Overhead Bridge Cranes

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

 

 

Overhead bridge cranes consist of several critical structural, mechanical, and electrical components that work together to lift and transport heavy loads efficiently. Below is a detailed breakdown of the main components and their roles.

1. Structural Components

A. Bridge Girder

Function: The primary horizontal beam that carries the trolley and hoist.

Types:

Single-Girder – One beam (lighter loads, cost-effective).

Double-Girder – Two parallel beams (higher capacity, more rigid).

B. Runway System

Function: Supports the crane's movement along the building.

Components:

Runway Rails – Steel tracks mounted on building columns or freestanding supports.

End Trucks – Wheeled assemblies that move the bridge along the runway.

C. End Trucks

Function: Enable the bridge to travel along the runway.

Components:

Wheels & Axles – Typically 4-8 wheels per truck (some with flanges for rail guidance).

Drive Motors – Electric or hydraulic for movement.

2. Lifting & Movement Components

A. Hoist Unit

Function: Lifts and lowers loads.

Types:

Electric Chain Hoist – For lighter loads (up to ~10 tons).

Wire Rope Hoist – For heavy-duty lifting (up to 500+ tons).

Key Parts:

Hoist Motor – Powers lifting/lowering.

Drum or Sprocket – Winds the wire rope or chain.

Brake System – Prevents load slippage.

 

B. Trolley Assembly

Function: Moves the hoist along the bridge girder.

Components:

Trolley Frame – Supports the hoist.

Trolley Wheels & Drive – Moves horizontally on the girder.

C. Hook Block & Lifting Attachments

Function: Connects to the load.

Types:

Standard Hook – General lifting.

Magnetic Lifter – For steel plates/coils.

Grab Bucket – For bulk materials (sand, grain).

3. Power & Control Systems

A. Power Supply

Options:

Conductor Bars (Bus Bars) – For continuous power in large facilities.

Festoon Systems (Cable Reels) – Flexible power/data cables.

Battery (for wireless operation).

B. Control System

Types:

Pendant Control – Handheld wired remote.

Radio Remote Control – Wireless operation.

Cabin Control – Operator cab for large cranes.

C. Safety & Automation Features

Limit Switches – Prevents over-travel.

Overload Protection – Blocks lifting beyond capacity.

Anti-Collision Systems – For multiple cranes in same runway.

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4. Support & Auxiliary Components

A. Bumpers & Buffers

Function: Absorbs impact at runway ends.

B. Lighting & Alarms

Warning Lights & Horns – For safety in busy facilities.

C. Lubrication System

Auto-Greasers – For wheels, gears, and bearings.

5. Comparison of Single vs. Double-Girder Components

Component	Single-Girder Crane	Double-Girder Crane
Bridge Structure	One I-beam	Two parallel girders
Hoist Position	Below girder	Between girders
Max Capacity	~20 tons	500+ tons
Lifting Height	Lower	Higher (no girder obstruction)

Sketch

 

Main technical

 

Space Efficiency

Operate above floor level, freeing up valuable floor space

No interference with ground-level operations

Ideal for facilities with limited space

Superior Lifting Capacity

Single-girder models handle up to 20 tons

Double-girder designs can lift 500+ tons

Suitable for extremely heavy industrial loads

Precision Handling

Smooth, controlled load movement

Variable speed options for delicate positioning

Excellent load sway control

Enhanced Safety

Reduced risk of ground-level accidents

Built-in overload protection systems

Anti-collision features for multiple cranes

Durability & Longevity

Heavy-duty steel construction

Minimal wear compared to mobile cranes

Service life of 25+ years with proper maintenance

Customization Options

Adjustable spans (up to 100+ feet)

Various power supply systems

Specialized lifting attachments available

Cost Effectiveness

Lower long-term operating costs than mobile cranes

Reduced labor requirements

Minimal maintenance needs

 

1. Manufacturing Facilities

Moving raw materials (steel, aluminum)

Positioning heavy machinery

Assembly line operations

Press feeding operations

2. Steel & Metal Processing

Handling steel coils (up to 50 tons)

Moving plates and beams

Loading/unloading from processing equipment

3. Warehousing & Logistics

Heavy pallet handling

Loading/unloading trucks

High-bay storage operations

4. Power Generation

Turbine maintenance

Generator handling

Transformer installation/removal

5. Automotive Industry

Stamping press operations

Engine assembly

Vehicle component handling

6. Aerospace Industry

Aircraft component movement

Engine handling

Large structural assembly

7. Paper & Printing Industry

Roll paper handling

Heavy machinery maintenance

Finished product movement

8. Shipbuilding

Large component assembly

Engine installation

Ship section movement

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%.