FEM Standard 5Ton Single Girder Overhead Crane

Core Components: Gearbox, Motor, Gear

Place of Origin: Henan, China

Warranty: 1 Year

Weight (KG): 5ton 

Video outgoing-inspection: Provided

Machinery Test Report: Provided

Selling Units: Single item

Single package size: 600X300X300 cm

Single gross weight: 200.000 kg

Main Components of a 5-Ton Single Girder Overhead Crane

The system can be broken down into four major subsystems:

1. Bridge Structure

This is the main traveling structure that spans the width of the bay.

Main Girder (Single Beam): The primary horizontal beam that spans the work area. For a 5-ton capacity, this is typically a rolled steel I-beam or, more commonly for better performance, a welded box girder (which offers superior stiffness and resistance to buckling).

End Trucks: The rigid steel structures located at each end of the main girder. They house the wheels, bearings, and drive mechanisms for moving the entire crane.

Crane Buffers / Bumpers: Rubber or polyurethane pads mounted on the end trucks to absorb impact when the crane reaches the end of its runway.

Hoist Motor: The electric motor that provides the power for lifting and lowering.

Wire Rope Drum: The cylindrical drum around which the wire rope is wound.

Wire Rope: The high-strength, flexible cable that does the lifting.

 

Hook Block: The assembly that includes the load hook, sheaves (pulleys), and hook latch.

Brake: An automatic, fail-safe brake that holds the load when the hoist motor is not engaged.

Trolley Frame: The frame that carries the hoist and runs on wheels along the bottom flange of the main girder.

Trolley Drive Motor: A smaller electric motor that powers the movement of the trolley back and forth along the girder.

3. End Carriage Drive System

This system provides the long-travel motion for the entire crane to move along the runway.

Drive Wheels: Typically, one end truck will have motor-driven wheels. For a 5-ton crane, this is often a single-end drive system (driving one side only).

Travel Motor(s): The electric motor(s) that power the drive wheels.

Idler Wheels: The wheels on the opposite end truck that are not powered but simply follow the driven end.

Gearboxes: Reduce the high speed of the electric motor to the low speed, high torque required to move the crane.

 

4. Runway System

This is the fixed, stationary structure on which the crane travels. It is often part of the building structure but is a critical component of the overall crane system.

Runway Beams: Typically wide-flange I-beams that are securely mounted to the building columns or support structure. The crane's end truck wheels run on the top flange of these beams.

Runway Rails: Sometimes, a flat steel rail is welded or bolted to the top of the runway beam to provide a hard, durable running surface and reduce wheel wear.

Crane Stops: Physical barriers at the ends of the runway beams to prevent the crane from running off the track.

Collector System / Festoon System: The means of delivering electrical power to the crane.

Conductor Bars: Insulated rigid bars mounted along the length of the runway.

Collector Shoes: Spring-loaded shoes on the crane that slide along the conductor bars to pick up power.

Festoon: An alternative system using a flexible cable carried on a trolley that rolls with the crane.

.

5. Electrical Control System

The "nervous system" of the crane, allowing the operator to control all functions.

Control Pendant / Radio Remote Control:

Pendant Station: A hanging control unit with buttons for Up/Down, Hoist Traverse (Left/Right), and Crane Travel (Forward/Backward). It is connected to the crane by a flexible cable.

Radio Remote Control: A wireless transmitter that allows the operator to control the crane from a distance without a physical tether, offering greater mobility and safety.

Main Disconnect Switch: A safety switch located on the bridge to completely cut off power for maintenance.

Control Panel / Panel Box: Contains the contactors, overload relays, variable frequency drives (VFDs - for smooth control), and other electrical components.

Limit Switches:

Hoist Upper Limit Switch: A critical safety device that automatically cuts power to the hoist motor to prevent the hook block from over-traveling and damaging the hoist.

End Limit Switches: Automatically stop the crane and trolley at the extremes of their travel to prevent collisions with the end stops.

Summary: How FEM Standards Dictate Component Selection

Component	Influence of FEM Classification
Girder	Sized for dynamic loads & deflection limits of a specific Duty Group.
Hoist Motor & Gearbox	Selected for thermal capacity & cycle life matching the Duty Group and Load Spectrum.
Brakes & Electrics	Chosen for a minimum number of reliable cycles (e.g., millions of operations for FEM 3m).
Wheels & Bearings	Rated for the calculated wheel load and total travel distance over the crane's life.

Sketch

 

Main technical

 

Key Advantages of a FEM 5-Ton Single Girder Overhead Crane

1. Cost-Effectiveness (Lower Initial Investment)

This is the most significant advantage.

Simplified Structure: With only one main girder, the design uses less steel and has fewer components (e.g., no need for a second girder, complex end truck connections for two girders). This directly translates to a lower purchase price.

Reduced Installation Costs: The crane is lighter and easier to assemble, which can reduce the time and labor costs for installation.

