Biggest Overhead Crane in The World

 

We are proud to unveil the world's biggest overhead crane, a cutting-edge marvel of engineering that redefines lifting capabilities across industries. Designed for extreme heavy-duty tasks, this crane stands at the pinnacle of innovation, combining state-of-the-art technology, robust design, and unmatched lifting power to meet the most demanding requirements in industries such as shipbuilding, heavy manufacturing, construction, and energy.

The biggest overhead crane in the World with a staggering lifting capacity of up to 2,000 tons, this crane is capable of handling the heaviest loads ever moved by overhead systems, enabling operations previously deemed impossible.Featuring a record-breaking span of up to 200 meters, the crane is designed to cover expansive areas with ease, making it ideal for large-scale industrial complexes and shipyards.Designed to handle a wide variety of loads, including oversized components, the crane is adaptable for use in different industries, from large-scale construction projects to complex maritime operations.

The biggest overhead crane in the World have advanced hoisting technology.It is equipped with cutting-edge hoisting technology, it ensures smooth, precise, and safe lifting, even for the most complex and oversized loads. The high-performance motors and gear systems provide exceptional power with minimal energy consumption.With a focus on sustainability, the crane incorporates energy-efficient features, including regenerative braking systems and environmentally-conscious materials, reducing its overall carbon footprint.

The biggest overhead crane in the World is not just for local use-it is built to be deployed in diverse geographical regions, featuring robust construction that withstands varying weather conditions, making it the go-to lifting solution for large projects worldwide.

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

Place of Origin：Henan, China

Warranty：1.5 years

Weight (KG)：65000 kg

Video outgoing-inspection：Provided

Machinery Test Report：Provided

Lifting mechanism：European winch trolley

Control method：Wireless Remote Control+Cab Control

Max. Lifting Height：30 m

Lifting speed：0.5/8m/min

Traveling speed：2-20m/min

Work Duty：A5/2M

Main electrical parts：Schneider

Crane feature：High Efficiency

 

 

1.Main beam

1) The main beam or girder of these massive cranes is typically constructed from high-strength steel to support the immense weight and load capacities required for lifting containers. The crane's main beam often spans hundreds of feet, with the crane itself having a lifting capacity that can exceed 50 tons (for general overhead cranes), and some specialized versions can lift much more.

2) The main beam of the largest overhead cranes is often referred to as the girder. It is the primary structural component that supports the crane's load and runs along the length of the crane. The girder is typically made from high-strength steel to handle the massive weight of the materials being lifted.

3) In the context of very large overhead cranes, such as those used in shipyards, steel mills, or large construction projects, the main beam must be designed to withstand not only the load but also dynamic forces that occur during crane operation. These cranes may feature double-girder designs for added strength and stability, with each girder working together to distribute the load evenly.For the largest cranes, the girder is often several meters long and can span entire factory floors, construction sites, or even dockyards. The size and specifications depend on the crane's lifting capacity and the specific application.

 

Lifting System

1) Motor: The motor of the lifting system in the biggest overhead crane in the world is a crucial component that allows the crane to lift and move massive loads. The largest and most powerful cranes in the world, such as those used in shipyards, steel mills, and heavy manufacturing facilities, often rely on electric motors that are specifically designed for heavy-duty lifting.

2) Reducer: A reducer (or gear reducer) in the lifting system of an overhead crane typically refers to the gear mechanism that reduces the speed of the motor's rotation and increases its torque. The main role of the reducer is to transmit power efficiently from the motor to the lifting drum or hoist mechanism, enabling heavy loads to be lifted and lowered smoothly.

3) Drum: The drum serves as the reel around which the lifting cable (or rope) winds and unwinds. This motion is driven by the crane's motor, and as the drum rotates, the rope either raises or lowers the load.In large cranes, the drum system is responsible for lifting some of the heaviest loads in the world, which could be several hundred tons or more.

4) Wire rope: The wire rope is typically made from high-strength steel, often alloyed with materials to increase tensile strength and durability.Advanced materials like galvanized steel or ropes with polymer coatings are used for additional resistance to corrosion and wear, especially in harsh environments like shipyards or offshore platforms.

5) Pulley block: In a large overhead crane system, the pulley block functions as part of the hoisting mechanism. It consists of a series of pulleys (or sheaves) through which cables or ropes pass. The system uses multiple pulleys to reduce the amount of force needed to lift extremely heavy loads.

