100 Ton Double Beam Gantry Crane

A 100 Ton Double Beam Gantry Crane is a heavy-duty lifting machine designed for handling extremely large and heavy loads in open yards, industrial zones, shipyards, rail yards, and construction sites. Built with two main girders supported by vertical legs that move along ground-mounted rails, this crane combines high lifting capacity, structural stability, and versatile operation.

Unlike overhead cranes, a gantry crane does not require a runway structure and is ideal for outdoor or semi-outdoor environments. The 100-ton capacity allows it to handle massive objects such as precast concrete sections, steel components, large machinery, or containers with ease.

Key Characteristics:

Lifting Capacity: 100 tons (customizable based on specific needs)

Structure: Double box-type or truss-type girders with robust steel legs

Span & Height: Adjustable according to site requirements

Operation: Electric drive system with optional wireless remote or cab control

Lifting Mechanism: Hoist or winch trolley running between the girders

Typical Design Options:

Rail-mounted or rubber-tyred gantry crane versions

Single or double trolley for better load distribution

Equipped with overload protection, anti-collision systems, and wind-proof locking devices

Optional maintenance platforms, lighting systems, and environmental protection covers

Use Cases:

Shipbuilding yards – lifting hull blocks or engines

Steel factories – moving steel plates, coils, beams

Railway yards – loading and unloading rail equipment

Precast concrete yards – handling massive panels or girders

Heavy equipment manufacturing – lifting oversized mechanical components

Core Components：Gearbox, Motor

Place of Origin：Henan, China

Warranty：2 years

Weight (KG)：22600 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Application：Widely

cantilever length：0-15m

Trolley running speed：20-40M/MIN

Working system：A5-A7

Lifting speed：5-15M/MIN

Crane running speed：30-50M/MIN

Control method：cabin control/wire rope remote control

Color：Request

1.Double Main Girders

Two heavy-duty box-type or truss-type beams run parallel across the span of the crane.

Made from high-strength low-alloy steel for durability and minimal deflection.

Serve as the track for the trolley and hoist.

Gantry Legs (Supporting Frame)

Vertical box-type or A-frame legs connect the girders to the ground-level end carriages.

Support the crane's weight and the load being lifted.

Designed to handle high axial and lateral loads with structural integrity.

Trolley with Hoist

Mounted between the double girders and moves horizontally across them.

Contains the lifting hoist, driven by powerful electric motors and gearboxes.

May feature:

Wire rope drum

Hooks or lifting beams

Brake systems

For 100-ton capacity, dual hoists or dual trolleys may be used for better load balance and safety.

3.End Carriages

Located at the base of each leg and house the wheel assemblies.

Allow the crane to travel along ground rails.

Contain drive motors and geared mechanisms for smooth and synchronized crane movement.

4.Crane travelling mechanism

1) Working principle

The crane is powered by an electric motor, which can be single or three-phase, depending on the crane's design and power requirements.The motor's power is transmitted to the wheels through a gearbox or transmission, causing the wheels to rotate.The wheels, often fitted with flanges, ensure that the crane stays aligned on the track, preventing derailment and enabling smooth movement.The crane is equipped with brakes that can be activated to stop the crane safely at any point on the track. These can be electromagnetic or mechanical brakes that engage when the motor is turned off.The operator controls the crane's travel through a control panel, which may include push buttons, joysticks, or a remote control. The system allows for forward, reverse, and emergency stopping.

2) Functions of the crane operating mechanism

1. Horizontal Movement

Function: The crane travelling mechanism allows the gantry crane to move laterally across the indoor space, positioning the hoist and trolley system over the desired work area.

Importance: This movement is essential for reaching different locations within the crane's operating area to lift, carry, and place loads as needed.

2. Load Transportation

Function: It facilitates the transportation of loads across the workspace, enabling the crane to transfer heavy materials from one point to another efficiently.

Importance: This is critical in manufacturing, shipping, and warehouses, where materials need to be moved to specific stations or storage areas.

3. Precision and Accuracy

Function: The travelling mechanism must be designed to provide smooth and precise movement, ensuring that loads are accurately positioned for lifting or dropping.

Importance: High precision reduces the risk of accidents, minimizes load swinging, and enhances productivity by enabling precise load placement.

4. Safety and Stability

Function: The crane's travel mechanism includes safety features such as limit switches, brakes, and sensors to monitor movement and stop the crane if it moves beyond safe limits.

