Global Industrial Gantry Crane

 

 

1)Global Industrial Gantry Cranes are usually used for loading and unloading and lifting and handling operations in open warehouses or along railways. Its structure includes bridges, trolley running mechanisms, trolleys and electrical equipment. The bridge adopts a box-shaped welded structure to ensure the strength and stability of the equipment. The equipment is suitable for a wide range of applications with a lifting capacity between 10 tons and 160 tons, a lifting height of up to 12 to 30 meters, and a span of 18 to 40 meters.

 

2) Global Industrial Gantry Cranes have a variety of operating methods, including ground operation, remote control operation and cab operation. Users can choose the most suitable operation method according to specific needs. The conductive form is divided into cable and busbar. One must be clearly selected when ordering. The design of the equipment takes into account different working environments, such as mechanical processing workshops, metal structure assembly workshops and smelting workshops, and is divided into A5 and A6 working levels according to the busyness of the work.

 

3) Global Industrial Gantry Cranes are not easy to work in flammable and explosive media or places with high humidity and corrosive gases. It is not suitable for lifting molten metals, toxic items, and two operating modes of ground and control room. The control room is available in two types: closed type and rear or side door for users to choose. The trolley running mechanism adopts separate drive mode, and there are two ways of driving and braking. One is to be completed by a conical motor, and the transmission is a "one open and one closed" gear rotation. The closed gear part is borrowed from the reducer of the LD type single beam crane; the other is an angular bearing box assembly with rolling bearings on the wheels, and the drive is completed by a squirrel cage or winding motor, a ZSC type vertical reducer and an electromagnetic or hydraulic brake.

 

Warranty：2 years

Weight (KG)：5000 kg

Feature：Gantry Crane

Application：warehouse, ports, yard, etc

Rated Lifting Moment：100kn

Color：Customized

Capacity：10-600t

Power supply：110V/220V/230V/380V/440V

Lifting mechanism：Electric Winch Trolley

Work Duty：A3-A6

 

 

 

1.Main beam

1) Main beam structure

Box-type structure: This structure is welded into a box shape by steel plates, which has the advantages of high strength and high rigidity. It is suitable for large-tonnage and super-large-tonnage gantry cranes.

Truss structure: The truss structure is welded by angle steel or I-beam, which has light weight and good wind resistance, but has large deflection and small rigidity, and is suitable for sites with small lifting weight.

Cellular beam structure: This structure combines the characteristics of truss and box beam, has large rigidity and reliability, and is suitable for sites with frequent use or large lifting weight.

2) Material process: The main beam is usually made of high-quality carbon structural steel or low-alloy structural steel to ensure sufficient strength and durability. The welding quality of the main beam directly affects its overall performance, so the welding process must be strictly controlled, and the basic form and size of the weld groove should meet the relevant standards.

3) Design features

Sufficient rigidity and strength: The main beam design must ensure sufficient rigidity and strength to withstand various loads during the lifting process.

Coordination with the overall structure: The design of the main beam needs to be coordinated with the overall structure to ensure the normal operation of the crane.

Weight optimization: While ensuring stability, the weight of the main beam is reduced as much as possible to reduce manufacturing costs and improve energy efficiency.

 

 

Lifting System

1) Main and auxiliary lifting mechanism

Main lifting mechanism: mainly used for lifting heavier objects, with slow but stable speed.

Auxiliary lifting mechanism: used for lifting lighter objects, with fast speed and high efficiency.

Height difference: usually the lifting height of the auxiliary lifting mechanism is higher than that of the main lifting mechanism.

2) Working principle

Motor drive: after the motor is started, the reel is driven to rotate through the reducer to wind or release the wire rope.

Pulley block function: The pulley block guides the wire rope so that the hook can rise or fall vertically.

Brake control: when the specified position is reached, the brake is activated to stop the reel from rotating and keep the hook position.

3) Technical features

High-efficiency performance: the lifting mechanism is reasonably designed, can respond quickly to operating instructions, and improve work efficiency.

Safe and reliable: equipped with a variety of safety devices, such as overload protection, limit switches, etc., to ensure safe operation.

Easy maintenance: using standardized parts, convenient maintenance and replacement, and extended service life.

 

3.End carriage

1) The end beam is usually made of box-shaped profiles with excellent anti-torsion performance to ensure that it can withstand large torque during lifting. The end beam is equipped with a full set of travel devices, including a modular system of reduction motors and travel wheels, which can be flexibly configured to meet the needs of different load capacities. The end beam is compact and directly connected to the main beam and other load-bearing structures of the crane through a track-type travel device, which is easy to install and maintain.

2) The travel wheel material used in the end beam has an excellent self-damping effect, which can achieve smooth operation and reduce damage to the track. Through the matching drive solution, the end beam can achieve smooth start-up and variable speed travel movement, improving the flexibility and efficiency of operation. The end beam uses ductile iron with self-lubricating effect, which can significantly reduce the wear of the travel wheels and crane tracks and extend the service life.

