With the rapid development of modern industry and the full application of new technologies and processes, social productivity has reached a new level. Due to the demands of market competition, crane production methods are also evolving from small-batch production to a direction of multi-variety, batch production.
Computerized and Automated Design and Production
In recent years, with the widespread use of electronic computers, many crane manufacturers have advanced from applying computer-aided design (CAD) systems to the modular design of cranes using computers. Under the guidance of rigorous scientific theory, standards and modular units for crane structures, mechanisms, and components are developed at multiple levels. The modular design of cranes is not only a reform in design methodology but will also impact the technology, production, and management levels of the entire crane industry. The update of old products and the development speed of new products will be significantly accelerated. For crane improvements, only a few modules need to be modified. New cranes can be designed by simply selecting different modules and reassembling them, increasing the degree of generalization and transforming small-batch production into relatively large-scale modular production. Additionally, cranes with different functions and specifications can be assembled using fewer modules to meet market demands and enhance competitiveness. For example, a newly developed FEM standard single girder overhead cranes with a compact structure can be assembled into a single-girder overhead crane using different modular units. This allows for more flexible combinations and broader applications.
Innovation and Application of Crane Control Components
Crane positioning accuracy is a critical requirement for cranes. Most cranes use angle code discs, gear chains, laser heads, and steel plate holes for this purpose. Improvements in crane lifting speed and brakes use low-speed cranes with precise hook positioning. The braking system of cranes also uses micro-processing for control and monitoring. Remote control systems are used in bridge cranes and other mobile lifting transport machinery, not only saving labor and improving work efficiency but also enhancing the working conditions of operators. The distance detection collision avoidance device on cranes uses radio signal-based collision prevention. This system consists of a three-phase system that monitors the front-end driving distance of the crane. It typically sends a warning signal first, then reduces the crane’s speed to 50%, and finally cuts off the motor’s power to brake the crane.
Application of New Materials and Processes
With the advancement of new steel industry technologies, steel quality has improved. When designing the strength of the crane’s main beam, higher allowable stress can be used, reducing the amount of material required for the crane (this does not mean less safety), thus reducing the weight and cost of the equipment. With the reduced weight of the crane, smaller power drive units can be used to start the crane, saving electricity and reducing costs. In machining, although precision casting is used with less cutting, especially with a high proportion of aluminum alloy castings, advanced, efficient machining centers, and CNC automatic machine tools are widely adopted. These not only ensure machining quality but also improve productivity and reduce costs.
Crane manufacturers, in order to quickly manufacture and assemble a variety of products, require close cooperation and coordination between enterprises, leading to specialization, standardization, and serialization. The use of standardized parts allows for quick assembly and installation, which makes it particularly important to reduce the processing and manufacturing of non-standard components. Using modular components instead of producing non-standard cranes helps reduce costs.