Rail-mounted container gantry cranes are indispensable and highly efficient loading and unloading equipment in modern ports and logistics centers, and their importance is self-evident. With outstanding performance and a wide range of application scenarios, these cranes play a crucial role in improving logistics efficiency and reducing operational costs. This manual aims to provide a comprehensive introduction to the product features, structural composition, installation and commissioning, operating instructions, safety regulations, and maintenance of rail-mounted container gantry cranes, helping users quickly get started and maximize the equipment's performance. Whether you are a beginner or an experienced operator, you can gain valuable reference information from this manual to ensure the safe and efficient operation of the equipment.
Product Overview
Introduction to Rail-Mounted Container Gantry Cranes
Rail-mounted container gantry cranes, commonly referred to as rail gantry cranes, are high-efficiency lifting equipment specifically designed for container terminals, logistics parks, and large storage facilities. These cranes feature a robust gantry structure and move along dedicated tracks to achieve precise horizontal movement, enabling efficient and safe loading, unloading, stacking, and transferring of containers. By combining advanced mechanical design principles with modern automation technology, rail gantry cranes significantly enhance container handling efficiency and ensure operational accuracy.
Main Functions and Application Scenarios
Rail-mounted container gantry cranes are equipped with several core functions, including container grabbing, lifting, transporting, and precise positioning and stacking. Their grabbing devices can accommodate containers of different sizes and weights, enabling rapid transfer and stacking within the yard through lifting and transporting operations. With their powerful lifting capacity and flexible operation, rail gantry cranes play a vital role in the logistics transportation system. They are widely used in seaports, river ports, railway freight yards, highway transfer stations, and large storage logistics centers, making them an indispensable key equipment in modern logistics transportation systems.
Technical Specifications and Performance Parameters
The technical specifications of rail-mounted container gantry cranes include lifting capacity, span, lifting height, and operating speed, among others. Lifting capacity, a critical parameter for crane performance, can be customized based on actual needs, ranging from tens to hundreds of tons. The span is designed according to the width of the site, typically reaching several tens of meters. The lifting height is determined based on the yard height and operational requirements, often reaching several tens of meters. Operating speed, including lifting speed, trolley travel speed, and gantry travel speed, is also a key factor affecting operational efficiency and is optimized to meet the demands of high-efficiency operations.
Structural Composition and Component Description
Gantry Structure
The gantry, as the core main structure of the rail-mounted container gantry crane, is designed and manufactured with consideration for mechanical strength, structural rigidity, and overall stability. The main beam is made of high-strength steel through welding or bolted connections, ensuring it can withstand the lateral loads generated during crane operations, such as the weight of containers and the loads from the lifting mechanism and trolley travel mechanism. It also maintains stable performance under extreme conditions like strong winds and earthquakes. The columns, key components supporting the main beam and maintaining its stability, are also made of high-strength materials and fixed to the ground or embedded parts through bolted connections. They must withstand significant vertical pressure and horizontal tension while ensuring the overall longitudinal (track direction) stability of the gantry. The crossbeam connects the two columns, forming a stable gantry structure. Typically made of I-beams or H-beams, the crossbeam is welded or bolted between the two columns. Its primary function is to enhance the gantry's rigidity and stability while reducing deformation and vibration caused by lateral loads.
Lifting Mechanism
The lifting mechanism is a critical part of the container gantry crane, responsible for the vertical lifting of containers. It consists of a motor, reducer, drum, wire rope, and spreader. The motor serves as the power source, driving the drum's rotation through the reducer, which reduces speed and increases torque. The drum is wound with wire rope, and the lifting and lowering of containers are achieved by retracting or releasing the wire rope. The spreader is a specialized tool customized according to the actual container size, ensuring precise grabbing and stacking.
Trolley Travel Mechanism
The trolley travel mechanism is installed on the gantry's main beam and is responsible for the horizontal movement of containers. It consists of a motor, reducer, wheels, and a drive device, enabling smooth and rapid movement along the track. The trolley travel speed can be adjusted according to operational requirements to meet efficiency needs in different scenarios. The motor provides power, which is transmitted through the reducer to reduce speed and increase torque, driving the wheels to move along the track. The drive device can adjust the trolley's travel speed to adapt to various operational needs and site conditions.
Gantry Travel Mechanism
The gantry travel mechanism is installed on the track and is responsible for the longitudinal movement of the entire crane. It consists of a motor, reducer, wheel set, and guiding device, ensuring smooth and accurate movement of the crane along the track. The gantry travel speed can also be adjusted according to operational requirements to adapt to different site conditions. The motor provides power, which is transmitted through the reducer to reduce speed and increase torque, driving the wheel set to move along the track. The guiding device ensures the crane maintains the correct trajectory and direction during operation.
