Industrial Bridge Crane

 

 

The industrial bridge crane is a type of overhead crane used in heavy-duty industries to move large, heavy, or cumbersome loads. It is typically used in manufacturing, warehousing, construction, and maintenance facilities where high lifting capacities and efficiency are required. Bridge cranes are mounted on fixed rails or beams that traverse along a wide area, allowing for easy horizontal movement of loads.

The industrial bridge crane is a single girder and features a single girder that supports the trolley and hoist system. It is ideal for smaller to medium-sized lifts and is typically lighter, more cost-effective, and suitable for lower ceiling heights.

The industrial bridge cranes are equipped with advanced control systems, typically via pendant, wireless, or remote control, which allow the operator to easily manage lifting and positioning tasks. This includes speed control, load monitoring, and safety features.

4)The industrial bridge crane is an indispensable tool for moving heavy loads with precision and safety in industrial settings. It improves operational efficiency, reduces labor costs, and enhances safety in environments where lifting and transporting heavy objects are routine. The right configuration can be chosen based on the facility's size, lifting requirements, and available space.

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

Place of Origin: Henan, China

Warranty: 1 Year

Weight (KG): 20000 kg

Video outgoing-inspection: Provided

Machinery Test Report: Provided

Lifting mechanism: Electric Hoist Trolley

Type: Single Beam Girder Overhead Crane

Control method: Ground Control+Remote Control

Lifting Capacity: 1-20ton

Girder Type: Single Box Girder

Color: Customer Request

Power supply: Local Industry Voltage

Lifting speed: 8/0.8m/min

Work Duty: A3-A4

 

 

1.Main beam

1) The main beam of an industrial bridge crane, also known as the bridge girder, is the primary structural component that spans the width of the crane's runway. It supports the weight of the hoist and trolley system, which carry the load being lifted. The main beam typically runs across the full length of the crane and is mounted on the runway rails, allowing the trolley (with hoisting mechanism) to move horizontally along the bridge.

The main beam is designed to efficiently distribute the weight of the hoist and any load being lifted, ensuring safe and stable operation.The ends of the main beam are connected to the crane's end trucks, which house wheels or rollers that allow the crane to move along its runway.

3) The most industrial bridge crane beams are made of high-strength steel or other durable materials to withstand heavy loads. Depending on the crane's capacity and span, the beam may be designed as a single girder or double girder. Overall, the main beam is a critical component that ensures the crane's structural integrity and lifting ability, making it essential for handling heavy loads safely in industrial settings.

2.Lifting System

Motor: The motor converts electrical energy into mechanical energy, which is used to drive the crane's lifting mechanism. It usually drives a winch or hoist system. Common motor types include AC motors (alternating current), typically used for their reliability and efficiency, and DC motors (direct current), which provide more precise speed and torque control.

Reducer: The reducer in an industrial bridge crane lifting system typically refers to a gear reducer (also called a gearbox). It is a critical component that reduces the speed of the motor's output while increasing torque to drive the crane's hoist or trolley mechanism. The reducer increases the torque that is transferred from the motor to the hoist, allowing the crane to lift heavy loads.

Drum: The drum of an industrial bridge crane lifting system is an essential component in the lifting and lowering process of the crane. It typically functions as the storage and winding mechanism for the crane's lifting cable or wire rope. The drum is designed to hold the lifting rope or cable when it's retracted. As the crane hoist mechanism operates, the rope is wound onto the drum as it lifts or unwinds as it lowers.

Wire rope: Wire ropes are usually made from steel for its high strength, durability, and resistance to wear and fatigue. Stainless steel or galvanized steel can also be used for environments with high corrosion risk. In a bridge crane system, wire ropes are used for hoisting materials in various industrial settings such as manufacturing plants, warehouses, and construction sites.

Pulley block: A pulley block in the context of an Industrial Bridge Crane lifting system refers to the set of pulleys, typically mounted in a housing or frame, that work together to guide and support the movement of the crane's load. The pulley block is a critical component of the crane's lifting mechanism, as it helps distribute the load and reduces the amount of force needed to lift heavy objects.

Lifting device: The lifting device is the part that comes into direct contact with the goods, usually a hook or electromagnetic suction cup, grab, etc. Designed for outdoor use, these lifting devices allow for mobility and versatility in a variety of applications, such as shipping yards, construction sites, and warehouses.

