Safety Systems RUBBER BUFFERS CELLULAR BUFFERS HYDRAULIC BUFFERS. KAT a-E

Transcription

1 Safety Systems RUBBER BUFFERS CELLULAR BUFFERS HYDRAULIC BUFFERS KAT a-E

2 Contents Buffer Basics General... Rubber buffers Programme Cellular buffers Programme Hydraulic buffers Programme Applications... Buffer characteristics... Buffer Projection Possible buffer arrangements... Buffer loads... Energy... Buffer stroke... Max. buffer load... Energy absorption... Deceleration Rubber Buffers Programme 170 s... 5 Quality degrees of the individual materials... 5 Wampfler standard quality... 5 Load diagrams for rubber buffers... 6 Load diagrams for wheel buffers... 7 Load capacity of safety buffers... 7 Rubber buffers with base plate or threaded bolt... 8 Rubber buffers with threaded bolt... 9 Wheel buffers Ramming buffers Conical rubber buffers Hollow rubber buffers Rubber to metal buffers Rubber to metal rails Cellular Buffers Programme 180 General Example of calculation Load diagrams Cellular buffers with base plate Cellular buffers with threaded bolt Lift buffers Hollow buffers Hydraulic Buffers Programme 190 General Operational principle Example of calculation Hydraulic buffers with central flange or foot mounting General Information Questionnaire Overview Safety Systems System design General information Overview of the complete Wampfler Programme

3 Modern production methods, constantly increasing working speeds and increasing demands for ergonomic working environment make greater demands on existing buffer systems. Due to the wide variety of the Buffer Basics Wampfler buffer Programme we can offer a solution for every application. A large standard range of rubber buffers, cellular buffers and hydraulic buffers is the basis for individual solutions. General Special designs are always possible on request. Applications: Travel limitation Energy absorption Elastic installation Damping isolation Soundproofing Rubber buffers Programme 170 Since the rubber buffers are built of a cost effective basic material, our Programme offers an economic solution for most technical requirements. The energy absorption of rubber buffers is limited due to their incompressible material. Applications Bulk handling plants Shipyards Freight terminals Cellular buffers Programme 180 Due to their excellent properties of energy absorption the cellular buffer Programme is a suitable complement to the rubber buffer Programme. Their volume compressibility allows long compression lengths, which allows very good retardation values. Bridge cranes Open-cast mining Shunting installations Hydraulic buffers Programme 190 For extreme requirements on energy absorption, low retardation values and defined load-length curves we recommend our hydraulic buffer Programme. A special throttling system allows individual specification of each application. Container terminals Gantry cranes Storage and retrieval machines Truck ramming buffers Front bumpers Bridge cranes Buffer characteristics The buffer characteristics are shown by the load-length curves. With rubber buffers the form of the curves mainly depend on the shape and the shore hardness of the rubber buffers. With cellular buffers the volumetric density is the decisive factor for their physical behavior. Due to the spring characteristic curve of rubber and cellular buffers (load F depending on the compression length s) the buffer final pressures, which are required for the specification of the neighboring components, can only be taken from the diagrams found by static tests. F s s Rubber buffers Cellular buffers Hydraulic buffers The spring characteristic curves of the hydraulic buffers can be adjusted by the throttling system. F A rectangular characteristic curve is desirable (characteristic factor k = 1.1). F Surface A 1 and A 2 A 1 = Loss of energy (hysteresis) A 2 = Restoring energy A 1 + A 2 = Energy absorbed by the buffer s 2

