C-Rail Systems for Crane Energy Supply

A crane and a mobile control push-button which moves in horizontal direction can receive energy and send control signals in any position by means of C-Rail systems. For this purpose, flat cables are placed according to the positions of crane and control push-button which have the maksimum distances from energy feeding point. Flat cables are fixed to cable trolleys which can move along the C-Rail. The length of flat cable between two adjacent cable trolleys are the same. Thus, when the crane and control push-button approach the energy feeding point, flat cables hang down maximum 1 m between two adjacent cable trolleys and are collected.

Crane control can be performed either suspended from the crane or independent from the crane. In the control systems independent from the crane there are two c-rails, one of them used for energy supply to crane, the other one used for crane control. The last one carries pendant control suspension trolley. For that reason, in calculation of c-rail materials, the quantities of cable trolleys, c-rail connection brackets and hanging brackets should be multipled by 2.

C-Rail System :

Cable Trolley :

The functions of cable trolleys are to carry the flat cables and to travel them along the c-rail. They have a very special and functional construction. Blue, red, yellow and green cable trolleys are mufactured. Their wheels are 4 roller bearings of 629ZZ, not PVC or balls placed. Their chasis and stud-bolts are made of special electrocadmium steel. PVC part consist four pieces. The body and washer has serrated surfaces to prevent sliding of flat cable between them.

The other two pieces are the designed nuts which can be manually opened or closed. Due to this speciality, mounting and demounting operations of these nuts are easly and quickly performed. The flat cable can be fixed in security by means of the special design which prevents loosen.

C-Rail :

C-Profile with 1.5 mm thickness, used to carry the cable trolleys which carry energy and control flat cables.
Material: Galvanised, bright
Cross section : 35 x 33 x 1.5 mm
Length : 6 mt.
Weight : 1.3 kg/m
Carrying capacity : 160 kg/m

Flat Cables :

They are the cables fixed to cable trolleys and used to transfer energy and control.
Working Temp. Range : -5 ile +70 °C
Nominal Voltage : 1.5 mm2 Uo/U 450/750 V

Hanging Arm Set :

Hanging arm set consist of c-rail support bracket which is a c-profile with 2 mm thickness, together with two clamps, bolt and nuts used to fix the hanging arm to the fixed construction.

The suitable distance of two hanging arms is from 1.5 to 2 meters. ( 1.5 mt < dist < 2 mt )
Material: Galvanised, bright
Cross section : 35 x 33 x 2 mm

Hanging Arm Set

Length :	400 mm	600 mm	800 mm	1000 mm
Weight :	0.700 kg	1.000 kg	1.300 kg	1.700 kg
Carrying capacity :	90 kg	65 kg	50 kg	40 kg

The Determination of Required Quantity of Hanging Arm Set :
L= Total c-rail length
L1= distance between hanging arms

Quantity =	L	+ 1 (if the result is a decimal,round up to bigger integer)
	L1

EXAMPLE 1:
L= 25 m (total c-rail length)
L1= 2 m (distance between hanging arms)

Quantity =	25	+ 1 = 14 (25/2=12.5+1=13.5 --> 14)
	2

13 pieces hanging arms are mounted as the distance between them is 2 m. The distance between 13th and 14th is 1 m.

EXAMPLE 2:
L= 6 m
L1= 2 m

Quantity=	6	+ 1 = 4
	2

EXAMPLE 3:
L= 6 m
L1= 1.5 m

Quantity=	6	+ 1 = 5
	1.5

EXAMPLE 4:
L= 13 m
L1= 1.625 m (distance between hanging arms)

Quantity=	13	+ 1 = 9
	1.625

L= 13 m
L2= 6 m (standard c-rail length)

Connection Bracket =	13	- 1 = 2
	6

According to this example, 9 hanging arm set and 9 c-rail hanging brackets are required. Since the distance between hanging arms are not selected as 1.5 m. or 2 m. (1.625 m. selected) in order to connect the c-rails 2 pieces of c-rail connection bracket are required too.

C-Rail Hanging Bracket :

They are used to fix c-rails to hanging arm. They consist of c-rail connection bracket, end stop and bolt and nut for the connection to hanging arm.

C-Rail Hanging Bracket

Note: In the single c-rail systems (pendant control is suspended from the crane) the required c-rail hanging bracket quantity is the same quantity of hanging arm set. But in the douıble c-rail systems (pendant control is independent from the crane), the required quantity of c-rail hanging bracket is the twice of hanging arm quantitiy.

C-Rail Connection Bracket :

It is used in connection of c-rails. It consist of a pair of brackets and 3 sets of bolts and nuts.

C-Rail Connection Bracket

The Determination of C-Rail Connection Bracket Quantity:
L= total c-rail length
L2= 6 (standard length of c-rail)

Quantity =	L	- 1 (if the result is a decimal,round up to bigger integer)
	L2

Note: If the pendant control is independent from the crane multiply this quantity by 2.

EXAMPLE 1:
L= 25 m
L2= 6 m

Quantity =	25	- 1 = 4
	6

EXAMPLE 2:
L= 24 m
L2= 6 m

Quantity =	24	- 1 = 3
	6

Note: If the distance between hanging arms is selected as 1.5 m or 2 m, there is no need for c-rail connection brackets since, c-rail connection points are the same point as c-rail hanging brackets are fixed to the hanging arms.

EXAMPLE 3:
L= 13 m
L1= 1.625 m (distance between hanging arms)

Hanging Arms =	13	+ 1 = 9
	1.625

L= 13 m
L2= 6 m (standard length of c-rail)

Quantity =	13	- 1 = 2
	6

According to this example, 9 sets of hanging arms and 9 pieces of hanging brackets are required. Since the distance between brackets are not selected as 1.5 m or 2 m (1.625 m) 2 pieces of c-rail connection brackets are also required.

EXAMPLE 4:
L= 13 m
L1= 2 m (distance between hanging arms)

Hanging Arms=	13	+ 1 =8
	2

L= 13 m
L2= 6 m (standard length of c-rail)

Quantity=	13	- 1 = 2
	6

According to this example, 8 sets of hanging arms and 8 pieces of hanging brackets are required. Since the distance between brackets is 2 m, there is no need for connection brackets. Since these c-rail connection points are the same points where c-rail hanging brackets are fixed to hanging arms.

End Stop :

They are used to prevent cable trolleys to reach two end points of c-rails. They are the sets of special nut and bolt.

Pendant Control Suspension Trolley :

Pendant control with push-button can be performed independent from the hoisting unit by means this trolley set at a height of 1-2 m from the floor along the girder. There are two alternatives as with buat or with socket.

Current Getting Trolley Set :

It is used to transfer the energy supplied from flat cable to the hoisting unit. This unit is composed of two pieces. Current getting trolley and towing arm.

Cable Trolley Towing Wire Rope :

It is ø3 mm special wire rope covered with nylon. It is used for fixing the cable trolleys in equal distance between them. It prevents, streching of flat cables during the movements of adjacent cable trolleys.

Cable Trolley Towing Chain :

It is a special chain used for fixing the cable trolleys in equal distance between them. It prevents, streching of flat cables during the movements of adjacent cable trolleys.

Sample Connection

A connection sample of hanging arm set and hanging bracket.