The 100 ton double girder overhead crane, as a key equipment for heavy material handling, plays a pivotal role in modern industrial fields. This crane is widely used in large factories, warehouses, ports, and other places due to its strong lifting capacity and stable operating performance. This design manual aims to comprehensively explain the design concept, mechanical structure, electrical system, control system, and manufacturing and installation process of the 100 ton double girder overhead crane, in order to provide detailed technical references for relevant technical personnel. By deeply analyzing its various technical parameters and performance indicators, readers will be able to fully understand the design highlights and practical application value of the crane, and thus better guide actual operation and maintenance work.

Design Overview

Introduction to Double Girder Overhead Crane

As a heavy equipment widely used in industrial environments, the core structure of a double girder overhead crane consists of two parallel main beams with sufficient strength and stiffness, and end beams located at both ends for positioning and support, forming a bridge system. This design ensures that the crane can maintain stability and effectively perform horizontal movement operations even when subjected to huge loads in the vertical direction. The double girder overhead crane achieves the lifting and handling of goods through the lifting mechanism, operating mechanism, and electrical and control systems. These components work together to enable the crane to efficiently complete cargo handling and lifting tasks in large workshops and warehouses. As a large equipment, the 100 ton double girder overhead crane has the characteristics of strong bearing capacity, wide operating range, and smooth operation, and is suitable for large workshops and warehouses. This crane has a rated lifting capacity of 100 tons and can meet the needs of various heavy lifting operations. Its operating mechanism is well-designed, ensuring stable operation even under high-intensity use and high operational efficiency. In addition, the electrical and control system of the 100 ton double girder overhead crane has a high degree of intelligence, which can achieve remote control or automatic operation, further improving the safety and accuracy of the operation.

Design purpose and principles

The purpose of this design is to develop a 100 ton double girder overhead crane that meets specific work environments and operational requirements. During the design process, we followed the following principles:

1. Strength and stiffness: Ensure that the crane structure can maintain sufficient strength and stiffness when subjected to ultimate loads, preventing safety hazards caused by deformation or damage.
2. Operational accuracy and stability: By optimizing the mechanical structure and control system, the operational accuracy and stability of the crane can be improved, and safety accidents caused by vibration or deviation can be reduced.
3. Electrical and control system: Advanced electrical components and control systems are used to achieve automation and intelligent operation, improving work efficiency and safety.
4. Economy and practicality: While meeting customer needs, consider manufacturing costs and maintenance convenience to ensure the economy and practicality of the product.

Scope of application and working environment

The 100 ton double girder overhead crane is widely used in large workshops, warehouses, shipyards, steel plants and other places that require heavy lifting operations. Their working environment is usually harsh, such as high temperature, high humidity, and high dust. Therefore, in the design process, the influence of these factors was fully considered and corresponding protective measures were taken to ensure the reliability and durability of the crane.

Main technical parameters and performance indicators

The main technical parameters of the 100 ton double girder overhead crane designed this time include: rated lifting capacity of 100 tons, customizable span according to customer needs, adjustable lifting height according to operational requirements, and operating speed that meets the requirements of efficient operation. In terms of performance indicators, we focus on the load-bearing capacity, smooth operation, positioning accuracy, as well as the stability and reliability of the electrical and control systems of the crane. Through the optimization design of these key parameters and performance indicators, our goal is to provide customers with an efficient, safe, and reliable 100 ton double girder overhead crane product.

Mechanical Structure Design

In mechanical structure design, the design of main beam and end beam is the key to carry the whole crane structure. High-quality steel is the ideal design material because of its high strength and good weldability. The fine cross-section design ensures that the main girder maintains sufficient strength and stiffness when it is subjected to huge loads. The cross-section shape of the main girder is optimized to meet the strength requirements and ensure sufficient stiffness, so that the structure can remain stable during operation. The design of the end girder, as the supporting structure of the crane, is also crucial. In order to increase the strength and stiffness of the endcarriage, a closed box structure is adopted and reinforcement bars are added in key areas. This design enables the endcarriages to remain stable when subjected to lateral forces without excessive deformation. In order to further improve the overall stability of the structure, the connection between the main beam and the end beams is also optimized. High-strength welding materials and advanced welding technology are used to ensure the strength and sealing of the connection. Connection ribs and reinforcement plates are also added to enable the structure to work better together during operation and improve overall stability.