4 Possible buffer arrangements 1 W 1) 2 W 1) 2 W 1) 4 W 1) Buffer Projection Buffer loads Expansion of the diameter with max. load: Rubber buffer: s = 0.5 h =^ D = 1.4 d Cellular buffer: s = 0.5 h =^ D = 1.25 d s = 0.7 h =^ D = 1.4 d 1) Absorption of the existing energy W perm Buffer loads Arrangement buffer against buffer (cellular buffers): permissible: h 1 + h 2 = < 2 d not permissible:h 1 + h 2 >2 d Impact surface diameter on buffers: D > 1.25 d D = Impact surface d = Buffer diameter Maximum permanent load: s max = 0.15 h The load on the buffers has to be central and perpendicular to the buffer base plate. It is not acceptable to weld on buffers. Fixing screws according to DIN 6912 or DIN Energy W = W kin + W pot The largest wheel pressure at the worst crab position should be considered Free oscillating masses are not taken into consideration Rotating chassis parts have to be considered by calculating a substitution mass Reduced speed v has to be included in the calculation according to DIN v = 100 % v nenn for crabs in general v = 85 % v nenn for cranes in general v = 70 % v nenn for cranes with speed-reducing equipment m A v W 2 A = 2 W pot = F v s W kin = m v 2 2 W kin = m 1 m 2 (v 1 + v 2 ) 2 2 (m 1 + m 2 ) m m Kr A = + m Ka (l - l 1 ) 2 l Mass against obstruction Crane against obstruction Mass against mass Crane against crane Calculation of the buffers for cranes s erf = > k Buffer stroke considering the max. deceleration a zul Max. buffer load F Pmax = k Maximum buffer load a max = k v 2 2 a zul W s v 2 2s Maximum deceleration Buffer stroke Deceleration s erf = > k Buffer stroke considering the max. buffer pressure F zul Energy absorption/h W h = n W Energy absorption per hour a mit = v 2 2s Median deceleration W F zul k = 1 for Elastomer k = > Rectangular characteristic k = > max. oscillation factor according to DIN a mit [m/s 2 ] = Median deceleration a max [m/s 2 ] = Maximum deceleration a zul [m/s 2 ] = Permissible deceleration F Pmax [kn] = Maximum buffer pressure F zul [kn] = Maximum permissible end force k = Characteristic factor l [mm] = Rail centres l 1 [mm] = Distance to the crab center of gravity m [kg] = Mass m 1 [kg] = Mass of body 1 m 2 [kg] = Mass of body 2 m Kr [kg] = Mass of crane m Ka [kg] = Mass of crab m A [kg] = Mass at rail A n = Frequency of impacts per hour s [mm] = Compression length of the buffer s erf [mm] = Required compression length v [m/s] = Speed v 1 [m/s] = Speed body 1 v 2 [m/s] = Speed body 2 v nenn [m/s] = Nominal speed W [J] = Energy W kin [J] = Kinetic energy W A [J] = Kinetic energy at buffer A W h [J] = Energy absorption per hour W max [J] = Max. energy absorption of the buffer W pot [J] = Potential energy 3

5 Rubber buffers Programme 170 Since the rubber buffers are built of a cost effective basic material, our Programme offers an economic solution for most technical requirements. The energy absorption of rubber buffers is limited due to their incompressible material.

