|
Tuma-Group sells spare parts and equipment for the KPL 5-30 floating crane. Spare parts for floating cranes KPL 5-30 project R99, R12A, 528, 81040, 1451:
- Reducer of the reach change mechanism assembly and parts: gear shaft, gear wheels, springs, etc.
- Swing eye bearing (connection of boom to trunk)
- Turning mechanism gearbox for floating cranes of project P99, 81040, 1451 assembled and parts for them: running gear (splined and keyed), vertical shaft, parts of the limiting torque coupling, high-speed gear shaft, bevel pair and other spare parts.
- Lifting and closing winches.
- Electric motors for swing, lift and reach mechanisms 80 kW, 75 kW. 37 kW.
- Control panels, contactors, switches, current collectors.
- Rails of the supporting device, rollers, bushings for them.
- Arrow and trunk blocks.
- Brake and drive coupling halves for lifting, turning and retracting mechanisms.
- Arrow and trunk blocks.
Type KPL 5-30, project 1451
Floating crane capacity 5 t
Vessel type:
Faucet type: full rotation grab.
Purpose of the vessel: performance of reloading works.
Place of construction: Svirskaya shipyard (Russia, Leningrad region, Nikolsky village); Gorodets Shipyard (Russia, Gorodets).
Register Class:"*ABOUT"
Characteristics:
Overall length (boom in stowed position): 45.2 m
Estimated length: 28.6 m Width: 12.2 m
Side height: 2.6 m
Average draft when loaded: 1.23 m
Loaded displacement: ~300 t
Crew (on watch): 2 people
Type KPL 5-30, project 528, 528B
Floating crane capacity 5 t
Vessel type: full-rotating load-lifting diesel-electric non-self-propelled floating crane.
Faucet type: full-rotary electric grab.
Purpose of the vessel: carrying out loading and unloading operations.
Place of construction: Plant "Nizhny Novgorod Motor Ship" (Russia, Bor);
Register Class:"*R"
Characteristics:
Project 528 /528B
Overall length (boom in stowed position): 38.5 m
Estimated length: 24.7 / 24.8 m
Width: 12.1 m
Side height: 2.5 m
Overall height (boom in stowed position): 8.93 m
Average draft when loaded: 0.87 m
Loaded displacement: 221.4 t
Number of crew seats: 11/8 people
Autonomy: 15 days
Main diesel generator power: 300 l. With.
Main diesel generator brand: DG200/1 (U08) (7D12 diesel, MS128-4 generator) or U18GS-2k (1D12B-2k diesel, GS104-4 generator)
Auxiliary diesel generator power: 20 l. With.
Auxiliary diesel generator brand: DG12/1-1 (diesel 2Ch10.5/13-2, generator MSA72-4A)
Type KPL-5-30, project 81040
Floating crane capacity 5 t
Vessel type: full-rotating load-lifting diesel-electric non-self-propelled floating crane.
Faucet type: full rotation grab.
Purpose of the vessel: carrying out reloading works.
Place of construction: Plant "Nizhny Novgorod Motor Ship" (Russia, Bor); Akhtubinsky Shipyard (Russia, Akhtubinsk).
Register Class:"*ABOUT"
Characteristics:
Overall length (boom in stowed position): 45.1 m
Estimated length: 28.6 m
Width: 12 m
Side height: 2.6 m
Average draft when loaded: 1.14 m
Loaded displacement: 349.7 t
Number of crew seats: 9 people
Autonomy: 20 days
Main diesel generator power: 330 l. With. (224 kW)
Main diesel generator brand: DGR224/750 (diesel 6Ch23/30, generator MCC375/280-750)
Auxiliary diesel generator power: 80 l. With. (58.8 kW)
Brand of auxiliary diesel generator: DGA50M1-9 (diesel 6Ch12/14, generator MSK83-4)
Type KPL-5-30, project R-99
Floating crane capacity 5 t
Vessel type: full-rotating load-lifting diesel-electric non-self-propelled floating crane.
Crane type: full-rotary grab electric.
