Explosion-proof Single Girder Overhead Crane

Core Components: Gearbox, Motor, Gear

Place of Origin: Henan, China

Warranty: 1 Year

Weight (KG): 10000 kg

Video outgoing-inspection: Provided

Machinery Test Report: Provided

Selling Units: Single item

Single package size: 600X300X300 cm

Single gross weight: 200.000 kg

An Explosion-proof Single Girder Overhead Crane consists of specialized components designed to operate safely in hazardous environments where flammable gases, vapors, or combustible dust may be present. Below is a detailed breakdown of its key components and their explosion-proof features:

1. Main Components of an Explosion-Proof Single Girder Overhead Crane

A. Bridge Girder (Main Beam)

Function: Supports the hoist and trolley, carrying the load along the runway.

Explosion-Proof Consideration: Made of high-strength steel with anti-corrosion treatment to withstand harsh environments.

B. End Trucks (End Carriages)

Function: Houses the wheels and drives the crane along the runway beams.

Explosion-Proof Features:

Wheel bearings & motors are sealed or flameproof.

Brakes are spark-resistant.

C. Hoist Unit (Explosion-Proof)

Types:

Electric Chain Hoist (for lighter loads)

Wire Rope Hoist (for heavier loads)

Explosion-Proof Features:

Motor: Encased in flameproof (Ex d) or increased safety (Ex e) housing.

Electrical components: Sealed to prevent sparks.

Limit switches: Explosion-proof rated.

D. Trolley (Explosion-Proof)

Function: Moves the hoist along the girder.

Explosion-Proof Features:

Trolley frame: Non-sparking materials.

Drive motor & gearbox: Compliant with ATEX/IECEx standards.

E. Runway System

Runway Beams: Support the crane's movement.

Explosion-Proof Considerations:

Conductors (if electrified): Enclosed or insulated to prevent arcing.

F. Electrical System (Critical for Explosion Safety)

Explosion-Proof Control Panel:

Housed in a flameproof (Ex d) or pressurized (Ex p) enclosure.

Pendant Control (or Radio Remote):

Explosion-proof pendant: Sealed buttons with no spark generation.

Wireless remote (optional): Intrinsically safe (Ex ia/ib).

Cable & Wiring:

Heavy-duty, abrasion-resistant with explosion-proof glands.

G. Safety Devices (Explosion-Proof Rated)

Limit Switches (Upper/Lower): Prevent over-travel (Ex-rated).

Overload Protector: Spark-proof mechanism.

Emergency Stop: Explosion-proof push-button.

.

2. Explosion-Proof Standards & Certifications

These cranes comply with international hazardous area classifications:

ATEX (EU): Zones 1, 2 (gases); Zones 21, 22 (dust).

IECEx (Global): Ex d, Ex e, Ex ia/ib ratings.

NEC/CEC (North America): Class I, II, III; Division 1 or 2.

4. Why These Components Matter

Prevent Ignition: Every electrical/mechanical part is designed to eliminate sparks or excessive heat.

Durability: Resistant to corrosion, dust, and chemical exposure.

Regulatory Compliance: Ensures legal operation in hazardous zones.

Sketch

Main technical

Advantages of Explosion-Proof Single Girder Overhead Cranes

Enhanced Safety in Hazardous Areas

Prevents sparks, arcs, and overheating that could ignite flammable gases, vapors, or dust.

Complies with ATEX, IECEx, NEC, and other explosion-proof standards.

Cost-Effective Solution

More affordable than double-girder cranes while still offering high load capacity (typically 1–20 tons).

Lower installation and maintenance costs due to simpler design.

Durable & Corrosion-Resistant

Built with high-grade steel and protective coatings to withstand harsh environments (e.g., chemical exposure, moisture).

Flexible & Customizable

Available with explosion-proof electric chain hoists or wire rope hoists.

Adjustable span, lifting height, and speed to fit different workspaces.

Low Maintenance & Reliable

Sealed motors and electrical components reduce wear and tear.

Explosion-proof limit switches and brakes enhance longevity.

Easy Installation & Operation

Lighter than double-girder cranes, requiring less structural support.

Options for explosion-proof pendant control or wireless remote.

Applications of Explosion-Proof Single Girder Overhead Cranes

These cranes are essential in industries where flammable substances are present:

1. Oil & Gas Industry

Refineries, petrochemical plants, offshore platforms

Handling pipelines, valves, and drilling equipment in Zone 1/Zone 2 (ATEX) or Class I Div 1/Div 2 (NEC) areas.

