Electrically Operated Overhead Travelling Crane

 

An electrically operated overhead travelling crane is a type of lifting equipment designed to move heavy loads horizontally and vertically in industrial environments such as warehouses, factories, and shipping yards. These cranes are mounted on overhead tracks or beams and provide a versatile solution for handling heavy and bulky items.

Key Features:

Electric Drive System:The crane operates using an electric motor, which provides consistent and reliable performance.

Equipped with variable speed controls for precise movements.

High Load Capacity：Available in different configurations with varying load capacities, typically ranging from a few tons up to several hundred tons.Suitable for lifting and transporting heavy machinery, steel beams, large components, and other industrial loads.

Versatility:Capable of performing a range of operations such as lifting, lowering, and horizontal movement.Can be customized with different types of hoists and trolleys for specific lifting needs.

Safety Features:Incorporates safety mechanisms like emergency stop buttons, overload protection, limit switches, and anti-collision systems.Equipped with sensors and monitoring systems to ensure safe operation.

Electrically operated overhead travelling cranes are an essential piece of equipment in many industrial settings due to their high efficiency, reliability, and safety features. By integrating advanced technology and safety protocols, these cranes are designed to optimize operations while maintaining a low environmental impact.

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

Place of Origin：Henan, China

Warranty：2 years

Weight (KG)：6000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Control Method：Cabin, Pendent or Remote

Color：Customized Color Acceptable

Work Duty：A5~A8

Power Supply：220v~480v 50hz~60hz 3ph

After Warranty Service：Video technical support

Feature：Bridge Crane

 

 

1.Main beam

The main beam of an electrically operated overhead traveling crane is a crucial structural component that supports the entire weight of the load being lifted and transported.

Design and Structure

Material: Usually made of high-strength steel to withstand heavy loads and stresses.

Shape: Often designed as a box beam or I-beam for optimal strength and support while minimizing weight.

Length: Varies based on the span of the crane and the area it needs to cover.

Function

Support Load: The main beam acts as the primary support for the hoist and trolley system, distributing the load evenly and maintaining stability.

Track for Travel: It holds the rail system on which the trolley or hoist travels, ensuring smooth movement along the crane's path.

Safety Considerations

Load Capacity: Proper calculation of the main beam's load capacity is essential to prevent overloading and potential structural failure.

Reinforcements: Can include additional cross members or supports to enhance the beam's rigidity and strength.

Overall, the main beam is a foundational part of the crane's construction, ensuring reliable and safe operation for lifting and moving heavy loads within industrial settings.

 

Lifting System

1) Motor: The motor for the lifting system of an electrically operated overhead travelling crane is a critical component designed to handle the heavy loads associated with crane operations.

2) Reducer: The reducer in the lifting system of an electrically operated overhead travelling (EOT) crane plays a crucial role in ensuring smooth and efficient lifting operations.The reducer reduces the speed of the electric motor and increases the torque required for the lifting mechanism.It enables precise control of the hoist's lifting and lowering movements.

3) Drum: The Drum of the Lifting System in an electrically operated overhead travelling crane is a critical component of the hoisting mechanism. Its primary function is to wind and unwind the wire rope or chain that lifts or lowers the load.

4) Wire rope: The wire rope used in the lifting system of an electrically operated overhead travelling crane is a critical component, as it directly affects the crane's efficiency, safety, and reliability.

5) Pulley block: The pulley block in the lifting system of an electrically operated overhead travelling crane is a critical component that enhances the crane's lifting capability by using mechanical advantage.

6) Lifting device: The lifting device is a critical component of the lifting system in an electrically operated overhead travelling crane. It is designed to safely and efficiently handle the lifting, lowering, and securing of loads during crane operations.

 

3.End carriage

1) The end carriage of an electrically operated overhead traveling crane is an essential part of the crane's structure. It consists of a platform or frame that runs along the length of the crane's rail system, allowing the crane to move horizontally across the span of the structure. The end carriage is mounted on wheels or wheel assemblies that move along the runway beams.

