DESCRIPTION, TECHNICAL SPECIFICATION, OPERATION, AND MAINTENANCE MANUAL FOR THE ISU-SYSTEM INNOVATIVER SATTELANHÄNGER UMSCHLAG

Transcription

1 DESCRIPTION, TECHNICAL SPECIFICATION, OPERATION, AND MAINTENANCE MANUAL FOR THE ISU-SYSTEM INNOVATIVER SATTELANHÄNGER UMSCHLAG INNOVATIVE SEMITRAILER HANDLING UNIT Seite 1 / 27

2 DESCRIPTION, TECHNICAL SPECIFICATION, OPERATION, AND MAINTENANCE MANUAL FOR THE ISU-SYSTEM INNOVATIVER SATTELANHÄNGER UMSCHLAG INNOVATIVE SEMITRAILER HANDLING UNIT Using normal mobile or gantry cranes at cargo terminals without any special facilities for trailers to place on pocket wagon types: 6-axis double pocket wagon type TWIN 6-axis double pocket wagon type T axis pocket wagon type T5 Contents Description and Equipment Page 5-17 Isu system elements single weights and loads.. Page 17 Loading condition... Page 18 Operation and maintenance..... Page Unloading Procedure. Page 26 Service and maintanance plan for ISU elements.. Page Seite 2 / 27

3 Connecting spreaderspreader adjusted to 20 Lifting belts Support Cross BeamMobile or permanent loading rampwheel Claw Components Seite 3 / 27

4 ISU Innovative / intelligenttrailer-transshipment Loading and unloading of Trailers to common pocket wagon types without any special means and only by using ordinary cranes and lifts at cargo terminals For the transport of commonly used large size trailers in Europe through the railway network, special wagons - so called pocket wagons are used. The pocket wagons have recessed loading pockets to accommodate the wheels of the trailer, so that trailers with the maximum height of 4m can be transported within the dimensional requirements of the railway profile. Placing and lifting of the trailer to or from the pocket wagon is done at the terminal with existing gantry cranes or mobile cranes. The trailer needs to be fitted with a lifting ledge at each of its long sides so that it can be fastened with the gantry or mobile crane and lifted with a so called crane spreader. Seite 4 / 27

5 Transhipment of trailer with cranes is problematic in general, because in Europe only a few trailers are fitted with lifting ledges. Also only a small number of new trailers are fitted with lifting ledges. Further it is by some types of trailers technically not possible to fit the mandatory lifting ledges for railway transport. Fitting trailers with lifting ledges also makes reinforcements of the trailer necessary resulting in payload losses and incurs additional costs for mandatory approvals. 1. ISU-System The ISU-System enables transhipment of road trailers possible with existing cranes not requiring additional equipment and installations at terminals to the following types of pocket wagons: Seite 5 / 27

6 Type TWIN Type T3000 Type T5 Each wagon comes in its basic version with one support beam two wheel grippers These components are placed into the mobile loading ramp at the access road or terminal prior to transhipment. Seite 6 / 27

7 The tractor or semi-trailer placing the trailer onto the mobile loading ramp and positioning the wheels above the wheel grippers. For a connecting spreader with lifting belts and 20 corner fittings is needed for lifting and placement. This connecting spreader is mounted to the lifting gear of the gantry or mobile crane. Seite 7 / 27

8 The gantry or mobile crane is positioned above the trailer, which is placed on the loading ramp. The lifting belts at the connecting spreader are connected to the outer ends of the support beam and the outer ends of the wheel grippers with a towing-hook. After that the trailer will be lifted and placed over the pocket wagon with its kingpin on the support beam facing downwards aligned with the front boogie of the pocket wagon. Seite 8 / 27

9 The trailer, aligned in parallel with the long axis of the pocket wagon, is placed on the trailer jack and secured. After that the lifting belts and towing hooks will be detached from the support beam and the wheel grippers. The wheel grippers are designed to place trailers with different wheel track width always in the centre of the pocket wagon. The trailer axis is placed in the centre of the pocked wagon though the wheel grippers. Another advantage of this transhipment system is that the wheel grippers are also used as wheel chock in the loading pocket of the pocket wagon and can fasten different wheel sizes through an adjustable wheel claw design and also provide protection for the kingpin in case of bumps. Here is a description of the elements and components of the ISU Stystem: Seite 9 / 27

10 The Terminal equipment: The ISU connecting spreader 20ft. An ISU connecting spreader with 20ft corner fittings, which is connected to the gentry or mobile crane, is kept at the terminal. The connecting spreader is fitted with lifting belts and safety hooks to lift the trailer with the support beam underneath the kingpin and at its wheel grippers. The lifting belts are fixed with screwable lifting yokes to make them easily detachable if required. Seite 10 / 27

