shear-pin force transducer series 5000-5300-5600
Contents
1. TT EL PERE TT 17 y 1779 E T T 1701000010 1060700700 4 i 4 4 L 4 4 4 i 4 L 4 k 4 4 4 4 4 4 4 4 L 4 4 I 4 L t 4 L 4 4 i L 4 t 4 L L 4 d L L t t L i 1 i 1 1 1 J NN A ANN KU J WWW Sensy com SHEAR PIN FORCE TRANSDUCER SERIES 5000 5300 5600 User s manual B oeiee e P e PE RU E OE O klon Et A 3 KS lee dg 60 MR 3 2 3 2 Operating conditions of load pin in isrener lt 4 III NE 4 A PP nm 1 V 4 22546 e m 9IOE nO OOO 9 0 FOTOS SDE CIN EEE EE EE 9 o m 10 4 1 RRA 10 4 2 4 20 MA 3 wire option J see 5 2 A 10 4 3 4 20 mA 2 wire option C see 5 2 sse 10 4 4 0 10V 1 5V 3 wire option T see 55 21 10 o Technical features ii ove 11 Os Wes Be We ed EEE 11 Se oe 0 12 D CPR ee 13 A EEE EE EN 13 VA eT Le eres ea NN NN NE 13 BR c SOC 14 0 0 COMMECION and cable GING Leie 14 6 4 Faradization OptONS EEE EEE 14 NNN 15 66 Eoad pi2. WWW sensy com 7 THEORY 1 1 Basic principles Strain gauge load cells The strain gauge sensor is one of the most widely used strain measurement components The most common type of strain gauge consists of an insulating flexible layer which supports a metallic foil pattern The gauge is mounted to the load cell by a suitable adhesive so as to deform together When a certain force is applied on the load cell body the resistance changes in the gauge This resistance can be converted to an electrical signal using a Wheatstone bridge In a Wheatstone bridge made of four gauges two gauges are under positive strain and two under negative When the gauge is deformed its electrical resistance changes This change can be converted to an electronic signal proportional to the applied force The Wheatstone bridge circuit shown below is used in load cells and other strain gauge sensors because it is not sensitive to electromagnetic disturbance SGI SG BT A W SGI G4 SG SG E e Excitation brown Excitation yellow Signal white Signal green Figure 1 Wheatstone Bridge circuit MA 5000 5300 5600 full EN Page 16 of 41 Rev 02 07 2010 WA 0 1 JR v 4 1 mmm 7 2 Mechanical dimensioning Figure 2 Finite element method applied on load cell 7 3 Sensitivity One of the most important characteristics of
3. WWW Sensy com The load pin is connected in a balanced Wheatstone bridge circuit and excited by a source of extra low voltage the transducer will produce an electrical output which is a direct linear function of the excitation voltage and the magnitude of the applied mechanical input When parasitic components are present on the sensor forces in a different direction than the sensitivity axis couples with unspecified axis they cause deformation on the load cell where the strain gauges are placed and produce a false result In the best case the parasitic components will have only a small influence on the behaviour of the load pin In the worst case the measurement will be substantially degraded It is important that the pins are mounted in the appropriate direction When parasitic forces are unavoidable SENSY designs special load pins that are not sensitive to such factors If the signal delivered by the load pin is too weak compared to the applied load the force is probably not being freely applied Binding can cause the deformation of the pin and alter its output The commonest form of binding is axial seizure This occurs when there is insufficient clearance between the side supports and the central thimble When the load is applied a large part of the force is taken up by this friction which reduces the result seen in the measurement When the load pin is subjected to certain
4. N Allowed movements eo Inclination SES e Pressure X and Y position of the arm in the working area cantral Load max 300 kg Measured load 154 kg Main 1 Main Z Diag Setup RIC AD OUT Main gt Spec A 9 20 Y 475 Main Sens 1 Sens 2 Spec Page 29 of 41 Rev 02 07 2010 Stern 1 CUSTOMIZED ELECTRONIC ENCLOSURES We design and manufacture custom made enclosures to suit your needs Complex load limitation Multiple displays Signal conditioner ATEX enclosures mg om ndasa 12 Sen i MA 5000 5300 5600 full EN Page 30 of 41 Rev 02 07 2010 www sensy com ME LIMITEUR DE CHARGE CE Etanch it IP 66 Tension disponible 24 60 VDC mod le CABIN 3B 110 220 380 VAC 48 Sw ACID 2000 uy zo eg Rev 02 07 2010 Page 31 of 41 MA 5000 5300 5600 full EN WWW Sensy com 12 RECORDING AND ANALYSIS OF OVERHEAD CRANE OPERATION USING LOAD PINS ERROR EVALUATION It is possible to measure the load lifted by a travelling crane by using a pin mounted at the balancing pulley mountings in x 2 or at its fixed point mountings in x 1 12 1 Measurement system errors load pin and electronics The errors specific to load pins are either mechanical or thermal The mechanical errors non linea
