分类： Selection Guides

PRIMARY DUTIES

Dies, Fixtures, Components and Maintenance

PLANT ZONES

Press, Body, Powertrain and Assembly

CRANE OPTIONS

Bridge, Underhung, Workstation or Semi-Gantry

CONTROL LEVELS

Manual, Assisted, Semi-Automatic or Automatic

1. Coil and Blank Receiving

Unload coils, sheet packs and production materials, then transfer them to storage or blanking lines. Coil orientation, attachment choice, surface protection, aisle clearance and delivery-vehicle exclusion determine the handling concept.

2. Press Shop and Die Store

Retrieve matched die sets, transport them along a protected route and position them at the press or die-change cart. High load, short change windows, offset centers of gravity and controlled seating make this the most demanding automotive crane duty.

3. Body-in-White and Welding

Handle fixtures, welding cells, robots, framing equipment and replacement tooling. Low headroom, crowded services and restricted robot zones often favor underhung, monorail or workstation arrangements.

4. Powertrain and E-Drive

Move engines, transmissions, motors, housings, machining fixtures and test equipment through defined stations. Smooth variable-speed motion, ergonomic controls and application-specific fixtures protect machined surfaces and assembly interfaces.

5. Battery and Paint Areas

Battery-pack assembly, cell production and paint operations have different cleanliness, fire and hazardous-area conditions. The approved environmental and area-classification documents—not the process name—determine enclosure, materials and explosion-protection requirements.

6. General Assembly and Maintenance

Support point-of-use lifting, conveyor work, fixture exchange, line-side replenishment and maintenance shutdowns. Coverage, approach, manual handling risk, parked-load location and unobstructed production flow shape the layout.

Bridge and Runway

Single- or double-girder, top-running or underhung architecture is selected from capacity, span, headroom, approach, building reactions, process coverage and required stiffness.

Hoisting Machinery

Wire-rope hoist or open-winch machinery is sized from gross load, lift, speeds, starts, load spectrum, precision, brake strategy and required production availability.

Die or Component Attachment

A die gripper, lifting beam, tong, C-hook, vacuum device, manipulator or certified hook rigging engages the declared load family and includes positive confirmation where the risk assessment requires it.

Motion and Positioning

Variable-frequency drives, controlled acceleration, creep speed, encoders, load-height feedback and anti-sway functions support stable travel and repeatable final approach.

Controls and Plant Interface

Pendant, radio, cabin or remote-control-room operation can integrate with press controls, WCS, MES, storage management, access gates and maintenance authorization.

Inspection and Recovery Access

Walkways, platforms, isolation stations, attachment stands, rescue provisions and component-removal paths are coordinated with production equipment before fabrication.

Load Family and Center of Gravity

Maximum and minimum mass, dimensions, lifting points, center-of-gravity range, surface restrictions and orientation are documented for every die, fixture, component and maintenance load.

Cycle and Availability

Die changes per shift, travel path, storage retrieval, press occupancy, average load, starts per hour, annual operating hours and recovery strategy determine mechanism duty and redundancy.

Placement and Approach

Required coordinates, allowable approach, final speed, die-cart interface, rack geometry, press centerline and permissible alignment error are specified as measurable acceptance values.

Building and Process Envelope

Runway elevation, roof, columns, presses, racks, robots, conveyors, utilities, access doors and neighboring cranes are checked in a coordinated three-dimensional clearance model.

Control and Data Scope

Manual, assisted or automatic operation; die identification; task source; station handshakes; protected areas; event records; cybersecurity and manual recovery are defined before controls are priced.

Environment and Maintenance

Press-shop vibration, lubricants, welding fumes, dust, heat, washdown, paint solvents, dry-room conditions and scheduled shutdown windows establish the protection and service concept.

Die Store Retrieval

The task identifies the die, rack position, mass, center of gravity, approved engagement points and destination. Rack clearances and pickup tolerance are incorporated into the attachment and positioning design.

Grip and Load Confirmation

Mechanical position, locking state, contact or pin engagement and load distribution can be monitored before hoisting. A confirmed signal does not override inspection of damaged or obstructed lifting points.

Protected Transfer

Position tracking, height limits, anti-sway, collision supervision and protected travel corridors control the movement between storage, inspection, maintenance and press-line stations.

Press Ready Handshake

The press, bolster, die cart, clamps, guards and access state must establish an approved transfer condition. The responsibility for each permissive is recorded in the interface matrix.

Precision Placement

Creep speed, load-height feedback, anti-sway and attachment adjustment support final alignment without using press equipment, racks or guides as uncontrolled mechanical stops.

Release and Traceability

Release is enabled only after support, position and station state are confirmed. Task completion records die identity, source, destination, time, alarms and any manual intervention.

Die Turning

Turning or inversion requires an engineered turning device, two-hook arrangement or dedicated station with defined load share and control sequence. Side pulling, dragging and improvised turnover are excluded.

Component Protection

Replaceable non-marking contact pads, controlled clamping force, soft motion profiles and approved support geometry protect machined surfaces, painted parts and precision fixtures.

Attachment Changeover

A multi-purpose crane requires a safe connection method, identified services, parking stands, retained capacity, changeover time and recovery procedure for an incomplete connection.

Gross Load and Net Capacity

Crane rated capacity must cover the heaviest die, mold, fixture or component plus the complete below-the-hook attachment and any suspended auxiliaries. The crane manufacturer accounts for the hook block and reeving within the machinery design. Eccentric centers of gravity and uneven load share are checked separately.

Duty from the Production Profile

ISO, FEM or CMAA classification is derived from operating hours, starts, load spectrum, travel, reversing and production consequences. A crane lifting the maximum die only occasionally can have a different duty from a lighter crane cycling continuously on an assembly line.

Accuracy and Repeatability

Positioning claims define measurement point, load, speed, axis, repeatability, environmental conditions and acceptance method. Structural deflection, rope stretch, sway, attachment compliance and rack or press tolerance all influence final placement.

Performance Data Required

• Maximum and minimum load with attachment
• Load dimensions, lifting points and center-of-gravity range
• Lifts per hour, shifts, annual hours and load spectrum
• Source, destination, travel distance and lift height
• Changeover time and required availability
• Final approach speed and placement tolerance
• Abnormal recovery and retained-load strategy

Task and Load Identity

WCS, MES, barcode, RFID or operator confirmation associates the physical die or component with mass, coordinates, process status and destination. Unidentified or conflicting loads enter a controlled exception state.

Position and Anti-Sway

Absolute or referenced coordinates, controlled acceleration, sway reduction, load-height feedback and final approach logic support stable movement without contact-based correction.

Press and Station Handshake

Ready, occupied, guarded, clamped, transfer enabled, release authorized, complete and fault states are exchanged with presses, die carts, racks, gates and maintenance systems.

Protected Areas and Collision Control

Restricted volumes, temporary maintenance zones, crane-to-crane separation, obstacle detection and speed-limited approaches are implemented under the approved risk assessment.

Operating Modes

Automatic, remote, local maintenance and recovery modes have defined authority, speed limits, permissives and transition conditions. Active mode and control ownership remain unambiguous.

Diagnostics and Recovery

Event logs, cycles, loads, sensor states and alarms support maintenance. Recovery covers incomplete gripping, lost position, unavailable destination, failed communications and power interruption.

Suspended-Load Exclusion

Pedestrian workstations, vehicle lanes and operator positions are kept outside the suspended-load path. Automatic operation uses controlled access and a defined safe state for zone entry.

Attachment Permissive

Hoisting and travel permissions can depend on verified engagement, load range and attachment configuration. Release remains inhibited until the load is supported and the destination is authorized.