6) Lifting device: The lifting device of the biggest overhead crane in the world typically refers to the hoist mechanism that is used to lift and lower heavy loads.

3.End carriage

1) The end carriage of an overhead crane refers to the part of the crane structure that supports the wheel assemblies and facilitates the movement of the crane along the rails. It is an essential component of the crane's travel mechanism.It is an essential component of the crane's travel mechanism.

2) For the world's biggest overhead cranes, end carriages are typically designed to be extremely robust and capable of supporting very heavy loads. The crane's end carriage allows the crane to travel along the rails, which are typically installed along the length of a production hall, shipyard, or any large industrial facility.

3) The end carriage works in tandem with other parts of the crane, such as the trolley (which moves the hoist), and the hoisting system. They must be perfectly synchronized to ensure smooth operation and to manage large, heavy loads.The end carriages must provide stability to prevent tilting and swaying, especially when transporting extremely heavy loads. This ensures that the lifting system remains precise and efficient.

 

4.Crane travelling mechanism

1) Working principle

The crane traveling mechanism is the system that allows the crane to move horizontally across its work area. It incorporates a series of tracks, wheels, motors, and structural supports designed for extremely heavy-duty applications in the case of the largest cranes. These cranes typically use advanced technologies to ensure smooth, stable, and safe operation while carrying heavy loads across long distances.

2) Functions of the crane operating mechanism

The primary function of the traveling mechanism is to allow the crane's hoist to move horizontally along the length of the crane's bridgeThis requires robust wheels, rails, and drive systems that can handle high stress.It provides fine control of the crane's movement along its rails, ensuring smooth, controlled travel for loading, unloading, and precise positioning of materials. This is especially important when handling large, delicate, or heavy loads.In modern overhead cranes, the traveling mechanism is typically driven by electric motors that can vary the speed and direction of travel. These motors are designed to provide smooth, consistent movement over long distances, even under heavy loads.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The trolley frame is the main structural component that supports the load and houses the various mechanisms responsible for the trolley's motion.

Travel Wheels: The travel wheels are mounted on the trolley frame and are responsible for guiding the trolley along the bridge girder or runway rails.These wheels are generally made of steel and are designed to handle the loads and the forces exerted during operation.

Drive device: The drive mechanism consists of an electric motor, gearboxes, and a system of drive shafts or coupling units.The motor typically powers the reduction gear or gearbox, which then drives the travel wheels.

2) Function of the trolley operating mechanism

The trolley traveling mechanism of a biggest overhead crane is a crucial component responsible for the movement of the trolley (the part of the crane that holds the hoisting mechanism) along the bridge or girder of the crane structure. It allows the hoisting mechanism (which lifts or lowers loads) to move horizontally across the crane's span, enabling the crane to cover a large area and transport materials efficiently.

6.Crane wheel

1) Function of wheels

The crane wheel allows the crane to move along its rail tracks. The design and materials used for the wheels ensure they can handle the extreme stress and forces exerted during operation.As the hoist lifts or lowers a load, the wheels help move the crane to the appropriate position, making it possible to shift heavy loads in any direction across the working area.The crane wheels play a role in maintaining the stability of the overhead crane while it operates. They help to evenly distribute the crane's weight across the rail tracks, reducing the risk of imbalance or tipping.

2) Design requirements

Regarding the crane wheel itself, the exact dimensions of the crane wheels on the world's largest cranes can vary depending on the design and application. However, the crane wheels on these massive overhead cranes can be enormous, often ranging from several feet in diameter (up to 8 to 10 feet) or more. These large wheels are specifically designed to support the immense weight and ensure the smooth movement of such giant structures.These wheels are engineered to be extremely durable, often made of specialized materials like high-strength steel, and designed to handle immense weights and forces during operation.

7.Crane Hook

1) The hook is usually made of high-strength alloy steel or carbon steel to ensure its strength and durability under high loads. The choice of materials should take into account fatigue resistance and wear resistance. The design of the hook is usually U-shaped or closed, which can effectively grasp and fix the material to prevent it from falling off during lifting. The surface of the hook is generally heat-treated or coated to improve its wear resistance and corrosion resistance.

