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Reliable technology for more drive WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors DFW-Bas travel units WS MT 2014 innovations

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Page 1: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Reliable technology for more driveWS-Bas wheel blocks

TG-Bas gearboxes

MT-Bas motors

DFW-Bas travel units

WS MT

2014 innovations

Page 2: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Demag Bas products – robust, durable engineering

Bas travel units on an EZDR-Bas double-rail crab – an example for the use of Demag Bas drive components

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Demag Cranes & Components is a world leader offering solutions for material flow, logistics and industrial drive applications with subsidiaries and production facilities worldwide – also in India.

The range of products includes:■■ cranes■■ hoists■■ drive technology■■ services.

We place uncompromising priority on meeting customers’ needs, so that our products and services can be seamlessly integrated into each customer’s value creation process.

Bas products – functionality driven by German engineeringWe have developed our Demag Bas products specifically with the world’s emerging markets in mind. The uncom-promising functionality and quality of these products have been designed to meet the high standards you have come to expect of German engineering.

In particular, Demag Bas products are:

■■ functional and reliable■■ tough and robust■■ safe and durable■■ economical to run■■ simple to operate■■ easy to maintain.

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Page 3: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Complete Bas travel unit comprising wheel block, gearbox and motor

WS-Bas wheel block

MT-Bas motor

TG-Bas gearbox

Bas drive components –for robust and functional travel units

Modular designDemag Bas drive components

■■ WS-Bas wheel blocks,■■ TG-Bas gearboxes and■■ MT-Bas motors

are perfectly matched and can each be supplied in various sizes.

Together with a torque bracket, they are combined to create functional Bas travel units for reliable and efficient drive solutions.

Simple integrationBas drive solutions have been developed for locally available travel rail designs, which guarantees seamless system integration and outstanding functionality.

Profile rail Flat steel rail

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Matching combinationMatching combinations of Bas drive components are used for the follow-ing drive solutions:

■■ DFW-Bas end carriages on ■■ EKKE-Bas single-girder overhead travelling cranes

■■ ZKKE-Bas double-girder overhead travelling cranes

■■ and as a tandem crane design.■■ EZDR-Bas double-rail crabs on

■■ ZKKE-Bas double-girder overhead travelling cranes

■■ and as a tandem crane design.

Besides their use in crane solutions, Bas drive components also offer potential for a wide variety of industrial travel applications.

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Page 4: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Bas travel units – perfectly matching components

WS-Bas wheel block■■ Safe and reliable travel ■■ Travel wheels of spheroidal-graphite cast iron with self-lubricating properties that are gentle on the travel wheel and track (GGG 70/QT700-2)

■■ Generous travel wheel tread in various sizes.

Torque bracket ■■ Excellent support of the drive for transmission of drive torque

■■ Can be fitted to the gearbox in four positions.

TG-Bas offset gearbox■■ Compact, space-saving design■■ Efficient connection between motor and wheel block.

Bas drive components for Bas travel units combine robust design with outstanding functionality. They are ideally suited for operation in:

■■ crane end carriages,■■ crane crabs and ■■ industrial travel applications.

Optimum configurationBas travel units consisting of:

■■ WS-Bas wheel block,■■ TG-Bas offset gearbox and■■ MT-Bas cylindrical-rotor brake motor

can be quickly assembled and installed together with a torque bracket. Simple assembly facilitates maintenance at a later date.

WS-Bas wheel blocks offer load capacities of up to 22 t. Depending on the application, they travel at speeds of 6.3 / 25 m/min or 10 / 40 m/min.

Bas travel unit components – technical data

Wheel block Gearbox

Travel speed for 50 Hz

Crab Crane end carriage

v = 25 m/min v = 25 m/min v = 40 m/min

Motor

WS-Bas 125 TG-Bas 20 MT-Bas 80A/80B MT-Bas 80A/80B MT-Bas 80B/90A

WS-Bas 160 TG-Bas 30 MT-Bas 80B/90A MT-Bas 80B/90A MT-Bas 90A

WS-Bas 200 TG-Bas 40 MT-Bas 90A MT-Bas 90A MT-Bas 90A

WS-Bas 250 TG-Bas 50 MT-Bas 112A MT-Bas 112A MT-Bas 112A

WS-Bas 315 TG-Bas 60 MT-Bas 112A MT-Bas 112A MT-Bas 112A

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Page 5: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

MT-Bas cylindrical-rotor brake motor

■■ Drive with integrated flywheel for smooth acceleration and deceleration

■■ Two speeds, fast main travel speed and creep speed for positioning operations

DFW-Bas end carriage:■■ pre-assembled steel superstructure with paint finish■■ incl. WS-Bas wheel block■■ vertically mounted drive consisting of a TG-Bas offset gearbox with an MT-Bas travel motor and torque bracket.

