wire rope hoist - stahl cranesmpplus.stahlcranes.com/fileadmin/xternedaten/schulungen/sh_as... ·...
TRANSCRIPT
![Page 1: Wire rope hoist - STAHL CraneSmpplus.stahlcranes.com/fileadmin/XterneDaten/Schulungen/sh_as... · The direct current of the brake is wired via terminals 3 + 4. On the one hand this](https://reader037.vdocument.in/reader037/viewer/2022102920/5a9e36997f8b9a2e688c161b/html5/thumbnails/1.jpg)
Wire rope hoist
![Page 2: Wire rope hoist - STAHL CraneSmpplus.stahlcranes.com/fileadmin/XterneDaten/Schulungen/sh_as... · The direct current of the brake is wired via terminals 3 + 4. On the one hand this](https://reader037.vdocument.in/reader037/viewer/2022102920/5a9e36997f8b9a2e688c161b/html5/thumbnails/2.jpg)
Wire rope hoists
Standard
Type Max. capacity
Rope hoist SH 25 t
Rope hoist AS70 125 t
Winch SHW8 /SW 160t/250t
© STAHL CraneSystems GmbH I Training Centre 29.08.2017 I 2
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Wire rope hoist
Type SH up to 25 t
SH 3
SH 4
SH 5
SHR 6
SH 6
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Wire rope hoist
SH Platform
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Classification Full load
operating
hoursFEM ISO
5m M8 12,500 h
4m M7 6300 h
3m M6 3200 h
2m M5 1600 h
1Am M4 800 h
1Bm M3 400 h
1Cm M2 200 h
Classification
Basic information
FEM (Federation of European Material Handling
Industry, Manufacturers' Association):
- The mechanism group in accordance with FEM is
an important design criteria for hoists
- Hoists with identical reeving and S.W.L. may be
classified differently
- The FEM classification correlates to a defined
lifetime in full load hours
- FEM groups correspond to ISO groups
The FEM classification is laid down for:
Rope drive: FEM 9.661
Mechanism: FEM 9.511
Motors: FEM 9.683
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Hoist model SH 4016–25 4/1 L2 KE SH 5016–25 4/1 L2 KE
S.W.L.Height of liftReevingHoisting speed
6,300 kg6 m4 / 1
6.3 / 1.0 m/min
6,300 kg6 m4 / 1
6.3 / 1.0 m/min
FEM classification 1Am 3m
Duty cycle of hoist motorSwitching operations/hour
40 / 20% DC 180 / 360 s / h
50 / 20 % DC240 / 480 s / h
DeadweightHeadroom C
370 kg490 mm
755 kg555 mm
Hook size RSN 2.5 RSN 4
Rope Rope safety factor
9.0 mm4 : 1
12.5 mm~ 8:1
Drum Rope sheave
167 mm160 mm
219 mm225 mm
Wheel 100 mm 140 mm
Classification
Wire rope hoists in 1Am and 3m
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Wire rope hoist SH
Gear
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All bearings and gearing is oil lubricated: life
time lubrication
Gearing with high hardened flanks
Low noise emission
SH 3 – SH 5 enclosed housing
SH 6 split housing
Wire rope hoist SH
Gear
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Wire rope hoist SH
Motor
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Wire rope hoist SH
Motor
Dual speed hoist motor
SH rope hoist: 2 windings (12/2-poled / 24/4-poled)
Standard protection class IP55
Motor rating up to 38kW standard
PTC temperature control standard
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Wire rope hoist SH
Brake
Two side magnetic brake
Asbestos free
Over dimensioned
Low-maintenance, no re-adjustment
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Wire rope hoist SH
Rope guide
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Enclosed rope guide
No over winding or slack rope
Cause of the solid material GGG 40 (GJS400-15)
robust and low-wear
No temperature limitation
Principle in fourth generation
(type C, N, AS, SH)
Reliable cause of the 360° clamping
Wire rope hoist SH
Rope guide
SH3 – SH5SH6
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Wire rope hoist
Type AS up to 125 t
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All bearings and gearing is oil lubricated:
Life time lubrication
Gearing with high hardened flanks
Low noise emission
SH 6 / AS 7 split housing
Wire rope hoist AS
Gear
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Wire rope hoist AS
Motor
Dual speed hoist motor
SH rope hoist: 2 windings
(12/2-poled / 24/4-poled)
Standard protection class IP55
Motor rating up to 38kW
standard
PTC temperature control
standard
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Wire rope hoist AS
Rope guide
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Enclosed rope guide
No over winding or slack rope
Cause of the solid material GJS400-15 robust
and low-wear
No temperature limitation
Reliable cause of the 360° clamping
Wire rope hoist AS
Rope guide
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Wire Rope hoist
Winch SHW 8 / SW
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Wire rope hoist
The following parts are used on the
wire rope hoists.
