Monorail Overhead Crane Systems

 

 

Monorail Overhead Crane Systems is a kind of lifting equipment that is horizontally mounted above workshops, warehouses and material yards. It is named because its two ends are located on tall concrete columns or metal brackets and its shape resembles a bridge. This type of crane uses the tracks laid on the elevated platforms on both sides to run longitudinally, and can make full use of the space under the bridge to lift materials without being hindered by ground equipment.

The technical parameters of Monorail Overhead Crane Systems include lifting capacity, span, working level, etc. For example, the safe working load of EXCELLIFT Monorail Overhead Crane Systems can reach up to 40,000 kg, and the lifting tonnage ranges from 125 kg to 40 tons. The maximum lifting capacity of LD type electric single-beam crane can reach 10 tons, the span is 7.5-25 meters, and the working level is A4-A6.

Monorail Overhead Crane Systems are easy to install and maintain, with superior performance, compact structure and light weight. Automatic welding and non-destructive testing are used to ensure product quality. Equipped with international brand drive system and variable frequency speed regulation function, it runs fast and smoothly.

4. Monorail Overhead Crane Systems are suitable for a variety of industrial scenarios such as petrochemicals, oil and gas, automobiles, electricity, nuclear power/energy, metallurgy, machinery manufacturing, papermaking, shipyards, marine engineering, garbage disposal, mining, etc. It is also an important tool and equipment for realizing the mechanization and automation of the production process in modern industrial production and lifting and transportation. When using a Monorail Overhead Crane Systems, a series of safety operating procedures must be followed, such as hanging a sign with the rated lifting capacity, prohibiting people on the bridge or transporting people with a hook, prohibiting driving a crane without an operating license or under the influence of alcohol, etc. In addition, it is necessary to conduct safety and technical inspections regularly and do a good job of pre-inspection and pre-repair work.

Warranty of core components：1 Year

Core Components：：Bearing, Motor, Gear

Warranty：1 Year

Weight (KG)：2000 kg

Feature：Bridge Crane

Condition：New

Crane type：Single Girder bridge crane

Max. Lifting Height：20M Or Customized

Electric Motor Voltage：AC380V or customized

Application：Factory, workshop, warehouse, power stain, logistic

Color：Customer's Requirements

Control method;Wireless Control/Pendent Control/Cabin

Span：10~35m or customized

Lifting Mechanism：Wire rope electric hoist or chain electric hoist

 

 

1.Main beam

1. The main beam is usually composed of an upper cover plate, a lower cover plate, vertical webs on both sides and internal ribs. This structural design enables the main beam to withstand loads from different directions while maintaining sufficient rigidity and stability.

2. The connection method between the main beam and the end beam has an important impact on the performance of the crane. Although the traditional welding connection is highly reliable, it cannot be disassembled once completed, which is not conducive to transportation and storage. Therefore, bolt connections are often used in modern designs, which are divided into three forms: lap joints, semi-lap joints and flat joints. The new combined pin device effectively avoids the "three-legged" phenomenon caused by manufacturing, installation errors or overloaded operation through flexible hinges, and improves the stability and safety of the crane.

3. In the design of the main beam, its load-bearing capacity, rigidity and stability need to be fully considered. This usually involves the selection of cross-sectional shapes (such as box beams, I-beams, etc.), the setting of stiffeners, and the selection of materials. At the same time, safety protection measures are also indispensable, including limit switches, safety protection doors and alarm devices, etc., to ensure the safety of operators and equipment.

Lifting System

1. Driving device: The driving device usually adopts an electric motor, which is connected to the high-speed shaft of the reducer through a coupling to provide the power required by the lifting mechanism. The motor can realize forward and reverse rotation, high and low speed rotation, and large and small torque rotation according to the change of power supply control.

2. Transmission device: The transmission device includes a reducer, a coupling and a transmission shaft. The low-speed shaft of the reducer drives the drum to rotate to realize the lifting and lowering movement of the goods.

3. Winding system: The winding system consists of a drum, a wire rope and a pulley block. The wire rope is wound on the drum, one end of which is connected to the hook, and the lifting and lowering of the goods is realized by the rotation of the drum.

4. Picking device: The picking device adopts different picking devices according to the type and form of the material to be lifted, such as hooks, grabs, etc., which are used to directly grab or lift the goods.

5. Brake and safety device: The brake is both a control device for the operation of the mechanism and a safety device, and is the focus of safety inspection. In addition, it is also equipped with safety devices such as overload limiter and rising limit position limiter to ensure safe operation.

