100 Ton Overhead Wire Crane

 

Key Features:

Capacity:

With a lifting capacity of up to 100 tons, this crane is built to handle very heavy loads like steel coils, machinery, or large construction components.

Bridge:

The crane operates on a horizontal bridge structure, which moves along rails mounted on elevated beams or structures. This bridge allows the crane to cover a large area and provides flexibility in movement.

Trolley and Hoist:

The trolley travels along the bridge, carrying the hoist. The hoist is equipped with wire ropes, which are more durable and capable of lifting heavy weights compared to chain hoists.

The hoist mechanism lifts and lowers the load, using wire ropes wound around a drum.

Wire Rope:

The wire rope is the key lifting element, known for its strength, flexibility, and ability to handle the weight and wear associated with large-capacity lifting. It is more resistant to abrasion and can handle higher tensile loads than chain mechanisms.

Control System:

Manual or automated controls are used to operate the crane. Operators can control the movements of the hoist, trolley, and bridge to position the load accurately.

Modern cranes often feature remote controls, which allow for safer operation from a distance.

Safety Features:

Equipped with multiple safety mechanisms such as limit switches, overload protection, and emergency stop systems to prevent accidents and ensure smooth operation.

Warranty：1 Year

Weight (KG)：3000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Color：Customized

Crane feature：Easy Operated Girder Bridge Crane

Capacity：0.5-10t

Type：suspension bridge crane

Power supply：110V/220V/230V/380V/440V

Control Method：Ground Control+ Remote Control (customized)

MOQ：1 Set

Lifting mechanism：Electric Hoist

Work Duty：A3-A5

After Warranty Service：Video technical support

Pictures & Components

 

 

1.Main beam

Design Features

1)Structural Profile

The main beam is typically fabricated from high-quality steel in an I-beam or box girder profile for strength and rigidity.

The design ensures durability while minimizing the beam's weight to reduce overall crane load.

2)Dimensions

The dimensions of the main beam depend on the bottom block overhead crane's capacity, span, and working environment.

Engineers design it to withstand dynamic and static forces, considering factors such as deflection limits and load distribution.

3)Flange and Web Construction

The flange (top and bottom parts of the beam) bears horizontal loads, while the web (vertical section) handles vertical loads.

Welded or rolled steel profiles enhance stability and load-bearing capacity.

4)Connection Points

The main beam connects to the end carriages or trucks, which allow the crane to move along the runway system.

Mounting brackets or attachments accommodate the hoist, ensuring smooth operation.

Hoist

The hoist is the lifting mechanism that raises and lowers the load. In a 100-ton overhead crane, the hoist typically uses wire ropes, which are strong and durable enough to handle very heavy loads.

The hoist includes a motor, gearbox, drum, and wire rope, which work together to wind and unwind the rope, lifting and lowering the load.

 

3.End carriage

1)Features of the End Carriage

Precision Alignment:Ensures that the bottom block overhead crane operates smoothly along the rails, reducing wear and tear.

Misalignment can lead to uneven load distribution and system failure.

Compact Design:Optimized for minimal weight while maintaining structural integrity.Helps reduce the overall load on the crane runway.

Anti-Derailment System:Safety mechanisms prevent the wheels from derailing during operation.

2)Materials and Manufacturing

Materials:Fabricated from high-grade steel for strength and resistance to deformation under heavy loads.Corrosion-resistant coatings are applied for outdoor or harsh environments.

Manufacturing Process:Precision machining ensures accurate alignment and dimensions.Quality control tests, including load and stress analysis, verify performance and safety.

 

4.Crane travelling mechanism

1)Working Principle

The electric motors drive the wheels through a gearbox and coupling system.

As the wheels turn, the bottom block overhead crane moves along the runway beams, allowing it to position the load as needed.

The movement can be controlled manually via a pendant or remotely using wireless controls.

2)Maintenance and Inspection

Regular Lubrication：Apply grease or oil to wheels, gearboxes, and bearings to minimize friction.

