Crane Equipment Research Articles

Five-mode quasilinear model of nonlinear dynamics of extended system

Distributed systems are widely used in practice. These are cosmic ligaments in the near-Earth space with a length of tens of kilometers. They approximate reinforced concrete piles in the soil when calculating the stress-strain state and assessing the technical condition; pipelines both in air and in liquid, underwater towed systems. Known underwater airlift systems of great length for the extraction of minerals (nodules) from the ocean floor with a length of 5-10 km. To solve the problems of the dynamics of such systems in various environments, the well-known mathematical models are not quite correct from the point of view of taking into account the variety of wave processes. It determines the need to build refined wave models. A new quasilinear mathematical model, which describes the nonlinear four-mode dynamics of the distributed system in the spatially inhomogeneous field of mass and surface forces, has been obtained. It is described by a nonlinear system of twelve first-order partial differential equations. For it, the principles of ultimate and hyperbolicity are fulfilled. Together with the boundary and initial conditions, it can be used to describe dynamics and statics of geometrically and physically nonlinear rod elements, piles in the ground, crane equipment ropes, mine lifts, aerial cableways, towed systems in liquid and gas flow, etc. For two-mode spatial reduction of the model, the theorem about correctness of Cauchy problem has been considered. As a result of the calculations, the earlier assumptions about the movement of the cable along its initial configuration were changed as the length of the cable changed. It has been found out that this assumption is only true for the initial transition participant. It is also established that at a given tachogram in the configuration of the towed line, there is a point of inflection, which shifts from top to bottom when lifting it. It can be a factor in the looping, contributing to the breakage of the cable system during towing.

Selecting Suitable, Green Port Crane Equipment for International Commercial Ports

Responding to the increasing global need for environmental protection, a green port balances economic vibrancy with environmental protection. However, because exhaust emissions (e.g., CO2 or sulfide) are difficult to monitor around ports, data on such emissions are often incomplete, which hinders research on this topic. The present study aimed to fill this gap in this topic. To remedy this problem, this study formulated a new data envelopment analysis (DEA) method for collecting CO2 emissions data at their source. This method was applied to collect real-world operating data from a large container-handling company in Taiwan. Specifically, we provide a real example using a novel green energy index to account for undesirable outputs. Our main objective was to formulate two methods that combine: (1) data envelopment analysis based on a modified slack-based measure, and (2) a multi-choice goal programming approach. The contributions of this paper included the finding that rubber-tired gantry cranes are the greenest and should be used in ports. Finally, our findings aid port managers in selecting port equipment that provides the best balance between environmental protection and profitability.

ОПРЕДЕЛЕНИЕ ПЕРЕГРУЗОЧНОЙ СПОСОБНОСТИ ЖЕЛЕЗНОДОРОЖНОЙ СТАНЦИИ И МЕРОПРИЯТИЯ ПО ЕЕ ОБЕСПЕЧЕНИЮ В НЕОБХОДИМОМ ОБЪЕМЕ УСТАНОВКОЙ ВРЕМЕННЫХ ПОГРУЗОЧНО-ВЫГРУЗОЧНЫХ УСТРОЙСТВ

in view of the fact that recently the economic cooperation between Russia and Iran in a number of production areas of the raw materials sector is expanding its program, the provision of mineral extraction with specialized and auxiliary equipment is being carried out. The paper deals with the organization of the delivery of cranes of Russian production on the automobile base of the type "Ivanovets" KS-6476 in the composition of 40 units to the objects of ore mining. Transportation of cranes by rail on the route: St. Petersburg (Russia)-Julfa (Azerbaijan) – Bandar Abbas (Iran) is justified. For transportation on the railways of Russia, the paper considers long-wheelbase platforms of model 13-491, on bogies of 1520 mm gauge. In order to comply with the dimensions on the railways of Iran, the transporters with a reduced floor level of the model 14-T116 on trolleys of 1435 mm gauge were selected. The reloading of equipment is planned to be carried out at the Julfa railway station of the Azerbaijan Railway. The results of the research, in our opinion, are certainly of practical importance for the transport industry, as the developed and proposed designs of loading and unloading devices allow for the reloading of equipment without the use of crane equipment using always available stocks of materials at cargo stations.

