Top Running Crane

Top Running Crane is a common lifting equipment, widely used in factories, warehouses, material yards and other occasions, mainly used for handling, loading and unloading and transporting various materials.

The main beam of the Top Running Crane usually adopts a box-type or I-shaped structure, which is light and sturdy. The lifting trolley is installed under the main beam and is responsible for the lifting and movement of materials. The electric hoist is usually a lifting mechanism, hung under the main beam, for vertical lifting of materials. The walking mechanism is driven by a motor to move the crane horizontally along the track. The control system includes operating buttons, electrical cabinets, control consoles, etc., which can be operated manually or remotely.

3. The single-beam design has a simple structure, is easy to install, operate and maintain, and has a relatively low cost. It is suitable for various working environments, and both walking and lifting can be smoothly controlled. It is equipped with safety measures such as overload protection, limit switches, and emergency shutdown to ensure safe operation. It can improve work efficiency and quickly complete material handling. Due to the single-beam structure, the bridge occupies less space and can operate in a small venue. Compared with double-girder bridge cranes, it has lower manufacturing and maintenance costs and is suitable for small and medium-sized enterprises or low-frequency usage occasions.

Warranty：1 Year

Weight (KG)：30000 kg

Feature：Bridge Crane

Condition：New

Rated Lifting Moment：As your demand

Max. Lifting Load：customized

Span：10.5-31.5m

Max. Wheel Pressure：74-780KN

Electric current：380V/50HZ, three-phase (As you local condition)

Steel products：Q235B(-20℃-40℃),Q345E(-40℃-40℃)

Power Source：3 Phase 380V 50hz

Type：single girder overhead crane

Working class：A3~A4

Main Lifting Mechanism：Electric hoist

Control Method：remote control

Pictures & Components

1.Main beam

1) The main beam of a Top Running Crane usually has the following common forms:

Box-type structure: The main beam is a closed box-shaped structure welded from steel plates. This structure has good torsion and bending resistance and is suitable for bridge cranes with larger spans.

I-beam structure: The main beam is made of I-beam material and is usually used for lighter and shorter span cranes. This structure is light in weight and has a low manufacturing cost, but its load-bearing capacity is relatively limited.

H-beam structure: Similar to I-beam, but with a slight improvement in structural strength, it is suitable for medium load occasions.

2) The main beam is usually made of high-quality carbon structural steel such as Q235B or Q345B. The choice of different materials depends on the working environment of the crane, the load requirements and the specific needs of the customer.

Q235B steel: Commonly used in Top Running Crane with medium and light loads, it has good weldability and plasticity.

Q345B steel: Higher strength, suitable for heavy load occasions, and can withstand large bending and torque.

Lifting System

1) Electric hoist: The lifting system of a Top Running Crane usually uses an electric hoist as a core component. The electric hoist integrates a lifting motor, a reducer, a drum, a wire rope or chain, etc., and realizes the lifting and lowering of goods through the drive of an electric motor.

2) Lifting motor: The motor is the power source of the lifting system. Usually a three-phase AC motor is used, which is efficient, stable and durable. The lifting motor is mostly equipped with a frequency converter, which can adjust the lifting speed according to the load conditions to achieve smooth and precise operation.

3) Reducer: In order to make the lifting process smoother, the reducer in the electric hoist converts the high-speed rotation of the motor into the low-speed rotation of the drum, improves the lifting capacity, and avoids equipment damage or excessive wear caused by direct drive.

4) Drum and wire rope/chain: The drum in the electric hoist lifts or lowers the cargo by winding a wire rope or chain. Wire ropes are usually made of high-strength materials and have a high load-bearing capacity; chains are more suitable for small loads. The choice of the two depends on the specific load requirements and lifting height.

5) Pulley block: Pulley blocks are often set in the lifting system to increase the lifting force and change the direction of the wire rope or chain. Pulley blocks can improve the efficiency of the system by reducing the load on the motor.

6) Limit switch: This device is used to detect the travel limit of the lifting system to prevent the lifting object from being raised too high or lowered too low. It is usually equipped with upper and lower limit switches to ensure safe operation.

 

3.End carriage

Functions of the end beam

1) Support the main beam:

The end beam is installed on both sides of the crane to support the weight of the main beam and run on the track through the travel wheels, so as to achieve the smooth movement of the main beam and the lifting trolley.

