Gantry Crane 120 Tons

 

Sure! Here's an introduction to a 120-ton gantry crane that you could use in a report, presentation, or technical overview:

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Introduction to 120-Ton Gantry Crane

A 120-ton gantry crane is a heavy-duty material handling system designed to lift and transport exceptionally large and heavy loads in industrial environments. Typically used in shipyards, manufacturing plants, construction sites, and large storage yards, these cranes are engineered to provide stability, precision, and power.

Unlike overhead cranes that are fixed to a building structure, gantry cranes operate on ground-level rails or wheels, supported by freestanding legs, allowing them to move freely across a designated area. This flexibility makes them ideal for outdoor applications or areas where overhead support structures are not feasible.

The 120-ton lifting capacity indicates the crane can safely hoist up to 120 metric tons (approximately 264,500 pounds), making it suitable for handling massive components like ship hulls, precast concrete segments, wind turbine parts, and heavy machinery.

Key features of a 120-ton gantry crane typically include:

Double girder design for enhanced strength and load distribution

High-torque hoisting mechanism for smooth, controlled lifting

Advanced control systems (manual, remote, or automated)

Durable structural steel construction for longevity and performance in harsh environments

Safety features such as overload protection, emergency stop systems, and anti-collision devices

The crane's design and configuration can be customized based on application needs, including span length, lifting height, rail type, and power source (electric or diesel).

 

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

 

 

1.Main Girder (Bridge Beam)

Function: The horizontal structure that spans the width of the crane and carries the hoist and trolley.

Details: Usually a double-girder configuration for heavy loads like 120 tons; made from high-strength steel.

Legs (Support Columns)

Function: Vertical supports that transfer the load from the girder to the ground or runway.

Details: Can be rigid or have a flexible design depending on the crane's mobility and terrain.

End Carriages / Wheels

Function: Mounted at the base of the legs, these allow the crane to move along ground tracks or a concrete floor.

Details: Equipped with drive motors and braking systems for controlled movement.

Hoist (Lifting Mechanism)

Function: Lifts and lowers the load using a drum, wire rope, or chain.

Details: For a 120-ton capacity, it's typically a heavy-duty electric wire rope hoist with precise speed control.

 

 

3.End carriage

1) The end carriage of a Double Main Girder Gantry Crane is a critical component of its structural and operational system. It connects the main girders to the wheels or tracks, providing stability and ensuring the crane's structural integrity.Equipped with wheels or bogies, the end carriage enables the crane to move along the tracks laid on the ground or across gantry beams.Distributes the weight of the crane and the load evenly across the wheels and tracks.

2) The end beam is typically made of high-strength steel to withstand heavy loads and environmental conditions.

3) The end beam is designed to support the specific load-bearing requirements of the crane.

4.Crane travelling mechanism

1) Working principle

The wheels are attached to axles or wheel blocks that help in distributing the load evenly across the crane.The drive motor activates the wheels through a system of gears and reducers, converting the motor's rotational force into torque.The wheels, mounted on the frame of the crane, roll along the rails on which the gantry structure is placed.The power to the wheels is transmitted via a combination of chains, belts, or direct coupling depending on the design of the crane.The crane traveling mechanism of a Double Main Girder Gantry Crane involves synchronized wheel and motor systems that enable the crane to move along its designated rails, with additional features ensuring safe, balanced, and efficient operation.

2) Functions of the crane operating mechanism

Horizontal movement: The primary function of the crane travelling mechanism is to move the entire crane structure along the rails or tracks that are placed on the ground or the sides of the installation area.

Support and Stability:The travelling mechanism ensures the crane is securely supported on the rails or tracks. It helps distribute the weight of the crane evenly and provides stability during movement.

Power Transmission:The crane travelling mechanism is powered by electric motors that drive wheels or gear systems. These motors convert electrical energy into mechanical energy, propelling the crane forward or backward.

Load Distribution:The travelling mechanism helps distribute the load evenly across the crane's wheels and tracks, preventing damage and ensuring the durability of the crane and its components.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The frame is typically made of high-strength steel to support the load and withstand the stresses during operation.

Wheel set: The trolley is equipped with wheels that run on the rails of the main girder. These wheels are often made of hardened steel or cast steel to ensure durability and wear resistance.

