How to Design a Customized Bridge Crane?

A briadge crane is a type of lifting equipment typically used in manufacturing, construction, warehousing, and other industries that require the efficient movement of heavy loads. Therefore, having a customized overhead crane that fits specific needs is crucial for the industry. 

Classification of Bridge Cranes 

• Classification by structure: e.g. Single Girder Overhead Crane, Double Girder Overhead Crane, Lower Suspension Overhead Crane, Double Trolley Overhead Crane, Multi-Trolley Overhead Crane, etc.

• Classification by lifting device: such as hook overhead travelling crane, grab overhead travelling crane, electromagnetic overhead travelling crane, container overhead travelling crane, etc.

• According to the use of classification: such as workstation overhead travelling crane, general-purpose overhead travelling crane, metallurgical overhead travelling crane, explosion-proof overhead travelling crane and so on.

Key Components of Bridge Cranes 

An overhead crane consists of several key components that work in tandem to facilitate smooth and reliable material handling. Key components include: 

• Bridge: The bridge is the main horizontal beam that spans the width of the facility. It supports the hoist and facilitates the movement of the load.

• Lifting equipment: Lifting equipment is responsible for lifting and lowering loads, such as hoists. It is mounted on and moves along the bridge so that the load can be precisely positioned.

• End beam: End beam are located at each end of the bridge. They support the bridge structure and provide stability during crane movements.

• Controls: Controls enable the operator to maneuver the crane and control the lifting, lowering and movement of the load. Modern cranes often utilize advanced control systems to improve accuracy and safety.

How to design and customize a bridge crane?

Below is a general overview of designing an overhead crane, and the parameters of the overhead cranes: 

• Lifting capacity: is the mass of the weight being lifted. The unit is kilogram or ton. Calculate the maximum weight to be lifted by the crane.

• Lifting height: refers to the distance of the hook center from the ground.

• Overhead crane span: It refers to the distance between the two rails center lines of the overhead crane is called the span of the crane.

• Working class: the working condition is an indicator of the whole machine, indicating the degree of full load of the crane lifting load and the number of lifting jobs. The working class of the crane is divided into 8 classes A1-A8, from light (A1-A3) to extra heavy (A8).

In addition, you should determine the working environment. Consider factors such as temperature, humidity and the presence of hazardous substances.

Design the structure

Calculate the size and strength of crane components such as girders, columns and runway beams.

Consider factors such as material strength, fatigue resistance and safety factors.

Check relevant design codes and standards, such as CMAA (Crane Manufacturers Association of America) or local codes.

Determine the hoisting mechanism

Select the appropriate hoisting system (wire rope hoist, chain hoist, etc.) based on load requirements.

Calculate the required hoisting speed, acceleration and deceleration.

Consider safety features such as limit switches, emergency stop buttons and overload protection devices.

Select the control system

Choose between manual, semi-automatic or fully automatic control systems.

Consider operator interfaces, safety features, and integration with other equipment.

Consider electrical and power requirements

Determine power source (voltage, frequency) and type of power transmission (cable reels, dragline systems, conductor bars).

Calculate electrical loads and specify necessary electrical components (motors, controllers, cables, etc.).

Evaluate safety features:

Include safety measures such as limit switches, emergency stop buttons, overload protection devices, and safety barriers.

Consider personnel safety during crane operation and maintenance.

Perform structural analysis

Use engineering software to analyze the crane structure and ensure that it can withstand the expected loads and forces.

Verify the stability, stress distribution and deflection of critical components.

Create detailed drawings

Prepare detailed fabrication and assembly drawings, including all necessary dimensions and specifications.

Include assembly sequences, welding details and material specifications.

Prototyping and Testing

Build and fully test crane prototypes to verify performance, functionality and safety.

Make any necessary adjustments or improvements based on test results.

Note that designing an overhead crane requires expertise in structural, mechanical and electrical engineering. Consider consulting a qualified professional or crane manufacturer for a safe and efficient design. After figuring out these steps, you'll be ready to customize your own bridge crane.