STRUCTURAL FRAME FOR A CRANE AND SIMILAR MACHINES, AND CRANE COMPRISING SUCH A STRUCTURAL FRAME

Abstract

The present invention relates to a structural frame of a crane, lifting device, material handler or a similar machine, comprising at least one elongate structural-frame strut. The invention also relates to such a machine comprising such a structural frame. According to a first aspect, it is proposed not to weld or screw a separate doubled panel or separate retaining lugs to the structural-frame element as a reinforcement, but rather to provide the structural-frame strut with integrally formed, seam-free reinforcement layers in the required, highly loaded region, in order to achieve an organically produced increase in wall thickness and/or cross section in a smooth and harmonious manner. These reinforcement layers are produced using 3D printing.

Claims

1. A structural frame of a crane, a lifting device, a material handler or a similar machine, comprising: an elongate structural-frame strut, wherein the structural-frame strut comprises an integrally molded-on, layered reinforcement portion.

2. The structural frame of claim 1, wherein the structural-frame strut has a hollow profile, and wherein the layered reinforcement portion is integrally molded onto the inside or outside of the hollow profile.

3. The structural frame according to claim 1, wherein a region of the reinforcement portion has a freeform element having a continuously and constantly changing wall thickness.

4. The structural frame according to claim 2, wherein the reinforcement portion comprises a honeycomb structure or tubular-bone structure inside the hollow profile.

5. The structural frame according to claim 1, wherein the reinforcement portion comprises a branched structure inside the hollow profile and irregularly shaped and/or three-dimensionally arranged branched struts extending in different directions.

6. The structural frame according to claim 5, wherein the branched struts have a wall thickness that changes gradually over the longitudinal extension of the branched struts and/or the branched struts have a cross-sectional dimension that changes gradually over the longitudinal extension of said branched struts.

7. The structural frame according to claim 1, wherein the reinforcement portion has a thickened portion in the wall thickness and/or cross section, and wherein the wall thickness and/or cross section has a gradual, seam-free transition between said thickened portion in the wall thickness and/or cross section and an adjacent structural-frame portion having a thinner wall thickness and/or a smaller cross sction.

8. The structural frame according to claim 1, wherein the structural-frame strut comprises two connecting portions for connection to other structural frame elements at opposite ends, wherein the structural-frame strut has a cross section that continuously and constantly changes gradually and/or a wall thickness that continuously and constantly changes gradually at least in a central portion between the two connecting portions, wherein the cross-sectional dimension and/or the wall thickness has a maximum in the central portion and/or is decreasing from said central portion towards opposite sides and/or increasing again at said connecting portions.

9. The structural frame according to claim 1, wherein when viewed in cross section the structural-frame strut has a wall thickness that changes in the peripheral direction, and gradually increases and gradually decreases again in the peripheral direction.

10. The structural frame according to claim 9, wherein when viewed in a longitudinal section the structural-frame strut has a changing wall thickness which gradually increases and gradually decreases again.

11. The structural frame according to claim 1, wherein the structural frame has a truss and said structural-frame strut forms a truss strut in the form of a longitudinal or transverse flange of the truss.

12. The structural frame according to claim 11, wherein the reinforcement portion is in a region of a node point of the truss at which a plurality of truss struts are interconnected.

13. The structural frame according to claim 12, wherein the plurality of truss struts are interconnected at a node point of the truss in an integral and seam-free manner, wherein the node point has a layered metal material construction from the use of 3D printing.

14. The structural frame according to claim 1, wherein the structural-frame strut has a longitudinal axis having a curved progression and a wall thickness that changes multiple times over the longitudinal axis and/or a cross-sectional dimension that changes multiple times over the longitudinal axis.

15. The structural frame according to claim 1, wherein the structural frame forms an elongate girder comprising a structural-frame enveloping surface at least in portions, which, when viewed in a longitudinal section, has a curved enveloping-surface sectional contour.