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Rope hoist components
Panel
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Rope hoist components
Panel / main contactor
Contactors: Brand Siemens or Telemecanique
Main contactor (switched through emergency
button in pendant)
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Rope hoist components
Panel / contactors
Contactors:
Travel
Hoist
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Rope hoist components
Panel / transformer
Control voltages 42, 48, 230 Volt, optional 110 V or
24 V DC
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Rope hoist components
Panel / Bridges
For the yearly inspection of the Emergency end limit switch
S260: Drive into the
Emergency stop.
S261: Drive back out of
the Emergency stop.
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Rope hoist components
Panel / rectifier
Brake rectifier
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The direct current of the brake is wired via terminals 3 + 4. On
the one hand this prevents the brake coil being charged by
feedback from the motor and thus prevented from closing, on
the other hand the brake closes faster
Terminals 5 + 6 are the connections for the brake coil
The over excitation (over voltage) time for outputs 5 + 6 (brake
coil) is determined by the resistor between terminals 7 + 8 . This
ensures that the brake is fed double voltage for a short time
(0.05-2 sec) when the control pendant is activated and thus
opens faster. This is particularly necessary for large brakes from
H62 upwards. These two terminals are not available on smaller
brakes.
Rope hoist components
Panel / rectifier
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3
U2N =
3
U1N =
Example:
Hoist motor operating voltage: 400V
400V : 1.73 = 231V
Slow Fast
Rope hoist components
Panel / rectifier
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Rope hoist components
Panel / gear limit switch
Hoisting limiting device:
Gear limit switch
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Gear limit switch:
The old standard for the hoist limit switch, was only
an emergency limit switch, for up and down, that
means two switches.
Rope hoist components
Panel / gear limit switch
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Gear limit switch:
The option was operational hoist limit switch, that
means a operational limit switch for up and down
and an emergency limit switch for up and down,
so four switches.
Rope hoist components
Panel / gear limit switch
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Gear limit switch:
The new standard is, an operational hoist limit
switch with four switches.
But function of the switches is now different
compare to the old one.
Rope hoist components
Panel / gear limit switch
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Condition monitoring system:
Rope hoist components
Panel / SLE3 / 22
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Function:
- Operation with dual channel load sensor 4 - 20 mA
- Motor management - adjusted via motor allocation table
- Operating hours counter
- Load cut-off - adjustable by switches
- Temperature-control for hoist and travel motors
- Crane test by means of test button
- Integrated function control (displayed by LED)
- Control of motor contactors only in economy connection
- Option relay programmable for special functions
Rope hoist components
Panel / SLE3 / SLE 22
SLE 3
Options relay output signal programmable to 95% of the
nominal load.© STAHL CraneSystems GmbH I Training Centre 29.08.2017 I 34
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LCD1
Load sensor with
two channel
safety category 2 for load monitor
Rope hoist components
Panel / SLE3 / SLE 22
15 V
24 V
sch
war
z
ora
ng
e
bra
un
rot
SLE3
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SLE 22
Crane test
Error display
Motor code(motor allocation table)
Cut-off point rough
Cut-off point fine
Operating hours counter
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Rope hoist components
Panel / SLE3 / SLE 22
Motor managment
Disabling time: When activation of the hoisting motion has been completed (creep hoist / main hoist)
the disabling time is started and until this has expired no start signal for
the same hoisting speed is accepted (prevention of inching operation)
Change of direction: During the disabling time the hoisting motion is braked via creep hoist, stopped,
then the hoist travels in the new direction in creep speed for a certain time and
then changes to main speed if selected. All times depend on the motor type
and are assigned automatically after selecting a motor code at the SLE21
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Rope hoist components
Panel - option
Optional to SLE22 the SMC22
Special features of the SMC:
- Permanent overload protection by automatic load control (ALC)
- Load spectrum recorder for load depended summation for
operating time.
