Overhaed Crane Manufacturing Process

2022-12-29 17:55:42

Structural Parts Manufacturing

In structural parts manufacturing, our company has a strong manufacturing capacity. We have a capacity of more than 50 thousand tons in a year and have the open-book, leveling, shearing shot blasting, painting, and drying capacity of a pre-processing production line. Our company has 5 sets of numerical cutting equipment; 60 units of semi-automatic cutting； more than 200 units of CO2 gas-shielded welding, submerged arc welding (flat, angle welding); more than 300 units of other welding. We have a variety of shears, school-level machines, bending machines, rolling machines, and other large-scale processing equipment. These devices provide a strong guarantee to improve the manufacturing capacity of structural parts.

Mechanical Processing

In mechanical processing, we have a 16-meter floor milling and boring machine, a maximum machining diameter of φ3150 large-scale and large vertical lathe hobbing machines, CNC heavy-duty horizontal lathes, all kinds of the horizontal boring machine, vertical machining centers, precision milling, large and rare equipment. These pieces of equipment provide security for the processing of all kinds of large-scale and high-precision crane parts.

Mechanical product refers to the whole production process from raw material to production. It includes blank manufacturing, machining, heat treatment, assembly, inspection, testing, painting, and another significant production process; also includes packaging, transportation, and other auxiliary processes. A factory can complete its production process, several factories can also complete it. Besides large-scale structural parts and some machining parts manufactured by our company, there are some parts from the outside co-processing and manufacturing plants.

Brief Introduction of Making Crane Process

Cranes made from the metal structure (the main beams, side beams, platform, ladder railings, small frame, etc.), machining parts, purchased parts (bearings, fasteners, standard parts, etc.), and spare parts (the commission units processing components: such as the hook) through assembling.

Production Process for Each Structure

1. Inspection of the incoming material: this means that the quality inspection department will check if the incoming materials (including steel, and welding material) have certifications, and verify them following the national standard and company. Recheck if necessary, chemical composition and mechanical strength will be inspected by random samples.

2. Pretreatment of Steel Surface: Before cutting the steel, shot and ball blasted, the surface of important parts reaches degree Sa2.5 of GB8923 standard. After removing the rust, paint the anti-corrosive primer at once.

3. primer painting
Primer spray will be painted immediately after shot blast to avoid rust of the surface. Type of prime coat: Different paint will be used according to different environment, and also different primer will be used on the basics of different final coat.
4. Marking off
mark the shape and processing lines on plate with sample plate,
handrail or diagram.
5.Plate-cutting
Cutting method: CNC cutting, semi-automatic cutting, shearing and sawing.
      Processing department will choose the appropriate cutting method, draw up procedure card, put in program and number.
6. Plate connection: some parts (such as web plate of main girder) will be connected by several plates. Plates will be connected according to size, mark and process requirements. Weld will be bevel cut by semi-automatic cutter and then treated by automatic submerged-arc welding.
7. Flaw detection: butt weld seam will be detected according to requirements because of its importance, grade is no lower than II regulated in GB3323, when detected by ray, and shall be no less than Ⅰ regulated in JB1152 when detected by ultrasonic. For unqualified parts, shaved by carbon arc gouging, re-weld after cleaning.
Equipment: TF-3125 X-ray detector.
8. Leveling:
level the plate after connecting,
     Method: （1）Mechanical leveling: equipment: roller plate leveler W43Q-32X2500
             （2）flame straightening
             （3）manual correction
9. Secondary mark, cutting:
      After connecting, detection and leveling, draw cutting lines (marking off) according to the required shape, size, cut them with semi- automatic cutting machine.
10.Assembly：
Take main girder as an example, assembly procedure as follows:
      1. Build platform: assemble it on the platform, flatness no more than 1 / 1000
      2. Web plate will be put on the platform, weld longitudinal reinforcement angle, generally it’s double-staggered intermittent welding;
      3. Cover-Plate will be tiled on the platform, mark the position of rib and web plate.
      4. Weld the ribs according to dot line on plate, apply manual and CO2 spot welding;
      5. Weld main and aux web plate on cover plate which will be "π" shape beam.
      6. Weld seams inside, (ribs, web and cover plate); (gas-welding), then paint antirust primer;
      7. After marking on platform, put “n” shape girder on lower plate; weld seams inside;
      8. Weld four main seams (automatic submerged-arc welding) and other seams (gas protection welding).
     9. Correction, limitation. Generally VSR will be used for large components, camber of main girder shall be 0.9-1.4S/1000 (S stands for span).

Why Custom a Crane Solution?

At Yuantai, we know that there is no "one size fits all" in the lifting field. Universal cranes are suitable for general factories, warehouses, etc. Besides, different applications have different needs for cranes. For example, steel industries often lift steel plates, so need electromagnetic cranes. Ports and docks often need to load ore, gravel, and other bulk goods, so need to grab bucket cranes. Chemical dangerous places often need to carry flammable and explosive materials, so need explosion proof cranes.

So, we provide customized cranes according to the special needs of our customers. Custom crane solutions offer many benefits in a variety of applications：

Improve efficiency: Cranes can use automatic controls, and special accessories to improve efficiency.
Break space constraints: In limited spaces, standard cranes may not fit due to their size. Custom cranes can be designed as compact or lightweight cranes.
Cost savings: Customized cranes can lead to long-term cost savings. Customized crane solutions ensure crane's performance is all necessary for your business.

Get Your Free Quote

I'm happy to help you with a crane solution and pricing. Please provide me with the following crane specifications:

What type of overhead cranes do you need? (i.e., overhead crane, gantry crane, etc.)
What lifting capacity do you need for your overhead crane?
What span of crane do you need?
What lifting height of overhead cranes do you need?
What material will the crane lift? (i.e., steel, concrete, etc.)
Will the crane be used indoors or outdoors?
Any special requirements for the crane? (i.e., explosion-proof, etc.)

If you have any crane needs, please contact us online or email us at cherry@ytcrane.com. WhatsApp/WeChat：+86 15093126500 . Our crane engineers will give you a suitable crane solution and a specific crane price within 24 hours.