 

 

3.End carriage

1. Structure and function of the end beam: The end beam is usually welded from steel plates, and has reinforcing ribs inside to increase strength and stability. The design of the end beam must take into account the connection method with the main beam to ensure the stability and reliability of the overall structure. The main function of the end beam is to support the main beam and transfer the load to the outriggers through the connection with the main beam, and finally to the foundation. The end beam also plays the role of maintaining the overall stability of the crane to prevent rollover or tilting due to uneven load or external factors.

2. Design and manufacture of the end beam: When designing the end beam, its bearing capacity, stiffness and stability need to be fully considered. This involves the selection of materials, the design of the cross-sectional shape, and the arrangement of the reinforcing ribs. At the same time, it is also necessary to consider the coordination with other components and the convenience of installation. The manufacture of the end beam usually adopts welding technology, and through precise cutting and assembly, the accuracy of the dimensions of each part and the quality of the weld are ensured. Strict quality inspection is also required during the manufacturing process to ensure that the end beam meets the design requirements and relevant standards.

 

4.Crane travelling mechanism

1. The driving mode of the crane running mechanism is divided into centralized driving and separate driving. Centralized driving is a driving mode in which a motor drives the wheels on both sides through a transmission shaft, while separate driving is a mode in which two identical motors (specifications) drive the wheels of the crane through couplings and reducers respectively.

2. The crane running mechanism must be equipped with brakes so that the crane can be safely stopped within the allowable braking range after the crane is powered off, and the brakes need to be checked and adjusted regularly to ensure their coordination and prevent the crane from twisting and biting the road during braking. At the same time, it is also necessary to install terminal limiters, and correspondingly install limiter safety touch scales at the two ends of the crane travel to ensure that the crane is running

3. The crane running mechanism consists of a motor, a controller, a coupling shaft, a transmission shaft, a reducer, an angular bearing box and crane wheels. The crane running mechanism runs on the crane beam and is responsible for the movement of the single-beam crane in the entire space of the workshop. When operating the remote control, the hook is lowered to the appropriate position, the weight is tied and hung, and then it continues to rise to the appropriate height. Then the crane is operated to run to the target location, the crane is operated to move the weight accurately to the air above the target location, and then the electric hoist is operated to place the weight accurately at the target location to complete the work.

 

5.Trolley travelling mechanism

1. The trolley running mechanism is mainly composed of three parts: the trolley frame, the lifting mechanism and the trolley moving mechanism. The trolley frame is a frame that supports and installs components such as the lifting mechanism and the trolley running mechanism, and is usually a welded structure. The lifting mechanism includes a motor, a brake, a reducer, a drum and a pulley block, which are responsible for the vertical lifting and lowering of heavy objects.

2. The driving mode of the trolley running mechanism is divided into two types: centralized drive and separate drive. Centralized drive is a driving mode in which a motor drives the wheels on both sides through a transmission shaft. Separate drive is a mode in which two identical motors (specifications) drive the wheels of the trolley through couplings and reducers respectively.

3. The trolley running mechanism runs on the bridge frame and is responsible for the movement of the entire lifting trolley in the width direction of the workshop. When operating the remote control, the hook is lowered to the appropriate position, the weight is tied and hung, and then it continues to rise to the appropriate height, and then the trolley is operated to run to the target location, and the electric hoist is operated to accurately place the weight at the target location to complete the work.

 

6.Crane wheel

1. The wheel group is composed of a wheel, an axle, a bearing and an axle end cap, and is usually machined with 45# steel. The operating mechanism of a Monorail Overhead Crane Systems is driven by the friction between the active wheel and the wheel track, which is also called adhesion or cohesion.

2. The wheel group runs on the running track of the crane, transmitting the load acting on the crane to the foundation supporting it. The distance between the centers of the trolley tracks is called the span S, and the action of running on this track is called trolley operation.

3. In order to ensure that there are large enough driving wheels (active wheels), the driving wheels should be properly arranged, and in any case, they should have a large enough wheel pressure. The driving wheels of the operating mechanism on the bridge crane are usually half of the total number of wheels, and are arranged symmetrically in four corners, so that the sum of the driving wheel pressures remains unchanged, slipping will not occur, and the mechanism can operate normally.

7.Crane Hook

1. The hook body is the part that directly contacts the heavy object and is usually made of high-strength steel to ensure its load-bearing capacity and durability. The pulley block is installed above the hook and connected to the drum through a wire rope to help achieve the vertical movement of the heavy object. Safety devices include locking devices, limit switches, etc., which are used to ensure the safety of the hook during operation.

2. When the operator starts the lifting mechanism, the motor drives the drum to rotate, and the wire rope drives the hook up or down through the pulley block, thereby realizing the vertical handling of the heavy object. The trolley moves laterally along the bridge track, and cooperates with the longitudinal operation of the trolley, so that the hook can move flexibly in three-dimensional space to complete the lifting task under complex working conditions.

