Bridge Crane For Coil

The bridge crane for coil handling is an advanced material handling system designed for safe, efficient and precise transport of coils in a variety of industrial environments, such as steel mills, aluminum fabrication plants and warehouses. The crane system combines innovative engineering design with rugged construction to ensure reliability and productivity in demanding operating environments.

The bridge crane for coil handling has customizable lifting capacity. It is designed to handle a variety of coil weights, from a few tons to more than 100 tons, depending on the operational needs. It has a dedicated coil gripper.

It is also equipped with dedicated lifting mechanisms such as C-hooks, magnets or vacuum lifters to ensure safe and damage-free handling of coils.

The bridge crane for coil handling has a high-precision control system. It uses advanced frequency conversion technology and anti-sway mechanisms to achieve smooth and precise movement. It is manufactured with high-strength steel and corrosion-resistant components to withstand harsh working environments and ensure long service life.

Core Components：Motor

Place of Origin：Henan, China

Warranty ：2 years

Weight (KG)：3000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Application：workshop

Lifting mechanism：Eliectric Hoist

Crane feature：Easy Operated Girder Bridge Crane

Control method：Wireless Remote Control

Power Source：Users' Local Power System

Color：Customized Color Acceptable

Lifting speed：Adjustable Speed

1.Main beam

The main girder of a bridge crane used for coil handling is a critical component, and its design and specifications are tailored to the specific requirements of the material being handled.

Typically, the main girder is a box girder or I-beam structure to ensure adequate strength and rigidity. For coil lifting, the girder may include specialized lifting accessories such as C-hooks, magnets, or clamps to securely clamp the coil.

High-quality steel (such as Q235 or Q345) is used for the main girder to improve durability and load-bearing capacity.

Appropriate surface treatments (such as anti-corrosion coatings) may be applied to extend service life.

The capacity of the main girder is designed to handle the weight of the coil, ranging from a few tons to hundreds of tons. Factors such as dynamic loads and safety factors are considered in the design.

The span of the main girder depends on the application of the crane and the width of the workshop or handling area. The beam is integrated with the hoist and pulley system to ensure smooth horizontal and vertical movement.

Lifting System

The lifting system of an overhead crane used to handle coils typically includes several key components and features to ensure safe, efficient and precise lifting of heavy and delicate loads such as steel or aluminum coils.

Motor: A powerful motor with variable speed control to adjust the lifting speed.

Wire Rope or Chain: A high-strength steel wire rope or chain is used to lift the load. For coils, wire rope is preferred due to its higher load capacity and smooth operation.

Drum: The wire rope is wrapped around a grooved drum to lift or lower the coil.

Braking System: A fail-safe brake ensures that the load remains secure during operation.

C-Hook: The C-hook grabs the inner diameter (ID) of the coil.

Electromagnetic Lifters: Suitable for lifting metallic coils, these devices use a magnetic field to grab the load.

Vacuum Lifters: For non-metallic or coated coils, a suction cup is used.

Clamps: Adjustable mechanical clamps can grip the outer diameter (OD) or sides of the coil.

3.End carriage

The end frame of a bridge crane used to handle coils plays a vital role in the entire system. It supports the bridge girders and allows smooth and reliable movement along the crane tracks.

The end frame of a coil crane is designed to handle the heavy loads typical of steel or metal coils, ensuring durability and high load capacity. Proper alignment ensures that the crane moves smoothly across the tracks without stressing the crane structure or compromising load stability.

4.Crane travelling mechanism

1) Working principle

The traveling mechanism is driven by electricity, supplied through conductive bars, festoon cables or cable drums. Typically, dual motors are used for synchronized and balanced movement of both sides of the crane. The rotation of the motor is transmitted to the wheels through a gearbox and couplings. The gearbox reduces the motor speed while amplifying the torque for heavy-load operation. The drive wheels mounted on the end frames propel the crane along the track beams. The idler wheels provide stability and support. The direction and speed are controlled by the operator through the control panel. Variable frequency drives (VFDs) are often used to smoothly adjust the speed, allowing for precise positioning of the coils. Brakes integrated into the motor or gearbox are used to slow down and stop the crane as needed.

2) Functions of the crane operating mechanism

Crane Movement Along the Bridge: The crane travel mechanism allows the bridge crane to move horizontally along the length of the bridge. It usually consists of a set of wheels or tracks mounted on the side of the bridge beam. This movement is essential for positioning the crane to different work areas, such as coil storage areas or workstations.

Precision Handling: Coils, especially steel coils, are heavy and need to be handled with care. The crane travel mechanism allows the crane to be precisely positioned, ensuring that the coils can be picked up, moved and placed with high precision, reducing the risk of damage.

