Crane On Rails

 

 

The lifting trolley of the Crane On Rails runs between two parallel main beams. It has a stable structure and strong carrying capacity, which is suitable for handling large tonnage heavy objects. The bridge moves along the tracks laid on both sides through the running mechanism, realizing the forward and backward movement of the crane on the I-beam or track. The lifting trolley runs horizontally on the bridge, and the lifting mechanism generally uses an electric hoist or winch to complete the lifting and lowering operation of the goods.

The span of the Crane On Rails can be customized according to the needs of the factory or site, with a large span range and strong flexibility. It can usually carry tens or even hundreds of tons of items, which is particularly suitable for large-scale production and heavy industrial scenes. Due to the double-beam structure, the crane has stronger stability and anti-lateral swing ability than the single-beam crane, which is suitable for frequent use and heavy lifting. Equipped with an electric control system, it is easy to operate and can improve the efficiency of material handling.

The Crane On Rails is equipped with multiple safety devices, such as limiters, anti-collision devices, emergency stop buttons, etc., to ensure the safety of operation. The various components of the crane are reasonably designed, easy to repair and maintain, and have a long service life. According to the specific needs of customers, different sizes, lifting weights and functional configurations can be provided to meet the use requirements of various special occasions.

4) Crane On Rails have become the preferred equipment for many heavy material handling occasions due to their high efficiency, safety and stability.

 

Warranty：1 Year

Weight (KG)：2000 kg

Feature：Bridge Crane

Condition：New

Rated Lifting Moment：50KN-3000KN

Max. Lifting Load：500ton

Span：10-80m

Color：Optional

Capacity：1-20t

Type：Double beam

Lifting mechanism：Eliectric Hoist

Work Duty：A3-A4

 

 

 

 

1.Main beam

1) The main beam of a Crane On Rails consists of two parallel main beams, usually welded or assembled. The two main beams are connected by transverse beams or reinforcement structures to ensure overall stability. The main beam is generally a box-type structure, welded with steel plates. The box-type structure has high strength and high rigidity, can withstand large bending moments and shear forces, and is suitable for carrying heavy cargo. In some small and medium-sized cranes, the main beam may use H-beams or I-beams. This structure is simple and lightweight, but has limited bearing capacity and is suitable for medium load occasions.

 

2) The main beam is usually made of high-strength steel with excellent mechanical properties and fatigue resistance. The choice of materials should take into account the stress and load changes that the main beam is subjected to during long-term work to ensure safety and durability. Commonly used steels include high-quality low-carbon steel or alloy steel such as Q235 and Q345, which have good weldability and processability.

 

3) The main beam adopts automatic or semi-automatic welding process to ensure the quality and strength of the weld. The welded main beam also needs to be inspected to ensure that there are no cracks or defects inside. The size and shape of the main beam must be very precise to ensure smooth installation and operation of the crane. Therefore, strict dimensional measurements and controls are carried out during the manufacturing process to ensure the straightness and lateral rigidity of the main beam.

 

Lifting System

1) Motor: The power source of the lifting system is the motor, which usually uses a dedicated lifting motor with large starting torque and good overload capacity, and can provide strong lifting power in a short time. The motor accurately controls the lifting speed of the cargo through the control system.

2) Reducer: The motor converts the high-speed, low-torque motor output into low-speed, high-torque movement through the reducer. Common types of reducers include worm gear reducers, gear reducers, etc., which can ensure smooth lifting movement and improve transmission efficiency.

3) Drum: The drum is the part where the wire rope is wound. It retracts and releases the wire rope by rotating to directly control the lifting and lowering of the hook or other slings. The size and material of the drum need to be designed according to the lifting weight and the specifications of the wire rope.

4) Wire rope: The wire rope carries the weight of the cargo and transfers the weight to the lifting mechanism through the pulley block. The selection of wire rope usually takes into account its strength, wear resistance and fatigue resistance to ensure safety and reliability during long-term work.

5) Pulley block: The pulley block reduces the lifting load and expands the load capacity by changing the path of the wire rope. The pulley block is scientifically and reasonably designed, which can effectively reduce the burden on the motor and improve the efficiency of the entire system.

6) Lifting device: The lifting device is the part that comes into direct contact with the goods, usually a hook or electromagnetic suction cup, grab, etc. Different application scenarios require different types of lifting devices to ensure safe and efficient material handling.