Drive device: Electric motors are commonly used to provide the necessary power for the trolley's movement A gearbox is used to control the speed and torque of the trolley's movement.Couplings connect the motor to the gearbox and ensure smooth transmission of power to the wheels.

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2) Function of the trolley operating mechanism

Horizontal Movement: The primary function of the trolley traveling mechanism is to move the trolley horizontally across the length of the main girders. This movement allows the crane to position the hoist over a desired load location.

Load Handling: By moving along the main girders, the trolley helps in positioning the hoist system accurately above the load, which is necessary for lifting and transferring goods efficiently.

Power Transmission: The traveling mechanism typically uses electric motors and gear systems to provide the necessary torque and speed for the trolley's movement. The motors can be either AC or DC, depending on the design and requirements of the crane.

Rails and Wheels: The trolley runs on rails that are mounted on the main girders. The wheels on the trolley are designed to travel along these rails, ensuring smooth and stable movement. The wheels may be fitted with flanges to prevent lateral movement and maintain alignment.

Safety Mechanisms: The traveling mechanism is equipped with safety features such as limit switches, braking systems, and overload sensors to prevent accidents and ensure the safe operation of the crane.

6.Crane wheel

1) Function of wheels

Load Bearing: In a double main girder gantry crane, each wheel supports a significant portion of the crane's load. The wheels must be engineered to handle both the static and dynamic loads imposed during lifting operations.

Material Handling and Safety: The design of crane wheels must ensure safe operation, especially when handling heavy or oversized loads. The wheels should be engineered to minimize noise and vibrations during operation.

Rail Compatibility: Crane wheels are designed to run on specific rail types (e.g., flat or curved tracks). The size and shape of the wheel flange must match the rail profile to ensure proper fit and smooth operation.

2) Design requirements

Material and Design: Crane wheels are typically made of high-strength steel or cast iron to withstand the heavy loads and stresses associated with lifting and transporting materials. The design often includes a flange to ensure proper alignment and prevent the wheels from derailing off the tracks.

7.Crane Hook

The crane hook of a double main girder gantry crane is an essential component used for lifting and transporting heavy loads.

Design and Structure

Material: Typically made of high-strength steel to withstand heavy loads and provide durability.

Shape: The hook often has a C-shape or a pointed end for securely holding lifting slings or chains.

Size and Capacity: It is designed to match the lifting capacity of the crane, which can range from a few tons to several hundred tons for large industrial cranes.

Types of Hooks

Single Hook: Common in standard applications, used for lifting a load from a single point.

Double Hook: Utilized when a more balanced load is needed, often in double main girder designs for higher lifting capacities.

Crab Hook: In gantry cranes, the hook may be mounted on a trolley or crab that runs along the girders.

Motor

The motor of a double main girder gantry crane is an essential component that provides the power necessary for lifting, traveling, and sometimes rotating the crane's hoist or trolley system.The motor's power rating must match the crane's capacity and the load it needs to lift. Typically, these motors range from a few kilowatts up to hundreds of kilowatts, depending on the lifting and traveling requirements.

Motors can be equipped with variable frequency drives (VFDs) for smooth speed adjustments and energy savings.Safety and control systems like overload protection, braking systems, and emergency stops are incorporated for safe operation.

The motor should be compatible with the electrical supply available at the operating site, which can vary (e.g., 380V/50Hz, 480V/60Hz).The motor in a double main girder gantry crane is used for operations such as lifting heavy loads, moving the crane along the tracks (longitudinal travel), and sometimes lateral movement (cross travel) of the hoist or trolley.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

A double main girder gantry crane, commonly used in heavy-duty operations, often incorporates safety mechanisms like sound and light alarm systems to ensure safe operations.

Sound Alarm (Horns/Buzzers): These are typically loud, audible devices that emit a distinctive sound to alert people in and around the working area. The sound level is designed to be high enough to be heard over operational noise.

Light Alarm (Flashing Lights/Beacons): Visual signals, such as flashing lights or rotating beacons, help alert personnel visually, especially in noisy environments where sound alarms may be insufficient.

2) Limit switch

A limit switch on a Double Main Girder Gantry Crane is a safety device used to prevent the crane from moving beyond a designated range. This ensures the protection of both the crane and its surroundings, as well as any loads being lifted.

Key Functions of Limit Switches:

Position Control: The limit switch helps monitor and control the position of the crane's trolley, hoist, and gantry to prevent over-travel and collisions.

