Training Material TRW+CRW+FRW
Training Material TRW+CRW+FRW
Training Material TRW+CRW+FRW
2014
Trailer Consultation
TrailerWIN ‐ CraneWIN ‐FrameWIN
The Guided Example
RD
2014
________________________________________________________________________
Trailer Consultation T:+358 6 831 9905
Kauppatori 2 as 10 F:+358 6 831 1008
67100 Kokkola [email protected]
Finland www.trailerwin.com
TrailerWIN – CraneWIN – FrameWIN
Guided example
Contents
TRUCK AND CRANE CALCULATION WITH TRAILERWIN, CRANEWIN AND FRAMEWIN: .......... 2
TRAILERWIN, STARTING THE CALCULATION ..................................................................................... 2
Choosing Chassis ................................................................................................................. 2
Choosing Crane: .................................................................................................................. 4
Choosing the Bodywork ...................................................................................................... 7
CRANEWIN ........................................................................................................................ 12
Principle of stability calculation in CraneWIN ................................................................... 12
Reading the stability diagram: .......................................................................................... 13
CHECKING STABILITY WITH CRANEWIN ......................................................................................... 14
Stability chart of Guided example ..................................................................................... 14
Modifications in CraneWIN ............................................................................................... 17
Changes to Crane and stabilizers in CraneWIN ................................................................. 21
Printing in CraneWIN ........................................................................................................ 22
SUBFRAME CALCULATION IN FRAMEWIN THEORY ............................................................ 24
STRESS CALCULATION : BENDING MOMENT ON U‐BEAM .................................................... 24
COMBINED BEAM : Chassis Frame + Subframe ................................................................ 24
Flexible mounting : subframe mounted with brackets or clamps ................................. 25
Rigid mounting : subframe mounted with shear resisting plates ............................... 27
CALCULATION WITH NEW STANDARD EN12999 ................................................................... 29
Choosing new calculation system EN12999 in FrameWIN ............................................... 29
About calculation system EN12999/EN13001 .................................................................. 29
FORMULAS AND SYMBOLS ........................................................................................................... 30
FRAMEWIN SUBFRAME CALCULATION FOR GUIDED EXAMPLE ........................................... 31
Adding the subframe in TrailerWIN calculation ................................................................ 39
1 Copyright © 2014 Trailer Consultation
TrailerWIN – CraneWIN – FrameWIN
Guided example
Truck and Crane Calculation with TrailerWIN, CraneWIN and FrameWIN:
We will step thru a calculation in TrailerWIN – CraneWIN – FrameWIN where we use a crane and
additional stabilizers. This example is only for learning use of program and should not be used as
a model for assembling cranes to chassis.
New button Begin/Start button
To easily find this calculation later, type in the
task name and customer name in the window
that pops up.
Then click on the
Truck button to
begin choosing the truck.
Choosing Chassis
From Chassis Window you can choose the chassis fabricate ‐> model series ‐> wheelbase and
finally cab.
In this example we choose: VOLVO
FH 62R Rear air tag FH 62R B3HA
4300 L2EH2 AIRIN‐HI
In Chassis data window you can check and change chassis weights and dimensions.
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Guided example
When you are ready, click OK.
Now you will get the chosen chassis in the big picture.
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TrailerWIN – CraneWIN – FrameWIN
Guided example
Choosing Crane:
To have a crane behind the cab do as follows
Click on the Equipment button.
In the following equipment window you will see the crane button (yellow crane) on the left side.
The other crane button (green crane) on the right side is for rear‐mounted crane.
Buttons for choosing the device type:
(Please check the TrailerWIN manual for more information regarding equipments.)
Crane (front of the body) Crane (rear of the body)
Click the yellow crane on the
left side.
Now you can choose the
crane model, in this example
we choose Hiab 244, and then
the model 244EP‐3 Duo.
Click OK.