Purpose of the vessel: loading and unloading operations.
Place of construction: Plant "Nizhny Novgorod Motor Ship" (Russia, Bor)
Register Class:"*ABOUT"
Characteristics:
Overall length (boom in stowed position): 45 m
Estimated length: 28.6 m
Width: 12.3 m
Side height: 2.6 m
Overall height (boom in stowed position): 10 m
Displacement with cargo: 333 t
Average draft with load: 1.1 m
Number of crew seats: 9 people
Autonomy: 20 days
Main diesel generator power: 330 l. With.
Main diesel generator brand: DGR224/750 (diesel 6Ch23/30-1, generator MCC375/280-750)
Auxiliary diesel generator power: 80 l. With.
Auxiliary diesel generator brand: DGA50-9 (diesel 6Ch12/14, generator MSK83-4)
TUMA-GROUP sells and supplies gearboxes, electric motors, and components for the KPL 5-30 floating crane.
From us you can buy gearboxes, electric motors, and components for the KPL 5-30 floating crane at low prices!
We have a bevel-cylindrical slewing gear for the KPL 5-30 floating crane. Project of floating crane KPL 5-30 R99. The rotation gearbox is completely ready for shipment.
1. Introduction 2. Initial data for design 3. Crane performance and operating mode of its mechanisms Lifting mechanism Boom system and reach change mechanism Slewing ring and turning mechanism Crane stability Control of crane mechanisms Conclusion Literatures
1. INTRODUCTION The floating crane can be installed on a pontoon or on a ship. A rotating part with a swinging boom is mounted on the crane pontoon. In longitudinal section, the pontoon has a rectangular shape with undercuts at the lower ends of the bow and stern parts. At the ends (in the center plane) of the pontoon of a crane with a lifting capacity of 5 tons (prototype KPL5-30) there are fairleads for installing pile pins. The metal body of the pontoon is divided into waterproof compartments by longitudinal and transverse bulkheads. The compartments house the engine room, where the main and auxiliary diesel generators are located; drainage, fire, sanitary and other systems; service and residential (for the crew) premises. On the deck of the pontoon there are anchor and mooring mechanisms, a rack for stowing the boom in a stowed position. Floating reloading cranes are full-rotating, equipped with grab-type lifting mechanisms, and can operate independently of the availability of power sources on shore to reload almost all dry cargo at unequipped berths. The lifting capacity at all boom radii is usually constant, which creates the opportunity, especially when working in grab mode, for continuous loading of ships. The designs of floating cranes, even with the same lifting capacity and maximum boom radius, may differ in the types of slewing bearings. (on a column or support circle) and a boom system (an articulated boom with a flexible or rigid guy, a straight boom with a leveling pulley). For floating cranes with a lifting capacity of up to 16 tons, the boom is lowered onto the pontoon strut using a lift-out mechanism without disconnecting the boom rods, which reduces the labor intensity of the work and reduces the time spent on laying the boom in the traveling position. Electric power is supplied to the rotating part mechanisms from a diesel generator located in the engine room of the pontoon, through the internal hole of the central axle and the current collector attached to it. It is also possible to connect the crane to shore power. The crane is attached to the pier or vessel with mooring ropes wound on the drums of mooring winches or capstans, or with two pile pins lowered into the ground through hawse doors at the end of the pontoon. The piles are lifted from the ground using mooring winches and a pulley system.
2. INITIAL DATA FOR DESIGN
Develop a project for a floating crane based on the KPL-5-30 prototype. With technical specifications provided in Table 1.
Technical characteristics of the designed crane Table 1 Speeds: lifting boom radius change m/min m/min Estimated lifting height: above rail head to rail head m m
. PERFORMANCE OF THE CRANE AND OPERATING MODE OF ITS MECHANISMS
The cargo transhipment technology for the wagon-ship operation option is schematically shown in Fig. 1.
Rice. 1 Diagram of the warehouse-ship crane operation variant. hp - lifting height of the load, hp=7 m; hop - height of lowering the load, hop=12 m; - angle of rotation of the crane = 180°; R1 - minimum boom radius, R1=8 m; R2 - maximum boom radius, R2=27 m.
