Winch Trolley Overhead Crane

A winch trolley overhead crane is a double girder overhead crane that integrates a winch-type hoisting system mounted on a trolley. The trolley moves laterally on the bridge girders, while the entire bridge travels longitudinally along the runway rails. The winch mechanism provides high lifting power and durability, often with multi-reeved wire ropes and drum systems.

 

Element	Details
Crane Type	Double Girder Overhead Crane
Hoisting Type	Electric Winch (Wire Rope Drum)
Use Case	Heavy-duty lifting & precise handling
Typical Loads	Steel coils, turbine parts, ship components
Control Options	Cabin, Remote, Pendant

 

• Capacity: 5-800/50ton
• Span length: 4-35m
• Lifting height: 3-50m
• Work duty: A4, A5, A6,A7
• Raged voltage: 220V~690V, 50-60Hz, 3ph AC
• Work environment temperature: -25℃～+50℃, relative humidity ≤85%
• Crane control mode: Floor control / Remote control / Cabin room

 

A winch trolley overhead crane is designed for heavy-duty material handling, especially in industries like steel manufacturing, power plants, shipyards, and infrastructure projects. Its key feature is the electric winch hoisting system mounted on a trolley that moves on a double girder bridge.

 

1. Double Girders

Structure: Two parallel steel beams forming the bridge of the crane.

Function: Support the trolley and distribute the load across the span.

Type: Welded box girder or rolled I-beam.

 

2. Winch Trolley

The core lifting unit mounted on the girders. It includes:

Electric Winch Motor: Provides the lifting force.

Wire Rope Drum: Wound with steel wire rope; enables vertical lifting.

Gearbox: Transfers and reduces motor speed to lifting motion.

Brake System: Ensures load holding and safe stop.

Hook Block or Lifting Attachment: Engages with the load (hook, magnet, grab, etc.).

Function: Moves side-to-side (cross travel) and lifts/lowers loads vertically.

 

3. End Carriages

Located at both ends of the bridge.

Contain travel wheels, motors, and gearboxes.

Function: Allow the entire crane to move along the runway rails (long travel).

 

4. Power Supply System

Typically consists of:

Conductor bars or cable festoon system

Function: Delivers electrical power to the motors, trolley, and control systems.

5. Control System

Control Panel (Electrical cabinet): Located on the trolley or bridge.

Control Methods:

Cabin Control (for operator onboard)

Pendant Control

Wireless Remote Control

Function: Manages lifting, traveling, and safety features.

 

6. Crane Rails & Runway Beam

Installed on the supporting structure of the workshop or gantry.

Function: Guide the crane's longitudinal movement.

7. Safety Systems

Limit Switches: Prevent over-travel of hook and trolley.

Overload Protection: Stops lifting if load exceeds capacity.

Buffer Devices: Reduce impact at rail ends.

Emergency Stop Systems

Anti-Collision Sensors (optional for multi-crane systems)

 

Optional Features

Variable Frequency Drives (VFD): For smooth speed control.

Load Weighing System

Auto-positioning & Sway Control

Specialized Hooks or Lifting Devices (e.g., magnets, grabs)

 

SKETCH

 

 

 

Advantages of Winch Trolley Overhead Crane

High Lifting Capacity
Handles extremely heavy loads, usually 20 to 500+ tons, with ease.
Enhanced Structural Stability
Double girder design + winch hoist = stable and safe lifting of large loads.
Continuous Duty Performance
Designed for frequent, long-term operations in harsh environments (Class A5–A8).
Precision & Control
The winch system allows for smooth and precise load handling, with multi-speed options.
Customizable Lifting Tools
Supports hooks, grabs, magnets, or spreader beams for versatile handling.
Long Lifting Height & Span
Suited for tall buildings or wide workshops with high working ranges.
Easy Maintenance & Durability
Built for long life cycles with low-maintenance components.

 

Winch trolley overhead cranes are ideal for industries requiring high-capacity, high-precision, and continuous lifting operations.

1. Steel Industry
Lifting steel coils, billets, slabs, and molten ladles.
Used in rolling mills, foundries, and steel storage warehouses.
2. Power Plants
Installing or maintaining turbines, generators, and transformers.
Heavy-duty equipment handling during construction or shutdowns.

3. Shipbuilding
Lifting ship engines, blocks, and structural sections.

Used in dry docks and assembly areas.

4. Heavy Machinery Manufacturing
Transporting machinery components during assembly.

Handling presses, casting molds, and machine beds.

5. Infrastructure & Construction
Bridge and highway construction – lifting precast segments, beams, or girders.

Used in dam building, tunnels, and large-scale civil projects.

6. Railways & Transportation
For lifting locomotive parts, bogies, or rail segments.

Also used in railcar assembly and maintenance workshops.

 

 

1. Design & Engineering
Requirements Analysis: Determine load capacity, span, lifting height, and operating environment.

CAD Modeling: Create 3D designs and structural calculations (stress analysis, deflection, etc.).

Material Selection: Choose suitable casting materials (typically cast steel or ductile iron) for key components like girders, end carriages, and hooks.

Regulatory Compliance: Ensure designs meet standards (ISO, DIN, FEM, or ASME).

2. Pattern Making & Mold Preparation
Pattern Creation: Wood or metal patterns are made for casting molds.

Sand Mold Preparation:

Use resin-bonded sand or green sand for mold cavities.

Cores (for hollow sections) are prepared separately.

3. Casting Process
Melting & Pouring:

Metal (e.g., carbon steel, alloy steel) is melted in a furnace.

Molten metal is poured into molds under controlled conditions.

Cooling & Solidification: Allow the casting to cool slowly to avoid defects.

Shakeout & Cleaning: Remove sand molds, and clean castings (shot blasting, grinding).

4. Machining & Finishing
Rough Machining: Remove excess material (gates, risers).

Precision Machining: CNC machining for critical dimensions (bearing seats, bolt holes).

Surface Treatment: Painting, galvanizing, or anti-corrosion coatings.

5. Fabrication of Bridge Girder & End Carriages
Welding/Assembly:

Fabricate box girders or I-beams (if hybrid design).

Weld/bolt end carriages (with wheels for movement).

Stress Relief Heat Treatment (if needed) to reduce residual stresses.

6. Assembly of Crane Components
Hoist & Trolley Installation: Mount electric hoist or wire rope system.

Rail & Runway Setup: Install crane rails on supporting structure.

Electrical System Integration: Wire motors, controls, limit switches, and safety devices.

7. Testing & Quality Control
Dimensional Inspection: Verify tolerances per design specs.

Non-Destructive Testing (NDT):

Ultrasonic, magnetic particle, or dye penetrant testing for cracks.

Load Testing:

Static Load Test: 125% of rated capacity.

Dynamic Load Test: 110% of rated capacity with movements.

Functional Test: Check braking, lifting, and travel operations.

8. Painting & Corrosion Protection
Apply primer and corrosion-resistant paint.

Markings (capacity, serial number, warnings) as per standards.

9. Packaging & Delivery
Disassemble (if needed) for shipping.

Protect critical components during transit.

10. Installation & Commissioning (On-Site)
Reassemble on the customer's runway.

Final alignment and calibration.

Operator training and handover.

 

 

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%.

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