Patent Application
20140202971
Large capacity, long-boom cranes are often required for building or assembling structures. Some cranes such as tower cranes are typically assembled on site and disassembled after work is completed. However, for many applications a more mobile, easily deployable crane is more suitable.
Where mobile telescoping cranes are larger and/or their duty loads increase, stability challenges arise. For example, as counterweight is added to a crane, rearward stability problems can manifest, particularly when the crane is on sloping ground. Some large telescoping cranes perform similarly to traditional tower cranes. When fully extended, telescoping members are oriented almost completely vertically, with a crane base, jib, masts, and boom disposed at the end of the telescoping members. As such a crane extends to greater heights, it is increasingly vulnerable to stress from loads and winds, to the detriment of the crane's stability and structural integrity.
One attempt to address this issue is with the Grove® GTK1100 mobile crane, manufactured by Manitowoc Companies, Inc. Among disadvantages of the GTK1100 solution is its requirement for multiple elevated outriggers disposed under the boom of the crane. Each of the elevated outriggers is coupled to the ground via multiple hinged or articulated supports anchored near ground-level outriggers. The elevated outrigger solution results in much additional hardware and weight, as well as a relatively large ground footprint, which can interfere with crane operations.
The elevated outriggers typically project laterally from a crane support structure at least 40 feet above the ground. The elevated outriggers are typically substantially horizontally disposed, and can project from a crane support structure at heights of preferably at least 80 feet above ground, more preferably at least 155 feet above ground, still more preferably at least 230 feet above ground, and most preferably at least 280 feet above ground. Each elevated outrigger typically has its own connection anchoring the elevated outrigger to the ground. Elevated outriggers typically do not attach to a tower structure for stability or support.
Accordingly, a need exists for a heavy-duty crane having greater stability and greater mobility. Decreased footprint and reduced size and weight are also desired.
Embodiments of enhanced stability cranes according to the present invention include a telescoping crane having enhanced stability compared to prior art cranes. Embodiments of enhanced stability cranes are remote-controlled rather than having an operator stationed in the crane base. In some embodiments, the crane is capable of lifting objects weighing about 110 tons to a height of about 400 feet. The crane typically includes a telescoping main support mast upon which a crane base resides. A boom and jib project upwardly from the crane base.
A clamping assembly resides on the main support mast and is configured to attach to a structure adjacent to the crane, in order to enhance stability. Multiple clamping assemblies can be distributed along the telescoping main support mast when the mast is extended. The structure is generally a tower structure that is columnar and vertical in shape and orientation, and frequently has an elliptical horizontal cross-section. Tower structures are typically, but not necessarily, wind turbine towers. Embodiments of enhanced stability cranes are portable and thus readily adapted to be moved and set up at a new location.
Embodiments of enhanced stability cranes present numerous advantages over the prior art, including but not limited to:
The terms and phrases as indicated in quotation marks (“ ”) in this section are intended to have the meaning ascribed to them in this Terminology section applied to them throughout this document, including in the claims, unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply regardless of the word or phrase's case, and to singular and plural variations of the defined word or phrase.
The term “or” as used in this specification and the appended claims is not meant to be exclusive; rather the term is inclusive, meaning either or both.
References in the specification to “one embodiment”, “an embodiment”, “another embodiment, “a preferred embodiment”, “an alternative embodiment”, “one variation”, “a variation” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment or variation, is included in at least an embodiment or variation of the invention. The phrase “in one embodiment”, “in one variation” or similar phrases, as used in various places in the specification, are not necessarily meant to refer to the same embodiment or the same variation.
The term “couple” or “coupled” as used in this specification and appended claims refers to an indirect or direct physical connection between the identified elements, components, or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.
The term “directly coupled” or “coupled directly,” as used in this specification and appended claims, refers to a physical connection between identified elements, components, or objects, in which no other element, component, or object resides between those identified as being directly coupled.