2) The hook is connected to the lifting mechanism through a wire rope and directly bears the weight of the hoisted object. During the lifting process, the hook needs to withstand the gravity from the material and its dynamic load. During lifting, the hook is raised and lowered through the lifting mechanism, allowing the material to move in the vertical direction while maintaining stability to ensure safety. The main function of the hook is to safely grab and lift various materials and ensure that the material does not fall off during movement. The design of the hook allows quick and easy connection with different types of hoists (such as lifting rings, grabs, magnets, etc.), improving the flexibility of the operation.

Motor

The motor of the biggest overhead crane is typically a large, industrial-grade electric motor designed to handle the high power and torque requirements of lifting and moving heavy loads.

2) The motor converts electrical energy into mechanical energy to drive the operating mechanism of the crane. The rotation of the motor transmits power to the wheels or lifting device through the reducer to achieve the movement of the crane. Modern motors are often used in conjunction with frequency converters to achieve precise speed control and adjustment to meet the needs of different working conditions.

3) Overhead cranes used for heavy lifting (such as in shipyards, steel mills, or large factories) often have motors that can range from hundreds of horsepower (HP) to several thousand HP.Most large overhead cranes use three-phase asynchronous (induction) motors, but some might use synchronous motors for high-precision control. The motor's capacity must match the crane's lifting capacity, often reaching up to 100 tons or more.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

The biggest overhead cranes in the world are often used in heavy industries such as shipbuilding, steel manufacturing, and large-scale construction. These cranes, due to their enormous size and complexity, require robust safety systems, including sound and light alarms, to ensure safe operation and prevent accidents.

Sound Alarms : Overhead cranes often use horn or siren-based sound alarms that emit loud, attention-grabbing sounds

The sound alarms are designed to be heard over long distances, often reaching 100 decibels or higher, and they will typically last until the issue is resolved or acknowledged.

Light Alarms (Visual Warnings): The crane may be equipped with a variety of light systems for visual signaling.The crane might be moving in a high-risk zone, so lights may flash to notify nearby personnel.

2) Limit switch

A limit switch on an overhead crane is a crucial safety component used to prevent over-travel or overloading of the crane's mechanisms. It ensures that the crane does not exceed its physical operating limits, protecting both the equipment and personnel from damage or injury. The switch typically works by interrupting the electrical circuit when the crane reaches the end of its travel range, either vertically or horizontally.

In the case of the largest cranes, like the one at the Port of Rotterdam or others used in heavy-duty applications, limit switches are part of an intricate safety system that includes:End-of-travel limit switches: These prevent the crane hook from going too far in any direction, ensuring it doesn't collide with the end stops or other parts of the structure.

Overload limit switches: These detect if the crane is lifting more than its rated capacity and will trigger safety protocols, like stopping the crane from further movement or giving an alarm.

Positioning limit switches: These are used in conjunction with other sensors to precisely control the positioning of the crane's components.

10.Safety Devices

1) Overload protection device: Load Moment Indicator monitors the crane's lifting capacity and warns the operator if the load is approaching or exceeding the maximum weight the crane can safely lift.Overload Limiters devices automatically stop the crane from lifting beyond its rated capacity, preventing damage to the crane and ensuring safety.

2) Anti-Sway and Anti-Tilt Mechanisms: Sway Prevention Systems help to reduce the swinging of the load (known as load sway) during lifting and lowering operations, providing smoother control and preventing accidents caused by sudden movements.Tilt Control Systems prevents tilting of the load or crane structure by maintaining proper balance and orientation of the load.

3) Emergency Stop System:Emergency Stop Buttons are strategically placed throughout the crane, the emergency stop buttons can immediately halt all crane movements in case of an emergency, ensuring a quick response to hazardous situations. In the event of a malfunction or sudden power loss, the crane's emergency braking system ensures the crane can come to a controlled stop.

4) Proximity Sensors sensors detect obstacles or personnel in the crane's path and can alert the operator to prevent collisions.This software monitors the crane's movement and ensures it doesn't collide with nearby equipment, structures, or other cranes.

5) Warning Systems: When the crane is in operation, it may have warning lights or sirens that alert surrounding personnel of potential hazards.Cabin Warning Signals could include flashing lights, horns, or buzzers that notify the crane operator of any unsafe conditions or alerts from the load moment indicator or other systems.

11.Control Mode

Operator Cabin: The crane has an operator's cabin located at a height for good visibility. The operator uses a combination of joysticks, buttons, and possibly touch screens to control the crane's movements.

PLC (Programmable Logic Controller): These cranes are generally controlled by a sophisticated PLC system that manages the various operations such as lifting, lowering, swinging, and trolley movements.The PLC processes input from the operator, sensors, and safety systems to ensure smooth operation.

