Zollern Winch 501fw

WINCH GEARBOXES

TRANSMISSION TECHNOLOGY

The Zollern factories The ZOLLERN GmbH & Co. KG is a company with worldwide operations, employing over 2400 employees in the business fields of transmission technology (automation, gears and winches, friction bearing technology), engineering elements, foundry technology and steel profiles.

WINCHES AND GEARBOXES

• • • • • • • • •

Winches and Gearboxes

3

Design and construction of rope winches with flange drive gearbox

4

Integrated rope drum

7

Rope fixing

8

Rope grooves and rope

9

Application factor K for lifting appliances

10

Guidance for group classification of a mechanism

10

Calculation of rope load Fnom on the rope drum

11

Calculation of rope diameters and rope drum diameters in acc. with DIN 15020

11

• Winding direction on rope drums • Available ratios for winches • Hydraulic control systems for rope winches • Recommended lubricants for ZOLLERN rope winches • Accessories for ZOLLERN Winches • Essential design data

WINCH GEARBOXES

11 15 16 16 16 17

2 3

WINCHES AND GEARBOXES

ZOLLERN Winches and Gears have proved that they can give the best performance even under the most arduous and unfavourable conditions. Their outstanding features and advantages are • compact, functional construction • rigid winch construction • modular design of gear unit • high efficiency • ease of maintenance • long service life • functional design The designer is thus offered on easily installed unit providing a cost-effective solution, even where space is limited.

Applications: • Truck-mounted/ mobile cranes • Derrick and shipboard cranes • Dockyard and wharf cranes • Building/ constructional cranes and materials handling equipment • Recovery and towing vehicles • Goods and personnel lifts • Container handling cranes • Loading and cargo-handling cranes The planet gear units used in winches can also be used for the slewing drives and traversing units of mobile cranes and other vehicles, so that all the gear drives are of the same construction and incorporate the same basic components.

DESIGN AND CONSTRUCTION OF ROPE WINCHES WITH FLANGE DRIVE GEARBOX

2 stage planetary gearbox Reduction ratios from 13.1:1 to 34.5:1 Gearbox mounted inside winch drum, Parking Brake and Hydraulic motor flange mounted externally. Input and output in opposite sense of rotation. Backstop option.

3 stage planetary gearbox Reduction ratios from 45.0:1 to 176:1 Gearbox mounted inside winch drum, Parking Brake and Hydraulic motor flange mounted externally. Input and output in opposite sense of rotation. Backstop option.

2 stage planetary gearbox with spur stage input Reduction ratios from 40:1 to 150:1 Gearbox mounted inside winch drum, Parking Brake and Hydraulic motor flange mounted externally, twin motor/brake option. Input and output in opposite sense of rotation. Backstop option.

WINCH GEARBOXES

Winch range

Lubrication

Output torques: 1.900 to 1.400.000 Nm. Rope load at the drum periphery: 20 kN to 1.700 kN. When calculating the rope load at the drum periphery, the mass of the weightcarrying and stop media as well as the efficiency of the rope drive must be allowed for (see page 11).

Gearbox and input drum bearings are splash lubricated within the gearbox oil bath. The end bearing is greased and can be supplied as a “sealed for life” unit on request. Recommended oils can be found from the table on page 16.

Notes

Oil maintenance

The output torques Tdyn, listed on pages 12/13 are based on FEM Standards I and IX as well as DIN 15020/ load conditions L2/ running time classification T5, in accordance with “Drive unit group M5”. Ambient temperature + 20 C° (FEM - Federation Europeenne de la Manutention).

An oil fill pipe is provided on the gear unit input flange. Service intervals are given on page 16.

Oil level A dip stick type level is provided.

4 5

Gear tooth forms

Cooling

Selected for optimum surface durability and bending strength; also for minimum sliding velocity, according DIN 3990. External gear teeth are case-hardened and ground; internal gears annealed and nitride hardened.

In high ambient temperatures or where the unit is directly exposed to sunlight forced cooling may be considered if the duty factor is high. Should cooling be required a cooler can be provided with the necessary gear unit connections.

Bearings

Input drive

All rotation parts run on rotation element bearings. Ball bearings are used to the input gearing, needle roller bearings for the planet wheels and self aligning bearings for the drum bearings.

A choice of hydraulic motor, electric motor or free-shaft. Input shaft with keyway or splined according to DIN 5480. A flexible coupling is used for link-up to the electric motor to connect the gear input shaft with the electric motor.