The hoisting mechanism, as the core component of the crane, is responsible for the lifting and transportation of goods. In order to realize the smooth lifting and landing of the goods, advanced winches and wire ropes are adopted as the main components. The winch has a stable transmission ratio and high efficiency, which can ensure the smoothness of the goods in the lifting process. The steel wire rope has high strength and wear resistance, and is able to withstand huge tensile force without being easily damaged. In order to further improve the safety of the hoisting mechanism, an overload protection device is also set. When the weight of the cargo exceeds the rated load of the crane, the device will automatically issue an alarm and take corresponding protective measures to avoid safety accidents caused by overloading.

The running mechanism is an important part of the crane, responsible for its movement on the track. In order to realize the smooth running and precise positioning of the crane, a high-performance motor and reducer are used as the power source. The motor has stable output power and high efficiency, which can ensure the smoothness of the crane in the process of operation. The reducer has a large transmission ratio and good load-bearing capacity, which can ensure the stability of the crane in high-speed operation. Precise transmission and control systems are also used to make the crane move more accurately and stably on the track. In order to prolong the service life of the running mechanism, the friction and wear of the track are also considered. Wear-resistant materials are used to make the track, making it have good wear resistance and corrosion resistance. A lubrication device is also set up to regularly lubricate and maintain the running mechanism to reduce the friction resistance and prolong the service life.

In the design of mechanical structure, the design of safety protection devices is an indispensable part. In order to ensure the safety of the crane, a series of safety protection devices are designed. Limit switches can limit the operating range of the crane to avoid safety accidents caused by excessive operation. Emergency stop button can quickly cut off the power supply in case of emergency to ensure the safety of personnel. The overload protection device can automatically issue an alarm and take corresponding protective measures when the weight of the cargo exceeds the rated load. Windproof device can fix the position of the crane to avoid accidents caused by strong wind. The use of these safety protection devices makes the crane safer and more reliable in operation.

Electrical System Design

Electrical control circuit design

Electrical control circuit is the core part of crane to realize automation and intelligent operation. We adopt advanced PLC (Programmable Logic Controller) and touch screen as the main control components, through accurate programming and repeated debugging, to realize the automation and intelligent operation of the crane.PLC controller has the functions of high-speed processing, logic judgment and real-time control, and can accurately control the various components of the crane according to the preset program. The touch screen serves as the human-computer interaction interface, which is convenient for operators to input commands and view information.

Under the premise of ensuring functionality, we also pay special attention to the reliability and stability of the electrical system. To achieve this goal, we adopted redundant design techniques and designed backup systems on key components to prevent the entire electrical system from failing if the main system fails. At the same time, we introduced self-diagnostic fault technology, which is able to monitor the operating status of the electrical system in real time and detect and warn of potential faults in a timely manner, thus greatly improving the reliability and safety of the electrical system.

Motor selection and configuration

As the power source of crane operation, the performance of the motor directly affects the operational efficiency and stability of the crane. We have carefully selected high-performance motors and made reasonable configurations according to the specific operational requirements of the crane, the working environment and the load size and other factors. These motors are characterized by high power, high efficiency and smooth operation, which can ensure that the crane’s needs are met during heavy-duty operation.

