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Grab Overhead Crane for Garbage

DATE: Sep 10th, 2023
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1. Product Introduction

The design and manufacturing of the grab overhead crane for garbage produced by Kingda crane comply with GB, FEM, IEC, and international general standards. Its structure includes a single layer trolley, a double layer trolley, single drum block, and a double drum block; Comprehensive weighing accuracy ≤ ± 1%;
It has three control modes: manual control, semi-automatic control, and fully automatic control. The three control modes can be freely switched, and manual priority is available in any automatic mode. At present, Kingda crane’s products have been widely used in garbage incineration treatment plants or waste to energy industry with daily processing capacities of 4800t/d, 3000t/d, 2400t/d, 1200t/d, 1000t/d, 800t/d, and less than 600t/d.

 
Technical Parameter
 
   Grab Overhead Crane for Garbage Main Technical Parameter
 SWL (t) 5 8 10      12.5  16     20
         grab characteristics volume (m3) 2 4 5  8  10     12
self weight (t) ~2   ~3.4 ~3.6      ~5.3 ~6.8    ~7.6
working class A8 A8 A8 A8  A8     A8
span S(m) 10.5 13.5 16.5 19.5 22.5 19.5 22.5 25.5 28.5 31.5 22.5 25.5 28.5 31.5 22.5 25.5 28.5 31.5  25.5 28.5 31.5 34.5  28.5 31.5 34.5
recommended speed lifting speed m/min   0~30   0~40 0~45      0~50       0~50   0~45
cross traveling speed   0~30   0~44 0~50      0~50     0~46.5   0~50
long traveling speed   0~50   0~50 0~65      0~70 0~67  0~63   0~65
power lifting motor Kw 30 63 90       132 160    200
cross traveling motor  0.55*2   1.5*2 2.2*2       3*2 3*2   5.5*2
long traveling motor   2.2*2 4*2 5.5*2     7.5*2 7.5*2   4*4   5.5*4
grab motor 15    18.5 22 30  37     45
total power   50.5   92.5 127.4       183 218   219    278
Max.wheel loading (kN)   75 80 85 90 95 125 132 141 148 157 145 155 165 175 178 188 198 208   218 124 130 138    158 163 168
traveling rail I20 I20 I20 I20  I20     I20
recommended long traveling rail 43kg/m 43kg/m   43kg/m     QU80      QU80   QU80
power source    3 AC    50Hz    380V
  
2. Overall Solutions
Overall Solutions

PLC Control System
The PLC system adopts Siemens S7-1500/1200 and other world top class brands, which can operate continuously in high electronic noise, radio frequency interference and vibration environment, without  reducing the performance of the system.
 
 

Electrical Driving System
ABB ACS880DTC torque control frequency converter is adopted for the electrical transmission of lifting, cross travel and long travel mechanisms to drive the motor. The frequency converter has self-learning function for motor parameters and excellent speed regulation performance, can cooperate with the control system to ensure that garbage grab crane’s all mechanisms can start smoothly and stop accurately.







Electrical Driving System
ABB ACS880DTC torque control frequency converter is adopted for the electrical transmission of lifting, cross travel and long travel mechanisms to drive the motor. The frequency converter has self-learning function for motor parameters and excellent speed regulation performance, can cooperate with the control system to ensure that garbage grab crane’s all mechanisms can start smoothly and stop accurately.
 

3. control Description

Control Function List
Control mode of the garbage grab overhead crane is divided into three working modes: manual, semi-automatic, and fully automatic. It can complete crane all actions, such as material moving, charging, and rearrange-stacking. The operation and control functions are shown in the table below:
                                                                 Control mode
             Action process
Manual
Semi-automatic
    Fully automatic
      Material moving
 Charging
Rearrange-stacking
   material level
man observation
   man observation
     automatic
   select grab point
man observation
   man observation
     automatic
   select charging point
man observation
   man observation
     automatic
   crane starting
    man operation
  automatic
     automatic
    move to grab point
    man operation
  automatic
     automatic
   grab fall down
    man operation
  automatic
     automatic
   garbage grab
    man operation
    man operation
     automatic
   grab and lift synchronously
 automatic
  automatic
     automatic
   lift grab
    man operation
  automatic
     automatic
    move to charging point
    man operation
  automatic
     automatic
   weighing,metering,count
 automatic
  automatic
     automatic
   open grab-unloading
    man operation
  automatic
     automatic
   back to grabing point
    man operation
  automatic
     automatic
   repeat above process
    man operation
  automatic
     automatic
    move to crane parking position
    man operation
  automatic
     automatic
  automatic fault diagnosis and alarm
automatic
  automatic
     automatic
  remote online fault diagnosis
yes
yes
yes
 
In any control mode, there is a manual control function, and manual control has the highest priority. At any time, as long as the operator touches the operating handle of the linkage platform, the automatic control mode will immediately stop and switch to manual mode.
 
