Короткий Анатолий Аркадьевич, заведующий кафедрой «Эксплуатация транспортных систем и логистика», доктор технических наук, профессор
344003, г. Ростов-на-Дону, пл. Гагарина, 1
Rostov-on-Don
Павленко Андрей Николаевич, доцент кафедры «Эксплуатация транспортных систем и логистика», кандидат технических наук, доцент
344003, г. Ростов-на-Дону, пл. Гагарина, 1
Rostov-on-Don
Панфилова Эльвира Анатольевна, доцент кафедры «Эксплуатация транспортных систем и логистика», кандидат философских наук, доцент
344003, г. Ростов-на-Дону, пл. Гагарина, 1
Rostov-on-Don
Симонов Дмитрий Николаевич, главный конструктор
346428, г. Новочеркасск, ул. Троицкая, 88
Novocherkassk
Introduction. The article presents an analysis of the destruction of welds that occurred during the operation of modular overhead cranes. Measures are proposed to prevent the occurrence of such defects in the future, reduce the likelihood of accidents and improve the safety of operation of overhead cranes with a welded modular construction. The relevance of the work is due to the fact that in the Russian Federation approximately 65% of the lifting cranes registered with Rostechnadzor have fulfilled the standard service life.
The work objective is to improve the safety of operation of modular overhead cranes and the reliability of their welded metal structures. Achieving the objectives of the work, based on the analysis of the destruction of metal structures of overhead cranes, a diagnostic map of welded joints of metal structures of end beams with modules of travelling wheels of overhead cranes was compiled. The use of the proposed diagnostic card in a production environment will significantly improve the quality of diagnostics of welded joints.
Materials and Methods. Investigations of accidents of load-bearing metal structures of cranes by methods of technical diagnostics of destruction of welds that occurred during the operation of overhead cranes of modular design have been carried out. This made it possible to develop a number of measures to prevent accidents of overhead cranes initiated by the destruction of their welded modular structures.
Results. Based on the analysis of accidents, a diagnostic map of destructing welded joints of metal structures of end beams with modules of travelling wheels of an overhead crane has been compiled. The use of the proposed diagnostic card will increase the reliability of welded metal structures and improve the quality of diagnostics of welded joints in production conditions.
Discussion and Conclusions. As a result of the analysis of structural failures of modular overhead cranes, a number of measures are proposed to prevent the formation of such defects, the occurrence of accidents due to them, and to improve the safety of operation of overhead cranes.
Введение. Представлен анализ разрушений сварных швов, возникших при эксплуатации мостовых кранов модульной конструкции. Предложены меры, позволяющие в дальнейшем предотвратить появление подобных дефектов, снизить вероятность аварий и повысить безопасность эксплуатации мостовых кранов со сварной модульной конструкцией. Актуальность работы обусловлена тем, что в РФ приблизительно 65 % зарегистрированных в Ростехнадзоре грузоподъемных кранов отработали нормативный срок службы.
Целью работы является повышение безопасности эксплуатации мостовых кранов модульных конструкций и надежности их сварных металлоконструкций. Реализуя цели работы, на основе анализа разрушений металлических конструкций мостовых кранов, составлена диагностическая карта сварных соединений металлоконструкций концевых балок с модулями ходовых колес мостового крана. Применение предлагаемой диагностической карты в производственных условиях позволит существенно поднять качество диагностики сварных соединений.
Материалы и методы. Выполнены исследования аварий несущих металлических конструкций кранов методами технической диагностики разрушений сварных швов, возникших при эксплуатации мостовых кранов модульной конструкции. Это позволило разработать ряд мер по предотвращению аварий мостовых кранов, инициированных разрушением их сварных модульных конструкций.
Результаты исследования. На основе проведенного анализа аварий составлена диагностическая карта разрушающихся сварных соединений металлоконструкций концевых балок с модулями ходовых колес мостового крана. Использование предлагаемой диагностической карты позволит повысить надежность сварных металлоконструкций и улучшить качество диагностики сварных соединений в производственных условиях.
Обсуждение и заключения. В результате проведенного анализа разрушений конструкций модульных мостовых кранов сформулирован ряд мер, позволяющих предотвратить образование подобных дефектов, возникновение из-за них аварий, повысить безопасность эксплуатации мостовых кранов.
Introduction. Currently, overhead cranes with welded modular construction get widespread use in the Russian Federation. They are widely used in technological processes at various manufacturing facilities, which determines the degree of mechanization of loading and unloading operations, affects the costs of products and other technical and economic indicators of production.
At the moment, in the Russian Federation, approximately 65 % of lifting cranes registered with Rostechnadzor have fulfilled their standard service life [
With the introduction of Technical Regulations TR CU 010/2011 "On the Safety of Machinery and Equipment"[3], TR CU 011/2011 "Elevator Safety"[4], TR CU 018/2011 "On the Safety of Wheeled Vehicles"[5] the term "lifting crane safety" can be considered as "design safety" at all stages of the life cycle: design, manufacture and operation. Design safety violation can lead to an accident of the lifting structure. The issues of ensuring the strength of crane metal structures are considered in works [2–6], and from the standpoint of crane safety as a complex technical system in work [
The work objective is to improve the safety of operation of modular overhead cranes and the reliability of their welded metal structures. Based on the analysis of the destruction of metal structures of overhead cranes, a diagnostic assessment checklist of welded joints of metal structures of end beams with modules of running wheels of overhead cranes has been compiled. The use of the proposed diagnostic assessment checklist in production conditions will significantly improve the quality of diagnostics of welded joints.