 

4.Crane travelling mechanism

1) Composition structure

Drive device: The core part of the trolley running mechanism, usually composed of an electric motor, a reducer and a brake, etc., responsible for providing power and controlling the running speed.

Transmission device: The power generated by the drive device is transmitted to the wheels or crawlers, so that the crane can move along the track.

Wheels and tracks: The wheels are installed on the end beams and contact the tracks laid on the ground, supporting the weight of the crane and guiding its horizontal movement.

2) Working principle

When the operator issues an instruction, the motor starts, reduces the speed and increases the torque through the reducer. The reducer transmits the power to the transmission device, and then converts the power into a horizontal movement force through the wheels or crawlers. The wheels roll along the track to ensure that the crane moves smoothly along the predetermined path.

3) Technical features

The trolley running mechanism is reasonably designed and can respond quickly to operating instructions and improve work efficiency. High-quality materials and precise manufacturing processes are used to ensure that the mechanism is stable and reliable during operation. Equipped with a variety of safety devices, such as limit switches, buffers, etc., to prevent the crane from derailing or colliding.

 

5.Trolley travelling mechanism

1) Drive motor: usually an electric motor, which drives the trolley to run along the track. The power and running speed of the motor depend on the working requirements of the crane.

2) Reducer: Reduces speed through gear transmission and enhances the output torque of the trolley to ensure smooth movement of the trolley.

3) Wheels: The trolley is usually equipped with multiple wheels (driving wheels and driven wheels) installed above or inside the double beam. The wheels run along the track on the main beam to ensure smooth and reliable movement of the trolley.

4) Guide rails: usually made of steel, installed on the upper surface or inside of the main beam, and the wheels of the trolley move along the guide rails to ensure precise operation.

5) Brake: The trolley running mechanism is equipped with an electric or mechanical braking system so that it can brake quickly and accurately when stopping to ensure the safety of the trolley's operation.

 

6.Crane wheel

1. Wheel type:

Driving wheel: driven by the driving device, responsible for driving the trolley to move along the track of the main beam. The driving wheel is generally connected to the motor, and the trolley is driven by the power of the motor.

Driven wheel: paired with the driving wheel, not directly connected to the motor, plays a role of auxiliary support and guidance. The driven wheel also rolls on the track, but does not participate in the drive.

Main wheel and guide wheel: some gantry cranes are equipped with guide wheels or side wheels on the wheels to ensure that the trolley moves in a straight line when moving and prevent lateral deviation.

2. Wheel material:

Steel wheel: Common crane wheels are made of high-strength steel, with strong wear resistance and load-bearing capacity, suitable for working under heavy load and high frequency.

Forged wheel: manufactured by forging process, with higher strength and longer service life, suitable for large-tonnage cranes.

7.Crane Hook

1) Hook type:

Single hook: Single hook is the most common form, with a simple structure and widely used in most lifting operations. Single hook is suitable for lifting most ordinary goods.

Double hook: Double hook is suitable for materials that are symmetrical or require two-point support, such as long objects. Double hooks can provide better balance and safety.

2) Use and maintenance of hooks:

During use, the hook needs to be checked regularly for deformation, cracks or wear, especially when lifting heavy objects, the hook will be under great pressure. If the hook has defects, it may cause major safety accidents.The rotating part of the hook should be lubricated regularly to maintain flexibility and prevent rust or jamming.Before each use, make sure that the safety lock is in good working condition to avoid accidental unhooking.

Motor

Drive and control of motors:

1) Electronic control system: The motors of cranes are driven and controlled by electronic control systems, which usually include control components such as contactors, relays, frequency converters and PLCs. The electronic control system can realize the functions of starting, stopping, accelerating, decelerating and braking the motors.

2) Variable frequency speed regulation: The frequency converter controls the speed by adjusting the frequency of the motor to achieve precise speed regulation. Using variable frequency speed regulation can not only reduce energy consumption, but also extend the service life of the motor and related machinery.

3) Overload protection: The motor is usually equipped with an overload protection device. When the motor load exceeds its rated value, the system will automatically cut off the power to protect the motor from damage.

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Sound and light alarm system & limit switch

1)Function of the sound and light alarm system

Start reminder: When the crane starts to run, the sound and light alarm system will automatically emit a loud warning sound, usually accompanied by flashing lights, to remind the staff and surrounding personnel that the crane is running.

Fault alarm: When the crane fails (such as overload, limiter failure, motor overheating, etc.), the sound and light alarm system will immediately sound an alarm to prompt the operator to check.

Emergency alarm: During the operation of the crane, if an emergency (such as power failure or mechanical failure) is detected, the system will send a continuous alarm signal through sound and light, requiring immediate measures.

