Professional Documents
Culture Documents
DL/T 5167-2002
Opinions were asked on the amendment content of this standard from relevant
units in written form in October 1998. Standard amendment working
conference was held in Zhengzhou city, Henan Province, in November 1999,
and principle, method and task were determined on the conference. The first
exposure draft of Design Specifications for Gate Hoist in Hydropower and
Water Resources Projects was issued in April, 2000, and was discussed and
amended on Changzhou Conference. Then it was issued again in May, 2000,
for more than 50 design institute, factory, college and research institute of
hydropower and water resource system, to give their opinions. In April, 2001,
first draft for approval was worked out, forming formal draft for approval after
discussion and supplement made on Chengdu conference. Examination of the
draft standard for examination was carried out on Hangzhou conference in
December, 2001, forming draft standard for approval after amendment.
This standard is applicable to fixed gate hoist and mobile gate hoist that mainly
adopt electric drive to open and close gate and trash rack in hydropower
project. Fixed gate hoist includes different types, such as winding type,
screw-rod type, hydraulic hoist and chain-type, and mobile gate hoist includes
portal hoist, trolley hoist and bridge hoist.
2. Normative Reference
The following documents contain contents which, through reference in this text,
composite provisions of this standard. For dated reference, subsequent
amendments (excepting corrigenda content) to, or revisions of, any of these
publications do not apply. Parties to agreements based on this standard are
encouraged to investigate the possibility of applying the most recent editions of
the standards indicated below. For undated references, the latest edition of the
normative document referred to applies.
4.0.1 This standard is the necessary regulation and technical basis of type
selection, arrangement, design and calculation of gate hoist. Where
discrepancies are found between this standard with other relevant design
standard, this standard will prevail.
4.0.2 Except hydraulic gate hoist, working class of gate hoist mechanism is
divided into 4 classes according to their design service life and load status (see
Table 4.0.2). Working class of the main hoisting mechanism is just the working
class of the gate hoist. For examples of working classes of gate hoist, see
Appendix A.
4.0.4 For selection of hoisting force, lift head, span and speed, see Appendix
A.
4.0.5 Gate hoist shall be equipped with relevant safety devices, such as brake,
load limiting device, moment limiting device, upper and lower caging device,
travel limiter, buffer, wind-prevention rail clamping device, anchorage,
hydraulic system protection and electric protection device.
4.0.8 Disassembly size and weight of gate hoist shall comply with
transportation provisions, and transportation unit shall have necessary rigidity.
5. Design Principle and Requirements
2. Gate hoist of multi-hole water release system usually use mobile gate hoist.
3. For gate hoist of hole-sealing gate used for diversion during construction,
the hoisting force shall satisfy the requirement that gate is hoisted under
certain delivery head, and accurate lifting indication device.
4. Gate hoist of tide gate and working water gate adopt one-gate-one-machine
arrangement.
5. Type of gate hoist used to control fast gate at water inlet of power plant and
outlet of pump plant shall adopt hydraulic or winding type fast gate hoist
through comprehensive technical and economic comparison according to
engineering arrangement, gate load during hoisting and lift head. The control
power supply that can fast shut circuit off shall be set according to
power-losing conditions of AC power supply of power plant.
6. When maintenance gate is set at water inlet of multiunit power plant, mobile
gate hoist is usually adopted, and maintenance gate hoist of flood system and
water release system shall be considered where conditions are allowed.
7. For gate hoist of multi-hole trash rack at water inlet of unit, auxiliary hoisting
mechanism can be set at upriver, or auxiliary hook and main hook can also be
adopted within span. If hydraulic structures are dispersedly arranged and gate
hoists are unconditionally used, mobile gate hoist can be set independently.
9. For assembly gate or gate that shall be hoisted step by step, mobile gate
hoist with automatic hooking beam operation is usually adopted.
In cold region where gate hoist will be operated in winter, the machine room
shall have lagging facility; in hot region where gate hoist will be operated in
summer, the machine room shall have cooling facility; in area where there are
frequent sandstorms, gear transmission of gate hoist is recommended not to
adopt open type, or completely-closed machine room can be set. Selection of
working oil or lubricating oil shall consider air temperature conditions at the
operation area.
5.1.4 In addition to the maximum lift head of gate, gate hoist shall also have
appropriate reserve. The maximum working lift head of gate hoist controlling
submerged hole arch door shall satisfy requirements to change side and top
water stop.
5.1.7 Movable block group shall adopt protective measures to prevent steel
cable from escaping from the slot. Movable block group that is submerged
under water is recommended to adopt sliding bearing axle, and anti-corrosion
measures shall be adopted on the surface. Seal device shall be adopted, if
rolling bearing is adopted.
5.1.8 When plane gate is lifted, the hoisting central line shall keep accordance
with the hoisting central line of the gate.
5.1.9 For mobile hoist having large hoisting force, hoisting tool and gate (or
sag rod) are recommended to adopt automatic hooking beam or manual hitch
bar. When connecting shaft is heavy and operation is difficult, fixed hoist is
recommended to adopt manual hitch bar.
5.1.11 Gate hoist that controls flood relief gate and other emergency gate must
be equipped with reliable stand-by power supply.
5.1.12 During selection of gate hoist series, hoisting force of gate hoist shall be
greater than or equal to calculated hoisting load.
5.1.13 Dropping speed of fast gate hoist of power plant shall be determined
according to requirements of holes, and decelerator shall be set to guarantee
that gate speed approaching to the bottom is not faster than 5m/min.
5.1.14 Dropping speed of gate controlled by fast gate hoist at outlet of pump
station shall be determined according to requirements of fast-closing hold, and
measures shall be adopted to control its speed approaching to be fully closed.
5.1.17 For gate that has requirement of refilling water with small opening, gate
hoist shall be equipped with travel switch or other devices to satisfy small
opening precision.