FULLY AUTOMATIC MODE                                                                                                                                                                                                         
In fully automatic mode, fully automatic garbage grab overhead crane has four processing steps :
 
 
       

 
Priority level:automatic charging>feeding scanning>automatic material transfer>automatic rearrange-staking
If the three buttons of "automatic charging", "automatic material tr- ansfer", and "automatic rearrange-stacking" are all set to "1", then automatic charging takes priority, followed by feeding scannin, au- tomatic material transfer again, and finally automatic rearrange st- acking. As long as the "automatic charging" signal is set to "1", the material grabbing and picking area is the charging area.
If the "automatic charging" signal is "0" and the "automatic material transfer" and "automatic rearrange-stacking" are set to "1", then the grabbing area is feeding area.
If "automatic charging " and " automatic material transfer" are set  to "0", and "automatic rearrange-stacking" is set to "1", the picking area is rearrange-stacking area.

 
material dumping area priority level: material incoming temporary storage area>rearrange-stacking temporary storage
As long as the signal for automatic material transfer is "1", material dumping area is storage area; Only "automatic rearrange-stacking" signal is set to "1", the material dumping area is the rearrange-stacking discharge area.
 
 
Fully Automatic Charging Process
 
Set the "Automatic charging" button to "1", and set the "Automatic Material Transfer" and "Automatic earrange-stacking" Feeding Port Scanning buttons to "0", the
garbage crane can automatically complete the charging process.
 
                                             
move to material picking area automatically
grab material in highest point automatically
traveling and chargingautomatically
If any hopper sends a feeding request, the garbage crane will automatically retrieve materials from thefeeding area and feed them tothe corresponding hopper.
If multiple hoppers issue a feeding request signal, the garbage crane will feed eachhopper one by one.
If there is no hopper feeding request signal and there is a material height scanning signal for the feeding door (when the feeding door isopened and closed, a scanning signal is issued), garbage crane will run to the corresponding feeding door to scan the garbage height. After completing the scanning, it will be in a waiting state.
If there is no feeding request from the hopper and no feeding scanning signal, the garbage crane will be in a waiting state.
 
Fully Automatic Rearrange-Stacking
Set "automatic rearrange-stacking" button to "1", "automatic charging/feeding", and "automatic material transfer" to "0".
 

                                           

move to rearrange-stacking area automatically
grab materialautomatically and send to rearrange-stacking mixing area
dump material in low areas automatically
 
Semi-Automatic Material Transfer Process
Set "automatic material transfer" to "1", "automatic feeding" and "automatic rearrange-stacking" to "0", the garbage crane  is in the automatic material transfer process. 

                                           

Automatic scanning of material level height
Automatically grab materials and send to temporary storage area
Automatic scanning of material level height
 
If feeding door does not send out feeding scanning signal and materialheight  infeeding area is greater than the set value, garbage crane will automatically grab material from the highest point or grid by grid in feeding area, and automaticallyplace it in the lowest grid or grid by grid intemporary storage area;
If there is a feeding scanning signal, the garbage crane will complete this operation and automatically scan  garbage height  at corresponding feeding door.
If material height of the in  feeding area is lower than the set value, the material transfer action stops.
 
 
Feeding Port Scanning
                                            
Automatic detection of feeding door
opening and closing 
Automatic travelling to the feeding area material height automatic scanning
 
If there is no automatic feeding signal and a feeding request signal, garbage crane will automatically run to the corresponding feeding port to scan the material height.
 
Fully Automatic Charging Process
 
                        
Fully Automatic Monitoring of Material Status inn Garbage Poll Semi-Automatic Monitoring of Material Status in Garbage Poll
semi-automatic operating mode
semi-aotomatic starting semi-aotomatic manual grabing and traveling semi-aotomatic dumping traveling semi-aotomaticfeeding /charging traveling Automatic parking
set the "semi-automatic button" to "1 "and all other  working mode buttons  to "0". At this time, the garbage crane is in a waiting state for semi auto-matic operation. manually select  the  grabbing position of garbage crane on the touch screen,and the garbage crane will automatically go to  the feeding area to grab the material. After grabbing the material,lift it to a certain height and wait for the next operation command. Manually select the feeding position on the touch screen, and the garbage crane will automatically run to the dumping area for spraying. After dumping, the grab will be raised to a certain height and in a waiting state. Garbage crane is in a waiting state after grabbing the material,by pressing loading button on touch screen, garbage crane will automatically run above the designated loading hopper to load.After loading is completed, garbage crane will automatically move to the garbage pit and wait for the next action. After completing other actions, the garbage crane is in a waiting state. Set the "Park" button to "1" and then "0", and the garbage crane will auto matically run to the designated parking position.
 
