20t Overhead Bridge Crane For Workshop

 

An overhead bridge crane for a workshop consists of multiple mechanical, electrical, and structural components working together to ensure safe and efficient material handling. Below is a detailed breakdown of its key components:

 

1. Structural Components

A. Bridge Girder (Main Load-Bearing Beam)

Single-Girder: One beam (cost-effective, for light/medium loads).

Double-Girder: Two parallel beams (higher capacity, better stability).

Material: Welded steel (box-type or I-beam construction).

B. End Trucks (End Carriages)

Located at each end of the bridge girder.

Equipped with wheels, motors, and brakes for longitudinal movement.

Runway Rails: Installed on workshop columns or ceiling structure for crane travel.

C. Runway System

Runway Beams: Support the crane's movement (typically I-beams or box girders).

Rail Tracks: Guide the crane wheels (flat-top or grooved rails).

Brackets & Supports: Secure the runway to the building structure.

2. Lifting & Hoisting Components

A. Hoist Unit

Electric Chain Hoist (0.5–10 tons) – Compact, ideal for light loads.

Wire Rope Hoist (5–100+ tons) – Heavy-duty lifting.

Motor: AC/DC or variable frequency drive (VFD) controlled.

Brake: Electromagnetic or hydraulic for safety.

 

B. Trolley Assembly

Moves horizontally along the bridge girder.

Trolley Frame: Supports the hoist.

Trolley Wheels & Drive Motor: Enables cross-travel.

Reducer Gearbox: Controls speed.

C. Hook Block & Lifting Accessories

Hook: Swivels for easy load attachment.

Shackles, Slings, or Grab Attachments (for specialized loads).

3. Drive & Motion Systems

A. Bridge Travel Drive

Travel Motors: Power longitudinal movement along runway rails.

Wheels & Axles: Steel wheels with bearings for smooth motion.

Buffers & Bumpers: Prevent collision at travel limits.

B. Trolley Travel Drive

Trolley Motor: Moves hoist along the girder.

Guide Rollers: Keep trolley aligned.

4. Electrical & Control Systems

A. Power Supply

Festoon System (cable trolley) or Conductor Bars (for power/data transmission).

Main Disconnect Switch: Emergency power cutoff.

B. Control Panel & Operator Interface

Pendant Control Station (push-button pendant for manual operation).

Radio Remote Control (wireless operation).

PLC (Programmable Logic Controller) – For automated cranes.

C. Sensors & Safety Devices

Limit Switches (prevents over-travel).

Overload Protection (cuts power if load exceeds capacity).

Anti-Collision System (for multiple cranes).

Emergency Stop Button (instant shutdown).

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5. Safety & Auxiliary Components

A. Braking Systems

Hoist Brake: Prevents load slipping.

Travel Brakes: Stops crane/trolley movement.

B. Lighting & Alarms

Warning Beacon & Buzzer (audible/visual alerts).

Work Area Lighting (for visibility).

C. Lubrication System

Automatic Greasing (for gears, bearings).

6. Optional Features for Workshops

Explosion-Proof Motors (for hazardous environments).

Variable Frequency Drives (VFDs) – Smooth acceleration/deceleration.

Weighing System (load cell for weight measurement).

Anti-Sway Technology (for precision positioning).

 

Sketch

 

Main technical

 

Key Advantages of Overhead Bridge Cranes in Workshops

✅ Space Optimization

Uses vertical overhead space, freeing up floor area for other operations.

No obstructions like forklift traffic or floor-mounted equipment.

✅ Increased Productivity & Efficiency

Faster load movement than manual lifting or forklifts.

Reduces material handling time in assembly lines and production areas.

Smooth and precise positioning for machining, welding, and assembly.

✅ Enhanced Worker Safety

Eliminates manual lifting, reducing strain injuries.

Reduces accident risks (e.g., forklift collisions, dropped loads).

Overload protection & emergency brakes prevent failures.

✅ Cost-Effective & Low Maintenance

Long lifespan with minimal upkeep (compared to forklifts).

Lower labor costs (fewer workers needed for lifting).

Energy-efficient motors (especially with VFD controls).

✅ Versatility & Customization

Adaptable to different loads (from small parts to heavy machinery).

Multiple control options (pendant, remote, or fully automated).

Can integrate with other workshop equipment (conveyors, CNC machines).

