1 Scope
This document specifies the following safety requirements for separable spreaders applicable to cranes, hoists and manual lifting equipment:
Steel plate grippers;
Vacuum suction cups;
Non-powered vacuum chucks
Powered vacuum chucks (pumps, venturi, turbines);
Lifting electromagnets (battery powered and mains powered); - Lifting permanent magnets;
Electrically controlled permanent magnets;
Hanging beams;
C-hooks;
Lifting forks;
Clamps.
The following additional requirements are not specified in this document:
a) the high level of cleanliness required for lifting appliances that come into direct contact with foodstuffs or pharmaceuticals for hygienic reasons
b) hazards arising from the handling of hazardous materials (e.g. explosives, hot melts. b) hazards arising from the handling of hazardous materials (e.g. explosives, hot melts, radioactive materials);
c) hazards arising from operation in explosive atmospheres;
d) noise hazards;
e) Electrical hazards;
f) hazards due to hydraulic and pneumatic components. This document does not apply to spreaders for lifting personnel.
This document does not apply to slings, steel (iron) water ladles, internal rising spreaders, buckets, double or multi-flap grabs, container spreaders.
2 Normative references
The contents of the following documents constitute the essential provisions of this document through the normative references in the text. Among them, note the date of the reference document, only the date of the corresponding version applies to this document; not note the date of the reference document, its latest version (including all the revision of the list) applies to this document.
ISO 4306-1 Cranes-Voeabulary - Part 1:General
ISO 4309 Cranes - Wire ropes - Care and maintenance, inspection and discard
ISO 4778 Chain slings of welded construction - Grades M (4),S(6) and T(8)
ISO 7531 Wire rope slings for general purposes - Characteristics and specifications
ISO 7593 Chain slings assembled by methods other than welding - Grade T(8)
3 Terms and definitions
The terms defined in ISO 4306-1, ISO 12100 and the following terms and definitions apply to this document.
3.1
Adhesion force
The force required to remove the load from a vacuum chuck (3.21) at the upper limit of the specified pressure range.
3.2
C-hook
"C" shaped device for lifting hollow loads. Example: see Figure 1.
Note: Hollow loads such as coils and tubes.
4 Safety requirements and/or measures
4.1 General requirements
The spreader shall comply with the safety requirements and/or measures of this clause. In addition, for relevant risks not mentioned in this document, the spreader shall be designed in accordance with the principles specified in ISO 12100.
4.1.1 Mechanical load-bearing elements
4.1.1.1 Requirements for static strength
The mechanical strength of the mechanical load bearing elements shall meet the following requirements:
a) The spreader shall be designed to withstand a static load of 3 times the rated load and shall not release the load even if permanent deformation occurs;
b) the spreader shall be designed to withstand a static load of more than the rated load without permanent deformation.
The spreader shall be capable of operating at an inclined angle of at least 6°. For spreaders designed to operate at an inclination, they shall be capable of operating at an inclination at least 6° greater than the working angle.
4.1.1.2 Requirements for fatigue strength
Verification of fatigue strength shall be carried out in accordance with ISO 8686 on the basis of the working level of the lifting tackle, which shall be marked on the lifting tackle or recorded on the documentation together with the load rating.
The range of stresses used in the fatigue rating shall be based on the maximum load as follows:
a) Vertical force is the sum of the gravitational force associated with the rated load plus the deadweight of the lifting tackle, multiplied by the dynamic load factor applicable to the lifting tackle, which shall be determined by the manufacturer in the design documentation
b) Horizontal force means a horizontal force that can be applied to the lifting device or lifting load at the same time and that produces a dynamic load effect in the vertical direction.
In a normal working cycle, the minimum stress in the stress range shall be 0 unless the deadweight of the lifting gear is greater than 20% of the rated load and the gravity of the lifting gear is not acting on the lifting load or on the ground.
The calculation of the ultimate fatigue strength of the structural details shall be in accordance with the requirements in ISO 8686 and ISO 20332.
4.1.2 Controls
The electrical control of the spreader shall comply with the requirements of IEC 60204-32.
