Low Headroom Bridge Crane

 

The low headroom bridge cranes are very delicate in dimension and dead weight. Such design could save the working space of customers' warehouses and increases its working efficiency. Comparing with the traditional bridge cranes, the low clearance overhead crane has low requirements in the minimum limiting distance from hook to the wall. It has a lower headroom requirement and a higher lifting height specification. A delicate and optimized design in its wheel pressure, so its dead weight is lighter than the traditional overhead cranes. Then, it, in turn, decreases a huge amount of money in the construction fees.

The low headroom overhead crane is an innovative lifting solution designed for facilities with limited overhead space. With its compact structure and optimized design, it is ideal for applications where space efficiency is critical.

The low headroom overhead crane maximizes lifting height while minimizing headroom requirements. Equipped with advanced motors and precision control systems, it operates smoothly and efficiently. Available in single and double beam configurations to accommodate a variety of lifting capacities and spans. Integrated overload protection, emergency stop function and rugged construction ensure long-term durability.

Core Components：PLC, Engine, Bearing, Gearbox, Motor, Pressure vessel, Gear, Pump

Place of Origin：Henan, China

Warranty ：1 Year

Weight (KG)：6000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

After-sales Service Provided：Engineers available to service machinery overseas

working duty：M5 or as your demand

power supply：380~410V 50 hz 3ph

control methods：cabin control, wireless remote control

Ambient temperature：-20~+40℃

other application：building hoist, ming hoist

Protection Degree：IP55,Button Controller:IP65

operating voltage：<=50

Main electrical parts：Siemens

 

 

1.Main beam

The main girder of a low headroom overhead crane is the central structural component that supports the crane and enables the hoist to move horizontally. In a low headroom overhead crane, the design of the main girder is optimized to minimize the overall height of the crane system, making it suitable for areas with limited vertical space.

The main girder is designed to reduce the height of the crane structure. This is often achieved by integrating the hoist near or inside the main girder, thereby reducing the required clearance between the crane and the ceiling.

The main girder is made of high-strength steel to ensure durability and the ability to handle heavy loads while maintaining a lightweight design. The main girder is connected to the end car or end truck, which houses the wheels that allow the crane to traverse along the track beam.

In a low headroom design, the crane and trolley mechanism are compact and positioned to maximize the lifting height. For example, the crane can be mounted on the side of the beam or inside a section.

The main girder is often treated with an anti-corrosion coating to ensure longevity, especially in challenging environments such as manufacturing plants or warehouses.

Lifting System

Low headroom lifting systems for bridge cranes are designed for environments with limited vertical space. These systems ensure efficient handling of materials without excessive overhead clearance.

Electric Hoist: Typically features a compact, low headroom design. Often features a trolley integrated into or mounted near the hoist to minimize the distance between the hoist hook and the beam.

Trolley: Low-profile design ensures the trolley runs close to the underside of the crane girder, reducing the required headroom. Can be a single-track or double-track system, depending on the application.

Bridge Girder: Single or double-beam, the hoist and trolley are positioned to maximize vertical lift in a tight space. Designed to provide structural strength while maintaining a low profile.

End Frame: Designed to support the bridge and ensure smooth lateral movement on the crane runway.

Control System: Modern cranes use variable frequency drives (VFDs) for smooth, precise control. A choice of remote controls or pendant-mounted controls ensures safe and flexible operation.

Features

Compact Design: The entire system is carefully designed to minimize the distance between the hook and the beam, maximizing the lifting height.

Efficient: High-performance motors and a rugged mechanism ensure efficient material handling in limited space.

Customizable: Solutions tailored for specific applications, including a wide range of capacities from light to heavy loads.

Easy to Install: Designed for quick assembly with minimal downtime during installation.

Durable: High-strength steel and advanced coatings protect against wear, corrosion and environmental factors.

3.End carriage

The end beam of a low-headroom overhead crane is a critical structural component designed to support and facilitate the horizontal movement of the crane along the track beam. This type of end beam is specifically optimized for low-headroom environments with limited overhead space.

The end beam is designed to minimize the space required between the crane and the ceiling, ensuring maximum hook access and lifting height.