16. The structural frame according to claim 15, wherein the enveloping surface, when viewed in cross section, has a curved enveloping-surface sectional contour that is not circular.

17. The structural frame according to claim 15, wherein the enveloping-surface sectional contour is elliptical or oval or droplet-shaped when viewed in cross section.

18. The structural frame according to claim 17, wherein the enveloping-surface sectional contour viewed in cross section changes in different cross sections that are spaced apart along the longitudinal extension of the structural frame, in relationship between the two main axes of the cross-sectional contour.

19. The structural frame according to claim 1, wherein the structural-frame strut comprises in part a hollow profile and in part of a solid-material profile.

20. The structural frame according to claim 1, wherein the at least one structural-frame strut comprises a plurality of metal layers integrally interconnected in a planar manner.

21. The structural frame according to claim 1, wherein the reinforcement portion comprises layers of a first metal material, and further comprising structural-frame portions spaced apart from said reinforcement portion, wherein the structural-frame portions comprise layers of a second metal material of a lower strength than the first metal material.

22. The structural frame according to claim 21, wherein a single material layer comprises a first layer portion made of the first metal material and a second layer portion made of the second metal material.

23. The structural frame according to claim 1, wherein the structural-frame strut comprises a plurality of layers and partially changes material properties within one layer, wherein a first layer has a high material strength and a second layer has a low material strength.

24. The structural frame according to claim 1, wherein strut portions having different material properties are provided in the cross section or longitudinal section of the structural-frame strut.

25. The structural frame according to claim 1, wherein the structural-frame strut is produced in portions by 3D printing.

26. A machine comprising a structural frame of claim 25.

27. The machine of claim 26, wherein the machine comprises a crane, a lifting device, a material handler, a cable excavator or a construction machine.

28. A tower crane comprising a structural frame of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The invention is explained in greater detail in the following on the basis of preferred embodiments and the associated drawings, in which:

[0033] FIG. 1 is a schematic side view of a rotating tower crane comprising an organically constructed structural frame, comprising a truss tower and a truss boom comprising structural- frame struts with bionic contouring,

[0034] FIG. 2 shows a structural-frame strut according to an advantageous embodiment of the invention in the form of a crane-trolley support of the crane trolley of the crane from FIG. 1, with the view (a) being a perspective outer view of the crane-trolley support and the view (b) being a perspective sectional view of the crane-trolley support which shows the reinforcement structures provided inside the crane-trolley support,

[0035] FIG. 3 is a perspective partial view of a structural-frame strut which comprises a hollow profile and an articulation eye formed therein, with the view (a) being a perspective outer view and the view (b) being a longitudinal section for showing the inner workings,

[0036] FIG. 4 is a perspective partial view of a structural-frame strut comprising a screw-connection end, with the view (a) being a perspective outer view and the view (b) being a perspective section for illustrating the changing wall thicknesses,

[0037] FIG. 5 is a perspective view of a structural-frame strut in the form of a pressure rod, the cross-sectional dimension of which tapers from a maximum diameter in the center of the rod towards the ends, with the view (a) being an outer view and the view (b) being a partial sectional view for illustrating the hollow profile,

[0038] FIG. 6 is a perspective view of a structural-frame strut in the form of a pressure rod comprising molded-on fastening flanges at the ends of the rod, with the view (a) being a perspective outer view and the view (b) being a partial sectional view for showing the stiffening ribs provided inside the hollow profile and the molded-on solid-material cross section of the fastening flange,

[0039] FIG. 7 is a perspective view of a structural-frame strut in the form of a flange element comprising a screw-thread neck, with the view (a) being an outer view and the view (b) being a sectional view for illustrating the progression of the wall thickness,