Efficiency

Seals

The efficiency of the gearstage is 98% and about 99% for the drum bearings including seals. Example: Rope winch with 2 planetary gear stages η overall = 0,98 x 0,98 x 0,99 = 0,95

Input and output are protected with radial shaft seals of double lip type. This prevents oil leakage and protects the unit from ingress of dirt or water. Where the unit is be used offshore or on-ship additional protection is provided with greased felt strips and secondary radial seals.

Mounting position

Brakes

Horizontal

A hydraulic multi disc parking brake with spring applied, pressure release operation is fitted. This fail safe device is a self contained piston/ brake with release pressure of 15 bar, 300 bar max. Line transient pressure of 0.5 bar permitted. The connection ports are metric M 12 x 1.5. Multi disc or barrel brakes with direct connection to the rope drum can be fitted for additional safety back up.

Winch fitted between flanges The flange at the driven end transmits the lateral force and reaction torque safely to the mounting structure. The opposite flange can be removed to enable the winch to be mounted and compensates for length and angle tolerances. It transmits lateral forces only.

Backstop

Electric motor

For special applications a backstop can be incorporated between the gear transmission and the parking brake. It operates as follows.

Standard electric motors cannot be mounted inside the winch drum. As opposed to Electric-Compact-Winch.

Operating conditions Lifting of load - Parking brake closed - Backstop open

Lowering of load - Parking brake open - Backstop closed

Geared limit switch a) electrical an electrical signal can be generated at various rope travel or end limit position. The switch positions are infinitely adjustable. The switch is flange mounted with drive from the rope drum through the bearing housing. b) hydraulic ZOLLERN geared limit switch operating as the electrical version – with a hydraulic signal.

The gear systems are designed for use in Central European conditions. Permissible oil temperatures -20°C to + 70°C. Environmental factors such as salt water, salt-laden air, dust, excessive air pressure, heavy vibration, high shock loads and extreme ambient temperatures, corrosive media, etc. must be stated.

Paint Primer This is a specially developed multi-primer with a two-component zinc-dust epoxy resin base. Colour: light silver-grey. A two component epoxy resin is most suitable for the finish coat.

Choice of gear unit In order to select the correct rope winch for a given application the output torque Tcalc calculated from the rope load and rope drum diameter must be multiplied by the factor K. Tdyn = Tcalc x K For application factor K and calculation of the rope load see pages 10/11.

WINCH GEARBOXES

INTEGRATED ROPE DRUM 6 7

With normal grooves

With special grooves Raising wedge

This is cast on to the drum on the opposite side of the rope entry and guides the rope from the first to the second layer.

Dummy-lay filling wedge

With grooves of this kind the difficulties encountered in multi-layer winding on to grooves of the usual kind do not arise, as the crossover points of the rope in each layer always lie in the same section of the drum and the lift of the rope into the next layer is precisely defined. 8 and more layers can be accommodated without difficulty.

Material for rope drum: - cast material (EN-GJS-400-15; EN-GJS-600-3; …) - steel (S355JO; …) Other material on request

This is cast on to the drum at the rope entry point and serves to fill the gap between the drum flange and the first rope turn.

1,5 . d d

Rope drum diameter D1

Drum flange diameter D2

D1 = 20 x d or as specified

D2 = D1 + 2 (z + 1) d

Length of rope

D2

D1

including 3 safety turns LS = LS L2 D1 d

( )( L2 -a p

)

D1 + 0,866 . d (n-1) n . π

= Length of rope [mm] = Length of drum [mm] = Diameter of drum [mm] = Diameter of rope [mm]

p n a

= Pitch of rope groove [mm] = Number of rope layers [-] = 1 for normal grooves [-] = 0,5 for special grooves

ROPE FIXING

Wedge lock for rope diameters up to 30 mm

Clamps for ropes with a diameter of more than 30 mm.

a) on the outside of the drum flange

a) on the outside of the drum flange

b) on the inside of the drum flange (for up to 2 rope layers only)

b) on the inside of the drum flange (for up to 2 rope layers)

c) within the barrel shell

c) on the drum by means of clamps. In an emergency the rope can be pulled out of the fixing without damage to either rope or drum.

WINCH GEARBOXES

8 9

ROPE GROOVES AND ROPE

α

Rope grooves

Deflection angle

On cast drums cleanly cast and trimmed, and at the flash line carefully ground. On welded drums all edges are deburred and radiussed.

