A freestanding modular gantry crane assembly and method of use thereof

Abstract

A freestanding modular gantry crane assembly and method of use is disclosed. In one form, the assembly includes at least two pairs of opposed crane support structures arranged in longitudinal rows on a support surface on opposite sides of a workspace, each of the support structures including: an inner frame member bordering the workspace and extending in a substantially vertical orientation; an outer frame member angled towards an upper end of the inner frame member in a direction perpendicular to a longitudinal axis of the workspace; a pair of running beams extending along the opposite sides of the workspace atop the crane support structures; a gantry transversely spanning between, and movably coupled to, the pair of running beams, said gantry configured to be movable back and forth along the beams; a cable drive trolley; and a cable drive assembly.

Description

A FREESTANDING MODULAR GANTRY CRANE ASSEMBLY AND METHOD OF USE THEREOFTECHNICAL FIELD

[0001] The present invention relates to a freestanding modular gantry crane assembly and method of use thereof. In particular, although not exclusively, the present invention relates to a freestanding modular gantry crane assembly for use in a rebuild facility.BACKGROUND

[0002] Gantry crane assemblies are commonly used to lift and move materials and machinery across a range of industries. Gantry cranes are especially common in rebuild facilities, i.e., purpose-built facilities for undertaking repairs, replacement, refurbishment, rebuilding, and servicing of large mining and construction equipment or parts thereof.

[0003] Generally, a rebuild facility is a purpose-built facility requiring a large footprint, extensive concrete foundations, and tall columns and cross bracings to accommodate large mining and construction equipment on two or more linear production lines and support two or more 30-tonne gantry cranes. The cranes are usually mounted to one or more load bearing walls of the facility.

[0004] Accordingly, a problem in general with rebuild facilities is that they are expensive to build and limited in their location and production layout. In turn, there is a scarcity of rebuild facilities meaning that the repairs, replacement, refurbishment, rebuilding, and servicing of large mining and construction equipment is delayed and subject to the availability and / or location of available rebuild facilities. Indeed, it is not uncommon for mining and construction equipment to be transported significant distances to available rebuild facilities at substantial cost.

[0005] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.SUMMARY OF INVENTION

[0006] Embodiments of the present invention provide a freestanding modular gantry crane assembly and method of use thereof, which may at least partially address one or more of the problems or deficiencies mentioned above or which may provide the public with a useful or commercial choice.

[0007] According to a first aspect of the present invention, there is provided a freestanding modular gantry crane assembly for use in a rebuild facility, said assembly including: at least two pairs of opposed crane support structures arranged in longitudinal rows on a support surface on opposite sides of a workspace, each of the support structures including: an inner frame member bordering the workspace and extending in a substantially vertical orientation; and an outer frame member angled towards an upper end of the inner frame member in a direction perpendicular to a longitudinal axis of the workspace; a pair of running beams extending along the opposite sides of the workspace atop the crane support structures; a gantry transversely spanning between, and movably coupled to, the pair of running beams, said gantry configured to be movable back and forth along the pair of running beams; a cable drive trolley movably coupled to the gantry and configured to be movable back and forth along the gantry; and a cable drive assembly for raising and lowering a load relative to the gantry, said cable drive assembly including a drive drum and a cable extending from the drive drum for coupling to the load.

[0008] Advantageously, the freestanding modular gantry crane assembly can be used without needing to be mounted to load bearing walls of a rebuild facility. Furthermore, the substantially vertical inner frame member directly supports the running beams and gantry without encroaching on the workspace, thereby maximising the useable area. Additionally, the angled outer frame member provides structural stability and lateral support to the assembly during operation. The modular design allows the assembly to be easily scaled by adding or removing pairs of opposed crane support structures to accommodate workspaces of varying lengths. In this manner, the freestanding modular gantry crane can be customised to suit a variety of facility sizes and layouts, and can accommodate multiple gantries operating simultaneously on the same pair of running beams.

[0009] As indicated, the modular gantry crane assembly is primarily for use with any facility intended to be used as a rebuild facility, including temporary rebuild facilities. It will therefore be convenient to describe the invention and methods with reference to this example application. However, a person skilled in the art will appreciate that the modular gantry crane assembly is capable of use in other applications such as for example, rail yards, shipping and container yards, scrap yards and the like.

[0010] As indicated, the crane support structures are configured to be arranged in longitudinal rows on a support surface, preferably parallel and linear longitudinal rows. The rowsmay define the workspace, or production line, therebetween within which large mining and construction equipment or parts thereof may be repaired, replaced, refurbished, rebuilt and / or serviced with the assistance of the gantry crane assembly.

[0011] The support surface may be any suitable sealed support surface, preferably a concrete slab. The support surface may be of a thickness of between about 100mm and about 500mm. Advantageously, the support surface need not be of a thickness required in purpose built rebuild facilities thereby enabling the freestanding modular gantry crane assembly to be used on most concrete slabs.

