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Design Specification of Hoist For Water Resources and Hydropower Engineering PDF
Design Specification of Hoist For Water Resources and Hydropower Engineering PDF
140
P 59
File No.: 210-2002
DL
PROFESSIONAL STANDARD OF
中华人民共和国行业标准
DL/T 5167-2002
2. Off-working state
Pz2 ≥ 1.1Pw2 + Pa - Pf (5.6.7-2)
Where,
Pz2 refers to clamping braking force generated by track clamp of running mechanism
along track direction, N;
Pw2 refers to maximum wind power of gate hoist under off-working condition along
running direction, N.
Friction factor between track and rail clamp (whose surface has scores and that has
been quenched) shall adopt 0.25, and the maximum operating force on manual rail
clamp shall not exceed 200N.
5.7 Safety Protection Device of Gate Hoist
In order to guarantee reliable operation of gate hoist, all sorts of gate hoists shall be
equipped with relevant safety devices.
5.7.1 Brake Apparatus
Besides hydraulic gate hoist, all mechanism of gate hoist shall be quipped with brake
apparatus. Screw rod gate hoist shall be equipped with brake apparatus according to
its structural type.
5.7.2 Load Limiter
Hoisting mechanism of gate hoist shall be equipped with load limiter (except in
special cases), and composite error of the load limiter shall not exceed 5%. The load
limiter can be of mechanical type or electrical type; hydraulic system shall be
equipped with overflow valve.
5. Wind coefficient C
1) for wind coefficient C of single-slice structure and single-piece object of gate hoist,
see Table 6.0.6-2.
2) For space structure with two or more pieces, the wind coefficient can adopt the
wind coefficient of single-piece structure. For calculation of windward area, see
Annex D.
3) Wind load of space truss with triangle cross section can adopt 1.25 times wind load
on projected area of truss vertical to wind.
4) When wind direction and structure form a angle, wind load on structure can be
calculated by dividing the wind load into two forces along two directions according to
the angle formed.
Table 6.0.6-2 Wind Coefficient C of Single-slice Structure
No. Structural type C
1 Plane girder made of molded steel (solidity ratio ψ=0.3 - 0.6) 1.6
5 1.3
10 1.4
Molded steel, steel plate, molded steel girder, steel 20 1.6
2 L/h
plate girder and box-section component 30 1.7
40 1.8
50 1.9
≤1
≤3
2
3 Circular pipe and tubular structure Qd 7
10
≥13
Closed driver's cab, machine room, balancing weight, steel rope and 1.1 -
4
objects. 1.2
Note: 1. In this table, L refers to length of structure or structural component, h refers
to height of windward face, m and q refer to calculation wind pressure (see
Table 6.0.6-1) (in N/m2); d refers to exterior caliber of pipe (in m);
2. When driver's cab is set on ground, C = 1.1, when it is suspended over
ground, C = 1.2.
8.4.6 Filter
1. Filtration precision of filter in hydraulic system shall be determined according to
filtration precision requirements of pump and value samples that have been selected.
2. Filter is recommended to be arranged at oil return mouth, and filterability shall be
greater than 3 times oil return capacity of oil pump. If filter is arranged at oil suction
mouth, filterability of oil suction filter shall be greater than 5 times oil suction
capacity of oil pump. Filterability of pressure filter shall be greater than 2 times oil
passing capacity. Filter is recommended to have pressure difference signal transmitter
and bypath relief valve.
3. Air filter set on oil tank shall have de-humidity function.
8.4.7 Hydraulic pipeline
1. Efforts shall be made to guarantee short pipe, less bending and neat arrangement,
and bending degree shall not be less than 90 degree. The minimum curvature shall not
exceed 3 times external caliber generally, and high-pressure and low-pressure pipes
shall be divided by obvious different colors.
2. If hose is adopted, the hose shall not be tensioned or tortured, and shall not abrade
with other objects during movement. Length of straight part from end to bending part
shall not be less than 6 times hose caliber, and bending radius shall not be less than 10
times external hose caliber.
3. Oil pipe shall adopt stainless steel seamless pipe. For calculation of relevant
diameter and wall thickness, see Annex H.
4. After installation and before debugging of hydraulic pipeline system, rinsing device
shall be adopted to rinse oil liquid circularly. After circular rinsing, cleanness of
pipeline system shall be able to reach requirements of item 3 of clause 1 in article
8.4.5.
5. Arrangement space among pipes shall be able to satisfy requirements of installation,
operation and maintenance of pipe, valve and flange.
6. During arrangement of pipeline, manual stop valve shall be equipped at connection
of pump station and hydraulic cylinder.
8.5 Calculation Principle of Parts
8.5.1 Calculation method
Strength calculation includes static strength calculation and fatigue strength
calculation.
Strength calculation methods refer to permissible stress method and safety factor
method.
Some parts (such as screw rod) shall also go through calculation of rigidity and
stability.
Long high-speed transmission shaft shall also go through verification of critical speed.
8.5.2 Calculation load
1. Fatigue calculation basic load:
1) Fatigue calculation basic load borne by parts of hoisting mechanism shall be
calculated by 0.6-1 time moment (or force) transmitted by hoisting force to the
calculation parts according to type of gate and working property. And fatigue
calculation basic load of parts on high-speed shaft shall be calculated according to
1.3-1.4 times rated moment of electromotor.
2) Fatigue calculation basic load of parts of running and returning mechanism shall be
the total moment of inertia moment and static resistance moment borne by parts
during starting of mechanism. And it can be estimated according to formula 8.5.2-1:
MImax = (1 2~2.0)Mn (8.5.2-1)
Where,
MIma refers to fatigue calculation basic load moment of calculation part, N·m;
Mn refers to moment transmitted from rated moment of electromotor to calculation
part, N·m。
Coefficients 1.2-2.0 refer to rigidity dynamic load coefficients, being related to the
ratio of drive characteristics of electromotor and rotation inertia moment of
calculation part.
2. The maximum working load shall be used to calculate static strength of calculation
part.
1) The maximum load of hoisting mechanism shall adopt 1-1.2 times moment (or
force) transmitted from hoisting force on to calculation part, and part on high-speed
shaft shall adopt the result of rated moment of electromotor multiplying 1.3-1.4. In
special cases, it can be verified according to the maximum running torque of
electromotor, and permissible stress of part can adopt 0.9σs of material.
2) If the maximum working load of running and returning mechanism is adopted
during starting or braking of mechanism, the maximum oscillatory torque borne by
part can be estimated according to formula 8.5.2-2:
MIImax = (1.1 - 1.5)Mnmax (8.5.2-2)
Where,
MIImax refers to the maximum oscillatory torque of calculation part, N●m.
When elastic vibration is considered, the biggest one among augmenting coefficient
of moment, system elasticity and damp shall adopt the smallest value.
3. The maximum off-working load shall be determined by combination of maximum
off-working wind load and weight of equipment. maximum off-working load belongs
to non-frequent load and it can be used to verify static strength of some components.
4. Special Load:
1) Buffer impact load: it refers to dynamic load generated during buffer impacts
running mechanism of mobile gate hoist. It can be estimated according to formula
8.5.2-3:
MIIImax = 0.25(R/i) Σ PImax (8 5.2-3)
Where,
MIIImax refers to moment generated during buffer impact on to drive shaft of running
mechanism, N●m;
R refers to wheel radius, m;
i refers to total transmission ratio of running mechanism;
Σ PImax refers to the total maximum wheel pressure during running of drive wheel of
calculation transmission mechanism, N.
2) Installation load: it shall comply with provisions of 6.0.8.
3) Test load: it shall comply with provisions of 6.0.12.
8.5.3 Number of stress cycles
During calculation of fatigue strength of transmission parts, number of stress cycles
shall be calculated within required design service life. If stress variation is absolute
value of 10% of maximum stress, number of stress cycles may not be calculated.
Number of stress cycles N can be calculated according to formula 8.5.3:
N = FZ (8.5 3)
Where,
F refers to number of stress cycles of part per hour;
Z refers to total design service life of part, h.
Generally, service life of mechanism parts shall be calculated according to design
service life of mechanism. In certain cases, due to economic consideration or
technical limitation, design service life of some parts may be different from design
service life of mechanism.
8.5.4 Strength limitation
During calculation of static strength, yielding limitation of material that has favorable
plasticity may be adopted as yielding point of parts.
If ratio of yielding limitation of material σs to extension strength σb is greater than 0.7,
in order to avoid brittle rupture due to exceeding yielding limitation of material, it is
stipulated that imagined yielding point shall be calculated according to formula
8.5.4-1 and 8.5.4-2:
3. Pulley and drum shall be made of cast iron generally, and its number shall not be
less than HT200 stipulated in GB/T 9439. Gate hoist with large capacity is
recommended to adopt cast steel or welding pulley; drum is commended to adopt
welding drum or progressively-welded cast steel.
4. Strength calculation and stability verification of drum:
If L≤3D, only maximum pressure stress on drum wall surface can be calculated.
If L>3D, besides calculation pressure stress, combined stress generated by bending
moment and torque shall also be verified.
If D≥1200mm and L>2D, besides strength calculation, drum wall shall also go
through stability verification. Where, D refers to bottom diameter of drum groove,
mm; L refers to drum length, mm.
