Double Gantry Crane Beam Rail Track

 

 

The double gantry crane beam rail track is a critical supporting and guiding system designed specifically for double girder gantry cranes. It provides a stable running surface for crane travel, ensures accurate alignment of the crane structure, and safely transfers loads from the crane to the ground foundation. This rail track system is widely used in heavy-duty material handling environments where high lifting capacity, long travel distance, and precise crane movement are required.

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Main Components

Crane Rails
High-strength steel rails (such as QU70, QU80, QU100, or QU120) designed to withstand heavy wheel loads and continuous operation.

Beam (Rail Support Beam)
Steel or reinforced concrete beams installed beneath the rails to support crane loads and distribute forces evenly to the foundation.

Rail Fastening System
Includes clips, bolts, pads, and base plates to securely fix rails to the beams while allowing slight thermal expansion.

Rail Pads / Elastic Pads
Installed between rail and beam to absorb vibration, reduce noise, and protect the beam structure.

End Stops and Buffers
Safety devices installed at rail ends to prevent crane derailment and absorb impact.

Foundation System
Concrete foundation with embedded anchor bolts ensuring long-term stability and alignment of the rail track.

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Advantages

High Load-Bearing Capacity
Designed to support heavy lifting operations and large-span double girder gantry cranes.

Excellent Stability and Alignment
Ensures smooth crane travel and precise positioning, reducing wear on crane wheels.

Long Service Life
Durable materials and proper fastening systems provide resistance to fatigue and deformation.

Low Maintenance Cost
Proper rail installation minimizes misalignment and reduces operational downtime.

Adaptable Design
Can be customized for different crane capacities, spans, and working environments.

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Applications

Heavy equipment manufacturing plants

Shipyards and dockyards

Bridge and precast concrete yards

Steel structure fabrication workshops

Container yards and logistics terminals

 

Rated Loading Capacity：5 ton, 10 TON, 100 ton, customized, 16/3.2 ton, 20/5 ton, 32/5 ton, 50/10 ton

Max. Lifting Height：40m, customized

Span：35m or clients' demands

Warranty：1 Year

Weight (KG)：20000 kg

Core Components：PLC, Engine, Bearing, Gearbox, Motor, Pressure vessel, Gear, Pump

Control way：Cab, wireless remote control or customized

 

 

 

1.Double Girders

Two parallel steel box girders or welded girders

Form the main load-bearing structure

Support the trolley and hoisting system

1.The main beam of an industrial gantry crane is a horizontal beam that spans the distance between two parallel tracks or rails. It is typically made of steel and serves as the primary structural component of the crane, providing support for the hoist mechanism, trolley, and load.

 

2.The main beam is designed to withstand the weight and forces generated by the crane's operations, including lifting, moving, and lowering heavy loads. It is also responsible for maintaining the stability and balance of the crane during operation.

 

3.The main beam can be either fixed or adjustable, depending on the specific needs of the application. Fixed beams are set at a specific height and cannot be adjusted, while adjustable beams can be raised or lowered to accommodate different load heights and clearance requirements.

 

4.Overall, the main beam is a critical component of an industrial gantry crane, providing the necessary strength and stability to handle heavy loads safely and efficiently.

Gantry Legs (A-Type or U-Type)

Support the girders and transfer loads to the ground

One or both legs may be rigid or flexible depending on design

Can include cantilever extensions if required

 

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Lifting Mechanism

2.1 Hoisting System

Electric wire rope hoist or winch trolley

Includes motor, reducer, brake, drum, and wire rope

Responsible for vertical lifting and lowering of loads

2.2 Trolley

Runs on rails mounted on top of the double girders

Enables cross travel (left and right movement)

2.3 Hook or Lifting Device

Crane hook, grab bucket, spreader, or special lifting tool

Selected according to the type of material handled

The lifting system of an industrial gantry crane is responsible for raising, lowering, and transporting heavy loads. It typically consists of several components working together to provide a reliable and efficient hoisting mechanism.

The main components of the lifting system include:Hoist Motor: The hoist motor is the power source for the lifting system. It generates the torque required to lift and lower the load. The motor's capacity is determined by the crane's lifting capacity and duty cycle.

