Buffers

DPZ cellular plastic buffers, DPG rubber buffers, DPH hydraulic buffers

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1097 EN 202 607 44 714 IS 883 1

 Manufacturer Mannesmann Dematic AG
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0, Telefax (+49 2335) 927676
Internet http://www.dematic.com

Buffers
Buffers with a high energy absorption capacity are required to prevent any critical
deformation in structural steelwork resulting from travel units colliding with each other
or with the end of a track.
This type of buffer is used in crane construction and wherever impact energy of a pre-
defined maximum force has to be absorbed.
The complete volume of the buffer is utilized as pressure is distributed over the whole
section of the buffer. Lateral deformation remains low even under maximum com-
pression.
The favourable diameter-to-length ratio of the buffer ensures that any displacement of
the buffers due to play in the guidance of the crane on the rails has no adverse effect.

Type DPZ DPZ cellular plastic buffers

Diagram shows cellular plastic buffer Due to its excellent physical qualities as regards elasticity, cushioning and energy
absorption, the cellular Polyurethane® material is particularly well suited for buffers.
The energy absorbed by cellular plastic buffers increases with the speed of impact.
End face with This results from the polytropic compression of the gases in the cellular structure.
knobbed surface The material is chemically resistant to ozone, oxygen, water, petrol and most oils and
industrial greases.
The buffer is fully functional at operating temperatures of – 20 °C to + 80 °C. In condi-
tions of high humidity in conjunction with high temperatures, the rubber buffer should
be used.

Set nut DPG rubber buffers

The buffer consists of a compact elastic rubber. This material features different char-
acteristics to that of the cellular plastic buffers.
The energy and final force curves for rubber buffers apply to both static and dynamic
loads.
Threaded pin This buffer material should preferably be used under conditions of high humidity. The
buffer is fully functional at operating temperatures of – 30 °C to + 70 °C.

Buffer with base plate

DPH hydraulic buffers
The buffer is an enclosed system consisting of maintenance free hydraulic elements.
Owing to almost uniform deceleration, this buffer makes it possible to achieve the
smallest possible braking force for the shortest possible brake path.
Sizes DPH 7 and DPH 350 are self-adjusting hydraulic buffers. DPH 25 and DPH 80
are adjustable buffers and may be adjusted by means of a ring for various damping
41826044.eps applications (depending on mass or speed).
The piston is automatically returned.
The permissible ambient operating temperatures range from – 12 °C to + 90 °C for
adjustable and to + 65 °C for self-adjusting buffers; using special seals and special oil
from – 40 °C to + 120 °C.
The maximum axial deviation of the impact direction from the piston rod axis is ap-
prox. 3°.
Hydraulic buffers can be installed in any position.
With the standard mounting arrangement using the adapter, threaded pin and set
nut, the hydraulic buffer has the same mounting dimensions as the cellular plastic and
rubber buffers and may thus be used to replace them at a later date in already exist-
ing installations.
Mounting variant II as illustrated in foot or neck mounting configuration is a space-
saving arrangement which may be implemented if it is possible to accommodate a
larger bore hole. In this case, a second nut is then required for the self-adjusting hy-
draulic buffers.

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Design and installation information

DPZ cellular plastic buffer with internal screw thread

suitable for RS wheel blocks and KTL travel units as well as RAM/RN wheel sets
l 1

d1

d3

d2
l 3

Set nut Threaded pin

M
with hexagon socket
l 2
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Weight Part no. ¹)

Size
d1 d2 d3 l1 l2 l3 M [kg]
DPZ 70 70 65 66 40 25 0,35 811 522 44

DPZ 100 100 95 100 45 30 0,73 811 523 44

M 12 M 12
DPZ 130 130 122 120 55 30 1,11 811 524 44

DPZ 160 160 155 150 55 40 1,7 811 098 44

DPZ 210 210 200 M 20 200 85 68 M 20 4,0 811 099 44

¹) Part no. includes cellular plastic buffer, threaded pin and set nut

DPG rubber buffer with internal screw thread

suitable for RS wheel blocks and KTL travel units as well as RAM/RN wheel sets
l1
d3
d1

d2

l3

Set nut Threaded pin

M

with hexagon socket

l2
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Weight Part no. ¹)