Press and Robot Interlocks

Press motion, robot zones, die-cart travel, clamps, guards and crane movement are coordinated so that conflicting commands cannot create an uncontrolled exposure.

Overload, Limits and Brakes

Rated-capacity protection, normal and final motion limits, brakes, buffers, travel warnings and monitored speed zones are selected under the governing code and risk assessment.

Paint and Solvent Areas

Explosion-protected equipment is supplied only where the approved hazardous-area classification identifies zones, gas or vapor groups, temperature class and equipment protection requirements.

Battery Production Boundary

Cell manufacturing, module assembly and finished-pack handling can have different dry-room, cleanliness, chemical, dust and fire conditions. The site assessment determines the applicable crane package.

Existing Building Verification

Reuse requires verification of rails, runway beams, roof trusses or suspension points, brackets, columns, connections, foundations, fatigue history and measured condition. Maximum and minimum wheel reactions, lateral forces and buffer loads are issued for structural review.

Clearance and Production Coordination

Bridge, trolley, attachment and load envelopes are checked against presses, die racks, robots, conveyors, ducts, cable trays, lighting and fire systems. Installation is planned around production shutdowns and protected line areas.

Maintenance Strategy

Access platforms, safe parking, isolation, inspection positions, rope and brake service, attachment maintenance and component-removal routes are defined before procurement. Critical spare strategy reflects the production consequence of downtime.

Site Data Required

• Building, runway and production-layout drawings
• Rail or suspension-point survey and allowable reactions
• Press, rack, robot, conveyor and utility envelopes
• Attachment parking and maintenance access
• Power, grounding and communication networks
• Erection opening, laydown area and shutdown window
• Environmental and hazardous-area documents

Design Review

Confirm load cases, classification, general arrangement, runway reactions, attachment, die range, placement performance, safety functions, interfaces and maintenance access.

Factory Acceptance Test

Verify assemblies, drives, brakes, limits, load protection, attachment logic, safety functions, interface simulation, operating modes, diagnostics and contracted documentation.

Site and Production Acceptance

Test proof loads, representative dies, all source and destination stations, cycle time, placement, interlocks, restricted zones, communications loss and manual recovery.

Automated Mould Transfer for an Automotive Stamping Workshop

Henan Mine Crane reports delivering a customized automated mould-handling crane for a domestic automotive manufacturer. The published scope identifies automatic positioning, WCS management, area protection, obstacle avoidance, a multidirectional special spreader, anti-sway, servo positioning and three operating modes.

The published safety functions include laser anti-collision, light-curtain area protection, image monitoring and a 3D-vision digital-twin function. The record states that the project was developed for mould transfer in an automotive stamping workshop.

View Published Automotive Project →

Primary Price Drivers

Capacity, span and lift; duty class and speeds; die gripper or lifting device; two-hoist or turning requirement; positioning and anti-sway; automatic controls; WCS, MES and press interfaces; safety zoning; building steel; documentation and local compliance.

Commercial Scope to Reconcile

Runway rails and steelwork; structural reinforcement; freight, insurance, duties and taxes; erection; electrification; commissioning; test loads; representative dies; line-interface testing; training; spares; warranty and production acceptance.

Technical Proposal

Design basis, crane arrangement, capacities, classification, speeds, attachment, load assumptions, precision, protection package, operating modes and stated deviations.

Interface Schedule

Runway reactions, power, communications, press and station I/O, coordinates, safety ownership, erection needs, civil boundaries and third-party responsibilities.

Attachment Documentation

Rated range, deadweight, dimensions, engagement, locking logic, proof test, inspection limits, wear parts, attachment stand and representative-load acceptance plan.

Safety and Controls

Risk-assessment inputs, safety-function list, restricted zones, interlock matrix, network behavior, isolation, emergency states, recovery and required conformity records.

Quality and O&M Records

Inspection and test plan, material and welding records as specified, coating reports, component certificates, manuals, lubrication plan, training and critical spares.

Commercial Schedule

Price, Incoterm, milestones, packing, freight boundary, installation, commissioning, training, acceptance, warranty, exclusions, validity and optional lifecycle services.

Load and Attachment Data

Load families; minimum and maximum mass; dimensions; center of gravity; lifting points; orientation; surface restrictions; photographs or drawings; proposed gripper, beam, tong, C-hook, vacuum device or rigging.

Process and Duty Data

Source and destination stations; changeover sequence; lifts per hour; shifts; annual hours; load spectrum; travel distance; target cycle; placement tolerance; availability and contingency.

Site and Environment Data

Span, lift, runway length, building and process drawings, allowable reactions, press and rack interfaces, temperature, dust, welding, paint, clean or dry-room requirements, power and destination.

Controls and Commercial Data

Operating modes; WCS, MES and PLC protocols; task and die identity; safety zones; governing standards; Incoterm; freight, installation, commissioning, test and documentation boundaries.

Which crane is used in an automotive press shop?

A process-duty double-girder overhead crane is commonly selected for heavy die storage and changeover. A dedicated die gripper, anti-sway, precision motion and press-line interfaces may be added when cycle frequency and automation justify them.

Is one crane suitable for the entire automotive plant?

Usually not. Press dies, body fixtures, powertrain components, assembly tasks and maintenance loads differ in mass, frequency, precision and environment. A plant-wide lifting plan assigns a suitable crane class to each zone.

How is die-handling crane capacity determined?

Capacity covers the heaviest die plus the complete gripper, beam or other below-the-hook device. Center of gravity, load share, acceleration, turning requirements and governing code are then applied.

Can the crane retrieve dies automatically?

Yes. Automatic retrieval can combine a die database, WCS tasks, position tracking, a dedicated gripper, anti-sway, protected zones and press handshakes. Safe exception handling and manual recovery remain mandatory design elements.

Does an automotive crane need millimetre-level positioning?

Only where the actual station and attachment require it. The purchase specification defines the measurement point, load, speed, repeatability and acceptance method rather than using an unsupported general accuracy claim.

Are explosion-proof cranes required in paint shops?

Only when the approved hazardous-area classification establishes the relevant zone and protection requirements. Solvent use or a paint-shop label alone does not determine the final crane certification.

How much does an automotive industry crane cost?

Public figures range from crane-only estimates and component kits to complete support systems. A defensible project price requires capacity, span, duty, attachment, automation, plant interfaces, building scope, destination and acceptance criteria.

Can an existing runway be reused?

Only after geometry, condition, fatigue history, rails, beams, columns, connections and foundations are verified against the proposed vertical, lateral, longitudinal and buffer reactions.

PRIMARY SYSTEM

Assembly Line Bridge Cranes

CAPACITY RANGE

0.5 t – 50 t

TYPICAL SPAN

7.5 m – 35 m

CONTROL OPTIONS

Pendant, Radio, PLC & Anti-Sway

Press and Stamping Shop

Double girder cranes change and transfer press dies, handle coil and blank feeding equipment and support press maintenance. Die handling is slow, precise, high-value lifting where hook approach, exact load control and reliability matter more than speed.

Body-in-White Shop

Cranes install and exchange welding fixtures, position body panels and subframe assemblies, and serve framing stations. Coverage must work around robots and conveyor steel, and every lift position has to repeat within the fixture tolerances of the station.

Powertrain Machining and Assembly

Engines, transmissions, cylinder heads and crankshafts are handled between machining cells, washing and test stations. These areas combine moderate loads with high cycle counts and demand controlled, gentle set-down on machined surfaces.

Final Assembly Line-Side Supply

Suspended and workstation crane systems feed seats, doors, batteries, fuel tanks, dashboards and powertrain units to the stations that install them. Low headroom, ergonomic effort levels and reach into the station without intruding on the line are the defining requirements.

