Within a foundry, the steel making process is designed to create high-quality steel products through melting, alloying, and refining raw materials. Cranes are essential throughout this process, handling materials, equipment, and finished products with precision and efficiency. As a trusted crane manufacturer, we are dedicated to providing custom crane solutions tailored to the specific needs of your foundry’s steelmaking operations.
Tailored Crane Solutions for Every Process in Your Foundry
Ironmaking Process: The Foundation of Steel Production
The ironmaking process is the first step in steel production, where iron ore is converted into molten iron in a blast furnace. This molten iron is later refined to produce steel. The process involves high temperatures and heavy materials, requiring cranes that can handle the bulk movement of materials and molten metal safely.
Crane Solutions For the Ironmaking Process:
Foundry Crane with Grab for Scrap Handling
Used to grab and move scrap steel, the grab crane for foundry picks up large chunks of scrap and transports them to the charging area. The grabs come in three main types: hydraulic, mechanical, and electric grabs.
Foundry Crane with Electromagnetic Chuck for Scrap Handling
The electromagnetic crane in a foundry is equipped with a powerful magnet to lift scrap steel into the scrap steel trough.
Foundry Crane for Charging
The charging crane for foundry lifts the scrap steel trough and accurately pours the material into the blast furnace, where the ironmaking process begins.
Steelmaking Process: Refining Iron into Steel
Once the molten iron has been produced, it needs to be refined to remove impurities and adjust its composition to meet specific quality standards. The steelmaking process primarily occurs in a converter (such as a Basic Oxygen Furnace or an Electric Arc Furnace), where the molten iron is turned into steel by injecting oxygen or using an electric current.
Crane Solutions for the Steelmaking Process:
Foundry Crane for Ladle Handling
After the molten iron is refined, it is transferred to large ladles that transport it to the next stage. Ladle cranes in a foundry are essential in this stage, as they handle the heavy ladles of molten steel and transport them from the furnace to the casting area. The foundry ladle crane can have structural configurations such as double-beam double-track, four-beam four-track, or four-beam six-track.
Casting Process: Shaping Steel into Useful Products
After the molten steel is refined, it needs to be cast into shapes that can later be processed into finished products. The casting process involves pouring molten steel into molds to create ingots, billets, blooms, or slabs, which are then further processed into specific steel products.
Cranes Used for the Casting Process:
Foundry Crane for Casting
The casting cranes in a foundry are used to lift and transport molds filled with molten steel during the casting process.
Foundry Crane for Billet Handling
After casting, billets – semi-finished steel products – need to be transported. Billet handling cranes for a foundry are designed to move and stack billets for further rolling or processing.
Rolling and Finishing: Finalizing Steel Products
Once steel is cast, it is often rolled and shaped into finished products, such as bars, plates, or sheets. The rolling process involves passing the steel through rollers to reduce its thickness and shape it into the desired form. This process can be done hot or cold, depending on the specific type of steel being produced.
Crane Solutions Used for the Rolling Process:
Foundry Crane for Coil Handling
These cranes are specially designed to handle steel coils in the rolling mill. Coil handling cranes feature specialized lifting equipment, such as coil tongs, to ensure safe and efficient material handling.
Foundry Crane with Electromagnetic Hanging Beam For Steel Handling
The electromagnetic cranes can lift steel products directly from the production line, particularly useful in moving hot steel plates, sheets and billets. These cranes are equipped with strong electromagnets that can easily lift ferrous materials without the need for slings or hooks.
Finished Steel Products: Storage and Shipping
After the steel is processed, it is either stored or shipped to customers as finished products such as beams, plates, or wire rods. The storage and shipping process involves moving finished products to warehouses or directly onto trucks or ships for delivery.
Crane Solutions for Finished Steel Products:
Regular Foundry Overhead Crane For Indoor Steel Product Handling
The overhead cranes are commonly used in warehouses and storage areas within a foundry to move finished steel products. With high lifting capacities and precise control, overhead cranes ensure safe and efficient handling of steel items, whether they are being moved to storage or prepared for shipping.
