100 Ton Lifting Hoist Portable Gantry Crane

 

100 Ton Portable Gantry Crane with Lifting Hoist – Introduction

The 100-ton portable gantry crane with lifting hoist is a robust and versatile material handling solution designed for lifting and transporting extremely heavy loads in various industrial settings. Engineered for strength, mobility, and efficiency, this high-capacity gantry crane is ideal for operations such as shipbuilding, heavy machinery maintenance, wind turbine assembly, and steel fabrication.

Key Features:

Lifting Capacity: 100 tons, suitable for extremely heavy-duty operations.

Portable Design: Despite its massive capacity, the crane features a modular and mobile structure, allowing for relocation and reassembly at different job sites.

Adjustable Height and Span: Customizable configurations to suit varying work environments and load dimensions.

Electric or Hydraulic Hoist: Equipped with a high-performance hoisting system for smooth and safe lifting operations.

Steel Construction: Built with high-grade steel for durability and resistance to mechanical stress and environmental conditions.

Safety Systems: Includes overload protection, emergency stop systems, and advanced control features for safe and efficient use.

Applications:

Heavy equipment manufacturing

Aerospace and shipyard operations

Infrastructure and construction projects

Renewable energy installations (e.g., wind turbine assembly)

Whether for indoor or outdoor use, the 100-ton portable gantry crane provides a balance of mobility and lifting power, offering a dependable solution where fixed cranes are impractical or unavailable.

 

Core Components：Bearing, Gear, Gearbox, Motor

Place of Origin：Henan, China

Warranty：1 Year

Weight (KG)：2000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Keywords：gantry crane

Color: Customized

Size: Customized

Design: computer optimization design

Safety: High flexible flat cable power

Application: construction industrial,workshop,warehouse

Working class: A3-A8

Certification: ISO,CE,BV,S GS,TUV

Power Source: 380~480V,customized

 

 

1.Main Beam (Girder)

The primary horizontal structure supporting the hoist and load.

Designed to handle high stress and prevent deformation under heavy loads.

Often fabricated from high-tensile steel and may be a single or double box girder.

Legs (Support Columns)

Vertical structures that support the main beam and connect it to the base or wheel assemblies.

May be fixed-height or telescopic for height adjustability.

 

Hoist (Lifting Mechanism)

Central lifting device that moves vertically to raise or lower loads.

Typically electric or hydraulic-powered with a high-capacity motor and gearbox system.

Comes with hook blocks, wire ropes or chains, limit switches, and overload protection.

Trolley (Cross Travel Mechanism)

Mounted on the main beam and carries the hoist horizontally across the crane span.

Electrically powered for smooth side-to-side movement.

 

3.End Carriages

Located at the base of each leg, housing the wheels or track systems for crane movement.

Support load transfer between the legs and the floor or ground.

 

 

4.Crane travelling mechanism

1) Working principle

The traveling mechanism is powered by electric motors connected to gearboxes, which provide the torque necessary for movement.

Drive wheels are mounted on the legs of the crane. These wheels roll along the rails on the ground or on elevated tracks, depending on the crane design.The wheels are typically driven by electrical motors through a system of reduction gears that adjust the speed and torque for smooth and controlled movement.

2) Functions of the crane operating mechanism

Movement along the Rails:The primary function of the traveling mechanism is to move the gantry crane along the crane rails installed on the ground or structure. This allows the crane to cover the entire working area, moving materials and loads from one point to another.

Support for the Gantry Structure:The traveling mechanism supports the entire gantry structure, which includes the main beam and cantilever. This support ensures stability and the safe operation of the crane during movement.

Lifting Load:As the gantry crane moves, the traveling mechanism facilitates the movement of loads horizontally, providing an effective means for lifting and transporting heavy materials across the working area.

Adjustable Speed and Positioning:It provides the ability to control the speed and positioning of the crane, which is crucial for precision in handling materials and ensuring safe operations.