5. Small plate 3 Screw stuck or brake washer 4 Dynamometric axle 6 Anti friction washer on ii ST CT LA MOUTING ON SPHERICAL BEARING 1 Centering ring 0 m 2 Screw stuck or brake washer 3 Small plate 4 Dynamometric axle 5 Heavy duty rod ends with female thread MA 5000 5300 5600 full_EN Page 8 of 41 Rev 02 07 2010 WWW Sensy com 2 3 Disassembly Disconnect the connector Remove the pin from its tare also remove it from the assembly thimble pulley block Remove the fastening screws of the locking plate Remove the locking plate Remove the pin Certain pins have internal extraction threads in which bolts can be placed Protect the pin from moisture and impacts 3 PERIODIC INSPECTIONS Make sure by appropriate means that the pin has not been jamming annually Check output for zero load annually Acceptable max 0 15 mV V for models 5000 5300 and 5600 6 mA for models 5000 C 5000 J 5300 C 5300 J 0 8 V for models 5000 t and 5300 t Make sure that the pin beam has not been knocked markings or corroded Some corrosive greases If there are no such signs of damage as described in the previous points simply apply preventive measures Annually In case of doubt use the diagnostic questionnaire provided with the documentation for the shear pin force transducer
6. DE SENSY SA ME PEUT ETRE COMPUNIQUE OU REPRODUIT SANS AUTORISATUN FOUTE 43 USIVE PROPERTY OF SENS T CANNOT BE REPRODUCED OR TRANSMITTED WITHOUT WRITTEN AUTHORIZE TION DATE DESSN CALQUE VERIFIE APPROUVE ECHELLE i 05 06 2002 AM AM AB TA N A DESIGNATION N PLAN CABLING 5000 DOUBLE BRIDOE CA 5000 DOBRI MOT6 ACAD CABLING 5008 DOUBLE BRIDGE Jug MA 5000 5300 5600 full EN Page 35 of 41 Rev 02 07 2010 f T T 4 4 4 4 4 i 4 i 4 4 4 4 4 4 den a5 4 do k m 2 i NO O dl Q dl d t zu k 4 moll me www sensy com Fonctional Bloc Diagram Load Pin Model 5000 Branch A MTTFd 48 years Output 4 20 mA Output 4 20 mA gt REEL Branch B MTTFd 48 years DITHMAR E ope rs a Load Pin Model 5000 DocumentN 5000 bloc EMME a MA 5000 5300 5600 full EN Page 36 of 41 Rev 02 07 2010 www sensy com 14 DRAWINGS LOAD CELLS C E Hoisting model 5000 stainless steel Range 1 1000 t IP65 IP68 option Ex DOUBLE SHEAR BEAM AXLE Cable length 6 m A I 4 40 if 4D gt 44 s Es 5 50006 30 6400Menuel_EN Page Son Rev 040772006 MA 5000 5300 5600 full EN Page 37 of 41 Rev 02 07 2010 www sensy co
7. a strain gauge sensor is its sensitivity sensitivity represents the variation of the output to nominal force The sensitivity is usually expressed in mV V electrical output signal divided by supply excitation voltage Take the example of a 150 KN load pin with sensitivity 0 9 mV V at 10 Volts supply the excursion of the signal reaches 9 mV 9000 uV when 150 kN is applied The dimensions of load pins are calculated according to the required sensitivity and customer s requirements Increasing the sensitivity involves locally reducing the cross section of the I beam profile figure 4 The Wheatstone bridge s signal also depends on the gauge factor usually noted K The gauge factor K is defined by AR IR gage gage Alll The gauge factor is the product of strain and the quotient of change in strain gauge resistance and unstrained resistance of the strain gauge Usually this factor is approximately 2 Increasing the gauge factor makes it possible to increase the sensitivity of a sensor while keeping the same mechanical deformations on the load pin body MA 5000 5300 5600 full_EN Page 17 of 41 Rev 02 07 2010 www sensy com Load High tonnes gn sensitivity 150 100 50 High safety factor Diameter mr Figure 3 Optimal zone capacity according to diameter 1 f your requirement does not fit the present diag