[0012] As mentioned, the at least two pairs of opposed crane support structures may be arranged in longitudinal rows on the support surface on opposite sides of the workspace.

[0013] Each of the support structures may include: an inner frame member bordering the workspace and extending in a substantially vertical orientation; and an outer frame member angled towards an upper end of the inner frame member in a direction perpendicular to a longitudinal axis of the workspace. Advantageously, by having an inner frame member extending generally vertical and an outer frame angled inwards, there is no encroachment of the crane support structures on the workspace, thus maximising the useability of the workspace.

[0014] Each of the inner and outer frame members may include a pair of opposed ends and an elongate body extending therebetween, preferably linearly.

[0015] The opposed ends may include a lower end and an opposed upper end.

[0016] The elongate body may be defined by at least one sidewall extending between the opposed ends.

[0017] The elongate body may be of solid or tubular construction, preferably the former.

[0018] In preferred embodiments, each of the inner and outer frame members are I-beams, also known as universal beams.

[0019] The lower end of each of the inner and outer frame members may include a flange extending at least partway around a periphery of the lower ends. Preferably, the flange extends entirely about the periphery of each lower end of each frame member.

[0020] Preferably, the flange includes one or more openings defined therein for receiving mechanical fasteners therethrough for fastening the lower ends of the inner and outer frame members to the support surface.

[0021] More preferably, the flange may be sized, shaped and orientated for abutment against the support surface. For example, the flange may be substantially planar.

[0022] In some embodiments, the flange may be of unitary construction with the frame members or the flange may be of separate construction to the frame members. In embodiments where the flange is of separate construction to the frame members, the flange may be connected to the frame members by one or more mechanical fasteners and / or conventional welding techniques.

[0023] The flange may have an area between about 1.5m2and about 0.4m2. The flange may have an area between about 1 m2and about 0.3m2. Preferably, the flange may have an area of about 0.25m2.

[0024] The outer frame member may be angled towards the inner frame member at any suitable angle. For example, the outer frame member may be angled at an angle of about 5°, about 7.5°, about 10°, about 12.5°, about 15°, about 17.5°, about 20°, about 22.5°, about 25°, about 27.5°, about 30°, about 32.5°, about 35°, about 37.5°, about 40° or even about 45° relative to a vertical axis, preferably between about 7.5° and about 17.5°.

[0025] The inner and outer frame members may be of any suitable length. The frame members may be of a same or differing lengths, preferably differing. Most preferably, the outer frame member is longer than the inner frame member.

[0026] The inner frame member may have a length as defined between the opposed ends of about 3,500mm, about 3,600mm, about 3,700mm, about 3,800mm, about 3,900mm, about 4,000mm, about 4,100mm, about 4,200mm, about 4,300mm, about 4,400mm, about 4,500mm, about 4,600mm, about 4,700mm, about 4,800mm, about 4,900mm, about 5,000mm, about 5,100mm, about 5,200mm, about 5,300mm, about 5,400mm, about 5,500mm, about 5,600mm, about 5,700mm, about 5,800mm, about 5,900mm, or even about 6,000mm, preferably about 5,532mm.

[0027] The outer frame member may have a length as defined between the opposed ends of about 4,000mm, about 4,100mm, about 4,200mm, about 4,300mm, about 4,400mm, about 4,500mm, about 4,600mm, about 4,700mm, about 4,800mm, about 4,900mm, about 5,000mm, about 5,100mm, about 5,200mm, about 5,300mm, about 5,400mm, about 5,500mm, about 5,600mm, about 5,700mm, about 5,800mm, about 5,900mm, about 6,000mm, about 6,100mm, about 6,200mm, about 6,300mm, about 6,400mm, about 6,500mm, about 6,600mm, about 6,700mm, about 6,800mm, about 6,900mm, about 7,000mm, about 7,100mm, about 7,200mm, about 7,300mm, about 7,400mm or even about 7,500mm, preferably about 6,338mm.

[0028] The outer frame member may typically be of a greater length than the inner frame such that the upper end of the outer frame member extends higher than the upper end of the inner frame member to define an offset space.

[0029] The offset space may be between about 300mm and about 600mm, preferably between about 400mm and about 500mm, more preferably about 493mm. The offset space may be provided to accommodate the running beam therein. Preferably, when positioned in the offset space, an upper end of the running beam aligns with the upper end of the outer frame member.

[0030] The inner and outer frame members may be joined together by one or more transversely extending cross frame members, preferably horizontally extending cross frame members.

[0031] In some embodiments, the inner and outer frame members may be joined together by one horizontally extending cross frame member.

[0032] In other embodiments, the inner and outer frame members may be joined together by two or more horizontally extending cross frame members.

