New Condition 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

1.Main beam

The main beam of a new condition single girder overhead crane is the primary horizontal structure that supports the hoist and trolley. It spans the width of the crane's working area and is responsible for carrying the load. Here are some key features of the main beam:
1)Structure & Design
Made from high-strength steel (Q235B/Q345B) to ensure durability and load-bearing capacity.
Box-type or I-beam (profiled steel) design, depending on the application and load capacity.
Welded and reinforced to minimize deflection under load.
2)Load Capacity & Span
Designed based on the rated lifting capacity (commonly 1T–20T for single girder cranes).
The span can be customized depending on the facility's layout.

2.Lifting System

Structural Integrity and Safety
1)Material Quality: The crane's girder and other critical components must be made from high-quality steel or appropriate alloy materials to ensure durability and strength.
2)Stress Testing: Regular stress tests should be performed to ensure the structural integrity of the crane, especially after any modifications or repairs.
3)Corrosion Resistance: The lifting system should have enhanced corrosion protection, such as galvanization or specialized coatings, to prolong its lifespan in harsh environments.
4)Redundancy Features: Incorporate redundant safety features like backup braking systems and secondary load-holding devices.

3.End carriage

Maintenance and Serviceability
1)Easy Access Panels: Design access panels for easy maintenance and inspection of internal components without needing to disassemble major parts.
2)Lubrication Points: Clearly mark lubrication points and use automated lubrication systems where feasible to ensure consistent maintenance.
3)Diagnostic Ports: Include diagnostic ports for connecting portable or permanent monitoring devices to assess the condition of the end carriage.
4)Wear Indicators: Implement visual or electronic wear indicators to signal when components are nearing the end of their service life.
5)Spare Part Availability: Ensure that spare parts for critical components are readily available to minimize downtime during repairs.

4.Crane travelling mechanism

Operational Efficiency
1)Sealed Bearings: Use sealed bearings to reduce maintenance and improve operational life by keeping out dirt and contaminants.
2)Low Friction Components: Utilize low friction materials for wheels and tracks to reduce energy consumption and wear.
3)Self-Aligning Wheels: Employ self-aligning wheels to maintain proper alignment and reduce the risk of derailment.
4)Variable Speed Drive (VSD): Integrate VSD technology for smoother starts, stops, and better control over the crane's movement.
5)Quick-Change Cords: Use quick-change cord systems to minimize downtime during cable replacements or maintenance.

5.Trolley travelling mechanism

Safety and protection devices
1) Multiple braking systems
Equipped with dual braking devices, such as normally closed electromagnetic brakes and mechanical brakes, ensure that the trolley can be reliably braked under any circumstances. When the motor is powered off or fails, the mechanical brake can automatically take effect to prevent the trolley from sliding.
The braking torque of the brake should be accurately calculated and tested to ensure that the trolley can be braked quickly and effectively under the rated load.
2) Overload protection device
Install a high-precision overload limiter to monitor the load of the trolley in real time. When the load exceeds the rated value, the overload limiter can automatically cut off the power supply of the motor and send out an alarm signal to avoid safety accidents caused by overload.
The overload protection device should have high reliability and stability and be able to operate normally in harsh working environments.
3) Limit switch
Set extreme limit switches at both ends of the trolley. When the trolley runs to the end of the track, it can stop automatically to prevent the trolley from derailing.
In addition, a travel limit switch should be set to control the operating range of the trolley to ensure that it works within the specified area.

6.Crane wheel

Structural design
1) Optimize the spoke structure
Use reasonable spoke design, such as H-type or box-type spokes, to increase the overall strength and rigidity of the wheel and reduce deformation under load. At the same time, optimize the thickness and shape of the spokes to achieve lightweight design, reduce the moment of inertia of the wheel, and improve starting and braking performance.
Carry out stress analysis and optimization of the spokes, and reasonably distribute the materials according to the stress conditions, so that the wheels can minimize the use of materials and reduce costs while ensuring performance.
2) One-piece or split design
Choose one-piece or split wheels according to different usage requirements and manufacturing processes. One-piece wheels have higher overall strength and stability, and are suitable for large-tonnage, high-working-level cranes; split wheels are easy to process, assemble and repair, and can extend the service life of the wheel by replacing the rim or hub, which has certain flexibility and economy.
For split wheels, ensure that the connection between the rim and the hub is tight and reliable to prevent loosening or displacement during use.

