain hoist based light lifting solutions.

Pillar jib cranes

9
XPCO
8 XICU

7
m

4
125 250 500 1000 1500 2000
Hollow Profile or I-profile
kg

Wall jib cranes X P C O

9
XPWO
XIWU Column or Wall jib
8
Over braced or
m

Under braced
7

6
125 250 500 1000 1500 2000
kg
 Workstation Cranes

Single girder bridge crane (XMS)

 articulated construction
 rigid construction
 low headroom construction

aximum load and span, single girder (XMS) and double girder (XMD)

16000

14000

12000

10000 Articulated trolley does

XMS
not have this support
mm 8000
XMD

6000

4000

2000

0
125 160 250 320 500 630 800 1000 1250 1600 2000
kg
Rigid construction Low headroom
Workstation Cranes

Double girder bridge crane

(XMD)

 articulated construction
 rigid construction
 low headroom construction

Articulated trolley does

not have this support

Rigid construction Low headroom

 Workstation Cranes

Monorail Crane
 Maximum load 2 tons
 Hoist moves on a monorail profile track, curved or straight

Profile types
Profile size increases with the load increase.
Same profiles are used also in single girder and double girder bridge cranes

UKA20 UKA30 UKA40

Basic mechanics theory

Gravity force

F=m*a

F = The force of the load [N]

m = The mass of the load [kg]

a = The acceleration of free fall [9.81m/s2 (32,18 ft/s2 )]

Basic force theory

Tension stress

Force
Force
Tension stress =
Cross-sectional area

Crossectional
area

=
F
A
Force
Basic force theory

Shear stress

Shear stress =
F ____Force_______

A Cross-sectional area
Basic force theory

Mass of the main girders and the trolley

A B

Mass of the load

Basic force theory

Compression / tension
F
Compression

Neutral center axis

F
Tension
Basic force theory

F Twist
Force distribution

F = Weight of load and trolley

Basic force theory

Force distribution

Trolley rail – web plate point

<- Rail

<- Web plate

Basic force theory

Maximum allowed deflection

y = L / 500

y = deflection due to SWL (Safe

Working Load) + Trolley mass

L = the span of the crane

In elasticity range
Main girders

Types of main girders

Box girder

I – Beam
Main girders

Main parts of an I-beam

Main girders

F
Operation of the
diaphragms

diaphragm
Main girders

The camber

To compensate the
deflection and to R = 2000 m
make sure that the trolley
does not need to travel up-
or down hills on the main
girder.
Main girders

Main girder stress calculation

True load

Static loads Dynamic loads Wind loads Earth quake

Gravity forces Crane movement

True stress
=
Calculated stress
Main girders

Main girder dimensioning

Calculated stress

Elastic limit Breaking limit bending Fatigue

True main girder dimensions

Crane Components

Hoist End Carriage

Main Girder

Power Supply

Pendant Controller
Travelling Machinery
 Main Girder

Main girder is a track for hoist trolley.

Girder types:

• Box girders are mainly used for top running

(double girder) trolley types, longer beams or
higher loads.

• I-beam girders are mainly used for underrunning

(normal headroom and low headroom) trolley
types, shorter spans or lower loads.

Top running Under hanging

I-Beam Main Girder

The I-beams of the IPE/INP type are mostly used in

single girder cranes with chain hoists.

HEB, HEA –type are usually used in double girder

cranes or single girder cranes with low headroom
hoists.

IPN + U –beam is more ridig than a simple I-beam.

Box-Type Main Girder

Diaphragms
Stiffeners

Rail

Top and
bottom
flange
Web- or
side plate
 End Carriages

End carriages travel the crane on the runway.

 Top Running End Carriages

op running end carriages drive on top of runway.

Joint plate

nd carriage types:

 2 wheel end carriages Fixing for crane

 4 wheel end carriages (bogie type) towing arm

Buffer
2-wheel end carriage

Wheel
diameter Derailment support

Wheel groove
4-wheel (bogie) end carriage
 Underrunning End Carriages

derslung end carriages drive on the bottom flange of runway beam.

Wheel sets
(idle)
derrunning = Underslung = Underhanging
Wheel sets
d carriage types: (driving)

4-wheel end carriages

Buffer

Wheel Main girder connection

diameter

Flange width
 Joint Types

int is a connection between main girder and end carriage.

Top running end carriages

Top connection, standard Top connection, medium

Side connection standard low Side connection, standard Side connection low
 Joint Types

Underslung end carriages

Standard connection Medium connection High connection

Joint Plates
• Joint plates are plates that are used between end carriage
and main girder
• Plates are welded to main girder and connected to end
carriage with bolts.
• Joint plates are used to increase crane capacity,
strengthen the connection.
Travelling Machineries

Travelling machinery is an electric drive unit

which is used to move the the load in
horizontal cross movements.
Components

 Gear box case

 Transmission parts
- Gear shafts (primary, intermediate and
secondary shafts)
- Gear wheels
- Bearings
 Motor and brake
- Brake can be a compact brake or DC
brake
Series

 ECH trolley drive (TMU); two sizes, two gear ratios

 WRH trolley drive (GEK); one frame size, one gear ratio
 Crane and WRH D-trolley drive (GES); three frame sizes, 4
gear ratios per frame size
 All gears are grease lubricated
Power Supply
Hoist Power Supply

Hoist power supply is a complex system which is

designed for controlling hoist or crane
movements.