Importance: These safety mechanisms are crucial to protect both the crane and the operators from potential hazards during operation.

5.Trolley travelling mechanism

1) Structural composition

1. Trolley Frame

Main Body: The main structural framework that supports all other components. It is usually made of steel or other heavy-duty metals to bear the load.

Brackets and Cross Members: Reinforce the structure and provide additional stability.

2. Travel Wheels and Axles

Travel Wheels: Mounted on the trolley frame, these wheels move along the rail system of the crane bridge.

Axles: Connect the travel wheels and allow them to rotate smoothly while supporting the load.

3. Drive Mechanism

Electric Motor: The primary power source that drives the wheels.

Gearbox and Transmission: Transfers power from the motor to the wheels, enabling movement. Some systems may use a direct drive, while others utilize a chain, belt, or gear train.

Brake System: Ensures safe stopping and holding of the trolley when stationary. It can be mechanical, electromagnetic, or hydraulic.

4. Track and Rail System

Rails on the Bridge: The surface on which the trolley wheels travel. These are often mounted on the top or bottom of the crane bridge.

Rail Supports: Secure the rails and maintain alignment over the entire length of the crane.

5. Electrical and Control Systems

Wiring and Cable System: Supplies power from the crane's power source to the motor, brake, and control units.

Control Panel: Interface for the operator to control the movement of the trolley.

Limit Switches and Sensors: Used to monitor the position and travel limits of the trolley to prevent over-travel and collisions.

6. Load Handling Mechanism

Hoist or Lifting Device: Typically mounted on the trolley to handle the load.

Hoist Frame and Hooks: The part that interfaces directly with the load.

Wire Rope or Chain: Used for lifting and lowering the load.

7. Structural Reinforcements and Supports

Side Plates and Stiffeners: Added to strengthen the trolley frame and minimize deflection or twisting.

Support Brackets: Reinforce attachment points for components like the motor and gearbox.

2) Function of the trolley operating mechanism

1. Horizontal Movement

The trolley moves along the crane's beam, enabling it to transport the hoist and payload to different locations within the crane's working span.

This allows the crane to cover a wide area in a workshop, warehouse, or manufacturing facility.

2. Load Transportation

The trolley carries the hoist and lifting equipment, which are essential for lifting and lowering loads.

It moves the hoist in a way that ensures the load can be positioned accurately over the desired area for lifting, lowering, or placing.

3. Flexibility and Efficiency

By enabling the trolley to travel along the crane's span, the mechanism improves the overall efficiency of lifting operations. This allows workers to transport goods quickly and safely across the width of the work area.

The system typically incorporates a motor-driven mechanism for smooth and controlled movement.

4. Drive System and Components

The trolley travelling mechanism usually consists of a drive unit, which can be electric or sometimes manual, depending on the crane design.

Wheels or rollers mounted on the trolley allow it to move along the rail or beam with minimal friction.

Motors and gears are commonly used to drive the trolley, providing controlled acceleration and deceleration to avoid sudden movements that could potentially damage equipment or pose safety risks.

5. Safety and Control

Advanced trolley travelling mechanisms include safety features like limit switches, which stop the trolley at the end of its travel path to prevent it from running off the track.

Modern systems may also have sensors or automated control mechanisms that enhance safety by detecting obstructions and automatically stopping or slowing down the movement.

6. Coordination with Other Crane Movements

The trolley's movement is coordinated with the hoisting mechanism and crane girder movement (if applicable) for efficient, three-dimensional operation (i.e., up/down, forward/backward, and side-to-side movements).

6.Crane wheel

1) Function of wheels

The crane wheels are designed to support the load of the gantry crane structure and facilitate its smooth movement across the rails. They play a crucial role in ensuring that the crane operates with stability and precision.

2) Design requirements

The wheels usually have a flange on the side to keep them on the rail, preventing derailment. Some wheels are designed with a tapered profile to accommodate wear and maintain stability over time.These wheels are typically made from high-strength materials such as forged steel or cast steel to handle the heavy loads and stresses encountered during operation. The surface may be hardened or treated to improve wear resistance and durability.

7.Crane Hook

1)A crane hook used in an indoor gantry crane is an essential component designed for lifting and carrying loads.The crane hook is attached to the hoist mechanism of the gantry crane, allowing it to lift and move heavy items.It typically features a sturdy, high-strength steel construction capable of supporting the maximum load capacity of the crane.Most crane hooks are designed with a safety latch or mechanism to secure the load during lifting and prevent accidental dislodging.