11 The excess length of the lifting yokes stabilises the trailer in the lifting gear of the crane. The arrangement of the 20ft corner fittings at the connecting spreader enables carrying the gear in a different container wagon in the same train. The floor ramp. The floor ramp helps to place the trailer over the wheel grippers and the support beams under the axis of the trailer. The wheel claw and the support beam are embedded in the floor ramp so that tractors with extremely low ground clearance can also use them. The wheel grippers can be used as wheel chocks and can be adjusted to different wheel diameters. Seite 11 / 27

12 The drive-on ramps at the floor ramp are fitted with common rubber parts to prevent slipping of the drive wheels. The floor ramp is placed on the access road close to the pocket wagon. Seite 12 / 27

13 The floor ramp is available in single and double version. The single floor ramp is used from one end only by the semitrailer driving forward or backward, while the double floor ramp can be access from both sides. The floor ramps are easily assembled from single tracks with cross connections. This enables to carry the floor ramp and the connecting spreader together with its components inside the combi-train. The wagon equipment: The wagon equipment consists of the wheel grippers and the support beam, which mounts the trailer at the same points as in the road traffic. Seite 13 / 27

14 The wheel gripper: The wheel grippers are designed with hinge-like wheel flaps so that it can safely and gently lift all common wheels. There are mounting points for the wheel claw belts on the wheel flaps, which connected to the lifting belts of the connecting spreader allow to claw, hold and lift the trailer by its wheels. Die support beam: The support beam is connected to the connecting spreader with lifting belts and safety hooks. Therefore the support beam has 4 lifting eyes. Seite 14 / 27

15 By lifting the support beam under the king-pin it will be locked automatically. At the bottom of the support beam is another king-pin which locks automatically when placed onto the trailer jack on the pocket wagon. Unlocking of the king-pin at the trailer jack and the support beam happens in the usual way by pulling the unlocking lever.. Seite 15 / 27

16 For the orientation of the crane operator the position of the trailer jack and the centre of the support beam are indicated with a red colour stripe. ISU system elements single weights: Floor-ramp single Floor-ramp double Support beam with lifting belt 2,200t = 22000N 2,700t = 27000N 0,340t = 3400N 2 wheel craws with lifting belt 0,400t = 4000N Connecting spreader with lifting belt 1,300t =13000N 1. Loads a) Single parts load Wheel grab (Radgreifer) Support traverse (Stützbocktraverse) 15t = N 21t = N b) Carrier load Wheel grab (Radgreifer) Support traverse (Stützbocktraverse) 15t = N 18t = N 2. Static study 2.1. Load: Maximal mass of semitrailer 39,0 t Seite 16 / 27

17 L o a d i n g c o n d i t i o n Each pocket of the wagon has two wheel grippers to lift the trailer at the axle side and one support beam to lift the trailer at the kingpin. Further more each ISU- Terminal needs minimum one mobile floor ramp in double version for drive-on with the trailer from both directions and one connecting spreader with 20 feet connection at the corner castings. On each pocket of the pocket wagon it is possible to load a 3-axle trailer according to the EU-regulation with following max. measurements: max (45 feet) SAnh 39 Tonnen Gesamtgewicht total trailer weight 39 tons Max.15 Tonnen Kontur ISO 1726 ø t (27t) (12t) Basis for loads distribution was recieved by ISU-SYSTEM. Visualisation is shown on the scheme (see below). Seite 17 / 27

18 Mandrel adapter head for trailer pocket wagons type T3000/T5 and Twin: Centre brackets are fitted near the wheel grippers for positioning and fixing the trailer onto the pocket wagons. Different sizes of mandrel heads at the wheel grippers ensure the trailers exact positioning in the middle of the base pan. The pocket wagons T3000 and T5 are fitted with mandrel heads of 38mm thickness and the Twin Pocket wagons are fitted will mandrel heads of 28 mm thickness. Please see drawing no. ISU 3023 for the Twin Pocket wagon and drawing no. ISU 3017 for pocket wagon type T3000 and T5. Transport of trailer with air suspension: After the trailer is placed on the pocket wagon and made ready for transport the air suspension must be empty. According to UIC article 7. TWIN T3000 / T5 Transport of trailer with air brake system: After connecting the belts to the equipment and before the lifting of the trailer the air brake has to be opened. The respective regulations and standards for a correct handling of the mobile or gantry crane need to be observed and fulfilled. Seite 18 / 27

19 Connecting spreader Gantry or mobile crane Lifting belt In the following the system is described. For the trans-shipment a gantry or mobile crane with connecting spreader and lifting belt is required. Furthermore a floor ramp has to be used. Here in double version for drive-on from both directions. Seite 19 / 27

20 Then two wheel grippers and one support beam are embedded into the floor ramp for lifting the trailer. Support Beam Wheel gripper The trailer is placed on the floor ramp with its wheels on top of the wheel grippers and the king-pin over the support beam. Seite 20 / 27

