Automated Intelligent Crane Manufacturer | Custom Solutions & Specifications

Decision makers who do industrial material handling can feel the accelerated pace of popularization of automated intelligent crane in recent years. Many purchasing managers, factory engineers, operation and maintenance supervisors looking for intelligent crane selection guide, easy to focus only on the rated tonnage and quotation, ignoring the specification suitability, functional utility and total cost of ownership of intelligent cranes, and finally either the configuration can not keep up with the pace of production, or the input exceeds expectations.

As a professional intelligent Crane manufactured supplier, Henan Mine Automated Crane Industrial has landed a large number of projects with different working conditions at home and abroad. This content of the intelligent crane specifications selection, core functions, scene adaptation, intelligent crane TCO analysis, operation and maintenance management of the core logic of all speak through, to help material handling decision makers clear from the selection of the whole process to the landing, selected to truly adapt to their own conditions of automated intelligent cranes.

the basic knowledge of intelligent Crane

Simply put, the intelligent crane is based on the traditional bridge, gantry lifting equipment, integrated sensor acquisition, automatic control, network communications and data management technology, high-end intelligent lifting equipment, but also the current industrial crane automation upgrade of the core carrier.

Unlike traditional manual cranes, it can complete standardized material handling through automatic positioning, anti-sway control, path planning and other functions, without the need for operators to manually control the whole process. Highly equipped intelligent unmanned Overhead Crane can realize the whole process of unattended operation, in the high temperature, dust, high-risk operation scenarios, the value is particularly prominent.

With the advancement of intelligent manufacturing, the technical maturity of this type of equipment is getting higher and higher, from the benchmark demonstration project gradually sinking to the regular reconstruction and expansion projects, suitable for more and more rich working conditions, is no longer the exclusive configuration of the port, large-scale steel mills.

 the core technology specifications selection points

Doing intelligent Crane specifications selection, basic parameter matching is a prerequisite for all intelligent functions to land, away from the working conditions to talk about the configuration is of no practical significance. Each parameter should be combined with on-site operational requirements check, blindly chasing a high or downgraded will affect the subsequent use of the effect.

The rated lifting capacity covers a wide range, 10-50 tons is common in light and medium-sized workshops, and 100-500 tons can be achieved in heavy-duty metallurgy and port scenarios. Single hook, double hook, special fixture support customization, according to the actual lifting weight to reserve a safety margin, do not get stuck in the rated upper limit selection. For example, steel mill intelligent Crane lifting steel coils, billets, load fluctuations, the margin should be left more adequate.

The span is customized according to the width of the plant, yard, conventional 10-40 meters, special sites can be made larger span. Intelligent cranes in ports and large logistics parks usually have larger spans to cover a wider operating area. Lifting height determines the stacking and operating range, ordinary workshop 9-15 meters mostly, wharf, high warehouse can be raised as needed.

The running speed should be selected in combination with the frequency of operation, the general 10-30m/min for empty walking, 20-60m/min for heavy walking, and 5-20m/min for lifting speed, which is not the faster the better, but should be matched with the precision of alignment and safety of operation, and can be increased appropriately for the high-frequency transit scene, and increased for the precision assembly scene. The high-frequency transportation scene can appropriately increase the walking speed, while the precision assembly scene should give priority to ensure the stability of low speed.

Positioning accuracy is the core indicator of intelligent overhead crane, ordinary configuration can do ±0.1-0.5 meters of fast positioning, high-precision laser plus encoder calibration program, can do ±10mm or even ±3mm, to match the needs of precision assembly, precision stacking. When doing intelligent Crane specification selection, according to the actual alignment needs to choose the accuracy level, do not blindly chase the highest matching.

The working level should match the intensity of operation, refer to the FEM or CMAA standard selection. High-frequency continuous operation scenarios, such as metallurgical intelligent cranes, three-shift production workshop, can not choose low working level equipment, otherwise it will accelerate the aging of the structure and components, significantly shortening the life of the equipment.

The mainstream power source is utility-powered electric models, low operating and maintenance costs; outdoor scenes without fixed power supply, you can choose diesel, hybrid or lithium solutions. Environmental adaptation should also be considered in advance, the seaport to do salt spray anticorrosion, dust workshop to do sealed dust, extreme high and low temperature scenarios to do special adaptation, IP protection level, corrosion levels should be clearly written into the technical requirements.

 Core Intelligent Functions

Sensor monitoring is the basis of all intelligent functions, but also the perception layer of the intelligent Crane safety system. Load sensors monitor the lifting weight in real time, triggering overload protection; position sensors track the real-time coordinates of the trolley, trolley, and hook; wind speed, temperature and humidity sensors collect environmental data, and all the data are summarized to the control system to provide data support for automatic operation.

