Wire rope hoists Standard
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1 Wire rope hoist
2 Wire rope hoists Standard Type Rope hoist SH Rope hoist AS70 Winch SHW8 /SW Max. capacity 25 t 125 t 160t/250t STAHL CraneSystems GmbH I Training Centre I 2
3 Wire rope hoist Type SH up to 25 t SHR 6 SH 6 SH 3 SH 4 SH 5 STAHL CraneSystems GmbH I Training Centre I 3
4 Wire rope hoist SH Platform STAHL CraneSystems GmbH I Training Centre I 4
5 Classification Basic information FEM (Federation of European Material Handling Industry, Manufacturers' Association): - The mechanism group in accordance with FEM is an important design criteria for hoists - Hoists with identical reeving and S.W.L. may be classified differently - The FEM classification correlates to a defined lifetime in full load hours - FEM groups correspond to ISO groups The FEM classification is laid down for: Rope drive: FEM Mechanism: FEM Motors: FEM Classification FEM ISO Full load operating hours 5m M8 12,500 h 4m M h 3m M h 2m M h 1Am M4 800 h 1Bm M3 400 h 1Cm M2 200 h STAHL CraneSystems GmbH I Training Centre I 5
6 Classification Wire rope hoists in 1Am and 3m Hoist model SH /1 L2 KE SH /1 L2 KE S.W.L. Height of lift Reeving Hoisting speed 6,300 kg 6 m 4 / / 1.0 m/min 6,300 kg 6 m 4 / / 1.0 m/min FEM classification 1Am 3m Duty cycle of hoist motor Switching operations/hour Deadweight Headroom C 40 / 20% DC 180 / 360 s / h 370 kg 490 mm 50 / 20 % DC 240 / 480 s / h 755 kg 555 mm Hook size RSN 2.5 RSN 4 Rope Rope safety factor 9.0 mm 4 : mm ~ 8:1 Drum Rope sheave 167 mm 160 mm 219 mm 225 mm Wheel 100 mm 140 mm STAHL CraneSystems GmbH I Training Centre I 6
7 Wire rope hoist SH Gear STAHL CraneSystems GmbH I Training Centre I 7
8 Wire rope hoist SH Gear All bearings and gearing is oil lubricated: life time lubrication Gearing with high hardened flanks Low noise emission SH 3 SH 5 enclosed housing SH 6 split housing STAHL CraneSystems GmbH I Training Centre I 8
9 Wire rope hoist SH Motor STAHL CraneSystems GmbH I Training Centre I 9
10 Wire rope hoist SH Motor Dual speed hoist motor SH rope hoist: 2 windings (12/2-poled / 24/4-poled) Standard protection class IP55 Motor rating up to 38kW standard PTC temperature control standard STAHL CraneSystems GmbH I Training Centre I 10
11 Wire rope hoist SH Brake Two side magnetic brake Asbestos free Over dimensioned Low-maintenance, no re-adjustment STAHL CraneSystems GmbH I Training Centre I 11
12 Wire rope hoist SH Rope guide STAHL CraneSystems GmbH I Training Centre I 12
13 Wire rope hoist SH Rope guide Enclosed rope guide No over winding or slack rope Cause of the solid material GGG 40 (GJS400-15) robust and low-wear No temperature limitation Principle in fourth generation (type C, N, AS, SH) Reliable cause of the 360 clamping SH6 SH3 SH5 STAHL CraneSystems GmbH I Training Centre I 13
14 Wire rope hoist Type AS up to 125 t STAHL CraneSystems GmbH I Training Centre I 14
15 Wire rope hoist AS Gear All bearings and gearing is oil lubricated: Life time lubrication Gearing with high hardened flanks Low noise emission SH 6 / AS 7 split housing STAHL CraneSystems GmbH I Training Centre I 15
16 Wire rope hoist AS Motor Dual speed hoist motor SH rope hoist: 2 windings (12/2-poled / 24/4-poled) Standard protection class IP55 Motor rating up to 38kW standard PTC temperature control standard STAHL CraneSystems GmbH I Training Centre I 16
17 Wire rope hoist AS Rope guide STAHL CraneSystems GmbH I Training Centre I 17
18 Wire rope hoist AS Rope guide Enclosed rope guide No over winding or slack rope Cause of the solid material GJS robust and low-wear No temperature limitation Reliable cause of the 360 clamping STAHL CraneSystems GmbH I Training Centre I 18
19 Wire Rope hoist Winch SHW 8 / SW STAHL CraneSystems GmbH I Training Centre I 19
20 Wire rope hoist The following parts are used on the wire rope hoists. STAHL CraneSystems GmbH I Training Centre I 20
21 Rope hoist components Panel STAHL CraneSystems GmbH I Training Centre I 21
22 Rope hoist components Panel / main contactor Contactors: Brand Siemens or Telemecanique Main contactor (switched through emergency button in pendant) STAHL CraneSystems GmbH I Training Centre I 22
23 Rope hoist components Panel / contactors Contactors: Travel Hoist STAHL CraneSystems GmbH I Training Centre I 23
