FEEDER SERVER MOBILE / RAIL / TWIN CONTAINER HANDLING IN FEEDER AND LARGE TERMINALS

Transcription

1 MBILE / RAIL / TWIN CNTAINER HANDLING IN FEEDER AND LARGE TERMINALS

2 Top performance and yet a lightweight on rails: the Feeder Server Rail

3 THE FEEDER SERVER. THE CRANE FR FEEDER TRAFFIC. A PERFECT CRANE SYSTEM FR CNTAINER HANDLING N FEEDER VESSELS. The rapid pace of globalisation is also transforming the container handling business. Terminals have expanded their capacity and in doing so orientated themselves to constantly growing vessel sizes. bviously cranes are growing too. Today outreaches of 50 m, 55 m, 60 m and more are the defining parameters for Post-Panamax cranes. Q INF The Feeder Server thus sets new standards in terms of: modular crane configuration performance and flexibility in terminal operation efficiency in use It is the guarantor of excellence in container handling in feeder terminals and large terminals. n the other hand, large terminals are not only served by large vessels, but also by smaller feeder vessels. These are often handled using the existing large gantry cranes. Not exactly an ideal solution, because it is inefficient. The large container cranes are not optimally adapted to the requirements of feeder vessel sizes. Relatively they are too large, too heavy, too powerful and not mobile and adaptable enough to allow transhipment from feeder vessels in close proximity to large ships. We have therefore designed a very special container crane. With its size adapted to feeder vessels, it allows faster positioning and more precise operation. In terms of operating speed, operating costs and economic efficiency, it is optimally adapted to the needs of smalle r vessel sizes. And where necessary it can be flexibly positioned between the existing gantry cranes, so that feeder vessels can be optimally served, namely directly adjacent to the large ships. Modern container logistics needs reliable cranes

4 MDERN GERMAN ENGINEERING: THE MDULAR, MBILE, ECNMICAL FEEDER SERVER. THE TECHNICAL CNCEPT. The first container gantry cranes in Europe were two units fully imported from the USA. Container cranes have been built on this side of the ocean from 1968 onwards first by Kocks. Since then we have played a key role in the ongoing development of container cranes. Thus the successful concept of the Boxer type of container gantry crane was the inspiration for the development of an innovative, mobile container crane for feeder terminals. ur engineers wanted to build a crane that can be optimally adapted to ships to be handled and can be moved in the backreach area of large gantry cranes; a crane with unprecedented flexibility, mobility and handling performance. With the Feeder Server the desire to build such an optimal crane system has taken concrete form. Q PTIMAL DIMENSINS In the technical design of the Feeder Server our engineers always had maximising performance while minimising op erating costs in mind. At the same time, the handling capacity of the Feeder Server had to meet the applicable standards for modern high-performance terminals. We based our calculations on small and medium-sized container ships up to the size of typical feeder vessels. After all, specialising in this ship size allows optimal adjustment of the outreach and lifting height of the Feeder Server. From the idea In this way we have also created ideal conditions for the crane operator. The low lifting height puts the driver closer to the load, shortens the ropes and allows faster and more precise operation than is possible with a large gantry crane. to the finished product: the Feeder Server is full of ideas of our engineers

5 Perfect harmony: loading a feeder vessel We based the design of the drives on the handling capacities of today s large terminals. Thanks to the adapted geometry compared with modern large cranes the Feeder Server needs much less drive power. So it is an economical crane by nature. Q LIGHTWEIGHT AND RBUST When designing the Feeder Server, right from the start the focus was on cutting down weight wherever possible; but of course also on a sturdy, torsionally rigid structure. To achieve both objectives we have subjected all components of the Feeder Server to a process of optimisation. Some examples: The boom system now consists of stability optimised box girders. This design offers a low profile at a minimum weight, low wind areas, yet with a high load-bearing capacity. The main hoist and boom hoist mechanisms are housed as modular components on the bridge girders. The clever arrangement of the winches on the bridge girder ensures optimal load distribution. This avoids the need for the heavy machine house structure. We took particular care in designing the trolley. It needs to be light and flat. A light trolley has key advantages regarding the dynamic stresses in crane operation. And the flatter the trolley is made, the more favourable the effect on the height of the whole structure. Both factors thus have a decisive influence on the total weight of the Feeder Server. Also important: the optimisation of speed and acceleration of the drives not only reduces the cost and weight of the drive components, but also the forces that must be absorbed by the gantry structure. f course we took this into consideration in our design.