5.2.1 Winch hoist is usually used to control gate which depends on gravity,
water column or other method to close, and one hoist is usually used to control
one gate.
5.2.2 In general conditions, gate hoist shall adopt on-site operation. If there are
several gate hoists, a centralized control room can be set for the operation.
5.2.3 Besides strength and reliability, chassis of gate hoist shall also be rigid
enough.
1. For high-lift gate hoist with rope guide, flange shall be set at place where
steel cable of rope reel returns; guide screw rod of rope guide shall consider
selection of helix angle, arch radius at top turning point as well type of wrap
angle of nut.
3. For high-lift gate hoist whose two double-connected pulley block reeving is
greater than 2, fixed pulley block shall be hinged onto bracket of the pulley
block, and disturbance of steel cable and rest bar of fixed pulley block shall be
prevented.
4. High-lift gate hoist adopting drum with broken line grooves shall consider
length of the broken line and inclination of rope groove. In addition, turning
flange shall be set at position where drum groove returns.
1. For top-exposed arch-gate winch hoist and pan type gate hoist whose
hoisting points are set before the water-supporting deck, the steel cable and
hoisting tools are generally set on the panel of tainter gate as close as possible,
and are recommended not to set movable pulley block; during arrangement,
connection method of steel cable, hoisting tools and lifting eye shall be
considered.
2. Top-exposed tainter gate winch hoist, whose hoisting points are set behind
the water-supporting deck, can be substituted by plain gate winch hoist or be
retrofitted. During arrangement, winding, turning method synchronous action of
double hoisting points shall be considered.
2. Elevation of gate hoist chassis bottom must be 0.21m- 0.2m higher than
travel route of gate top.
3. During operation of gate, steel cable shall not rub with gate flap, and
included angle between connection line of lifting eye center and lifting center of
gate hoist and the vertical line when the gate is fully opened shall not exceed
15 degree.
5.3.1 Electric screw rod gate hoist shall have reliable safety protection device
for electric or mechanical overload.
5.3.2 Manual and electric double-duty or manual screw rod gate hoist shall be
equipped with safety handle bars.
5.3.3 When manual mechanism and machine are connected with each other,
manual and electric double-duty shall have safety measures to break all circuit.
5.4.2 Double hoisting point hydraulic gate hoist shall adopt relevant
synchronous measures according to different factors, such as type, size,
structural stiffness and lateral support of the gate to be controlled. During
operation of top-exposed tainter gate, if the tainter gate has reliable lateral
support and strong torsional stiffness, hydraulic system can adopt throttle
governing and deviation-correction circuit may not be set. In addition,
capacity of gate hoist is recommended to have appropriate reserves. If
hydraulic gate hoist adopts deviation-correction circuit, closed-loop control
shall be adopted, and reliable travel measuring system shall be adopted
according to requirements of synchronous precision. Also, pipe system is
recommended to be arranged symmetrically.
5.4.3 Reasonable arrangement of tainter gate hydraulic hoist shall give integral
consideration to hoisting capacity, travel, obliquity and swing angle.
5.4.6 Safe and reliable travel supervision device shall be adopted according to
supervisory precision and requirements of hydraulic gate hoist; gate opening
instrument is recommended to adopt multi-rotation absolute sensor; stop
device with different theory is recommended to be set for extreme-position limit,
and shall not be substituted by overflow valve.
5.4.8 Piston rod of hydraulic cylinder of hydraulic gate hoist must adopt
anti-corrosion measures.
5.4.10 Beside fast valve hydraulic gate hoist, hydraulic fluid port of lower-cavity
of hydraulic cylinder is recommended to set hydraulic safety locking device.
5.5.1 China gate hoist is mainly used to control top-exposed working gate.
5.5.2 Lifting speed of chain gate hoist shall not exceed 1m/min generally.
5.5.3 Double hoisting point chain gate hoist shall have reliable synchronous
devices to guarantee synchronous operation of the two hoisting points.
5.5.4 In order to prevent the chain from touching water during gate hoisting,
chain-withdrawing device shall be set at one end of chain.
5.6.1 Span of mobile gate hoist and lifting height of working platform (dam crest,
tailrace platform) shall be able to satisfy requirements of gate operation and
trash rack.
5.6.2 Operational load and travel load of mobile gate hoist shall be determined
according to concrete conditions.
5.6.3 Generally, control and operation are realized on mobile gate hoist.
5.6.5 According to concrete arrangement, mobile gate hoist with small capacity
can also adopt electric hoist and monorail trolley.
Anti-overturn stability of gate hoist shall be calculated under the worst load
combination according to working conditions listed in Table 5.6.6-2. If moment
of all load and gate hoist to overturn side is equal to or greater than zero
( M 0 ), the gate hoist can be deemed as stable.
Safety of gate hoist against wind and slide shall be verified according to the
following two working conditions:
Pz l 1.1Pw1 + Pa Pf (5.6.7-1)
Where,
Pwl refers to the maximum wind power along running direction under working
state, N;
When braking force Pzl is greater than adhesive force of wheel, Pzl shall be
substituted by adhesive force between wheel and track, and its adhesive
coefficient shall adopt 0.12.
2. Off-working state
Where,
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.
In order to guarantee reliable operation of gate hoist, all sorts of gate hoists
shall be equipped with relevant safety devices.
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.
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.
5.7.4 Buffer
5.7.5 Anemoscope
Exposed mobile gate hoist shall be equipped with anemoscope at upper part of
gate hoist where the wind is not blocked. When wind speed is faster than
limited working wind speed, the anemoscope shall be able to alarm to stop
work and automatically cut off power supply of running mechanism.
Exposed mobile gate hoist shall be equipped with rail clamp. When
off-working-state wind pressure exceeds 700N/m2 or the gate hoist may be
flooded, traction cable or other anchor device must be adopted.