24 Rope hoist components Panel / transformer Control voltages 42, 48, 230 Volt, optional 110 V or 24 V DC STAHL CraneSystems GmbH I Training Centre I 24
25 Rope hoist components Panel / Bridges For the yearly inspection of the Emergency end limit switch S260: Drive into the Emergency stop. S261: Drive back out of the Emergency stop. STAHL CraneSystems GmbH I Training Centre I 25
26 Rope hoist components Panel / rectifier Brake rectifier STAHL CraneSystems GmbH I Training Centre I 26
27 Rope hoist components Panel / rectifier The direct current of the brake is wired via terminals On the one hand this prevents the brake coil being charged by feedback from the motor and thus prevented from closing, on the other hand the brake closes faster Terminals are the connections for the brake coil The over excitation (over voltage) time for outputs (brake coil) is determined by the resistor between terminals This ensures that the brake is fed double voltage for a short time ( sec) when the control pendant is activated and thus opens faster. This is particularly necessary for large brakes from H62 upwards. These two terminals are not available on smaller brakes. STAHL CraneSystems GmbH I Training Centre I 27
28 Rope hoist components Panel / rectifier Slow Example: Hoist motor operating voltage: 400V 400V : 1.73 = 231V Fast 1N = U 3 2N = U 3 STAHL CraneSystems GmbH I Training Centre I 28
29 Rope hoist components Panel / gear limit switch Hoisting limiting device: Gear limit switch STAHL CraneSystems GmbH I Training Centre I 29
30 Rope hoist components Panel / gear limit switch Gear limit switch: The old standard for the hoist limit switch, was only an emergency limit switch, for up and down, that means two switches. STAHL CraneSystems GmbH I Training Centre I 30
31 Rope hoist components Panel / gear limit switch Gear limit switch: The option was operational hoist limit switch, that means a operational limit switch for up and down and an emergency limit switch for up and down, so four switches. STAHL CraneSystems GmbH I Training Centre I 31
32 Rope hoist components Panel / gear limit switch Gear limit switch: The new standard is, an operational hoist limit switch with four switches. But function of the switches is now different compare to the old one. STAHL CraneSystems GmbH I Training Centre I 32
33 Rope hoist components Panel / SLE3 / 22 Condition monitoring system: STAHL CraneSystems GmbH I Training Centre I 33
34 Rope hoist components Panel / SLE3 / SLE 22 Function: - Operation with dual channel load sensor 4-20 ma - Motor management - adjusted via motor allocation table - Operating hours counter - Load cut-off - adjustable by switches - Temperature-control for hoist and travel motors - Crane test by means of test button - Integrated function control (displayed by LED) - Control of motor contactors only in economy connection - Option relay programmable for special functions SLE 3 Options relay output signal programmable to 95% of the nominal load. STAHL CraneSystems GmbH I Training Centre I 34
35 schwarz orange braun rot Rope hoist components Panel / SLE3 / SLE 22 safety category 2 for load monitor LCD1 Load sensor with two channel SLE3 24 V 15 V STAHL CraneSystems GmbH I Training Centre I 35
36 SLE 22 Crane test Operating hours counter Error display Motor code (motor allocation table) Cut-off point rough Cut-off point fine STAHL CraneSystems GmbH I Training Centre I 36
37 Rope hoist components Panel / SLE3 / SLE 22 Motor managment Disabling time: When activation of the hoisting motion has been completed (creep hoist / main hoist) the disabling time is started and until this has expired no start signal for the same hoisting speed is accepted (prevention of inching operation) Change of direction: During the disabling time the hoisting motion is braked via creep hoist, stopped, then the hoist travels in the new direction in creep speed for a certain time and then changes to main speed if selected. All times depend on the motor type and are assigned automatically after selecting a motor code at the SLE21 STAHL CraneSystems GmbH I Training Centre I 37