Size
d1 d2 d3 l1 l2 l3 M [kg]
DPG 63 63 56 67 40 13,7 0,32 811 016 44

DPG 80 80 71 84 45 13,7 0,59 811 017 44

M 12 M 12
DPG 100 100 90 105 55 13,7 1,13 811 018 44

DPG 160 160 151 131 55 13,7 4,4 811 066 44

DPG 200 200 189 M 20 166 85 20 M 20 8,4 811 067 44

¹) Part no. includes rubber buffer, threaded pin and set nut

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 DPH hydraulic buffer
Standard mounting variant with adapter, threaded pin and set nut suitable for RS
wheel blocks and KTL travel units as well as RAM/RN wheel sets

Standard mounting variant with adapter Mounting variant II

Foot or neck mounting config.

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Size Energy Effective Hydraulic buffer Adapter P in Part no. ¹)

absorption mass Stroke Length Thread Weight

Epu mpu H l1 d3 l3 d2 M l l2

[Nm] [kg] [kg]

DP H 7 113
²)
self 68 + 25,4 149,9 102 23 0,26 M 12 167 40 811 294 44
M 25 x 1,5
adjusting 1130
500
DPH 25 UNF
230 + 50,8 189 17 25,4 0,76 M 12 207 40 811 295 44
adjustable 1¼ - 12
80000
54
DPH 80 UNF
780 + 76 246 23 38 2,1 M 12 267 40 811 296 44
adjustable 1¾ - 12
9500
DPH 350 1360 4)
self 3390 + 152 450 38 60 4,7 M 20 478 40 811 297 44 N
M 64 x 2
adjusting 6800

¹) Part no. includes hydraulic buffer, nut, adapter, threaded pin and set nut
²) Second nut required for mounting variant II with foot or neck mounting configuration

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Diagram 1
Cellular plastic buffer
DPZ 70 cellular plastic buffer
50

Flexibility range s [mm]

40
stationary stationary

v = 60 m/min v = 60 m/min
30 v = 120 m/min v = 120 m/min

20

10

600 400 200 5 10 15 20

Energy Epu [Nm] Buffer final forces Fpu [kN]
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Diagram 2
Cellular plastic buffer
DPZ 100 cellular plastic buffer
80

70
Flexibility range s [mm]

60
stationary stationary
50
v = 60 m/min v = 60 m/min
40
v = 120 m/min v = 120 m/min
30

20

10

800 600 400 200 10 20 30 40 50 60

Energy Epu [Nm] Buffer final forces Fpu [kN]

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Diagram 3
Cellular plastic buffer
DPZ 130 cellular plastic buffer 90

80
Flexibility range s [mm]

70

60

50
stationary stationary
40
v = 60 m/min v = 60 m/min
30
v = 120 m/min v = 120 m/min

20

10

1600 1200 800 400 20 40 60 80

Energy Epu [Nm] Buffer final forces Fpu [kN]
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 Diagram 4
Cellular plastic buffer
DPZ 160 cellular plastic buffer
120

100
stationary stationary

Flexibility range s [mm]

80 v = 60 m/min v = 60 m/min

v = 120 m/min v = 120 m/min

60

40

20

5000 4000 3000 2000 1000 40 80 120 160

Energy Epu [Nm] Buffer final forces Fpu [kN]

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Diagram 5
Cellular plastic buffer
DPZ 210 cellular plastic buffer 180

160

140

120
Flexibility range s [mm]

100
stationary stationary
80
v = 60 m/min v = 60 m/min
60
v = 120 m/min v = 120 m/min
40

20

8000 6000 4000 2000 40 80 120 160

Energy Epu [Nm] Buffer final forces Fpu [kN]
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Diagram 6
Rubber buffer
DPG 63 rubber buffer
30