EZDR-Bas double-rail crab with:■■ four WS-Bas wheel blocks■■ one horizontally mounted drive on each side.

Bas drive components in operation

Application 1

Application 2

Driven

Driven

Non-driven

Non-driven

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Page 6: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

WS-Bas wheel block – strong design

WS-Bas wheel blocks feature a strong, enclosed housing and travel wheels made of spheroidal-graphite cast iron. They have been specially developed for locally available travel rail systems:

■■ three sizes with travel wheel diameters from 125 to 315 mm

■■ load capacities up to 22 t■■ involute splined hollow shaft ■■ for driven or non-driven applications

■■ fast and simple installation, e.g. for top connection in a crane end carriage

■■ special guide plate for track gauge adjustment following alignment.

Travel wheels made of spheroidal-graphite cast iron

■■ Effective reduction of travel vibration that is kind to the rail

■■ Low friction and high resistance to wear thanks to self-lubricating properties

■■ Guide flange on both sides■■ Large tread, fine increments in 5 mm steps up to 110 mm depending on the size.

The guide plate is welded to the steel superstructure of the DFW-Bas end carriage following alignment. The plate guides the WS-Bas wheel block and is used to adjust the track gauge. It eliminates the need for re-alignment if the wheel block system is replaced.

At a glance

■■ Three sizes, travel wheel diameters: 125, 160, 200, 250 and 315 mm

■■ Designed to match TG-Bas and MT-Bas components

■■ Load capacity: up to 22 t per wheel

■■ Travel wheel tread: 55 to 110 mm

■■ Low friction and high resistance to wear thanks to self-lubricating properties

■■ Simple assembly and alignment.

Generously dimensioned travel wheels make WS-Bas units robust and enable them to be used on almost all travel rails

Complete Bas travel unit with a WS-Bas wheel block – bolted to a TG-Bas offset gearbox via a flanged torque bracket

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Page 7: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

l1

w4

w2

w3

w1

l3

h4

l2

h2

d3

h3

h1

d5

b2

b1 3)

d4

d2d1 2)

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1)

1)

1)1)

M20 1)

l1

w4

w2

w3

w1

l3

h4

l2

h2

d3

h3

h1

d5

b2

b1 3)

d4

d2d1 2)

132

1)

1)

1)1)

M20 1)

A cellular plastic buffer can be installed in the d5 threaded hole on the end of the wheel block.

The machined connecting surface featuring d4 threaded holes enables the top of a WS-Bas unit to be attached to the steel superstructure of the end carriage.

The torque bracket is bolted to the machined connecting surface on one side of the wheel block.

Wheel block

Max. load capacity

[t]

d1 2) d2 d3 d4 d5 b1 3) b2 h1 h2 h3 h4 l1 l2 l3 w1 w2 w3 w4

[mm]

WS-Bas 125 5 125 150 N35 M12

M12

55, 65, 75, 85

120

100

52 162.5 4.5 206 120 145 211 102.5 106 165

WS-Bas 160 7 160 190 N45 M16 120 69 198 6.5 248 148 180 229.5 110 114 170

WS-Bas 200 10 200 235 N50 M20 122 92 250 6.5 296 180 220 248 120.5 124 180

WS-Bas 250 16 250 286 N65 M20 M12 65, 75, 85, 100 135 100 116 305 6.5 360 210 260 280 136.5 140 200

WS-Bas 315 22 315 350 N75 M20 M12 75, 85, 95, 110 146 102.5 141 375.5 8.5 436 230 300 299 149.5 149.5 200

1) Only for WS-Bas 315 2) Travel wheel diameter 3) Standard travel wheel treads

Load capacities and dimensions

The main dimensions of WS-Bas wheel blocks can be seen in the table below.