Remote Control: In some cases, cranes of this scale can also be operated via a remote control system, where operators can oversee operations from a safe distance or even from the ground.

Safety Systems: To avoid accidents due to overloading, misalignment, or environmental factors (like wind), there are multiple redundant safety systems in place, including load cells, wind speed detectors, and emergency stop functions.

Automatic Positioning Systems: For high precision, automatic positioning systems help place loads with high accuracy. These systems use sensors and GPS technology for real-time adjustments.

Load Monitoring: The crane's load sensors track the weight of the lifted object in real-time to prevent overload. Overload protection systems automatically halt operations if the load exceeds safe limits.

Variable Frequency Drives (VFDs): These drives are used to control the speed of the crane's motors. They provide smooth acceleration and deceleration, which is crucial for preventing jerky movements, especially when lifting massive loads.

Computer-Aided Control: Modern cranes are often integrated with computer systems that provide diagnostic data, performance statistics, and help to plan lifting operations more efficiently.

Safety and Monitoring Software: The crane's control system is often integrated with software that monitors the health of the crane and its components. This software provides data on things like the crane's structural integrity, motor performance, and other critical metrics.

Wind and Environmental Considerations: Given the size of the Taisun crane and the extreme weights it lifts, weather conditions-particularly wind-are closely monitored. The crane has sensors and control algorithms that determine whether it is safe to operate under specific weather conditions.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12.Sketch

 

Main technical

 

 

 

 

Ability to Handle Extremely Heavy Loads

The primary advantage is its capability to lift and move extremely heavy loads, far beyond the capacity of standard cranes. This is particularly beneficial in industries such as shipbuilding, aerospace, steel production, and heavy machinery manufacturing, where large and heavy components are the norm.Some of the world's largest overhead cranes can lift weights of hundreds of tons, which is essential for moving massive pieces of equipment or infrastructure.

Improved Efficiency and Productivity

By allowing the transportation of large loads within a factory or construction site, the crane significantly reduces the need for manual labor and smaller cranes, increasing overall productivity.Larger cranes can move heavy items with fewer operations, reducing downtime and speeding up assembly or manufacturing processes.

Maximized Space Utilization

Overhead cranes are often used in environments where floor space is limited. By moving heavy objects vertically along a track above the ground, these cranes help optimize the available space below, keeping work areas organized and safe.Large overhead cranes can be used to access high-clearance areas, which can be crucial for assembling large structures or accessing hard-to-reach locations.

Enhanced Safety

Overhead cranes allow heavy loads to be moved without human operators needing to manually handle them, which reduces the risk of accidents or injuries from lifting and moving heavy materials.These cranes often come with safety features like load monitoring systems, collision avoidance sensors, and emergency stop functions, ensuring both the safety of the operators and the integrity of the materials being moved.

Precision and Control

Large overhead cranes offer superior control over the movement of heavy loads, which helps prevent accidents, ensures that items are placed accurately, and reduces the risk of damage during transportation.Advanced control systems and automation capabilities allow these cranes to operate with a high degree of precision, even when lifting or moving loads at great heights or distances.

Long-Term Investment and Durability

The largest cranes are typically built to last for decades, with minimal maintenance required if they are well-maintained. Their robust design ensures they can handle the harshest environments and demanding workloads without compromising performance.These cranes are often a significant investment, but their ability to meet industrial needs for years or even decades makes them valuable assets for companies involved in large-scale construction or manufacturing projects.

Versatility

Despite their size, these cranes can be used in a wide range of applications. In addition to moving heavy materials, they can be outfitted with various attachments (such as magnets, grabs, or specialized lifting hooks) to handle different types of loads.Some of the largest cranes are used in the construction of ships, aircraft, and large structures like bridges, demonstrating their versatility across industries.

Improved Operational Flexibility

The ability to move heavy loads across long spans of a facility or worksite provides increased flexibility. Large cranes often have long travel distances, so they can move items over vast areas, allowing for more dynamic workflows.

Reduced Operational Costs

While the initial investment may be significant, the operational costs over time can be lower than using multiple smaller cranes. With higher lifting capacities and fewer lifts needed, larger overhead cranes reduce the frequency of maintenance and improve the overall cost-efficiency of lifting operations.