The term “operatively coupled,” as used in this specification and appended claims, refers to a physical connection between identified elements, components, or objects, wherein operation of one of the identified elements, components, or objects, results in operation of an other of the identified elements, components, or objects. For example, where multiple tension members 165 are operatively coupled to a boom drum 111 (see
The terms “removable”, “removably coupled”, “removably disposed,” “readily removable”, “readily detachable”, “detachably coupled”, “separable,” “separably coupled,” and similar terms, as used in this specification and appended claims, refer to structures that can be uncoupled, detached, uninstalled, or removed from an adjoining structure with relative ease (i.e., non-destructively, and without a complicated or time-consuming process), and that can also be readily reinstalled, reattached, or coupled to the previously adjoining structure.
Directional and/or relationary terms such as, but not limited to, left, right, nadir, apex, top, bottom, vertical, horizontal, back, front and lateral are relative to each other and are dependent on the specific orientation of an applicable element or article, and are used accordingly to aid in the description of the various embodiments and are not necessarily intended to be construed as limiting.
The term “tower structure,” as used in this specification and appended claims, refers to substantially vertically oriented structures including, but not limited to, wind turbine towers and smoke stacks, or parts thereof. Tower structures are typically, but not necessarily, cylindrical, conical, or approximately cylindrical or conical. For example, wind turbine towers and smoke stacks typically taper toward their tops, and may thus not be strictly cylindrical, but may be characterized as approximately cylindrical. Despite tapering toward the top, they may not be strictly conically shaped either, but may be characterized as approximately conical. Some tower structures are hyperboloid, and are thus narrower at a midsection and wider at a top and bottom. A tower structure typically has a horizontal cross-section that is elliptical. The elliptical horizontal cross-section is typically, but not necessarily, circular. Some columnar structures have cross-sections that are polygonal. The polygonal cross-sections are typically, but not necessarily, straight sided regular polygons.
The term “wind turbine,” as used in this specification and appended claims, refers to devices designed and configured to harness wind energy, and includes devices commonly referred to as windmills, wind chargers, wind pumps, wind power plants, and wind turbines.
The terms “substantially vertical,” “substantially vertically oriented,” and similar terms, as used in this specification and appended claims, refer to an orientation within 7.5 degrees of vertical. Where a structure or device is referred to as being “substantially vertically” oriented, it means a centrally disposed longitudinal axis of the structure or device is within 7.5 degrees of vertical.
The terms “substantially horizontal,” “substantially horizontally oriented,” and similar terms, as used in this specification and appended claims, refer to an orientation within 22.5 degrees of horizontal. Where a structure or device is referred to as being “substantially horizontally” oriented, it means a central longitudinal axis of the structure of device is within 22.5 degrees of horizontal.
The term “proximate,” when used in this specification and appended claims to describe a location with respect to a structure end or terminus, means being within 20% of the structure length of the end or terminus For instance, where a jib is pivotably coupled to a boom proximate a second end of the boom, and the boom is 60.1 feet long, the jib is coupled to the boom within 12.02 feet of the boom second end.
The term “at,” when used in this specification and appended claims to describe a location with respect to a structure end or terminus, means being within 5% of the structure length of the structure end or terminus For instance, where a boom is pivotably coupled to a crane base at a boom first end and the boom is 37.6 feet long, the boom is coupled to the crane base within 1.88 feet of the boom first end.
The term “crane load,” as used in this specification and appended claims, refers to a load lifted or lowered by the crane while being suspended from the boom or jib. The crane load is typically, but not necessarily, also moved laterally by the crane. The crane load is typically not a component of the crane.
The term “approximately,” as used in this specification and appended claims, refers to plus or minus 10% of the value given.
The term “about,” as used in this specification and appended claims, refers to plus or minus 20% of the value given.
Except where the terms “substantially horizontal” or “substantially vertical” are recited, the term “substantially,” as used in this specification and appended claims, means mostly, or for the most part.
The term “generally,” as used in this specification and appended claims, means mostly, or for the most part.
