KINGPOST CRANE APPARATUS & METHOD

INVENTOR: BOBECK, Mark, a US citizen, of 14806 Long Oak Drive, Houston,

Texas 77070, US.

CROSS-REFERENCE TO RELATED APPLICATIONS

In the US, this is a continuation application of US Patent Application Serial No. 13/426,428, filed 21 March 2012, which is a nonprovisional patent application of US Provisional Patent Application Serial No. 61/454,838, filed 21 March 2011, both of which are hereby incorporated herein by reference.

Priority of US Patent Application Serial No. 13/426,428, filed 21 March 2012, incorporated herein by reference, is hereby claimed. In the US, priority of US Provisional Patent Application Serial No. 61/454,838, filed 21 March 2011, incorporated herein by reference, is hereby claimed.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO A "MICROFICHE APPENDIX"

Not applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to lifting devices, namely cranes. More particularly, the present invention relates to an improved knuckle boom king post crane apparatus that employs a rack and pinion mechanism to articulate one boom section relative to another boom section and a unique knuckle boom luffing arrangement.

2. General Background of the Invention

A knuckle boom crane is a hydraulically powered articulated arm that can be fitted to a support structure, usually a truck or trailer. The jointed sections of the boom can be folded into a small space when the crane is not in use.

Several articulated boom crane constructions have been patented. Examples of possibly relevant patents can be found below. The following US Patents for cranes listed in the table below are each incorporated herein by reference:

TABLE

BRIEF SUMMARY OF THE INVENTION

The present invention provides an improved knuckle boom crane arrangement that is supported upon a kingpost wherein the crane's ability to handle tubulars, as well as loads of all sizes and weights, is achieved with continual safety demands associated with the handling of such products.

The present invention thus provides an improved crane design that can be mounted upon a kingpost, such as for example a 72" (1.83m) OD columns or other size. Main and auxiliary winches can be provided which are drilling duty compliant (for example, API spec 2C 7 ^th edition) and equipped with an external fail safe drum brake system for additive dynamic braking redundancy.

The present invention is additionally equipped with galvanized rope, axial piston drive, hydraulic dynamic braking and boom mounted winches to eliminate hook block fouling issues when booming down.

The present invention provides a control cabin that affords exceptional operator sight to see a working area.

The present invention provides efficient main boom tubular design, structurally optimized to reduce weight and available in various length configurations, such as for example, a standard 80' (24.4 m) length.

The present invention provides a boom assembly that houses the main winch, dead end, gross overload protection or GOP, constant tension device, spherical bearing head pins, articulating cylinders and luffing sheaves.

The present invention provides a cylinder actuated rack and pinion system for jib articulation.

The present invention provides a main block parking area to allow the jib boom use without dismantling.

The present invention provides a main block 75 ton (68,039 kg) capacity at maximum 80' (24.4 m) working radius, two-part reeving, drilling duty compliant with built-in ATB (anti-tube lock). With the present invention, the jib boom can be a box type construction, light weight and available in various length configurations (such as standard 60' (18.3 m) length). The jib boom assembly houses the auxiliary winch, reversible sheave nest, articulating pinions and pipe handling attachments.

The present invention enables a wide range of drill pipe, casing and riser handling attachments.

The present invention provides an auxiliary block, such as for example 33 ton (29,937 kg) capacity, drilling duty compliant, built-in ATB.

The present invention provides an optimized bull gear and pinion design to provide smooth and secure slewing operations.

The present invention provides a fully enclosed prime mover for maximum machinery protection with removable panels to facilitate maintenance. The present invention provides standard OSHA compliant walkways, decks and ladders to facilitate inspection and maintenance.

The present invention provides Nylatron upper and lower self aligning bearing assemblies which are easy to maintain and replace with simple hand tools.

The present invention provides a continuous luffing system reeving.

The present invention provides a rack and pinion jib boom articulation arrangement, gear phasing to reduce tooth loading and increase redundancy.

The present invention thus provides design features such as improved pipe handling, constant torsion winches, tubular main boom, redundant drives and braking, can be PLC controlled, data logging, wherein hook block reconfiguration is eliminated, and having application to jack up rigs, semi-submersible platforms, drill ships, TLPs, spars and other platforms.

