Overhead Traveling Crane Research Articles

A Review of Failure Analysis of Different Part of Electric Overhead Traveling Crane

Abstract: This review paper gives the discrimination of various failure analysis accomplish to find Crane hook, Rope, Rope Drum, Coupling, Gear and Motor Shaft failure. These are very significant parts of EOT crane used for lifting, lowering and move with the help of links or rope and highly liable component which are always subjected to failure due to amount of stress, dynamic and statistic load concentrations which can lead to its failure. To minimize the failure of different part of EOT Crane by Using safe design with appropriate manufacturing processes and obstructive mechanical maintenance techniques. Failure of any parts of crane causes the unneeded shutdown and its lead to heavy loss. The main aim of this paper is to study various component of EOT crane failure analysis and finding out root cause failure of different parts of crane. Through this paper various literature have been comprehensively compared to get Crane hook, Rope, Rope Drum, Coupling, Gear and Motor Shaft failure analysis. Keywords: Crane hook, Rope, Rope Drum, Coupling, Gear and Motor Shaft, Stress, EOT Crane, techniques, etc.

Analisis Kegagalan Permukaan Kontak Rail dan Wheel pada Overhead Travelling Crane

For the sake of the smooth process of cement production, it is necessary to maintain each component of the production. One of the tools that play an important role in the maintenance and production of cement is the Overhead Traveling Crane, which is a combination of a separate lifting mechanism with a frame to lift and move loads that can be hung freely or attached to the crane itself. The problems that arise in the Overhead Traveling Crane include the reverse direction of the motor rotation due to an error in the motor connection, the motor cannot start due to a disconnected power supply, the occurrence of bending (curving) on ​​the girder due to lifting operations that exceed the maximum capacity which can also accelerate service life. of the girder, wear on the wheel due to high workload during operation. Due to the need for very long use, periodic maintenance is needed so that it can be in normal condition for a long time. The main parts that support the overall weight of the crane are rails and wheels. This journal discusses the analysis of failures that occur due to contact between rails and wheels that occur in a cement factory. Failure analysis is done by testing the hardness of both the wheel and the rely which is considered to have failed or is no longer suitable for use. Then review the results of direct field observations with data from hardness tests and literature studies related to wheels and rails. after that it was concluded that the company considered for the procurement of rails and wheels. The conclusion obtained is that the hardness value on the rail is lower than on the wheel. Resulting in failure of the rail so that the rail must be replaced.

Multi-Gene Genetic Programming-Based Identification of a Dynamic Prediction Model of an Overhead Traveling Crane.

This paper proposes a multi-gene genetic programming (MGGP) approach to identifying the dynamic prediction model for an overhead crane. The proposed method does not rely on expert knowledge of the system and therefore does not require a compromise between accuracy and complex, time-consuming modeling of nonlinear dynamics. MGGP is a multi-objective optimization problem, and both the mean square error (MSE) over the entire prediction horizon as well as the function complexity are minimized. In order to minimize the MSE an initial estimate of the gene weights is obtained by using the least squares approach, after which the Levenberg–Marquardt algorithm is used to find the local optimum for a k-step ahead predictor. The method was tested on both a simulation model obtained from the Euler–Lagrange equation with friction and the experimental stand. The simulation and the experimental stand were trained with varying control inputs, rope lengths and payload masses. The resulting predictor model was then validated on a testing set, and the results show the effectiveness of the proposed method.

An innovative integrated modelling of safety data using multiple correspondence analysis and fuzzy discretization techniques

In this study, we have proposed an innovative integrated methodology to handle a mix of categorical and numeric safety data. We have augmented the traditional multiple correspondence analysis (MCA) through the use of fuzzy discretization approach, t-SNE technique and fuzzy c-means clustering. The fuzzy discretization approach transforms the continuous variables to categorical variables to make them analyzable using MCA. R2-profile is adopted to obtain the best number of hidden dimensions representing the maximum categorical information. Then, t-SNE technique is used to represent the high dimensional categorical information in a 2D map to visualize the significant categorical associations. Then, fuzzy c-means clustering (FCM) is used to group the categories in different clusters based on their membership degree. To determine the optimal number of clusters, cluster validity indices are used. Davies-Bouldin (DB) Index, Dunn’s (DU) Index and Silhouette (SW) coefficients are used to determine the quality of clustering solutions. The proposed methodology is tested using electric overhead traveling (EOT) crane related near-miss incidents and found that our approach is effective. From managerial implication point of view, several safety rules are generated and subsequent safety countermeasures are proposed. Further, the results obtained through FCM is compared with K-means (KM) algorithm and unsupervised fuzzy c-means clustering (UPFCM). FCM outperforms KM and UPFCM on the basis of quality of solutions.