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Guided example
On the following screen You can choose the crane
position: folded or unfolded during transport. You also
choose the position of stabilizer legs for the crane.
Note that choosing different positions will affect also
the weight calculation because COG is taken into
account from the position of boom.
In the following
Crane Data Window
you can check and
edit crane weight
and dimension data.
You can also choose
stabilizer leg model.
You can go back to
Crane Position
window by clicking
the button above
ok‐button.
Click Ok
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Guided example
The chosen crane appears on the chassis.
Now we want to move the crane rearwards.
We can do this with 3 different methods.
1. Double‐Click the red dimension number at the top of the
picture (hot dimension) 486, and type new value 650, and then
click OK.
2. Drag the crane with your mouse from the small grey rectangle under the crane.
The crane moves to a new
place, but be aware that very
exact movements are difficult
with this method.
3. Click on the Equipment
button, and choose the crane
in question from the list. You
will now come back to the
Crane Data Window.
Type in the new value: 650
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Guided example
The Bodywork Window opens. Here You can choose standard body types and also get body‐
drawings from DXF‐files on the left scroll‐box. (See TrailerWIN manual for more instructions.)
If you’ve already chosen the bodywork, you will now see the Body data window instead.
Input box
To go back to choose the body type, click Menu: Truck ‐ Body
type and choose the desired body type.
In this example we choose Open Body button
Now the Body data window appears.
The program first calculates the body length to optimize the rear axle weight to near maximum
allowed, when the body is evenly loaded.
If you have a specific body length that you’d like to have, you can type this length into the input
box.
Click Ok.
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Guided example
You can also change the body length later directly from picture; double‐click the red dimension
or drag the small grey rectangle at the end of the body with your mouse.
Change
body length
Next You will see the rear overhang Towing coupling window. Here You can modify the rear
overhang of the frame. You can also choose different types of trailer couplings and rear
bumpers if needed. This window will always appear after You have chosen a body. You can´t add
a trailer without first having a trailer coupling on the truck.
We choose low‐mounted trailer coupling and click ok.
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Guided example
Now you see:
The axle weight without load and with load, under the picture.
First row shows axle loads without payload and the second row with payload.
The numbers in brackets "{64%}" mean that the front axle takes 64% of the vehicle weight.
For changing the max. allowed front‐axle load, click the chassis button
change to 7500
Change G.V.W. front axle to 7500 kg, we must also change total weight manually if needed. In
this case 26000 kg is ok. Click OK button.
If we now want to see, what the optimum body length with these weights is, we click the
Bodywork button again.
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TrailerWIN – CraneWIN – FrameWIN
Guided example
Optimize
body length
In bodywork window, click the Optimum button
You will see that the body length changes.
Body weight (body own weight) can be given in Body data window as kg/m or in the Load data
window as total body weight or kg/m.
Click the Load button on the toolbar.
We change load spaces own weight kg to value 500 kg.
Then click OK.
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Guided example
Now you have succesfully built up the truck in TrailerWIN.
! ! Remember to save the calculation regularly:
Click on the Save Button or from Menu File – Save As:
Save
Use a logical name. It helps you to find this calculation later.
You have several options to save drawings and print out the calculation. For more details, please
check TrailerWIN manual.
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Guided example
CraneWIN
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Guided example
The circle diagram shows stability in all directions. Truck front is upwards in the picture.
Imagine the boom in the picture to this direction, for which you want to read stability. The point
where the boom direction line crosses the red stability curve, shows the stability.
If this point is for example on scale circle 2.0, the stability is 2.0 to this direction (see example
point on the picture).
Note that You can also see the tilting line in the diagram. It is shown as black lines between
stabilizers and to the middle of the front axle.
Later we will see how we can modify the tilting line on front axle.
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TrailerWIN – CraneWIN – FrameWIN
Guided example
Checking stability with CraneWIN
Now you can check the Crane Stability.