Considering the heat dissipation problem of the motors under long-time high load operation and the potential hazardous factors in the working environment, we have especially adopted advanced heat dissipation devices and comprehensive protective measures. The heat dissipation device includes fan cooling, oil cooling and other means to ensure that the motor can effectively reduce the temperature during operation and maintain a stable working condition. Protective measures cover waterproof, dustproof, corrosion-resistant and other aspects to cope with a variety of complex working environments, to ensure that the reliability and durability of the motor is fully guaranteed.

Sensors and detection devices

In order to realize precise control and positioning of the crane, we have equipped a series of high-precision sensors and detection devices. Common sensors include displacement sensors, weight sensors, angle sensors and so on. These sensors are able to monitor the running status of the crane and cargo information in real time, and transmit the data to the control system for processing and analysis. Through the application of sensors and detection devices, we realize the precise control and positioning of the crane, making the operation more accurate and efficient.

Electrical safety protection measures

Electrical safety protection measures are an indispensable part in the design of crane electrical system. We use a variety of electrical protection equipment to ensure the safety of the electrical system, such as leakage protector, short circuit protector, overload protector and so on. When the electrical system has an abnormal situation such as leakage, short circuit or overload, these protection devices can cut off the power supply in time to prevent accidents. We also set up grounding devices and lightning protection devices to improve the lightning strike and interference resistance of the electrical system, which further guarantees the safety of the electrical system.

Control System Design

PLC control system design

In the automation and intelligent transformation of cranes, PLC control system plays a crucial role. After we deeply understand the operating characteristics and working environment of various cranes, we carefully choose the high-performance PLC controller as the core component of the whole control system. Through the use of advanced programming technology and sophisticated debugging process, we successfully connect the PLC control system with the crane’s various functional modules seamlessly to realize the precise control and intelligent operation of the crane’s components.

Human-machine interface design

In order to provide a clear, intuitive and efficient interactive experience, we use a high-performance touch screen monitor as the main component of the human-machine interface. The interface design pays attention to details and adopts an intuitive and easy-to-use operation mode, so that the operator can easily get started and quickly master the various control operations of the crane. At the same time, we fully consider the safety and convenience, set up a wealth of alarm functions on the interface, so that in the event of abnormalities in the crane, it can be the first time to send a warning to the operator, and guide him to take appropriate countermeasures.

Control system programming and commissioning

Programming and debugging of the control system is the key link to ensure that the crane can operate accurately and stably according to the predefined logic and process. According to the specific operational requirements of the crane, the working environment and safety regulations, we have carefully written a detailed and rigorous control program code, and with the help of professional debugging tools and methods, we have repeatedly tested and verified the program to ensure that its correctness and reliability in the actual operation of the crane reaches the highest standards. During the debugging stage, we pay special attention to the stability, response speed and anti-interference ability of the control system, and through continuous optimization and improvement, the whole control system reaches the optimal state in terms of performance.

Fault diagnosis and alarm system

In order to significantly improve the reliability and safety of the crane, we fully utilize advanced fault diagnosis technology and alarm devices to build a comprehensive and efficient fault diagnosis and alarm system. This system is able to monitor in real time the operating status and potential failure information of all key components of the crane, including but not limited to motor temperature, bearing vibration, hydraulic system pressure, electrical wiring status and so on. Once any abnormality or potential malfunction is detected, the system will immediately notify the operator through the preset alarm mode and guide him to take appropriate measures to deal with it according to the preset emergency plan. Through this real-time monitoring and early warning mechanism, we can ensure that the crane failure problems are found and solved at the first time, thus maximizing the protection of the normal operation of the equipment and the safety of the operators.

Manufacturing and Installation Processes

Material selection and processing requirements

The selection of materials and processing quality directly affect the performance and service life of the crane. According to the design requirements of the crane and the working environment, we select high-quality materials with high strength, high toughness, corrosion resistance and other characteristics to ensure that the crane can maintain good performance and stability during heavy-duty operation. These materials not only have excellent physical properties, but also have a high degree of reliability and durability, which can meet the requirements of cranes in a variety of complex working conditions. Strict processing requirements are set. During material processing, we use advanced processing equipment and techniques to ensure that the dimensional accuracy and surface quality of each component meets the design standards. Meanwhile, we also pay attention to the control and management of the processing process, and strengthen the supervision and inspection of the processing process to ensure that each component can reach the high quality level.

