FEDERATION EUROPEENNE DE LA MANUTENTION SECTION! HEAVY LIFTING APPLIANCES: F.E.M. 1.001 34 EDITION REVISED 1998.10.01 RULES FOR THE DESIGN OF HOISTING APPLIANCES BOOKLET 2 CLASSIFICATION AND LOADING ON STRUCTURES AND MECHANISMS: TAKNAF MAN TAKRAF Férdertechnik GmbH {Nur zur Information! Ken Anderungedtenst For information ony #Witheut amendment service? The total 3rd Edition revised comprises booklets 4 to 5 and 7 to 9 Copyright by FEM Section | Also available in French and GermanDocument prepared by the technical commission of FEM (European Handling Federation) Section | « Heavy lifung and handling equipment » FEM Section | Secretary Cosette OUSSAUGEY 39-41, rue Louis Blane 92400 COURBEVOIE 5 92038 PARIS LA DEFENSE CEDEX Fax 33147 176260 E-mail Mips@wanadoo tr Document available near the following National Commttioas BELGIUM FABRIMETAL Rue des Drapiers, 21 B- 1050 BRUXELLES Fax 3225102301 CZECH REPUBLIC Association of Czechoslovak Manufacturers of Transport and Liftng Equipment SYMAS, Kralovo Pole Cranes, as CZ 61200 BRNO. 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Postbus 190 NL- 2700 AD ZOETERMEER, Fax 3179 353 13 65 NORGE Norwegian FEM Groups Federation of Norwegian Engineonng Indusines Oscars Gate 20 J Box 7072 H N-- 0308 OSLO 3 Fax 47 22 59 66 69 PORTUGAL FENAME - Federagao Nacional do Metal (ANEMM) Estrade do Pago do Lumar Polo Tecnologico de lisboa - Lote 13, P - 1600 LISBOA, Fax 351171504 03 SCHWEWZ/SUISSE/SVIZZERA Verein Schwerzenscher Maschinen- ladustneler (VSt) Kirchenweg 4 CH 8032 2URICH Fax 411 384-48 48 ‘SUOMI Federaton of Finnish Metal, Engincoring and Electrotechnical Industies - FIMET Etelaranta 10 PO BOx10 FIN -00131 HELSINKI Fax 3589624 462 SVERIGE Swedish Association of Suppliers of Mechanical Handing Equipment MHG Storgatan 5 Box 5510 S- 11485 STOCKHOLM Fax 46 6 660 33 78.The third edition of the "Rules for the design of hoisting appliances" dated 1987.10.01 included 8 booklets. An addition to this edition was compiled in 1998. This addition is incorporated in booklet 9, which also replaces booklet 6. This booklet forms part of the "Rules for the design of hoisting appliances" 3rd edition revised, consisting of 8 booklets : Booklet 1 - Object and scope Booklet 2 - Classification and loading on structures and mechanisms Booklet 3 - Calculating the stresses in structures Booklet 4 - Checking for fatigue and choice of mechanism components Booklet 5 - Electrical equipment Booklet 7 - Safety rules Booklet 8 - Test loads and tolerances | Booklet 9 - Supplements and comments to booklets 1 to 8 NOTE: Booklet 9 must not therefore be used separately.BOOKLET 2 CLASSIFICATION AND LOADING ON STRUCTURES AND MECHANISMS CONTENTS Clause Page GROUP CLASSIFICATION OF HOISTING APPLIANCES. 2a 23 AND THEIR COMPONENT PARTS = General plan of classification 2udade 23 = Classification of hoisting appliances as a whole Bhs 23 « Classification systen 22d. 23 + Classes of utilization 2.1.2.2. 23 + Load spectrum 223. ao + Group classification of hoisting appliances 22a. 26 + Guidance on group classification of an appliance 2125. 26 ~ Classification of individual mechanisms es @ whole 2bde 26 + Classification systen Qbdede 26 + Class of utilization 2eLs3s2s 28 + Loading spectrum 2uLs3.3s 28 + Group classification of individual mechanisms as a whole Be eBad, 29 + Guldance for group classification of individval mechanisns as a whole 2.1.3.5. 29 = Classification of components Dedede 2 + Classification systen Dedede au + Classes of utilization 2.1.4.2. zu + Stress spectrun 2.1.4.3. 212 + Group classification of conponents 2a. Ded LORDS ENTERING INTO THE DESIGN OF STRUCTURES 22 2015 = Prinetpal loses 2.21. 215 = Loads due to vertical mations 2.2.2. 215 + Loads due to hoisting of the working load 2.2.2.1. 216 ++ Values of the dynanic coefficient ¥ 2221s, 216 + Loads due to acceleration (or deceleration) of the hoisting motion and to vertical. shock loadings when travelling along rail tracks 2.2.2.2. ar + Special case 2.2.2.3. 27 = Loads due to horizontal motions Sy 2.2.3. 2019 « Horizontal effects due to accelerations (or decelerations) 2.2.3.1 219 ++ Traverse and travel mations 22311. 2019 + Slewing and luffing (Gerricking) motions 2231.2, 220 « Effects of centrifugal force 2.2.3.2. 2-20 + Transverse reactions due to rolling action 220 + Buffer effects Sp 2a ++ Buffer effects on the structure 221 222 + Suffer effects on the suspended load 21~ Loads due to clinatic effects + Wind action ++ Wind pressure t+ Design wind conditions Wind load calculations ++ Force coefficients + Snow Toad + Temperature varlations = Miscellaneous loads + Loads carried by platforms (CASES OF LOROING 2.3. 2030 -caseT + 23d 231 Case IT: 232. 231 = Case IIT : Appliance subject to exceptional loads 2.3.3. 231 = Choosing the amplifying coefficient Ye 2.3.h. 2032 SEISMIC EFFECTS 2.8 232 LOADS ENTERING INTO THE DESIGN OF MECHANISMS 2.5. 2033 = Type Sy leads 2.51. 233 = Type Sq loads 2.5.2. 233 CASES OF LOADING 238 = Case I: Normal service without wind 2.34 + Type Sy Loads 23 + Type Sa loads 234 case II : Nomal service with wind 235 + Type Sq loads 235 = Type Sp loads: 255 = Case IIE : Exceptional loads 235, + Type Sy loads 2035 + Type Sp loads 2036 = Application for calculating Sy 2036 |» Hoisting motions 2036 + Horizontal motions 237 + Conbined motions 237 APPENDIX HARMONISATION OF THE CLASSIFICATIONS OF APPLIANCES AND MECHANISHS Ae2sLeLe 239 CALCULATION OF LOADS DUE TO ACCELERATION OF HORIZONTAL MOTIONS 2.2.3. 2.85, LIST OF SYKBOLS AND NOTATIONS See booklet 1 2222 bbe Balas 2eL2e1. 