200 Ton Double Girder Rail Mounted Gantry Crane

 

A 100-ton Double Girder Rail Mounted Gantry Crane (RMG) is a large, heavy-duty lifting system designed primarily for outdoor operations where heavy loads must be lifted, moved horizontally, and positioned with high precision. Featuring two main girders and rail-mounted traveling mechanisms, this type of crane offers superior strength, stability, and reach compared to single-girder models.

Key Features:

Capacity: 100 tons, suitable for oversized or extremely heavy loads.

Structure: Double-girder design for enhanced load distribution and minimal deflection.

Mobility: Rail-mounted, allowing the crane to travel long distances along fixed tracks.

Span: Can be customized based on site needs, often ranging from 18 to 35 meters or more.

Height: Lifting height is typically adjustable according to operational requirements.

Components: Includes a hoisting trolley (which moves along the girders), electrical systems, cabins for operator control (or remote control options), and safety features like overload protection and emergency stop systems.

Applications:

Heavy industrial plants (steel mills, shipyards)

Container yards and intermodal terminals

Construction sites involving large prefabricated components

Power plants and precast concrete handling

Large fabrication yards

Advantages:

Efficient and precise handling of massive loads

High working efficiency, suitable for frequent and intensive use

Designed for outdoor use with weatherproof features

Lower maintenance costs due to robust design

Can be fully customized for specific site or industry requirements

Working Principle: The crane's hoisting mechanism lifts the load vertically. The trolley, moving along the two girders, provides lateral movement, while the entire crane travels along the rails for longitudinal movement. Together, this enables complete three-dimensional coverage of a working area.

 

Core Components:Engine, Bearing, Gearbox, Motor, Gear

Place of Origin:Henan, China

Warranty:2 years

Weight (KG):50000 kg

Video outgoing-inspection:Provided

Machinery Test Report: Provided

Application: Outdoor

Keywords: Gantry Crane

Rated Loading Capacity: 50Ton

Cross travelling speed: 44.6m/min

Long travelling speed: 47.1m/min

Control way: cabin

Power supply: Cable reel

Steel track: QU80

Power: 3-phase AC 50HZ 380V

Certification: CE ISO

 

 

 

1.Double Main Girders

Heavy-duty steel beams forming the main load-carrying structure.

Designed for minimal deflection under heavy loads.

Often fabricated using box-girder or truss designs, depending on application.

End Carriages (Legs and Beams)

Connect the main girders to the ground rail system.

Include robust steel structures with wheels that move along the rails.

Legs may be A-type, U-type, or gantry frame type, depending on clearance requirements

 

Hoisting Trolley

Moves horizontally along the main girders.

Includes:

Hoisting Mechanism: Motor, gearbox, wire rope drum, hook block, and braking system.

Trolley Frame: Supports the lifting mechanism.

Travel Mechanism: Motors and wheels enabling trolley movement.

 

 

3.End carriage

1) The end carriage of a double girder gantry crane is a critical component that connects the crane structure to its wheels and facilitates its movement along the runway or ground tracks. For the largest double girder gantry cranes, the end carriage must be robustly designed to handle the immense loads and ensure smooth operation.

2) The end carriages are designed to distribute the load from the girders evenly to the wheels.High-strength steel or equivalent materials are typically used to ensure durability and load resistance.For large gantry cranes, end carriage dimensions are tailored to the specific span and load requirements of the crane.

3) The end carriage transfers loads from the crane's girders and hoist to the rails or ground. For the largest gantry cranes, this may include vertical loads (from lifting) and horizontal loads (from braking or wind).To ensure proper operation, the end carriages must be precisely aligned with the rails. Misalignment can lead to increased wear or operational hazards.

 

 

4.Crane Travel Mechanism

Provides longitudinal movement along the rail tracks.

Powered by electric motors coupled with reduction gears.

Equipped with wheels (typically double-flanged steel wheels) designed for heavy loads.

Often includes synchronized drive systems to ensure smooth travel.

 

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: High-strength steel is commonly used to ensure the frame can handle the substantial weight and stresses during operation.

