European-type Double Girder Gantry Crane

 

Key Features

1. Structural Design

Double Box Girders: Reinforced steel construction for heavy loads.

End Carriages: Equipped with high-grade wheels for smooth rail movement.

Modular Design: Customizable span, height, and lifting capacity.

2. Hoisting Mechanism

Top-Running Hoist: Moves on rails above the girders (higher lift height).

Wire Rope Hoist (Standard): For capacities up to 500+ tons.

Chain Hoist (Optional): For lighter-duty precision lifting.

3. Drive & Control System

Travel Drives:

Motorized Travel: AC/DC motors with variable frequency drives (VFDs) for smooth operation.

Crab Steering: Allows diagonal movement for precise positioning.

Control Options:

Pendant Control (standard).

Radio Remote Control (wireless operation).

Operator Cabin (for heavy-duty applications).

4. Safety & Automation

Overload Protection: Load cells & limit switches.

Anti-Sway System: Reduces load swing for precision.

Collision Avoidance: Laser sensors for multi-crane environments.

PLC Automation: For automated lifting sequences (optional).

 

Comparison: European vs. American vs. Chinese Double Girder Gantry Cranes

Feature	European-Type	American-Type	Chinese-Type
Design	High precision, modular	Ultra-heavy-duty	Cost-effective
Capacity	5-500+ tons	10-1000+ tons	5-320 tons
Span	Up to 50m+	Up to 60m+	Up to 40m
Hoist Type	Top-running wire rope	Twin hoists for extreme loads	Standard wire rope
Control	Pendant/radio/cabin	Cabin/fully automated	Basic pendant
Automation	PLC & anti-sway common	Advanced AI integration	Limited
Price	Premium	Very High	Budget-friendly

 

Lifting Capacity: 35 metric tons (35,000 kg)
Span: 10m–35m (customizable)
Lifting Height: 6m–20m (adjustable)
Hoist Type: Double-girder with electric wire rope hoist (QD-type)
Travel System: Motorized (rail-guided or rubber-tired)
Wheel Type: Steel wheels (for rails) / Pneumatic tires (floor use)
Control System: Cabin-operated or remote control
Power Supply: 380V/50Hz (3-phase)
Structural Steel: Q345B (high-strength) with corrosion-resistant coating

This heavy-duty lifting system consists of carefully engineered components working in harmony to handle extreme loads (5-500+ tons) with precision. Here's the complete technical breakdown:

1. Primary Structural Components

Main Girders (2x)

Fabricated from high-grade steel (S355JR/S460ML)

Box-type construction with internal stiffeners

Typically 1.2-3m height depending on span

Includes runway beams for hoist movement

End Carriages

Welded steel construction with machined wheel paths

Contains drive mechanisms and buffer systems

Anti-climb safety features

 

 

2. Hoisting System

Trolley Assembly

Dual-girder top-running configuration

4-8 wheel groups with hardened treads

Includes cross-travel motor (7.5-30kW typical)

Hoist Unit

European-standard wire rope hoist (DEMAG, ABUS)

2/1 or 4/1 reeving system

Drum diameter: 450-1200mm

Brake system: Dual-circuit fail-safe

 

3. Drive & Power Systems

Travel Drives

AC squirrel cage motors (10-100kW)

Frequency inverters for smooth acceleration

Bevel gear reducers (1:20 to 1:40 ratio)

Power Supply

Festoon systems or conductor bars

400V/50Hz 3-phase standard

Emergency power-off circuits

 

4. Control & Safety Systems

Operator Interfaces

IP54-rated pendant stations

CAN-bus radio remote controls

Full cabin options with HVAC

Safety Components

Load moment indicators (Class IV)

Redundant limit switches

Anti-collision laser scanners

Wind speed monitors (for outdoor)

5. Mechanical Components

Wheel Assemblies

Forged steel wheels (Ø300-800mm)

Double-flange design

SKF/FAG bearings

Buffers & Bumpers

Hydraulic energy absorbers

Polyurethane end stops

6. Electrical Systems

Control Cabinet

PLC-based (Siemens/Allen-Bradley)

PROFIBUS communication

Condition monitoring ports

Sensors

Absolute encoders for position

Load cell systems

Thermal sensors for motors

7. Optional Systems

Automation Packages

Automatic positioning (±5mm)

RFID container tracking

Remote diagnostics

Special Environments

ATEX packages

Corrosion protection (C5-M)

High-temperature kits

SKETCH

Main technical

 

1. Superior Lifting Performance

Higher Capacity: Handles 5-500+ tons vs single girder's 1-20T limit

Greater Span: Up to 50m+ with minimal deflection (L/800 standard)