Paint Shop and Utilities

Cranes maintain dipping, drying and treatment equipment, handle skids and carriers, and support the process tanks and ovens that run continuously. Environment class, enclosure protection and maintenance access drive the specification in this area.

Maintenance and End-of-Line Operations

Workshop and workstation cranes support equipment repair, test bays, wheel and headlamp alignment areas and general logistics. These cranes lift infrequently but must be available on demand, since downtime in a running plant is measured in lost vehicles per hour.

For most line-side and machining loads up to 20 t, a single girder crane with an electric hoist is the most economical configuration and covers the majority of assembly applications. European-style single girder cranes raise this baseline with FEM-oriented duty design, lower dead weight, better hook approach and smoother travel — the standard choice where high cycle counts, close tolerances or restricted building capacity apply.

Where loads grow — press dies, skid systems, powertrain modules, complete fixtures and maintenance of heavy process equipment — double girder cranes take over, adding hook height, stiff long-travel behaviour and heavy-duty hoisting machinery. Double trolley versions handle long and flexible parts such as shafts, axles, rail segments and long weldments that would overload a single hook point or distort during lifting.

Suspended underhung systems bolt to the building roof steel instead of running on elevated runway rails, so they reach into stations at low headroom with minimal steelwork. Multi-point suspension designs cover wide or irregular bays. Intelligent hoist cranes close the loop with controlled positioning, anti-sway and operator guidance for the highest-accuracy stations.

01 · Load Spectrum per Station

List every load at every lifting point with its fixture, spreader or tooling weight. The heaviest combination at the busiest station — not the average — sets the rated capacity for the whole system.

02 · Takt Time and Cycle Profile

Convert line takt into lifts per hour, travel distances and full-load ratio per station. These numbers set the ISO duty class of hoist, trolley and travel mechanisms — the difference between a line-speed crane and an early failure.

03 · Positioning Accuracy and Anti-Sway

Define the positioning tolerance at each station and the acceptable residual sway at set-down. These requirements select between standard speed control, frequency inverter control with crawl steps, and closed-loop anti-sway positioning.

04 · Headroom and Building Interface

Confirm clear height, roof steel capacity, existing conveyor and utility positions, and the clearance the process needs below the hook. Low buildings push the specification towards top-running, double girder or suspended configurations.

05 · Environment and Cleanliness Class

Paint shops, clean zones and battery areas impose dust, temperature and contamination limits on motors, brakes and controls. The enclosure and protection class is specified per area, not per building.

06 · Control and Line Integration

Define interlocks with conveyors, robots, skid systems and safety circuits, the control positions operators will use, and any interface to plant PLC or monitoring systems. Integration scope changes the electrical boundary of the offer.

07 · Ergonomics at the Station

Where operators handle loads manually, specify the permissible operating force, the reach envelope into the station and the precision of inching control. Ergonomic limits are production limits on an assembly line.

08 · Project Boundary and Compliance

Assign runway or suspension steel, conductor systems, installation, commissioning, load testing, spares and certification in writing before comparing offers, and state the standards the documentation must satisfy for the plant’s market.

Wheel Loads and Rail Seats

Maximum and static wheel loads, with and without load, are verified against the runway beams and building columns. A crane change on an existing runway always starts with this check, not with the catalogue.

Suspended Loads on Roof Steel

Underhung and multi-point suspension systems hang from the building structure. The roof steel capacity, bracing positions and allowable deflection decide whether suspension is viable and how the load paths are arranged.

Clearance to Conveyors and Automation

Hook coverage is mapped against conveyors, skid tracks, robot cells and process tanks. The crane must reach the defined pick-up and set-down points without entering protected volumes or intruding on safety zones.

Power Feed and Conductor Systems

Conductor bars or festoon systems are routed along the runway with isolation, earthing and maintenance positions defined. Power feed placement affects plant electrical layout and must be fixed early in the project.

Pendant and Radio Control

Pendant control keeps the operator at a fixed position beside the load; radio remote frees them to watch the load and the station. On assembly stations, radio control is usually the more productive and safer choice.

Frequency Inverter Travel and Hoist

Stepless speed control with defined acceleration and crawl steps lets the operator place loads without shock. On machined powertrain components, controlled set-down is a quality requirement, not a comfort feature.

Anti-Sway and Positioning Control

Closed-loop anti-sway and target positioning reduce swing, shorten waiting at the station and protect fixtures and parts. Encoder feedback and slow-approach zones place the hook within repeatable tolerances cycle after cycle.

Interlocks and Plant Systems

Where cranes share space with conveyors, robots or skid systems, interlocks, zone limits and signal exchange with the plant controller are engineered into the crane control. The interface scope belongs in the contract, not in site improvisation.

The Default Duty Trap

Many general-purpose offers are built to infrequent-use classifications. On a station cycling every takt, those mechanisms consume their design life early. Duty class must be specified from the measured cycle profile, never left to the supplier default.

Fatigue and Structural Allowance

High-cycle welding details, wheel and rail contact and brake engagement counts are fatigue items. The structure is engineered for the number of cycles the line will actually run, not for a nominal tonnage figure.

Maintenance-Friendly Design

Wear parts, brakes and limit systems are arranged for fast access inside short production breaks. Maintenance positions and inspection routes are defined at design stage, because unplanned line stops cost vehicles, not minutes.

Documentation and Testing

Structural calculations, test certificates, overload and static load test reports and defined acceptance criteria support commissioning and the plant’s own safety and audit systems. Documentation scope is agreed before production starts.

An automotive assembly crane project typically covers several crane families at once: standard and European-style single girder cranes for line-side and machining areas, double girder cranes for the press shop and powertrain, and suspended systems feeding the final assembly stations. Henan Mine Crane plans such projects around a common engineering baseline, so that control behaviour, spares and documentation stay consistent across the different areas of the plant.

A complete supply definition states the crane structure and machinery, the hoist and control system, the runway or suspension interface, conductor systems, the safety functions required at each station, the overload and acceptance testing regime, and the delivery, installation and commissioning responsibilities. Where the plant’s own engineering team installs, supervision, commissioning and load testing remain part of the package.

Standard configurations are typically delivered within 30 to 45 days after drawing approval, with engineered or automation-equipped cranes on confirmed project schedules. Multi-crane programs are sequenced against the plant’s shutdown and ramp-up calendar.

ASSEMBLY CAPACITY COVERAGE

0.5 t – 50 t

CRANE FAMILIES APPLIED

6 Product Platforms

STANDARD DELIVERY

30 – 45 Days

ENGINEERED DUTY RANGE

A3 – A6 Assembly Service

Load and Station Data

Part weights with fixtures and tooling at every lifting point, heaviest combination, lift frequency per station and the full production shift pattern.

Building and Geometry Data

Clear height, span or rail centers, travel lengths, roof steel or runway capacity, conveyor and automation positions, and the hook coverage each station requires.

Process and Accuracy Data

Positioning tolerance at set-down, acceptable residual sway, required speeds and inching behaviour, and any interlocks with conveyors, robots or plant systems.

Commercial and Site Data

Voltage and frequency, destination and Incoterm, installation responsibility, required certifications and documentation, spares level and requested delivery schedule.

What crane does an automotive assembly plant use?

Assembly plants use a combination of systems: single and European-style single girder bridge cranes for line-side and machining areas, double girder cranes for press shops and powertrain handling, double trolley cranes for long parts, and suspended workstation systems for ergonomic part supply at stations.

How is an assembly crane different from a standard workshop crane?

The difference is duty and control, not just tonnage. Assembly cranes are classified for high cycle counts tied to takt time, use stepless speed control with crawl and anti-sway behaviour for repeatable positioning, and integrate with conveyors, robots and plant safety systems.