The present invention provides an improved crane apparatus, namely a knuckle boom kingpost marine crane. The present invention features a knuckle boom and kingpost mounting (API Type "E" Cranes "KingPost"). In the prior art, knuckle boom marine cranes have been mounted upon a slew roller bearing mounting (API Type "C" Cranes "Roller Bearing"). This has been the case with truck mounting knuckle boom cranes, which are thus also slew bearing mounted.

In the prior art, articulation has been by means of extensible cylinders (hydraulic cylinders) which tend to be range limited. In some cases, longer booms require jib removal and re-reeving to handle larger loads.

The present design combines cylinders with a toothed gear or rack that allows for one hundred eighty (180) degrees of motion combined with the ability to store or tuck the jib into a storage position to thus eliminate the problems associated with traditional designs when handling larger loads with the main hook.

Improved main hook location and functionality are thus incorporated into the design of the present invention. The present invention has application in the retrofit of existing cranes as well.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: Figure 1 is a perspective view of a preferred embodiment of the apparatus of the present invention;

Figure 2 is a side, elevation view of a preferred embodiment of the apparatus of the present invention;

Figure 2A is a partial side, elevation view of a preferred embodiment of the apparatus of the present invention;

Figure 3 is a side, elevation view of a preferred embodiment of the apparatus of the present invention;

Figure 4 is a side, elevation view of a preferred embodiment of the apparatus of the present invention;

Figure 5 is a fragmentary side elevation view of a preferred embodiment of the apparatus of the present invention;

Figure 6 is a side fragmentary view of a preferred embodiment of the apparatus of the present invention;

Figure 7 is a partial perspective view of a preferred embodiment of the apparatus of the present invention;

Figure 8 is a fragmentary view of the preferred embodiment of the apparatus of the present invention;

Figure 9 is a fragmentary view of the preferred embodiment of the apparatus of the present invention;

Figure 10 is a fragmentary view of the preferred embodiment of the apparatus of the present invention;

Figure 11 is a fragmentary view of the preferred embodiment of the apparatus of the present invention; and

Figure 12 is a fragmentary view of the preferred embodiment of the apparatus of the present invention.

DETAILED DESCRIPTION

Figures 1-12 show a preferred embodiment of the apparatus of the present invention designated by the numeral 20 in figures 1-12. Crane apparatus 20 provides a knuckle boom kingpost crane arrangement 20 having a supporting frame or king post 1. The kingpost 1 supports frame 3 which contains prime mover 12 (e.g., diesel engine) and a cabin 23 having human operator 24. (See Figures 1, 8).

A main boom 4 pivotally attaches to cabin frame 3. A jib boom 8 is provided that is pivo tally attached to main boom 4. At the joint or pivotal connection 33 of main boom 4 to jib boom 8, there is provided a cylinder actuated rack and pinion system for jib articulation which is designated by the numeral 5 in figures 1-6. Jib boom 8 has jib tip sheave nest 9 for containing sheaves and rigging that enable auxiliary block 10 to be lifted and lowered. (See Figures 1-2.) The crane apparatus 20 of the present invention provides a main block parking area 6 for enabling a main block or hook 7 to be parked which allows the jib boom 8 to be used without dismantling the main block/hook 7. In figures 1 and 7, the parking area 6 includes a yoke portion 25 that includes spaced apart arms 26, 27 with opening or recess 28 in between arms 26, 27.

Figure 1 shows a main winch 2A, auxiliary winch 2B, and a boom (luffing) winch 2C. The winches 2A, 2B, 2C can be drilling duty compliant with API Spec. 2C 7 ^th edition. The winches 2A, 2B, 2C can be equipped with external fail safe drum braking systems for additive dynamic braking redundancy. The winches 2A, 2B, 2C would preferably be equipped with galvanized rope, axial piston drive, hydraulic dynamic braking, and stiffened boom mounts to eliminate hook block fouling issues when booming down.

The main boom 4 design can be a tubular design, structurally optimized to reduce weight and available in a number of different length configurations such as a standard 80' (24.4 m) length as an example. The boom 4 is the form of an assembly that houses the main winch 2A, dead end, GOP, constant tension drive, spherical bearing heel pin, articulating cylinders 18 and luffing sheaves.

