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Overhead Crane Types

If you’re thinking about investing in an overhead crane for your operation, selecting the right one is essential for maximizing efficiency and safety. With a variety of options available, understanding the different types of overhead cranes is the first step toward making an informed decision. In this article, we’ll look at the various overhead crane types, helping you identify the perfect fit for your business needs and ensuring your lifting operations run smoothly.

different types of overhead cranes

What Are The Different Types of Overhead Cranes

Overhead bridge cranes are broadly categorized based on their design, structure, application and working environment. The following are the subtypes of overhead cranes:

Types of Overhead Cranes Based on the Design And Structure

Single Girder Type Overhead Crane

Single Girder Overhead Crane

The single girder overhead crane features one main horizontal beam (the girder) supported by two end trucks. This type is typically used for lighter lifting capacities and is more cost-effective for small to medium-sized applications.

Applications: Ideal for smaller workshops, assembly lines, and light industrial operations.
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Double Girder Overhead Crane

The double girder overhead cranes are built with two parallel main girders, which offer superior strength and load distribution compared to single girder models. These cranes can lift much heavier loads, making them suitable for industrial facilities handling large equipment or materials.

Applications: Common in manufacturing plants, steel mills, shipyards, and power stations where heavy-duty lifting is required.
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Double Girder Type Overhead Crane
Top Running Type Bridge Crane

Top Running Overhead Crane

The top running overhead crane runs on a track mounted on the top of the building’s support structure. It uses an overhead bridge that spans the width of the area to be served. The wheels are located on the top flange of the runway beams, providing a more substantial load-bearing structure.

Applications: Found in large industrial environments such as steel plants, heavy manufacturing, and large-scale warehouses.
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Under Running Overhead Crane

Under running crane, or underhung crane, runs on a track mounted beneath the overhead support structure. The wheels of the crane run along the bottom flange of the runway beam, allowing it to be lighter in structure and more compact compared to top running cranes.

Applications: Used in smaller factories, warehouses, or environments where overhead space is limited.
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Underhung Type Bridge Crane

Types of Overhead Cranes Based on the Use and Environment

Explosion Proof Type Overhead Crane

Explosion Proof Overhead Crane

Explosion proof cranes are used in hazardous environments where flammable gases, vapors, or dust are present. This type of overhead crane is equipped with explosion-proof electrical components to prevent sparking or ignition in dangerous atmospheres. There are also specially designed motors, switches, and control panels that are sealed to resist external hazards.

Applications: Chemical processing plants, petrochemical plants, power plants, oil refineries, or mining operations.
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Grab Overhead Crane

The grab cranes are designed to lift bulk materials or loose materials like sand, gravel, coal, or scrap metal using a grab bucket or grapple. The grab bucket or clamshell mechanism can be manual, electric or hydraulic powered, depending on the material being lifted.

Applications: Ports, docks, steel mills, scrap yards, and mining sites.
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Grab Type Overhead Crane
Electromagnetic Type Overhead Crane

Magnetic Overhead Crane

The magnetic overhead cranes are used for lifting ferrous materials, such as scrap metal, steel plates, or coils, using an electromagnet. The crane’s magnetic system is controlled to attract or release metal objects precisely.

Applications: Steel mills, scrap yards, warehouses, and metal manufacturing plants.
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Steel Mill Overhead Crane

The steel mill cranes are designed specifically for the heavy-duty tasks involved in steel manufacturing processes such as moving molten metal, steel coils, and slabs. This type of bridge crane is built with high heat-resistant materials to handle extreme temperatures. It is also equipped with specialized lifting mechanisms, such as ladle hooks, to handle molten metal or steel slabs.

Applications: Steel mills, foundries, and other heavy manufacturing plants dealing with metal production and processing.
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Types of Overhead Cranes in Steel Mill

Benefits of Choosing the Right Type of Overhead Crane

Enhanced Efficiency and Productivity

Choosing the right bridge crane type ensures that it matches the specific demands of your operations. For example, double girder cranes provide superior load capacity for heavy-duty applications. By aligning the crane type with your operational needs, you can minimize downtime, optimize workflow, and achieve higher productivity.

Improved Safety

A crane designed for your specific applications reduces the risk of accidents and equipment failures. For instance, explosion proof cranes are indispensable for hazardous environments, such as chemical plants or oil refineries. Properly selecting and configuring the crane ensures safer operations and protects your workforce and equipment.