Single or double girder for an assembly line?

Most line-side loads up to 20 t are served by single girder cranes at lower cost. Double girder becomes the right choice for loads above 20 t, for maximum hook height under the roof, or for stiff, precise handling of press dies, skids and powertrain modules.

How much does an automotive assembly crane cost?

Current market positions place single girder assembly cranes between roughly US$2,900 and 22,000 on an equipment basis, European-style single girder systems between US$13,000 and 49,000, and double girder assemblies from about US$10,000 for lighter units to US$80,000 for press shop die handling. Freight, duty and installation typically add 20–50 % over the equipment price.

Can the crane work with conveyors and robots in the same bay?

Yes, when it is engineered that way. Hook coverage is mapped against conveyor and robot positions, zone limits and interlocks are built into the crane control, and signal exchange with the plant controller is defined in the interface specification before manufacture.

What is the delivery time?

Standard configurations are typically delivered within 30 to 45 days after drawing approval. Cranes with anti-sway positioning, line integration or multi-crane program sequencing run on confirmed project schedules agreed before production starts.

APPLICATION

High-Bay AS/RS Warehouses

STRUCTURES

Single or Double Column

LOAD TRANSFER

Project-Selected Fork System

SYSTEM INTERFACES

WMS · WCS · PLC · Conveyor

Pallet High-Bay Storage

Automated inbound, storage, relocation and outbound handling for standardized pallets in high-density rack systems.

Tote and Container Storage

Lightweight configurations for totes, bins, containers and smaller load units requiring compact aisle geometry and frequent cycles.

Production Buffer Warehouses

Controlled storage between manufacturing processes, with task exchange between production planning, conveyors and warehouse control.

Special Load-Carrier Systems

Project-specific forks, supports, sensors and transfer logic for non-standard carriers, containers or process fixtures.

01 / LOAD UNIT

Carrier and Payload Definition

Load-unit dimensions, weight range, centre of gravity, underside geometry, stability and allowable overhang establish the transfer interface.

02 / RACK AND AISLE

Storage Geometry and Tolerances

Rack elevations, aisle length, transfer clearances, rail alignment, guide tolerances and maintenance access determine the machine envelope.

03 / THROUGHPUT

Cycle Model and Peak Demand

Single-cycle, dual-cycle and peak task profiles establish motion performance, machine quantity, buffering and availability requirements.

04 / TRANSFER

Fork Depth and Handover

Single-depth, double-depth and special transfer arrangements require different fork stroke, detection, support and cycle-time calculations.

05 / CONTROLS

Automation Responsibility

The interface schedule assigns WMS, WCS, PLC, network, identification, conveyor, cybersecurity and acceptance-testing responsibilities.

06 / LIFECYCLE

Availability and Recovery

Maintenance access, diagnostic depth, spare parts, recovery procedures and redundancy are aligned with the required system availability.

STEP 01

Task Release

The warehouse system releases a validated storage, retrieval or relocation task with the required load and destination data.

STEP 02

Load Handover

Conveyor and stacker-crane controls confirm load identity, position, readiness and transfer permission before movement begins.

STEP 03

Coordinated Travel

Long travel and lifting are coordinated to approach the assigned rack location while controlling structural response and settling time.

STEP 04

Protected Transfer

Position and occupancy conditions are checked before the fork extends, transfers the load and returns to its travel position.

STEP 05

Status Confirmation

Completion, location and equipment status are returned to the control hierarchy for inventory records and the next task assignment.

Single-Column and Double-Column Designs

Single-column construction can reduce moving mass and support compact aisle arrangements when payload, storage height and dynamic behaviour permit. Double-column construction provides a framed carriage guidance arrangement for applications requiring greater stiffness, heavier load handling or demanding operating cycles.

The final structure is selected through load analysis, aisle geometry, dynamic response, positioning requirements, drive duty and maintainability. Lightweight box-type structural members may be applied where mass reduction and rigidity must be balanced.

Fixed-Aisle, Track-Switching and Turnout Arrangements

A fixed-aisle stacker crane provides dedicated access and predictable capacity within one aisle. Track-switching and turnout arrangements allow a compatible machine to serve more than one aisle when the throughput calculation, route availability and recovery strategy support shared equipment.

Multi-aisle operation requires coordinated route control, transfer-position interlocks and a capacity assessment covering both normal production and planned maintenance conditions.

The load-handling device is specified from the carrier underside, storage depth, support arrangement, permitted clearances and transfer direction. Single-depth, double-depth and special telescopic solutions require different fork strokes, deflection control, detection logic and cycle calculations.

• ✓Transfer authorization based on machine position, fork status and interface readiness
• ✓Fork anti-push-off protection for controlled handling at the rack location
• ✓Load-presence and storage-position conditions integrated into the project control logic
• ✓Protected transition between storage racks, stacker crane and conveyor handover stations

Space Utilization and Energy Management

A rigid-flexible column concept and compact equipment envelope can support high-density storage where the structural calculation, rack geometry and service clearances permit. The layout is coordinated with the aisle rail, top guidance, maintenance access, buffer conveyors and fire-protection strategy.

An optional energy-feedback module can return regenerative energy produced during lowering and deceleration to the electrical system. Its application is assessed against motion frequency, load profile, electrical architecture and project energy objectives.

Motion Interlocks

Travel, lifting and fork movements are permitted only when the defined machine and interface conditions are satisfied.

Transfer Protection

Position, load and handover signals are evaluated before rack or conveyor transfer, with fork anti-push-off protection integrated into the sequence.

Access Control

Fenced zones, access points and maintenance procedures are coordinated with the warehouse layout and applicable project requirements.

Fault Recovery

Alarm classification, safe reset conditions, manual recovery steps and responsibility boundaries are documented for service personnel.

Project Engineering

Layout review, equipment boundary, performance calculation, interface schedule, structural verification and maintainability assessment.

Manufacturing Control

Fabrication, assembly, drive installation, electrical integration and inspection are managed against the approved project specification.

Technical Deliverables

Agreed drawings, parameter schedules, interface records, operating information, maintenance documentation and acceptance records.

01. Interface Readiness

Rail, rack, power, network, conveyor, identification and access conditions are checked against approved interface data.

02. Mechanical and Electrical Setup

Machine alignment, guidance, drives, sensors, control panels and communication links are installed and verified.

03. Functional Commissioning

Operating modes, motion, positioning, fork transfer, interlocks, alarms and system handshakes are commissioned in stages.

04. Performance Acceptance

The agreed test plan verifies functions, interfaces, representative load handling, throughput conditions and recovery procedures.

Inspection Planning

Scheduled checks aligned with duty, environment, critical assemblies and operating records.

Diagnostics

Alarm history, status information and defined troubleshooting paths support structured fault isolation.

Spare Parts

Recommended commissioning, operational and critical spares can be defined from the service strategy.

Training

Operating, maintenance and recovery training can be included within the agreed delivery scope.

Load and Carrier Data

Dimensions, maximum and typical weight, centre of gravity, underside arrangement, stability, overhang and identification method.

Rack and Building Layout

Storage height, aisle length and width, rack levels, storage depth, rail path, top guidance, transfer stations and service zones.

Throughput Model

Inbound and outbound rates, single and dual cycles, peak duration, task distribution, working hours and availability target.

System Interfaces

WMS/WCS architecture, PLC and network requirements, conveyor handshakes, barcode or RFID, data ownership and cybersecurity conditions.

Site Conditions

Installation location, temperature, humidity, dust, electrical supply, fire strategy, access restrictions and applicable regulations.