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Page 8: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

TG-Bas gearbox – space-saving design

TG-Bas offset gearboxes can be used to implement particularly space-saving and efficient drive designs:

■■ parallel-shaft gearbox with spur wheels

■■ high efficiency■■ compact aluminium housing.

Optimum torque transmissionTorque is transferred to the wheel block by a drive shaft that features involute splines and a flange-fitted torque bracket:

■■ easy installation on site■■ particularly suited for reversing operation typically found in travel applications

Designed to meet application requirementsThe torque bracket can be fitted to the offset gearbox in four positions:

■■ vertical, e.g. for travel drives■■ horizontal, e.g. for crab drives.

At a glance

■■ Three sizes■■ Designed to match WS-Bas and MT-Bas components

■■ Travel speeds: 25 and 40 m/min (in combination with WS-Bas and MT-Bas)

■■ Excellent torque transmission due to drive shaft with involute splines

■■ Torque bracket can be fitted in four positions.

Designation Transmission ratio (i)

25 m/min 40 m/min

TG-Bas 20 44.14 27.96

TG-Bas 30 55.73 36.11

TG-Bas 40 73.45 44.32

TG-Bas 50 87.4 56.4

TG-Bas 60 107 77.2

Complete Bas travel unit with a compact TG-Bas offset gearbox – connected to a WS-Bas wheel block via a torque bracket

Gearbox transmission ratios

Horizontal mounting position

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Page 9: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

MT-Bas motor – robust design

MT-Bas cylindrical-rotor brake motors are specially designed for travel applications and are a perfect match for TG-Bas offset gearboxes.

Ideal for travel applications■■ 8/2-pole motor for two speeds■■ DC disc brakes which are held by springs when no voltage is applied.

Reliable operation and long service life

■■ High-inertia drive to ensure smooth operation of the entire travel unit

■■ Thermal contacts to protect against overheating

■■ IP54 enclosure■■ Ambient temperature: up to + 45 degrees C

Motor Output [kW]20 / 40% CDF

MT-Bas 80 A 8/2 0.06 / 0.25

MT-Bas 80 B 8/2 0.09 / 0.37

MT-Bas 90 A 8/2 0.18 / 0.75

MT-Bas 112 A 8/2 0.42 / 1.7

The variable torque bracket position enables the geared motor to be installed vertically or horizontally – to suit the available space.

Motor outputs

Vertical mounting position

At a glance

■■ Three sizes■■ Designed to match WS-Bas and TG-Bas components

■■ Ideal for travel applications■■ Outputs: up to 1.7 kW■■ Two speeds: 8/2-pole■■ Standard wide voltage range: 380 – 415 V at 50 Hz

■■ Other special voltages available:

■■ 380 V at 60 Hz■■ 440 V at 60 Hz

MT-Bas motors and TG-Bas gearboxes are supplied as complete geared motors – available as finely graded motor/gearbox combi nations

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Page 10: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Perfectly matching components –complete Bas travel units

Wheel block Gearbox MT-Basmotor

h5 h6 w5 w6 w7 w8 xA 1) AC AG

[mm]

WS-Bas 125 TG-Bas 20 80 A 8/2 104 241 676 133.5 226.5 5 6 134 110

WS-Bas 125 TG-Bas 20 80 B 8/2 104 241 676 133.5 226.5 5 6 134 110

WS-Bas 160 TG-Bas 30 90 A 8/2 129 274 741 144 247.5 13 5 162 110

WS-Bas 200 TG-Bas 40 90 A 8/2 148 292.5 778.5 164.5 277 11 10 162 110

WS-Bas 250 TG-Bas 50 112 A 8/2 178 366.5 916.5 191.5 331.5 8 9 250 110

WS-Bas 315 TG-Bas 60 112 A 8/2 218 406.5 955.5 205 371 9 16,5 290 110

1) xA = ground clearance

Bas travel units – dimensions

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w7

w5

w8

xA

w6 AG

AC

h5

h6

w7

w5

w8

xA

w6 AG

AC

h5

h6

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Page 11: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Perfect planning –drive solutions tailored to meet your needs

Our online planning tool enables you to find the right solution to meet your design requirements quickly and conveniently. You can configure a drive solution to meet your needs on our web-based platform and receive all important data and information for the relevant product. A practical and intuitive user interface helps you find the right solution to meet your needs quickly and easily.

