Integrated mechanization and automation of loading and unloading operations in transport and cargo systems

Main operating parameters

It should be noted that this technology can be used in unfavorable environmental conditions, with strong temperature changes and high humidity.

The maximum operating weight is usually sufficient to handle large volumes of construction material. That is why KKS-10 is often used on railways, ports and other similar places.

And also where there are a large number of various containers, unloading and loading them manually takes an extremely long time.

The span length is sufficient to carry out all kinds of activities even in a warehouse with a very large area.

In most cases, it is enough for successful work on an area whose size is 400 m2.

The load can be lifted to a height that allows it to be placed in railway cars without any difficulty, as well as high loading platforms with non-opening sides.

So cars with trailers simply drive up under the boom of the gantry crane in question, after which the required amount of cargo is placed in them.

The reach of the console on both sides is quite large, which makes it possible to carry out various types of work not only strictly in the center of the span, but also in other places.

This is very convenient, since often the location of various items and containers on the territory of the warehouse does not allow the truck to maneuver through it.

In this review you will read the operating features of the latest modifications of KamAZ-53215.

The speed of work is quite high, even if it is carried out with the maximum possible weights.

That is why the KKS-10 is often used in various types of production where a conveyor is used - with the help of this equipment you can very quickly carry out all kinds of work. For example, loading bulk materials into an extruder or loading cement into a special mixer.

The weight of the crane, which is several tens of tons, in no way affects the productivity of its work.

Control system

The KKS-10 gantry crane (technical characteristics and design are described above) controls lifting and fixing devices using cam controllers mounted in the operator's cabin. The system of these regulators includes starting resistances for transforming the rotation speed of electric motors.

The lifting unit has a number of limitations:

• According to lifting and load heights.
• In terms of moving carts along the monorail.
• When the crane moves along its path.

For these purposes, limit switches are used, which are in contact with the power supply circuit of the fuses and relays serving the specified mechanisms. When the cart reaches its extreme working positions or lifts the load to the maximum height, the corresponding switch is triggered, the serviced part of the mechanism is de-energized, and it is braked. Another function of the controllers is to block the entrance door to the cabin. If it is not closed, the activation of working devices is excluded.

terms of Use

Despite the unpretentiousness of the technology in question, it must be remembered that for normal operation some important points must be taken into account.
KKS-10 is designed to operate in the following conditions:

• operating temperature range : from -40 to +40 degrees;
• mode group for normal operation – 3K;
• there should be no flammable or explosive substances under the beam.

The temperature range in which the KKS-10 operates is quite wide, but if necessary, you can slightly exceed its limits to a greater extent.

Various types of cables in polymer insulation can simply be broken - it becomes brittle and brittle in the cold. And since the cable moves along with the working part, the probability of such an incident is quite high.

On the beam itself there is an asynchronous three-phase motor in which voltage is present. Therefore, during operation there is always the possibility of sparks occurring as a result of insulation failure or improper operation.

If they come into contact with flammable materials, a fire may occur.

Electric motor

All work is carried out using a special three-phase electric motor, marked as MTF-211-6, which has a long service life.

It has the following technical characteristics:

• maximum power – 7.5 kW;
• shaft rotation speed at rated load – 940 rpm;
• rated current present in each phase is 18.1 A;
• the amount of current present in the rotor is 4.5 A;
• the voltage created between the individual rings is 3.3 V;
• Efficiency – 78,5 %.

Construction device

The KKS-10 gantry crane has a standard design. This is one of its most important advantages over similar models from other manufacturers.

If a breakdown of any kind occurs, it is not difficult to detect it and determine the cause. It's also quite easy to fix.

If necessary, you can purchase the necessary spare parts at any specialized store or at the factory.

The main components of the entire working mechanism of KKS-10 are the following parts:

• a pair of gearboxes (RCD-350, Ts2U-200);
• ring gear;
• running drive wheel;
• gear;
• drive shaft;
• bearing shell;
• electric motor;
• intermediate shaft;
• gear coupling;
• brake mechanism type TKG-200;
• brake pulley

The crane beam moves along the tracks using special wheels (double-rib). They are marked as K2R-500×100. The life of the lifting mechanism in question directly depends on the quality of this part.

The service life is also affected by the correct installation of these wheels and the tracks themselves. If assembled and installed incorrectly, the service life may be shortened.

The next most important component of the KKS-10 crane mechanism is the TKG-200 brake. It is a device that regulates the movement of all executive bodies of a given gantry crane.