- Temperature controlled (lift and drive)
- Registration of operating data, for example operating hours,
motor switching's and load cycles
- Elimination of inching operation
- Slack rope cut off (for example lifting beam)
- optional connection of signal transmitter, load display
- Data interchange with PC, either RS232 or USB
- Activation of the crane-test, via button or the PC-Software
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Rope hoist components
Panel / SLE3 / 22
Motor Type S1 S3 t L[ms]
t S[ms]
t R[ms]
t A[ms]
t b[ms]
Unknown 0 600 1250 1250 500 500
12/2H33 1 250 500 500 0 250
12/2H422 250 500 500 0 250
12/2H623 250 500 500 0 250
12/2H714 400 750 750 300 300
12/2H725 400 750 750 300 300
12/2H736 400 750 750 400 400
12/2H91
12/2H92 7 600 1250 1250 500 500
Ex-Motor
A-xxx A 400 750 750 0 0
Frequency
converter F 0 0 0 0 0
© STAHL CraneSystems GmbH I Training Centre 29.08.2017 I 39
t L : delay times to slow speed
t S : delay times to fast speed
t R : delay for change of direction
t A : starting time over the slow speed
t B : braking time over the slow speed
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Wire rope hoist component
Overload protection
Per EU machine directive, a load limiter is required for hoists with capacities over 1.000 kg
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There are three different types of sensors which are used for the standard
overload protection:
Compressive forced sensor
LCD 1 (LET 1)* sensor, used for several falls at SH hoists and AS hoists (since 2013)
Shear forced sensor
LSD (LEI)* sensor, used for single fall at SH
LBD 1, 2, 3 (LET 8* / LET 9*) sensors used at the SHW8
LBD 3 (Load Bear Dualsensor) used for 6/1 AS
Displacement sensor
LGD (LAS)* sensor, used for AS7 hoists
*one channel
Wire rope hoist component
Overload protection / sensors
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Overload protection standard SH wire rope hoist with LCD 1 Sensor
Functionality:- The rope is reeved into the rope lock. As soon as the load pulls the rope lock, the arm gets
pulled down and puts pressure on to the sensor.
Load
Wire rope hoist component
Overload protection / Compressive force sensor
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AS(R)7 wird mit folgender Lasterfassung ausgestattet:
Einscherung 2/1, 4/1, 4/2-1, 8/2-1 -> dualer Drucksensor LCD
Seilzug KomponentenAS7 Lasterfassung
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Standard Sensor LCD 1 cut through the middle
Wire rope hoist component
Overload protection / Compressive forced sensor
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Standard sensor LCD 1, functionality
2 DMS
(strain gauge)
+
resistors
15 Volt 24 Volt
U
I
4 – 20 mA
Wire rope hoist component
Overload protection / Compressive forced sensor
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Mounting position
Wire rope hoist component
Overload protection / Compressive forced sensor
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Overload protection standard SH wire rope hoist with LSD Sensor
Functionality:- The gearbox is overhung mounted to the frame - As soon as the load is on the hook, the gearbox tries to turn around, but the sensor looms into
the frame, so the gearbox pushes the sensor against the frame and measures the load.
Wire rope hoist component
Overload protection / Shear forced sensor
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AS7 will be equipped with:
Reeving 6/1 -> Dual shear force Sensor LBD
Wire rope hoist component
Overload protection / Shear force sensor
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The sensor LSD has the same principal function as the LCD 1
Wire rope hoist component
Overload protection / Shear forced sensor
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Standard sensor LSD, functionality
DMS
(strain gauge)
+
resistors
15 Volt 24 Volt
U
I
4 – 20 mA
Wire rope hoist component
Overload protection / Shear forced sensor
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Moving force
Pretension
force
Rope drum
Gearbox
Gear sensor
Load
- As soon as there is load on the hook, the gear is moving because of its helical
gearing, away from the sensor.
- The movment of the sensor can be measured in mA.