38 Rope hoist components Panel - option Optional to SLE22 the SMC22 Special features of the SMC: - Permanent overload protection by automatic load control (ALC) - Load spectrum recorder for load depended summation for operating time. - Temperature controlled (lift and drive) - Registration of operating data, for example operating hours, motor switching's and load cycles - Elimination of inching operation - Slack rope cut off (for example lifting beam) - optional connection of signal transmitter, load display - Data interchange with PC, either RS232 or USB - Activation of the crane-test, via button or the PC-Software STAHL CraneSystems GmbH I Training Centre I 38
39 Rope hoist components Panel / SLE3 / 22 Motor Type S1 S3 t L [ms] t S [ms] t R [ms] t A [ms] t b [ms] Unknown /2H /2H /2H /2H /2H t L : delay times to slow speed t S : delay times to fast speed t R : delay for change of direction t A : starting time over the slow speed t B : braking time over the slow speed 12/2H /2H91 12/2H Ex-Motor A-xxx A Frequency converter F STAHL CraneSystems GmbH I Training Centre I 39
40 Wire rope hoist component Overload protection Per EU machine directive, a load limiter is required for hoists with capacities over kg STAHL CraneSystems GmbH I Training Centre I 40
41 Wire rope hoist component Overload protection / sensors There are three different types of sensors which are used for the standard overload protection: Compressive forced sensor LCD 1 (LET 1)* sensor, used for several falls at SH hoists and AS hoists (since 2013) Shear forced sensor LSD (LEI)* sensor, used for single fall at SH LBD 1, 2, 3 (LET 8* / LET 9*) sensors used at the SHW8 LBD 3 (Load Bear Dualsensor) used for 6/1 AS Displacement sensor LGD (LAS)* sensor, used for AS7 hoists *one channel STAHL CraneSystems GmbH I Training Centre I 41
42 Wire rope hoist component Overload protection / Compressive force sensor Overload protection standard SH wire rope hoist with LCD 1 Sensor Functionality: - The rope is reeved into the rope lock. As soon as the load pulls the rope lock, the arm gets pulled down and puts pressure on to the sensor. Load STAHL CraneSystems GmbH I Training Centre I 42
43 Seilzug Komponenten AS7 Lasterfassung AS(R)7 wird mit folgender Lasterfassung ausgestattet: Einscherung 2/1, 4/1, 4/2-1, 8/2-1 -> dualer Drucksensor LCD STAHL CraneSystems GmbH I Training Centre I 43
44 Wire rope hoist component Overload protection / Compressive forced sensor Standard Sensor LCD 1 cut through the middle STAHL CraneSystems GmbH I Training Centre I 44
45 Wire rope hoist component Overload protection / Compressive forced sensor Standard sensor LCD 1, functionality 15 Volt 24 Volt 2 DMS (strain gauge) + resistors U I 4 20 ma STAHL CraneSystems GmbH I Training Centre I 45
46 Wire rope hoist component Overload protection / Compressive forced sensor Mounting position STAHL CraneSystems GmbH I Training Centre I 46
47 Wire rope hoist component Overload protection / Shear forced sensor Overload protection standard SH wire rope hoist with LSD Sensor Functionality: - The gearbox is overhung mounted to the frame - As soon as the load is on the hook, the gearbox tries to turn around, but the sensor looms into the frame, so the gearbox pushes the sensor against the frame and measures the load. STAHL CraneSystems GmbH I Training Centre I 47
48 Wire rope hoist component Overload protection / Shear force sensor AS7 will be equipped with: Reeving 6/1 -> Dual shear force Sensor LBD STAHL CraneSystems GmbH I Training Centre I 48
49 Wire rope hoist component Overload protection / Shear forced sensor The sensor LSD has the same principal function as the LCD 1 STAHL CraneSystems GmbH I Training Centre I 49
50 Wire rope hoist component Overload protection / Shear forced sensor Standard sensor LSD, functionality 15 Volt 24 Volt DMS (strain gauge) + resistors U I 4 20 ma STAHL CraneSystems GmbH I Training Centre I 50
51 Wire rope hoist component Overload protection / Displacement sensor - As soon as there is load on the hook, the gear is moving because of its helical gearing, away from the sensor. - The movment of the sensor can be measured in ma. Rope drum Gearbox Gear sensor Load Pretension force Moving force STAHL CraneSystems GmbH I Training Centre I 52
52 Wire rope hoist component Overload protection / Displacement sensor Chip Sensor housing Magnet Spring STAHL CraneSystems GmbH I Training Centre I 53
53 Wire rope hoist component Overload protection / Displacement sensor Function The spring pushes against the brass plate in the Gearbox Magnet Sensor F V ma U N S STAHL CraneSystems GmbH I Training Centre I 54