On this page you can find information about in which cases the KamAZ-5320 is capable of lifting a load greater than its own weight.

By clicking on the following link https://spez-tech.com/tehnika/gruzovie-avto/zil/modifikatsii-431412-i-ih-harakteristiki.html, you will find a description of the technical characteristics of the ZIL-431412 car.

TKG-200 implements control of the following actions:

• reduction of driving speed;
• full stop;
• hold.

TKG-200 is driven by a special hydraulic pusher. Its main purpose is to convert electrical energy into mechanical energy.

The working part of this braking device is special pads that slow down movement due to the friction force that arises when they are compressed.

The TKG-200 can use hydraulic pushers of various types:

They are all interchangeable and work on the same principle.

Gear couplings, gears, and shafts have a standard design and number of teeth. All parts of this type used in assembling the KKS-10 at the factory are made of high-strength steel that is corrosion-resistant.

That is why you can fearlessly use this equipment in a warehouse without a roof - this will in no way affect the quality of work. It is only necessary to lubricate the working parts in a timely manner.

Lifting and reserving

The lifting mechanism of the KKS-10 crane is represented by a winch with one drum and an electric drive. The turns of the branches of the lifting rope pass along two counter grooves. The brake with pads is mounted on the gear shaft. A gear is fixed at one end, transmitting rotation to the screw of the control switch. It adjusts the maximum hook lift.

Locking mechanism for self-assembly of the KKS-10 crane

The operation of the lifting mechanism is based on the longitudinal movement of the rotating screw nut. A fixed number of turns means the maximum lift of the hook, after which the nut is locked with the distributor pin. He turns off the engine and applies the parking brake.

The reeving system of the KKS 10 crane technically consists of ropes coming off the drum and bypassing the stationary coupling of the pulley block. They are clamped onto a traverse with a main hook and two hanging side slings. Such a system makes it possible to avoid distortion of the transported object with a displaced center of gravity on parts of the pulley remote from each other.

The mechanisms are characterized by ease of assembly and maintenance, as well as increased technical reliability and service life compared to other models of gantry cranes. Perhaps the crane will not show outstanding results when working in extreme conditions, but for servicing projects in central Russia, its popularity is technically justified.

Price

One of the most important advantages of the KKS-10 gantry crane is its low cost. The price of this equipment depends on the length of the span and can vary from 4 to 10 million rubles. :

Bridge-type lifting unit - gantry crane KKS-10

The KKS-10 gantry crane is a special special equipment, which is a bridge-type lifting unit on supports, moving on wheels and having a fully electric control. This is a two-cantilever, self-assembling equipment with a specific span length, which is placed directly in open areas or in production premises for lifting loads.

Gantry crane KKS-10

Many special equipment factories are engaged in the production of gantry (or overhead) cranes, the largest of which in the Russian Federation are located in Moscow, Rostov-on-Don, St. Petersburg, Yekaterinburg, Novosibirsk, etc.

Photo of the KKS-10 gantry crane

Application area

A gantry crane is a unique machine and irreplaceable in cases where the approach of other lifting equipment is difficult or impossible.

KKS-10 gantry cranes are used both in construction and in all other places where it is necessary to work with large loads:

• At railway stations.
• At the cargo port.
• In open warehouses.
• In the construction of vast complexes.
• At loading areas of industrial zones.
• In the construction of large engineering structures.
• For servicing hydraulic systems.

Model features

KKS-10 in different configurations may have the following distinctive features:

1. For ease of use for different purposes, KKS-10 gantry cranes can be manufactured with different span lengths - standard or individual by agreement with the customer.
2. Vertical supports can be equipped with additional racks that have a constant panel spacing.
3. The operator's cabin can be either permanently fixed or with the ability to move along the length of the bridge.

Overall dimensions of the KKS-10 crane

In addition, the crane can be equipped with various working equipment:

• Kryukov for the standard method of picking up loads with a KKS-10 zk crane.
• Grab for transportation within the work site and loading of bulk cargo.
• Electromagnetic for working with metal loads, in particular scrap metal.

Area of ​​use

The KKS-10 gantry crane is indispensable in cases where the use of other loading equipment is not possible. The design does not take up much space, while covering large areas. KKS-10 is indispensable in areas where it is necessary to work with large-sized cargo. It will be used:

• at railway enterprises;
• at the cargo port;
• in logging;
• in the construction of large-sized complexes;
• on construction sites;
• at factories of reinforced concrete products;
• in open warehouses;
• over large areas;
• in industrial workshops as a loading device;
• for working with hydraulic systems.