The end beam is made of strong materials such as steel to withstand heavy loads and frequent use. Welded or bolted connections ensure durability and structural integrity. Equipped with high-precision wheels (usually made of forged steel), it can run smoothly on the crane track beam. The wheels are usually mounted on anti-friction bearings to reduce wear and improve performance.

The end frame is usually designed with sealed components for easy maintenance to reduce downtime. Depending on the span and capacity of the overhead crane, the end frame can be customized to meet specific operating requirements. The end frame is usually paired with a single-beam or double-beam overhead crane, depending on the weight and operational needs.

 

 

 

 

 

 

4.Crane travelling mechanism

1) Operation principle

The crane receives power via a busbar or cable festoon system. The travel motor is powered and controlled to drive the crane along the track beam. Both end frames are driven simultaneously to prevent misalignment. Advanced controls ensure smooth acceleration and deceleration, reducing load sway. The travel speed can be adjusted according to the load and operating requirements. Modern systems use frequency converters for variable speed control. Limit switches prevent the crane from overspeeding. Anti-collision systems are used when multiple cranes are operating on the same runway.

2) Low Headroom Design Features:

The hoist is integrated into the end frame or placed on a specially designed trolley, minimizing the distance between the hook and the beam. This design maximizes the lifting height, even in areas with low ceilings.

 

 

 

 

5.Trolley travelling mechanism

How it works: The motor powers the gear reducer, which drives the wheels of the trolley. The trolley moves along the bridge beam, carrying the hoist and the load. The compact structure ensures that the load is as close to the bridge beam as possible, reducing the overall height of the crane and optimizing headroom utilization. A guide wheel or similar alignment mechanism ensures that the trolley remains stable and aligned during operation. Limit switches prevent the trolley from reaching the end of the bridge beam, ensuring safe operation.

Low-headroom design features

Compact design: The hoist and trolley mechanism are integrated into a single compact unit to minimize the overall height.

Side-mounted hoist: In many designs, the hoist is mounted beside the trolley rather than underneath it, further reducing the required headroom.

Tight wheelbase: The wheels are closely positioned, allowing the crane to operate in tight spaces.

Low-clearance gearbox: A specialized gearbox with a flat design is used to save space.

6.Crane wheel

1) Operation principle

Track rolling: When the crane moves, the motor drives the wheel to rotate, and the wheel rolls on the track, thereby realizing the lateral movement of the crane.

Load distribution: The design of the wheel group is usually a multi-wheel structure, which can effectively disperse the total load of the crane, reduce the pressure on the track, and extend the service life of the track and wheels.

Guidance function: The design of the wheel should also take into account the guidance function to ensure that the crane remains in the center of the track when moving to prevent derailment or tilting.

2) Maintenance and care

Regular inspection: The wear of the wheel needs to be checked regularly to ensure good contact between the wheel and the track to prevent accidents caused by excessive wear.

Lubrication: The bearings of the wheel need to be lubricated regularly to reduce friction, improve operating efficiency, and extend service life.

Cleaning: The part where the wheel contacts the track needs to be kept clean to prevent friction damage or wear caused by debris.

7.Crane Hook

Main features of hooks

1) Material: Hooks are usually made of high-strength steel to ensure their strength and toughness under high loads. Common materials include carbon steel or alloy steel, which can withstand large tensile and impact forces.

2) Shape design: The shape of the hook is generally "C" or "U" to firmly hang the load while preventing the load from slipping. The depth and width of the hook should be considered during the design to accommodate materials of different shapes and sizes.

3) Safety device: The hook is usually equipped with an anti-unhooking device, such as a safety buckle or locking device, to ensure that the load will not accidentally fall off during the lifting process.

4) Load capacity: The design of the hook needs to take into account the rated lifting weight of the crane, and there will usually be corresponding markings to ensure that its load capacity is not exceeded during use.

Motor

The motor of a low-headroom overhead crane is a critical component to ensure efficient and reliable lifting and traveling operations.

Key Features of the Motor:

Compact Design: Low-headroom cranes are designed for highly restricted spaces. The motor is usually compact to minimize the overall size.