A first embodiment enhanced stability crane 100 is illustrated in
The crane base 106 resides on a main support mast 114, which can be referred to as a main mast. The main support mast 114 of the first embodiment comprises multiple telescoping sections in order to have variable length capability. Other variations include a main support mast having a fixed length. The crane base 106 is disposed at a first end 116 of the main support mast. Multiple clamping assemblies 108 are coupled directly to the main support mast 114. The clamping assemblies are configured to grasp a tower structure by use of grasping members 109. The grasping members 109 of the first embodiment crane 100 are horizontally opposed arcuate appendages configured to grasp or clamp a tower structure with a pincer-like action. The clamping assemblies generally grasp the tower with substantially uniform pressure, and typically, but not necessarily, apply pressure of about 10 pounds per square inch or less to the tower structure during grasping, in order to avoid damaging the tower. The grasping appendages are typically, but not necessarily, electrically actuated. Embodiments include hydraulically or pneumatically actuated grasping appendages. The clamping assemblies grasp or clamp the tower structure in a readily releasable manner, and typically do not attach to the tower structure with bolts or other threaded fasteners that run from a clamping assembly to a tower structure. Similarly, the clamping assemblies are not welded or otherwise permanently or semi-permanently affix to the tower structure.
The arcuate appendages include a relatively plastic material disposed on their surfaces configured to contact the tower structure, in order to reduce incidence of scratching, denting, or otherwise marring or damaging the tower structure. The relatively plastic material can be polyethylene or other material including, but not limited to, natural or synthetic polymers, cork, composites, fabric, or elastomeric material.
In some embodiments, grasping members include flexible bands or straps that wrap a tower circumference and tighten thereupon. The flexible bands or straps can include metals and metal alloys. Variations of flexible bands or straps comprise fibers including, but not limited to, Kevlar® and other aramid fibers, polyolefin fiber, polyester fiber, glass fiber, and carbon fiber. The fibers can be utilized in woven and non-woven fabric. For the purposes of this specification and appended claims, aramid includes para-aramid, meta-aramid, and other long-chain synthetic polyamides.
Embodiments of grasping members include inflatable chambers configured to expand against the tower structure when inflated. The inflatable chambers inflate by filling with fluid under positive pressure. The fluid is typically a non-flammable gas such as, but not limited to air or nitrogen. Variations include chambers having outer membranes comprising polyvinyl chloride (PVC) coated fabric, urethane coated fabric, or chlorosulfonated polyethylene. In some embodiments, the chambers include bladders residing within the outer membranes. The bladders typically, but not necessarily, comprise urethane or PVC.
A main mast second end 118 is coupled directly to a platform assembly 126. The platform assembly 126 of the first embodiment comprises a trailer bed 128. Multiple ground-level outriggers 130 attach to the platform assembly and engage the ground in order to provide a stable platform. The outriggers 130 include jacks 132 adapted to accommodate variations in ground surface variability. The outriggers 130 of the first embodiment are typically removed for transport. An operational configuration of the platform assembly 126, which includes eight outriggers 130 installed, is illustrated in
The platform assembly 126 also serves as a trailer or semi-trailer for transporting the crane 100. The platform assembly thus includes wheels 127 configured to bear the crane 100 in its fully collapsed configuration, and to roll at highway speeds with the crane so borne. The platform assembly 126 further includes a mast cradle 133 for cradling the main support mast 114 on the platform assembly 126 when the mast 114 resides in a prone orientation, as shown in
As best seen in FIGS. 1 and 3-4, the main support mast 114 of the first embodiment is coupled to the platform assembly 126 by a mast coupler 119 that has both pivoting and sliding functions. The pivoting function of the mast coupler 119 enables the main support mast 114 to adjust between a prone orientation as shown in
The enhanced stability crane 100 further comprises a boom 140 pivotably coupled to the crane base 106 at a boom first end 144. In the fully deployed configuration, a jib 148 is pivotably coupled to the boom at a boom second end 146. In the fully collapsed configuration illustrated in
Conversely, in the fully deployed configuration illustrated in
In the fully deployed configuration and during normal operation, the jib 148 typically projects upwardly from the boom second end 146. Maximum jib height 103 is measured or calculated with the boom 140 being within approximately 12 degrees of vertical and the jib 148 at approximately 9 degrees from vertical, and with the main support mast 114 fully extended, as best shown in
In the fully deployed configuration illustrated in
The crane 100 further comprises a jib support assembly. The jib support assembly includes the first boom mast 156, the second boom mast 160, and a jib tension assembly. The jib tension assembly includes multiple tension members 165, a cable cluster 166, and a yoke 167. The multiple tension members 165 are operatively coupled to a boom drum 111 (see
The jib support assembly is configured to rotate the jib 148 about its coupling to the boom 140, thus raising or lowering a jib upper end. Persons skilled in the art recognize that raising or lowering the jib upper end raises or lowers the jib height, and also changes the reach of the crane. Accordingly, raising the jib upper end can be used to move a crane load toward the main support mast, and lowering the jib upper end can be used to move the crane load away from the main support mast.
