100 Tons Double Beam Girder Gantry Crane Machine

 

. Overview

A 100-ton double beam gantry crane is an ultra-heavy-duty lifting system designed for industrial applications requiring extreme load capacities. This robust machine combines structural strength with precision control to handle massive loads safely and efficiently.

2. Key Specifications

Structural Parameters

Capacity: 100 metric tons (can be customized up to 500+ tons)

Span: 10-40 meters (adjustable based on application)

Lifting Height: 6-30 meters (customizable)

Work Duty: A5-A7 (heavy to severe service)

Ambient Temperature: -20°C to +50°C (special options available)

Performance Characteristics

Lifting Speed: 0.5-8 m/min (variable frequency control)

Trolley Travel Speed: 5-20 m/min

Gantry Travel Speed: 10-30 m/min

Positioning Accuracy: ±5mm (with anti-sway system)

 

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 Structural Components

A. Double Box Girders (Primary Load-Bearing Structure)

Material: High-tensile steel (Q345B/Q460C) with welded construction

Internal Reinforcements: Vertical/horizontal stiffeners to prevent buckling

Deflection Control: ≤1/800 of span under full load (per FEM/ISO standards)

Surface Treatment: Shot blasting + epoxy coating (300μm minimum)

B. End Carriages (Supporting Structure)

Welded Steel Construction: Box-type design with internal diaphragms

Wheel Assemblies:

Wheels: Forged 55Mn steel, heat-treated (HB 300-380)

Wheel Diameter: 800-1000mm (depending on load distribution)

Bearings: Spherical roller bearings (SKF/FAG) with automatic lubrication

Buffers: Hydraulic or spring-type (1500kJ+ energy absorption)

C. Cross Beams & Bracing

Diagonal Bracing: Reduces lateral torsion during travel

Anti-Walk Systems: Prevents girder skewing (for spans >30m)

 

Lifting Mechanism

A. Main Hoist (100-ton Capacity)

Motor: Dual 75kW AC motors (S1 duty, IP55 protection)

Gearbox: Hardened helical gears (service factor ≥1.5)

Wire Rope: 34mm diameter, 1960MPa grade (6x36WS+IWR construction)

Drum: Grooved design with 5+ dead wraps, rated for 100,000 cycles

Hook Block: Forged 100D hook with rotating sheave assembly

B. Trolley System

Frame: Welded steel with reinforced crossbeams

Travel Motors: 4x 7.5kW (frequency-controlled)

Wheel Load Distribution: ≤25 tons/wheel (with equalizing beams)

Guide Rollers: Nylon-coated to prevent girder flange wear

C. Auxiliary Hoist (Optional 20-ton)

Independent System: Separate trolley with 22kW motor

Use Case: Tooling handling or precision positioning

 

3.End carriage

1)The end carriage of a cantilever gantry crane is an essential component that supports the crane's movement along the runway or ground track. It is located at both ends of the main girder and connects the crane to its traveling system.

2) The end beam is made from high-strength steel for durability and load-bearing capacity.Designed to ensure stable movement of the crane, even under heavy loads.

3) Functions of the End Carriage:

Support:Carries the weight of the crane and its load.

Mobility:Facilitates longitudinal movement of the crane along the track or runway.

Stability:Ensures balanced operation, preventing tipping or unwanted movements during lifting.

Load Distribution:Distributes the load evenly across the wheels, protecting the crane's structure and minimizing stress on the track.

 

 

4.

Travel Drive System

A. Longitudinal Travel (Gantry Movement)

Drive Configuration: 4-corner motorized (4x 15kW)

Transmission:

Reducer: Hardened gear units (ratio ~1:50)

Couplings: Flexible disc-type for misalignment tolerance

Rail System:

Rails: QU120 (120mm head width) with fishplate joints

Foundation: Piled concrete with rail clamps

B. Anti-Derailment Features

Flange Guards: 10mm steel plates overlapping rail heads

Limit Switches: Cam-operated for end-of-track detection

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.

Motor

The motor of a cantilever gantry crane is a crucial component responsible for driving the various movements of the crane, such as the hoisting, trolley travel, and gantry movement. Depending on the design and size of the crane, the motor can vary in type and specifications. The motors are typically controlled by a PLC (Programmable Logic Controller) or VFDs (Variable Frequency Drives) to adjust speeds and torque for efficient operation.

Hoisting Motor:Purpose: Drives the hoist to lift and lower the load.Motor Type: Typically an electric motor, often an AC induction motor.Power: Varies depending on the load capacity, ranging from a few kW to several hundred kW.

Travelling Motor (Trolley Movement):Purpose: Moves the trolley along the gantry rail.Motor Type: Usually a three-phase AC motor.Power: Selected based on the required speed and capacity of the trolley.

Gantry Traveling Motor (Bridge Movement):Purpose: Moves the entire gantry structure along the ground rail, allowing it to span over the load area.Motor Type: A heavy-duty electric motor, often with a variable speed drive (VSD) for fine control.Power: Similar to the trolley motor but typically higher, as it needs to move the entire crane structure.

.

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

 

 

1. Unmatched Lifting Capacity & Structural Integrity

Heavy-duty performance: Engineered to handle 100+ ton loads with a 25% safety margin (FEM/ISO standards)

Dual-girder design: Provides superior rigidity with ≤L/800 deflection at full load (vs L/700 for single girder)

Reinforced steel construction: Uses Q460C high-tensile steel with computer-optimized cross-sections

2. Precision Load Control

Micro-speed options: 0.5-1 m/min precision mode for millimeter-accurate positioning

Anti-sway technology: Active load stabilization reduces swing by 80% compared to conventional cranes

Dual-hoist synchronization: For balanced lifting of oversized loads (optional tandem lift up to 200 tons)

3. Enhanced Safety Systems

Triple braking system:

Primary: Electromagnetic disc brake

Secondary: Mechanical caliper brake

Emergency: Spring-applied fail-safe brake

Smart load monitoring: Real-time weight display with automatic overload cutoff

Collision avoidance: Laser/radar systems for multi-crane operations

4. Operational Efficiency Features

Fast travel speeds: Up to 30 m/min with VFD control (50% faster than standard gantry cranes)

Energy recovery: Regenerative drives feed 15-20% power back to grid during lowering

Low maintenance design:

Sealed-for-life wheel bearings (50,000+ hour service life)

Automatic lubrication systems for all gears

5. Customization Capabilities

Modular design: Easily upgradable to 150-200 tons with bolt-on reinforcements

Special environment packages:

Arctic version (-40°C operation)

Corrosion-resistant (C5-M coating for marine use)

Explosion-proof (ATEX Zone 1 certification)

Automation ready: Pre-wired for integration with smart factory systems

6. Cost-Saving Advantages

Longer service life: 30+ year design lifespan (vs 15-20 years for standard cranes)

Reduced downtime:

98% mechanical availability

Quick-change components for fast repairs

Labor savings: One operator can handle loads requiring multiple cranes

7. Industry-Specific Benefits

✔ Energy sector: Handles turbine rotors and reactor vessels
✔ Shipbuilding: Moves complete engine blocks (100-150 ton units)
✔ Bridge construction: Erects precast segments with precision
✔ Heavy manufacturing: Positions massive press molds and dies

Technical Superiority

Finite Element Analysis (FEA) verified: All critical components stress-tested at 125% load

Certified performance: Meets ISO 8686, FEM 1.001, and CMAA Class D standards

Smart diagnostics: IoT-enabled predictive maintenance alerts

 

 

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%.