15 Ton Single Overhead Bridge Crane

Main Structural Components

These are the core parts that form the crane's framework and allow it to move.

Bridge & Main Girder: The bridge is the primary structure that spans the width of your workspace. In a single girder crane, it consists of a single Main Girder beam that supports the entire lifting mechanism . The girder is typically a strong "box-type" structure, sometimes combined with an I-beam for the trolley to run on .

End Trucks (or End Carriages): These are located at both ends of the main girder and house the wheels that allow the entire crane to travel back and forth along the runway rails . They are also equipped with rubber bumpers to cushion potential impacts .

Lifting & Moving Mechanisms

These components are responsible for the vertical lifting and horizontal movement of the load.

Hoist & Trolley: This is the core lifting mechanism.

The Trolley is a frame that moves horizontally along the main girder .

The Hoist, mounted on the trolley, does the actual lifting. For a 15-ton capacity, this is almost always an electric wire rope hoist for its strength and durability . It consists of a motor, a drum that winds the rope, a gearbox, and the hook .

Bridge & Trolley Drives: These are the motor and gearbox assemblies that power the crane's movement. They often feature Variable Frequency Drives (VFDs) to provide smooth acceleration and deceleration, which reduces load swing

Control & Power Systems

These systems are the "brain" and "nervous system" of the crane, allowing the operator to control it safely.

Control System: The operator controls the crane using either a wired pendant station or a radio remote control . The main control panel houses the electrical components like contactors and drives to manage the crane's functions .

Power Supply (Festoon System): This system safely delivers electricity to the moving trolley and hoist. It often uses a C-track festoon system, which is a track with hanging cable trolleys that carry flat cables to the moving components .

Safety Devices: Modern cranes come with several mandatory safety features, including:

Overload Limit Switch: Automatically stops the hoist if it tries to lift a load exceeding 15 tons .

Emergency Stop System: Allows the operator to immediately cut all power to the crane's motions .

Lifting Height Limit Device: Prevents the hook from being raised too high .

 

6. Hook Block

The load handling device

Includes:

Hook

Pulley system (sheaves)

Designed with safety latch to prevent load slipping

7. Electrical System and Power Supply

Function: The crane requires electrical power to operate the motors, control systems, and remote.

Components:

Power Supply: The crane typically operates on 380V, 415V, or 480V industrial power for larger systems.

Circuit Breakers: Safety devices to protect the crane from power surges or electrical faults.

Cables: Heavy-duty cables deliver power from the source to the crane's various components.

8. Electrical System

Powers and controls the crane

Includes:

Control panel

Wiring & cables

Festoon system or conductor bars

👉 Ensures safe and reliable operation

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9. Control System

Interface used by operator

Common types:

Pendant control (wired)

Wireless remote control

Cabin control (rare for single girder)

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10. Runway System

Rails on which the crane travels

Supported by building structure or columns

Includes:

Rail tracks

Rail clamps & buffers

 

11. Safety Features

Emergency Stop System: A manual emergency stop button on the remote control and control panel to immediately halt all crane operations.

Anti-Sway System: Some cranes are equipped with an anti-sway system to minimize swinging of the load during movement.

Obstacle Detection: Sensors detect nearby obstacles, ensuring safe operation and preventing collisions.

12. Structural Components (Frame, Girders, etc.)

Function: These parts provide the rigidity and strength needed to carry heavy loads.

Types:

Single Girder: Lighter-duty cranes.

Double Girder: Heavy-duty cranes capable of lifting larger loads.

Materials: Typically made of high-strength steel to ensure durability under heavy load conditions.

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⚙️ Optional / Advanced Components

Variable Frequency Drive (VFD) – smooth speed control

Anti-sway system – improves load stability

Load display system

Remote monitoring / smart controls

 

Sketch

 

Main technical

 

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Core Advantages of a 15-Ton Single Girder Crane

💰 Cost-Effective: Requires less steel and has a simpler design, making it about 25-35% cheaper than a double girder model. This saves on manufacturing, shipping, and installation.

🏗️ Building-Friendly (Lower Loads): The lighter weight puts less stress on your facility's support columns and foundation, often eliminating the need for expensive structural reinforcements.

📐 Space-Saving (Low Headroom): Its compact design requires less vertical space, maximizing the usable lifting height within your existing building clearance.

🔧 Easy to Install & Maintain: The uncomplicated structure with fewer components means a quicker installation and simpler, less frequent maintenance.

🔄 Operational Versatility: Well-suited for a wide range of tasks, including loading/unloading trucks, moving palletized goods in warehouses, handling machinery in repair shops, and feeding light assembly lines.

 

🏭 Applications

Moving heavy machinery components, feeding assembly lines, handling large injection molds (e.g., for rubber/plastic parts), positioning sub-assemblies

Handling bundles of bar stock, sheet metal, pipes, and tubes. Specialized use: In pickling operations, where a crane lowers and raises pipes through a series of chemical dipping tanks

Lifting pre-cast concrete panels, steel beams, heavy machinery components, and handling materials for solar panel installation

Lifting vehicle chassis, engines, large diesel generators, and other heavy components for maintenance and overhaul

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Loading/unloading trucks, moving palletized goods and large crates, organizing bulk storage in high-bay facilities

 

🏗️ Crane Production Procedure

The manufacturing of a 10 Ton Single Girder Overhead Bridge Crane follows strict quality control standards to ensure safety, durability, and performance.

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🔩 1. Design & Engineering

Confirm customer requirements:

Lifting capacity (10 ton)

Span & lifting height

Duty class (A3–A5)

Perform:

Structural calculations

Load analysis

Deflection and stress checks

👉 Output:

General arrangement drawings

Manufacturing drawings

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🔧 2. Raw Material Preparation

Select high-quality steel (e.g., Q235 / Q345)

Inspect materials for:

Thickness

Surface defects

Mechanical properties

👉 Only approved materials proceed to fabrication

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🔨 3. Girder Fabrication

Cutting & Forming

CNC cutting of steel plates

Bending and shaping

Welding

Automatic submerged arc welding for main girder

CO₂ welding for auxiliary parts

Assembly

Assemble girder sections and stiffeners

👉 Ensures high structural strength and precision

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🔍 4. Welding Inspection

Non-destructive testing (NDT):

Ultrasonic testing (UT)

Magnetic particle testing (MT)

👉 Detects internal and surface defects

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⚙️ 5. Machining Process

Precision machining of:

Wheel sets

Bearing housings

End carriages

👉 Guarantees alignment and smooth operation

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🧩 6. Component Assembly

Install:

End carriages

Electric hoist

Trolley mechanism

Drive systems

👉 Mechanical parts are aligned and secured

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⚡ 7. Electrical System Installation

Install:

Control panels

Motors and wiring

Limit switches and safety devices

👉 Includes grounding and insulation checks

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🎨 8. Surface Treatment & Painting

Shot blasting (rust removal)

Primer coating

Final paint finish (custom color available)

👉 Improves corrosion resistance and appearance

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🧪 9. Testing & Quality Inspection

No-load Test

Check operation without load

Load Test

Static test: 125% rated load

Dynamic test: 110% rated load

Functional Testing

Hoisting, traveling, braking, and control systems

👉 Ensures compliance with safety standards

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📦 10. Packaging & Delivery

Disassemble into transportable parts

Secure packaging for:

Girder

Hoist

Electrical components

👉 Delivered by container or bulk shipment

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📋 11. Installation & Commissioning (Optional)

On-site installation guidance

Rail alignment and system setup

Final operational testing

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%.