2.16226 GROUP CLASSIFICATION OF HOISTING APPLIANCES AND THEIR COMPONENT PARTS GENERAL PLAN OF CLASSIFICATION In the design of a hoisting anoliance and its component parts, account must be taken of the duty which they will be required to perform during their duration of use ; for this purpose group classification is employed of : = the appliance as a whole 5 = the Indivicval mechanisns as a whole ; = the structural and mechanical components. This classification is based on two criteria, nanely + = the total duration of use of the item considered ; = the hook load, loading or stress spectra to which the item is subjected. CLASSIFICATION OF HOISTING APPLIANCES AS A WHOLE CLASSIFICATION SYSTEM Bppliances as a whole ere classified in eight groups, designated by the syabols AL, A2, «++, AB respectively (sea section 2.1.2.4.), on the basis of ten classes of utilization and four load spectra. CLASSES OF UTILIZATION 8y duration of use of a hoisting appliance is meant the nunber of hoisting cycles whion the appliance performs. A hoisting cycle is the entire sequence of operations commencing when a load is hoisted and ending et the monent when the appliance is ready to hoist the next load. ‘The total duration of use is 8 computed duration of use, considered as a guide value, commencing when the eppliance is put into service and ending when it is Finally taken out of service. ‘On the basis of the total duration of use, we have ten classes of utilization, designated by the symbols UO, UL, ..., UB. They are defined in table 7.2.1.2.2.2,1,.2.3. Table 7.2-1.2.2. ~ Classes of utflization Total curation of use Syabol (nunber thax of hoisting cycles) wo tax € 16 000 uw 16000 6 m°/s) the appropriate shape coefficients are applied to the corresponding frontal areas. here gusset plates of normal size are used in welded lattice construction no al~ onance for the additional ares presented by the plates is necessary, provided ‘the lengths of individual mebers are taken between the centres of node points. ‘Shape coeffictents chtained from wind-tunnel or full-scale tests may also be used. 2025T.2.2.ded sda Force coefficients Terodyrani Slenderness 1/2 of 1/0 (1) : ; : Type Dee eee. <5 | wo [a |x |o | |>s0 Folled sections [] ais fias fas fae faye fas | ye i Rectangular hollo« | sections w t0 356 nn na fayas [5 153] 255 | 55 | 16 ‘square | and 258 x 857 mm ; ae wer fuos faz jie fre jas | ne other sections 1430 | 1,35 | 1,60 | 1465 | 1,70 | 1,80 | 1,80 circular sections where « | i 7 | meio fous < sate 0,60 | 0,70 | 9,80 | 0405 | 0,50 | 0,90 | 9,90 members: Devs y 6 m/s 0,60 | 0,65 } 0,70 | 0,70 | 0,75 | 0,80 1 0,80 Be Rectangular 2. fayss | airs | 95 | 2,20 | 2,20 holton sectsons | pe 1 |uvao} 1455 | 2,75 | 1,05 | 1,90 square snd 0,5 |1,0 | 1,20 bo | 438 140 258 x 457 2 0 yo fa scat 0,25 [0,80 | 0,90 ye 1 a 7 | | a | Flat-sided sections 1,70 ee Circular sections lattice tattle | graze # Devs < 6 m2/s 1,10 Ove % 67/5 0,80 Rectenguler clad vachinery | structures on grourd 110 * or solid base (1) See Figure 2.2.4.1-4.1. 2.26(1) Aerodynamic slenderness + breadth of section a Vi > «In lattice construction the lengths of individual menbers are taken between the centres of adjacent node points. See diagran below (11) soltesty sotto ~ #tee.of solid oats Af lL xbh enclosed area Ap TL x B seats as T mi als 4, S Yr Vet = (411) spacing ratio = —sistance betwezn facing sides breadth of menbers across wind front b for “a” take the smallest possible value in the georetry of the exposed face. sadth of section across wind front depth of section parallel to wind flow (av) Section ratio = Definitlons : Aerodynamic Slenderness, Solidity Ratio, ‘Spacing fatio, and Section fatfo 2-272.2.4.1.4.2, Multiple frames of members : shielding factors here parallel franes or nenbers are positioned so that shielding takes place, the wind loads on the windward frane or mesber and on the unsheltered parts of those behind it are calculated using the appropriate shape coefficients. The wind load on the sheltered parts is multiplied by a shielding factor n given in table T.2.2.4,1.4,2, Values of 7 vary with the solidity and spacing ratios as defined in figure 2.2.4.1.4.14 Table 1.2.2.4.1.4.2. Shielding coefficients specing ratio Solidity ratio A/Ay ah on | 02 0.3 ery 0.5 0.5 0.75 | oo | 0.32 | 0.21 | O15 1.0 a.s2 | 0.75 | 059 | 0.43 | 0.25 2.0 ass | oso | o63 | 0.50 | 0.33 4.0 no | os | 0.76 | 06s | 0.55 : 5.0 ro | 095 | os | 0.8: | 0.75 6.0 Lo | 10 1.0 1.0 1.0 \inere @ nunber of identical franes or members are spaced equicistantly behind each other in such a way thet each rane shields those behind it, the shielding effect is ascumed to increase up to the ninth frane and to renain constant thereafter. The wind loads are calculated as follows + On the Ist. frane FL = AeqeCe inv On the 2nd. frame Fp = mAace inN on the nth frame (nt) (where n is fron 3 to 8) Te Reap inw eee subsequent. Fy = nPodegeeh Teli The total wind load is thus + where there are up to 9 frames F elienerente en Vinge; total a grep LaDy in 1-0 Le nent ante vente (oon Jaa ce Frotal rarce (=) 4 a= sf] inn Note - The term 1% used in the above formula is assumed to have a lover Limit of 0,10, It is teken as 0,10 whenever TK < 0.10, 2282.204183. Lett. Lattice towers In calculating the "face-on" wind load on square towers, in the absence of a detailed calculation, the solid area of the windward face is multiplied by the following overall force coefficient : For towers composed of flat sided sections Lraen For toners conposed of circular sections where D-V, <6 m/s, 41-Q +n) where OV, 26 n?