Overhead cranes: equipment and components
Overhead cranes equipment and components consist of various primary and auxiliary parts that contribute to the crane’s operation and safety. These components include the motor, rails, brakes, hook, chain or wire rope, controllers, and safety systems, each playing an essential role in the lifting and handling of heavy loads. Using high-quality equipment and components, along with regular maintenance, significantly enhances the crane’s efficiency and safety, while also extending its service life
Crane Hook
The crane hook, known in English as a ‘Crane Hook,’ is one of the most crucial components in cranes, with its primary role being the lifting and moving of heavy loads. This hook is usually attached to the end of a wire rope or chain and, thanks to its robust and specialized design, it can securely handle and transfer heavy loads in a controlled manner. The crane hook is made of high-strength steel and is designed to withstand the pressures and tensions exerted by heavy loads.
The significance of the crane hook in load handling lies in its role as the connection point between the load and the crane. It must evenly distribute the weight force to ensure the safe movement of the load. Crane hooks are typically equipped with safety features like safety locks and automatic mechanisms to prevent slipping or dropping of the load. Using standard, high-quality hooks not only ensures safe lifting operations but also extends the crane’s service life and minimizes potential risks in industrial environments.
Crane trolley
The double girder crane trolley is one of the primary components of overhead cranes, installed on two parallel girders, responsible for moving loads along the crane girders. This trolley typically includes a hoisting system, wire rope or chain, travel motors, and safety brakes. Its robust design and structure enable it to move heavy loads safely and steadily. Additionally, the double girder crane trolley features high-quality, precision wheels that allow smooth travel along the installed rails, transferring loads with minimal vibration and deviation.
One of the important features of the double girder crane trolley is its high flexibility and load-bearing capacity, making it ideal for heavy industrial environments such as steel, petrochemical, and automotive industries. These trolleys are often equipped with advanced control systems and safety features, such as emergency brakes and positioning sensors, which help operators move loads with greater accuracy and prevent unwanted incidents. Due to the heavy loads the double girder crane trolley handles, regular maintenance and inspection of its wheels, motors, wire ropes, and safety equipment are essential to increase the lifespan of the equipment and ensure overall operational safety.
End Truck
End Truck, also known as “Carriage” or “End Trolley,” is one of the essential components in overhead cranes, enabling horizontal movement along rails installed on the ceiling. This section includes several sturdy wheels and a drive system that allows smooth travel along the rails, providing controlled movement of the crane within the workspace. End trucks are installed on both sides of the crane’s main girder, evenly distributing the weight of the load and the crane onto the rails. These components are made from durable, high-quality materials to withstand high pressure, vibrations, and wear from continuous movement, ensuring the crane’s safety and efficiency.
End trucks are generally categorized into single-girder and double-girder types. Single-girder end trucks are suitable for lighter loads and light industrial applications. In contrast, double-girder end trucks are designed for heavy-duty applications and larger loads, distributing the weight more evenly—an essential feature for industrial environments with demanding conditions. Advanced control and motor systems in these end trucks enable precise and controlled movement, increasing productivity and safety in industrial operations. Choosing the right type of end truck based on load capacity, application, and environmental conditions is crucial for the optimal performance of the overhead crane system
Overhead crane wheels
Overhead crane wheels are one of the main components of this type of crane, used for movement and load transportation. These wheels are made from high-strength materials, such as steel, to withstand heavy weights and resist wear. Overhead crane wheels are divided into two main types: guide wheels and drive wheels. Guide wheels are used to direct movement, while drive wheels enable horizontal movement with the help of the crane motor. The quality and performance of these wheels have a significant impact on the efficiency and lifespan of the crane, making the choice of appropriate type and material highly important in the industry.
Guide Rope
Wire rope guide for an overhead crane is a component used to guide and properly position the wire rope within the pulleys, preventing it from slipping or twisting. This part plays a critical role, especially during the lifting and moving of heavy loads, by protecting the wire rope from wear and damage. The wire rope guide keeps the rope on the correct path by adjusting its movement, contributing to the safe and smooth operation of the overhead crane. Selecting the right guide and regularly inspecting it is essential to preserve the lifespan of the wire rope and enhance the crane’s safety
coupling
The coupling in an overhead crane acts as a key component responsible for transferring power and motion from the motor to the hoisting mechanisms. This part helps reduce mechanical shocks and vibrations during operation, preventing damage to major crane components like the motor and gearbox. Depending on the type and capacity of the crane, various types of couplings can be used, such as elastomeric, gear, and disc couplings. Selecting the appropriate type of coupling is essential for extending the crane’s service life and improving operational safety and efficiency
electric motor
The electric motor of overhead cranes is a key component in the drive systems of these cranes, playing a vital role in moving and lifting loads. This motor is directly connected to the gearbox, providing the mechanical power needed to move crane structures such as the hoist, and enabling horizontal and vertical movements, as well as other crane parts.
Types of electric motors include:
•AC Motors (Alternating Current)
•DC Motors (Direct Current)
•Synchronous Motors
•Asynchronous Motors
Each type serves specific functions and is selected based on the requirements of the crane and its operational environment
GearBox
The gearbox in overhead cranes is a key component for controlling movement and increasing transmitted power, responsible for adjusting speed and torque. This system is connected to the electric motor and, through gears and various mechanisms, transfers the motor’s generated force to other crane components. By converting the high speed of the motor to the required speed and torque, the gearbox enables the safe and precise handling of heavy loads
How the gearbox is connected to the electric motor
The gearbox is connected either directly or through a coupling to the output shaft of the electric motor. In this connection, the coupling acts as an intermediary that absorbs the shocks and vibrations caused by the motor’s operation, providing smoother transmission. This connection is typically done in two ways:
1. Direct Coupling:
•In this case, the motor shaft and the gearbox are directly connected to each other. This method is used when high precision is required in power and torque transmission. Direct coupling is commonly used in cranes that handle heavy loads and require precise power transfer.
2. Coupling Connection (Flexible Coupling):
•In this method, a coupling is placed between the motor shaft and the gearbox shaft. Couplings can come in various types (such as elastomeric or gear couplings) and help absorb vibrations and reduce shocks. This type of connection minimizes mechanical shocks to the motor and gearbox, thereby increasing their service life
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