Integration with Other Mechanisms:The crane traveling mechanism works in coordination with other components such as the hoisting mechanism and trolley system to enable efficient lifting and movement of loads.

Safe Operation and Stability:The traveling mechanism ensures smooth, safe movement of the crane along the rails, minimizing risks associated with jerky or unstable movement that could damage equipment or compromise safety.

Powered by Motors:The mechanism is typically powered by electric motors or hydraulic systems that provide the necessary power for movement. These motors are designed to offer reliable operation under heavy loads.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The frame is the main structural support of the trolley, providing the necessary rigidity and strength to bear the load.It is typically made of high-strength steel to ensure durability and resistance to deformation under heavy loads.

Wheel set: The wheels are often mounted on axles, and the bearings inside these wheels are designed for high load-bearing capacity and smooth operation.

Electric Drive Motor: The trolley's movement is powered by an electric motor, which drives the wheel system via a gearbox and a system of pulleys or chains.The motor is typically installed on the trolley frame and is connected to the wheels through a drive mechanism, allowing for both forward and backward motion.

2) Function of the trolley operating mechanism

1. Horizontal Movement of the Hoist

The trolley, which carries the hoisting mechanism, moves horizontally along the gantry rail. This horizontal movement enables the crane to lift and lower materials over a large area, such as a yard, dock, or warehouse.

2. Smooth and Precise Positioning

The trolley traveling mechanism is designed for precise control of the trolley's position. This is critical for ensuring that loads are picked up and placed accurately at the desired locations.

3. Support for the Hoisting Mechanism

The hoist system is typically mounted on the trolley. The trolley traveling mechanism allows the hoist to traverse the length of the gantry, ensuring that the lifting equipment can cover the full area needed for operations.

4. Load Distribution and Stability

The trolley helps distribute the load evenly across the crane's structure. As the trolley moves, the load is kept stable, reducing the risk of imbalance that could lead to accidents.

5. Speed Control

The trolley traveling mechanism includes motors, gears, and sometimes variable frequency drives (VFDs), which provide the necessary speed control for the trolley's movement. This helps in adapting to different operational needs, whether moving slowly for precision or quickly for efficiency.

6. Integration with Other Crane Movements

The trolley traveling mechanism is integrated with the gantry's vertical (hoisting) and longitudinal (gantry traveling) movements. It works in coordination with these functions to ensure smooth and synchronized operation, making it easier to perform complex lifts and transfers of materials.

7. Safety and Load Handling

The mechanism often includes safety features, such as limit switches or sensors, to prevent the trolley from exceeding its operational boundaries or colliding with obstacles, enhancing the safety of the entire crane operation.

6.Crane wheel

1) Function of wheels

The wheels provide support for the crane structure and are essential for allowing the gantry crane to travel along its track.They also absorb the forces generated by the crane's weight and operational movements, distributing these forces to prevent damage to the track and other crane components.

Depending on the crane's purpose and the loads it handles, the wheels are engineered to handle different weight capacities. Larger cranes or those used for heavier lifting will have larger, more robust wheels.

2) Design requirements

Crane wheels are typically made of high-strength steel or alloy materials to withstand the weight of the crane and its load while enduring constant motion and heavy loads.The wheels are often designed with a flange to ensure smooth and stable movement along the rails and to prevent them from derailing.

7.Crane Hook

The crane hook of a cantilever gantry crane is an essential component in the lifting and handling process. This hook is used to attach and support loads during hoisting operations.

The hook is typically made of high-strength steel to handle heavy loads. It has a curved shape, with a deep throat for secure attachment to slings, chains, or other lifting devices.The hook usually has a safety latch to prevent the load from accidentally coming loose during operation.

The primary function of the crane hook is to connect the crane's lifting mechanism (such as the hoist) with the load. It moves along the gantry crane's beam (which is supported by the legs of the gantry structure) and can be raised or lowered depending on the lifting requirements.

Power Supply System

May include cable reels, conductor bars, or festoon systems.

Supplies power to the hoist, trolley, and drive systems.

