European Single Girder Overhead Crane With Electric Hoist

 

A European Single Girder Overhead Crane with Electric Hoist consists of several key components designed for efficient and safe material handling. Below is a detailed breakdown of its main parts:

 

1. Main Bridge (Single Girder)

The primary horizontal beam that spans the work area.

Typically made of rolled steel (I-beam or box girder) for strength and rigidity.

Designed according to FEM 1.001, DIN, or EN 13001 standards.

2. End Carriages (End Trucks)

Support the bridge girder and enable crane movement along the runway.

Types:

Top-running (runs on rails mounted on runway beams).

Under-running (suspended from the bottom flange of runway beams).

Equipped with wheels (double or four-wheel configuration) and buffers to absorb shocks.

3. Electric Hoist

The lifting mechanism attached to the girder.

Types:

Chain Hoist (e.g., Demag DC-chain, ABUS EHB) – Compact, ideal for light-duty lifting.

Wire Rope Hoist (e.g., Demag DMR, Verlinde Eurochain) – Higher lifting capacity, smoother operation.

Features:

Lifting Motor – Powers hoisting motion.

Brake System – Ensures safe load holding.

Hook Block – For attaching loads.

Limit Switches – Prevents over-hoisting/lowering.

4. Crab Unit (Trolley)

The assembly that carries the hoist along the girder.

Includes:

Trolley frame with wheels.

Travel motor & gearbox for cross-travel movement.

Guides or rollers to prevent skewing.

5. Runway System

The track on which the crane travels.

Components:

Runway beams (steel I-beams or box sections).

Rail (usually square or round bar) for smooth movement.

Support brackets & connections to the building structure.

6. Electrical System

Control Panel – Houses contactors, relays, and overload protection.

Power Supply – Festoon system, cable reels, or conductor bars for electricity transmission.

Control Devices:

Pendant control (push-button pendant) – Manual operation.

Radio remote control – Wireless operation.

Frequency inverter (optional) – For smooth speed control.

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7. Safety & Auxiliary Components

Limit Switches – For hoist and crane travel limits.

Anti-Collision System – Prevents crane clashes in multi-crane setups.

Emergency Stop (E-stop) – Instantly cuts power in emergencies.

Load Limiter – Prevents overloading.

Warning Devices – Buzzer or beacon for alerts.

8. Optional Add-Ons

Variable Frequency Drive (VFD) – For smoother acceleration/deceleration.

Crane Weighing System – Displays load weight in real-time.

Explosion-Proof (ATEX) Components – For hazardous environments.

Automatic Lubrication System – Reduces maintenance.

Sketch

 

Main technical

 

Cost-Effective Solution

Lower initial cost compared to double girder cranes due to simpler design and reduced material usage.

Cheaper installation and maintenance.

Space-Saving Design

Compact structure, ideal for facilities with limited headroom.

Under-running versions (if used) maximize vertical lifting space.

Energy Efficiency

Electric hoists consume less power compared to hydraulic or pneumatic systems.

Regenerative braking (in some models) improves energy efficiency.

Smooth & Precise Operation

Electric hoists allow for variable speed control (with optional VFD).

Anti-sway technology (optional) ensures precise load positioning.

Low Maintenance

Fewer moving parts than double girder cranes.

Sealed bearings and corrosion-resistant coatings enhance durability.

High Safety Standards

Complies with FEM, DIN, and EN 13001 safety norms.

Equipped with overload protection, limit switches, and emergency stop.

Modular & Customizable

Can be tailored for different capacities (0.5T to 20T) and spans (up to ~30m).

Options like explosion-proof hoists, remote control, and automation available.

Easy Installation & Relocation

Lightweight structure simplifies installation.

Some models can be disassembled and reinstalled in new locations.

 

1. Manufacturing & Assembly Lines

Handling raw materials, machinery parts, and finished products.

Used in automotive, aerospace, and electronics manufacturing.

2. Warehousing & Logistics

Loading/unloading goods, pallet handling, and stacking.

Ideal for distribution centers and cold storage facilities.

3. Steel & Metal Processing

Moving metal sheets, coils, and structural beams.

Used in foundries, forging, and CNC machining workshops.

4. Paper & Printing Industry

Transporting paper rolls and heavy printing equipment.

Ensures smooth workflow in large-scale printing plants.

5. Automotive & Aerospace

Lifting engines, chassis, and aircraft components.

Used in assembly and maintenance hangars.

6. Construction & Building Material Handling

Moving precast concrete, steel beams, and construction tools.

Useful in prefabrication plants.

7. Power Plants & Heavy Machinery Maintenance

Handling turbines, generators, and heavy mechanical parts.

Used in maintenance and repair operations.

8. Food & Beverage Industry

Hygienic versions available for food processing plants.

Used for handling bulk ingredients and packaging.

9. Chemical & Pharmaceutical Industry

Explosion-proof (ATEX) models for hazardous environments.

Handling barrels, tanks, and chemical containers safely.

10. Mining & Mineral Processing

Used in workshops for equipment maintenance and material transport.

 

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%.