Wire rope hoist component
Overload protection / Displacement sensor
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Chip
MagnetSensor housing
Spring
Wire rope hoist component
Overload protection / Displacement sensor
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U
mA
VN
S
F
Function
The spring pushes against the brass plate in the Gearbox
Magnet Sensor
Wire rope hoist component
Overload protection / Displacement sensor
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Mounting position
Wire rope hoist component
Overload protection / Displacement sensor
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Standard pendant type STH
(made by Telemecanique)
Operator has to move with the crane
Max. crane speed 63 m/min with
pendant controls (BGV D6 §17)
Pendant mounting position:
Mobile along crane bridge
Standard features:
Strain release cable
Emergency-off button
Wire rope hoist component
Control – Pendant controlled
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Standard pendant STH- Two-step buttons- Up to 3 drives can be controlled by
single pendant- Plug connection
Options- Warning light- Key switch- Horn switch- Selector switch I, I+II, II- Other buttons
Wire rope hoist component
Control – Pendant station types
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quadrix Most compact transmitter
Dead weight 330 g
Two step push buttons
On-button
Rechargeable battery
micron 6 Industry standard
Dead weight 450 g
Two-step push buttons
Key switch
Emergency-off button
Selector switch I, II, I+II
Changeable batteries
LC-Display can retrieve data
from crane electronics
spectrum Comprehensive options
Dead weight 1.800 g
Joystick control
Changeable batteries
LC-Display can retrieve data from crane
electronics
Wire rope hoist component
Control – radio transmitter types
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Wire rope
General
Structural design of a steel wire rope:
A steel wire rope is made up with a large
number of steel wires (1).They are
twisted together to strands (2a,2b).
Some types of rope have also plastic
inserts (4).
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Wire rope
Basic definitions
Direction of lay:
The direction of lay of the rope, is the direction of the helical line of the outer strands.
There is right-handed and left-handed rope.
Right-handed (Z) Left-handed (S)
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Wire rope
Basic definitions
Direction of lay:
Not only the rope has a direction of lay, the strands do also.
Ordinary
(cross) lay:Long lay:
Right-handed
sZ
Right-handed
zZ
Left-handed
zS
Left-handed
sS
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Wire rope
Ordinary and long lay ropes
Ordinary (cross lay) rope:
In most cases a ordinary rope suits better than a long lay rope.
With ordinary ropes you can see broken wires generally earlier than on a long lay rope.
That means more safety, because only if you see the broken wires you know when to change the rope
before it gets dangerous.
Long lay rope:
The over lay rate in the rope groove is better than on ordinary ropes, that’s the reason why the use of
long lay ropes is preferred in places where you have a very high dead load. The most cases where they
are used is for multilayer spin, because the outer wires can’t catch the other rope liner, and so it doesn’t
get damaged.
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Wire rope
Rotation resistant rope
Rotation resistant rope:
A rotation resistant rope under tension will turn minimal around it’s own axis.
That means I need a rope swivelling anchorage point for multiple reeving.
Swivel
When do I use a rotation resistant rope?
- Lifting an unguided load on a single fall
- Lifting an unguided load on several falls at a great lifting height
Opposite torque moments in a none-rotating rope
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Wire rope
Non-rotation resistant rope
Standard rope:
A non-rotation resistant rope under tension tries to rotate around it’s own axis.
That means I need a fixed anchorage point.
When do I use a none-rotation resistant rope?
- Lifting a guided load.
- Lifting an unguided load on several falls at a small lifting height.
- Lifting loads with right-handed and left-handed ropes operating in pairs.
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Wire rope
Summary: Rotation resistant, none-rotation resistant
Non-rotation resistant
Rotation resistant
Rotation resistant
Non-rotation resistant
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Wire rope
Summary: Rotation resistant, non-rotation resistant
Why don’t we always use a rotation resistant rope?
Rotation resistant rope have a few disadvantages:
- higher price
- shorter lifetime
- with a guided load, the rope can’t really settle, so it will break earlier
- it is very difficult to check the wear
- the allowed deflection angle is only 1,5° (none-rotation resistant rope 3,5°)
We only use a rotation resistant rope only if we need it.
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Rope
worn rope
Broken wires:
Broken wires are the main reason that a rope must be changed.
Broken strands:
If the full strand is broken, the rope has to be change immediately.
Reduction of the diameter:
As soon as the rope diameter is less than 10 % from the new rope, the rope has to be
changed.
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Rope
deformation
Corkscrew:
If the measurement x is 1/3 of the diameter, the rope must be changed.
Bird caging:
It’s caused by twisting the rope, the become longer than the rope.
x
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Seil
Ablegereife
Formation of loops:
If looping is visible as on the picture,
change the rope imedately.
Flatness, kinks:
With permanent deformations the
rope must be changed.
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Seil
Ablegereife
Tightened kink:
Formed if a loop sling was
applied to tighten it.
Rope bend:
A rope bend is formed if the
rope is pulled over a sharp
edge.