Hoist Drum(s) or Sheave Assembly: The hoist drum or sheave assembly is connected to the hoist motor through a reduction gearbox. As the motor turns, it rotates the drum or moves the sheaves, which in turn raises or lowers the wire ropes or chains.

3.In summary, the lifting system of an industrial gantry crane is a complex but essential component that enables the crane to perform its primary function: lifting and moving heavy loads safely and efficiently.

 

 

3.End Beams

Installed at the bottom of gantry legs

Support traveling wheels and drive systems

Ensure correct rail gauge and crane stability

1.The end carriage of an industrial gantry crane is a critical component that connects the crane to the runway beam or rail on which it travels.

2.Here are the key features and functions of the end carriage:

Structure and Functionality

Rollers or Wheels: The end carriage typically has several rollers or wheels that ride along the top of the runway beam or rail. These are designed to minimize friction and allow for smooth movement of the crane.

Bearings and Axles: To support the weight and movement, the rollers or wheels are mounted on axles with bearings that ensure they can rotate freely without excessive wear.

Locking Mechanism: Some end carriages may include locking mechanisms that can secure the crane in a fixed position when not in use or during maintenance.

Adjustment Mechanisms: There may be adjustment mechanisms to fine-tune the alignment and ensure that the crane moves straight along the runway beam without deviation.

3.The end carriage is vital for the stable and reliable operation of the gantry crane. It ensures that the crane can move smoothly and efficiently along the runway beam, carrying out its hoisting and transporting functions with precision. Proper maintenance and inspection of the end carriage are crucial to prevent issues that could affect the crane's performance or lead to safety hazards.

4.Traveling System

3.1 Crane Traveling Wheels

Heavy-duty steel wheels with flanges

Run on the beam rail track

3.2 Traveling Drive Mechanism

Motors, reducers, brakes, and couplings

Provides longitudinal movement along the rail track

1.The crane traveling mechanism of an industrial gantry crane is responsible for moving the crane horizontally along its runway beams or rails. This mechanism allows the crane to transport loads over a larger area, making it extremely useful in warehouses, shipyards, and other industrial environments where heavy items need to be moved around a broad expanse.

2.Here are the key components and features of the crane traveling mechanism:

Components of the Traveling Mechanism

Drive Units (Traction Units): These are typically electric motors that provide the power to move the crane. The number of drive units can vary depending on the size and capacity of the crane; some cranes may have multiple motors for each side to distribute the load.

Gearboxes: Gearboxes are used to reduce the high speed of the motor to a lower speed suitable for the crane's travel. They also increase the torque output, which is necessary to move the crane and its load.

Wheels or Rollers: Large wheels or rollers are mounted on axles and are driven by the motor through the gearbox. These wheels or rollers ride along the top of the runway beams or rails and are crucial for stable movement.

3.The traveling mechanism is one of the most critical components of an industrial gantry crane, as it determines the crane's mobility and range of operation. Proper maintenance and regular inspections are crucial to ensure that the traveling mechanism operates smoothly and safely. Any issues with this mechanism can significantly impact the crane's performance and safety, making it vital to address any problems promptly.

 

5.Trolley travelling mechanism

1.The trolley traveling mechanism of an industrial gantry crane is responsible for moving the hoist or lifting mechanism horizontally along the crane's main beam or gantry. This allows the crane to position the load precisely in the transverse direction.

2.The trolley traveling mechanism consists of several key components:

Components of the Trolley Traveling Mechanism

Drive Unit: Typically an electric motor, the drive unit provides the power to move the trolley. The size and capacity of the motor depend on the crane's lifting capacity and the required speed of the trolley.

Gearbox: The gearbox reduces the high speed of the motor output to a lower speed suitable for the trolley's travel. It also increases the torque, which is necessary to move the hoist mechanism and any attached load.

Wheels or Rollers: The trolley rides on wheels or rollers that are mounted on axles. These wheels or rollers travel along the flanges or tracks on the main beam, allowing the trolley to move back and forth.