3. The hook is usually made of high-quality alloy steel, with high strength and toughness, and can withstand large loads. Its design must meet a certain safety factor, usually 1.5 to 2 times the rated lifting weight, to ensure that it will not break or deform under extreme conditions. The hook needs to be regularly subjected to non-destructive testing and load testing to ensure its safety and reliability during use.

Motor

1. The motor body is usually composed of a stator and a rotor. The stator generates a magnetic field, and the rotor rotates in the magnetic field to generate torque. In order to ensure that the motor does not overheat during long-term operation, it is usually equipped with an air-cooled or water-cooled cooling system.

2. The motor works based on the principle of electromagnetic induction. When the current passes through the coil of the stator, a rotating magnetic field is generated. This magnetic field interacts with the conductor in the rotor to generate electromotive force and current, which in turn causes the rotor to rotate. The motor converts electrical energy into mechanical energy and transmits power to the operating mechanism of the crane through a transmission device (such as a reducer, coupling, etc.) to achieve the lifting, lowering and lateral movement of heavy objects.

3. The power of the motor must match the lifting weight and operating speed of the crane to ensure that the crane can operate smoothly and efficiently. In order to protect the motor from overload damage, it is usually equipped with an overload protection device such as a thermal relay or an electronic overload protector. The insulation level of the motor should meet relevant standards to prevent electrical failures and safety hazards.

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Sound and light alarm system & limit switch

1. Sound and light alarm system: The sound and light alarm system usually consists of sensors, controllers, sound and light alarms, and power supplies. When the operating state of the crane exceeds the preset safety range (such as overload, overspeed, etc.), the sensor will detect abnormal signals and transmit them to the controller, which will then trigger the sound and light alarm to issue a sound and light alarm to remind the operator to take corresponding measures. The sound and light alarm system should have the characteristics of high sensitivity, good stability, and strong anti-interference ability to ensure accurate and reliable operation in various working environments.

2. Limit switch: The limit switch is mainly composed of contacts, springs, and housings, and is usually installed on the running track or key components of the crane. When the crane runs to the preset limit position, the limit switch will be triggered, cutting off the corresponding power source and stopping the movement of the crane to prevent accidents caused by the crane exceeding the safety range. The limit switch should have the characteristics of reliable action, quick response, and long service life to ensure that the power source can be accurately cut off at critical moments.

10.Safety Devices

1. Limit switch: The limit switch is used to limit the operating range of the crane to prevent it from exceeding the safety limit. When the crane reaches the preset limit position, the limit switch will trigger and cut off the power supply to stop the movement of the crane.

2. Overload protector: The overload protector is used to prevent the crane from overloading. When the weight hoisted by the crane exceeds the rated lifting weight, the overload protector will automatically cut off the power supply to prevent the crane from overloading. The overload protector usually determines whether it is overloaded by detecting the tension of the wire rope or hook.

3. Buffer: The buffer is used to absorb the impact force generated by the crane during operation and reduce damage to the crane structure and cargo.

4. Anti-collision device: The anti-collision device is used to prevent the crane from colliding with other objects during operation. When the distance between the crane and other objects is too close, the anti-collision device will sound an alarm and take corresponding measures, such as slowing down or stopping operation. Common anti-collision devices include infrared anti-collision devices and laser anti-collision devices.

5. Other safety devices

Emergency stop button: Used to quickly cut off the power supply and stop all movements of the crane in an emergency.

Safety lock: used to lock certain parts of the crane to prevent accidental operation during non-working hours.

Sound and light alarm system: sounds and lights alarms when abnormal conditions occur in the crane to alert the operator.

11.Control Mode

1. Ground control: The operator directly operates the crane through the controller on the ground. This control method is suitable for small or simple cranes, and the operator can directly observe and command the movement of the crane. The ground control method is simple and intuitive, which is convenient for the operator to observe and command. At the same time, since the operator is close to the crane, he can respond to emergencies quickly.

2. Control room control: The operator sits in the control room and remotely controls the crane through a joystick or button. The control room is usually equipped with various safety devices and instruments to monitor the operating status of the crane in real time. The control room control method can provide a better field of view and comfort, and reduce the fatigue of the operator. At the same time, the control room is usually equipped with various safety devices and instruments to monitor the operating status of the crane in real time and improve safety.

3. Remote control: The operator remotely controls the crane through a remote control. The remote control is usually equipped with a wireless communication module to achieve long-distance control and signal transmission. The remote control method has greater flexibility and convenience, and the operator can operate far away from the crane, reducing safety hazards. At the same time, the remote control method can also achieve multi-person collaborative work and improve work efficiency.

