Double Beam Overhead Travelling Crane

 

A Double Beam Overhead Travelling Crane is a high-performance lifting solution designed to handle heavy-duty materials in industrial settings. Engineered for reliability and efficiency, this crane is ideal for applications in factories, warehouses, shipyards, and construction sites.

A Double Beam Overhead Travelling Crane is built with two parallel beams to ensure maximum stability and load-bearing capacity. Capable of handling loads from 5 tons to over 500 tons, tailored to your operational requirements. Advanced control systems provide smooth and accurate lifting, positioning and lowering actions. Compatible with a wide range of lifting mechanisms including hooks, magnets and grabs to meet different material handling needs. Made of high-quality materials and equipped with safety features such as overload protection, emergency stop and anti-collision system.

Double Beam Overhead Travelling Cranes simplify material handling processes, reducing labor and time. Durable structures ensure long service life with minimal maintenance. Tailored to specific industry needs, including span, lifting height and speed.

Core Components: Engine, Bearing, Gearbox, Motor, Pressure vessel

Place of Origin: Henan, China

Warranty: 1 Year

Weight (KG): 2000 kg

Video outgoing-inspection: Provided

Machinery Test Report: Provided

Power supply: 3 Phase AC 380V 50HZ

Control method: remote Control, pendent control,cabin control

Lifting mechanism: Electric Hoist or trolley

Crane type: Double Girder

Travelling speed: 20m/min,30m/min

Lifting speed: 0.8/5m/min 1/6.3m/min

Main electrical parts: Schnider

Work Duty: A4-A7

Crane Feature: Widely

 

1.Main beam

1) The main beam of a double beam overhead travelling crane is the central structural component that supports the load and ensures the stability and operation of the crane. The crane features two parallel beams running along its length, providing increased strength and stability compared to a single beam design.Typically constructed from high-strength steel to handle heavy loads and minimize deflection.Often an I-beam or box girder design for maximum load-bearing capacity and rigidity.

The main beam's function

Supports the trolley or hoist mechanism, which moves horizontally along the beams.

Bears the vertical and horizontal loads during crane operation.

Ensures even weight distribution across the span of the crane.

3) Advantages of the main

Higher Load Capacity: Compared to single beam cranes, double beam cranes can handle significantly heavier loads.

Larger Span: Ideal for facilities with wide spans and long lifting distances.

Flexibility: Can accommodate additional lifting devices, such as multiple hoists.

Lifting System

1) Motor: The motor of the lifting system in a double beam overhead travelling crane is a critical component responsible for raising and lowering loads.

2) Reducer:The reducer lowers the high-speed rotation from the crane motor to a manageable speed for lifting and lowering operations.The reducer in the lifting system of a double-beam overhead travelling crane plays a critical role in controlling the lifting mechanism's speed and torque.

3) Drum: The Drum of the Lifting System in a double-beam overhead travelling crane is a crucial component for controlling the lifting and lowering of heavy loads.

4) Wire rope: The wire rope transmits the lifting force from the hoist or drum to the hook or lifting mechanism, enabling safe and efficient lifting of loads.It must handle dynamic loads, tension, bending, and abrasion during crane operations.

5) Pulley block: A pulley block in the lifting system of a double beam overhead traveling crane plays an important role in the operation and efficiency of the lifting mechanism. It generally consists of a combination of pulleys, sheaves, and ropes or chains.

6) Lifting device: The lifting device of a double beam overhead travelling crane is an essential component designed to lift and lower loads efficiently and safely. It consists of various subcomponents that work together to achieve the required lifting and handling tasks.

3.End carriage

1)The end carriage of a double beam overhead traveling crane is a critical component that supports and allows the movement of the entire crane structure along the runway. Typically made of steel, the end carriage is designed to withstand the weight of the crane's structure, including the bridge beams, hoists, and any load it carries.

2) End carriages are equipped with wheels that run on the crane runway beams. These wheels are often equipped with anti-tilt and anti-skew features to ensure smooth and stable movement.

