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1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefr
2、om, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2002 Society of Automotive Engineers, Inc. All rights reserved. No part of
3、this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER:Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4
4、970 (outside USA) Fax: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS:http:/www.sae.org SURFACE VEHICLE STANDARD J159 REV. OCT2002 Issued1970-03 Revised2002-10 Superseding J159 APR1994 (R) Rated Capacity System 1.ScopeThis SAE Standard applies to cranes when used in lifting service that are equi
5、pped with Rated Capacity Systems. 1.1PurposeThe purpose of this document is to establish the minimum performance and tolerance criteria of systems used to warn or to indicate to the operator and/or other responsible persons when the load being lifted approaches, meets and exceeds the rated capacity
6、on the applicable rated capacity chart of the crane. 2.References 2.1Applicable PublicationsThe following publications form a part of this specification to the extent specified herein. 2.1.1NEMA PUBLICATIONAvailable from the National Electrical Manufacturers Association, www.NEMA.org, 1300 North 17t
7、h Street, Suite 1847, Rosslyn, VA 22209. NEMA-12 (U.S. Code) 2.1.2IP (INTERNATIONAL ELECTROTECHNICAL COMMISSION) PUBLICATIONAvailable from American National Standards Institute (ANSI), Customers Service, 25 West 43rd Street, 4th floor, New York, NY 10036-8002. TP: +1 212 642 4900 TF: +1 212 398 0023
8、 email: infoansi.org URL: webstore.ansi.org. IP-65 (International Protection Code - IEC 144/855420) 3.Definitions 3.1Rated Capacity Indicator (RCI)A system consisting of devices, when applied to a crane, sense crane loading, boom length (telescopic only), boom angle, and which automatically provide
9、an audible/visual signal when the Actual Load approaches, reaches and/or exceeds the Rated Capacity value. 3.2Rated Capacity Limiter (RCL)A system consisting of devices which, when applied to a crane, sense crane loading, boom length (telescopic only), boom angle, and which automatically provide an
10、audible/visual signal when the loading conditions approach, reach and/or exceed the rated capacity values. When the Actual Load exceeds the Rated Capacity, the system supplies a signal to a function kick-out system. SAE J159 Revised OCT2002 -2- 3.3Function Kick-Out System (FKO)A device which when ac
11、tivated prevents the loading on the crane to be increased beyond the point at which the FKO occurred. 3.4Crane ConfigurationThe physical arrangement of the crane as prepared for the particular operation in conformance with the manufacturers operating instructions and Rated Capacity Chart. 3.5Actual
12、LoadThe weight of the load being lifted including all additional equipment such as wire rope, blocks, slings, etc. as defined by the manufacturers Rated Capacity Chart. 3.6Rated CapacityThe value shown on the applicable Rated Capacity Chart of the crane for the particular configuration, boom length,
13、 angle and/or function of these variables. For radii and/or angles outside those shown on the Rated Capacity Chart, the rated capacity is considered to be zero. 3.7Boom LengthThe straight line through the center line of the boom pivot pin to the centerline of the boom point hoist sheave pin, measure
14、d along the longitudinal axis of the boom. 3.8Boom AngleThe angle between the longitudinal centerline of the boom base section and the horizontal plane. 3.9Radius of LoadThe horizontal distance from a vertical projection of the cranes axis of rotation to the supporting surface, before loading, to th
15、e center line of the vertical hoist line(s) or tackle with the load applied. 4.Performance Tolerance Criteria 4.1Warning and Limit SignalsVisual and/or audible signals shall have the visual signal clearly visible to the operator under any normal operating conditions, and the audible signal shall be