High Efficiency: The motor is usually designed to be energy-efficient, reducing operating costs.

Variable Frequency Drive (VFD) Compatibility: Many low-headroom cranes use motors that are compatible with VFDs to provide smooth speed control, reduce wear and improve safety.

Torque Requirements: The motors of these cranes are optimized for high starting torque to efficiently handle heavy loads.

Duty Cycle: The motor should be matched to the duty cycle required for a specific application, such as intermittent or continuous use.

Cooling: The motor may be equipped with a forced cooling system to ensure reliable operation even under demanding conditions.

Braking System: The motor usually has an integrated or external electromagnetic brake to hold the load securely when the crane is stationary.

Protection and Insulation: The motor is usually designed with a high IP rating (e.g. IP54 or higher) to protect against dust and moisture. The insulation class (e.g. F or H) provides thermal protection.

Type of motor used:

Asynchronous motor (induction motor): Widely used due to its simplicity, reliability and cost-effectiveness.

Synchronous motor: Provides precise speed control, making it suitable for high-precision lifting tasks.

Servo motor: Used in advanced crane systems due to its excellent positioning accuracy and dynamic response.

Permanent magnet motor: Lightweight and highly efficient, it is becoming increasingly popular in modern crane designs.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

The sound and light alarm system for low headroom overhead cranes is an important safety feature that helps prevent accidents during crane operation.

Audible alarm (sound alarm): A siren, buzzer or horn that emits a loud sound. Used to warn nearby personnel about crane movement, load handling or other operational risks. Can produce a continuous or intermittent tone depending on the situation.

Visual alarm (light alarm): A flashing or rotating light, usually red, amber or blue, to attract attention. Usually LED-based for increased visibility and energy efficiency. Mounted at multiple points on the crane for 360-degree visibility.

2) Limit switch

A limit switch in a low headroom overhead crane is a safety device used to control or limit the movement of the crane. It prevents the crane or trolley from overtravel, ensuring that the crane operates within safe limits.

Crane limit switch: prevents the hook or load from being too high or too low.

Travel limit switch: limits the travel of the crane trolley or bridge to a specified area.

Rotary or lever limit switch: usually activated by mechanical movement (such as a cam or lever). Converts movement into an electrical signal to cut power when the limit is reached.

Weight-operated limit switch: prevents the crane from being overloaded. Detects overload and interrupts operation to prevent damage or accidents.

Electronic (intelligent) limit switch: uses sensors to provide precise control and feedback. Commonly used in modern cranes to improve safety and efficiency.

10.Safety Devices

Low headroom overhead cranes are used in applications with limited vertical clearance. Ensuring safety is key to their operation.

1. Overload protection device

Monitors the weight of the load and prevents lifting of loads that exceed the crane's capabilities.

If the load exceeds the safe limit, an alarm is issued to the operator and the operation may be automatically stopped.

2. Limit switch

Hoist limit switch: prevents the hoist from exceeding its upper or lower limit.

Travel limit switch: prevents the crane or trolley from moving out of the designated operating area.

3. Anti-collision device

Prevents the crane from colliding with other equipment or structures, especially when multiple cranes are operating in the same area.

4. Emergency stop button

Allows the operator to immediately stop the operation of the crane in an emergency.

5. Overheat protection

Installed in the motor and electrical system, it shuts down the operation if the temperature exceeds a safe level.

6. Buffer device

Absorbs energy and prevents mechanical damage when the crane unexpectedly reaches the end of the track.

7. Phase failure protection

Protects the crane's electrical system when the power phase fails or is unbalanced.

8. Anti-sway system

Minimizes load swing during lifting or trolley movement, ensuring stability and safety.

9. Braking system

Ensures that cranes and trolleys stop safely when operations stop. Modern systems often use fail-safe brakes that activate when power is lost.

10. Wire rope safety features

Wire rope inspection: Ensures that the rope is in good condition to prevent accidents.

Drum guard: Keeps the wire rope securely wrapped around the drum.