6 Natural caoutchouc rubbers are characterised by their very high elasticity and tensile strength. Other qualities are their notch impact resistance and good abrasive resistance. Among all Elastomers these have the highest mechanical and dynamic load capacities. Natural caoutchouc is not resistant to electrolytic liquids, aliphatic, aromatic and chlorinated hydrocarbons. Oil and natural gas are the basic materials for synthetic caoutchouc. For many years this has been a substitute material for natural caoutchouc, but today this synthetic caoutchouc is used increasingly as first choice for many applications. Today there are a wide range of synthetic caoutchoucs, whose properties allow a variety of applications thereby, establishing the use of rubber technology within modern methods. Moreover, rubber is not merely a chemical substance, but a compound of many different materials. The varied mechanical and anti-corrosive Rubber buffers s Quality degrees of the individual materials properties can only be achieved by a recipe of several hundred substances. Caoutchouc as a macromolecular material provides the elastic components of the rubber. The mechanical properties, such as breaking elongation, resilience elasticity, strength and continuous breaking strength are dependent on it. The addition of chemicals and other additives and the subsequent vulcanization process make the material useful. The multitude of additive combinations as well as the many physical forms means that for most problems there is a solution. International abbreviation NR CR SBR EPDM NBR VMQ Chloroprene caoutchouc Styrene Butadiene caoutchouc Ethylene Propylene Terpolymere Nitril Butadiene caoutchouc Natural caoutchouc Silicone caoutchouc Abrasive strength Breaking elongation Tearing resistance Resilience elasticity Tearing strength not reinforced Tearing strength reinforced Temperature stability hot air +90 C +120 C +100 C +150 C +130 C +200 C Temperature stability coldness -50 C -30 C -40 C -40 C -40 C -80 C Resistance to alcali Resistance to aging Resistance to aging Electric insulation resistance Oil and grease resistance Ozone resistance Acid resistance Hot water Quality degrees of the materials properties: 1 = very good, 2 = good, 3 = satisfactory, 4 = adequate, 5 = unsatisfactory, 6 = inadequate Wampfler Standard Quality N-Quality Resilient, resistant to aging Satisfies all standard operating conditions Operating temperature: -30 C bis +70 C Hardness: 70 ± 3 Shore A S-Quality Seawater-, ozone-, weather-, oil-proof, acid resistant to the greatest possible extent Operating temperature: -30 C bis +80 C Hardness: 70 ± 5 Shore A 5

7 Rubber buffers Load diagrams for rubber buffers Determination of the buffer final pressure F and compression length s for the absorption of energy W The diagrams are valid for solid-rubber buffers with h = 0.8 d 1 Example: W = 150 J; Buffer d 1 = 63 mm; h = 50 mm; s = 45% h = mm = 22.5 mm; F = 17.5 kn Energy-length diagram Load F [kn] Energy W [J] Load-length diagram ø ø ø ø ø Buffer sizes d 1 = 40 to 100 [mm] Compression length s in % h Determination of the buffer final pressure F and compression length s for the absorption of energy W The diagrams are valid for solid-rubber buffers with h = 0.8 d 1 Energy-length diagram Load F [kn] Energy W [J] Load-length diagram ø ø ø ø ø Buffer sizes d 1 = 125 to 315 [mm] Compression length s in % h 6

8 Rubber buffers Load diagrams for wheel buffers Energy-length diagram Load F [kn] Energy W [J] Load-length diagram Compression length s [mm] Load capacity of safety buffers If rubber buffers are used as safety buffers with low frequency of load applications, you can calculate with a 50 % higher energy absorption. This results in an increase of the final pressure by approx. 55 % and an extension of the compression length to 57 % h. The expanded diameter D is increased to approx. 1.6 d 1. Example Rubber buffer: ø 50 mm Possible energy absorption: W = J = 150 J Thus max. final pressure: F = kn = 24,8 kn Max. compression length: s = mm = 22,8 mm Expanded diameter: D = mm = 80 mm It is possible with an energy of 100 to 150 J to use a smaller rubber buffer Ø 50 mm instead of the next larger buffer size. 7

9 Rubber: Quality N Rubber: Quality S Rubber buffers With steel base plate Catalogue-No. W max. F Weight d 1 h a d 2 R s [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] x032 1) x040 1) x050 1) ) Conical form, see drawing rubber buffers page 11 Rubber: Quality N or S With strengthened steel base plate (steel mill type) Catalogue-No. W max. F Weight d 1 h a d 2 R s [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] With stainless steel base plate (V2A) Catalogue-No. W max. F Weight d 1 h a d 2 R s [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] With a threaded bolt and steel plate Bolts: Steel, galvanised Rubber: Quality N or S Catalogue-No. W max. F Weight d 1 h d 2 l R s [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] M M M M M M

10 Rubber buffers With two threaded bolts and steel plate Bolts: Steel, galvanised Rubber: Quality N or S Catalogue-No. W max. F Weight d 1 h d 2 e l R s [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] M M M M M With one or two threaded bolts and vulcanized steel plate Base plate: Steel, acid resistant Bolts and nuts: stainless steel (V4A) Rubber: Quality S Construction for size d 1 = mm Construction for size d 1 = mm Catalogue-No. W max. F Weight d 1 h b d 2 e l R [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] x032 1) M x040 1) M x050 1) M M M M M M M ) Conical form, see drawing rubber buffers page 11 9