 

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Sound and light alarm system & limit switch

1) Sound and light alarm system

The sound and light alarm system for a Cantilever Gantry Crane is designed to enhance safety by providing visual and audible signals in case of abnormal conditions or hazards. These alarms help warn operators, workers, and personnel in the vicinity of potential risks.

Sound Alarm (Horn or Siren):Purpose: Alerts personnel to an emergency or abnormal situation.Sound: Typically loud and attention-grabbing, such as a siren or a horn with varying patterns (continuous, intermittent, or pulsed) to signal different types of alerts.Placement: Usually installed at the crane's control cabin, near the gantry, or at strategic locations where workers are most likely to be present.

Light Alarm (Strobe Light or Flashing Beacon):Purpose: Provides a visual alert that can be seen in areas where sound alone might not be effective (e.g., in noisy environments or at a distance).Light Type: Flashing or rotating strobe lights or beacons are commonly used, often with different colors to indicate different warning levels.

Red: Critical alarm (dangerous situation).

Yellow/Amber: Caution (warning or a non-urgent issue).

Blue: May indicate operational status or a different specific condition.

2) Limit switch

A limit switch on a cantilever gantry crane is a safety device used to prevent the crane from over-traveling or moving beyond its predefined limits. It is an essential component for ensuring the proper and safe operation of the crane. The cantilever gantry crane typically consists of a large structure with a bridge and hoisting mechanism, which is often used in industrial environments like ports or warehouses for lifting and moving heavy loads.

Function of the Limit Switch:

Position Detection: The limit switch detects when the crane's hoist or trolley has reached its designated end position (either fully raised, lowered, or moved along the track). This helps prevent mechanical damage caused by over-travel.

Safety: It acts as a fail-safe to stop the crane from moving if it reaches its boundary. This reduces the risk of accidents and protects both the crane and surrounding equipment.

Automation: Limit switches can be connected to the crane's control system. When the limit switch is triggered, it sends a signal to the control system to stop the crane or reverse its direction.

Types of Limit Switches for Gantry Cranes:

Mechanical Limit Switch: This type uses a physical actuator to open or close contacts when the crane reaches a limit. It is a commonly used, simple, and cost-effective solution.

Magnetic Limit Switch: These use magnetic fields to detect the position of a target without direct contact, providing a more durable and longer-lasting solution.

Proximity Limit Switch: It detects the presence of a target without contact, using a sensor, and is often used in more advanced or higher-speed applications.

10.Safety Devices

1) 1. Overload Protection Device

Prevents the crane from lifting loads exceeding its rated capacity.

Activates an alarm or cuts off power to the lifting mechanism when the load exceeds safe limits.

2. Limit Switches

Hoisting Limit Switch: Stops the lifting mechanism when the hook reaches its upper or lower limit to prevent over-hoisting or over-lowering.

Travel Limit Switch: Restricts the horizontal movement of the crane or trolley to avoid collisions or derailments.

Boom Angle Limit Switch (if applicable): Ensures the boom does not exceed safe angular limits.

3. Emergency Stop Button

Allows operators to instantly halt crane operations in case of an emergency.

Usually installed in multiple accessible locations on the crane and remote controls.

4. Anti-Collision Devices

Uses sensors (proximity sensors or lasers) to detect obstacles or other equipment in the crane's path, preventing collisions.

May include audible alarms or automatic braking systems.

5. Wind Speed Monitoring System

Monitors wind speed and issues alerts when it exceeds safe levels for operation.

Some systems automatically lock the crane or anchor it during high winds.

6. Braking System

Mechanical Brakes: Ensures the load remains stationary when not in motion.

Emergency Braking System: Activates during power failure or system malfunction.

7. Rail Clamp or Storm Lock

Locks the crane in position during storms or high winds to prevent movement.

8. Buffer System

Installed at the end of the crane's travel path to absorb impact and reduce damage during accidental over-travel.

9. Load Moment Indicator (LMI)

Monitors the load moment and alerts the operator if the crane approaches its tipping point.

