Kuangshan Crane Custom Overhead Crane Design Solutions: Smart, Safe, and Tailored for Your Industry

With the increasing demand for material handling equipment in steel, electric power, water conservancy, metallurgy, intelligent manufacturing and other industries, the overhead crane design not only has to meet the load carrying capacity, but also has to take into account structural safety, space utilisation and intelligent control.With more than 20 years of industry deposits and global project experience, Kuangshan Crane provides you with one-stop bridge crane design services from concept to delivery.

Kuangshan Crane is one of the largest crane manufacturers in China, specialising in the research, development, design and manufacture of bridge and gantry cranes with:

• More than 2,700 employees, including a team of 300+ engineers
• Intelligent manufacturing base with an area of more than 680,000 square metres
• Annual production capacity of 80,000 sets of bridge and gantry cranes.
• ISO, CE and other international certifications 

We not only provide equipment, but also engineering design solutions to adapt to a variety of complex working conditions.

Kuangshan’s Overhead Crane Design Service Types 

kuangshan Crane provides diverse overhead crane design services to meet the needs of different industries and scenarios. Our core service types include:

• Single girder overhead travelling crane: suitable for light load and short span scenarios from 1-20 tonnes, cost-effective and widely used in small and medium-sized factories and warehouses.
• Double girder overhead travelling crane: supporting heavy-duty and long-span applications from 5-500 tonnes with high stability, suitable for heavy industry, ports and large-scale manufacturing.
• High-end/Heavy Duty/Explosion Proof Overhead Crane Design: For special needs, kuangshan Crane provides high-end customised cranes, such as heavy-duty cranes (over 500 tonnes) and explosion-proof cranes for flammable and explosive environments.
• Industry-specific overhead cranes: Exclusive lifting equipment tailored for aerospace, intelligent unmanned, foundry and other industries to ensure high precision and reliability.

LD Single Girder Overhead Crane

FEM Standard Single Girder Overhead Crane

LX Single Girder Underslung Crane

LH Double Girder Overhead Crane

FEM Standard Double Girder Overhead Crane

Double Girder Overhead Crane With Grab Bucket

QC Elektromagnetické mostové jeřáby

LHB Explosion-Proof Double Girder  Overhead Cranes

Isolation Overhead Cranes For Aluminum Smelters

Each type can be individually designed to meet the needs of the customer, from standard to complex lifting scenarios.

Understanding The Customer’s Needs: The Basis for Precise Design 

In order to design the most suitable overhead travelling crane, kuangshan Crane understands the customer’s specific needs and ensures that the equipment is perfectly adapted to the work scenario. The engineering team will liaise with the customer on the following key parameters:

• Lifting capacity (tonnage): specify the maximum load to determine the main beam structure and hoist type.
• Span: Customise the span of the bridge according to the width of the plant to optimise the use of space.
• Lifting height: Determine the lifting height according to the height of the plant and material handling requirements.
• Usage Scenario: Define the usage of the equipment, such as production line, storage and handling, rubbish station, power plant or clean workshop.
• Power supply voltage conditions: support for 220V, 380V, 415V, 440V and other voltage configurations, adapted to different regional power grids.
• Use of environmental conditions: for high temperature, high dust, high altitude, humid environments, ultra-low temperature, clean workshop or flammable and explosive places, design special protective measures, such as anti-corrosion coating, sealing system or explosion-proof function.
• Factory installation conditions: analyse the headroom size and layout of the factory to ensure that the top row or bottom row rail system is compatible with the factory structure.
• Note: Customers can request special features such as intelligent control, automated operation or customised grippers.

Through a comprehensive needs analysis, kuangshan Crane is able to provide cost-effective and safe design solutions to ensure that each crane precisely meets the customer’s production objectives.

Team of Professional Crane Engineers: 

Our design team consists of experienced engineers who are familiar with international standards such as CMAA, ASME, ISO, etc. and specialise in the use of advanced CAD and simulation software to ensure accurate and efficient designs. Our engineers work closely with customers to provide one-stop service from demand analysis to solution optimisation.

Liam: senior crane engineer 

Liam is one of the core members of Kuangshan Crane’s technical team. Since joining the company in 2003, Liam has participated in and led the design of more than 500 sets of large-scale cranes covering metallurgical steel mills, hydroelectric power plants, waste treatment plants, high-temperature, heavy-duty and other complex conditions. He is good at the design of main girder structure optimisation, double girder heavy load system, anti-fatigue calculation and so on.