[0033] For example, in some such embodiments, the support structure may include a first cross frame member extending between the inner and outer frame members at or near the lower end of each frame member and a second cross frame member extending between the inner and outer frame member at or near the upper end of each frame member.

[0034] Like the inner and outer frame members, the cross frame members may be of tubular or solid construction, preferably the latter. Most preferably, the cross frame members have an I-beam cross section.

[0035] Advantageously, the cross frame members afford increased support and / or bracing to the modular gantry assembly.

[0036] The various frame members may be joined together using conventional welding techniques and / or with one or more mechanical fasteners.

[0037] The upper end of the inner frame member may have a bracket mounted thereto, or extending therefrom, for fastening to a running beam received thereon, preferably a lower surface of the running beam.

[0038] The bracket may be of any suitable size, shape and orientation. Typically, thebracket is plate-shaped and having a substantially horizontal orientation.

[0039] The upper end of the outer frame member may likewise have a bracket mounted thereto, or extending therefrom, for fastening to a running beam received on the associated inner frame member, preferably an outer side surface of the running beam.

[0040] Again, the bracket may be of any suitable size, shape and orientation, typically plateshaped and having a substantially vertical orientation.

[0041] The brackets may be fastened to the upper end of each frame member using conventional welding techniques and / or via one or more mechanical fasteners.

[0042] Generally, the brackets located on each of the upper ends of the inner and outer frame members may have one or more openings defined therein for receiving mechanical fasteners therethrough for fastening to the running beam.

[0043] As indicated, the assembly may include at least two pairs of opposed crane support structures arranged in longitudinal rows on the support surface, preferably linear longitudinal rows.

[0044] Of course, a person skilled in the art will appreciate that the two pairs of opposed crane support structures represent a minimum modular unit and that the assembly may include more than two pairs of opposed crane support structures.

[0045] For example, in some embodiments, the assembly may include two pairs of opposed crane support structures, such that each crane support structure defines a corner of the workspace.

[0046] In other embodiments, the assembly may include three, four, five, six, seven, eight, nine or even ten pairs of opposed crane support structures arranged along opposed sides of the workspace.

[0047] In such embodiments, the crane support structures may preferably be evenly spaced in opposed pairs along longitudinal sides of the workspace.

[0048] In some embodiments, the crane support structures may all be of the same structure as hereinbefore described.

[0049] In other embodiments, the opposed pairs of crane support structures located at each end of the workspace may include the inner frame member, the outer frame member and a second outer frame member. Preferably, these such opposed pairs of crane support structuresare positioned at corners of the workspace.

[0050] The second outer frame member may be angled towards an upper end of the inner frame member in an orientation parallel to a longitudinal axis of the workspace, preferably extending beyond an end of the workspace.

[0051] As indicated, a pair of running beams extend along opposite sides of the workspace atop the crane support structures. Preferably, the pair of running beams rest atop the inner frame member of each crane support structure.

[0052] Each of the running beams may be of any suitable size, shape and construction and may be formed from any suitable material or materials, preferably structural grade steel.

[0053] The running beams may each include a pair of opposed ends and an elongate body extending longitudinally therebetween, preferably in a linear orientation.

[0054] The elongate body may be of tubular or solid constructions, preferably the latter.

[0055] In preferred embodiments, each running beam may be an I-beam with an l-shaped cross section. The l-shaped cross section may include an upper flange defining an upper surface of the running beam, an opposed lower flange defining a lower surface of the running beam and a web extending centrally between the upper flange and the lower flange in a substantially vertical orientation.

[0056] The upper flange of each running beam may include downwardly extending edge portions. Preferably, the downwardly extending edge portions are orthogonally angled relative to the upper flange. An outermost edge portion may preferably be fastened to the bracket mounted thereto, or extending from, the upper end of the outer frame member of the support structure, typically with one or more mechanical fasteners and / or conventional welding techniques.

[0057] Each running beam may be of any suitable length to extend a length of the workspace.

[0058] In preferred embodiments, each running beam may include a rail extending linearly at least partially between the opposed ends for movably coupling the gantry thereto.

[0059] The rail may include any form of guided or directional conveyance. For example, the rail may include a track. The rail may be of any suitable size, shape and construction and may be formed from any suitable material or materials. The rail may be of unitary or separateconstruction to the running beam.

[0060] Suitably, the rail may extend longitudinally atop the upper surface of each running beam so as to guide movement of the gantry back-and-forth along the running beam.

[0061] As indicated, the assembly includes a gantry transversely spanning between, and movably coupled to the pair of running beams. Preferably the gantry is movably coupled to the pair of running beams for movement back-and-forth along the running beams.

[0062] The gantry may be of any suitable size, shape and construction and may be constructed from any suitable material or materials for supporting the cable drive trolley and cable drive assembly relative to the crane support structures and running beams.