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Rope hoist trolley
Stationary
Type Lifting
capacity up
to (kg)
Standard-
Reeving
Reeving for
true vertical lift
Stationary
SH 3 3.200 1/1,
2/1,
4/1
2/2-1,
4/2-1
■
SH 4 6.300 ■
SH 5 12.500 ■
SHR 6 16.000 ■
SH 6 25.000 1/1, 2/1, 4/1 2/2-1, 4/2-1,
8/2-1
■
AS 7 125.000 2/1, 4/1, 6/1,
8/1
2/2-1, 4/2-1,
8/2-1
■
SHW 8 160.000 - 4/2-1, 8/2-1,
12/2-1
■
Standard Option
■ □ Different possibilities for crane builders or manufactures
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Rope hoist trolley
OE
Type Lifting capacity
up to (kg)
Standard-
Reeving
Reeving for true
vertical lift
Double girder
crab OE
SH 3 3.200 1/1,
2/1,
4/1
2/2-1,
4/2-1
■
SH 4 6.300 ■
SH 5 12.500 ■
SHR 6 16.000 ■
SH 6 25.000 1/1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 ■
AS 7 125.000 2/1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 ■
SHW 8 160.000 - 4/2-1, 8/2-1, 12/2-1 ■
Standard Option
■ □
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Rope hoist trolley
OE
Hoist installed on top of bridge girders, thus best
usage of available height
Typically used for capacities > 5 ton
Total headroom from top of crane to hook is equal
to total headroom of trolley. Overall headroom is
independent from height of crane girders.
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Type Lifting capacity
up to (kg)
Standard-
Reeving
Reeving for true
vertical lift
Mono rail
trolley KE
SH 3 3.200 1/1,
2/1,
4/1
2/2-1,
4/2-1
■
SH 4 6.300 ■
SH 5 12.500 ■
SHR 6 16.000 ■
SH 6 25.000 1/1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 □
AS 7 125.000 2/1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 □
SHW 8 160.000 - 4/2-1, 8/2-1, 12/2-1
Rope hoist trolley
KE
Standard Option
■ □
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Available up to 16 ton
Most economical solution for cranes up to 10/16 t
Crane headroom = hoist headroom + bridge girder height
Headroom depends on flange width of bridge
Rope hoist trolley
KE
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Type Lifting capacity
up to (kg)
Standard-
Reeving
Reeving for true
vertical lift
Mono rail
trolley UE
SH 3 3.200 1/1,
2/1,
4/1
2/2-1,
4/2-1
■
SH 4 6.300 ■
SH 5 12.500 ■
SHR 6 16.000 □
SH 6 25.000 1/1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 □
AS 7 125.000 2/1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 □
SHW 8 160.000 - 4/2-1, 8/2-1, 12/2-1
Rope hoist trolley
UE
Standard Option
■ □
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Up to 25 ton: 8 wheel trolley UE-S77.
Up to 50 ton: possible with 12 wheels
Typical application: maintenance hoist
on monorail track (in power stations etc.)
Advantage:
Only one bridge girder required
Disadvantages:
Heavy dead weight
Long headroom (trolley and bridge)
Over 16 ton, UE is more expensive than OE. Cost and
bridge girder height make cranes in this capacity range
impractical
Rope hoist trolley
UE
© STAHL CraneSystems GmbH I Training Centre 29.08.2017 I 77
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Type Lifting capacity
up to (kg)
Standard-
Reeving
Reeving for true
vertical lift
Mono rail
trolley DKE
SH 3 3.200 1/1,
2/1,
4/1
2/2-1,
4/2-1
■
SH 4 6.300 ■
SH 5 12.500 ■
SHR 6 16.000 □
SH 6 25.000 1/1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 □
AS 7 125.000 2/1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 □
SHW 8 160.000 - 4/2-1, 8/2-1, 12/2-1
Rope hoist trolley
DKE
Standard Option
■ □
© STAHL CraneSystems GmbH I Training Centre 29.08.2017 I 78
![Page 78: Wire rope hoist - STAHL CraneSmpplus.stahlcranes.com/fileadmin/XterneDaten/Schulungen/sh_as... · The direct current of the brake is wired via terminals 3 + 4. On the one hand this](https://reader037.vdocument.in/reader037/viewer/2022102920/5a9e36997f8b9a2e688c161b/html5/thumbnails/78.jpg)
These trolleys are used on
runways with small curve radius
Rule of thumb:
wheelbase = curve radius
Rope hoist trolley
DKE
© STAHL CraneSystems GmbH I Training Centre 29.08.2017 I 79
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> Lifting technology
> Drive technology
> Control technology
Thanks for your attention
STAHL CraneSystems
STAHL CraneSystems GmbH