This type of automatic hooking beam is manly used in operation of large and
medium gates. During design, water shall be prevented from enterring
electromotor, oil pump and junction box, and reliability of signal transmitter and
strength of cable shall be guaranteed. Hoisting speed of cable drum shall be in
accordance with the speed of lifting mechanism.
During design of suck kind of hooking beam, running parts and locking devices
controlling the hook shall be considered, so as to prevent failure due to
corrosion, sand and other impurities.
This kind of automatic hooking beam is mainly used to control large and
medium gates. During design, hooking and clamping object shall match with
each other.
1. The gate shall better stop water at upper stream. Where gate stops water at
down stream, safety and reliability of underwater work shall be considered.
4. Relative rotation and sliding parts of automatic hooking beam shall adopt
lubricating and anti-corrosion measures.
6. Load
Different gate hoists may have different load requirements. Load combinations
listed bellow is applicable to gate hoist of different types.
Hoisting load refers to the maximum hoisting force, holding force and
pressure acted on lifting eye connecting gate hoist and gate (or sag rod,
automatic hooking beam).
Running inertia force refers to the inertia force generated by weight of gate
hoist, trolley and running load during start or stop of running mechanism.
Considering structural dynamic effect of gate hoist or trolley during sudden
start or variation of driving force, running inertia force shall be 1.5 times result
of weight multiplying running acceleration, but shall not exceed adhesive force
between driving wheel and track. For acceleration (deceleration), see Annex B.
Impact load of fixed connect of buffer and buffer arresting device shall be
calculated according to impact condition of rated running speed.
2. During calculation of impact load, kinetic energy of hoisting weight will not
be considered for gate hoist whose hoisting weight can swing freely. But
hoisting weight shall be considered for gate hoist having guide frame to limit
hoisting weight from swinging.
1. Exposed mobile gate hoist shall consider wind load. Wind load can be
divided into working-state wind load and off-working-state wind load.
Working-state wind load refers to the maximum calculated wind power that
gate hoist can bear in normal operation. Off-working-state wind load refers to
the maximum calculated wind power that gate hoist can bear under off-working
condition.
Where,
In the above calculation, the worst condition action of wind power on gate hoist
shall be adopted.
q 0.613v2 (6.0.6-2)
Where,
Calculation wind pressure can be divided into three types, such as qI, qII and
qIII. Among these three types, qI refers to calculation wind pressure of gate
hoist under normal working state, and it can be used for drag calculation during
selection of motor power and verification of heat-exerting of mechanical
components; qII refers to the maximum wind pressure in working state, and it
can be used to calculate strength, rigidity and stability of mechanical
components and to verify overload capacity of drive device and anti-overturn
stability of full machine in working state; qIII refers to calculation wind pressure
in off-working state, and it can be used to verify strength and anti-overturn
stability of mechanical components and metallic structure of gate hoist and for
design calculation of wind-prevention and slide-prevent device and anchorage
of gate hoist.
Calculation wind pressures of gate hoist are listed in Table 6.0.6-1. If local
weather data are available, the calculation wind pressure shall be calculated
according to the most-frequent maximum wind speed provided in local weather
data.
4. Altitude variation coefficient of wind pressure Kh
Working state calculation wind pressure of gate hoist shall not consider
variation of altitude (Kh=1). Variation coefficient Kh of wind pressure following
altitude in off-working state shall be calculated according to formula 6.0.6-3
and 6.0.6-4.
Where,
In the calculation, the height can be divided into isotonic wind segment at
every 20m, and then using the coefficient Kh of height of midpoint at each
segment to multiply the calculation wind pressure.
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.
Snow load is only considered at area where there is snow frequently, and its
value shall be determined according to local relevant data.
If gate hoist is movable on track, when installation gradient is not greater than
0.3#, gradient load can not be considered, otherwise, gradient load shall be
calculated according to practical gradient.
When basic intensity of earthquake at area where gate hoist is used is equal to
or greater than 7 degrees, horizontal earthquake load shall be considered.
Before gate hoist is used, dynamic load and static load tests shall be carried
out. The testing field shall be solid and plane, and wind speed shall not exceed
8.3m/s generally. Dynamic test shall adopt 110% of rated load, and static test
shall adopt 125% of rated load. The test shall be carried out to the worst
position of the gate hoist. Where there are special requirements, special
consideration can be taken.
Large mobile gate hoist can also adopt hydraulic dynamometer to carry out the
test. During the test, testing regulations must be established to regulate
load-adding order and methods which shall be observed.
7. Material
7.1.3 Gray pig iron casting shall adopt HTl50, HT200 and HT250 stipulated in
GB/T 9439.
7.1.4 Ductile cast iron shall adopt QT450-10 and QT500-7 stipulated in GB/T
1348.
7.2 Forging
7.2.1 Carbon steel forging shall adopt 20, 25, 35, 45, 50Mn and 65Mn
stipulated in GB/T 699.
7.2.2 Alloy steel forging shall adopt relevant materials stipulated in GB/T 3077.
7.2.3 Stainless steel forging shall adopt relevant material stipulated in JB/ZQ
4295.
7.3.1 Generally, structural metallic material shall adopt 0235 stipulated in GB/T
700 or Q345 stipulated in GB/T 1591.
7.3.3 When temperature at local area where the gate hoist is used is equal to
or lower than -20, Q235D or Q345D shall be adopted.
2. Automatic and semi-automatic welding shall adopt welding wire and welding
flux shall conform to strength of main metal.
7.4.2 Riveting material
Generally, riveting material shall adopt ML2, ML3, Q235 and Q215 stipulated
in GB/T 116i.
7.4.3 Bolting
1. Common bolt
Materials of bolt and stud shall comply with provisions of GB/T 3098.1 and
GB/T 3098.3, and nut material shall comply with provisions of GB/T 3098.2
and GB/T 3098.4.
