Rubber- and cellular buffers

Rubber- and cellular buffers

Industrial Brakes · Thrusters · Pressure Oil Pumps · Couplings · Hydraulic Buffers · Cellular Buffers
Rail Pliers · Sheaves · Hook Blocks · Crane Rail Wheels · Rail Clamps · Reparation · Service

Buffers with high energy absorption capacity are required

on cranes to avoid deformation of structural components
when the crane strikes against the runway limit stop. For this
purpose, a special cellular buffer has been developed which
is also useful in any other application where impact energy
with a limit maximum load is to be converted.
Polyurethane®, a cellular material with excellent physical
properties, is used for the buffer body whose elasticity
and energy absorption capacity are materially improved
by the cellular structure. Due to the specific properties of
the plastic material employed and to the action of the gas Cellular buffers at the travel unit of a 900 t gantry crane
occluded in the cells, the energy absorption increases with
impact velocity.
There is no limit stop that would restrict the compression of
the buffer body, so that even in the case of a violent collision
the cushioning effect is maintained till the end of impact. Cellular buffers at the
travel unit of a 200 t
shipyard crane

Cellular buffers at the travel

units of two 175 t ladle cranes

The entire buffer volume is utilized to absorb energy, since

the impact load will be distributed throughout the buffer‘s
cross-sectional area. The buffer undergoes very little radial
expansion even under the largest possible compression.
A favourable diameter-to-length ratio in conjunction with
non-slip face make the cellular buffer virtually insensitive
to axial misalignment due to the crane‘s normal wheel/rail
clearance.
The buffer material provides chemical resistance to ozone,
oxygen, water, gasoline and most oils and industrial lu-
bricants. The buffer works silently. Its shock-absorbing
capacity is fully retained over a temperature range from
– 40°C to + 80°C.
Cellular buffers at the
travel unit of a 250t ladle
crane and at the end stop
of the crane track

KoRo IBS GmbH Stockumer Straße 28 Tel. 0049 2302 70 78 7- 0 Mail: [email protected]
58453 Witten (Germany) Fax 0049 2302 70 78 7-10 Web: www.koro-ibs.de
 Rubber Buffer GPZ/GPP

Type GPZ

Type GPP

Energy Weight
Wheel End
Size Dimensions absorption
travel force kg
characteristic
d1 a d2 e h l s M kJ1) mm1) kN1) KPG GPP
40 50 5,5 40 32 28 2 M 8 0,05 16 10 0,07 0,08
50 63 6,5 50 40 33 2 M10 0,10 20 16 0,14 0,15
63 80 6,5 63 50 32 3 M10 0,20 25 25 0,26 0,31
80 100 9,0 80 63 37 3 M12 0,39 32 39 0,50 0,59
100 125 9,0 100 80 36 4 M12 0,78 40 62 0,98 1,20
125 160 11,0 125 100 46 4 M16 1,57 50 98 1,90 2,30
160 200 11,0 160 125 44 6 M16 3,14 63 157 4,10 4,90
200 250 13,0 200 160 49 6 M20 6,18 80 245 7,80 9,50
250 315 13,0 250 200 47 8 M20 12,30 100 392 16,40 19,40
315 400 - 315 250 - - - 24,50 125 618 - -
1)
These values are only valid for strokes that occur in crane operations

Rubber buffer with thread:

Rubber quality: NK/SBR 70 +/-5 Shore A
Other qualities upon request
Metal parts are white zinc-plated

Rubber buffer with baseplate:

Material plate: S 235 JR

Customer-specific design upon request

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 1 of 12

 Cellular Buffer KPZ
Data sheet

Energy
Wheel
Size absorption End force Weight
travel
characteristic
d1 l1 l2 M kJ (max)*** mm* kN** kN (max)*** kg
KPZ 70 70 0,9 46,2 18 37 0,4
KPZ 100 105 45 2,6 70,0 27 70 0,8
M 12
KPZ 130 125 5,1 84,0 45 105 1,2
KPZ 160 155 55 9,2 105,0 95 150 1,8
KPZ 210 205 85 M 20 20,0 140,0 120 270 4,1
* recommended maximal deformation (70% of H)
** at recommended max. deformation and 120 m/min
*** data for impact speed of 240 m/min
for lower speeds is the max. energy absorption reduced
data can be taken from the characteristics

Reliabilities:
Polyetherurethane is in the temperature range -40 ° C to +80 ° C max.
Transient temperature peaks up to +110 °C are possible.
Polyetherurethane is resistant to oils, fats and other chemicals and has good resistance to
hydrolysis, too.