11 Rubber buffers Wheel buffers with fixing holes Catalogue-No.: x150 Technical details Weight: 0.65 kg Energy W max : 550 J Load F: 50 kn Base plate: Steel Rubber. Quality N or S Wheel buffers with threaded bolt and steel insert Catalogue-No.: x150 Technical details Weight: 0.77 kg Energy W max : 1000 J Load F: 100 kn Base plate: Steel Bolts: Steel, galvanised Rubber: Quality N Ramming buffers with fixing holes and steel inserts Catalogue-No. Weight h l 1 l 2 b 1 b 2 d 1 d 2 a e 1 e 2 e 3 [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] x x x x x x Rubber: Quality N

12 Rubber buffers Conical rubber buffer with threaded bolt Base plate: Steel, galvanised Threaded bolt: Steel, galvanised Rubber: Quality N Catalogue-No. W max F Weight d 1 d 2 d 3 h 1 h 2 l [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] x x x M x x x x x M x x x x x M x x x x x M x x x x x M x x x x x M x x x x x M x x x x x x x M x x x x x x x M x x x x

13 Rubber buffers Conical rubber buffer with fixing holes and steel plate Base plate: Steel, galvanised Rubber: Quality N Catalogue-No. W max F Weight d 1 d 2 d 3 d 4 d 5 h 1 h 2 [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] x x ø x x x x ø x x x x ø x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

14 Rubber buffers Conical rubber buffers with interior thread Base plate: Steel, galvanised Rubber: Quality N Catalogue-No. W max F Weight d 1 d 2 d 3 h 1 h 2 t [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] x x M x x x M x x x x M x x x x x M x x x x x M x x x x x M x x x x x x M x x x x x x x M x x x

15 Hollow rubber buffers Hollow buffers with two interior threads Base plate: Steel, galvanised Catalogue-No./ Weight d 1 h 1 h 2 d 2 d 3 d 4 e s t Code-No. [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] x053/... 1) x063/... 1) M x080/... 1) ) The Catalogue number has to be completed with the code-number. See order example for hollow buffers. Hollow buffers with threaded bolt Base plate: Steel, galvanised Threaded bolt: Steel, galvanised Catalogue-No./ Weight d 1 d 2 d 3 h 1 h 2 h 3 l R Code-No. [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] x040/... 1) x063/... 1) M x080/... 1) x050/... 1) x080/... 1) M x100/... 1) x125/... 1) M ) The Catalogue number has to be completed with the code-number. See order example for hollow buffers. Hollow buffers with fixing hole and steel plate Base plate: Steel, galvanised Threaded bolt: Steel, galvanised Catalogue-No. / Weight d 1 d 2 d 3 h 1 h 2 h 3 R Code-No. [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] x063/... 1) x080/... 1) x080/... 1) x100/... 1) x125/... 1) ø ) The Catalogue number has to be completed with the code-number. See order example for hollow buffers. 14

16 Hollow rubber buffers Hollow buffers with interior thread Base plate: Steel Catalogue-No./ Weight d 1 d 2 d 3 h 1 h 2 h 3 t R Code-No. [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] x063/... 1) M x080/... 1) x080/... 1) M x100/... 1) x125/... 1) M ) The Catalogue number has to be completed with the code-number. See order example for hollow buffers. Order example for hollow buffers Order example for hollow buffers Code-number Rubber- Hardness material Shore A.../514 Natural caoutchouc NR 40.../517 Natural caoutchouc NR 71.../527 Neoprene CR 70 Example of order details x040/517 Code-number Height h 1 [mm] Diameter d 1 [mm] Type The hollow buffers type , and cannot impact against each other. 15