We get to the CraneWIN Program by clicking on the CraneWIN button or by choosing Menu
Special ‐ CraneWIN.
CraneWIN will now start and all data will automatically be transferred from TrailerWIN to
CraneWIN.
Note that modifications made in CraneWIN will not be copied back to TrailerWIN :
This diagram shows, that the stability is very bad and additional stabilizer legs are absolutely
needed.
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Guided example
Click on the End‐button to go back to the TrailerWIN picture and add stabilizers.
Click on the equipment button.
Stabilizers
Choose Stabilizer legs‐button and You will then see a list of Manufacturers of Stabilizers.
We click on Maxistab and choose model 3 EHA/S.
In the following window You can check and edit data for the stabilizer.
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Guided example
The chosen stabilizers are now added to the picture and it is now possible to test the stability
again:
Click on the "CraneWIN" button again.
Now we can see that the stability is much better, but there are still problems to the front.
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Guided example
Modifications in CraneWIN
As we can see from the picture, the Tilting line goes to the middle of the front‐axle. If we want
to see how much it affects to set the Tilting line to the middle of the front wheels, we can click
on the Tilting Line‐ button.
Here we can choose 3 different positions for
the tilting line; in the middle of front axle
(no stabilizing effect sideways), between
wheel and midpoint or in the position of
wheel. Note that we can also give own
values in the textboxes.
Choose the “best” option:
in the middle of the wheel.
Now we can see that the stability still isn’t good enough and we will need front stabilizers too.
We can check the stability with front stabilizers in CraneWIN by giving own measurements to
the Tilting line. However then the weight of front stabilizers would not be in the TrailerWIN
weight calculation.
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Guided example
We will do a quick check to see how this works:
Click on the “Tilting line” ‐button
Fill in the value 475 for width (950/2)
and ‐1500 for longitual direction
because we want to check the stability
when we have a stability point in front
of front axle. Then click “OK”.
Be aware that by doing it this way,
we’re not taking into account the
stabilizing effect of the front
stabilizers, this method is only for
checking purposes.
Note also that the measurement
shown in TrailerWIN is to the first
point of stabilizer leg, not the middle of the stabilizer leg.
As we can see the stability is very good but the weights of the front stabilizers are not taken into
account here.
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Guided example
To do this correctly we add the front stabilizers in TrailerWIN.
Go back to TrailerWIN and choose the
Equipment button again. Then choose
stabilizer and scroll down the list to the
end.
Choose Front Stabilizers and make
necessary modifications to the data.
Click ok.
Now we can see the front stabilizers in the TrailerWIN picture and they are also added into the
weight calculation. This way the weight of the front stabilizers will also be in the stability
calculation.
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Guided example
Go back to CraneWIN and check the stability once again.
Now we can see that the stability is very good in all directions. Now we also have the weight of
the front stabilizers in the calculation. They do not affect the stability forwards because they are
in the tilting line but to other directions their weight will be taken into account in the
calculation.
----------------------------------------------------------------------------------
Forwards
kg x m = kgm
----------------------------------------------------------------------------------
Chassis weight Front axle 4576 x 1.510 = 6910
Chassis weight Rear axle 4181 x 6.351 = 26554
Weight of support legs 459 x 2.343 = 1075
Weight of extra support legs 420 x 8.080 = 3394
Front Stabilizers 250 x 0.000 = 0
Crane weight 2620 x 0.678 = 1776
----------------------------------------------------------------------------------
Stabilizing moment Sum = 39709
----------------------------------------------------------------------------------
Load * Max outreach 1980 x 7.582 = 15012
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TrailerWIN – CraneWIN – FrameWIN
Guided example
Crane button
Here You can make changes to Lifting capacity,
outreach, weights and COG‐point of the crane.
For changing Stabilizer legs data click on the
Legs‐button.
Here You can make modifications to all support
leg data.
Note that these changes will not be saved back into TrailerWIN, You must save this CraneWIN
calculation separately to a CraneWIN file.