Material buffer:
Mixed cellular polyetherurethane 500 – 600 kg/m³
Material symbol >PUR<

Pin: 8.8

These buffers aren’t usable as springs.

Usage of buffer against buffer H max. <= 1,5 x D

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 2 of 12

 Cellular Buffer KPZ
Characteristics

Bump stop KPZ 70

static v=1m/s v=2m/s static v=1m/s v=2m/s

75 75
50 50

60 60
40 40

Wheel trvael in [%]

Wheel travel [mm]

Wheel travel [mm]

Wheel trvael in [%]
45 45
30 30

20 30 20 30

10 15 10 15

0 0 0 0
0 5 10 15 20 25 30 35 40 0,0 0,1 0,2 0,3 0,4 0,5

Force [KN] Energy absorption [KNm]

Bump stop KPZ 100

static v=1m/s v=2m/s static v=1m/s v=2m/s
75 75
70 70
60 60
60 60
Wheel trvael [mm]

Wheel trvael in [%]

Wheel trvael in [%]

Wheel trvael [mm]

50 50
45 45
40 40
30 30 30 30

20 20
15 15
10 10

0 0 0 0
0 10 20 30 40 50 60 70 80 0,0 0,2 0,4 0,6 0,8 1,0

Force [KN] Energy absorption [KNm]

Bump stop KPZ 130

static v=1m/s v=2m/s static v=1m/s v=2m/s
75 75
90 90
80 80
60 60
Wheel trvael in [%]

70 70
Wheel trvael [mm]

Wheel trvael in [%]

Wheel trvael [mm]

60 60
45 45
50 50
40 30 40 30
30 30
20 15 20 15
10 10
0 0 0 0
0 20 40 60 80 100 120 0,0 0,4 0,8 1,2 1,6 2,0

Force [KN] Energy absorption [KNm]

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 3 of 12

 Cellular Buffer KPZ
Characteristics

Bump stop KPZ 160

static v=1m/s v=2m/s static v=1m/s v=2m/s

75 75

100 100
60 60

Wheel trvael in [%]

Wheel trvael [mm]

Wheel trvael in [%]

Wheel trvael [mm]

80 80
45 45
60 60
30 30
40 40

20 15 20 15

0 0 0 0
0 40 80 120 160 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
Force [KN] Energy absorption [KNm]

Bump stop KPZ 210

static v=1m/s v=2m/s static v=1m/s v=2m/s
160 75 75

140 140
60 60
120 120
Wheel trvael [mm]

Wheel trvael [mm]

Wheel trvael in [%]

Wheel trvael in [%]

100 100
45 45
80 80

60 30 60 30

40 40
15 15
20 20

0 0 0 0
0 50 100 150 200 250 300 350 0 1 2 3 4 5 6 7 8
Force [KN] Energy absorption [KNm]

Example for the calculation of the kinetic energy [KNm]

and the selection process of a bump stop

Application: Mass against impact static v=1m/s v=2m/s

2 75
Calculation formula: W=½mv 90
example
80
Characteristics: Mass m = 2000 Kg 70
60
Wheel travel in [%]

Velocity v = 1.0 m/s

Wheel travel [mm]

60
45
Deformation % = 70% 50

Calculation: W = ½ × 2000 × 1.0 40

30
30
= 1000 Nm
20 15
= 1.0 KNm
10

Selection: Bump stop 0

0,0 0,4 0,8 1,2 1,6 2,0
0

KPZ 130 Energy absorption [KNm]