Installation of physical simulation of wind load on crane structures

The purpose of the paper is to reproduce a standard wind flow (laminar, turbulent, pulsating modes) to study the impact on crane structures, with the aim to obtain the load values of crane elements most closely approximate to real conditions. When creating an installation, which is related to the field of experimental aerodynamics, the "principle of simulating the main factors determined by the operating conditions of the research object" is adopted to ensure the r eproducibility of test results to the maximum extent. To confirm the performance efficiency of the proposed installation device, its computer model is developed using the CAD software SolidWorks. The computer model parameters are in full geometric agreement with the dimensions of the developed real installation. The use of the installation makes it possible to study the dynamic effect of the wind on the stability of crane structures in various operation modes (change in wind speed, in the mode of load operation, in operation conditions at the wall, etc.). The proposed installation allows to simulate the loads on crane equipment with the possibility of characteristics expanding, for example, its carrying capacity. The generated computer model of the installation makes it possible to reveal the physical picture of wind flow distribution at the installation outlet. The results of wind flow simulation on the proposed installation are confirmed on a computer model with a high degree of convergence of results at wind speeds of 2.5 m/s and lower The installation proposed by the authors will allow to simulate: the value of the real average statistical wind load of various intensity; pulsating component of the wind load; vortex excitation; increase of the available aerodynamic research capability for a real crane structure. The developed installation is a calibration device for external impacts of the wind force on the crane structure.

Big Data Fast Analysis Method of Random Stress Spectrum for Crane Equipment

With the increase of service time, the random stress spectrum of crane equipment causes cumulative damage. Cumulative damage induced crack initiation is one of the important failure modes of crane equipment. Through the rapid analysis of the random stress spectrum obtained in real time by the structural health monitoring system of lifting equipment, the cumulative damage of the structure can be analyzed and the remaining life of the structure can be predicted. In this paper, based on the traditional rain flow counting method, the big data fast analysis method of random stress spectrum is studied by adopting stack data structure. The program of fast rain flow counting method based on stack structure with two parameters is compiled. The fast rain flow counting method based on stack structure is used to analyze and calculate the big data of stress monitoring collected by the structural health monitoring system of metallurgical crane, and the stress amplitude-mean-frequency matrix of the hot spot area of fatigue damage of the main girder is obtained, which lays an important foundation for the health status diagnosis of metallurgical crane equipment.

Intelligent crane robot based on internet of things

Robots are applied more and more widely to realise the cold rolling warehouse area automatic unmanned operation. The application method of Internet of Things (IoT) is adopted to study the key technologies such as the intelligence and automation of the crane, and unmanned transformation is carried out on the basis of manual operation. Through the internet information exchange, crane automatic control, anti-sway control, spreader intelligent transformation and other technical means, to realise the crane equipment automatic operation. The practice results show that, under the application of IoT, the automatic transformation of crane has greatly improved the production level, reduced the production cost, improved the economic benefit, reduced the management cost and reduced the safety hidden danger and provided the theoretical basis and solutions for realising the intelligent operation in the factory warehouse area. Owing the great difference between the actual operating environment and the ideal operating environment, it is necessary to further improve the operating accuracy and system stability, and reduce the error of the crane actuator, so as to realise the omni-directional automatic control of the unmanned crane.

Intelligent crane robot based on internet of things

Robots are applied more and more widely to realise the cold rolling warehouse area automatic unmanned operation. The application method of Internet of Things (IoT) is adopted to study the key technologies such as the intelligence and automation of the crane, and unmanned transformation is carried out on the basis of manual operation. Through the internet information exchange, crane automatic control, anti-sway control, spreader intelligent transformation and other technical means, to realise the crane equipment automatic operation. The practice results show that, under the application of IoT, the automatic transformation of crane has greatly improved the production level, reduced the production cost, improved the economic benefit, reduced the management cost and reduced the safety hidden danger and provided the theoretical basis and solutions for realising the intelligent operation in the factory warehouse area. Owing the great difference between the actual operating environment and the ideal operating environment, it is necessary to further improve the operating accuracy and system stability, and reduce the error of the crane actuator, so as to realise the omni-directional automatic control of the unmanned crane.

Methods to ensure durability and improvement of reliability of bridge cranes of General purpose during their operation

The paper notes that lifting and transport machines are an integral part of any type of production, since they serve all types of technological processes. Cranes greatly contribute to the smooth operation of the process equipment, so ensuring the quality and increasing the productivity of the crane equipment allows you to improve the performance of the process equipment. The directions and possible ways of improving the designs of General-purpose bridge cranes to increase the durability and improve the reliability of their operation are considered. The main reasons for the need to upgrade bridge cranes in operation are given. The analysis of the main principles of crane equipment modernization is given. The issues of modernization of load-lifting bridge cranes in order to increase productivity, ensure structural improvement, safety in operation, and technical and economic efficiency are considered. To determine the degree of manufacturability of the design, indicators are proposed, for which the classification according to the main evaluation criteria is given. The economic assessment of the feasibility of modernizing the crane economy is given.