8. and consult the manufacturer Check the integrity of the cable MA 5000 5300 5600 full EN Page 9 of 41 Rev 02 07 2010 4 WIRING 4 1 Typical load cell output signal 1 Excitation yellow 2 Signal green 3 Signal white 4 Excitation brown 5 Sense grey 6 Sense pink 4 2 4 20 mA 3 wire option J see 85 2 Commun yellow 1 1 Common yellow 2 Signal green 4 Excitation brown Excitation Brown 4 Common yellow Excitation brown 4 Commun yellow 1 1 Common yellow 2 Signal green 4 Excitation brown MA 5000 5300 5600 full EN Page 10 of 41 Rev 02 07 2010 5 TECHNICAL FEATURES 5 1 General SENSY load pins generally present 1 combined error This uncertainty arises from the combination of several errors Error related to temperature drift with temperature changes the mechanical behaviour of the steel is modified and the strain gauge bridge measures a deformation which is interpreted as an applied force The stain gauge bridge is compensated by temperature sensitive resistances for a range from 10 to 45 C other compensation ranges on request Non repeatability two different loadings in identical mechanical conditions do not deliver the same signal Hysteresis error applyin
9. 11 of 41 Rev 02 07 2010 mv 9 2 Electronic Different types of output signals are available to suit the reguirements of the measurement circuits Typical load cell output is expressed in mV V Example for 10V typical power supply the load pin for a 200 kN applied force with 1 0 mV V output will deliver 10mV 10000 LV with 100kN applied force it will deliver 5mV 5000pV Option J 4 20 mA internal amplifier card three wire the force measurement is converted into a current output This amplifier allows long cable lengths between the sensor and its instrumentation After factory calibration load 0 delivers 4mA and maximum load delivers 20mA Option C 4 20 mA internal amplifier card two wire current loop offers advantages similar to option J Option T 0 10 V 1 5V for hoisting applications internal amplifier card three wire the signal is converted to 0 10V 1 5V output Other amplifier options RS232 RS485 for direct communication with computer profiBus etc O one opos aat Resistive 4 20 mA 4 20 mA 0 10V 1 5 V 2 Wire 3 Wire 3 Wire From 100 45 C From 20710 80 C From 50 to 85 C PO Nominal signal range 12 30V on request Type MA 5000 5300 5600 full EN Page 12 of 41 Rev 02 07 2010 WWW Sensy com 6 OPTIONS 6 1 Greasing hole Grease fitting 6 2 Helical greasi
10. Emors due NNN a a ee E 32 12 2 Errors due to hoisting L e emmener eme eee ee hnali 32 12 2 1 Errors due to the heignt of Me Cable a di 32 222 Esse TM 3E PG DOCKS uscar 32 12 2 3 Errors due TO dynamic phenomena H 33 a DOUBLE Ee IN c 34 o oO A o A A 37 40 MA 5000 5300 5600 full_EN Page 2 of 41 Rev 02 07 2010 WWW Sensy com 1 INTRODUCTION The shear pin force transducer consists of a cylindrical pin or shaft instrumented with strain gauges to sense shear strains caused by load Load pins can be integrated into any mechanical systems by simple replacement of an existing pin SENSY designs and produces a broad range of standard and custom made load pins Clevis pin tailoring their dimensions to your installation Shear pin force transducers are designed for the following applications Load limitation load indication load recording of hoisting equipment such as overhead cranes EOT jib cranes gantry cranes container cranes etc Control of strains on civil engineering structures such as suspended road bridges boat lifts dams etc Industrial weighing on mobile and grapple cranes steel plant cranes silos etc Force measurement on mechanical systems such as hydraulic jacks rolling mills steel coating machinery test benches etc SENSY offers associated electronics tailored to each application SENSY load pins a
11. and in compliance with the specifications of the electronic unit used The installation technician will ensure the integrity of the cable after assembly at site Any damage to this cable or to one of the conductors will require replacement by SENSY The load is uniformly distributed over at least 80 of the distance between the junction plates Written agreement by the manufacturer is mandatory for particular service conditions 2 2 Operation The shear pin force transducer is designed to withstand occasional static overload without damage up to 2 x the Nominal Load case of test load for an overhead crane In any case a higher overload static or dynamic is not acceptable Where the bore rotates on the pin pulley precautions must be taken to avoid jamming of the pin o Selflubricated rings o greasing o use of a ball bearing In case of jamming the pin must to be returned to us for inspection Make sure that there is no restraint on the deformation of the pin The load handled must be free and compatible with the nominal load of the system o no anchorage to the ground or support o no collision with another load or structure o nojamming MA 5000 5300 5600 full_EN Page 4 of 41 Rev 02 07 2010 L SS CS WWW Sensy com o nO impact produced by another load falling on the handled load The pin must not be subject to impacts related to the