“Behind every drawing, what carries the customer’s safe operation for decades.” –Liam

Harvey: crane technical expert 

Harvey is responsible for the technical consulting and customisation of non-standard crane solutions for overseas project customers, and has been involved in large-scale power station and automated workshop bridge projects in many countries in Southeast Asia, Africa and the Middle East.

“Accurately understanding every detail of customers is the key to achieving reliable design.” –Harvey

Tina: crane OEM expert 

Tina has solid knowledge in the crane field, and has been responsible for the selection of crane structure, pre-sales and after-sales technical support with OEM partners. She is particularly good at the selection of bridge cranes for special working conditions, such as explosion-proof, anti-corrosion and clean environment bridge cranes, as well as intelligent lifting equipment interfaced with MES systems.

“No matter OEM customers or end users, my goal is always to make the equipment run stably and land quickly.” –Tina

Kuangshan Crane’s technical strength is the core of its leading position in the industry.

Strict Standards: Meeting Global Market Demands 

At Kuangshan Crane, every overhead crane design is not based on experience, but is based on international authoritative standards, combined with industry conditions, to ensure that every design has global applicability, safety and implementability.

Design Source to Ensure Safety and Global Applicability 

Our overhead crane design strictly follows the following major standard systems:

• CMAA (Crane Manufacturers Association of America) 70/74 standard: applicable to the North American market, ensuring the bridge structure is stable, the operation is smooth, and the electronic control system responds accurately;
• FEM European standards: emphasising fatigue life, structural lightweight and energy efficiency, suitable for high-frequency operation and automated production scenarios;
• ISO international standard: covering crane classification, load combination, safety assessment and other aspects, is a common basis for export;
• ASME/ANSI standard: applicable to North American projects, covering the whole process of structure, electrical and safety maintenance;
• GB/T Chinese national standards: to ensure compliance with domestic application scenarios and adapt to complex terrain and climate;
• IECEx / ATEX explosion-proof standard: applicable to chemical, coal mine, semiconductor and other flammable and explosive environments, supporting Zone 1/2 and other multi-region requirements.

Design Verification Process 

In the project design phase, we integrate the above standards into engineering calculations, structural modelling, selection analysis, fatigue assessment and other aspects, and strictly control the following elements:

• Structural safety factor: main beams, secondary beams and end beams are all calculated and verified in strict accordance with the standards.
• Service life analysis: the structure is graded according to CMAA or FEM, and the design service life is 10~20 years.
• Explosion-proof and special protection design: Provide customised safety design solutions for high dust, high humidity, high temperature and clean plant environments.
• Material and welding standard: AWS D1.1 welding standard is implemented, and the weld seam can be tested by ultrasonic/MPI non-destructive testing.
• Load Test Requirements: The equipment can be tested according to 125% static load and 110% dynamic load before leaving the factory.
• Electrical and control system standards: the design of the electrical control cabinet complies with IEC standards and supports CE/UL and other international certification requirements 

International Certification Support 

Kuangshan Crane’s overhead cranes have passed several certification systems, including:

• ISO 9001 Quality Management System Certification
• ISO 14001 Environmental Management System Certification
• ISO 45001 Occupational Health and Safety Certification
• CE Compliance: meets EU market access requirements.
• SGS third party certification (on request): Independent testing and compliance report by SGS can be arranged upon customer request.

These standards are not only the embodiment of Kuangshan Crane’s design philosophy, but also the cornerstone of our customers’ trust worldwide.

Intelligent Production Line:

Kuangshan Crane has advanced automated production lines, fully equipped with intelligent manufacturing equipment and strict quality inspection system. This system enables the design scheme to be efficiently and accurately transformed into actual products. The whole process, from material cutting, main beam assembly to welding of key components and assembly of the whole machine, is highly automated, which realises the accurate reproduction of the design dimensions, tolerances and structural process, and greatly guarantees the consistency and reliability of the products.

Compared with manual operation, the weld seam formed by robot welding has a beautiful appearance, uniform width, flat surface and almost no defects. The uniform weld effectively reduces the structural risk of stress concentration, and the average weld height is higher than that of manual welding, which significantly improves the overall structural strength and fatigue life. This not only ensures that the bridge crane meets design expectations in actual operation, but also helps to cope with complex and demanding application scenarios.

Meanwhile, intelligent production significantly shortens the delivery cycle and improves the customisation efficiency, which is the key guarantee for Kuangshan to turn ‘high standard design’ into ‘high quality product’.

These technical advantages enable kuangshan Crane to deliver high quality, customised overhead cranes quickly.