4.1.3 Handles
Spreaders requiring manual guidance shall be fitted with handles to avoid finger injuries. If the product has its own handle, it is not necessary to install a handle.
4.1.4 Requirements for slings as part of a spreader
If slings are an integral part of the spreader, they shall comply with the requirements of ISO 4778, ISO 7531, EN 1492-1, EN 1492-2 and EN 1492-4.
4.1.5 Storage stability
At the end of use, the spreader shall be removable and stable for storage. A spreader is considered stable if it can be tilted 10° in any direction without tipping over. This can be ensured by the shape of the spreader or by adding supplementary equipment (e.g. supports).
5 Verification of safety requirements and/or measures
5.1 General rules
Compliance with each safety requirement and/or measure shall be verified in accordance with the methods specified in Table 1 and the requirements of Appendices A to G (see Chapters 4 and 6).
For products designed and produced in single units, type verification and independent verification shall be carried out. For products produced in series, product type verification should be carried out for one or more representative series of the series and independent testing should be carried out for each product produced.
5.2 Fatigue strength verification by test
The test arrangement shall produce stress changes corresponding to the maximum and minimum vertical load events described in 4.1.1.2. This includes the release of the full clamping force between the individual 16 working cycles.
The designed number of working cycles of the lifting spreader shall not be greater than 1/3 of the average life of the spreader under test (at least 3 units) or, if the number of spreader under test does not exceed 7, the designed number of working cycles shall not be greater than 1/2 of the minimum life obtained by the test.
5.3 Minimum classification
The minimum classification of a lifting spreader is LCD1. It is not necessary to verify the fatigue strength of the equipment if the following conditions are met:
Static strength meets the requirements of 4.1.1.1;
Made of steel with a yield stress not exceeding 500 MPa;
Excluding structural details where the fatigue strength is less than class 50 in ISO 20332.
6 Information for use
6.1 Manuals for use
6.1.1 General rules
In order to enable the user to correctly select, install, use and maintain the separable spreader during its normal service life, the user manual for the equipment supplied shall provide at least the following information and guidance (see ISO 12100; 2010, 6.4.5):
a) a brief description;
b) load rating;
c) design purpose;
d) characteristics of the load, including performance, and the number of parts that can be lifted at one time;
e) determination of the range of use;
f) instructions for operation and use;
g) installation, fixing, connection, separation and adjustment of the equipment on the crane;
h) handling and storage of the equipment;
i) stability (where applicable); j) temperature range for operating the spreader;
k) Restrictions on use in special environments (e.g. high humidity, explosive, salt spray, acidic, alkaline), chain slings in accordance with ISO 4778 and ISO 7593 are not suitable for use in pickling tanks due to the risk of hydrogen embrittlement;
l) Restrictions on the handling of dangerous goods (e.g. molten substances, radioactive substances)
m) prohibition of persons under the load;
n) special training of the operator if necessary;
o) dynamic load factor of the device.
6.1.2 Special information
6.1.2.1 Sheet metal clamps
In addition to the basic information specified in 6.1.1, the following special information should be provided in the instruction manual for the steel plate clamp:
a) Lifting one part vertically at a time;
b) turning the steel plate on the ground;
c) operation of the safety locking device;
d) surface condition of the clamped parts (grease, paint or coating);
6.2 Marking
6.2.1 General rules
The load rating of the spreader, the hazard warning and the safety instructions should be clearly marked.
The load rating of the lifting spreader shall be marked in a visible place on the main structure. If the lifting appliance consists of several lifting devices, each of which can be detached from the whole, these shall also be marked with their respective load ratings.