[0063] A person skilled in the art will appreciate that the length of the gantry is dependent on the width of the workspace or production line defined between the longitudinal rows of crane support structures. In this regard, the gantry may have a length of about 10,000mm, about 11 ,000mm, about 12,000mm, about 13,000mm, about 14,000mm, about 15,000mm, about 16,000mm, about 17,000mm, about 18,000mm, about 19,000mm, about 20,000mm, about 21 ,000mm, about 22,000mm, about 23,000mm, about 24,000mm or even about 25,000mm, typically the gantry may have a length ranging between about 12,000mm and 19,000mm.

[0064] Generally, the gantry may be formed from metal. Preferably, the gantry is formed from steel with a high tensile strength grade to support at least a 25-tonne load.

[0065] The gantry may be of unitary construction or may be formed from two or more gantry pieces joined together, typically the latter.

[0066] The gantry may include a pair of opposed ends and an elongate body extending therebetween. The elongate body may be of solid or tubular construction.

[0067] In some embodiments, the elongate body may be defined by at least one sidewall extending between the opposed ends, preferably at least four sidewalls defining a substantially rectangular cross sectional shape. The at least four sidewalls may include a top wall, an opposed bottom wall, and opposed sidewalls.

[0068] In other embodiments, the gantry may include at least one I-beam, or girder, with an l-shaped cross section. As previously described with reference to the running beams, the I- shaped cross section may include an upper flange defining an upper surface of the gantry, an opposed lower flange defining a lower surface of the gantry and a web extending centrally between the upper flange and the lower flange in a substantially vertical orientation.

[0069] In such embodiments, the lower flange may include a rail extending linearly at least partially between the opposed ends for movably coupling the cable drive trolley thereto. The rail may be of unitary or separate construction to the gantry. For example, in some embodiments, the rail may be defined in, or mounted to, the lower flange. In other embodiments, the rail may be of separate construction and may be mounted and / or supported atop the flange.

[0070] In yet other embodiments, the gantry may include two I-beams, or girders, with an I- shaped cross section. The two I-beams, or girders may be arranged in a stacked or side-by- side arrangement.

[0071] Again, the rail may include any form of guided or directional conveyance. For example, the rail may include a track. The rail may be of any suitable size, shape and construction and may be formed from any suitable material or materials.

[0072] In yet other embodiments, the gantry may include a pair of opposed end portions and an elongate body extending therebetween. The elongate body may be as previously described with reference to the frame members and running beams.

[0073] The opposed end portions may extend orthogonally downward relative to the elongate body for movably coupling to the running beams.

[0074] The end portions may be of unitary or separate construction to the elongate body.

[0075] In some embodiments, the opposed end portions and the elongate body may be movably coupled together for raising and lowering a height of the elongate body relative to the support surface. Preferably, the opposed end portions and the elongate body may be movably coupled together by an actuator or actuating mechanism.

[0076] Any suitable type of actuator or actuating mechanism may be used.

[0077] In some embodiments, the actuator may be an electrically powered screw jack or screw actuator.

[0078] Advantageously, having orthogonally angled edge portions provides further clearance or lift height without having to increase the height of the crane support structures.

[0079] As indicated, the gantry may be movably mounted to the running beams so as to be movable back-and-forth along the beams and along a longitudinal length of the workspace. The gantry may be movably mountable to the running beams in any suitable way.

[0080] Generally, the opposed ends or end portions of the gantry may each include a railmounting portion configured to be mountable to and movable along the rail defined on the upper surface of each running beam.

[0081] The rail mounting portion may include one or more wheels or rollers configured to engage with and be moveable along the rail. The one or more wheels or rollers may be profiled wheels or rollers configured to enable linear movement along the rail but not lateral separation from the rail.

[0082] In some embodiments, the gantry may further include an actuating mechanism for moving the gantry back-and-forth along the rails. Any suitable type of actuating mechanism may be used.

[0083] For example, in some embodiments, the actuating mechanism may include one or more linear actuators, such as, e.g., a pneumatic ram, a hydraulic ram or a rigid chain actuator (also known as a linear chain actuator, a push-pull actuator, an electric chain actuator, a zip chain actuator or a column forming actuator).

[0084] In other embodiments, the actuating mechanism may include a servomotor or stepper motor configured to roll the gantry along the rails.

[0085] In yet other embodiments, the actuating mechanism may include a hydraulically, pneumatically, or electrically powered screwjack or screw motor.

[0086] In yet other embodiments, the actuating mechanism may include a drive motor, such as, e.g., an electric or hydraulic motor or combustion engine operatively associated with a drive chain, winch or cable for rolling the gantry along the rails.

[0087] As indicated, the assembly includes a cable drive trolley movably coupled to the gantry and configured to be movable back and forth along the gantry in a transverse direction relative to a longitudinal axis of the workspace.

[0088] The cable drive trolley may be of any suitable size, shape and construction for supporting the cable drive assembly relative to the gantry.