10. Safety Interlocks

Ensures specific operations, such as lifting, trolley movement, or boom adjustment, cannot be performed simultaneously in an unsafe manner.

11. Audible and Visual Warning Systems

Alarms: Alert nearby personnel during crane operation or in the event of a fault.

Signal Lights: Indicate the crane's operational status.

12. Wire Rope Inspection and Safety Features

Rope Overwind Protection: Prevents the wire rope from being wound improperly, which could lead to accidents.

Rope Break Detection: Detects breakage or slack in the wire rope and halts the operation.

13. Operator Cabin Safety Features

Ergonomically designed controls to minimize operator fatigue.

Fire extinguishers and other emergency equipment are typically available in the cabin.

14. Automatic Crane Monitoring System (Optional)

Monitors critical parameters such as load, speed, and temperature.

Records operational data and faults for maintenance and troubleshooting.

11.Control Mode

1)1. Manual Control

Description: Operators manually control the crane using push-button pendants, levers, or control panels directly on-site.

Features:

Simple to use and maintain.

Suitable for less complex lifting tasks.

Applications: Used in smaller-scale operations or locations with low automation requirements.

2. Remote Control

Description: Operators use a wireless remote control device to operate the crane from a safe distance.

Features:

Improved safety by allowing the operator to stay clear of the load.

Greater operational flexibility.

Can handle more complex movements.

Applications: Warehousing, logistics yards, and other environments requiring higher precision.

3. Cabin Control

Description: The operator sits in a cabin attached to the crane and controls operations using joysticks or control panels.

Features:

Provides the operator with a clear view of the load and working area.

Suitable for heavy-duty and long-duration operations.

Applications: Large-scale industrial sites, such as shipyards, steel mills, or construction sites.

4. Semi-Automatic Control

Description: Some operations (like repetitive movements) are automated, while others require manual input.

Features:

Reduces operator workload.

Increases efficiency for repetitive tasks.

Applications: Assembly lines, logistics hubs, and tasks involving repeated lifting and positioning.

5. Fully Automatic Control

Description: The crane operates autonomously based on pre-programmed instructions or sensor inputs.

Features:

High precision and efficiency.

Eliminates human error and reduces labor costs.

Often integrated with smart systems or IoT for monitoring and data analysis.

Applications: Ports, automated warehouses, and environments requiring high-speed, precise operations.

6. Hybrid Control (Manual + Automatic)

Description: Combines manual and automatic control options, allowing flexibility based on task requirements.

Features:

Adaptable to varying operational needs.

Enhances efficiency without sacrificing control.

Applications: Sites that require both human supervision and automation.

12.Sketch

 

Main technical

 

 

Here's a clear and professional breakdown of the advantages of a 100-ton portable gantry crane with lifting hoist:

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Advantages of a 100 Ton Portable Gantry Crane with Lifting Hoist

High Lifting Capacity

Capable of lifting extremely heavy loads (up to 100 tons), making it ideal for heavy-duty industrial applications.

Portability & Mobility

Unlike fixed cranes, this gantry crane can be moved and relocated across different job sites or within a facility, reducing the need for multiple lifting systems.

Flexible Installation

Does not require permanent foundations or rail systems, making setup quicker and more cost-effective-especially for temporary or changing work environments.

Versatile Applications

Suitable for a wide range of industries including shipbuilding, heavy manufacturing, construction, power generation, and aerospace.

Customizable Design

Adjustable span and height options can be tailored to specific operational needs, increasing usability in diverse environments.

Reduced Operational Costs

Minimal infrastructure requirements and reusable design lower long-term investment and maintenance costs.

Enhanced Safety Features

Equipped with safety systems such as overload protection, emergency brakes, and limit switches to ensure safe lifting operations.

Ease of Operation

Controlled via pendant, remote control, or cabin, offering precise handling and reducing operator fatigue.

Heavy-Duty Construction

Engineered with high-strength steel and industrial-grade components to ensure durability and long service life under harsh working conditions.

