Modular Crane Carbody Connection System for Rapid Assembly
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Solution Overview
Problem
Conventional crane designs face challenges in easily disassembling and reassembling carbody components, particularly due to the complexity of connecting crawlers to the carbody and integrating ring gear and roller path sections, which increases setup time and costs.
Innovation Solution
A carbody connection system that allows the crane to be disassembled into interchangeable side and end cross members, with a trunnion connection system for crawlers, enabling side-by-side assembly and permanent attachment of ring gear and roller path sections for efficient reassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bolted connections are used to attach crawlers to the carbody, then the connection can sustain tremendous loads, but the disconnection and re-connection process becomes difficult and time-consuming
Solution Approach 1:
The connection system is divided into separate modular components: carbody connection assemblies with connection plates, crawlers with corresponding connection interfaces, and trunnions as intermediate elements. This segmentation allows each component to be independently manufactured, transported, and quickly assembled without requiring complex bolted connections, thereby reducing setup time while maintaining connection strength through dedicated connection interfaces.
Solution Approach 2:
Trunnions serve as intermediary elements between the carbody and crawlers. The trunnion connection system includes trunnion assemblies that can be attached to the carbody and then receive the crawlers, simplifying the overall connection process. This intermediary structure enables quicker assembly and disassembly compared to direct bolted connections between crawlers and carbody, addressing both the strength requirement and time reduction goal.
2Adaptability or versatility
If the carbody is disassembled into individual members for transport, then mobility is improved, but the reassembly process becomes complex and requires precise alignment
Solution Approach 1:
The carbody is segmented into modular carbody members that can be independently transported. Each carbody member includes integrated connection assemblies with connection plates and interfaces that standardize the reassembly process. This segmentation strategy enables easy disassembly for mobility while the standardized interfaces reduce reassembly complexity by providing predetermined connection points and alignment features.
Solution Approach 2:
The connection assemblies are designed with universal interfaces that can accommodate different carbody members and configurations. The connection plates and interfaces are standardized across all carbody members, allowing them to be assembled in various sequences and configurations without requiring complex alignment procedures. This universality simplifies the reassembly process while maintaining the mobility benefits of disassembly.
3Ease of manufacture
If ring gear and roller path sections are bolted onto the carbody after assembly, then the carbody can be assembled from parts, but this time-consuming process creates difficulties in achieving close alignment
Solution Approach 1:
The ring gear sections and roller path sections are merged with the carbody members as integrated components rather than separate attachments. This means the ring gear and roller path are built into the carbody member structures themselves during manufacturing, eliminating the need for post-assembly bolting operations. This integration ensures precise alignment is achieved during the manufacturing process rather than requiring field alignment, while still allowing the carbody to be assembled from individual members.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A mobile lift crane (10) includes a carbody (12) made from two side members (11) and two end cross members (13) connected to each other with a carbody connection that can be disconnected such that the side members (11) and end cross members (13) can be individually transported between job sites and reassembled at a new job site. Preferably the two side members (11) are interchangeable with each other when making the carbody (12) , and the two end cross members (13) are also interchangeable with each other. Further, each of the side members (11) and end cross members (13) preferably has a section of a roller path and section of a ring gear (31) attached to them while being transported and assembled.