Enlarged brick blocks as an alternative to masonry

Brick structures are one of the most common and useful construction materials. However, brick laying consists of the most labor-intensive processes with the largest part of manual works. The main purpose of the research is to find an alternative technology for the brick structures construction that have geometric and physical parameters of brickwork, the processes of which are less labor-intensive and more mechanized. Using factory-made enlarged brick blocks was suggested in the article as an alternative. A brick block is a factory - made element of a brick wall structure that is installed in the design position by crane equipment. By reducing the part of manual labor in installing the brick block, the total duration of construction is reduced while maintaining the final result – a brick wall. The research method was a comparative analysis of the resulting indicators of construction of structures made of individual bricks and installation of enlarged brick blocks. As a model for comparative analysis, a brick wall of specified parameters was proposed, on the basis of which calculations were made. The results show diagrams of labor and material resources spent on the construction of the wall for the two technologies under consideration. Based on the results obtained, we can conclude that it is possible to use enlarged brick blocks of high factory readiness as an alternative to masonry.

The safety assessment of lifting equipment using artificial intelligence methods

The article is devoted to the problem of using artificial neural networks to assess the risk of developing emergencies during the operation of lifting crane equipment. The data sources are telemetric measurements from microcontroller load limiters, as well as data from technical and daily inspections of equipment condition, in the last case the data may be fuzzy.

Key Performance Indicator Development for Ship-to-Shore Crane Performance Assessment in Container Terminal Operations

Since the introduction of containerization in 1956, its growth has led to a corresponding growth in the role of container seaborne traffic in world trade. To respond to such growth, requirements for setting up the common standards in various kinds of container harbor equipment, and identifying performance indicators to assess container handling equipment performance have increased. Although the operating systems in ship-to-shore cranes may be different at each container terminal, the four main movements are the same: hoist, trolley, gantry, and boom. By determining in this work the hour metrics for each movement, it was possible to define the key performance indicators to be adopted and assess ship-to-shore crane performance. The research results identified that the mean time between failures is decreasing because of the accumulation of long-lasting heavyweight operations, while the number of maintenance of machine parts incidents and man-hours is steadily increasing. The key performance indicators offer a management tool to guide future ship-to-shore container crane inspection and the results provide useful insights for future container crane equipment operation improvements.

Application of the principle of hydraulic cranes on the conductivity tester

This research is based on the idea that the need for an innovative experimental learning media in the study of electrolyte and non-electrolyte solutions. The innovative experimental learning media produced in this study is miniature cranes to test the electrical conductivity of electrolyte and non-electrolyte solutions. Crane equipment with hydraulic power is widely used to lift heavy loads at construction sites. The working principle of hydraulic cranes that utilizes the nature of the pressure of the liquid in the hydraulic pump according to Pascal’s Law. The working principle of the hydraulic pump has been applied to design a solution of electrical conductivity test equipment. The hydraulic system of a large device has been modified using tools and materials that are easily available in everyday life. The design of the electrical conductivity test equipment is composed of a hydraulic pump made from used injection hydraulic hose and hydraulic fluid. When the hydraulic pump is given pressure, the fluid (colored liquid) will continue the pressure through the hydraulic hose to the hydraulic working cylinder, so that the crane connected to the two electrodes can move. As a current source, Power bank circuits are used with a USB (Universal Serial Bus) cable and 5 Watt LED lights for conductivity indicators. Miniature props with hydraulic working principles are expected to provide new experiences in the electrical. Miniature props with hydraulic working principles are useful as innovative, interesting and learning media fun for students.

Features of Industrial Buildings’ Technical Survey, Repair and Renovation

The features of the technical survey of industrial buildings and structures exploited for a long time are considered, using the example of industrial enterprises in the city of Zaporizhzhia. The problems of combining architecture, structural foundations and technology of production processes in modern conditions are identified. The specifics of the implementation of the recommended events for the repair and strengthening of the main load-bearing and enclosing structures are analyzed. It should be noted that many structural reinforcement solutions are difficult to implement nowadays for many reasons. For example, it is practically impossible to implement soil consolidation during the plant operation. The reasons are the numerous underground technological communications, groundwater, which level fluctuates with the tendency to rise, and so on. Often, soil hardening is more expensive than demolition or new construction. The ways of reconstruction and renovation of industrial buildings are determined. In recent decades, the problem of renovation of industrial buildings has intensified. The rapid improvement of the technological process does not allow it to be carried out in traditional non-mobile «boxes». Heavy duty crane equipment becomes unnecessary. Bulky cells and other floor-mounted process equipment are being replaced by small-sized and low-energy equipment. Variant design of renovation schemes is also complicated by the transfer of production from the public sector to private entrepreneurs. A graph of the duration of exploitation, the degree of wear of structures and the dynamics of renovation changes is built. The graph clearly demonstrates that new technologies can continue to function for 10…20 years. Depending on the type of production technology, in the future the need for its modernization sharply increases, and after 50 years of operation – partial or complete replacement of the equipment or complete shutdown. Thus, the direction of renovation should be laid even with the introduction of the latest advanced technologies. Recommendations on the interconnection of problems of technical survey of industrial buildings, their repair and renovation are developed.

