ROPE WINCHES AND GEARBOXESTRANSMISSION TECHNOLOGY The ZOLLERN Group The ZOLLERN Group is an international company with over 3000 employees. Our fields of activity include transmission technology (automation, gears and winches), plain bearing technology, mechanical engineering components, foundry technology and steel profiles. WINCH GEARBOXES • ZOLLERN Winch Gearboxes • Design and Construction • Integrated Rope drum • Rope fixing • Rope grooves and Rope • Application Factor K • Classification Guidance • Calculation of Rope load • Calculation of Rope diameters and Rope drum diameters • Winding Direction on Rope drums • Technical Data • Supporting Frame Machining Tolerances • Gear Reduction Ratios • Hydraulic Control Layouts • Recommended Lubricants • Accessoires for ZOLLERN Winches • Application Questionnaire 3 4 7 8 9 10 10 11 11 11 12 14 15 16 16 16 17 WINCH GEARBOXES 2 3 ZOLLERN WINCH GEARBOXES ZOLLERN Winch Gearboxes have proved highly successful under extreme operating conditions. Their principal features and most significant advantages are • compact dimensions • ease of maintenance • long operation life • high performance • modular design of gear unit • functional design With these characteristics the machine designer will get a ready to install unit and will achieve economic solutions even in confined space conditions. Potential applications: • mobile cranes • construction cranes and conveyors • material and working elevators • loading and cargo handling cranes • shipboard and deck cranes • rescue and wrecker salvage trucks • dockyard and harbour cranes • offshore cranes • container gantries • access platforms ZOLLERN gears use components common to our complete range (Winches, Slewing Units, Industrial Gears, Free Fall Winches) giving the advantage of volume production: cost savings from standard parts, reduced lead times, tested and proven designs across the whole range and readily available spares for units in service. DESIGN AND CONSTRUCTION OF ROPE WINCHES WITH FLANGE DRIVE GEARBOX 2 stage planetary gearbox Ratios from i = 21 to 29 Gearbox mounted inside winch drum, Parking Brake and Hydraulic motor flange mounted externally. Input and output in opposite sense of rotation. 3 stage planetary gearbox Ratios from i = 45 to 147 Gearbox mounted inside winch drum, Parking Brake and Hydraulic motor flange mounted externally. Input and output in opposite sense of rotation. 2 stage planetary gearbox with spur stage input Ratios from i = 40 to 150 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. WINCH GEARBOXES Winch Gearbox Range Output torques: 1,750 to 1,500,000 Nm. Rope load: 17 to 1,950 kN. In calculating the rope load care must be taken to include reeving, hooks and an allowance for reeving efficiency (see page 11). Lubrication All gears and anti-friction bearings are splash lubricated. Service intervals and recommended lubricants are given in the table on page 16. The end support bearing can be grease packed for lifetime operation – requiring no further service attention. Oil change An external fill/breather/drain pipe is fitted to the drive flange of winch gearbox. Oil level Oil level is checked by either dip stick or sight glass. Notes The output torques Tdyn max, listed on pages 12/13 are based on FEM Standards I/3rd edition/load conditions L2 running time classification T5, in accordance with ‘Drive unit group M5’. Ambient temperature +20 C° (FEM - Federation Europeenne de la Manutention). 