World's Largest Gantry Crane

 

The world's largest gantry crane is an advanced heavy-lifting solution designed for industrial and infrastructural applications that demand exceptional lifting capacity, stability, and precision. Engineered for durability and efficiency.

The world's largest gantry crane have unrivalled lifting capacity and are designed to handle extremely heavy loads, often exceeding several hundred tonnes. world's largest gantry cranes also feature a sturdy double girder for increased load-bearing strength and stability.

The world's largest gantry crane is tailored to specific operational needs and adapt to a variety of working environments. Adjustable height to manage different levels of operation

The largest double girder gantry cranes are made with high-grade steel and corrosion-resistant components for long service life.Designed to withstand harsh environments, including extreme weather and frequent use.

The world's largest gantry crane features a modern drive system that reduces power consumption and optimizes performance.A regenerative braking system increases energy savings.Integrated with PLC-based systems and remote controls for user-friendly operation.Safety features like anti-sway mechanisms, overload protection, and emergency stop functions.

The world's largest gantry crane exemplifies engineering excellence, providing unparalleled performance for the most demanding industrial applications.It is ideal for handling oversized loads in ports, shipyards, power plants, construction sites, and large-scale manufacturing facilities.

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

Place of Origin:Henan, China

Warranty:2 years

Weight (KG):50000 kg

Video outgoing-inspection:Provided

Machinery Test Report: Provided

Application: Outdoor

Keywords: Gantry Crane

Rated Loading Capacity: 50Ton

Cross travelling speed: 44.6m/min

Long travelling speed: 47.1m/min

Control way: cabin

Power supply: Cable reel

Steel track: QU80

Power: 3-phase AC 50HZ 380V

Certification: CE ISO

 

 

Pictures & Components

 

 

1.Main beam

The main beam of the largest double-girder gantry crane is a critical structural component, responsible for supporting the crane's load and ensuring the stability of the entire structure during lifting and transportation operations.

Double Girder Configuration: Consists of two parallel girders that provide higher load-carrying capacity compared to single-girder cranes. This design is essential for large spans and heavy-duty applications.For the largest gantry cranes, spans can exceed 200 meters, depending on the application (e.g., shipbuilding or container handling).

The height of the main beam varies based on lifting requirements and operational clearances.The web and flange thicknesses are engineered for optimal stress distribution to prevent buckling or bending under maximum loads.Typically made from high-strength steel to handle enormous loads while minimizing structural deformation.Girders are fabricated using welded box or I-beam structures for added rigidity and load distribution.

Some of the largest double-girder gantry cranes have a lifting capacity exceeding 20,000 tons, as seen in shipyard or heavy industry cranes.The main beam is designed to bear both the static and dynamic loads imposed during lifting, moving, and braking.

The design and construction of such main beams require advanced engineering, precision fabrication, and robust safety standards to ensure operational reliability and longevity.

 

Lifting System

1) Motor: The motor of the lifting system in the largest double girder gantry cranes is a critical component, designed for robust performance and precise control to handle massive loads.

2) Reducer: The reducer of the lifting system in the largest double girder gantry crane is a critical component designed to transmit torque from the motor to the hoisting mechanism while reducing the motor's rotational speed to achieve the required lifting speed.

3) Drum: The drum lifting system in the largest double girder gantry cranes plays a crucial role in handling heavy loads efficiently and safely. This component is a part of the hoisting mechanism that enables the crane to lift, lower, and hold materials.

4) Wire rope: The wire rope used in the lifting system of the largest double girder gantry crane is a critical component that ensures safe and efficient load handling.

5) Pulley block: The pulley block is designed to handle massive loads, sometimes several hundred tons, given the size of the crane. It is made from high-strength steel or alloy to withstand the intense forces involved in lifting.

6) Lifting device: The lifting device of the largest double girder gantry crane is typically composed of several key components, each designed to handle massive loads with high precision. These cranes are used in various heavy-duty applications, such as in shipyards, construction sites, and large-scale manufacturing operations.