/s 1A The value of n {s taken from table 2.2.4.1.4.2, for a/b = 1 according to the solidity ratio of the windsard face. Te maxizun wind Icad on a square tover occurs when the wind blows on to a corner. In the absence of a detailed calculation, this load can be considered as 1.2 tines thet developed with “Pace-on" wind on one side. Parts inclined in relation to the wind direction Individual senbers, frames, ete here the wind bloas at an angle to the longitudinal axis of a menber or to the surface of a frane, the wind Joad in the direction of the wind is obtained from : Feaqty sin? tn where F, A, q and Cp are as defined in 2.2.441.3. and @ 45 the angle of the wind (8 < 90°) to the longitudinel axis or face. Lattice trusses and towers there the wind blows at an angle to the longitudinal axis of a lettice truss or tower, the wind load in the direction of the wind is obtained from : F = Agel pK inn where F, A, q and Cp are as defined in 2.2.4.1.3. and Kg = . which cannot be Less than 0,35 or greater than 1. 50 (1,7 - 2) s Where © is the angle of the wind in degrees (@ < 90°) to the Longitudinal exis of the truss or tower. Sp Is the area in n# of the bracing menbers of the truss or toner projected on to its windward plane. Sis the area in m? of all (bracing and main) menbers of the truss or tover projected on to its windward plane. The value of Kp is assumed to have lower and upper Limits of 0.35 and 1.0 respectively. It As taken as 0,35 whenever the calculated value < 0.35 and as 1.0 whenever the calculated value > 1.0, 22922st. 2s 2.2.8.3. 2.2.5 212,504 2.3. SNOW LOAD ‘Snow loads shall be neglected in the design calculations for overhead travelling cranes, bridge cranes and jib cranes. TEMPERATURE VARIATIONS considered only in special cases Stresses due to tenperature variations shall such as when menbers are not free to expand. In such cases, the maxinun tenperature fluctuation shall be taken to be : = 20°C to + asec. MISCELLANEOUS LOADS LOADS CARRIED BY PLATFORMS Access gangvays, driver's cabins and platforms shall be designed to carry the following concentrated loads : 3000 N for maintenance gangeays and platforms where materials my be placed, 1500 N for ganguays and platforms intended only for access of personnel, 500 Nas the horizontal force which may be exerted on handrails and toe-guards. These Icads are not to be used in the calculations for girders. CASES OF LOADING Three different cases of loading are to be considered for the purpose of the celcula~ tions = the norking case without wind, = the working case with Limiting working wind, = the case of exceptional loadings. Having determined the various loads in accordance with section 2.2, account is taken of @ certain probability of exceeding the calculated stress, which results from ingerfect methods of calculation and unforseen contingencies, by applying an anplifying coefficent Yo, which varies according to the group classification of the appliance. ‘The values of this coefficient Yo are indicated in clause 2.3.4. 203023d 2.3.2 2.3.3. CASE I : APPLIANCE WORKING WITHCUT WIND The following shall be taken into consideration : the static loads due to the dead weight Sp, the loads due to the working load S multiplied by the dynamic coeffi- ciert ¥, and the two most unfavourable horizontal effects Sy anong those defined in clause 2.2.3., excluding buffer forces. ALL these Joads must then be multiplied by the anplifyiny cu2ffici An cleuse 2.3.4., viz: Ye Spe ¥ + Sp In cases where travel motion takes place only for positioning the appliance and Is rot normally used for moving loads the effect of this motion shall not be con bined with another horizontal motion. this is the case for exanple with a dockside crane which, once it has been positioned,handles a series of loads at a fixed point. CASE II : APPLIANCE WORKING WITH WIND The loads of case t are taken to uhich are added the effects of the Lisiting working wind Sy defined under 2.2.0.1.2.1. (table 1.2.2.4.1,2.1.) and, where, applicable the lead due to tenperature variation, viz + Yo Sg + PSL + Sy) + Sy Note - The dynanic effects of acceleration and retardation do not have the same values in case II as in case I, for mhen a wind is blowing the «ccelerating or braking tines are not the same as when still conditions prevail. CASE III : APPLIANCE SUBJECTED TO EXCEPTIONAL LOADINGS Exceptional loadings occur in the following cases : = appliance out of service with maximum wind ~ appliance working and subjected to a buffer effect. = appliance undergoing the tests indicated in booklet 8. The highest of the following combinations shall be considered = a) The loads Sq due to the dead weight, plus the load Sy max due to the maximun vind as mentioned under clause 2.2.4.1.2.2. (including the reactions of the anchorages) ') the loads Sg due to the dead weight and S_ due to the working load plus the greatest buffer effect Sy as ewisaged in clause 2.2.3.4, ¢) the loads Sg due to the deed weight plus the highest of the tno loads YO, 5 and QS, } 01 and Op being the coefficients by which the safe working load is multiplied for the dyranic test (0) and for the static test (G2) as in clauses Bull. and 8.1.2. 