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11 months ago

MDA Technologies 3/2016

MDA Technologies 3/2016

Keeping the load safely

Keeping the load safely hooked MEASUREMENT AND CONTROL Shaun Prince Mobile gantry cranes are used to transport precast elements for wind turbines or bridges. For the design, a powerful software is needed. In this case, the control of the winch was simulated with Automation Studio — Shaun Prince Upon realizing that standard gantry cranes available on the market did not meet their specific conditions and requirements, Max Bögl Transport und Geräte GmbH & Co. KG decided to develop and build their own custom model. With the collaboration of Grunau & Schröder Maschinentechnik (GSM), a joint project was created and led to the development of the Travellift, a mobile gantry crane with a capacity of 65 tons. GSM, a division of Bauer Maschinen GmbH founded in 1993, is a service company specialized in mechanical engineering. Max Bögl Transport & Geräte GmbH & Co. KG, a division of Max Bögl group, is one of the five largest construction companies in Germany. In this collaboration, GSM was responsible for the entire design and engineering of the mobile gantry crane prototype. In the early stages of the project, a feasibility study and pre- dimensioning of the crane was carried out. During predimensioning, the specifications of the mechanical, electronic, and hydraulics systems were established. Based on this design, compliance to all applicable guidelines, standards and safety regulations were verified. In a second step, the machine safety and structural analysis of the bearing structure was done in close cooperation with external companies. The complexity of the design and project management challenges were present throughout all phases of the project including the elaboration of the overall concept, procurement coordination, communication and coordination with external companies, and schedule control. During later project phases, all details of the hoisting gear, the hydraulic power unit and the chassis frame’s drive systems and controls were implemented. To do so, design software solutions like SolidWorks 2015, Automation Studio and AUTOCAD were used. Author: Shaun Prince B.Eng, Project Manager, Development of Hydraulics & Drive Technology at the company Grunau & Schröder Maschinentechnik GmbH in Drolshagen, Germany MDA Technologies 3/2016

The lift and carry crane in detail It is the Travellift’s job to pick up various workpieces, to lift them, transport and position them. The Travellift lifts the item to be transported using two winches via a crossbeam. The raised items can then be moved. Thanks to the arrangement and variable maneuverability of the wheels, the items can be maneuvered and loaded in a variety of ways. The Travellift is hydraulically powered. The hydraulic energy is generated by a diesel motor, which drives the hydraulic pumps. The Travellift’s chassis consists of four wheel units with hydraulically powered gearboxes, which are each individually maneuverable. To achieve the maximum degree of maneuverability when transporting workpieces, the Travellift has five methods of steering which can be selected via the two steering type selector switches, one installed in the driver’s cabin and one available using radio-controlled remote access. The continuous activation of the drive motor from 0 – 15 km/h is achieved thanks to an electronic accelerator pedal and direction of travel switch. Steering is activated by an electronic steering force simulator (steer-by-wire). There is, therefore, no direct Simulation of the winch control During project planning of the winch control, safe holding of the winch was simulated under real operating conditions. Automation Studio, a simulation software developed by Famic Technologies, was used to simulate the hydraulics and electrical systems. In particular, the behavior of the brakelowering valves that have been flanged on the winches’ hydraulic motors was analyzed under the following operational states: n Stop of the winches by withdrawing the control lever n Stop by control outage = Emergency Stop Category 1, no electric energy, diesel engine still running n Stop by outage of diesel engine = Emergency Stop Category 0 The most critical operation state “the Emergency Stop Category 0” will be explained in detail in the following section. mechanical connection between the steering wheel and the wheels. The steering force simulator displays the intended value for the angle of steering. A safety angle display unit is built in the center point of each wheel-bearing, which detects the actual value of the steering axis. The lift working area is divided into two lifting hoists and two traveling trolleys, which are also hydraulically powered. They are steered using a control lever in the right hand seat console. The hydraulic aggregate forms the central power supply for energy supply and the steering unit for all hydraulic and electronic users of the Travellift. Designing the hydraulic aggregate involved the most extensive work due to the complex, multiple requirements for all of the functional demands, including installation space regulations as well as fuel emissions and noise regulations. The Travellift was installed and commissioned under the management and supervision of Grunau & Schröder Maschinentechnik at Max Bögl. Following a Features of Use n Handles different shapes of structural components n High driver vehicle dynamics n Speed of travel up to 13 km/h fully loaded - 15 km/h empty n Exact and direct steering behavior n Different types of steering for maximum maneuverability n Quick but also delicate and precise control of the functions n Working capacity 16-20 hours/day n High full throttle ratio (with 3 liters) n Exhaust Emissions Guideline Level 4 final n Sound Pressure Level Lp ≤ 80 db(A) at 5 meters Removal because of neighboring housing settlements successful six-month test phase with two shifts working each day we are planning to produce further pieces of equipment. MDA Technologies 3/2016

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