4 5 Gear Design 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. Cooling Cooling may be required where the unit is to operate continuously in direct sunlight or high ambient temperature environments. Cooling may be also required if the power on time is high. ZOLLERN can provide suitable coolers. Bearings All rotation parts run on rotation element bearings. Ball bearings are used to support the input gearing, needle roller bearings for the planet wheels and self aligning bearings for the drum support bearings. Input Options ZOLLERN’s modular system provides for hydraulic or electric motor input interfaces. Flange mounted or free shaftwith key to DIN 5480. Seals Efficiency The efficiency per planetary stage is 98% and about 99% for the drum bearings including seals. Example: Rope winch with 2 planetary gear stages η total = 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 Horizontal Brakes 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, single disc or barrel brakes with direct connection to the rope drum can be fitted for additional safety back up. Fitting ZOLLERN’s winch gearbox is designed to be flange mounted in a fabricated steel structure. The drive end mounting flange reacts rope load and transmission torque, the non drive end reacts rope loads only and can be safely removes to facilitate fitting of the winch drum and gearbox. Backstop For special applications a backstop can be incorporated between the gear transmission and the parking brake. It operates as follows. Lifting of load - Parking brake closed - Backstop open Lowering of load - Parking brake open - Backstop closed Electric motor Standard electric motors cannot be mounted inside the winch drum. As opposed to Electric-Compact-Winch. Operating conditions 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. 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 support housing. b) hydraulic ZOLLERN geared limit switch operating as the electrical version – with a hydraulic signal. Paint Primer This is a specially developed multi-primer with a twocomponent zinc-dust epoxy resin base. Colour: Grey white. 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 Tdyn calculated from the rope load and rope drum diameter must be multiplied by the factor K. Tnom = Tdyn x K ≤ Tdyn max For application factor K and calculation of the rope load see pages 10. 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. 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. Material for rope drum: - ductile graphite iron (EN-GJS-400-15; EN-GJS-600-3) - steel (S355JO) Other material available on request Rope drum diameter D1 1,5 . d Drum flange diameter D2 D2 = D1 + 2 (z + 1) d D1 = 20 x d or as specified d Length of rope including 3 safety turns LS = LS L2 D1 d D2 ( )( L2 -a p D1 D1 + 0,866 . d (z-1) ) z.π 1000 p z a = Pitch of rope groove [mm] = Number of rope layers [–] = 1 for normal grooves [–] = 0,5 for special grooves = Length of rope [m] = Length of drum [mm] = Diameter of drum [mm] = Diameter of rope [mm] ROPE FIXING Wedge lock a) on the outside of the drum flange Rope Clamps 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 Rope grooves On cast drums cleanly cast and trimmed, and at the flash line carefully ground. On welded drums all edges are deburred and radiussed. α Fleet angle To achieve acceptable rope winding - 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. Rope groove lead/pitch Right-hand lead on standard design Left hand lead Direction of rope lay Rope lay should be in the opposite sense to drum lead. For example: right-hand rope lay left-hand rope lay APPLICATION FACTOR K FOR WINCHES Symbol Running time classification Mean running time per day in hours, related to one year Life in hours 8 years, 200 days/year Load conditions L1 L2 L3 L4 M log M log M log M log L L L L T2 over 0,25 to 0,5 400 to 800 T3 over 0,5 to 1 800 to 1 600 T4 over 1 to 2 1 600 to 3 200 T5 over 