The first embodiment enhanced stability crane 100 further comprises a boom actuating assembly 141 coupled directly to the boom 140 and the crane base 106, and configured to rotate the boom about the pivotable coupling 142 between the boom and the crane base. The boom actuating assembly 141 of the first embodiment typically includes two six inch double acting 4-stage Hyco® telescoping hydraulic cylinders weighing approximately 1,400 pounds each.
The crane 100 further comprises a main support mast erector assembly 115 adapted to rotate the mast 114 about a pivot point on the mast coupler 119, thus raising or lowering the mast first end 116 and structures residing thereupon. The main support mast erector assembly 115 typically comprises telescoping hydraulic cylinders.
The boom 140, jib 148, first boom mast 156, and second boom mast 160, are typically latticed, and are designed based on stock parts and attachments for a Kobelco® SL 6000 hydraulic crane, scaled to approximately 60% of the stock SL 6000 parts. The boom 140 can be approximately 37.6 feet long and weigh approximately 50,700 pounds. The boom 140 typically includes a boom base section, a tapered boom section, and a luffing boom top section.
The jib 148 can be approximately 60.1 feet long and weigh approximately 13,900 pounds. The jib 148 typically includes a jib top section, two jib insert sections, and a jib base section.
The first and second boom masts 156, 160 are typically, but not necessarily, identical. Each of the boom masts can be approximately 35.4 feet long and weigh approximately 26,600 pounds. The boom masts each typically include two mast top sections. For each boom mast, wide ends of the two mast tops are butted together to create a boom mast that is widest at the middle and tapers toward each end.
Referring now to
As best seen in
With 360 degrees of rotation enabled, the first embodiment enhanced stability crane 100 has a maximum ground operating radius 190 of at least approximately 55 feet, resulting in a ground working area of at least approximately 9503 square feet. However, the crane 100 can not work effectively at a center of the ground working area within a radius of about 9 feet. The result is an effective working area of at least approximately 9249 square feet that is annular in shape because it has a 9 foot radius vacancy in its middle. The operating radius is determined with the boom within 15 degrees of vertical and the jib at 45 degrees from vertical.
The main support mast can comprise eight telescoping sections. The sections are typically, but not necessarily, cylindrical, and are usually thinner and longer proceeding from bottom to top of the mast. In some embodiments, the sections are between about 9 feet and 7 feet in diameter, and between about 50 feet and 37 feet in length. Telescoping main support masts are typically hydraulically actuated.
The hoist mechanism 102 by itself typically has a maximum jib height of about 106.4 feet, with the boom-jib assembly contributing approximately 96.1 feet. Maximum jib height is determined with the boom within 12 degrees of vertical and the jib within 9 degrees of vertical. Coupling between the main support mast and the hoist mechanism typically adds about 5.2 feet to overall crane height. Accordingly, the first embodiment enhanced stability crane 100 has a maximum jib height of about 412 feet when the main support mast is fully extended. With a block and tackle assembly hanging 12 feet below the jib upper end, the maximum hook height is 400 feet. The crane 100 can thus lift a crane load of up to 110 tons (222,000 pounds) to approximately 400 feet. Other embodiments have a maximum jib height of preferably at least 262 feet, more preferably at least 328 feet, and most preferably at least 400 feet. Variations are capable of lifting, to about a maximum jib height, preferably at least 60 tons (120,000 pounds), more preferably 80 tons (160,000 pounds), and most preferably at least 100 tons (200,000 pounds).
A grasping member first set 109A typically grasps the tower structure 180 at a height of about 44 feet. As best seen in
Typically the crane 100 extends incrementally as it adds sections to, and thus increases the height of, the tower structure 180. After adding an upper section to the tower structure, the crane typically extends, grasps the tower structure at a higher point for stability, and subsequently lifts another upper section of the tower structure to again add height to the tower.