2) Key Functions and Components:

Structural Frame: Provides the base that supports the entire assembly and allows for attachment of other crane components like the hoist and trolley.

Wheels and Wheel Assemblies: Enable the end carriage to move smoothly along the runway beams. These are often equipped with bearings for reduced friction and smooth movement.

Drive Mechanism: Usually includes a motor and gearbox that powers the movement of the wheels. The drive system allows the crane to travel back and forth along the runway.

Electrification: The end carriage has an electrical system that supplies power to the drive motor, controls, and any other electrical components.

Braking System: Provides safe stopping and holding of the crane in position during operation. This could be mechanical or electromagnetic brakes.

Control System: Typically equipped with electrical controls for maneuvering the crane, including a remote control or operator's panel.

 

 

4.Crane travelling mechanism

1) Working principle

Power Transmission:The electric motor receives electrical power and converts it into mechanical energy.This energy is transmitted through the gearbox, which adjusts the torque and speed as needed.Torque Transfer to Wheels:The gearbox output drives the wheel axles through couplings or shafts.The driven wheels roll on the crane's runway rails, propelling the crane in the desired direction.Control Mechanism:The operator uses a control panel, remote control, or cabin controls to command the motor for forward, reverse, or variable speed motion.

2) Functions of the crane operating mechanism

Longitudinal Movement (Crane Travel):Allows the entire crane to move along the length of the runway beams.Enables the crane to cover a large operational area for efficient material handling.

Precise Positioning:Ensures the crane can be stopped and positioned accurately over a specific location to lift or place loads.

Load Transfer:Facilitates the transportation of heavy loads across the workspace efficiently and safely.

Smooth Operation:Provides smooth and controlled motion to minimize vibrations and sudden jerks that could damage the crane, the load, or the surroundings.

Integration with Control Systems:Works with the crane's electrical control system for coordinated operations, including speed control and safety mechanisms.

Adaptability to Varied Speeds:Offers variable speed control to allow precise movement and enhance operational safety.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The trolley frame is usually steel or a high-strength alloy.Provides the structural base for mounting other components and supports the load.

Wheel set: High-strength steel or cast iron with hardened tread surfaces. Flanged to prevent derailment.Typically four wheels, though configurations may vary based on capacity and design.

Drive device: Electric motor, often three-phase induction motor for reliability and efficiency.Provides the power for trolley movement.

Braking System:Engaged when power is cut off to prevent unintended movement.Provide additional safety and enable maintenance operations.

2) Function of the trolley operating mechanism

Horizontal Movement of the Load：The trolley traveling mechanism allows the load to be moved horizontally across the span of the crane bridge, facilitating precise positioning.

Load Distribution：The mechanism ensures even weight distribution across the crane bridge during operation, preventing localized stress and extending the lifespan of the crane structure.

Smooth Operation：Equipped with motors, gearboxes, wheels, and rails, the trolley mechanism ensures smooth and controlled movement to enhance operational safety and efficiency.

Precise Load Handling：Enables the operator to position the load accurately over the desired location, critical in assembly operations or material placement.

6.Crane wheel

1) Function of wheels

The crane wheel of an electrically operated overhead travelling crane is a critical component responsible for supporting and guiding the crane along the runway beams.

Load Capacity:Engineered to support the full load of the crane and the lifted goods.Calculated based on the crane's maximum load capacity and operating conditions.

2) Design requirements

Wheels are generally designed with a tread profile that matches the rail to ensure smooth movement and minimal friction.

May include flanges to keep the wheel aligned on the rail.

Typically made from high-strength steel or alloy steel to withstand wear and heavy loads.

Materials often include forged or heat-treated steel for enhanced durability.

7.Crane Hook

The crane hook is a critical component of an electrically operated overhead travelling crane. It serves as the primary load-handling device, designed to securely and efficiently lift, hold, and transport heavy materials.

Features of the Crane Hook:

Material: Typically made from high-grade forged steel or alloy steel for excellent strength and durability.