12. applicable for pins used in overhead crane operations HOIS with electronic load limitation devices SAFETY COMPONENTS MARKETED SEPARATELY SENSY S A certifies that the load cells described below and intended for load limitation are in accordance with the essential requirements defined in the European Directive 89 392 EEC modified by the 93 68 EEC Directive relating to safety components and 89 336 EEC modified by the 92 31 EEC Directive relating to Electromagnetic compatibility The technical data supporting this compliance are held at the disposal of the authorities for the full statutory period This declaration is only valid for uses strictly according to the specifications and instruction manual accompanying and characterising each of our products These load cells are defined by their control and dimensional data sheets attached which are to be read and kept in a safe place See the general conditions for use on the back of this certificate Products concerned Models 5000 5300 5600 Resistive load cell Associated electronics CRANE BOY BRIDGEBOY INDI BOY 5000 C 5000 J and 5300 C 5300 J Amplifier 4 20 mA integrated Associated electronics MARK E CRANE BOY P DISP BOYP BRIDGEBOYP These load cells have been designed for hoisting devices and may be used with other electronic load limiters In this case in order to comply with the CE requirements the customer must verify compatibility between the electronics in accordan
13. ce with the referenced directives in industrial environment and SENSY load cells Regulations EN954 1 category 1 extension 2010 2011 rule FEM 9761 NBN 52 010 52 011 EN50281 2 EN50282 2 According to ISO 13849 and IEC 62061 SIL Date 20th July 2005 JM GILLET Production Manager MA 5000 5300 5600 full EN Page 40 of 41 Rev 02 07 2010 www sensy com For option C6 or I use in EX zone Caution The use of sensors in EX zones is only permitted with EX marked sensors supplied with a certificate issued by an accredited organisation Sensors must be used with appropriate safety equipment intrinsic safety Zener barrier or isolator conforming to the required standards shown on the certificate The use of junction boxes and cable extenders must be considered in the choice of protection After specifying all the components it is mandatory to check that the sensors output voltage remains compatible with the electronics used and the required accuracy SENSY S A Z I Jumet All e Centrale B 6040 JUMET Tel 32 71 25 82 00 Fax 32 71 37 09 11 www sensy com MA 5000 5300 5600 full EN Page 41 of 41 Rev 02 07 2010
14. conditions of use case of a swinging mono shaft colliding with the winch chassis in the swing of the pulley block Load pin Locking plate Fastening screw Washers MA 5000 5300 5600 full EN Page 5 of 41 Rev 02 07 2010 h m o 8 gt 2 NN O zs 1l 4 J ul NMPAS de www sensy com MOUTING ON BEARING 1 Pulley 2 Ball bearing 3 Small plate 4 screw stuck or brake washer 5 Dynamometric axle 6 Ring to hold bearing y y SSR 27 Rem aay MOUNTING WITH SELF LUBRICATING BRONZE RING 1 Sheave 2 Self lubrificating bronze ring 3 Small plate 4 Screw stuck or brake washer 5 Dynamometric axle 6 Anti rotating screw brake with glue 7 Case hardened steel ring 8 Anti friction washer TEFLON js K N SS 920 HO NS Co X NN Nu LIZ L JE S WV Ka Z I L Y E uec P LL ES J SS SS ENNS MA 5000 5300 5600 full_EN Page 7 of 41 o Co 4 Oy s M Rev 02 07 2010 e 5 o o TO GITT ium y o IILLLLLI Let wit J EN ZAL L d www sensy com F L Ld 4 MOUNTING ON ROLLER I Roller 2
15. d and to a position T bull Zone 1 maximum load 250 kg m 13 12 T 11 o A Zone 2 maximum load 100 kg 8 LL an mm 360 B E s AAS JEP 0 C S This system also takes account of the influencing parameters which can modify the curves For example the position of the outriggers and slewing platform Position Outriggers are extended horizontally from the chassis Variable parameter U Pressure Minimal pressure on the outriggers This value is variable MA 5000 5300 5600 full_EN Page 27 of 41 Rev 02 07 2010 PAO B Inclination Back view Outriggers are extended vertically to level and stabilise the crane Variable parameter 10 3 Factory calculated charts with or without outriggers wt ELE ot ad 1 M a LLL ve vm E 9 ua E Es a 5 W 3 I I PG mm 4 Ex HEN ld l TRE eee Ten I NSL 13 12 11 10 9 8 7 6 5 4 3 2 1 0 2 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 Radius m Radius m On Stabilisers On Tyres Encoding of the curves is easy using a PC or a display The system can handle up to 14 curves Each curve can be adjusted with 15 points MA 5000 5300 5600 full_EN Page 28 of 41 Rev 02 07 2010 State of the sensors Maximum authorised loading according to the curve Real time load 10 4 Main display MA 5000 5300 5600 full_EN