Grounds for the decision to strengthen reinforced concrete structures after short-term impulse loads, using Alluriquin HPP as an example

Introduction. Floorings of the turbine hall and installation sites of the HPP (PSS) are one of the most important reinforced concrete structures, as during operation they are subjected to significant process duties, including those not provided for by the project. Thus, during the testing of crane equipment on the floor surface of the installation site of the Alluriquin HPP under construction, the cargo weighing 22 tons fell, under the influence of which the floor slab was punched, which required a comprehensive study of the condition of the reinforced concrete structure of the floor and the surrounding area of the failure of structures, as well as the development of measures to strengthen the damaged structure. Materials and Methods. Visual and instrumental studies of the stress and strain state (SSS) of the reinforced concrete structure of the turbine hall slab and surrounding structures were carried out with the use of optical devices (MPB-3 reading microscope), Schmidt hammer to determine the strength of concrete structures, as well as the “reinforcement load removal” method to determine the actual stresses in the reinforcement of structures. Results. The punching of the reinforced concrete floor of the installation site with vertical displacements of the edges of through cracks up to 12 mm, as well as the system of cracks formed during the fall of cargo was revealed. The actual stresses in the reinforcement are determined by the “reinforcement load removal” method. On the basis of finite element modeling the actual condition of structures during the period of cargo fall and after the removal of the load is obtained. On the basis of the analysis of results of field and design studies the schematic diagram of strengthening of structures by carbon composite materials is developed. Conclusions. The actual SSS of the reinforced concrete floor of the installation site and its support structures during the period of the cargo fall and after the termination of the impulse load is established. The vertical displacement of the edges of the crack of the floor punching was 17.5 mm during the period of the fall of the load and 12 mm after the removal of the impulse load. Crack opening width in reinforced concrete structures in the cargo drop area reached 2 mm. At the moment when the cargo fell on the floor slab, the values of stresses in the reinforcement cage reached 200 MPa; after the impact — 76.2 MPa. With a view of the subsequent safe operation of the reinforced concrete floor and surrounding structures the basic schemes of their strengthening by external reinforcement on the basis of carbon fiber have been developed, which have been proved by calculation.

On the visual reality and monitoring of gantry cranes using FBG sensing

ABSTRACT The gantry crane is an important and representative rotary rail loading and unloading crane. In order to ensure the safe and reliable operation of the gantry crane, it is particularly important to monitor its condition. Many ports still use the traditional after-sales maintenance system. And, the equipment and means for fault detection and repair are also backward. This paper proposes a design of a human-computer interaction system for gantry crane equipment on-line monitoring. The virtual reality technology is used to display the monitoring data and analysis results of the gantry crane in the three-dimensional space in real time. We sample the stress and temperature signals of the gantry crane using Fibre Bragg Grating sensors installed in some structural key points. The sensors are connected to the fibre grating demodulator of the monitoring room through a transmission fibre. Signals collected by the sensors are processed and analysed to diagnose the condition of the gantry crane. The system presents the crane’s operating status to the user in a realistic ‘virtual environment’, so that the fault information can be quickly and accurately fed back.

Fault diagnosis system of bridge crane equipment based on fault tree and Bayesian network

A spreader is an important part of a crane used on wharfs for loading and unloading operations. Because of the spreader’s complex structure, poor operation environment, frequent collision accidents, etc., breakdowns and faults often occur, and the causes for the faults are complex. Based on the historical fault data of the spreaders accumulated during their online service for 13 years, by determining top events and boundary conditions using the induction and deduction methods, a complete spreader fault tree is built with three layers of fault phenomena, fault classification, and fault causes. Then, based on the fault tree, a Bayesian network for the spreader fault diagnosis is constructed by establishing the transformation algorithm from the fault tree to the Bayesian network. The junction tree method is used for accurate inference of spreader faults based on the Bayesian network. Finally, a spreader fault diagnosis system is developed, and a case verification is carried out. The system would be of great help to crane operation engineers in fault diagnosis, and it effectively uses historical fault data to support subsequent maintenance.

