Installation and construction plan of 10-ton gantry crane in steel bar yard

 As an important part of the construction project, the efficiency and safety of the steel bar yard are directly related to the progress and quality of the entire project. As an important lifting equipment in the steel bar yard, the formulation of the installation and construction plan of the 10 ton gantry crane is particularly important. The plan aims to ensure that the installation process of the gantry crane is both efficient and safe, so as to meet the actual needs of the steel bar yard. Through the careful selection of the installation location, proper treatment of the ground, strict inspection of the equipment and full preparation of the installation tools, we will lay a solid foundation for the installation of the gantry crane. Next, the plan will elaborate on the key links such as the foundation construction, main assembly, electrical system and safety equipment installation of the gantry crane to ensure that each step meets the specifications, and finally verify the performance and safety of the gantry crane through strict quality inspection and trial operation.

Installation and Construction Overview

The installation and construction of the 10T gantry crane in the steel bar yard is a complex and delicate project, the purpose of which is to ensure that the gantry crane can have stable operating performance and high working efficiency after it is put into use. In order to achieve this goal, we have formulated a detailed and comprehensive installation and construction plan. The plan covers all aspects from the initial installation location selection, foundation construction, main structure assembly process, to the final electrical system and safety equipment installation.

In terms of installation location selection, considering the convenience of hoisting operations, structural stability and safety of later maintenance, the foundation construction link is crucial. The team needs to strictly follow the design plan to carry out foundation treatment, embedded parts setting and concrete pouring to ensure the firmness and flatness of the gantry crane installation foundation. The main assembly process requires operators to have high-precision operating skills and rich practical experience.

The installation of electrical systems and safety equipment should not be ignored. Including but not limited to the installation and commissioning of control systems, drive devices, various sensors, and guardrails, etc., must be carried out in accordance with the specifications to ensure the overall operation effect and safety of the gantry crane. Through scientific and reasonable construction steps and a strict quality control system, ensure that every link meets the design requirements and meets the actual use needs.

Pre-installation preparations

Installation location selection and ground treatment

Before installing the gantry crane, it is necessary to conduct a comprehensive inspection of the steel bar yard to understand the environment, topography and landforms of the site. Select an area with flat terrain, no obstacles and a foundation bearing capacity that meets the requirements as the installation location. In terms of ground treatment, the ground needs to be cleaned, weeds, gravel and other debris removed, and leveled and compacted. Ensure that the ground is solid and flat to meet the installation requirements of the gantry crane. At the same time, calculate and determine the bearing capacity of the foundation based on the size and weight of the gantry crane. If the foundation bearing capacity is insufficient, the foundation needs to be reinforced to ensure the stability and safety of the gantry crane.

Equipment inspection and acceptance

After the equipment arrives, it is necessary to conduct a comprehensive inspection of all components of the gantry crane. Including key components such as the main beam, outriggers, trolleys, and overhead cranes, ensure that they are intact and the specifications and models are correct. At the same time, check the technical documents such as drawings and instructions that come with the equipment to ensure that they are complete and accurate. Only after confirming that the equipment is correct can it be accepted and the relevant procedures can be handled. This step is crucial to ensure the integrity and compliance of the equipment and provide guarantees for subsequent installation and use.

Installation tools and equipment preparation

In order to successfully complete the installation of the gantry crane, the required tools and equipment need to be prepared in advance. According to the needs of the installation and construction, prepare the necessary tools and equipment such as cranes, wrenches, screwdrivers, measuring tools, etc. in advance. Ensure that all tools and equipment are in good condition and can meet the construction requirements. At the same time, count the required materials such as bolts, nuts, gaskets, etc. to ensure that they are sufficient in quantity and the specifications and models are correct. These preparations will provide strong support for the subsequent installation work and improve work efficiency and quality.

Gantry crane foundation construction

Track foundation construction

Track foundation construction plays a vital role in the gantry crane installation project. First, the technicians need to study and understand the design drawings and specification requirements of the gantry crane in detail, and accurately calculate the foundation position and size of each track according to the drawings to ensure that the foundation layout not only meets the space and load-bearing requirements required for the operation of the equipment, but also takes into account the actual conditions and safety regulations of the construction site.

After determining the location of the track foundation, the foundation excavation work is carried out. This step requires the operators to correctly perform excavation, cleaning and compaction operations in accordance with the prescribed safety factors and construction standards to ensure the bearing capacity and stability of the foundation. The next step is the steel bar binding link. The technicians need to accurately calculate and configure steel bar materials with sufficient strength and durability to ensure the firmness of the track foundation structure.

Concrete pouring is a key step in the construction of the track foundation. During the construction process, the appropriate concrete materials are strictly selected according to the design plan, and the concrete ratio is controlled, including the proportion of cement, aggregate, admixture and water, to ensure that the concrete reaches the strength grade and working performance required by the design. During the pouring process, concrete is evenly poured into the mold by mechanical or manual means, and is fully vibrated and compacted to eliminate internal voids and surface unevenness, so that the surface flatness of the concrete foundation meets the installation accuracy requirements.