[0089] Generally, the cable drive trolley may include at least a mounting plate and one or more rail mounting portions for mounting to, and movement along the gantry. The cable drive trolley may be movably mountable to the gantry in any suitable way.

[0090] Typically, in embodiments in which the lower flange of the elongate body of the gantry defines a rail, the cable drive trolley may include a pair of rail mounting portions configuredto hook around or about the lower flange and be movable therealong.

[0091] In other embodiments, the gantry may define a channel and the one or more rail mounting portions may be configured to be mountable and slidable along the channel.

[0092] The rail mounting portions may include one or more wheels or rollers configured to engage with and be moveable along the rail.

[0093] The cable drive trolley may further include an actuating mechanism for moving the trolley back-and-forth along the gantry. Any suitable type of actuating mechanism may be used.

[0094] For example, in some embodiments, the actuating mechanism may include one or more linear actuators, such as, e.g., a pneumatic ram, a hydraulic ram or a rigid chain actuator (also known as a linear chain actuator, a push-pull actuator, an electric chain actuator, a zip chain actuator or a column forming actuator).

[0095] In other embodiments, the actuating mechanism may include a servomotor or stepper motor configured to roll the trolley along the gantry.

[0096] In yet other embodiments, the actuating mechanism may include a hydraulically, pneumatically, or electrically powered screwjack or screw motor.

[0097] In yet other embodiments, the actuating mechanism may include a drive motor, such as, e.g., an electric or hydraulic motor or combustion engine operatively associated with a drive chain, winch or cable for rolling the trolley along the gantry.

[0098] As indicated, the assembly includes a cable drive assembly for raising and lowering a load relative to the gantry.

[0099] The cable drive assembly may be of any suitable size, shape and construction.

[0100] As indicated, the cable drive assembly may include a drive drum and a cable extending from the drive drum for coupling to the load.

[0101] The cable may usually be a steel wire cable, preferably a closed loop cable.

[0102] The cable may extend from the drive drum and connect to a retention device, such as, e.g., a hook or clip, for releasably connecting to a load.

[0103] To lower the retention device, the drive drum may rotate in a first direction and let out cable. To raise the retention device, the drive drum may rotate in an opposite direction and wind in the cable.

[0104] The drive drum may be of any suitable size, shape and construction. The drive drum may include a spool and a motor for driving rotation of the spool. The motor may be an electric, hydraulic or combustion motor, for example.

[0105] In some embodiments, the assembly may include more than one cable drive trolley and operatively associated cable drive assembly movably mounted to a gantry. For example, the assembly may include two, three or even four cable drive trolleys with operatively associated cable drive assemblies. Each trolley and assembly may be configured for independent operation.

[0106] In some embodiments, the assembly may include more than one gantry movably coupled to the running beams. For example, the assembly may include two, three, four or even five gantries all movably coupled to the running beams.

[0107] According to a second aspect of the present invention, there is provided a method of using a freestanding modular gantry crane in a rebuild facility, said method including: moving a gantry longitudinally along a pair of running beams positioned atop at least two pairs of opposed crane support structures, wherein each of the support structures includes: an inner frame member bordering a workspace and extending in a substantially vertical orientation; and an outer frame member angled towards an upper end of the inner frame member in a direction perpendicular to a longitudinal axis of the workspace; and moving a retention device coupled to the gantry in a transverse direction across the gantry using a cable drive trolley; and positioning equipment or a part thereof at a workspace defined between the opposed crane support structures; and raising and lowering the equipment or part thereof using the retention device while moving the equipment or part thereof along the workspace and rebuilding the equipment.

[0108] The method may include one or more features or characteristics of the freestanding modular gantry crane assembly as hereinbefore described.

[0109] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0110] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.BRIEF DESCRIPTION OF DRAWINGS

[0111] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0112] Figure 1 is a schematic of a freestanding modular gantry crane assembly according to an embodiment of the present invention;

[0113] Figure 2 is an end view of a support structure of the assembly shown in Figure 1 ;

[0114] Figure 3 is a side view of the support structure shown in Figure 2;

[0115] Figure 4 is an upper perspective view of the support structure shown in Figures 2 and 3;

[0116] Figure 5 is an upper perspective view of a support structure according to another embodiment of the present invention; and

[0117] Figure 6 is a flow chart showing steps in the method of using the freestanding modular gantry crane assembly shown in Figure 1 according to an embodiment of the present invention.DETAILED DESCRIPTION

[0118] Figure 1 to 5 show a freestanding modular gantry crane assembly (100) and parts thereof for use in a rebuild facility according to an embodiment of the present invention.

[0119] Referring to Figure 1 , the freestanding modular gantry crane assembly (100) includes opposed pairs of crane support structures (110) arranged in longitudinal rows on a support surface (800) on opposite sides of a workspace (700).