Regular Foundry Gantry Crane For Outdoor Steel Product Handling
Gantry cranes are often employed in outdoor storage yards or large shipping areas within a foundry. They are capable of lifting heavy steel products, such as coils, beams, and plates, and can move them across long distances with ease.
Rubber Tyred Foundry Gantry Crane For Flexible Steel Handling
In a foundry, rubber tyred gantry cranes provide a versatile and mobile lifting solution for handling finished steel products in large yards. These cranes are equipped with rubber tires, allowing them to move freely over different surfaces, making them ideal for transporting steel products between storage areas and shipping points.
Specifications of Different Types of Foundry Cranes
Specs of Regular Overhead Crane in Foundry
| Technical Parameter of AQ-QDX European Standard Double Girder Crane | |||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Capacity | t | 5 | 10 | 16 | 20 | 32 | 50 | 75 | 100 | 160 | 200 | 250 | 320 |
| Span | S(m) | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 |
| Lifting height | m | 6~18 | 6~18 | 6~18 | 6~18 | 6~16 | 6~16 | 6~24 | 6~24 | 6~24 | 6~20 | 6~20 | 6~24 |
| Lifting speed | m/min | 1.07~10.7 | 0.81~8.1 | 0.73~7.3 | 0.58~5.8 | 0.49~4.9 | 0.4~4 | 0.37~3.7 | 0.32~3.2 | 0.25~2.5 | 0.24~2.4 | 0.21~2.1 | 0.2~2 |
| Trolley speed | m/min | 3.3~33 | 3.3~33 | 3.2~32 | 3.2~32 | 3.36~33.6 | 2.9~29 | 2.92~29.2 | 2.9~29 | 2.65~26.5 | 2.5~25 | 2.5~25 | 2.4~24 |
| Crane speed | m/min | 6.8~68 | 6.8~68 | 5.4~54 | 5.4~54 | 5.6~56 | 5.4~54 | 4.8~48 | 5.26~52.6 | 4.67~46.7 | 5.2~52 | 5.2~52 | 4.15~41.5 |
| Work duty | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | A3~A5 | |
| Track type | P38 | P38 P43 | P43 | P43 | QU70 | QU80 | QU100 | QU100 | QU120 | QU120 | QU120 | QU120 | |
Specs of Regular Gantry Crane in Foundry
| Technical Parameter of AQ-MG Double Girder Gantry Crane | ||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Capacity | t | 5 | 10 | 16 | 20 | 32 | 50 | 75 | 100 | 160 | 200 | 250 | 320 | 400 | 450 | 500 |
| Span | S(m) | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 | 18~35 |
| Lifting height | m | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 | 6~18 |
| Lifting speed | m/min | 11.5 | 8.5 | 7.9 | 7.2 | 6 | 5.9 | 4.7 | 3.9 | 3.5 | 3.5 | 2.2 | 2.3 | 1.5 | 1.5 | 1.5 |
| Trolley speed | m/min | 37.2 | 37.4 | 40.1 | 40 | 37 | 31.3 | 38.2 | 33.9 | 22.5 | 29 | 28 | 16.6 | 10 | 10 | 11.5 |
| Crane speed | m/min | 37.7 | 37.7 | 40.1 | 40.1 | 38 | 44 | 38.3 | 32.3 | 28 | 28 | 50 | 28 | 18 | 18 | 16 |
| Work duty | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | A3-A7 | |
| Track type | P43 | P43 | P43 QU70 | P43 QU70 | P50 QU80 | QU80 | QU80 | QU100 | QU100 | QU100 | QU120 | QU120 | QU120 | QU120 | QU120 | |
Specs of Grab Crane in Foundry
| Technical Parameter of AQ-QZ Double Girder Grab Bucket Bridge Crane | |||||
|---|---|---|---|---|---|
| Capacity | t | 5 | 10 | 16 | 20 |
| Span | S(m) | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 |
| Lifting height | m | 6~18 | 6~18 | 6~26 | 6~26 |
| Lifting speed | m/min | 39.3 | 39.3 | 32.7 | 30.7 |
| Trolley speed | m/min | 44.6 | 31.7 | 31.1 | 31.1 |