17 Rubber to Metal Buffers Cylindrical buffers Type A; Type B; Type C; Type D; Type E; Selection table: Buffer dimensions Code-No. [ ] d 1 h 1 d 2 l [mm] 1) t [mm] 2) [mm] [mm] [5] [6] [7] [8] [9] [5] ) M M ) M M M M M M M M M M M M M M M M M M M M ) Screw length 2) Thread length 3) Type / not available Selection table: s Base plate and screw: Steel, galvanised Code-No. 1 2 Natural coautchouc NR Neoprene CR Select. table: Shore hardness Code-No. Hardness Shore A x040/615 Selection table: Buffer dimensions Code-No. [ ] d 1 h 1 d 2 l [mm] 1) t [mm] 2) [mm] [mm] [5] [6] [7] [8] [9] [5] M M M M M M M M M M M M M M M M M M M M M Example of order details Code-No. shore hardness Code-No. material Code-No. screw length l [mm], depth of thread t [mm] Height h 1 [mm] Diameter d 1 [mm] Type Minimum order quantities Buffer diameter up to d 1 [mm] Minimum order quantity [Piece]

18 Rubber to Metal Buffers and Rails Bottle neck buffers (special types) All buffers on request. Please note the minimum order quantities on page 16. Type AC; Catalogue-No.: Type BC; Catalogue-No.: Type CC; Catalogue-No.: Parabolic buffers Suction foot buffers Type DP; Catalogue-No.: Type EP; Catalogue-No.: Type DS; Catalogue-No.: Buffers on request. Please note the minimum order quantities on page 16. Rubber to Metal Rails Type ES; Catalogue-No.: Buffers on request. Please note the minimum order quantities on page 16. Type A; Type F; Selection table: Buffer dimensions Code-No. [ ] b h L s [mm] [mm] [mm] [mm] [1] [2] [3] Selection table: Buffer dimensions Code-No. [ ] b h L s [mm] [mm] [mm] [mm] [1] [2] [3] Example of order details x040/XXX Specialtype 01-P ) Hole and L x on customer s request 4 = 40 Shore A; 5 = 55 Shore A; 7 = 70 Shore A 1 = NR natural caoutchouc; 2 = CR Neoprene (only on request) Code-No. metal thickness s [mm] Height h [mm] Width b [mm] Type 17

19 Cellular buffers Programme 180 Due to their excellent properties of energy absorption the cellular buffer Programme is a suitable complement to the rubber buffer Programme. Their volume compressibility allows long compression lengths, which allows very good retardation values.

20 Cellular buffers General Cellular buffers are characterized by high energy absorption with long compression lengths. This results in low final pressures and favorable retardation values. Cellular buffers are made from a cellular Polyurethane Elastomer with high structural resistance. Their principal quality is the volume compressibility, which is responsible for their relatively low transverse expansion during load application. Cellular buffers are resistant to aliphatic hydrocarbons, such as oil and grease, and against ageing. A general resistance can therefore be assumed for technical applications. The cellular body is only partially resistant to hydraulic oil and shows signs of deterioration after long exposure to hot water and water vapor. The cellular buffers are not resistant to strong acids and leaches. The operating temperature is between 20 C and +80 C. Generally special types are only offered and supplied on request. If cellular buffers are mounted over 3 m high they have to be secured by installation of safety ropes. of the cellular body Standard quality Cellular Polyurethane Elastomer with volumetric weight 0.53 g/cm³ Special quality For dynamic load and high elasticity Special volumetric weight 0.35 g/cm³ (soft) to 0.65 g/cm³ (hard) Example of calculation Example of calculation Type of installation: Crane without speed-reducing equipment according to DIN (v = 85% v nenn ) Arrangement of buffers: Buffer against buffer (crane) Buffer against obstruction (crab) Speed: v Kr = 150 m/min (crane) v Ka = 150 m/min (crab) Mass: m Kr = 20 t (crane) m Ka = 4 t (crab) Type of buffer: Cellular buffer 1. Step Moving mass with worst crab position m m Kr A = + m Ka (l - l 1 ) 2 l m A = kg 2 m A = kg kg m A = kg ========== kg ( ) Step Calculation of the kinetic energy and selection of buffers Crane W A = W A = m A v 2 v = 0.85 v nenn = m/s kg (2.125 m/s) 2 2 Crab W = W = m v kg (2.5 m/s) 2 2 W A = J Energy absorption per buffer (2 buffers): W = J Energy absorption per buffer (2 buffers): W buffer = W A 2 = J W buffer = W 2 = 6250 J Chosen: Buffer x315 With W max. = J According to selection table page 21 Chosen: Buffer x300 With Wmax. = 6600 J According to selection table page 21 Type has been chosen, since the buffers are installed at a height of more than 3 m. 19