3.End carriage

1) The end carriage of an industrial bridge crane refers to the part of the crane that supports the bridge girder and allows the bridge to move along the length of the crane's runway. The end carriage is typically located at both ends of the bridge, providing the necessary structure to enable the horizontal motion of the crane along the rails.

2) The end carriage usually has wheels that run on rails, allowing the bridge crane to move horizontally along the length of the runway. These wheels are typically equipped with bearings to ensure smooth operation. The end carriage often includes a motor or drive system that powers the movement along the runway. The end carriage frame is designed to support the weight of the crane bridge and the load it is lifting. It is made from strong materials like steel to ensure it can handle the forces involved.

3) Bearings help reduce friction between the wheels and the rails, allowing smooth movement. The structure of the end carriage may also include additional components to support the movement and ensure stability. The end carriage is typically connected to the bridge girder via a set of attachment points or a coupling mechanism that allows for both horizontal movement and some degree of vertical alignment.

 

4.Crane travelling mechanism

1) Working principle

The operator starts the electric motor, which activates the drive system. The motor converts electrical energy into mechanical energy to move the crane.The motor powers the wheels, which are mounted on the end trucks. These wheels run on the rail tracks (runways) placed along the length of the crane's travel path. By reversing the motor's rotation, the crane can move in the opposite direction. A variable frequency drive (VFD) or other controllers can adjust the motor speed for precise movement control. The wheels, rail tracks, and drive mechanism work together to ensure smooth, controlled horizontal movement of the crane across the workspace. The end trucks also distribute the crane's weight evenly along the tracks.The speed of the crane's travel can be adjusted based on operational needs, such as fast travel for transporting goods or slow, careful travel for precise positioning.

2) Functions of the crane operating mechanism

Hoisting Mechanism (Lifting) Function: Raises and lowers the load by lifting it with a hoist drum, rope, or chain.

Travelling Mechanism (Longitudinal Movement) Function: Moves the crane bridge along the track or runway, allowing it to traverse the length of the crane bay.

Trolley Movement Mechanism (Cross Travel) Function: Moves the hoisting mechanism (typically a trolley with the hoist) along the width of the crane bridge.

Bridge Movement Mechanism (Cross Bridge) Function: Allows the crane bridge to move across the entire span of the crane, covering the full operational area.

Braking System Function: Stops or slows down the crane's movement in a controlled and safe manner.

Control System Function: The control system monitors and commands the operation of the crane's movements, speed, and load handling.

Load-Sensing Mechanism Function: Monitors and controls the load weight to prevent.

Safety Mechanisms Function: Provides protection to prevent accidents or damage during crane operation.

5.Trolley travelling mechanism

1) Structural composition

1. Trolley Frame: The main structural element that supports all the mechanical and electrical components.

2. Travelling Wheels (Trolley Wheels): To allow the trolley to move along the bridge girder.

3. Drive Mechanism (Electric Motor and Gearbox): Provides the necessary motion to move the trolley along the bridge.

4. Brake SystemPurpose: To control the speed and stop the trolley when necessary.

5. Trolley Travel Rails: Provide the track on which the trolley moves.

6. Suspension System: Supports the trolley's movement and ensures smooth travel along the track.

7. Electrical/Control System: For controlling the motion and operation of the trolley.

8. Overload Protection System: To prevent damage to the trolley or load due to excessive weight.

9. Lubrication System: To ensure that all moving parts (wheels, axles, and gears)

10. Shock Absorbers/Dampers: To absorb impact and reduce vibrations during trolley operation.

11. Safety Features: To enhance safety during trolley movement.

12. End Stops and Buffers: Prevent the trolley from running off the track at the ends of the bridge.

13. Track Alignment and Support System: Ensures that the rails or tracks remain aligned during operation.

2) Function of the trolley operating mechanism

The primary function of the trolley operating mechanism is to move the trolley along the crane bridge, typically in a lateral direction (perpendicular to the runway beams). This mechanism ensures that the hoisting unit can be positioned over a specific area for load lifting and lowering.

6.Crane wheel

The industrial bridge crane wheel is a crucial component of a crane system, typically used in overhead or gantry cranes. These wheels support the weight of the crane and enable it to move along a track or rail system.