For strength calculation and stability verification of drum, see Annex G.
8.6.3 Gear and worm gear transmission
1. Common gear material
Small gear shall adopt high-quality carbon steel or alloy constructional steel; and big
gear shall adopt cast carbon steel or alloy cast steel. Material selection and heat
treatment hardness shall match with gears.
Usual materials of worm gear: worm wheel shall adopt copper base alloy or zinc base
alloy, and small equipment and equipment used to transmit small load can also adopt
cast iron; worm rod shall adopt high-quality carbon steel or alloy constructional steel.
2. Where gear adopts soft tooth surface or half-hard tooth surface, hardness of tooth
surface of small gear shall be 30HB higher than the hardness of big gear; when gear
adopts hard tooth surface, hardness of tooth surface of small and big gear shall be
basically identical.
3. Gear transmission shall calculate contact strength of tooth surface and bending
strength of gear. For closed-type gear transmission, tooth surface is recommended to
adopt half-hard tooth surface.
Worm gear is mainly used in mechanism (such as returning mechanism and running
mechanism) having large transmission rate and close structural arrangement. Strength
calculation of gear worm shall be based on calculation contact strength on tooth
surface, bending strength of worm wheel tooth shall go through verification; if worm
rod is also used as transmission shaft, strength calculation and rigidity calculation
shall be carried out on shaft basis.
8.6.4 Shaft
1. Shaft material: usual material of shaft shall adopt medium carbon steel; and the
most-commonly-used material is 45 stipulated in GB/T 699, and 35SiMn, 42SiMn,
40MnB, 40Cr and 40 CrNi alloy steel can also be adopted.
2. Original size of shaft can go through preliminary strength calculation according to
permissible stress method. Shaft structure can be determined according to the
preliminary size obtained and all necessary factors, and then practical safety
coefficient of dangerous section shall be determined and its rigidity shall be
calculated.
3. Critical rotation speed of shaft: if rotation speed of long transmission shaft exceed
400r/min, beside calculation of strength and rigidity, critical rotation speed shall also
be verified and shall satisfy requirements of formula 8.6.4-1:
Where,
nmax refers to practical maximum rotation speed of shaft, r/min;
ncr refers to critical rotation speed, r/min;
d1 refers to interior diameter of shaft, mm; when solid shaft is adopted, d1=0;
d2 refers to exterior diameter of shaft, mm;
L refers to supporting space of shaft, m.
4. Calculation of shaft rigidity can adopt the following values:
1) Maximum deflection shall not exceed 0.0003 time space among supporting points
generally.
2) Maximum deflection of shaft with gear shall not exceed 0.01-0.03 time gear
module generally.
3) Maximum deflection angle caused by deflection at supporting point shall not
exceed 0.001 rad generally.
Where,
p refers to breaking load of chain, N;
nr refers to safety coefficient; nr=5 - 5.5.
Single-segment chain shall go through breaking load test and assembled chains shall
go through load test. Testing load shall be equal to 50% of breaking load.
Chain wheel of piece-type hoisting chain is integrated with shaft generally, and
number chain wheel tooth is recommended to be 9 - 12. Chain wheel that is usually
used underwater shall adopt sliding bearing and shall have anti-corrosion measures.
8.6.14 Oil Pump
Type of oil pump shall be determined according to requirements of system on
performance of oil pump. Specification of oil pump shall be determined according to
required maximum working pressure and maximum working flow of oil pump.
For maximum working pressure and maximum working flow of oil pump, see Annex
H.
8.6.15 Hydraulic components
1. Type of hydraulic components shall be determined according to working
requirements of hydraulic system, and its maximum working pressure and rated flow
shall satisfy requirements of working conditions.
2. Overflow cock set to guarantee safety of hydraulic cylinder shall adopt
direct-action structure.
3. During selection of throttling valve and speed control valve, relevant characteristics,
such as regulating range and minimum stable flow shall be considered.
4. Electromagnet of electromagnetic directional valve or electro-hydraulic change
valve shall adopt direct-flow wet structure, and its working state is recommended to
be display by indication lamp.
5. Number of pressure gauge shall be determined according to requirements of
hydraulic system. If there are supervisory requirements, pressure sensor shall be
configured according to relevant requirements.
8.6.16 Hydraulic cylinder
1. Strength calculation of cylinder wall. Strength of cylinder wall shall be calculated
according to the following two conditions:
1) Section far enough from flange and supporting flange. Cylinder wall stress at this
position is longitudinal stress and hoop stress generated by working pressure in
cylinder;
2) Section connecting cylinder body and flange. Stress generated by working pressure
in cylinder at this position shall add longitudinal stress and hoop stress generated by
bending moment meanly distributed on cylinder wall at flange.
Strength of cylinder wall can be calculated according to Annex H.
2. Main structural parameters of hydraulic cylinder can be determined according to
Annex H. Calculation length of piston rod shall be determined according to fixed
form of hydraulic cylinder, and for conversion coefficient of calculation length, see
Annex H. During calculation of slenderness ratio of piston rod, inertia moment is
recommended to be calculated according to rod having sudden variation, and
allowable slenderness ratio of piston rod is recommended to be less than 200 in
pressure, and shall be less than 250 in tension.
3. Longitudinal stability calculation:
1) For pressure piston rod, when calculation length L is greater than 10 times diameter
d (L refers to distance from supporting center of cylinder body to rod end connection
point when piston rod is fully pulled out), stability calculation shall be carried out.
2) Longitudinal stability of hydraulic cylinder shall be calculated under condition that
piston rod is fully pulled out and bears maximum downward pressure.
3) For stability calculation of hydraulic cylinder, see Annex H.
4. Piston rod surface shall adopt chrome-plating anti-corrosion measure, and material
can adopt medium carbon steel, alloy steel and stainless steel.
5. Seal: generally, seal of hydraulic cylinder adopts V-type, O-type and Y-type seal
ring.
1) V-type combined seal rings are used for dynamic seal between piston and inner
wall of cylinder body, and piston rod and end cover.
2) O-type seal ring is generally used for static seal between end cover and cylinder
body, piston and piston rod.
3) Y-type seal ring can also be adopted for dynamic seal between piston and inner
wall of cylinder body.
6. Dust ring shall be set at end where hydraulic cylinder piston rod is pulled out. If
necessary, impurity-scraping and ice-scraping rings can be adopted.
9. Structure
9.1 Calculation Principle
Permissible stress method is adopted for calculation in this code. Metallic structure of
gate hoist shall go through strength, stability and rigidity calculations, and shall
satisfy specified requirements. During calculation, plastic influence of material is not
considered generally, and fatigue strength will not be calculated.
Structure shall be calculated according to two load conditions: 1. Strength, rigidity
and stability will be calculated according to maximum working load; 2. Strength and
stability will be calculated according to maximum working load and special working
load.
9.2 Load Combination
Load combination stated in this article is applicable only to structural and connection
calculation of mobile gate hoist; for load combination, see Table 9.2.
Table 9.2 Load and Load Combination
Load combination
Load combination Class I
Name of load Class II
Ia Ib Ic Id Ie Ia Ib Ic Id
Self-weight load √ √ √ √ √ √ √ √ √
Hoisting load of main hoisting
√
mechanism
Running load √ √ √
Hoisting inertia force √ √ √
Inertia force of trolley √
Wind load in working state √ √ √ √ √ √ √
Wind load in off-working state √
Lateral force caused by oblique
√ √ √
running
Impact load √
Test load √
Earthquake load √
Hoisting load of auxiliary
√ √
hoisting mechanism
Note: 1. Different combinations of load are used to calculate different position of
structure.
2. If temperature load, snow load, installation load and gradient load need to be
considered, they can be added to the load listed in this table.
9.3.3 In class-I load condition, for permissible stress of welding joint, see Table 9.3.3.
9.3.4 For permissible stress of rivet, bolt and pin connections, see Table 9.3.4.
9.3.5 Permissible stress value of Table 9.3.2 - 9.3.4 shall be 15% higher than values in
the class-II load condition.
Table 9.3.3 Permissible Stress of Welding Joint under Class-I Load Condition
Buried arc automatic, Buried arc automatic,
semi-automatic welding semi-automatic welding and
Type and manual welding manual welding using E50 welding
of Type of stress symbol using E43 welding rod rod
weld Q235 Q345
Group Group Group Group Group Group Group
I II III I II III IV
compression [σn] 160 150 145 230 220 205 190
Buried arch automatic
[σ1] 160 150 145 230 220 205 190
welding
Examination Precise
[σ1] 160 150 145 230 220 205 190
of weld quality method
Butt tension of buried arch
weld automatic or
Common
semi-automatic [σ1] 135 120 115 200 190 175 165
method
manual
welding
Shear [τ] 95 90 85 165 130 120 110
Tension,
corner
compression [τt] 115 105 100 160 150 140 130
fillet
and shear
Note: 1. Common method for examination of welding joint refers to visual examination, measurement and hole-drilling examination;
precise method refers to supplement examination by radiant ray, magnetic particle and ultrasonic on basis of common
method;
2. Permissible stress of overhead weld shall multiply 0.8;
3. Permissible stress of field weld shall multiply 0.9;
4. Where single side of single-angle welded component is connected, the connected side shall be any side of equal leg angle
steel and short side of unequal leg angle steel, and permissible stress of welding joint shall multiply 0.85.
