Electric Overhead Traveling Crane

 

Core Components

Main Girder

Single I-beam or box-type steel construction

Typically spans 5-25 meters

Designed for capacities up to 20 tons

End Trucks

Wheeled assemblies at each end

Contain drive motors, gears, and wheels

Allow longitudinal movement along runway

Hoist Unit

Electric wire rope or chain hoist

Mounted on trolley for cross-travel

Includes motor, gearbox, drum, and brake

Trolley Assembly

Carries the hoist along girder

Manual or powered movement

Low-headroom designs available

Runway System

Supporting rails (PFC/CR/I-beam)

Properly aligned and leveled structure

Includes rail clamps and stops

Electrical Components

Power Supply System

Festoon system (most common)

Alternative: Conductor bars or cable reels

3-phase power (380V/415V/480V)

Control System

Pendant control (standard)

Optional radio remote control

Control panel with safety features

Safety Devices

Upper/lower limit switches

Overload protection

Emergency stop button

Warning buzzer/light

Motion Components

Bridge Drive

Dual motors (one per end truck)

Gear reducers (worm or helical)

Forged steel wheels with flanges

Trolley Drive (if powered)

Integrated with hoist package

Typical speed: 10-20 m/min

Hoist Mechanism

Lifting motor with brake

Wire rope/chain and drum

Hook block with safety latch

.

Optional Accessories

Crane scales

Anti-sway system

Variable frequency drives

Remote monitoring

Special hooks/magnets

Key Features

✔ Cost-effective design
✔ Lower headroom requirement
✔ Easier installation
✔ Energy efficient operation
✔ Suitable for light-medium duty

 

Sketch

 

Main technical

 

Superior Lifting Capacity

Handle loads from 1 to 550+ tons

Outperform forklifts and manual hoists in heavy-duty applications

Full Workshop Coverage

Three-dimensional movement (up/down, left/right, forward/backward)

Access entire work area without floor obstructions

Enhanced Safety Features

Built-in overload protection

Emergency stop systems

Fail-safe brakes and limit switches

Reduced manual handling risks

Operational Efficiency

Faster load movement than alternatives

Precise positioning capability

Continuous operation with minimal fatigue

Space Optimization

Utilizes overhead space

Keeps floor area clear for other operations

Low headroom designs available

Cost Effectiveness

Lower long-term costs than mobile cranes

Reduced labor requirements

Minimal maintenance needs

Customization Options

Various control systems (pendant/remote/cabin)

Special attachments (magnets, grabs, etc.)

Explosion-proof or high-temperature versions

 

1. Manufacturing Facilities

Moving raw materials and finished products

Positioning heavy machinery

Assembly line operations

2. Steel & Metal Industries

Handling coils, plates, and ingots

Foundry operations (with heat-resistant models)

Scrap metal processing

3. Warehousing & Logistics

Loading/unloading trucks

High-bay storage operations

Container handling

4. Power Generation

Turbine maintenance

Transformer handling

Fuel rod management (nuclear)

5. Automotive Sector

Stamping press servicing

Engine assembly

Vehicle component handling

6. Construction Materials

Precast concrete handling

Steel beam installation

Building material distribution

7. Paper & Printing

Large paper roll handling

Printing press maintenance

Finished product storage

8. Mining & Bulk Handling

Ore processing

Coal/sand/aggregate movement

Using grab attachments

 

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%.