Materials of stainless steel bolt, screw, stud and nut shall comply with
provisions of GB/T 3098.6.
3. High-strength bolt
Materials of high-strength bolt, nut and washer shall comply with provisions of
GB/T 1231 and GB/T 3633.
8. Mechanism
8.1.1 Electromotor
3. Except for fast gate hoist, mean acceleration of mechanism shall not be less
than 0.3m/s2.
8.1.2 Detent
1. If there is one set drive device and one detent, braking safety coefficient of
the detent shall not be less than 1.75.
2. If there is one drive device and two detents, braking safety coefficient of
each detent shall be calculated according to total braking moment and shall
not be less than 1.25;
3. If there are two sets of drive devices having rigid connection and one detent
is set for each, braking safety coefficient of each detent shall be calculated
according to total braking moment and shall not be less than 1.25.
4. If there are two sets of drive devices having rigid connection and two detents
are set for each, safety coefficient of each detent shall be calculated according
to total braking moment and shall not be less than 1.1.
8.1.3 Decelerator
Ramp resistance refers to the resistance generated during mechanism with full
load travels along a gradient.
8.2.2 Electromotor
8.2.3 Detent
Generally, main drive wheel shall not slip on track during start or braking of
running mechanism. During verification, adherence coefficient between steel
wheel and track shall adopt 0.12 for outdoor work; 0.15 for indoor work; and
0.2-0.258 when there are sands on steel track.
8.3.2 Electromotor
8.2.3 Detent
1. Volume of oil tank shall satisfy working requirements of gate hoist and
storage of hydraulic oil.
2. If electromotor unit of oil pump is arranged on the tope of oil tank, top plate
of the oil tank shall have enough rigidity.
3. Structural design of oil tank shall consider filling and discharging of hydraulic
oil and cleaning of oil tank. Oil pointer shall be set at easily-visible position on
tank wall, and the highest and lowest oil level shall also be marked. Bottom of
the oil tank shall be made into a gradient oblique to oil outlet.
4. Oil suction pipe and oil return pipe shall be as far as possible from each
other and shall be isolated by clapboard. Height of the clapboard shall not be
lower than 3/4 height from the highest oil level to tank bottom. If sieve is set on
the clapboard, the clapboard shall be higher than the highest oil level.
5. Oil suction pipe and oil return pipe shall be inserted lower than the lowest oil
level, and distance from the oil suction pipe to tank bottom shall not be less
than 2 time pipe caliber, and to tank wall shall not be less than 3 time pipe
caliber. The lowest oil level shall be 100mm higher than the oil suction pipe and
shall be larger than 3 times pipe caliber. Distance from oil return pipe to tank
bottom shall be less than 2 times of pipe caliber. Pipe ends shall be obliquely
cut with 45 degree, and oil outlet shall face tank wall.
7. Where oil re-filling tank is set, volume, setting elevation, pipeline joint and
caliber of oil re-filling tank shall be able to guarantee sufficient oil filling at
upper cavity when hydraulic cylinder piston drops.
8. If hydraulic gate hoist is set in cold region and will be operated in winter,
heating device and thermometer are recommended to be set. During operation
of heating device, local overheating of hydraulic oil shall be prevented.
9. Vent with air filter, oil filling orifice with filter screen and magnetic device shall
be set on oil tank.
2) Hydraulic work oil shall have the following characteristics, such as favorable
lubrication, anti-oxidation, corrosion-free, fire resistance, anti-emulsification,
damage-free for sealing material and shall have certain foam-eliminating
capacity.
3) Hydraulic work oil shall be pure and shall not have mechanical impurities
and water. Cleanness of hydraulic oil shall reach class 7-9 of NASl638
standard or class 16/13 - 18/15 of GB/T 14039. Servo system shall be selected
according to requirements of valve block.
2. Dynamic viscosity of work oil shall be selected according to type of oil pump,
working temperature and system pressure, see Table 8.4.5.
3. If hydraulic gate hoist is set in low-temperature region and will be used in all
seasons, when oil cylinder is arranged outdoor and there is no equipment to
heat oil liquid, freezing point of hydraulic oil shall be at least 15 - 20 lower
than the lowest environmental temperature.
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.
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.
Some parts (such as screw rod) shall also go through calculation of rigidity and
stability.
Where,
MIma refers to fatigue calculation basic load moment of calculation part, Nm;
Mn refers to moment transmitted from rated moment of electromotor to
calculation part, Nm
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 0.9s of material.
Where,
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:
Where,
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.
N = FZ (8.5 3)
Where,
2. Quality of material;
4. size of parts;
8.5.7 Abrasion
For parts that are often exposed to abrasion in operation, wearing amount of
the frictional face shall be guaranteed within allowed range. For detent, clutch
and sliding bearing, pressure intensity p on unit area of section and
characteristic coefficient pv (p multiply related speed to frictional surface) shall
be verified, so as to guarantee its wearing amount within allowable value. For
allowable physical quantity of material of frictional surface, see Annex E.
Generally, lifting hook and lifting folk shall adopt high-quality low-carbon killed
steel or low-carbon alloy steel.
Lifting shaft shall adopt high-quality carbon steel or alloy constructional steel.
During design of lifting hook or lifting folk, plane elasticity bent lever method
shall be adopted for calculation. Generally, lifting hook or lifting folk can be
selected according to hoisting force and working class.
Lifting shaft shall consider the worst condition, and its calculation load shall be
the maximum working load and its working state can adopt static load.
1. Generally, steel cable of gate hoist shall adopt galvanized steel cable
(especially in underwater working condition), and linear contact lay steel cable
shall be adopted preferentially. Multiple-wound steel cable is recommended to
adopt metallic-corer steel cable; and mono-wound steel cable that is often
submerged under water is recommended to adopt asbestos-core steel cable.