Manufacturing process

Manufacturing process is the key to ensure the quality and efficiency of crane manufacturing. We have developed a detailed manufacturing process flow according to the design requirements of the crane and the characteristics of the manufacturing process. It includes steps such as material preparation, component processing, assembly and commissioning. During the manufacturing process, we pay attention to the quality control of each link and strengthen the inspection and supervision of the manufacturing process to ensure that the quality and performance of each component meet the design requirements. We also pay attention to the optimization and innovation of the manufacturing process to continuously improve the manufacturing efficiency and product quality.

Installation and commissioning steps

Installation and commissioning is an important part to ensure the normal operation of the crane. We have formulated detailed installation and commissioning steps and strictly follow them. In the installation process, we focus on the positioning and fixing of the crane to ensure the stability and safety of the crane. We accurately complete the installation position and connection relationship of each component to ensure that the overall structure and function of the crane can be correctly realized. During the commissioning process, we focused on the operating performance of the crane and the working status of the control system, and made corresponding adjustments and optimizations. By testing and evaluating the operational performance of the crane, we ensure that it can operate stably and efficiently under various working conditions; and we test and debug the functions of the control system to ensure that the commands can be executed accurately and timely.

Quality testing and acceptance standards

Quality inspection and acceptance is an important means to ensure that the quality and performance of cranes meet the design requirements. We have formulated strict quality testing and acceptance standards, and carried out comprehensive testing and acceptance work on the crane. It includes appearance inspection, performance test and safety protection device inspection. In the appearance inspection, we check the overall appearance of the crane to ensure that there is no damage to its surface, no deformation and other defects; we check the connection of key components to ensure that they are firmly and reliably connected. In the performance test, we test and evaluate the performance indexes of the crane, such as lifting capacity, hoisting speed, running stability, etc., to ensure that it meets the design requirements and national standards. The safety protection devices are tested and debugged to ensure that their functions are normal and reliable. Through the implementation of quality inspection and acceptance work, we ensure that the quality and performance of the crane meet the design requirements and satisfy the expectations of customers.

Overview of Quality Inspection and Acceptance Standards

Testing/acceptance items	Testing/acceptance content	Standards/Requirements
Visual inspection	Overall appearance	No surface damage, deformation or other defects
	Key component connection	The connection is firm and reliable
Performance Testing	Lifting capacity	Meets design requirements and national standards
	Lifting speed	Meets design requirements and national standards
	Operational stability	Smooth operation without abnormal vibration or noise
Inspection of safety protection devices	Various functional tests	Functions are normal and reliable, such as overload protection, limit protection, etc.
	Debugging and Testing	All instructions can be executed accurately and promptly

Quality inspection details and standards

Testing process	Detecting details	Judgment criteria
Material quality	Material certificate	The material meets the design requirements and has characteristics such as high strength, high toughness, and corrosion resistance
	Machining accuracy	Dimensional accuracy and surface quality meet design standards
Manufacturing process	Process implementation	Strictly manufacture according to the established process flow
	Quality supervision	The quality control records for each stage are complete and there are no quality issues or omissions
Installation quality	Positioning and fixation	Accurate installation position, secure fixation, and no looseness
	Component connection	All components are connected correctly and the fasteners are not loose
Debug process	Operational performance	Smooth operation without any abnormal noise or vibration
	Control system	Control instructions respond quickly without delay or misoperation
Acceptance process	Acceptance documents	Complete acceptance documents, including quality inspection reports, performance test reports, etc.
	Integrated assessment	Quality and performance meet design requirements and satisfy customer needs

Safe Operating Procedures and Maintenance

Safe Operation Regulations

In order to ensure the safe and efficient operation of cranes, we have formulated a set of comprehensive and detailed safety regulations for crane operation. This set of regulations covers the preparation work before operation, the key precautions in the daily operation process and the proper handling methods in the face of emergencies.