Brake System: A braking system is integrated into the trolley to control its movement and to hold it in position when needed. This can be a mechanical brake, an electromechanical brake, or a dynamic braking system.

3.The trolley traveling mechanism is crucial for precise positioning of the load in the transverse direction. It allows the crane to place loads accurately at different points along the length of the gantry. Proper maintenance and regular inspections are essential to ensure that the trolley mechanism operates smoothly and safely. Any issues with this mechanism can significantly impact the crane's operational efficiency and safety, making it vital to address any problems promptly.

 

6.Crane wheel

1.The crane wheel of an industrial gantry crane is a critical component that allows the crane to move along its runway beams or rails. These wheels are designed to support the weight of the crane, its load, and any additional dynamic forces generated during operation.

2.Here are the key features and functions of crane wheels:

Features of Crane Wheels

Material: Crane wheels are typically made from high-strength materials such as steel or cast iron to ensure they can withstand the heavy loads and stresses involved in lifting operations.

Size and Configuration: The size of the wheels varies depending on the capacity and design of the crane. They can be larger for heavier cranes to distribute the load more evenly. The number of wheels per axle and the number of axles per crane can also vary based on design requirements.

3.Crane wheels play a vital role in the mobility and stability of industrial gantry cranes. They are responsible for transferring the weight of the crane and its load to the runway beams or rails while allowing for smooth travel. The durability and efficiency of the crane's movement largely depend on the quality and condition of these wheels.

4.Proper maintenance of crane wheels, including regular inspections and timely replacement of worn components, is crucial for the safe and reliable operation of the crane. Neglecting wheel maintenance can lead to increased downtime, reduced efficiency, and potential safety hazards.

 

7.Crane Hook

1.The crane hook of an industrial gantry crane is a critical component that allows the crane to lift and move various loads. The hook is the point of contact between the crane's hoisting mechanism and the load, making it a crucial interface for safe and efficient operations.

2.Here are the key features and functions of crane hooks:

Features of Crane Hooks

Material: Crane hooks are typically made from high-strength steel or alloy steel to ensure they can withstand the heavy loads involved in lifting operations. The material is chosen for its durability and resistance to wear and tear

Design: The design of the hook includes an opening at the top where it attaches to the hoist rope, chain, or other lifting device. The bottom part of the hook has a curved shape that allows it to securely engage with lifting points on the load.

Safety Latch: Many hooks are equipped with a safety latch or locking mechanism to prevent the load from accidentally slipping off. This latch must be manually opened to release the load at the desired location.

Load Ratings: Each hook is rated for specific maximum loads, and it is essential to use hooks that are rated for the intended loads to ensure safety and compliance with regulations.

 

Motor

The motor of an industrial gantry crane is a critical component that provides the power necessary for lifting and moving loads. Motors in gantry cranes are typically electric and can be categorized into two main types based on their function: the hoisting motor and the travelling (or traversing) motor.

The hoisting motor is responsible for lifting and lowering the hook or grab that engages with the load. This motor's primary function is to control the vertical movement of the crane's loading mechanism.

Crane motors are the powerhouse of industrial gantry cranes, providing the energy required for both lifting and moving operations. The performance, reliability, and safety of the crane are heavily dependent on the motors' efficiency and durability. Proper selection, maintenance, and regular inspections of these motors are crucial for ensuring the crane operates smoothly and safely. Any issues with the motors can lead to operational inefficiencies, increased downtime, and potential safety risks, making prompt attention to motor problems essential.

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Sound and light alarm system & limit switch

1.Industrial gantry cranes are equipped with a sound and light alarm system and limit switches to enhance safety and operational efficiency. These components play crucial roles in preventing accidents and ensuring that the crane operates within its designated parameters.

2.Sound and Light Alarm System

The sound and light alarm system is designed to alert personnel in the vicinity of the crane about its operational status. This system is particularly important in environments where the crane operates in close proximity to workers or where visibility is limited.

3.Limit Switches

Limit switches are electronic devices that serve as critical safety features on industrial gantry cranes. They detect the position of the crane or its components and cut off power when the crane reaches its operational limits, preventing potential accidents and damage.