231These three cases are expressed by the formulae + 2) 85+ S¥max b) So4 5+ Sp (LD ©) Sg+¥ oR oF Sor OS Note 1 - It should be noted that the checks under (c) ore only to be made in cases where the working load, when assuned to act alone, produces stresses opposed in direction to those caused by the dead weight up to the point at whicn the static test loed does not exceed 1,5 times the safe working lead. Note 2 - hhen using decelerating devices in advance of buffer impact under the conditions mentioned in clause 2.2.3.4,1. Sp will be taken to be the highest load resulting either from the retardation previously ceused by the decelerating device or fron that finally caused by the buffer. CHOOSING THE AMPLIFYING COEFFICIENT Yo 2 | | oti Ton | on | | | ofa |= | | | 2 SEISMIC EFFECTS Sore SE ee er eter nae of load swing resulting from the shock are neglected because this swing only loads the structure when the other effects have been practically absorbed. This coment does not apply to rigidly guided Loads which cannot swing. 23228 25d 215.26 LOADS ENTERING INTO THE DESIGN OF ..ZCHANISHS Mechanisms are subjected to two kinds of loading : 42) The loads, represented by the symbol Sy, which cre directly dependent upon the torques everted on the mechanisms by the motors or the brakes. b) The loads, represented by the symbol Sg, which are independent of motor or brake action but nhfch are deternined by the reactions which act upon the echanical parts and which are not balanced by a torque acting on the drive shafts (1). TYPE Sy LOADS The loads of this type to be considered are : ) Sq loads, corresponding to a vertical displacenent of the centre of gravity of moving parts of the appliance other than the working load. b) Sy loads, corresponding to a vertical displacenent of the working lead as defined in clause 2.2. for structures. ©) Syp Joads, corresponding to frictional forces which have not been allowed for in calculating the efficiency of the mechsnisa (see clause 4.2.6.1,1., booklet 4). 4) Syq loads, assoclated with acceleration (or braking) of the motion. 8) Syqq loads, corresponding to the effect of the working wind assumed for the ‘appliance. TYPE Sp LOADS The loads of this type to be considered are : 18) Spg loads due to the weights of components which act on the part under conside- ration ; b) Sq loads due to the working load as defined in clause 2.2., for structures. ©) Sq loads due to the accelerations or decelerations of the various notions of the appliance or its parts , as calculated according to clause 2.2.3.1. for structures, insofar as the order of magnitude of these loads is not negligible compared to the Sag and Sq losds. 4) Syy loads due ta the Limiting working wind Sy or to the maximum wind Sy nox (see clause 2.2.4.1,), insofar as the order of magnitude of these loads is not negligible. a In a travel aotion, for instance, the loads due to the vertical reaction on the rail wheels and the transverse loads that stress the whee! axle but are not trans- nitted to the components of the driving mechanism. 233266 CASES OF LOADING Tree cases of leading are to be coneidered in the calculations + Case 1: Noma service without wind Case LI: Normal service with wind Case IIE : Exceptional loadings. ‘A naximum load must be determined for each case of loading which serves as the basis for the calculations. Clearly, case I and IT are one and the sane in the case of appliances nhich fare not exposed to wind. note ‘the various loadings being determined as indicated in paragraph 2.5., account is taken of a certain probability of exceeding the calculated stress, which results fron inperfect methods of calculation and unforseen contingencies, by epplying an anplifying coefficient Yq depending on the group in which the mechanisn is classified. The values of this coefficient Yq are indicated in table T.2.6. Table 1.2.5. Values of amplifying coefficient Ym vechantsn eee tale ete aiert| os 2.6.16 CASE I — NORMAL SERVICE WITHOUT WIND The maximum 103d Symex 1 OF the Sy type (see clause 2.5.) is determined by conbining the loads Sugs Svs Svs and Syq defined in clause 2.5.1. which can be expressed by the relation = eee eee Sumaxt > (Sve + Sau + Sue + Sa) Yin It must be pointed out that it is not the combination of the maximun values of each of the terns in this relation thet must be considered, but the value resulting fron the most unfavourable conbination that could actually occur in practice. 2.6.1.2, TYPE Sp LOADS ‘The maxinun 108d Samay 1 of the Sg type (see clause 2.5.) is determined by conbining the loads Sagy Seiv Sane defined in clause 2.5.2. which can be expressed by the relation Seer Spmaxi = (Gag * Sa + Sea) Yo The note in clause 2.6.1.1, sbove applies here also.2.6.2. 2.6.2, 2.6.2. 2.64 2.6. ole De oe CASE TI~ NORMAL SERVICE WITH WIND TYPE Sy LOADS The maxinum load Symax Tt of the Sy type (see clause 2 5.) fs determined by com bining the loads Syg, Sj, aid Syp defined in clause 2.5.1. with one of the folioning two corbinations : fa) the load Syq and the load Sjyyg corresponding to @ 80 N/n® wind 1b) the load Syy-25 corresponding to a 250 N/n® wind. ‘The higher of the tho values expressed by the relations set out below is taken : Sumax 11 = Gug + Si + See + Bun + Sue) Ym or Sumax tt = Gag + Se + Se + Suazs) Yo the note in clause 2.6.1.1. applies here also. TYPE Sq LORDS The maximum load Samay 11 OF the Sg type (see clause 2.5.) is daternined by combining the loads Sag, Sq end Sap defined 4m clause 2.5.2. wlth Sayz5 which corresponds to a 250 N/a® wind, as expressed by the relation Samax it = Gag + Sar + Sea + Sr 25) Ym The note in clause 2.6.1.1. applies here also. CASE III — EXCEPTIONAL LOADS TYPE Sy LOADS The maximum load Snax 111 Of the Sy type defined under clause 2.5. 1s detensined by considering the maxima load that the motor can actually transmit to the mecha nism, allowing for Limitations due to practical operating conditions. the values of Simax IIT @F@ specified In clause 2.6.4. 