 

3.End carriage

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

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

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

 

 

4.Crane travelling mechanism

1) Working principle

The working principle of the crane's traveling mechanism involves a combination of electrical and mechanical systems to achieve controlled, smooth horizontal movement.The electric motor receives power from a source (such as a power supply from a busbar or cable). The motor's rotation drives the gear system, which in turn rotates the travel wheels mounted on the crane's bogies.The travel wheels rotate, causing the entire crane structure to move along the rails. Since the wheels are mounted on either side of the crane's girder, the force is distributed evenly, helping in balanced movement.The speed of the crane's travel is controlled by varying the frequency of the motor supply or by using a variable frequency drive (VFD). This allows the crane to move at the desired speed, whether slow for precision or fast for large movements.

2) Functions of the crane operating mechanism

The crane traveling mechanism in a double girder gantry crane is essential for the crane's overall functionality, enabling it to move efficiently within its operational area, transport heavy loads safely, and enhance productivity. It integrates seamlessly with the lifting and hoisting mechanisms to offer a comprehensive solution for material handling in large industrial environments.

5.Trolley travelling mechanism

1) Structural composition

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

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

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

2) Function of the trolley operating mechanism

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

6.Crane wheel

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

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

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

7.Crane Hook

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

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

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

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

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

Motor

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

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

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

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Sound and light alarm system & limit switch

1) Sound and light alarm system

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

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

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

2) Limit switch

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

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

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

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

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

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

10.Safety Devices

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

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

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

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

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

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

11.Control Mode

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

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

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

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

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

12.Sketch

 

 

 

Main technical

 

 

High Lifting Capacity: Double girder gantry cranes are designed for extremely heavy loads, often exceeding hundreds of tons. Their dual-girder structure ensures better load distribution and strength, making them ideal for demanding applications.

Extended Span and Coverage:They can span large distances, covering extensive work areas, which is essential for industries like shipyards or construction sites that require the movement of heavy materials across broad areas.

Stability and Durability:The double girder configuration offers superior structural integrity and resistance to dynamic forces, making them stable even under high-stress operations or adverse environmental conditions.

Precision in Operations:These cranes are equipped with advanced control systems, enabling precise positioning and handling of loads, critical for delicate operations like assembling large machinery or vessels.

Flexible Application:They can handle a wide variety of loads, from containers and prefabricated structures to raw materials, making them versatile across industries.

Space Efficiency:Since gantry cranes operate on ground rails rather than requiring overhead runways, they eliminate the need for additional structural supports, saving space and reducing infrastructure costs.

Cost-Effective Over Time:For outdoor or large-scale operations, these cranes can be more cost-effective than building permanent overhead crane structures, especially when mobility and flexibility are needed.

Customization Options:The largest double girder gantry cranes are often custom-built to fit specific industrial needs, including span, load capacity, and environmental conditions like wind or corrosive environments.

Enhanced Safety Features:Modern double girder gantry cranes come with safety enhancements such as anti-sway mechanisms, overload protection, and emergency stop systems, ensuring safer operations for heavy loads.

Capability for Multi-Trolley Systems:These cranes can be designed to support multiple trolleys, allowing simultaneous lifting and precise movement of different components, increasing operational efficiency.

 

 

Heavy Manufacturing: Used for lifting and assembling large ship components like hulls, engines, and turbines. Handling large steel plates, beams, and structural components.Transporting and installing turbines, generators, and other heavy equipment.

Construction: Lifting heavy precast concrete beams, girders, and segments for bridges.Handling materials like concrete blocks, turbines, and gates for hydropower projects.Moving large prefabricated sections or steel structures.

Ports and Logistics: Moving large shipping containers in port terminals.Transporting materials like coal, minerals, or aggregates.

Aerospace and Defense:Lifting and assembling large aircraft parts such as fuselages, wings, and engines.Transporting spacecraft or rocket components during assembly and testing.

Mining: Handling large mining equipment or transporting extracted materials. Assisting in the maintenance of heavy mining machinery.

Energy: Lifting and placing reactor components and containment structures. Handling and installing large turbine components like blades and nacelles.

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

Crane production procedure

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

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

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

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

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

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

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

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

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

Workshop view:

The company has installed an intelligent equipment management platform, and has installed 310 sets (sets) of handling and welding robots. After the completion of the plan, there will be more than 500 sets (sets), and the equipment networking rate will reach 95%. 32 welding lines have been put into use, 50 are planned to be installed, and the automation rate of the entire product line has reached 85%.