As a core piece of equipment in the heavy industry sector, the stability and safety of the electrical system of a casting crane directly impact production efficiency and operational safety. This electrical manual aims to comprehensively introduce the electrical system of casting cranes, from system overview to operation guidelines, maintenance and care, upgrades and retrofits, and safety regulations. The content is detailed and practical, providing valuable guidance and assistance to both novice operators and experienced maintenance personnel. By gaining an in-depth understanding of the structure and principles of the electrical system and mastering the correct operation and maintenance methods, the operational efficiency and safety of casting cranes can be significantly enhanced, safeguarding the production operations of enterprises.
Electrical System Overview
Introduction to the Electrical System of Casting Cranes
Casting cranes are heavy-duty industrial equipment specifically designed for the casting industry, with their electrical systems being a critical component for achieving efficient and stable operation. The system integrates multiple functions such as power drive, control logic, safety protection, and communication, aimed at meeting the complex demands of heavy lifting and transportation during the casting process. To satisfy the high requirements for lifting and transporting heavy objects in the casting process, the electrical system of casting cranes achieves rapid response and precise execution of various operational commands through complex circuit layouts and precise component coordination.
Main Components of the Electrical System
The electrical system of casting cranes mainly consists of the following parts: the power system, control system, protection system, and communication system. The power system is responsible for providing stable power supply; the control system includes various control devices and circuits to execute the crane's operational commands; the protection system, such as overload and short-circuit protection, ensures the safe operation of the electrical system; the communication system is used for data transmission and command reception between the crane and the ground control station.
Working Principle of the Electrical System
The working principle of the electrical system is based on the conversion and transmission of electrical energy. The power system converts high-voltage electrical energy into low-voltage electrical energy suitable for crane use through transformers, which is then distributed to various actuators such as motors and brakes via switches, relays, and other components in the control system. Simultaneously, the control system ensures that each actuator operates according to predetermined programs and sequences through complex logical judgments, thereby realizing the various functions of the crane.
Safety Performance of the Electrical System
The safety performance of the electrical system is a crucial guarantee for the reliable operation of casting cranes. The system design fully considers various fault conditions such as overload, short circuit, and grounding, and incorporates corresponding protective measures. Additionally, the electrical system is equipped with self-diagnostic functions that can monitor the working status of each component in real-time. Upon detecting any abnormalities, it immediately initiates alarms or shutdown protection to ensure the safety of the crane and its operators.
Electrical system diagram of casting crane
Electrical System Operation Guide
Startup and Shutdown Procedures
Before starting up, operators should carefully inspect all components of the electrical system, including but not limited to cables, switches, and motors, to ensure they are intact and securely connected. Additionally, operators should review the equipment manual or relevant operating procedures to confirm that all components are in normal working condition. After verifying everything is correct, follow the established startup procedure to sequentially turn on the power switches at each level.
During shutdown, operators should first stop all operations and wait until the crane has completely ceased movement. Then, disconnect the power switches in the reverse order. Throughout the shutdown process, ensure that the electrical system is fully powered off to prevent damage to electrical components or the occurrence of safety incidents.
Operation Methods for Major Electrical Equipment
Major electrical equipment includes motors, controllers, and protectors. The operation of these devices must comply with the corresponding equipment manuals or operating procedures. For example, before starting a motor, confirm that it is in the correct working state, including checking whether parameters such as motor speed and current meet the requirements. Controller operations must follow the prescribed action sequence to avoid misoperation that could lead to equipment damage or safety incidents. Protectors should be adjusted and tested within the set parameter range to ensure their proper functioning.
Parameter Setting and Adjustment of the Electrical System
The parameter setting and adjustment of the electrical system have a direct impact on the crane's performance. Operators need to reasonably set key parameters such as motor speed and brake torque based on the crane's working conditions and operational requirements. Additionally, regular parameter adjustments and calibrations should be performed to ensure the crane remains in optimal working condition.
During the parameter setting and adjustment process, operators must strictly adhere to relevant standards and requirements. For example, when adjusting motor speed, make gradual adjustments and observe whether the actual speed reaches the set value. When adjusting brake torque, ensure the brake can reliably stop and meet operational requirements. Furthermore, regular comprehensive inspections and calibrations of the electrical system should be conducted to ensure its proper operation and improve accuracy.
Emergency Shutdown and Fault Handling
In emergency situations, such as safety incidents or equipment failures, operators must immediately press the emergency stop button to cut off the electrical system's power supply, ensuring the crane safely shuts down. At the same time, operators should possess certain fault diagnosis capabilities to quickly locate the fault point based on fault symptoms and alarm information and take effective measures to resolve the issue.