4.Both the sound and light alarm system and limit switches are integral to the safe operation of industrial gantry cranes. The alarm system ensures that personnel are aware of the crane's movements and operational status, reducing the risk of collisions or other hazards. Limit switches, on the other hand, automate safety by physically preventing the crane from operating beyond its design limits. Together, these systems contribute to a safer workplace and protect both the crane equipment and the personnel working around it. Proper maintenance and regular testing of these systems are essential to ensure they function reliably and effectively.

10.Safety Devices

Overload Protection Devices

Overload protection devices are designed to prevent the crane from operating beyond its safe working load limits. These devices monitor the load being lifted and will either send an alert or shut down the crane if the load exceeds the specified limit. This is crucial for preventing structural damage to the crane and avoiding accidents that can occur due to overloading.

Limit Switches

As mentioned earlier, limit switches automatically stop the crane when it approaches the end of its travel range or when any of its components reach their operational limits. These switches are essential for preventing the crane from exceeding its physical boundaries, which could result in damage to the structure or collision with obstacles.

Anti-Collison Devices

Anti-collison devices are particularly important in environments where multiple cranes operate in close proximity or where there is significant ground traffic. These devices use sensors, cameras, or other technologies to detect the presence of other objects in the crane's path and either alert the operator or automatically halt the crane's movement to prevent a collision.

Emergency Stop Buttons

Emergency stop buttons are manually operated controls that allow the crane operator or any authorized personnel to immediately stop all crane operations in case of an emergency. These buttons are strategically placed within easy reach of the operator and are often red and highly visible.

Brake Systems

Brake systems on industrial gantry cranes are designed to hold the load securely in place when not in motion and to provide controlled stopping during operations. These brakes can be mechanical, electrical, or a combination of both, and they are critical for preventing unexpected load movements that could lead to accidents.

Levelness Indicators

Levelness indicators are used to ensure that the crane is level during operation, especially when lifting precise or delicate loads. Uneven lifting can cause loads to shift, potentially leading to loss of control and accidents. These indicators help operators maintain the crane's balance and stability.

Safe Working Load Indicators

Safe working load indicators clearly mark the maximum safe load capacity for the crane. This information is vital for operators to ensure that the crane is not overloaded and operates within its design specifications.

 

11.Control Mode

1.Manual Control

Direct Intervention: The crane operator directly controls the hoisting and traveling movements of the crane using handwheels, levers, or push buttons. This mode requires skilled operators who can manually synchronize the movements to achieve the desired positioning of the load.

Simple Mechanisms: Manual control systems are generally simpler in design and may be less prone to complex failures.

Limited Precision: The precision of the crane's movements is limited to the operator's skill and experience.

2.Semi-Automatic Control

Assisted Operation: The crane operator uses control devices such as joysticks or paddle switches to command the crane, but the system includes automated features that assist in controlling speed and synchronization.

Enhanced Safety: Semi-automatic systems often include safety features like automatic stops at load limits or travel limits.

Improved Efficiency: These systems can improve operational efficiency by reducing the need for highly skilled operators.

3.Fully Automatic Control

Programmable Logic Controller (PLC): The crane's operations are governed by a PLC, which can be programmed to perform specific sequences of operations automatically.

Precise Control: Fully automatic systems offer precise control over the crane's movements, allowing for complex maneuvers to be executed consistently.

Reduced Human Error: Automated systems reduce the potential for human error, enhancing safety and reliability.

Remote Operation: In some cases, fully automatic cranes can be operated remotely, removing the operator from potentially hazardous environments.

4.Radio Control

Wireless Operation: The crane operator uses radio transmitters to control the crane from a distance, which can be particularly useful in environments where visual contact with the crane is limited.

Increased Flexibility: Radio control allows operators to move freely around the work area while maintaining control of the crane.

Safety Considerations: Proper frequency management and security measures must be in place to prevent interference or unauthorized operation of the crane.

5.Computer Control

Advanced Systems: Some gantry cranes may employ computer systems that integrate advanced features such as machine vision, artificial intelligence, and data analysis to optimize operations.