KKS is a specialized lifting mechanism for working in open and closed areas; it is used in hangars. Gantry cranes are often used in conveyor production. Designs of this type are characterized by mobility. This unpretentious equipment is highly productive and has a long service life of up to 20 years or more.

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Device

The KKS-10 gantry crane has the following features and capabilities:

• The entire structure of the crane - the supports and the bridge itself - has a lattice structure, which significantly reduces its weight while maintaining strength and load capacity, and also provides a better overview of the work being performed.
• The crane is equipped with a suspended cargo monorail trolley. A deck with fencing is installed above the monorail to allow walking along the entire length of the bridge.
• The entrance to the crane and to the cabin is equipped with a flexible support in the form of a ladder.
• To prevent loosening of the moving mechanisms of the cargo trolley and cabin, special rollers are installed, mounted on the main frame with support on the lower chord of the bridge.
• The power cable is suspended and securely fastened to the brackets.
• For modern models, several control methods are used: both from the cabin and from the ground by wire, as well as using a remote control transmitting a radio signal.
• Repair platforms are provided on the console.
• The safety of the operation of all systems and mechanisms is ensured by the presence of control devices and devices: equipment extreme position limiters, tilt sensors, buffer devices, wind pressure alarm, and sound alarm.

Control

The lifting and movement of KK cargo can be controlled from the ground or from the cabin.

Electrical method - from the crane operator's cabin. From a height, cargo of any size is clearly visible; the cabin can be equipped with an on-board computer for more accurate placement of cargo.

Mainly used for lifting capacities >10t and requires an experienced crane operator.

The operation of KKS-10 is prohibited at temperatures below -40ºС: • the lubricant of the components thickens; •moisture particles trapped on the rubbing surfaces freeze, causing serious damage during operation.

Cranes with this type of control are required to be registered with technical supervision authorities. The crane operator's cabin can be stationary or mobile .

The fixed one is attached to one of the sides of the crane and is recommended for short span lengths and lifting heights.

The mobile cabin is mounted on a mobile crane trolley, which is convenient for large span lengths and lifting heights.

The process can be controlled from the surface of the earth using a wireless or pendant control panel. This method is more often used in enclosed spaces with small cargo dimensions, with sufficient visibility from the floor.

Remote control of the mechanism does not require additional education for employees.

For gantry cranes without a cabin with a lifting capacity of up to 10 tons registration with technical supervision authorities is not required

Specifications

The list of technical characteristics of the KKS-10 gantry crane is reflected in the following table:

In the video you can watch the installation process of the KKS-10 gantry crane:

Classification

According to their purpose, CC can be divided into 3 groups:

• general purpose - transshipment, used for loading/unloading various cargoes in open production/warehouse areas and in enclosed spaces such as hangars, load capacity = 3.2-50t;

• construction and installation : assembly of industrial equipment, shipbuilding, installation of large-sized reinforced concrete products, bridge supports and trusses, capacity = 300-400t.

Both categories are mostly equipped with a hook suspension, span length = 8-80m, lifting height = 7-30m.

• special : shipbuilding, hydroelectric power stations, thermal power plants, maintenance of dams, locks. They are equipped with special load grippers: grabs, electromagnets, pincer grips, and are additionally mechanized with a mounting boom, jib crane, etc.

Special cranes of large standard sizes are produced, which can be calculated together with the design of the structure being built, for example, a hydroelectric power station or a bridge.

Load capacity - up to 900t, span ≈ up to 130m, lifting height - up to 80m.

Gantry cranes are self-erecting , while others are mounted using special equipment.

KK are produced in different standard sizes, the models have a wide range of technical parameters:

• load capacity - from 5 to 1600t;
• load lifting height - from 3 to 100m;
• spans - from 20 to 130m;
• load lifting speeds - from 0.1 to 32 m/min;
• movement of cranes - up to 100 m/min, trolleys - up to 40 m/min.

• 5-10t;
• 12-50t;
• Cranes with pre-tensioned beam, with a load capacity from 15 to more than 50 tons.

The preferred application is for gantry cranes with flexible load suspension - hook cranes , as well as grab cranes (KKTGK) and magnetic cranes (KKM).

Some models have the ability to lengthen the crossbar and supports using inserts. This allows you to change the lifting capacity from 15 to 50t, the span from 32 to 62m and the lifting height from 7 to 30m.