2) Achieve horizontal movement:

The end beam is connected to the electric drive device. Through the cooperation of the drive wheel and the guide rail, the crane can move horizontally in the working area to expand the working coverage.

3) Ensure smooth operation:

The design of the end beam must ensure the precise cooperation between the travel wheel and the track to avoid derailment and shaking. At the same time, the buffer device can reduce the impact generated during the movement and ensure the smooth operation of the crane.

 

4.Crane travelling mechanism

The working process of the crane running mechanism is as follows:

1) Start: The crane running mechanism is started through the electronic control system, the motor starts working, drives the reducer to reduce the speed and output the appropriate torque.

2) Transmission: The reducer transmits power to the travel wheel through the coupling, drives the travel wheel to rotate along the track, and drives the entire crane to move along the track.

3) Control: The operator adjusts the running speed and direction of the crane through the control system to make the crane move smoothly. The motor of the crane running mechanism is usually equipped with a frequency converter, which can achieve stepless speed adjustment and improve control accuracy.

4) Stop: When it is necessary to stop or reach the predetermined position, the brake device works to quickly stop the movement of the crane, and prevents the crane from exceeding the safety range through the limit switch.

5.Trolley travelling mechanism

The trolley running mechanism is operated by an electrical control system. Its working principle is as follows:

1) Drive start:

The trolley running mechanism is started by the control system, the motor starts to run, and the drive reducer converts the high-speed output of the motor into a low-speed and high-torque output.

2) Transmission and travel:

The reducer transmits power to the driving wheel of the trolley through the coupling, driving the trolley to move on the track of the main beam, thereby driving the electric hoist and the suspended materials to move in the horizontal direction.

3) Control and braking:

The travel speed, direction and position of the trolley can be adjusted by operating the control system. The trolley running mechanism is equipped with a braking device to stop or slow down the movement of the trolley to ensure the accuracy and safety of the operation.

4) Positioning and stopping:

The trolley running mechanism is usually equipped with a limit switch. When the trolley runs to the set limit position, the limit switch will automatically cut off the power supply to prevent the trolley from crossing the safety range.

6.Crane wheel

The wheels achieve horizontal movement of the crane by contacting the track. The specific working principle is as follows:

1) Electric drive:

The motor in the crane's trolley or car running mechanism transmits power to the wheel shaft through a reducer and a coupling.

2) Wheel rotation:

After the power is transmitted to the wheel, the wheel rotates around the bearing, contacts the track, and drives the crane along the track through friction.

3) Guidance and balance:

The rims on both sides of the wheel can effectively limit the lateral movement of the wheel, ensure the correct running direction of the crane on the track, and avoid deviation or derailment.

4) Load-bearing function:

The wheel directly bears the weight of the crane and its load, and evenly distributes this weight to the track to ensure the stability of the crane during movement.

7.Crane Hook

Common problems and maintenance of hooks

1) Wear:

Due to long-term contact with the load, the hook mouth and stress-bearing parts are prone to wear. The wear of the hook should be checked regularly and polished or replaced if necessary.

2) Deformation:

Under overload or strong impact, the hook may bend or deform. Damaged hooks should be found and replaced in time to avoid accidents.

3) Cracks:

During use, the hook may produce tiny cracks due to metal fatigue or stress concentration. Regular inspection and maintenance are very important, especially under high load and frequent use.

4) Corrosion:

When the hook is exposed to a humid or corrosive environment, it may rust or corrode. Anti-rust treatment should be done and the hook should be avoided from being in a harsh environment for a long time.

Motor

When selecting a motor, the following performance parameters need to be considered:

1) Rated power: The maximum power that the motor can continuously output, usually in kilowatts (kW). The power should be determined based on the rated load and operating frequency of the crane.

2) Speed: The rotation speed of the motor, usually expressed in revolutions per minute (RPM). Different applications require motors with different speeds.

3) Starting torque: The maximum torque generated by the motor at start-up must be large enough to overcome the static friction of the load and ensure smooth start of lifting or moving.

4) Working efficiency: The energy conversion efficiency of the motor under rated load. The higher the efficiency, the lower the energy consumption.

5) Insulation grade: The insulation material grade of the motor's internal windings, usually F or H, determines the motor's ability to withstand high temperatures.