2 to 4 3 200 to 6 300 T6 over 4 to 8 6 300 to 12 500 T7 over 8 to 16 12 500 to 25 000 T8 over 16 25 000 to 50 000 Collective coefficient km to 0,125 0,125 to 0,250 0,250 to 0,500 0,500 to 1,000 M1 0,90 M2 0,90 M3 1,05 M4 1,32 M2 0,90 M3 0,92 M4 1,09 M5 1,36 M3 0,92 M4 0,96 M5 1,17 M6 1,46 Drive unit class Application Factor K M4 0,9 M5 1 M6 1,23 M7 1,53 M5 0,92 M6 1,07 M7 1,28 M8 1,58 M6 1,1 M7 1,3 M8 1,53 M8 1,8 M7 1,36 M8 1,6 M8 1,89 M8 2,22 CLASSIFICATION GUIDANCE According FEM section I, 3rd edition, table T.2.1.3.5. Type of appliance Designation Erection cranes Stocking and reclaiming transporters Stocking and reclaiming transporters Workshop cranes Particulars concerning nature of use (1) Hoisting M2 – M3 Hook duty Grab or magnet M5 – M6 M7 – M8 M6 M8 M6 – M7 M4 – M5 Slewing M2 – M3 M4 M6 M4 M6 M5 – M6 M4 – M5 Type of mechanism Luffing M1 – M2 – – – – M3 – M4 – Traverse M1 – M2 M4 – M5 M6 – M7 M4 M6 – M7 M6 – M7 M4 – M5 Travel M2 – M3 M5 – M6 M7 – M8 M5 M7 – M8 M4 – M5 M4 – M5 Overhead travelling cranes, pigbreaking cranes, Grab or magnet scrapyard cranes Bridge cranes for unloading, bridge cranes for containers Other bridge cranes (with crab and/or slewing jib crane) Bridge cranes for unloading, bridge cranes (with crab and/or slewing jib crane) Drydock cranes, shipyard jib cranes, jib cranes for dismantling Dockside cranes (slewing, on gantry, etc.), floating cranes and pontoon derricks Dockside cranes (slewing, on gantry, etc.), floating cranes and pontoon derricks Floating cranes and pontoon derricks for very heavy loads (usually greater than 100 t) Deck cranes Deck cranes Tower cranes for building Derricks Railway cranes allowed to run in train Mobile cranes Hook Hook duty Grab or magnet a) Hook or spreader duty b) Hook duty Grab or magnet Hook duty Hook duty Grab or magnet M8 M5 – M6 M6 – M7 M7 – M8 M3 – M4 M4 M5 – M6 M4 M2 – M3 M3 – M4 M3 – M4 M5 – M6 M4 – M5 M5 – M6 M6 – M7 M3 – M4 M3 – M4 M3 – M4 M5 M1 – M2 M2 – M3 M2 – M3 M3 – M4 M4 – M5 M5 – M6 M6 – M7 M3 – M4 M3 – M4 M3 – M4 M4 M1 – M2 M2 – M3 M2 – M3 M7 – M8 M4 – M5 – – – M2 M4 – M5 M3 – – – M4 – M5 M5 – M6 M3 – M4 M4 – M5 – M3 M3 – M4 M3 – – – WINCH GEARBOXES CALCULATION OF ROPE LOAD FNOM ON THE ROPE DRUM Rope load Fnom Fnom = (mload + mtackle) g · 1 n · ηs · Ψ [N] Efficiency of rope drives ηs = (ηR)i · ηF = (ηR)i · 1 1 - (ηR)n · n 1 - ηR 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) 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 For compensating pulleys no efficiency value must be considered. For Ψ = vibration coefficient see FEM-Section 1, 3. Edition October 1998 10 11 2-stranded pulley block n=2 Twin pulley tackle 4-stranded, comprising 2 pulley blocks each 2-stranded 2 x (n = 2) CALCULATION OF ROPE DIAMETERS AND ROPE DRUM DIAMETERS IN ACC. WITH DIN 15020 Coefficient c Gear drive group Rope diameter dmin = c · √ S S = Rope pull in N C = Coefficient in mm/√ N Rotationfree wire ropes 2 Coefficient h1 Coefficient h2 = 1 Rope drum diameter Dmin = h1 · h2 · dmin Non rotationfree wire rope 14 16 18 20 22,4 25 Rotationfree or low-rotation wire rope 16 18 20 22,4 25 28 Non rotationfree wire ropes 1 570 Nominal strength of individual wires in N/mm 1 770 1 960 2 160 2 450 1 570 0,0800 0,0750 – – – – – – 0,0900 1 770 0,0850 1 960 0,0800 0,0900 1 Bm 1 Am 2m 3m 4m 5m 0,0850 0,0900 0,0850 0,0950 0,106 0,118 0,132 0,0950 0,106 0,118 0,132 0,150 WINDING DIRECTION ON ROPE DRUMS Right-hand Rope pull overshot Rope pull undershot Left-hand Rope pull overshot Rope pull undershot Rope entry Rope entry Rope entry Rope entry G4 Integrated drive unit Oil pipe connection ports H1 Drive unit with spur gear Sizes 4.13 to 4.29: the oil pipe connection ports are on the