16. derloads and overloads while loading trucks The difference between weighing with grapple and statutory weighing is about 1 2 MA 5000 5300 5600 full EN Page 25 of 41 Rev 02 07 2010 WWW Sensy com 10 NEW APPLICATION LOAD LIMITATION ON MOBILE CRANES SENSY has developed a load limitation system for mobile plant combining a series of advanced technologies for complex mechanical applications Load limitation will increase the operating safety of your machines and will enhance the safety of their surroundings Our easy to use and flexible software guarantees you ease of configuration and a wide range of settings 10 1 General diagram The vehicle is equipped with sensors at several points lattice boom boom point and outrigger These instruments are connected to a computer which authorises or refuses lifting according to the position and load When the combination of loads and the new position become critical only retraction is authorised for example telescopic shortening of the arm MA 5000 5300 5600 full EN Page 26 of 41 Rev 02 07 2010 10 2 Load limiter operation This electronic safeguard enables you to optimise the crane by limiting the position of the arm according to the applied load It is possible to define different curves for each applied load Each point in the zone is related to a maximum loa
17. e preferential direction as shown by the arrow A variation of 3 is acceptable Verify that the force on the centre of the pin is in the direction shown by the arrow placed on the dynamometer The data sheet provided also mentions this information The pin must be mounted freely in its seating tolerance H9 h9 sufficient for load limitation tolerances H7 h7 are better for load measurements In the case of rotary applications we strongly recommend mounting with bearings tolerance h6 required optionally on load pins 5000 5600 standard on 5300 mounting with bushing may be suitable for low rotation speeds tolerance h7 optional In this case the manufacturer s specific pressure recommendations must be respected The pin must work only in shear It should not normally be subject to parasitic strains such as torsion flexion traction or axial compression It is therefore necessary to decouple the forces by appropriate mounting e g use of rolls or rings of well lubricated bronze The pin cannot be seated by force or by applying heavy impacts Nevertheless you may use a wooden mallet to ensure proper adjustment After seating the pin it must not have an axial clearance of more than 1 compared to its seating position The delivered cable must not be extended but must be kept as short as possible It is mandatory to connect the pin to its electronic unit according to the colour codes specified on the pin datasheet exclusively
18. g the same force the signal is different when the force is increasing than when it is decreasing Non linearity error a load pin does not have perfect signal linearity between zero and full load The curve is slightly bent Resolution error corresponds to the smallest resolution of the digital device Calibration error during the calibration process an error can occur due to the uncertainty 0 01 of the applied force Combined error Non repeatability Creep over 30 min Zero reset Reference temperatures Compensated temperatures Operational temperatures Storage temperatures Thermal drift of zero Nominal sensitivity Initial range of zero Input resistances Output resistances Insulation resistance Recommended power supply Maximum power supply Nominal load Acceptable maximum load Breaking load 10 C DE o 106 mV V mV V Q Q MQ 5 12 JoF S JoF S JoF S 100 200 150 300 gt 500 The specific combined error of the pins is about 0 5 Nonetheless the installation conditions may have a negative influence on the linearity and especially on the hysteresis The greater the support surfaces the greater the errors specific pressure lt 50N mm In order to obtain higher characteristics shape the pin to limit areas of friction between the pin shaft and the bore and use specific pressures gt 100N mm According to sensitivity F S Full scale MA 5000 5300 5600 full EN Page