[0120] Each support structure (110) includes: an inner frame member (120) bordering the workspace (700) and extending in a substantially vertical orientation; and an outer frame member (130) angled towards an upper end of the inner frame member (120) in a direction perpendicular to a longitudinal axis of the workspace (700).

[0121] The assembly (100) further includes a pair of running beams (140) extending along opposite sides of the workspace (700) atop the crane support structures (110); a gantry (150)transversely spanning between, and movably coupled to, the pair of running beams (140), said gantry configured to be movable back and forth along the pair of running beams (140); a cable drive trolley (160) movably coupled to the gantry (150) and configured to be movable back and forth along the gantry (150); and a cable drive assembly (170) for raising and lowering a load relative to the gantry (150), said cable drive assembly (170) including a drive drum and a cable extending from the drive drum for coupling to the load.

[0122] The support surface (800) is a concrete slab having a thickness of between about 100mm and about 500mm.

[0123] Referring to Figure 2, each support structure (110) includes: an inner frame member (120) bordering the workspace and extending in a substantially vertical orientation; and an outer frame member (130) angled towards an upper end of the inner frame member (120) in a direction perpendicular to a longitudinal axis of the workspace (700). Advantageously, by having an inner frame member (120) extending generally vertical and an outer frame member (130) angled inwards, there is no encroachment of the crane support structures (110) on the workspace (700), thus maximising the useability of the workspace (700).

[0124] Each of the inner and outer frame members (120, 130) include a pair of opposed ends and an elongate body extending linearly therebetween. The opposed ends include an upper end (121 , 131) and a lower end (122, 132).

[0125] Each of the inner and outer frame members (120, 130) are I-beams.

[0126] Referring to Figure 4, the lower end of each of the inner and outer frame members (120, 130) include a flange extending at least partway around a periphery of the lower ends (122, 132).

[0127] The flange includes openings defined therein for receiving mechanical fasteners therethrough for fastening the lower ends (122, 132) of the inner and outer frame members (120, 130) to the support surface (800).

[0128] The flange is planar and is oriented for abutment with the support surface (800; not shown).

[0129] Referring back to Figure 2, the outer frame member (130) may be angled towards the inner frame member (120) at an angle of about 7.5° relative to a vertical axis.

[0130] The inner frame member (120) has a length of about 5,532mm. The outer frame member (130) has a length of about 6,338mm.

[0131] As shown, the outer frame member (130) is of a greater length than the inner frame member (120) such that the upper end (131) of the outer frame member (130) extends higher than the upper end (121) of the inner frame member (120) to define an offset space (210). The offset space is about 493mm and is provided to accommodate the running beam (140) therein. The running beam (140) is positioned in the offset space as shown in Figure 3.

[0132] The inner frame member (120) and the outer frame member (130) are joined together by two transversely extending horizontal cross frame members.

[0133] A first cross frame member (111A) extends between the inner frame member (120) and the outer frame member (130) near the upper ends (131, 121) and a second cross frame member (111 B) extends between the inner frame member (120) and the outer frame member (130) near the lower ends (132, 122).

[0134] Like the inner frame member (120) and the outer frame member (130), the horizontal cross frame members (111) are I-beams.

[0135] Advantageously, the cross frame members (111) afford increased support and / or bracing to the modular gantry assembly (100; not shown).

[0136] The various frame members (120, 130), including the cross frame members (111) are joined together using conventional welding techniques.

[0137] Referring again to Figure 4, the upper ends (121, 131) of the inner and outer frame members (120, 130) each have a bracket mounted thereto (420, 410) for fastening to a running beam (140; not shown) received thereon.

[0138] The bracket (420) is plate shaped and is of a substantially horizontal orientation.

[0139] Conversely, the bracket (410) is plate-shaped and is of a substantially vertical orientation.

[0140] The brackets (410, 420) are fastened to the upper ends (121, 131) of each of the inner frame member (120) and the outer frame member (130) using conventional welding techniques.

[0141] Both brackets (410, 420) include openings defined therein for receiving mechanical fasteners therethrough for fastening to the running beam (140; not shown).

[0142] Referring to Figure 5, a person skilled in the art will appreciate that the two pairs of opposed crane support structures (110; not shown) represent a minimum modular unit and thatthe assembly (100) can include more than two pairs of opposed crane support structures (110; not shown). Indeed, and in the embodiment shown, corners of the workspace (700; not shown) can include a corner crane support structure (510).

[0143] The corner crane support structure (510) is similar to the support structure (110; not shown), and includes an inner frame member (520), an outer frame member (530), and a second outer frame member (540). The second outer frame member (540) is angled towards an upper end (521) of the inner frame member (520) in an orientation parallel to a longitudinal axis of the workspace (700; not shown), preferably extending beyond an end of the workspace (700; not shown).

[0144] Referring back to Figure 1 , and as indicated, a pair of running beams (140) extend along the opposite sides of the workspace (700) atop the crane support structures (110).