Sketch

Main technical

 

 

1. Simple structure

The structure of the Monorail Overhead Crane Systems is relatively simple, mainly consisting of three parts: mechanical, electrical and metal structure. This simple structure makes the crane relatively easy to manufacture, install and maintain.

2. Low cost

Compared with other types of cranes, the manufacturing cost and use cost of the Monorail Overhead Crane Systems are relatively low. This makes it the preferred lifting equipment for many small and medium-sized enterprises and factories.

3. Strong adaptability

Monorail Overhead Crane Systems are suitable for cargo lifting in various occasions, especially in places where space is limited or frequent movement is required. For example, in workshops, warehouses, docks and other places, Monorail Overhead Crane Systems can play their advantages. In addition, Monorail Overhead Crane Systems can also be customized and modified according to different needs to adapt to different working environments and tasks.

4. Easy to operate

The operation of the Monorail Overhead Crane Systems is relatively simple and intuitive, and the operator can operate the crane through ground control, control room control or remote control. This convenient operation method reduces the difficulty of training and work intensity of the operator.

5. Easy maintenance

Since the Monorail Overhead Crane Systems has a simple structure and fewer components, its maintenance and maintenance are also relatively simple. Operators can regularly inspect and lubricate the crane to promptly detect and deal with potential problems.

6. Safe and reliable

Monorail Overhead Crane Systems are equipped with a variety of safety devices, such as limit switches, overload protectors, buffers and anti-collision devices, which can effectively prevent accidents and ensure the safety of operators.

 

 

1. Industrial production

In industrial production, Monorail Overhead Crane Systems are often used for material handling and loading and unloading work inside workshops. It can quickly and accurately lift, move and place various raw materials, semi-finished products and finished products to improve production efficiency.

2. Warehousing and logistics

In the field of warehousing and logistics, Monorail Overhead Crane Systems are one of the important logistics equipment. It can help warehouse managers quickly complete the warehousing, outbound and inventory of goods, and improve warehousing efficiency.

3. Construction

In construction,Monorail Overhead Crane Systems are mainly used for vertical transportation and horizontal movement of building materials (such as steel, concrete, bricks, etc.). It can lift building materials from the ground or low to high, or transfer them between different construction areas, reduce the labor intensity of workers and improve construction efficiency.

4. Port terminal

In port terminals, Monorail Overhead Crane Systems are one of the common lifting equipment. It is mainly used for loading and unloading and transshipment of containers, and can quickly and safely lift containers from ships to shore, or from shore to ships.

5. Other fields

In addition to the fields mentioned above, single-girder bridge cranes can also be used for equipment installation, maintenance and overhaul in industries such as electricity, railways, and chemicals. In these fields, single-girder bridge cranes have been widely used for their simple structure, convenient operation, and strong adaptability.

 

 

1. Design stage

During the design stage, engineers will carry out detailed design and calculation according to customer needs and actual application scenarios. This includes determining the size, load capacity, span, lifting height and other key parameters of the crane. The stability, safety and reliability of the crane need to be considered during the design process to ensure that it can meet the requirements of relevant standards and specifications.

2. Material preparation

According to the design drawings and specification requirements, purchase the required raw materials and parts. Inspect and screen the purchased materials to ensure that their quality meets the requirements. At the same time, pre-process the parts that need to be processed, such as cutting, welding, grinding, etc.

3. Manufacturing stage

During the manufacturing stage, workers process and assemble parts according to the design drawings and process requirements. This includes cutting steel, welding structural parts, processing transmission parts, etc. Heat treatment or surface treatment of key parts to improve their wear resistance and corrosion resistance.

4. Assembly stage

Assemble the manufactured parts to form a complete crane structure. During the assembly process, attention should be paid to the connection and fixing methods between the various components to ensure the stability and reliability of the entire structure. Perform preliminary inspection and adjustment on the assembled crane to ensure the flexibility and accuracy of its moving parts. At the same time, install necessary safety devices and instruments, such as limit switches, overload protectors, buffers, etc.

5. Commissioning stage

During the commissioning stage, the crane is subjected to comprehensive performance testing and safety inspection. This includes no-load test, load test, stability test and other items. According to the test results, the crane is adjusted and optimized to ensure that its various performance indicators meet the design requirements. At the same time, the operators are trained and guided to ensure that they can use and maintain the crane correctly.

6. Pre-factory inspection

Before leaving the factory, the crane is subjected to final quality inspection and acceptance. This includes appearance inspection, dimensional measurement, functional testing and other aspects. After ensuring that the crane meets the relevant standards and customer requirements, it is packaged and shipped. At the same time, necessary technical information and instruction manuals are provided to facilitate customers to understand and use the crane.

 

 

 

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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