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Sound and light alarm system & limit switch

1) The working principle of the sound and light alarm system is usually as follows:

Monitoring status: Monitor the status of the crane (such as overload, running direction, limit position, etc.) through sensors or switches.

Triggering alarm: Once an abnormal situation (such as overload, reaching the limit) is detected, the control module will immediately trigger the sound and light alarm, making a sound and flashing lights to alert the operator and surrounding personnel.

Reset: After handling the abnormal situation, the operator can reset the alarm system through the control panel or switch.

2) The working principle of the limit switch is as follows:

Monitoring movement: The limit switch monitors the movement status of the crane (such as the lifting position of the hook) through mechanical contacts or electronic sensors.

Triggering signal: When the hook or trolley moves to the set limit position, the limit switch will generate a signal, cut off the power supply or send an alarm signal.

Safety shutdown: After the limit switch is triggered, the crane's motor will stop working immediately to avoid equipment damage or safety accidents.

10.Safety Devices

1) Limit switch: used to monitor the limit position of lifting and lowering to prevent the hook from exceeding the safe height or falling to the ground. When the hook reaches the set limit position, the limit switch will cut off the power supply. 2) Overload protection device: used to monitor the load of the crane to prevent overload operation. The load is monitored in real time through the sensor. When the load exceeds the set value, the overload protection device will sound an alarm and cut off the power supply to prevent the crane from overloading.

3) Safety hook: prevent the hook from accidentally falling off during the lifting process to ensure the safety of the hoisted objects.

4) Braking device: ensure that the crane can brake safely and effectively when it needs to stop or slow down. During operation, the braking device will brake quickly when the control signal is released to prevent the hoisted objects from falling.

5) Sound and light alarm system: used to provide warnings during operation to remind operators to pay attention to safety. When abnormal conditions are detected (such as overload, reaching the limit), the system will sound and light alarms to remind operators and surrounding personnel.

6) Electrical protection device: prevent electrical system failures or short circuits to protect the safety of cranes and operators.

9) Operation monitoring system: Real-time monitoring of the crane's operating status, including speed, load, position, etc. Through sensors and monitoring equipment, the crane's working status can be remotely monitored, and faults can be discovered and handled in a timely manner.

10) Personnel safety protection device

Safety guardrail: Set up safety guardrails in the crane's operating area to prevent people from entering by mistake.

Safety warning signs: Post safety warning signs around the crane to remind operators to pay attention to safety.

11.Control Mode

1) Manual control: Directly control the various movements of the crane through a manual controller (such as a rocker, button panel, etc.). The operation is simple and intuitive, suitable for small or lightly loaded cranes. The skill requirements for the operator are low.

2) Electric control: Through an electric control system, the movement of the crane is controlled by electrical components (such as contactors, relays, etc.). Flexible operation, suitable for small and medium-sized cranes. Fast response speed, can achieve a variety of functions (such as start, stop, speed regulation, etc.).

3) Wireless remote control: The crane can be controlled at a long distance by operating the crane through a wireless remote control. It is easy to operate and is especially suitable for large or complex operation scenes.

4) PLC control: Use a programmable logic controller (PLC) for intelligent control, and realize various operating states and safety protection of the crane through programming.

5) Computer control: Remote control and monitoring through a computer or industrial computer, usually combined with a SCADA (supervisory control and data acquisition) system. It can achieve centralized control of multiple cranes, suitable for large factories or warehouses.

 

Sketch

Main technical

 

 

1. Simple structure

The design of Top Running Crane is relatively simple, mainly composed of main beam, end beam, running mechanism and lifting mechanism, which is easy to manufacture and install.

2. Small footprint

Due to its unique structure, Top Running Crane usually occupies less ground space and is suitable for working environment with limited space.

3. Flexible operation

The operator can easily control the various functions of the crane by manual, remote control or automation, which improves work efficiency.

4. Economical and practical

The manufacturing cost of Top Running Crane is relatively low, and the maintenance and operation costs are also relatively economical, which is suitable for small and medium-sized enterprises and general factories.

5. High lifting efficiency

Top Running Crane can quickly complete lifting and handling tasks, improve work efficiency and shorten operation time.

6. High safety

A variety of safety devices (such as limit switches, overload protection, sound and light alarm systems, etc.) are used to effectively prevent accidents and ensure the safety of operators.