16、sufficiently loud to be heard over engine and machinery noise, and shall be clearly distinguishable from ambient noise. 4.1.1WARNING SIGNAL - APPROACH TO OVERLOADAn audible and visual signal (preferably a yellow light) is to be activated at 92% 5% of Rated Capacity. The signal shall continue to func
17、tion as long as the load, radius or angle parameters exceed the 92% 5% values. Also, the warning signal shall be clearly distinguishable from the overload signal. 4.1.2OVERLOAD AND LIMIT SIGNALAn Audible and Visual signal (preferably a red light) is to be activated at no more than 105% of Rated Capa
18、city and also when the radius or angle shall fall outside of the cranes Rated Capacity Chart. Also, when a Rated Capacity Limiter is employed to actuate an optional crane control Function Kick-Out System (FKO), the FKO is to be activated at no more than 105% of Rated Capacity. These signals shall co
19、ntinue to function as long as the load, radius, and angle parameters are exceeded. 4.2Additional FunctionsWhen actual load, rated capacity, radius, boom angle or boom length are displayed as additional functions of a Rated Capacity System the displayed function is to conform to the following provide
20、d that the system accuracy always conforms to 4.1.1 and 4.1.2. 4.2.1ACTUAL LOADWhen Actual Load is displayed as an additional function of a Rated Capacity System its accuracy shall be such that the indicated load is 100% +10% 0% of the Actual Load. 4.2.2RADIUSWhen Radius is displayed as an additiona
21、l function of a Rated Capacity System its accuracy is to be such that the indicated radius is 100% +10% 0% of the Actual Load Radius. 4.2.3BOOM LENGTHWhen boom length is displayed as an additional function of a Rated Capacity System its accuracy is to be such that the indicated length is 100% 2% of
22、the actual length. SAE J159 Revised OCT2002 -3- 4.2.4BOOM ANGLEWhen Boom Angle is displayed as an additional function of a Rated Capacity System its accuracy shall be as follows: For boom angles 65 degrees or higher the indicated angle is to be neither greater than the actual boom angle nor more tha
23、n 2 degrees less than the actual boom angle. For boom angles less than 65 degrees the indicated angle is to be neither greater than the actual boom angle nor more than 3 degrees less than the actual boom angle. 4.2.5RATED CAPACITYWhere rated capacity is displayed as an additional function of a Rated
24、 Capacity System the capacity displayed shall be the capacity determined from the applicable capacity chart of the crane 200 lb. Where the system cannot meet the preceding accuracy criteria, conspicuous labeling or signaling is to be provided indicating that this accuracy cannot be met. 5.System Mec
25、hanical Requirements 5.1Shock and VibrationThe RCI/RCL system shall be able to withstand the shock and vibration of the machine under normal operating conditions while maintaining specified accuracy. 5.2ProtectionRCI/RCL components directly exposed to the elements (installed externally on the machin
26、e) shall be protected to a minimum level of NEMA-12 (U.S. code) or IP-65 (International Protection Code - IEC 144/ 855420). Components that are installed within manufacturers machine enclosure shall be protected to manufacturers specifications. 5.3Temperature EffectSpecified accuracy is to be mainta
27、ined over ambient temperature variations of 30 C to +50 C (22 F to +122 F) without external adjustment. 5.4RFI/EMIThe RCI/RCL system shall be sufficiently protected against Radio Frequency Interference and Electro-Magnetic Interference under normal (design) operating conditions of the machine. 5.5St
28、rength MarginWhen any part of the RCI/RCL system is employed in the load supporting system so that its failure could cause the load to be dropped, its strength margin is to be not less than the minimum strength margin of the other load supporting members. 5.6Operation CheckThe system is to include a
29、 means for the operator or other responsible persons to determine that it is operative prior to crane use. 5.7TestingThe system is to be performance tested by the installer initially and by the user at intervals recommended by the manufacturer(s), or at any time there is an indication of inaccuracy.