To achieve acceptable rope winding

Rope groove lead/ pitch Right-hand lead on standard design

- the deflection angle α must with special grooves be not less than 0,5° in order to prevent the rope from riding up the drum flange and to ensure that it is guided securely on to the next layer. - the deflection angle α must not exceed 1,5° in order to prevent the rope in the first layer being pulled against the grooves and, where a number of layers occur, to enable even winding up to the drum flanges. If the deflection angle is greater, the working life of the rope will be negatively affected.

Left hand lead

Direction of rope lay For example:

right-hand rope lay

left-hand rope lay

APPLICATION FACTOR K FOR LIFTING APPLIANCES Symbol Running time classification

Mean running time per day in hours, related to one year Life in hours 8 Years, 200 Days/Year

Loading cond.

log

L2

M

L3

M

log

T4

T5

T6

T7

T8

over 0,25 to 0,5

over 0,5 to 1

over 1 to 2

over 2 to 4

over 4 to 8

over 8 to 16

over 16

400 to 800

800 to 1 600

1 600 to 3 200

3 200 to 6 300

6 300 to 12 500

12 500 to 25 000

25 000 to 50 000

Drive unit class 1)

to 0,125

M1 0,90

M2 0,90

M3 0,92

M4 1

M5 1,07

M6 1,18

M7 1,24

0,125 to 0,250

M2 0,90

M3 0,92

M4 0,95

M5 1

M6 1,14

M7 1,24

M8 1,48

0,250 to 0,500

M3 0,94

M4 1

M5 1,07

M6 1,18

M7 1,24

M8 1,48

M8 1,56

0,500 to 1,000

M4 1,04

M5 1,07

M6 1,18

M7 1,24

M8 1,48

M8 1,65

M8 1,88

L

L

log

L

log

L

M

L4

T3

km M

L1

T2

1)

(Example: M5-L2-T5 is equivalent to k=1)

GUIDANCE FOR GROUP CLASSIFICATION OF A MECHANISM According FEM section I, 3rd edition, table T.2.1.3.5.

Type of appliance Designation

Particulars concerning nature of use (1)

Erection cranes

Type of mechanism Hoisting

Slewing

Luffing

Traverse

Travel

M2 – M3

M2 – M3

M1 – M2

M1 – M2

M2 – M3

Stocking and reclaiming transporters

Hook duty

M5 – M6

M4

–

M4 – M5

M5 – M6

Stocking and reclaiming transporters

Grab or magnet

M7 – M8

M6

–

M6 – M7

M7 – M8

Workshop cranes

M6

M4

–

M4

M5

Overhead travelling cranes, pigbreaking cranes, Grab or magnet scrapyard cranes

M8

M6

–

M6 – M7

M7 – M8

M6 – M7 M4 – M5

M5 – M6 M4 – M5

M3 – M4 –

M6 – M7 M4 – M5

M4 – M5 M4 – M5

M8

M5 – M6

M3 – M4

M7 – M8

M4 – M5

Bridge cranes for unloading, bridge cranes for containers Other bridge cranes (with crab and/or slewing jib crane)

a) Hook or spreader duty b) Hook duty

Bridge cranes for unloading, bridge cranes (with crab and/or slewing jib crane)

Grab or magnet

Drydock cranes, shipyard jib cranes, jib cranes for dismantling

Hook duty

M5 – M6

M4 – M5

M4 – M5

M4 – M5

M5 – M6

Dockside cranes (slewing, on gantry, etc.), floating cranes and pontoon derricks

Hook duty

M6 – M7

M5 – M6

M5 – M6

–

M3 – M4

Dockside cranes (slewing, on gantry, etc.), floating cranes and pontoon derricks

Grab or magnet

M7 – M8

M6 – M7

M6 – M7

–

M4 – M5

M3 – M4

M3 – M4

M3 – M4

–

–

M4

M3 – M4

M3 – M4

M2

M3

M5 – M6

M3 – M4

M3 – M4

M4 – M5

M3 – M4

M4

M5

M4

M3

M3

Derricks

M2 – M3

M1 – M2

M1 – M2

–

–

Railway cranes allowed to run in train

M3 – M4

M2 – M3

M2 – M3

–

–

M3 – M4

M2 – M3

M2 – M3

–

–

Floating cranes and pontoon derricks for very heavy loads (usually greater than 100 t) Deck cranes

Hook duty

Deck cranes

Grab or magnet

Tower cranes for building

Mobile cranes

WINCH GEARBOXES

Hook

CALCULATION OF ROPE LOAD FNOM ON THE ROPE DRUM Rope load Fnom

Efficiency of rope drives 1 n · ηs

Fnom = (mload + mtackle) g ·

· Ψ [N]