Time-Saving

Speeds up loading, unloading, and assembly operations, boosting productivity on job sites.

 

 

 

1. Construction Industry

Lifting heavy construction materials like steel beams, concrete blocks, and other construction components.

Transporting and positioning materials at construction sites.

2. Manufacturing Facilities

Handling large components or machinery in production lines.

Moving raw materials or finished goods within the plant.

3. Shipyards and Ports

Loading and unloading containers or cargo from ships.

Transporting heavy ship components or maintenance equipment.

4. Warehousing and Logistics

Stacking and organizing goods in outdoor or indoor storage areas.

Loading and unloading trucks or railcars.

5. Aerospace and Aviation

Handling large aircraft components, such as fuselages, wings, or engines.

Supporting maintenance and assembly operations.

6. Railway Yards

Lifting and positioning railway components like tracks or bogies.

Loading and unloading railway cargo.

7. Steel Mills and Foundries

Moving heavy steel plates, coils, or castings.

Handling molten metal containers.

8. Mining and Heavy Industries

Transporting heavy equipment and materials in mining operations.

Handling large machinery for assembly or repair.

9. Power Plants

Installing or maintaining turbines, generators, and other heavy power equipment.

Transporting fuel or waste containers in nuclear or thermal plants.

Crane production procedure

1. Design and Engineering

Requirement Analysis

Understand the client's specifications (load capacity, span, height, working environment, etc.).

Determine operational parameters: lifting height, travel speed, working frequency, etc.

Preliminary Design

Create conceptual designs and 3D models.

Choose materials based on strength and environmental conditions.

Detailed Engineering

Develop detailed engineering drawings (structural components, mechanisms, electrical systems).

Perform stress and fatigue analysis to ensure safety.

2. Material Procurement

Source high-quality materials, including:

Steel plates and profiles for structural components.

Motors, gearboxes, and other mechanical parts.

Electrical systems and control components.

Inspect materials to ensure compliance with quality standards.

3. Fabrication

Structural Component Fabrication

Cut, weld, and assemble the steel structures (main girder, cantilever arms, legs, etc.).

Ensure precise alignment and dimensions.

Perform surface treatment (e.g., shot blasting, painting) for corrosion protection.

Mechanical Assembly

Assemble mechanical parts (trolley, hoist, wheels, etc.).

Install motors, gearboxes, and drive systems.

Electrical Assembly

Install electrical components (control panels, cables, sensors).

Wire and connect the system to ensure functionality.

4. Quality Inspection

Material Inspection

Verify material certification and conduct tests (e.g., tensile tests).

Structural Inspection

Inspect weld quality (e.g., ultrasonic testing).

Ensure dimensional accuracy and surface finishing.

Assembly Inspection

Check alignment and functionality of all parts (mechanical and electrical).

Load Testing

Conduct static and dynamic load tests to ensure safe operation.

5. Factory Acceptance Testing (FAT)

Conduct a comprehensive trial run, including:

Full load and overload tests.

Functionality of all safety devices (e.g., limit switches, emergency brakes).

Smooth operation of trolley, hoist, and crane travel.

Document results and obtain client approval.

6. Disassembly and Packing

Disassemble the crane into transportable sections.

Pack components securely to prevent damage during transportation.

Label and prepare a packing list for efficient reassembly.

7. Transportation

Deliver the crane components to the installation site using appropriate transportation methods.

8. Installation and Commissioning

On-Site Assembly

Assemble structural components and mechanical systems.

Install electrical systems and control panels.

Calibration and Testing

Recalibrate the crane system for site-specific conditions.

Perform on-site load testing to verify performance.

9. Handover

Provide training to the client's personnel on safe operation and maintenance.

Deliver technical documentation (user manual, maintenance guide, certificates).

Obtain final approval and acceptance from the client.

10. After-Sales Support

Offer warranty services and maintenance support.

Provide spare parts and technical assistance as needed.

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%.