Materials and Methods. Analysis of the operation of overhead cranes by technical diagnostics methods [
Results. The service life of lifting machines is regulated by state standards, technical specifications and other regulatory documents. Each crane has a certain service life specified in its technical data sheet. As a rule, the service life of a crane is determined by the service life of its load-bearing metal structures.
For example, the reliability requirements according to GOST 27584-88[7] set the parameters for indoor overhead cranes not less than the values given in Table 1
Table 1
Indicator of service life and reliability for overhead cranes
Thus, for a crane of the 6K, 7K mode group with 1.5 shift work per day and the number of cycles of 5 per hour, the established no-failure operating time will be 64000/300×12×5=3.5 years.
The load-bearing metal structure of the double-girder overhead crane, shown in Fig. 1, consists of two span beams, along which a cargo trolley with a lifting mechanism moves, and two end beams with a crane mounting on them.
The typical metal structure of the end beam of a double-girder overhead crane, shown in Fig. 2, consists of belts (upper and lower), vertical walls and diaphragms placed inside the beam. As a rule, the vertical walls of the beams are made of a single sheet.
Fig. 2. General view of a typical metal structure of the end beam of a double-girder overhead crane: 1 — upper and lower belt; 2 — vertical walls; 3 — crane mounting
To install the undercarriage of a double-girder overhead crane, axle boxes with running wheels are attached to the end beams shown in Fig. 3.
Recently, modular designs of end beams with bolted (Fig. 4) or welded (Fig. 5) flange connections have become widespread.
Modular design makes it possible to reduce the dimensions of the end beams of the crane during its transportation to the installation site, but requires higher qualifications of specialists who install the crane in production conditions, especially modular construction with welded flange connection.
The presence of a flange connection complicates the design of the end beam. In practice, there are accidents of overhead cranes caused by the destruction of the welded flange connection, shown in Fig. 6, of the undercarriage wheel module, both drive and loose, with an end beam.
The analysis of the causes of destruction of flange connection welds illustrated in Fig. 7, modular structures of overhead cranes allows us to prevent the appearance of such defects in the future, to increase the reliability of welded metal structures, to work out methods of diagnostics of welded joints in production conditions.
Based on the results of the survey using non–destructive testing methods [9–17], a diagnostic assessment checklist of welded joints of metal structures of end beams with modules of running wheels of an overhead crane with a lifting capacity of 10 tons was compiled, shown in Table 2.
Table 2
Diagnostic assessment checklist of welded joints of metal structures of end beams with modules of running wheels of an overhead crane with a lifting capacity of 10 tons
The connection unit of the undercarriage wheel module should be attributed to a heavy-loaded structure that receives loads from the crane's own weight, depends on the position of the cargo trolley in the crane span and the weight of the load lifted, receives dynamic loads from the state of the crane runway. The coefficient of shocks during the movement of the crane reaches a value of K = 1.3–1.4, and the horizontal component of the wheel pressure is R = 0.5 N, which should be taken into account when calculating the strength and durability of the structure.
Discussion and Conclusion. The study presented above, in terms of improving safety of operation of modular overhead cranes and the reliability of their welded metal structures, shows that:
Received 25.09.2022.
Revised 11.10.2022.
Accepted 11.10.2022.
About the Authors:
Korotkiy, Anatoliy A., Head, Department of Operation of Transport Systems and Logistics, Don State Technical University (1, Gagarin sq., Rostov-on-Don, 344003, RF), Dr. Sci. (Eng), Professor,
Pavlenko, Andrey N., Associate professor, Department of Operation of Transport Systems and Logistics, Don State Technical University (1, Gagarin sq., Rostov-on-Don, 344003, RF), Cand. Sci. (Eng), Associate professor,
Panfilova, Elvira A., Associate professor, Department of Operation of Transport Systems and Logistics, Don State Technical University (1, Gagarin sq., Rostov-on-Don, 344003, RF), Cand. Sci. (Philosoph), Associate professor,
Simonov, Dmitriy N., Chief designer, Engineering Consulting Center "Thought" NSTU LLC (88, Troitskaya str., Novocherkassk, 346428, RF),
Claimed contributorship
Conflict of interest statement
The authors do not have any conflict of interest.
All authors have read and approved the final manuscript.
[1] Federal Law No. 116-FZ of 21.07.1997 (as amended on June 11, 2021) "On Industrial Safety of Hazardous Production Facilities". Available from:
[2] Federal Norms and Rules in the field of industrial safety "Safety rules for hazardous production facilities where lifting facilities are used". Available from:
[3] TR CU 010/2011 Technical Regulation of the Customs Union "On the Safety of Machinery and Equipment". Available from:
[4] TR CU 011/2011 Technical Regulation of the Customs Union "Elevator Safety". Available from:
[5] TR CU 018/2011 Technical Regulation of the Customs Union "On the Safety of Wheeled Vehicles". Available from:
[6] GOST 33709.1-2015 Cranes. Vocabulary. Part 1. General. Available from:
[7] GOST 27584-88 Electric overhead travelling cranes and gantry cranes. General specifications. Available from:
[8] GOST 14771-76 Gas-shielded arc welding. Welded joints. Main types, design elements and dimensions. Available from:
[9] GOST 27751-2014 Reliability for constructions and foundations. General principles. Available from:
The authors declare that there are no conflicts of interest present.