Mobile Girder Rail Gantry

 

A mobile single girder rail gantry is a type of crane designed to move along rail tracks and provide lifting and transportation capabilities in various industrial environments. It is commonly used for handling heavy materials and goods in manufacturing, construction, and logistics. The crane features a single girder structure that supports the lifting mechanism.This design is more compact and cost-effective compared to double girder gantries, while still offering reliable performance for most lifting operations.

The gantry is equipped with wheels or rail-mounted systems, allowing it to move easily along the rails.This mobility is ideal for large facilities or outdoor environments where goods need to be transported over long distances.These gantries are designed to lift a wide range of loads, typically between 1 ton and 30 tons, depending on the specific model and configuration.The lifting mechanism is equipped with hoists, pulleys, and sometimes hook-based or magnet-based attachments.

3)The gantry is mounted on rails for precision movement, which is useful in applications such as container yards, steel plants, and warehouses.It ensures stability and efficiency when moving heavy loads along a fixed track.Built from high-quality steel and engineered for durability, these gantries are resistant to wear and can function in harsh environments.Safety features like overload protection, emergency stop buttons, and sensors help ensure safe operation during loading and unloading activities.The gantry crane can be operated by a simple control panel, offering either manual or remote operation.Operators can control the movement of the crane with ease, improving productivity in demanding work environments.

Warranty：1 Year

Weight (KG)：9860 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Application：Industrial Workshop Plant

Lifting Mechanism：Electric Hoist

Crane type：Sing Girder Gantry Crane

Girder Type：Single Box Girder

Control method：Remote Control

Work Duty：A4

Power Source：3 Phase 380V 50hz/ Customized

After-sales Service Provided：Online Support Provided

Color：Customized

 

 

 

Main beam

1)Structural Composition:

Material: Typically made from high-strength steel, such as carbon steel or alloy steel, the main beam is engineered to withstand heavy loads and environmental conditions.

Design: The beam usually adopts a box-type or I-beam design, depending on the specific requirements of the crane. The design choice affects factors like weight, stability, and ease of fabrication.

Dimensions: The beam's length, height, and width are customized to the crane's lifting capacity and track length. The longer the beam, the greater the distance it must span to support heavier loads.

2)Functionality:

Load Distribution: The main beam is responsible for bearing the weight of the load being lifted, along with the forces from the trolley, hoists, and rail systems.

Support for Other Components: The main beam acts as a foundation for other key components such as the trolley (the part that moves along the beam), the hoisting mechanism, and the end beams (which support the gantry's wheels and rails).

Flexibility: The main beam is designed to handle dynamic forces during the lifting process, including acceleration, deceleration, and load swings.

Lifting System

How the Lifting System Works:

1)Load Lifting:

The operator uses the control system to activate the hoist, which begins winding the chain or rope around the drum, causing the lifting hook or attachment to rise and lift the load.

The hoist operates in conjunction with the trolley, which moves horizontally along the beam to position the load at the required location.

2)Load Lowering:

To lower the load, the hoist motor reverses, allowing the chain or rope to unwind from the drum and bringing the load back down to the ground or to the required position.

3)Horizontal Movement:

The trolley can also move horizontally along the main beam, powered by its own drive motor or manually. This allows the load to be positioned exactly where it is needed.

 

3.End carriage

1. Support for the Gantry Structure:

The end carriage serves as the foundation for the crane's main girder, which spans between the two end carriages. It provides the structural support required to handle heavy lifting operations.

2. Mobility:

The end carriage enables the gantry to move along the rail system, facilitating horizontal travel over long distances. This mobility is crucial in environments such as shipping yards, warehouses, or manufacturing plants where loads need to be moved over large areas.

3. Stability:

The end carriage provides stability to the gantry crane, ensuring it remains balanced during operation, especially when lifting heavy or unbalanced loads.

The wheels or rail-mounted system prevent the crane from tipping over or shifting out of alignment during use.

4. Load Handling:

The end carriage contributes to the effective distribution of loads by supporting the main girder and lifting system, allowing the crane to perform efficient load handling in various industrial applications.

 

4.Crane travelling mechanism

How the Traveling Mechanism Works:

1)Powering the Movement:

The operator activates the traveling mechanism by turning on the drive motor via the crane's control system.