ηs = (ηR)i · ηF = (ηR)i ·

Meaning: i is the number of rope pulleys between the rope drum and pulley block or load (e. g. with the lifting gear on jib cranes) n is the number of rope strands in a single pulley block. A single pulley block is the total number of rope strands and rope pulleys for a single rope running on to a rope drum (see illustration)

1 1 - (ηR)n · n 1 - ηR

ηR is the efficiency of a single rope pulley ηF is the efficiency of the pulley block ηs is the efficiency of the rope drive

The efficiency of a rope pulley depends not only from its type of bearing used in it (friction or antifriction), but also upon the ratio rope pulley diameter: rope diameter (D:d), upon the design of the rope and upon the rope lubrication. If no more exact values have been obtained by experiment, the following values are to apply with friction bearings ηR = 0,96 with anti-friction bearings ηR = 0,98

2-stranded pulley block n=2

Twin pulley tackle 4-stranded, comprising 2 pulley blocks each 2-stranded 2 x (n = 2)

For compensating pulleys no efficiency value must be considered. For Ψ = coefficient of vibration see FEM-section 1 2nd Edition Dec. 1970, Page 15

CALCULATION OF ROPE DIAMETERS AND ROPE DRUM DIAMETERS IN ACC. WITH DIN 15020 Coefficient c

Coefficient h1

Rope diameter dmin = c · √ S

Gear drive group

S = Rope pull in N

C = Coefficient in mm/√ N

Non rotationfree wire ropes

Rotationfree wire ropes

Coefficient h2 = 1

Rope drum diameter Dmin = h1 · h2 · dmin Non rotationfree wire rope

Rotationfree or low-rotation

Nominal strength of individual wires in N/mm2 1 570 1 770 1 960 2 160 2 450

1 570

1 770

wire rope 1 960

1 Bm

0,0850

0,0900

0,0850

0,0800

14

16

1 Am

0,0900

0,0900

16

18

0,0800

0,0750

0,0850

– –

0,0950

2m

0,0950

–

0,106

18

20

3m

0,106

–

0,118

20

22,4

4m

0,118

–

0,132

22,4

25

5m

0,132

–

0,150

25

28

WINDING DIRECTION ON ROPE DRUMS Left-hand

Right-hand Rope pull overshot

Rope entry

Rope pull undershot

Rope entry

Rope pull overshot

Rope entry

Rope pull undershot

Rope entry

10 11

L 3 stage unit L 2 stage unit

Length depending on motor/brake size

X

A M max. X

Flange connection

F8

G

F7

Flange connection

F S6

D0

Optional end bearing

G6 F6 F5 Flange connection

Flange connection G5

S

S5 T2

ZHP EG 4.13 4.15 4.19 4.20 4.22 4.24 4.25 4.26 4.27 4.29 4.31 4.32 4.33 4.34 4.36

Nominal gearbox ratings Output torque (Nm)

Typical line pull

Tdyn. T (max.stat.) I ≤ 70 I ≤ 70 F(nom) I > 70 I > 70 (kN) 1 900 3000 20 – – – 4 500 7200 37 4 700 7 500 39 7 100 11 500 47 7 400 12 000 49 11 000 17 500 66 11 500 18 500 69 19 000 30 500 97 19 500 31 000 101 23 500 38 000 109 24 000 38 500 112 33 000 53 000 137 34 000 54 000 141 45 000 72 000 173 46 000 73 000 177 57 000 92 000 199 58 000 93 000 202 93 500 149000 279 96 000 153 000 288 136 000 217 000 358 139 000 222 500 366 198 000 317 000 476 200 000 320 000 481 247 000 395 000 524 250 000 400 000 531 336 000 537 000 651 340 000 544 000 659 555 000 888 000 926 560 000 896 000 935

GG

T1

T2

Flange connection – Gear unit to frame Bolts class 10.9

Max input D O G1 speed approx. location

G2 pcd

G3 outer

Ø

Ø ± 0,2

Ø

180

125

145

260

155

185

300

190

225

340

200

255

390

230

280

440

270

320

480

300

350

520

330

390

570

355

420

670

430

480

770

515

565

830

580

630

930

670

720

1030

720

770

1200

840

900

G4 fixing

G5

G6

W

Flange connection Gear unit to drum

SS S1 S2 location pcd

S3 outer

S4 fixing

FF S5

S6

F1 location

F2 pcd

Ø

Ø ± 0,2

nmax. γ rpm

Depending on motor and brake arrangement 2000…5000 rpm

TYPE

S

C

30° 167 12 * M 10 20° 213 16 * M 12 20° 255 16 * M 16 20° 285 16 * M 16 15° 315 22 * M 16 15° 355 22 * M 16 15° 385 22 * M 20 15° 425 22 * M 20 15° 460 22 * M 24 15° 530 22 * M 24 15° 615 24 * M 30 15° 680 24 * M 30 12° 770 30 * M 30 10° 820 36 * M 30 10° 960 36 * M 36