In terms of pre-operation preparation, firstly, the operator is required to understand and familiarize with the performance parameters, structural characteristics and working principle of the crane in detail, to ensure that he has the necessary theoretical knowledge and skill base. Next, a comprehensive inspection of the crane, including but not limited to: confirming the spreader, wire rope, hydraulic system, electrical control system and other key components of the state is normal, as well as confirming the safety of the environment at the operating site, such as no obstacles blocking, no personnel close to the danger zone and so on. At the same time, according to the actual operational needs, reasonable planning of lifting routes and lifting programs to ensure that the entire operation process is smooth and safe.

In the daily operation process, the operator must strictly abide by the relevant safety regulations and operating procedures, maintain a high degree of vigilance, and always pay attention to the observation of the crane’s operating status. In the lifting operation, we should ensure that the connection between the spreader and the lifting object is firm and reliable, and avoid overloading, partial load, etc.; in the operation process, try to avoid rapid acceleration or deceleration to reduce the wear and tear on the various parts of the crane; when encountering bad weather such as strong winds, heavy rain, etc., we should suspend the operation in accordance with the regulations, so as to avoid accidents.

For the handling of emergencies, we have developed a detailed emergency plan. For example, in the event of power failure, hydraulic system failure, etc., the backup power supply should be activated quickly or manual operation should be carried out according to the preset procedures; in the event of serious potential accidents such as accidental slipping of suspended objects or loss of control of the equipment, the emergency stopping device should be activated immediately and it should be ensured that all the relevant personnel are evacuated to the safe area quickly. In addition, operators are also required to conduct regular simulation drills to familiarize themselves with and master all kinds of emergency measures, so as to really be able to cope with emergencies calmly.

By strictly following the above safety regulations, not only can we minimize the safety risks during crane operation, but also effectively extend the service life of the crane to ensure that it serves the production and life in an efficient and safe state.

Routine maintenance

Routine maintenance is essential to keep the crane running normally and extend its service life. We have developed a rigorous routine maintenance program and require operators to strictly follow the plan. Maintenance work covers a number of aspects. The first is cleaning, to keep the appearance of the crane neat and tidy, and regularly clean up dust and dirt to ensure the appearance of the equipment is beautiful. The second is lubrication work, regular inspection and replacement of lubricants to ensure that the components can run smoothly and reduce wear and tear. In addition, regular inspections are also important, through which potential problems can be identified and solved to prevent equipment failure. The execution of these routine maintenance tasks is essential to keep the crane running normally and extend its service life.

Regular Inspection and Repair

In order to ensure that the performance and safety of our cranes meet the requirements, we have established a detailed regular inspection and maintenance program. According to the plan, we carry out comprehensive inspections and maintenance work on all parts of the crane. These inspections include checking the wear and tear of components, testing the electrical system and commissioning the control system. Through the implementation of regular inspection and maintenance, we are able to detect and deal with crane faults in a timely manner to ensure the performance and safety of the cranes. At the same time, we also emphasize the training and technical guidance for operators to equip them with the necessary inspection and maintenance skills so that they can detect and deal with problems in a timely manner in their daily work.

Troubleshooting and Emergency Response

In order to cope with possible failures and abnormalities of cranes, we have formulated detailed troubleshooting and emergency handling plans. These plans cover common causes and phenomena of failure, as well as the corresponding troubleshooting methods and emergency measures. We not only carry out training and drills, but also require operators to accumulate experience in their daily lives to improve their troubleshooting and emergency handling abilities. When the crane malfunctions, the operator can quickly determine the cause of the malfunction and take corresponding measures to eliminate or emergency treatment to ensure the normal operation and safety of the crane.