The motor powers the gearbox, which transmits motion to the wheels on the end carriages. These wheels roll along the rail system, moving the gantry crane horizontally.

The operator can control the speed and direction of movement, with many cranes offering variable-speed controls for precise movement.

2)Horizontal Movement:

As the wheels move along the tracks, the entire gantry crane (including the main girder and lifting system) travels from one end of the rail to the other.

The crane can cover long distances, and this horizontal travel is essential for transporting loads within a fixed area.

3)Braking and Stopping:

When the crane reaches the desired position or the operator needs to stop, the braking system is activated.

Depending on the crane's configuration, braking can occur automatically when the operator releases the control or when a limit switch detects that the crane has reached its designated stopping point.

4)Guidance and Alignment:

The wheels, guided by the rails, ensure that the gantry crane stays aligned and travels in a straight line. Misalignment in the rail system or wheel system can lead to wear and damage, so regular maintenance and checks are required to ensure proper alignment.

5.Trolley travelling mechanism

The trolley traveling mechanism in a mobile girder rail gantry crane is a key system that allows the trolley (the part of the crane that carries the hoist and lifting mechanism) to move horizontally along the main girder (the horizontal beam of the crane). This movement is crucial for positioning the hoist and the load over different areas of the crane's work zone. The trolley traveling mechanism ensures that the load can be accurately placed in the desired location while keeping the movement smooth and controlled.

The trolley is the mobile platform that moves along the girder, supporting the hoist and lifting mechanism. It typically contains the hoist motor, rope or chain system, and other components responsible for the vertical lifting of the load.The trolley must travel smoothly along the girder beam without any misalignment, as this affects both safety and efficiency in load handling.

6.Crane wheel

1)The crane wheel is a crucial component of a mobile girder rail gantry crane, as it allows the crane to move along its tracks or rail system. These wheels are mounted on the end carriages or trolleys and bear the weight of the entire crane, including the load being lifted, ensuring smooth and stable movement over the rail track. Proper design, material selection, and maintenance of the crane wheels are essential for the safety, efficiency, and longevity of the gantry crane.

2)The crane wheels are responsible for bearing the entire weight of the crane, including the main girder, hoist, end carriages, and the load being lifted. This requires strong, durable wheels capable of supporting substantial weight and stresses.The wheels, driven by the traveling mechanism (powered by the electric motor and drive system), allow the crane to move horizontally along the tracks. They enable the crane to cover large distances in the operational area.

3)mooth Operation: Well-designed and maintained wheels ensure the crane moves smoothly and efficiently along the rail system.

Increased Lifespan: Proper wheel design and maintenance extend the service life of both the wheels and the crane itself.

Enhanced Safety: Preventing derailments and minimizing the risk of accidents is critical. Well-maintained wheels contribute to overall crane safety.

7.Crane Hook

Hook Design:

1)Single Hook: The most common type used in mobile girder rail gantry cranes is the single hook design. This simple, robust design allows for the lifting of a variety of loads, from small parts to large industrial components.

2)Double Hook (if applicable): In some cases, a double hook setup is used for increased lifting capacity or for stabilizing heavier loads. This can help balance large or unbalanced loads during lifting.

3)Shape: The hook is typically curved or C-shaped, with a rounded throat and opening at the top, providing a secure place to attach lifting slings, chains, or other load-handling devices.

4)Throat Opening: The throat opening of the hook is critical for the safe and secure attachment of slings or chains. It should be sized appropriately to fit various lifting devices while maintaining strength and avoiding wear.

Motor

1)Efficiency and Performance: High-quality, well-maintained motors ensure that the crane performs its duties efficiently, lifting heavy loads and moving along rails with minimal energy consumption.

2)Safety: Motors designed with safety features, such as overload protection, reduce the risk of accidents during crane operation.

3)Durability: Properly selected and maintained motors can provide years of reliable service, even under challenging operating conditions.

4)Cost-Effective Operation: Energy-efficient motors and control systems, such as VFDs, reduce electricity costs and extend the life of the motor, making them more cost-effective in the long run.

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Sound and light alarm system & limit switch

Sound and Light Alarm System:

1)Safety Alert: The primary purpose of the sound and light alarm system is to alert both the crane operator and people working in the area to potential hazards, such as when the crane is operating near its maximum capacity or if it's entering an unsafe zone.