Table 9.3.4 Permissible Stress of Rivet, Bolt and Pin Connection N/mm2
Rivet, bolt, pin steel Steel grade of component
Type of grade Q235
Type of stress symbol
connection ML2,
Q235, 35 Group I Group II Group III
ML5
Rivet Shear [τ] 135 - - - -
connection Bearing [σc] - 320 300 290
(type-I hole) Nail-head pulling [σ] 85 - - - -
Finished bolt Tension [σ] 125 - -
(type-I hole) shear [τ] 125 - -
Common bolt
compression [σc] 290 275
connection
Tension [σ] 125 - -
Common bolt
shear [τ] 90 - -
connection
compression [σc] 190 185
Bending [σ] 150 - -
Pin connection Shear [τ] 90 - -
Compression [σc] 190 185
Table 9.3.4 (Continue)
Where,
σm refers to local compression stress, N/mm2;
p refers to concentrated load, N;
δ refers to thickness of web plate, mm;
a refers to action length of concentrated load; a shall be block length for slide block
and be 50mm for wheel;
hy refers to distance from component top (without track) or track top (with track) to
upper edge of calculation height of web plate, mm.
When there are large positive stress σ, large shear stress τ and local pressure stress σm
on the same calculation position, conversion stress shall also be verified according to
formula 9.4.1-2.
Where,
σ and σm shall carry their positive and negative sign separately.
9.4.2 Strength calculation of structural component connected by high-strength bolt
Strength of axial tension and axial pressure structural components connected by
high-strength bolt shall be calculated according to formula 9.4.2-1.
Where,
N refers to axial force of component, N;
Z refers to number of high-strength bolt through which component is connected to one
end of node plate or jointed plate;
Z2 refers to number of high-strength bolts on calculation section (bolts on the outmost
line);
A refers to net area of verification section, mm2.
9.4.3 Calculation of connection strength
1. Welding connection: when there is positive stress and shear stress at butt-welding
position, connection strength shall be calculated according to formula 9.4.3-1:
Where,
σh refers to conversion stress of weld, N/mm2;
[σ] refers to permissible stress of weld, N/mm2, see Table 9.3.3.
2) When high-strength bolt connection bears shear force on frictional surface and
external pull along stud shaft direction, permissible bearing force on each
high-strength bolts shall be calculated according to formula 9.4.3-2, but Pg shall be
substituted by (Pg-1.4Pt), where Pt refers to external pull borne by each high-strength
bolt along its axial direction, and this external pull shall not exceed 70 of pre-pull
Pg. )
3) Number Z of high-strength bolt required for connection shall be calculated
according to formula 9.4.3-3:
Z=N/[P] (9.4.3-3)
Where,
N refers to axial force on connection, N;
[P] refers to permissible load of one high-strength bolt, N.
9.5 Stability Calculation
9.5.1 Axial pressure component
1. Besides strength and rigidity conditions, axial pressure components shall also verify
whole stability and local stability.
2. Slenderness ratio of component:
1) Permissible slenderness ratio of components shall not exceed values listed in Table
9.5.1-1.
Table 9.5.1-1 Permissible Slenderness Ratio of Component (λ)
Tension Compression
Name of Component
component component
For chord member
Primary bearing structural 150 120
of truss
component
For whole structure 180 150
Secondary bearing structural component (such as
200 150
other rod of main truss and chord of auxiliary
truss)
Other component 350 250
Where,
σsrefers to yielding point of material, N/mm2.
3) When component is of composite cancelled structure, conversion slenderness ratio
of whole structural component can be calculated according to formulas listed in Table
9.5.1-2. For single piece of lacing-bar combined compression component, when
slenderness ratio is greater than conversion slenderness ratio, stability shall also be
calculated.
Table 9.5.1-2 Calculation Formula of Conversion Slenderness Ratio λh of
Cancelled Component
Type of
Surface shape of Meaning of
Item lacing Calculation formula
component symbol
material
λy refers to
slenderness ratio
of imaginary
axis;
λ1 refers to
slenderness of
single-limb to 1:1
axis, its
Lacing calculation shall
1
plate adopt net
distance between
lacing plates
(rivet connection
component shall
adopt distance
between edge of
lacing plate and
center of rivet).
A refers to total
gross sectional
Lacing
2 area of all chord
bar
rods cut from
section of
component;
A1 refers to total
gross sectional
area of all
oblique lacing
bars cut from
section of
component.
λ1 refers to
slenderness of
single-limb to 1:1
axis, its
calculation shall
adopt net
Lacing distance between
3
plate lacing plates
(rivet connection
component shall
adopt distance
between edge of
lacing plate and
center of rivet).
A1x refers to total
gross sectional
area of all
oblique lacing
bars within plane
which is cut from
section of
component and
which is vertical
Lacing to x-x axis;
4
bar A1y refers to total
gross sectional
area of all
oblique lacing
bars within plane
which is cut from
section of
component and
which is vertical
to y-y axis;
θ refers to angle
Lacing between plane
5
bar where lacing bar
is and x axis.
Note: 1. Single limb slenderness ratio of lacing plate combination component shall not
exceed 40, and size of lacing plate shall comply with the following
provisions: width of lacing plate along longitudinal direction of column
shall not be less than 2/3 of distance between axial lines of limb component,
and thickness shall not be less than 1/40 of the distance, and shall not be
less than 6mm;
2. Obliquity between oblique lacing bar and axial line of structural component
shall be kept within 40-70 degrees.
2. Where bending member fails to comply with the aforesaid conditions, its whole
stability shall be verified. For details, see Annex J.
9.5.4 Local Stability of Plate
1. Local stability of web plate
1) When ratio of height of web plate h0 to thickness δ (h0/δ)≤70 (60) (including
number in the bracket is applicable to Q345 and number out of the bracket is
applicable to Q235), transverse ribbed stiffener can be determined according to
structure. In order to support steel track, short transverse ribbed stiffener or
track-bearing beam shall be adopted. In this case, space among short ribbed stiffeners
shall be determined according to local bending stress conditions of steel track and
flange plate. Generally, space among short ribbed stiffener shall not exceed 750mm
and height is about 0.3h.
2) When 70 (60) < (h0/δ) ≤ 160 (135), transverse ribbed stiffeners shall be set and
verification shall be carried out.
3) When 160 (135) < (h0/δ) ≤ 240 (200), besides transverse ribbed stiffeners,
longitudinal ribbed stiffener shall also be set at (1/5 - 1/4)h height of compression
edge, and verification shall be carried out.
4) When 240 (20) < (h0/δ) ≤ 320 (270), besides transverse ribbed stiffeners, two lines
of longitudinal ribbed stiffeners shall be set at compression area, where the first line
shall be set at (0.15-0.20)h to compression edge of web plate, and the second line
shall be set at (0.35-0.40)h to compression edge of web plate, and verification shall be
carried out.
5) When (h0/δ) > 320 (270), calculation shall be carried out according to local stability
requirements of high web plate.
2. Local Stability of Compression Flange Plate:
1) When ratio of out-extending width of compression flange plate with I-shaped
section along each side to thickness of compression flange plate with I-shaped section
is not greater than 15 for Q235 and not greater than 12 for Q345, local stability of
compression flange plate may not be calculated.
2) For box section, local stability may not be calculated if ratio of central distance of
web plate b0 to thickness of compression web plate δy satisfies the following
requirements: For Q235 (b0/δy)≤ 60 and for Q345 (b0/δy)≤ 50.
Where flange plate is wide, one or more pieces of longitudinal ribbed stiffener shall
be set, to satisfy the aforesaid (b0/δy)≤ 60 (50). Stability may not be calculated when
inertia moment Iz3 of longitudinal ribbed stiffeners can satisfy clause 2 of 9.5.6.
9.5.5 For calculation of local stability of plate, see Annex J.
9.5.6 Requirement of structural side of ribbed stiffener
1. When local stability of web plate can be satisfied, spacing n among transverse
ribbed stiffener of web plate shall not be less than 0.5h, and shall not exceed the
bigger one of h0 and 2m, where ho refers to height of web plate.
Size of transverse ribbed stiffener of web plate shall be determined according to
formula 9.5.6-1 and 9.5.6-2:
Where,
b1 refers to out-extending width of transverse ribbed stiffener, mm;
δ1 refers to thickness of transverse ribbed stiffener, mm.
When web plate has both transverse ribbed stiffener and longitudinal ribbed stiffener,
besides the aforesaid provisions, transverse ribbed stiffener shall also satisfy:
Izl ≥ 3h0δ3 (9.5.6-3)
Where,
Izl refers to inertia moment of section of transverse ribbed stiffener to central line of
thickness of web plate, mm4;
δ refers to thickness of web plate, mm.
For ribbed stiffener with box section, when transverse ribbed stiffener is jointed by 4
pieces of plates, inertia moment Izl of longitudinal plate against contact line shall not
be less than 1.5h0δ3.
In addition, longitudinal ribbed stiffener of web plate shall also satisfy requirements
of formula 9.5.6-4 and 9.5.6-5:
Where,
Iz2 refers to inertia moment of section of longitudinal ribbed stiffener of web plate
against central line of web plate thickness, mm4;
a - see Fig. 9.5.6 Spacing among Transverse Ribbed Stiffener, mm.