19. impacts or overload the zero signal can be modified The signal is shifted over the full effective range during the measurement It is necessary to re inspect the load pin and return it to the manufacturer In the best case the zero drift is not significant and the pin has not suffered any permanent deformation The instrumentation must be recalibrated In certain case after an impact or severe overload the load pin may be permanently deformed Based on the degree of the deformation SENSY can decide whether the load pin can be repaired or must be replaced The sensor can take overloads of 150 without being damaged 200 for hoisting design MA 5000 5300 5600 full EN Page 21 of 41 Rev 02 07 2010 Electromagnetic fields can influence the signal delivered by the load pin To prevent these disturbances it is important to avoid the proximity of high voltage power lines 7 4 6 Electrical zero drift Measurement can be disturbed by electrical zero drift due to modification of the strain gauges resistances caused by induced current or incorrect power supply 1 5 Calibration The load pins are factory calibrated using a compression facility in order to simulate real application conitions For custom made load pins the calibration can deviate up to 5 compared to on site calibration because of the mechanical environment that cannot be 100 reproduced in our facto
20. loads rarely stay still and the resulting acceleration is added to that of gravity This influence can be lessened by processing the signal of the load pin with adequate filtering in the electronics and by waiting for the load to be still Finally we can say that the global measurement error is around 1 to 2 in applications where the dimensions of the load pin are coherent and where the hoisting device is in good condition MA 5000 5300 5600 full_EN Page 33 of 41 Rev 02 07 2010 mv 13 DOUBLE BRIDGE OPTION SENSY can provide sensors with redundant strain gauge bridge In this design two separate strain gauge bridges are bonded on both sides of a single proof body This arrangement offers the advantage of having two independent measuring legs for a single load cell As an example refer to the functional block diagram for 2710 BKL 20KN This is advantageous when the reliability of the force measurement is crucial In this case the logic device has to compare the two independent signals This feature is also useful for any industrial eguipment which reguires a Single measurement signal but where the maintenance operations are delicate In this case if there is a fault condition instead of replacing the sensor all that is reguired is to switch to the second measuring leg MA 5000 5300 5600 full EN Page 34 of 41 Rev 02 07 2010 NEN ST NE PROPRIETE
21. m LOAD CELL Hoisting model 5300 stainless steel Range 0 5 50t IP65 TU cae DOUBLE SHEAR BEAM AXLE JE D if D gt 44 aai tm 5300 C G A ONLY b UR U 3 L HE qr I MA i dl sD h6 q po PT E M LAN L 20 0 ti 63001 5300C Female BRN Satna or 5300J 2 Wires 4 20mA 3 Wires TI fe BROWN Ex wc HEROIN z ME SAE A els LR 1 eee ae HERH Bep 8 am FEMALE MALE CONNECTOR DIN 45322 850 8 3 0 88 C0 Manuel EN Page Gen Rev 0407 2008 MA 5000 5300 5600 full EN Page 38 of 41 Rev 02 07 2010 www sensy com LOAD CELLS C E Hoisting model 5600 stainless steel Range 0 5 6 3 t IP65 DOUBLE SHEAR BEAM AXLE Cable length 6 m 7 41 AN Ir L S5 REFERENCE DIMENSIONS CAPE fa min Imel o fo os rx we Loewe DJ o N S Rew 11 03 97 8000 8300 8800 Manuel EN Page 7on Rev 0407 2006 MA 5000 5300 5600 full EN Page 39 of 41 Rev 02 07 2010 WWW Sensy com 15 WARRANTY The warranty is applicable subject to compliance with the installation recommendations and general principles of use Any particular use not described in the present document is subject to prior written agreement by SENSY S A which is mandatory to maintain its compliance Only