Training Simulator for Acquiring Operational Skill to Operate Overhead Traveling Crane while Suppressing Load Sway

The present study addressed an advanced system that was designed to teach the skills needed to operate an electric overhead traveling crane. In the operation of an overhead traveling crane, to ensure the safe and efficient transport of a load, an operator must be able to suppress the sway of that load. However, considerable training is needed to master this skill. Furthermore, the beginners may cause accidents by operating the crane incorrectly. Therefore, in the present study, we devised a training system in which an operator can safely and efficiently master the operation of an electric overhead traveling crane while suppressing the load sway. In this approach, the operational conditions in which the load sway is suppressed can be derived theoretically. The operational conditions are displayed by the crane simulator as visual instructions in a virtual working environment. The efficacy of the proposed skill training approach with the crane simulator was verified through experiments whereby novices used the crane simulator to perform the task of transporting a load while suppressing load sway.

Challenges and Safety in Erection and Commissioning of 280/85 Tons Single Failure Proof EOT Crane at PFBR

The Electric overhead traveling (EOT) crane installed in Prototype Fast Breeder Reactor (PFBR), Reactor Containment Building (RCB) is the largest capacity EOT crane installed in any nuclear power plants in India with some unique features of its own. It has been built with a single failure proof concept which is one of the prime requirements of a nuclear facility as per the standards of NUREG/IS. It is a double bridge girder type; the girder used in this crane is a single structure having a length of 34.8m without any joints as designed by IGCAR/BHAVINI (first of its kind). The span of the EOT crane is 33.4m and installed at a height of 42m from the ground level with the lifting height of 42.5m. This crane was manufactured by an Indian company M/s. UNIQUE CRANE, NASIK. Two hooks (280 tons / 85 tons) are connected in the same trolley sharing the Long Travel (LT). Load testing of the complete crane was done at factory before transporting it to PFBR site. The components of the crane were assembled in PFBR site. The erection methodology adopted was distinct w. r. t the site condition, as the components which were handled were very heavy, available space for installation was restricted and the head room was also very less. This erection has been completed successfully and very safely without any notable incidents. This activity is a biggest achievement / milestone in the nuclear industry in India. Later the EOT crane was commissioned, load tested with 350 tons load (negligible deflection) and being operated successfully without any incidents so far. This was achieved by accurate erection procedure, stringent Quality Assurance Plan (QAP), Job Hazard Analysis (JHA) and Safe Operation Procedure (SOP). Many challenges were faced during manufacturing, testing, erection and load testing at site. This paper deliberates those challenges.

Decision support system for safety improvement: An approach using multiple correspondence analysis, t-SNE algorithm and K-means clustering

An attempt has been made to develop a decision support system (DSS) for safety improvement using a multi-step knowledge discovery process involving multiple correspondence analysis (MCA), t-SNE algorithm and K-means clustering. MCA is used for dimension reduction and perceptual mapping from categorical data. Usually, the first two dimensions are used for perceptual mapping if these two dimensions explain a significant percentage of variance. Otherwise, the traditional method of two dimensional mapping, leads to loss of important categorical information involved with other dimensions. Considering the above, a novel R2-profile approach, as an alternate to inertia based approach, is adopted to obtain the desired number of dimensions to be retained without loss of significant amount of information. t-SNE technique reduces the high dimensional data into two dimensional (2D) map, which provides the associations amongst different categories. K-means clustering grouped the 2D categories in homogenous clusters as per the similarities of the categories. A novel kernel category based chi-square distance method is proposed to identify sub-clusters within a cluster which subsequently provides useful rules for safety improvement. The methodology also provides a logical approach of dimension reduction in a form called ‘funnel diagram’. Finally, the DSS is applied to analysing near miss incidents occurred in electric overhead traveling (EOT) crane operations in a steel plant. Several safety rules are identified and safety interventions are proposed.

Application of the Combined Vibration Analysis Method of the Overhead Traveling Crane to Prevent Negative Impact on the Structure and Personnel

The subject of the study is the application of the combined method of vibration analysis for the study of dynamic phenomena in the elements of the overhead traveling crane structure that affect both the durability and reliability of structural elements and the health and efficiency of maintenance personnel. Research methodology - simulation of cargo lifting dynamics using Matlab Simulink and SolidWorks software, using combined calculations in which the system response generated from the solved system of differential equations in Matlab Simulink was used to excite the crane support structure during the FEM simulation in SolidWorks. The goal is to identify the vulnerabilities in the construction of overhead traveling cranes, by examining the dynamic phenomena in the structure and the effect of vibration on the safety of the crane's operation, on health, and the capacity of the operating personnel. Conclusion of the study. The proposed method allows more accurately and less costly to predict the response of the crane structure to various dynamic effects, particularly lifting and lowering the load. The presented models of FEM and rigid masses can become the basis for studies based on an integrated approach that integrates the dynamic model with the CE model. The influence of the action of various vibration frequencies on the machinist's body of the overhead traveling crane is analyzed.

