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Electro-hydraulic Marine Knuckle Boom Crane with Folding Telescopic Boom, SWL 1000 kg, Hook Outreach 10.3 m, Hoisting Height 11 m

Izhora Hydrosystems LLC offers electro-hydraulic marine knuckle boom cranes with a folding telescopic boom, marine execution, SWL 1000 kg, hook outreach up to 10.3 m, and hoisting height up to 11 m, intended for cargo handling operations on open decks requiring high precision and operational reliability, including:

  • ship-to-shore cargo loading and unloading;
  • ship-to-ship cargo transfer operations;
  • cargo handling and repositioning on deck;
  • loading and unloading of cargo holds.

The project was developed for the manufacture and supply of a knuckle boom crane with folding telescopic boom for a Russian Navy vessel, within the framework of import substitution, in compliance with the following requirements:

  • Technical Specification;
  • Rules of the Russian Maritime Register of Shipping (RS);
  • Order of the Minister of Defence of the Russian Federation No. 792 dated 21 December 2017;
  • OST 5R.5599-92 “Hydraulic Systems. Manufacturing and Installation. General Provisions”.

Originally designed for installation on a naval vessel, the knuckle boom crane with folding telescopic boom may also be applied on civilian vessels, other floating units, as well as on stationary and mobile installations. Izhora Hydrosystems LLC is ready to adapt and modify the design to meet customer-specific requirements, as well as the structural and operational characteristics of a particular vessel or ship.

Advantages of the Electro-hydraulic Knuckle Boom Crane with Folding Telescopic Boom

Due to the specific boom design incorporating telescopic sections and multiple articulated joints (knuckle points), a fully folding knuckle boom crane provides a wider working range compared to a conventional stiff boom crane, allowing it to perform a broader spectrum of cargo handling operations.
For example, cargo can be handled through small cargo hatches or narrow openings by extending the telescopic boom sections. The boom can be slewed 180° to either side, providing 360° continuous slewing capability.

The electro-hydraulic marine knuckle boom crane with folding telescopic boom manufactured by Izhora Hydrosystems LLC is characterized by the following features:

  • Cost efficiency, not linked to foreign currency exchange rates.
  • High reliability and maintainability, as the knuckle boom crane is manufactured within the import substitution program using domestically produced materials and components, which also allows installation on Russian Navy vessels.
  • Operational versatility: when equipped with optional attachments, the crane can be used for a wide range of applications, from general cargo handling to firefighting operations.
  • Manipulator-mode cargo handling without the use of a hoisting winch. In this configuration, a dedicated tool or load-handling attachment is mounted directly on the boom nose.
  • Full regulated service life prior to factory overhaul of 10000 operating hours or 13 years, whichever occurs first.
  • Single-operator operation and maintenance.
  • Availability in basic configuration or with optional equipment, including design adaptation to specific operational tasks or installation conditions.

Basic Configuration

Depending on the vessel class and operating area, Izhora Hydrosystems LLC adapts the design of the electro-hydraulic knuckle boom crane with folding telescopic boom to comply with the requirements of the Russian Maritime Register of Shipping (RS) or the Russian River Register (RRR).

Boom slewing of 180° to either side provides 360° continuous working area coverage, while the presence of a hoisting winch enables a wide range of cargo handling operations. For operator convenience and safety, a guarded operator control platform is provided on the slewing structure of the crane. The fully folding telescopic knuckle boom crane and its control equipment are designed to be compact.

Optional Equipment

When ordering an electro-hydraulic knuckle boom crane with folding telescopic boom, a range of optional equipment may be selected to extend operational capabilities or improve convenience during cargo handling operations, including:

  • 360° continuous slewing, without operational limits or the need to return to a neutral position.
  • Integrated hydraulic power unit (HPU) built into the crane structure.
  • Additional control stations and/or installation of an operator cabin.
  • Boom-mounted floodlights for illumination of the cargo handling area.
  • Special executions: explosion-proof, tropical, arctic, and cargo-passenger versions.
  • Constant tension winch (load-following system).
  • Monitoring, control, and data recording system for crane operating parameters.