F0 nS (8.6.2-1)
Where,
n refers to the minimum safety coefficient of steel cable, see Table 8.6.2-1;
S refers to the maximum static working pull of steel cable, N; when lift head is
larger than 50m, weight of steel cable shall also be considered.
The maximum declination angle of steel cable winding in and out from pulley
groove shall not exceed 3.5 degree generally.
Where steel cable is wound in or pulled out from drum, deviation angle of steel
cable from two sides of screw shall not exceed 3.5 degree generally.
For single drum or multiple-wound drum, angle that steel cable deviates from
vertical plane of drum is recommended not to exceed 2 degree.
D0min = ed (8.6.2-2)
Where,
If D1200mm 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.
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.
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.
Where,
d1 refers to interior diameter of shaft, mm; when solid shaft is adopted, d1=0;
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.
8.6.5 Decelerator
8.6.6 Coupling
Mc Mt (8.6.6-1)
Mc nMIImax (8.6.6-2)
Where,
8.6.7 Bearing
Standard value of lifting force and holding force (or downward pressure) shall
be adjusted according to requirement of gate. If necessary, lifting force and
holding force (or downward pressure) can be limited separately.
2. Position control: gate hoist shall have extreme-position limiter, and other
positions (such as filling valve of gate) can be controlled according to concrete
requirements. When gate hoist reaches control position, power supply shall be
cut off automatically or alarm signal shall be given out.
Running mechanism shall be equipped with travel limiter. When big and small
trolley reach extreme positions, power supply shall be cut off automatically and
alarm signal shall be given out.
8.6.10 Buffer
Buffer shall be designed according to impact kinetic energy (see 6.0.5). Buffer
shall be designed according to the maximum impact force generated during
gate hoist runs in rated speed, and strength safety coefficient shall be 1.15
under such condition.
Gate host can adopt spring buffer, rubber buffer and hydraulic buffer. Small
gate hoist adopt spring buffer, but wooden buffer can also be adopted.
1. Wheel material shall adopt 45, 65Mn stipulated in GB/T 699, ZG 340-640
stipulated in GB/T 11352, and ZG35CrMnSi and ZG34CrNiMo stipulated in
JB/ZQ 4297.
2. Generally, diameter of wheel shall not exceed 1.25m. When rated running
load is carried, wheel tread shall be calculated according to fatigue; if
maximum load is lifted, wheel tread shall be calculated according to strength.
For calculation of wheel tread, see Annex G.
3. Medium and small gate hoist shall adopt P-type railway steel track generally,
large gate hoist can adopt QU-type crane-special track. For strength
calculation formula, see Annex G. Track of electric block shall adopt rolled I
bar.
Generally, lift bolt of screw rod gate hoist adopts Q275 stipulated in GB/T 700
and 35 and 45 stipulated in GB/T699.
Load bearing nut shall be made of cast bronze generally. And those having low
relative slip speed can adopt cast iron or ductile cast iron.
1. Lift bolt: slenderness ratio of pressure screw rod 200, tension screw rod
250. Slenderness ratio of important screw rod shall be appropriated
reduced.
Besides tension and pressure, screw rod also bear twisting moment. Screw
rod of oscillating-type screw rod gate hoist also bears bending moment. For
calculation of bending moment, see Annex G.
2. Load-bearing nut: working height H of nut shall be determined according to
allowable bearing stress on screw surface. For relevant calculation, see Annex
G.
Where,
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.
For maximum working pressure and maximum working flow of oil pump, see
Annex H.
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;
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
9.3.3 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
Type Type of stress symbol Buried arc automatic, Buried arc automatic,
of semi-automatic welding semi-automatic welding and
weld and manual welding manual welding using E50
using E43 welding rod welding rod
Q235 Q345
Group Group Group Group Group Group Group
I II III I II III IV
compression [n] 160 150 145 230 220 205 190
Butt tension Buried arch automatic [1] 160 150 145 230 220 205 190
weld welding
Examination of Precise [1] 160 150 145 230 220 205 190
weld quality of method
buried arch Common [1] 135 120 115 200 190 175 165
automatic or method
semi-automatic
manual
welding
Shear [] 95 90 85 165 130 120 110
corner Tension, [t] 115 105 100 160 150 140 130
fillet compression
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;
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
Type of Type of stress symbol Rivet, bolt, pin Steel grade of component
connection steel grade Q235
ML2, Q235, Group I Group II Group III
ML5 35
Rivet Shear [] 135 - - - -
connection Bearing [c] - 320 300 290
(type-I hole) Nail-head pulling [] 85 - - - -
Finished bolt Tension [] 125 - -
(type-I hole) shear [] 125 - -
Common bolt compression [c] 290 275
connection
Common bolt Tension [] 125 - -
connection shear [] 90 - -
compression [c] 190 185
Pin connection Bending [] 150 - -
Shear [] 90 - -
Compression [c] 190 185
Table 9.3.4 (Continue)
Type of Type of stress symbol Rivet, bolt, pin Steel grade of component
connection steel grade
Q345
ML2, Q235, Group I Group Group Group
ML5 35 II III IV
When there is concentrated load on top flange of girder, local pressure stress
of web plate shall be calculated according to formula 9.4.1-1.
Where,
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 , large shear stress and local pressure
stress m on the same calculation position, conversion stress shall also be
verified according to formula 9.4.1-2.
Where,
Where,
Where,
Where,
Z=N/[P] (9.4.3-3)
Where,
Where,
1) For structural component with box section, when ratio of sectional height
and width between two web plates is not greater than 3; or the section can
guarantee lateral stiffness (such as space truss) of structure;
2) Rigid plates are laid on compression flange plate thickly and can resist
against torsion and horizontal displacement;
2. Where bending member fails to comply with the aforesaid conditions, its
whole stability shall be verified. For details, see Annex J.
2) When 70 (60) < (h0/) 160 (135), transverse ribbed stiffeners shall be set
and verification shall be carried out.