30、 6.General Requirements 6.1Installation and MaintenanceInstallation and maintenance of the rated capacity device and maintenance of the crane are to be in accordance with the appropriate manufacturers recommendations to attain system accuracy. 6.2IdentificationLabels are to be conspicuously placed o
31、n a system component(s), in the operators cab, and/ or displayed on the RCI/RCL giving the following information: a.Identification of applicable load rating chart and rating conditions. b.Units of measure as applicable. c.Basic operating instructions and precautions, including recommended intervals
32、for performance testing. d.Device manufacturers name, address, device model number and serial number of the RCI/RCL. SAE J159 Revised OCT2002 -4- 6.3ManualManual(s) containing installation, operation, test, and service information is (are) to be provided by the manufacturer and shall be available to
33、 the operator or to other responsible persons at all times unless the manuals are supplied by the crane manufacturer. 7.Performance Evaluation Tests 7.1General Testing RequirementsTest Personnel are to be familiar with the system operation and the manufacturers recommended test procedures, and to te
34、st the system for all functions. 7.1.1System tests are to be conducted using appropriately configured crane and specified load rating chart. 7.1.2For system calibration, or calibration verification, two or more test loads are to be employed for each of the following configurations to establish compl
35、iance with 4.1 and 4.2 (unless otherwise specified by the Crane Manufacturer or the Rated Capacity System manufacturer): a.Maximum Boom Length and Maximum Radius (Min. Angle). b.Maximum Boom Length and Minimum Radius (Max. Angle). c.Minimum Boom Length and Maximum Radius (Min. Angle). d.Minimum Boom
36、 Length and Minimum Radius (Max. Angle) unless the test weight restricts safe operation in this area, then the test shall be made at the minimum safe operating radius. 7.1.3For periodic calibration checks, two or more test loads are to be employed to activate the alarms. 7.1.4TEST DATATest forms are
37、 to include, but not be limited to, the following information: a.Owner(s) b.Crane manufacturer, model, and serial number. c.Device manufacturer, model, and serial number. d.Crane configuration at time of test, method of test load application, location of load sensor, radius/ angle sensor, and test r
38、eadings. e.A statement that the system met (did not meet) the performance criteria of 4.1 and 4.2 or that recalibration was necessary in order to achieve the required accuracy. The system accuracy calibration is to be part of such report. 7.1.5All test records are to be signed and dated. A copy of t
39、he current test record is to be available to the operator upon request. 7.2Test ProceduresThe following test procedure or equivalent is to be used: 7.2.1KNOWN WEIGHT a.Test load to be applied by suspending known weights accurate to 1%. If the weights of additional equipment such as blocks, slings, s
40、ensors, etc., are included in the test load, the total load is to be known to an accuracy of 1%. Starting with the load at short radius (load within rating) lift load and increase radius slowly until the limit signal is activated. Measure and record radius. Two or more readings are to be taken with
41、each test load. Similarly, check the warning signal. b.Determine the system accuracy in accordance with 7.3. SAE J159 Revised OCT2002 -5- 7.3ComputationsFor each radius measured with the above test, refer to the applicable crane manufacturers load rating chart and determine the rated load. At radii
42、between those listed on the load rating chart, rated load shall be determined by (load chart instructions) (linear interpolation) unless otherwise specified by the crane manufacturer. The system accuracy is to be determined from Equation 1: (Eq. 1) 8.Notes 8.1Marginal IndiciaThe change bar (l) locat
43、ed in the left margin is for the convenience of the user in locating areas where revisions have been made to the previous issue of the report. An (R) symbol to the left of the document title indicates a complete revision of the report. PREPARED BY THE SAE CRANES AND LIFTING DEVICES COMMITTEE Test Lo
44、ad Rated Load -100% of Rated Load= SAE J159 Revised OCT2002 RationaleThe purpose of the revised draft is three fold. The following goals were accomplished by the revisions. The following table summarizes the changes that were made and compares the results with ISO 10245-2. 1. To harmonize as much as
45、 possible SAE J159 with ISO 10245-2 2. To ensure that the Rated Capacity System always allows lifting 100% of Rated Load. 3. To add Rated Capacity System accuracy values. Relationship of SAE Standard to ISO StandardNot applicable. ApplicationThe purpose of this document is to establish the minimum p
46、erformance and tolerance criteria of systems used to warn or to indicate to the operator and/or other responsible persons when the load being lifted approaches, meet and exceeds the rated capacity on the applicable rated capacity chart of the crane. Reference Section NEMA-12 (U.S. Code) IP-65 (International Protection Code - IEC 144/855420) Developed by the SAE Cranes and Lifting Devices Committee