22. n n Era e rus ea RR 15 A 16 1 Basic principles Stram gauge load Le e 16 12 Mechanical dimensioning a A A A A kn ko eines 17 eo eines cence 17 1 4 Factors in signal deterioration SR blank m 20 7 4 1 Disturbances related to force misalignment ran 20 7 4 2 Disturbances related to parasitic forces anspent eksakte Za 21 7 4 3 Disturbances related to binding or wrong assembly sees ee ee eee essere eee essere eee 21 TAA Disturbances related to impact or overload dater merisier nee tenir tat ennemi pta ot 21 7 4 5 Disturbances related to spurious electromagnetic signals KK RK nn nn 22 a e AMORC U A9 22 A AA 22 INN EEE 23 A 0 o JE 23 8 2 New BITEN Ra MU e em s ate Neos s 23 A 00 R T 24 DP 24 9 NEW Application load limitation and DYNAMIC WEIGHING inner 25 10 NEW Application load limitation on MOBILE CRANES esse 26 10 1 General ls T 26 10 2 Load limiter operation ne en pk ee o nan 27 10 3 Factory calculated charts with or without outriggers sn 28 VENN P R O ee A EA E Te 29 DE E eae le fe erg hol EEE EEE EEE EEE EEE 30 12 Recording and analysis of overhead crane OPERATION using load pins Error evaluation 32 12 1 Measurement system errors load pin and electronics 32 iE a eV Ai o A o 32 PARA
23. ng groove Greasing groove MA 5000 5300 5600 full EN Page 13 of 41 Rev 02 07 2010 T T N 4 T T I p www sensy com Open clevis sockets Load Cell Shackles 6 3 Connector and cable gland options Standard use radial connector Option A axial connector Options G radial cable gland Options GA axial cable gland Standard Axial cable land Option GA Axial connector Option A Radial cable gland Option G 6 4 Faradization options Standard faradization not connected to the load cell Option f faradization connected to the load cell MA 5000 5300 5600 full_EN Page 14 of 41 Rev 02 07 2010 www sensy com 6 5 Multidirectional pin The multidirectional pin enables measurement of the amplitude and the direction of the force The pin consists of two bridges with a 90 phase shift S is the signal of bridge N 1 S2 is the signal of bridge N 2 The angle between the force and the direction of the bridge N 1 um E SI The angle between the force and the direction of the bridge N 2 The amplitude of the force is Section A A OI 6 Load pin with external thread MA 5000 5300 5600 full EN Page 15 of 41 Rev 02 07 2010
24. nt safety set points and a built in display Each of them activates a relay specially designed dedicated and configured for hoists and crane load TEST applications An internal monitoring system controls and guarantees perfect functioning of the load cell and the electronics by a 4th relay positive safety A Test button makes it easy to check the integrity of the CRANE BOY system 3 independent safety set points configurable for overload intermediate load and or slack cable detection 4 20 mA 0 10 V RS 232C RS485 ModBus 8 4 DISP PAX The DISP PAXP is the ideal display for visualising the loads lifted at remote distances thanks to its 4 20mA input Among its local display features the DISP PAXP offers various functions such as tare max and min peak and hold detection and even a summing function DISP PAXD model 4 20 mA and 0 10 VDC input 85 to 250 VAC power supply DISP PAXS model mV input summing option 85 250 VAC 24 VAC 48 VAC 10 30 VDC power supply DISP PAXP model 4 20 mA and 0 10 VDC input summing option 85 250 VAC 24 VAC 48 VAC 10 30 VDC power supply MA 5000 5300 5600 full EN Page 24 of 41 Rev 02 07 2010 n 9 NEW APPLICATION LOAD LIMITATION AND DYNAMIC WEIGHING This device comprising a load pin and a DISP PAX makes it possible to display the total load It is possible to control the net weight The advantage of this device is that is avoids un
25. ram other mechanical solutions are applicable MA 5000 5300 5600 full EN Page 18 of 41 Rev 02 07 2010 www sensy com FORGE Deformation zone Section A A Figure 4 Load pin model The sensitivity is controlled by adjusting the beam thickness strain gauge Figure 5 Detailed view of the bonded strain gauge in its location MA 5000 5300 5600 full EN Page 19 of 41 Rev 02 07 2010 WWW Sensy com T 4 Factors in signal deterioration Deterioration of signals can lead to incorrect readings Please pay attention to the following factors in order to avoid signal disturbances The sensing axis of the load cell must be close to the load direction Maximum 3 alignment error can be accepted If the alignment error is higher than 396 the sensitivity of the axis will decrease causing a false result The sensitivity depends directly on the cosine of the angle formed by the i sensitivity axis and the load direction U measured COS corrected gt For load cells functioning with 4 20 mA the correction is I 4mA __ measured m AmA corrected gt COS p Caution The offset between the sensing axis and the load direction cannot exceed 10 degrees Load direction MA 5000 5300 5600 full_EN Page 20 of 41 Rev 02 07 2010
