Overhead Crane For Coal Mining

Core Components: Gearbox, Motor, Gear

Place of Origin: Henan, China

Warranty: 1 Year

Weight (KG): 50000 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 Structural Components

Component	Description	Special Features for Coal Mining
Bridge Girder	Primary load-bearing structure	- Heavy-duty steel construction (often grade Q345B) - Corrosion-resistant coatings - Explosion-proof designs available
End Trucks	Support structure with wheels	- Reinforced for high duty cycles (M5-M8) - Flameproof wheel materials
Runway System	Rails for crane movement	- Heat-treated rails for heavy loads - Dust-proof rail clamps

 

 

2. Lifting Mechanism

Component	Description	Mining Adaptations
Hoist Unit	Electric or hydraulic lifting system	- Explosion-proof motors (ATEX/IECEx certified) - IP65 protection against dust/water
Wire Rope & Sheaves	Lifting cable and pulley system	- Abrasion-resistant steel ropes - Non-sparking sheave materials
Hook Block	Load attachment point	- Forged steel construction - Optional rotating mechanism

 

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. Electrical Systems

Component	Mining-Specific Features
Explosion-Proof Control Panel	- Sealed enclosures - Intrinsically safe circuits
Festoon/Cable Reel System	- Dust-resistant cable carriers - Flame-retardant cables
Variable Frequency Drives (VFDs)	- Spark-proof speed control - Overload protection

6. Safety Components

Safety Device	Purpose in Mining Operations
Load Moment Indicator	Prevents overload in dusty conditions
Anti-Sway System	Critical for precise coal handling
Spark-Proof Brakes	Essential for explosive atmospheres
Dust Extraction Ports	Prevents coal dust accumulation

 

7.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.

8.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.

9.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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10.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.

11.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.

 

12.Control Modes for Coal Mine Overhead Cranes

Pendant Control (Standard)

Wired or wireless handheld units

IP65-rated dust/waterproof designs

Explosion-proof models available (ATEX certified)

Typical range: 30-100m for wireless

Cabin Control

Pressurized operator cabins with air filtration

HVAC systems for extreme temperatures

Enhanced visibility with dust-resistant windows

Vibration-dampened seats for operator comfort

Remote Radio Control

2.4GHz frequency hopping technology

Dual-transmitter redundancy systems

Emergency stop with auto-braking

Battery life monitoring (typically 8-12 hours)

Semi-Automatic Control

Pre-programmed lifting paths

Auto-positioning for repetitive tasks

Collision avoidance systems

Load stabilization algorithms

Fully Automated Control

Integrated with mine management systems

RFID container/load identification

AI-based predictive movement

Real-time performance monitoring

 

Special Mining Adaptations:

Intrinsically safe components for explosive atmospheres

Redundant control systems (fail-safe operation)

Dust-sealed connectors and switches

Thermal monitoring for critical components

 

Safety Features:

Deadman switches on all controls

Emergency power-off circuits

Load path restriction programming

Anti-sway algorithms for precise positioning

 

Typical Applications by Control Mode:

Pendant: General workshop maintenance

Cabin: Heavy equipment installation

Remote: Coal processing areas

Automated: Repetitive material handling

 

These control systems are designed to maintain reliability in high-dust environments while providing precise load handling capabilities required in mining operations.

Sketch

 

Main technical

 

 

Advantages of Coal Mine Bridge Cranes

Heavy-Duty Performance

Capacities from 5-500+ tons for handling mining equipment

M5-M8 duty classification withstands 24/7 operation

50,000+ load cycle design life

Enhanced Safety

ATEX/IECEx-certified explosion-proof models

Spark-resistant brakes and motors

Integrated overload protection systems

Harsh Environment Adaptation

IP65-rated dust/water protection

Corrosion-resistant coatings (hot-dip galvanized)

-20°C to +50°C operational range

Precision Handling
±10mm positioning accuracy with anti-sway
Variable frequency drive control
Remote/automated operation options

Space Efficiency
Zero ground space occupation
Full workshop coverage
Clear span up to 35m

 

 

Key Applications

Underground Mining

Equipment installation/maintenance

Tunnel support handling

Explosion-proof monorail systems

Coal Processing Plants

Crusher/pulverizer maintenance

Conveyor system installation

Clamshell grab coal handling

Surface Operations

Dragline/excavator assembly

Railcar/truck loading

Heavy component transfer

Wash Plants

Dense media separation vessel service

Screen deck maintenance

Magnetite recovery systems

Maintenance Workshops

Engine/transmission overhaul

Bucket tooth replacement

Hydraulic system repair

 

Specialized Configurations

Grab Bridge Cranes: For coal stockpile management

Underslung Cranes: Low-clearance underground installations

Gantry Systems: Outdoor coal yard operations

Monorails: Linear material transport systems

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%.