21 The standard spreader with the connecting spreader is placed above the trailer by the wheel grippers and the support beam. The lifting belts of the connecting spreader are attached to the wheel grippers and the support beam. Seite 21 / 27

22 The trailer is lifted by the wheel grippers and the support beam which locks the kingpin under the use of a gantry or mobile crane Seite 22 / 27

23 placed above the pocket wagon and made ready for transport. Seite 23 / 27

24 The operators detach the lifting belts from the wheel grippers and the support beam. The support beam and the wheel grippers, which are also used as wheel chocks, remain inside the pocket wagon during transport. The trailer cargo train is ready for transport to the destination. Seite 24 / 27

25 U n l o a d i n g P r o c e d u r e To unloading the trailer from the cargo train at the arrival station, the following has to be to done: The trailer must be liftted with the standard spreader and the connecting spreader from the cargo train and placed on the floor ramp exactly in between the yellow positioning markers. The axle with the wheel grippers is placed in its position. Very important: Bevore the support beam can be put into position, the lock at the kingpin must be unlocked. Only when the wheel grippers and the support beam are in the correct and exact position, the lifting belts can be removed. The air suspension can be filled up in order to mount the trailer with the tractor. 1. General Service and maintenance plan for ISU elements the maintenance and repair is used to ensure and restore the operational capability of the ISU elements of a maintenance section of basically the same as that for the corresponding double pocket wagons type. The ISU elements, as well as the double pocket wagons designed for a 6-year maintenance cycle at a stated useful life of 36 years. Wear parts require special maintenance. The following maintenance and service plan is based on an average mileage of the car and load pocket with the ISU elements in the operational use of 150,000 km per year. Furthermore it is assumed that 500 ISU trailer lifting's per year. Basis for the inspection and maintenance are operating railway EEO regulations, provisions of the UIC and the service and maintenance requirements of the recruiting path for the ISU system and the maintenance provisions for lifting. Seite 25 / 27

26 2. Maintenance and service levels in the repair and maintenance plan 3 steps be distinguished: 1. step: maintenance by visual inspection during the first 6 years: Visual inspection of all lifting belts and fasteners for cracks. cross-beam: visual inspection of cross-beam kingpin mechanism at function. and check for ease movement and possibly worn out, damaged or lost parts. Visual inspection on the cross-beam for welding cracks. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. wheel grippers: visual inspection of wheel grippers for welding cracks. Function of the hinge parts to function smoothly and easy to handle Replace any lost items. Grease hinge parts, if necessary. Visual inspection if the guide cones are tight. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. daughter spreader: visual inspection of the hinge parts with socket bolts for locking the attached lifting belts. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. loading ramp : visually inspect for damaged or lost parts. check all ISU components for visible deformation. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. 2. step Revision with reconditioning: The 2. step is used in the 6-year rhythm, alternating with the level 3 executed, after 6, 18 and 30 according to the maintenance of the double pocket wagon. Also work individually as described in step 1: cross-beam: visual inspection of cross-beam kingpin mechanism at function. and check for ease movement and possibly worn out, damaged or lost parts. Visual inspection on the cross-beam for welding cracks. Check and correct any ease attrition parts like the operating lever, replace if necessary; replace kingpin lock system when visible deformation is identified. Visual inspection of weldings and correction if necessary. Seite 26 / 27

27 wheel grippers:: Test the function of the hinge parts and check wear and tear. Grease and lock hinge parts and pins. Correct visible deformation. Replace / repair the missing parts. Visual inspection of weldings and correction if necessary. daughter spreader: visual inspection of the hinge parts with socket bolts for locking the attached lifting belts. Visual inspection of weldings and correction if necessary. loading ramp : visually inspect for damaged or lost parts. check all ISU components for visible deformation. If paint damage occurs despite these precautions, it can be coloured by using commercial acrylic paint in the appropriate RAL color of the part. 3.step Revision with full work-up : The 3rd stage is in the 6-year rhythm, alternating with the step 2 executed, after 12 and 24 years after the commissioning of the ISU elements. The work to be performed is similar to those of step 2. 3 Workshop activities : The maintenance work must only be undertaken in suitable workshops. They must have the necessary approvals of the railway supervisory authority and the operating railway. The staff must have the necessary qualifications. In the workshop, the relevant maintenance rules and documentation of the operating railway must exist. Necessary measuring and test equipment must be identified, registered and checked regularly. The workshop should be clean, well lit and heated in winter, so that highquality results are possible. Storing spare parts and supplies, such as paints and fats must be in clean, dry rooms. For welding, the welding certification in accordance with DIN regulations must be available. The qualification of welders shall comply in accordance with EN Compliance with the generally recognized rules for occupational health and safety are guaranteed. Hans Tandetzki Geschäftsführer Fritz Farke Geschäftsführer ISU System GmbH Hans Tandetzki /H.Tan Edition 2. Edition Edition Seite 27 / 27