In figure 7, the numeral 6 indicates generally a main block parking area to allow jib boom use without dismantling of the main block 7. Main block 7 can be for example a 75 ton (68,039 kg) capacity at maximum 80' (24.4 m) working radius, two part reeving, drilling duty compliant with built-in ATB. Main block 7, main boom 4 and main winch 2A are rigged with cable for enabling main block 7 to be lifted and lowered.

The jib boom 8 is preferably of a box type construction, being light in weight and available in various length configurations (60' (18.3 m) length as an example). The jib boom 8 assembly houses the auxiliary winch 2B, a reversible sheave nest, articulating pinions 17, and any selected pipe handling attachments. (See Figures 4-5, 9). An auxiliary block 10 is supported by the jib boom 8 as shown in Figures 1-5. Auxiliary winch 2B, jib boom 8 and auxiliary block 10 are rigged with cable to enable auxiliary block 10 to be lifted or lowered by rotating winch 2B. A slewing drive can be provided. The slewing drive utilizes an optimized bull gear and pinion design to provide smooth and secure slewing operations. Numeral 13 in the drawings indicates generally the walkways, decks, and ladders that facilitate inspections and maintenance (see figures 4, 8). Such walkways, decks, and ladders 13 can be OSHA compliant.

Nylatron upper and lower self aligning bearing assemblies (see figure 8, bearings 11, 14) can be provided, which are easy to maintain and replace with simple hand tools. The present invention also provides a continuous luffing system 15 using wire line or wire cable to raise and lower the main boom 4. (See figures 6, 8.) As part of the luffing system, wire cable is rigged to the luffing winch 2C. First sheaves 31 connect to an upper portion of cabling 34 above the first sheaves 31 , the cabling also rigged to second sheaves 32 (see figure 1- 4, 7 - 8). A lower portion of cabling 35 is rigged to sheaves 31 and winch 2C below the first sheaves 31 (see figures 1 - 4, and 8). The upper 34 and lower portions 35 define an obtuse angle during a lifting or lowering of the main boom (see figures 1 - 4 and 8). The second sheaves 32 are at the joint or pivotal connection 33 of main boom 4 to jib boom 8. The winch 2C pays out cable to lower main boom 4. The winch 2C retrieves cable to raise main boom 4. (See figures 1, 6.)

The rack and pinion system 5 enables 180° jib boom 8 articulation (see figures 1 and 6). Gear phasing is provided to reduce tooth loading and increase redundancy (see figures 1 and 6). The rack and pinion arrangement 5 includes rack or rack gear 16, pinion gear 17 and hydraulic cylinder 18 having extensible rod 19. The extensible rod 19 is connected to the rack or rack gear 16 as shown in figures 1-7. In this fashion, when the cylinder 18 extends the extensible rod 19, it also extends the rack or rack gear 16 which then rotates the pinion gear 17.

The various positions of the jib boom 18 can bee seen by comparing figures 1 and 3-4 and 6. As the rack 16 moves downwardly (see arrow 22 in figure 4), the pinion 17 rotates to extend the jib boom 8 away from the main boom 4. This rotation of the jib boom 8 with respect to the main boom 4 is indicated schematically by the arrow 21 in Figure 4. The arrow 22 indicates the downward movement of the rack 16 as cylinder 18 retracts rod 19.

Figure 9 illustrates that the jib boom 8 sheave nest 9 can be used to support a pipe/riser handler 30. Such devices 30 are commercially available and can be used to lift a section of pipe 29. Such a pipe/riser handler 30 eliminates the need for a person to manually couple a section of pipe to the boom 8. There are typically three forms of pipe to handle on a drilling rig for example including drill pipe, riser pipe and casing. All three forms of pipe require a different handling attachment. Grippers or magnets for pipe and casing can be used as well as ID handlers for riser pipe, all known attachments which can be purchased and fitted to the crane apparatus 20 of the present invention.