Besides a comprehensive product overview, our planning tool provides you with all the technical data you need for project engineering. 2D and 3D CAD geometry files that can be fully integrated into your design drawings are available to support your installation layout planning.

Your benefits with our Demag Designer tool:

■■ Complete and up-to-date product information

■■ Fast and individual selection■■ Detailed information can be downloaded immediately

■■ Plausible configuration■■ Fast response times for quotation compilation

■■ Simple handling thanks to a user-friendly interface

■■ Multilingual user interface■■ Direct orders via the Demag Shop system: www.demag-shop.com

A mouse-click away: the online planning tool for Bas travel units37

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Page 12: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

All data at a glance –simple planning and ordering

Wheel block Torque bracketGeared motor

TG-Bas gearbox MT-Bas motor

Wheel block Travel wheel dia.[mm]

Load capacity[t]

Weight[kg]

Part no.(set)

Gearbox Transmission ratio

(i)

Travel speed[m/min]

for 50 Hz operation

Weight[kg]

Motor Weight[kg]

WS-Bas 125 125 5 1.9 755 155 61

TG-Bas 20 44.14 6.3/257 MT-Bas 80 A 8/2 15

MT-Bas 80 B 8/2 15

TG-Bas 20 27.96 10/407 MT-Bas 80 B 8/2 15

MT-Bas 90 A 8/2 22

WS-Bas 160 160 7 2.6 755 255 61

TG-Bas 30 55.73 6.3/2510 MT-Bas 80 B 8/2

MT-Bas 90 A 8/2 22

TG-Bas 30 36.11 10/40 10 MT-Bas 90 A 8/2

WS-Bas 200 200 10 4.6 755 355 61TG-Bas 40 73.75 6.3/25 17 MT-Bas 90 A 8/2 22

TG-Bas 40 44.32 10/40 17 MT-Bas 90 A 8/2 22

WS-Bas 250 250 16 8.8 755 455 61TG-Bas 50 87.4 6.3/25 46 MT-Bas 112 A 8/2 46

TG-Bas 50 56.4 10/40 46 MT-Bas 112 A 8/2 46

WS-Bas 315 315 22 13.0 755 555 61TG-Bas 60 107 6.3/25 60 MT-Bas 112 A 8/2 46

TG-Bas 60 77.2 10/40 60 MT-Bas 112 A 8/2 46

Bas travel units – technical data

WS-Bas wheel blocks: technical data

Standard travel wheel tread [mm]

Weight [kg] Part no.

WS-Bas 125

55 25 755 101 61

65 25 755 103 61

75 24 755 105 61

85 24 755 107 61

WS-Bas 160

55 37 755 201 61

65 37 755 203 61

75 36 755 205 61

85 36 755 207 61

WS-Bas 200

55 63 755 301 61

65 63 755 303 61

75 62 755 305 61

85 61 755 307 61

WS-Bas 250

65 94 755 401 61

75 93 755 403 61

85 92 755 405 61

100 91 755 408 61

WS-Bas 315

75 136 755 502 61

85 135 755 504 61

95 133 755 506 61

110 131 755 509 61

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Page 13: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Wheel block Torque bracketGeared motor

TG-Bas gearbox MT-Bas motor

Wheel block Travel wheel dia.[mm]

Load capacity[t]

Weight[kg]

Part no.(set)

Gearbox Transmission ratio

(i)

Travel speed[m/min]

for 50 Hz operation

Weight[kg]

Motor Weight[kg]