Cost Savings

Investing in the right overhead crane types leads to long-term cost savings by: reducing maintenance and repair costs due to proper application, lowering energy consumption with efficient designs, preventing costly downtime caused by equipment inadequacies or malfunctions.

Prolonged Equipment Life

Selecting a crane suited to your workload and operational environment extends its service life. For instance, a double girder crane with a higher duty cycle is better suited for heavy, frequent use compared to a single girder crane. Ensuring the crane’s components, such as hoists and trolleys, are appropriately rated prevents premature wear and tear.

How to Select the Right Type of Overhead Bridge Crane

Choosing the right overhead crane model is crucial to ensure efficient, safe, and cost-effective material handling operations. Here are the key considerations and steps to guide you in selecting the most suitable type of overhead crane:

Understand Your Application Requirements

  • Load Capacity: Determine the maximum weight the crane will need to lift. Bridge type cranes come in capacities ranging from 1 ton to over 500 tons.
  • Lifting Height: Assess the vertical distance required to lift and position loads.
  • Span: Measure the distance the crane needs to cover between the runway beams.
  • Operating Environment: Consider factors such as indoor or outdoor use, exposure to extreme temperatures, and the presence of hazardous materials.

Identify Your Operational Needs

  • Frequency of Use: Determine how often the crane will be used. For heavy-duty, continuous operations, select a crane with a high-duty cycle.
  • Speed: Choose the appropriate lifting, traveling, and hoisting speeds to match your workflow.
  • Control Options: Decide between pendant control, wireless remote control, or cabin control. Cabin control or remote control overhead crane can enhance safety and convenience.

Choose Safety Features

  • Anti-sway systems to minimize load movement.
  • Overload protection to prevent lifting beyond capacity.
  • Emergency stop buttons and limit switches for added safety.

Consider Customization and Future Expansion

Consider if your operations might require additional features or expansions in the future. Modular designs can accommodate growth without replacing the entire crane system.

Evaluate Cost and Budget

Factor in the initial cost, installation, maintenance, and operating expenses. While overhead crane price is a critical consideration, prioritize quality and reliability to ensure long-term value.

For professional assistance in selecting the right type of overhead crane, reach out to Aicrane. Our experienced team is dedicated to understanding your unique operational needs and providing tailored lifting solutions that enhance efficiency, safety, and productivity.

Future Prospects for Bridge Crane Types

Over the years, technological advancements and innovations in bridge type crane design have significantly enhanced their performance, efficiency, and safety. As industries continue to evolve, so too will the future prospects for different types of bridge cranes.

Integration of IoT

Smart Overhead Cranes: Integration of IoT and AI

One of the most prominent trends in the future of overhead bridge cranes is the integration of the Internet of Things (IoT) and Artificial Intelligence (AI).

Smart bridge cranes equipped with IoT sensors can continuously monitor crane performance, detect potential malfunctions, and predict maintenance needs, ultimately reducing downtime. AI can optimize crane operations by improving load management, enhancing efficiency, and minimizing human error.

Automated Overhead Cranes: Autonomous Operation

As automation continues to disrupt industries worldwide, overhead cranes are also benefiting from robotic technology. The move toward overhead crane automation is not only a way to improve productivity but also to reduce the reliance on human operators for certain tasks. Automated overhead cranes can operate without direct human intervention, guided by pre-programmed instructions or dynamic control systems.

Energy-Efficient and Eco-Friendly Bridge Cranes

In response to growing environmental concerns, overhead cranes are moving towards greater energy efficiency and sustainability. Innovations in electric drives, regenerative braking systems, and hybrid power solutions are helping reduce the energy consumption of cranes. Future bridge cranes will likely feature more energy-efficient motors and advanced systems that minimize energy waste during operation.

Overhead Cranes With Advanced Safety Features

Future overhead cranes will be equipped with even more advanced safety features to prevent accidents and improve overall workplace safety. New sensor technologies and real-time monitoring systems will play a pivotal role in ensuring the safety of both the crane operators and the surrounding workforce.

For example, advanced proximity sensors and AI algorithms will allow overhead cranes to avoid obstacles, including other cranes, workers, or machinery, even in busy environments.

At Aicrane, we are committed to providing custom overhead crane solutions tailored to your specific needs, ensuring optimal efficiency and safety in every application. As we move forward, we will continue to focus on advancing crane technology, delivering innovative, safer, and more efficient lifting solutions for a wide range of industries. If you need a new custom bridge crane, don’t hesitate to reach out to Aicrane. Our team of experts is ready to help you choose the right crane solution to elevate your operations. Contact us today for a consultation!

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