2) Specifications:

Load Capacity: Varies according to the crane's design, from several hundred kilograms to tens of tons.

Material: Typically forged or cast steel with high tensile strength to resist bending and breaking.

Safety Features: Latches or safety hooks are incorporated to prevent accidental release, and may include features like locking pins or manual/automatic mechanisms..

Motor

1) The motor of an indoor gantry crane is a crucial component for its operation. It provides the necessary power to move the crane's hoist, trolley, and bridge along their respective tracks. The choice of motor depends on several factors, including the crane's load capacity, speed requirements, and application specifics..

2) The motor should be powerful enough to handle the crane's maximum load and provide adequate torque for lifting and horizontal movement.Common power ratings range from a few kilowatts (kW) to several hundred kW, depending on the crane's size and capacity.Motors typically come with built-in braking systems to ensure safety during lifting and to prevent the load from dropping when power is cut.Electromagnetic brakes or mechanical brakes are often used to secure the motor when it stops.

3) Motors can be fitted with variable frequency drives (VFDs) to enable adjustable speed control. This is useful for fine-tuning lifting operations and ensuring smooth starts and stops.For precise movements, some gantry cranes use dual-speed motors, allowing for both low and high-speed operation.The motor should be designed for durability, with sealed bearings and minimal maintenance requirements to reduce operational downtime.

Regular inspection and maintenance are essential to prolong the life of the motor and avoid costly failures.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

A sound and light alarm system for an indoor gantry crane is designed to enhance safety by providing visual and audible warnings to operators and personnel in the vicinity. This system helps prevent accidents by alerting people when the crane is in use or approaching critical points of operation.

Sound Alarm (Horn or Siren):Types: Electric horns, sirens, or buzzers.Purpose: To provide an audible warning when the crane is operating, moving, or approaching a hazardous area.

Volume: Must be loud enough to be heard over ambient noise in the workspace, but not so loud as to cause hearing damage or discomfort.

2) Limit switch

A limit switch on an indoor gantry crane is a safety device that is used to control and restrict the movement of the crane's hoist, trolley, or bridge. It ensures that the crane operates within designated safe boundaries and prevents over-travel that could damage the equipment, cause operational malfunctions, or pose safety risks to personnel and other equipment in the area.

Key Functions of a Limit Switch on an Indoor Gantry Crane:

Over-Travel Protection: Stops the crane's movement when it reaches its maximum allowable travel limits, preventing the crane from moving past its design boundaries.

Position Feedback: Provides feedback to the control system to indicate the current position of the crane's components, such as the hoist or trolley.

Emergency Cutoff: Acts as an emergency stop to shut down the movement if any malfunction occurs, helping prevent accidents and damage.

10.Safety Devices

1) 1. Overload Protection

Overload Limiters: These devices prevent the crane from lifting weights that exceed its rated capacity, ensuring that the crane operates within safe limits.

Load Cells: Installed to monitor and measure the weight of the load being lifted and trigger alarms or shutdowns when an overload is detected.

2. Emergency Stop Button

Emergency Stop Switch: Provides a quick way to halt the crane's movement in case of an emergency, preventing potential accidents and damage.

3. Anti-Collision Systems

Bumper Sensors: These sensors detect nearby objects or structures and activate a braking mechanism to avoid collisions.

Proximity Sensors: Help detect if the crane is approaching a dangerous area and prevent movement when it's unsafe.

4. Limit Switches

End-of-Travel Limit Switches: Automatically stop the crane when it reaches the end of its track to prevent damage to the crane or surrounding structures.

Height Limit Switches: Ensure the hook or hoist does not move beyond a predetermined height, protecting against lifting items too high.

5. Signal and Warning Systems

Warning Lights: Alert nearby personnel when the crane is in operation.

Audible Alarms: Produce sounds to indicate when the crane is moving or approaching an area that requires caution.

Horn and Bell Systems: Used for signaling operators and nearby workers of the crane's movements.

6. Remote Control and Safety Locks

Wireless Remote Controls: Allow operators to control the crane from a safe distance.

Safety Lock Mechanisms: Ensure the crane cannot be operated unintentionally or by unauthorized personnel.