gear mounting flange. Sizes 4.31 and above: the oil pipe connection is on the gearbox face. TYPE 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 4.38 4.40 4.44 Nominal gearbox ratings Output torque (Nm) Typical Max line input D O G1 pull speed approx. location nmax. Fnom (kN) 17 18 33 34 46 48 67 69 95 98 116 119 143 147 180 184 213 220 304 313 395 408 549 566 637 660 760 787 1 038 1 073 1 450 1 520 1 820 1 950 2 540 2 650 Ø (rpm) 180 260 300 Depending on motor and brake arrangement 2000…5000 rpm 340 390 440 480 520 570 670 770 830 930 1 030 1 200 1 360 1 530 1 800 125 155 190 200 230 270 300 330 355 430 515 580 670 720 840 1 060 1 160 1 250 G Flange connection – Gear unit to frame Bolts class 10.9 G2 pcd G3 outer G4 fixing G5 G6 S Ø Flange connection – Gear unit to drum Bolts class 8.8 S3 outer S4 fixing S5 S6 F1 location H2 H2 FF F2 pcd Ø Ø ± 0,2 140 175 200 200 230 230 260 310 310 350 375 375 435 435 490 680 680 850 S1 S2 location pcd Tdyn max I ≤ 70 I > 70 1 650 1 750 4 000 4 150 7 000 7 300 11 200 11 600 18 800 19 400 25 000 25 500 35 000 36 000 47 000 48 000 61 000 63 000 102 000 105 000 150 000 155 000 229 000 236 000 300 000 311 000 392 000 406 000 623 000 644 000 1050000 1100000 1400000 1500000 2400000 2500000 Tstat max I ≤ 70 I > 70 2 650 2 800 6 400 6 650 11 200 11 700 18 000 18 500 30 000 31 000 40 000 41 000 56 000 57 500 75 000 77 000 97 500 101 000 163 000 168 000 240 000 248 000 366 500 377 500 480 000 497 500 627 000 649 500 997 000 1 030 500 1 680 000 1 760 000 2 240 000 2 400 000 3 840 000 4 000 000 Ø ± 0,2 145 Ø Ø ± 0,2 185 245 290 320 360 400 440 480 520 590 690 755 840 900 1 055 1 320 1 420 1 725 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 22 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° 1 120 36 * Ø 39 # 10° 1 390 36 * Ø 33 # 10° 1 490 36 * Ø 33 # 7,5° 1 820 48 * M 33 30° 167 12 * M 10 20° 185 213 16 * M 12 20° 225 255 16 * M 16 20° 255 285 16 * M 16 15° 280 315 22 * M 16 15° 320 355 22 * M 16 15° 350 385 22 * M 20 15° 390 425 22 * M 20 15° 420 460 22 * M 24 15° 480 530 22 * M 24 15° 565 615 24 * M 30 15° 630 680 24 * M 30 12° 720 770 30 * M 30 10° 770 820 36 * M 30 10° 900 960 36 * M 36 # 10° 1 140 1 210 36 * M 30 # 10° 1 240 1 310 36 * M 30 # 7,5° 1 350 1 441 48 * M 30 16 24 25 25 25 25 30 30 38 38 47 47 47 47 56 78 78 105 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 26 26 25 145 225 265 295 330 370 400 440 470 550 640 700 790 850 1 000 1 240 1 340 1 630 10 10 12 12 16 16 20 20 24 24 30 30 30 30 36 45 45 55 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 13 13 25 120 150 175 175 200 200 230 260 260 300 325 325 375 375 430 600 600 750 Rating according to FEM section I Drive unit class M5 Load condition L 2 (P = const. / nab = 15 rpm) Running time class T5 # With clamping sleeves ZOLLERN have a policy of continuous product improvement, and detail may be changed without notice. WINCH GEARBOXES LENGTH DEPENDING ON MOTOR/BRAKE SIZE FLANGE CONNECTION A M max X L 3 stage unit L 2 stage unit X F8 F7 FLANGE CONNECTION S6 Connecting flange for geared limit switch D0 G6 FLANGE CONNECTION F6 F5 FLANGE CONNECTION G5 S5 T2 L2 INSTALLATION DIMENSION C T2 W 4.38 and 4.40 have same connecting flange as 4.36 12 13 Flange Connection – End support bearing to frame – Bolts class 8.8 F3 outer F4 fixing F5 F6 F7 F8 H1 H2 A C Mmax. Assembly length = L2 + 2 * T2 + W depending on design T1 min. 2-sta- 3-stages ges T2 W L approx. frame 2-sta- 3-stathick- ges ges X min. TYPE ZHP EG 10 15 15 15 15 20 20 20 20 25 30 30 40 40 50 50 50 70 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 4.44 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 30° 12 * Ø 33 30° 12 * Ø33 15° 24 * Ø33 Ø ness – 