21 Cellular buffers Load diagrams Determination of the buffer final pressure F and compression length s for the absorption of energy W Example: W = 0.4 kj; Puffer d 1 = 100 mm; h 1 = 100 mm; s = 65% h 1 = mm = 65 mm; F = 21 kn Energy-length diagram Load-length diagram Load F [kn] Energy W [kj] ø ø ø ø ø Buffer sizes d 1 = 80 to 200 [mm] Compression length s in % h Determination of the buffer final pressure F and compression length s for the absorption of energy W Energy-length diagram Load-length diagram Load F [kn] Energy W [kj] ø ø ø ø ø Buffer sizes d 1 = 250 to 600 [mm] Compression length s in % h 20

22 Cellular buffers With base plate Cellular buffer without safety rope Cellular buffer with safety rope Catalogue-No. W max F Weight d 1 h 1 a d 2 e h 2 s [J] [kn] [kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x / x X-XXXxXXX Example of order details Height h 1 [mm] Diameter d 1 [mm] 1 = without safety rope; 2 = with safety rope Programme Cellular body: Cellular Polyurethane Elastomer with high structural strength Base plate: Steel, undercoated, black Safety rope device: Steel rope, galvanised If cellular buffers are mounted over 3 m high, they have to be secured by the installation of safety ropes, type

23 Cellular buffers With threaded bolt and foamed steel plate Cellular body: Cellular Polyurethane Elastomer with high structural strength Bolt: Steel, galvanised Catalogue-No. W max F Weight d 1 h 1 d 2 h 2 l [J] [kn] [kg] [mm] [mm] [mm] [mm] x x M x x x M x x x M x x x M x x x M x x x M x x x M x x x M x Lift buffers with steel plate Application For the limitation of lift cabins and counter weight Calculation according to DIN-EN 81 Catalogue-No. Weight d 1 h 1 s [kg] [mm] [mm] [mm] x x x x x x x x x x Spring body: Cellular Polyurethane Elastomer with high structural strength Base plate: Steel 22

24 Cellular buffers Hollow buffers Catalogue-No. d 1 h d 2 [mm] [mm] [mm] x x x x x x x x x x x x x x x x x x x x Cellular Vulcolan Load values at 40 % deformation (only theoretical values) Volumetric density [kg/dm 3 ] Pressure [ M P a ] Vulcolan hollow buffer made of compact Vulcolan on request. 23

25 Hydraulic buffers Programme 190 For extreme requirements on energy absorption, low retardation values and defined loadlength curves we recommend our hydraulic buffer Programme. A special throttling system allows individual specification of each application.