6 Q INNVATIVE VARIANT: THE FEEDER SERVER MBILE The light and rigid design of the Feeder Server is the basis of an innovative alternative: the Feeder Server Mobile. This special Feeder Server can move freely on the terminal, whereby the wheel loads are comparable with those of other mobile equipment. This is possible through a mobile travel mechanism, which consists of rubber-tyred wheels with hydraulic drives and steering. The Feeder Server Mobile can move independently of crane rails and be flexibly positioned between the large cranes. This means, if necessary, a defective crane can be replaced within the shortest possible time. It can be used in previously inaccessible corners of the pier thus optimally exploiting existing berths. The Feeder Server Mobile is thus ideally suited for terminals on which no crane rails or none with sufficient loading capacity are available. And when there are no vessels to be unloaded it can easily act as a yard crane. Q MDULAR SERIES CRANE The largely uniform geometry and performance data of the Feeder Server enable a highly standardised and modular design. Adaptations to local conditions, such as outreach, rail gauge, supply voltage, etc. are no problem. The core components such as the lifting and travel mechanisms of the Feeder Server are designed and optimised in such a way that no job-specific adjustments need to be made. In short: The Feeder Server is the crane for feeder terminals and large terminals. Q INF Typical Feeder Server features totally precise: short ropes, electronic anti-sway and target positioning system absolutely low-maintenance: optimised rope-reeving system, highquality, low-maintenance components very low wear: minimised number of components extremely light and strong: dynamic deformations occurring under extreme conditions are calculated and minimised extremely manoeuvrable and flexible: the Feeder Server Mobile can practically turn on a sixpence and take every corner The Feeder Server consists of standardised modules and only needs to be adapted to local conditions

7 Close to the load: the Feeder Server is optimally adapted to the dimensions of today s feeder vessels

8 THERE ARE MANY REASNS FR CHSING THE FEEDER SERVER. THE MST CMPELLING ARE: THE TECHNICAL HIGHLIGHTS. No wear on the travel girder: trolley travel mechanism with directly driven wheels Special feature: low-profile boom structure ptimised for a low profile: the Feeder Server trolley 01 THE TRLLEY The trolley is the core component of a container crane. Its dead weight, size and performance features directly affect the whole crane. ur engineers have therefore paid particular attention to perfect design in this area. The low-profile design runs below the boom. This makes it possible to keep the crane height low while minimising the effective width of the boom-trolley system. Which has a beneficial effect on the total weight. The operator s cab is coupled to the trolley with a separate support structure, and is pulled along by it. The special feature of the wheels and guide rollers of main and cabin trolley: they are plastic coated and thus guarantee shockabsorbing movement and low noise emission. In addition, the plastic coating prevents wear on the travelling profile. Each trolley wheel is directly driven and the drives are equipped with an electronic anti-skid control. The direct drive significantly improves the positioning accuracy of the trolley. It also saves on trolley drive ropes and pulleys. And fewer components mean: less wear and maintenance. 02 THE BM SYSTEM The boom system consists of the waterside boom and the landside bridge girder. Both are built as monobox girders and are thus optimised in stability and weight. The structure is extremely simple to maintain. From the outside, it can be easily reached via the trolley, the interior is corrosion- and maintenance-free, since it is hermetically sealed and pressure tested. The boom pivot points on the waterside boom and the ties are designed as hinged joints with low-maintenance bushings and are of course within easy reach (via platforms). The boom joint is located above the box girder and is sized so that it can take over the vertical and horizontal forces. It guarantees shock-free passage of the trolley from the bridge girder to the boom. n the upper chord of the bridge girder are the housings for the main hoist and boom hoist mechanisms and the electrical control system, also the rope tower through which the lifting ropes pass. The travelling profiles for the trolley are welded below the lateral web plates. The lower chords of this girder are dimensioned in such a way that even under extreme loads they do not