Through the above processes, a solid and flat gantry crane track foundation is completed. This will provide strong support for the subsequent gantry crane installation work, ensure that the gantry crane is stable and smooth during operation, and effectively extend the service life of the equipment.

Running track installation

The installation of the running track is the cornerstone of the overall performance of the gantry crane. Before starting the installation, the track is first pre-treated, including removing surface dirt and rust, and performing necessary corrections and rust removal to ensure the cleanliness and service life of the track. The technicians need to accurately calculate the installation position and precise size of each track based on the design drawings and on-site measurement data to ensure that the track layout meets the design requirements.

After completing the track pre-treatment, use professional equipment to accurately place the track on the constructed foundation. In this process, it is necessary to use measuring instruments to continuously check the horizontal and vertical positions of the track to ensure that it meets the design standards. At the same time, special attention should be paid to controlling key parameters such as the spacing and height difference of the tracks, which directly affect the stability and smoothness of the gantry crane during operation.

As each track is precisely in place, the track is finely adjusted with the help of professional measuring instruments and adjustment tools. Ensure that each track remains flat and straight throughout its entire length, and its relative position to other tracks is accurate. Such work is essential to maintaining the stability and accuracy of the gantry crane during operation.

During the installation of the running track, it is also necessary to strictly follow the relevant construction specifications and safety requirements, and take effective safety protection measures to prevent accidents. At the same time, it is necessary to ensure that the construction personnel have the corresponding professional skills and qualifications to ensure the quality of the project.

Gantry crane main assembly

Main beam and outrigger assembly

The main beam and outrigger are the main load-bearing components of the gantry crane and are also the basic structure of the entire gantry crane. Before assembly, the main beam and outrigger need to be thoroughly cleaned and inspected. Cleaning work includes removing surface dirt, oil stains and moisture to ensure that the surface is clean and tidy. Inspection work includes careful inspection of the size, shape and material of the main beam and outrigger to ensure that they meet the design requirements and there is no damage or deformation on the surface.

According to the design drawings and assembly process requirements, the main beam and outrigger need to be assembled accurately. This usually involves using equipment such as cranes to hoist the main beam and outrigger to the predetermined position, and performing welding, bolting and other processes. During the assembly process, the assembly accuracy and welding quality need to be strictly controlled. This includes using advanced measuring equipment and welding processes to ensure that the connection parts of the main beam and outrigger can be accurately docked, and to ensure that the welding quality meets the design requirements.

Assembly of trolley and overhead crane

The trolley and overhead crane are the moving and lifting mechanisms of the gantry crane and one of its core components. Before assembly, the various components of the trolley and overhead crane need to be thoroughly cleaned and inspected. Cleaning work includes removing surface dirt, oil stains and moisture to ensure that the surface of each component is clean and tidy; inspection work includes careful inspection of the size, shape and material of each component to ensure that it meets the design requirements and there is no surface damage, deformation and other problems.

According to the design drawings and assembly process requirements, the various components of the trolley and overhead crane need to be assembled accurately. This usually involves using equipment such as cranes to lift the components to the predetermined position, and to debug and test run them. During the assembly process, the assembly accuracy and debugging quality also need to be strictly controlled. This includes the use of advanced measuring equipment and debugging technology to ensure that the operation of the trolley and overhead crane is smooth and reliable and meets the design requirements.

Lifting and fixing of the legs

After the legs are assembled, the legs are lifted and fixed. First, a crane is needed to lift the legs to the predetermined position. During the lifting process, the stability and safety of the legs need to be ensured to avoid shaking or tilting. Then, the position and height of the legs are adjusted using measuring tools to ensure that they meet the design requirements. Finally, the legs are finally fixed and welded. During the fixing process, the stability and safety of the legs need to be ensured to avoid looseness or deformation.

Lifting and connection of the main beam

After the legs are fixed, the main beam is lifted and connected. First, a crane is needed to lift the main beam to the predetermined position. During the lifting process, the stability and safety of the main beam need to be ensured to avoid shaking or tilting. Then, the main beam is connected to the legs. During the connection process, the connection parts need to be kept clean and dry to avoid poor connection or welding quality problems. Next, the connection parts of the main beam are welded and bolted. During the welding process, the welding quality and welding sequence need to be controlled to avoid problems such as welding deformation or cracks. During the bolt connection process, the bolt tension and connection sequence need to be controlled to ensure the stability and reliability of the connection. Finally, the connection parts of the main beam and the legs are fully inspected and tested. This includes steps such as inspecting the appearance of the connection parts, measuring the connection quality, and commissioning the entire gantry crane.