26. re made of high strength stainless steel and measure a wide range of loads and forces from 500 N 50 kgf to 10 MN 1000 tf 1 1 Force measurement equipment SENSY force measuring load pins are designed to withstand forces up to 1 5 times higher than the nominal load without any metrological damage The mechanical design of the pins is carried out using dedicated calculation software CAD and finite elements software are used to define and confirm the robustness of the pin designs in various environments industrial laboratories harsh marine conditions etc In force measurement applications the sensitivity of SENSY load pins can reach 1 5 3mV V 1 2 Hoisting equipment Hoisting load pins are specifically designed for fatigue and occasional static forces 2 times higher than their nominal load without any metrological and mechanical damage Beyond twice the nominal load the reliability of the measurements is no longer guaranteed drift beyond 200 The breaking load is above 5 times the nominal load Hoisting load pins are designed to withstand severe dynamic cycles MA 5000 5300 5600 full EN Page 3 of 41 Rev 02 07 2010 WWW Sensy com 2 OPERATING CONDITIONS OF LOAD PIN IN HOISTING DEVICES 2 1 Installation The delivered pin must be used in the conditions specified in the technical datasheet and according to the described conditions The force on the pin must be applied in th
27. rity hysteresis and non repeatability depend mainly on the load pin dimensions or the quality of the supports For standard SENSY pins mounted in H6 toleranced bores the error is about 0 596 of the nominal load of the bridge It can be reduced to around 0 2 on demand on the condition that the load pin is profiled On a special pin whose length diameter ratio is too small this error can go up to about 5 Zero drift and sensitivity according to the temperature are usually insignificant because they do not go over 0 196 for 10 C 12 1 2 Errors due to control electronics The errors due to the control electronics are usually insignificant because they do not go over 0 1 12 2 Errors due to hoisting device The higher the load the smaller the part of cable supported by the load pin The size of this error depends on the ratio between the cable weight and the nominal load hoisted The only way to cancel this error is to always perform the measurements at the same height The consequence of friction in the various pulleys is that the apparent load on the load pin seems lighter when the load is being hoisted and heavier when the load is being lowered It is possible to lessen the influence of this friction by always taking the measurement after the same hoisting or lowering action MA 5000 5300 5600 full EN Page 32 of 41 Rev 02 07 2010 Hoisted
28. ry at a cost effective price level It is highly recommended to carry out a calibration on site using a minimum 60 of the nominal load allowing for the tare pulley block pulley etc MA 5000 5300 5600 full EN Page 22 of 41 Rev 02 07 2010 L SS CS HA A5 EUMD A9 A E 8 ELECTRONICS 8 1 New Bridgeboy 1R The BRIDGEBOY 1R is designed in combination with a load cell for load limitation of hoisting devices and particularly overhead cranes EOT The BRIDGEBOY 1R provides positive safety it puts itself in alarm mode whatever the detected fault may be Available on BRIDGEBOY 1R a test button makes it easy to check normal operation of the whole load limitation circuit 8 2 New Bridgeboy 3R The BRIDGEBOY 3R is designed in combination with a load cell for load limitation with 3 set points of hoisting devices and particularly overhead cranes EOT Details of the set points Overload detection Slack cable detection Intermediate load detection The BRIDGEBOY 3R provides positive safety it puts itself in alarm mode whatever the detected fault may be Available on BRIDGEBOY 3R a test button makes it easy to check normal operation of the whole load limitation circult MA 5000 5300 5600 full EN Page 23 of 41 Rev 02 07 2010 8 3 Crane boy CRANE BOY CRANE BOY is a load limiter integrating 3 independe
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