93,5 111 117 132 152 168 184 195,5 233 235 268 298 335 385 460 497 460 545 675 675 160 200 225 225 260 260 290 360 360 400 425 425 500 500 550 750 750 950 12 15 15 15 18 18 18 25 25 30 35 35 40 40 40 50 50 60 8 8 10 10 12 12 15 15 15 15 15 15 15 15 15 20 20 25 20 25 30 30 35 35 40 50 50 50 70 70 80 80 90 80 80 110 36 50 64 64 71 71 78 92 92 104 134 134 144 144 180 180 180 230 – 26 26 26 26 26 30 30 30 30 – – – – – – – – 40 55 60 60 60 60 75 75 90 90 110 110 110 120 120 130 130 115 55 70 75 75 75 80 95 95 110 115 140 140 160 160 190 170 170 210 130 140 170 140 170 170 160 210 200 200 200 150 150 140 110 – – – 165 185 190 225 245 270 270 305 325 370 375 465 470 495 685 960 1 235 – – 255 290 295 345 405 395 445 455 520 540 695 720 760 970 1 320 1 650 1 750 70 85 95 95 100 100 120 120 140 145 180 180 180 200 240 230 195 220 10 15 15 15 15 20 20 20 20 25 30 30 40 40 50 60 60 80 170 225 245 270 300 325 350 375 420 465 515 590 675 700 875 1 195 1 320 – – 295 340 350 410 460 480 510 560 620 685 815 925 975 1 160 1 555 1 735 1 690 SUPPORTING FRAME MACHINING TOLERANCES 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 support and sub support as deflections during installation and subsequent operation can take up working tolerances. These are given in the accompanying table. G/Box flange connection Type ZHP 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 Ø 0,1 B The fixing hole centres should lie within 0,1 of a theoretical cylinder about the winch centreline. AB Ø A Support frame connection αG 20° 20° 20° 20° 15° 15° 15° 15° 15° 15° 15° 15° 12° 10° 10° 10° 10° 0,2 0,2 0,2 0,2 0,2 0,2 0,4 0,4 0,4 0,4 0,6 0,6 0,6 0,6 0,8 0,8 0,8 αF 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 60° 0,2 Maximum permitted deviation ΔH from the centreline in relation to L1 L1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 AB Type ZHP 4.13 4.15 4.19 AB Ø B 250 0,1 500 0,2 0,2 0,2 0,2 0,2 750 0,2 0,2 0,2 0,2 0,2 0,2 0,2 0,2 1 000 1 500 2 000 2 500 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,4 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,7 0,7 0,7 0,7 0,7 0,7 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,2 0,2 0,2 0,2 0,3 0,3 0,3 0,3 0,3 0,4 0,4 0,4 0,4 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,1 0,1 0,2 0,3 0,3 0,3 0,3 0,3 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 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 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 WINCH GEARBOXES GEAR REDUCTION RATIOS Ratio 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 2-stages – coaxial 21 25 29 3-stages – coaxial 45 53 60 63 70 71 83 93 99 107 112 127 147 4-stages – coaxial 173 206 245 267 301 317 357 429 464 557 670 761 866 1000 Other ratios available on request 14 15 HYDRAULIC CONTROL LAYOUTS Simplified view open loop closed loop RECOMMENDED LUBRICANTS FOR ZOLLERN ROPE WINCHES Table of Lubricants Type/Specification Lubricants to DIN 51502 Mineral Oils to DIN 51 517 T3 CLP 220 Aral Avia BP Castrol Esso Fuchs Gulf Klüber Mobil Shell Texaco Total Degol BG 220 Gear RSX 220 Energol GR-XP 220 Alpha SP 220 Spartan EP 220 Renolin CLP 220 EP Lubricant HD 220 Klüberoil GEM 1-220 N Mobilgear 630 Omala 220 Meropa 220 Carter EP 220 Synthetic Lubricants to CLP PAO 220 Aral Degol PAS 220 Avia Synthogear 220 EP Enersyn HTX 220 – – – – Klübersynth GEM 4-220 N Mobil SHC 630 Omala HD 220 – Carter SH 220 PG 220 Degol GS 220 Avilub VSG 220 Energol SG-XP 220 – Umlauföl S 220 Renolin PG 220 – Klübersynth GH 6-220 Mobil Glygoyle 30 Tivela WB Synlube CLP 220 Carter SY 220 Grease to DIN 51825 KP 2 K Aralub HLP 2 Avialith 2 EP Energrease LS-EP 2 Spheerol EPL 2 Grease Beacon EP 2 Fuchs Renolit FEP 2 Gulf Crown Grease