Electrical system and safety equipment installation

Electrical system installation

As the core component of the gantry crane, the electrical system plays a vital role. It not only provides a continuous source of power support for the various functions of the gantry crane, but also collects, processes and transmits various operation signals to ensure the precise control and safe operation of the equipment. Before the formal installation, all electrical equipment and lines need to be thoroughly cleaned and carefully inspected. Cleaning work includes but is not limited to removing dust, debris and moisture inside the equipment to ensure good contact of the electrical equipment and avoid short circuits or failures caused by foreign objects; inspection work covers comprehensive testing of equipment performance, such as insulation resistance, grounding resistance, line integrity and functional verification of each component, etc., to ensure that all electrical components are in normal condition.

During the installation process, operations must be carried out strictly in accordance with the design drawings and established installation process requirements. This includes but is not limited to: accurately arranging and fixing the positions of various electrical equipment to ensure that their spatial layout meets both the requirements of electrical principles and the needs of actual operating space; reasonably laying out cable lines and taking protective measures to prevent line damage caused by mechanical wear or chemical corrosion, which affects the stable operation of the electrical system; rigorously and meticulously wiring electrical lines, following the correct wiring sequence and process standards, ensuring that all wiring terminals are firm and reliable, clearly marked, and avoiding heating or safety hazards caused by poor contact.

During the entire installation phase, the installation quality must be strictly controlled, especially the supervision of wiring quality. This covers every link from equipment fixing, line laying to final wiring, and strives to minimize the installation error of the electrical system through refined management and professional technical means, so as to ensure that the entire electrical system can operate efficiently, safely and stably, and provide a solid guarantee for the efficient operation of the gantry crane.

Safety equipment installation and commissioning

Safety equipment plays a vital role in gantry cranes. Once there is a problem with the installation quality or commissioning quality, it will directly affect the operation safety of the entire equipment and the life safety of the operators. Therefore, all safety equipment needs to be fully and carefully inspected and tested before installation. The inspection content should include multiple aspects such as the appearance integrity, functional normality, and performance stability of the equipment. For example: check the sensitivity of the limit switch, the braking effect of the brake, the sealing performance of the protective cover, etc. The test covers a comprehensive verification of the performance of the equipment, such as actual testing of the response time of the alarm device and the effectiveness of the emergency stop button.

When installing safety equipment according to the design drawings and installation process requirements, it is necessary to pay attention to the installation position of each device must be accurate and correct, and the fixation must be firm and reliable to ensure that it can play a normal protective role; for the installation of key safety components such as hydraulic systems and pneumatic systems, special attention should be paid to prevent internal damage or functional failure caused by improper installation; various pipelines and lines introduced during the installation process should be sealed to prevent leakage from affecting the normal operation of the equipment.

After the installation is completed, comprehensive commissioning must be carried out. The debugging content includes but is not limited to: checking whether the linkage of safety equipment meets the design requirements; whether the action of each protection device is accurate; whether the alarm signal corresponds to the actual fault situation, etc. Through repeated debugging and verification, it is ensured that all safety equipment can work normally according to the preset logic, and can respond quickly and take effective measures to protect when potential danger occurs.

Installation quality inspection and trial operation

Installation quality inspection

After the installation construction is completed, the installation unit needs to conduct a comprehensive and detailed quality inspection of the gantry crane. The scope of the inspection should cover the connection quality of each component, including the firmness and integrity of bolts, welding and other parts; quality inspection of welding parts to ensure that there are no welding defects such as cracks and pores; measure the installation accuracy of key components to ensure that they meet the design drawings and technical requirements. Functional testing and performance testing of the electrical system are also required, including comprehensive inspection of the control system, drive device, safety protection device, etc., to ensure that its operation is stable and reliable and meets the design requirements and usage requirements. During the inspection process, the inspection results and existing problems should be recorded in detail to provide a basis for subsequent processing and rectification work.

Trial operation and debugging

After the quality inspection is qualified, the trial operation and debugging of the gantry crane are carried out. During the trial operation, each function of the gantry crane needs to be tested one by one, including lifting function, moving function, braking function, etc. It is also necessary to monitor and debug the electrical system and safety equipment in real time to ensure its smooth and reliable operation. During the trial operation, the trial operation data and existing problems should be recorded in detail to provide a basis for subsequent processing and rectification. Through trial operation and debugging, the actual operation status of the gantry crane can be better understood, and existing problems can be discovered and handled in a timely manner to ensure that it meets the design requirements and usage needs.

Safety measures and precautions

Construction safety measures

During the construction process, it is necessary to always implement and enforce various safety operating procedures and safety production systems formulated by the state and enterprises. This is the basic document to ensure the smooth progress of construction activities and prevent safety accidents. All construction personnel must receive systematic safety education and training before taking up their posts, fully understand and master the safety operating procedures related to construction, and ensure the personal safety of themselves and others. The training content should cover but not be limited to: construction site safety, high-altitude operation safety, electricity safety, mechanical equipment operation safety, chemical use safety, etc., through the combination of theoretical teaching and practical operation, to enhance the safety awareness of construction personnel and the ability to deal with emergencies in various complex construction environments.