9 deform. There is no wear from the tro l - l ey running wheels because they are plastic coated. The booms can bear the greatest of loads in container and general cargo operation. By exploiting stability reserves, in special cases even very heavy loads can be handled. And if the Feeder Server Mobile ever has to make itself very small, (optionally) the waterside boom can be easily lowered within the gantry. So you can also move the Feeder Server Mobile around under the booms of large cranes. 03 THE GANTRY The gantry is designed to be torsionally rigid and low-vibration to counter the expansion forces from the movability. The light box design with an infill of diagonals and bracings ensures dimensional stability and accurate crane behaviour both in traversing and in unloading operation. The gantry: light, torsionally rigid, maintenance-free The convenient crane: all parts are easily and safely accessible In addition to stairs, an elevator also provides easy access to the crane for both operator and maintenance staff. We have optimised the gantry structure to meet the criteria of maximum precision and short erection times. For example: for installations on the terminal the flange joints allow rapid assembly of the waterside and landside structure. The connections of the gantry sides with each other and with the bridge girders are designed with maintenance-free bolts. Furthermore: all gantry components are hermetically sealed inside and therefore maintenance-free. 04 ACCESS Despite the compact design, of the trolley in particular, the Feeder Server makes no compromises in terms of comfort, convenience and safety. All components can be easily reached via ladders, stairs, platforms and landings and are easily replaced if necessary with the help of maintenance cranes. Also convenient: a passenger lift is standard equipment 05 THE MAIN HIST AND BM HIST MECHANISMS The main hoist mechanism consists of two identical winches and is housed in a separate housing on the landside end of Convenient access via lift or stairs the bridge girder. Through the use of planetary gears inside the drums and the parallel arrangement of drums, a very compact unit is achieved. The two drives are connected to each other via a connecting shaft and a clutch. This guarantees the synchronised running of the drums and when disengaged allows the tilting movement of the spreader in a longitudinal direction (trim). Should one of the engines ever fail, the other can continue with reduced lifting speed. The hoisting ropes are reeved through the pulleys in the rope tower. The tilting movement of the spreader in the transverse direction (list) and the rotation (skew) are controlled by means of a spindle drive. verload protection and antisnag are also handled via these pulleys. With the boom hoist mechanism we also place the greatest emphasis on a compact and weight saving design. The mechanism is located in a housing adjacent to the boom joint and consists of a drum, which is equipped with Lebus shells, and the two ropes reeled in multiple layers. A permanently mounted auxiliary drive ensures that the boom hoist mechanism remains operational even in the case of the electrical drive system failing.