No. 2 Centoplex 2 EP Mobilux EP 2 Alvania EP 2 Multifak EP 2 Multis EP 2 Attention: Mineral and PAO-based gearbox oils are not to be mixed with PG (polyglycol)-based synthetic oil. Greases with different soap bases are not to be mixed. Lubrication frequency Oil 1st oil change after 200 operating hours Grease 2nd oil change after 1000 operating hours further oil change after every 1000 operating hours; at least once a year Once a week or on recommissioning Lubrication type only according indication in the installation drawing resp. in the maintenance manual. ACCESSORIES FOR ZOLLERN WINCHES (ON REQUEST) • Winch frame • Lay-on roller • Spooling guide • Load holding valve • Rope limit switch • Fail save brake WINCH GEARBOXES • Rope tension control • Cam limit switch (hydraulic/electric) • Bevel gear input • Switch speed gearbox (hydraulic/manual) • Differential (Vario-speed) drive system ZOLLERN – Winch Gearboxes Application Questionnaire Company/Address Proper department Number of inquiry Demand Application Date Person concerned Telephone-No. Email Used for Telefax-No. (e.g. mobile crane, ship-offshore-harbour cranes, tower cranes) (e.g. hoisting-, luffing-, pulling winch) Operating conditions – Design criteria (All values related to Rope loads and winch ratings No. of ropes on drum w Nominal line pull (for each rope) Line pull at drum F1 [kN] Rope speed v1 [m/min] Empty hook Line pull at drum Fempty [kN] Rope speed vempty [m/min] Installed power P [kW] Rating acc. to FEM Section I Drive unit class Load conditions Running time class M L T Approval acc. to classification society ABS DNV GL LRS RMRS Others F1 first/ top rope layer) Line pull at drum F [kN] Alternative rating Load F1 Tdyn cond. [kN] [Nm] 1 2 3 4 v1 n1 Time slice [m/min] [min -1] [%] 16 17 Fempty v1 Rope speed v [m/min] for P = constant vempty 100 % Calculated life time Safety against Yield strength with Tdyn Fdyn [hour] [–] Break Tstat Fstat z [Nm] [kN] [–] Technical data Diameter of rope drum Length of drum between flanges Rope diameter Rope groove pitch D1 L2 d p [mm] [mm] [mm] [mm] Drum Lead right left Type of rope groove DIN 15061 Special grooveless Position of rope anchor drive side opposite to drive No. of rope layers Length of rope to be wound including 3 safety turns Ls [m] [mm] [–] Diameter of drum flanges D2 Ratio i Drive hydraulic motor Manufacturer Type Available oil flow Q Available differential pressure ∅ p Drive electric motor Manufacturer Type Power [kW] Speed [rpm] Control (Frequency inverter; ON/OFF; Softstarter) Voltage, AC/DC Starting torque Breakdown torque Power-on time Starting per hour TA Tk ED [Nm] [Nm] [%] [l/min] [bar] Brake Apply as Parking brake Service brake Design Spring loaded multi disc brake with backstop Brake motor Steel mesh guard Rope guard Rope drum End support bearing End support bearing with plate Fail save brake Disc brake Drum brake Actuation hydraulically electric min. release pressure max. release pressure expected back pressure [bar] [bar] [bar] Scope of supply Motor Load holding valve Brake for drive unit Motor flange Reaction torque arm Winch frame Lay-on roller Rope spooling device Rope tension control Rope Rope limit switch Geared limit switch Incremental encoder Hydraulic power pack Frequency control Hydraulic control Approval Material Certificates Remarks and special operating conditions Please fill in all known data. ZOLLERN plants 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] Laucherthal plant 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] France plant Plain Bearing Technology 62, Rue Pierre Curie ZOLLERN TLC SAS B.P.No 1055 F-78131 Les Mureaux CEDEX Tel. +33 1 34 74 39 00 Fax +33 1 34 74 28 52 eMail