Figure 9.5.6
When transverse or longitudinal ribbed stiffener doesn't adopt batten but adopt mold
steel, the part (whose width is 20δ) welded to the ribbed stiffer can be included in the
section of ribbed stiffener, and practical inertia moment against center-of-gravity line
of the section can be calculated, and requirements of formula 9.5.6-4 and 9.5.6-5 shall
be satisfied.
2. Longitudinal ribbed stiffener of flange plate shall satisfy requirements of formula
9.5.6-6:
Where,
fIz3 refers to inertia moment of section of longitudinal ribbed stiffener of flange plate
against central line of flange plate thickness, mm4;
b0 - see Fig. 9.5.6 Center Distance of Web Plate, mm;
δy - see Fig. 9.5.6 Thickness of Flange Plate, mm;
m refers to number of longitudinal ribbed stiffener of flange plate.
9.6 Rigidity Requirement
Rigidity can be divided into static rigidity and dynamic rigidity. Static rigidity is
expressed by static elastic deformation value of structure and structural components at
certain position when specified load is added on certain position; generally, for gate
hoist, dynamic rigidity of vibration system is only verified when there are relevant
requirements.
Static rigidity requirements of bridge-type, platform-type and gantry hoist are as
follows:
When rated load is added at midspan or at worst position (at lifting-start position for
platform-type and single-direction gantry hoist), due to vertical static deflection yL
caused by rated hoisting load and weight of trolley at midspan, the following
requirements shall be satisfied:
Midspan deflection of bridge-type and bi-direction-type gate hoists:
When working class is Q1 and Q2, yL≤ L/700 (9.6-1)
When working class is Q3 and Q4, yL≤ L/800 (9.6-2)
Where,
L refers to span of gate hoist.
For gantry hoist with cantilever, when trolley with full load is at effective working
position of cantilever, vertical static deflection at this position:
yL≤ Lc/350 (9.6-3)
Where,
Lc refers to effective working length of cantilever.
Generally, horizontal midspan displacement value of bridge-type and platform-type
gate hoist is recommended to be controlled at:
ys≤ L/2000 (9.6-4)
For gantry of gantry hoist, the horizontal displacement along the two directions is
recommended to be less than 1.5H‰ under the worst load combination. Where H
refers to height from track level (upper flange of main girder for single-direction hoist)
of big trolley to track level of small trolley.
When small trolley gantry and mechanical equipment are installed directly on
platform trolley bracket and gantry of single-direction hoist shall be appropriately
strengthened. When the maximum vertical static deflection is used as component of
freely supported beam, it is recommended to be controlled to be:
ye≤ L/2000 (9.6-5)
Where,
L refers to span of trolley, platform trolley and single-direction gantry hoist.
For cantilever, L is recommended to be controlled to be
ye≤ Lc/1000 (9.6-6)
Where,
Lc refers to effective working length of cantilever.
9.7 Gantry Structure
9.7.1 Structural type of gantry
According to operating requirements, gantry structure can be designed into without
cantilever, single-cantilever, double-cantilever and semi-gantry type. According to
different sectional structure, gantry structure can be designed into box section, plate
girder and lattice section type (truss and strut).
Generally, connection between gantry leg and main girder shall be of rigid connection,
namely rigid leg.
9.7.2 Calculation principle of internal gantry force
1. Within gantry plane: for gantry having two rigid legs, calculation figure of static
structure shall be adopted for calculation of internal force of main girder, and
calculation figure of once hyperstatic structure shall be adopted for calculation of
internal force of leg.
2. Within plane of leg: for connection between leg and lower transverse girder, when
ratio of leg rigidity to beam rigidity is greater than 0.6, the internal force shall be
calculated according to triple hyperstatic structure; when the ratio is less than or equal
to 0.6 and other section of leg is larger this area, the internal force shall be calculated
according to once hyperstatic structure. For simple calculation figure, see Figure
9.7.2.
3. Combination of various loads added on gantry hoist during running shall be used as
conditions to verify internal force of gantry structure.
4. For large gantry hoist, the internal force is recommended to be calculated by
computer according to space system.
Figure 9.7.2 Calculation Figure for Gantry in Leg Plane
9.8 Constructional Requirement
9.8.1 General principle
1. Efforts shall be made to guarantee simple structure, definite force bearing of main
bearing structure, and impact of concentrated stress shall be reduced.
2. Structural design must be convenient for manufacture, examination, transportation,
installation and maintenance. Exposed and underwater structures (such as hooking
beam) must avoid water accumulation.
3. Thickness of steel plate and mold steel limb of main bearing structure shall not be
less than 5mm.
4. Main bearing structural components can adopt different connection methods at
different positions, but two different connection methods shall not be adopted at the
same position.
5. For welded beam, besides position close to bearing position, lower part of
transverse ribbed stiffener shall not be directly welded on tension flange plate, and
shall break at position not less than 50m far from inner surface of tension flange plate.
For wide flange (such as where people can pass) box beam or single-web plate beam,
in order to avoid deformation of tension flange plate during construction and
transportation, lower part of transverse ribbed stiffener can be welded to 10mm -
16mm thick tie plate. And then tie plate can be welded together with tension flange
plate with longitudinal weld, see Fig. 9.8.1-1.
6. Butt welds of web plate and flange plate of welded beam are recommended not to
be arranged on the same section, and spacing among them shall not be less than
200mm; transverse ribbed stiffener shall be departed from butt weld of parallel web
plate, and spacing among them shall not be less than 200mm.
7. When track is laid on compression flange plate of welded beam and wheel pressure
is added, if track just faces web plate, web plate and compression flange plate are
recommended to adopt successive penetrated weld, and transverse ribbed stiffener
must be chamfered at connection between ribbed stiffener and web plate (see Figure
9.8.1-2). In condition where wheel pressure is transmitted by transverse ribbed
stiffener or by participation of transverse ribbed stiffener, the transverse ribbed
stiffener shall also be welded tightly with compression flange plate. Length of weld
under bearing surface of track shall not be less than 1.4 times bearing width of track.
In addition, double-side weld shall be adopted and double-side stagger weld or
single-side intermittent weld can be adopted on other positions.
Figure 9.8.1-1 Arrangement of Welded Box Beam and Single Web Plate Transverse
Ribbed Stiffener
Figure 9.8.1-2
8. Thickness of truss gusset plate shall be selected from Table 9.8.1 according to
internal force of web rod.
Table 9.8.1 Thickness of Gusset Plate
9. Generally, for main beam of gantry hoist and bridge-type hoists, midspan camber
shall be 0.001L, where L refers to span. Upwarp degree of cantilever end shall be
Lc/350, where Lc refers to effective working length of cantilever.
9.8.2 Weld connection
1. Weld metal: weld metal is recommended to match with body metal. If different
types of steel with different strengths are welded, welding material that matches with
low-strength steel can be adopted.
2. Butt weld: groove type of butt weld shall comply with provisions of GB/T 985 and
GB/T 986.
In main bearing structures, if butt weld between plates with different thicknesses or
widths, transit gradient not exceeding 1:4 shall be made from one or both sides, see
Figure 9.8.2-1.
Figure 9.8.2-1
3. Fillet weld:
1) For minimum height hwmin of fillet weld, see Table 9.8.2 (when thickness of
welding piece is less than 4mm, minimum height of weld shall be the same as welding
piece). Generally, maximum height of fillet weld shall not exceed 1.2 times thinner
welding piece.
2) For main structure bearing dynamic load, surface of fillet weld shall be made into
concave arch or straight line. Ratio of right-angle side of weld to side weld shall be
1:1, and to end weld shall be 1:1.5. Overlapped length shall be equal to or longer than
5 times thickness of thinner welding piece, see Figure 9.8.2-2.
Figure 9.8.2-2
3) Minimum calculation length of fillet weld at side or end shall be 8hw. Maximum
calculation length of side weld shall be 40hw when bearing dynamic load, shall be
60hw when bearing static load. Overlong part will not be considered in calculation.
4. In primary welding connection, intermittent welding with small thickness can be
adopted, net distance among intermittent welding shall not exceed 15δmin in
compression component and shall not exceed 30δmin in tension component.
Table 9.8.2 Minimum Height of Fillet Weld(hwmin) mm
DC system shall adopt control by master controller and control panel generally.
Multiple fixed gate hoists can adopt centralized control and separate control; fixed
gate hoist can also adopt remote control and field control according to concrete
working requirements. If possible, field control of gate hoist can adopt programmable
controller.
10.6 Conducting Wire and Feeder Device
10.6.1 Conducting wire
Conducting wire of gate hoist must adopt copper-core stranded conductor. Type of
conducting wire shall be selected according to laying method, ambient temperature
and voltage class. Generally, rubber insulation wire, cable and plastic insulated cable
can be adopted, and conducting wire with small section may also adopt plastic
insulated wire.
Wiring on gate hoist must adopt multi-strand single-core conductor whose sectional
area shall not be less than 1.5mm2 and multi-core conductor whose sectional area
shall not be less than 1mm2. Sectional area of conduction can not be considered for
connection wires of electric devices, oil-pressure servo mechanism and sensor
components.