2. Lightweight and Space-Efficient Design

Lower Headroom Requirement: The hoist is typically mounted directly under the girder (top-running), requiring less vertical space (headroom) than a double girder crane. This is a critical advantage in buildings with low ceiling heights.

Reduced Wheel Load: Because the entire crane is lighter, the load transferred to the building's support structure (runway beams or columns) is lower. This can lead to savings in the cost of reinforcing existing structures or in the design of new buildings.

3. Ideal for Light to Moderate Duty Cycles

A FEM-standard crane is classified (e.g., FEM 1Am, 2m) to match its intended use. For a 5-ton single girder, this typically covers:

Intermittent Use: Perfect for workshops that don't require continuous, 24/7 operation.

Standardized Workflows: Excellent for repetitive tasks like loading/unloading machines, moving materials in a warehouse, or positioning components on an assembly line.

4. Simplicity and Reliability

Easier Maintenance: The simpler mechanical and structural design means there are fewer parts to maintain and inspect.

Reduced Downtime: Simplicity often leads to higher reliability and easier troubleshooting.

5. Flexibility and Customization

Despite being a standard design, these cranes are highly adaptable:

Span Flexibility: They can be manufactured to fit a wide range of building spans.

Hoist Options: Can be paired with various 5-ton electric hoists (wire rope or chain) to suit specific needs (e.g., speed, precision, control type).

Control Options: Available with pendant (push-button) control, radio remote control, or cabin operation.

6. Compliance and Safety

Built to a Recognized Standard: "FEM Standard" is a mark of quality. It ensures the crane is designed with proper safety factors, calculated for deflection, and built to perform reliably under its specified duty class.

Integrated Safety Features: Comes with standard safety devices like overload limiters, end limiters for travel and hoisting, and emergency stop functions.

 

Key Application Areas

This type of crane is a workhorse in industries where efficient, reliable, and safe movement of materials up to 5 tons is required.

1. Manufacturing & Assembly Plants

Automotive: Moving engine blocks, transmissions, body panels, and sub-assemblies between workstations on the production line.

Metal Fabrication: Handling raw materials (steel coils, sheets, bars), moving work-in-progress between punching, bending, and welding stations, and loading finished products.

Machinery & Equipment: Positioning heavy machine components during assembly and for loading/unloading from CNC machines, lathes, and presses.

2. Warehousing & Logistics

Loading Bays: Unloading heavy goods from trucks and distributing them to storage or staging areas.

Storage Areas: Handling palletized goods, heavy equipment, and bulky items that are too heavy for standard forklifts.

Distribution Centers: Moving large appliances, industrial products, and packaged goods.

3. Workshop & Maintenance Bays

Repair Shops: Lifting vehicles, agricultural machinery, or industrial equipment for inspection and repair.

Maintenance Departments: Removing and installing heavy motors, pumps, gearboxes, and other components from production machinery.

Tool Rooms: Handling large molds, dies, and fixtures.

4. Paper & Printing Industry

Handling large rolls of paper from storage to the printing presses and moving finished printed materials.

5. Small to Medium-Sized Foundries

Moving molds, cores, and small-to-medium castings after the casting process.

 

Production Procedure: 5-Ton Single Girder Overhead Crane (FEM Standard)

1. Project Review & Material Procurement

Input: Customer order, technical specifications, and general arrangement drawings.

Activities:

Design Finalization: Engineering team finalizes all design calculations (for girder, end carriages, hoist, etc.) according to FEM 1.001 (Structural Design) and FEM 9.511 (Hoists) standards. This ensures the crane is rated for Class 2 (Light) / Class 3 (Moderate) service as per FEM.

Bill of Materials (BOM) Generation: Create a complete list of all required raw materials (steel plates, profiles, bars) and purchased components (hoist, electric motors, wheels, gearboxes, electrical panels, cables, etc.).

Material Ordering: Procure certified raw materials (e.g., S235JR or Q235B steel) with Mill Certificates. Order the main hoist unit, travel motors, and other key components from qualified suppliers.

Output: Approved drawings, complete BOM, and all materials/components in the warehouse.

2. Main Girder Fabrication

This is the most critical structural component.

Input: Steel plates and profiles (typically I-beams or box sections are used).

Activities:

Cutting: Steel plates for the end caps/stiffeners are cut to size using CNC plasma or flame cutting machines for precision.

Web/Flange Preparation: If using a welded box girder, the web and flange plates are prepared. The main beam (if a rolled I-beam is used) is cut to the required span length.

Pre-Assembly & Tack Welding: The girder components are assembled on a flat, level welding platform. Jigs and fixtures are used to ensure straightness and correct camber (the pre-set upward bend to counteract deflection under load). Components are tack-welded in place.

Full Welding: Certified welders perform full, continuous welding. Submerged Arc Welding (SAW) is often used for long, main seams for high quality and penetration. Manual Metal Arc Welding (MMA) or Gas Metal Arc Welding (GMAW/MIG) is used for other joints.