Wheel set: Large, durable wheels are mounted on the trolley to allow smooth movement along the gantry rails or beams. These wheels are designed for heavy-duty operations and may be equipped with bearings for better efficiency.

Drive device: High-power electric motors drive the trolley, usually using variable speed drives for precise control. These motors are located within the trolley frame.

2) Function of the trolley operating mechanism

The trolley travel mechanism of the largest double girder gantry crane plays a critical role in the crane's operation by moving the hoisting mechanism (or hook) horizontally along the length of the crane's span.The trolley is responsible for moving the load horizontally across the crane's beam (double girder structure). This allows the crane to position the load at different locations within its working area.By traveling along the girders, the trolley can transport loads across the entire span of the crane, facilitating the lifting and placing of heavy materials or equipment in various positions within the crane's working range.The trolley travel mechanism allows for precise positioning of the load along the beam, which is crucial for tasks that require accurate placement, such as loading/unloading containers, large construction materials, or heavy industrial equipment.

6.Crane wheel

The crane wheel of a double girder gantry crane, particularly one designed for heavy-duty or large-scale applications, is a critical component. It is engineered to support and facilitate the movement of the crane along its runway tracks.

Typically made of high-strength forged steel or cast steel, such as 42CrMo4 or 65Mn, to endure high loads and resist wear.Heat-treated for improved durability and resistance to deformation under heavy loads. Tread Profile: Precision-machined to fit the rail perfectly, ensuring smooth operation and minimal wear. Larger cranes require larger diameter wheels to distribute the load effectively and reduce stress on the rail and wheel.Designed to bear the immense static and dynamic loads of the crane, which can weigh several hundred tons, including the load being lifted.

Some wheels are powered (drive wheels) to move the crane, while others are idlers. The drive wheels are connected to motors and gearboxes to provide traction.Bearings and wheel surfaces are often lubricated to reduce wear and prolong lifespan.Regular inspections are critical to monitor for cracks, wear, or deformation.

7.Crane Hook

The crane hook of the largest double-girder gantry crane is a critical component, specifically designed to handle heavy-duty lifting tasks in industrial environments such as shipyards, steel mills, and large construction sites.

For the largest gantry cranes, the hook may handle loads in the range of hundreds of tons, depending on the crane's rated capacity. For instance, hooks for 500-ton or larger cranes are common in specialized industries.

Made from high-strength alloy steels like forged carbon steel or alloy steel to provide the necessary tensile strength and durability.Heat-treated for enhanced toughness and resistance to wear and deformation.

Hooks are generally single or double hooks, with double hooks used for better load distribution in high-capacity systems.May feature a rotating design to allow precise positioning of the load.

Hooks are often customized based on the specific lifting needs of the application, such as lifting containers, coils, slabs, or other heavy objects.

Motor

1) The motor of the largest double girder gantry crane is a critical component as it powers the lifting and moving mechanisms. These motors are typically chosen based on the crane's capacity, operational requirements, and environmental conditions.

2) The motors in the largest gantry cranes can have power ratings in the range of hundreds of kilowatts, depending on the crane's load capacity (e.g., 500 tons or more).Motors are sized to ensure smooth operation even under maximum load conditions.

3) Operates on industrial power supplies, typically 380-690V AC, with higher voltage systems used for ultra-heavy cranes.Some cranes use multiple motors for redundancy, ensuring that one motor failure does not halt operation.Equipped with emergency stop systems and overload protection.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

The sound and light alarm system of a double-girder gantry crane is a critical safety component designed to alert personnel in the crane's vicinity about its operation or potential hazards.

Audible Alarm (Sound): Produce loud and distinctive sounds to warn workers.High-decibel siren or buzzer (typically 80-120 dB, adjustable based on site requirements).

Visual Alarm (Light): Provide a visible warning, especially in noisy environments or for hearing-impaired workers.Flashing LED or strobe lights with high visibility.Different colors for specific warnings (e.g., red for emergency, yellow for caution).

2) Limit switch

A limit switch is a crucial safety and operational device in a double girder gantry crane, particularly for the largest and most heavy-duty models. Its primary function is to ensure the safe operation of the crane by restricting its motion within defined parameters to prevent accidents or equipment damage.