Alignment Checks：Ensure proper alignment of wheels and rails to prevent uneven wear and derailment.

Inspection：Periodically check for wear on wheels, motors, and couplings.

Replacement：Replace worn-out or damaged parts promptly to avoid operational delays.

5.Trolley travelling mechanism

1)Working Principle

The motor generates power, which is transmitted to the gearbox.

The gearbox reduces the motor's speed and increases torque to drive the wheels.

The wheels roll along the girder flange, moving the trolley horizontally.

The operator controls the trolley's direction and speed using a pendant, remote, or automated system.

2)Features and Benefits

Smooth Operation：High-quality wheels and precision drives ensure consistent and smooth movement.

Load Versatility：Can handle a wide range of load capacities, depending on the bottom block overhead crane's specifications.

Positioning Accuracy：Variable speed control allows precise positioning of the hoist for lifting tasks.

Durability：Robust construction and wear-resistant materials extend the mechanism's service life.

6.Crane wheel

Types of Wheels

1)Flanged Wheels

Design: Have flanges on the edges to keep the bottom block overhead crane aligned with the rails.

Applications: Commonly used for cranes operating on standard rail systems.

2)Flat Wheels

Design: Lack flanges and rely on external guidance systems for alignment.

Applications: Suitable for guided tracks or specific industrial setups.

3)Double-Flanged Wheels

Design: Feature flanges on both sides, providing extra stability.

Applications: Ideal for high-precision or heavy-duty applications.

7.Crane Hook

Key Components of a Crane Hook

1)Hook Body:The curved structure that holds the load.Precision-forged and heat-treated for strength and durability.

2)Safety Latch:A spring-loaded latch that ensures the load remains secured during lifting.Prevents the load from slipping off the hook.

3)Bearing or Swivel Assembly:Allows the hook to rotate freely for better load alignment.Reduces stress on the bottom block overhead crane rope or chain.

4)Shank or Eye:Connects the hook to the crane's lifting mechanism (e.g., wire rope or chain).

Motor

The crane is equipped with several electric motors, responsible for powering the movement of the bridge, trolley, and hoist.

These motors are usually AC motors designed to provide the necessary power for lifting and moving heavy loads.

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Sound and light alarm system & limit switch

Integration and Operation

1)Sound and Light Alarm System

Automatically activates when the crane is in motion, lifting a load, or during emergency situations.

Can also be manually operated as a warning signal during maintenance or hazard situations.

2)Limit Switch

Installed at critical points such as the hook's upper and lower limits, the trolley's end positions, and the runway ends.

Interacts seamlessly with the crane's electrical control system to stop operations instantly when limits are reached.

10.Safety Devices

1. Limit Switches

Function: Prevent over-travel of the crane, trolley, or hoist.Protects crane components and enhances operator control.

2. Overload Protection Device

Function: Monitors the weight being lifted and prevents the crane from operating if the load exceeds its rated capacity. Protects against equipment failure and ensures workplace safety.

3. Sound and Light Alarm System

Function: Alerts nearby personnel of crane operations through loud audible signals and flashing lights.Reduces the risk of accidents in busy or noisy environments.

4. Emergency Stop Button

Function: Instantly halts crane operations in case of an emergency.Ensures quick response to prevent accidents or equipment damage.

5. Anti-Collision System

Function: Prevents collisions between two cranes operating on the same runway or with nearby structures.Enhances safety in multi-crane environments.

6. Buffer Stops

Function: Absorbs the kinetic energy of the crane to prevent hard impacts at the runway ends.Protects the crane structure and runway from damage.

7. Anti-Sway Control System

Function: Reduces the swaying of the load during lifting or travelling operations. Improves precision and safety in load handling.

8. Overheat Protection for Motors

Function: Monitors motor temperature and stops operation if overheating occurs. Prevents motor damage and reduces downtime.

11.Control Mode

1)Pendant Control:A wired controller suspended from the crane.

Operated by an individual standing on the ground near the crane.

