Equipment Description

Design Standards
2. Steel structure section
3 Mechanical parts
4. Electrical Control Section
5 Surface treatment
6 Tests
7 files

Design Standards

Structure and Machinery
European Society for Material Handling Part 1, Design Rules for Lifting Mechanisms of Heavy Lifting Equipment
Third edition on October 1, 1987, reference number F E.M.1.001
The above standards are similar to the latest DIN, ISO, BS, CMAA. But there may be slight differences from FEM.

Steel structure manufacturing
Welding standards: DIN18800，BLATT7
Crane design and structural standards: DIN15018，BLATT2
Welding grade: DIN8563，BLATT3

Brakes and couplings: according to DIN15434, VDE0580, KONE or DIN15431 standards.

a hook
DIN15401 single hook
DIN15402 Double Hook
Inspection certificate for DIN15404 hook

Electrical equipment: VDE0113, VDE0100, and CEE

Motor
IECRecommendations34-1， 34-5 and 72-1.
Select the motor according to FEM standards and fully comply with Swedish crane standard IKH6.30.1

Gearbox: Designed according to ISO/DIS6336/II-6336/V (DIN51150) standard.

explain:
When determining the final design parameters, our company's cranes pay attention to the requirements and safety guidelines of local customers, so their products can meet FEM and relevant Chinese standards during operation.

2. Steel structure section
2.1 Main beam section
The main beam adopts European optimized design, with light weight and reasonable structure;
The main beam is a box girder or H-beam structure, welded from steel plates;
The steel plate material is domestic steel (Q235B) made of Fe37 or similar materials;
The main weld seam adopts submerged arc automatic welding and non-destructive testing;
A maintenance platform (maintenance walkway) is arranged on the driving side of the double girder crane along the main beam direction;
The vertical deflection is 1/800, and the web arch degree is cut by 40m CNC cutting for the entire plate cutting;
After welding, the entire beam is shot blasted, stress relieved, and rust removed to achieve Sa2.5 level
Epoxy zinc rich paint, thickness 120 μ m
2.2 End beam section
End beam material: S355J2G3/EN10025 (Fe52D, equivalent to Chinese standard 16Mn);
The end beam is formed by welding rectangular steel pipes or steel plates, and the formed end beam is positioned and processed once on a CNC boring and milling machine to ensure dimensional accuracy and fit tolerance;
Each end beam is equipped with wheels with double rims, buffers, and anti derailment protection devices;
The main beam and end beam are connected by 10.9 grade high-strength bolts to ensure the structural strength and accuracy of the entire machine.

3 Mechanical parts
3.1 European lifting mechanism
3.1.1 Structural Form
Four in one integrated design of motor, brake, gearbox, and limit switch, compact structure
Side mounted flexible drive system, European three-point static support

3.1.2 Lifting motor
Squirrel cage, dual winding pole changing dual speed motor
Protection level IP55, F-class insulation
Power continuity rate 60% ED
Built in thermistor overheat protection
Direct drive output, eliminating coupling, high transmission efficiency, low-carbon and energy-saving
The motor casing is formed by stamping aluminum tubes
3.1.3 Gearbox
Compact reducer for European cranes, small in size and light in weight
The gear material is chromium molybdenum nickel alloy, and world-renowned brand wear-resistant bearings are used
CNC automatic gear machining center production, hard tooth surface (HRC60), after grinding treatment
Half grease lubrication, completely sealed, no oil leakage,
Maintenance free
3.1.4 Brakes
Electromagnetic disc brake, coaxial with the motor, with fast braking response
Brake pad lifespan: no less than 1 million normal uses and no less than 500 emergency braking cycles
Normally closed design, the lifting mechanism is in a braking state when power is cut off, ensuring safety
Large friction area, constant braking torque
Adjustable brake pad clearance (i.e. adjustable braking torque)
Friction pads are asbestos free and environmentally friendly
Fully sealed, dust-proof, maintenance free