Obvious safety warning signs should be set up at the construction site, such as no smoking, no fireworks, beware of falling, beware of poisoning and other eye-catching warning signs to prevent unrelated personnel from entering the dangerous area, and full-time safety officers should be equipped to conduct regular inspections to promptly discover and correct unsafe behaviors and eliminate potential safety hazards. At the same time, construction personnel are encouraged to actively participate in safety management, report potential risks, and jointly create a safe and orderly construction environment. During the construction process, effective safety protection measures must be taken according to the characteristics of different operations. For example, when working at height, set up a stable safety net and safety belt; when working in a deep pit, ensure that there is sufficient lighting and guardrails; when using electrical equipment, follow the relevant operating procedures and wear insulating protective equipment, etc.

Safety training for construction personnel

In order to ensure that the overall safety quality of the construction team and the operating skills of each construction worker meet the requirements of the specifications, comprehensive safety training must be carried out regularly. The training content not only includes the safety operating procedures in daily construction, the relevant safety production systems of the enterprise and the country, but also covers the safety protection measures and emergency response methods in various construction environments. Through systematic and professional training, it aims to enable each construction worker to fully understand and master safety knowledge, and improve their self-protection awareness and practical operation skills during the construction process. At the same time, a strict assessment and evaluation mechanism is established to conduct regular safety knowledge assessment and operation skill assessment of construction personnel to ensure that they always maintain a high level of safety awareness and good work habits. For those who fail the assessment, retraining is required until they meet the standards, so as to ensure that the safety literacy of the entire construction team is always at a high standard.

Emergency response plan

It is inevitable to encounter various unexpected emergencies and emergencies during the construction process, such as fire, explosion, collapse, epidemic, etc. In order to respond quickly and effectively when a crisis occurs, a detailed and highly operational emergency response plan must be formulated. The plan should include: a clear emergency organization and its division of responsibilities, a detailed emergency response process (including early warning, activation, response, escalation, and release), sufficient emergency resource guarantees (such as manpower, material resources, information, etc.), and an emergency linkage mechanism with relevant departments. Through the formulation and implementation of the plan, casualties and property losses can be minimized in emergencies. At the same time, in order to ensure the effectiveness and practicality of the emergency response plan, drills and evaluations should be organized regularly. Drills can simulate real scenarios and test the feasibility of the plan; evaluation is a summary and feedback of the drill results, and improvements and perfection are made to existing problems, so that the plan always keeps pace with the times.

Installation and construction plan of 10-ton gantry crane in steel bar yard

Overview and explanation of the minimum turning radius of electric chain hoists

 As an important tool in the field of modern material handling, the performance and efficiency of the electric chain hoist are directly related to the smoothness and safety of the production line. Among numerous performance indicators, the minimum turning radius is a particularly critical factor, which is directly related to the operational flexibility and applicability of the hoist in complex spaces. Understanding and optimizing the minimum turning radius of the electric chain hoist can not only improve operational efficiency, but also effectively avoid safety hazards during operation. This article will delve into the concept, influencing factors, and multidimensional effects of the minimum turning radius of electric chain hoists on equipment performance, aiming to provide valuable reference and guidance for practitioners in related fields.

Overview of electric chain hoist

Definition and purpose of electric chain hoist

As an advanced lifting equipment, the working principle of the electric chain hoist is to use electric drive to lift and lower heavy objects through the meshing of the chain and sprocket. This type of lifting equipment has the characteristics of compact structure, easy operation, and stable lifting, and is widely used in various fields such as industrial production lines, warehousing and logistics, and construction sites. In material handling and assembly operations, electric chain hoists play a crucial role, greatly improving work efficiency and reducing labor intensity, becoming an indispensable part of modern industrial production.

Structure and working principle of electric chain hoist

The electric chain hoist is mainly composed of components such as electric motor, reducer, brake, sprocket, chain, and control system. After the power is turned on, the motor drives the reducer to operate, which in turn drives the sprocket to rotate. The chain then circulates along the sprocket groove to achieve the lifting and lowering of heavy objects. At the same time, the brake ensures rapid braking in case of power outage or emergency, ensuring operational safety.

The electric motor is the power source of the electric hoist, providing necessary power. The reducer is located between the motor and the sprocket, and its main function is to reduce the high-speed rotation of the motor to adapt to the speed requirements of the sprocket. The brake is an important guarantee for the safety of electric hoists, as it can quickly brake when needed to prevent accidents. The sprocket and chain are the core parts of the lifting mechanism, and the sprocket drives the weight up or down through the chain. Finally, the control system is the brain of the electric hoist, controlling the operation of the entire device.

Main features of electric chain hoist

The electric chain hoist, with its unique structure and design, exhibits many advantages. For example, compact structure, small space occupation, easy installation and maintenance; Improved stability, low noise, and minimal environmental impact; Easy to operate, precise control can be achieved through remote control or joystick; Strong adaptability, able to meet the lifting needs of heavy objects of different weights and shapes. These characteristics make the electric chain hoist highly favored in industrial production and logistics fields.