7. Anti-Sway Devices

Sway Prevention Systems: Minimize load swinging by using dampers or control algorithms that stabilize the load during movement.

8. Brake Systems

Emergency Brakes: Automatically activate in the event of a power failure or when a sudden stop is needed.

Manual Brakes: Used for additional control when stopping or securing the crane during non-operation periods.

11.Control Mode

1)1. Manual Control Mode

Description: Operated by a crane operator using a handheld pendant or joystick.

Features: The operator has direct control over the crane's movement, including the hoist, trolley, and gantry movement.

Use Case: Suitable for tasks that require detailed handling and adjustments, such as lifting or moving delicate items.

2. Remote Control Mode

Description: Allows the operator to control the crane using a wireless remote control.

Features: Enhances mobility for the operator, enabling them to manage the crane from a distance.

Use Case: Useful for improving safety and efficiency in environments where the operator needs to move around the crane's area.

3. Automatic Control Mode

Description: The crane operates autonomously based on pre-programmed settings or commands.

Features: Includes the use of sensors, cameras, and software that guide the crane through its tasks with minimal human input.

Use Case: Ideal for high-precision operations or repetitive tasks where the same movements are required consistently.

4. Semi-Automatic Control Mode

Description: Combines manual operation with automated functions.

Features: The operator can initiate or guide the crane but relies on automated systems for certain movements, like positioning or speed adjustments.

Use Case: Used when operators need assistance with repetitive tasks but still require oversight.

5. Joystick or Panel Control Mode

Description: Operated using a control panel or joystick that manages all crane functions.

Features: Offers more precise control over the crane's operations, often used in applications requiring complex or multi-directional movements.

Use Case: Common for cranes in areas where manual operation is preferred but requires more fine-tuned control.

12.Sketch

Main technical

1. Exceptional Lifting Capacity

Designed to lift up to 100 tons or more with ease.

Suitable for handling oversized and ultra-heavy components like steel structures, precast elements, and machinery.

✅ 2. Superior Structural Strength and Stability

Double girder design distributes load stress evenly, minimizing deflection and improving durability.

Provides greater stability during lifting, especially for long or bulky items.

✅ 3. Wide Operational Coverage

Capable of covering large spans and high lifting heights, allowing access to a wide workspace.

Ideal for large yards, docks, and assembly areas where overhead support structures are not feasible.

✅ 4. Customizable Configuration

Supports multiple trolley/hoist arrangements, various spans, and different lifting heights.

Can be tailored to suit specific site layouts and operational requirements.

✅ 5. Efficient Material Handling

Equipped with electric or hydraulic hoists, variable frequency drives (VFD), and remote controls for smooth, precise movements.

Improves loading/unloading efficiency, especially in repetitive heavy-duty tasks.

✅ 6. Ground Rail Operation

Eliminates the need for complex building support structures.

Operates on ground-level rails, maximizing space utilization in open areas.

✅ 7. Enhanced Safety Features

Integrated with overload protection, emergency brakes, limit switches, and anti-collision systems.

Optional wind-proof locking, rail clamps, and anti-derailment devices for outdoor safety.

✅ 8. Weather-Resistant and Durable

Engineered for outdoor or semi-outdoor use.

Components are often treated with corrosion-resistant coatings, ensuring long service life in harsh environments.

✅ 9. Flexible Control Options

Offers multiple control modes:

Pendant

Wireless remote

Operator cabin

Improves operator safety and convenience, especially in high-risk environments.

✅ 10. Reduced Labor and Operating Costs

Automates heavy lifting tasks that would otherwise require multiple workers and lifting equipment.

Increases overall productivity and cost-efficiency over time.

1. Manufacturing and Assembly:

Production Facilities: Indoor gantry cranes facilitate the movement of heavy parts and components during production and assembly processes.

Assembly Lines: They can transport components between different sections of an assembly line efficiently, improving productivity.

2. Warehousing and Storage:

Stock Management: Used to move and organize heavy or bulky items within a warehouse, maximizing space and optimizing workflow.

Loading and Unloading: Gantry cranes assist in loading and unloading materials from trucks or storage areas.

3. Maintenance and Repair:

Heavy Equipment Servicing: In maintenance shops or service centers, they are used to lift and maneuver heavy machinery or parts for repairs.

Parts Handling: They assist in moving large parts, such as engines or mechanical assemblies, to and from maintenance areas.