3.1.5 Limit switch
Cam rotating four level limit switch
Adjustable 4-point upper and lower limit positions, programmable settings
Phase loss protection, precise phase sequence control
The deceleration limit function realizes deceleration before stopping, and the deceleration operation improves the service life and safety of the brake
Fully sealed, dust-proof, maintenance free
3.1.6 Rollers and wire ropes
The steel wire rope is fixed with a fixture, and at least 2 turns of the steel wire rope are fixed in place
Adopting heavy-duty bearings from world-renowned brands
Made of seamless steel pipe and processed with rope groove
3.1.7 Rope guide
Ductile iron European style rope guide has low wear on steel wire ropes, long service life, good toughness and elasticity
Anti loosening rope design, which can maintain the tension of the steel wire rope even if the hook is lowered to the ground
Easy disassembly and easy replacement

3.1.8 Steel Wire Rope
High strength steel wire rope, with a breaking strength of 2160N/mm2, small diameter, and good curvature
Galvanized, no need to apply anti rust oil, maintenance free
Original imported steel wire rope

3.1.9 Hook
European crane specific hook, forged with 34CrMoV according to DIN17200 standard
Adopting world-renowned brand anti-wear roller bearings
The hook can rotate 360 degrees
Equipped with a spring-loaded safety buckle to prevent slipping



3.2 Large and small vehicle walking mechanism
3.2.1 Running the motor
Specialized squirrel cage motor for European cranes
The continuously variable transmission runs smoothly without crawling, reducing the shaking of heavy objects during start-up and shifting
Protection level IP55, F-class insulation
Motor continuity rate 60% ED
Fully sealed, maintenance free
Built in thermistor overheat protection
The motor casing is formed by stamping aluminum tubes

3.2.2 Walking gearbox
European crane specific three in one reducer, small in size and light in weight
The gear material is chromium molybdenum nickel alloy and wear-resistant bearings are used
CNC automatic gear machining center production, hard tooth surface (HRC60), after grinding treatment
Half grease lubrication, maintenance free
Direct drive design, directly output to the wheels without coupling, high transmission efficiency, low-carbon and energy-saving

3.2.3 Brakes
Electromagnetic disc brake, normally closed design
Brake pad lifespan: no less than 1 million normal uses and no less than 500 emergency braking cycles
Large friction area, constant braking torque, adjustable brake pad clearance (i.e. adjustable braking torque)
Friction pads are asbestos free and environmentally friendly
Fully sealed, dust-proof, maintenance free
3.2.4 Wheels
European direct drive design
Ductile iron or alloy steel forging, surface hardening treatment
Adopting self-aligning roller bearings

3.2.5 Limit switch
Using mechanical cross lever limit or infrared photoelectric wireless limit switch
Deceleration limit function improves brake life and safety
Reflectors or limit levers are installed at both ends of the walking direction
Equipped with automatic reset function
Protection level IP65

3.3 Whole machine structure
European modular design, low height, light weight, and low wheel pressure
Small ultimate size, increasing effective working area
Reduce the height of the factory building and save construction costs
Plug in electrical connection, easy to install and maintain
Low carbon and environmentally friendly
4 Electrical part
4.1 Safety monitoring unit specially developed for cranes (standard)
A safety monitoring device specifically designed for cranes;
The security monitor microprogram has the following security monitoring functions:
Calculate the remaining safe working cycle of the lifting mechanism
Accumulated lifting working time
Accumulated overload times
Accumulated starting times of lifting motor
Overheating protection and alarm for lifting motor
Overload protection and alarm
Brake pad thickness warning

4.2 Professional Vector Frequency Conversion Control System for Cranes
The performance of cranes has been developing with the advancement of speed control system technology. Our company's cranes have always been pioneers in applying vector frequency conversion technology to crane operations;
The variable frequency stepless speed regulation of the crane produced by our company is a proven and successful solution. Its unique product features can fully meet the needs of safe and efficient crane operation;
The frequency converter adopts Schneider products;

Variable frequency system
Ensure precise positioning of the load
Reduce the shaking of heavy objects
Expand speed range
Adjustable acceleration
Smooth braking
easy operation