During the fault handling process, operators must follow the corresponding operating procedures and safety requirements. For example, when dealing with faults such as damaged electrical components or poor connections, first cut off the power supply and take appropriate safety measures. When handling control system faults, check whether the relevant software and hardware devices are functioning properly. Additionally, for faults that cannot be resolved, promptly contact maintenance personnel for repair.
Electrical System Maintenance and Care
Daily Maintenance and Inspection
Daily maintenance and inspection are the foundation for ensuring the normal operation of the electrical system. Operators need to regularly clean, tighten, and inspect various components of the electrical system. For example, check whether the terminal connections are loose, whether the cables are damaged, and whether the components are overheating. Through regular cleaning and tightening, issues such as poor contact or short circuits caused by dust and looseness can be avoided. Additionally, the inspection results should be recorded to provide a reference for subsequent maintenance and care.
Regular Maintenance and Care Plan
Based on the usage conditions of the electrical system and the manufacturer's recommendations, a regular maintenance and care plan should be established. The plan should include the replacement cycles of components, cleaning and lubrication requirements, as well as necessary adjustments and tests. Through regular maintenance and care, potential fault risks can be identified and addressed in a timely manner, extending the service life of the electrical system. At the same time, regular maintenance and care can improve the operational efficiency of the electrical system and reduce repair costs.
Diagnosis and Troubleshooting of Common Faults
Common faults in the electrical system include motor faults, controller faults, and protector faults. For these faults, operators need to possess certain fault diagnosis capabilities. Based on fault symptoms and alarm information, combined with the working principles of the electrical system and component characteristics, operators should conduct step-by-step troubleshooting and localization. Once the fault point is identified, effective methods should be taken to repair or replace the faulty component. During the repair process, attention must be paid to operational safety, adhering to relevant safety regulations and operational requirements.
Safety Precautions for Maintenance and Care
When performing maintenance and care on the electrical system, safety operating procedures must be strictly followed. For example, cut off the power supply, wear protective equipment, and use specialized tools. Additionally, attention must be paid to safety requirements such as fire prevention and explosion prevention to ensure the personal safety of operators and the stable operation of the electrical system. When maintaining and caring for the electrical system, relevant safety operating procedures must be observed. First, the power supply must be cut off to avoid safety hazards caused by live operations. At the same time, operators should wear protective equipment such as insulated gloves and safety goggles to prevent accidents. The use of specialized tools is also essential, as these tools are specially designed to better meet the maintenance and care needs of the electrical system. Furthermore, during the maintenance and care process, attention must be paid to safety requirements such as fire prevention and explosion prevention. Electrical equipment may have hazardous factors such as high temperature and high pressure, so corresponding safety measures must be taken to ensure the personal safety of operators.
As a leader in the field of heavy equipment manufacturing, the design and calculation instructions of the 120T gantry crane are the key to ensuring the safe and efficient operation of the equipment. The instructions not only cover the main performance parameters of the crane, such as rated lifting capacity, lifting height, travel distance and operating speed, but also deeply analyze the structural composition and design details of the crane. From the precise coordination of the crane and the traveling assembly, to the stable support of the legs and bracket assembly, to the ingenious design of the main beam assembly and the beam shoulder pole, each one reflects the engineers' deep understanding of mechanics and mechanical principles. In addition, the instructions also elaborate on the core elements of the crane design, including the selection of the lifting mechanism, the motor configuration of the operating mechanism, the calculation of the reducer and gear ratio, etc., presenting a comprehensive and systematic design solution to readers.
Detailed description of the main performance parameters of the crane
Rated lifting capacity and lifting height
As a heavy lifting equipment, the core performance of the 120T gantry crane is reflected in the rated lifting capacity and lifting height. The crane is designed with a rated lifting capacity of 120 tons, which means that under normal working conditions, it can safely lift and carry cargo weighing no more than 120 tons. This parameter is crucial to ensure safe and efficient operation. The lifting height is the vertical distance from the center line of the crane hook to the ground. For different operation scenarios, the required lifting height is also different. The lifting height of this crane is designed to meet the needs of different operation scenarios, ensuring that the goods can be lifted and lowered to the specified position smoothly and accurately.
Trolley travel distance and whole machine running speed
The trolley travel distance refers to the maximum distance that the crane moves horizontally on the track. This parameter directly affects the working range and flexibility of the crane. For 120T gantry cranes, the trolley travel distance is carefully designed to meet a wide range of operation needs. The whole machine running speed is an important indicator to measure the working efficiency of the crane. The crane achieves a faster whole machine running speed while ensuring safety, which improves the operating efficiency. At the same time, the crane also has excellent whole machine running stability, ensuring that there will be no shaking or instability during high-speed operation.