[0040] FIG. 8 is a view of details of the node point between multiple truss struts of the structural frame of the crane in FIG. 1, with the view (a) being a perspective outer view, the view (b) being a longitudinal section for showing the honeycomb stiffening structure inside the truss strut, the view (c) being a side view, the view (d) being a cross section, the view (e) being a sectional view of an enlarged detail of the honeycomb structure, the view (f) being a tubular-bone structure and the view (g) being a branched structure, and

[0041] FIG. 9 is a perspective view of a node point of the structural truss frame of the crane from FIG. 1, in which the wall thicknesses of the hollow profile are partially thickened in the region of the connection points of the truss struts, with the view (a) being an outer view, the view (b) being a section view for illustrating the thickened portion in the wall thickness in the connecting region, the view (c) being a side view and the view (d) being a cross section.

DETAILED DESCRIPTION

[0042] As shown in FIG. 1, the structural frame 8 according to the invention is part of a crane 1 and can form the boom 3 and the tower thereof, where the crane is designed as a rotating tower crane. It is noted, however, that the structural frame may also be part of other comparable machines having highly loaded structures, with it being possible for such other machines to be a cable excavator, a leader, a lifting device such as a wheel loader or a material handler such as an excavated-material conveyor or a construction machine, for example.

[0043] As FIG. 1 also shows, the structural frame 8 may in particular be designed as a truss or truss girder, but the structural frame may also comprise other structural frame components, such as the outrigger 7 of the crane.

[0044] As shown in FIG. 1, the crane 1 may be designed as a rotating tower crane which comprises an upright tower 2 that supports an approximately horizontally extending boom 3 and optionally a counter-boom. A hoist rope 5 can be lowered from the approximately horizontally extending boom 3, which rope has a load hook 6, it being possible for the hoist rope 5 to extend from a crane trolley 4 that can be moved along the boom 3.

[0045] When viewed as a whole, the structural frame 8 in the form of the tower 2 and/or boom 3 may have organic and/or bionic contouring. For example, in a deviation from previous, conventional tower and/or boom enveloping surfaces, an enveloping surface surrounding the tower 2 and/or an enveloping surface 16 enclosing the boom 3 may have curved outer contouring, which may have an arcuate curvature when viewed in either longitudinal direction. For example, the tower 2 and/or its enveloping surface 16 may have slightly pear-shaped or slightly spherical outer contouring. The enveloping surface 16 of the boom 3 may comprise a planar base surface, along which the crane trolley 4 can be moved, as well as an arcuately curved rear surface; cf. FIG. 1. The cross section of the enveloping surfaces 16 of the tower 2 and/or the boom 3 may vary in terms of shape and dimensions here, as has been explained in greater detail at the outset. For example, the enveloping surface 16 of the tower 2 at the foot and/or the shoulder thereof may be somewhat more circular in cross section, while in a central portion of the tower the enveloping surface 16 may have more elliptical or oval cross-sectional contouring.

[0046] Alternatively or additionally to such organic enveloping surfaces, the structural frame 8 may also comprise organically and/or bionically contoured structural-frame struts 9 in the form of longitudinal flanges and/or cross members which may in principle have straight longitudinal extensions, but may also have curved progressions of the longitudinal axis, with it being possible for said structural-frame struts 9 to also be multi-axially curved and/or to have radii of curvature that change multiple times and/or gradually changing radii of curvature when viewed along the longitudinal extension thereof.

[0047] As shown in greater detail in FIGS. 2 to 9, the structural-frame struts 9 of the structural frame 8 may have partially different or varying wall thicknesses, cross-sectional dimensions or material characteristics in order to adapt the relevant structural-frame component as optimally as possible to the relevant load and the resulting flows of force and diffusion of stresses. In particular, the parts of the structural frame may comprise partial reinforcement portions 11 which may have a layered construction and may be integrally molded onto the rest of the body of the structural frame element in a seam-free and planar manner.