A pinned connection can join jib boom 8 to main boom 4. Figures 10-12 illustrate an example of such a pinned connection of jib boom 8 to main boom 4. (See also Figure 1.) In figures 11 and 12, the upper end portion of main boom 4 is shown. Each pinion gear 17 includes preferably a pair of pinion gear sections. In figures 7 and 10-11, these pairs of pinion gears include a first pair 36, 37 and a second pair 38, 39. Rack gear 16 can provide a pair of rack sections 43, 44, which engage the pair of pinion gears 36, 37. The rack section 43 engages the pinion gear section 36. The rack section 44 engages the pinion gear section 37. Similarly, the rack section 45 engages the pinion gear section 38. The rack gear section 46 engages the pinion gear section 39. Thus, the rack sections 43 and 46 are outer rack sections. The rack sections 44, 45 are inner rack sections. As shown in figures 6-7, the teeth of pinion gear sections 38, 39 do not have to be aligned. Similarly, the teeth of pinion gear sections 36, 37 do not have to be aligned. Thus, the teeth of rack sections 43, 44 do not have to be aligned. Similarly, the teeth of rack sections 45, 46 do not have to be aligned.

Bolted connections 47 can be used for attaching the pinion gear sections 36, 37 together. Similarly, the pinion gear sections 38, 39 can be held together with bolted connections 47. Plates can be provided in between the pinion gear sections 36, 37 and 38, 39. Plate 48 is provided in between the pinion gears section 43, 44. Plate 49 is provided in between pinion gears sections 38, 39. Plates 48, 49 can be at attached to the arms 26, 27 of yoke portion 25 as shown in figures 7 and 10. This connection of the plates 48, 49 to the yoke 25 can be a welded connection. The bolted connections 47 can secure an assembly of the pinion gear sections 36, 37 to plate 48. Similarly, the bolted connections 47 can bolt together the assembly of pinion gear sections 38, 39 and plate 49.

A sleeve or bearing at 51 is provided for receiving pin or joint or pinned connection 33 as shown in figure 12. Arrow 52 in figure 12 illustrates that pin 33 can be removed laterally for disengaging main block sheave assembly 40 from pin 33. The sheave assembly 40 can include for example sheaves 41, 42 and sleeve 50. Such a removal of the sheave assembly 40 enables it to be serviced separately from the boom sections 4 and 8. Arrow 53 in figure 12 illustrates removal of sheave assembly 40 from pin 33.

Plates 54, 55 in figure 12 are connectors that join pin 33 and boom 8 to boom 4.

Each plate 54, 55 can be welded to main boom 4. Each plate 54, 55 carries a bearing, sleeve or bearing sleeve 51 that supports pin 33. (See figures 1 and 11-12).

The following table is a further numerical listing of the features of the apparatus of the present invention.

slewing operations.

12) Fully enclosed prime mover for maximum machinery protection with removable panels to facilitate maintenance.

13) Standard OSHA compliant walkways, decks, and ladders to facilitate inspections and maintenance.

14) Nylatron upper and lower self aligning bearing assemblies easy to maintain and replace with simple hand tools.

15) Continuous luffing system reeving.

16) Rack and pinion, 180° jib boom articulation, gear phasing to reduce tooth loading and increase redundancy.

PARTS LIST:

The following is a list of parts and materials suitable for use in the present invention, corresponding to reference numerals used in the drawings.

Parts Number Description

1 kingpost/supporting frame

2A main winch

2B auxiliary winch

2C boom (luffing) winch

3 frame

4 main boom

5 cylinder actuated rack and pinion system for jib articulation

6 main block parking area

7 main block/hook

8 jib boom

9 jib tip sheave nest

10 auxiliary block

11 kingpost upper bearing

12 prime mover

13 walkway/ deck/ladder

14 kingpost lower bearing

15 luffing system

16 rack/rack gear 17 pinion gear/gear section

18 hydraulic cylinder

19 extensible rod

20 crane apparatus

21 arrow

22 arrow

23 cabin

24 operator

25 yoke portion

26 arm

27 arm

28 recess

29 pipe section

30 pipe/riser handler

31 first sheaves

32 second sheaves

33 pin/joint/pivotal connection

34 wire rope section/cabling

35 wire rope section/cabling

36 pinion gear section

37 pinion gear section

38 pinion gear section

39 pinion gear section

40 sheave assembly/main block

41 sheave

42 sheave

43 outer rack section

44 inner rack section

45 inner rack section

46 outer rack section

47 bolted connection

48 plate

49 plate 50 sleeve

51 sleeve/bearing/bearing sleeve

52 arrow

53 arrow

54 plate

55 plate

All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.

The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.