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 4 of 12

 Cellular Buffer ZPP
with baseplate

label: ZPP D x H/L

Energy absorption Wheel End

Size Weight
characteristic travel force
D H L E A d2 T kJ** kJ (max) mm* kN* kg
80 80 90 80 110 12,5 10 1,4 1,5 56,0 43 1,3
100 110 2,6 3,2 70,0 2,0
100 100 125 12,5 10 70
150 160 3,8 4,6 105,0 3,8
125 125 137 125 160 17,0 12 5,5 6,6 87,5 118 3,1
160 172 10,7 12,4 112,0 5,5
160 160 200 17,0 12 180
240 252 16,0 18,5 168,0 6,4
200 214 20,0 25,0 140,0 10,0
200 200 250 21,0 14 270
300 314 30,0 37,0 210,0 11,8
250 250 265 250 320 21,0 15 43,0 49,0 175,0 460 16,5
315 330 86,0 96,0 220,5 27,5
315 315 400 21,0 15 730
475 490 128,0 142,0 332,5 49,0
400 420 188,0 190,0 300,0 66,0
400 400 500 25 20 1250
600 620 282,0 290,0 450,0 81,0
* recommended maximal deformation
** at recommended max. deformation

Reliabilities:
Polyetherurethane is in the temperature range -40 ° C to +80 ° C max.
Transient temperature peaks up to +110 °C are possible.
Polyetherurethane is resistant to oils, fats and other chemicals and has good resistance to
hydrolysis, too.

Material buffer:
Mixed cellular polyetherurethane 500 – 600 kg/m³
Material symbol >PUR<

Material Plate:
S 235 JR
These buffers aren’t usable as springs.
Usage of buffer against buffer H max. <= 1,5 x D

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 5 of 12

 Cellular Buffer ZPZ

label: ZPZ D x H

Energy absorption
Size Wheel travel End force Weight
characteristic
D H L M kJ** kJ (max) mm* kN* kg
80 80 1,4 1,5 56,0 43 0,35
100 2,6 3,2 70,0 0,55
100 70
150 3,8 4,6 105,0 0,80
125 125 5,5 6,6 87,5 118 1,00
35 M12
160 10,7 12,4 112,0 1,90
160 180
240 16,0 18,5 168,0 2,80
200 20,0 25,0 140,0 3,50
200 270
300 30,0 37,0 210,0 5,20
250 250 43,0 49,0 175,0 460 8,60
315 M24 86,0 96,0 220,5 14,80
315 730
475 80 128,0 142,0 332,5 21,00
400 188,0 190,0 300,0 29,10
400 M30 1250
600 282,0 290,0 450,0 41,60
* recommended maximal deformation
** at recommended max. deformation

Reliabilities:
Polyetherurethane is in the temperature range -40 ° C to +80 ° C max.
Transient temperature peaks up to +110 °C are possible.
Polyetherurethane is resistant to oils, fats and other chemicals and has good resistance to
hydrolysis, too.

Material buffer:
Mixed cellular polyetherurethane 500 – 600 kg/m³
Material symbol >PUR<

Pin: 8.8

These buffers aren’t usable as springs.

Usage of buffer against buffer H max. <= 1,5 x D

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 6 of 12

 Cellular Buffer ZPP/ZPZ

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 7 of 12

 Cellular Buffer ZPP/ZPZ

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 8 of 12

 Cellular Buffer ZPP/ZPZ

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 9 of 12

 Cellular Buffer
Material data sheet

Material:
Mixed cellular polyetherurethane
Material symbol >PUR<
The integral foam system is used for the production of flexible integral foam with body panel
densities of 500 – 600 kg/m³
Hardnesses of 25 – 75 Shore A can be accomplished.

Reliabilities:
Polyetherurethane is in the temperature range -40 ° C to +80 ° C max.
Transient temperature peaks up to +110 °C are possible.
Polyetherurethane is resistant to oils, fats and other chemicals and has good resistance to
hydrolysis, too.

Safety instructions:
Our recommendation for the max. permissible deformation of the impact buffer is around 70% of the
buffer height. The buffer has to be precautionary replaced in case of exceedance of the respective
max. permissible load range. Energy storing buffers are not suited for usage in which the rated
speed is higher than 4m/s.

The buffers are safety components and are subject to a natural aging process. Therefore, they have
to be checked regularly, e.g. in the context of the annual crane examination acc. to BGV D6 resp.
UVV/VBG 9 and 9a (see also VDI 3575).