Increased Hook Height: Top-running design provides 15-30% more vertical space

2. Enhanced Structural Integrity

Twin girders distribute load evenly, reducing stress concentrations

FEM 1.001 classification ensures 25+ year service life

<0.5mm/m alignment tolerance for precision operations

3. Advanced Control Systems

SIL3 safety-rated PLC controls

Predictive maintenance capabilities via IoT sensors

Anti-sway systems achieve ±5mm positioning accuracy

4. Operational Efficiency

30% faster trolley speeds (up to 60m/min) compared to Asian counterparts

Energy recovery systems reduce power consumption by 15-20%

Automated workflows increase throughput by 40%

5. Safety Features

Redundant braking systems (mechanical + regenerative)

360° collision avoidance with 10m detection range

Load monitoring with ±1% accuracy

6. Customization Options

Modular design allows 200+ configuration variants

ATEX, corrosion-resistant, or cryogenic versions available

Can integrate with existing smart factory systems

 

Heavy Industry

Steel Mills: Handling 40-ton coils at 800°C

Foundries: Moving 100-ton molds with precision

Transformer Stations: Installing 300-ton power units

 

Energy Sector

Wind Turbine Assembly: Positioning 80-ton nacelles

Nuclear Plants: Handling radioactive components

Hydroelectric Projects: Moving turbine components

 

Transport Infrastructure

Shipyards: Assembling 500-ton ship blocks

Bridge Construction: Precisely placing 200-ton segments

Railway Workshops: Lifting complete train cars

 

Advanced Manufacturing

Aerospace: Positioning aircraft fuselages (±2mm)

Automotive: Robotic cell integration

Space Industry: Satellite handling in cleanrooms

 

Specialized Applications

Magnetic Load Handling: For transformer production

Explosive Environments: ATEX-certified versions

Subzero Operations: -40°C Arctic versions

 

 

The production of a 35-ton Rubber Tire Gantry Crane (RTG) involves several key stages, from design and material procurement to assembly, testing, and commissioning. Below is a detailed production procedure:

1. Design & Engineering
Conceptual Design: Determine crane specifications (span, lifting height, power system, etc.).

Structural Analysis: Use CAD/CAE software (e.g., SolidWorks, ANSYS) to ensure load-bearing capacity and stability.

Electrical & Hydraulic Design: Plan power distribution, control systems, and motion mechanisms.

Regulatory Compliance: Ensure adherence to standards (ISO, FEM, OSHA, etc.).

2. Material Procurement
Steel Fabrication: High-quality steel (Q345B or equivalent) for beams, legs, and girders.

Rubber Tires & Bogies: Heavy-duty, non-marking rubber tires with a swivel mechanism.

Hoist & Trolley: 35-ton electric or hydraulic hoist with anti-sway technology.

Electrical Components: Motors, PLCs, sensors, and cables.

Hydraulic System (if applicable): Pumps, cylinders, and valves.

3. Fabrication of Major Components
A. Gantry Frame Fabrication
Cut and weld steel plates/beams to form the legs, girders, and end carriages.

Machine mating surfaces for precise assembly.

Shot-blast and prime surfaces for corrosion protection.

B. Trolley & Hoist Assembly
Assemble the trolley frame with wheels, motors, and gearboxes.

Mount the 35-ton hoist (wire rope or chain) with brakes and limit switches.

C. Rubber Tire Bogies
Fabricate wheel bogies with swivel and locking mechanisms.

Install hydraulic or electric drive motors for travel.

4. Electrical & Control Systems
Install PLC-based control system for smooth operation.

Wire power supply, sensors, and safety devices (e.g., overload protection, emergency stop).

Test radio remote control or cabin-operated system.

5. Assembly & Integration
Erect the gantry structure (legs and top beam).

Mount the trolley and hoist onto the girders.

Install bogies and rubber tires (ensure proper alignment).

Connect electrical and hydraulic systems.

6. Testing & Quality Control
A. Load Testing
Static Load Test: 1.25 × rated capacity (43.75 tons) to check structural integrity.

Dynamic Load Test: Verify performance under operational conditions.

B. Functional Tests
Travel Test: Check smooth movement along the runway.

Lifting & Lowering: Ensure precision and safety.

Safety Checks: Verify limit switches, brakes, and emergency stops.

C. Paint & Finishing
Apply final anti-corrosion paint (typically epoxy-based).

7. Commissioning & Delivery
On-site assembly (if shipped in modules).

Operator training for safe usage.

Final inspection & handover.

 

 

 

 

 

 

 

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.

Hot Tags: european-type double girder gantry crane, China european-type double girder gantry crane manufacturers, suppliers, factory