Heavy Duty Forging Crane

Бүтээгдэхүүний танилцуулга

Forging crane is a kind of heavy-duty overhead crane equipped with forging lifting, carrying, and turning devices, lifting range is 180~550 tons, which is one of the key equipment in the large-scale forging manufacturing process. Forging crane mainly through the forging press on the metal billet pressure, so that it produces plastic deformation to obtain a certain mechanical properties, a certain shape and size of the product, forging crane used for metal billet lifting, turning, and through the setting of buffer to avoid damage to the mechanism or structural components due to the impact of the load.

Weihua, as a well-known heavy duty crane manufacturer and supplier in China, we can provide one-stop customized solutions according to the specific requirements of our customers, including ultra-high-temperature-resistant spreaders (up to 1000℃ continuous operation), special lifting systems for vacuum conditions, ATEX certified explosion-proof forged cranes, as well as other customized solutions for special working conditions. Feel free to contact our team.

Types Of Forging Cranes

Forging cranes are mainly categorized into two types:

• Double girder and double rail single trolley structure: adopting a box-type double main girder design, with rail gauge of 8-35m, configured with 1 main trolley, a lifting capacity of 50-500t, suitable for a small and medium-sized forging workshop layout.
• Three-beam four-rail double trolley structure: three main beam bearing systems, double trolleys work together, the total lifting capacity of up to 800t, especially designed for large-scale die forging hydraulic machine supporting.

Its structural design depends on the layout of the forging plant and the tonnage of the forging equipment configuration. Below 3000t hydraulic press requires a double beam, above the recommended three beams.

Working Principle

When the forging crane is in operation, the main crane hook and the secondary hook work together to lift the metal workpiece, and adjust the angle of the workpiece through the special flip spreader, and accurately place it on the anvil of the hydraulic press, and the hydraulic system starts to carry out the forging process. This process is repeated several times until the part reaches the required specification. The crane is fitted with cushioning and emergency brakes to reduce the large impact forces generated during forging. The Forging Crane is also used for lifting operations such as material handling within the plant and for installation and maintenance of equipment.

Өргөдөл

Forging cranes are mainly used in the field of metal heat processing, with high temperature resistance, impact resistance, accurate positioning, and other characteristics, used in various types of forging production lines, to meet the billet transfer, workpiece turning, forging, and pressing with the key process requirements. The following are the specific scenes and lifting materials:

• Free forging workshop: used for lifting ingots, forging billets (≤600℃), frequent lifting of high-temperature billets, and needs to cooperate with the forging hammer for multi-directional forging.
• Die forging production line: used for lifting pre-formed forgings, molds (1-50t), high-precision positioning (±3mm), and die forging machines to work together.
• Ring rolling machine: used for lifting ring-shaped forgings (diameter ≤ 8m), needs to be equipped with C-shaped hooks or special spreaders to realize the large-diameter workpiece turning.
• Special alloy forging: for lifting titanium alloy/high-temperature alloy billets, anti-pollution spreader (without copper plating).
• Nuclear power forging: used for lifting a pressure vessel cylinder (≤400t).
• Aerospace forging: for hoisting landing gear billets, turbine disks.
• Metallurgical continuous casting workshop: for lifting ladle, continuous casting billet (≥800℃ short contact), with high temperature resistant reinforced design (ceramic fiber heat-insulating hook).

Forging Crane Parts

The forging crane is mainly composed of the electric control system, main and auxiliary trolleys, running mechanism, bridge, spreader as well as turner and other components. The following are the basic functions and characteristics of each component:

• Electric control system: adopts PLC+frequency conversion control program, with multi-agency linkage control function, in line with GB/T 3811-2008 standard.
• Lifting mechanism (including main and vice trolley): The main trolley is equipped with a double braking system, the lifting speed is adjustable from 0.5-5m/min, and the vice trolley assists in completing the turning operation and specific operation.
• Running mechanism: four corners of the eight-wheel drive arrangement, moving along the track; trolley running speed of 20-30m/min, equipped with an anti-skew device.
• Bridge system: the main bearing structure, using a high-quality steel plate welding box structure, equipped with an anti-vibration buffer device.
• Specialized spreader and material turning device: Spreader and Tipping Device: Used for grasping and tipping the workpiece, the workpiece can be accurately positioned and adjusted in angle during the forging process.

Specifications

Онцлогууд

• Multiple safety protection systems: Equipped with the mechanical anti-impact device and multiple anti-overload protection mechanisms, real-time monitoring of load status through force sensors, stable operation under 1.4 times static load and 1.2 times dynamic load conditions, in line with ISO 4301 safety standards.
• Optimized bridge structure design: Adopting a three-beam and four-rail layout, the main and secondary beams use a wide flange offset rail box structure, which has been verified by finite element analysis to increase the structural strength by 30% and the dynamic stiffness by more than 1/800, which can effectively inhibit the vibration and deformation.
• Intelligent material tumbler operating system: The integrated hydraulic servo control tipping machine supports 0-90°accurate tipping (positioning accuracy ±1°) and is equipped with a torque limiter, realizing the seamless connection between workpiece lifting and molding process.
• Advanced Simulation and Verification System: Computer-aided engineering (CAE) technology is used for multi-physical field simulation, including structural stress analysis, kinematic simulation, and fatigue life prediction.
• Modularized Architecture: Adopts a modularized design with a combination of bolted and articulated joints to support rapid disassembly and maintenance.

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