4.3 Electrical Description
The cranes produced by our company are powered by safety sliding contact wires
The sliding contact wire is a compact composite sliding contact wire with anti-corrosion and insulated casing.
Lightweight, easy to install, maintenance free, operating temperature range: 30 ° C to+60 ° C
Advantages such as high conductivity and reduced voltage, with a load duration of up to 80% and low voltage drop
The collector has a high sliding speed, reaching up to 250m/min at the fastest, ensuring continuous power supply
The power supply of the entire machine is controlled by a manual main power switch, so that the power can be easily cut off during crane maintenance or when the crane is not working for a long time;
The circuit goes through the main switch, then from the main fuse to the main contactor with an emergency stop button, followed by various protection switches;
The cranes produced by our company have protective functions required by safety regulations:
Voltage loss protection
Grounding protection
Short circuit protection
Overheating protection
overload protection
Overspeed protection
Limit protection
Overcurrent protection
Lack of phase protection, etc
The control circuit is output by a transformer with a control voltage of 48V. This control voltage regulator ensures sufficient power output when lifting and the operation of large and small vehicles occur simultaneously;
The crane is controlled by a ground flashlight door, spacecraft cab, or remote control, and all lifting and walking actions are independent and can be operated simultaneously;
The ground operation handle adopts TE products with a protection level of IP65, suspended with soft and fine steel wire, and the flashlight door is equipped with an independent slide that is separated from the lifting mechanism and can move freely along the main beam;
The control box is made of steel plate and has undergone anti-corrosion treatment on the surface. Opening the box cover requires a special key or screwdriver. Reasonable layout of internal components for easy maintenance;
Protection level IP55, with waterproof protection function, ambient temperature:< 45C, humidity<90%;
The main power supply of the crane is three-phase four wire 380V (+/-10%), 50Hz (+/-5%);
The fixed cables used for cranes are multi-core and plastic insulated. The control cable adopts a multi stranded copper core cable with a cross-sectional area of at least 1.5mm2. The dimensions of other cables comply with international safety regulations;
All wires are marked with colors, numbers, or wire numbers for easy identification. All external cables are marked with wire numbers. Fixed cables are arranged in cable trays or with protective sleeves (galvanized steel pipes);
Car towing cable system:
The trolley towing cable system includes: elastic flat cable, towing trolley (with bracket), and sliding groove
Flat cables use rubber insulation with good elasticity
The cable is fixed and suspended on the trolley bracket of the towing trolley
The towing trolley moves in the groove, and the I-beam groove is connected to the main beam through the support rod
The trolley bracket ensures that the towing cables do not interfere with each other under any circumstances
All cables are plug-in connections, using international standard aviation sockets that correspond one-to-one and are easy to connect;
The main contactors and other electrical components are made of Siemens or Schneider (TE) products.

5 Surface treatment
After welding and forming, the entire main beam of the steel plate must undergo stress relief shot blasting pretreatment, with a grade of SA2.5
The steel structure paint is epoxy zinc rich paint, with two bottoms and two surfaces, and the total coating thickness is not less than 120um
Main beam steel structure color: RAL1028 (medium yellow)
The paint of the components is E120 (gearbox, motor, hook, brake, trolley, etc.). The standard topcoat color is:
Lifting unit RAL7021 (gray black)
Motor, gearbox RAL7021 (gray black)
The purchased parts shall retain their original paint standards
The inside of the electrical cabinet is also painted
During shipment, all metal surfaces are protected against moisture and dampness

6 Tests
Factory testing and quality control of general bridge cranes
The standard inspection and testing of the cranes produced by our company meet the needs of the vast majority of customers.
If required, our company's cranes can be inspected by a third party to ensure that the equipment is manufactured according to technical requirements. But a fee will be charged for this part of the testing.
If required, our company's cranes can also arrange for customer specified inspections and tests, and such tests and detailed test procedures must be approved by both parties before the test. But a fee will be charged for this part of the testing.
We welcome customers to be present during factory testing before shipping/shipment.
steel structure
All raw materials come with factory qualification certificates
All welders have qualification certificates
The main welds have undergone non-destructive testing
Mechanical part
The hook has an approved certificate, including an ultrasonic testing report
Certificate of Conformity for Steel Wire Rope
Gears undergo no-load testing and hardness testing
Motor testing includes resistance, insulation resistance, high voltage, short circuit measurement, and no-load test
install
Pre installed cable tray ensures correct span and positioning
Using an optical measuring instrument to check wheel alignment and ensure accuracy
test
Check the functionality of the entire vehicle and adjust the various speeds and hook distances through the factory's no-load test