Static characteristics of multicells jointed FRP tower with mass on its top

The size of steel tubular guyed towers has become very big, expensive to transport and to erect in the field since a special crane equipment is needed for erecting the tower components. Moreover, steel is very susceptible to corrosion which causes loss of strength. The paper provides recommendations for the analysis, design and fabrication a lightweight multicells glass-fiber reinforced polymer (GFRP) guyed tower. The experimental work involved material testing, fabricating the tower and testing it with a secured mass of 163 kg, 1 kW vertical turbine, mounted on its top under static loading to evaluate the structural performance of the tower. A nonlinear finite element model was developed to analyze the tower holding a mass on its top. A superimposed failure envelope was developed to predict the tower’s failure load using different failure theories. The deflections and stresses obtained from experimental testing compared well with the theoretical results; and therefore, validated the developed model.

Design of Smart Forestry Cableway

Abstract In order to create a new product – a smart forestry cableway, a market survey was conducted among 118 companies belonging to the private sector and dealing with the exploitation of massive wood. Most of the respondents were owners of articulated forestry tractors, agricultural tractors equipped with forestry, crane equipment and various cableways. The aim of the study was to identify the main characteristics, which the buyer considers when purchasing the future product, for developing a smart prototype model. We collected information concerning the main elements that are influencing the design of a new product like: access to spare parts, easy to repair and to use, the quality of new product, efficiency, price, access to service, versatile and with many accessories, robustness, reliability, affordable parts and fast delivery, technical support, low machine consumption and comfort.

МЕТОДИКА ПРОГНОЗИРОВАНИЯ ВРЕМЕНИ ВЫПОЛНЕНИЯ ОПЕРАЦИИ ПО ПЕРЕВАЛКЕ НАВАЛОЧНЫХ ГРУЗОВ

The process of transshipment of bulk cargo within the Eastern cargo terminal of the sea port of Novorossiysk has been considered. A method for calculating the performance of the crane group has been developed, taking into account the interaction of cordon and rear crane subgroups. The method is based on the practical process flow charts of Novorossiysk port for processing coal, cast iron and iron ore. There has been presented the designed method for calculating the coefficient of predicted performance of cargo handling for transshipping the bulk cargoes (e.g., coal, iron ore and cast iron) based on the data on performance of crane equipment, allocated resources (handling equipment and dock machine operator teams). The forecast performance ratio allows to determine whether the operation schedule is ahead or behind the standard of the process flow charts. The method of calculating the forecast time of transshipment of bulk cargoes has been offered, subject to the influence of meteorological factor on productivity of cargo operations. The formulas for calculating the estimated time of the cargo operations at all possible mutual locations on the time axis of the segments of the weather conditions and the time of the operation have been given.

КОМП’ЮТЕРНИЙ ТА НАТУРНИЙ ЕКСПЕРИМЕНТ ПРИ ВИЗНАЧЕННІ НАПРУЖЕНЬ І ДЕФОРМАЦІЙ МЕТАЛОКОНСТРУКЦІЇ ПРИЧАЛЬНОГО КОНТЕЙНЕРНОГО ПЕРЕВАНТАЖУВАЧА

In this work, an approach to estimating the residual life of load-lifting machines that have been in operation for a long time, using mathematical modeling using the finite element method to determine stress fields and identify the most dangerous zones, was considered. The analysis shows that the average age of cranes is outside the allowed limits. The issue of updating the fleet of lifting machines and technical re-equipment of industrial enterprises requires time and large capital expenditures. The purchase of new crane equipment raises the question of its cost, design and manufacture time, methods of its transportation to the destination, installation, its settings and other current problems, implies a long waiting time and significant capital costs. Recently, methods and technologies have been introduced into engineering practice, which allow today, at relatively low cost, to significantly increase the operational resource of the existing load-lifting machinery fleet. The development of modern technology can significantly reduce the wear and destruction of elements of metal structures of crane equipment and their mechanisms, by establishing frequency control, was not available in this form in previous years. To obtain real loads arising in the metal structures of the loaders, a full-scale experiment was carried out by using strain gauges at the maximum possible load and then comparing the obtained data with the calculated ones. The research methods are mathematical, a full-scale experiment and statistical. The conclusions about the current state of the metal structures of the individual lifting machine and about the conditions for the possibility of further operation of the metal structures of these control panels were drawn based on the obtained results. (Based on the results obtained, conclusions were drawn about the current state of the metal structures of the individual lifting machine and about the conditions for the possibility of further operation of the metal structures of these control panels.) The approach to solving this problem can be applied to most types of lifting machines in operation.