Productivity is nothing more than the mass of cargo handled in 1 hour of work.
where is the mass of the load; Number of cycles per hour. cargo weight: Let's determine the number of cycles per hour: 
where is a coefficient taking into account the combination of cycle operations, assumed to be 0.8; Time for securing the load: Time to lift the load to a height:
 With
Time for turning the crane with a load and back; 
Boom extension change time; 
Load lowering time:
Time to unsling from load: Gripper installation time: 
Average duration of activation of crane mechanisms: lifting mechanism rotation mechanism departure mechanism 
4. LIFTING MECHANISM
The load lifting mechanism is designed for lifting, holding, adjusting, lowering loads, as well as activating grabs The lifting mechanism of a hook crane consists of a hook, cargo ropes, guide blocks, and identical single-drum winches. Each winch is equipped with an electric motor, a clutch, a double-block brake, a gearbox, and a coupling for connecting the gearbox to the drum. One of the winches is called closing, the other - supporting. The ropes wound onto the drums of these winches are named accordingly - closing and supporting. The hook crane has 2 lifting mechanisms. A prerequisite for the design of the lifting mechanism is a speed control device. The lifting mechanism is equipped with a set of devices that ensure safe operation, such as: load limiter (LOL), limit switches for lifting height and lowering depth.
Rope calculation The calculation of the lifting mechanism begins with the selection of a cargo rope. The steel rope of the cargo winch is selected according to GOST, taking into account the breaking force
where is the maximum force in the rope branch; Rope utilization rate; For cranes with clamshell operation. Let us determine the maximum force in the rope branch:
where is the acceleration of free fall; Number of ropes leaving the end blocks; Taking into account the found breaking force, a double lay steel rope of type LK-R 6x19 wires with one organic core with a diameter of 24 mm, GOST 2688-80 is suitable for the designed crane. Block calculation The blocks are calculated and selected taking into account the ropes passing through them. According to GOST rules, the diameter of the block is determined:
Let us depict the rope block according to the calculations made for the designed crane in Fig. 2.
Rice. 2 Rope block Drum calculation 1. - cutting step; 
Drum groove depth: 
Groove radius: 
Rice. 3 Groove profile for rope with single-layer winding
Drum diameter: Drum section thickness: Drum length: 
where is the length of the drum cutting; Determine the length of the uncut part of the drum A- length of the uncut part of the drum. 
Total number of threading turns; 
where are the working turns; 
H1=23 m=23000 mm; H2=15 m=15000 mm;
Spare coils; Fastening threads; Determine the length of the drum cutting Determine the length of the drum 
Fig.5 Fastening the rope to the drum with pads
Calculation of the electric motor of the lifting mechanism
Let's determine the required power of the crane:
where is the overall efficiency of the mechanism; 
Since the designed crane has a hook mode of operation, two electric motors with the following power are used: Guided by the above calculations, we select an engine of type MTN 711-10 with a power N 80 kW and rotation speed 580 rpm. Gearbox calculation To select a gearbox, we need to know the gear ratio: where is the drum rotation frequency; 
Taking into account the found gear ratio, we select the RM-850 gearbox, which has a high-speed shaft rotation speed of 600 rpm, power at duty cycle = 40% - 69 kW, at duty cycle = 100% - 27.9 kW. Brake calculation Calculation and selection of a brake begins with finding the value of the braking torque: 
where is the braking coefficient; Torque; 
where is the number of winches; 
Taking into account the braking torque, we select a shoe brake driven by an electro-hydraulic pusher type TKG-400M with a brake pulley diameter of 400 mm and a braking torque of 1500 Nm. 5 BOOM SYSTEM AND MECHANISM FOR CHANGING BOOM REACH The mechanism for changing the boom radius with a boom device is designed to change the radius of the serviced area. With variable reach, the distance from the load to the center of rotation of the crane changes and the crane services the area between two circles with radii equal to the maximum (Rmax=30m) and minimum (Rmin=8 m) boom reach. The crane we are designing uses an articulated boom system, consisting of a boom, a trunk and a guy. The guy is flexible, in the form of a rope. The geometric dimensions of the boom, trunk and guy rope must be such as to ensure the ability to move the load to a given height and a given maximum and minimum boom reach. The flexible guy is hinged on the trunk with a constant shoulder, i.e. a constant distance from this hinge to the point of connection of the boom with the trunk. The trunk, hingedly connected to the boom, can move relative to the boom in its plane. In order to reduce power consumption by the mechanism for changing the reach, the boom systems are balanced by a movable counterweight with variable reach. Mechanism for changing boom extension on the designed crane it is sector-crank. In a sector-crank mechanism, the gear sector is driven by a gear. The sector, rigidly attached to the counterweight rocker arm, has a common axis of rotation with the rocker arm, supported by supports. When the gear rotates, the gear sector together with the rocker arm rotates, and the force of the boom rod, pivotally connected to the rocker arm and the boom, causes the boom to swing. The kinematic diagram of the mechanism for changing the boom reach is shown in Fig. 5.