2235266.3.2. 2.6 ult. 2b stale TYPE Sp LOADS Since the consequences of én overload due to collision with a buffer or fouling are far less serous for a nechanism than for the structure, the exceptional loading to be taken is that given under paragraph a) of clause 2.3.3. in the structures chapter. This gives + Samax 111 = Seq + Seamax In cases where additional mooring or guying means are used to ensure innobility or stability under maxima wind, the effect of these devices on the mechanism mst, be taken into account where applicable. APPLICATION OF THE ABOVE CONSIDERATIONS FOR CALCULATING Sy ‘he mechanisns of hoisting appliances perform one of the Following functions + = Purely vertical displacenents of the centre of gravity of moving masses (e.a+ hoisting motions). = Purely rorizontal displacenents in which the centre of gravity of the mving asses as a whole shifts horizontally (e.g. traverse, travel, slewing or counter- balanced luffing motions). = Movenents combining an elevation of the centre of gravity of the moving masses with a horizontal displacement (e.g. non-counterbalanced luffing). HOISTING MOTIONS For type Sy loads, the formula reduces to the following : case t and 1 : Sueaxt = Ga + Sie) Ya tn this case the lead due to the hoisting acceleration is neglected because it is small compared to Sw. case 111 : Sunax tit = 166 Ga. + Se) Bearing in mind the general rules of clause 2.6.3.1., It 1s assuned that the maxima Joads thet can be transnitted to hoisting mechanisis are Limited in practice to 41,6 tines the Snax t lead (1). a In a hoisting motion it is inpossible under normal working conditions to transmit to the mechanism loads greater then those due to the hoisting of the working load, as the effects of acceleration are negligible. de A greater load could result only from mishandling (poor judgement of the load, et: On the basis of experience gained over many years of practice with widely differing hoisting appliances it is now accepted that @ coefficent of 1,6 gives adequate safety. It must be stressed that the use of excessively ponerful motors should be avoided.2.6.4.2, HERTZGNTAL NOTIONS, Case I - The formula reduces to : Gye + Sua) Ya Sunaxt Case IL - The higher of the following two values is taken : Swmax tt > Gur + Sua + Svs) Yn Sumax tt = Gyr + Sau25) Yn Case ILE - For Symax rrr the lead corresponding to the maxinun torque of the rotor (or the brake) is ‘teken unless cperating conditions Linit the torque actually trans~ ited, through wheel slip on the rails, or through the use of suitable Limiting nears (e.g. hycraulfc coupling, torque limiter, etc.). In this case the value actually transnitted must be taken (1). 2.6.4.3, COMBINED MOTIONS case I and If : For cases I and 11, the 1034 Synay 17 (2) is determined by applying the general formula defined in clauses 2.6.1.1, ond 2.6.2.1. Case TI: The load caused by applying the maximum motor torque Sycmax can be taken for the teaximun valUe Syirax 111+ This often wnculy high value is sinays acceptable since it enhances safety. Jt must be used when tha power thvolvud for raising the centres of gravity of the noving masses is negligible corpared to the power nesded to overcone accelerations or nind effects. Conversely, when the effect of the accelerations or the wind 1s negligible in compa ison with’ the effect of displacing the centres of gravity of the moving masses vertically, this value 1s too high ard Syqax 111 Cen be calculated from the formula + SMmax 111 = 156 Smax IT Between these tno Limiting values, each individual case should be exarined according to the motor chosen, the nethod of starting end the relative magnituces of the loads due to inertia and wind effects on the one hand and those due to raising of ‘the centres of gravity on the other. Without exception, when operating conditions limit the torque actually transnitted to the mechanism (see clause 2.6.4.2.), this Limiting torque will be token as the value of Sypmax if it is less than the values defined above. a lhereas Jn the case of hoisting motions the loads normally transmitted to the mecha nism are Linited by the load lifted, in horizontal motions the saxinum torque of the motor can always be transmitted to the mechanism if no aechanical Limitation exists. This is why a different way of evaluating Symax 111 has been specified according to whether @ hoist aotion or other notion is being considered. 2 of Snax rin the case of appliances not subjected to mind, 2.372-38APPENDIX A — 2.1.1. HARMONISATION OF THE CLASSES OF UTILIZATION OF APPLIANCES AND MECHANISMS The present appendix sets out to denonstrate a method by which it is possible in any cases to derive the class of utilization of mechanisas fron that of appliances as a whole and fron certain parameters characterizing the duty to be performed. The starting point is the average duration ty, (in seconds) of a hoisting cycle as defined in clause 2.1.2.2. This is therefore the tine necessary to perform all the operations in such a cycle. The total duration of use T of the appliance, expressed in hours, is then given by the relation : fae 3600 T here N represents the eunber of hoisting cycles determining the class of utilization of the appliance. Table T.A.2.1.1.1. gives the values of T for cycle durations of 30 - 480 s in accor darce with the class of utflization of the appliance. The nunber of hoisting cycles is the maximus nurber for this class of utflization ; these values are, hoveve adjusted to 15 625, 31 250 and 62 500 respectively for class UD, UL and U2, in order to