Ø

Ø ± 0,2

16

5

145

185

24

5

225

245

25

5

265

290

25

5

295

320

25

5

330

360

25

5

370

400

30

5

400

440

30

5

440

480

38

5

470

520

38

5

550

590

47

5

640

690

47

5

700

755

47

5

790

840

47

5

850

900

56

5

1000

1055

Ø 30° 203 12 * Ø 11 20° 265 18 * Ø 11 15° 310 24 * Ø 14 15° 340 24 * Ø 14 20° 390 18 * Ø 18 15° 430 24 * Ø 18 20° 480 18 * Ø 18 15° 520 24 * Ø 22 20° 560 18 * Ø 26 15° 630 24 * Ø 26 15° 750 24 * Ø 33 15° 815 24 * Ø 33 12° 890 30 * Ø 33 10° 950 36 * Ø 33 10° 1120 36 * Ø 39

10

9

120

140

10

9

150

175

12

9

175

200

12

9

175

200

16

9

200

230

16

9

200

230

20

9

230

260

20

9

260

310

24

9

260

310

24

9

300

350

30

9

325

375

30

9

325

375

30

9

375

435

30

9

375

435

36

9

430

490

4.38 4.40 Nominal ratings to FEM section I 3rd edition 1987

Group classification M5, state of loading L 2 class of utilisation T5, (nout mean = 25 rpm; P [kW] = const.)

WINCH GEARBOXES

Winch corresponding to European Norm Draft CEN TC 151 (Edition 14/12/90)

ZOLLERN have a policy of continuous product improvement, and detail may be changed without notice.

H2 H2

G4 Cut out for lube oil pipework 4.13 to 4.29 – required in winch frame From 4.31 – oil filling within gear flange

H1

12 13

Flange Connection – End bearing to frame – Bolts class 8.8 F3 outer

F4 fixing

F5

F6

F7

F8

Ø

160 200 225 225 260 260 290 360 360 400 425 425 500 500 550

Assembly length E = T1 + 2 • T2 + W depending on design H1

H2

A

C

Mmax.

T1 min. 2-sta- 3-stages ges

T2

W L approx. frame 2-sta- 3-stathick- ges ges

X min.

ZHP EG

ness

Ø 60° 6*Ø9 60° 6 * Ø 11 60° 6 * Ø 11 60° 6 * Ø 11 60° 6 * Ø 14 60° 6 * Ø 14 60° 6 * Ø 18 60° 6 * Ø 22 60° 6 * Ø 22 60° 6 * Ø 22 60° 6 * Ø 26 60° 6 * Ø 26 60° 6 * Ø 33 60° 6 * Ø 33 60° 6 * Ø 33

TYPE

4.13

12

8

20

36

–

–

40

55

130

160

–

70

10

165

–

10

15

8

25

50

26

93,5

55

70

140

180

250

85

15

220

290

15

15

10

30

64

26

111

60

75

170

200

280

95

15

255

330

15

15

10

30

64

26

117

60

75

140

230

320

95

15

275

375

15

18

12

35

71

26

132

60

75

170

250

350

100

15

305

415

15

18

12

35

71

26

152

60

80

170

260

370

100

20

315

425

20

18

15

40

78

30

168

75

95

160

270

400

120

20

350

485

20

25

15

50

92

30

184

75

95

210

330

440

120

20

400

505

20

25

15

50

92

30

195,5

90

110

200

330

440

140

20

425

545

20

30

15

50

104

30

233

90

115

200

360

520

145

25

455

620

25

35

15

70

134

–

235

110

140

200

360

540

180

30

500

685

30

35

15

70

134

–

268

110

140

150

440

630

180

30

565

750

30

40

15

80

144

–

298

110

160

150

465

665

180

40

670

870

40

40

15

80

144

–

335

120

160

140

480

680

200

40

685

895

40

40

15

90

180

–

385

140

190

110

660

920

240

50

850

1100

50

4.15 4.19 4.20 4.22 4.24 4.25 4.26 4.27 4.29 4.31 4.32 4.33 4.34 4.36

Please refer to your ZOLLERN representative

4.38

Please refer to your ZOLLERN representative

4.40

Installation instructions To ensure correct operation of the winch, the frame location centres must be within the specified tolerances and the flange pieces square to the base plate. Care should be taken to design an adequately rigid and sub as