 System is made by using mechanical and

electrical components in different

configurations according customer needs.
 Main power is supplied to machines (hoist,
crane) via cables (flat or round).
 Control signals for movements (hoisting,
moving) are supplied via separate cables.
 Limiting devices (limit switches, safety
devices) are also supplied via same system.
Hoist Power Supply

Flat cables and cable

trolleys
 Main power and control signals are

transported via flat cables between bridge

electric panel and hoist panel.
 Flat cables are fixed to the cable trolleys.
 Cable trolleys run on a C-track
 1st track is for the hoist power supply
 2nd track is for sliding pendant hanger
Hoist Power Supply

Energy Chain

Crawler type solution where power and

control cables are inside crawler which runs
in a route channel that is mounted on the
top of lower flange of I–beam.
Energy chain
 Option

 Only for I-beam main girders

 Only for remote controlled cranes
 Smaller dimensions for the crane

Route channel
Crane Power Supply

Crane power supply system feeds the main

power from power supply to crane bridge
cubicle

Crane power towing arm

 Crane power townig arm connects crane

power supply, festoon or conductor to crane
electric panel.
 Usually towing arm is bolted on the side of
end carriage.
 If crane is equipped with bridge travelling Towing arm

limit switch, limit switch is also fixed on the

towing arm
 Crane Power Supply

Copper conductor type power supply

 Power is fed through copper conductor rails and

moved to crane bridge panel with collectors and
towing arm.

2 basic models of ductor

 Click ductor = 4 m (13 ft) long quick installation

parts
 Continuous ductor = seamless conductor for
runway length
Festoon type power supply

Power for crane can also be delivered with with

festoon type solutioon, similar to hoist power
supply.
Collector trolleys
Crane Power Supply
Bridge Electric Panel

Bridge electric panel is a nerve center for crane

or crane movements controlling designed
applications.
 Electric panel includes whole crane drive
logics which has been built with mechanical
and electrical components.

 All information on driving the crane goes

through this panel.

 Controlling of crane functionality is due to

crane electric panel design and thus panel
size varie from small (400 mm * 400 mm) (1’
3 ½”* 1’ 3 ½”) up to length of several meters
(inverters, PLC’s etc.) For example Electric
panel line which is 6 m (20 ft) long can be
1,5 m (5 ft) tall.
Electric Controls
Pendant and Remote Controllers

Industrial cranes are almost in all cases operated

with handheld controller.
Pendant Controller

Pendant controller is a pusbutton station which is used by operator for controlling

crane movements.

 Pendant is sliding on festoon c-track

independent of hoist movement.

 In some cases pendant can be fixed on

the hoist unit.

 In case of remote controller, pendant is

located in bridge panel as ”spare”
controlling device if needed.
Load display (optional)
Main power Emergency stop pushbutton
Hoist operation
Trolley operation
Bridge operation
Radio Controllers

Radio controller is a push-button or joystick type

controller which is used by operator for wireless
controlling of the crane.
 Optional feature

 Safer controlling of the crane for the operator

 2 product families available:

- Rad for standard applications
- Remox for special applications to control also
lights, lifting devices etc.

Push-button controllers

 2 step push-buttons for every movement direction

Joystick controllers

 2 multi-step joysticks for 3 movement direction

Speed Controls
Hoisting Speed Controls

Purpose of hoisting speed controls is to make the

hook move vertically according command comming
from the crane user.

Contactor control

 Standard feature in hoisting motion

 Controls hoisting movement, up/down

 Mechanical contactors

 2 speeds, high/low

Contactors
 Hoisting Speed Controls

Inverter control

 Optional control

 Controls hoisting movement, up/down

 Controls speed by controlling motor frequency

 Variable speed control

 Soft start and stop of motions through slow speed

Hoisting inverter in bridge electric panel

 Travelling Speed Controls

Purpose of travelling speed controls is to make the hook

move horizontally according command comming from the
crane user.

Inverter control
 Standard control in trolley movement

 standard control in bridge movement

 Controls speed by controlling motor frequency

 Smooth start and stop with ramp

 Variable speed control

Contactor control inverter in bridge electric panel

 optional control in bridge movement

 Optional control in trolley movement

 Mechanical contactors

 2 speeds, high/low
Condition Monitoring

Condition Monitoring Unit is to supervise and protect

the hoist.
 Measures the use of the hoist and prevents the
hoisting or lowering in case a potential dangerous
situation is detected

Can be used both in 2-speed and in variable speed

controls

Protection
 Overload protection

Supervision
 Hoist motor overheating supervision
Condition Monitoring unit in hoist panel
 Run and fault supervision
 Is running safe
 Is motor actually running when requested

 Supply voltage phase supervision

 Sudden load increase supervision

* Some additional supervisions as option
 Starting and stopping through slow speed
 In 2-speed applications
Condition Monitoring

Monitoring
 Monitoring items read through the display
 Display can also be located as remote

 Primary monitoring items according to

ISO/FeM regulations
 Hoist Safe Working Period, SWP%
 Starts counter
 Run time counter
Monitoring SWP%
 From monitoring items also additional
information of the hoist usage.
Crane application

Steel mail Power plant

Crane application

Paper mill industry

Steel mill
Crane application

Waste power plant

NOT JUST LIFTING
THINGS, BUT ENTIRE
BUSINESS