Analysis of the concept of minimum turning radius

Definition of minimum turning radius

The concept of minimum turning radius is mainly applied in the description of operational performance in the fields of vehicles, mechanical equipment, and special equipment, especially for modern lifting equipment such as chain electric hoists. Its definition refers to the minimum arc radius that the front wheels or guiding components need to pass through when turning during the operation of the equipment. This parameter not only reflects the maneuverability of the equipment during turning, but is also an indispensable technical indicator in the design, manufacturing, and operation processes.

For electric chain hoists, the specific meaning of the minimum turning radius is the minimum spatial range that can ensure the smooth completion of circular motion of their front wheels or guiding components without mechanical interference, collision, or damage when turning in a narrow space under specific working conditions, such as different tonnages and sizes of electric chain hoists. This range is usually influenced by multiple factors such as the size of the hoist itself, suspension method, working environment, and safety operating standards.

Application of minimum turning radius in electric chain hoist

In the practical application scenarios of electric chain hoists, especially when facing complex and narrow working environments, the concept of minimum turning radius is particularly crucial. It directly determines whether the electric chain hoist can efficiently and safely carry out heavy object handling, assembly, and lifting operations in these confined spaces. Therefore, for operators and equipment managers, a deep understanding and precise grasp of the minimum turning radius of the electric chain hoist not only helps to improve work efficiency and avoid operational difficulties caused by insufficient space, but also effectively prevents safety accidents and ensures the safety and stability of the entire operation process. Meanwhile, making reasonable use of the minimum turning radius parameter can also help optimize the workflow and improve overall work efficiency.

Factors affecting the minimum turning radius of electric chain hoist

The structural factors of the hoist itself

The self structure of the electric chain hoist has a decisive impact on its minimum turning radius. For example, the chain length, sprocket diameter, and reducer structure of a hoist can limit its flexibility in turning. A long chain will increase the radius of the hoist when turning, a small sprocket diameter will reduce the torque transmission efficiency of the hoist, and a complex reducer structure will increase the volume and weight of the hoist. By optimizing these structural parameters during the design and manufacturing process, the minimum turning radius can be reduced to a certain extent, improving the applicability of the hoist.

Load weight and shape factor

The weight and shape of the load will also affect the minimum turning radius of the electric chain hoist. Excessive load weight will increase the resistance of the hoist during turning and increase the minimum turning radius; Irregular shaped loads may increase the resistance of the hoist during turning, resulting in an increase in the minimum turning radius. Therefore, when selecting a chain electric hoist, it is necessary to consider the actual load situation comprehensively.

Limiting factors of operating environment

Factors such as the size of the operating environment and the distribution of obstacles can also limit the minimum turning radius of the electric chain hoist. In narrow or complex environments, hoists need to adjust their steering more flexibly to adapt to changes in the environment. This requires hoists to have high flexibility and adaptability in their design. Meanwhile, factors such as environmental temperature and humidity can also affect the performance of the electric chain hoist, reducing its work efficiency and service life.

Safety regulations and standard factors

In order to ensure the safety and reliability of electric chain hoists during operation, the country and industry have formulated a series of safety regulations and standards. These specifications and standards provide clear requirements for the minimum turning radius of hoists. Therefore, in the design and manufacturing process, it is necessary to strictly comply with these specifications and standards to ensure that the performance of the hoist meets the relevant requirements. In addition, a series of tests and validations are required to ensure the safety and reliability of the hoist.

The influence of minimum turning radius on the performance of loop electric chain hoist

The impact on work efficiency

The size of the minimum turning radius directly affects the flexibility and efficiency of the electric chain hoist during operation. In narrow or complex environments, if the minimum turning radius of the hoist is too large, it may lead to operational difficulties and low efficiency. When the minimum turning radius is too large, the hoist requires more space and distance during turning and movement, which can lead to a decrease in work efficiency. Therefore, by optimizing the structural design of the hoist and reducing the minimum turning radius, operational efficiency can be significantly improved. The optimized design of the electric chain hoist can better adapt to narrow and complex working environments, improving work efficiency.

Impact on security performance

The electric chain hoist needs to withstand significant loads and impact forces during operation. If the minimum turning radius is too small, it may cause interference or damage to the hoist during turning, leading to safety accidents. Therefore, setting a reasonable minimum turning radius is one of the important measures to ensure the safety performance of hoists. In order to ensure the safety performance of the hoist, it is necessary to fully consider the requirement of minimum turning radius in the design process.

The impact on equipment lifespan

The size of the minimum turning radius will also have an impact on the equipment lifespan of the electric chain hoist. In frequent turning and turning operations, if the minimum turning radius of the hoist is too small, it may lead to increased wear on components such as chains and sprockets, shortening the service life of the equipment. Therefore, in the design and use process, it is necessary to fully consider the impact of the minimum turning radius on the lifespan of the equipment. By setting the minimum turning radius reasonably, the wear and damage of components can be reduced, and the service life of equipment can be extended.