[0048] Irrespective of locally varying, in particular organically contoured strut and/or layer geometries, partially different material properties may however also be implemented, in particular locally increased material strength and/or locally increased corrosion resistance and/or locally varying elasticity and/or flexibility. This may, for example, be obtained by layers of different materials, or also by layers of materials that are identical but have different material properties, for example due to different melting processes, melting points or irradiation temperatures, irradiation intensities and/or irradiation durations. Alternatively or additionally, however, different materials may also be used within the same printed layer, for example a harder material may be used in one portion of the same layer and a softer material may be used in another portion of the layer.

[0049] In particular, the following local adaptations can be made to the material properties and/or materials in the printing process:

[0050] higher material strengths at the bearing stresses of holes, in order to make it possible to absorb high contact stresses (bearing stresses) and to nevertheless maintain the toughness of the surrounding material

[0051] higher material strengths of the entire bolt eye, in order to keep the geometry of the eye as compact as possible

[0052] production of corrosion-resistant surfaces, e.g. in holes that cannot be protected by anti-corrosive coatings, in particular if there is movement between the connecting elements in the event of load changes

[0053] production of corrosion-resistant surfaces in regions in which component movements take place but the surfaces cannot cost-effectively be rendered corrosion-resistant using other measures (e.g. friction bearings)

[0054] production of corrosion-resistant surfaces in regions in which wheels move and alternative anti-corrosion measures are complex or not durable

[0055] production of less rigid but resilient regions at points at which there are cross-sectional changes and the resulting notch effect reduces the structural durability of the components

[0056] production of wear-resistant surfaces only where they are needed, e.g. on the raceway of rollers on boom elements over which crane trolleys pass.

[0057] Alternatively or additionally to such partially varying material properties, however, locally varying strut properties can also be obtained by the number and/or the progression and/or the geometry of the material layers locally changing and/or strut geometries being varied, in particular organically and/or continuously varied, in cross section and/or longitudinal section.

[0058] For example, FIG. 2 shows a structural frame element 9 of the crane trolley 4 of the crane 1 from FIG. 1, with said structural frame element 9 having approximately U-shaped contouring when viewed as a whole. In this case, the structural frame element 9 may be designed as a hollow profile 10 at least in portions. In the particularly highly loaded transition and unwinding portions between the legs and in the central region of the central leg, reinforcement portions 11 may be formed in the inside of the hollow profile 10, which may for example be in the form of reinforcement ribs and/or a tube profile. Advantageously, the structural frame element 9 of the crane trolley 4 may be manufactured from a metal material using 3D printing, such that the reinforcement portions 11 are constructed in layers in the inside of the hollow profile 10.

[0059] As shown in FIG. 3, a structural-frame strut 9 may also have an approximately straight longitudinal extension and have a connecting portion 15 at at least one end for connection to other structural frame elements. Such a connecting portion 15 may for example be in the form of a molded-on bolt eye or a flange eyelet, with it being possible for said connecting means 15 to be integrally molded onto the hollow profile 10 of the structural frame element in a seam-free manner. As shown in FIG. 3, the structural frame element may comprise both hollow-profile portions and solid-material portions, with the transitions between the solid-material portions and the hollow-profile portions advantageously being designed to be harmonious and gradual, in particular due to a rounded transition of the hollow-profile wall into the solid-profile portion.

[0060] In the region of said reinforcement portion 11, which may form a solid-material portion, layers of higher-strength material may be formed in order to achieve higher strengths specifically in the region of the connecting means.

[0061] As shown in FIG. 4, a structural-frame strut 9 may have not only circular or rounded cross-sectional profiles, but also a hollow profile 10 having an angular and/or polygonal cross section.

[0062] The wall of the hollow profile 10 gradually transitions, towards the connecting portion 15, into the solid-material portion of said connecting portion 15. In particular, a reinforcement portion 13 may have a thickened portion 14 in the wall thickness which, when viewed in cross section, may extend over the entire periphery of the hollow profile 10, but also only in segments of the cross section, as shown in FIG. 4.