3) When 160 (135) < (h0/) 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/) 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/) > 320 (270), calculation shall be carried out according to local
stability requirements of high web plate.
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 y satisfies the
following requirements: For Q235 (b0/y) 60 and for Q345 (b0/y) 50.
Where flange plate is wide, one or more pieces of longitudinal ribbed stiffener
shall be set, to satisfy the aforesaid (b0/y) 60 (50). Stability may not be
calculated when inertia moment Iz3 of longitudinal ribbed stiffeners can satisfy
clause 2 of 9.5.6.
Where,
When web plate has both transverse ribbed stiffener and longitudinal ribbed
stiffener, besides the aforesaid provisions, transverse ribbed stiffener shall also
satisfy:
Izl 3h03 (9.5.6-3)
Where,
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 1.5h03.
Where,
Figure 9.5.6
When transverse or longitudinal ribbed stiffener doesn't adopt batten but adopt
mold steel, the part (whose width is 20) 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.
Where,
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.
Where,
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,
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,
ye Lc/1000 (9.6-6)
Where,
Generally, connection between gantry leg and main girder shall be of rigid
connection, namely rigid leg.
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. Thickness of steel plate and mold steel limb of main bearing structure shall
not be less than 5mm.
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.
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.
2. Butt weld: groove type of butt weld shall comply with provisions of GB/T 985
and GB/T 986.
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
1. In main bearing structure, cup head rivet shall be adopted, and diameter d of
the rivet shall be 13mm - 22mm generally, and sunk rivet is only adopted in
special conditions, but sunk rivet shall be adopted in nail rod tension
connection.
2. Total thickness of rivet steel plate shall not exceed 5d. Where the total
thickness exceeds 5d, bolt connection is recommended to be adopted.
8. Permissible distance from rivet and bolt shall comply with values listed in
Table 9.8.3.
2. Height difference and transverse dislocation of track level at joints shall not
exceed 1mm. Connection joint of trolley track shall not exceed 2mm, and
connection joint of big trolley shall be 1mm - 3mm generally (excepting
temperature joint).
2. When height of working inclined ladder exceeds 10m, the ladder shall be
connected by segments, and rest platform must be set at each connection
part.
4. Firm handrail must be set at landing, working platform and inclined ladder,
and vertical height of handrail shall not be less than 1m. Middle handrail shall
be set at about 450mm to plate, and baffle plate shall be set at place not less
than 70 mm at bottom. If there are limitations, height of handrails on trolley
platform of bridge-type hoist and gantry hoist may be less than 1m.
5. Design of net space size, operation device, display instrument and chair in
cab shall comply with relevant provisions of labor protection and safety.
6. Cab shall have favorable visibility, and tempered glass or other shatter-proof
glass shall better be adopted for the cab.
10. Electrics
10.1 Electromotor
10.3 Resistor
10.3.4 resistor with 4 or less boxes can be stacked up; spacing among boxes
of resistors with over 4 boxes shall not be less than 80mm, and thermal baffle
resistor bracket can be adopted among boxes.
10.3.5 External connection wire of resistor with connectors shall have a nude
part and measures shall be adopted to prevent the nude part from short-circuit.
If resistors are used outdoor, a cover shall be set for heat elimination and rain
proof.
Generally, gate hoist shall be equipped with the following electric protection
devices: short-circuit protection, over-current protection, no-voltage protection,
null-position protection, open-phase protection, position-limit protection,
overload protection, main isolation switch and emergency switch that can cut
main power supply off. If DC transmission system is adopted, field-loss
protection and over-speed protection shall be set.
Gantry, bridge-type and platform-type gate hoist shall also be equipped with
travel protection and channel-mouth switch.
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.
Bending radius of cable laying shall not be less than 10 times external
diameter of cable.
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 40mm40mm4mm. 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.
If power is supplied by cable drum, voltage loss of cable drum shall not belong
to internal voltage loss of gate hoist.
10.8.1 Lighting
If single accumulator is adopted for power supply, voltage shall not exceed 24V,
and supply voltage of portable lighting device shall not exceed 36V.
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.
10.9 Earthing
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.
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.
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
For mobile gate hoist, running speed of trolley shall be 5m/min - 10m/min, and
running speed of big trolley shall be 10m/min - 25m/min.
Horizontal lateral force during oblique running of gate hoist can be proximately
calculated according to the following formula:
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;
B refers to spacing among gate hoists, m; where there are 4 wheels on one
track, B shall adopt spacing among exterior wheel axles; when there are 8
wheels on one track, B shall adopt distance between two central lines of
wheels; if horizontal guide wheel is adopted, B shall adopt horizontal distances
among wheels.
Figure C.1 Position of Trolley of Gate Hoist and Wheel Pressure during
Running
Figure C.2 Relation between and L/B
Annex D (Informative) Calculation Data of Wind Load
Windward area of gate hoist structure and object shall be calculated according
to the worst windward direction, and projection area on plane vertical to wind
direction shall be adopted.
Where,
D.1.2 For two parallel structures with same height and type, wind-shielding
action of the front piece to the back piece shall be considered, and total
windward area A = A1 +A2 (D.2)
Where,
D.1 For 3 pairs n-pieces parallel structures with the same type, same height
and same spacing, under action of longitudinal wind power, overlapping
wind-shielding effect of multiple-pieces structure shall be considered, and total
windward area of structure shall be determined according to the following
formula:
Where,
Figure D.3 Parallel Structure Size Relation of Components with I-shaped Cross
Section
Figure D.5 Size Relation of Component with Box Section and Trapezoidal
Section
G.1 Drum
Where,
refers to thickness of drum wall (for cast iron min12mm, for cast steel
min15mm), mm;
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, Nmm;
Mw refers to bending moment borne by drum, Nmm;
Where,
For sSteel:
Main load of drum shaft with large gear shall include: Smax (maximum pull of
steel cable), Pj (weight of drum and drum shaft), Pc (weight of large gear), Po
(periphery force of large gear) and Pr (radial force of large gear). Pal and Pbl
refer to counter force under action of Smax and Pj. Horizontal bending force,
vertical bending moment and relevant bending stress of each sections can be
calculated separately according to force calculation diagram of drum shaft.