Adaptive impact on application scenarios

The application scenarios of electric chain hoists are diverse, and different scenarios have different performance requirements for hoists. By setting the minimum turning radius reasonably, the adaptability of the hoist to different application scenarios can be improved. For example, in a narrow warehouse, it is necessary to choose a hoist with a smaller minimum turning radius to meet operational requirements; On open construction sites, the minimum turning radius can be appropriately increased to improve work efficiency. Therefore, understanding and mastering the impact of minimum turning radius on the performance of loop chain electric hoists is of great significance for improving their adaptability in different application scenarios. In different application scenarios, it is necessary to choose the appropriate minimum turning radius according to actual needs to improve the adaptability and operational efficiency of the hoist.

As a core tool in the field of material handling, the minimum turning radius of the electric chain hoist is an important indicator for measuring equipment performance and applicability. We are well aware that in complex and ever-changing work environments, the minimum turning radius of the electric chain hoist is directly related to the flexibility and safety of operation. Therefore, when designing and manufacturing electric chain hoists, Dongqi Crane always pays attention to optimizing the structure of the hoist, such as chain length, sprocket diameter, and reducer structure, in order to reduce the minimum turning radius and improve the applicability and operational efficiency of the equipment. At the same time, we also fully consider the impact of factors such as load weight and shape, operating environment limitations, etc. on the minimum turning radius, and are committed to providing customers with more flexible, efficient, and safe lifting solutions, ensuring that customers can achieve efficient and stable material handling in various work scenarios.

Overview and explanation of the minimum turning radius of electric chain hoists

10 ton gantry crane foundation design for track plate factory

 

Design Overview

In order to meet the production needs of the track plate factory, a 10 ton gantry crane foundation design for track plate factory gantry crane is specially designed. The gantry crane will be used to hoist and transport track plates. Its foundation design must ensure stability and safety, and comply with relevant engineering specifications and geological conditions. The following is a detailed description of the foundation design of the gantry crane.

Design Basis

• Foundation engineering theory: based on the basic principles of foundation treatment, foundation selection and structural design.
• Geological exploration data: including key data such as foundation bearing capacity and soil properties.
• Data provided by the gantry crane manufacturer: including parameters such as the size, weight, and maximum hoisting capacity of the gantry crane.
• National relevant design specifications: such as "Code for Design of Building Foundations" (GB50007-2002), "Code for Design of Concrete Structures" (GB50010-2002), etc.

Design parameters

• Gantry crane specifications: 10T, the span is determined according to the actual site, and the floor height is set to a reasonable height according to the hoisting requirements.
• Foundation bearing capacity: According to geological exploration data, the characteristic value of foundation bearing capacity is not less than XXXKPa.
• Foundation form: reinforced concrete strip foundation is adopted to ensure stability and durability.
• Concrete strength grade: C30, meeting the structural design requirements.
• Steel bar configuration: According to the force analysis and structural requirements, the steel bars are reasonably configured to improve the bearing capacity and crack resistance of the foundation.

Foundation design

Foundation bottom surface design:

• According to the wheel pressure distribution of the gantry crane and the bearing capacity of the foundation, the size and shape of the foundation bottom surface are designed. Ensure that the bottom surface is evenly stressed to avoid local damage.

Steel bar configuration design:

• A certain number of steel bars are configured on the bottom surface to improve the compressive strength of the foundation.
• Steel mesh is configured on the top surface, which together with the stirrups constitutes an overall force system to improve the crack resistance and bearing capacity of the foundation.
• Others are configured according to the structural requirements to ensure the stability of the steel cage.

Expansion joint setting:

• In order to cope with the expansion and contraction deformation caused by temperature changes, a 20mm wide expansion joint is set every 20m.

Foundation position determination:

• The foundation position is determined according to the position of the beam pedestal to ensure that the running track of the gantry crane matches the production line.

Foundation verification

• Foundation bearing capacity verification: According to the maximum wheel pressure of the gantry crane and the characteristic value of the foundation bearing capacity, the foundation bearing capacity is verified. Ensure that the foundation bearing capacity meets the design requirements.
• Foundation deformation verification: According to the foundation compression modulus and load distribution, the deformation of the foundation is calculated. Ensure that the foundation deformation is within the allowable range to avoid adverse effects on the operation of the gantry crane.

Foundation internal force calculation

• Calculation of bending reinforcement of the foundation positive section: According to the bending moment and shear force on the foundation, calculate the required number and diameter of steel bars. Ensure that the configuration of steel bars meets the structural design requirements.
• Calculation of shear reinforcement of the foundation inclined section: Considering the shear force on the foundation, calculate the shear bearing capacity of the inclined section. Ensure the safety and stability of the inclined section.