2)Wireless Remote Control:Uses radio frequency (RF) or infrared (IR) signals to control the crane wirelessly.

3)Cabin Control (Driver's Cabin):A cabin is installed on the crane where an operator directly controls the crane using joysticks, buttons, or a control panel.

4)Automated/Programmed Control:The crane is programmed to perform specific tasks autonomously without direct manual input during operation.

 

12.Sketch

 

Main technical

 

 

Advantages

A 100-ton overhead wire crane offers several advantages, particularly in industries requiring the lifting and movement of very heavy loads. Its capacity and durability make it an essential tool for a wide range of applications. Below are the key advantages of a 100-ton overhead wire crane:

1. High Lifting Capacity

Heavy Load Handling: With a 100-ton capacity, the crane can easily lift and move extremely heavy objects such as steel beams, machinery, turbines, and construction materials. This makes it ideal for industries like steel manufacturing, shipbuilding, and power plants.

2. Durability and Strength

Wire Ropes: The use of wire ropes provides superior strength and longevity compared to chain-based systems. Wire ropes are highly resistant to wear and tear, making them suitable for heavy-duty operations.

Robust Construction: The crane is built with strong, durable materials capable of withstanding the high stresses involved in lifting heavy loads, ensuring long service life even in harsh environments.

3. Efficiency

Fast and Precise Operation: The crane allows for quick lifting, lowering, and horizontal movement, improving overall efficiency in material handling. Operators can control the precise positioning of loads, speeding up processes in production lines or construction sites.

Continuous Operation: These cranes are designed for continuous, heavy-duty use, enabling extended periods of operation without frequent breakdowns or maintenance, which enhances productivity.

4. Improved Safety

Load Control: The crane offers excellent control over load movements, reducing the risk of accidents. The wire rope system provides smooth lifting and lowering, ensuring the safety of both the load and the surrounding environment.

Safety Features: Equipped with essential safety mechanisms like limit switches, overload protection, brakes, and emergency stop systems, the crane prevents accidents such as over-travel, overloading, or sudden load drops.

5. Wide Application Range

Versatility: A 100-ton overhead wire crane is versatile, able to handle different types of heavy loads in various industries, including steel mills, foundries, construction, shipyards, and power plants.

Handling Large Areas: The overhead structure allows the crane to cover large workspaces and handle heavy materials over wide areas, providing greater flexibility in terms of material positioning and movement.

6. Cost-Effective for Heavy Lifting

Reduces Manual Labor: By handling heavy loads with precision and efficiency, the crane minimizes the need for extensive manual labor. This not only saves time but also reduces labor costs and potential risks to workers.

Lower Maintenance Costs: The durable wire rope and robust construction require less frequent maintenance compared to other lifting mechanisms, resulting in lower operational costs over the long term.

7. Enhanced Precision and Control

Smooth Operation: The wire rope hoist allows for smooth lifting and lowering, giving operators precise control over load movements. This is especially beneficial in delicate operations or when positioning loads with extreme accuracy.

Multiple Control Options: These cranes can be controlled via cabin operation, pendant control, or wireless remote control, providing operators with flexibility in handling and improving overall safety by allowing operation from a distance.

8. Space Utilization

Efficient Use of Vertical and Horizontal Space: Overhead wire cranes are mounted on elevated structures, allowing the efficient use of floor space in factories and warehouses. The crane can move materials over obstacles, maximizing workspace utilization.

9. Reduced Wear and Tear on Rigging Equipment

Minimal Rigging Requirements: The strong wire ropes reduce the need for additional rigging equipment, such as slings or chains, which are more prone to wear and tear. This helps reduce maintenance costs and downtime related to rigging equipment failures.

10. Customizable

Tailored for Specific Needs: A 100-ton overhead wire crane can be customized for specific industrial applications, including different lifting speeds, hoist configurations, and additional features such as magnets or specialized hooks. This flexibility ensures the crane meets specific operational requirements.