Crane wheels are generally made of high-strength steel to withstand heavy loads and harsh environments. They may also be heat-treated for enhanced durability and wear resistance.The wheels are typically designed with a flange (raised lip) around the edge to keep the wheel on track. This ensures stability and prevents the crane from derailing.

7.Crane Hook

1) The crane hook is a crucial part of the crane's lifting mechanism. It's the component that holds and lifts the load. Typically, crane hooks are made from steel or other durable materials to withstand the heavy stresses of lifting. The hook often has a latch or safety mechanism to prevent the load from falling off.

2) The industrial bridge crane is a type of crane commonly used in factories, warehouses, and other industrial settings to lift and move heavy materials. The "bridge" refers to the horizontal structure that spans across the workspace, typically running on rails or beams. These cranes are often used for lifting large loads and are powered by electric motors.

Motor

The industrial bridge crane motor is typically used to power the various motions of a bridge crane system. These cranes are designed to move heavy loads along a horizontal plane, and the motor plays a key role in the crane's ability to lift, move, and position these loads with precision.

The AC Motors: Most industrial bridge cranes use alternating current (AC) motors due to their reliability, cost-effectiveness, and ease of maintenance. These motors are commonly used for large-scale operations and are typically more efficient in continuous use.

DC Motors: Direct current (DC) motors can offer better control over speed and torque, making them ideal for applications requiring precise load control or variable speed operation. However, they may require more maintenance compared to AC motors.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

A sound and light alarm system for an industrial bridge crane is an important safety feature designed to warn workers of potential hazards or malfunctions.

Sound Alarm:Horns or Sirens produce loud sounds to alert personnel of an emergency or a specific situation.Buzzers or Beepers may be used for less urgent but still important notifications, such as warning of crane operation or travel.

Light Alarm: Flashing Lights: LED or strobe lights that flash to draw attention. Colors can signify different alerts (e.g., red for danger, yellow for caution).Visibility: Lights should be bright and visible from a distance, especially in low-light conditions.

Control Panel: A centralized unit that allows operators to activate or deactivate alarms, adjust settings, and monitor system status.Alarms can be triggered automatically based on sensor inputs (e.g., if a load is too heavy or if someone enters a danger zone). Operators can activate alarms manually in specific situations (e.g., during maintenance or emergencies).

2) Limit switch

Limit switches on outdoor gantry cranes are crucial for safety and operational efficiency. They are used to prevent the crane from moving beyond its designated limits, which helps avoid collisions and accidents.

Functions: The Position Monitoring: Limit switches monitor the position of various moving parts, such as the trolley (which moves along the bridge) and the hoist (which moves vertically). When these parts reach their maximum or minimum travel points, the limit switch is triggered to stop the motion.

Types: Mechanical Limit Switches rely on physical contact with a moving part. When the part makes contact, it activates the switch to either cut off power or trigger another action. Proximity Limit Switches are non-contact switches that detect the presence or absence of an object through electromagnetic fields or infrared sensors. Rotary Limit Switches are often used to monitor the rotation of the crane's drum or motor, triggering a stop when a preset limit is reached. Cable-Operated Limit Switches are typically used for more complex crane setups where a cable runs through the crane to sense position and trigger the limit switch.

10.Safety Devices

Overload Protection System Function: Prevents the crane from lifting loads beyond its rated capacity, which could lead to equipment failure or accident.

Limit Switches Function: Protects the crane from moving beyond its safe operating limits.

Anti-Sway Mechanism Function: Reduces the swinging motion of the load during lifting, lowering, or traveling.

Emergency Stop Button Function: Allows the operator or other personnel to stop the crane in case of an emergency.

Infrared or Laser Sensors Function: Prevents the crane from colliding with obstacles or personnel.

Load Indicator Function: Displays the current load weight being lifted.

 

 

11.Control Mode

Manual Control (Pendant Control) Description: This is the simplest and most commonly used control mode, where the operator uses a hand-held pendant (remote control) to operate the crane. The pendant typically has buttons or joysticks to control the crane's movement, including lifting, lowering, and horizontal movement along the bridge and trolley.It's suitable for small to medium-sized operations.