Beam crane running speed and lifting speed
The beam crane is an important part of the crane, and its running speed directly affects the handling efficiency of the goods. The running speed of the beam crane of the 120T gantry crane has been optimized to move the goods quickly and smoothly while ensuring safety. This feature enables the crane to better meet various emergency or high-efficiency operation requirements. The lifting speed is the speed of the hook lifting and lowering. The lifting speed of the crane is reasonably designed and can be flexibly adjusted according to the weight of the cargo and the operation requirements. Whether it is light cargo or heavy cargo, the crane can achieve fast and accurate lifting operations.
Crane performance parameter relationship diagram
Adaptability to slope and running track foundation
In order to adapt to different terrains and working environments, the 120T gantry crane was designed with its adaptability to slopes in mind. Within a reasonable slope range, the crane can maintain stable operation. This feature enables the crane to better adapt to various complex working environments. At the same time, the running track foundation is also a key factor in ensuring the safe and stable operation of the crane. The running track foundation of the crane is designed to be sturdy and can withstand the huge pressure and vibration generated by the crane during operation. Whether it is indoor or outdoor operation, the crane can maintain a good operating state.
Crane structure composition and design
Beam crane and running assembly structure
As the core working component of the crane, the main function of the beam crane is to undertake the lifting, lowering and horizontal movement of goods. It consists of a beam, a crane motor, a reducer, a drive wheel, a guide wheel, a wire rope and a pulley block. The hanging beam usually adopts a box-shaped or truss structure, which has sufficient strength and rigidity to withstand the pressure and bending moment caused by the weight of the cargo; the driving motor provides power, transmits power through the reducer, drives the driving wheel to rotate, so that the hanging beam can run smoothly and quickly on the track; the running assembly is an important mechanism for the crane to move on the track. It consists of components such as wheels, bearings, shafts, tracks and guide devices. The wheels bear all or most of the weight of the crane and roll on the track, allowing the crane to move easily on the track; the bearings play a role in reducing friction and improving the flexibility of wheel rotation; the shafts are used to connect the wheels and bearings and transfer loads; the track is the track of the crane's operation, usually fixed on the building or the ground, providing a stable operating foundation for the crane; the guide device ensures that the crane maintains the correct direction and position during operation.
Outrigger and bracket assembly structure
The outrigger is an important supporting component of the crane. Its structural design must ensure that the crane can stably carry the weight of the cargo and additional loads during operation, while maintaining good anti-overturning performance. When designing the outrigger, factors such as the overall layout of the crane, the working radius, and the stability requirements need to be considered. The outriggers are usually designed with a box-shaped or H-shaped cross section, which has sufficient strength and rigidity to withstand the pressure and shear force caused by the weight of the cargo; the bracket assembly is used to connect the outriggers and the main beam. Its structural design needs to ensure the overall stability of the crane and facilitate installation and maintenance. The bracket assembly usually includes connecting plates, reinforcing ribs, mounting seats and other components.
Design of main beam assembly and hanging beam shoulder pole
As the main load-bearing component of the crane, the main beam connects the outriggers and the hanging beam crane. Its design directly affects the overall rigidity and stability of the crane. When designing the main beam, factors such as its load-bearing capacity, deformation and vibration need to be considered. The main beam usually adopts a box-shaped or truss structure, which has sufficient strength and rigidity to withstand the pressure and bending moment caused by the weight of the cargo; the hanging beam shoulder pole is a key component connecting the hanging beam and the cargo, and its design needs to take into account the weight, shape and handling requirements of the cargo. The shoulder pole usually adopts a box-shaped or circular cross-section design, which has sufficient strength and rigidity to withstand the pressure and shear force caused by the weight of the cargo. At the same time, the installation position and angle of the shoulder pole also need to be considered to ensure the stability and safety of the goods during handling.
Cable bracket and crane cable suspension
The cable bracket is an important component for fixing and supporting the crane cable. It is usually composed of brackets, connecting plates, bolts, etc., which can ensure that the cable will not be damaged or disturbed during the operation of the crane. The design of the cable bracket needs to take into account factors such as the weight, length and running trajectory of the cable to ensure that the cable always remains stable during operation; the crane cable is an important component connecting the crane and the traveling assembly. It is responsible for providing power and control signals to the crane and the traveling assembly. The crane cable is usually composed of a conductor, an insulating layer, a sheath, etc., and needs to have sufficient strength and wear resistance to ensure that it can maintain good performance during long-term use. The reasonable design of the cable bracket and the crane cable suspension ensures the safe and reliable operation of the crane's electrical system.
Crane travel limit and rail clamp configuration
The crane travel limit is a key component to prevent the crane from exceeding the working range. It usually consists of a travel switch, a limit wheel, etc., which can automatically stop the crane when it approaches the limit position to avoid accidents. The travel switch is an automatic control switch. When the limit wheel is touched, it can send a stop signal to stop the crane; the track clamp is an important component used to fix the crane on the track. It usually consists of a clamp, a spring, etc., which can fix the crane on the track under the action of external forces such as wind. The clamp is an adjustable clamping device that can be fixed on the track. When external forces such as wind act, the clamp can generate enough friction to fix the crane.