26 Hydraulic buffers minimize the dynamic load of systems during the moment of the buffer impact. They are used anywhere, where reliability, operational security and availability are important factors. The system of throttling allows precise buffer pressures and optimum load-length characteristic curves. Undesirable energy peaks are avoided, masses to be slowed down are decelerated evenly and the kinetic energy is reduced linearly. Due to the closed, hydro-pneumatic system any installation position of the hydraulic buffers is possible. In addition the closed Piston diameter: 50, 63, 80, 100, 125, 160 mm Stroke lengths possible from mm (gradation 50 mm) Special strokes possible on inquiry Operating temperature: -30 C to +70 C Higher temperatures possible on inquiry Impact speed: 0.5 m/s to 5 m/s General Technical details Hydraulic buffers system protects the throttling system from tampering and so from modification of the defined characteristic curves. Applications for hydraulic buffers are anywhere, where moving masses have to be decelerated reliably. Fixing options: Central flange, foot mounted Colour: Standard RAL 1012, lemon yellow, layer thickness 80 µm Special colours available on request Piston rod chromium plated Layer thickness 40 µm Maintenance: low maintenance, interval approx. 5 years Operational principle Hollow piston rod 2. Gas volume 3. Separating piston 4. Throttle tube 5. Cylindrical tube 6. Hydraulic oil The basic principle of the hydraulic buffer construction mainly consists of two factors: Separation of oil and gas volume by means of the movable separating piston Flow of the hydraulic oil through the throttling system During buffer impact the hydraulic oil (6) is pressed through the throttle holes of the throttle tube (4) whose size and quantity are designed. The consequence of this throttling is the transformation of kinetic energy into heat energy. The hydraulic oil (6) now flows into the trunk piston bar (3), which is sealed by the separating piston (1) and compresses the enclosed gas volume (2). After release of the hydraulic buffer the compressed gas volume expands and presses the oil back into the cylindrical tube (5). The piston bar returns into its normal position. Example of calculation Details Mass: m = 50 t Nominal speed: v = 1.2 m/s Max. permissible deceleration: a zul = 3.5 m/s² Number of buffers per trolley: n = 1 piece Energy W [kj] Calculation of the existing energy W = 1/2 m v² W = 1/ kg (1.2 m/s)² W = Nm W = 36 kj Calculation of the required compression length s v 2 erf = k 2 a zul (1.2 m/s) s 2 erf = m/s 2 s erf = m ( chosen 250 mm) Intersection diagram: W = 36 kj; f = 250 mm; Buffer ø 80 mm Catalogue-No.: x250 Hoist length s [mm] 25

27 Hydraulic buffers With central flange or foot mounting Order code for order details 0190 XX-XXX x XXXX Stroke length [mm] Piston diameter [mm] 00 = central flange 10 = foot mounted Programme Piston Stroke d 1 d 2 d 3 d 4 d 5 l 1 l 2 l 3 l 4 a ø s [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] Hydraulic buffer with central flange Hydraulic buffer with foot mounting

28 Hydraulic buffers With central flange or foot mounting Example hydraulic buffer with foot mounting Piston-ø 63 mm, stroke length 300 mm x 0300 Stroke length [mm] Piston diameter [mm] 00 = central flange 10 = foot mounted Programme Piston Stroke Max. energy absorption Max. buffer Static restoring energies Max. angular deflection 3) Weight ø s per stroke 1) per hour 2) pressure Start of stroke End of stroke approx. [mm] [mm] [kj/stroke] [kj/h] [kn] [kn] [kn] [º] [º] [kg] ) Referred to characteristic factor 1.1 2) For ambient temperature +30 C 3) For max. buffer pressure 27

29 Hydraulic buffers With central flange or foot mounting Order code for order details 0190 XX-XXX x XXXX Stroke length [mm] Piston diameter [mm] 00 = central flange 10 = foot mounted Programme Hydraulic buffer with central flange Piston Stroke d 1 d 2 d 3 d 4 d 5 l 1 l 2 l 3 l 4 a ø s [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] Hydraulic buffer with foot mounting

30 Hydraulic buffers With central flange or foot mounting Example hydraulic buffer with central flange Piston-ø 100 mm, Stroke length 400 mm x 0400 Stroke length [mm] Piston diameter [mm] 00 = central flange 10 = foot mounted Programme Piston Stroke Max. energy absorption Max. buffer Static restoring energies Max. angular deflection 3) Weight ø s per stroke 1) per hour 2) pressure Start of stroke End of stroke approx. [mm] [mm] [kj/stroke] [kj/h] [kn] [kn] [kn] [º] [º] [kg] ) Referred to characteristic factor 1.1 2) For ambient temperature +30 C 3) For max. buffer pressure 29