Manual Working Image
In manual mode, the operation of the garbage crane is completed by garbage crane operator. Set "semi-automatic button" and "fully automatic button" to zero, and at this time, the garbage crane is in manual mode.
The long traveling mechanism, cross traveling mechanism, lifting mechanism, and grab opening / closing of the garbage crane are all controlled by handles or buttons on the linkage platform. For example, to drive the bridge to the left at fourth gear speed, simply manipulate long traveling handle to left at fourth gear, and the bridge will run at fourth gear speed.
The control of lifting and trolley mechanisms in manual mode is the same as long traveling mechanism. The opening and closing of the grab is controlled by the aircraft head button on the lifting handle. Clicking "Open" will open the grab, and clicking "Close" will close the grab, meeting the requirements of manual material grabbing, charging/feeding, and discharging
 
Manual Working Image
 

 
Calibration instructions Warning
● lifting origin point calibration: open operating setup switch-press lifting calibration switch-close setup switch
● crossandlong traveling origin point calibration:open operating setup switch-press cross and long traveling
     origin position calibration switch - close setup switch  
● landing calibration:open operating setup switch-press landing calibration switch - close setup switch 
● empty grab calibration:open operating setup switch-press emprty grab calibration switch - close setup switch 
● full grab calibration:open operating setup switch-press full grab calibration switch - close setup switch 
● crane parking calibration:open operating setup switch-crane parking calibration switch - close setup switch 
● 1# hopperpositioncalibration:open operating setup switch-1# hopper position calibration switch - close setup
     switch 
● 2# hopperpositioncalibration:open operating setup switch- 2# hopper position calibration switch - close setup
     switch
● 3# hopperpositioncalibration:open operating setup switch- 3# hopper position calibration switch - close setup
    switch
● each decelerationpositioncalibration:open operating setup switch - each deceleration corresponding position calibration switch - close setup switch 
● Calibration operations can only be carried out after the crane is started, and calibration process must be
     strictly followed during calibration; 
● After the calibration of cross and long traveling origin position crane parking and each hopper positions,
   semi-automatic operation verification should be carried out. Carefully observe the operation path in
    advance to see if it is abnormal.
● If it is abnormal,immediately snap the emergency stop button and re-calibrate.The lifting deceleration
    bypass and trolley deceleration bypass should be used in a timely manner under special circumstances
   and are not allowed to be used during normal operations.When the signal light is white, there is a
   deceleration limit, and when the signal light is green, there is no deceleration limit.
comprehensive
protection
lifting
mechanism
trolley
mechanism
bridge
mechanism
communication
diagnosis and settings
fault alarming exit
 

4. Innovative Technology




Anti-swayTechnology Precise Positioning Technology
Adopting patented technology invented by Kingda crane, comprehensively utilizing  the physical principle of load swing and the model  is established  by measured crane experimental data,to calculate and predict amplitude and loadswing phase.Based on this simulated manual operation environment, PLC high-level language programming control box on-site communication technology is used to control garbage crane's long and cross traveling speed inreal-time, significantlyreducing crane's swing range and greatly improving garbage's production effi-ciency.  By  adopting patented technology invented by kingda crane,real-time monitoring and feedback of the garbage crane'soperatingpositions of cross /long traveling and grab, to obtain accurate three-dimensional positions of the grab space.Coupled with  frequency converter cont-rol box's anti-sway function,fixed point adjustments are added toeach mechanism to ensure positioning accuracy and greatly improve
working efficiency of the garbage crane.
 
Intelligent Estimate Technology
Adopting  Kingda crane's  invention patent, in order to ensure that the garbage crane can automatically determine appropriate garbage grabbing position, the garbage storage pit is virtual divided into a grid of unit units.During garbage crane’s operation,the entire garbage storage pit is scanned in real time,and the height of materials in each grid of garbage pit is recorded. Then, the height of garbage in corresponding grid is represented by a change in color. Garbage crane automatically selects and compares, and calculates the optimal grip-ping point.
 
Data Archiving and Monitoring Technology
Using configuration software,establish a  real-time monitoring animation that can reflect the three-dimensional position and grab status of the garbage crane in real  time, and monitor status of garbage crane's key components in real time and dyn amically. Archive historical data, archive queries, and print reports on the main parameters and alarm information of the garbage crane.
Remote Service Technology
In order to ensure the reliable operation of garbage crane, crane’s standard confi guration is a remote service system with remote monitoring and diagnosis functio ns through a wide area network. Remote monitoring and diagnostic functions can provide customers with historical data query, rapid repair services for product fail ures, preventive maintenance of equipment, and basic data support for equipmen t failures and safety accidents for regulatory authorities.
 