reduce the number of different values for T. The next step is to determine for each mechanism the ratio cy betneen the duration of use of the mechanisn during a hoisting cycle and the average duration tye of the cycle, Table T.A.2,141.2. gives the total durations of use Ty of the mechanism depending fon the total duration of use of the appliance, and for various conventional values of the ratio Qj. This table also shows the class of utilization of the mechanism. The various classes are represented by the stepped areas. It is thus sufficient to determine the class of utilization of the appliance by reference to table T.2.1.2.2., the average duration of the hoisting cycle and the values of G; in order to obtain the classes of ut{lization of the mechanisms. From the curves of the nonogran T.A.2.1.1.3. the classes of ut{Lization for the mechanisms in terns of these three paraneters can be found directly. 2039Table T.A.20161e1. Total duration of use (1) of Lifting appliances in hours, T JAverage duration or a Roisting Seem [wo] ul wel ol] uf»| «|v {| » |» s ws | 390 | 7e0 | 1565/3125 | 5250] 12 500] 25 cco} 50 000]> so coo @ zo | so }1000 | 2035! 2165] 9335] 16665] 35 335] 66 665]> 66 605 5 ys} 650 [1300 | 2608| 5210} 10415] 20935] a1 6es] 95 335] > 93 335 30 50 | reo {1565 | 3128 | 6 250 | 12 500} 25000} 50 000] 100 000 > 100 o00 420 520 | 1.010 | 2.005 | 4165 | 2335 | 16 665) 33.335] 66 665] 135 335|> 133 335 0 ea |i2m |22s| sno | 1005 | 209 sie] 65355] 1655] tee 1s veo |1 56 | 3125 | 6 20 | 22 500 | 25 000| s0 000) 120 con] ao coo] > 220 ony 210 bh c40 | 2.095 | 4165 | 6 355 | 16 665 | 53 335 | 66 605] 153 3255 200 000 300 1 30 | 2608 | 5210 | 10 ais | 20 035 | ar ces | e3 235| 166 685] > 200 coo 6 1 ses [3.125 | 6 250 | 12 scm | 2s 000 | 50 000 | 100 c00| 200 oc0| > 200 000 20 12s [5 ais |7 250 | 14 505 | 29 165 | 59 355 | 116 66s [> 200 ooo co cas [4 165 | 0 255 | 26685 | 29 235 | 65 aos [138 235] > 20 om 2-40Table T.A.2.1.1. Total curation of use Ty (in hours) of mechsnisns in terns of T and a ‘lass of i Nalues of a utilization ) 1,00 08 0,80 0,25 0,16 0,10 for mechenisn 130 130 8 52 3 a 3 195 335, 123 78 43 3 20 260 260 164 108 55 a 26 325 35 205 130 8 32 33 380 390 206 356 98 6 2 520 520) 228 208 130 33 52 a 650 650 “aio 260 163 6 780 760 49) 312 135, % 1 080 T owe 655 ale 220 108 1 300 1300 19 320 325 10 1 565 1565, 386 626 391 137 1325 1825 1iso |__ 730 256 wis 2 085 2 085 aia 208 2 605 2 6s 1 6a 21 Sh 3 125 3125 1 969 33 3 605 seis] 2 236 365 4 16s 416s |__2 62 1 a7 5 210 320 [3 22 1 521 6 250 620 | 3938 4 625 7250 T70 | 4585 1 3 9 8335 8335 32 200 | 33a 10 as 10 a5 6 2 604 1 042 7 12 soa 12 500 7 3125 1 250 14 985 1a 585 5 eae 1959 16 665 16 665 4 166 1667 20635 | 20835 5 209 2 088 a 2500 |_25000 | 15750 | 10 000 6 250 2 500 ziss [29165] 1837 | _u 666 721 2917 33335 | 33335 |_ zou [iss | 8 334 3330 ales | a1 66s [26209 | 16 666 | 10 16 4167 i 50 000 a.00 | 31500 | 20000 | _12 soo 5 000 sesss | se335 ] 36 751 |_23 334 |" 14 580 5 334 ec ces | 66665 |_aios9 [26 665 | 16 666 6 667 a3335 | 93335 [32501 | 33358 | 20 830 8354 ue 100 00 | 100000 | 63.000 | 40.000 |_25 co0 10 000 us 665 | 116665 | 7399 |_06 666 [29 166 Li 667 ass 335 | ass 335] sa oo [ss 354 | 33 33 13 334 16 665 | 166 665 | 100 999 | 66 566 | a1 665 16 667 200000 | 200000 | 12600 | socco | sooo | 3200 20 900 > 20.000 }> 20000 |> 126 000 |>80c0a |>s0000 | > 32cc0 | > 20000 18 9 2th102. 0 10° 108 Table T-A.2.1.1.3. Classes of utilizetion for appliances and aschantsms Class of utilization fer appliances 2042 Class of utilization for mechanismsEXOMPLE OF APPLICATION Dockside cargo crane. ‘The class of utilization for the appliance will be US. A hoisting cycle comprises the following operations : = hoisting of Load 5 = travelling + ~ slewing ; = lowering + = unhooking af lead 5 = hoisting empty ; = slewing $ ~ travelling = Lowering enpty ; = hooking on of new load, ‘The average tine for completion of the cycle will be estinated at 150 s. The ratios Gj will be estinated as follows = hoisting (hoisting and lowering) : a = 0.53 = slewing (2 directions) $y = 0.25 = travelling (d0.) 1a; = 0.10 Table T.A.2.1.1.1, gives us for class US and tye = 150s ¢ T= 20 835h For the various mechanisns, table 7.A.2.1.1.2. gives us, for T = 20 835 h, the folloning total durations Ty and classes of utilization : = hoisting (oq = 0.63) Ty = 13 26h 7 ~ slewing fay = 0.25) 21, = 5 209m TS ~ travelling (j= 0.10) 1 Ty = 208h TH From the curves in table T.A.2.1.1.3. the same conclusions are drawn on the basis of the ordinate tre = 150 s (broken line). 20032-44APPEWDIX A — 2.2.3. CALCULATION OF LOADS DUE TO ACCELERATIONS OF HORIZONTAL MOTIONS PART 1 ~ METHOD BASIC DATA Let v be the steady horizontal velocity of the point of suspension of the load, either ‘at the end of the acceleration period, or at the beginning of the braking period, according to whether an acceleration or a breking process is being considered, and fan inaginary horizontal force in the same direction as v, applied at the point of suspension of the load and producing the sane effect on the motion under consideration as the accelerating or decelerating torque applied by the motor or the brake. PROCEDURE The different quantities set out below must be calculated in succession. Equivalent mass (n) The inertia of all moving parts other than the load, in the motion under consideration, is replaced by a single equivalent mass assuned to be concentrated at the point of suspension ef the load and given by the relation : tye? oye inere : ng = is the total mass of all elements, other than the load, undergoing the sane pure linear sotion as the point of suspension of the load = the monent of inertia of a part undergoing a rotation during the motion under considerstion, this monent of inertia being considered about the axis of rotation, and ny = the angular velocity of the part referred to, about its axis of rotation, corresponding to the linear velocity v of the point of suspension of the load. The sun E covers all parts in rotation (structure, mechanisns, motor) during the ration considered. However, in the case of mechanisms, the inertia of components other than those directly coupled to the motor shaft can be ingored. 