2)Warning for Load Handling: The system helps ensure that workers are aware when heavy loads are being lifted or when the crane is in motion, reducing the risk of accidents.

3)Indicating Movement or Actions: The sound and light alarms are also used to signal various crane movements like traveling along tracks, hoisting, or moving the trolley, providing clear warnings to surrounding personnel.

Limit Switches:

1)Prevention of Overtravel: Limit switches prevent overtravel, which could damage the crane structure or cause dangerous conditions by preventing the crane from exceeding its operational boundaries.

2)Protecting Crane Components: They help protect critical components of the crane (like motors, cables, or tracks) from stress, wear, and potential damage caused by excessive movement.

3)Safety Protection: The limit switches are crucial for safety, as they prevent the crane from performing dangerous movements, ensuring the crane operates within a safe range at all times.

10.Safety Devices

1. Overload Protection Device:

Prevents the crane from lifting loads that exceed its rated capacity, reducing the risk of structural damage or crane failure.

The device monitors the weight of the load being lifted and automatically stops the crane's hoisting action if an overload is detected.

2. Limit Switches:Prevents the crane from traveling or hoisting beyond its safe operational limits. Limit switches are used to define the maximum and minimum positions for various crane movements (e.g., hoisting height, horizontal travel, trolley movement).

3. Emergency Stop Button (E-Stop):Allows the operator to immediately stop the crane in the event of an emergency or dangerous situation.The emergency stop button is typically located in the operator's cabin or on the crane's control panel. Pressing it cuts off power to the crane's movement mechanisms, halting the crane's actions instantly.

4. Anti-collision System:Prevents the crane from colliding with other cranes, structures, or equipment in the area.Proximity Sensors or Radar-based Systems: These systems detect nearby obstacles (including other cranes, buildings, or equipment) and warn the crane operator of an impending collision. If necessary, the system can automatically stop the crane or slow down its movement to avoid a collision.

11.Control Mode

1)Manual Control Mode:

In manual control mode, the crane operator directly controls the crane's movements through a set of physical controls (e.g., joysticks, buttons, or switches). This mode requires constant attention and input from the operator, as they are responsible for every movement of the crane.

2)Remote Control Mode:

In remote control mode, the crane is operated via a wireless control unit, which can be a handheld transmitter or a pendant controller. The operator is not confined to the crane cabin and can control the crane from a safe distance.

3)Cabin Control Mode:

In cabin control mode, the crane is operated from a control cabin that is mounted on the crane. The operator remains inside the cabin, using a joystick or a set of buttons to control the crane's movements.

4)Automatic Control Mode (Automated or Semi-Automated):

In automatic or semi-automatic control mode, the crane's operations are partly or fully controlled by an automated system. This mode is often used for repetitive tasks or in situations where precision and speed are critical.

12.Sketch

 

 

Main technical

 

 

1. Flexibility and Mobility:

Moveable Along Tracks: Mobile girder rail gantry cranes can travel along rail systems, offering flexibility in moving loads across large areas. Their ability to move from one location to another within a facility or yard enhances operational efficiency and versatility.

2. Cost Efficiency:

Reduced Infrastructure Investment: Mobile gantry cranes can eliminate the need for permanent infrastructure such as large foundations or complex overhead cranes. This reduces initial installation costs, making them more economical in certain applications.

3. Heavy Load Lifting Capacity:

High Load Handling: Mobile girder rail gantry cranes are designed to handle heavy and oversized loads, making them ideal for industries like shipbuilding, heavy machinery manufacturing, and container handling at ports. They offer robust lifting capacities, ensuring safe handling of substantial materials.

4. Large Working Area Coverage:

Wide Coverage: Mobile gantry cranes can cover expansive areas, particularly in large outdoor or indoor industrial facilities. By moving along tracks, they can access various locations, which helps improve productivity and reduce handling time.

5. Improved Safety:

Operator Safety: These cranes often come with advanced safety features such as overload protection, limit switches, sound and light alarms, and emergency stop functions. The operator can also control the crane from a safe distance, especially if using remote control or in cabin control mode.

6. Minimal Ground Preparation:

No Need for Deep Foundations: Unlike some traditional cranes that require significant groundwork or specialized foundations, mobile girder rail gantry cranes often require minimal preparation for the rails. This can reduce both time and cost of installation.

