Development of container goat crane, cl. 32t

Introduction.

The diploma project considered a comprehensive mechanization of loading and unloading operations at a railway container warehouse with the design development of a goat container crane, Q = 32 t.

The crane is intended for transportation of large-capacity containers of standard sizes 1A, 1C. Crane span Lcr = 25000mm. Length of lcons consoles = 500 mm.

1. Integrated mechanization of the railway container depot.

This project considers the complex mechanization of the railway warehouse. A high degree of automation of loading and unloading operations of this warehouse was made possible due to the fact that cargo on it is stored in large-capacity containers.

Containers are standardised by external and internal dimensions and locations of cargo storage gripping devices. In the corners of containers there are special elements - fittings used as container supports during their tabulation and as elements for catching containers during their reloading.

Due to the fact that large-capacity containers weighing 10t (1D) and 25t (1BB, 1B) in LPG are usually not used, when automating a railway warehouse, we will assume that all cargo turnover on it occurs in containers weighing 32t (1A) and 20t (1C).

Since the cargo turnover of the warehouse is closely related to the time of loading and unloading operations, the purpose of automation is to reduce the time for their implementation and, as a result, increase the cargo turnover of the warehouse and maximize the profit from the use of storage areas. In addition, the purpose of automation is to remove maintenance personnel from the loading and unloading area to prevent industrial injuries.

As a means of automating the warehouse during the diploma project, a goat container crane was chosen, the feasibility of which is justified by a large warehouse area, which complicates the use of ground loaders. In addition, this increases the storage capacity by storing containers in 2 tiers and reducing the gaps between containers due to the lack of need to leave driveways for loaders.

As a load-gripping device in the crane, it is proposed to use a special load-gripping device - a spreader. The spreader automatically engages and disengages the container without the participation of a slinger. When the spreader is lowered on the container, the T-shaped pins enter the holes of the fittings and rotate 90 degrees, engaging the spreader with the container. After transporting the container, the pins return to their original position, releasing the container.

For precise guidance of spreader on container the call-up is made rotary. It is also possible to work with several types of containers. If it is necessary to change the container size instead of the container 1C, the spreader grasps the frame for working with the container 1A and electrical connectors are connected to this frame for operating the bayonet rotation mechanisms.

The goat container crane is made with two load-carrying consoles, on which it is limited by 1C containers, which makes the structure cheaper and at the same time does not affect the operation of the warehouse, since there is enough storage space for 1A containers between the crane supports. At the same time, the crane supports are designed so that the containers 1C pass through them without turning the grip, which accelerates the loading and unloading operations.

2. Brief description of the designed gantry crane.

The designed crane is a container goat crane designed for servicing a railway container warehouse completely filled with cargo containers, with half of them weighing 20t and the other half weighing 32t. During a work shift, the size of overloaded containers changes, on average, four times a day.

All elements of steel structure - box section. Span structure consists of 2 main and 2 end beams resting on 4 supports connected to each other in pairs by braces. The crane movement mechanism consists of balancers and eight running trolleys assembled in pairs under each support and having an individual drive.

Freight trolley is a welded frame installed on four double-flanged drive wheels and moving along crane bridge. On the frame of the goat crane trolley there is a lifting mechanism and a movement mechanism of the trolley.

Lifting mechanism represents two-drum winch.

The movement mechanism of the freight trolley consists of two drives: one drive - for each pair of running wheels.

The distance horizontally between the axes of the rails of the crane track is called the crane span, and the distance between the axes of the running wheels or between the axes of the balance trolleys is called the crane base. The distance between the longitudinal axes of the rigged rails is called the track of the trolley. The span of the designed crane is 25000mm, and the base is 14000mm. The track of the trolley is 13500mm, and the base is 2500mm.

11. Safety requirements for the designed crane.

11.1. Introduction.

The object discussed in this section is a 32-ton goat container crane installed on railway and factory container sites. The crane is operated outdoors. We will analyze the environmental factors that negatively affect the maintenance personnel during the crane operation. These factors can be conditionally divided into:

• Harmful, i.e. factors that constantly affect the maintenance personnel, regardless of their actions.

• Potentially hazardous, i.e. factors that may occur in case of faults of the crane system and improper actions of maintenance personnel.

For the crane in question, the following harmful factors can be identified:

• Vibrations occurring during operation of crane mechanisms, when running wheels interact with rail tracks during movement and when crane steel structure oscillates from dynamic loads during lifting.

• Noise generated during operation of crane mechanisms, when running wheels interact with rail tracks during movement and when loads interact with the base to which they are lowered.

For the crane in question, the following potential hazards can be identified:

• High height on which the crane operator's workplace is located.

• Availability of high voltage power electrical cables.

• Availability of combustible materials in the service personnel work area.

11.2.Operability safety devices.

11.2.1.Aleries, platforms and stairs, fences of movable parts.

Galleries, platforms and stairs on the cranes are provided for their maintenance, repair and control, and must comply with the requirements of GOST 12.2.06781 and Gosgortekhnadzor.

Galleries, passageways and crane platforms shall have fences on the outside. For the designed crane, the end beams used for the passages have a flooring and a fence on the outside. The crane freight trolley has a flooring, since the equipment installed on it cannot be serviced from the bridge gallery. At that, a guard is installed on the end sides of the trolley. The flooring of the platforms and galleries is metal, eliminates the possibility of sliding legs (steel corrugated sheets).

