45 Ton Double Girder Overhead Crane

A 45-ton double girder overhead crane is a heavy-duty lifting solution designed for industrial applications requiring high capacity, precision, and durability. Here's a detailed breakdown of its features, components, and typical applications:

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Key Features of a 45-Ton Double Girder Overhead Crane

High Load Capacity

Designed to lift and move loads up to 45 tons (90,000 lbs) safely and efficiently.

Suitable for heavy industries like steel, mining, construction, and manufacturing.

Double Girder Design

Two parallel girders provide greater strength, stability, and hook height compared to single-girder cranes.

Allows for higher lifting heights and longer spans (up to 30m+ depending on design).

Robust Construction

Made of high-quality steel (typically Q235B or Q345B) for durability.

Reinforced end carriages and trolley system to handle heavy loads.

Hoisting Mechanism

Equipped with a heavy-duty wire rope hoist (e.g., 45-ton capacity with dual brakes for safety).

Optional frequency-controlled lifting for smooth operation.

Trolley and Crab Unit

The trolley runs on top of the girders, carrying the hoist and hook.

Can include auxiliary hoists (e.g., 5-ton or 10-ton secondary hoist) for multi-lifting tasks.

End Trucks & Runway System

Driven by heavy-duty wheels (forged steel or polyurethane) on rails.

Powered by AC motors with variable frequency drives (VFD) for precise control.

Control Options

Pendant control (wired or wireless remote).

Cabin-operated for large cranes (with ergonomic seats and controls).

Automated systems (for smart factories).

Safety Features

Overload protection (load limiter).

Emergency stop, limit switches, and anti-collision systems.

Insulated systems for hazardous environments (e.g., explosion-proof).

 

Comparison with Single-Girder Cranes

Feature	Double Girder (30T)	Single Girder (30T)
Hook Height	Higher (no lower beam obstruction)	Lower
Durability	More robust for heavy-duty use	Lighter duty
Span	Better for long spans (>25m)	Limited span
Cost	Higher initial cost	More economical

 

Capacity:45 metric tons (can be customized for higher loads if needed).

Span: Typically ranges from 10m to 35m (customizable based on workshop layout).

Lifting Height: Standard is 6m–30m (adjustable per requirements).

Work Class: A5–A7 (moderate to heavy-duty cycles).

Operating Speed:

Hoisting: 1.5–10 m/min (variable speed options).

Trolley Travel: 10–30 m/min.

Bridge Travel: 20–60 m/min.

Power Supply: 3-phase, 380V/415V, 50Hz (or as per regional standards).

A 45-ton double girder overhead crane is a heavy-duty lifting system used in industries like steel, construction, shipping, and manufacturing. Here are its key components:

1. Bridge Structure

Main Girders (2 Nos.) – The primary load-bearing beams that span the width of the bay.

End Trucks (2 Nos.) – Located at each end, housing wheels and motors for crane movement along the runway.

2. Hoisting Mechanism

Hoist Motor – Powers the lifting operation.

Wire Rope/Drum or Chain Hoist – Lifts and lowers the load (typically wire rope for 45-ton capacity).

Hook Block – Equipped with a heavy-duty hook for load attachment.

Drum or Sheaves – Guides the wire rope for smooth operation.

3. Trolley & Travel Mechanism

Trolley Frame – Moves along the bridge girders to position the hoist.

Trolley Drive Motor – Powers trolley movement across the crane span.

Wheels & Rails – Ensure smooth trolley travel.

4. End Carriages & Runway System

Wheels (4 or more) – Support the crane on the runway rails.

Buffers/Bumpers – Absorb impact at travel limits.

Runway Beams – Support the crane's movement along the building structure.

5. Electrical System & Controls

Cabin or Pendant Control – Operator interface (can be radio remote-controlled).

Festoon System/Cable Reel – Manages power and control cable movement.

Limit Switches – Prevent over-travel of hoist and trolley.

Variable Frequency Drives (VFDs) – Ensure smooth acceleration/deceleration.

6. Safety Components

Overload Protection – Prevents lifting beyond capacity.

Emergency Stop (E-Stop) – Immediate shutdown in emergencies.

Anti-Collision System – Used in multi-crane setups.

Brakes – Fail-safe brakes on hoist, trolley, and bridge.

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7. Optional Features

Crane Weighing System – Displays load weight.

Automatic Positioning System – For precise load placement.

Explosion-Proof Design – For hazardous environments.

This crane is designed for high load capacity, durability, and precision handling in industrial applications.

Sketch

Main technical

 

 

A 45-ton double girder overhead crane is a heavy-duty lifting solution designed for industrial applications requiring high capacity, precision, and durability. Here are its key advantages:

1. High Load Capacity & Stability

Designed to handle 45 tons or more with ease.

Double girder construction provides superior strength and stability compared to single girder cranes.

Better load distribution reduces stress on the crane structure.

2. Long Span & Wide Coverage

Ideal for large workshops, warehouses, and industrial facilities.

Can cover wider spans (up to 30-35 meters or more) without intermediate supports.

3. Higher Lifting Height

The double girder design allows for greater hook height since the hoist is placed between the girders (not below them like in single girder cranes).

