100 Ton Warehouse Overhead Crane

A warehouse overhead crane is a type of material handling equipment used to lift and move heavy loads within a warehouse or industrial facility. It consists of a bridge that spans across the width of the building and runs along elevated tracks mounted on the sidewalls, enabling it to move in two directions (longitudinally and transversely). The crane is equipped with a hoist mechanism, which is responsible for lifting and lowering loads, typically controlled by an operator.

• Capacity: 5-800/50ton
• Span length: 4-35m
• Lifting height: 3-50m
• Work duty: A4, A5, A6,A7
• Raged voltage: 220V~690V, 50-60Hz, 3ph AC
• Work environment temperature: -25℃～+50℃, relative humidity ≤85%
• Crane control mode: Floor control / Remote control / Cabin room

1.Bridge

Function: The primary structure that spans across the width of the warehouse. It supports the hoist and trolley, allowing them to move along the crane's tracks.

Types:

Single Girder: One main horizontal beam.

Double Girder: Two parallel beams for heavier loads.

2. Main girder

A steel mill overhead crane main girder is the primary horizontal beam that supports an overhead crane in a steel mill. The main girder is typically made of high-strength steel and is designed to support the weight of the hoist and any material being lifted. It is supported by a trolley, which runs along the length of the girder, allowing the crane to move horizontally. The main girder is one of the most important components of an overhead crane, and its strength and durability are essential for ensuring safe and efficient operation in a steel mill environment.

3.Hoist

Function: The lifting mechanism of the crane. The hoist moves vertically to raise or lower the load.

Types:

Electric Wire Rope Hoist: Used for heavier loads and precise positioning.

Chain Hoist: Suitable for lighter loads.

4.End Trucks

Function: These are located at both ends of the bridge and house the wheels that allow the bridge to travel along the runway.

Connection: They connect the bridge to the runway and provide mobility along the length of the warehouse.

5. Crane traveling mechanism

The crane traveling mechanism refers to the system of components that enable the crane to move horizontally along the steel mill. This system consists of a motor, gears, wheels, and brakes. The motor provides power for the movements of the crane, while the gears and wheels transmit this power to the wheels that are in contact with the steel mill. The brakes are used for controlling the speed and direction of the crane. The traveling mechanism allows the crane to move smoothly and efficiently along the length of the steel mill, ensuring that it can access all parts of the area it is designed to cover.

6. Trolley traversing mechanism

1) The trolley traversing mechanism of a steel mill overhead crane is the mechanism responsible for moving the trolley along the bridge of the crane. The trolley is the assembly that holds the hoist and moves along the bridge to position the hoist over the work site.

2) The trolley traversing mechanism consists of a motor, gearbox, and wheels that allow the trolley to move smoothly and precisely along the bridge. The motor provides the power to turn the gearbox which then turns the wheels that move the trolley.

3) The trolley traversing mechanism may also have a brake system to hold the trolley in position when it is not in use. Additionally, the trolley may have a limit switch to prevent over travel and ensure the trolley stays within the operating range of the crane.

4) Overall, the trolley traversing mechanism is a critical component of the steel mill overhead crane, and it should be properly maintained and inspected regularly to ensure safe and reliable operation.

7. Crane wheel

1) A steel mill overhead crane is a type of industrial crane that is used in steel mills to move heavy materials and equipment. It is typically designed to operate in harsh environments with high temperatures, dust, and other challenging conditions.

2) The crane wheel is an important component of the steel mill overhead crane. It is used to support and rotate the hoist and trolley assembly, allowing the crane to move materials in any direction. Crane wheels are typically made from high-strength steel or cast iron to withstand the heavy loads and high stress of the crane's operation. They are also equipped with bearings to reduce friction and ensure smooth operation.

3) Overall, the steel mill overhead crane with its crane wheel is a critical piece of equipment in the steel manufacturing process, allowing materials to be moved quickly and safely throughout the facility.

8. Crane hook

Steel mill overhead crane is a type of crane that is specifically designed and used for lifting and moving heavy materials in steel mills. The crane is equipped with a hook that is used to grab and lift heavy loads. The crane can be operated manually or with the help of remote control.

The crane hook is an essential part of the steel mill overhead crane. It is attached to the crane's trolley or hoist and is used for lifting and moving materials. The hook is designed to withstand heavy loads and is made of high-quality steel. The hook can be fitted with various attachments such as slings, chains, or ropes, depending on the material being lifted.

The crane hook is available in different sizes and capacities depending on the application. Hooks with a capacity of up to 500 tons are commonly used in steel mills. The hook is also designed to prevent the load from slipping or falling, ensuring the safety of workers and materials.

Overall, the steel mill overhead crane and its hook are critical components in the steel-making industry, helping to move large and heavy materials with ease and safety.

9.Electric Motor

Function: Powers the movement of the bridge, trolley, and hoist. It provides the necessary energy for lifting, lowering, and moving the load.

10. Sound and light alarm system & limit switch

1) A steel mill overhead crane may come equipped with a sound and light alarm system, as well as limit switches for added safety measures.