 

3.End carriage

1) The end beam is usually a box-type structure or an I-beam structure with high strength and rigidity. The box-type end beam is welded from steel plates and can effectively resist the torque and bending moment generated during the operation of the crane. A wheel set is installed on the end beam, which consists of a driving wheel and a driven wheel, responsible for the longitudinal movement of the crane along the track. The wheels are usually made of wear-resistant alloy steel or cast steel, with high load-bearing capacity and wear resistance.

2) The end beam is connected to the main beam by bolts or welding to form a complete bridge structure to ensure overall stability. The connection between the end beam and the main beam requires high precision to ensure the smooth operation of the crane and the integrity of the structure. The end beam is mainly used to carry the weight of the crane bridge and transfer it to the track on the ground through the wheels. At the same time, it also supports and stabilizes the main beam so that it can withstand various forces during the lifting process.

3) The driving wheel on the end beam is responsible for the travel of the bridge, pushing the crane to move forward and backward on the track to realize material transportation in space. The drive system can be equipped with a variable frequency speed regulation device to accurately control the movement speed of the crane. By installing limit switches or sensors, the end beam can automatically stop when the crane reaches a predetermined position to prevent collision or deviation from the track.

 

 

4.Crane travelling mechanism

1) Working principle

Power transmission: The motor transmits power to the wheel set through the reducer, and the wheels roll on the track to achieve the forward and backward movement of the crane. The design of the reducer allows the crane to run smoothly under low speed and high torque conditions.

Control system: The crane traveling mechanism of modern cranes is usually equipped with advanced control systems, including frequency converters, PLCs, etc., to achieve precise speed regulation and position control.

2) Functions of the crane operating mechanism

Horizontal movement: The crane operating mechanism is responsible for the horizontal movement of the crane in the working area and supports the operation of the lifting crane on the main beam.

Load distribution: Through the configuration of multiple wheels, the load can be evenly distributed on the track, reducing the pressure of the unit track and reducing track deformation and wear.

Positioning accuracy: The crane traveling mechanism can accurately stop at the specified position to ensure the safety and accuracy of the lifting operation.

5.Trolley travelling mechanism

1) Structural composition

Trolley frame: The trolley frame is the main body of the trolley operating mechanism. It is usually made of steel welded structure with high strength and rigidity, and can carry the lifting mechanism and hoisting equipment.

Wheel set: The trolley frame is equipped with multiple wheels, usually including driving wheels and driven wheels. The wheel set is designed to have good contact with the rails of the main beam to ensure smooth movement.

Drive device: The driving device of the trolley is generally composed of an electric motor and a reducer. The motor drives the trolley to move through the reducer to provide the necessary power.

2) Function of the trolley operating mechanism

Lateral movement: The main function of the trolley operating mechanism is to enable the lifting trolley to move laterally on the main beam, thereby achieving accurate positioning and handling of the goods.

Load bearing: The trolley can carry the weight of the lifting mechanism and the hoisted object. The design must ensure that its structural strength is sufficient to support the maximum load.

Operation flexibility: The flexibility of the trolley enables the crane to operate in different positions, improving work efficiency.

6.Crane wheel

1) Function of wheels

Mobile support: The main function of the wheels is to support the movement of the crane on the track and ensure the smooth operation of the crane.

Load distribution: The wheels help to evenly distribute the load of the crane, reduce the pressure on the track, and increase the service life of the equipment.

2) Design requirements

Strength and rigidity: The wheels must have sufficient strength and rigidity to withstand the dead weight of the crane and various dynamic loads.

Wear resistance: Due to the continuous friction between the wheels and the track, the wheel material must have good wear resistance to extend the service life.

Anti-skid design: The wheel surface should be designed to be anti-skid to avoid sliding or slipping under heavy load.

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

1) Common motor types, including asynchronous motors and synchronous motors, have the advantages of simple structure and stable operation, and are suitable for most crane applications. In situations where higher starting torque and adjustable speed performance are required, DC motors may be used to provide smooth acceleration and deceleration.

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) The motor is responsible for driving the operation of the trolley and the car, enabling the crane to move on the track for lifting and positioning of materials. The motor lifts the heavy objects to the required height through the lifting mechanism (such as the winch) to meet the requirements of different operations.

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Sound and light alarm system & limit switch

1) Sound and light alarm system

The sound and light alarm system usually includes sound alarms and flashing lights, which are mainly used to send warning signals during the operation of the crane to improve the safety of operation.

Danger warning: When the crane is about to start or end work, the system will send out sound and light signals to alert the surrounding personnel.

Overload alarm: When the crane reaches or exceeds the safe load, the sound and light alarm system will automatically activate to remind the operator to take measures to avoid potential safety hazards.