For consultation or to place an order for an electro-hydraulic knuckle boom crane with folding telescopic boom, please contact our sales team:
Phone: +7 (812) 339-61-68
E-mail: contact@i-hydro.ru

Development History and Design Features of the Electro-hydraulic Marine Knuckle Boom Crane with Folding Telescopic Boom

The request for the design and manufacture of an electro-hydraulic knuckle boom crane with folding telescopic boom was received from a trading company that was unable to source a Russian-made equivalent of the Palfinger INMAN IM 150 crane specified in the vessel project. A key requirement for the marine crane was a strict weight limitation: the total mass was not to exceed 2400 kg. However, when all Russian Maritime Register of Shipping (RS) strength margins and regulatory requirements were taken into account, the initial calculated mass exceeded 3 t.

To meet the allowable weight limit while maintaining the required safe working load and boom outreach, the design engineers of Izhora Hydrosystems LLC were required to address a number of non-standard engineering challenges. As a result, the design of the electro-hydraulic knuckle boom crane with folding telescopic boom incorporates hollow pins, thin-walled boom sections, and extensive weight optimization across nearly all structural assemblies. The development process was particularly demanding, as weight reduction had to be achieved without compromising the structural strength, durability, and operational reliability of the load-handling equipment.

Once the design of the electro-hydraulic knuckle boom crane with folding telescopic boom was completed and approved, the manufacturing stage commenced. The production facility mastered a complex argon-shielded welding process for thin-walled boom structures, ensuring the required mechanical strength and quality of welded joints.

Operating Conditions and Operational Features of the Electro-hydraulic Marine Knuckle Boom Crane

For a knuckle boom crane with folding telescopic boom installed on deck, two main operating positions are defined:

Electro-hydraulic Marine Knuckle Boom Crane with Folding Telescopic Boom in Stowed Position

Stowed position, in which the crane occupies minimum deck space;

Working position, in which boom luffing and telescoping are used to adjust the outreach and maximum hoisting height, while the hoisting winch is used for lifting and lowering the load.

Working Position of the Electro-hydraulic Marine Knuckle-Boom Crane with Folding Telescopic Boom

The hydraulic telescopic knuckle boom crane is designed to operate within an ambient temperature range from –25°C to +50°C and under wind loads of up to 400 Pa. Cargo handling operations may be performed under a continuous heel of up to 5° to either side, trim by bow or stern of up to 2°, and at sea states up to Sea State 4. Operation is not adversely affected by fog, periodic seawater spray, or vessel-induced vibration.

In the stowed position, the electro-hydraulic knuckle boom crane with folding telescopic boom withstands ambient temperatures from –45°C to +50°C and wind loads of up to 2000 Pa, and remains operational after prolonged heel of up to 15° to either side or trim by bow or stern of up to 5°.

The Safe Working Load (SWL) of the crane depends on the sea state and the boom outreach at which cargo handling operations are performed.
On calm water, the SWL is:

  • 1,000 kg at a boom outreach from 1.5 to 5.0 m;
  • 600 kg at a boom outreach from 2.02 to 10.0 m.

At sea states up to Sea State 4, the SWL is de-rated to 625 kg and 280 kg, respectively.

Cargo handling operations may be controlled by a single operator from either a fixed control station or a portable remote control pendant. When the portable control pendant is in use, simultaneous control from the fixed control station is disabled, except for the emergency stop function.

Preparation for operation includes inspection of all critical assemblies of the telescopic knuckle boom crane, verification of system readiness, and confirmation that no personnel are present within the working area. After releasing the hook block from its stowed securing arrangement, energizing the crane, and checking all electro-hydraulic systems, cargo handling operations may commence. Upon completion of operations, power is switched off, the crane is returned to the stowed position, and the hook block is secured by a bolted connection.

In emergency situations, such as loss of electrical power supply or failure of the control system during cargo handling operations, provisions are made for manual completion of the working cycle. In this case, an assistant operates a manual hydraulic pump supplying the working fluid, while control is carried out via the directional control valves at the fixed control station.

During cargo handling operations, all boom movements may be performed sequentially at maximum speeds, or simultaneously in permitted combinations, with a corresponding reduction in operating speed.