Lifting and Lowering: The crane travel mechanism, in conjunction with the hoist, is responsible for lifting and lowering the coils. The load can be raised to the appropriate height and moved along the bridge to the desired location.

Load Stability: The travel mechanism helps maintain the stability of the crane when carrying the load, preventing the sway or swing that can occur during horizontal movement of the coils.

Efficient Transport: By enabling the crane to travel along the entire bridge, the crane's ability to cover a large working area can be maximized, allowing coils to be efficiently transported from storage to processing or loading areas.

Safety: The travel mechanism ensures that the crane can move smoothly along its path, reducing the possibility of accidents, especially when moving large and heavy coils, which can be dangerous if dropped or mishandled.

5.Trolley travelling mechanism

1) Working principle

The operation of the traveling mechanism of a bridge crane trolley involves an electric drive system that moves the trolley along the bridge's tracks. The operator carefully controls it using a remote control or control panel to move the coil load horizontally and vertically, ensuring efficient and safe handling. The system is designed to provide precise movement and safety functions to avoid accidents and protect the crane's components.

2) Function of the trolley operating mechanism

Horizontal Movement: The primary function of the trolley travel mechanism is to provide horizontal movement across the span of a bridge crane. This enables the crane to move a load, in this case a coil, from one side to the other along the length of the bridge.

Load Positioning: The trolley is able to precisely position the load. With the handling of coils, which are often heavy and fragile, this precision is critical to avoid damage and ensure safety during lifting and transportation.

Coordination with Bridge and Hoist: The trolley is part of a larger crane system that consists of a bridge (which moves along tracks) and a hoist (which moves vertically). The movement of the trolley works in coordination with the hoist to transfer the coil from one point to another, aligning it with the desired loading or unloading area.

Safety Features: The trolley mechanism typically has safety systems such as limit switches, overload protection, and anti-sway control to ensure smooth operation and avoid accidents, especially when handling large, heavy coils.

Efficient Coil Handling: Coils are often handled in industries such as steel manufacturing or metal processing that require precision and speed. The trolley travel mechanism enables the crane to quickly transport the coils to storage, processing, or shipping locations.

Adjustable Speed ​​and Control: The trolley can run at different speeds to handle coils of varying weights and sizes. Some advanced systems even have variable frequency drives for smooth acceleration and deceleration, which is critical for handling sensitive or heavy loads like coils.

6.Crane wheel

Function

The crane wheel is part of the traveling mechanism that enables the overhead crane to move along the horizontal axis.

It is designed to bear heavy loads and enable the crane to transport coils safely and efficiently.

It must ensure precise movement to avoid load instability, especially when handling heavy or delicate coils.

Design Features

Material: Made of high-strength materials such as forged or cast steel to resist wear, deformation and high pressure. Materials used include 42CrMo4 or equivalent grades for excellent load-bearing capacity.

Wheel Shape: Wheels are usually flanged to maintain proper alignment on the track and prevent derailment. The tread can be hardened to minimize wear and extend service life.

Types of Crane Wheels

Single Flange: Ensures alignment and prevents derailment.

Double Flange: Provides additional safety, especially for large capacity cranes.

Flat Tread: A specific design for track and rail alignment.

7.Crane Hook

The crane hook of an overhead crane is a specialised coil lifting device used to handle heavy metal coils or coils, such as steel or aluminium coils, in industrial environments.

Hook Design: C-shaped hooks are commonly used to handle coils as it passes through the centre (eye) of the coil Made of high-grade alloy steel for strength and durability.

Capacity: Load capacities are usually custom made ranging from a few tons to hundreds of tons.

Rotation Mechanism (optional): Some hooks are equipped with a 360° rotation mechanism to align with the load for precise placement.

Insulation Coating: A protective coating can be applied to prevent damage to the coil surface.

Safety Features: Latch mechanism prevents accidental unhooking. Overload indicator for safety.

Counterweight: Maintains balance when lifting asymmetric or different weight coils.

Motor

Motors used in overhead cranes handling coils often need to meet specific requirements depending on the application, load capacity, and operating environment.

Motor Types

AC Motors: Commonly used in overhead cranes due to their durability and efficiency. Typically, squirrel cage induction motors are preferred.

DC Motors: Used in applications requiring precise speed control, but less common now due to advances in AC motor drives.

Servo Motors: Used for high-precision control, often used in modern cranes with advanced automation.

The motor must be matched to the lifting capacity of the overhead crane. For coil handling that may involve heavy steel coils, a large capacity motor (e.g., 10-50+ tons) may be required.

The motor should be designed for heavy duty operation and is typically classified as a FEM/ISO duty class, such as M5, M6, or higher, for frequent starts/stops and high usage.