Generally, wires shall be laid in grooves or metallic ducts. Where it is inconvenient to
lay wires in grooves or metallic ducts or there is relative displacement, wires can be
laid in flexible tubes. Cable can be laid directly. Protective measures shall be adopted
at place where there are mechanical damage, chemical corrosion and oil corrosion.
Wires of different mechanism, AC and DC and different voltage classes shall be laid
in different tubes, illuminating wires are recommended to be laid separately.
Single-core conducting wire whose AC current capacity is over 25A shall not be
allowed to be laid in metallic duct. Junction box shall be set at connection and branch
point of conducting wires, junction box installed outdoor shall have rain-proof
measures and wire holes shall have covers.
Bending radius of cable laying shall not be less than 10 times external diameter of
cable.
10.6.2 Feeder device
1. Feeder device of trolley: cable, copper wire, mold steel or other conducting
material can be adopted. Selection of type and specification shall satisfy requirements
of current capacity and voltage loss in gate hoist. Diameter of copper slide wire shall
not be less than 6mm, and size of angle steel shall not be less than
40mm×40mm×4mm. Feeder device of trolley shall be set at place where is convenient
for maintenance. If nude conducting material is adopted as feeder device of trolley,
safety protection measures shall be set near the device.
Rigid slide wire shall be installed on fixer of isolated slide wire. Spacing among fixer
bracket shall not exceed 3m, length of slide wire extending out of bracket shall not
exceed 0.8m; distance between adjacent slide wire shall not be less than 130mm
vertically and shall not be less than 270mm horizontally. Current collector of rigid
slide wire shall be weighted by self weight or spring, so as to guarantee favorable
connection with slide wire during running, and current collector shall not incline or
decline during running.
Flexible slide wire shall be equipped with middle support, insulation of middle
support shall be installed on rigid bracket, and tension devices shall be adopted at both
ends of slide wires. Selection of current collector: low capacity and common electric
segment can adopt current collector of single pulley type; failure may be caused by
temporary break of current collector with high capacity, so double-pulley folk-type
bracket shall be adopted.
If mobile cable is adopted for feeder device of trolley, fixed contact box shall be set
on brackets of big trolley and small trolley, and cables shall be arranged tightly. In
addition, cable shall be abraded or shall not bear over tension during running of
trolley and mobile bracket shall be able to move flexibly.
2. Feeder device of big trolley: cable drum or slide wire device can be adopted. When
travel distance is long, capacity is large and cable-drum wound cable must be adopted,
high-voltage power supply can be adopted, and power supply can be transferred to all
mechanism after being stepped down by transformer installed on gate hoist.
10.7 Voltage Loss
Where AC power supply is adopted, voltage loss from low-voltage busbar of power
supply transformer to any terminal of electromotor shall not exceed 15% of rated
voltage during peak current. Generally, voltage loss in gate hoist may be 4%, and may
be 6% for gate hoist that is not often operated.
If power is supplied by cable drum, voltage loss of cable drum shall not belong to
internal voltage loss of gate hoist.
10.8 Lighting, Single and Communication
10.8.1 Lighting
Appropriate lighting shall be available in machine room, electric room, passage,
ladder and cab of gate hoist, and shall comply with relevant standards. Design and
arrangement of working lighting shall not affect visual field of operating personnel in
normal operation. Voltage of fixed lighting power supply shall not exceed 220V, and
metallic structure must not be used as lighting circuit.
If single accumulator is adopted for power supply, voltage shall not exceed 24V, and
supply voltage of portable lighting device shall not exceed 36V.
10.8.2 Signal and communication
State of main power supply of gate hoist shall have obvious signal indication in
operation room. Malfunction signal and alarm signal can be set according to
requirements. Signal device can adopt audible signal and signal lamp, and these
devices shall be set within visual and audible field of relevant personnel.
Telephone, wireless interphone and loudspeaker can be adopted as dispatching and
working communication facilities at power plant.
10.9 Earthing
Reliable earthing shall be made to all electric equipments, metallic enclosure not
carrying current under normal condition, metallic wire tube and metallic cover of
cable and step-down side of safety lighting. Unreliable electric connection between
wheel and track can be caused by non-conducting deposited dust, so mobile gate hoist
shall be equipped with special earthing wire, and earthing trunk is recommended to be
adopted to steel structure where there are many weld.
Users shall be responsible for earthing of big track and fixed gate hoist, and the
earthing shall comply with requirements of relevant codes.
Earthing branch of single low-voltage electric equipment shall adopt copper wire, and
according to mechanical strength, allowable minimum section area shall be 4mm2 for
exposed nude wire, and shall be 1.5mm2 for insulated wire.
Sectional area of earthing wire shall be reviewed according to possible earthing
short-circuit current and thermal stability, and shall not be less than the following
value generally: steel: 800mm2; copper: 50mm2.
When cab of mobile gate hoist is connected with main structure by bolt, number of
earthing point shall not be less than two. Earthing wire must not be used as
current-carrying zero line.
10.10 Miscellaneous
For electric equipments of gate hoist used in humid tropic zone, dry heat zone and
high-altitude zone, design and selection shall satisfy relevant requirements.
10.11 Working Scope of Electric Design
Working scope of electric design shall include the following content: instruction and
calculation letter, electric principle figure, panel arrangement figure, terminal
installation and wiring figure, field installation and wiring figure, list electric
equipments and materials, as well as structure and manufacture figure of fixed electric
equipments.
Annex A (Informative Annex) Hoisting Force, Lift Head, Span and Speed Series
of Gate Hoist Date and Example of Working Class of Gate Hoist
A.1 Hoisting Force Series
Table A.1 Hoisting Force Series kN
Where,
∑P refers to total wheel pressure that may appear on the hoist side where lateral force
is added frequently (it is related trolley position), see Figure C.1;
λ refers to horizontal lateral force coefficient, and it shall be determined according to
Fig. C.2.
Where,
A1 refers to overall area of structure or object, A1 = h×l, see Figure D.1;
φ refers to solidity ratio of structure, namely, φ=A/A1, see Figure D.1.
Where,
φ1 refers to solidity ratio of the front (first) structure;
AII refers to overall area of the front (first) structure, m2.
If formula D.3 is adopted to calculated windward area A and formula 6.0.6-1 is
adopted to calculated total wind load, due to different types of each structure, wind
coefficient of one structure shall be multiplied.
Table D.1 Solidity Ratio of Structure φ
Solid structure and object 1.0
Windward structural type Mechanism 0.8-1.0
and object Truss made of mold steel 0.3-0.6
Steel pipe truss structure 0.2-0.4
Figure D.5 Size Relation of Component with Box Section and Trapezoidal
Section
Figure D.7 Wind-shielding Conversion Coefficient of Truss Structure
D.2.3 In truss-type tower frame with square section or like-square section, if oblique
web rod within the same segment of current parallel truss is arranged reversely,
wind-shielding conversion coefficient of the next truss is about 2 time value when
web rod is arranged along the same direction (for values of truss web rod arranged
along the same direction, see Table D.2).
D.2.4 Wind coefficient C of component (beam) with single trapezoidal section under
action of lateral wind power shall be 1.2.
Annex E (Informative) Permissible Physical Quantity of Commonly-used
Friction Surface Material
Table E.1 Maximum Permissible Physical Quantity of Detent and Clutch Surface
[pv]
2 N.m/(mm2.s)
[p] N/mm Without lubrication
For control
Material of For support
of decline
frictional
surface For
For control Block Belt Block Belt Friction Allowable
support of type type type type coefficient temperature℃
decline
Asbestos
rubber
0.8 0.4 5 2.5 2.5 1.5 0.42-0.48 220
rolling best
against steel
Asbestos
steel wire
0.6 0.3 5 2.5 2.5 1.5 0.35 220
braking belt
against steel
Where,
A refers to multi-layer wound coefficient related to winding layers of steel cable; its
value shall be selected from Table G.1;
Smax refers to maximum pull of steel cable, N;
δ refers to thickness of drum wall (for cast iron δmin≥12mm, for cast steel δmin≥15mm),
mm;
t refers to pitch spacing of screw grooves on drum, mm;
[σp] refers to permissible compression stress, N/mm2;
for steel: [σp]=σs/1.5 (σs refers to yielding point)
for cast iron: [σp]=σb/4.25 (σb refers to compression intensity).
]
Table G.1 Multi-layer Wound Coefficient
When L>3D, conversion stress generated by bending moment and torque shall be
calculated according to formula G.2:
Where,
MF refers to conversion moment, N·mm;
Where,
K refers to stability coefficient;
pw refers to critical stress of stability, N/mm2;
For sSteel:
Where,
M refers to torque transferred by sheet, N·mm;
n refers to number of sheet;
d1 refers to exterior aperture of sheet, mm;
d2 refers to interior aperture of sheet, mm;
D refers to diameter of center circle among sheets, mm.
Torque is directly transferred by bolt between drum and large gear through reamed
hole, and it also plays connection role. Shear stress of bolt used for reamed hole shall
be calculated according to formula G.5:
Where,
d1 refers to diameter of stick part of bolt used for reamed hole, mm;
For meaning of other symbols, see relevant definition stated above.