Safety Shutdown: If the crane moves past its allowed limits, the limit switch signals the control system to stop the motor and prevent damage or hazardous situations.

Emergency Stop: It can act as an emergency cutoff to shut down the crane when it approaches the limits of its track or rail, preventing it from derailing or causing accidents.

Types of Limit Switches Used:

Mechanical Limit Switches: Activated by physical contact, often using a lever or cam that triggers the switch when moved by the crane's motion.

Electronic Limit Switches: Use sensors (e.g., inductive, capacitive, or optical sensors) for non-contact detection, providing higher durability and reducing wear and tear.

Rotary Limit Switches: Typically used in applications where rotational motion needs to be monitored, such as in hoists.

Linear Limit Switches: Used for applications where linear travel is monitored, commonly found in the movement of the trolley.

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Safety Devices

Function: Protects equipment and personnel.

Includes:

Overload protection system

Emergency stop buttons

Limit switches (for hoist travel, trolley end, etc.)

Anti-collision sensors

Alarms and warning lights

11.Control Mode

1)1. Pendant Control

Description: The crane operator uses a wired control pendant to manage the movement of the crane and hoist.

Advantages: Simple to use, cost-effective, and provides direct control from a safe distance.

Usage: Commonly used in stationary or semi-stationary operations where the operator can be close to the crane.

2. Radio Remote Control

Description: Operators use a wireless control unit, which communicates with the crane via radio signals.

Advantages: Offers more flexibility as the operator can control the crane from a greater distance and access hard-to-reach areas.

Usage: Ideal for more complex operations and environments where operator mobility is essential.

3. Cabin Control

Description: The operator sits in a cabin on the crane itself and controls it using a combination of joysticks, buttons, or other controls.

Advantages: Provides a better view of the working area and greater precision in controlling the crane.

Usage: Suitable for heavy-duty operations or when a higher level of control is needed for positioning and maneuvering.

4. Automated Control (Semi-Automatic and Fully Automated)

Description: The crane can be controlled by programmed commands or integrated with automated systems for autonomous operation.

Advantages: Reduces human intervention, improves precision, and enhances safety for repetitive tasks.

Usage: Often used in large-scale operations where high efficiency and continuous operation are necessary.

5. Hybrid Control

Description: Combines manual operation (using pendant, remote, or cabin control) with automated features that can be engaged as needed.

Advantages: Offers versatility for operators who need to switch between manual and automated modes for specific tasks.

Usage: Common in systems designed to be adaptable to various operational requirements.

12.Sketch

 

Main technical

 

 

 

Here are the main advantages of a 120-ton gantry crane, especially when used in heavy-duty industrial applications:

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Advantages of a 120-Ton Gantry Crane

High Load Capacity

Designed to lift extremely heavy loads (up to 120 tons), making it ideal for industries such as shipbuilding, heavy machinery manufacturing, power plant construction, and wind energy.

Versatile Installation

Can be installed indoors or outdoors, and does not require an existing building structure (unlike overhead cranes), which reduces construction costs in open areas.

Mobility and Flexibility

Rail-mounted or rubber-tired versions offer mobility across wide work areas, which is ideal for transporting loads between different zones in a facility or yard.

Customizable Span and Height

Gantry cranes can be tailored with various spans, lifting heights, and speeds to suit specific operational needs.

Efficient Material Handling

Reduces manpower and time required to move large, heavy items, improving productivity and workflow in large-scale operations.

Robust and Durable Structure

Built with high-strength steel and heavy-duty components to withstand continuous use and harsh environments (like marine or outdoor industrial areas).

Advanced Safety Systems

Equipped with overload protection, emergency stops, limit switches, and sometimes anti-sway systems, ensuring safe operation even under full load.

Cost-Efficient for Large Loads

More economical and practical than using multiple smaller cranes or other heavy-lifting machinery for very large loads.

Reduces Dependence on Forklifts or Cranes with Limited Reach

Can handle oversized or irregular-shaped items that may be difficult to lift or position using other equipment.

Remote or Cabin Operation

Offers safer working conditions with remote controls or cabin operation, keeping the operator away from dangerous lifting zones.