2) The sound and light alarm system is designed to alert nearby workers or pedestrians of the crane's movements. This is especially important since steel mill overhead cranes are often used in busy industrial settings with heavy foot and vehicle traffic.

3) Limit switches, on the other hand, are safety devices that are designed to prevent the crane from moving beyond a certain point. These switches are typically located at both ends of the hoist or bridge, and when they are tripped, the crane will automatically shut down. This prevents the crane from crashing into other machinery or people, and it can also prevent the load from falling.

4) Overall, these safety features are essential for any steel mill overhead crane, as they help to ensure the safety of workers and prevent accidents from occurring.

11. Safety Devices

There are several safety devices that can be installed on a steel mill overhead crane to ensure safety of workers and equipment. Some of the common safety devices include:

1) Overload protection: This device is used to ensure that the crane does not lift more weight than its capacity. It is usually installed in the form of load cells, which measure the weight of the load being lifted and automatically cut off the power to the hoist when the weight limit is exceeded.

2) Limit switches: These devices are used to limit the movement of the crane in certain directions, such as preventing the crane from moving beyond the designated limits of the working area. These switches can be installed on the trolley, bridge or hoist.

3) Emergency stop buttons: These buttons are installed at strategic locations throughout the crane system and can be used to shut down the entire system in the event of an emergency.

4) Anti-collision sensors: These sensors help to prevent collisions between the crane and other objects or equipment in the work area. They are typically installed on the crane bridge and/or trolley.

5) Warning lights and alarms: These devices provide audible and visual warnings to alert workers of potential danger, such as when the crane is in motion or the load is about to be lifted or lowered.

6) Steel bumpers: These devices are used to protect the crane and other equipment from accidental collisions. They are usually installed at the ends of the crane bridge and trolley.

12. Control Mode

The control mode of a steel mill overhead crane can vary depending on the specific crane and its intended use. However, most modern steel mill overhead cranes utilize a range of control modes to ensure safe and efficient operation.

Some common control modes for steel mill overhead cranes include:

1) Pendant control: This type of control involves the use of a handheld pendant that allows the crane operator to control the movement of the crane from a safe distance.

2) Radio control: Similar to pendant control, radio control involves the use of a handheld device to remotely operate the crane. Radio control offers greater mobility and flexibility than pendant control, allowing the operator to move freely around the worksite.

3) Cabin control: Some steel mill overhead cranes come equipped with a cabin or control room where the operator can sit and control the crane. This allows for greater visibility and control over the crane movement.

4) Automated control: In some cases, steel mill overhead cranes are automated, meaning they are programmed to carry out specific tasks without the need for human intervention. Automated control can improve efficiency and safety, but requires careful programming and monitoring to ensure proper operation.

5) Regardless of the control mode used, all steel mill overhead cranes must adhere to strict safety standards and regulations to prevent accidents and injuries in the workplace.

13. Sketch

Warehouse overhead cranes offer several advantages that enhance the efficiency, safety, and productivity of material handling operations within a warehouse or industrial setting. Some of the key advantages include:

1. Increased Efficiency

Overhead cranes allow for the quick and efficient lifting and transportation of heavy loads across the warehouse. They minimize the time and effort needed to move materials compared to manual or forklift-based handling.

2. Maximized Space Utilization

Since overhead cranes operate on elevated runways, they do not occupy floor space, freeing up more room for storage, workstations, or movement of people and other equipment. This maximizes the available space in the warehouse.

3. Improved Safety

Overhead cranes reduce the need for manual labor and heavy lifting, thereby lowering the risk of injuries related to lifting heavy objects. They also minimize the chances of accidents involving forklifts or other ground-based vehicles.

4. Handling of Heavy Loads

These cranes are designed to handle extremely heavy loads that may be impossible or inefficient to move with other equipment like forklifts. They can lift and transport materials weighing several tons with ease.

5. Precision and Control

Overhead cranes offer precise control over the movement of loads, allowing for accurate placement. This level of control can be critical when handling fragile or sensitive items, or when precise positioning is required during loading, unloading, or assembly processes.

6. Reduced Labor Costs

By automating the lifting and moving processes, overhead cranes reduce the reliance on manual labor, which can lead to lower labor costs and increased operational productivity.

7. Versatility

Overhead cranes are versatile and can be used in various industries such as manufacturing, warehousing, automotive, and steel production. They can handle a wide range of materials, from raw materials to finished products.

8. Durability and Longevity

Built to withstand heavy-duty operations, overhead cranes are durable and have a long service life, making them a cost-effective investment. Regular maintenance ensures reliable performance over many years.

9. Customization Options

Overhead cranes can be customized to suit specific operational needs, such as load capacity, lift height, span, and speed. This flexibility makes them suitable for a wide range of applications and industries.

10. Enhanced Workflow

By streamlining the movement of materials, overhead cranes contribute to a more organized and smooth workflow. They can eliminate bottlenecks and improve the overall flow of goods throughout the warehouse.