Extrusion stress shall be calculated according to length Lφ of bolt used for sheet or
reamed hole transferring torque and according to formula G.6:
Where,
P refers to calculation load of hook, N;
e1 refers to distance from center of gravity of section to interior side of section, mm;
K refers to shape coefficient of A-A section; A-A section is usually used as trapezoidal
section (see Figure G.4), h≈D、b1≈0.67h、b2≈0.4b1, K≈0.1;
A refers to area of A-A section, mm2;
D refers to diameter of lifting hole of hook, mm.
G.2.1.3 Strength calculation of thread and screw rod of hook head.
(1) Tension stress of screw rod neck shall be calculated according to formula (G.12)
Where,
d0 refers to diameter of screw rod neck, mm.
(2) Bending stress of screw rod neck shall be calculated according to formula G.13:
Where,
d refers to exterior diameter of thread, mm;
d1 refers to interior diameter of thread, mm;
n refers to number of working thread;
h refers to height of thread root, mm.
(3) Extrusion stress of contact surface of thread shall be calculated according to
formula G.14:
Where,
t refers to spacing among thread, mm;
Figure G.5 Relation Figure for Size of Lifting Folk
H refers to height of thread contact surface, mm.
G.2.2 Lifting folk
G.2.2.1 Strength calculation of folk body:
Tension stress at internal side of A-A section shall be calculated according to formula
G.15:
Where,
P refers to calculation load of lifting folk;
a refers to conversion coefficient of stress; it shall be selected according to
in Figure G.6.
Interior stress of axle hole on B-B section shall be calculated according to formula
G.16:
Where,
K refers to shape coefficient of C-C section; for rectangular section
Where,
B refers to width of lifting plate, mm;
a refers to stress concentration coefficient; it shall be selected according to d/B and
Figure G.8.
Where,
R=B/2, mm。
G.3 Wheel Trolley
G.3.1 Calculation of fatigue strength of wheel tread
Calculation load Pc of fatigue strength on wheel tread shall be calculated according to
formula G.21:
Where,
Pmax refers to maximum wheel pressure of big trolley or small trolley during running
with load, N;
Pmin refers to minimum wheel pressure of big trolley or small trolley during running
with load, N.
Line fatigue strength of line contract on wheel tread shall be calculated according to
formula G.22:
Where,
K1 refers to permissible line contract stress constant related to material,
N/mm2; steel wheel K shall be selected from Table G.2;
D refers to diameter of wheel tread, mm;
b refers to effective contact width between wheel tread and track, mm;
c1 refers to rotation speed coefficient, see Table G.3;
c2 refers to working class coefficient, see Table G.4.
Line fatigue strength of point contract on wheel tread shall be calculated according to
formula G.23:
Where,
K2 refers to permissible point contact stress constant related to material, N/mm2; steel
wheel K2 shall be selected from Table G.2.
R refers to larger value of curvature radius of wheel tread and track, mm;
m refers to coefficient determined according to ratio of curvature radius of track head
and wheel tread (r/R); it shall be selected from Table G.5.
G.3.2 Contact strength calculation of wheel tread
Calculation load Pb of contact strength of wheel tread shall be maximum wheel
pressure of gate hoist under maximum hoisting load.
Line fatigue strength of line contract on wheel tread shall be calculated according to
formula G.24:
Pb≤2.2K1Db (G.24)
Table G.2 K1 and K2 Values
σb K1 K2
500 3.8 0.053
600 5.6 0.1
650 6.0 0.132
700 6.6 0.171
>800 7.2 0.245
Note: 1. σb refers to tension strength of material that has not be treated, N/mm2.
2. Generally, steel wheel may need to go through heat treatment; line contact
can adopt HB = 300 - 340, point contract can adopt HB = 340 - 380, and
depth of heat treatment can be 15mm - 20mm. During determination of
permissible value of K1 and K2, σb of material that has not be treated shall
be adopted.
3. When ductile cast iron is adopted,σb≥500N/mm2, K1 and K2 shall be
selected according to σb=500N/mm2.
Where, meaning of symbols are same with those defined in formula G.22.
Line fatigue strength of point contact on wheel tread shall be calculated according to
formula G.25:
Pb≤3.3K1Db (G.25)
Where, meaning of symbols are same with those defined in formula G.23.
Table G.5 Value of Coefficient m
r/ 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.15 0.10 0.05
R
m 0.38 0.40 0.42 0.44 0.46 0.49 0.53 0.60 0.41 0.80 0.67 1.28
8 0 0 0 8 0 6 0 6 0 0 0
Note: 1. When r/R adopts other values, m value can be calculated according to
interpolation method;
2. r shall be smaller curvature radius of two surface contacted, mm.
G.4 Track
For track under action of strength calculation load Pb of wheel, see Figure G.9.
Figure G.9 Track Wheel Strength Calculation
G.4.1 foundation bearing stress of track bottom plate can be calculated according to
formula G.26. When center distance between two adjacent rolling wheels is less than
3hk, approximate calculation can be made according to formula G.27:
Where,
σb refers to wheel strength calculation load, N;
hk refers to track height, mm;
Bk refers to width of bottom plate of track, mm;
L refers to middle distance between two adjacent rolling wheels, mm.
If track foundation is made of concrete, permissible bearing stress [σ0] shall be
adopted according to Table G.6.
Table G.6 Permissible Stress of Concrete [σ0] N/mm2
Symbol Concrete grade
G.4.2 Bending stress of track section can be calculated according to formula G.28:
Where,
Wk refers to resistance moment of track section, mm3;
Meanings of Pb and Hk are same with definition stated above.
B.4.3 Local bearing stress of track neck can be calculated according to formula G.29:
Where,
δ refers to distance from track neck to track level, mm;
t refers to thickness of track neck, mm.
G.4.4 Bending stress of bottom plate of track can be calculated according to formula
G.30:
Where,
c refers to length of cantilever of bottom plate, mm;
δ refers to thickness of bottom plate, mm;
G.5 Calculation of load-bearing nut of hoisting screw rod
G.5.1 strength calculation of hoisting screw rod:
Due to that hoisting force is usually greater than closing force, so hoisting force shall
be adopted as strength calculation load of P1.
Twisting moment Mk borne by hoisting screw rod can be calculated according to
formula G.31.
Where,
P1 refers to hoisting force, N;
a refers to lifting angle of thread;
Where,
Where,
μ refers to frictional coefficient of gantry pillars;
d0 refers to diameter of pivot shaft of gantry pillar, mm.
Bending stress of hoisting screw rod can be calculated according to G.34;
Where,
M refers to bending moment,
d1 refers to interior diameter of thread, mm.
Axial stress of hoisting screw rod can be calculated according to formula G.35:
Where,
P1 refers to hoisting force, N;
d1 refers to interior diameter of thread, mm.
Combined stress of hoisting screw rod can be calculated according to formula
G.36:
Where,
refers to bending stress, N/mm2;
refers to axial stress, N/mm2;
refers to yielding point of material, N/mm2;
Where,
P2 refers to closing force, N;
E refers to elastic modulus of material, N/mm2;
n refers to stability safety coefficient; it shall be 1.8 - 3 generally;
Conversion coefficient of length; ;
L refers to practical length of tension calculation of hoisting screw rod, mm;
d1 refers to interior diameter of thread of screw rod, mm;
When slenderness ratio of hoisting screw rod and there is additional bending
moment action, calculation shall be made according to formula G.38:
Where,
P2 refers to closing force, N;
2. Slenderness ratio
Where,
Z refers to number of working teeth of thread; it shall adopt 10 when it exceeds 10;
h refers to height of thread;
Where,
The maximum working pressure of the oil pump shall be calculated according to
Formula :
Where,
The rated working pressure of the oil cylinder;
Where:
: The maximum working flow of the oil cylinder working at the same
time;
K: the leakage coefficient of the system; 1-1.3;
The rated pressured of the hydraulic pump shall be greater than or equal to 1.25P1. If
there are test behaviors, the requirements on the test pressure shall be met.
H.1.2 Calculation of the Electromotor Power
The driving power (P) of the hydraulic pump shall be calculated according to:
Where,
: The driving power of the hydraulic pump, kW;
H.2 Calculation of the Diameter and Wall Thickness of the Oil Pipe
H.2.1 Calculation of the Diameter of the Oil Pipe
The internal diameter (d) of the oil pipe shall meet requirements on the flow and flow
speed. It shall be calculated according to:
Where:
Where:
: Safety factor;
Where,
Frictional resistance, N;
The pressure difference on both sides of the piston packing, Mpa;
: The pressure difference on both sides of the piston rod packing, Mpa;
The frictional compensation coefficient of the piston rod packing ring; for
thickness of
Where,
The cylinder wall thickness, mm;
The additional thickness considering the wall thickness tolerance and the
corrosion; commonly, it is rounded up to the nominal thickness;
Where,
safety coefficient
where,
longitudinal stress,
Hoop stress,
The rated pressure in the cylinder.
Other symbols shall refer to Figure H.1.
Figure H.1 Calculation Schedule of the Cylinder Flange Strength
At the section of the cylinder and the flange joint, the strength calculation of the
cylinder wall shall be carried out by overlaying with the longitudinal stress and hoop
stress due to the evenly-distributed bending moment (M0). The reduced stress
shall be calculated according to:
Where,
Figure H.2 Calculation Schedule of the Single-action Cylinder Rigid Mount Piston
Rod
Where,
Where,
If the lateral displacement ( ) generated on the end of the piston rod, the
relevant horizontal force (the piston rod at the upper limit position), N;
Where,
The bending moment due to the friction in the gate ear, It shall
be calculated according to:
Where,
The friction factor at the piston rod ear; it shall be selected according to Table
H.2.