 

 

Here's a list of common and specialized applications for a 120-ton gantry crane across various industries:

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Applications of a 120-Ton Gantry Crane

Shipbuilding and Marine Yards

Lifting and positioning ship hull sections, engines, and large steel components

Transporting assembled modules across dry docks

Ideal for block assembly and heavy fabrication

Precast Concrete and Infrastructure Projects

Handling large concrete beams, bridge segments, and girders

Used in construction of bridges, flyovers, and highways

Steel and Metal Fabrication Yards

Moving heavy steel plates, structural components, and large metal assemblies

Assisting in welding, cutting, and assembly operations

Wind Turbine Manufacturing

Lifting nacelles, towers, and blades during assembly and transport

Used both indoors for production and outdoors for staging

Power Plant Construction

Installing heavy turbines, transformers, and reactors

Facilitating the assembly of structural and mechanical components on-site

Railway and Locomotive Workshops

Lifting train bodies, bogies, and heavy mechanical parts

Used in both manufacturing and maintenance depots

Aerospace Industry

Handling large aircraft parts, molds, and tooling

Transporting components between assembly stages

Mining and Heavy Equipment Manufacturing

Moving massive components like crushers, drill rigs, and excavators

Supporting fabrication, maintenance, and assembly operations

Port Terminals and Logistics Yards

Loading and unloading oversized cargo or machinery from ships or railcars

Occasionally used as a backup to container gantry cranes

Shipbreaking and Recycling Yards

Lifting and moving dismantled ship parts for processing or recycling

 

 

 

1. Design and Engineering

Blueprint and Structural Design: Engineering teams design the crane based on specifications, considering the weight, span, lifting capacity, and working environment.

Component Specifications: Detailed specifications for components such as the main girders, end beams, hoist system, trolley, and electrical components are prepared.

2. Material Selection and Procurement

Steel Material Selection: High-strength steel materials are chosen for the main girders, columns, and other critical parts.

Procurement: Materials, such as steel plates, sections, bolts, and electrical components, are sourced and inspected for quality.

3. Cutting and Pre-Fabrication

Cutting and Shaping: Steel components are cut, shaped, and welded into preliminary forms according to the design specifications.

Pre-Fabrication Assembly: Components such as beams and girders are pre-assembled to verify that they fit together properly.

4. Welding and Structural Assembly

Welding: Main girders, columns, and other structural components are welded to create a sturdy framework. Specialized welding techniques are used to ensure strength and durability.

Structural Assembly: The main girders and end beams are assembled, ensuring precise alignment for balanced load distribution.

Quality Control: Welding seams and joints are inspected using non-destructive testing (e.g., ultrasonic or X-ray testing) for any structural defects.

5. Machining and Finishing

Machining of Parts: Critical parts such as the wheels, trolley components, and hoists undergo machining for proper fitting and smooth operation.

Surface Treatment: Steel parts are cleaned and subjected to surface treatments like sandblasting and coating to prevent rust and enhance durability.

Painting and Coating: Protective coatings are applied for weather resistance, with a primer followed by top coats.

6. Assembly of Crane Components

Main Girder Assembly: The two main girders are mounted and aligned.

End Beam Installation: End beams are fixed to the main girders, forming the frame of the crane.

Hoist and Trolley Installation: The hoist mechanism and trolley are mounted on the main girder rails and tested for alignment and operational smoothness.

7. Electrical and Control Systems Installation

Wiring and Cabling: Electrical wiring is installed for power supply, control circuits, and safety systems.

Control Panel and Safety Features: The control panel is mounted, with safety features such as limit switches, emergency stops, and overload protection integrated and tested.

Control System Programming: The crane's control system is programmed and tested for correct operation.

8. Testing and Quality Assurance

Load Testing: The crane is subjected to load tests to ensure it can handle its rated capacity without issues.

Operational Testing: Functional tests are performed to check movements, responsiveness, braking systems, and electrical operations.

Inspection and Certification: The crane undergoes final inspections to verify compliance with safety regulations and standards. Certification may be issued by relevant authorities.

9. Final Adjustments and Delivery Preparation

Final Adjustments: Any minor adjustments are made to ensure smooth operation.

Documentation: Operation manuals, maintenance guidelines, and certification documents are prepared for delivery.

Packaging and Shipping: The crane is packaged securely for shipment, ensuring all parts are protected during transit.

10. Installation and Commissioning (at Site)

On-site Assembly: The crane is assembled at the customer's location if required.

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%.