25
Flexibility range s [mm]

20

15

10

400 300 200 100 5 10 15 20

Energy Epu [Nm] Buffer final forces Fpu [kN]

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Diagram 7
Rubber buffer
DPG 80 rubber buffer
40

Flexibility range s [mm]

30

20

10

500 400 300 200 100 10 20 30

Energy Epu [Nm] Buffer final forces Fpu [kN]

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Diagram 8
Rubber buffer
DPG 100 rubber buffer 50

40
Flexibility range s [mm]

30

20

10

1000 800 600 400 200 10 20 30 40 50

Energy Epu [Nm] Buffer final forces Fpu [kN]

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Diagram 9
Rubber buffer
DPG 160 rubber buffer
70

60
Flexibility range s [mm]

50

40

30

20

10

2000 1000 10 20 30

Energy Epu [Nm] Buffer final forces Fpu [kN]

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 Diagram 10
Rubber buffer
DPG 200 rubber buffer 80

70

60

Flexibility range s [mm]

50

40

30

20

10

600 400 200 50 100 150 200 250

Energy Epu [Nm] Buffer final forces Fpu [kN]

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Diagram 11
Hydraulic buffer selection

Energy
Epu [Nm] v [m/min]

200 100 80
DPH 350 5000 60

DPH 350
40
31,5
1000
DPH 80
DPH 80 20
500

DPH 25 DPH 25 12,5

100

DPH 7
50 DPH 7

10

Mass
50 10 5 1 0,5 300 600 1250 2300 4000 6300 10000 mpu [kg]
Final end forces 1000 5000 8000
Fpu [kN]

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Calculation and selection

1 General Buffers calculated according to DIN 15 018

Buffers for cranes and crabs are calculated by considering one side of the installation.
The most unfavourable position of the load must be considered
• for cranes: crab or travelling hoist in the extreme approach position
• for crabs and carriages: consider the mass centre S

2 Definitions, symbols R1, R2 [kg] wheel loads resulting from deadweight and rigidly attached loads
and units mpu [kg] mass acting on one buffer
v [m/min] max. travel speed
Epu [Nm) energy acting on one buffer
Fpu [kN] buffer final forces

3 Calculation procedure
3.1 Determine the masses acting
on the buffer mpu See diagram

(see 3.1 and 4.1)

For cranes: mpu = R1 + R2 For crabs and carriages: mpu = R1 + R2

Rigid stop with no

R1 counter-part buffer
R1

R2 R2

Crab in extreme approach Stop with counter-part buffer

dimension
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3.2 Determine the energy acting on

Energy acting on one buffer Epu
one buffer Epu With/without
System speed
Collision against rigid Collision against stop Collision between two units with the
reduction
structure with buffer 1) same buffers

mpu ⋅ v ² mpu ⋅ v² mpu 1 ⋅ mpu 2 ⋅ (v1 + v2 )²

without Epu = Epu = Epu =
Crane
9965 19930 (
19930 mpu 1 + mpu 2 )
mpu ⋅ v ² mpu ⋅ v ² mpu 1 ⋅ mpu 2 ⋅ (v1 + v2 )²
Epu = Epu = Epu =
( )
w i th
14694 29388 29388 mpu 1 + mpu 2

mpu ⋅ v ² mpu ⋅ v² mpu 1 ⋅ mpu 2 ⋅ (v1 + v2 )²

Epu = Epu = Epu =
( )
without
7200 14400 14400 mpu 1 + mpu 2
Crab
mpu ⋅ v ² mpu ⋅ v² mpu 1 ⋅ mpu 2 ⋅ (v1 + v2 )²
Epu = Epu = Epu =
( )
w i th
14694 29388 29388 mpu 1 + mpu 2

1) applies to buffers of the same size 9

 3.3 Calculate the buffer final forces
Fpu, select buffer size
Select buffers using the diagrams on pages 6 to 9 and read off the buffer final force.
The buffer length must only be utilized to approx. 65 % of its capacity for cellular
plastic buffers, and only up to approx. 50 % for rubber buffers. For greater capacity
go up to the next size of buffer. With two cranes on one track, all buffers on the sides
of the cranes facing each other must be identical.