11. Minimal Maintenance

Overhead cranes require relatively minimal maintenance when properly installed and used. Regular inspections and preventive maintenance programs help extend their lifespan and ensure safe operation.

In summary, warehouse overhead cranes significantly improve material handling operations by offering enhanced efficiency, safety, and productivity, making them essential for modern warehouses and industrial facilities.

Warehouse overhead cranes are widely used in various industries and warehouse environments due to their ability to handle heavy materials efficiently and safely. Some of the key applications of overhead cranes include:

1. Manufacturing Facilities

Application: In manufacturing plants, overhead cranes are used to move raw materials, heavy components, and finished products between different stages of production. They help streamline the assembly process by lifting and positioning parts accurately.

Examples: Automotive manufacturing, machinery production, and electronics assembly.

2. Storage and Warehousing

Application: Overhead cranes help in managing large volumes of materials or products in warehouses by lifting and moving heavy goods to and from storage racks, loading docks, or transportation vehicles. They optimize space by operating above floor level.

Examples: Moving large boxes, pallets, or heavy equipment within storage areas.

3. Shipping and Logistics

Application: In logistics centers, overhead cranes are used for loading and unloading shipping containers, heavy machinery, or bulk materials from trucks, trains, or ships. They improve the speed and safety of cargo handling operations.

Examples: Ports, freight terminals, and logistics distribution centers.

4. Steel and Metal Handling

Application: Overhead cranes are essential in steel and metal processing industries for handling heavy steel plates, coils, beams, and other metal materials. They provide precise control for positioning and transporting these materials during cutting, welding, or assembly processes.

Examples: Steel mills, metal fabrication plants, and shipyards.

5. Automotive Industry

Application: In automotive manufacturing and assembly plants, overhead cranes are used to lift and move vehicle components, such as engines, frames, and body parts, between different workstations. They ensure smooth and efficient production processes.

Examples: Car, truck, and bus manufacturing facilities.

6. Power and Energy Sector

Application: Overhead cranes play a key role in the energy sector, particularly in handling heavy components like transformers, turbines, and generators. They are used in power plants for the installation, maintenance, and repair of critical equipment.

Examples: Hydroelectric, nuclear, and thermal power plants.

7. Construction Industry

Application: In construction, overhead cranes are used to lift and move heavy building materials, such as concrete blocks, steel beams, and precast structures. They help in transporting materials to different levels of construction sites.

Examples: High-rise building construction, bridge building, and industrial projects.

8. Mining Industry

Application: Overhead cranes are used in mining operations to lift and move heavy mining equipment, machinery, and extracted materials. They ensure safe handling of large loads in harsh environments.

Examples: Loading mined ores, moving drilling equipment, and maintenance of mining machinery.

9. Paper and Pulp Industry

Application: In the paper and pulp industry, overhead cranes handle heavy rolls of paper, raw materials, and finished products. They are also used in equipment maintenance and installation.

Examples: Moving paper rolls in storage areas or production lines.

10. Chemical and Petrochemical Industry

Application: Overhead cranes are used in chemical plants and refineries for handling heavy equipment, chemical reactors, or containers with hazardous materials. They ensure the safe transport of materials in controlled environments.

Examples: Lifting and positioning large chemical tanks, pumps, or processing equipment.

11. Aerospace Industry

Application: In the aerospace industry, overhead cranes are used to assemble large aircraft components, such as fuselages, wings, and engines. They provide precise handling and positioning, which is crucial for the assembly of aircraft.

Examples: Airplane and spacecraft manufacturing and maintenance.

12. Heavy Equipment Repair and Maintenance

Application: Overhead cranes are used in maintenance facilities for lifting and moving large and heavy equipment, such as construction vehicles, engines, and industrial machinery. They assist in repairs and overhauls.

Examples: Equipment maintenance shops, heavy vehicle repair centers.

These diverse applications demonstrate the versatility and critical role of overhead cranes in a wide range of industries, where efficient and safe handling of heavy materials is essential to operations.

The steel mill overhead crane production procedure involves several steps, including:

1. Design and engineering: The first step in the production procedure involves the design and engineering of the crane. This includes determining its capacity, size, and other specifications based on the requirements of the customer.

2. Material procurement: Once the design is finalized, the materials required for the crane are procured. This includes steel plates, beams, cables, motors, and electrical components.

3. Cutting and shaping: The steel plates and beams are cut and shaped to the required size using CNC plasma cutting machines, shearing machines, and other equipment.

4. Welding: The different components of the crane are welded together using MIG and TIG welding processes. The welds are inspected for quality and strength.

5. Assembly: The different components of the crane are assembled together, including the hoist, trolley, bridge, and end trucks.

6. Painting and coating: The crane is painted and coated to protect it from corrosion and other environmental factors.

7. Electrical installation: The electrical components of the crane, such as the control system and motor, are installed and tested.

8. Load testing: Once the crane is fully assembled, it is loaded with weights to test its capacity and performance.

9. Final inspection and delivery: The crane undergoes a final inspection to ensure that it meets all safety and quality standards. It is then packed and delivered to the customer.

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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