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Guided example
Printing in CraneWIN
When you have finished the calculation you can print out the stability chart and stability
calculation.
To do this, choose print from Menu.
You can choose to print all pages or select a part of the calculation.
You can preview the text‐page before printing by selecting Picture‐
Text from the menu.
This is the same information that will be printed out on printer.
On the next page you can see a part of the text as a print out. You can see that all calculations
are presented here to help checking the calculation.
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Guided example
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Distance Cranes slewing centre - First front axle mm 1108
Crane weight kg 2620
Dist. Cranes slew. centre - COG of crane at max outreach
mm 1940
Outreach mm 10200
Lifting capacity kg 1980
Chassis weight Front axle kg 4576
Chassis weight Rear axle kg 4181
Dist. Cranes slew.centre - Centre line of truck mm 150
Dist. Cranes slew. centre - Centre of support legs beam
mm < = -354
> = -196
Span of support legs mm 5790
Weight of support legs kg 459
Distance Extra support legs - Front axle mm 6570
Span of extra support legs mm 5000
Weight of extra support legs kg 420
Front Stabilizers :
Distance Extra support legs - Front axle mm -1510
Span of extra support legs mm 950
Weight of extra support legs kg 250
Distance Front axle - Rear axle support point mm 4841
Track front axle mm 2000
Track Rear axle mm 1800
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CRANES STABILITY CALCULATION (Measures from tilting line)
----------------------------------------------------------------------------------
----------------------------------------------------------------------------------
Rearwards right
kg x m = kgm
----------------------------------------------------------------------------------
Chassis weight Front axle 4576 x 2.951 = 13506
Chassis weight Rear axle 4181 x 2.614 = 10931
Weight of support legs 459 x 2.893 = 1328
Weight of extra support legs 420 x 2.494 = 1047
Front Stabilizers 250 x 3.057 = 764
Crane weight 2620 x 0.785 = 2056
----------------------------------------------------------------------------------
Stabilizing moment Sum = 29632
----------------------------------------------------------------------------------
Load * Max outreach 1980 x 7.475 = 14801
----------------------------------------------------------------------------------
Tilting moment Sum = 14801
----------------------------------------------------------------------------------
Stability factor n 29632 / 14801 = 2.00
----------------------------------------------------------------------------------
Maximum load 1980 kg
----------------------------------------------------------------------------------
----------------------------------------------------------------------------------
----------------------------------------------------------------------------------
Forwards right
kg x m = kgm
----------------------------------------------------------------------------------
Chassis weight Front axle 4576 x 1.403 = 6422
Chassis weight Rear axle 4181 x 4.825 = 20173
Weight of support legs 459 x 1.992 = 914
Weight of extra support legs 420 x 6.047 = 2540
Front Stabilizers 250 x 0.336 = 84
Crane weight 2620 x 0.140 = 368
----------------------------------------------------------------------------------
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TrailerWIN – CraneWIN – FrameWIN
Guided example
SUBFRAME CALCULATION IN FRAMEWIN THEORY
Bending moment M at a certain cross‐section makes the normal stress on a longitudinal fiber
at a distance y from the neutral axis of the beam:
My M
I W
The second moment Ix (moment of inertia) and section modulus Wx of a symmetrical U‐
cross‐section area can be calculated as follows: 3 3
BH bh
Ix
12 12
Ix I 2
Wx x
COMBINED BEAM : Chassis Frame + Subframe H 2 H
Subframe can be mounted on different systems:
Flexible mounting : subframe mounted with brackets or clamps
Rigid mounting : subframe mounted with shear resisting plates
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Guided example
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TrailerWIN – CraneWIN – FrameWIN
Guided example
With a flexible mounting Ix and Wx can be calculated for a combined beam as follows:
IC I F IS
IF IS
WC eC max eF1 , eF 2 , eS1 , eS 2
eC
Maximum normal stresses with bending moment M at a combined beam cross‐section with
flexible mounting are :
M eF1
F1 on chassis frame lower fibers
IC
M eF 2
F2 on chassis frame upper fibers
IC
M eS1
S1 on subframe lower fibers
IC
M eS 2
S2 on subframe upper fibers
IC
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TrailerWIN – CraneWIN – FrameWIN
Guided example
With a rigid mounting the calculation of Ix and Wx for a combined beam turns out to be more
complicated :
At first we have to calculate the centroid (Center of gravity) yC for the combined cross‐section.