Diagram 3 (see 3.3 and 4.3)

90

80
73
70
Flexibility range s [mm]

Flexibility range s [mm]

60

50
stationary stationary
40
v = 60 m/min v = 60 m/min
30
v = 120 m/min v = 120 m/min
20

10

1600 1200 800 400 20 40 60 80

709 18

Energy Epu [Nm] Buffer final forces Fpu [kN]

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4 Calculation example • crane, flexibly attached load

for cellular plastic • wheel loads: R1 = 1935 kg, R2 = 2485 kg
• long travel speed v = 40 m/min
buffers
• travel against a rigid stop without a counterpart buffer and without a reduction in
speed.

4.1 Calculate mpu as in 3.1 mpu = R1 + R2 = 1935 kg + 2485 kg = 4420 kg

mpu ⋅ v ² 4420 ⋅ 40 ²
4.2 Calculate Epu as in table 3.2 Epu = = = 709 Nm
9965 9965

4.3 Find Fpu, select buffer size Selected: Size DPZ 130
Fpu as in diagram 3
flexibility range s = 73 mm < 65 % of (l1 = 120) = 78 mm
buffer final forces = 18 kN
Order details:
DPZ 130 cellular plastic buffer, part no. 811 524 44

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5 Calculation example • crane, flexibly attached load
for rubber buffers • wheel loads: R1 = 1935 kg, R2 = 2485 kg
• long travel speed v = 40 m/min
• travel against a stop with a counterpart buffer and without a reduction in speed.

5.1 Calculate mpu as in 3.1 mpu = R1 + R2 = 1935 kg + 2485 kg = 4420 kg

mpu ⋅ v ² 4420 ⋅ 40 ²
5.2 Calculate Epu as in table 3.2 Epu = = = 355 Nm
19930 19930

5.3 Find Fpu, select buffer size Selected: Size DPG 80

Fpu as in diagram 7
flexibility range s = 35 mm < 50 % of (l1 = 84) = 42 mm
buffer final forces = 23,5 kN
Order details:
DPG 80 rubber buffer, part no. 811 017 44

Diagram 7 (see 3.3 and 5.3)

40

35

30
Flexibility range s [mm]
Flexibility range s [mm]

20

10

500 400 300 200 100 10 20 30

355 23,5

Energy Epu [Nm] Buffer final forces Fpu [kN]

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 • crane, flexibly attached load
6 Calculation example
• wheel loads: R1 = 1935 kg, R2 = 2485 kg
for hydraulic buffers • long travel speed v = 40 m/min
• travel against a rigid stop without a counterpart buffer and without a reduction in
speed.

6.1 Calculate mpu as in 3.1 mpu = R1 + R2 = 1935 kg + 2485 kg = 4420 kg

mpu ⋅ v ² 4420 ⋅ 40²

6.2 Calculate Epu as in table 3.2 Epu = = = 709 Nm
9965 9965

Diagram 11 (see 3.3 and 6.3)

Energy Energy
Epu [Nm] Epu [Nm]

v [m/min]

200 100 80 DPH 350 5000

5000 60

DPH 350
40
31,5
1000
1000 DPH 80
709 34 709
DPH 80 20 500
500
DPH 25
DPH 25 12,5

100 100

DPH 7
50 DPH 7 50

10 10

300 600 1250 2300 4000 6300 10000 10 5 1 0,5

1000 4420 5000 8000 11,2

Mass Final
mpu [kg] forces
Fpu [kN]
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6.3 Find Fpu, select buffer size as in diagram 11

with Mpu = 4420 kg and
v = 34 m/min (85 % of nominal travel speed according to DIN 15 018)
Selected:Size DPH 80
stroke: 76 mm
buffer final forces = 11,2 kN
Order details:
DPH 80 hydraulic buffer, part no. 811 296 44

Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter Subject to alteration
Printed in Germany MBR/0199/5H

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