[0145] Each of the running beams (140) is an I-beam with an l-shaped cross section made of structural grade steel.

[0146] The l-shaped cross section includes an upper flange (141) defining an upper surface of the running beam, an opposed lower flange (143) defining a lower surface of the running beam (140) and a web (142) extending centrally between the upper flange (141) and the lower flange (143) in a substantially vertical orientation.

[0147] The upper flange of each running beam (140) includes downwardly extending edge portions, orthogonally angled relative to the upper flange (141). An outermost edge portion is fastened to the bracket (410) mounted thereto the upper end (131) of the outer frame member (130) of the support structure (110) with one or more mechanical fasteners.

[0148] Each running beam (140) includes a rail extending linearly at least partially between opposed ends for movably coupling the gantry (150) thereto. The rail includes a track.

[0149] The rail extends longitudinally atop the upper surface of each running beam (140) so as to guide movement of the gantry (150) back-and-forth along the running beam (140).

[0150] As shown, the assembly (100) includes a gantry (150) transversely spanning between, and movably coupled to, the pair of running beams (140) for movement back-and-forth along the running beams (140).

[0151] The gantry (150) can be of any suitable length to span between the crane support structures (110) arranged in longitudinal rows on the support surface (800) on opposite sides of a workspace (700). Typically, the gantry (150) has a length of between about 12,000mm andabout 19,000mm.

[0152] The gantry (150) is formed from steel with a high tensile strength grade to support at least a 25-tonne load.

[0153] The gantry (150) includes a pair of opposed end portions and an elongate body extending therebetween. The opposed end portions extend orthogonally downward relative to the elongate body for movably coupling to the running beams (140).

[0154] Advantageously, having orthogonally angled end portions provides further clearance or lift height without having to increase the height of the crane support structures.

[0155] At least the elongate body of the gantry (150) includes at least one I-beam, or girder, with an l-shaped cross section.

[0156] As previously described with reference to the running beams (140), the l-shaped cross section includes an upper flange defining an upper surface of the gantry, an opposed lower flange defining a lower surface of the gantry and a web extending centrally between the upper flange and the lower flange in a substantially vertical orientation.

[0157] The lower flange includes a rail extending linearly between the opposed ends for movably coupling the cable drive trolley (160) thereto. The rail is of unitary construction with the gantry (150).

[0158] Similar to the rail described with reference to the running beam (140), the rail includes a track.

[0159] As indicated, the gantry (150) is movably mounted to the running beams (140) so as to be movable back-and-forth along the running beams (140) and along a longitudinal length of the workspace (700).

[0160] The opposed ends of the gantry (150) each include a rail mounting portion (180) configured to be mountable to and movable along the rail defined on the upper surface of each running beam (140).

[0161] The rail mounting portion (180) includes a roller configured to engage with and be moveable along the rail. The roller is a profiled roller configured to enable linear movement along the rail but not lateral separation from the rail.

[0162] The gantry (150) further includes an actuating mechanism for moving the gantry back-and-forth along the rails.

[0163] As indicated, the assembly (100) includes a cable drive trolley (160) movably coupled to the gantry (150) and configured to be movable back and forth along the gantry (150) in a transverse direction relative to a longitudinal axis of the workspace (700).

[0164] The cable drive trolley (160) includes a mounting plate and a rail mounting portion for mounting to, and movement along the gantry (150). The cable drive trolley (160) includes a pair of rail mounting portions configured to hook around the lower flange of the gantry (150) and be movable therealong.

[0165] The trolley (160) further includes an actuating mechanism for moving the cable drive trolley (160) back-and-forth along the gantry (150).

[0166] As indicated, the assembly (100) includes a cable drive assembly (170) for raising and lowering a load relative to the gantry (150).

[0167] The cable drive assembly (170) includes a drive drum and a cable extending from the drive drum for coupling to the load.

[0168] The cable is a closed loop cable. The cable extends from the drive drum and connects to a retention device, in this instance a hook (171).

[0169] To lower the hook (171), the drive drum rotates in a first direction and lets out cable. To raise the hook (171), the drive drum rotates in an opposite direction and winds in the cable.

[0170] The drive drum includes a spool and a motor for driving rotation of the spool. The motor is electric.

[0171] The assembly (100) includes two cable drive trolleys (160) and operatively associated cable drive assemblies (170) movably mounted to the gantry (150). Each cable drive trolley (160) is configured for independent operation.

[0172] A method (600) of using the assembly (100) as shown in Figure 1 is now described with reference to Figure 6.

[0173] At step 610, the gantry (150) is moved longitudinally along the pair of running beams (140) positioned atop the two pairs of opposed crane support structures (110).

[0174] At step 620, a hook (171) coupled to the gantry (150) is moved along the gantry (150) in a transverse direction using the cable drive trolley (160).