With dimension yC we calculate zF and zS and then the second moment of combined cross‐
section IC and the section modulus for the combined cross‐section WC.
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Guided example
A F y F AS ( H F y S )
yC
A F AS
z F yC y F
z S H F y S yC
I C ( I F A F z F 2 ) ( I S AS z S 2 )
IC
WC eC max( y C1 , y c2 )
eC
Maximum normal stresses with bending moment M at a combined beam cross‐section with
rigid mounting are :
M y C1
F on frame lower fibers
IC
M y C2
S on subframe upper fibers
IC
In both cases :
The normal stress distribution in figures:
Young's modulus E for chassis frame material = Young's modulus E for subframe material.
With all steel qualities E 210 000 N/mm2
Safety factor can be calculated:
Re
n Re Yield point ; for material Fe52, Re 350 N / mm 2
calculated stress
Bending Moment M
In FrameWIN software by Trailer Consultation the bending moment M is the lifting moment of
the crane multiplied by dynamic coefficient ( default = 1.3 ).
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Guided example
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TrailerWIN – CraneWIN – FrameWIN
Guided example
Formulas and symbols
Formula for calculating stresses and safety factor
1 ϕ2 2 ϕ1
Symbols and coefficients
Gf = Crane own weight without boom system
Gb = Boom system weight (or total crane weight)
Yb = Center of gravity for boom system (or crane)
P = Payload
R = Center of gravity for payload
Vh = Rising/lowering hook speed used for calculating Ф1, Ф2
Vhmax = Maximum hook speed
γp1 = Partial safety factor for payload
For Load combination A1 safety factor γp1 = 1.22
For Load combination C1 safety factor γp1 = 1.1
γp2 = Partial safety factor for crane weight
For Load combination A1 safety factor γp2 = 1.34
For Load combination C1 safety factor γp2 = 1.1
Ф1 = Crane weight factor for dynamic effects when rising/lowering suddenly stops
Ф1 = 1.1 or max Ф2
Ф2 = Payload factor for dynamic effects when rising/lowering suddenly stops.
Ф2 =1.05 + 0.17 Vh
For Load Combination A1 :
Vh = Vhmax for Hoist Drive Class 1 (HD1)
Vh =0.5 Vhmax for Hoist Drive Class 4 (HD4)
Vh =0 for Hoist Drive Class 5 (HD5)
For Load Combination C1:
Vh = Vhmax for Hoist Drive Classes 1 and 4 (HD1 / HD4)
Vh =0.5 Vhmax for Hoist Drive Class 5 (HD5)
W = Bending moment
g = 9.81 Nm (=1 kg)
σa = Calculated stress
γm = Safety factor
γm >= 1.1
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Guided example
31 Copyright © 2014 Trailer Consultation
TrailerWIN – CraneWIN – FrameWIN
Guided example
Click in Menu: Edit – Chassis
Frame
In the lower left corner You see
2 listboxes, one for
Manufacturer and second list for
models.
These lists are not complete and
other options might be available.
In this window the measurement
between the subframe‐beams
can also be edited.
In this window select frame
Volvo FRAME88P/F
360x90x8+277x80x5 Selection of Chassis Frames
from Manufacturer list
The profiles can also be edited by choosing Menu
Edit – Edit Chassis Frame Profil
The measures of the profile can then be
edited in a graphics view of the Frame
profile:
The subframe profiles can be edited the
same way by first selecting one of the
added profiles and choosing menu
Edit‐ Edit Profile.