7.Crane Hook

Precision and processing technology
1) High-precision processing
The manufacturing of the hook should adopt advanced CNC processing equipment and technology to ensure that the dimensional accuracy and surface roughness meet high standards. For example, the diameter tolerance and hook size of the hook should be controlled within a very small range to ensure the matching accuracy with other parts.
The surface of the hook is finely processed, such as grinding and polishing, to make its surface roughness reach a lower value, reduce the friction coefficient, and improve the smoothness of the lifting operation.
2) Quality inspection
Strengthen the quality inspection of the hook, including raw material inspection, metallographic structure analysis after heat treatment, non-destructive testing, etc., to ensure that the internal quality and surface quality of the hook meet the relevant standards and specifications.
Carry out load tests, and perform static and dynamic load tests on the hook according to a certain multiple of the rated load to test the load-bearing capacity and safety of the hook to ensure that it can work safely and reliably in actual applications.

8.Motor

Maintenance and management
1) Easy maintenance
The motor's structural design should be easy to maintain and overhaul. The motor's end cover, junction box and other parts should be easy to disassemble and install, making it convenient for maintenance personnel to inspect, repair and replace parts. At the same time, the motor's internal structure should be simple and clear, easy to clean and maintain, and reduce maintenance time and cost.
Provide detailed maintenance manuals and technical information to guide users to perform correct maintenance and maintenance operations. The maintenance manual should include the motor's technical parameters, maintenance cycle, maintenance methods, troubleshooting and other contents to help users better manage and maintain the motor.
2) Intelligent monitoring and diagnosis
Equipped with an intelligent monitoring system to monitor the motor's operating status in real time, such as temperature, vibration, current, voltage and other parameters. Data is collected through sensors and transmitted to the control system for analysis and processing to promptly detect abnormal conditions and potential faults of the motor.
With fault diagnosis function, when the motor fails, it can accurately determine the fault type and location and provide corresponding solutions. At the same time, the intelligent monitoring system can also record the motor's operating data, providing a scientific basis for the maintenance and management of the motor.

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9.Sound and light alarm system & limit switch

1) Sound and light alarm system
The sound and light alarm system should have multiple alarm functions, such as overload alarm, limit alarm, fault alarm, etc., and can send different alarm signals to the operator in a timely and accurate manner so that the operator can take corresponding measures. For example, when the lifting weight exceeds the rated load, the system will issue a continuous high-pitched alarm sound accompanied by a flashing red light; when the crane runs to the limit position, the system will issue an intermittent low-pitched alarm sound and display a yellow light.
2) Limit switch
The limit switch should have a high-precision limit function, which can accurately control the operating range of the crane and avoid safety accidents caused by the crane exceeding the limit position. The use of advanced sensor technology and precise mechanical structure design ensures that the action accuracy of the limit switch reaches the millimeter level or even higher, meeting the requirements of high-precision positioning of new single-beam bridge cranes.

10.Safety Devices

1) Anti-overload device
The use of high-precision and high-reliability weighing sensors can detect the lifting weight in real time and accurately. Its accuracy should reach a high level, such as the error control within ±2% of the rated load, to ensure that the early warning signal is issued in time when approaching the rated load to prevent overload operation.
2) Limit protection device
The lifting height limiter should have a precise positioning function, and can stop accurately before the crane hook rises to the limit position, and the positioning accuracy should reach the centimeter level. Advanced limit switch and sensor technology are used to ensure the reliability and stability of the limiter.
3) Buffer and collision protection device
High-performance buffers such as rubber buffers, spring buffers or hydraulic buffers are installed at both ends of the crane or at parts that may collide with other objects. The buffer should have good energy absorption performance, can effectively absorb the collision energy generated during the operation of the crane, and reduce the damage to the crane structure and personnel caused by the collision.

11.Control Mode

1) Frequency conversion speed control
The frequency converter adjusts the speed of the motor by changing the frequency of the power supply, thereby realizing stepless speed regulation of the crane. In the lifting mechanism, the frequency conversion speed regulation can automatically adjust the speed of the motor according to the change of the load, making the lifting process smoother and reducing impact and shaking.
For example, when lifting lighter objects, the motor can run at a higher speed; when approaching the rated load, the speed of the motor will automatically decrease to ensure safety.
2) PLC programmable logic controller control
PLC implements various control logics for the crane through programming. It can receive input signals from operators, sensors, etc., and output control signals to actuators such as motors and brakes after logical operations.
For example, during the operation of the crane, the PLC can determine whether it has reached the limit position or encountered obstacles based on the signals of sensors such as the lifting height, trolley position, and trolley position, and send control signals in time to stop the operation of the crane.
3) Remote control control
The remote control sends control signals to the receiving device on the crane through wireless communication technology, and the receiving device converts the signals into electrical signals to drive the operating mechanism of the crane. Remote controllers usually use radio waves or infrared rays as transmission media. For example, operators can hold a remote controller and easily control the lifting, lowering, and operation of cranes and trolleys within a certain distance.