3) The end carriage has a frame that connects the wheels to the main crane bridge and supports the entire load. This frame is engineered to distribute loads evenly and maintain structural integrity.End carriages play a pivotal role in providing stability, mobility, and safety for the overhead traveling crane, making them essential for its efficient operation.Controls and Safety Systems: Safety measures such as limit switches, brakes, and sensors are often installed on the end carriages to control movement, prevent overspeed, and ensure safe operation.

 

4.Crane travelling mechanism

1) Working principle

The system receives electrical power from an external source (e.g., a rail or cable system running along the crane's path).The motors drive the wheels through a gear and transmission system. These wheels are fixed on each end of the crane bridge to allow movement along the track.The operator controls the direction and speed of the crane's movement via a control panel, which operates the motor. The crane can move forward or backward along the rails. In the case of double beam cranes, each beam (on either side of the crane) typically has its own set of motors and drive wheels. The coordination between these components ensures stable movement and prevents uneven loading on the crane structure.

2) Functions of the crane operating mechanism

Movement Across the Bridge: The primary function is to move the entire bridge structure, which supports the hoisting mechanism, horizontally along the runway rails or tracks. This allows the crane to cover the entire length of the workspace or facility.

Positioning and Precision: The traveling mechanism enables precise positioning of the crane over the work area. This is essential for accurately placing or retrieving loads at specific locations within the span of the crane.

Load Handling and Transport: The crane's traveling system helps in transporting loads from one end of the facility to the other, ensuring that heavy or bulky items can be moved safely and efficiently across the space.

Synchronization of Movement: For double beam overhead cranes, the traveling mechanism needs to synchronize the movement of both beams to ensure balanced operation and stability. This prevents uneven load distribution and potential damage to the crane structure or the load being lifted.

Safety and Control: The traveling system is equipped with safety features to prevent accidents. These include limit switches, emergency stop buttons, and anti-collision devices that control the movement of the crane and protect operators and other personnel in the workspace.

Variable Speed and Acceleration: The traveling mechanism is designed to provide variable speed control and smooth acceleration/deceleration. This is crucial for delicate operations and ensures that the load is moved without sudden jerks that could lead to damage or accidents.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The frame forms the central body of the trolley and is built to support the entire load carried by the hoist. It is made from steel sections that provide the strength needed to handle heavy loads.

Wheel set: Mounted on each end of the trolley frame, these wheels run on the rails or tracks of the overhead beams. They are typically made of high-strength steel and are designed to bear the weight of the trolley and its load.

Drive device: The trolley is powered by an electric motor coupled with a gearbox that controls the rotation and movement of the wheels.

2) Function of the trolley operating mechanism

Horizontal Movement: The primary function is to enable the trolley to travel smoothly along the crane's bridge beams, allowing for precise positioning of the load over the workspace.

Load Handling: It moves the hoist (which is mounted on the trolley) across the span of the crane, facilitating the handling of heavy materials and ensuring they can be lifted, moved, and placed as needed.

Operational Efficiency: The mechanism supports fast and reliable movement of the trolley to maximize operational efficiency and productivity.

6.Crane wheel

1) Function of wheels

Support: Each wheel carries a portion of the crane's load and supports the double-beam structure.

Movement: Wheels rotate on bearings or bushings, allowing smooth and efficient movement along the crane runway or track.

Load Distribution: Wheels are spaced and designed to distribute the load evenly, which helps prevent excessive stress and potential structural issues.

2) Design requirements

Material: Typically made of high-strength steel or forged alloy to withstand heavy loads and long-term wear.

Shape: Often has a flanged design to ensure secure tracking along the rails and prevent derailing.

Size: Varies depending on the size and capacity of the crane. Larger cranes will have bigger wheels to handle the increased load.

7.Crane Hook

A crane hook of a double beam overhead travelling crane is a critical component used for lifting and transporting heavy loads. This hook is typically suspended from a trolley that moves along the two beams of the crane, enabling it to travel horizontally across the span of the structure.

The hook is usually made from high-strength steel or other alloy materials to withstand the high loads it is subjected to.It can be a single-hook or a double-hook configuration, depending on the weight and type of loads it needs to lift. The hook often features a safety latch or locking mechanism to ensure the load remains secure during lifting.It consists of the hook body, a swivel, and sometimes a shank, which is attached to the lifting mechanism (usually a hoist).