Crane scheme design
Main performance and lifting mechanism of the crane beam crane
As an important part of the crane, the performance of the crane beam crane directly determines the operation capacity and efficiency of the crane. The main performance parameters include lifting capacity, operating speed, lifting height, etc. The lifting capacity refers to the maximum weight of the cargo that the crane can safely and effectively carry, the operating speed refers to the speed at which the crane moves on the track, and the lifting height refers to the height of the cargo from the ground to the highest lifting position. The reasonable setting of these parameters is crucial to meet specific operation requirements and ensure operation safety. The lifting mechanism is the core component of the crane, which is responsible for the lifting and lowering of the cargo. In the 120T gantry crane, the crane is well designed and manufactured, and its lifting mechanism uses advanced technology and materials to ensure smooth and accurate lifting and lowering of the cargo.
Operating mechanism design and motor selection
The operating mechanism is a key component for the crane to move on the track, and its design directly affects the operating efficiency and stability of the crane. The design of the operating mechanism includes the layout and selection of components such as tracks, wheels, and bearings. The layout of the track needs to take into account the running trajectory and stability of the crane, and the selection of wheels and bearings needs to take into account factors such as the carrying capacity and friction of the operating mechanism. The motor is the main power source for driving the operating mechanism. The selection of the motor needs to take into account parameters such as power, speed and torque to ensure the normal operation of the operating mechanism. In the 120T gantry crane, the operating mechanism is reasonably designed and the motor is properly selected, ensuring the smooth and fast operation of the crane.
Reducer and gear ratio calculation
The reducer is an important component in the crane transmission system. It can convert the high-speed rotation of the motor into a low-speed, high-torque output to meet the operation needs of the crane. The design of the reducer needs to take into account factors such as transmission efficiency, noise and vibration. The gear ratio is one of the key indicators of the reducer performance. The calculation of the gear ratio needs to take into account the motor speed and load requirements to ensure the efficiency and stability of the transmission system. In the 120T gantry crane, the reducer and gear ratio are carefully calculated and selected to ensure the efficiency and stability of the transmission system.
Structural scheme and beam shoulder pole design
The structural scheme is the overall framework of the crane design, which determines the overall layout and performance characteristics of the crane. The design of the structural scheme needs to take into account factors such as the use environment, operation requirements and safety requirements of the crane. As a key component connecting the lifting beam and the cargo, the design of the beam shoulder pole needs to take into account the weight, shape and handling requirements of the cargo. The design of the beam shoulder pole needs to take into account the weight and shape of the cargo to ensure the stability and safety of the cargo during the handling process. At the same time, the design of the beam shoulder pole also needs to take into account the convenience and comfort of the operator to improve the operating efficiency. In the 120T gantry crane, the structural scheme and beam shoulder pole design have been optimized to ensure the load-bearing capacity and stability of the crane.
Steel structure design and optimization are of great significance in engineering practice
Weight ratio of steel structure of gantry crane
As the core load-bearing component of gantry crane, the weight of steel structure accounts for a considerable proportion of the entire crane structure, which directly affects the overall performance and manufacturing cost control of the crane. For 120T gantry crane, the weight ratio of steel structure is carefully designed and optimized, so that the self-weight is minimized while ensuring that the crane has sufficient load-bearing capacity and stability, thereby saving material costs and improving the working efficiency and economic benefits of the whole machine.
Calculation of strength, stiffness and stability of steel structure
The strength, stiffness and stability of steel structure are the core standards for evaluating the performance of 120T gantry crane. Strength calculation involves factors such as allowable stress and cross-sectional dimensions of steel to ensure that the crane will not undergo plastic deformation or fracture when bearing rated load; stiffness calculation focuses on the deformation degree of steel structure under load to maintain the stability of its shape and size; and stability calculation focuses on the overall and local buckling behavior of steel structure to ensure that the crane always maintains a balanced state during operation and prevent accidents caused by instability. After rigorous mechanical analysis and numerical simulation, the steel structure design of the 120T gantry crane fully meets the requirements of various performance indicators.
Main beam structure optimization design and mathematical model
As a key component for the gantry crane to carry and transfer loads, the structural design of the main beam has a decisive influence on the performance and stability of the whole machine. For the 120T gantry crane, we adopted advanced design concepts and mathematical models to deeply optimize the main beam structure. Specifically, by establishing a three-dimensional model, using finite element analysis methods, and combining simulation technology, the cross-sectional shape, size configuration, and material selection of the main beam were repeatedly calculated and iteratively optimized, aiming to improve the strength utilization and bending stiffness of the main beam, while improving its dynamic response characteristics.