5. Monitoring System

monitoring system includes monitoring screen
 


6. Weighting System
 


There is weighing device (equipped with 4 weighing sensors) installed on the crane trolley for weighing measurement and overload protection. The weighing sensor is installed between the upper and lower trolley frame, allowing lifted object’s weight to fully act on the sensor,improving weighing accuracy.The static weighing accuracy is better than ± 1%, and it also has an overload alarm function.
When the crane is located above the feeding hopper, the garbage caught by grab is automatically weighed. Each reading includes: garbage net weight, feeding position, and time.Each feeding hopper is equipped with its own counter and the weight reading is transmitted to the DCS system. This allows the crane to automatically record and organize the operating conditions and f eeding amount, automatically archiving them into Excel or Word reports, which can be printed and copied; The report includes each incinerator and the total amount of waste entering the furnace, including shift, day, week, and month reports.
 
monitoring system includes monitoring screen

7. Position detecting

Sensors are installed to detect the height of garbage in garbage bin and the position of garbage crane’s lifting, cross traveling and long traveling, respectively detecting the lifting height of garbage and the position of the lifting mechanism, as well as cross traveling and long traveling mechanisms.
Garbage height is detected using a laser scanning system, and the position of garbage crane’s lifting mechanism,cross traveling mechanism and long traveling mechanism are detected using an encoder.
According to the coordinate positions provided by encoders of each crane mechanism, the frequency converters of each crane mechanism drive the motors to this position
Equipped with a position correction device, it avoids position errors caused by wheel slip.
There is a "soft limit" designed in the program for functions such as proximity protection and parking protection.
 
Laser scanning device  Absolute encoder
 
The laser scanning system is installed in workshop or on the crane to scan the height of the garbage in garbage pool in real time.The height value is transmitted to the PLC for processing,which grabs highest point in garbage pool and places it in hopper for incineration.It is also used for mixing and material transfer processes. According to the actual situation of the garbage pool, a"step-by-step" method can also be used to grab materials,completing the process of loading, mixing, and moving materials.
 

8. Grab

Multi-Jaws Hydraulic Grab
Grab adopts multi-jaws hydraulic grab, low center of gravity.
Four point 'V' shape
The connecting steel wire rope between crane and grab is arranged in a four point "V" shape to reduce twisting during use of the grab and collisions between grab and building. A transitional chain is used to connect grab and steel wire rope.
reventing tipping
The grab is equipped with sensor device that can detect tilt of the grab and prevent it from tipping over.
Dynamical system
he power supply voltage of multi-jaws hydraulic grab is 380-600V, and the open-close of grab is completed by a hydraulic oil pump driven by an electric motor. Control system is transported to the control room through cables on the cable drum.
Independent control buttons
The grab has a set of independent control buttons for personnel controlling operation.
 

9. Safe Distance

 

Protective measures should be taken between two grab cranes to prevent collisions. In order to maintain an  appropriatedistance between two cranes, anti-collision devices are used. If the distance between cranes is closer than a specified distance, the power supply driving the motor of the mechanism will be automatically cut off. Two switch off points are programmed: first, cut off full speed but allow travel at low speed, and then stop according to the end switch point.The position detection error of traveling direction can be adjusted in crane control system


10. Security Protection

 

 

11. Power Supply and Cable Installation

Both the long traveling and cross traveling are powered by cables, which use flexible circular towing cables (flat towing cables) for power supply




 
For secure and proper installation, all cables between the low-voltage switch and crane operating room, as well  as between low-voltage switch and main power supply box, fixed type cables (CEFR cables) are used, and  installed in cable ducts or conduit


11.Control system and External Interface


  
-Discharging door  
Opening and closing status of the discharging door, as well as crane's fault signal, will be sent to the crane PLC;
Crane in working state, PLC transmits crane’s working status signal and the signal of entering in to discharging
door area (switch value) to the discharging door control system,to open or close discharging door conveniently, and protect grab.
-Crane PLC and DCS communication
Crane PLC to DCS DCS                                                                                                                                                                                                              cumulative value of crane grab feeding needs to be transmitted to DCS
Single from DCS to PLC                                                                                                                                                                                                            level signal of each feeding hopper is connected to the crane PLC 
DCS transmits the working status signal of each incineration line to crane PLC.


13.Product Achievement

Kawata Enviroment Equipment Group Co. Ltd
Environmental Protection Engineering

Biomass Power Project
Environmental Protection Engineering

Domestic Waste Incineration Cogeneration Project

Biomass Energy Project

Environmental Energy Project

Waste Incineration Power Generation Project
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