Ability to Perform in Extreme Environments

Large overhead cranes can be designed to withstand challenging environmental conditions, such as extreme temperatures, hazardous materials, or high levels of dust and debris. This makes them suitable for use in places like power plants, chemical processing facilities, or steel mills.

 

 

Shipbuilding:The Taisun crane is primarily used for constructing large ships, including very large crude carriers (VLCCs), oil tankers, and floating platforms. Its massive lifting capacity is essential for moving heavy components, such as ship hull sections and floating dock segments, that are too large for conventional cranes.

Offshore Oil and Gas Industry:The crane is instrumental in the assembly of offshore drilling rigs and platforms. It can handle the immense weight of the structures and equipment required for offshore oil exploration.

Heavy Industrial Equipment Handling:It is used to lift and move massive industrial equipment and machinery that exceed the capabilities of smaller cranes. This can include large-scale factory components, generators, turbines, and more.

Wind Turbine Construction:The crane can be used to lift and position large components for offshore wind turbines, especially in the case of turbines with gigantic nacelles and blades. The ability to lift extremely heavy and large components is vital for the renewable energy sector.

Storage and Transport of Heavy Cargo:Taisun's lifting capacity allows it to handle exceptionally heavy cargo, often for long-distance transport. It can load and unload cargo from ships or barges, and has been used in large-scale logistics operations involving oversized equipment or vehicles.

Research and Development:The crane also serves as a tool for experimental setups and testing in industries that require heavy lifting for prototyping, R&D, and testing of new designs.

Crane production procedure

Design and Engineering: The process begins with a comprehensive analysis of the load capacities, span, and operational requirements of the crane. These specifications are gathered based on the needs of the client (e.g., a large shipyard, factory, or construction site).Engineers use computer-aided design (CAD) and finite element analysis (FEA) to create the crane's structural design, ensuring it can safely lift massive weights over significant distances.This includes choosing the right materials (steel, cables, electrical components, etc.), deciding on crane dimensions, load capacities, and calculating power requirements for the motor systems.

Material Procurement: The primary material used in the construction of the crane is usually high-strength structural steel. Given the crane's size and weight, the steel must meet specific strength, durability, and fatigue resistance standards.For the crane's mechanisms (motors, hoists, gears, wheels, etc.), high-performance materials are sourced. These components may be custom-designed or selected from specialized manufacturers.

Fabrication and Manufacturing: Large steel plates are cut into sections that will form the main beams, girders, and structural components. CNC (computer numerical control) machines are typically used for precision cutting.After cutting, the sections are welded together. For a crane of this size, welding is done carefully to avoid warping or structural defects, often using robotic welding machines for precision and consistency. The hoisting mechanism, including the drum, ropes, motors, and gearing, is assembled separately before being integrated into the crane.

Subassembly and Main Assembly: The main horizontal beam or girder (the bridge of the crane) is assembled in large sections, often in a factory specially designed to handle such heavy components.Cross girders are fabricated, and the crane's travel mechanism (which allows the crane to move along its runway) is assembled. This includes the trolley system and the rail system for the crane to move along.A crane of this size will often have a control cabin, which is assembled with specialized electronics and control systems for operators to handle the crane's complex operations.

Integration of Components: Electrical systems, including high-voltage power supply, control panels, and communication systems, are integrated. These systems control the crane's movement, speed, lifting, and load management.Large cranes incorporate numerous safety systems, including overload protection, emergency brakes, limit switches, and sensors to ensure smooth, controlled operation.

Testing and Calibration: The crane undergoes rigorous testing to verify its load-bearing capabilities, as well as its ability to operate under various dynamic conditions.Before delivery, the crane is tested for its operational performance-checking all movements, speed, load control, and response to commands.Sensors, control systems, and safety features are calibrated to ensure the crane operates according to the design specifications.

Transportation and Installation: Due to the crane's enormous size, it is often shipped in disassembled sections, with each part transported to the installation site by land or sea.Upon arrival at the installation site, the crane is assembled. This may require the use of smaller cranes or other heavy equipment to lift and position the large components.Once assembled on-site, the crane undergoes final testing to ensure that all systems are functioning correctly in the field.

8. Commissioning and Handover: The crane's operators and maintenance personnel are trained on how to use the equipment and perform basic troubleshooting. After successful commissioning, the crane is handed over to the client with a full set of operational manuals and maintenance schedules.Many manufacturers offer ongoing support and maintenance contracts to ensure the crane operates reliably for decades.

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%.