Kinematic diagram fig.
6 ROTARY DEVICE AND ROTARY MECHANISM
The slewing bearing and rotation mechanism are used in all load-lifting cranes, which provide for the rotation of part of their structure around a vertical axis. All of them belong to full-rotary and part-rotary cranes. There are two main types of full-rotation devices: on a platform (for our crane), on a column. In a slewing crane, the turning part rests on wheels or rollers that move along a circular rail (rail ring) attached to a support drum. The turning mechanism on the turntable consists of an electric motor, an elastic coupling with a brake pulley, a double-block brake, and a gearbox with a vertical shaft, at the end of which a spur gear is mounted on a key. When rotating, this gear is pushed off from a stationary gear (rigidly attached to the support drum) and runs around it, providing the turntable with rotation around a vertical axis at a certain frequency.
To protect shafts and gears from overload, a friction gear is installed in the gearbox, consisting of driving friction disks, driven lower and upper friction pressure disks, and a spiral/pressure spring. The following devices are used in the rotating support and rotation mechanism for safe operation: blocking the brake of the rotation mechanism; built-in limit torque clutch, which slips in cases of sudden start-up or sudden braking of the rotation mechanism, as well as in case of jamming of the rotating part. The rotation mechanism has to overcome resistance: friction forces (in the mechanism itself); inertia forces (during acceleration, braking and when changing speed in general); wind loads.
Calculation of the load acting on the trunk guy wire.
7. CRANE STABILITY Stability- this is the ability of a pontoon with a rotating part to return to its original position after the cessation of external forces causing its inclination. Due to the imbalance of the boom system, when taking a load onto a hook or into a grab, the center of gravity of the rotating part almost always does not coincide with the vertical axis, so a heeling moment appears, tilting the pontoon at a certain angle. Under the influence of a heeling moment, the pontoon with the rotating part comes out of equilibrium. The shape of the underwater part of the pontoon will change when it tilts, and the center of gravity of the part of the pontoon immersed in water will move to another point, resulting in a moment that counteracts the tilt. This moment is called restorative. After the heeling moment ceases, the pontoon with the rotating part must return to its original position under the influence of the righting moment. When creating and operating river floating cranes, the concept of static stability is used. The measure of static stability is the restoring moment. The permissible value of the static heel angle according to the River Register Rules should not exceed 3030//. The dynamic heel angle that occurs when the cargo is broken or heavy winds should be no more than 60.