Motor

1)A double beam overhead travelling crane typically uses a hoist motor to lift and lower the load and travelling motors to move the crane along its rails. The motor specifications depend on the crane's load capacity, speed requirements, and other operational needs.

2) Type of Motor

Hoist Motor:

This motor controls the vertical movement of the hoist. It is usually a three-phase AC motor with a high torque rating to handle heavy loads.Common types include squirrel cage induction motors for general use or DC motors for better control in applications requiring variable speed.

Travelling Motors:

These motors control the movement of the crane along the overhead beams. They are typically three-phase AC motors that may be geared for added torque.They can use frequency drives or variable speed drives to adjust the speed as needed.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

A double beam overhead traveling crane equipped with a sound and light alarm system is designed to enhance safety during operation by alerting nearby personnel of potential hazards or movements.

Sound Alarm (Hooter/Buzzer):Function: Emits a loud sound to alert workers in the vicinity when the crane is in operation or when it encounters a warning or emergency situation.Types: Can be a continuous or intermittent tone, depending on the urgency of the alert.Power Source: Can be powered by the crane's main electrical system or an independent power source for reliability.

Light Alarm (Flashing Light/Beacon):Function: Provides a visual signal to indicate the crane's operation status or an alert condition.Types: Flashing or rotating lights (e.g., strobe lights) that make it easy for workers to see the warning from a distance, even in bright daylight.Colors: Often uses different colors like red (danger), yellow (caution), or green (safe status) to indicate different levels of alert.

2) Limit switch

A limit switch on a double beam overhead traveling crane is an essential safety component. It is used to stop or control the movement of the crane's bridge, trolley, or hoist when it reaches a designated limit, preventing damage or accidents.

Upper and lower limits: The limit switch is used to set the upper and lower movement limits of the crane. When the lifting mechanism or trolley reaches the set limit position, the limit switch will cut off the power supply or sound an alarm to prevent it from exceeding the safety range.

Prevent collision: The limit switch can effectively prevent the crane from colliding with other equipment or obstacles, ensuring the safety of equipment and personnel.

Automatic stop: In the event of a malfunction or accident, the limit switch can realize the automatic stop function to prevent accidents.

10.Safety Devices

1) 1. Overload Limit Switch

Function: Prevents lifting beyond the crane's rated capacity, avoiding damage to the crane and potential accidents.

Operation: Automatically stops the crane or hoist when the load exceeds the predetermined weight limit.

2. Limit Switches

Function: Stops the crane at predefined points along its travel path to prevent accidental collisions or damage.

Types: Can include end-of-travel limit switches that stop the crane when it reaches the end of its runway and vertical travel limit switches for the hoist.

3. Anti-Collision Device

Function: Prevents collisions between cranes operating in the same area, enhancing workplace safety.

Operation: Uses sensors or other monitoring systems to alert operators or automatically stop the crane if an obstruction or another crane is detected.

4. Emergency Stop Button

Function: Allows operators to immediately stop the crane's operation in the event of an emergency.

Placement: Typically located in easily accessible positions for quick response.

5. Warning Lights and Alarms

Function: Alerts nearby workers when the crane is in operation or moving to warn them of potential hazards.

Types: Audible alarms, flashing lights, or sirens.

6. Brake Systems

Function: Stops the crane or hoist from moving unintentionally and holds the load securely in place.

Types: Mechanical and electromagnetic brakes for reliable stopping power.

7. Load Sway Prevention System

Function: Reduces the swinging motion of the load while lifting or moving to enhance stability and control.

Technology: Often uses sensors and control systems that adjust the crane's operation to minimize load sway.

8. Safety Hooks

Function: Ensures the hook cannot accidentally open or release the load.

Design: Equipped with safety latches or locks that prevent the load from detaching unintentionally.

9. Temperature Sensors

Function: Monitors the temperature of critical components (like motors and brakes) to avoid overheating and potential failures.

Alerts: Automatically triggers shutdown or alert notifications if a temperature threshold is reached.

10. Emergency Power Off (EPO) System

Function: Cuts off all power supply to the crane in case of a serious fault or emergency.