2085Mean acceleration or deceleration (iq) : Jn = where m, is the mass af the load Mean duration of acceleration or deceleration (Tq) Mean Inertia forces : ‘The acceleration corresponding to the acceleration Jq at the point of suspension of the load is calculated for each conponent part in motion. Multiplying this accele- ration by the mass of the component considered gives the mean inertia force it sustains, In the particular case of the load itself, this force of inertia Foy will be given by: F, =™ In Period of osetilation Ty = neanfl £ = the length of suspension of the load when it is in its uppermost position (values of £ below 2,00 m need not be taken into consideration) and, a = the acceleration due to gravity. vatue of + wed tunen the systen driving the motion controls the acceleration end the deceleration and maintains it at a constant value, u is taken equal to 0 irrespective of the masses m and my. Value of 8 : 8 fi Value of th: With the values ebtained for Wand 8, the graph in figure A.2.2.1, is used to find ‘the corresponding value of Yn. Inertia forces to be considered in the desicn of the structure The forces of inertia which take account of dynanic effects and which aust therefore be considered in the structural calculations are obtained as follows : = Inertia force due to the load : Y + Fon = Inertia force on moving parts other than the load : trice the mean inertia forces. JUSTIFICATION A justification of the method given above follows in part 2 of this appendi pard2 Que PART 2 — EXPLANATION OF THE METHOD, STATEMENT OF THE PROBLEM A hoisting appliance is @ physical systen consisting essentially of = concentrated masses (hook load, counterieights, ...) end distributed masses (girders, ropes, ..-)y = elastic connections between these masses (girders, ropes, ...). If such a system, originally in a state of equilibrium, is subjected to a varying Losd, it does not tend progressively tovards a new state of equilibrium even If ‘the few load applied is itself constant. on the contrary, it is set ina more or Less complex oscillating motion about this new state of equilibrium. Ouring this motion, the various internal loads and stresses of the system can exceed - sonetines to a marked extent - the values they would have assuned had the system been in static equilibrium under the influence of the new load. Such a situation arises curing acceleration or deceleration (braking) of @ horizontal motion of a hoisting appliance. Thus if, starting fron 4 position of rest, an appli- ance or part of an spplisnce begins 2 motion of translation or rotation, the component parts of the systen undergo accelerations and are therefore subjected to inertia Forces. Once a steady speed is attained, the acceleration ceases, the inertia forces disappear and the external load undergoes a new variation. ‘The angle through which a rotating systen turns (e.g. the rotating part of a crane) during the tine for which inertia forces are applied 1s generally relatively small. This being so, no apprecisble error wil] be involved if one assumes that each point An the system folloas a straight path during this tine, Since, moreover, there {s no difference of principle between the treatment used for linear motions and wotions of rotation, in what follows the linear sation will be considered in greater detail (chapter 2), whereas only a short note (chapter 3) will cover rotation. CALCULATING THE LOADS IN THE CASE OF A LINEAR MOTION GENERAL DATA Tt 4s now proposed to examine the particular case of braking of the travel motion of a complete overhead travelling crane when it 1s carrying a load suspended fron its hoisting rope. Other cases encountered in practice can be dealt with in siniler fashion. Considering figure A.2.1. let + my be the mass of the suspended load, the total mass of the overhead travelling crane Including the crab (see note below concerning the inertia of the motor and of the machinery driving the motion), x @ coordinate defining the position of the crane along its track (nore precise ly, Xx represents the coordinate of the point of suspension of the hoisting rope along en axis parallel to the direction of travel), 207a coordinate defining the position of the centre of gravity of the 4 ‘suspended load along an axis of the sane direction, sense and origin as the axis of x, 2 = x, = x a coordinate expressing the horizontal displacenent of the load relstive to the crane. Let us assume that at the instant ¢ = 0 the overhead travelling crane is moving in the positive sence of the x axis at a velocity v, and that the load is at rest relative to the crane. oz mith: 2¢ = 92) o, mith g If the brake is applied to the travel mechanism at the instant t = 0, it will give rise from that Snstant to a horizontal braking force parallel to, but of opposite sense to, the x axis at each point where a driving wheel is in contact with its rail. To simplify matters, let