| Crane speed | m/min | 93.6 | 86.5 | 75.1 | 76.9 |
| Work duty | A5~A7 | A5~A7 | A5~A7 | A5~A7 | |
| Track type | P43 QU70 | P43 QU70 | QU70 | QU70 | |
Specs of Electromagnetic Crane in Foundry
| Technical Parameter of AQ-QC Electromagnetic Crane | |||||||
|---|---|---|---|---|---|---|---|
| Capacity | t | 5 | 10 | 16 | 20 | 32 | 50 |
| Span | S(m) | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 |
| Lifting height | m | 6~16 | 6~16 | 6~16 | 6~16 | 6~18 | 6~16 |
| Lifting speed | m/min | 15.5 | 13.3 | 13 | 9.7 | 9.5 | 7.8 |
| Trolley speed | m/min | 37.2 | 37.4 | 40.1 | 40 | 37 | 31.3 |
| Crane speed | m/min | 70.6 | 70.6 | 74.3 | 75.1 | 64.9 | 58.5 |
| Work duty | A5~A7 | A5~A7 | A5~A7 | A5~A7 | A5~A7 | A5~A7 | |
| Track type | P38 | P38 P43 | P43 | P43 | QU70 | QU80 | |
Specs of Casting Crane in Foundry
| Technical Parameter of AQ-YZ Casting Crane | ||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Capacity | t | 5 | 10 | 16 | 20 | 32 | 50 | 74 | 100 | 125 | 140 | 160 | 180 | 200 | 225 | 240 | 280 | 320 |
| Span | S(m) | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 10.5~31.5 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 | 13~31 |
| Lifting height | m | 6~16 | 6~16 | 6~16 | 6~16 | 6~16 | 6~16 | 6~20 | 6~20 | 6~20 | 6~22 | 6~22 | 6~24 | 6~24 | 6~24 | 6~24 | 6~24 | 6~24 |
| Lifting speed | m/min | 12.5 | 13 | 10.8 | 9.9 | 9.7 | 7.6 | 6.4 | 7.5 | 7.5 | 6.84 | 6 | 7.2 | 8 | 8 | 10 | 10 | 9 |
| Trolley speed | m/min | 39.5 | 44.9 | 44.6 | 45.9 | 43.5 | 39.3 | 37.2 | 38 | 38 | 38 | 37 | 38 | 40 | 40 | 38 | 36 | 36 |
| Crane speed | m/min | 118.6 | 114.9 | 103.5 | 103.5 | 88 | 77.5 | 77 | 77 | 79.7 | 73 | 77.8 | 86 | 86 | 87 | 87 | 76 | 63 |
| Work duty | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | A6~A8 | |
| Track type | P38 | P38 P43 | P43 QU70 | P43 QU70 | QU70 | QU80 | QU100 | QU120 | QU120 | QU120 | QU120 | QU120 | QU120 | QU120 | QU120 | QU120 | QU120 | |
Key Features of Foundry Cranes
Heat Resistance
- Heat-resistant hoists and trolleys: Designed to resist thermal expansion and maintain operational efficiency under extreme conditions.
- Insulated electrical systems: Specialized wiring, motors, and control panels are built to resist heat damage, ensuring safe and continuous operation.
- Heat shields and protective coatings: Foundry bridge cranes feature thermal protection on critical components to protect against metal splashes and radiant heat.
Durability and Strength
- Heavy-duty steel construction: Cranes in foundries are constructed from high-strength, corrosion-resistant steel to withstand constant exposure to extreme temperatures and rough handling.
- Reinforced components: Critical parts like the bridge, hoist, and trolley are reinforced to prevent damage from heavy loads and the abrasive foundry environment.
Advanced Control Systems
- Remote control systems: Our foundry cranes for sale are equipped with remote controls that allow operators to control the crane from a safe distance, preventing exposure to heat and potential accidents.
- Variable speed drives (VSD): These allow for precise control of crane movements, ensuring smooth and controlled load handling.