Safety: Ensures immediate response to a critical issue, preventing further damage or injury.

11. Inspection and Maintenance System

Function: Regular checks and pre-operation safety protocols help identify potential issues before they become dangerous.

Features: May include automated inspection reminders and logging systems.

12. Load Cell and Monitoring Systems

Function: Provides real-time feedback on the weight of the load being lifted and ensures that it does not exceed safe operating limits.

Safety: Integrated with overload limit switches to trigger warnings or cut-offs.

13. Crane Cabin Safety

Function: Ensures the operator's safety by having secure cabins with safety bars, emergency exits, and climate control for optimal operating conditions.

 

11.Control Mode

1) 1. Cabin Control (Pendant Control)

Operator's Cabin: The crane is operated from an enclosed or open operator's cabin mounted on the crane. The cabin can be located at either end of the crane and provides full control of all movements, including lifting, traveling, and trolley movement.

Joystick/Push-button Panel: Operators use joysticks or push-button panels to control the crane's operations from the cabin.

2. Remote Control

Wireless Remote: The crane can be operated using a wireless remote control, giving operators more flexibility and allowing them to move around the workspace while controlling the crane. This control method is often used for safety and efficiency in large areas or for operations requiring quick movement.

3. Pendant Control (Wired Control)

Hanging Pendant: The operator uses a control pendant connected to the crane with a cable. This allows for precise control while standing on the ground and is commonly used for localized operations or in environments where a cabin may not be practical.

Buttons and Joystick: Similar to cabin control, pendant controls feature buttons and a joystick or switch for the various crane functions.

4. Automated Control

Programmable Logic Controller (PLC): Some modern overhead cranes can be operated in an automated or semi-automated mode using PLCs or computer-based systems. The crane can follow pre-set paths or perform repetitive tasks automatically, which improves precision and efficiency.

Sensors and Safety Features: Automated systems often include sensors that monitor load weight, position, and safety features that stop or adjust the crane's operation in case of malfunctions.

5. Dual Control (Manual and Automated)

Combination of Modes: In many modern double beam overhead cranes, operators can switch between manual control (using cabin, remote, or pendant) and automated control for specific tasks. This dual-control system provides flexibility and is often used in industries that require both precision and human oversight.

12.Sketch

 

 

Main technical

 

 

1. Higher Load Capacity

Double beam cranes can handle heavier loads compared to single beam cranes, often with capacities exceeding 20 tons.

The two beams provide enhanced structural strength and support.

2. Greater Span and Coverage

They can accommodate wider spans, making them suitable for large facilities.

Provides comprehensive coverage over a workspace.

3. Improved Hook Height

The design allows the hoist to be mounted between the two beams, increasing the vertical lifting height.

Ideal for operations requiring high lift.

4. Durability and Longevity

Built for heavy-duty applications and longer lifespans with reduced maintenance.

Robust construction minimizes wear and tear during intensive operations.

5. Flexible and Versatile Applications

Suitable for diverse industries such as manufacturing, steel mills, shipyards, and warehouses.

Can be customized with additional features like magnetic lifts, grab buckets, or specialized hooks.

6. Enhanced Safety Features

Offers better load stability, reducing risks during lifting and transporting.

Equipped with advanced control systems for precise handling.

7. Supports Heavy Equipment

Can incorporate larger trolley systems and additional equipment.

Handles more complex lifting requirements efficiently.

8. Operational Efficiency

Reduces the time and effort required for material handling tasks.

Compatible with advanced automation and remote control systems.

9. Cost-Effectiveness for Heavy Loads

While initial investment may be higher, the crane's capacity and efficiency result in long-term cost savings.

 

 

1. Manufacturing Industries

Heavy Equipment Manufacturing: Used for handling large and heavy components like turbines, generators, and machinery parts.

Automotive Industry: For lifting and transporting automobile parts during assembly or maintenance.

Steel and Metal Fabrication: Essential for moving steel plates, beams, and other metal structures.

2. Construction Industry

Used for lifting heavy construction materials such as concrete blocks, beams, and prefabricated structures.

Common in bridge-building projects and large infrastructure developments.