Variable frequency drives (VFDs) are often used with motors to provide smooth acceleration, deceleration, and speed control. This is essential for safe handling of coils to prevent damage.

Sound and light alarm system & limit switch

1) Sound and light alarm system

The sound and light alarm systems for overhead cranes handling coils are designed to ensure safety and alert the operator or nearby personnel to operating conditions or hazards. These alarms are critical in heavy machinery environments, especially when handling heavy or potentially hazardous materials such as coils.

Audible alarm: Usually a siren or buzzer that emits a loud sound to alert the operator and nearby personnel to different situations. Depending on the urgency, its pitch or duration may vary (e.g., a continuous sound for an emergency or a series of short sounds for a warning).

Light alarm (beacon): A flashing light (usually a rotating beacon or LED) that visually displays the current status of the crane. Typically, different light colors are used to indicate different alarms:

Red light: Severe warning or emergency situation (e.g., crane malfunction, overload situation).

Yellow/amber light: Warning alarm (e.g., the crane is near its load limit and needs maintenance).

Green light: Indicates that everything is normal.

Blue light: Sometimes used to indicate that the crane is in use, usually as a safety measure for nearby workers.

2) Limit switch

Limit switches on overhead cranes used to handle coils are a critical component to ensure safe and efficient operation of the crane. These switches are designed to limit the movement of the crane's hoist, trolley, or bridge, preventing overtravel beyond safe operating limits. They are often used in applications where precise positioning is critical, such as handling coils that can be heavy and sensitive.

Types of Limit Switches:

Mechanical Limit Switches: These switches are activated using physical contact with the crane's moving parts. They can be mounted on the crane structure and detect when the hoist or trolley reaches a specific position.

Electronic Limit Switches: These switches operate without physical contact. They rely on sensors, such as proximity sensors, to detect the position of the crane's moving parts. They are more durable and require less maintenance than mechanical switches.

Rotary Limit Switches: These are often used on cranes for precise rotation control. They monitor the rotation of the crane or hoist and stop the rotation when a set limit is reached.

Pull Rope Limit Switches: Used in situations where the crane moves longer distances. The switch activates when the rope is pulled when the crane reaches the limit of travel.

10.Safety Devices

Overhead cranes used for coil handling, especially in industries such as steel mills or warehouses, must be equipped with a variety of safety devices to protect workers, equipment and loads.

Overload protection: prevents the crane from lifting loads that exceed its rated capacity.

Anti-collision device: ensures that the crane does not collide with other equipment, structures or other cranes in operation.

Emergency stop (E-Stop): allows the operator to stop the crane immediately in an emergency.

Hoist limit switch: prevents excessive movement of the hook in the up and down directions.

Anti-sway control: reduces load sway to improve safety during operation, especially when moving heavy coils.

Overheat protection: prevents overheating of the crane motor or hoist mechanism.

Load positioning system: ensures precise positioning of the coil, reducing the risk of dropping or damaging the coil.

Warning indicator: alerts the operator and nearby personnel to crane movement, potential hazards or equipment failure.

Emergency power supply: ensures that critical safety functions continue to operate in the event of a power outage.

Safety hook and sling: ensure that the coil is lifted safely and prevents it from falling off during movement.

11.Control Mode

The control mode of overhead cranes used to handle coils usually depends on the type of crane, the load, and the operating environment.

Manual control mode: The crane operator controls the crane manually using a pendant or radio controller.

Automatic control mode: The crane follows a preset programmed path or instructions.

Semi-automatic control mode: The crane performs most actions automatically, but the operator can intervene in certain tasks or emergencies.

Remote control mode: The crane is controlled via a wireless remote control, allowing the operator to move the crane from a safe distance.

Cranes with load positioning systems: Some advanced cranes are equipped with load positioning systems that automatically adjust the position of the load, ensuring it is always stable.

12.Sketch

Main technical

Enhanced Load Handling: Bridge cranes are designed to lift heavy and bulky loads, such as metal coils, with ease. Their robust construction and high lifting capacities make them ideal for handling large coils, which can weigh several tons.

Precision and Control: These cranes are equipped with advanced control systems that provide precise lifting and positioning. This is crucial when handling coils, as it minimizes the risk of damage to the load and surrounding infrastructure.

Safety Features: Bridge cranes typically come with multiple safety features, such as overload protection, emergency stops, and anti-sway mechanisms, which ensure safe operation when handling potentially hazardous loads like coils.

Efficient Workflow: The ability to move loads across large distances within a factory or warehouse enhances productivity. This reduces downtime and minimizes the need for manual labor, leading to faster handling and increased operational efficiency.