Appendix A (prescriptive) general validation method
Appendix B (prescriptive) Steel Plate Clamp Validation Method
Appendix C (prescriptive) Vacuum suction cup validation method
Appendix D (normative) Lifting magnet validation method
Appendix E (prescriptive) Method of validation of hanging beams
Appendix F (prescriptive) Lifting fork validation method
Appendix G (prescriptive) method of verification of clamping pliers
1 Scope
2 Normative references
3 Terms and definitions
4 Safety requirements and/or measures
5 Verification of safety requirements and/or measures
6 Information for use
Appendix A (prescriptive) general validation method
Appendix B (prescriptive) Steel Plate Clamp Validation Method
Appendix C (prescriptive) Vacuum suction cup validation method
Appendix D (normative) Lifting magnet validation method
Appendix E (prescriptive) Method of validation of hanging beams
Appendix F (prescriptive) Lifting fork validation method
Appendix G (prescriptive) method of verification of clamping pliers
1范围
本文件规定了下列适用于起重机、葫芦和手动起重设备的可分吊具的安全要求:
钢板夹钳;
真空吸盘;
非动力真空吸盘﹔
动力式真空吸盘(泵、文丘里管、涡轮);
起重电磁铁(蓄电池供电和主电源供电);-起重永磁铁;
电控永磁铁;
挂梁;
C型钩;
起重叉;
夹钳。
本文件没有规定下列附加要求:
a)由于卫生原因,直接接触食品或药品的起重吊具所需的高等级清洁度﹔
b)因搬运有害材料(例如:爆炸物﹑热熔物.辐射材料)导致的危险;
c)在爆炸性环境下操作导致的危险;
d噪声危害;
e)电气危害;
f）由于液压和气动元件造成的危害。本文件不适用于提升人员的吊具。
本文件不适用于吊索、钢(铁)水包,内涨式吊具、吊斗、双瓣抓斗或多瓣抓斗、集装箱吊具。
2规范性引用文件
下列文件中的内容通过文中的规范性引用而构成本文件必不可少的条款。其中,注日期的引用文件,仅该日期对应的版本适用于本文件;不注日期的引用文件,其最新版本(包括所有的修改单)适用于本文件。
ISO 4306-1起重机术语第1部分:通用术语(Cranes-Voeabulary - Part 1:General)
ISO 4309起重机钢丝绳保养维护检验和报废(Cranes - Wire ropes - Care and maintenance, inspection and discard)
ISO 4778焊接吊链M(4),S(6)和T(8)级[Chain slings of welded construction - Grades M (4),S(6) and T(8)]
ISO 7531 一般用途钢丝绳吊索特性和技术条件( Wire rope slings for general purposes - Characteristics and specifications)
ISO 7593非焊接吊链T(8)级[Chain slings assembled by methods other than welding - Grade T(8)]
3术语和定义
ISO 4306-1,1SO 12100界定的以及下列术语和定义适用于本文件。
3.1
附着力adhesion force
在规定的压力范围的上限,从真空吸盘(3.21)上卸下载荷所需要的力。
3.2
C型钩C-hook
用于提升空心类载荷的“C”形设备。示例:见图1.
注:空心类载荷例如卷材类和管子类。