7. Increased Productivity:

Efficient Load Handling: These cranes are designed to optimize workflows, reduce handling times, and increase material movement efficiency across the site. Their ability to transport large loads swiftly across designated paths reduces downtime, leading to higher productivity levels.

 

 

1. Port and Container Handling

Loading and Unloading Containers: In ports, mobile gantry cranes are widely used for loading and unloading containers from ships to trucks or vice versa. Their ability to move along a set of rails across vast storage yards allows them to efficiently handle large volumes of cargo.

2. Construction Sites

Heavy Lifting and Material Handling: Mobile gantry cranes are ideal for lifting heavy materials such as steel beams, concrete blocks, or large construction components at construction sites. The crane's mobility allows it to be moved across different parts of the site as required.

Transportation of Materials Across the Site: These cranes can be used to move materials from storage to work areas, reducing the need for additional equipment like forklifts and increasing the speed of construction processes.

3. Shipbuilding and Shipyards

Boat and Ship Building: In shipyards, mobile girder rail gantry cranes are used to transport and position heavy shipbuilding materials such as steel plates, engines, and other large components. Their mobility across the yard allows for efficient handling of parts between assembly stations.

4. Steel Mills and Heavy Manufacturing

Handling Steel and Metals: In steel mills and manufacturing plants, these cranes are commonly used to move heavy rolls of steel, metal sheets, and other large industrial components between various stages of production or processing.

5. Railroad and Rail Yard Operations

Lifting Railcars and Locomotives: Mobile gantry cranes are utilized in rail yards to lift, maintain, and move railcars or locomotives for repair or transportation. Their mobility and lifting capacity make them an excellent tool for moving heavy railway equipment.

 

 

1. Design and Engineering Phase

The process begins with a clear understanding of the client's specifications, including lifting capacity, span, rail system type, environment (indoor/outdoor), and specific operational needs. Based on these requirements, engineers perform calculations for load capacity, structural integrity, and safety features. They also determine factors like the crane's stability, required motor power, rail structure, and lifting mechanism.

2. Material Procurement

High-quality raw materials such as steel plates, beams, wires, and cables are procured according to the specifications outlined in the design phase.Suppliers are carefully chosen based on the required quality standards, delivery schedules, and cost-effectiveness. Materials are inspected upon delivery to ensure compliance with the specifications.

3. Fabrication and Assembly of Structural Components

Steel plates and beams are cut to the required dimensions using advanced cutting tools like laser cutters, CNC machines, or oxy-fuel cutting.After cutting, the components are welded together to form the crane's main structure. High-strength welding processes are used to ensure the joints are strong and durable.Welded joints are carefully inspected for structural integrity using non-destructive testing methods such as ultrasonic or X-ray inspection.

4. Trolley and Lifting Mechanism Assembly

The trolley, which carries the hoist and lifting mechanism, is assembled using steel beams. It is designed to fit precisely within the crane's rail system for smooth travel. The hoisting mechanism, including the winch, motors, ropes, and hook, is installed on the trolley. These components are designed for heavy-duty lifting and are carefully calibrated to ensure efficient and smooth operation.

5. Assembly of Crane Components

The main girder is mounted onto the end carriages, and the whole structure is assembled. Precision is key during this process to ensure alignment and balance. The trolley assembly is placed onto the rails of the gantry structure. This involves precise alignment to ensure smooth and efficient movement along the crane rails.The lifting mechanism is tested by attaching loads and checking for smooth operation, stability, and performance under different conditions.

6. Testing and Quality Control

The crane is first subjected to static load tests, where loads are applied to verify the crane's structural integrity and lifting capacity.The crane undergoes dynamic testing, including trolley movement, hoisting, and full gantry travel, to assess operational performance. This ensures all components, including wheels, motors, and electrical systems, work as intended.

7.Painting and Coating

Surface Preparation: The crane components are cleaned and prepped for painting to prevent rust and ensure durability.

Painting: Protective coatings are applied to the crane's structure, typically with corrosion-resistant paints to protect against weathering and wear. The crane is often painted in the company's color scheme for branding purposes and visibility.

Drying: The painted crane is allowed to dry completely before moving on to the next phase.

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%.