Design:

Single Hook: Used for lighter loads and simpler operations.

Double Hook: Ideal for balancing and handling heavier loads.

Load Capacity: The hook's size and rating depend on the crane's maximum load capacity.

Operation and Mechanism:

The hook is connected to the crane's hoisting mechanism via a hook block or directly to the wire rope.

Motor

An electric overhead travelling (EOT) crane typically uses motors to facilitate its operations. These motors are critical for driving the various functions of the crane, such as hoisting, traversing, and travelling.

2) Modern EOT cranes integrate Variable Frequency Drives (VFDs) to control motor speed and torque dynamically, improving efficiency and operational precision.

3) Type of motor

Hoist Motor

Function: Drives the hoisting mechanism for lifting and lowering loads.

Type: Usually a squirrel cage induction motor or a slip ring motor.

Key Features:High starting torque.Robust construction to handle heavy loads.Often equipped with braking systems to ensure safe load handling.

Cross Travel Motor

Function: Moves the hoist trolley across the crane bridge.

Type: Squirrel cage motors with variable speed drives are common.

Key Features:Smooth operation to ensure precise positioning of the load.Can handle frequent starts and stops.

Long Travel Motor

Function: Drives the crane along the runway rails.

Type: Induction motors paired with gearboxes or direct drives.

Key Features:Designed for continuous duty operation.equipped with a soft start mechanism to reduce wear and tear.

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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 electrically operated overhead travelling crane is a safety feature designed to alert nearby personnel of the crane's movement or operations, helping to prevent accidents in industrial environments.

Audible Alarm (Sound):Emits a loud warning signal, such as a siren, buzzer, or beeping sound.Typically triggered during crane movement (forward, backward, or lateral) or when lifting/lowering loads.Can be programmed for varying sound patterns to indicate different actions or danger levels.

Visual Alarm (Light):Flashing lights, often in bright colors like red, yellow, or blue.Mounted on the crane or its trolley for maximum visibility.Can use LED strobes or rotating beacons to grab attention.

2) Limit switch

A limit switch for an electrically operated overhead travelling crane (EOT crane) is a safety device used to prevent the crane or its components from exceeding predetermined travel limits. These switches ensure safe operation, protect against mechanical damage, and help avoid accidents.

Hoist Limit Switch:Used to limit the vertical movement of the hoist.Prevents over-hoisting (raising the hook too high) or over-lowering.Typically features a mechanical lever or cam mechanism that activates the switch.

Travel Limit Switch:Installed on the bridge or trolley to restrict horizontal movement.Prevents the crane or trolley from colliding with end stops.

Rotary Limit Switch:Used to control the rotational movement of specific components.Often seen in jib cranes or specific mechanisms of an EOT crane.

Cross Travel and Long Travel Limit Switches:Designed to limit the side-to-side (cross travel) and end-to-end (long travel) movements of the crane.

How It Works: A limit switch is triggered by physical contact with a cam, lever, or actuator when the crane reaches the predefined travel limit.Once activated, it sends a signal to the control panel to stop or reverse the motion, ensuring safety.

10.Safety Devices

1) 1. Limit Switches

Hoist Limit Switch: Prevents the hook from overhoisting or over-lowering.

Travel Limit Switch: Stops the crane or trolley when it reaches the end of its travel path.

2. Overload Protection Devices

Load Limiters: Monitors the load weight to prevent lifting beyond the crane's capacity.

Overload Alarms: Audible or visual alarms to alert operators about overload conditions.

3. Emergency Stop Buttons

Strategically placed buttons allow the crane to be stopped immediately in case of an emergency.

4. Anti-Collision Devices

Infrared or ultrasonic sensors prevent collisions between two cranes operating on the same runway.

5. Buffer Stops

Installed at the ends of the crane runway to absorb impact and prevent derailment.

6. Rail Clamps and Wheel Brakes

Prevent the crane from moving unintentionally, especially in high wind conditions.

7. Load Indicators

Digital or analog devices to display the current load being lifted.