[email protected] www.zollern.fr Sweden plant ZOLLERN Norden AB P. O. Box 233 SE-73224 Arboga Tel. +46 58 91 60 35 Fax +46 58 91 20 02 eMail
[email protected] www.zollern.se Portugal plant ZOLLERN & Comandita 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] China plant ZOLLERN (Tianjin) Machinery Co., LTD. Transmission Technology No. 79, 11th Avenue TEDA 300 457 Tianjin Peoples Republic of CHINA Tel. +86 22 66 23 18 60 Fax +86 22 25 32 38 10 eMail
[email protected] USA plant 283 Lockhaven Drive Suite 204 Houston TX 77073 ZOLLERN USA North America L.P. Tel. +1 71 36 73 79 02 Fax +1 71 36 73 79 50 eMail
[email protected] Dorsten plant ZOLLERN Dorstener Antriebstechnik GmbH & Co. KG Transmission Technology Gears Hüttenstraße 1 D-46284 Dorsten Tel. +49 23 62 67 21 0 Fax +49 23 62 67 41 0 eMail
[email protected] Romania plant 0317235 Pecica FN Ferma 20 S.C. Zollern S.R.L. Arad - Romania Plain Bearing Technology Alte Leipziger Strasse 117 ZOLLERN BHW Gleitlager D-38124 Braunschweig Tel. +49 53 12 60 50 GmbH & Co. KG Fax +49 53 12 60 52 22 eMail
[email protected] Braunschweig plant Sales offices France ZOLLERN S.à.r.l 6A rue Gutenberg F-57200 Sarreguemines Tel. +33 3 87 28 45 02 Fax +33 3 87 28 45 03 eMail
[email protected] www.zollern.fr Plain Bearing Technology Rolandsweg 16 – 20 ZOLLERN BHW Gleitlager D-37520 Osterode am Harz Tel. +49 55 22 31 27 0 GmbH & Co. KG Fax +49 55 22 31 27 99 eMail
[email protected] Osterode plant Great Britain Zollern UK Limited Castle Hill 1, The Stables Kenilworth GB-CV8 1NB Tel. +44 19 26 51 54 20 Fax +44 19 26 85 34 11 eMail
[email protected] www.zollern.co.uk Brazil plant Plain Bearing Technology Av. Manoel Inácio Peixoto, 2147 ZOLLERN BR-36771-000 Cataguases MG Transmissoes Mecanicas Tel. +55 32 34 29 53 02 LTDA Fax +55 32 34 29 53 26 eMail
[email protected] Italy ZOLLERN Italiana S.r.L. Via della Ciocca, 9 I-21026 Gavirate (VA) Tel. +39 03 32 46 20 59 Fax +39 03 32 46 20 67 eMail
[email protected] www.zollern.it Aulendorf plant Mechanical Engineering Components Sandweg 60 ZOLLERN D-88322 Aulendorf Maschinenbauelemente Tel. +49 75 25 94 81 33 GmbH & Co. KG Fax +49 75 25 94 81 00 eMail
[email protected] Netherlands ZOLLERN Nederland B.V. Kerkstraat 37 5253 AN Nieuwkuijk Tel. +31 73 51 11 00 9 eMail
[email protected] Fax +31 73 51 15 10 0 www.zollern.nl Soest plant ZOLLERN AluminiumFeinguss Soest GmbH & Co. KG Foundry Technology Overweg 15 D-59494 Soest Tel. +49 2921 7896-0 Fax +49 2921 7896-17 eMail
[email protected] www.zollern-afs.de Russia ZOLLERN Ltd. 115114, Russia, Moscow Derbenevskaja nab., 11, A 6. Stock, Office 66 Tel. +7 495 91 36 85 0 eMail
[email protected] Fax +7 495 91 36 85 1 www.zollern.ru WINCH GEARBOXES CONTACT 18 19 ZOLLERN GmbH & Co. KG Transmission Technology Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 90 Fax +49 75 86 95 95 75 eMail
[email protected] ZOLLERN GmbH & Co. KG Automation Division Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 95 86 Fax +49 75 86 95 95 85 eMail
[email protected] Gears and Winches Division Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 95 47 Fax +49 75 86 95 95 75 eMail
[email protected] Hydrostatic Systems Division Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 95 38 Fax +49 75 86 95 97 15 eMail
[email protected] Herbertingen plant We offer comprehensive project management: • Many years of project experience • CAD masters • Project meetings on-site and plant inspections • Detailed, binding offers ZOLLERN GmbH & Co. KG ZOLLERN Transmission Technology Heustraße 1 D-88518 Herbertingen Tel. +49 75 86 95 90 Fax +49 75 86 95 95 75
[email protected] www.zollern.com Z213 11.2011 Errors and Omissions excepted. www.revoLUZion.de