Data Collection: Computer-controlled cranes can collect operational data, which can be used for maintenance planning and operational optimization.

Interface Options: Operators may interact with the crane through touch screens or other advanced interfaces, providing detailed feedback and control options.

 

12.Sketch

 

 

 

A double gantry crane (double girder gantry crane) offers superior performance for heavy-duty and large-span lifting operations. Its design provides high strength, stability, and operational flexibility.

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1. High Lifting Capacity

Suitable for medium to ultra-heavy loads

Capable of handling large and concentrated loads safely

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2. Strong and Stable Structure

Double girder design evenly distributes loads

Excellent resistance to bending, torsion, and deformation

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3. Large Span and High Lifting Height

Ideal for wide working areas and tall lifting requirements

Efficient use of vertical and horizontal space

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4. Smooth and Precise Operation

Stable trolley and crane traveling systems

Reduced vibration and swing during lifting and movement

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5. High Working Efficiency

Faster lifting, trolley travel, and crane travel speeds

Suitable for continuous and frequent operation

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6. Flexible Configuration

Can be equipped with hooks, grabs, spreaders, or special lifting tools

Supports cabin, pendant, or remote control operation

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7. Long Service Life

Durable steel structure and high-quality components

Lower wear on wheels, rails, and mechanical parts

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8. Safe and Reliable

Equipped with multiple safety devices

Suitable for outdoor and harsh working environments

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9. Low Maintenance Cost

Stable structure reduces alignment and wear issues

Easy access for inspection and maintenance

 

 

A double gantry crane is widely used in heavy-duty, large-span, and outdoor material handling operations where high lifting capacity and stable performance are required.

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1. Bridge and Precast Concrete Yards

Lifting and transporting precast beams, girders, and slabs

Commonly used in highway, railway, and metro construction projects

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2. Shipyards and Dockyards

Handling ship components, blocks, and heavy steel structures

Suitable for outdoor and coastal working environments

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3. Steel Structure Fabrication Plants

Lifting large steel beams, plates, and welded assemblies

Supporting production, assembly, and storage processes

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4. Ports and Logistics Terminals

Handling heavy cargo, containers, and special equipment

Ideal for long travel distances and high-duty cycles

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5. Power Plants and Energy Projects

Installation and maintenance of turbines, generators, and transformers

Used in thermal, hydro, wind, and nuclear power facilities

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6. Heavy Equipment Manufacturing

Assembly and movement of large machinery and industrial equipment

Improves production efficiency and safety

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7. Marble, Granite, and Stone Yards

Lifting and transporting stone blocks and slabs

Provides stable handling of heavy and irregular loads

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8. Railway and Metro Construction

Handling rails, sleepers, and prefabricated components

Used in track laying and infrastructure construction

 

 

1. Design and Engineering

Detailed Engineering: Develop detailed engineering drawings and specifications, including the main beam, hoist, trolley, end carriages, and other components.

Simulation and Modeling: Use computer-aided design (CAD) and simulation tools to model the crane's performance and optimize its design.

2. Material Selection

Material Specifications: Select high-quality materials that meet the requirements for strength, durability, and heat resistance. Common materials include high-strength steel, alloys, and specialized coatings.

Procurement: Source materials from approved suppliers, ensuring they meet the necessary quality and certification standards.

3. Component Fabrication

Cutting and Shaping: Cut and shape raw materials into the required components, such as beams, columns, and brackets. This may involve processes like plasma cutting, laser cutting, and machining.Welding and Assembly: Weld components together to form the crane's structural elements. This includes welding the main beam, end carriages, and other load-bearing parts.

4. Assembly

Sub-Assembly: Assemble individual components, such as the hoisting system, trolley, and end carriages, into sub-assemblies. This involves fitting parts together and ensuring proper alignment.Main Assembly: Combine sub-assemblies to construct the complete crane structure. This includes mounting the hoist and trolley on the main beam, attaching the end carriages, and installing the control systems.

5. Integration of Systems

Electrical Systems: Install electrical components, including motors, control panels, wiring, and sensors. Ensure that the crane's electrical systems are properly integrated and tested.