11. Increased Workplace Safety

Less Manual Handling: With the crane taking over the heavy lifting, manual handling of large or heavy materials is minimized, reducing the risk of injuries to workers.

Emergency Features: Equipped with features such as overload protection and emergency stop systems, these cranes enhance safety during lifting operations.

Summary of Advantages:

High lifting capacity of up to 100 tons for handling heavy materials.

Durable wire ropes provide long-lasting performance and reduced maintenance.

Efficient operation speeds up material handling processes and improves precision.

Comprehensive safety features ensure safe operation and reduce workplace accidents.

Versatility across industries like steel, construction, shipbuilding, and energy.

Cost-effective in terms of reduced labor and maintenance costs.

Maximizes space utilization, allowing for efficient use of floor and overhead space.

In conclusion, a 100-ton overhead wire crane offers unmatched strength, efficiency, and safety, making it an ideal solution for handling heavy loads in a variety of industrial settings.

 

 

Application:

1. Manufacturing Industry

Transporting raw materials and finished products across production lines.

Assisting in assembly operations for machinery, vehicles, and equipment.

2. Warehousing and Logistics

Loading and unloading goods in warehouses and distribution centers.

Organizing inventory by lifting and placing heavy items on shelves.

3. Construction Industry

Lifting construction materials like steel beams, concrete panels, and tools.

Assisting in assembly processes on construction sites.

4. Maintenance and Repair Workshops

Handling machinery and equipment for repair and servicing.

Transporting components within workshops or service bays.

5. Steel and Metal Processing

Transporting raw steel and metal sheets between processing machines.

Lifting and positioning heavy metal components during cutting, welding, or assembly.

6. Chemical and Pharmaceutical Industry

Lifting drums, tanks, and other containers in chemical processing plants.

Assisting in the assembly and maintenance of equipment in cleanrooms.

Crane production procedure

1. Requirement Analysis and Design:

Analyze the client's operational needs, including capacity, span, lifting height, and working environment.Develop a technical design using CAD software.Include detailed specifications for the main components: girder, hoist, end carriages, and controls.Ensure the design adheres to international standards such as ISO, FEM, and CMAA.

2. Material Procurement:High-quality steel plates for the main girder and end carriages.Standardized components for hoists, motors, and trolleys.Verify materials meet required specifications and standards before production.

3. Fabrication of Components

a. Main Girder:Steel plates are cut to size using CNC plasma or laser cutting machines.Weld sections of the girder (e.g., I-beams or box beams) using robotic or manual welding techniques.

Ensure precision to maintain strength and dimensional accuracy.

b. End Carriages：Machine and assemble steel sections for the end carriage.Attach wheel assemblies and bearings.

c. Hoist and Trolley:Procure pre-manufactured hoists or assemble them in-house.Mount lifting mechanisms, motors, brakes, and controls onto the trolley.

d. Electrical Systems:Assemble the electrical control box with contactors, inverters, and safety relays.Install wiring for motors, limit switches, and sensors.

4. Surface Treatment:Use sandblasting or shot-blasting to remove rust and impurities from steel surfaces.Apply anti-corrosion primer and finish with a durable topcoat.Use specialized coatings for environments like chemical plants or outdoor installations.

5. Component Assembly:Attach the hoist and trolley to the main girder.

Mount end carriages and wheels to the girder ends.Install the electrical control panel, wiring, and other accessories.Check alignment and mechanical integrity during assembly.

6. Quality Inspection：Ensure all dimensions match the design specifications.Verify welds using NDT methods for structural integrity.Conduct static and dynamic load tests to verify performance under rated loads.Test electrical systems for functionality, safety, and reliability.

7. Pre-Delivery Testing:Simulate real-world operations, including lifting, traveling, and stopping.Verify the functionality of limit switches, overload protection, and alarms.Ensure smooth and consistent operation under various conditions.

8. Packaging and Transportation:Disassemble large components (e.g., girder and end carriages) for easier transportation.Wrap components in protective material to prevent damage during transit.Provide manuals, testing certificates, and compliance documentation.

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%.