self blocking rail clamps

8/12/2019 Self Blocking Rail Clamps

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R I M AR I M AR I M AR I M A O F F I C I A LO F F I C I A LO F F I C I A LO F F I C I A L C A T A L O GC A T A L O GC A T A L O GC A T A L O G U E U EU EU E 1 / 1 2

SELF BLOCKING RAIL CLAMPS

JULY 2008

CATALOGUE TA


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DecriptionDecriptionDecriptionDecription

These rail clamps are storm brakes suitable for highforces: from 250 to 1500 kN.

They are self-blocking type; in case a force acts on thecrane and tends to put the same into motion, they presson the rail sideways. This pressing gets stronger as thecrane moves. The rail clamps can withstand horizontalforce only.The value of forces indicated are calculated with frictioncoeff. of 0.25 (see after).As the real coeff. in normal conditions is much higher(approx 0,59 - TUV German register certificated), therail clamps can generate higher forces. Higher safety

and braking shoes life are guaranteed

Advantages of self-blocking system

Thanks to its working concept, the holding force givenby the self-blocking rail clamp is a reaction to the forceapplied by the wind. The force given by the clamp isequal to the force of the wind deducted the force givenby gantry brakes; this means that also the pressingforce applied by the jaws to the rail side surface is, in all

condition, the minimum needed to hold the crane in itsposition with proper safety factor.The clamp start pushing on the rail sides only if thewind force overcomes the gantry brakes capacity.

All what above allows total intensity and working hoursin a year to be almost negligible.

With regard to braking shoes, optimized design, carefulchoice of material, developed heat treatment cycles

(combining correct surface hardness and necessarycore ductility), guarantee both best performances andlong life.

Above described features lead to following advantages:

1) Jaws duration is very long (our experience is that jaws life reaches also 10 years)minimising replacement needs.

2) All mechanical components are working quite seldomand most of times under lowloads, minimizing maintenance needs.

3) Rails are preserved from wear and damages

Further advantages of self-blocking system

Independence of the holding force from thefatigue deriving from heavy duty cycle (theabsence of springs renders this device suitableto the continuous open/close applications)

Fast opening with law power: opening is made just rising up the light weight of the calliper (notworking against strong springs and wastingenergy)

Working at low pressure with life advantage forhydraulic components

Particular suitability to high speed cranesthanks to the free movement:

Since while the crane is travelling, the braking calliper islifted up over the rail level, we can adopt a very widegap between guides and rails (10 mm or more), with thebenefit of very seldom contacts.This, together with accurate choice of guide materialsand treatment allows a long duration of guides.

Friction coefficient (TUV certified)

On new generation of self blocking rail clamps it hasbeen applied a very innovative concept of variablefriction coefficient.To maximize the safety, calculated average workingfriction coefficient is around 0,25, while the frictioncoefficient of our braking shoes it is much higher (0.59also in the worst conditions, i.e. presence of grease onthe rail, certified by German Register TUV). Real highvalues of working friction coeff. (always belowguaranteed level) are needed only in extreme wind loadconditions, therefore very seldom.

Advantages in comparison with spring types

We would like to underline here the maindisadvantages of spring rail clamps (and railbrakes) respect to self blocking type:

- The transversal (vertical) force applied by the jawsto the rail side (top) surface is always at maximumvalue, causing both wear of rails and wear of jaws(maintenance manual of spring clamps indicate acontrol of jaws wear and relevant periodicalsubstitution)

- The holding force decreases with wear of jawsrequesting than, to keep the needed safety of the

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- In case a fast opening is required, a big powerhydraulic unit must be used with high cost andwaste of energy since cylinders are workingagainst the strong spring force.

- Rail brakes need to be installed only at centre ofgantry equalizers.

System is operated at very low pressure level (abt 7,5MPa) increasing largely the duration of hydrauliccomponents, while on spring rail clamps pressure arequite high (more 15 Mpa). Higher values of pressurecould be found only in case rail clamps have to beunlocked after high wind load application.

Technical features

- Installation: side bolted;- Vertical float = 12 mm ;- Horizontal float = 40 mm ;- Tolerance respect to nominal width of the rail =

1.5 mm (or more upon request);- Opening time (signal for operation) = 4 s ;- Closing time = adjustable from 4 to 12 s ;- Duty = 24 hours full operation per day;- Life: 2.000.000 cycles

On request these values can be modified.

Utilization / functioningUtilization / functioningUtilization / functioningUtilization / functioning

This rail clamps are to be considered as parkingdevices (safety against the movement caused by wind)and they work pressing on rail sides.The jaws are connected to the frame by a swinging

pendulum device. In closed position (ready to work)the jaws lean on the upper surface of rail but they don'tapply any force to the side-surface of the rail. When thewind force is stronger than the blocking force given bythe gantry drive brakes, and a small movement of thecrane starts, the inclined planes of the blocks, movingwith the crane frame, oblige the rollers to push thefriction shoes against the sides of the rail.(See scheme of working principle according to drawingat page 9/10/11).

RaRaRaRail ililil

Braking shoes of our rail clamp have been designed towork on rails commonly on the market whose hardnessis between 200 and 270 HB ( = 70 to 90 daN/mm).The certification of TUV are referred to above given

l f il h d

Width 1.5mm

Max misalignmentof 1mm

Clearance railwidth

D + 40

Channel features

Not suitable for this kindof rail joint

6

2

1mm

Suitable for this kind ofrail joint


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OPERATINGOPERATINGOPERATINGOPERATING

Opening of Rail Clamps

A hydraulic cylinder in pressure opens the rail clamps,this is achieved by:

a) starting the motor of the hydraulic unit byclosing its remote control switch,

b) energising the coil of the electric pilot checkvalve installed in the unit.