3. Warehousing and Storage Facilities

Handles the movement and stacking of heavy goods in large warehouses.

Efficient for inventory management in logistics centers.

4. Ports and Shipyards

Shipbuilding: Used for lifting and assembling large ship components.

Cargo Handling: Moves heavy shipping containers or other bulk cargo efficiently.

5. Power Plants

In hydroelectric, thermal, and nuclear power plants, these cranes are used to lift turbines, generators, and maintenance equipment.

6. Mining Industry

Handles heavy mining equipment and materials, including ores and machinery.

7. Railway Yards and Workshops

Assists in the maintenance and assembly of railway cars and locomotives.

8. Paper and Pulp Industry

Used for handling large rolls of paper or pulp, ensuring smooth operations in production and processing.

9. Aerospace Industry

Facilitates the assembly and maintenance of aircraft by handling large and delicate parts like fuselages and wings.

10. Heavy Engineering Projects

Integral in oil and gas refineries, where heavy pipelines, pumps, and machinery are frequently moved and installed.

 

 

1.1. Design and Engineering

Customer Requirement Analysis: Gather specifications such as capacity, span, lifting height, working environment, and operating conditions.

Conceptual Design: Develop basic structural layouts, operational features, and preliminary load calculations.

Detailed Design: Create detailed engineering drawings and structural calculations using CAD software. Include:

Double-girder structure

Hoist/trolley design

End carriage

Electrical and control systems

Compliance: Ensure designs meet international standards (e.g., ISO, FEM, DIN).

2. Material Procurement

Steel: High-quality structural steel for girders, supports, and other components.

Mechanical Components: Motors, gears, wire ropes, bearings, and trolleys.

Electrical Components: Control panels, sensors, switches, and wiring.

Special Components: Anti-corrosion coatings, explosion-proof systems (if required).

3. Fabrication

3.1 Girder Manufacturing

Cutting: Cut steel plates for top and bottom flanges, web plates, and stiffeners to size.

Welding: Assemble and weld parts to form double girders.

Conduct non-destructive testing (NDT) on welds.

Stress Relief: Perform heat treatment to relieve welding-induced stresses.

Machining: Drill precise holes for end trucks, trolleys, and hoist mountings.

3.2 End Carriages

Weld and machine end carriage structures.

Install wheels and bearings to match the track gauge.

3.3 Trolley and Hoist Assembly

Assemble the hoist mechanism, including the motor, drum, and wire rope.

Fit the trolley frame to ensure smooth movement along the girders.

3.4 Electrical Systems

Manufacture or procure the electrical control panel.

Assemble control systems, wiring, and sensors.

Integrate Variable Frequency Drives (VFDs) if needed for smoother operations.

4. Pre-Assembly

Combine the girders, trolleys, end carriages, and electrical components into a single structure.

Conduct alignment checks and ensure accurate assembly of moving parts.

5. Surface Treatment

Cleaning: Shot-blasting or sandblasting to remove rust and impurities.

Coating: Apply anti-corrosion paint or powder coating.

Special Coatings: Use fireproof or chemical-resistant coatings for specific environments.

6. Quality Control and Testing

6.1 Dimensional Inspection

Verify all dimensions match the design specifications.

6.2 Load Testing

Perform static and dynamic load tests:

Static: Test with 125% of the rated load capacity.

Dynamic: Test with 110% of the rated load capacity during movement.

6.3 Operational Testing

Test hoist and trolley movement, braking systems, and electrical operations.

Calibrate limit switches and overload protection devices.

6.4 Certification

Ensure compliance with industry standards and provide necessary documentation.

7. Packing and Delivery

Dismantling: Disassemble the crane for transportation.

Packaging: Use reinforced packing materials to prevent damage during transit.

Shipping: Arrange logistics for delivery to the installation site.

8. Installation and Commissioning

On-Site Assembly: Reassemble the crane structure and components.

Track Installation: Align and secure the crane's tracks or rails.

Testing: Conduct final on-site tests to ensure full operational readiness.

Handover: Provide operational training and deliver manuals to the client.

9. After-Sales Service

Offer regular maintenance checks and support.

Supply spare parts and technical assistance as needed.

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%.