SyncHoist: High Accuracy Hoisting & Positioning

Since the advent of hydraulic jacks or lifting cylinders, construction engineers have had the capability to raise and relocate structures, bridges or buildings of almost any size and tonnage – even entire city centres to allow new underground installations such as subways or essential repair work.  

In theory there are no limits….. the greater the weight, the more cylinders are employed. But the extend of a straight lift has always been limited to the plunger stroke length of the cylinders used. To lift beyond that limit stage lifting has involved additional holding arrangements to permit the replacement or repositioning of cylinders for the next stage in the lifting operation.

Geometric Positioning
With the use of single cranes heavy loads, such as large construction segments, can move long vertical distances with relative high speed. For the geometric positioning of heavy loads in a vertical and horizontal plane it happens that multiple cranes are used in the lifting industry.

Synchronizing movements in this fashion has proved to be difficult and risky. Also from a lifting accuracy standpoint this application has often resulted in damaging the load and/or support fixtures and even putting the workers at risk.

In addition, sudden crane starts and stops create oscillations during the critical stages of the lifting process. Weather conditions also play an active role when using multiple cranes during heavy load positioning applications.

This is where the value of the Enerpac SyncHoist system comes in. The Enerpac SyncHoist system is a hydraulically operated auxiliary attachment for high precision load positioning with cranes. With the use of a single crane, the load can now be precisely maneuvered in a vertical and horizontal plane, while reducing risk and cost and vastly improving operating speed and worker safety. Also, when using the Enerpac SyncHoist system weather conditions play a less critical role in comparison to applying multiple cranes.
A perfect marriage
Today, however, Enerpac hydraulic expertise combined with heavy lifting know-how brings unlimited possibilities to move, position and control heavy loads and large objects. Lifting power is provided by the crane while the integrated Enerpac intelligent SyncHoist System guarantee a smooth and high accuracy counterweighing and positioning of heavy loads and structures. Accurate positioning can be managed in the top of the crane by the crane operator or by the construction workers on the roof with the use of remote control units.
 
High Accuracy Hoisting – Integrated Hydraulic Solution
Hoisting, moving and positioning with high accuracy can now be done using one crane with Enerpac integrated hydraulics. In many construction hoisting applications the hydraulic control of load movement makes the demand for more than one crane redundant. This integrated hydraulic solution turns hoisting into an efficient and cost effective handling and ensures better control of vertical transportation and load positioning – reduces costs of hiring additional cranes, assembling time and requires less space on the construction site. In conventional hoisting one crane is used for each lifting point. Now, with the Enerpac SyncHoist System one crane can handle multiple lifting points with an accuracy of ± 1 mm.
Hydraulic System Integration
Between the cables of the crane hydraulic cylinders will be included. Each lifting point has it’s own cable and cylinder. These cylinders are double-acting pulling cylinders. The double-acting function allows precise control of both lifting and lowering adjustments in each cable. The maximum hydraulic pressure is 700 bar while the cylinder pulling capacity depends on the type of application. However, the maximum load is only limited by the lifting capacity of the cable, not by the hydraulic system. The hydraulic system features management of digital and electronic signals. The cylinders are equipped with stroke sensors measuring the exact plunger travel. In this way every movement of all lifting points can be checked at the same time. Plunger strokes of 1500 mm are not uncommon in hoisting and positioning applications with 4 or 6 lifting points. The maximum positioning accuracy with Enerpac SyncHoist is +/- 1 mm, but the elasticity of the cables must be considered.

Hydraulic system management can be done by digital and analogue signals. The type of remote control unit depends of the system function: for most applications a manual control is sufficient but for counterweighing and pre-programmed movements a PLC-control unit is necessary.  

Important advantages:
Cost reduction from using a single crane vs. multiple cranes High accuracy (+/- 1,0 mm)
Eliminates risk of damage
Improved productivity
Safer working environment

Ease of use:

• Once the load is moved within a short distance of its final position (using a single crane), the Enerpac SyncHoist system positions the load with high accuracy.

• No need to crane jogging i.e. sudden starts & stops of the crane, causing oscillations of the wire rope and premature wear of crane brakes.
• Operating simplicity such as wireless remote control and read outs.

The Enerpac SyncHoist System can be used for a wide variety of functions such as high accuracy relocating, pre-programmed relocating, pre-programmed twisting or turning and counterweighing (determining centre of gravity).

Typical applications:

• Positioning of roof sections, concrete elements, steel structures etc. in the construction industry.
• Precise positioning of turbines, transformers, fuel rods etc. in the utility industry.
• Precise machinery loading, mill roll changes, bearing changes etc. in the heavy industry.
• Precise positioning of pipe lines, blow out valves etc. in the petrochemical and oil & gas industry
• Relocating and positioning of ship segments in shipbuilding industry.

A unique position
 Enerpac has proven to be the reliable partner for controlled hydraulic movement and weighing, moving and high accuracy positioning of high tonnage loads and large structures. Enerpac SyncHoist systems with integrated PLC-controls are beyond today’s standards as it comes to overcome critical requirements as precise counterweighing and relocating structures to their final position and ascertain not only a safe but also a cost effective handling and transportation.