The power is sufficient to release the rail clamps withoutmoving the crane.

Closing of Rail Clamps

Since clamp must close onto the rail only after cranestop, clamp closure is delayed through the use of afixed flow regulator shop calibrated for a delay of 8 s.Different values can be given upon request at order;shorter values are not recommendable sincedangerous.In addition to this an adjustable flow regulator isprovided to increase the delay up to further 4 s.The fixed flow regulator solution has been adopted tominimize the variation of the delay upon temperaturevariation.We suggest the client to inform us always aboutrequested delay at order, to optimize thecalibration.

Assembly DescriptionAssembly DescriptionAssembly DescriptionAssembly Description

Rail Clamps

Each rail clamp is composed by:

- Steel framework with lifting lugs and removablehinged inspection doors;

- Steel levers and counterweight;

- Pins in stainless steel AISI 420;- Heat treated steel rollers and sliding blocks;- Guides with rail sweeping device;- Steel jaws with braking shoes in 39NiCrMo3,

knurled. quenched and tempered;- Hydraulic cylinder for rail clamp opening with piston

road in NIKROM (carbon steel + Ni + Cr); The

Closed

Open


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Hydraulic Unit (acc. dwg page 7/8)

It is suitable for sea-environment, completelyassembled, wired, oil filled and flushed (acc. NAS 9).Cover in carbon steel with hinged door. All the electrical components are wired on option intoelectrical box (protection IP 55)

Emergency manual opening device

For the emergency manual opening device we use astainless steel tie rod assembled inside the rail clamp.To open the rail clamp is requested only the turning of anut by a standard key tool.The advantages of this system in comparison with theone with hand pump are the following:- The opening is possible even in case of damage of

the cylinder or of the flexible hose for theconnection to the cylinder.

- The rail clamp remains open in the time withabsolute security while in the hand pump executioneventual small leakages into the cylinder or into thecock valves may cause the undesired closing of therail clamps.

Standard painting (only frame and externalparts)

Total thickness : 210 micron.

- Surfaces preparation: Sandblasting SA 2 .- 1Coat: Moist curing inorganic two-component zinc

primer. Consists on complex ethyle silicate andzinc dust in high rate (>86% in dry film).Thickness = 70/80 micron

- 2 Coat: Two-component epoxy-polyamide primerand undercoat with zinc phosphate and micaceousiron oxide.Thickness = 80/90 micron

- 3 Coat: Two-component aliphatic acryl-urethanebased paint no yellowing. Reacoatable for longtime.Thickness = 60/70 micron

Final colour: Standard RIMA RAL 5019.

Fluids for normal temperatures

- Hydraulic oil: ISO VG 15.- Grease: SKF LGLT2

The logic control of the rail clamps closing isestablished by the user. The rail clamps are usuallyclosed at the end of the crane work, or on signal of asuitable anemometer which signals that the wind speedis higher than the max. allowed speed.

As the electro-valve has to be always excited, themagnet must be in direct current; if the customer wantsto feed the coil valve with alternated current, a suitablerectifier is to be supplied.

WarrantyWarrantyWarrantyWarranty

12/18 monthsWarranty is subject to the following condictions:

A) The electric diagram is made accordingly to thescheme we suggest (SCE-TA-01) or is madeaccordingly to a scheme designed by client but inany case approved by us.

B) All maintenance procedures described in themanual provided with the supply are observed. Inparticular must be strictly observed the rulesrelevant to cleanliness and filters replacement.

In case one or more of above conditions should not berespected, the guarantee will be considered not valid.

TestingTestingTestingTesting

All the rail-clamps are tested on a test bench beforedelivery, at a nominal force power.

DocumentationDocumentationDocumentationDocumentation

The documentation is worded according to EG(89/392/EWG) e Euro-EN 292-1/2; 1991 D rules.


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ExecutionsExecutionsExecutionsExecutions

Standard execution

- Working temperature: -20, +40- Environment: marine

- Installation with side flange- Hydraulic unit integrated in the clamp, filled with oil

and provided with terminal box- Limit switch that signals clamp open- Limit switch for maintain rail clamp open.

Special execution (on request, with extraprice)

- Working temperature different from standard- Double side flanges or upper flange (with hydraulic

unit supplied separately from rail clamps)- Hydraulic unit suitable to operate with more than

one rail clamps- Electrical board (on plate or box IP55);

- Limit switch which signals "rail clamps closed- Horizontal and vertical clearance increased- Security side stowage pins (to insert suitable holes

on the quay)- Manufacturing according Q.C.P. different from our

standard (Nuclear plan or special application)- Language of documentation different from standard- Certificates of materials (EN 10204-2.2, EN 10204-

3.1 o EN 10204-3.2) for all main components.

Withouthydraulic unit

Without hydraulic unit,with hand pump


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ALIMENTAZIONE / CIRCUITI DI POTENZAMAINS / POWER CIRCUITSRESEAU / CIRCUIT DE PUISSANCENETZANSCHLU / KRAFTSTROMKREIS

6DESCRIZIONE COMMESSA / DESCRIPTION / JOB DISEGNATORE / DRAWN BY

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/ DATETel. +39-2-9650694 Fax. +39-2-9657860

Via E. Fermi , 255I - 21042 - Caronno P.lla (VA) - Italy

Web: http://www.rimagroup.com

230 Vac 24 Vac

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ELETTROVALVOLE E SEGNALIELECTROVALVES ANS SIGNALSLECTROVANNES ET SIGNALISATIONSELEKTROVENTILE UND SIGNALE


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DISPOSIZIONE PIASTRA COMPONENTIELECTRIC PANEL LAYOUTIMPLANTATION PLATINE ARMOIRESCHALTSCHRANK INNENEINRICHTUNG


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self blocking rail clamps

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