FEM Standard Bridge Crane
Products Description
Why Choose a FEM-Compliant Single Girder Crane?
✔ Safety Assurance – Tested for structural integrity and electrical safety.
✔ Longer Lifespan – Proper duty classification prevents premature wear.
✔ Legal Compliance – Required for CE Marking in Europe.
✔ Better Resale Value – Certified cranes are preferred in industrial markets.
Key FEM Standards for Single Girder Overhead Cranes
1. FEM 1.001 – General Rules for Classification of Mechanisms
Defines duty groups (classes) based on usage intensity:
FEM 1Am to 4m (Light to Very Heavy Duty).
Single girder cranes typically fall under FEM 1Am (light duty) to 2m (medium duty).
2. FEM 9.511 – Rules for the Design of Hoisting Appliances
Covers structural design, load calculations, and safety factors.
Specifies permissible stresses for girders, end carriages, and connections.
3. FEM 9.755 – Testing and Acceptance Criteria
Requires load testing (static & dynamic) before commissioning.
Static Test: 125% of SWL (Safe Working Load).
Dynamic Test: 110% of SWL under working conditions.
4. FEM 9.683 – Electrical Equipment Requirements
Guidelines for motors, controls, brakes, and safety devices.
Compliance with IP ratings (Ingress Protection) for different environments.
FEM Duty Classification for Single Girder Cranes
| FEM Class | Usage Intensity | Typical Applications |
|---|---|---|
| FEM 1Am | Light Duty (≤ 2,000 cycles/year) | Workshops, occasional use |
| FEM 1Bm | Moderate Duty (~20,000 cycles/year) | Warehouses, assembly lines |
| FEM 2m | Heavy Duty (~100,000 cycles/year) | Frequent industrial use |
(Note: Single girder cranes are usually FEM 1Am to 2m; higher classes may require double girder designs.)
Lifting Capacity 1 – 20 tons (custom up to 50+ tons)
Span 5 – 30 meters
Lifting Height 3 – 30 meters
Lifting Speed 1 – 20 m/min (adjustable)
Trolley Speed 5 – 30 m/min
Crane Travel Speed 10 – 60 m/min
Power Supply 380V/415V, 50Hz (3-phase)
Duty Class FEM A3-A5 (Medium to Heavy Duty)
Pictures & Components
1. Main Load-Bearing Components
(A) Single Girder (Bridge Beam)
Material: High-quality S355JR steel (per EN 10025).
Design:
Box girder (welded construction, FEM 9.511 compliant).
Rolled I-beam (for lighter-duty cranes).
Deflection Limit: ≤ Span/700 under rated load (FEM 9.755).
Welding Standards: EN 1090 (CE-certified welding procedures).
(B) End Carriages (End Trucks)
Wheel Configuration:
Single-wheel (FEM 1Am - light duty).
Double-wheel (FEM 1Bm/2m - medium/heavy duty).
Wheel Material: Forged steel or nylon-coated (for noise reduction).
Drive Mechanism:
Geared motor (FEM 1.001 duty-rated).
Brakes (holding torque ≥ 1.5 x SWL).
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2. Lifting Mechanism (Hoist & Trolley)
(A) Electric Hoist (FEM-Classified)
Types:
Chain Hoist (FEM 1Am-1Bm, ≤5 tons).
Wire Rope Hoist (FEM 1Bm-2m, up to 20 tons).
Key FEM Requirements:
Duty Cycle Rating (FEM 1.001).
Overload Protection (110% cut-off).
Thermal Protection (motor safety).
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(B) Trolley (Cross Travel Unit)
Drive System:
Geared motor (FEM-classified).
Limit switches (FEM 9.683 compliant).
Wheel Alignment: Prevents rail wear (FEM 9.511).
3. Runway System (Supporting Structure)
Runway Beams:
EN 10025 steel (S235JR/S355JR).
Deflection limit: ≤ Span/600 (FEM 9.755).
Rail Type:
A45/A55 crane rails (DIN 536).
Square/round bar rails (for light-duty).
Rail Clamps: Prevents crane movement when parked.
4. Electrical & Control System (FEM 9.683)
(A) Power Supply & Wiring
Voltage: 380V/415V, 3-phase, 50Hz (IEC standard).
Cable Management:
Festoon system (for bridge travel).
Energy chain (for trolley travel).
(B) Control & Safety Devices
Control Options:
Pendant control (IP54, FEM 9.683).
Radio remote (EN 61000-6-2 EMC compliance).
Safety Features:
Overload limiter (110% SWL cutoff).
Emergency stop (EN 60204-1).
Upper/lower limit switches (FEM 9.755).
5. Safety & Auxiliary Components
(A) Structural Safety
Bumpers (end stops): Rubber or hydraulic (FEM 9.511).
Anti-collision system (for multiple cranes).
(B) Operational Safety
Warning devices: Horns & beacon lights (FEM 9.683).
Insulated hook (for explosive environments).
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6. FEM Testing & Certification
(A) Mandatory Tests (FEM 9.755)
Static Load Test: 125% SWL (10 min hold).
Dynamic Load Test: 110% SWL (operational test).
Electrical Safety Test: Insulation resistance, grounding.
(B) Documentation
FEM Design Calculations Report.
CE Declaration of Conformity (EN 13001, EN 60204).
Test Certificates (Factory Acceptance Test).
Comparison: FEM vs. ISO Components
| Component | FEM Requirements | ISO Equivalent |
|---|---|---|
| Girder Design | Span/700 deflection | ISO 4301 (similar) |
| Hoist Duty Class | FEM 1Am-4m | ISO M1-M8 |
| Electrical Safety | FEM 9.683 | IEC 60204-1 |
Sketch
Main technical
Advantages
Enhanced Safety & Reliability
Strict FEM 9.755 load testing (125% static, 110% dynamic) ensures structural integrity.
Mandatory overload protection, limit switches, and emergency stops reduce accident risks.
Optimized for Duty Cycles
FEM 1Am-2m classification matches crane capacity to usage intensity, preventing premature wear.
Higher-grade S355JR steel girders and forged wheels extend lifespan.
Legal Compliance in Europe
Meets CE Marking requirements (EN 13001, EN 1090, EN 60204-1).
Required for EU market sales and industrial safety regulations.
Cost-Effective Long-Term Performance
Precise FEM calculations minimize over-engineering, saving material costs.
Lower maintenance due to durable components (e.g., FEM-rated motors, IP54 electricals).
Customizable for Specific Needs
Configurable hoist types (chain/wire rope), duty classes, and control systems (pendant/remote).
Application:
1. Manufacturing & Assembly Lines
Automotive: Engine/component handling (FEM 1Bm-2m).
Machinery: Moving heavy parts in workshops.
2. Warehousing & Logistics
Loading bays: Stacking pallets (FEM 1Am-1Bm).
Distribution centers: Medium-duty material transfer.
3. Construction & Steel Fabrication
Steel beam handling (FEM 2m, box girders for heavy loads).
Prefab concrete transport.
4. Energy & Heavy Industry
Power plants: Turbine maintenance (explosion-proof options).
Mining: Equipment handling (corrosion-resistant designs).
5. Aerospace & Automotive
Aircraft parts lifting (high-precision FEM-classified hoists).
Workshop maintenance (light-duty FEM 1Am).
6. Paper, Printing & Packaging
Paper roll handling (FEM 1Bm, VFD for smooth operation).
Crane production procedure
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%.
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