Delivery Boundary

Equipment, rails, controls, software, conveyors, installation, commissioning, testing, training, documentation and spare-parts scope.

What is an automated warehouse stacker crane?

It is a rail-guided storage and retrieval machine that travels within a warehouse aisle, lifts a carriage to rack level and transfers unit loads between storage locations and material-flow interfaces under automatic control.

When is a single-column design appropriate?

Single-column construction may be selected when the payload, storage height, stiffness, motion profile and service-access requirements support a lighter and more compact structure. Engineering verification determines its suitability.

Can one stacker crane serve multiple aisles?

Track-switching or turnout configurations can serve compatible aisle paths. The decision requires verification of transfer time, route availability, peak throughput, recovery access and capacity during maintenance.

Does the stacker crane connect with an existing WMS or WCS?

Integration can be developed around an existing warehouse software environment when protocols, task ownership, data fields, alarm handling, network conditions and testing responsibilities are defined in the interface schedule.

How is stacker-crane throughput determined?

Throughput is calculated from aisle geometry, storage-location distribution, transfer time, travel and lift motion, fork cycle, buffering, single and dual cycles, peak demand and equipment availability. Maximum travel speed alone does not define system capacity.

Which load data are essential for fork selection?

Required data include carrier dimensions, payload range, underside geometry, support positions, centre of gravity, stability, overhang, storage depth, permitted clearance and transfer direction.

Can energy recovery be included?

An optional energy-feedback module can recover regenerative energy during lowering and deceleration. Feasibility depends on the motion profile, operating frequency, load distribution and facility electrical system.

What determines the final stacker-crane price?

Major cost drivers include payload, storage height, aisle length, machine quantity, structural configuration, fork depth, performance, control scope, software interfaces, site conditions, installation, testing, training and spare-parts requirements.

EQUIPMENT FAMILY

PTM / Pot Tending Crane

PRIMARY APPLICATION

Prebaked-Anode Potlines

FUNCTION PACKAGE

Selected by Pot Process

PRICE BASIS

Engineered Project Quote

Process Machine

The PTM performs repeatable pot operations; it is not only a lifting bridge with a hook.

Multi-Tool Platform

Each mechanism has its own load, reach, motion, duty, accuracy and process interface.

Potline-Specific Design

Bridge geometry, tool envelope and control logic follow the actual cell technology and bay layout.

Harsh-Duty Protection

Electrical, thermal, dust, fume and magnetic-field conditions are part of the design basis.

01 / POT TECHNOLOGY

Cell Geometry and Pitch

Define cell type, centerline pitch, hood arrangement, anode layout, access side, working zones and no-go envelopes.

02 / ANODE SYSTEM

Anode and Clamp Data

Record new and spent anode mass, dimensions, stem arrangement, clamp interface, extraction stroke and placement tolerance.

03 / REQUIRED TOOLS

Process Function Schedule

List crust breaking, feeding, anode changing, bath cleaning, tapping, busbar work, cover handling and maintenance functions.

04 / PRODUCTION

Cycle and Availability

State pots served, shifts, planned tool cycles, peak demand, standby philosophy, recovery time and maintenance windows.

05 / POTROOM

Runway and Clearances

Verify rail span, elevation, approaches, wheel-load limits, longitudinal geometry, building deflection and erection route.

06 / ENVIRONMENT

Heat, Dust, Fumes and Field

Supply measured ambient and radiant heat, magnetic-field map, conductive dust, fluoride fume and ventilation conditions.

07 / CONTROL

Manual, Assisted or Automated

Define cabin, remote station, tool interlocks, pot identification, positioning, data exchange and automatic sequence boundaries.

08 / SUPPLY SCOPE

Interfaces and Acceptance

Fix the limits for runway, power, compressed air, fume extraction, installation, testing, training, spares and documentation.

Crust Breaking and Working-Hole Opening

A guided breaker opens the electrolyte crust at defined positions. Tool reach, impact requirement, alignment and debris control follow crust condition and cell geometry.

Anode Changing

The anode mechanism releases the clamp interface, extracts the spent assembly, handles the replacement anode and positions it at the designated location. Mass, stem form, center of gravity and placement tolerance are essential inputs.

Bath and Residue Removal

A cleaning or grab tool can remove crust pieces, residual material and selected bath deposits from the working area before placement of the new anode.

Alumina and Cover-Material Feeding

A metered feeding arrangement distributes alumina, fluoride additions or cover material where specified. Storage volume, discharge rate, dust containment and refill interface form part of the procurement data.

Aluminum Tapping Support

The PTM can carry or position a tapping trolley, pipe or ladle interface. Vacuum generation, weighing and ladle transport boundaries must be clearly allocated between crane and plant systems.

Busbar and Pot Maintenance

An insulated auxiliary hoist or dedicated frame may support approved busbar-related work, hood handling, pot superstructure service and controlled maintenance lifts.

Auxiliary Handling

A general auxiliary hoist can handle approved tools, maintenance parts and consumables within the defined capacity, isolation and exclusion-zone rules.

Bridge and Traveling System

The bridge distributes tool and trolley loads to the potroom runway while providing the required approaches above the cell row. Wheel arrangement, drives, braking and structural stiffness follow the operating spectrum, rail geometry and positioning requirement.

Tool Trolley and Rotation

A traversing tool trolley positions the working mechanisms across the cell. A rotating carriage or turret can orient tools to the operating face. Interlocks prevent incompatible motions, tool collision and operation outside approved envelopes.

PLC, Drives and Positioning

Variable-frequency drives and PLC control can coordinate bridge, trolley, rotation and tool motions. Pot identification, travel-position feedback, tool-height measurement, load monitoring and sequence permissions can be integrated at the automation level specified for the project.

Operator Environment

The cabin location, visibility, filtration, cooling, heat shielding, fume protection and emergency egress are developed from the potroom hazard assessment. Remote or assisted operation can reduce routine exposure while retaining controlled recovery procedures.

Electrical Isolation

Insulation points, creepage distances, monitoring and maintenance-access rules are selected from the plant electrical design and the maximum credible potential difference. Isolation must cover the complete current path, including tools, hoists, structures and service connections.

Heat and Fume Resistance

Heat shields, component location, cooling, material selection and cable protection reduce exposure to hot cell surfaces and radiant heat. Corrosion-resistant finishes, sealed enclosures and protected ventilation address fluoride-bearing fumes.

Dust and Magnetic-Field Compatibility

Alumina and carbon dust affect cooling, contacts, sensors and mechanical interfaces. Enclosure rating, filters and cleaning access follow the measured load. Electrical and control components are selected and positioned for the documented magnetic field.

Safe-Failure Response

Overload protection, limits, braking, anti-collision, motion interlocks, emergency stops and recovery modes are defined by the project risk assessment. Redundancy is applied where the consequence and governing design basis require it.

Integrated Aluminum Production Lifting Program

A published Henan Mine Crane aluminum-industry program combines three equipment groups: multifunction suction handling equipment, anode carbon block stacking cranes and multifunction aluminum electrolysis units. The program addresses raw-material movement, carbon-block storage and reduction-cell operations as separate but connected process zones.

The electrolysis unit integrates shell breaking, anode replacement, residue cleaning and cover-material loading. Sensor-based height measurement, tightening control and automatic operating functions can be applied according to the selected automation scope.

View Aluminum Industry Project

Electrolytic Aluminum Crane Configuration

Henan Mine Crane also publishes an electrolytic-aluminum equipment family for high-duty aluminum liquid transfer, anode handling, cell maintenance and plant material movement. The configuration demonstrates the need to match working class, protection, attachment and control method to the exact process rather than specifying a general metallurgical crane.