2)Function of limit switch

Position control: The limit switch can accurately control the operating position of the crane to prevent the trolley, trolley or hook from exceeding the preset range.

Safety stop: When the crane runs to the set maximum limit, the limit switch will automatically cut off the power supply and stop the crane from continuing to run to prevent collision or derailment.

Prevent overwinding: The limit switch in the lifting mechanism can prevent the hook from overwinding, that is, after the hook rises to the top, the system will automatically stop the operation of the motor to prevent the wire rope from being over-tightened or broken.

10.Safety Devices

1) Overload limiter: used to detect the weight of the load lifted by the crane to prevent overloading. If the weight exceeds the set value, the system will automatically cut off the power supply or sound an alarm to remind the operator.

2) Electromagnetic brake: provides reliable braking function, automatically brakes when the motor is powered off or fails, and prevents the heavy object from sliding down or losing control.

3) Safety hook and lock: ensure that the sling and hook are firmly connected to prevent the risk of material sliding during the lifting process.

4) Safety clamp: installed on the lifting mechanism to prevent the hook from losing control during the descent process and provide additional safety protection.

5) Safety net and guardrail: set up safety nets and guardrails in the working area of ​​the crane to prevent people from entering the dangerous area by mistake.

6) Electrical protection device: including overcurrent protection, overheating protection and short circuit protection to prevent electrical faults from causing fire or equipment damage.

7) Emergency stop button of the control system: in an emergency, the operator can quickly cut off all power and stop the operation of the crane immediately.

8) Regular maintenance and overhaul: Develop regular maintenance and overhaul plans to ensure that all safety devices are functioning properly and eliminate potential faults in a timely manner.

 

11.Control Mode

1) Manual control: The operator controls the various functions of the crane (such as lifting, running, trolley movement, etc.) through manual joysticks or buttons. This method is simple and intuitive, and is suitable for small or medium-tonnage cranes. Or the operator uses a wireless remote control to control the movement of the crane, which provides a larger range of activities and flexibility, and is suitable for some complex or dangerous working environments.

2) Automatic control: The use of a programmable logic controller (PLC) for control can realize automatic operation and improve work efficiency and safety. The PLC system can be programmed to implement complex control logic, such as automatic upper and lower limits, overload protection, etc.

3) Frequency conversion control: Using a frequency converter to adjust the speed of the motor can achieve smooth acceleration and deceleration, reduce the impact on the mechanical system, and extend the service life of the equipment. This control method is usually used for cranes with high speed requirements.

4) Integrated control system: The various control functions of the crane are integrated into a central control platform, and the operator can manage and monitor the entire crane through an interface, including lifting, moving, positioning and other functions.

5) Remote control: Through wireless network connection, the operator can control the crane from a safe distance, which is suitable for operations in dangerous environments and reduces the safety risks of the operator.

 

12.Sketch

 

Main technical

 

 

1) Flexible operation: It can be configured with a variety of control methods, such as manual, remote control, automation, etc., which is flexible to operate and adapt to different working environments and needs.

2) Long service life: With high-strength materials and excellent manufacturing technology, Global Industrial Gantry Cranes have a long service life and good durability.

3) Convenient maintenance: The simple structure and easy replacement and repair of components make daily maintenance more convenient and reduce maintenance costs.

4) Wide range of applications: It can be used in workshops, warehouses, docks and other occasions, and can operate flexibly in indoor and outdoor environments to adapt to different work needs.

5) Space saving: Due to its gantry structure, it can be operated efficiently in a limited space, which is suitable for occasions with limited space.

6) High safety: It is equipped with a variety of safety devices (such as limit switches, overload protection, sound and light alarm systems, etc.) to ensure safety during operation and reduce the possibility of accidents.

7) Economic efficiency: Compared with other types of cranes, Global Industrial Gantry Cranes are generally more economical in terms of carrying capacity, maintenance cost and energy consumption, and are suitable for long-term investment.

8) Strong load-bearing capacity: The double-beam design enables it to withstand large loads, suitable for lifting heavy objects, and is widely used in manufacturing, logistics and other industries.

9) Good stability: Due to its double-beam structure, the crane has relatively high stability, can operate safely over a large range, and reduce the risk of overturning.

10) Smooth operation: The motor-driven trolley and cart move smoothly, can achieve precise lifting and moving, reduce the impact on materials, and are suitable for delicate operations.

 

 

1) Manufacturing: Global Industrial Gantry Cranes are commonly used in machinery manufacturing, automobile manufacturing, shipbuilding and other industries, mainly for handling large equipment and components, such as engines, ship parts, heavy machine tools, etc. In steel mills and metallurgical industries, Global Industrial Gantry Cranes are used to handle steel, steel coils and other heavy metal products.