G/Box flange connection

deflections during installation and subsequent operation can take up working tolerances. These are given in the accompanying table.

frame connection

Type ZHP

AB

αG ±

A

Ø

AB

Ø

B

Maximum permitted deviation ∆H from the centreline in relation to L1

Type ZHP

αF ±

L1 ±

250

500

750

0,1

0,2

0,2

0,3

4.13

1 000 1 500 2 000 2 500

4.13

0,1

0,3

20°

0,2

0,2

60°

1

4.15

0,1

0,3

20°

0,2

0,3

60°

1

0,2

0,2

0,3

4.15

4.19

0,1

0,4

20°

0,2

0,3

60°

2

0,2

0,2

0,3

4.19

4.20

0,1

0,4

20°

0,2

0,3

60°

2

0,2

0,2

0,3

0,4

4.20

4.22

0,1

0,4

15°

0,2

0,3

60°

2

0,2

0,2

0,3

0,4

4.22

4.24

0,1

0,4

15°

0,2

0,3

60°

2

0,2

0,3

0,4

0,5

4.24

4.25

0,1

0,5

15°

0,4

0,4

60°

2

0,2

0,3

0,4

0,5

4.25

4.26

0,1

0,5

15°

0,4

0,5

60°

3

0,2

0,3

0,4

0,5

4.26

4.27

0,1

0,5

15°

0,4

0,5

60°

3

0,3

0,4

0,5

4.27

4.29

0,1

0,5

15°

0,4

0,5

60°

3

0,3

0,4

0,5

4.29

4.31

0,2

0,5

15°

0,6

0,5

60°

3

0,3

0,4

0,5

4.31

4.32

0,2

0,5

15°

0,6

0,5

60°

3

0,3

0,4

0,5

0,7

4.32

4.33

0,2

0,5

12°

0,6

0,5

60°

3

0,3

0,4

0,5

0,7

4.33

4.34

0,2

0,5

10°

0,6

0,5

60°

3

0,3

0,4

0,5

0,7

4.34

4.36

0,3

0,5

10°

0,8

0,5

60°

3

0,3

0,4

0,5

0,7

4.36

Ø 0,1 B

0,2

The fixing hole centres should lie within 0,1 of a theoretical cylinder about the winch centreline.

AB

The locating flange diameter should be flat within 0,2 about the winch centreline.

Surface to kept free of oil/ grease

Surface to kept free of oil/ grease

A

Ø

B

F2

B A

F1

G1

G2

∆H

Ø

G4

αG

F4

αF

AB

AB L1

WINCH GEARBOXES

AVAILABLE RATIOS FOR WINCHES

Type

4.13

4.15

4.19

4.20

4.22

4.24

4.25

4.26

4.27

4.29

4.31

4.32

4.33

4.34

4.36

4.38

4.40

approx. 13 15 18 21 25

35 45

Gear unit ratios i

53 63 70 83 84 95 99 107 113 114 129 136 147 176

Please refer to your ZOLLERN representative

29

14 15

HYDRAULIC CONTROL SYSTEMS FOR ROPE WINCHES

open loop

closed loop

Simplified view

RECOMMENDED LUBRICANTS FOR ZOLLERN ROPE WINCHES Type/Specification

Aral

Avia

BP

Chevron

Esso

SAE 90 EP * MIL-L-2105 B

ARAL Gear oil Hyp 90

AVIA Gear oil Hypoid 90 EP

BP Multi-purpose gear oil EP SAE 90

CHEVRON Universal gear lubricant SAE 90

ESSO Gear oil GX 90

Lith. MZ-Grease NLGI 3 K 2 K DIN 51825

ARAL Multi-purpose grease ARAL Grease HL 3

AVIA Multi-purpose grease

BP Multi-purpose grease L 3 BP Energr. LS 3

CHEVRON Dura-Lith Grease 3

Beacon 3 ESSO Multi-purpose grease

Type/Specification

Fuchs

GULF

Mobil

Shell

Texaco

SAE 90 EP * MIL-L-2105 B

FUCHS Gear oil Hypoid EW SAE 90

GULF Multi-Purpose gear lubricant SAE 90

MOBILUBE HD 90

SHELL Spirax HD 90

Multigear lubricant EP 90

Lith. MZ-Grease NLGI 3 K 2 K DIN 51825

FUCHS Grease FWA 220 – FUCHS Multi-purpose grease

GULF Crown Grease No. 3

Mobilgrease MP Mobilux

Shell Retinax A SHELL Alvania Grease R 3

Marfak All Purpose Glissandro FL 30

* Mineral oil based, before using biodegradable oil (e.g. synthetic oil) please consult the manufacturer

Lubrication frequency Oil: 1st oil change after 200, 2nd oil change after 1000, further oil changes after every 1000 operating hours; at least once a year. Grease: Once a week or on recommissioning.