[0175] At step 630, equipment or a part thereof requiring rebuilding is positioned on theworkspace (700) defined between the opposed crane support structures (110).

[0176] At step 640, the equipment or part thereof, is raised and lowered using the hook (171) while moving the equipment or part thereof along the workspace (700) and rebuilding the equipment.

[0177] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0178] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0179] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

CLAIMS1. A freestanding modular gantry crane assembly for use in a rebuild facility, said assembly including: at least two pairs of opposed crane support structures arranged in longitudinal rows on a support surface on opposite sides of a workspace, each of the support structures including: an inner frame member bordering the workspace and extending in a substantially vertical orientation; and an outer frame member angled towards an upper end of the inner frame member in a direction perpendicular to a longitudinal axis of the workspace; a pair of running beams extending along the opposite sides of the workspace atop the crane support structures; a gantry transversely spanning between, and movably coupled to, the pair of running beams, said gantry configured to be movable back and forth along the pair of running beams; a cable drive trolley movably coupled to the gantry and configured to be movable back and forth along the gantry; and a cable drive assembly for raising and lowering a load relative to the gantry, said cable drive assembly including a drive drum and a cable extending from the drive drum for coupling to the load.

2. The assembly of claim 1 , wherein the at least two pairs of opposed crane support structures are arranged in parallel and linear longitudinal rows on opposite sides of the workspace.

3. The assembly of claim 1 or claim 2, wherein each of the inner frame member and the outer frame member are I-beams.

4. The assembly of any one of claims 1 to 3, wherein each of the inner frame member and the outer frame member include a flange extending at least partway around a periphery of lower ends of the frame members for receiving one or more fasteners therethrough for fastening the lower ends to the support surface.

5. The assembly of any one of claims 1 to 4, wherein the outer frame member is angled towards the inner frame member at an angle between about 7.5° and about 17.5° relative to a vertical axis.

6. The assembly of any one of claims 1 to 5, wherein the outer frame member is of greater length than the inner frame member such that an upper end of the outer frame member extends higher than the upper end of the inner frame member to define an offset space.

7. The assembly of claim 6, wherein the offset space is sized to accommodate one of the pair of running beams therein.

8. The assembly of claim 7, wherein when positioned in the offset space, an upper end of the one of the pair of running beams aligns with the upper end of the outer frame member.

9. The assembly of any one of claims 1 to 8, wherein each of the crane support structures includes a first cross frame member extending between the inner and outer frame members at or near the lower end of each of the frame members and a second cross frame member extending between the inner and outer frame members at or near the upper end of each of the frame members.

10. The assembly of any one of claims 1 to 9, wherein the upper end of the inner frame member has a bracket mounted thereon, or extending therefrom, for fastening one of the pair of running beams thereto.

11. The assembly of claim 10, wherein the bracket is fastened to an outer side surface of the one of the pair of running beams.

12. The assembly of any one of claims 1 to 11 , wherein each of the pair of running beams is an I-beam having an upper flange defining an upper surface of the running beam, an opposed lower flange defining a lower surface of the running beam and a web extending centrally between the upper flange and the lower flange in a substantially vertical orientation.

13. The assembly of any one of claims 1 to 12, wherein each of the pair of running beams includes a rail extending linearly at least partially between opposed ends of the beam for movably coupling the gantry thereto.

14. The assembly of any one of claims 1 to 13, wherein the gantry includes an actuating mechanism for moving the gantry back-and-forth along rails on the running beams.

15. The assembly of any one of claims 1 to 14, wherein the cable drive trolley is movable back and forth along the gantry in a transverse direction relative to a longitudinal axis of the workspace.

16. The assembly of claim 15, wherein the cable drive trolley includes a mounting plate and a rail mounting portion for mounting to, and movement along, the gantry.

17. The assembly of claim 16, wherein the cable drive trolley further includes an actuating mechanism for moving the cable drive trolley back-and-forth along the gantry.

18. The assembly of any one of claims 1 to 17, wherein the assembly includes two cable drive trolleys each having its own cable drive assembly.

19. The assembly of claim 18, wherein each said cable drive trolley and its cable drive assembly is configured for independent operation.

20. A method of using a freestanding modular gantry crane in a rebuild facility, said method including: moving a gantry longitudinally along a pair of running beams positioned atop at least two pairs of opposed crane support structures, wherein each of the crane support structures includes: an inner frame member bordering a workspace and extending in a substantially vertical orientation; and an outer frame member angled towards an upper end of the inner frame member in a direction perpendicular to a longitudinal axis of the workspace; and moving a retention device coupled to the gantry in a transverse direction across the gantry using a cable drive trolley; positioning equipment or a part thereof at a workspace defined between the opposed crane support structures; and raising and lowering the equipment or part thereof using the retention device while moving the equipment or part thereof along the workspace and rebuilding the equipment.

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