At the level of automatic control, intelligent Crane anti-sway control and automatic target positioning are the most commonly used basic functions. Dual closed-loop servo control can control the positioning accuracy at the millimeter level, and the path planning algorithm supports the automatic operation of a single device, as well as multi-machine cooperative operation. Many customers do automation upgrades, the first landing is these two features, the investment is not high but the benefits are obvious.

Advanced configuration can be added to the algorithmic analysis, machine vision to identify the material and the surrounding environment, algorithms to optimize the scheduling rhythm, assessment of structural fatigue state, to further enhance operational stability. Higher-order projects can also do digital twin, the establishment of a virtual model of the equipment, simulation of the operating process, optimize the scheduling program.

Intelligent Crane remote monitoring through the Industrial Internet of Things to transmit data to the cloud platform, operating parameters, fault alarms synchronized in real time. Operation and maintenance personnel do not have to go to the scene can initially troubleshoot the problem, software upgrades, log management can be completed remotely, cross-regional, multi-site management scenarios advantages are particularly obvious.

Intelligent Crane predictive maintenance is a practical and strong cost reduction function, the motor, reducer temperature, current, vibration data collected in real time, the system projects the remaining life of the components, and issue an early warning. Compared with the after-the-fact maintenance that is broken and then repaired, it can significantly reduce unplanned downtime, and is also one of the core functions to pull down the full life cycle cost of intelligent Crane.

The safety system is multi-level, collision avoidance, electronic limit, emergency stop protection, multi-hook synchronization control, with torque-controlled inverter system, safety redundancy is much higher than traditional equipment. Outdoor models should also be matched with wind speed monitoring and wind protection to further enhance the safety of operations in complex environments.

 the mainstream application scenarios

Port intelligent cranes are the most mature application of the scene, fully automated shore bridge, dock automation gantry crane can be 24 hours of continuous operation, many large-scale global hub port has completed the scale of intelligent transformation, operational efficiency and labor cost advantages are outstanding.

Steel mill intelligent cranes, metallurgical intelligent cranes are mainly used for steel coils, billets, iron ladle handling, intelligent transformation can reduce the number of operators on the scene, reduce the risk of high-risk environment operations, with the intelligent Crane predictive maintenance can also reduce the loss of production line downtime.

Workshop intelligent cranes are suitable for automotive, power equipment, machinery manufacturing and other assembly lines, can accurately distribute materials, reduce manual intervention, suitable for automated production line production beat, enhance the efficiency of the entire production line.

Warehouse logistics intelligent Crane with three-dimensional warehouse to do unmanned loading, unloading and handling, enhance the efficiency of warehousing turnover, suitable for large logistics parks, e-commerce warehousing, empty container yard and other scenes.

Energy, mining and other industries also have corresponding specialized models, such as mining intelligent cranes, power plant intelligent lifting equipment, to adapt to heavy-duty, high-risk operational needs, to enhance the safety of field operations.

 Selection and total cost of ownership (TCO)

Many customers choose to look only at the purchase price of equipment, in fact, calculate the total cost of ownership of intelligent Crane, to cover procurement, energy consumption, maintenance, downtime losses, residual value and other dimensions, short-term low price is not necessarily cost-effective in the long term. Doing intelligent crane TCO analysis is a necessary part of professional procurement.

First clear core requirements: maximum lifting weight, lifting height, span, frequency of operation, shift arrangements, matching the level of work according to industry standards, do not lower the configuration in order to lower the budget. Reliable intelligent Crane manufacturing suppliers, will first check the working conditions and then report the program, rather than directly push the standard model.

Automation level according to the need to choose, not the more full the better. Only need accurate alignment, choose the basic automatic positioning models will be enough; to unmanned operation, and then on a full set of sensing and scheduling system. Initial investment in high program, long-term labor saving, improve efficiency, return cycle depends on the actual amount of work, high-frequency operation of the scene will return much faster.

Environmental protection can not be saved, poor working conditions, the rate of wear and tear of low-cost equipment will far exceed expectations, later maintenance costs are higher. For example, the coastal harbor intelligent Crane, if the corrosion protection level is not enough, three or five years will appear obvious rust, overhaul cost is very high.

Energy consumption, electric drive than diesel models have lower operating and maintenance costs. Although the intelligent system increases sensing and software investment, operational efficiency is improved, downtime is reduced, and most projects can recover the incremental cost in a few years. The advantage of customized intelligent Crane solutions is that they can be configured flexibly according to budget and demand, without having to pay for features that can not be used.

Maintenance costs should also be included in the accounting, sensors, PLC, communication module maintenance costs should be reserved in advance. With intelligent Crane predictive maintenance models, long-term maintenance costs will be lower than traditional equipment, downtime losses are also less.