Cab (Stationary or Cabin Control) Description: In this mode, the operator controls the crane from a cab or cabin mounted on the crane's bridge. The cab can be stationary or move with the crane. This control system is more commonly found in larger, heavy-duty cranes.

Radio Remote Control Description: This mode uses wireless communication to control the crane from a remote location. It is commonly used in environments where the operator needs to be mobile or far from the crane, such as outdoor yards or construction sites.

Sketch

 

Main technical

 

 

Precise Load Handling: Industrial bridge crane can move loads accurately within a defined area, reducing the time spent on manual labor or less efficient equipment like forklifts.

Faster Operations: With the industrial bridge crane, tasks like loading, unloading, and moving materials or machinery are faster, improving overall operational efficiency.

Reduced Manual Handling: By lifting and moving heavy loads automatically, bridge cranes significantly reduce the risk of accidents, strain injuries, and fatigue associated with manual handling or less specialized equipment.In industries where hazardous materials or machinery are present, bridge cranes can be operated remotely, minimizing human exposure to dangerous conditions.

Cost Savings：By automating the lifting and transportation of heavy loads, bridge cranes reduce the need for manual labor, leading to cost savings in the long term.

Heavy Load Handling: Industrial bridge cranes are capable of lifting very heavy loads (up to several tons or more), making them ideal for industries such as construction, automotive manufacturing, steel production, and shipbuilding.

Heavy-Duty Construction: Designed to handle repetitive, high-stress work environments, industrial bridge cranes are built for durability and can last many years if properly maintained.

Streamlined Material Movement: Materials and products can be efficiently moved from one area to another, minimizing the need for additional equipment and ensuring smooth transitions in the production line or warehouse.

Energy Efficient: Modern bridge cranes are often designed to be energy efficient, using electric power systems that reduce overall energy consumption compared to older hydraulic or pneumatic systems.These systems are generally quieter than other heavy-lifting equipment like forklifts or diesel-powered cranes.

 

 

:Material Handling: They are used to move raw materials, components, or finished goods throughout the production process.

Assembly Line Support: Large machinery, engines, or heavy components can be positioned or assembled using overhead cranes.

Building Material Transport: Cranes are used to move construction materials (steel beams, concrete blocks, etc.) around large construction sites.

Heavy Equipment Lifting: Cranes assist in placing and positioning heavy machinery or structural components during building projects.

Turbine and Generator Assembly: In power plants, these cranes are used to assemble or disassemble large turbines, generators, and other heavy equipment.

Equipment Servicing: Overhead cranes are frequently used in maintenance shops to lift and maneuver large or heavy equipment for repairs or upgrades.

Turbine and Generator Assembly: In power plants, these cranes are used to assemble or disassemble large turbines, generators, and other heavy equipment.

 

 

1. Design and Engineering

First, requirements gathering is carried out to understand the load capacity, span, height and application environment. Then detailed engineering drawings and specifications are created, taking into account factors such as wind loads, seismic conditions and material selection. Finally, 3D modeling is carried out, using CAD software to create a 3D model of the crane for better visualization and planning.

2. Material Selection

Choose the right material (such as steel or aluminum) based on the strength, durability, and weight requirements. Procure materials from reliable suppliers.

3. Manufacturing Components

Cut, shape, and weld materials to engineering specifications. Machine components such as wheels, cranes, and other parts to precise dimensions. Apply protective coatings (such as galvanizing or painting) to increase durability and corrosion resistance.

4. Assembly

Assemble individual components (such as gantry, outriggers and hoist) in a controlled environment.

Final assembly brings all sub-assemblies together to build the complete crane. Ensure all parts align and fit.

5. Quality Control

Conduct inspections at various stages of production to ensure compliance with standards and specifications. Perform load testing and safety checks to ensure the crane can handle the intended loads safely.

6. Documentation

Prepare user manuals, maintenance guides, and compliance documentation.Obtain necessary certifications for safety and compliance with local regulations.

7. Delivery and Installation

Deliver the crane to the installation site using appropriate logistics. Assemble and erect the crane on-site, ensuring it is securely anchored and operational.

8. Training and Maintenance

Provide training for operators on how to use the crane safely.Establish a maintenance schedule for regular inspections and servicing.

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%.