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Guided example
Now we go to Calculation Method and choose EN12999, EN 13001 Calculation system.
Click on Menu Options –
Calculation System
The window will then show data used for calculating Dynamic forces of the crane.
In this case we will choose C1 for Load Combination‐ Exceptional load and HC1‐HD5 Automatic
Speed Control. The vertical hook speed we change to 1.7 and the safety Factor to 1.4.
Click Ok.
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TrailerWIN – CraneWIN – FrameWIN
Guided example
Next we will change the option for Subframe to a hollow
section beam:
Profile shape button
Click on the Profile shape‐button and select the Rectangular
hollow section (Vertical).
Choose profile 160x80x5 from profile Size list.
Profile Size button
Click Ok and go back to main‐window.
We go on adding a vertical plate between the Chassis frame
and Subframe
Add Profile button
Choose Add Profile – Plate Vertical
Modify the x‐placement to ‐5 so it will go outside the
Chassis Frame and Subframe.
Modify the height of the plate to 250 and move the plate so
it will reach the top of the subframe by changing the y
measure to ‐90.
We can now see that on Flexible mounting the safety factor
on Chassis Frame is 1.27 but if we use a Fixed mounting we
can reach a safety factor of 1.81.
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TrailerWIN – CraneWIN – FrameWIN
Guided example
We continue adding more profiles. We now add a horizontal
plate on top of subframe that fills up the gap between the
frame‐beams.
Click on Subframe button or Menu Edit‐Subframe
Then click Add Profile –button
Choose Plate horizontal plate
Modify the measures, width to 500 and placement of the
sideplate in x‐direction to ‐5
Here we must notice that the width of the horizontal plate has to be set to MIDPOINT OF TRUCK
.
Now when we reinforced to top of the subframe we will get
more force on lower part of the subframe. Instead of reinforcing
the lower flange of subframe we can choose to reinforce the
Truck frame on the bottom instead by inserting a L‐
reinforcement outside lower part of Truck frame.
Choose Add profile ‐ L‐Reinforcement for Chassis beam.
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Guided example
Next window shows the profile of the reinforcement. Here we modify the reinforcement to add
more strength to the lower part of frame by modifying the measures as follows:
Now we must change the x‐ and
y‐measures to get the
reinforcement to outside of
Chassis frame. Change x‐
measure to ‐10 and y‐measure
to ‐310.
Click the small Ok‐button.
Now we have a good safety factor for Flexible mounting
also.
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Guided example
When Printing You will get two pages. First page a detailed drawing of the Subframe:
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Guided example
On the other page You will get details about the calculation as seen on screen:
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Guided example
This calculation is purely based on the kg/m mass of different beams and gives You only rough
weight data. In this case the subframe mass is calculated as 47.7 kg/m. We will use a value of 50
kg/m in TrailerWIN.
Go back to the TrailerWIN calculation and select
Subframe button:
In this window You can now make selections for
Subframe. First we choose the type of front‐end by
choosing the radio‐buttons:
Then we can use our value for weight of subframe in
kg/m or we can use a total Subframe weight in the next textbox.
Then we can change start‐ and endpoint of subframe by entering x1‐ and x2‐values or by giving a
length (L). You can also use mouse and drag the yellow boxes to modify length.
Here we use the first option and modify the length of the subframe to 1400mm.
Type of first end or no subframe
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Guided example
The Subframe is now shown as a gray rectangle below the crane in the big picture:
On the text‐page we can also verify that all equipments are listed in the weight calculation:
This Guided example is only for learning use of the programs and shall not be used as a good
practice of assembling Crane to a chassis. The subframe profile is only for practicing program use
and must not be used as a model for good design of subframe.
For more information please use the Manuals in PDF‐format in TrailerWIN/Manual‐directory.
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