View Electrolytic Aluminum Solution

Design Basis

The contract design basis identifies the governing crane, machinery, electrical and structural requirements. Applicable codes may include EN, ISO, IEC, FEM, CMAA or project-specific national standards, but the agreed hierarchy and editions must be fixed before detailed design.

Engineering Review

Deliverables can include general arrangement drawings, wheel loads, structural calculations, mechanism selection, tool envelopes, electrical single-line diagrams, PLC architecture, cause-and-effect logic, interlock matrix and utility requirements.

Fabrication and Inspection

Material traceability, welding procedures, dimensional checks, nondestructive examination, machining records, assembly inspection, coating controls and purchased-component certificates can be included in the approved inspection and test plan.

Factory Acceptance

Factory testing verifies drive direction, brakes, limits, alarms, interlocks, control modes, tool motions and communications to the extent possible before shipment. Site process interfaces are completed during commissioning with approved simulation and live-operation procedures.

Site Readiness

Confirm runway survey, rail condition, erection access, lifting plan, utilities, laydown area, shutdown windows and potroom work permits before delivery.

Mechanical and Electrical Installation

Bridge assembly, rail alignment, festoon or conductor installation, tool commissioning and plant-network integration follow approved method statements.

Functional and Process Testing

Testing progresses from no-load motion and interlocks to proof testing, dry process simulation and controlled potline trials under the agreed acceptance plan.

Training and Handover

Operator, electrical, mechanical and automation training should cover normal operation, tool change, alarm response, isolation, recovery and preventive maintenance.

Machine and Tool Package

Bridge size, tool trolley, anode equipment, breaker, cleaner, feeder, tapping arrangement, hoists, hydraulics and pneumatics.

Controls and Protection

PLC, drives, positioning, plant communications, operator cabin, remote operation, insulation, cooling, enclosures and fume protection.

Project Delivery

Documentation, testing, packaging, ocean freight, insurance, runway or power scope, installation, commissioning, training and spares.

Is a pot tending machine the same as an overhead crane?

It uses an overhead traveling bridge, but it is a process machine with dedicated tools, controls and protections. A conventional hook crane cannot perform the full pot-tending sequence without extensive purpose-specific engineering.

Which operations can be integrated?

Typical options include crust breaking, anode changing, residue removal, alumina or cover-material feeding, tapping support, busbar-related lifting and maintenance handling. The approved operating procedure determines the final combination.

What capacity should be specified?

Each mechanism requires a separate capacity or performance value. Anode-tool load, auxiliary-hoist SWL, tapping load, breaker energy and feed volume cannot be represented accurately by one headline tonnage.

Can the PTM be automated?

Manual, assisted and higher-automation configurations are possible. Automation can include pot identification, position control, height measurement, tool permissions, sequence control, production data exchange and fleet scheduling where the plant interfaces support them.

How is electrical safety addressed near energized cells?

The electrical study defines credible current paths and required insulation points. Tool interfaces, hoists, structural sections, service connections, earthing, monitoring and maintenance procedures are coordinated as one isolation system.

How are fluoride fumes and conductive dust managed?

Protection can include sealed electrical enclosures, selected materials and coatings, filtered ventilation, cooling, protected cables, serviceable dust barriers and interfaces to plant fume-extraction systems.

Can an existing potroom runway be retained?

Retention is possible only after verifying rail geometry, alignment, support condition, wheel-load capacity, longitudinal forces, clearances and erection access against the proposed machine.

What determines the number of PTMs required?

Pot count, travel distance, process cycles, peak workload, tool-change time, preventive maintenance, availability target and standby philosophy determine fleet size. A cycle and availability model should support the decision.

Why is a public online price not a reliable project budget?

Advertisements rarely define tool count, process performance, duty, automation, environmental protection, runway scope, testing, delivery or commissioning. Two listings with the same nominal tonnage can represent fundamentally different machines.

What should be included in the final acceptance plan?

The plan should cover documentation, dimensional inspection, material and welding records, no-load and load tests, limits, brakes, interlocks, tool simulations, communication tests, site process trials, training and handover criteria.

Anode Carbon Block Stacking Crane

Automated or operator-controlled handling of green, baked or prepared anode carbon blocks in storage and transfer areas.

Insulated Bridge Crane

Purpose-designed electrical isolation for approved lifting duties in high-current industrial environments.

Double-Trolley Insulated Overhead Crane

Two insulated trolley mechanisms for coordinated handling where load geometry and process access require separate lifting points.

Double-Girder Casting Crane

High-duty metallurgical crane platform for project-defined molten-metal ladle transfer and controlled handling.

Intelligent Grab Double-Girder Crane

Bulk-material handling with a project-selected grab, positioning and automated operating functions.

Double-Girder Bridge Crane

General heavy-duty lifting for maintenance bays, component handling and non-process plant operations.

PLANT AREAS

Carbon Plant, Potroom & Cast House

HANDLING SCOPE

Anodes, Materials, Vessels & Equipment

DESIGN CONDITIONS

Heat, Field, Dust, Fumes & Duty

PRICE BASIS

Engineered Project Quote

01 · Pot Tending Machine / Multifunction Crane

A traveling process machine for prebake potlines. Tool options can support crust breaking, anode handling, residue removal, material feeding, tapping assistance and maintenance handling. Each tool, motion, permission and process interface is defined against the cell technology and approved operating sequence.

02 · Multifunction Suction and Material Crane

A dedicated system for collecting, transferring and distributing approved process material. Suction performance, material path, filtration, discharge control and dust containment are engineered from bulk density, particle size, temperature, moisture, transfer rate and pickup or discharge coordinates.

03 · Anode Carbon Block Stacking Crane

A heavy-duty overhead crane with a mechanical or hydraulic profiled clamp for green or baked anode blocks. The attachment, clamping force, stacking pattern, block protection, positioning system, auxiliary hoist and warehouse-management interface are selected for the production flow.

04 · Insulated Bridge Crane

A single- or double-trolley bridge crane with coordinated insulation barriers for maintenance and material handling near energized electrolysis equipment. The insulation points, monitoring, earthing philosophy, operating restrictions and test criteria follow the plant electrical risk assessment.

05 · Crucible and Molten Aluminum Handling Crane

A project-specific metallurgical crane for transferring a defined crucible, ladle or transport vessel. Capacity includes the filled vessel and all lifting attachments. Hoist arrangement, brakes, limits, heat shielding, route protection, operator location and emergency response must match the process and local rules.

06 · Maintenance and Auxiliary Overhead Crane

A hook crane for pumps, motors, ducts, cell components, workshop equipment and scheduled shutdown work. It can use a compact electric-hoist or open-winch arrangement according to load, duty and headroom, with environmental upgrades where the service zone requires them.

Heat and Thermal Management

Radiant heat, hot air and thermal cycling are evaluated at the bridge, trolley, cabin, electrical enclosure, cable, sensor, lubricant and attachment. Shields, spacing, selected materials, cooling and inspection access are applied where the measured duty requires them.

Magnetic-Field Compatibility

Field data and equipment locations guide the selection and positioning of drives, sensors, communication devices and control hardware. Protection is verified for the specified field conditions; “anti-magnetic” is not treated as an undefined marketing label.

Insulation and Electrical Isolation

The electrical study identifies credible current paths and required barriers. Structural interfaces, hooks or tools, hoists, service connections, earthing, monitoring and maintenance procedures are coordinated as one insulation system with defined inspection and test criteria.

Dust, Fumes and Corrosion Protection

Protected enclosures, selected seals and cables, filtered ventilation, serviceable barriers, suitable coatings and interfaces to plant extraction are specified from the actual carbon dust, alumina, fluoride-bearing fume and cleaning regime.

