Upper Spillway Gate Gantry Crane: Reliable Solution for Dam Gate Hoisting and Hydropower Station Operations

The upper spillway gate gantry crane is a mobile hoisting machine with a gantry-type structure, installed on the dam crest and operating along the crest rails. It features vertical lifting, horizontal traveling, and slewing functions, serving as an indispensable piece of equipment in hydraulic and hydropower engineering.

It is primarily used for gate hoisting, equipment maintenance, and trash cleaning operations. With the addition of a hydraulic lifting beam, it can efficiently lift and position large radial or flat gates with high precision.

Unlike conventional gantry cranes, the upper spillway gate gantry crane is specifically engineered to withstand the challenging environmental conditions of dam sites—such as high wind speeds, humidity, temperature variation, and prolonged outdoor operation. Its structure, stability, and protection systems have been comprehensively enhanced to ensure safe and reliable performance under complex working conditions.

Main Components

Each subsystem of the gantry crane is designed with strict mechanical analysis and engineering verification to ensure high strength, durability, and operational reliability:

• Gantry Structure (Main Girder, Legs, and Connecting Beams): Key structural components such as the main girder, legs, and drum are made from high-strength low-alloy structural steel (e.g., Q690, Q960). Finite Element Analysis (FEA) is performed to verify combined loads (dynamic, impact, and wind), with a safety factor of 1.8–2.5 (compared to 1.2–1.5 for standard gantry cranes). The main girder adopts a “box-type section + dense stiffener layout,” effectively reducing deflection (e.g., ≤20 mm under rated load for a 2000-ton gantry with a 50 m span).

• Hoisting Mechanism: Designed for stable low-speed lifting during generator component handling, the hoisting system adopts “multi-motor synchronous drive + variable frequency control,” with a minimum lifting speed of 0.1 m/min (compared to 0.5 m/min in typical gantry cranes). This prevents creeping and ensures smooth movement. For gate hoisting, it features waterproof drums with chrome plating and corrosion-resistant galvanized or stainless steel wire ropes. The hook assembly includes an underwater depth sensor that provides real-time feedback to prevent collision between the gate and dam or riverbed.

• Crane and Trolley Traveling Mechanisms: Equipped with a dual-feedback “laser positioning + encoder” system, the positioning accuracy of both trolley and crab reaches ±2 mm (standard gantry cranes: ±5–10 mm). The system integrates an anti-sway control (≤1°) to ensure precise alignment of stator, rotor, and turbine pit components, with automatic load swing correction functionality.

• Hydraulic Lifting Beam System: Enables quick and safe beam connection and disconnection, improving operational efficiency. Various beam types are available for flat, radial, and emergency gates.

• Electrical Control System: Electrical cabinets feature protection level IP65 or higher (standard gantries: IP54) and are equipped with heaters and dehumidifiers to prevent moisture damage. Motors and sensors are waterproof, and all cable joints are sealed. The insulation resistance requirement is ≥2 MΩ (standard: ≥1 MΩ), ensuring long-term electrical safety.

Technical Specifications

Custom designs available for lifting capacities up to 10,000 KN and greater lifting heights.

Uainishaji wa Bidhaa

The upper spillway gate gantry crane is categorized by the number of hoisting points and traveling direction:

The single-hoist design is suitable for hoisting and maintenance of single-leaf or lightweight gates. It features a simple structure, light weight, and easy installation.

The double-hoist structure enables synchronized lifting of large radial gates or segmented gates, providing higher lifting stability and better balance.

This type of gantry crane operates in a single direction along the dam crest to complete gate hoisting or maintenance tasks. It is suitable for projects where gates are arranged linearly and hoisting operations are concentrated on one side.

The bidirectional gantry crane can travel in both directions along the dam crest, improving operational flexibility. It is especially suitable for large hydropower stations and multi-bay spillway projects.

Operating Environment and Design Features

The upper spillway gate gantry crane operates in harsh dam-top and spillway environments characterized by high humidity, strong winds, temperature fluctuations, and corrosive exposure. To ensure safety and reliability under these extreme conditions, the crane is optimized for strength, corrosion resistance, waterproofing, and intelligent maintenance:

• Corrosion and Moisture Protection:
  Main structural components use high-strength low-alloy steel (Q690/Q960) with sandblasted surfaces and fluorocarbon coatings. Electrical systems meet IP65 protection grade, and all components—motors, control cabinets, terminals—feature waterproof sealing.
• Wide Temperature Adaptability:
  Hydraulic systems use all-climate hydraulic oil (-30°C to 60°C) with integrated heating and cooling; electrical components are industrial-grade for extreme environments.
• Wind and Anti-Slip Safety:
  Triple wind-protection system (anemometer, hydraulic rail clamp, and anchoring device) automatically locks the crane during strong winds; end-stop brakes prevent trolley sliding.
• High Precision and Heavy-Duty Capability:
  Box-section girders with FEA-optimized structure ensure minimal deflection under rated load. The hoisting system achieves 0.1 m/min minimum speed and ±2 mm positioning accuracy.
• Underwater and Sloped Track Adaptation:
  Waterproof drums and galvanized ropes enable underwater operation; equipped with anti-slip and slope-running capability for complex dam terrains.
• Smart Maintenance and Durability:
  Integrated health monitoring collects vibration, temperature, and stress data for predictive maintenance. Key components are designed for a 20-year service life, with remote diagnostics and factory maintenance support.