8. Electrical Safety Devices

Circuit Breakers: Protect against electrical overloads or short circuits.

Earth Fault Relays: Detect and respond to electrical faults.

Insulated Control Panels: Reduce the risk of electrical shock.

9. Audible and Visual Alarms

Warning Horns: Alert personnel about crane movement.

Flashing Lights: Indicate the crane is in operation.

10. Anti-Sway Systems

Reduces load swinging to improve stability and safety during crane operation.

11. Fall Protection Systems

Safety harnesses or lifelines for operators working at heights during maintenance.

12. CCTV Cameras

Provide a clear view of the operating area to ensure precise control and safety.

11.Control Mode

1. Pendant Control

Description: A handheld controller connected to the crane via a cable or wireless link.Features:Manual control with buttons or switches.

Operators can directly control the crane's movements while staying close to the load.Advantages:Cost-effective and straightforward to use.

Allows precise manual operation.

2. Wireless Remote Control

Description: A wireless handheld device (like a radio transmitter) that allows the operator to control the crane remotely.Features:Freedom of movement for the operator.Can include a joystick or push buttons.Advantages:Increased safety by allowing the operator to stay away from hazardous zones.No physical connection to the crane, offering greater flexibility.

3. Cabin Control

Description: The crane operator is seated in a cabin mounted on the crane.Features:Levers, pedals, and switches for precise control.

A better view of the operation area from an elevated position.Advantages:Suitable for heavy-duty and complex operations.

Enhanced operator comfort during prolonged operations.

4. Automatic/Programmed Control

Description: The crane operates based on pre-programmed instructions or input from sensors and control systems.Features:Integration with PLC (Programmable Logic Controller) or CNC (Computer Numerical Control) systems.

Automated path-following and task execution.Advantages:Highly efficient for repetitive tasks.Reduces dependency on manual operation.

5. Joystick Control

Description: Often used in combination with cabin or remote controls, a joystick provides intuitive control over crane movements.Features:Proportional control for smooth operation.Advantages:Simple and precise movement control.

12.Sketch

Main technical

 

1. Efficiency and Productivity

High Speed and Precision: EOT cranes can handle heavy loads quickly and precisely, improving overall productivity.

Continuous Operation: Designed for long operating hours, ensuring high efficiency in demanding industrial environments.

2. Safety

Reduced Manual Handling: Minimizes the need for manual lifting, reducing workplace injuries.

Remote Operation: Many EOT cranes are equipped with remote control systems, keeping operators at a safe distance from heavy or hazardous loads.

Integrated Safety Features: Include overload protection, emergency stop systems, and anti-collision devices.

3. Versatility

Wide Range of Applications: Suitable for industries such as manufacturing, warehousing, construction, steel production, and shipbuilding.

Customizable Design: Can be tailored to specific requirements like load capacity, span, and lifting height.

4. Cost-Effectiveness

Reduced Labor Costs: Automates material handling, reducing the need for manual labor.

Durability and Longevity: Built to withstand heavy use, leading to a long service life with minimal maintenance costs.

5. Space Optimization

Efficient Use of Space: Operates overhead, freeing up floor space for other activities or equipment.

High Load Capacity in Compact Design: Can handle very heavy loads without requiring a large footprint.

6. Environmentally Friendly

Energy Efficiency: Electric operation is cleaner and more efficient compared to fuel-powered systems.

Low Noise Operation: Contributes to a quieter working environment compared to other types of cranes.

7. Ease of Operation and Maintenance

User-Friendly Controls: Modern EOT cranes are equipped with intuitive controls, making them easy to operate.

Accessible Components: Designed for straightforward maintenance and inspection, reducing downtime.

 

 

1. Manufacturing Industry

Transporting raw materials, semi-finished, and finished products within production lines.

Handling heavy components like machinery parts, engines, and tools during assembly processes.

2. Warehousing and Logistics

Loading and unloading goods from trucks or containers.

Efficiently stacking and organizing heavy goods in storage areas.

3. Construction

Lifting and placing construction materials such as steel beams, concrete blocks, and prefabricated components.