7. Strong carrying capacity

Although it is a single-beam design, the carrying capacity of a Top Running Crane can reach several tons to dozens of tons according to specific needs, which can meet the needs of handling various heavy objects.

8. Easy maintenance

Due to its simple structure, the daily maintenance and overhaul of a Top Running Crane is relatively easy, reducing downtime.

 

 

1. Manufacturing Industry

In the manufacturing industry, single-girder bridge cranes are often used for the handling of mechanical equipment, loading and unloading of heavy objects, and material transportation of production lines to improve production efficiency.

2. Warehousing and Logistics

In the warehousing and logistics industry, single-girder bridge cranes are used for stacking, handling, and loading and unloading of goods. It can move and operate quickly, and is suitable for efficient warehouse management.

3. Construction Sites

On construction sites, single-girder bridge cranes can be used to hoist construction materials, such as steel, concrete components, etc., to facilitate construction.

4. Ports and Wharfs

In ports and wharfs, single-girder bridge cranes are used for loading and unloading of ships, handling containers and other goods, and improving port operation efficiency.

5. Power Industry

In the power industry, single-girder bridge cranes are used for the handling and installation of large-scale power generation equipment, such as transformers, generators, etc., to ensure the safe and efficient installation of equipment.

6. Automobile Manufacturing

In automobile manufacturing plants, single-girder bridge cranes are often used for the assembly and handling of vehicle parts to assist in the efficient operation of production lines.

7. Mining and Metallurgy

In the mining and metallurgical industries, single-girder bridge cranes are used for the handling of ore, installation and maintenance of equipment, and improve work efficiency.

8. Shipbuilding and Aerospace

In shipyards and aerospace manufacturing centers, single-girder bridge cranes are used for the lifting and movement of heavy components to ensure the smooth production process.

 

 

1. Demand Analysis and Design

Demand Collection: Communicate with customers to understand their specific needs, including lifting capacity, span, lifting height, use environment, etc.

Design Plan: According to the needs, carry out structural design and determine the main parameters, such as the shape of the main beam, material specifications, power system, etc.

Technical Drawings: Draw detailed technical drawings, including the size, material and assembly method of each component.

2. Material Procurement

Material Selection: According to the design requirements, select suitable materials, such as steel, mechanical parts, electrical components, etc.

Supplier Confirmation: Contact qualified suppliers to confirm the purchase and delivery time of materials.

3. Processing and Manufacturing

Main Beam Processing: Cut, weld and form the main beam according to the design drawings, usually using steel for welding and forming.

End Beam and Bracket Processing: Make end beams, brackets and other connecting parts to ensure coordination with the main beam.

Trolley and Running Mechanism Manufacturing: Manufacture the trolley and running mechanism of the crane, including motors, reducers, tracks, etc.

Lifting Mechanism Manufacturing: Manufacture the lifting mechanism, usually including drums, hooks, chains or ropes, etc.

4. Assembly

Component assembly: Assemble the processed components (main beam, end beam, trolley, lifting mechanism, etc.) to form a complete crane structure.

Electrical system installation: Install electrical components such as motors, control systems, limit switches, sound and light alarm systems.

Debugging and inspection: After the assembly is completed, preliminary debugging and inspection are carried out to ensure that each component is working properly.

5. Testing

Static test: Perform static load test on the crane to confirm its load-bearing capacity and structural stability.

Dynamic test: Perform dynamic operation test to check the operation of each moving part, including lifting, walking, braking and other functions.

Safety test: Test whether the safety device (such as limit switch, overload protection, etc.) is working properly.

6. Quality inspection

Quality audit: Perform quality control in each production link to ensure that all components and assemblies meet the design standards.

Final inspection: After completing all tests, conduct final inspection to ensure that the product meets relevant industry standards and customer requirements.

7. Delivery and installation

Packaging and transportation: Qualified cranes are properly packaged to prevent damage during transportation.

On-site installation: according to customer requirements, a professional team will be dispatched to carry out on-site installation and commissioning.

Customer training: training the customer's operators to ensure that they can operate the crane safely and effectively.

8. After-sales service

Maintenance support: providing regular maintenance and maintenance services to ensure the long-term stable operation of the crane.

Troubleshooting: establishing a rapid response mechanism to handle the faults and problems encountered by customers during use.