WS-Bas 125 125 5 1.9 755 155 61

TG-Bas 20 44.14 6.3/257 MT-Bas 80 A 8/2 15

MT-Bas 80 B 8/2 15

TG-Bas 20 27.96 10/407 MT-Bas 80 B 8/2 15

MT-Bas 90 A 8/2 22

WS-Bas 160 160 7 2.6 755 255 61

TG-Bas 30 55.73 6.3/2510 MT-Bas 80 B 8/2

MT-Bas 90 A 8/2 22

TG-Bas 30 36.11 10/40 10 MT-Bas 90 A 8/2

WS-Bas 200 200 10 4.6 755 355 61TG-Bas 40 73.75 6.3/25 17 MT-Bas 90 A 8/2 22

TG-Bas 40 44.32 10/40 17 MT-Bas 90 A 8/2 22

WS-Bas 250 250 16 8.8 755 455 61TG-Bas 50 87.4 6.3/25 46 MT-Bas 112 A 8/2 46

TG-Bas 50 56.4 10/40 46 MT-Bas 112 A 8/2 46

WS-Bas 315 315 22 13.0 755 555 61TG-Bas 60 107 6.3/25 60 MT-Bas 112 A 8/2 46

TG-Bas 60 77.2 10/40 60 MT-Bas 112 A 8/2 46

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Page 14: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Pre-assembled sets of end carriages –solutions ready for installation to meet individual requirements

Pre-assembled pairs of end carriages for single-girder overhead travelling cranes

Pre-assembled pairs of end carriages for double-girder overhead travelling cranes

Tandem design for double-girder overhead travelling cranes

DFW-Bas L-E crane end carriages

DFW-Bas L-Z crane end carriages

DFW-Bas L-T crane end carriages

ekt

ekt

ekta

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Page 15: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

Demag Bas travel unit technical data

Our Bas travel units are used in travel applications for steel crane and hoist structures and related mechanical engineering superstructures. They feature a compact, modular design and can be connected direct to crane girders and load-bearing structures. Bas travel units consist of a torsionally rigid box section and complete travel units with geared motors and wheels from the Demag

Crane end carriages Wheel base ekt / ekta [mm]

1,500 2,000 2,500 3,150 3,550 4,000 4,250 4,750 5,000 5,100 5,450 5,800

DFW-Bas L-E

125/… ■ ■ ■ ■ ■

160/… ■ ■ ■ ■

200/… ■ ■ ■ ■

DFW-Bas L-Z

160/… ■ ■ ■

200/… ■ ■ ■ ■ ■

250/… ■ ■ ■ ■ ■

315/… ■ ■ ■ ■

DFW-Bas L-T250/… ■ ■ ■

315/… ■ ■ ■ ■

Bas modular system. They can be configured for a wide range of load capacities for solutions to meet specific application requirements for safe crane and machinery travel motions that are kind to the rails.

At a glance

■■ Torsionally rigid, welded box-section design

■■ Pre-assembled steel superstructure with golden yellow finish coat (RAL 1004)

■■ Variants:■■ DFW-Bas L-E for single-girder overhead travelling cranes

■■ DFW-Bas L-Z for double-girder overhead travelling cranes

■■ DFW-Bas L-T in tandem configuration for double-girder overhead travelling cranes

■■ Wheel bases from 1,500 to 5,800 mm

■■ Travel drive designed for the required travel speed and load

■■ Long-travel speeds up to 10/40 m/min

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Page 16: WS-Bas wheel blocks TG-Bas gearboxes MT-Bas motors ...4.imimg.com/data4/KR/MC/MY-5286700/bas-drive-components.pdfComplete Bas travel unit comprising wheel block, gearbox and motor

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Dynamic markets need dependable solutions

Easy to maintain The Bas drive system for crane installations consists of functional and reliable components. Maintenance and repair – whether on complete units or individual components – are quick and easy on this quality product designed and built to European standards. If you do not do your own maintenance, service and repair, Demag’s Service engineers with their technical experience and skills are ready to help quickly and efficiently.

Reliable spare parts supply Spare parts for the Bas drives system are supplied:

■■ quickly and flexibly through our integrated network of branch offices and partners

■■ with absolute reliability for many years

■■ at particularly attractive value- for-money prices.

Demag ServiceYour reliable partner – ensuring safe and efficient operation and maintaining the value of your investment.

Related documentation■■ EKKE-Bas, ZKKE-Bas brochure, ident. no.: 213 700 44■■ DR-Bas rope hoist brochure, ident. no.: 213 693 44

Demag Cranes & Components (India) Pvt. Ltd.Gat No 330, 332, 333, 334, Nanekarwadi (Chakan)Tal-Khed, District Pune - 410501 IndiaPhone: +91 2135 614200 Fax: +91 2135 614300 Email: [email protected]

Capable after-sales service ensures the highest degree of availability

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