Fault prompt: When there is a failure or abnormality in the equipment, the sound and light alarm system can issue an alarm in time to remind the operator to check and maintain.

2) Limit switch

The limit switch is a safety protection device for the crane, which is used to control the operating range of the crane to prevent it from exceeding the preset safety position.

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) Overload protection device: used to monitor the load of the crane, ensure that the equipment automatically stops when the rated load is reached or exceeded, and prevent accidents caused by overload. The sensor monitors the load weight in real time, and triggers an alarm or cuts off the power when it exceeds the set value.

2) Braking system: ensure that the crane can stop quickly and safely when it stops or in an emergency. Common braking systems include electromagnetic braking, mechanical braking and hydraulic braking.

3) Safety hook and safety lock: prevent the hanging objects from falling off during the lifting process. The safety hook is usually designed with an anti-falling device, and the safety lock will not be enabled when the hook is not fully closed.

4) Anti-overturning device: ensure that the crane will not overturn during operation. Through reasonable structural design and counterweight, instability can be prevented when lifting heavy objects.

5) Emergency stop device: in an emergency, it can quickly cut off the power supply and immediately stop all operations of the crane. The emergency stop switch should be set in a position that is easy for the operator to access so that it can be used quickly when needed.

6) Safety operating procedures: provide necessary safety training for operators to ensure that they understand the safe operating procedures of the equipment and reduce human errors. Regularly inspect and maintain equipment to ensure that all safety devices are functioning properly and improve safety.

 

11.Control Mode

1) Manual control: The operator directly controls the various operating mechanisms of the crane through buttons or switches on the manual control panel. Simple operation, suitable for small or short-term operations; can be quickly adjusted according to specific needs.

2) Wireless remote control: The various functions of the crane are controlled by a wireless remote control, and the operator can operate at a safe distance. Improves the flexibility and safety of operation, especially suitable for complex or dangerous working environments.

3) Wired remote control: Operate through the control line connected to the crane, and the operator inputs instructions through a handheld controller. Compared with wireless remote control, the signal is stable and not easily interfered with, which is suitable for operation in a fixed area.

4) Automated control: Automated operation is achieved through PLC (Programmable Logic Controller) or computer system, and the operation of the crane is controlled according to the preset program. Improves the accuracy and consistency of operation, suitable for large-scale and repetitive operations, and reduces interference from human factors.

5) Frequency conversion control: The speed of the motor is adjusted by the frequency converter to achieve precise control of the operating speed of the crane. It can smoothly accelerate and decelerate, improve the safety and efficiency of lifting operations, and reduce the impact on equipment.

12.Sketch

Main technical

 

 

1) High load-bearing capacity

Crane On Rails adopt a double main beam structure, which can carry heavier loads and are suitable for lifting heavy materials. They are often used in industries such as steel, shipbuilding and heavy machinery manufacturing.

2) Strong stability

The double-beam design provides better stability and rigidity, which can effectively reduce the tilting and shaking when lifting heavy objects, ensuring safe operation.

3) Large lifting height

Due to the design of the main beam, Crane On Rails can provide a larger lifting height, which is suitable for high-altitude operations and large space environments.

4) Wide span range

This type of crane can be designed with different spans according to needs, suitable for various sites, can cover a larger working area, and improve work efficiency.

5) Flexible operation

Crane On Rails are usually equipped with trolleys and large vehicles, which can move flexibly on the main beam to achieve multi-directional lifting and adapt to complex operation requirements.

6) Safe operation

Equipped with a variety of safety devices, such as overload protection, limit switches and sound and light alarm systems, to ensure safety during operation and reduce the risk of accidents.

 

 

Manufacturing: Used to lift billets, steel and other heavy materials in steel mills. Lift large mechanical parts and tools in machine tool workshops.

Construction: Used to lift building materials such as concrete components, steel structures and other heavy equipment. Handle heavy materials in the construction of high-rise buildings.

Shipbuilding: Used to lift and move large hulls, cabins and equipment, suitable for complex shipbuilding processes.

Warehousing and logistics: Used to lift and stack heavy objects in large warehouses and logistics centers to improve operating efficiency. In ports and container terminals, Crane On Rails are used to move containers and have strong adaptability.

Mining: Used to lift heavy equipment, ores and other materials in mines to adapt to harsh working environments.

Power industry: Equipment installation and maintenance in power plants, especially in high-altitude operations. Used to lift and move heavy power generation equipment.