 

🏭 Metal Fabrication & Welding Shops

Moving steel plates, beams, and pipes for cutting/welding.

Handling large fabricated structures with precision.

🚗 Automotive & Machinery Workshops

Lifting engines, transmissions, and chassis during assembly.

Positioning heavy components in machining centers.

⚙️ CNC & Machine Tool Shops

Loading/unloading heavy workpieces into lathes, mills, and presses.

Handling molds and dies in tool & die shops.

📦 Warehousing & Logistics

Moving palletized goods or machinery in storage areas.

Loading/unloading trucks in logistics hubs.

🔧 Maintenance & Repair Facilities

Lifting industrial equipment for servicing.

Handling heavy motors, pumps, and generators.

🏗️ Construction & Heavy Equipment Workshops

Assembling bulldozers, cranes, and excavators.

Moving large structural components.

⚡ Power Plants & Energy Sector

Handling turbines, transformers, and generators.

Maintenance of heavy electrical equipment.

 

1. Design & Engineering
Requirement Analysis: Confirm load capacity, span, lift height, automation level, control mode, and safety features based on customer needs.

Structural Design: Design the single girder main beam, end carriages, trolley, and hoist assembly using CAD software.

Electrical & Control Design: Develop control system schematics including PLC programming, motor selection, VFDs, sensors, alarms, and safety interlocks.

Simulation & Validation: Use FEA (Finite Element Analysis) for structural integrity and dynamic simulation for motion control.

2. Material Procurement
Source high-quality steel (Q345B or equivalent) for main beam and components.

Acquire motors, hoists, VFDs, PLCs, limit switches, and alarm systems from trusted suppliers.

Ensure all components meet relevant certifications and standards (ISO, CE, GB).

3. Main Beam Fabrication
Cutting: Steel plates cut to size using CNC flame/plasma cutting machines.

Forming: Roll or shape plates into the I-beam or box girder profile.

Welding: Perform welding of flanges, web, and stiffeners following welding procedure specifications (WPS).

Heat Treatment: Stress relief if necessary to reduce welding deformation.

Machining: Drill holes for end carriage and trolley mounting; machine crane rails if integrated.

Inspection: Check weld quality (X-ray or ultrasonic), dimensions, and surface finish.

4. End Carriage & Trolley Assembly
Frame Fabrication: Cut and weld end carriage frames and trolley frames.

Wheel Assembly: Mount wheels and fit bearings; assemble drive motor and gearbox.

Installation: Attach wheels to frames and mount brakes and limit switches.

Testing: Static and dynamic tests on wheels and brakes for smooth rotation and load bearing.

5. Hoist Assembly
Assemble wire rope or chain hoist on the trolley.

Install hook block, safety latch, load limiter, and load sensors.

Connect hoist motor, gearbox, brake, and encoders.

Conduct functional tests on hoisting speed, lifting capacity, and braking.

6. Electrical Wiring & Control System
Install motor cables, control cables, and communication lines.

Mount PLC, VFDs, contactors, and safety relays in the control cabinet.

Wire limit switches, alarms, emergency stop, and sensors.

Program PLC with automated control logic, safety interlocks, and diagnostics.

7. Surface Treatment
Cleaning: Remove rust, oil, and debris from all steel parts.

Primer Coating: Apply anti-corrosion primer.

Final Paint: Spray high-durability industrial paint to protect against wear and corrosion.

Curing: Allow proper drying time to ensure finish quality.

8. Pre-Installation Testing
No-Load Tests: Run crane, trolley, and hoist without load to verify movement, speed, and control.

Load Test: Perform rated load test per standards to ensure lifting capacity and structural integrity.

Safety Device Check: Verify operation of overload limiter, limit switches, emergency stop, and alarms.

Automation Validation: Test automated sequences, positioning accuracy, and sensor feedback.

9. Packing & Shipping
Disassemble parts if necessary for transport.

Protect components with rust-proofing, padding, and secure packing.

Prepare documentation including user manuals, maintenance guides, and test certificates.

10. Installation & Commissioning (On-Site)
Reassemble crane components at customer site.

Align crane rails and secure runway structure.

Connect power and control wiring.

Calibrate sensors and test automated control functions.

Train operators and maintenance personnel.

Hand over documentation and certification.
 

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%.