H.6.2 The calculation of the piston rod with the single-action cylinder installed on the
rotation mount:
The piston rod of the single-action cylinder installed on the rotation bearing, the
bending moment (Figure H.3) due to the friction between the rotation bearing and the
ear as well as the pull shall be received. The stress shall be calculated according to:
Where,
Where,
The bending moment due to the friction in the gate ear, It shall
be calculated according to:
The bending moment due to the friction i the oil cylinder cylinder body
Where,
The friction factor in the rotation bearing of the oil cylinder body shall be
selected according to Table H.2.
H.6.1 The calculation of the piston rod with the double-acting cylinder installed on the
rigid mount.
H.6.3.1 If there is no lateral displacement in the gate and the piston rod receives the
pull or pressure, the pull and compressive stress shall be calculated according to
Formula (H.11).
Where,
The reduced length of the piston rod, mm; it is related with the fixed form of
the oil cylinder body, as shown in Figure H.4.
Table H.3 The Longitudinal Bending Coefficient ( ) of the Piston Rod Receiving
Pressure in the Center
Flexibility 0 10 20 30 40 50 60 70 80 90 100
λ
Material
1.00 0.99 0.97 0.95 0.92 0.89 0.86 0.81 0.75 0.69 0.60
1.00 1.00 0.98 0.95 0.93 0.90 0.84 0.80 0.74 0.66 0.59
Flexibility 110 120 130 140 150 160 170 180 190 200
λ
Material
0.52 0.45 0.40 0.36 0.32 0.29 0.26 0.23 0.21 0.19
0.43 0.38 0.32 0.28 0.27 0.24 0.21 0.19 0.17 0.15
Where,
The bending moment due to the friction in the gate ear, It shall
be calculated according to Formula (H.13):
Where,
the piston rod. According to the conditions, the flexibility and the reduced
eccentricity rate ( ) shall be selected according to Table H.4.
Where,
Where,
Table H.4 Permissible Stress Reduction Coefficient Under the Longitudinal Bending
of the Piston Road Eccentrically Compressed
H.6.4 The piston rod of the double-acting cylinder installed on the rotation bearings
receives the pull (pressure) force and the bending moment. The stress on the piston
rod shall be calculated according to Formula (H.14). Also, the stability shall be
checked according to Formula (H.10).
If ,
If b>0.4m,
Figure H.6 Calculation Schedule of Double-acting Cylinder Rotation Bearing
Where,
: The inertia moment of the piston rod and the oil cylinder body section,
mm4;
The reduced eccentricity (m0) shall be decided according to the bending moment
diagram feature (Figure H.3) of the piston rod, the ratio between bending moments on
both ends, the conditional flexibility and the relative eccentricity rate (m)
according to the Table H.5.
The relative eccentricity shall be calculated according to Formula (H.21):
Where,
The larger value between M1 and M2, the end bending moments.
(b) When the door rotates the angle of , the load diagram and the bending moment
diagram.
(c) When the door rotates the angle of , the load diagram and the bending moment
diagram.
Where,
The bending moment due to the friction on the shaft neck of the rotation
bearing beam;
The moment to the oil cylinder rotation center from the friction of the tail
bracket.
The gross weight of the oil cylinder including the hydraulic oil.
The diameter of the end weight bearing wheel, mm;
The diameter of the wheel and axle of the end weight bearing wheel, mm
The force arm of the rolling friction; it shall be 0.5mm-0.6mm;
The friction factor of the rotation shaft neck; it shall be selected according to
Table H.1.
The radius from the tail weight bearing wheel to the oil cylinder rotation
center, mm;
During the stability calculation, the conditional flexibility ( ) shall be calculated
according to Formula (H.21).
The reduced length (L0) shall be decided according to Figure H.6 and Formula (H.20):
The relative eccentricity shall be calculated according to Formula (H.21):
the converted eccentricity (m0) shall be decided according to the bending moment
diagram feature (Figure H.7), the ratio between bending moments on both ends, the
Table H.8 Pollution Class of Hydraulic Pressure System Hydraulic Pressure System
Actuating Medium Solid Particles
Where,
The calculated axial pressure, N;
The axial compression member stability factor selected according to the
maximum length-diameter ratio of the structure or the maximum presumed one; it
shall look up in Table J.1 and J.2.
The compensation factor for the axle load stability shall be calculated
according to Formula (J.4) or looked up in Table (J.3) and Table (J.4). The
smaller value of the Euler critical load Nex and Ney. They shall be calculated according
to the following formula:
zero,
Wx and Wy refer to resistance moment of section of structural component, mm3;
comply with conditions listed clause 1 of 9.5.3 , shall be 1, those that fail to
comply with the conditions, value of can be selected according to Table J.8 and
formula J.9.
refers to coefficient; it shall adopt 0.15 for section with common open.
Table J.1 Stability Coefficient of Q235 Steel Axial Central Compression Component
Table J.2 Stability Coefficient φ of Q345 Axial Central Compression Component
Table J.3 Correction Coefficient ψ of Axial Compression Stability of Q235 Steel
Table Correction Coefficient ψ of Axial Compression Stability of Q345 Steel
Table J.5 a Value of I-shaped Section
Table J.6 a Value of Groove Section
stability of component can be verified according to formula J.1 and J.2; value can
be selected according to Table J.7 or be calculated according to formula J.8 and J.9.
2
other grades, selected from table shall multiply ( , N/mm ).
4. when is not less than 2, whole stability needs not to be verified; if values are
greater than 2.5 times values listed in this table, they shall be converted. Values of
that are not listed in this table are greater than 3.60.
Where,
refers to whole stability coefficient; when calculation result is greater than 0.8,
its value shall be selected from Table J.8;
K2 and k3 refer to coefficients, and their values shall be selected from Table J.9 and
Table J.10;
K1 refers to coefficient, and its value shall be selected according to the following
provisions:
For double-end simple supported member with axially-symmetrical combination
sections:
When ,
When ,
For double-end simple-supported components having reinforced compression flange
plate and axial-symmetric web plate:
When ,
When ;
For double-axle symmetrical cantilever component with combined section k1 = 1;
Where,
refers to yielding point of steel material, N/mm2, Q235 shall adopt 240N/mm2.
Table J.8 Stability Coefficient
Table J.9 Coefficient K2 and K3 of Double-end Simple-supported Component with
I-shaped Section
Note: Concentrated load refers to the condition where a few concentrated loads are added
within 1/3 scope of midspan; loads in other conditions shall be considered as evenly
distributed load.
Symbols as above.
J.3 Local stability calculation of steel plate
J.3.1 The calculation on the critical stress of compression stress (σ1), shearing strength
(τ) and local crushing stress ( ) shall according to Formula J.13, Formula J.14, and
Formula J.15:
Where:
Where:
Where:
The signification of ψ refer to Table J.11
Particular case:
While local pressure affect on the fringe of plate, during calculation, the value of
or will set down as o. If the critical combined stress (include the particular
case as above) over 0.75σ5, according to Formula J.18 to calculate the reduced critical
combined stress.
Where:
J.20. when ,
If , then
Table J.11 Flection coefficient of local clapboard
No. Load condition a=a/b K
1 uniform or
nonuniformity
compression
2 uniform or
nonuniformity
compression
3 flexion
mainly caused
by pressure Flexion coefficient (No. 1) while
5 single side
partial
compression
Notes: 1 is the maximum crushing stress of plate, is the stress ratio of two
terminals; respective with the value of positive or negative.
2 To the lengthways ribbed stiffener whose web plate under the partial pressure, the flection
coefficient of above section can refer to the No.6 item of Table J.11; the flection coefficient of
bellow section can refer to the No.5 item if the extended width of partial pressure is confirmed.
For two or more lengthways ribbed stiffeners, the calculation of flection coefficient also refer to
above principles.
axial of plate, ;
Where:
n——safety factor, set down as 1.5 for I type load and 1.3 for II type load;
σq——Imaginary proportional limit, chooseσ5.
The calculation of partial stability shall base on Formula J.21.
Where:
Pn——Motor rated power while adjusting the load duration factor, kW;
P——Hoisting load, N;
v——Raising speed, m/s;
η——Total efficiency of mechanism;
λm——Allowable overload multiples of motor torque while adjusting the load
duration factor (rated value or actual value of technical provision).
H——Coefficient; base on the voltage loss (alternating current motor is 15%, without
regard to continuous current motor), allowable error of maximum running torque or
locked-rotor torque (winding type asynchronous motor is 10 % , cage type
asynchronous motor is 15% and without regard to continuous current electromotor),
and hoisting 1.25 times of rated load, the H of winding type asynchronous motor set
down as 2.1, cagy type asynchronous motor set down as 2.2 and continuous current
electromotor set down as 1.4;
m——Quality of motor。
K.2 Running mechanism motor
(K.2)
Where:
PgΣ——The gravitation of all motion parts, N;
ω——Coefficient of friction drag, see Table 5.6.7;
m0——Coefficient of slope drag, the roadway laying on reinforced beam or steel
beam set down as 0.001;
Pw——Wind resistance, N, according to the maximum calculated wind pressure (qII)
of working order as detailed in Item 6.6, indoor Pw set down as 0;
Where
P5 - Average power of steady state, kW;
G - Mean coefficient of steady-state load,G1=0.7, G2=0.8, G3=0.9, the
rating of G see Table N.1 of Annex N;
The rest symbols are the same with the formula (K.1) in Annex K.