Sketch

Main technical

1) Simple design: Compared with traditional cranes, its structure is simpler, usually consisting of a main beam and end beams at both ends, without complex support structures, making installation and maintenance more convenient. For example, in some small factory or warehouse renovation projects, single-beam bridge cranes can be quickly installed and put into use.
2) High space utilization: Due to its simple structure, it occupies less space in the height direction and can be used in lower factory buildings, which is particularly suitable for places with limited factory height. At the same time, its compact design also allows the crane to operate freely in a narrow space. For example, in the equipment renewal of some old factories, the new single-beam bridge crane can better adapt to space restrictions.
3) Beautiful appearance: The surface is coated with epoxy zinc-rich paint, which not only has good anti-corrosion properties, but also has beautiful appearance and good gloss. It can maintain a good appearance even in harsh industrial environments, which enhances the image of the entire workplace.
4) Smooth operation: The use of advanced frequency conversion technology and three-in-one drive mechanism realizes the smooth operation of starting and braking, reduces the impact and vibration during the hoisting process, and improves the hoisting accuracy. It is especially suitable for the hoisting of precision equipment and fragile items.
5) Flexible operation: The flashlight door is flexibly designed and can be connected to the trolley or moved freely on the main beam alone, which is convenient for operators to adjust the position according to actual needs; the large and small trolleys can achieve variable frequency stepless speed regulation, which can meet the lifting speed requirements under different working conditions.
6) Safe and reliable: The power supply system adopts a safe busbar power supply and is equipped with a phase loss protection function. At the same time, a highly flexible flat cable is used to supply power to the trolley, which has a grounding protection function. All electrical connections use heavy-duty aviation plugs and sockets to ensure the stability and reliability of the crane's electrical system.

1) Manufacturing industry
It is used to lift raw materials, semi-finished products and finished products, such as the handling of car bodies in automobile manufacturing plants, the lifting of large parts in mechanical processing plants, etc., to improve production efficiency and reduce the labor intensity of workers.
It can be used in conjunction with other equipment to realize automated material transportation on the production line, such as accurately lifting parts to designated locations for assembly on the assembly line.
2) Logistics and warehousing industry
In the warehouse, it can be used for loading, unloading, stacking and handling of goods, and can quickly and efficiently complete the entry and exit operations of goods, improving the efficiency of warehousing and logistics.
It can be used in conjunction with the shelf system to facilitate the storage and retrieval of goods, and is suitable for various types of warehouses, such as general cargo warehouses, e-commerce warehouses, etc.
3) Construction industry
On construction sites, it is used to lift construction materials such as steel bars, cement, bricks, etc., as well as large building components such as prefabricated panels, steel beams, etc., to speed up construction progress.
It can be installed in areas that cannot be covered by large lifting equipment such as tower cranes to carry out local material lifting operations and improve construction flexibility.
4) Metallurgical industry
For lifting high-temperature metal liquids or solids, such as steel ladles and iron ladles in steelmaking furnaces, cranes are required to be resistant to high temperatures and corrosion.
In metallurgical workshops, they can also be used to lift large metallurgical equipment and parts, as well as to transport finished steel products.
5) Power industry
For the installation and maintenance of large and medium-sized equipment in power plants, such as the overhaul and replacement of generators and steam turbines, single-beam bridge cranes are required for lifting.
In the construction and maintenance of power lines, they can also be used to lift power equipment such as transformers and switchgear in places such as substations.
6) Food processing industry
In food processing plants, they are used to lift raw materials, semi-finished products and finished products, such as bulk materials such as flour, sugar, and edible oil, as well as loading and unloading of packaged food.
Due to the high hygiene requirements of the food processing industry, new single-beam bridge cranes are usually made of easy-to-clean materials such as stainless steel and are equipped with anti-pollution devices to meet hygiene standards.