Stress Relieving (if required): For larger cranes or specific FEM classes, the girder may undergo heat treatment (Vibratory Stress Relief or Thermal Stress Relief) to minimize internal welding stresses.

Machining: The running surface for the hoist trolley is machined (milled or ground) to ensure a smooth, level track.

Quality Control (QC):

Visual inspection of welds.

Dimensional check for straightness, camber, and squareness.

Non-Destructive Testing (NDT): Ultrasonic Testing (UT) or Magnetic Particle Inspection (MPI) on critical welds.

3. End Carriage (End Truck) Fabrication

Input: Steel plates, shafts, wheels, and bearings.

Activities:

Frame Fabrication: The two side frames of the end carriage are cut and welded.

Wheel Assembly: Wheels, bearings, and axle are assembled into the housing.

Assembly: The wheel assemblies are mounted onto the end carriage frames. The frames are connected by a cross shaft or a rigid box section to maintain squareness.

QC: Check wheel alignment, axle parallelism, and smooth rotation of wheels.

4. Surface Treatment & Painting

Input: Fabricated girder and end carriages.

Activities:

Surface Preparation: All components are shot-blasted to SA 2.5 (Near-White Metal) standard to remove rust, mill scale, and create a clean, profiled surface for paint adhesion.

Priming: Immediately after blasting, a high-quality, corrosion-resistant epoxy primer is applied.

Intermediate & Top Coat: After the primer cures, an intermediate and final top coat (usually polyurethane enamel) is applied in the specified color. Paint thickness is measured with a dry film thickness gauge.

QC: Visual inspection for complete coverage, check for runs/sags, and verify dry film thickness.

5. Mechanical Assembly

Input: Painted girder, end carriages, hoist unit, and travel drives.

Activities:

Girder to End Carriage Mounting: The main girder is bolted or welded onto the end carriages. Laser alignment is used to ensure the end carriages are perfectly square to the girder.

Hoist Unit Mounting: The 5-ton electric wire rope hoist is mounted onto the girder's trolley frame or directly onto the girder (for a simple, fixed configuration).

Drive Unit Installation: The long travel and cross travel (if applicable) motor drives, gearboxes, and couplings are installed.

Auxiliary Items Installation: Install the crane bumper/stoppers, ladder, and maintenance walkway (if any).

QC: Check all bolt torques, alignments, and clearances.

6. Electrical System Installation

Input: Pre-assembled crane structure, electrical panels, cables, collectors, and limit switches.

Activities:

Panel Wiring: The main control panel and pendant station are wired according to the electrical schematic.

Cable Tray & Festoon System Installation: Install the cable feeding system (often a festoon or conductor bar system) for the crane's long travel motion.

Component Mounting & Wiring: Install and wire all components:

Limit Switches: Hoist upper/lower limit switches, long travel end limit switches.

Motors: Wire the hoist, trolley, and bridge travel motors.

Collectors: Install the main power collectors (sliding or roller type) for the 3-phase power supply.

QC: Continuity and megger (insulation resistance) tests on all circuits before power-on.

7. Factory Acceptance Testing (FAT)

Before disassembly for shipment, a full functional test is performed.

Input: Fully assembled crane.

Activities (as per FEM 9.511 & ISO 9927-1):

Visual Inspection: Confirm all parts are correctly installed and secured.

No-Load Test: Run the crane, trolley, and hoist in all directions to check for smooth operation, unusual noise, and correct travel direction.

Load Test:

Static Load Test: Lift a test load of 6.25 tons (125% of SWL) and hold it at a safe height for 10 minutes. Inspect for any permanent deformation or defects in the structure and brakes.

Dynamic Load Test: Lift a test load of 5.5 tons (110% of SWL) and perform all operational functions (hoisting, lowering, traveling) to verify performance under dynamic conditions.

Functionality Tests:

Verify all limit switches function correctly.

Test the emergency stop button.

Check brake performance (holding and stopping distance).

Measure motor current and noise levels.

Output: A formal test report with all results and a certificate of conformity.

8. Dismantling, Packaging & Shipping

Activities:

Marking: All major components are marked with unique tags corresponding to the assembly drawings for easy re-assembly on site.

Dismantling: The crane is carefully disassembled into logical, shippable packages (Girder, End Carriages, Hoist, Electrical Panel, etc.).

Packaging: Components are packaged in wooden crates or on sturdy pallets to prevent damage during transit. Electrical components are wrapped in waterproof material.

Documentation: Operation & Maintenance manuals, test certificates, and packing lists are prepared and included with the shipment.

9. Site Installation & Commissioning (Optional, provided by manufacturer)

Activities: The manufacturer's or a certified installer's team will:

Re-assemble the crane on the customer's runway.

Perform alignment checks.

Re-connect all electrical systems.

Conduct a final on-site load test and commissioning in the presence of the customer.

---

This comprehensive procedure ensures that the 5-Ton Single Girder Overhead Crane is manufactured to a high standard of quality, safety, and performance, fully compliant with the rigorous requirements of the FEM standard.

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%.