4安全要求和/或措施
4.1一般要求
吊具应符合本条款的安全要求和/或措施。另外,对于本文件没有提到的相关风险,吊具应按照ISO 12100规定的原则进行设计。
4.1.1机械承载件
4.1.1.1 静强度的要求
机械承载件的机械强度应满足以下要求:
a)吊具的设计能承受3倍于额定载荷的静载荷,即使发生了永久变形,也不释放载荷;
b)吊具的设计能承受倍于额定载荷的静载荷,而不会发生永久变形。
吊具至少应能在倾斜角度为6°的倾斜状态下正常工作。对设计为倾斜作业的吊具,至少应能在比工作角度大6°的倾斜状态下正常工作。
4.1.1.2疲劳强度的要求
疲劳强度的验证应按ISO 8686的规定在起重吊具工作级别的基础上进行,工作级别应标记在起重吊具上或与额定载荷一起记录在文件上。
疲劳评定中使用的应力范围应以如下的最大载荷为基础:
a)垂直力是与额定载荷相关的重力加上起重吊具的自重之和,乘以适用于该起重吊具的动载系数后得到的力,该动载系数应由制造商在设计文件中确定﹔
b)水平力是指一种可以同时施加在起重装置或提升载荷上,并在垂直方向上产生动载效应的水平作用力。
在正常的工作循环内,除非起重吊具的自重大于额定载荷的20%,并且起重吊具的重力没有作用在提升的载荷上或地面上,否则应力范围中的最小应力取0。
结构细部极限疲劳强度的计算应符合ISO 8686和ISO 20332中的要求。
4.1.2控制
吊具的电气控制应符合IEC 60204-32的要求。
4.1.3 把手
需要手动导向的吊具应装有把手,避免手指受伤。如果产品上有自带的手柄,则不用再安装把手。
4.1.4作为吊具组成部分的吊索的要求
如果吊索是吊具的组成部分,应符合ISO4778,ISO 7531,EN 1492-1、EN 1492-2和EN 1492-4的要求。
4.1.5存放稳定性
使用结束后,吊具应能取下,并稳定存放。吊具向任何方向倾斜10°都不会翻倒,则认为是稳定的。可以通过吊具的形状或增加辅助设备(例如支架)来保证。
5安全要求和/或措施的验证
5.1通则
应按照表1规定的方法和附录A~附录G的要求来验证是否符合每个安全要求和/或措施(见第4章和第6章)。
对于单件设计和生产的产品,应进行型式验证和独立验证。对于系列生产的产品,应对该系列的一个或多个有代表性的系列产品进行产品型式验证,且对每个生产的产品都进行独立试验。
5.2通过试验验证疲劳强度
试验安排应产生与4.1.1.2中所述的最大和最小垂直载荷事件相对应的应力变化。这包括在各个16工作循环之间释放全部夹紧力。
起重吊具设计的工作循环次数不应大于被测试吊具(至少3台)的平均寿命的1/3,如果被测试吊具数量不超过7台,设计工作循环次数不应大于测试得到的最小寿命的1/2。
5.3最小分级
起重吊具的最小分级是LCD1.设备满足以下条件时,不需要验证其疲劳强度:
——静强度满足4.1.1.1的要求;
——用屈服应力不超过500 MPa的钢材制成;
——不包括疲劳强度低于ISO 20332中的50级的结构细节。
6使用信息
6.1使用手册
6.1.1通则
为了让用户在可分吊具正常的使用寿命期间对其正确选择、安装、使用和维护,针对所提供设备的使用手册中应至少提供以下信息和指导(见ISO 12100;2010,6.4.5):
a)简要说明;
b)额定载荷;
c)设计用途;
d)载荷的特性,包括性能,以及一次能吊运的零件数量;
e)使用范围的确定;
f)操作和使用说明;
g)设备在起重机上的安装、固定、连接、分离和调整;
h)设备的搬运和存放;
i)稳定性(在适用情况下);j)操作吊具的温度范围;
k)在特殊环境中的使用限制(例如,高湿度﹑爆炸性、盐雾﹑酸性、碱性),符合ISO 4778和ISO 7593要求的链式吊索,由于氢脆化的危险不宜在酸洗槽使用;
l)处理危险货物的限制(例如,熔融体、放射性物质)﹔
m)禁止吊物下有人;
n)必要时对操作者进行特殊培训;
o)装置的动载系数。
6.1.2特殊信息
6.1.2.1钢板夹钳
在钢板夹钳使用手册中除了提供6.1.1中规定的基本信息外,还应提供以下特殊信息:
a)一次垂直提升一个部件;
b)在地面上翻转钢板;
c)安全锁紧装置的操作;
d)被夹持零件的表面状况(油脂、油漆或涂层);
6.2标识
6.2.1通则
吊具的额定载荷﹑危险报警和安全说明都应清晰的标记出来。
起重吊具的额定载荷应在主结构上可见的地方标记。如果起重吊具是由多个提升装置构成,每个都能从整体上拆分,则这些提升装置也要标明其各自的额定载荷。
附录A(规范性）一般验证法
附录B(规范性)钢板夹钳验证方法
附录C(规范性)真空吸盘验证方法
附录D(规范性)起重磁铁验证方法
附录E（规范性)挂梁验证方法
附录F(规范性)起重叉验证方法
附录G(规范性)夹钳验证方法