Security and Environment:

The buffer do not contain substances with hazardous characteristics according to Chem/GefStoffV
and can be disposed with the usual trash.Country-specific regulations might have to be
regarded.The details of this technical data sheet are based on our current level of knowledge and
apply as nonbinding advices. Therefore, the user is not freed of an examination for suitability for the
intended use. Hence, the application-oriented possibility lies in the field of responsability of the
recipients of our products, as well as eventual trademark rights of third parties, existing laws and
regulations. Apart from that apply the requirements of our general sales and delivery conditions.

www.koro-ibs.de subject to change V.10/140225 chapter 19 page 10 of 12

 Cellular Buffer
Material data sheet

1 General Buffer calculation acc. to DIN 15 018

remarks The determination of buffers for crane and jack operation is made for one side of the
system. The respective unfavourable load position has to be assessed.
The following applies for:
Crane => jack in smallest start dimension
Jack => consideration of the center of mass S

2 Naming, R1 ... R4 [kg] wheel loads resulting from deadweight and rigidly carried along
formula loads
symbols, units mpu [kg] mass acting on one buffer
and v [m/s] max. travel speed
calculations Epu [Nm) energy acting on one buffer
Fpu [kN] buffer end force

2.1 Determination of the masses acting

on the buffer mpu
For cranes:
1
mpu = R1 + R2 + ( R3 + R4 + ... Rn ) )
For jack:
m pu = max. from (R1 + R3) or (R2 + R4)

1) for cranes with more than 4 wheels/side

2.2 Determination of the energy acting

on the buffer Epu

Installation Energy acting on buffer Epu

for reduction Stroke against
System Stroke against Collision of two
of the fence with
rigid fence systems with equal buffers
velocity buffer 2)

mpu *v2 mpu *v2 mpu1 * mpu2 *(v1 +v2 )2

without Epu = Epu = Epu =
2,768 5,536 5,536*(mpu1 +mpu2 )
Crane
mpu *v2 mpu *v2 mpu1 * mpu2 *(v1 +v2 )2
with Epu = Epu = Epu =
4,082 8,164 5,536*(mpu1 +mpu2 )

mpu *v2 mpu *v2 mpu1 * mpu2 *(v1 +v2 )2

without Epu = Epu = Epu =
2 4 5,536*(mpu1 +mpu2 )
Jack
mpu *v2 mpu *v2 mpu1 * mpu2 *(v1 +v2 )2
with Epu = Epu = Epu =
4,082 8,164 5,536*(mpu1 +mpu2 )
2
) applies for equally sized buffer

www.koro-ibs.de subject to change V.10/140217 chapter 19 page 11 of 12

 Cellular Buffer
Technical information

Mixed cellular polyetherurethane integral foam (Polyetegral)

SYSTEM DESCRIPTION Polyol-Component: Mixture from Polyol, activators,

(A-Component) stabilizers, and if necessary colours

Isocyanat- Component:: Preparation from

(B- Component) Diphenlymethandiisocyanat (MDI)

APPLICATION PURPOSE The integral foam system assigned for the production of soft - flexibly
integral foam parts with shaped part densities of 250 - 700 kg/m³ and
Shore A hardnesses of 25 - 70. Inserts can be over foamed.

LABORATORY VALUES The testing bodies were produced with a high pressure reaction in-
jection machine with defined production parameters in a steel mould in
the dimensions 200x200x40 mm.
Density 1) 250 kg/m³ and 2) 500 kg/m³

TESTS Measures Dimension Test provision

To Part 1) 2)
Total density 250 500 kg/m³ DIN 53 420
Shore hardness 50 70 A DIN 53 505

Compression set
(Area temperature, 72 hrs,
30 minutes after decompression) 1,9 1,7 % DIN 53572

Related to the skin (d=1 mm)

Density 950 970 kg/m³ DIN 53 479
Tensile strength 6,5 7,6 N/mm² DIN 53 504
Elongation at break 145 175 % DIN 53 504
Tear propagation resistance 3,5 6 N/mm DIN 53 515

At the foam
Density 172 430 kg/m³ DIN 53 420
Tensile strength 48 125 N/cm² DIN 53 571
Elongation at break 110 145 % DIN 53 571
Tear propagation resistance 17,2 32 N/cm DIN 53 575

www.koro-ibs.de subject to change V.10/140217 chapter 19 page 12 of 12