Cranes : design, practice, and maintenance: 2nd

Foreword xv Foreword to second edition xvii Preface xix Chapter 1 Introduction 1 1.1 History 1 1.2 Power 6 1.3 Some types of cranes and lifting equipment 9 1.4 Capacities, number of cycles, cycle-time 16 – Container quay cranes 16 – Grab unloaders 20 1.5 The influence of wind and storms 25 1.6 Hatchless container vessels 35 Chapter 2 Wire ropes 39 2.1 Wire rope reeving systems 39 2.2 Influencing the lifetime of wire ropes 40 2.3 Drum diameters and wire rope sheave diameters 41 2.4 The choice of wire ropes 41 2.5 Fleet angles; grooves on drums and in wire rope sheaves 42 2.6 The bending angle over sheaves; the ultimate tensile limit 46 2.7 The lifetime of wire ropes 47 2.8 Wire rope strength 48 Chapter 3 Drives; calculating motor powers 49 3.1 Driving systems 49 – The squirrel cage motor with fluid coupling 49 – The slipring motor 50 – The Ward–Leonard drive 51 – Direct current full-thyristor systems 52 – Alternating current drives with frequency control 52 – Hydraulic drives 55 3.2 Numbers of wire rope sheaves in the hoisting mechanisms of different reeving systems 56 3.3 Calculating the requisite power of the hoisting motors 58 viii Cranes – Design, Practice, and Maintenance 3.4 Calculating the needed power of the trolley travelling motors 66 3.4.1. Direct driven trolleys or motor trolleys; wheel slip control 69 3.4.2. Trolleys pulled by wire ropes or rope driven trolleys 72 3.4.3. Rope driven trolleys for grab unloaders with a main and auxiliary trolley 76 3.5 Hoisting the boom; calculating the power needed for the boom hoist motor 82 3.6 Calculating the needed power of the crane-travelling motors. Wheelslip control – how to calculate the forces through skewing of the crane and trolley 85 3.7 The rating of the motors 91 3.8 The root-mean-square calculation 94 3.9 The current supply of a crane by a diesel generator set: calculating methods and warnings 94 3.10 Calculating the power needed for the slewing motors of level luffing cranes 101 3.11 Calculating the power needed for the luffing motor of level luffing cranes 108 Chapter 4 Brakes 113 4.1 Modern brakes 113 4.2 Hoisting brakes; lowering the load; emergency stop 118 4.3 Hoisting brakes; lowering the load; braking by full motor torque 123 4.4 Hoisting brakes; hoisting the load; braking by full motor torque 127 4.5 Hoisting brakes; hoisting the load; emergency stop 130 4.6 Svendborg brakes 134 4.7 Calculating the brake time and braking distance of a crane 136 4.8 The acceleration of a crane by wind at the beginning of an emergency stop 139 4.9 Storm pins and storm brakes 141 Chapter 5 Standards 147 5.1 CEN 147 5.2 FEM 148 5.3 ISO 149 5.4 DIN; BS; JIS 153 Contents ix Chapter 6 Sagging and slapping of the wire ropes; rock and roll of the spreader; machinery trolleys versus wire rope trolleys; twin-lift; positioning; automatic equipment identification (AEI) 155 6.1 Sagging and slapping of the wire ropes; other hoist wire rope systems for container quay cranes and grab unloaders 155 6.2 The rock and roll of the spreader 159 6.3 Advantages and disadvantages of machinery trolleys versus wire rope driven trolleys 160 6.4 Container transport with twin-lift spreaders; long twin-lift; Bramma Tandemlift. Connecting the spreader to the headblock 162 6.5 Sway and swing; automation of the trolley travelling mechanism 167 6.6 The positioning of a hoisting mechanism; automation 173 6.7 Automatic positioning for crane travelling mechanisms 173 – Encoder systems 174 – Sensor systems 176 – Hall magnets with electronic measuring rulers 176 – Detectors with linear absolute encoders 176 – Antenna–transponder systems 177 – Radar systems 178 – Laser systems 179 – The influence of wind and eccentric loading of the container 179 – The prevention of skew 180 6.8 The automatic identification of containers 180 – Tags 180 6.9 Electronic Data Interchange (EDI) 183 – General 183 – GPS and DGPS 184 – Automatic vehicle and container location 185 – Scanning 185 – Container inspection by X-ray 187 – Seal recognition 187 – CSC plate control 187 – Checking the damage to containers 188 6.10 GE Toshiba Automation Systems; crane automation 188 x Cranes – Design, Practice, and Maintenance 6.11 The Stewart Platform Reeving 193 6.12 Checking the alignment of containers etc. with Laser Scanners 194 6.13 Spreader Positioning System 196 6.14 Camera-Monitor Systems 198 Chapter 7 Construction and calculation methods on strength and fatigue 201 7.1 Materials 201 – For steel constructions 201 – For mechanisms 203 7.2 Welding 203 7.3 Bolts 208 7.4 Construction of box and lattice girders etc. 210 7.5 Boom-ties; diagonals 216 7.6 Calculations on strength and on fatigue 220 – The fatigue load 221 – Fatigue in structures 222 – Fatigue in mechanism components as shafts etc. 255 – Pressure between shafts and steel constructions 259 – Design details 260 7.7 The natural frequency 261 Chapter 8 Wheels and tracks 263 8.1 Calculating the wheel diameters of fast-running trolleys (ûH100m
min) 263 8.2 Calculating the wheel diameter of a crane travelling wheel for normal speeds (ûGup to 60m
min) 264 8.3 Differences in wheel loads, due to breaking forces 265 8.4 Rails and rail constructions 267 8.5 Trolley travelling rails and boom hinge points 270 8.6 Wear and tear of a crane rail 276 8.7 Buffers 276 Chapter 9 Miscellaneous 279 9.1 Overload preventers 279 9.2 Snag loads 279 9.3 Anti-collision systems 286 9.4 Cable reels 287 9.5 Festoon systems: current and data supply to the trolleys 288 9.6 Inductive power transfer and data transmission 290 Contents xi 9.7 Hoppers 294 9.8 Apron feeders; conveyors 295 9.9 Electronic Tracking Guide System 298 9.10 Gears 299 9.11 The Promo-Teus Conveyor Belt System 305 Chapter 10 Maintenance 309 Artwork sources 317 Index 325