4. Construction:

Building Projects: Ideal for indoor construction sites where lifting heavy building materials, equipment, or prefabricated sections is needed.

Storage of Materials: Help organize building materials and tools within a confined space.

5. Shipping and Packaging:

Production Line Support: In packaging facilities, indoor gantry cranes are used for moving heavy packages or containers to shipping areas.

Custom Handling: They can be configured to handle specific packages or products with specialized attachments.

6. Industrial Plants and Factories:

Heavy Industry: Common in plants dealing with steel, metals, machinery, or any heavy industrial products.

Quality Control and Inspection: Used to move large items to different areas for inspection or testing.

Crane production procedure

1.1. Design and Planning

Initial Design: Engineers create a design based on specifications, such as load capacity, span, lifting height, and usage environment.

Structural Analysis: Software tools and manual calculations are used to ensure the crane can handle the anticipated load and operating conditions.

Bill of Materials (BOM): A comprehensive list of all required materials is prepared to facilitate procurement and planning.

2. Material Preparation

Selection: Quality steel, typically low-carbon or alloy steel, is selected for the main structural components.

Cutting and Shaping: Materials are cut and shaped according to design specifications using CNC machines, laser cutters, or other precision tools.

3. Welding and Assembly

Frame Assembly: The main frame is welded together. This includes the gantry structure, cross beams, and end beams.

Reinforcements: Additional supports or stiffeners are welded as required to ensure stability.

Inspection: Welds are inspected visually and using non-destructive methods like ultrasonic or X-ray tests to check for defects.

4. Machining and Precision Work

Drilling and Tapping: Holes for bolts and other fasteners are drilled and tapped.

Grinding and Finishing: Any rough edges are smoothed to ensure safety and proper fit.

Precision Fitting: Components such as wheels, axles, and hoist mechanisms are assembled and tested for proper alignment and fit.

5. Installation of Electrical and Control Systems

Wiring: Electrical wiring is installed to power the hoist, motors, and control panels.

Control Systems: The crane's control system, including pendant controllers, remote controls, and safety interlocks, is mounted and integrated.

Testing: The electrical system is tested to ensure there are no faults and all components function correctly.

6. Lifting Mechanism and Hoist Installation

Hoist Assembly: The hoist is mounted onto the crane's main structure.

Drive System: The drive system, which includes motors and gearboxes, is installed and aligned.

Test Runs: Initial test runs are conducted to check the hoist's operation and ensure smooth movement without any anomalies.

7. Surface Treatment

Cleaning: The entire crane is cleaned of any debris or residue.

Painting/Coating: The crane is painted or coated with a protective layer to prevent rust and corrosion. This can include primers and top coats.

Curing: The coating is cured using heat if required, to enhance durability.

8. Final Assembly and Integration

Component Assembly: Final components like bumpers, limit switches, and safety features are attached.

System Integration: All parts, including the electrical and mechanical systems, are connected and double-checked for compatibility.

Calibration: The crane's control systems are calibrated for load balance and precision.

9. Testing and Quality Assurance

Static Load Testing: The crane is tested under a static load, which is usually its maximum rated capacity, to ensure it can handle the weight without issues.

Dynamic Load Testing: The crane is operated under dynamic conditions, lifting and moving loads to ensure smooth performance.

Safety Checks: Safety features, such as emergency stops and limit switches, are verified.

Final Inspection: The entire system undergoes a thorough inspection, including mechanical, electrical, and safety checks.

10. Documentation and Handover

Certification: The crane is certified to meet local and international safety standards.

Manuals and Documentation: User manuals, maintenance guides, and certificates of compliance are prepared.

Handover: The crane is formally handed over to the customer, including training on its use and maintenance.

11. Shipping and Installation

Disassembly (if needed): Parts are disassembled for transportation if the crane is too large.

Packing: Components are securely packed to prevent damage during transport.

On-Site Installation: The crane is assembled and installed at the client's location, with final checks performed to ensure it is ready for use.

This procedure ensures that indoor gantry cranes are manufactured to be safe, reliable, and meet the required performance specifications for industrial applications.

Workshop view:

The company has installed an intelligent equipment management platform, and has installed 310 sets (sets) of handling and welding robots. After the completion of the plan, there will be more than 500 sets (sets), and the equipment networking rate will reach 95%. 32 welding lines have been put into use, 50 are planned to be installed, and the automation rate of the entire product line has reached 85%.