54 Wire rope hoist component Overload protection / Displacement sensor Mounting position STAHL CraneSystems GmbH I Training Centre I 55
55 Wire rope hoist component Control Pendant controlled Standard pendant type STH (made by Telemecanique) Operator has to move with the crane Max. crane speed 63 m/min with pendant controls (BGV D6 17) Pendant mounting position: Mobile along crane bridge Standard features: Strain release cable Emergency-off button STAHL CraneSystems GmbH I Training Centre I 56
56 Wire rope hoist component Control Pendant station types Standard pendant STH - Two-step buttons - Up to 3 drives can be controlled by single pendant - Plug connection Options - Warning light - Key switch - Horn switch - Selector switch I, I+II, II - Other buttons STAHL CraneSystems GmbH I Training Centre I 57
57 Wire rope hoist component Control radio transmitter types quadrix Most compact transmitter Dead weight 330 g Two step push buttons On-button Rechargeable battery micron 6 Industry standard Dead weight 450 g Two-step push buttons Key switch Emergency-off button Selector switch I, II, I+II Changeable batteries LC-Display can retrieve data from crane electronics spectrum Comprehensive options Dead weight g Joystick control Changeable batteries LC-Display can retrieve data from crane electronics STAHL CraneSystems GmbH I Training Centre I 58
58 Wire rope General Structural design of a steel wire rope: A steel wire rope is made up with a large number of steel wires (1).They are twisted together to strands (2a,2b). Some types of rope have also plastic inserts (4). STAHL CraneSystems GmbH I Training Centre I 59
59 Wire rope Basic definitions Direction of lay: The direction of lay of the rope, is the direction of the helical line of the outer strands. There is right-handed and left-handed rope. Right-handed (Z) Left-handed (S) STAHL CraneSystems GmbH I Training Centre I 60
60 Wire rope Basic definitions Direction of lay: Not only the rope has a direction of lay, the strands do also. Ordinary (cross) lay: Long lay: Right-handed Left-handed Right-handed Left-handed sz zs zz ss STAHL CraneSystems GmbH I Training Centre I 61
61 Wire rope Ordinary and long lay ropes Ordinary (cross lay) rope: In most cases a ordinary rope suits better than a long lay rope. With ordinary ropes you can see broken wires generally earlier than on a long lay rope. That means more safety, because only if you see the broken wires you know when to change the rope before it gets dangerous. Long lay rope: The over lay rate in the rope groove is better than on ordinary ropes, that s the reason why the use of long lay ropes is preferred in places where you have a very high dead load. The most cases where they are used is for multilayer spin, because the outer wires can t catch the other rope liner, and so it doesn t get damaged. STAHL CraneSystems GmbH I Training Centre I 62
62 Wire rope Rotation resistant rope Rotation resistant rope: A rotation resistant rope under tension will turn minimal around it s own axis. That means I need a rope swivelling anchorage point for multiple reeving. Swivel When do I use a rotation resistant rope? Opposite torque moments in a none-rotating rope - Lifting an unguided load on a single fall - Lifting an unguided load on several falls at a great lifting height STAHL CraneSystems GmbH I Training Centre I 63
63 Wire rope Non-rotation resistant rope Standard rope: A non-rotation resistant rope under tension tries to rotate around it s own axis. That means I need a fixed anchorage point. When do I use a none-rotation resistant rope? - Lifting a guided load. - Lifting an unguided load on several falls at a small lifting height. - Lifting loads with right-handed and left-handed ropes operating in pairs. STAHL CraneSystems GmbH I Training Centre I 64
64 Wire rope Summary: Rotation resistant, none-rotation resistant Rotation resistant Non-rotation resistant Rotation resistant Non-rotation resistant STAHL CraneSystems GmbH I Training Centre I 65
65 Wire rope Summary: Rotation resistant, non-rotation resistant Why don t we always use a rotation resistant rope? Rotation resistant rope have a few disadvantages: - higher price - shorter lifetime - with a guided load, the rope can t really settle, so it will break earlier - it is very difficult to check the wear - the allowed deflection angle is only 1,5 (none-rotation resistant rope 3,5 ) We only use a rotation resistant rope only if we need it. STAHL CraneSystems GmbH I Training Centre I 66