- Anti-sway systems: Foundry cranes often include anti-sway technology, which minimizes load swinging, ensuring the safe and precise movement of molten metal and other heavy materials.
High Safety Standards
- Overload protection: Foundry cranes are equipped with sensors and systems that automatically prevent lifting loads that exceed safe operating limits, reducing the risk of accidents.
- Emergency stop buttons: Foundry cranes are fitted with emergency stop buttons at key locations, allowing operators to quickly halt the crane in case of an emergency or malfunction.
- Safety limit switches: These prevent the foundry and steel mill crane from operating beyond its safe limits, helping to avoid damage to the equipment or potential accidents.
Types of Lifting Devices for Foundry Cranes
Let’s look at some of the most commonly used lifting devices for foundry cranes, each designed to meet specific needs of the foundry environment.
Molten Metal Ladle Lifting Devices
Foundry cranes lifting molten metal ladles requires specialized lifting devices that can handle extreme temperatures. Our custom ladle lifting devices are designed with heat-resistant materials and protective coatings to ensure the safety of operators and the integrity of the load. These devices can also feature tilt mechanisms to help pour molten metal into molds or other containers.
Electromagnetic Lifting Devices
Electromagnetic lifting devices are perfect for foundries dealing with steel or iron products. The electromagnetic overhead cranes in a foundry use electromagnets to lift heavy metal parts such as billets, ingots, and scrap metal. Custom electromagnetic lifters can be tailored to accommodate various shapes and sizes of metal components, offering a secure grip without damaging the material. These devices are ideal for applications where traditional hooks or slings would be inefficient or unsafe.
Coil Tongs
For foundries that work with steel coils or other cylindrical materials, custom coil tongs are an essential tool. These tongs are designed to securely grip and lift steel coils without causing deformation or damage. Coil tongs are built to handle coils of varying sizes and weights, ensuring that the coil handling crane in foundry is both versatile and reliable.
Tilt-rotator Systems
Tilt-rotator systems for foundry cranes are crucial when handling large, heavy, and delicate loads that require rotating or tilting during the lifting process. Custom tilt-rotator systems can rotate loads in precise increments, improving flexibility and control when lifting heavy castings or molten metal ladles. These systems are particularly useful for tasks like pouring metal from ladles or placing large molds into position.
Grab Lifting Devices
Grabs are essential lifting devices for foundries that need to handle bulk materials, such as scrap metal. These grabs have a unique design that allows them to “grab” and lift large volumes of materials with ease. Custom crane grab buckets can be designed with varying bucket sizes, shapes, and capacities to meet the specific needs of a foundry’s operations. They can be equipped with hydraulic or mechanical opening and closing mechanisms for secure gripping, and heavy-duty materials ensure they can withstand the wear and tear of high-impact lifting.
Billet Tongs
Billet tongs are specially designed lifting devices used to grab and hold steel billets during their transportation through the foundry. Typically, these tongs have adjustable gripping arms to accommodate billets of varying sizes. Made from high-strength steel, these tongs are built to endure the high temperatures and pressures involved in handling steel products. The locking mechanisms ensure a secure grip on the billets, preventing slippage or accidental release during lifting and transport.
A Comprehensive Guide to Installing a Foundry Crane
Foundry cranes are subjected to high heat, dust, and abrasive environments, so the installation process is more complex than regular overhead bridge cranes. Here’s a breakdown of the steps involved in installing a foundry crane:
Step 1: Site Assessment and Pre-Installation Preparation
Before any physical installation begins, a comprehensive site survey is conducted. The following factors are evaluated:
- Environmental conditions: Heat levels, potential dust, and exposure to chemicals or metals.
- Structural integrity of the building: Ensure that the overhead structure can support the weight and dynamic forces of the foundry bridge crane.
- Clearance: Checking for sufficient headroom, floor space, and load paths for the crane.
After the survey, we will prepare a detailed installation plan, including custom drawings if required, and confirm the compatibility of the crane with the building’s structure.