Transportation industry: Used to move heavy goods and improve cargo loading and unloading efficiency.

 

 

1. Design stage: Understand the specific needs of customers, including load-bearing capacity, span, height and use environment. Carry out preliminary design according to the needs and draw scheme drawings, including structural design, power system and control system design. Carry out structural strength, stability and dynamic analysis to ensure that the design meets relevant standards and specifications.

2. Material preparation: Select suitable materials according to design requirements, such as high-strength steel, aluminum alloy, etc., to ensure good mechanical properties and durability. Purchase the required raw materials and components according to the design drawings, including motors, reducers, hooks, control systems, etc.

3. Processing and manufacturing: Cut the steel and process the main beam, end beam and other structural parts according to the design dimensions. Connect the cut parts by welding to form the main structural frame of the crane. Finish the welded components, including drilling, turning and milling, to ensure the matching accuracy of each component.

4. Assembly: Preliminary assembly of the processed components to check the stability and matching of the structure. Install the lifting mechanism, trolley running mechanism and trolley running mechanism to ensure that all moving parts can run smoothly.

5. Electrical system installation: Install motors, inverters, control panels and other electrical components to ensure that the electrical system is connected correctly. Arrange the cable lines reasonably to ensure safety and beauty, and reduce interference and wear.

6. Commissioning and testing: Test the various functions of the crane, including lifting, moving, braking and alarm systems, to ensure that all functions are normal. Carry out safe load tests to ensure that the crane operates stably under maximum load and meets safety standards.

7. Inspection and quality control: Carry out quality inspections on each link of production to ensure that all components meet design and standard requirements. Carry out qualification certification according to relevant regulations to ensure that the equipment meets national and industry standards.

8. Delivery and installation: Transport the manufactured crane to the customer site. Install it at the customer site, including fixing the foundation, commissioning and connecting the power supply. Provide operation training to customers to ensure that they can use the equipment safely and effectively, and officially deliver it for use.

 

 

 

 

 

 

Material Inspection

Quality Inspection: Strict quality inspection is carried out on the purchased raw materials to ensure that they meet the design requirements and national standards.

Material Storage: Qualified materials are stored according to classification to prevent corrosion or damage.

Cutting and Forming

Steel Cutting: Use plasma cutting, laser cutting or flame cutting and other technologies to cut the steel according to the size of the design drawing.

Forming Processing: Form the steel plate through bending, rolling, welding and other processes to manufacture the main beam, end beam and other structural parts.

Welding

Component Welding: The cut and formed steel parts are welded into the main structures such as the main beam, end beam and trolley. The welding process needs to be strictly controlled to ensure the structural strength and welding quality.

Weld Inspection: Use non-destructive testing technology (such as ultrasonic testing, radiographic testing) to inspect the welds to ensure that there are no cracks or other defects.

Machining

Precision Machining: Precision machining is performed on the key components of the crane, such as wheel sets, bearing seats, pulleys, etc., to ensure their dimensional accuracy and surface quality.

Assembly of the whole machine

General assembly: On the basis of pre-assembly, the overall assembly of the crane is carried out, including the final installation of the main beam, end beam, lifting mechanism, walking mechanism, etc.

Commissioning and testing

Under dynamic conditions, the operating performance of the crane is tested, including the testing of lifting, walking, steering and other functions. The overall size of the assembled bridge crane is checked to ensure that all dimensions meet the design requirements.

Spraying and anti-corrosion treatment

Surface treatment Rust removal: Rust removal on the surface of the crane, common methods include sandblasting, pickling, etc. Primer spraying: Spray anti-corrosion primer on the treated surface to prevent metal oxidation and corrosion. Topcoat spraying Color spraying: Spray topcoat according to customer requirements or industry standards to give the crane a protective and decorative effect. Marking: After spraying, mark the crane's identification information in accordance with the specifications, such as model, rated load, etc.

Factory and installation

Packaging and transportation

Packaging protection: Protectively package the key components of the crane to prevent damage during transportation. Transportation arrangement: According to the equipment size and transportation conditions, select a suitable transportation method to transport the crane to the customer's site.

Acceptance and delivery

Customer acceptance

On-site acceptance: The customer conducts on-site acceptance of the crane according to the contract requirements and technical specifications to check the performance and quality of the equipment.

Problem rectification: If any problems are found, the manufacturer needs to rectify them in time to ensure that the equipment fully meets the customer's requirements. Delivery and use Operation training: The manufacturer usually trains the customer's operators to ensure that they can operate the crane correctly and safely.

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