If torque is transferred between drum and large gear through sheet, connection
bolt bears no shear, and only plays as connection effect, see Figure G.2. Shear
force of sheet shall be calculated according to formula G.4:
Where,
M refers to torque transferred by sheet, Nmm;
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:
Steel cable shall be fixed on to the drum by pressure plate, see Figure G.3.
Tension stress of pressure plate bolt shall include tension stress generated by
driving force and tension force generated by bending of bolt caused by friction
between washer and pressure plate.
When a = 3:
If groove of pressure plate is round, tension stress of pressure plate bolt shall
be calculated according to formula G.8:
When a = 4:
If groove of pressure plate is round, tension stress of pressure plate bolt shall
be calculated according to formula G.10:
Where,
(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.
Where,
t refers to spacing among thread, mm;
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.
Where,
(1) Bearing stress of hole wall of lifting plate shall be calculated according to
formula G.18:
Where,
P refers to load borne by one lifting plate, N;
(2) Tension stress on horizontal section of axle hole of lifting plate can be
calculated according to formula G.19:
Where,
(3) Tension stress on vertical cross-section of axle hole of lifting plate can be
calculated according to formula G.20:
Where,
R=B/2, mm
G.3 Wheel Trolley
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.
Where,
Where,
R refers to larger value of curvature radius of wheel tread and track, mm;
Where, meaning of symbols are same with those defined in formula G.23.
G.4 Track
For track under action of strength calculation load Pb of wheel, see Figure G.9.
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,
refers to distance from track neck to track level, mm;
t refers to thickness of track neck, mm.
Where,
c refers to length of cantilever of bottom plate, mm;
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.
Where,
P1 refers to hoisting force, N;
a refers to lifting angle of thread;
f refers to sliding frictional coefficient between screw rod and nut; it is related to
material and processing precision; it shall adopt 0.07-0.15 generally, or
average value 0.12 can be adopted;
Where,
Where,
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.
Where,
P1 refers to hoisting force, N;
d1 refers to interior diameter of thread, mm.
Where,
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;
Where,
P2 refers to closing force, N;
2. Slenderness ratio
Where,
Where,
Meanings of other symbols have same meaning with those defined above.
Note: sand casting material shall adopt small value, and die cast metallic
material shall adopt the bigger one.
Annex H (Informative) Calculation Data for the Hydraulic Gate Hoist
Where,
The maximum working flow of the oil pump can be calculated according to:
Where:
: The maximum working flow of the oil cylinder working at the same
time;
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.
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
The internal diameter (d) of the oil pipe shall meet requirements on the flow
and flow speed. It shall be calculated according to:
Where:
The wall thickness ( ) of the oil pipe shall be calculated according to:
Where:
: Safety factor;
Where,
Frictional resistance, N;
H.4.1 The length (l) of the rod bush shall be 0.8-1.5 times of the diameter of the
piston rod. If it is tilt or horizontally arranged, the larger value shall prevail. The
guide distance (under the full extension state of the piston rod, the distance
from the center of the guide sleeve of the plunger to the center of the rod bush)
of the tilt or horizontally allocated oil cylinder shall be greater than (D/2+H/20),
But shall be no less than three times of the diameter of the piston rod. D is the
diameter of the plunger and H is the journey of the hydraulic cylinder.
H.4.2 The width (b) of the plunger shall be 0.6-1.0 time of the internal diameter
of the oil cylinder.
H.4.3 During the initial selection, the diameter of the piston rod shall be 0.4-0.6
time of the internal diameter of the oil cylinder. Then, the strength calculation
and stability calculation is carried out.
H.5.1 The cylinder wall thickness (d) shall be calculated according to the
moderate thickness of
Where,
safety coefficient
where,
longitudinal stress,
Hoop stress,
The rated pressure in the cylinder.
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
Where,
H.6.1 The calculation of the piston rod with the single-action cylinder installed
on the rigid mount:
H.6.1.1 If there is no lateral displacement for the gate and the piston rod
receives the pull. The tension force can be calculated according to:
H.6.1.2 If the lateral displacement happens to the gate (as shown in Figure
H.2), the piston rod will receive the pull and being moment. The stress of the
piston rod shall be calculated according to:
Where,
Where,
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 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,
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.
Material
1.0 0.9 0.9 0.9 0.9 0.8 0.8 0.8 0.7 0.6 0.6
0 9 7 5 2 9 6 1 5 9 0
1.0 1.0 0.9 0.9 0.9 0.9 0.8 0.8 0.7 0.6 0.5
0 0 8 5 3 0 4 0 4 6 9
Flexibility 110 120 130 140 150 160 170 180 190 200
Material
0.5 0.4 0.4 0.3 0.3 0.2 0.2 0.2 0.2 0.1
2 5 0 6 2 9 6 3 1 9
0.4 0.3 0.3 0.2 0.2 0.2 0.2 0.1 0.1 0.1
3 8 2 8 7 4 1 9 7 5
H.6.3.2 If the gate possible has the lateral displacement, the piston rod will
receive the pull (pressure) and the bending moment, considering the behavior
(Figure H.5) of the protruded oil cylinder of the piston rod. The stress shall be
calculated according to Formula (H.16). The stability shall be calculated
according to Formula (H.17).
Where,
Where,
bending of the piston rod. According to the conditions, the flexibility and
the reduced eccentricity rate ( ) shall be selected according to Table H.4.