Technical Specifications of the Electro-hydraulic Marine Knuckle Boom Crane with Folding Telescopic Boom

Telescopic Boom of the Electro-hydraulic Marine Knuckle Boom Crane
  • Hook outreach: 1.5 to 10.3 m
  • Maximum hoisting height: 11 m
  • Maximum lowering: 35 m
  • Hoisting / lowering speed: ≥ 18 m/min
  • Slewing speed (no load): ≥ 1 rpm
  • Slewing angle: 360° (continuous)
  • Crane weight: 2300 kg
  • Hydraulic system working pressure: ≤ 28 MPa
  • Working fluid: AUP hydraulic oil, TU 38.1011258-89
  • Power consumption: ≤ 22 kW
  • Electrical power supply: 3-phase / 380 V / 50 Hz

General Arrangement and Design of the Electro-hydraulic Knuckle Boom Crane with Folding Telescopic Boom

  1. Structure housing;
  2. Slewing system;
  3. Slewing drive;
  4. Column;
  5. Luffing section;
  6. Telescopic boom;
  7. Hoisting winch;
  8. Hook block;
  9. Luffing hydraulic cylinder;
  10. Slewing hydraulic cylinder;
  11. Hydraulic cylinders for telescopic boom extension.
General Arrangement and Design of the Electro-hydraulic Marine Knuckle Boom Crane with Folding Telescopic Boom

When installing the marine telescopic knuckle boom crane on deck, the welded base of the structure housing is welded to the vessel foundation. The slewing system together with the slewing drive is then mounted onto the base.

The control cabinet, installed on the front wall of the frame, houses the electrical and hydraulic control equipment, operating controls for working motions, and indication devices. External elements include power supply connection points, connectors for the portable remote control pendant cable, and the main power isolator switch. The fixed control station is installed on deck in close proximity to the knuckle boom crane.

A column rotating about its vertical axis is mounted on the slewing system. The luffing section and the luffing hydraulic cylinder are articulated to the column, connecting the structure housing with the telescopic boom. These components enable folding of the crane boom into the stowed position, as well as adjustment of the boom outreach and maximum hoisting height.

The telescopic boom, used to vary outreach and hoisting height, is a mechanical assembly consisting of four individual welded sections and three hydraulic cylinders for extension and retraction. A winch mounting bracket is installed on the fixed telescopic section, while the outermost movable section is fitted with a wire rope sheave and the hook block.

The marine deck electro-hydraulic knuckle boom crane with folding telescopic boom is equipped with five drive systems:

  • Crane slewing drive;
  • Boom luffing drive;
  • Telescopic boom lifting drive;
  • Telescopic boom extension drive;
  • Hoisting winch drive.

Operational Safety of the Deck Electro-hydraulic Knuckle Boom Crane

Safe operation of the marine deck knuckle boom crane with folding telescopic boom is ensured by its design features, as well as by strict compliance with the requirements specified in the Operation and Maintenance Manual. For example, a minimum clearance of not less than 1 m shall be maintained between the load and any obstacle, and during crane movements the hook shall be kept at least 2 m above obstacles.

During operation of the electro-hydraulic marine knuckle boom crane with folding telescopic boom, the following structural and electrical protection and safety interlock functions are provided:

  • Protection against overloads, short-circuit current, and leakage current;
  • Interlocking of simultaneous control from the fixed control station and the portable remote control pendant;
  • Overload protection, preventing lifting of loads exceeding 10% above the rated load in calm water conditions and 25% above the rated load at Sea States 2–4;
  • Automatic load de-rating when boom outreach exceeds 5 m;
  • Upper and lower limit protection of the hook block during winch rope pay-out and reeling-in;
  • Limitation of the crane slewing angle to prevent damage to electrical cables and hydraulic piping;
  • Power supply and drive activation inhibition after actuation of any emergency stop push-button or upon detection of a control system fault.

Documentation and Warranty

As, in the stowed position, the electro-hydraulic knuckle boom crane with folding telescopic boom occupies minimal volume when fully folded, it is supplied fully assembled to facilitate on-site installation and minimize transportation costs. Spare parts included in the spares and tools set, as well as certain components, are securely packed in crates to ensure their integrity during transportation. The scope of supply also includes a complete set of accompanying documentation, including the Installation and Operation Manual and the Product Data Sheet.

To ensure safe and efficient operation of the marine electro-hydraulic knuckle boom crane, the manufacturer, Izhora Hydrosystems LLC, has developed a comprehensive set of technical documentation containing all necessary information on the crane design, operating principles, technical characteristics, and measures to ensure operational safety and reliability.

Subject to strict compliance with the requirements for maintenance, routine repair, and operation of the marine electro-hydraulic knuckle boom crane with folding telescopic boom, Izhora Hydrosystems LLC guarantees operation of the equipment until major overhaul for a period of 10000 operating hours or 13 years, whichever occurs first.

For consultation or to place an order for an electro-hydraulic knuckle boom crane with folding telescopic boom, please contact our sales team:
Phone: +7 (812) 339-61-68
E-mail: contact@i-hydro.ru