[0063] Advantageously, when viewed over its longitudinal extension, a structural-frame strut 9 may also have a varying cross section, with it being possible for a larger or maximum cross section which decreases or minimizes towards the ends of the structural-frame strut 9 to be provided in particular in a central portion 9m of the structural-frame strut 9. As a result, a greater buckling resistance can be achieved in the central portion 9m, and this is advantageous in particular when using the structural-frame strut 9 as a pressure rod. If the structural-frame strut 9 is subjected to bending stress, higher bending stresses can be resisted in an improved manner by such a cross-sectional dimension that increases towards the center of the strut.

[0064] Alternatively or additionally to such a change in diameter, the structural frame element may also have a wall thickness that changes over the length, as shown by the view (d), which also shows that the structural-frame strut 9 may be formed as a hollow profile 10. In particular, the wall thickness of the hollow-profile portion may increase towards the center of a strut and/or decrease towards the ends of a strut, with it optionally being possible to even provide another thickened portion of the wall at the ends of the strut, in order to provide improved resistance to forces to be introduced and/or connecting means to be fastened there.

[0065] As shown in FIG. 6, connecting portions 15, which may for example be in the form of connecting flanges, may be molded directly onto the end portions of the structural-frame strut 9, with it being possible for said connecting portions 15 to be in the form of the end flange as a solid-material body, while the strut body may otherwise be designed as a hollow profile 10.

[0066] Irrespective thereof, inner reinforcement portions 11 in the form of transverse stiffening walls may be provided in a hollow-profile portion 10 of the structural frame element 9; cf. FIG. 8, view (b).

[0067] As shown in FIG. 7, a structural-frame strut 9 may also comprise an integrally molded-on, seam-free screw-joint portion 18, which can likewise be constructed in layers in said manner, in particular produced using 3D printing. In this case, the threaded portion 18 may be designed as an external thread and/or an internal thread.

[0068] As shown in FIG. 8, a plurality of structural-frame struts 9, for example in the form of a longitudinal flange and a plurality of cross members, may be interconnected at a truss node of the truss 8, with it being possible for said plurality of structural-frame struts 9 to be integrally interconnected in a seam-free manner and so as to be made of homogeneous material, for example by producing the node point and the associated strut portions using 3D printing.

[0069] In this case, the interconnected truss struts 9 may be designed as a hollow profile 10 at least in part and/or at least in portions.

[0070] Alternatively or additionally, said structural-frame struts 9 may be reinforced in the region of the node point by means of a reinforcement portion 11, which reinforcement portion 11 can advantageously be arranged inside the hollow profile 10.

[0071] As shown in FIG. 8, view (e), the reinforcement portion 11 may comprise a honeycomb structure 13, which can bring about a significant increase in strength while still providing a light construction.

[0072] Alternatively or additionally to such a honeycomb structure 13, the reinforcement portion 11 may also comprise a tubular-bone structure 17, in which a plurality of tubes extend beside one another and may be integrally interconnected; cf. view (f) in FIG. 8.

[0073] Alternatively or additionally, the reinforcement portion 11 may also comprise a branched structure 13, in which a plurality of branching struts extend in different, three- dimensionally oriented longitudinal extensions and form a birds-nest type of reinforcement structure. In this case, the branching struts of the branched structure 13 may comprise a straight or curved/arcuate longitudinal extension, with the branching struts advantageously being integrally interconnected; cf. view (g) in FIG. 8.

[0074] As shown in FIG. 9, alternatively or additionally to such internal structures, the reinforcement portion 11 may also comprise thickened wall portions 14, in particular in the region of the interconnection of a plurality of truss struts 9. In particular, a hollow profile may comprise a thickened portion 14 in the wall thickness in the region of the node point between different structural-frame struts 9, which thickened portion may have a smooth, in particular gradual transition to the comparatively thinner wall thickness of the adjoining strut portions.