Hoist Limit Switch:Prevents the hook or load block from traveling too high or too low.Ensures that the wire rope does not over-tighten or unwind completely, which could lead to snapping or tangling.

Travel Limit Switch:Limits the horizontal movement of the crane or trolley along the gantry or runway beams.Prevents collisions with end stops or other equipment by halting movement at preset points.

Slew Limit Switch:Restricts the rotation of the crane to specific angles.

Load Limit Switch (Overload Protection)：Detects when the crane is lifting more than its rated capacity.Stops operations to prevent mechanical failure and accidents.

Wind Speed Limit Switch: For outdoor gantry cranes, monitors wind speed.

10.Safety Devices

1) Overload protection device:Prevents the crane from lifting loads exceeding its rated capacity.

2) Limit Switches: Prevent the crane from moving beyond its designated operational area.

3) Emergency Stop System: Allows operators to immediately stop all crane operations in case of an emergency.

4) Anti-Collision Systems: Prevents collisions with other cranes, objects, or structures in the operating area.

5) Wind Speed Alarm and Locking Devices: Ensures the crane's stability during high winds, especially for outdoor cranes.

6) Load Moment Limiter: Prevents the crane from tipping due to excessive load or improper load distribution.

11.Control Mode

1) Manual control: The operator directly controls the various operating mechanisms of the crane through buttons or switches on the manual control panel. Simple operation, suitable for small or short-term operations; can be quickly adjusted according to specific needs.

2) Wireless remote control: The various functions of the crane are controlled by a wireless remote control, and the operator can operate at a safe distance. Improves the flexibility and safety of operation, especially suitable for complex or dangerous working environments.

3) Wired remote control: Operate through the control line connected to the crane, and the operator inputs instructions through a handheld controller. Compared with wireless remote control, the signal is stable and not easily interfered with, which is suitable for operation in a fixed area.

4) Automated control: Automated operation is achieved through PLC (Programmable Logic Controller) or computer system, and the operation of the crane is controlled according to the preset program. Improves the accuracy and consistency of operation, suitable for large-scale and repetitive operations, and reduces interference from human factors.

5) Frequency conversion control: The speed of the motor is adjusted by the frequency converter to achieve precise control of the operating speed of the crane. It can smoothly accelerate and decelerate, improve the safety and efficiency of lifting operations, and reduce the impact on equipment.

12.Sketch

 

 

 

Main technical

 

 

Advantages of 100-ton Double Girder Rail Mounted Gantry Crane

Extremely High Lifting Capacity

With a 100-ton rating, it handles extremely heavy and oversized loads easily - ideal for industries like steel production, shipbuilding, and container handling.

Strong and Stable Structure

The double-girder design provides excellent load distribution, high rigidity, and reduced beam deflection, even under full load.

Perfect for frequent heavy-duty operations.

Long Span and Wide Coverage

Rail-mounted design allows the crane to cover large outdoor yards or factory areas.

Flexible spans (often 18–35 meters or more) accommodate a variety of site layouts.

Efficient Material Handling

Smooth, coordinated movement across three axes (hoisting, trolley travel, and crane travel).

Shortens material handling time and improves production efficiency.

High Precision and Control

Advanced control systems (like PLCs, variable frequency drives) enable precise positioning.

Options for cabin control, pendant control, or wireless remote control.

Durability and Longevity

Made with heavy-duty, weather-resistant materials.

Suitable for all-weather outdoor use, with corrosion protection for long service life.

Reduced Labor and Operational Costs

Heavy lifting tasks are mechanized, minimizing the need for manual labor.

Reduces the risk of workplace accidents and fatigue.

Customizable Design

Span, lifting height, working speed, and other specifications can be tailored to specific site and project requirements.

Can be equipped with specialized attachments like magnets, grabs, or spreaders.

Enhanced Safety Systems

Equipped with overload protection, anti-collision devices, emergency brakes, wind locks, and other critical safety mechanisms.

Ensures safe operation even under challenging conditions.