Supporting large-scale construction projects with precise handling of heavy loads.

4. Steel Industry

Handling molten metal and steel products in smelting plants.

Transporting rolls, slabs, and ingots within the steel production process.

5. Automotive Industry

Managing assembly lines by moving car components like engines and chassis.

Loading and unloading vehicles or parts in manufacturing plants.

6. Power Plants

Assisting in the installation and maintenance of heavy equipment such as turbines, generators, and transformers.

Transporting fuel and ash within thermal power plants.

7. Ports and Shipyards

Loading and unloading cargo from ships.

Handling heavy containers and ship parts during shipbuilding and repair.

8. Aerospace Industry

Lifting and assembling large aircraft components.

Supporting maintenance activities with precise handling of delicate equipment.

9. Mining Industry

Handling raw materials like ore and coal.

Assisting in the maintenance of heavy mining equipment.

10. Paper and Textile Industries

Moving large paper rolls, fabric rolls, or other bulky items.

Streamlining production processes with effective material handling.

11. Chemical and Petrochemical Plants

Handling heavy equipment and tanks used in production.

Transporting chemicals or hazardous materials safely.

 

 

1. Requirement Analysis and Design

Requirement Gathering:

Understand client specifications (capacity, span, speed, duty cycle, etc.).

Consider operational environment (indoor, outdoor, hazardous areas, etc.).

Preliminary Design:

Conceptualize crane structure and components.

Ensure compliance with international standards (e.g., ISO, EN, ASME).

Detailed Engineering:

Structural analysis and calculation (finite element method if needed).

Design the electrical and mechanical systems.

Prepare detailed drawings (general arrangement, part drawings).

2. Material Procurement

Raw Materials:

High-grade steel for crane girders.

Standardized materials for components like hoists, motors, and gears.

Electrical Components:

Motors, control panels, wiring, and safety devices.

Inspection:

Conduct quality checks on incoming materials and components.

3. Fabrication

Cutting and Shaping:

Cut steel plates and beams to the required dimensions.

Use CNC machines for precision.

Welding:

Weld girders, end carriages, and other structural components.

Ensure compliance with welding standards (NDT tests may be required).

Machining:

Machine parts like wheels, shafts, and couplings.

Ensure tight tolerances for smooth operation.

Surface Treatment:

Apply shot blasting to remove impurities.

Apply corrosion-resistant coating or painting.

4. Assembly

Structural Assembly:

Assemble girders, end carriages, and cross-travel mechanisms.

Electrical Assembly:

Install motors, control panels, and wiring systems.

Hoist Assembly:

Attach the hoist to the crane as per design.

Gear and Drive Mechanism:

Assemble drive mechanisms for smooth and controlled movement.

5. Quality Testing

Structural Integrity Test:

Verify load-bearing capacity through static and dynamic tests.

Dimensional Checks:

Ensure proper alignment and assembly.

Electrical Testing:

Test control systems, wiring, and safety interlocks.

Operational Tests:

Perform no-load, partial-load, and full-load tests.

Verify travel speeds and braking systems.

Safety Checks:

Test limit switches, emergency stop systems, and overload protection.

6. Final Adjustments and Inspections

Fine Tuning:

Adjust alignment, tensions, and settings for optimal performance.

Inspection:

Conduct a final inspection by the quality assurance team.

Certification:

Provide certification of compliance and testing results.

7. Packaging and Delivery

Disassembly (if required):

Disassemble large components for transportation.

Packaging:

Use protective packaging for safe transport.

Logistics:

Arrange shipment to the client's location.

8. Installation and Commissioning

On-Site Assembly:

Reassemble crane components at the client's location.

Installation:

Install on runway beams or supports.

Commissioning:

Perform on-site testing and ensure crane operates as designed.

Training:

Train the client's personnel on operation and maintenance.

9. After-Sales Support

Maintenance Plans:

Provide routine inspection and servicing schedules.

Spare Parts Supply:

Ensure availability of critical spare parts.

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%.