Motion, Load and Collision Control

VFD motion, controlled acceleration, service and emergency braking, overload protection, travel limits, anti-collision, protected zones and process interlocks support predictable operation. Required redundancy follows the load consequence and purchaser risk assessment.

Operator Protection and Visibility

Cabin location, remote controls, cameras, alarms, access platforms, isolation points and emergency recovery are planned around the task. The operating concept reduces personnel exposure while preserving sufficient visibility for the approved process.

Design basis

Approved process and load schedule, duty calculation, environmental data, general arrangement, tool envelopes, wheel loads, utilities, code matrix and responsibility boundary.

Control documentation

Electrical single-line diagrams, PLC and network architecture, operating modes, permissions, interlock matrix, alarm list, recovery logic and plant communication schedule.

Manufacturing records

Material traceability, welding procedures, welder qualifications, dimensional checks, NDT records, coating inspection and purchased-component certificates as contracted.

Factory acceptance

Drive, brake, limit, alarm and interlock checks; tool motions; control modes; communications; simulated sequences and purchaser witness points defined in the approved test plan.

Site Readiness

Confirm runway survey, rail condition, building capacity, erection access, lifting plan, laydown area, utilities, extraction interfaces, shutdown windows and potroom work permits before shipment.

Installation

Bridge and trolley assembly, rail alignment, conductor or cable installation, cabin and service connections, process-tool installation and plant-network integration follow approved method statements.

Commissioning

Testing progresses from no-load movement and interlocks to proof testing, dry process simulation and controlled production trials. Acceptance values, materials, cell availability and witness responsibilities are agreed in advance.

Lifecycle Support

Training covers operation, tool change, isolation, alarms and recovery. Preventive maintenance is organized by bridge, mechanisms, process tools, hydraulics or pneumatics, electrics, insulation and environmental protection.

Machine and tools

Bridge, trolleys, hoists, process tools, clamps, suction system, hydraulics, pneumatics, cabin and access platforms.

Controls and protection

Drives, PLC, positioning, communications, automation, insulation, cooling, enclosures, cameras and environmental protection.

Project delivery

Engineering, documentation, inspection, FAT, packing, freight, insurance, spares, training, installation and commissioning.

Facility interfaces

Runway, rails, conductor system, structural reinforcement, utilities, extraction, network integration and production-trial support.

01 · Plant and process

New plant, expansion or replacement; pot technology; production area; pot count; operating schedule and required crane role.

02 · Building and runway

Layout, sections, rail span, runway length, rail elevation, headroom, columns, end approaches and allowable wheel loads.

03 · Loads and attachments

Anode, carbon block, crucible, maintenance load or process material data; drawings, mass, temperature and required lifting device.

04 · Process functions

Required tools, pickup and discharge points, stacking pattern, anode-change sequence, tapping support and maintenance operations.

05 · Performance

Capacities, lifting heights, speeds, cycles per hour, shifts, availability target, positioning needs and standby philosophy.

06 · Environment

Ambient and radiant temperatures, dust, fumes, humidity, altitude, magnetic-field measurements, electrical potentials and cleaning method.

07 · Controls and utilities

Power supply, compressed air, extraction, network protocol, manual or automatic modes, MES interface and data requirements.

08 · Compliance and acceptance

Destination country, governing code, purchaser standards, inspection authority, witness points and required certification documents.

09 · Delivery and site scope

Destination port or site, trade term, packing, freight, installation, commissioning, production trials, training and local labor.

10 · Schedule and lifecycle

Required delivery date, shutdown window, spare-parts policy, maintenance capability, documentation language and support plan.

Is an aluminum smelter crane the same as a pot tending machine?

Not always. A pot tending machine is one specialized aluminum smelter crane used for electrolytic-cell servicing. A complete smelter may also require suction cranes, anode stacking cranes, insulated bridge cranes, molten-aluminum handling cranes and auxiliary maintenance cranes.

Which operations can a pot tending machine perform?

Depending on the approved tool package, operations can include crust breaking, anode changing, residue handling, material feeding, tapping assistance and maintenance lifting. The final functions follow the pot technology and plant operating sequence.

How is aluminum smelter crane capacity selected?

Each load and mechanism is calculated separately. The rated load includes the handled item and attachment tare, while process tools may need their own force, volume, torque, energy or positioning specification. One nominal tonnage cannot define the complete machine.

Can the crane operate near energized electrolysis cells?

Yes, when the crane and operating procedure are engineered for the verified electrical conditions. The project must identify credible current paths, insulation barriers, monitoring, earthing, testing, maintenance controls and prohibited operating conditions.

How are magnetic fields, heat and fumes addressed?

Measured site data guide equipment selection and location. Typical measures include selected drives and sensors, shielding or separation, heat barriers, cooling, protected enclosures, filtered ventilation, suitable cables and coatings, and serviceable dust or fume barriers.

Can an existing runway be retained?

Only after its geometry, alignment, rail condition, support capacity, wheel-load reserve, longitudinal forces, clearances and erection access are verified against the proposed crane. A runway survey and structural review should precede final manufacture.

Can aluminum smelter cranes be automated?

Manual, assisted, semi-automatic and higher-automation configurations are possible. Options can include position feedback, identification, automatic sequences, tool permissions, vision assistance, data exchange and fleet scheduling where process consistency and plant interfaces support them.

What determines the number of cranes required?

Pot count, bay length, travel distance, cycle time, peak workload, attachment changes, maintenance duration, availability target and standby philosophy determine fleet size. A production-cycle and availability model should support the decision.

Why do public prices vary so widely?

Listings frequently omit span, duty, process tools, automation, environmental protection, runway scope, testing, freight, installation and commissioning. Two products with the same nominal capacity may have entirely different functions and lifecycle obligations.

What should be included in final acceptance?

Acceptance normally covers documentation, visual and dimensional inspection, mechanism and safety-function tests, load testing, tool operation, controls and communications, dry process simulation, controlled production trials, training and handover records as defined in the contract.

PRIMARY LOADS

Fuselage, Wings, Engines and Tooling

PLANT ZONES

Fabrication, Subassembly and Final Assembly

CRANE OPTIONS

Underhung, Bridge, Monorail or Workstation

CONTROL PRIORITIES

Synchronized, Low-Sway and Fine Positioning

A single aircraft factory can require several lifting architectures. Heavy machining cells, composite production, subassembly bays, final assembly lines and maintenance areas have different loads, operating frequencies, floor-space constraints and acceptance criteria.

The crane schedule is therefore developed by production zone and load family rather than by applying one standard crane throughout the plant.

Composite and Machining Areas

Molds, fixtures, autoclave tooling, machined structures and raw materials require defined attachment interfaces, protected surfaces and clearance around production equipment.

Fuselage Subassembly

Panels, frames and barrel sections can require long spreaders, multiple hoists, rotation control and micro-speed alignment with jigs or adjoining structures.

Wing and Empennage Assembly

Long, flexible structures require approved support points, controlled load sharing, low sway and sufficient hook approach around assembly fixtures.

Final Assembly

Fuselage joining, wing installation, engine handling and system integration can use underhung networks or bridge cranes with synchronized hoists and protected work zones.

Tooling and Fixture Logistics

Assembly jigs, drill templates, access platforms and calibrated fixtures require repeatable transfer routes, safe parking positions and traceable lifting accessories.

Plant and Equipment Maintenance

Cranes can support robots, machine tools, ventilation equipment and process-line maintenance without assigning precision aircraft loads to a general maintenance crane.

Approved Load Interface

Aircraft engineering data defines lifting points, point-load limits, component stiffness, support direction, center-of-gravity range and prohibited contact areas.