Comparison table of main beam structure before and after optimization (performance parameters)
Parameters/indicators
Before optimization
After optimization
Enhancement
Main beam strength utilization rate
_
Elevation
_
Bending stiffness
_
Elevation
_
Dynamic response characteristics
_
Enhancement
_
Carrying capacity
Clear value 1
Clear value 1（Elevation）
Clear the value %
Stability
Clear description1
Clear description2（reinforce）
_
Material Cost
_
Diminish
_
Work efficiency
_
Raise
_
Comparison table of main beam structure before and after optimization (design and verification method)
Stage/Method
Before optimization
After optimization
Note
Design concept
Traditional design
Advanced design
_
Mathematical Models
_
Finite element analysis combined with simulation simulation
_
Cross-section shape and dimensions
_
Optimized Configuration
_
Material Selection
_
Optimized selection
_
Verification method
Clear method 1
Finite element simulation, model test, performance test
Including but not limited to
Optimization effect verification
_
Significant improvement and enhancement
Adjust according to actual test feedback
Safety and reliability
_
Further guarantee
_
Analysis and verification of optimization results
After the optimization design is completed, the effectiveness and feasibility of the optimization scheme are effectively proved by detailed analysis and verification of the optimized 120T gantry crane, including but not limited to finite element simulation analysis, model test and performance test under actual working conditions. These verification results show that compared with the traditional design scheme, the optimized crane has significantly improved its carrying capacity, especially in high-intensity working environment, and can still maintain stable performance; its stability has also been significantly enhanced, reducing the risk of accidents caused by structural instability. In addition, based on the actual test feedback, we have made targeted adjustments and improvements to some detailed designs to further ensure the safety and reliability of the 120T gantry crane in actual application.
Wind protection and stability calculation
Wind load calculation and structural deadweight
As an indispensable consideration for cranes in the working environment, wind load has an important impact on the stability of cranes. In order to ensure the safe and efficient operation of cranes under wind loads, detailed and accurate wind load calculations must be performed. This calculation process involves many factors, such as the structural size of the crane, material properties, wind speed, wind direction and wind pressure distribution in the working environment. Through the comprehensive analysis of these parameters, the stress state of the crane under specific wind load conditions can be accurately obtained, thus providing a reliable basis for structural design. Structural deadweight is also one of the key factors affecting the stability of the crane. The deadweight of the structure not only affects the overall stability of the crane, but also has a profound impact on the dynamic performance and carrying capacity of the crane. Therefore, when designing and calculating the 120T gantry crane, the influence of its structural deadweight must be fully considered to ensure its safety and reliability in normal operation and extreme conditions. Through reasonable wind load calculation and structural deadweight analysis, the 120T gantry crane can operate stably in various complex environments, effectively improve work efficiency and reduce safety risks.
Gantry crane lateral stability calculation
Lateral stability is one of the issues that need to be focused on during the operation of the crane. In order to ensure the stability of the crane under the action of lateral wind load, it is necessary to perform lateral stability calculation on it. Lateral stability calculation is an important means to prevent the crane from tipping over or overturning during operation. Through this calculation, the response characteristics of the crane under the action of lateral wind load, such as roll angle, rollover critical wind speed and other parameters, can be determined. Based on these parameters, the structural design of the crane can be optimized to improve its lateral stability. The lateral stability calculation of the 120T gantry crane has been carefully designed and analyzed to ensure the safe operation of the crane under lateral wind loads.
Cable wind rope design and anti-overturning calculation
The cable wind rope is a key component to prevent the crane from overturning under wind loads. In order to ensure the effectiveness and reliability of the cable wind rope, it needs to be carefully designed and anti-overturning calculated. The design of the cable wind rope needs to consider multiple factors, such as material selection, rope diameter, fixing method, etc. These factors will affect the load-bearing capacity and tensile strength of the cable wind rope. Therefore, the designer needs to carry out detailed design and calculation according to actual needs and working environment to ensure that the cable wind rope can effectively prevent the crane from overturning. Anti-overturning calculation is an important means to evaluate the stability of the crane under wind load. Through this calculation, the anti-overturning capacity of the crane at a specific wind speed and wind direction can be determined. This requires considering multiple factors, such as the structural size, weight, center of gravity position of the crane, etc. Through the calculation and analysis of the anti-overturning capacity, it can be evaluated whether the stability of the crane under wind load meets the requirements. The cable guy rope design and anti-overturning calculation of the 120T gantry crane are reasonable, ensuring the crane's anti-overturning ability under wind loads.