Where,
Where,
The reduced length (L0 shall be decided according to Figure H.6 and Formula
(H.20):
If ,
If b>0.4m,
Where,
: The inertia moment of the piston rod and the oil cylinder body
section, mm4;
bending moments on both ends, the conditional flexibility and the relative
eccentricity rate (m) according to the Table H.5.
Where,
The larger value between M1 and M2, the end bending moments.
During the calculation of the K=Mmin/Mmax, the smaller value of the M1 and M2,
end bending moments (absolute value) shall be Mmin and the larger, Mmax.
The calculation of the piston rod of the horizontal type double-acting cylinder:
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). The load diagram
and the bending moment diagram of the piston rod shall refer to Figure H.7.
The bending moment M1 due to the friction in the ear shall be calculated
according to Formula (H.13):
The bending moment M2 due to the friction in the oil cylinder bearing shall be
calculated according to Formula (H.22):
(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
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 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):
both ends, the conditional flexibility ( ) and the relative eccentricity (m) in
Table H5.
H.7 Pollution Class of Dubbing Solid Particles in NAS1638 shall refer to Table
H.7.
Pollution Class of Actuating Medium Actuating Medium Solid Particles for the
Hydraulic Pressure System in GB/T 14039 shall refer to Table H.8.
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:
The gross sectional area of the structure, mm2;
component,
adopt zero,
Wx and Wy refer to resistance moment of section of structural component,
mm3;
that comply with conditions listed clause 1 of 9.5.3 , shall be 1, those that
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 of Q345 Axial Central Compression
Component
Table J.3 Correction Coefficient of Axial Compression Stability of Q235 Steel
Table Correction Coefficient of Axial Compression Stability of Q345 Steel
Table J.5 a Value of I-shaped Section
Table J.6 a Value of Groove Section
When bending component can not comply with condition of clause 1 of 9.5.3,
whole stability of component can be verified according to formula J.1 and J.2;
.
3. This table is only applicable to Q235 steel; when values listed in this table are used in
Values of that are not listed in this table are greater than 3.60.
Where,
K2 and k3 refer to coefficients, and their values shall be selected from Table
J.9 and Table J.10;
When ,
When ,
For double-end simple-supported components having reinforced compression
flange plate and axial-symmetric web plate:
When ,
When ;
Symbols as above.
J.3.1 The calculation on the critical stress of compression stress (1), shearing
strength () and local crushing stress ( ) shall according to Formula J.13,
Formula J.14, and Formula J.15:
Where:
Where:
Thickness of plate, mm
J.3.2 The calculation on the critical combined stress of compression stress (1),
shearing strength () and local crushing stress () shall according to Formula
J.17
Where:
Particular case
While local pressure affect on the fringe of plate, during calculation, the value
Where:
J.3.3 Allowable stress of local stability and the calculation of local stability:
The calculation of allowable stress of local stability base on Formula J.19 or
If , then
2 uniform or
nonuniformity
compression
3 flexion
mainly
caused by Flexion coefficient (No. 1)
pressure while
4 Pure shear
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.
Where:
nsafety factor, set down as 1.5 for I type load and 1.3 for II type load;
qImaginary proportional limit, choose5.
The calculation of partial stability shall base on Formula J.21.
Annex K (Informative Annex) Overload check of motor
Where:
PnMotor rated power while adjusting the load duration factor, kW
PHoisting load, N;
vRaising speed, m/s
Total efficiency of mechanism
mAllowable overload multiples of motor torque while adjusting the load
duration factor (rated value or actual value of technical provision).
K.2
Where:
PgThe gravitation of all motion parts, N
Coefficient of friction drag, see Table 5.6.7
m0Coefficient of slope drag, the roadway laying on reinforced beam or
steel beam set down as 0.001;
PwWind 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,G10.7, G20.8, G30.9,
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.
Where:
G - Mean coefficient of steady-state load, G10.75, G20.80, 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.
Where:
G - Mean coefficient of steady-state load, G10.60, G20.60, The
rating of G see Table N.1 of Annex N;
M1 - The resistance torque of the equivalent ramp caused by inclination,
Nm;
Mw - Equivalent wind resistance torque calculated according to the
calculating wind pressure q1 (see Article 6.6.3); Nm;
The rest symbols are the same with the formula (K.3) in Annex K.
L.1.3 CZ value
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, - Conversion factor, generally take the values stated in Table L.1;
Table L.1 g,
Coefficient g
Winding-type asynchronous motor 0.25 0.5
Where:
C - Inertia increment rate,
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.
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.
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, 25or 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 Working environment temperature
environment operating temperature +25 +30 +35 +40 +45 +50 +55 +60 +65 +70 +75
temperature, of wire core;
+25 +60 1.000 0.926 0.845 0.756 0.655 0.535
+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
+45 +65 1.323 1.225 1.118 1.000 0.866 0.707
+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
Conducting Load Wire core section mm2
wire model continuity 1.5 2.5 4 6 10 16 25 35 50 70 96 120 150
BX, BXR 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
copper 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
core,
rubber
thread
CYYCW, 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
CF, CFR 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
single-core
cable
YC, YCW, 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
CF, CFR 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
three-core
cable
Table P.3 baseline value of current-carrying capacity of conducting wire
Wire Copper core cable Heavy type cabtyre cable Marine cable
core BX, BXR BV, BVR Heating time YC, YCW YC, YCW CF, CFR CF, CFR three-core
section copper core, copper core constant, s single-core cable three-core cable single-core cable cable
mm2 rubber thread plastic wire
Current-carrying capacity A at Current-ca Heati Current-ca Heati Current-ca Heati Current-ca Heati
25 rrying ng rrying ng rrying ng rrying ng
Op Tube-thr Op Tube-thr Op Tube-thr capacity A time capacity A time capacity A time capacity A time
en ough b en ough en ough at 25 const at 25 const at 45 const at 45 const
layi layi layi ant, s ant, s ant, s ant, 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.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".