Construction precautions

• Foundation construction: Carry out foundation construction according to the design drawings to ensure that the foundation size, shape and steel bar configuration meet the requirements.
• Concrete pouring: Use qualified concrete materials and pour and vibrate according to construction specifications. Ensure the quality and density of concrete.
• Maintenance and testing: After the concrete is poured, it is fully maintained. At the same time, the foundation is inspected and accepted to ensure that it meets the design requirements.

Conclusion

This design designs the foundation of a 10T gantry crane based on the production needs and geological conditions of the track plate factory. Through detailed design calculations and explanations of construction precautions, the safety and stability of the foundation design are ensured. This design can provide strong support for the production of the track plate factory and meet the needs of lifting and transportation.

(Note: The specific values ​​in the above design, such as the characteristic value of the foundation bearing capacity, the concrete strength grade, etc., need to be specifically calculated and determined according to the actual situation. At the same time, other factors such as geological conditions and climatic conditions need to be considered in the design process.)

Calculation Table of Foundation Reaction Force

Calculation Table for Basic Bending Distance

10 ton gantry crane foundation design for track plate factory

Design of 40.5t rail mounted container gantry crane

 

Introduction

Under the background of global economic integration, international economic and trade activities are becoming more frequent. As a bridge connecting ocean transportation and land economy, the transportation efficiency and throughput capacity of ports directly affect the smoothness of the entire supply chain, and thus are related to the healthy development of the economies of various countries and even the global economy. Especially in the global trade pattern, the efficiency of cargo loading and unloading transportation in ports is particularly important. Rail-mounted container gantry cranes (RMGs) have become one of the indispensable key loading and unloading equipment in modern ports due to their high efficiency and reliability, and play a decisive role in improving the overall operating efficiency and economic benefits of ports.

In order to adapt to the growing cargo throughput and diversified loading and unloading needs, this design aims to deeply explore the potential for improving the loading and unloading efficiency of port machinery, and carefully design and build a 40.5t rail-mounted container gantry crane with high load capacity, large span operation capacity and strong lifting height. This crane will adopt advanced structural design concepts and optimization solutions to ensure that the loading and unloading operation speed and automation level are maximized under the premise of ensuring safety, thereby effectively alleviating the operating pressure of busy ports, reducing logistics costs, and promoting the sustainable and healthy development of global trade.

Design Overview

Functions and Applications

Rail-mounted container gantry cranes are mainly used for loading and unloading and stacking operations in container cargo yards. This crane can lift one container over three containers within the travel distance of the gantry crane. It has an outreach of 13 meters on both sides, plus a working length of 60 meters within the span of the gantry, forming an 86-meter-long trolley operation line. The crane can stack 21 rows of containers within the span of the gantry and load and unload containers in the lane at the outreach.

Main Technical Parameters

• Lifting capacity: 40.5t
• Track gauge: 35 meters (or adjusted according to specific needs)
• Span: 60 meters (working length)
• Outreach: 13 meters
• Lifting height: designed according to specific needs

Structural design

Main structure

The main structure of this crane adopts high-strength steel plates and advanced welding technology to build a stable and efficient box-shaped welded structure. The core part of the structure is the top horizontal frame composed of two off-track box-shaped main beams and two parallel box-shaped cross beams. Through precise calculation and high-quality welding materials, they ensure that the entire frame can provide sufficient strength and rigidity when bearing vertical loads. The two off-track box-shaped main beams extend along the track direction and support most of the weight of the crane, while the cross beams ensure the stability of the gantry and sufficient static load capacity.

Two U-shaped vertical frames are designed at both ends of the main beam. They are composed of two vertical legs and a horizontal lower cross beam. The legs are connected to the main beam by flanges and bolts. This connection method not only ensures the firmness of the structure, but also facilitates installation and maintenance. The lower cross beam forms a right angle with the legs, further enhancing the stability of the entire structure. In addition, all connection parts use high-strength bolts and flanges to ensure that there will be no loosening or deformation problems in a high-intensity working environment.

Hoisting device design

This crane is equipped with a full-rotation telescopic hoisting device, which has the functions of opening, closing, locking and telescopic, and these operations can be completed remotely in the driver's cab. According to actual operation requirements, the hoisting device can be flexibly configured to a standard length of 20 feet or 40 feet, and it also has the option of a double-box hoisting device, making the crane more widely applicable and efficient.

Operating mechanism

The operating mechanism of the crane covers key components such as the lifting mechanism, trolley operating mechanism, trolley mechanism and anti-sway mechanism. Among them, the lifting mechanism, trolley operating mechanism and trolley operating mechanism mostly adopt advanced AC frequency conversion control technology to achieve precise and efficient motion control. The lifting mechanism is usually designed as a single drum form, and can also be specially customized as a double-drum open structure according to special needs to adapt to different lifting operation scenarios.

Driver's cab design

The driver's cab adopts a suspension support design and has the characteristics of self-closure. It is installed on the driving track under the main beam to ensure that the driver has a stable field of vision and a good working environment during operation. The driver's cab is equipped with a complete operating console for controlling various mechanisms of the crane, making operation easier.