2. Chemical & Pharmaceutical Manufacturing

Transporting flammable solvents, powders, and reactive chemicals.

Used in mixing, packaging, and storage areas with explosive atmospheres.

3. Grain & Food Processing

Flour mills, sugar plants, grain silos (combustible dust – Zone 21/22).

Prevents dust explosions during material handling.

4. Mining & Explosives Manufacturing

Safe lifting in coal mines, gunpowder factories, and munitions storage.

Spark-resistant components prevent detonation.

5. Aerospace & Automotive (Paint Booths)

Handling fuel tanks, batteries, and flammable paints/sprays in confined spaces.

6. Waste Treatment & Recycling

Operating in biogas plants where methane and other explosive gases may accumulate.

1. Design and Engineering
Initial Consultation: The process begins with discussions between the manufacturer and the customer to understand the crane's operational requirements, such as load capacity, span, lifting height, and environment (e.g., indoor or outdoor use, temperature conditions, etc.).

Engineering & Customization: The design team customizes the crane, including the structure, lifting system, and radio remote control features. Detailed engineering drawings and specifications are prepared, ensuring the crane meets all required standards and safety codes.

Control System Design: The radio remote control system is integrated into the design, with attention to ease of use, range, safety features (emergency stop, overload protection), and compatibility with the crane's other systems.

2. Material Selection and Procurement
Structural Materials: High-quality materials like steel are sourced for the crane's main beam, girder, end carriages, and other structural components. These materials are selected for their strength, durability, and ability to withstand heavy loads.

Mechanical Components: The components for the hoisting system, trolley, crane wheel, motors, gearboxes, and radio remote control system are procured from reliable suppliers.

Electrical Components: Wiring, electrical panels, switches, safety devices, and other electrical components for the crane's control system are also sourced.

3. Fabrication and Manufacturing
Main Beam Construction: The steel is cut, welded, and assembled to form the main girder (single beam) of the crane. This process often involves precision cutting, bending, and welding to meet specific design tolerances.

End Carriage Fabrication: The end carriages, which support the crane's travel mechanism, are fabricated and assembled. These components are designed for stability and strength, ensuring smooth crane movement along the tracks.

Assembly of Lifting Mechanism: The hoist, hook, and lifting mechanism are assembled, with motors, gears, and pulleys integrated into the system. The lifting system is tested for load-bearing capacity and smooth operation.

Trolley and Crane Traveling Mechanisms: The trolley and crane traveling mechanisms are built and assembled. This includes the wheels, motor, and rail system, ensuring smooth movement of the crane along the rails.

Radio Remote Control Installation: The radio remote control system is installed. This includes fitting the necessary receivers, antennas, and integrating the control system with the crane's electrical and mechanical systems.

4. Electrical and Control System Integration
Wiring and Electrical Systems: The electrical wiring is installed, connecting the hoisting system, control panel, motors, and radio remote control system. The wiring is tested for safety and compliance with electrical codes.

Control Panel Assembly: The crane's control panel is assembled and integrated with the radio remote control system. It is tested for responsiveness and safety features, including emergency stop and overload protection.

Safety Features: Safety devices such as limit switches, overload sensors, and sound and light alarms are installed and integrated into the control system. These systems ensure safe crane operation and prevent damage.

5. Testing and Quality Control
Load Testing: The crane is subjected to a load test to ensure it can handle the specified weight capacity. The test is done using calibrated weights to verify the crane's performance under operational conditions.

Operational Testing: The crane undergoes a full operational test, where it is run through its motions (lifting, lowering, traveling, etc.) using the radio remote control. The crane's response to commands, including emergency stop and safety alarms, is closely monitored.

Electrical & Mechanical Testing: All electrical systems, including the radio remote control, are tested for functionality and safety. The motors, brakes, and electrical wiring are inspected for proper operation.

Inspection for Compliance: The crane is inspected for compliance with local and international standards (such as ISO, CE, or OSHA) to ensure it meets safety regulations. The structure, load-bearing components, and safety systems are thoroughly checked.

6. Final Assembly
Final Assembly and Inspection: After testing, the crane is fully assembled, with all components securely attached and double-checked for accuracy. The radio remote control is configured, and the system is tested one last time to ensure seamless integration.

Painting & Finishing: The crane is painted with protective coatings to prevent corrosion and improve its appearance. The final finishing touches are added to the structure, including any labeling or safety markings.

Documentation: All necessary documentation, including manuals, certificates of compliance, test reports, and warranty information, are prepared for the customer.
 

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%.