10 The main hoist mechanism: compact power pack of premium components The boom hoist mechanism: a drum with compact multi-layer winding No drum without hydraulic safety brake rope fix point with adjustment pulley set hoisting gear trolley hoisting gear headblock pulley set landside boom Easy maintenance: all drive components can be easily reached and replaced using auxiliary cranes Rope system of the stationary main hoist mechanism In addition to the service brakes, the drums of the main hoist and boom hoist mechanisms are equipped with hydraulic safety brakes. In the event of over-speed, emergency stop or power failure, they engage immediately and safely stop the current load or the boom. 06 THE MBILE TRAVEL MECHANISM The Feeder Server can be equipped with a rail travel mechanism or an innovative mobile travel mechanism. The mobile travel mechanism is a combination of rail and tyre travel mechanism. For travelling the entire crane is raised with the help of the tyre travel mechanism. The Feeder Server can then be steered and overcome uneven surfaces. The wheels are individually powered and controlled hydraulically. By means of manual or pre-programmed steering angle adjustment the Feeder Server Mobile can turn corners, move sideways and turn on a sixpence. It is steered by means of a portable wireless remote control. In the working position the crane is lowered onto the load distribution supports and tyre bogies, which are kept under pressure. This means the corner pressures resulting from operations can be optimally distributed into the ground. For quick positioning at the ship s hold, the crane moves on a rail on the load distribution supports in the range of ± 750 mm. Travel straight ahead at the ship is steered inductively by means of a catenary wire laid in the ground. 07 THE RAIL TRAVEL MECHANISM Rail travel mechanisms guarantee optimum performance of the Feeder Server. They do this with a system of bogies, which distribute the corner pressures evenly across the running wheels (driven individually or in pairs). We have also developed submersible travel mechanisms for use in flood prone areas and where necessary, we can also make rail travel mechanisms that can accommodate curves. Makes the container gantry crane mobile: the Feeder Server mobile travel mechanism High performance, low wheel loads: the rail travel mechanism

11 Reliable: power supply by diesel generator set Cab with excellent visibility 08 THE DRIVER S CAB As a full-view cockpit the cab offers plenty of comfort and an optimal view. The noise and heat insulated cabin has ample room for the necessary control instruments and displays. These are designed according to ergonomic principles and arranged in such a way that the crane operator always has everything under control. Electric heating and air conditioning pro vide the necessary crane operator comfort. A workplace that takes into consideration the high demands on staff and motivates them to top performance. 09 THE ELECTRIC PWER SUPPLY The Feeder Server Mobile is powered by two diesel generators. If one of the generators should fail, it can continue with reduced performance. Important: the diesel tanks are large enough for multi-day operation. With the rail version the setup is different: here the power comes from a shore power supply via motor-powered cable reel. 10 THE ELECTRNIC CNTRL SYSTEM The freely programmable electric control of the Feeder Server is based on proven industrial components that communicate via bus to the state-of-the-art digital three-phase frequency converters. Anti-sway guiding of the hoist load and optimised hoist load guiding can be realised for optimal operating conditions. Semi-automatic or fully automatic operation guarantees consistently high handling rates over long periods of operation. Power supply via motor-powered cable reel Reliable connection to trolley and spreader: the festoon system Driver seat with CMS monitor 11 THE CRANE MANAGEMENT SYSTEM Cranes from Kocks demonstrate their high standard of service not least with the comprehensive and intelligent software package SIS (Service Information System). The modular system for the areas of information, fault finding and diagnostic, service, statistics and project management is included as standard. Access to all relevant information: via SIS

12 THE THERY: MAXIMUM HANDLING CAPACITY WITH ABSLUTE RELIABILITY. THE PRACTICE: THE FEEDER SERVER. THE FEEDER SERVER IN USE. The Feeder Server: the backbone of terminal operation The Feeder Server is used everywhere containers need to be loaded and un loaded by feeder vessels. Here it shows itself to be an extremely efficient and reliable system with high performance. It is the ideal crane for terminals where maximum flexibility and mobility are required, and for locations where there was previously no crane infrastructure to be found. Another advantage is that it is possible to realise additional operating modes for the Feeder Server, for example magnetic or motor grab operation. So a pure container crane becomes a multipurpose crane. What distinguishes the Feeder Server: quick change of location optimal adaptation to feeder vessel requirements high handling capacity high positioning accuracy optimised operating speeds low maintenance low dead weight extremely quiet handling operation long service life high resale value