11.Control Mode

1)The control mode of low headroom overhead crane depends on the specific requirements of the operation, environment and user preference.

1. Pendant control: The crane is controlled using a wired pendant control panel suspended from the crane. The operator walks beside the crane to operate it.

2. Remote control: Operated using a wireless remote control. The operator can control the crane from a safe distance.

3. Cab control: The cab is connected to the crane and the operator controls the crane from inside the cab.

4. Automatic or semi-automatic control: The crane operates automatically according to pre-programmed commands. Semi-automatic systems allow some human intervention.

5. Joystick control: Controlled using a wired or wireless joystick panel.

12.Sketch

 

Main technical

 

Low-headroom overhead cranes offer several benefits, especially in space-constrained industrial and warehouse environments.

Low-headroom cranes are designed with compact dimensions that allow them to operate effectively in spaces with low ceilings or restricted headroom. They maximize lifting heights and make efficient use of vertical space.

The compact design often reduces the need for structural modifications and is less expensive to install than standard cranes. Ideal for existing facilities where increasing ceiling height is not an option.

Because the hoist is closer to the bridge girder, these cranes allow for greater hook access from the side, maximizing the reach of the crane. This design facilitates precise and efficient material handling, even in tight spaces.

Low-headroom cranes are typically lightweight and put less stress on supporting structures, which can reduce maintenance costs and extend the life of a building.

 

 

Low headroom overhead cranes are designed for environments with limited vertical space. Their compact design optimizes available headroom, making them suitable for a variety of applications.

Ideal for plants with low ceilings where standard cranes may not fit. Used for lifting and transporting heavy machinery, assembly parts, and raw materials.

Used in warehouses with limited vertical space to efficiently move goods and materials. Ideal for stacking and sorting heavy items in confined areas.

Essential for lifting and assembling automotive parts in low headroom workshops. Often used in production lines or repair shops.

Ideal for lifting tools, equipment, or sheet metal in small manufacturing shops. Suitable for environments that require a compact lifting solution.

Used for maintenance and repair in shipyards with low decks or limited space. Helps lift smaller components such as engines or ship parts.

Suitable for power plants with limited overhead space to mount standard cranes. Used for maintenance of turbines, generators, and other heavy equipment.

Suitable for underground facilities or low-ceiling mining installations. Helps move heavy mining equipment and materials.

Used in processing plants with limited space. Often used to efficiently transport raw materials or finished products.

Used in assembly lines with low ceilings where precise handling of parts is critical. Helps maintain and repair aircraft in tight spaces.

 

 

The production process of low headroom bridge cranes usually involves several key stages to ensure high-quality manufacturing and compliance with safety standards.

1. Preparation: Analyze customer requirements (capacity, span, operating environment, and lifting height). Create CAD drawings and 3D models to determine dimensions and specifications. Perform structural and dynamic analysis to ensure safety and stability. Ensure that the design complies with international standards such as ISO, FEM, or ASME.

2. Procurement of materials: Select high-quality materials (steel plates, motor components, and cables). Procure components such as wire ropes, hoists, electrical systems, and wheels from reliable suppliers.

3. Steel cutting and fabrication: Cut steel plates to required sizes using CNC plasma or laser cutting machines. Assemble main beams, end beams, and other structural components using precision welding techniques. Clean steel components using sandblasting to remove rust and apply anti-corrosion coatings.

4. Assembly: Attach the low headroom trolley, end trolley, and hoisting mechanism to the bridge structure. Install electrical components, including control panels, limit switches, and wiring. Test the functionality of each component (such as motors and gearboxes) before final assembly.

5. Quality Control: Inspect welds for defects using non-destructive testing (NDT) techniques such as ultrasonic or radiographic testing. Measure dimensions and tolerances to ensure compliance with design specifications.

Perform load tests and operational tests to verify crane performance under different conditions.

6. Painting and Finishing: Use industrial-grade paint for long-lasting protection against wear and corrosion. Add safety markings and labels according to customer or industry standards.

7. Pre-Delivery Testing: Perform complete system testing under simulated operating conditions. Verify that low-headroom design meets operational requirements (e.g., low headroom).

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%.