Wind protection and stability calculation diagram
Calculation of lifting lugs and strength verification of welds
As a key component connecting the lifting beam and the cargo, the rationality of the design of the lifting lug directly affects the efficiency and safety of cargo handling. In order to ensure the safety and reliability of the lifting lug, the designer needs to perform detailed calculations and analyses on the lifting lug, including the calculation of parameters such as the size, strength, and stiffness of the lifting lug, as well as the strength verification of the weld. Through strict calculation and verification of the lifting lugs and welds, it can be ensured that the lifting lugs have sufficient load-bearing capacity and safety during operation, avoiding safety hazards caused by excessive loads or weld quality problems. The calculation of the lifting lugs and the strength verification of the welds of the 120T gantry crane are strict, ensuring that the load-bearing capacity of the lifting lugs during operation and the strength and toughness of the welds meet the design requirements.
This technical specification is intended to provide a comprehensive set of technical parameters and performance requirements for the latest customized 450t gantry crane in detail to ensure that it can meet the various needs of hull manufacturing on the slipway. This crane is designed for the slipway operating environment and has powerful lifting, turning, lifting and moving functions.
This crane can not only cope with the complex and changeable working conditions in the hull manufacturing process, but also complete various operating tasks efficiently under the premise of ensuring safety. Its technical parameters and performance requirements have been strictly tested and verified to ensure that it can still operate stably in various harsh working environments and has excellent durability and reliability.
At the same time, in order to meet the various needs of the crane in the hull manufacturing process, we have also comprehensively optimized the design of the crane to improve its overall performance and operating efficiency. Whether it is lifting height, lifting capacity or ease of operation, it has reached the industry-leading level.
Model and structure
Model overview: 450tX71m shipbuilding gantry crane is a heavy-duty lifting equipment designed for large-scale shipbuilding projects. It is a large-span and large-lifting height crane with small upper and lower models. It has excellent carrying capacity and a wide operating range, and is an indispensable and important tool for the shipbuilding industry.
Detailed explanation of structural composition: The entire 450tX71m shipbuilding gantry crane is mainly composed of three parts: metal structure, mechanical equipment and electrical control device. Each part cooperates with each other to ensure the stable and efficient operation of the crane.
Metal structure: The metal structure is the skeleton of the crane, carrying the weight and operating load of the entire equipment. It includes key components such as the main beam, rigid outriggers, flexible outriggers, lower crossbeams, trolley power supply brackets, trolley running tracks, and escalator railings. These components are manufactured through precise design and process to ensure the structural strength and stability of the crane.
Mechanical equipment: The mechanical equipment is the power core of the crane and is responsible for driving the crane to perform various actions. It includes two trolleys and their operating mechanisms, power supply devices, crane trolley operating mechanisms, windproof rail clamps and anchoring devices. These devices realize the precise, fast and reliable operation of the crane through advanced transmission and control technologies.
Electrical control device: The electrical control device is the nervous system of the crane, responsible for controlling and monitoring the operating status of the crane. It includes key components such as elevator, linkage platform in the cab, lifting capacity display, electrical control panel, resistor and electrical control circuit. These components realize the automation, intelligence and remote monitoring functions of the crane through the intelligent control system, greatly improving the operation efficiency and safety.
Technical parameters
Lifting capacity:
Lifting capacity of upper trolley: 2×150t, the allowable lifting capacity difference between the two hooks is 50t.
Lifting capacity of lower trolley: main hook 250t, auxiliary hook 20t.
The weight of the upper and lower trolleys turning over the hull section in the air: 300t.
The maximum weight of the upper and lower trolleys jointly lifting the main engine (the distance between the two trolleys ≥15m): 450t.
Lifting capacity of maintenance crane: 5t.
Crane span and base distance: span 71m, base distance 28m.
Lifting height:
Lifting height of upper trolley: 70m.
Lifting height of lower trolley: main hook 70m, auxiliary hook 70m.
Lifting height of maintenance crane: 82.7m.
Working speed of each mechanism of the crane:
Upper trolley hook: When the lifting weight is 150t, the speed is 0~5m/min; when the lifting weight is 60t, the speed is 0~10m/min.
Lower trolley: When the main hook lifts 250t, the speed is 0~5m/min; when the main hook lifts ≤100t, the speed is 0.5~10m/min; when the auxiliary hook lifts 20t, the speed is 1~10m/min; when the auxiliary hook lifts ≤8t, the speed is 1~20m/min.
Trolley travel speed (when the wind speed is ≤14m/s): 0~30m/min.
Crane travel speed: 0~45m/min.
Maintenance crane lifting speed: 8m/min.
Other parameters:
Distance between the lifting point and the center line of the rigid leg track: 4m for the upper trolley, 5m for the main hook of the lower trolley, and 2m for the auxiliary hook of the lower trolley.