ACCESSORIES FOR ZOLLERN WINCHES (ON REQUEST) • Winch frame • Lay on roller • Spooling guide • Over centre valve • Rope pay out limit switch • Safety disc-brake

WINCH GEARBOXES

• Drum rotation limit switch (hydraulic/ electric) • Bevel input gearbox • Change speed gearbox (manual) • Change speed gearbox (hydraulic) • Differential speed drive (Vario-speed-winch)

ZOLLERN – Rope winches Essential design data Company/Address Proper department Number of inquiry Demand Application

Person concerned Telephone-No. Email Used for

Date

(e.g. mobile crane, shipboard, off-shore, mobile wharf, construction crane)

Telefax-No.

(e.g. lifting, luffing, level luffing gear)

Operating data - Design criteria (All values based on 1st rope layer) Rope pull on drum Rope velocity Rope pull on drum Rope velocity

F1 v1 F2 v2

P K

[kW]

Rope pull on drum Rope velocity Rope pull on drum Rope velocity Rope pull on drum Rope velocity Rope pull on drum Rope velocity

F1

F1 v1 F2 v2 F3 v3 F4 v4 Rope pull on drum F [kN]

Rope pull on drum F [kN]

Installed power Regulation factor

[kN] [m/min.] [kN] [m/min.]

F2 v1

[kN] [m/min.] [kN] [m/min.] [kN] [m/min.] [kN] [m/min.]

F2 F3 F4

v2

[-]

16 17 [kN] [hrs.] [kN] [m/min.]

Design in acc. with FEM Section I and DIN 15020 Gear drive group Running time class. Loading cond.

F1

v1 v2 v3 v4

Rope velocity v [m/min.]

Safety factor (e.g. 1,5) against yield strength of material with rope pull on drum of F1 Calculated service life in operating hours h with rope pull on drum of F1 and rope velocity v1

Design in acc. DIN Design Principles on lifting gear Operatig hour class. Hazard class. Standard cond. Lifting class.

Rope velocity v [m/min.]

Acceptance in acc. with Classification Society GL, LROS, DNV, USSR etc.

Technical data Diameter of rope drum Length of rope drum between drum flanges Diameter of rope Rope groove lead

D1

[mm]

L2 d p

[mm] [mm] [mm]

Direction of drum lead right-hand left-hand Type of drum groove DIN 15061 special grooveless Point of rope fixture drive-side opposite to drive

Number of rope layers Length of rope to be wound including 3 safety turns

Drive hydraulic motor

Drive electric motor

Make Type Available displacement Q Available pressure ∆p

Make Type Power Speed revs

[l/min] [bar]

[kW] [min.]

n

[-]

Ls

[mm]

Diameter of drum flanges D2 Gear transmission i

[mm] [-]

Voltage, kind of current Starting torque Overload torque Duty factor Starts per hours

[Nm] [Nm] [%]

TA Tk ED

Brake Used as Parking brake Service brake

Design spring loaded multi disc brake with addit. back stop band brake

Operation hydraulic electromagnetic

Remarks and special operating conditions

Please complete this sheet and return.

Minimum release pressure Maximum release pressure Anticipated back-pressure

[bar] [bar] [bar]

Factories of the Zollern group of companies Laucherthal factory

Steel profiles Postfach 12 20 ZOLLERN GmbH & Co. KG D-72481 Sigmaringen Tel. +49 75 71 70 24 6 Fax +49 75 71 70 27 5 eMail [email protected]

Foundry technology Postfach 12 20 D-72481 Sigmaringen Tel. +49 75 71 70 44 0 Fax +49 75 71 70 60 1 eMail [email protected]

Mannheim factory

Sales: Tel. +49 7571 70246 Fax +49 7571 70275 eMail [email protected]

ZOLLERN ISOPROFIL GmbH & Co. KG

Portugal factory

Steel profiles Postfach 24 03 59 D-68173 Mannheim Tel. +49 62 18 45 90 Fax +49 62 18 45 92 63 eMail [email protected]

factory

62, Rue Pierre Curie B.P.No 1055 ZOLLERN TLC SAS F-78131 Les Mureaux CEDEX Tel. +33 1 34 74 39 00 Fax +33 1 34 74 28 52