Installation and commissioning

Installation plan

The installation process of the rail-mounted double-girder container gantry crane is relatively complex and requires precise planning and execution. Due to the large size and complex structure of this type of crane, it is necessary to select appropriate lifting equipment and methods. A common installation plan is to use tools such as pulley blocks, winches and wire ropes to first lift and fix the door legs (i.e., U-shaped door frames) vertically to ensure the verticality and accurate position of the door legs. Next, use a mast crane to lift the main beam horizontal frame above the door legs and accurately connect it to the door legs to form a stable gantry structure. Finally, use the same lifting equipment to lift the trolley components into place and install them accurately.

At the construction site, the impact of road and operating conditions on the lifting equipment must be considered. For the installation of large cranes, truck cranes are preferred as the main lifting equipment. Its advantages are strong mobility, ability to adapt to complex construction site environments, and sufficient lifting weight and operating height. At the same time, in order to ensure the safe and efficient completion of the installation task, the construction site should ensure good road traffic capacity so that the crane can enter and exit the site smoothly; the working space should be large enough to meet the safe working radius and height required during the hoisting process; and the impact of factors such as obstacles and underground pipelines on the hoisting operation should be fully considered to ensure the smooth progress of the entire installation process.

Debugging and inspection

After the installation of the crane is completed, comprehensive debugging and inspection work must be carried out. The debugging content includes but is not limited to mechanical structure debugging, electrical system debugging, and safety protection device verification. Through the no-load test, the operating stability of the crane, the flexibility and coordination of the movements of each mechanism are verified; through the full-load test, the load-bearing capacity, braking performance, and the strength and reliability of each component of the crane are tested. In addition, the safety of the crane needs to be evaluated to ensure that it meets the relevant national standards and specifications and effectively eliminates potential safety hazards.

Technical features and innovations

Large tonnage, large span, high lifting capacity design

The crane has a designed lifting capacity of 40.5 tons. Its large tonnage design allows it to easily cope with the lifting needs of various weight classes of cargo in various heavy lifting operations. The large span means that the crane has a wider operating range. Whether it is a warehouse with a large space, a dock or a complex and changeable construction site, it can be easily covered, significantly improving the operating capacity and flexibility. The high lifting height is a highlight of this crane, which can meet the needs of lifting ultra-high cargo and reduce the loss of cargo during transportation and storage, thus ensuring the safety and efficiency of operations.

Environmentally friendly and energy-saving drive system

This crane adopts mains power drive mode, which eliminates the noise and harmful emissions produced by traditional internal combustion engines and achieves green and environmentally friendly operations. The mains drive system provides stable and efficient kinetic energy for the crane. It is especially suitable for fixed places that require long-term continuous operation, such as docks, warehouses, etc. It effectively reduces carbon emissions while ensuring operational needs, and actively responds to sustainable development. and the call for green logistics.

Intelligent management and precise operation system

The crane can be equipped with an advanced whole-ship container positioning scanning system and CNC system, which can automatically find the coordinates of the container through computer operation and perform precise docking and lifting. This intelligent management system greatly improves work efficiency and quality, reduces manual operation errors, and achieves precise operations. It not only reduces the labor intensity of workers, but also greatly improves the automation and service level of the entire operating process.

Conclusion

In this design, we adhere to the core principle of improving the efficiency of port machinery loading and unloading, and carefully design a 40.5-ton rail-mounted container gantry crane with large tonnage carrying capacity, large span operating range and ultra-large lifting height. This crane is designed to meet the efficient, safe and environmentally friendly operation needs of modern ports. Through the deep integration of modern design concepts and technical means, including the use of advanced parametric modeling methods and three-dimensional simulation design software, and the use of mature finite element analysis theory to conduct detailed mechanical performance analysis and optimization of the whole machine structure, it ensures that the designed crane has excellent structural rationality, safety and reliability while maintaining high strength and durability.

The successful design of this 40.5-ton rail-mounted container gantry crane will undoubtedly play a key role in improving the efficiency of port cargo loading and unloading. Its large tonnage design capacity can cope with the challenges of loading and unloading various heavy goods, and the large span operating range enables the crane to flexibly perform various complex operations in a wide space. In addition, the ultra-large lifting height further enhances the crane's adaptability to different cargoes and scenarios, enabling it to efficiently complete various loading and unloading tasks, whether in deep-water docks or multi-storey warehouses.

Against the backdrop of global economic integration and the rapid development of international trade, the design of this new crane not only conforms to the trend of the times, but is also an important step in promoting the modernization of port logistics. Its implementation will save labor costs for ports, increase cargo turnover speed, and enhance logistics efficiency, thereby effectively promoting the intelligent and automated process of ports, further optimizing global supply chain management, and injecting new vitality into promoting economic globalization and the development of international trade.

Design of 40.5t rail mounted container gantry crane