Step 2: Assembly of the Foundry Crane Components
Once the site has been prepared, assembly begins. The foundry crane will typically be delivered in components: main girders, end trucks, hoists, trolley, control system, and other related accessories.
- Bridge and trolley installation: The overhead rails are set up first, followed by the assembly of the crane bridge. The bridge is mounted on the rails, ensuring that it moves smoothly and precisely.
- Hoist installation: The hoist system is assembled and installed, carefully checking for correct alignment and load balancing.
- Electrical connections and fire-safety features: Electrical components, including the control panel, motors, and power supplies, are installed with particular attention to fire and explosion prevention.
Step 3: Alignment and Calibration
After the crane is assembled, the alignment and calibration of the system are essential to ensure smooth operation:
- Vertical and horizontal alignment: This ensures that the crane runs correctly on its rails without deviating from its path.
- Calibration of lifting mechanisms: The hoist, trolley, and bridge systems are calibrated to ensure they lift and move materials accurately.
- Safety checks: Testing all safety devices (overload protection, limit switches, emergency stops, etc.) to ensure they are properly integrated.
Step 4: Load Testing and Inspection
After the crane is installed and aligned, it undergoes a thorough load testing phase. This phase is especially critical for foundry cranes due to the hazardous environment they operate in. The following steps are taken:
- Static load test: A test with a load equal to the crane’s rated capacity is performed to ensure the crane can lift and handle heavy, molten, or scrap materials without compromising safety.
- Dynamic load test: The crane is tested under actual working conditions to ensure it performs smoothly without excessive vibration or movement.
- Final inspection: A comprehensive inspection ensures that all components, especially safety features, are fully operational.
Step 5: Final Commissioning
Once the crane passes the load tests and inspection, it undergoes the final commissioning process. This includes final adjustments and checks to ensure that all functions (hoisting, traveling, turning) are in optimal working condition.
Step 6: Operator Training
Before the crane is handed over to the customer, our team provides operator training. In a foundry, operators need to be specifically trained to handle the unique safety hazards associated with molten metal and other dangerous materials.
In order to ensure your foundry crane is set up quickly, safely, and effectively, Aicrane also offers installation support to customers worldwide:
- For customers requiring hands-on assistance, we provide onsite installation services with a dedicated team of experienced engineers.
- For clients who prefer remote assistance or have an in-house team, we provide comprehensive online installation guidance.
By choosing Aicrane, you benefit from not only high-quality cranes but also expert overhead crane installation services that ensure your equipment will provide years of reliable and safe operation in the harsh foundry environment.
Why Buying a Foundry Crane from Aicrane is a Smart Choice
Investing in a foundry crane is a major decision that will impact the safety, efficiency, and productivity of your operations. By choosing Aicrane, you’re selecting a partner who understands the complexities of the foundry industry and is committed to providing high-quality, tailored solutions.
Here is why choosing Aicrane for your foundry crane needs is a smart decision for your operations.
Custom Solutions Tailored to Foundry Needs
We know that a one-size-fits-all solution won’t work in the foundry industry, which is why we offer customized crane solutions designed specifically for your operation. From regular overhead cranes to scrap handling cranes or molten metal handling cranes, we work closely with you to design a solution that meets your exact foundry lifting requirements.
Robust and Reliable Manufacturing Quality
We design our foundry cranes to be robust and reliable, using premium materials and advanced manufacturing techniques. We focus on durability, ensuring that each crane performs consistently over the long term, even in the most challenging environments.
Competitive Pricing
At Aicrane, we offer foundry cranes that combine high quality with competitive pricing. Through streamlined production processes, efficient supply chain management, and in-house manufacturing of key components, we are able to reduce costs without compromising on performance or safety.
After-Sales Service and Support
We offer exceptional after-sales service and support, ensuring that your crane continues to perform optimally throughout its lifespan, including maintenance services, spare parts supply, and more. Our dedicated after-sales team is always here to support you, ensuring that your foundry operations run smoothly for years to come.
Searching for a dependable foundry crane manufacturer? Get in touch with us today for a customized quote and discover how Aicrane can support your foundry’s operations with cost-effective, high-performance lifting solutions!