Industry References 

kuangshan Crane’s overhead travelling crane service has been successfully applied in several high-end industries, demonstrating its excellent customisation capabilities:

Henan Kuangshan Bridge Crane Helps China’s Aerospace

In recent years, China’s aerospace industry has ushered in rapid development, a new generation of launch vehicle production demand is rising year by year, the required solid rocket engine composite shells and other ancillary urgently need large-scale production, Henan Mining, as an important supplier of lifting equipment for the Space Academy IV, has undertaken various types of aerospace products in the production process of lifting operations.

More than 20 sets (sets) of large-span, high-precision new cranes manufactured by our company have been successfully delivered and used for the production of supporting materials for major projects in China’s aerospace to provide equipment to ensure the smooth implementation of manned spaceflight, lunar exploration, BeiDou navigation, Mars exploration and other major aerospace tasks.

Kuangshan Crane Helps Construction Of A Thermal Power Project in Indonesia

This project is a key project of Indonesia’s ‘One Belt, One Road’ and is located in Green Mountain Industrial Park, Morowali Regency, central Sulawesi, Indonesia. The two 120t new double girder cranes manufactured by the company for this project help the construction of 3 sets of 380MW supercritical primary intermediate reheat condensing coal-fired generating units with the technical advantages of safety, reliability, smooth operation and accurate positioning.

Clean Explosion-Proof Bridge Cranes for the Semiconductor Industry

The customer mainly produces semiconductor-grade polysilicon and strongly requires a dust-free design (air cleanliness class 4, i.e., less than 10,000 particles of 0.1 µm in one square metre) and the presence of flammable and explosive gases in the workplace. class 4, i.e., less than 10,000 particles of 0.1 µm in one square metre) and the presence of flammable and explosive gases in the workplace. The explosion-proof level of the crane is dIICT4.

The main configuration of this bridge machine is as follows. High-sealed explosion-proof driving mechanism; maintenance-free self-lubricating type bearings; motor, reducer, brake, electrical detection combined into one; main beam adopts high-strength alloy steel; rotating part, connecting part and protection part adopt stainless steel; full-automatic operation; anti-swaying automatic precise positioning (positioning accuracy up to millimetre).

Kuangshan Crane’s Unmanned Intelligent Grab Bucket Overhead Crane

Unmanned intelligent grab crane is designed and developed for radiation, high temperature, dust, strong corrosion and other special operating environments, our company has developed an unmanned grab crane that integrates advanced intelligent technology. Unmanned intelligent grab crane can achieve three-dimensional scanning, automatic positioning, automatic identification, automatic obstacle avoidance, automatic grasping and other functions, equipment positioning accuracy, repeatability within 5 mm.

Kuangshan Crane unmanned intelligent grab cranes have been successfully applied in many major projects in China, such as Baowu Group Shaoguan Steel Plant 250,000 tonnes rotary kiln furnace project, Ning Steel No. 2 blast furnace technical improvement project, Zhongtian Fine Steel ironmaking EPC project. In addition, it has been exported to Georgia, Vietnam and other countries.

360T Casting Crane for Steel Mills

360t casting crane is the largest casting crane in China. Crane girder and trolley frame are processed by the company’s large-scale processing equipment as a whole, which effectively improves the assembly precision and performance; it has the functions of self-diagnosis of faults and accurate operation and positioning; each mechanism adopts redundancy design and cooperates with the safety monitoring system, which ensures and improves the reliability and stability of the crane’s operation.

These cases highlight kuangshan Crane’s design capability and industry influence in complex scenarios.

Delivery Guarantee 

kuangshan Crane wins customers’ trust with efficient and reliable delivery process:

• Rapid response: from requirement communication to design proposal generation, kuangshan Crane provides quick response, usually completing the preliminary design within 3-5 working days.
• Precise Manufacturing: Relying on intelligent production lines to ensure short manufacturing cycle and stable quality.
• Professional Installation: Implemented by experienced installation team to ensure the perfect fit between the equipment and the plant. https://www.kscranegroup.com/posts/overhead-crane-installation/
• After-sales support: Kuangshan Crane has accumulated many years of projects and is equipped with regular maintenance services in some countries.
• Equipped with international service team, supporting English, Russian, Arabic, French and other multilingual services, to ensure worry-free docking of overseas projects.

kuangshan Crane promises to deliver high-quality cranes on time and provide lifelong technical support to help customers achieve production goals.

Shrnutí 

With more than 20 years of industry experience, advanced technology and customer orientated service, Henan Mining (kuangshan Crane) provides safe and efficient overhead crane design and manufacturing solutions to customers worldwide. From single girder to heavy-duty explosion-proof cranes, our customised service meets diverse needs and ensures that equipment excels in industries such as aerospace, smart manufacturing and foundry.

krystal

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E-mailem: krystalli@kscranegroup.com