4. Durability & Long Service Life

Built with heavy-duty steel for long-term reliability.

Resistant to deformation, even under frequent heavy loads.

5. Smooth & Precise Operation

Equipped with high-quality motors, brakes, and controls for smooth lifting and traversing.

Advanced variable frequency drives (VFD) enable precise load positioning.

6. Customizable Options

Can be fitted with remote control, anti-sway systems, overload protection, and automation features.

Available in explosion-proof, high-temperature, or outdoor variants.

7. Low Maintenance & Reduced Downtime

Robust construction means fewer breakdowns.

Easy access to components for maintenance.

8. Safety Features

Overload limiters, emergency stop, and fail-safe brakes ensure safe operation.

Compliance with ISO, FEM, DIN, or ASME standards.

9. Cost-Effective for Heavy Lifting

More efficient than using multiple smaller cranes.

Reduces labor costs and speeds up material handling.

10. Versatile Applications

Used in steel plants, mining, shipyards, power plants, and heavy manufacturing.

Suitable for foundries, logistics, and large-scale construction.

Conclusion:

A 45-ton double girder overhead crane is ideal for industries needing high-capacity, reliable, and long-span lifting solutions with enhanced safety and precision.

 

A 45-ton double girder overhead crane is a heavy-duty lifting solution designed for industrial applications requiring high capacity, precision, and reliability. Here's a detailed look at its applications, features, and benefits:

Key Applications

Steel & Metal Industry

Handling heavy steel coils, plates, and structural beams.

Loading/unloading in rolling mills and foundries.

Power Plants & Heavy Machinery

Moving turbines, generators, and large equipment during assembly/maintenance.

Shipbuilding & Ports

Lifting ship sections, engines, and heavy cargo.

Mining & Cement Plants

Transporting large crushers, kiln parts, and bulk materials.

Automotive & Aerospace

Handling heavy molds, presses, and aircraft components.

Construction & Infrastructure

Erecting pre-cast concrete segments and bridge components.

 

The production procedure for a 45-ton Double Girder Overhead Crane involves several key stages, from design to final testing. Below is a detailed step-by-step overview:

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1. Design & Engineering

Load & Span Calculation: Determine crane capacity (45 tons), span (distance between rails), lifting height, and duty cycle (FEM/ISO classification).

Structural Design:

Main girders (box-type or truss design)

End carriages (for movement along rails)

Hoist and trolley mechanism

Electrical & Mechanical Design:

Motor power, gearbox, brakes, and control system

Wiring, pendant/radio remote control, or cabin operation

Software & Simulation: Finite Element Analysis (FEA) for stress testing.

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2. Material Procurement

Steel Plates & Profiles: High-quality Q235B/Q345B steel for girders.

Electrical Components: Motors (hoist/travel), brakes, limit switches, and control panels.

Mechanical Parts: Wheels, gears, wire ropes, hooks, and bearings.

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3. Fabrication of Main Components

A. Double Girder Fabrication

Cutting & Welding: CNC plasma cutting for precision; automatic submerged arc welding (SAW) for girders.

Assembly: Align and weld girders with end carriages.

Shot Blasting & Painting: Anti-rust treatment (primer + topcoat).

B. Hoist & Trolley Assembly

Hoist Mechanism:

45-ton electric wire rope hoist (or chain hoist).

Drum, motor, gearbox, and brake assembly.

Trolley Frame: Fabrication and mounting of wheels, motors, and rails.

C. End Carriages

Frame Construction: Welded steel with wheel assemblies.

Buffers & Bumpers: Installation for collision protection.

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4. Electrical System Installation

Wiring & Controls:

Power supply (3-phase AC)

Variable Frequency Drives (VFDs) for smooth operation

Pendant/remote control system

Safety Devices:

Overload limiter

Limit switches (upper/lower travel)

Emergency stop

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5. Assembly & Integration

Erection of Girders: Mount double girders onto end carriages.

Trolley & Hoist Installation: Position trolley between girders; secure hoist.

Rail Alignment: Ensure runway rails are level and parallel.

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6. Testing & Quality Control

A. Factory Testing (Before Shipment)

No-Load Test: Run crane without load to check movement, brakes, and controls.

Load Test:

Static Test: 1.25 × rated load (56.25 tons) for 10 mins.

Dynamic Test: 1.1 × rated load (49.5 tons) with movements.

Safety Checks: Verify limit switches, emergency stop, and overload protection.

B. On-Site Testing (After Installation)

Re-run load tests under customer supervision.

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7. Painting & Corrosion Protection

Final Coating: Weather-resistant paint (e.g., epoxy zinc-rich primer).

Markings: Labels for load capacity, warnings, and manufacturer info.

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8. Packaging & Delivery

Disassembly (if needed): For easy transport.

Packaging: Waterproof wrapping for sea/land shipping.

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9. Installation & Commissioning (On-Site)

Runway Beam Inspection: Ensure proper alignment and strength.

Crane Assembly: Reassemble girders, hoist, and electrical systems.

Final Testing: Conduct load tests and operator training.

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%.