us assune that the crab is located at aid-span of the nain girders of the overhead travelling crane. It follows by symmetry thet the totel force at each rail is the sane. Let us designate its projection on the x axis by £ (with F > 0), 50 that the total braking force acting on the systen In notion 2 (crane plus load) is equel to F in absolute value. If the systen were conposed of rigidly interconnected masses, this would result in a deceleration of absolute value Jqy given by the relation : £ aa am Sn = 2-48Tt sust not be forgotten however that F originates in the braking torque applied to the travel mechanism which must not only brake the travel inertia of the crane and the load but also the rotstionel inertia of the driving motor and the inter vening machinery. Generally speaking, one can neglect the rotating inertia of all conponents other than those integral with the motor shaft. In many cases, however, the inertia of the latter must be taken into account and the relation (2.1.1.) holds good only provided that m incorporates an equivalent mass mg given by the relation : mg v2 = Iq Wy? (2.1.2) where Iq = fs the monent of inertia of all the conponents integral with the motor shaft (neluding the motor itself, of course) and (jy = the angular velocity of the motor corresponding to the travelling soeed v of the crane Under the effect of the deceleration Ja, the suspension rope cannot retain its vertical position. Its nen position of equilibrium is inclined to the vertical at an angle op, given by the relation : Sa = arctg 3 21.3.) Oy 35 ¢ where g is the acceleration due to gravity. In this case the rope exerts @ horizontal force on the crane whose projection Feq on the x axis is given by : (2.1.8.) Fem * 81 in In point of fact, the system is not rigid, the deceleration is not constant and is not therefore given by (2.1.1.), the load and its suspension rope adopt an oscilla- {ting motion, and the horizontal force developed by the zope on the crane can assume values differing greatly from (2.1.44). 8y @ similar reasoning, one may conclude that the deceleration of the system gives rise to inertia forces which act on each component part of the crane and the crab, but that because of the elasticity of the girders the systen will undergo an oscilla~ ting moticn in the course of which the stresses will be subject to fluctuations which must be estimated. The next two paragraphs deal in succession with the effect of the inertia forces on the load and on the girders. EFFECT OF INERTIA FORCES ON THE LOAD In determining the notion which the load executes after the brake is applied, one can neglect the novenent of the point of suspension due to girder flexibility in @ horizontal plane. The anplitude of this movenent is, in fact, very stall com pared with the anplitude of swinging of the load. Calculations can therefore be carried out with the crane considered as a systen which is not subject to deformation. rane is The projection Fe on the x axis of the force exerted by the rope on the given by the relation : aus (2.2.1) Fo=mg 2009winere £ is the suspension length of the load. It will be noted that Fy £5 propar~ Uonal to the cisplacenent z of the loed with respect to its position of initisl equilibriun, just as {f it were an elastic restoring force. The equations of motion can be written mx") = my a (2.2.2.) wey = mg LE eget 2.2.5) while, asouning x= 0, for t = 0, the initial conditions are as follows : for t =9, (2.2.8) (2.2.5) (2.2.60, (22. Let: 9 au? (2.2.8.) 2 4 5 2 M8 way wy? + oy? = a? (2.2.10.) fat, (2.2) Equations (2.2.2.) and (2,2.3.) then become + whe 26 ute <0 (2.2.12) "uy? 22 Jo 2.2.13.) whence 2 uy? 2 = Jo (2.2.18) With the initial conditions of (2.2.4,) to (2.2.7.), the solution to these equations As given by + Jo ; 222, (1+ cosy 8) 2.2.18.) 2 oe w?,, wd vo gt = 2 + 22 sin gt 2s.) Gear eee 250The complete expression for x is of no direct interest to us. Let Jo a = aq (2.2.47.) it can then be seen nithout difficulty that zp is the position of equilibrium that can be assumed by the load during a constant deceleration of the crane equal to the value Jy defined by (2.1.1.), i.e. during the deceleration that would be obtained by applying the braking force F to the total mass (crane plus load) in motion, this amass being assuned to constitute a rigid system. The value 2 =z defining the losd displacenent corresponds to the horizontal force Fons defined by (2.1.4.) exerted by the rope on the crane. Conpexison between (2.2.14), (2.2.15.) and (2.2.17.) then shows that : fe = Fem (1 ~ 00s apt) 2.2.18.) If the decelerstion period of the crane lasts for a tine ty such that : ty > (2.2.19) St will be seen that Fo nonentarily becones twice Fons oF in other words, that its maximum value Fonagx 48 given by the relation + Fomax = 2 Fom (2.2.20.) If the condition (2.2.19.) is not satisfied, this means that the crene has stopped ‘before the load has reached its maximum displacenent z = 2 zm. However, after the ‘crane stops, the load will usually continue to oscillate, so the rope will continue to exert a varying horizontal force on the crane, and the maximum value which this can attain nust be sought. It Is easy to verify that after the crane has stopped, the mation of the load 1s defined by the expression joey (1g) EE sin tg) (2a 2q = %q (1 ~ 08 Wy ty) (2.2.22) 2'g = Up Zp Sin Ub ty (2.2.23.) where ty is the smallest positive value of t that makes the expression (2.2.16.) for x" equal to zero. The maximum value Fe pax 885uned by Fe is then given by the relation : Pee peers tt ont ea 251