The distance between the lifting point and the center line of the flexible leg track is: 4m for the upper trolley, 4m for the main hook of the lower trolley, and 7m for the auxiliary hook of the lower trolley.
Crane travel track: QU100.
Maximum wheel pressure of the crane travel wheel: 440KN.
The installed capacity of the whole machine: about 1000KW, three-phase four-wire system, 6.6KV50Hz, and can be powered by a cable drum device.
Design and manufacturing standards
Crane design and manufacturing must comply with the following standards and specifications:
GB3811-83 "Crane Design Specifications"
GB6067-85 "Safety Regulations for Lifting Machinery"
GB5905-86 "Crane Test Specifications and Procedures"
GB/T14406-93 "General Gantry Crane"
GB50278-98 "Construction and Acceptance Specifications for Lifting Equipment Installation Projects"
CB/T8504-95 "Technical Regulations for Gantry Cranes in Shipyards"
Detailed description of materials and components
For the main structural parts of the crane, such as the main beam, rigid outriggers, flexible outriggers, etc., we strictly use Q345B high-quality steel plates for manufacturing, or use marine steel plates with a yield limit equivalent to Q345B to ensure their high strength, high toughness and good welding performance. These structural parts are the main load-bearing parts of the crane, so the use of high-quality materials is crucial.
The main load-bearing components such as the upper trolley frame, the lower trolley frame, and the large balance beam of the crane walking mechanism are also made of Q345B high-quality steel plates, and are pre-treated before manufacturing, such as sandblasting and anti-corrosion treatment, to improve the corrosion resistance and service life of the steel.
All parts on the crane, including bolts, nuts, bearings, gears, etc., are made of high-quality steel or other high-strength and high-wear-resistant materials to ensure their strength, rigidity and stability. We pay attention to every detail to ensure the stability and reliability of the overall performance of the crane.
Comprehensive analysis of safety devices and protection measures
Safety protection devices such as lifting height limiter, lifting weight limiter and overspeed protection must be installed on the crane. These devices can monitor the operating status of the crane in real time. Once an abnormal situation is found, measures should be taken immediately to ensure the safety of personnel and goods.
Travel switches or travel limit bumpers should be installed on the upper and lower trolley walking mechanisms and the crane trolley walking mechanisms, and buffer devices should be installed at both ends of the upper and lower trolleys to prevent the crane from colliding or exceeding the set range during operation, causing damage or accidents.
We specially installed two sets of trolley walking correction devices to ensure that the crane remains stable during walking by real-time monitoring and adjusting the walking distance deviation between the rigid legs and the flexible legs to avoid dangerous situations such as tilting or overturning.
At the highest point of the crane, we set up air defense lights and anemometers. Air defense lights can provide sufficient light at night so that operators can clearly see the surrounding environment and goods; while anemometers can monitor wind speed and wind direction in real time to ensure that the crane can operate safely in bad weather. These measures together constitute a comprehensive safety protection system for the crane, providing a strong guarantee for the safety of personnel and goods.
Natural conditions and working environment requirements
Wind pressure: The gantry crane can withstand a wind pressure of 250N/m² under the condition of maximum working wind force 7. At the same time, in order to ensure the safety of the crane in the non-working state, the designed basic wind pressure should reach 1000N/m² to cope with potential risks under extreme weather conditions.
Temperature: Taking into account the climate differences in different regions, the crane has the ability to adapt to the working environment around zero degrees. This means that whether in the cold northern region or other areas with suitable temperature, the crane can operate stably and meet various operating needs.
Other key requirements
Electrical components: The electrical components of the crane should strictly follow the relevant national standards and have corresponding authoritative certification. This ensures the safety and reliability of the electrical system and reduces the safety hazards caused by electrical failures.
Working noise: To ensure the comfort of operators and the surrounding environment, the noise level of the equipment during operation should be strictly controlled and not more than 75dB. This helps to reduce noise pollution and protect the hearing health of operators.
Unit of measurement: The measurement units of all instruments and meters of the crane should be uniformly based on the international system of units, which will help improve the accuracy and comparability of measurements and facilitate international exchanges and cooperation.
Safety protection and environmental protection requirements: The safety protection, environmental protection, fire protection and other aspects of the crane must strictly comply with relevant national standards. This includes setting up complete safety protection devices, taking environmental protection measures to reduce emissions, and equipping effective fire-fighting equipment to ensure the safety, environmental protection and efficient operation of the crane.
This technical specification provides detailed technical parameters and strict requirements for the design and manufacture of customized 450t gantry cranes. In the actual production and use process, all parties should strictly follow the requirements of this specification to ensure that all aspects of the crane design, manufacture, installation, commissioning and operation meet the standards, so as to achieve safe, reliable and efficient operation of the crane and meet various operational needs.