66 Rope worn rope Broken wires: Broken wires are the main reason that a rope must be changed. Broken strands: If the full strand is broken, the rope has to be change immediately. Reduction of the diameter: As soon as the rope diameter is less than 10 % from the new rope, the rope has to be changed. STAHL CraneSystems GmbH I Training Centre I 67
67 Rope deformation Corkscrew: If the measurement x is 1/3 of the diameter, the rope must be changed. x Bird caging: It s caused by twisting the rope, the become longer than the rope. STAHL CraneSystems GmbH I Training Centre I 68
68 Seil Ablegereife Formation of loops: If looping is visible as on the picture, change the rope imedately. Flatness, kinks: With permanent deformations the rope must be changed. STAHL CraneSystems GmbH I Training Centre I 69
69 Seil Ablegereife Tightened kink: Formed if a loop sling was applied to tighten it. Rope bend: A rope bend is formed if the rope is pulled over a sharp edge. STAHL CraneSystems GmbH I Training Centre I 70
70 Rope hoist trolley Stationary Type Lifting capacity up to (kg) Standard- Reeving Reeving for true vertical lift Stationary SH /1, 2/2-1, SH /1, 4/2-1 4/1 SH SHR SH /1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 AS /1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 SHW /2-1, 8/2-1, 12/2-1 Standard Option Different possibilities for crane builders or manufactures STAHL CraneSystems GmbH I Training Centre I 71
71 Rope hoist trolley OE Type Lifting capacity up to (kg) Standard- Reeving SH /1, Reeving for true vertical lift 2/2-1, Double girder crab OE SH /1, 4/2-1 SH /1 SHR SH /1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 AS /1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 SHW /2-1, 8/2-1, 12/2-1 Standard Option STAHL CraneSystems GmbH I Training Centre I 72
72 Rope hoist trolley OE Hoist installed on top of bridge girders, thus best usage of available height Typically used for capacities > 5 ton Total headroom from top of crane to hook is equal to total headroom of trolley. Overall headroom is independent from height of crane girders. STAHL CraneSystems GmbH I Training Centre I 73
73 Rope hoist trolley KE Type Lifting capacity up to (kg) Standard- Reeving Reeving for true vertical lift Mono rail trolley KE SH /1, 2/2-1, SH 4 SH /1, 4/1 4/2-1 SHR SH /1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 AS /1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 SHW /2-1, 8/2-1, 12/2-1 Standard Option STAHL CraneSystems GmbH I Training Centre I 74
74 Rope hoist trolley KE Available up to 16 ton Most economical solution for cranes up to 10/16 t Crane headroom = hoist headroom + bridge girder height Headroom depends on flange width of bridge STAHL CraneSystems GmbH I Training Centre I 75
75 Rope hoist trolley UE Type Lifting capacity up to (kg) Standard- Reeving Reeving for true vertical lift Mono rail trolley UE SH /1, 2/2-1, SH 4 SH /1, 4/1 4/2-1 SHR SH /1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 AS /1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 SHW /2-1, 8/2-1, 12/2-1 Standard Option STAHL CraneSystems GmbH I Training Centre I 76
76 Rope hoist trolley UE Up to 25 ton: 8 wheel trolley UE-S77. Up to 50 ton: possible with 12 wheels Typical application: maintenance hoist on monorail track (in power stations etc.) Advantage: Only one bridge girder required Disadvantages: Heavy dead weight Long headroom (trolley and bridge) Over 16 ton, UE is more expensive than OE. Cost and bridge girder height make cranes in this capacity range impractical STAHL CraneSystems GmbH I Training Centre I 77
77 Rope hoist trolley DKE Type Lifting capacity up to (kg) Standard- Reeving Reeving for true vertical lift Mono rail trolley DKE SH /1, 2/2-1, SH 4 SH /1, 4/1 4/2-1 SHR SH /1, 2/1, 4/1 2/2-1, 4/2-1, 8/2-1 AS /1, 4/1, 6/1, 8/1 2/2-1, 4/2-1, 8/2-1 SHW /2-1, 8/2-1, 12/2-1 Standard Option STAHL CraneSystems GmbH I Training Centre I 78
78 Rope hoist trolley DKE These trolleys are used on runways with small curve radius Rule of thumb: wheelbase = curve radius STAHL CraneSystems GmbH I Training Centre I 79
79 STAHL CraneSystems GmbH Thanks for your attention STAHL CraneSystems > Lifting technology > Drive technology > Control technology
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