Energy-Efficient Options

Modern designs include energy-saving motors and regenerative braking systems, which reduce power consumption and operational costs.

 

 

Applications of 100-ton Double Girder Rail Mounted Gantry Crane

Shipbuilding Industry

Lifting and assembling large ship components such as hull sections, engines, and heavy modules.

Supporting construction and repair operations in shipyards.

Steel Plants and Metal Yards

Handling heavy steel coils, billets, ingots, structural beams, and plates.

Transporting raw materials and finished products within large yards.

Container Terminals and Ports

Moving and stacking heavy shipping containers.

Loading and unloading container ships alongside quay cranes.

Construction Industry

Lifting and positioning large prefabricated components such as bridge sections, tunnel segments, and large beams.

Used for major infrastructure projects like highway and railway bridge building.

Power Plants and Energy Projects

Handling heavy equipment like generators, turbines, transformers, and nuclear plant components.

Supporting maintenance and installation tasks in hydropower and thermal power stations.

Precast Concrete Plants

Moving heavy concrete blocks, slabs, columns, and beams in production yards.

Assisting in assembly and transportation operations.

Mining Industry

Transporting heavy mining equipment and large ore containers.

Assisting in maintenance operations for large-scale mining machinery.

Heavy Machinery Manufacturing

Moving machine bases, industrial parts, and fabrication materials during production.

Supporting assembly lines for large industrial equipment.

Railway Yards

Lifting and placing railway tracks, rail vehicles, and heavy repair equipment.

Supporting construction and maintenance of railway infrastructure.

Aerospace Industry

Handling large aerospace structures such as fuselage parts and satellite equipment.

Assisting in manufacturing and assembly processes.

Railways: Moving railcars, engines, and tracks during production or maintenance.

Crane production procedure

Design and Engineering: Identify the crane's purpose, load capacity, span, height, speed, and working environment.Create detailed CAD models and structural analyses for the girders, gantry legs, and trolley system to ensure load handling capacity and compliance with standards (e.g., FEM, ISO, or CMAA).Determine the types of motors, hoisting mechanisms, rail systems, and control systems to be used.Include safety systems like anti-collision devices, limit switches, overload protection, and wind-resistance mechanisms.

Material Procurement: Source high-grade steel (often Q345 or equivalent) for girders, legs, and other structural components.Purchase hoisting mechanisms, motors, drives, brakes, and control panels. Acquire paints and coatings for corrosion resistance.

Fabrication of Components: Use CNC cutting machines to shape the steel plates.Weld the plates into the box or I-beam sections for girders and legs, following strict quality standards.Perform stress-relieving heat treatment to prevent deformation during use.Use ultrasonic or radiographic testing to ensure weld integrity.Fabricate and assemble gears with precisionAssemble the hoisting drum and wire ropes.Create precise grooves and surfaces for wheels and rail contact.Fit wheels, axles, and other mechanical components.Assemble and program control panels, variable frequency drives (VFDs), and PLCs (Programmable Logic Controllers).Install wiring for motors, limit switches, and sensors.

Pre-Assembly: Assemble the major components (girders, legs, trolley) in the workshop to check alignment and fit.Make adjustments or refinements as needed.Apply anti-corrosion coatings or paint.

Transportation to Site: Dismantle the crane into transportable components.Arrange heavy-haul vehicles or ships for transportation, considering the crane's size and weight.

On-Site Assembly: Ensure rail tracks or crane runways are installed and aligned.Use heavy-duty cranes to erect and position the girders, legs, and trolley. Securely join components.

Commissioning and Testing: Perform no-load, rated-load, and overload tests to ensure stability and functionality.Verify safety devices like limit switches and emergency stops.Check rail alignment and trolley travel.Validate the control systems, sensors, and power connections.

Final Inspection and Handover:Conduct a final inspection with the client or certifying authority.Provide documentation, including operating manuals, maintenance schedules, and test certificates.Train operators and maintenance staff on proper crane operation and upkeep.

Maintenance and Support:Offer periodic inspections, spare parts, and after-sales support to ensure long-term reliability.The production process demands high precision, rigorous testing, and adherence to international standards to ensure safety and performance.

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%.