L.1.1.2 Electromotor of running mechanism
Where:
G - Mean coefficient of steady-state load, G1=0.75, G2=0.80, the rating of
G see Table N.1 of Annex N;
Pw - Wind resistance, N, Calculated as the wind pressure of the gate hoist
under the normal operating status;
The rest symbols are the same with the formula (K.2) in Annex K.
L.1.1.3 The electromotor of traversing mechanism
Where:
G - Mean coefficient of steady-state load, G1=0.60, G2=0.60, The rating of G
see Table N.1 of Annex N;
M1 - The resistance torque of the equivalent ramp caused by inclination, N·m;
Mw - Equivalent wind resistance torque calculated according to the calculating
wind pressure q1 (see Article 6.6.3); N·m;
The rest symbols are the same with the formula (K.3) in Annex K.
Where
Pa - Dynamic power, kW
Ta - The mechanism starting time under normal operating conditions, s;
The rest symbols are the same with the formula (N.2) in Annex N.
L.1.3 CZ value
L.1.3.1 Converted to the full start times
Where
Z - Converted full start times per hour;
d0 - Full start times per hour;
di - Startup or incomplete startup times per hour;
f - Electric retarding times per hour;
g, τ- Conversion factor, generally take the values stated in Table L.1;
Table L.1 g, τ
Coefficient g τ
Winding-type asynchronous motor 0.25 0.5
Where:
C - Inertia increment rate,
-Flywheel torque converted to the motor shaft from the moving quality and
rotating quality out of electromotor, kg·m2。
L.1.3.3 CZ value
CZ value, the result of the inertia increment rate C multiplying the converted full start
times per hour, is the important parameters impacting the heating of electromotor
under startup and braking status.
L.2 Heating verification
For the convenience of application, Annex M lists the allowable output power of
YZR series winding-type asynchronous machine under different load duration
factors (FC values) and under different CZ value. If P ≥ Pa (average power of
steady state), then heating checkout of electromotor is eligible.
Annex M (Informative Annex) The allowable output capability (P) of YZR series
electromotor under different load duration factor (FC value) and under different
CZ values (the average startup multiples K= 1.7)
Annex N (Informative Annex) The electromotor of gate hoist
mechanism FC, CZ and G values in the capacity selection calculation
N.1 The load duration factor FC value, CZ value and mean coefficient of steady-state
load G of each components of different gate hoists shall be calculated according
to the actual load. If the details of the load condition is not available, then it can
be selected from Table N.1.
Table N.1: FC value, CZ value and G value
Type Chain-type fixed winding type Mobile
Hoisting device
Revolution hoisting
mechanism
Trolley running
mechanism
Cart running
mechanism
Traversing
mechanism
Note: the load duration factor of mechanism PC value is designed for the occasions that the working
cycle length shall not be less than 10 min, and calculated according to the following formula:
Where:
Iz - Current-carrying capacity of conducting wire, A;
Ka - The laying correctness factor of cables or tube-through wires, generally, the correctness factor of tube-through wire is 0.9 and the
cable is 0.8;
Kt - The ambient temperature correctness factor and normal value see Table P.1. Kt value can be calculated according to Formula (P.2);
T1 - The maximum operating temperature of wire core; ℃;
T0 - Working environment temperature,℃;
T2 - Rated working environment temperature, 25℃(or 45℃);
Kj - The load duration factor correctness factor of repeated short-time duty system, the working cycle time adopts 10 min, the accepted
value see Table P.2. Kj value can be calculated according to Formula (P.3);
FC - Load duration factor;
T - The heating time constant of conducting wire, the accepted value see Table P.3; s;
Ig - The baseline value of wire current-carrying capacity, the accepted value see Table P.3, A.
Table P.1: the temperature correction factor Kt of the current-carrying capacity of conducting wire, Kt
Rated working The maximum operating Working environment temperature
environment temperature of wire core;
+25 +30 +35 +40 +45 +50 +55 +60 +65 +70 +75
temperature,℃ ℃
+60 1.000 0.926 0.845 0.756 0.655 0.535 - - - - -
+25 +65 1.000 0.935 0.865 0.791 0.707 0.612 0.500 - - - -
+70 1.000 0.943 0.882 0.816 0.745 0.667 0.577 0.471 - - -
+65 - 1.323 1.225 1.118 1.000 0.866 0.707 - - - -
+45 +70 - 1.265 1.183 1.095 1.000 0.894 0.775 0.632 - - -
+75 - 1.195 1.134 1.069 1.000 0.926 0.845 0.756 0.655 0.535 -
+80 - 1.173 1.118 1.061 1.000 0.835 0.866 0.791 0.707 0.612 0.500
Table P.2 the load duration factor correctness factor of conducting wire, Kj
Load Wire core section mm2
Conducting wire model
continuity 1.5 2.5 4 6 10 16 25 35 50 70 96 120 150
BX, BXR copper core, rubber 25% 1.313 1.417 1.477 1.50 1.614 1.678 1.754 1.790 1.834 1.849 1.876 1.880 1.898
thread 40% 1.149 1.212 1.249 1.296 1.336 1.377 1.425 1.448 1.476 1.486 1.503 1.505 1.517
CYYCW, CF, CFR 25% 1.250 1.304 1.324 1.398 1.461 1.520 1.604 1.645 1.701 1.742 1.84 1.807 1.830
single-core cable 40% 1.111 1.143 1.155 1.200 1.240 1.277 1.330 1.356 1.391 1.417 1.444 1.459 1.473
YC, YCW, CF, CFR 25% 1.490 1.531 1.590 1.640 1.696 1.750 1.808 1.803 1.838 1.865 1.877 1.902 1.912
three-core cable 40% 1.258 1.284 1.321 1.353 1.388 1.422 1.460 1.456 1.479 1.495 1.510 1.519 1.526
Table P.3 baseline value of current-carrying capacity of conducting wire
Copper core cable Heavy type cabtyre cable Marine cable
BX, BXR copper
BV, BVR copper YC, YCW YC, YCW three-core CF, CFR single-core CF, CFR three-core
core, rubber Heating time
Wire core plastic wire single-core cable cable cable cable
thread constant, s
core
Current-carrying capacity A at 25℃
section Current-carr Heatin Current-carr Heatin Current-carr Heatin Current-carr Heatin
Ope Ope Ope
mm2 ying g time ying g time ying g time ying g time
n Tube-thro n Tube-thro n Tube-thro
capacity A consta capacity A consta capacity A consta capacity A consta
layi ugh b layi ugh layi ugh
at 25℃ nt, s at 25℃ nt, s at 45℃ nt, s at 45℃ nt, s
ng ng ng
1.5 27 18 24 17 86 184 - - - - 20 152 14 307
2.5 35 25 32 24 116 248 37 179 26 347 26 179 19 347
4 45 33 42 31 138 295 47 190 34 419 35 190 25 419
6 58 43 55 41 172 368 52 235 43 497 44 235 32 497
10 185 60 75 57 212 453 75 282 63 613 61 282 44 613
16 110 77 105 73 267 571 112 336 84 774 81 336 58 774
25 145 100 138 95 370 791 148 438 115 1050 105 438 77 1050
35 180 122 170 115 442 945 183 506 142 1020 135 506 94 1020
50 230 154 215 146 573 1230 226 626 176 1270 165 626 120 1270
70 285 193 265 183 641 1370 289 746 224 1540 205 746 145 1540
96 345 235 325 225 797 1700 353 917 273 1870 250 917 180 1870
120 400 270 375 260 820 1750 415 1040 316 2180 290 1040 205 2180
150 470 310 430 300 980 2090 - - - - 335 1200 240 2450
a The aforesaid figures are abstracted from section 26, Electrical Engineering Manual (1979, Probation version), taking continuous duty system ( FCI100%), the
current-carrying capacity at +25℃ (or +45℃) ambient temperature as baseline values.
B. In the table, the current-carrying capacity of tube-through wires is based on that three single-core wire pass through the steel tube in air. In order to simplify the
procedure, the cable used in gate hoist, no mater its wiring mode, laying position, generally adopt three single-core wire to adopt section; when the quantity exceed
three, the adopted section shall properly decrease the current-carrying capacity.
Annex Q
(Informative Annex)
Explanations on the Text Description
Q.1 Wording explanation
Table Q.1 Wording explanation
Extent Positive Negative
Very strict Must Strictly prohibit
Strictly do under normal Shall "shall not" or "be request
condition not to"
Allow a few of selections, "it's appropriate to" or It's not inadvisable to
but can do so under the "generally"
available conditions firstly
It shall do under general As much as possible
conditions but it has some
difficulties to do so due to
the technical-economic
reasons
Can do under some It's approved to
conditions
Q.2 In the context, the specified standards, specifications or the other relevant
regulations shall be carried out, the statement is "carry out ...according to", or
"meet the requirements of ..."; for the non-compulsive enforcement of the
specific standards, specifications and the other provisions, the statement is "make
references to".