1) Design and planning
Determine technical parameters: Determine the crane's lifting capacity, span, lifting height, working speed and other technical parameters according to customer needs and the actual situation of the place of use. For example, the crane used for lifting goods in indoor warehouses may have a lifting capacity of less than 5 tons and a span of less than 20 meters; while the crane used for production and lifting in large factories may have a lifting capacity of tens or even hundreds of tons, and the span will increase accordingly.
Structural design: Carry out the structural design of the crane according to the technical parameters, including the design of the main beam, end beam, outrigger, walking mechanism, lifting mechanism, etc. Designers need to use mechanical principles and engineering experience to ensure the structural strength, stability and reliability of the crane. For example, the design of the main beam should take into account the maximum bending moment and shear force to be borne, and select the appropriate cross-sectional shape and size.
Material selection: Select appropriate raw materials according to design requirements, such as steel model and specifications. Generally, high-strength, low-alloy steel, such as Q345B, is selected to ensure the load-bearing capacity and durability of the crane. At the same time, for some key components, such as wire ropes and brakes, reliable quality and standard accessories should also be selected.
2) Cutting and pretreatment
Steel cutting: Cut the purchased steel according to the designed size. Common cutting methods include flame cutting, plasma cutting, laser cutting, etc. For example, flame cutting can be used for thicker steel plates; laser cutting can be used for thin plates or parts with higher precision requirements. The edges of the cut steel need to be polished to remove burrs and oxide scale.
Steel pretreatment: Pretreatment of the cut steel, including shot blasting and surface cleaning. Shot blasting can effectively remove impurities such as rust and oxide scale on the surface of steel, and improve the surface quality and coating effect of steel. The surface of the pretreated steel should have a certain degree of roughness to facilitate subsequent coating.
3) Welding and assembly
Main beam welding: Assemble the cut steel plates into the shape of the main beam and then weld them. The welding of the main beam generally adopts welding methods such as submerged arc welding or gas shielded welding to ensure the welding quality. During the welding process, attention should be paid to controlling welding deformation and adopting reasonable welding sequence and process parameters. For example, for a longer main beam, the segmented welding method can be used, first welding the middle part and then welding to both ends to reduce welding deformation.
End beam and outrigger welding: The end beam and outrigger are welded to the main beam to form the bridge structure of the crane. The welding of the end beam and outrigger should also pay attention to controlling the welding deformation and welding quality to ensure the overall strength and rigidity of the bridge.
Assembly of other components: Assemble other components such as the walking mechanism, lifting mechanism, and electrical system to the bridge. The installation of the walking mechanism and lifting mechanism should be carried out strictly in accordance with the design requirements to ensure its flexible operation, safety and reliability. The installation of the electrical system should pay attention to the rationality and safety of the wiring to avoid problems such as line confusion and short circuit.
4) Surface treatment and painting
Surface treatment: The assembled crane is subjected to surface treatment, such as shot blasting and phosphating treatment again to improve the adhesion of the coating. Phosphating treatment can form a phosphate film on the surface of the steel to enhance the corrosion resistance and wear resistance of the coating.
Painting: Painting operations are carried out according to customer requirements and environmental conditions. Painting generally includes multiple layers of coating such as primer and topcoat. Each layer of coating must be evenly applied and the thickness must meet the standard requirements. For example, the primer can be epoxy zinc-rich primer, which has good anti-corrosion performance; the topcoat can be polyurethane topcoat, which has good weather resistance and decorative properties. After painting, the crane should be placed in a well-ventilated environment to dry or dry.
5) Debugging and inspection
No-load debugging: After the crane is assembled, no-load debugging should be carried out first. Start each operating mechanism of the crane to check whether it is running normally, whether there is abnormal noise, whether the motor and brake are working reliably, etc. For example, check whether the wheels of the walking mechanism can rotate flexibly and whether the drum of the lifting mechanism can wind the wire rope normally.
Load debugging: After the no-load debugging is normal, load debugging is carried out. Gradually load according to a certain proportion of the rated load to check the performance of the crane under load. During the load debugging process, the stress, strain, deflection and other parameters of the crane should be monitored to ensure that they are within the allowable range. At the same time, it is also necessary to check whether the braking performance of the brake meets the requirements.
Safety device inspection: Inspect the safety devices of the crane, such as limit switches, overload protection devices, emergency brake devices, etc. These safety devices are important components to ensure the safe operation of the crane, and their operation must be reliable. For example, the limit switch should be able to cut off the power supply in time when the crane reaches the limit position to prevent the crane from collision and damage.
6) Packaging and transportation
Packaging: Cranes that have passed the commissioning inspection are packaged. Generally, moisture-proof and shock-proof packaging materials such as plastic film and foam pads are used to package the crane. For some large cranes, wooden box packaging can also be used to increase the strength and stability of the packaging.
Transportation: Choose the appropriate transportation method based on factors such as the size, weight and transportation distance of the crane. Common transportation methods include road transportation and rail transportation. During transportation, fixation and protection measures should be taken to prevent the crane from collision and damage.

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%.