13 WHY KCKS? BUILDING CRANES SINCE THE CMPANY KCKS. Q KNW-HW Kocks is considered a pioneer in the development of container cranes in Europe. We have been building highperformance ship unloaders since 1913 and we are the world leader in Goliath cranes. We set standards for the high performance of cranes. ur engineers consistently apply the proven rules of German engineering to the ongoing further development and design work on the cranes. Designing and classification for continuous operation is carried out particularly conscientiously. Q SERVICE For us, perfect service and maintenance are part of a good product. We therefore give our customers personnel intensive training in crane theory and practice. We want to make sure that continuous availability of the cranes is always guaranteed. If there should be a failure in spite of all this, we are there to help quickly, flexibly and unbureaucratically. Day and night. Q PARTNER APPRACH The Feeder Server is an extremely durable product. Choosing it signals the beginning of a comprehensive customer/supplier relationship which is often manifested in repeat and follow orders. We therefore attach great importance to ensuring this relationship is fair and with long-term benefits for both parties. Just so you know for us this starts long before the contract is signed. We ll be happy to advise you at any time, just give us a call. The goal is always the same: increased efficiency, safety and environmental friendliness of the cranes. Q QUALITY To us quality means: a sophisticated product concept, profound know-how in the fields of design and control as well as the greatest accuracy with regard to fabrication and execution. It goes without saying that our engineers meticulously test and check all mechanical and electrical components. All this provides decisive advantages: maximum efficiency and reliability of the cranes low operating costs long service life (even under the toughest operating conditions) Home of Kocks Krane in Bremen

14 THE FEEDER SERVER THE KEY TECHNICAL DATA. THE FEEDER SERVER AT A GLANCE. FEEDER SERVER MBILE Q Capacity below spreader Q utreach waterside Q Rail span Q utreach landside Q Hoisting height above/below rail Q Main Hoist nominal load/empty Q Trolley travel Q Crane travel Q Boom raising Q Handling capacity Q Wheel load in motion Q Area load in crane operation 35 t 30 m 18 m 10 m 15 m / 12 m 40 m/min / 90 m/min 120 m/min 40 m/min 6 min 40 moves/h approx. 135 kn/tyre max. approx. 270 kn/m² FEEDER SERVER RAIL Q Capacity below spreader Q utreach waterside Q Rail span Q utreach landside Q Hoisting height above/below rail Q Main Hoist nominal load/empty Q Trolley travel Q Crane travel Q Boom raising Q Handling capacity Q Maximum wheel load 40 t m m 16 m 27 m / 12 m 50 m/min / 120 m/min 150 m/min 45 m/min 5 min approx. 40 moves/h approx. 300 kn/wheel

15 FEEDER SERVER TWIN Q Capacity below spreader Q utreach waterside Q Rail span Q utreach landside Q Hoisting height above/below rail Q Main Hoist nominal load/empty Q Trolley travel Q Crane travel Q Boom raising Q Handling capacity Q Wheel load 65 t 38 m m 16 m 27 m / 12 m 50 m/min / 120 m/min 150 m/min 45 m/min 5 min 80 moves/h approx. 400 kn/wheel Feeder vessel on the way into port: the Feeder Server guarantees quick turnaround

16 KRANUNIN. WRLD MARKET LEADERS UNITED. Kranunion is an association of three crane manufacturers who have specialised in lifting and transporting heavy loads: KIRW ARDELT KCKS is the world market leader for railway cranes and slag pot carriers is the world market leader for double jib level luffing cranes is the world market leader for Goliath cranes and a pioneer in the development of container cranes Central to all Kranunion products are the technical design concepts created by our experts. f course, we continue to optimise those fundamental concepts even further in the interests of our customers. Kranunion products are therefore based on practical requirements and are a symbiosis of tradition and innovation combining the tried and tested with the new. Customers who choose Kranunion choose great German engineering skill: for environmentally-friendly and safe, modern technology, for low operating costs, for high performance and reliability. KCKS WESERSTRASSE 64 D BREMEN / GERMANY PHNE +49 (0) FAX +49 (0) INF@KCKSKRANE.DE WWW KCKSKRANE.DE KCKS IS A MEMBER F KRANUNIN.