2) Warehousing and logistics: In large logistics warehouses, Global Industrial Gantry Cranes are used to handle containers, large cargo and heavy objects, greatly improving the work efficiency of warehouses. In ports and docks, Global Industrial Gantry Cranes are used to load and unload containers, bulk cargo and large cargo, such as large cargo handling on ships.

3) Construction and infrastructure: In bridge engineering, Global Industrial Gantry Cranes are used to lift and carry large building materials such as steel beams and concrete components.

4) Energy industry: Global Industrial Gantry Cranes are widely used in power plants, especially thermal and hydropower plants, to maintain key equipment such as large generators, transformers, boilers, etc. In the wind power industry, cranes are used to install and maintain the towers and blades of wind power equipment.

5) Mining: In the field of mining and mineral processing, double-girder gantry cranes are used to move ores, equipment and other heavy materials. They are commonly used in open-pit mines, concentrators and smelters.

6) Aerospace: In aerospace manufacturing, double-girder gantry cranes are used to move precision and heavy equipment such as aircraft parts, rockets and satellites, ensuring accuracy and safety during operation.

7) Shipbuilding: In shipyards, double-girder gantry cranes are used to lift and transport hulls, decks and other large ship parts, and are widely used in the process of hull construction, assembly and repair.

8) Railway and rail transportation: In the railway industry, double-girder gantry cranes are used to move rails, train carriages and large locomotive equipment, suitable for railway track laying and maintenance work.

 

 

1) Demand analysis and design: According to the specific needs of customers (such as lifting capacity, span, work site, etc.), carry out detailed technical analysis to determine the specifications and functional requirements of the crane. Design the main components of the Global Industrial Gantry Crane, such as the main beam, trolley, and outriggers, to ensure that they meet national standards and customer requirements. Use CAD software for detailed 3D modeling to ensure the rationality and safety of the structure. Design the electronic control system, including motors, control boxes, inverters, limit devices, and safety alarm systems, to ensure the automation and ease of operation of the crane.

2) Material procurement: According to the design plan, purchase the required steel, motors, electrical components, wire ropes, pulleys and other raw materials to ensure that all materials meet the relevant quality standards and requirements.

3) Manufacture of steel structure: According to the design drawings, cut and weld the steel plates to form the basic structure of the main beam and outriggers. High-strength steel is usually used to ensure the strength and durability of the crane. Manufacture the lifting trolley, including the motor, brake, wheels and its frame structure. The welding of the main beam and the outrigger needs to be strictly controlled, and the welds need to be non-destructively tested (such as ultrasonic or X-ray flaw detection) to ensure that the welding quality is defect-free.

4) Machining: The wheel is one of the core components of the Global Industrial Gantry Crane. It needs to be precisely processed by lathes and other machining equipment to ensure that its diameter, roundness and surface finish meet the requirements. The gears and couplings used in the transmission system need to be processed with high precision to ensure their good coordination with the motor and transmission system. Drilling and milling grooves are required on the main beam, trolley and other components to ensure the accurate installation of motors, pulleys and other components.

5) Surface treatment: Sandblasting is performed on steel structural parts to remove the oxide layer and rust on the surface to ensure the adhesion of subsequent painting. Anti-corrosion treatment is performed on the main beam, outrigger, trolley and other components, usually spraying anti-corrosion paint, anti-rust paint and topcoat to ensure the durability of the crane in harsh environments.

6) Installation of electrical system: Install the crane's motor, inverter, control cabinet, limit switch and other electrical equipment to ensure that it can achieve accurate lifting, movement and positioning. According to the electrical design plan, carry out cable wiring and electrical component connection to ensure that the electrical system can run smoothly.

7) Assembly: Assemble the processed main beam, outriggers, trolleys and other parts, and fix them by bolts or welding. Install pulleys, drums and other parts, and correctly thread the wire rope to ensure that the hook can be lifted and lowered normally. Install the trolley on the main beam to ensure that it can run smoothly. Install the wheels on the trolley and install the track in the working area of ​​the crane to ensure that the trolley can run stably on the track.

8) Debugging and testing: Test the various functions of the crane, including lifting, moving, braking and limit devices, without load to ensure that all functions are normal. Load the weight within the safe range, test the crane's load capacity, running stability, braking effect and various safety devices to ensure that they meet the design requirements.

9) Quality inspection: Check the appearance quality of welds, spraying, etc. to ensure that the crane has no obvious defects. According to national or industry standards, test the various performance indicators of the crane to ensure that they meet the design requirements. After all tests are passed, the factory inspection is carried out to ensure that the quality of the crane is fully qualified.

10) Transportation and installation: The assembled crane is disassembled into parts and transported to the installation site specified by the customer. The crane is reassembled according to the on-site conditions and the final adjustment and positioning are carried out. Secondary commissioning is carried out at the customer's site to ensure that the crane can operate normally in the actual working environment.

 

 

 

 

 

 

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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