Order of Transfer Trajectory Using Touch Interface in Overhead Traveling Crane and Transfer Trajectory Planning with Load Sway Suppression Based on Ordered Trajectory

Order of Transfer Trajectory Using Touch Interface in Overhead Traveling Crane and Transfer Trajectory Planning with Load Sway Suppression Based on Ordered Trajectory

Development of Safety and Efficiency Training System for Operation with Suppressing Load Vibration in Overhead Traveling Crane

Development of Safety and Efficiency Training System for Operation with Suppressing Load Vibration in Overhead Traveling Crane

天井クレーンにおける搬送物の障害物回避と荷振れ抑制を考慮した軌道計画および初期軌道設計による軌道計画の高速化

天井クレーンにおける搬送物の障害物回避と荷振れ抑制を考慮した軌道計画および初期軌道設計による軌道計画の高速化

固有振動数成分除去法による天井走行クレーンの制振

固有振動数成分除去法による天井走行クレーンの制振

Vibration Control of Overhead Traveling Crane by the Eliminating Method of the Natural Frequency Component

Vibration Control of Overhead Traveling Crane by the Eliminating Method of the Natural Frequency Component

天井クレーンにおける障害物衝突回避のための動的操作制限を実現する操作支援システム

天井クレーンにおける障害物衝突回避のための動的操作制限を実現する操作支援システム

Measurement and Modeling of Job Stress of Electric Overhead Traveling Crane Operators.

BackgroundIn this study, the measurement of job stress of electric overhead traveling crane operators and quantification of the effects of operator and workplace characteristics on job stress were assessed.MethodsJob stress was measured on five subscales: employee empowerment, role overload, role ambiguity, rule violation, and job hazard. The characteristics of the operators that were studied were age, experience, body weight, and body height. The workplace characteristics considered were hours of exposure, cabin type, cabin feature, and crane height. The proposed methodology included administration of a questionnaire survey to 76 electric overhead traveling crane operators followed by analysis using analysis of variance and a classification and regression tree.ResultsThe key findings were: (1) the five subscales can be used to measure job stress; (2) employee empowerment was the most significant factor followed by the role overload; (3) workplace characteristics contributed more towards job stress than operator's characteristics; and (4) of the workplace characteristics, crane height was the major contributor.ConclusionThe issues related to crane height and cabin feature can be fixed by providing engineering or foolproof solutions than relying on interventions related to the demographic factors.

917 固有振動数成分除去法による天井走行クレーンの制振

917 固有振動数成分除去法による天井走行クレーンの制振

The Optimization Design of Overhead Traveling Crane's Box Girder

The box girder overhead traveling crane is one kind of hoisting machine, which is widely used in factories, mines and other enterprises. Its main structure is box girder, which accounted for the largest proportion of the whole weight. In order to improve the performance of the whole machine and reduce energy consumption, an optimization model is established on the basis of the whole stress analysis and it was applied to make specific optimization design.

Obtaining and Predicting of Equivalent Load Spectrum for Overhead Traveling Crane Based on Support Vector Machines

Crane load spectrum is the basis data of the evaluation of fatigue life, obtaining the large samples data need to consume large amount of time and finance. For exploring and initiating a new way of obtaining and predicting the crane load spectrum, the present essay uses Support Vector Machines (SVM) to establish the non-linear mapping relation between this type of crane's work cycles and different rated weights and lifting loads, namely equivalent load spectrum of crane. The Engineering example demonstrates: it is feasible to construct the equivalent load spectrum for some type of crane using SVM. Meanwhile, the equivalent load spectrums of the typical or future crane in this type could be obtained and predicted through the trained SVM model. It has provided the reliable data for the reliability analysis and fatigue life prediction of crane.

Safety Assessment of the General Overhead Traveling Crane Metal Structure Based on BP Neural Network

Safety assessment of bridge crane metal structure is widely needed. A general bridge safety assessment model of metal structure based on BP neural network is established. BP neural network is suitable for the problem that is not fully known and the adaptability of the dynamic system, and can facilitate the assignment and statistics of the safety evaluation system. Matlab7.0 software is used for the network training process. Through the training, samples to be tested were verified for the feasibility of the security model. The security model based on BP neural network for the general overhead traveling crane structure could provide a safety assessment and evaluation methods.

The Application of EMD and ARMA Bi-Cepstrum Fault Diagnosis Method in Gearbox of Overhead Traveling Crane

For the time varying of signals, empirical mode decomposition (EMD) is occupied to modulate signals; auto-regressive moving average (ARMA) of higher accuracy is used to establish model for the signal principal components; then parametric bi-cepstrum estimation is implemented and fault feature is extracted. The test results about gearbox of overhead traveling crane indicate: the feature quefrency can be obtained through method of EMD and ARMA model parametric bi-cepstrum estimation.It is a kind of effective fault diagnosis and stability evaluation method.