The dimensions of the hatch for the entrance to the platforms and galleries arranged in the flooring are taken as 500x500 mm. Free height above the flooring of galleries, platforms and passages, with the exception of the flooring of end beams and trolley, 1800 mm. The width of the gallery provides a free passage of 500 mm. The height of the railing with railings of galleries, passages and platforms is 1000 mm with a continuous covering at the bottom to a height of 100 mm.

Inclined stairs have an angle of inclination of not more than 75 °, are guarded with railings and have a width between railings of 600 mm, The pitch of the steps is the same along the entire height of the stairs. Clamps with a distance between them of 500 mm are installed on the upper platform.

Easily accessible parts of the lifting machine in motion, which may be the cause of an accident, must be closed with firmly fixed metal removable fences, allowing convenient inspection and lubrication. Mandatory fencing is subject to:

- couplings with protruding bolts and keys;

- shafts of bridge type cranes movement mechanisms at

speeds greater than 50 rpm.

Shafts of other mechanisms of lifting machines, which are located in places intended for the passage of maintenance personnel, are also subject to fencing.

All non-insulated current-carrying parts of the crane electrical equipment, including switches, contactor panels and resistance boxes, shall be protected in case of their location, which does not exclude accidental touching of persons in the cockpit on galleries and platforms of the lifting machine, as well as near it. Non-insulated current-carrying parts of the circuit breakers supplying voltage to the main trolley wires or to the supply cable shall also be protected.

The main trolley wires located along the crane track and their current collectors are not available for accidental contact with them from the crane bridge, stairs, landing platforms and other platforms where people may be located, which is provided by the appropriate location or fencing of wires and current collectors.

Trolls are fenced along the entire length and at the ends.

Lifting equipment, cockpits and fences of cranes, trolleys, grips are painted in yellow signal color. The main meaning of the yellow signal color is a warning, a possible danger. The contrasting color is black. Warning painting of objects and elements (except for open movable parts of production equipment: handles, flywheels) should be made in the form of alternating inclined strips at an angle of 4560 ° with a width of 30200 mm of yellow signal and black colors with a width ratio of strips of 1:1. The width of the strips should be set depending on the size of the object and the distance from which the warning should be visible.

11.2.2. Electrical safety.

Electrical machines, devices and instruments for control of crane mechanisms are installed in accordance with the rules of Gosgortekhnadzor, the requirements of PUE and the corresponding RTM. Distance between electric motor housings, other electrical equipment and crane steel structures shall be at least 300 mm. To service electrical machines, the width of the free passage between the crane steel structures and the electrical equipment housings must be at least 600 mm (in light up to 1000 mm).

Magnetic controllers and control cabinets are installed on the crane bridge at a distance of at least 150 mm from the fence for the possibility of laying wires at the rear. The protective panel is located on the cockpit wall with the width of passage in front of the panel front not less than 600 mm, the chopper handle must be at a height not more than 1700 mm from the floor level. Starting resistors shall be located at a distance of not less than 300 mm from magnetic controllers and not less than 150 mm from floor level.

On cranes in power circuits, it is not allowed to lay copper wires with a section of less than 2.5 mm2 with insulation for a voltage below 500 V. It is allowed to use wires with aluminum multi-conductor cores with a section of not less than 16 mm2. Control circuits use copper wires with a section of at least 1.5 mm2, aluminum wires with a section of at least 4 mm2, for communication, television and telecontrol circuits - a wire with a section of 2.5 mm. The grade of wires used for installation and the method of protection are selected according to PTM 24.090.3778.

Wiring on metal structures, in cabins and inside machine rooms is performed in steel ducts or pipes by wires of PR, PRG types (catalog 19.23.0581 "Power wires with rubber insulation"; GOST 2052075) or by cable of KRPT, KRPS types (GOST 1349777 "Power cables flexible for voltage 660 V").

It is recommended to remove from the ducts and pipes to the motors, resistors and limit switches in flexible metal hoses and connect the hoses to the electrical equipment according to OST 24.09.0875.

The current supply with rigid trolleys is used when supplied from the AC network with a frequency of 5060 Hz, voltage of up to 660 V and from the DC network with a voltage of up to 500 V. The selection of the profile of the trolls is determined by the design of the current collectors and the required section.

Contacts of safety devices and devices (limit switches, hatch interlocks, cockpit doors, emergency circuit breaker, etc.) shall be operated to break the electrical circuit.

Electrical diagram of hoisting machine electric motors control shall exclude:

- self-start of electric motors after voltage recovery in

mains supplying the lifting machine;

- starting of electric motors not according to the specified acceleration scheme;

- starting of electric motors by contacts of safety devices

(contacts of limit switches and interlocking devices).

To supply voltage to the main trolley wires, a switch must be installed in an accessible place for disconnection. The switch supplying voltage to the main trolley wires shall have a device for locking it in the off position.

The inlet device (protective panel) of the crane must be equipped with an individual contact lock with a key (key-mark), without which voltage cannot be supplied to the crane.

11.2.3. Fire safety.

Crane equipment shall be made in accordance with the requirements of RD 24.090.9189 "Lifting machines. Main requirements for reconstruction for use in fire hazardous areas "and TP RD 24.090.9689" Lifting machines for fire hazardous areas. Basic Design Requirements. "

Control cockpit heating devices, crane electrical equipment shall be fire safe, Electrical insulation and vibration insulation flooring shall comply with fire safety standards.

Crane steel structures shall be refractory coated.

When extinguishing electrical equipment, use carbon dioxide fire extinguishers O-5 or O-U-2. Sand tanks shall also be provided.

Based on fire safety requirements, the distance from buildings to stacks of roundwood and lumber shall be at least 15 and 30 m, respectively.