Intelligent Crane vs Conventional Crane Core Parameters English Comparison Table

 installation and commissioning and operation and maintenance management

Intelligent Crane installation and commissioning has a clear process requirements, can not be as simple as ordinary overhead crane lifting power on the use. Before installation, the site should be verified, the track, beam bearing and flatness should meet the design requirements, grounding and communication lines laid in place in advance.

After the equipment is lifted and positioned, the electric control cabinet, frequency converter, all kinds of sensors and operation terminals are installed in turn, and the power supply and network are connected. During the debugging stage of the system, configure the PLC and frequency conversion parameters, verify the intelligent functions such as anti-sway and positioning one by one, and complete the load test and safety performance verification. Before delivery, we give special training to the operators and maintenance personnel, and complete the acceptance after passing the test.

Daily inspection can not be less, bolt fastening, wire rope wear, electrical interfaces, braking devices, safety devices, every shift to check, there are abnormalities in a timely manner. Preventive maintenance is done according to the cycle, regular replacement of lubricating oil, inspection of brakes, reducers, sensors, cables, according to the manufacturer's manual.

Equipment with predictive maintenance function, combined with vibration, temperature, current data to prejudge the life of components, the establishment of maintenance database, more accurate than purely regular maintenance, but also can further pull down the full life cycle cost of intelligent Crane. Control system software should be updated regularly to repair loopholes and supplement functions. Operation logs and maintenance records are archived and retained for subsequent optimization.

During the life cycle of the whole machine, arrange overhaul according to the plan, and replace the core components in time to the life, which can not only prolong the service time of the whole machine, but also protect the safety of operations.

Frequently Asked Questions (FAQ)

Do intelligent Crane selection, the core to see what parameters?

First check the rated lifting capacity, span, lifting height, working level of these basic parameters, and then according to the operational requirements to determine the positioning accuracy, automation level, environmental protection level, and finally combined with the budget and the total cost of ownership of intelligent cranes to make a comprehensive judgment.

Can intelligent Crane predictive maintenance really reduce operation and maintenance costs?

It can. Through real-time monitoring of temperature, vibration, current data of core components such as motors, gearboxes, etc., the aging trend of components can be detected in advance, and scheduled maintenance can be arranged to avoid the loss of production downtime caused by sudden failures, which in the long run can significantly reduce the total operation and maintenance costs.

What site information is required for a customized smart Crane solution?

At least to provide site drawings, maximum lifting weight, frequency of operation, environmental conditions, automation needs, existing system interface requirements of this information, engineers can issue accurate customized solutions and quotes.

How much difference is there between the total cost of ownership of intelligent Crane and traditional equipment?

Depends on the intensity of operation. High-frequency three-shift operation scenario, intelligent cranes, although the purchase price is high, but manpower savings, downtime reduction, efficiency gains are obvious, a few years will be able to recover the difference in price, the full life-cycle cost but lower; low-frequency operation scenario, you can choose the basic automation configuration, do not have to go on the full set of unmanned features.

Ordinary old cranes can be upgraded to intelligent cranes?

Most of the in-service Crane can do intelligent transformation, add sensors, upgrade the electronic control system, increase the anti-sway and positioning functions. Specifically depends on the structure of the equipment, electronic control system adaptability, reliable manufacturers will first do site surveys and then out of the transformation program.

Conclusion

Intelligent Crane has been the direction of development of industrial material handling, selection without blindly chasing a high match, combined with their own working conditions, budget and long-term planning, choose to match the configuration is good. Do a good job of intelligent crane specifications selection, calculate the total cost of ownership of intelligent Crane, with standardized operation and maintenance management, the equipment will be able to create a stable value in the full life cycle.

Why choose our intelligent Crane program?

Henan Mine Crane is a professional automated crane industrial equipment manufacturers and solution providers, engineering team can be customized according to the customer's working conditions of the intelligent Crane program, products in line with FEM, CMAA, ISO and other types of industry standards, is a trusted intelligent Crane manufacturers customized service providers.

Our equipment has passed the relevant quality and safety certification, integrated with IoT and automatic control technology, covering the full range of configurations from basic positioning to fully unmanned operation, and can provide a full set of intelligent functions such as predictive maintenance, remote monitoring and safety protection of intelligent cranes, and support the docking of factory management systems, such as ERP, MES, and WMS.

From site survey, installation and commissioning to operation training, lifelong technical support, the whole process of follow-up services, there are a number of projects at home and abroad landing experience, can quickly respond to the needs of customers around the world. If you have intelligent Crane procurement, intelligent transformation of old equipment needs, welcome to contact our automation technology team, we will be based on your site conditions, issued by the appropriate selection program.