31 Questionnaire For the calculation of buffers Please fill in this questionnaire very carefully, so that we will be able to work out a firm offer. If you have any questions please call our experts. Type of buffer Type of load Rubber buffer Cellular buffer Hydraulic buffer Mass horizontally against obstruction: Mass horizontally against mass horizontally: Mass driven against obstruction: F m, v m 1, v 1 m 2, v 2 m, v Mass vertically (free fall): m h Special case: Technical parameters Mass: [kg] Force: [N] Speed: [m/s] Height of fall: [m] Energy: [J] Max. permissible final pressure: [N] Max. permissible deceleration: [m/s 2 ] Operating temperature: [ºC] Ambient temperature: Others: Arrangement of the buffers Mounting for rubber buffers 1 W 2 W 2 W Several buffers: piece 4 W Base plate with 4 hoes 2 threaded bolt Mounting for rubber and cellular buffers Hollow Base plate with 4 hoes 1 threaded bolt Mounting for hydraulic buffers 1 interior thread 2 interior thread With central flange With foot mounting 1 interior thread 1 threaded bolt Threaded bolt on both sides Please send the offer to the following address: Company: Customer-number: Dep./attention: Address: Telephone: Telefax: Wampfler AG Rheinstrasse D Weil am Rhein-Maerkt Phone +49 (0) Fax +49 (0) info@wampfler.com FB E

32 Overview Safety Systems Safety switch strips For the protection of shearing and punching spots for indoor and outdoor use Cable connection can be adjusted by the customer after installation EC-construction approved / safety category 3 according to EN Forced-separating redundant safety contact chain for the direct integration into the control circuit Safety bumpers To prevent collision and for the protection of persons on hangar gates, RGU s, hoist units, moving trolleys, special machines etc. Recognition of collision early due to an active 360 safety contact chain within the collision surfaces Sturdy construction for indoor and outdoor use Direct integration into the safety circuit without control unit EC-construction approved / category 3 according to EN Pressure sensitive mates Safety element for the protection of risk areas even under ardvous conditions Sturdy construction IP 65/IP 67 EC-construction approved / category 3 according to EN Single mats up to 1.5 x 3 m with rectangular surface or as requested Can also be placed on grates or expanded metal Signal transmission systems Spiral cable and small chain systems for protected signal cable transmission Compact, sturdy construction for easy assembly Travel distance up to 23.5 m Can be operated horizontally and vertically Buffer Application on machines, cranes, vehicles, hoists As safety buffers or impact element Rubber buffers Cellular buffers Hydraulic buffers System Design Safety and availability of your systems are the key elements of our safety concepts. We are pleased to help you with our experience from risk analysis up to the testing and commissionary. Development of special safety concepts Coordination and support for the approval by BG and authorized offices Training and advice Safety components according to customers requirements General Information We reserve the right to carry out modifications to the product in the course of technical development any time without prior notice. Please note our general terms of business. We will send them to you on request. Reprint, even in parts, is only permitted with our approval. 31

33 Full-Liner worldwide! Right round the globe, our numerous subsidiary companies and agents and our 500 staff members are ready to meet your most demanding requirements. We work in close cooperation with our customers to develop very special solutions, researching new areas of technology and turning them into futureoriented products. To help you reach your targets, we offer you innovative technology with the highest quality, combined with a service that starts with consultation, and doesn t stop after installation. Our worldwide marketing and communication network ensures a fast and rapid response. All our expertise is at your disposal, wherever you need it. Handling Systems Equipment carriers, tool transporters, handoperated overhead conveyor systems, jib booms, turntables, underslung cranes, cable winders, hose winders, balancers, electrical and pneumatic accessories, workbenches. Safety Systems Switch strips, bumpers, spiral cable systems, enclosed small chain systems, sensitive pressure mats, rubber buffers, cellular buffers, hydraulic buffers, damping elements, rubber to metal hoist units. Energy Supply Systems Cable trolley systems, energy guiding chains, flat cables, round cables, hoses, conductor bar systems, spring-loaded and motor-driven cable reels, slip ring bodies. 32