Embodiments of enhanced stability cranes according to the present invention can lift crane loads as described above without relying on elevated outriggers to augment stability. Clamping assembly of an enhanced stability crane usually stabilizes the crane sufficiently, and elevated outriggers are thus typically absent.
The first embodiment enhanced stability crane preferably has a dry mass, without added counterweights, of preferably less than 110,000 kilograms, more preferably less than 100,000 kilograms, and most preferably approximately 95.5 kilograms.
A first method of using an enhanced stability crane is depicted in a flow chart of
The second trailer typically includes the platform assembly 126. The platform assembly 126 with the main support mast 114 lying prone thereupon is typically transported by towing behind a road tractor. The platform assembly 126 thus acts as a trailer or semi-trailer. The road tractor and platform assembly 126 together forming a tractor-trailer rig familiar to persons skilled in the art. The tractor-trailer rig can also be referred to as a semi-trailer truck.
The second operation 1102 of the first method comprises establishing the platform assembly 126 at the job site, which includes adjusting the platform assembly 126 to an operational configuration with the ground-level outriggers 130 installed. In the operational configuration as illustrated in
The third operation 1103 comprises raising the main support mast 114. Raising the main support mast includes sliding the mast 114 horizontally, best seen in
Raising the main support mast 114 further includes operating the mast erector assembly 115 to raise the mast first end 116 and rotate the mast 114 about a pivot point disposed on the mast coupler 119. The main support mast 114 is raised/rotated until it resides in an upright configuration. Motion of the mast first end 116 as the main support mast 114 is raised is indicated in
The fourth operation 1104 comprises engaging the tower structure 180 with the clamping assembly 108. The clamping assembly 108 engages the tower structure 180 by grasping the tower structure 180 securely with the grasping members 109. So secured, the enhanced stability crane 100 is much more stable, and is thus more resistant to destabilizing forces such as those created by wind, and by acceleration and deceleration of crane loads. The clamping assembly 108 is illustrated with a grasping member first set 109A engaged with the tower structure 180 in
A fifth operation 1105 comprises elongating the main support mast 114 by extending an upper main mast section 117 from its nested position within main mast lower sections, to its partially extended position shown in
A sixth operation 1106 comprises unfolding the boom 140, jib 148, and boom masts 156, 160, whereupon the enhanced stability crane 100 is in the fully deployed configuration. The boom, jib, and boom masts are shown partially unfolded in
A seventh operation 1107 comprises further elongating the telescoping main support mast 114 by extending middle main mast sections 124, and grasping the tower structure 114 with grasping member second set 109B, grasping member third set 109C, and grasping member fourth set 109D, as best illustrated in
An eighth operation 1108 comprises lifting and moving the crane load 181 with the first embodiment enhanced stability crane 100. The crane load 181 of the seventh operation is a wind turbine tower first upper section, which will be installed on the base section of the tower structure 180, whereupon the upper section becomes part of the tower structure. As the tower structure becomes taller through addition of upper sections, the main support mast 114 typically elongates also, and grasps the tower structure at higher points in order to stabilize the crane 100 as it grows higher.
The first method of using the first embodiment enhanced stability crane 100 requires minimum set up area of 3800 square feet. The required set up area is approximately 52 feet by 73 feet.
The various embodiments and variations thereof, illustrated in the accompanying Figures and/or described above, are merely exemplary and are not meant to limit the scope of the invention. It is to be appreciated that numerous other variations of the invention have been contemplated, as would be obvious to one of ordinary skill in the art, given the benefit of this disclosure. All variations of the invention that read upon appended claims are intended and contemplated to be within the scope of the invention.
The present patent application claims priority to and incorporates by reference in its entirety, U.S. patent application Ser. No. 61/508,442, filed 15 Jul. 2011, having the same inventors as the present application and titled ENHANCED-STABILITY, HEAVY-DUTY, TELESCOPING CRANE AND METHODS OF USE.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US12/46820 | 7/14/2012 | WO | 00 | 3/24/2014 |
| Number | Date | Country | |
|---|---|---|---|
| 61508442 | Jul 2011 | US |