8 CONTROL OF CRANE MECHANISMS
The control devices are designed and installed in such a way that the control is convenient and does not make it difficult to monitor the load-handling member and the load. The direction of the handles and levers corresponds to the direction of movement of the mechanisms. Symbols of the directions of caused movements must be indicated on the devices and will be preserved during their service life. Individual positions of the handles are fixed; the clamping force in the zero position is greater than in any other position. Push-button devices intended for reversing starting of the mechanism have an electrical interlock that prevents the supply of voltage to the reversing devices when both buttons are pressed simultaneously. The crane control cabins comply with the State Standard Rules and other regulatory documents. The control cabin and control panel are located so that the crane operator can monitor the load-handling device and the load during the full operating cycle of the crane. The control cabin is located in such a way that during normal operation of the crane with a minimum reach of the boom, the possibility of a load or load-handling member hitting the cabin is eliminated. The crane cabin is equipped with: an indicator for changing the boom radius, an anemometer, signaling devices and provides free visibility and access to them. The cabin glazing is designed in such a way that it is possible to clean the glass both from the inside and outside. The lower windows on which the crane operator can stand with his feet are protected by gratings capable of supporting his weight. Sun shields are installed in the cabin. The floor in the cabin has a flooring made of non-metallic materials that prevent slipping and is covered with a dielectric mat. The door to enter the cabin is sliding and equipped with a lock on the inside. The area in front of the cabin entrance is fenced. The crane is equipped with a device for locking the door from the outside when the crane operator leaves the crane. Entry into the cabin through the hatch is not permitted. The cabin is equipped with a stationary seat for the crane operator, arranged so that you can operate the equipment while sitting and monitor the load. The seat is adjustable in height and in the horizontal plane for ease of operation and maintenance of control devices. The crane cabin is designed and equipped in such a way that it ensures proper temperature conditions and air exchange in accordance with regulatory documents.
9.CONCLUSION
The design of the crane as a lifting and transport machine and a floating structure must provide: the necessary reserves of buoyancy, stability, unsinkability and strength of the pontoon hull; reduction of yaw rate during crane operation; high-performance reliable operation when reloading bulk and piece cargo; autonomy of operation for a certain time at various berths, regardless of shore sources of supply of electricity, fuel, lubricant, etc.; minimal manual labor costs; safety during maintenance, repair and reloading operations; ease of assembly of units during manufacture, installation and dismantling with the least amount of adjustment work; convenient access to places for lubrication and inspection of critical components; remote control of the rotating part mechanisms, main and auxiliary power plants or their automation; the smallest weight of the pontoon with a rotating part (so that the crane can be lifted onto the slip for inspection and repair of the rotating part of the hull); the ability to tow under bridges, power lines and through locks for classes I and III inland waterways; safety of vehicles and cargo during transshipment operations. You also need to remember about the living and working conditions of the floating crane crew; When designing a floating crane, it is necessary to take into account that crew members work and rest on board the floating crane for a long time. Therefore, living conditions on board require a good ventilation system made with the latest technology; water supply system; heating system; for accommodation - spacious and comfortable cabins; for active recreation - equipped gym; equipped premises for cooking and eating. Currently, great attention is paid to the environmental problem; therefore, I believe that the floating crane should be equipped with containers for collecting subsoil water, waste water, and household waste; because the crane can operate autonomously for a long time in remote areas of the river basin. When designing a crane, it is necessary to equip it with fire safety control systems and modern fire extinguishing systems.
10. LIST OF REFERENCES USED floating crane mechanism stability 1. V.V. Avvakumov Transport hubs and terminals. Tutorial. - Omsk. NGAVT, 2001 - 90 p. 2. V.D. Burenok Guidelines for completing a course project in the discipline Port hoisting and transport machines. - Novosibirsk. NIIVT, 1985 - 31 p. V.D. Burenok Guidelines for performing test work in the discipline Port handling equipment “Calculation of a grab-conveyor loader.” - Novosibirsk. NIIVT, 1992 - 32 p. I.A. Ivanov Guidelines for performing laboratory work in the discipline “Transport terminals and handling equipment.” - Novosibirsk. NGAVT, 2001 - 22 p. N.P. Garanin Port lifting and transport equipment. Textbook for water science institutes. trasp. - M.: Transport, 1985 - 311 p. Z.P.Sherle, G.G.Karakulin, A.P. Kazakov, Yu.I. Vasin Handbook of a river port operator. - M.: Transport, 1967 - 416 p.
| 