Space Optimization: Unlike traditional forklifts or other lifting equipment, a bridge crane utilizes the overhead space, freeing up floor space for other activities. This is especially useful in crowded or limited work environments.

Durability and Longevity: Built to withstand heavy usage, bridge cranes are made of high-quality materials designed to last for many years. This reduces maintenance costs over time.

Customizable Design: Bridge cranes can be tailored to the specific needs of the coil handling operation. Features such as adjustable hooks, special coil lifting attachments, and varying lifting capacities can be incorporated into the design.

Reduced Risk of Coil Damage: With specialized coil lifting attachments and precise control, bridge cranes help reduce the risk of damaging coils during handling, preserving their quality and minimizing loss.

Minimized Worker Strain: By automating the lifting and moving of coils, bridge cranes reduce the physical strain on workers, leading to fewer workplace injuries and fatigue.

Versatility: In addition to coils, these cranes can handle various other materials, making them versatile for different industrial applications, thus increasing the overall utility of the crane system.

Coil Lifting and Transporting: Bridge cranes are ideal for lifting coils, especially large or heavy ones, because of their high load capacity and ability to travel along a fixed track. They can easily lift coils from storage areas and move them to production lines or shipping areas.

Precise Positioning: The crane's ability to move along a horizontal and vertical axis allows for precise positioning of coils. This is crucial in processes such as feeding coils into machines or stacking them in a specific arrangement in storage areas.

Coil Turning: Some bridge cranes can be equipped with special hooks or coil lifters designed for rotating coils, making it easier to orient the coils as needed for processing or storage.

Safe Handling of Heavy Coils: Coils, especially those made of metal or steel, can be heavy and difficult to handle manually. Bridge cranes provide a safe and efficient way to move these coils, reducing the risk of accidents or injuries associated with manual lifting.

Minimizing Damage: Bridge cranes are designed to handle materials delicately, which helps to reduce the risk of damage to the coil. The proper lifting equipment, like coil grabs, can ensure that coils are lifted evenly and securely, preventing deformation.

Storage Management: In coil storage areas, bridge cranes can be used to organize and stack coils efficiently. The ability to move coils vertically and horizontally allows for optimal use of warehouse space and improves inventory management.

Integration with Other Equipment: Bridge cranes can be integrated with other equipment such as conveyor belts, which streamlines the process of moving coils from one stage of production to another, improving workflow efficiency.

1. Design and Planning

The first step is to gather the specific needs of the customer, including the weight and dimensions of the coils, the lifting capacity, and operational environment.The crane's design is created using CAD software, considering factors like lifting height, span, type of control system (manual or automated), and safety features.Engineers perform structural analysis to ensure the crane can safely handle the load and function under all expected conditions.

2. Material Selection

High-strength steel is typically used for the frame and structural components to ensure durability and safety. For lifting coils, durable wire ropes or lifting chains are chosen, depending on the load capacity and environment. Motors for hoisting, trolleys, and the bridge are selected based on the load and operating environment. Electrical components are chosen to ensure reliable performance.

3. Fabrication of Components

The main structure of the bridge crane is fabricated by welding steel plates into the desired shape and size.These are fabricated and welded to support the rails and allow the crane to move along the span.The hoist, which consists of a motor, gearbox, drum, and rope, is fabricated. It's designed for smooth and reliable lifting.The trolley carries the hoist across the bridge, and is assembled using robust materials to ensure it can travel smoothly and support the load.Wiring, control panels, and safety sensors are installed and configured.

4. Assembly

The fabricated bridge beam, end trucks, and other components are assembled into the crane frame.The hoist and trolley system is installed on the bridge, ensuring proper alignment and functionality.Electrical wiring for the controls, motors, and safety systems is completed.

5. Testing and Quality Control

A load test is conducted to ensure that the crane can lift coils or other heavy materials safely without any issues.The crane's movement is tested across the bridge, ensuring that all components function as designed, including the hoist, trolley, and bridge movement. Various safety tests are performed, including emergency stop, overload protection, and limit switches.

6. Finishing Touches

The crane is painted with an anti-corrosion coating to ensure long-term durability, especially in harsh environments like steel mills or warehouses.After painting, the crane undergoes a final inspection to ensure that all components are functioning correctly.

7. Shipping and Installation

The crane is disassembled (if necessary) for transport and shipped to the customer's site.The crane is assembled on-site, and the electrical system is connected to the local power supply.After installation, the crane undergoes a final set of operational tests, and staff are trained on how to operate and maintain the crane.

8. Maintenance and After-Sales Support

Regular checks and servicing are scheduled to ensure optimal performance and extend the crane's lifespan.Availability of spare parts is ensured for quick repairs.

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%.