Control Systems: Implement and configure control systems, such as programmable logic controllers (PLCs), remote controls, and safety devices. Verify that the control systems function correctly and are calibrated.

6. Testing and Quality Assurance

Pre-Operational Testing: Conduct pre-operational tests to check the crane's functionality, including load testing, operational testing of the lifting and traveling mechanisms, and control system checks.

Safety Testing: Verify that safety features, such as limit switches, alarms, and emergency stops, are working correctly and meet safety standards.

Inspection: Perform a detailed inspection of the crane's structure and components to ensure compliance with design specifications and quality standards.

7. Final Adjustments and Calibration

Fine-Tuning: Make any necessary adjustments to optimize the crane's performance and ensure smooth operation. This may include calibrating sensors, adjusting controls, and fine-tuning the lifting system.

Documentation: Prepare and review documentation, including operation manuals, maintenance guides, and safety instructions.

8. Delivery and Installation

Transport: Arrange for the transport of the crane to the installation site, ensuring that it is handled and shipped safely to prevent damage.

Installation: Oversee the installation of the crane at the customer's facility, including assembly, alignment, and connection to power sources and control systems.

Training: Provide training for operators and maintenance personnel to ensure they are familiar with the crane's operation and safety procedures.

9. Commissioning and Handover

Commissioning: Conduct final commissioning tests to verify that the crane operates correctly under real-world conditions and meets performance specifications.

Handover: Officially hand over the crane to the customer, providing all necessary documentation, including certificates of compliance, warranty information, and maintenance schedules.

 

 

 

Material Inspection

Quality Inspection: Strict quality inspection is carried out on the purchased raw materials to ensure that they meet the design requirements and national standards.

Material Storage: Qualified materials are stored according to classification to prevent corrosion or damage.

Cutting and Forming

Steel Cutting: Use plasma cutting, laser cutting or flame cutting and other technologies to cut the steel according to the size of the design drawing.

Forming Processing: Form the steel plate through bending, rolling, welding and other processes to manufacture the main beam, end beam and other structural parts.

Welding

Component Welding: The cut and formed steel parts are welded into the main structures such as the main beam, end beam and trolley. The welding process needs to be strictly controlled to ensure the structural strength and welding quality.

Weld Inspection: Use non-destructive testing technology (such as ultrasonic testing, radiographic testing) to inspect the welds to ensure that there are no cracks or other defects.

Machining

Precision Machining: Precision machining is performed on the key components of the crane, such as wheel sets, bearing seats, pulleys, etc., to ensure their dimensional accuracy and surface quality.

Assembly of the whole machine

General assembly: On the basis of pre-assembly, the overall assembly of the crane is carried out, including the final installation of the main beam, end beam, lifting mechanism, walking mechanism, etc.

Commissioning and testing

Under dynamic conditions, the operating performance of the crane is tested, including the testing of lifting, walking, steering and other functions. The overall size of the assembled bridge crane is checked to ensure that all dimensions meet the design requirements.

Spraying and anti-corrosion treatment

Surface treatment Rust removal: Rust removal on the surface of the crane, common methods include sandblasting, pickling, etc. Primer spraying: Spray anti-corrosion primer on the treated surface to prevent metal oxidation and corrosion. Topcoat spraying Color spraying: Spray topcoat according to customer requirements or industry standards to give the crane a protective and decorative effect. Marking: After spraying, mark the crane's identification information in accordance with the specifications, such as model, rated load, etc.

Factory and installation

Packaging and transportation

Packaging protection: Protectively package the key components of the crane to prevent damage during transportation. Transportation arrangement: According to the equipment size and transportation conditions, select a suitable transportation method to transport the crane to the customer's site.

Acceptance and delivery

Customer acceptance

On-site acceptance: The customer conducts on-site acceptance of the crane according to the contract requirements and technical specifications to check the performance and quality of the equipment.

Problem rectification: If any problems are found, the manufacturer needs to rectify them in time to ensure that the equipment fully meets the customer's requirements. Delivery and use Operation training: The manufacturer usually trains the customer's operators to ensure that they can operate the crane correctly and safely.

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