Sales offices

Foundry technology Rua Jorge Ferreirinha, 1095 Apartado 1027 P-4470-314 Vermoim MAIA Tel. +351 22 94 14 68 1 Fax +351 22 94 14 69 5 eMail [email protected]



ZOLLERN S.à.r.l 13, Rue Allwies F-57200 Sarreguemines Tel. +33 3 87 95 35 14 Fax +33 3 87 95 35 21 eMail [email protected] www.zollern.fr

No. 33, 7th Avenue TEDA-TIANJIN 300 457 Peoples Republic of CHINA Tel. +86 22 25 32 38 11 Fax +86 22 25 32 38 10 eMail [email protected]

Great Britain

Zollern UK Limited Castle Hill Kenilworth GB-CV8 1NB Tel. +44 19 26 51 54 20 Fax +44 19 26 85 34 11

Drive technology Gears Hüttenstraße 1 D-46284 Dorsten Tel. +49 23 62 67 0 Fax +49 23 62 67 40 3 eMail [email protected]

Italy

ZOLLERN Italiana S.r.L. Via C. Battisti, 1 I-21045 Gazzada (VA) Tel. +39 03 32 46 20 59 Fax +39 03 32 46 20 67 eMail [email protected] www.zollern.it

Braunschweig factory

Drive technology Friction bearing technology ZOLLERN BHW Gleitlager Postfach 32 13 GmbH & Co. KG D-38022 Braunschweig Tel. +49 53 12 60 50 Fax +49 53 12 60 52 22 eMail [email protected]

Netherlands

ZOLLERN Nederland B.V. Postbus 134 NL-5150 AC DRUNEN Tel. +31 41 63 22 92 0 Fax +31 41 63 20 93 6 eMail [email protected] www.zollern.nl

Osterode factory

Sweden

Kvalitetsstal AB P. O. Box 233 SE-73224 Arboga Tel. +46 58 91 60 35 Fax +46 58 91 20 02 eMail [email protected] www.kvalitetsstal.se

USA

ZOLLERN North America L.P. 9364 Wallisville Rd., Suite 150 Houston, Texas 77013 USA Tel. +1 71 36 73 79 02 Fax +1 71 36 73 79 50 eMail [email protected]

ZOLLERN & Comandita

China factory ZOLLERN (Tianjin) Maschinery Co., LTD.

Dorsten factory ZOLLERN Dorstener Antriebstechnik GmbH & Co. KG

Drive technology Friction bearing technology ZOLLERN BHW Gleitlager Rolandsweg 8 – 12 GmbH & Co. KG D-37520 Osterode am Harz Tel. +49 55 22 31 27 0 Fax. +49 55 22 31 27 99

Brazil factory ZOLLERN LTDA

Drive technology Friction bearing technology Av. Manoel Inácio Peixoto 2147 BR-36770-000 Cataguases MG Tel. +55 32 42 92 00 2 Fax +55 32 42 92 00 3 eMail [email protected]

eMail [email protected] www.zollern.co.uk

Aulendorf factory

Engineering elements Postfach 12 65 ZOLLERN GmbH & Co. KG D-88322 Aulendorf Tel. +49 75 25 94 81 30 Fax +49 75 25 94 81 00 eMail [email protected]

WINCH GEARBOXES

www.zollern.com

18 19 ZOLLERN GmbH & Co. KG Drive Technology Gears and Winches Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 95 47 Fax +49 75 86 95 95 75 eMail [email protected]

ZOLLERN GmbH & Co. KG Drive Technology Heustraße 1 D-88518 Herbertingen

Automation Division Tel. +49 75 86 95 95 86 Fax +49 75 86 95 95 85 eMail [email protected]

Herbertingen factory

We offer comprehensive project management: • Many years of project experience • CAD masters • Project meetings on-site and plant inspections • Detailed, binding offers

Gears and Winches Division Tel. +49 75 86 95 95 47 Fax +49 75 86 95 95 75 eMail [email protected]

Friction Bearings Division Tel. +49 75 86 95 95 20 Fax +49 75 86 95 97 15 eMail [email protected]

www.revoLUZion.de

ZOLLERN Getriebe + Winden Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 90 Fax +49 75 86 95 95 75 [email protected] www.zollern.com

Z237 09.2004

ZOLLERN GmbH & Co. KG