Net Capacity at Every Point

Capacity includes the aircraft component, spreader, fixtures, slings and accessories. Individual hoists are checked for unequal load share and credible center-of-gravity positions.

Synchronization and Positioning

The specification states permissible height difference, skew, tilt, travel accuracy, repeatability, measurement point, load condition and acceptance method.

Production Duty

Lifts per shift, load spectrum, travel distance, loaded time, starts, inching, shifts and design life establish the crane and mechanism classification.

Building and Floor Access

Runway reactions, roof support points, deflection, headroom and floor obstructions determine whether a top-running, underhung or freestanding structure is practical.

Process Environment

Temperature, dust, composite fibers, clean-area requirements, paint or solvent operations, electromagnetic restrictions and washdown needs are documented by zone.

Henan Mine Crane publishes a multi-support double-girder underhung platform for aircraft manufacturing plants, maintenance hangars, aerospace assembly workshops and other large-span facilities. Multiple suspension points distribute the crane reactions across compatible roof or runway supports while keeping the production floor free of crane columns.

The platform can be configured with frequency-controlled lifting and travel, wireless or cabin control, multiple runway lines and project-specific attachments. Final capacity, span, speeds, duty, support reactions and control functions are selected from the approved aircraft process and building data.

Multi-point lifting is specified when the component cannot accept a concentrated single-point load or when orientation must be maintained during transfer. The number and position of lifting points follow aircraft or tooling engineering data rather than a generic formula.

Each hoist is rated for its maximum credible share of the load. Encoders, load monitoring or other feedback can supervise relative position and force. The control system coordinates lifting and lowering, limits differential movement and establishes a safe response to a drive, sensor, brake or communication fault.

Independent point adjustment may be included for final alignment. The permitted trim range, sequence, speed and authority are defined so that fine adjustment cannot create an unacceptable structural load.

Load Share
Maximum and minimum force at every lifting point across all approved orientations.

Synchronization
Permissible relative height, tilt and travel difference under defined load and speed.

Fine Adjustment
Controlled individual-point movement for docking, fitting and fixture alignment.

Fault Response
Safe stop, load retention, diagnosis and approved recovery without load instability.

Custom Spreader Beam

Fixed or adjustable beams establish the required lifting-point spacing and sling direction. Beam deflection, deadweight, headroom and attachment parking are included.

OEM-Approved Lifting Fixture

A dedicated fixture can locate on defined hard points and control orientation. Mechanical locking, confirmation sensors and secondary retention follow the approved design basis.

Soft Slings and Surface Protection

Sling material, edge protection, contact pressure, cleanliness and replacement criteria are matched to coatings, composites and finished aircraft surfaces.

Powered Rotation or Tilting Fixture

Rotation and tilt support assembly or inspection where the component interface permits it. Speed, range, holding brake and unbalanced torque are specified.

Vacuum Lifting Device

Suitable panels require validated surface condition, curvature, porosity, seal geometry, reserve vacuum, alarms and a defined energy-loss response.

Engine and Landing-Gear Tooling

Purpose-built cradles and beams control center of gravity, clearance and installation orientation during removal, transfer and positioning.

Motion Performance

Variable-frequency drives support smooth acceleration, deceleration and low-speed movement. Closed-loop feedback can be added where the contract defines positioning or synchronization performance. Brake selection covers normal stopping, holding, emergency states and load recovery.

Operating Modes

Pendant or wireless control supports direct operation. Assisted modes can add target zones, speed restrictions, anti-sway and alignment functions. Automatic modes require validated task data, station permissions, obstacle strategy and controlled manual recovery.

Plant Interfaces

Interfaces can include fixture-ready signals, station occupancy, access gates, production systems, load identification, position tracking, event records and maintenance data. Ownership of every signal and safe state is defined in the interface schedule.

Aircraft assembly bays contain jigs, access platforms, automated equipment and wide component routes. Columns or floor rails can restrict production. Multi-support underhung systems distribute reactions across several roof or runway lines and maintain an open production floor.

The structural assessment covers maximum and minimum vertical reactions, lateral and longitudinal forces, buffer loads, simultaneous crane positions, runway or roof deflection, connection forces, tolerances, fatigue, seismic criteria and erection loads.

Existing buildings require a condition survey and verified drawings. New buildings require coordinated crane loads before the steelwork is finalized. Crane geometry, electrification, maintenance access, fire systems, lighting, ducts and overhead process services are resolved in the coordinated layout.

Controlled Clean Area

Particle-control measures can include enclosed drives, compatible coatings, controlled lubrication, protected festoons, cleanable surfaces and a maintenance plan aligned with the declared room classification.

Composite Dust and Fibers

Composite machining or trimming areas require an environmental assessment covering conductive fibers, enclosure protection, cooling, cleaning access and electrical equipment exposure.

Paint and Solvent Areas

Explosion-protected equipment is selected only from the approved hazardous-area classification, gas or vapor group, temperature class, zone, ambient range and required conformity route.

A general aircraft assembly hall does not automatically require cleanroom or explosion-proof construction. Each production zone is assessed separately so that electrical protection, materials and maintenance controls match the actual environment.

Where a classified hazardous area is confirmed, the crane package can require protected motors, brakes, controls, limit devices, cable systems, enclosures and operating procedures compatible with the governing explosion-protection framework.

Core Protective Functions

Overload and overtravel protection, motion limits, emergency stop, brake monitoring where specified, anti-collision, restricted zones, alarm states and safe isolation.

Factory Acceptance Test

Document review, mechanism operation, controls, alarms, interfaces, load or simulated-load testing, synchronization, positioning, abnormal states and recovery sequences.

Site Acceptance Test

Runway geometry, electrification, rated and proof loads, station access, representative tooling, interfaces, accuracy, production sequence, training and handover records.

Production Acceptance

Approved representative loads verify attachment engagement, point-load behavior, synchronization, component clearance, placement, cycle and controlled exception handling.

Documentation

Approved drawings, calculations as contracted, certificates, electrical diagrams, software backups, test records, manuals, inspection plans, spare-parts data and training records.

Lifecycle Control

Scheduled inspection, attachment records, calibration where required, brake and rope monitoring, lubrication, critical spares, change control and operating-data review.

24 Equipment Sets Delivered to an Aerospace Research Institute

Henan Mine Crane reports delivering 24 equipment sets to a space research institute, including six lower-rotating girder bridge cranes placed into operation. The published application covers precision transfer of aerospace power components and structural parts.

The published crane platform combines PLC and inverter closed-loop vector control, remote, manual and tablet operating modes, a servo-controlled attachment with extension and rotation, personnel and obstacle detection, and remote equipment monitoring.

The delivery passed acceptance by the Xi’an Institute of Special Equipment Inspection and Testing. The operating data and performance requirements for a new aircraft manufacturing project are established from its own components, plant layout and acceptance plan.

View Published Aerospace Project →

Crane Structure
Capacity, span, lift, support arrangement, duty, wheel or roof reactions and access.

Lifting System
Number of hoists, load monitoring, synchronization, micro-speed and braking architecture.

Aircraft Tooling
Spreader, fixtures, powered axes, surface protection, sensors, stands and proof testing.

Project Services
Freight, erection, commissioning, calibration, representative-load tests, training and warranty.

Design Basis

Load families, approved lifting points, attachment, crane classification, motions, accuracy, environment, standards and exclusions.

General Arrangement

Plan, elevation, hook approaches, clearances, support positions, maintenance access, electrification and maximum reactions.

Attachment Package

Rated point loads, deadweight, engagement, locking, powered motions, proof test, inspection criteria and storage stand.

Control Description

Operating modes, synchronization, speed zones, interlocks, alarms, communications, fault handling and manual recovery.

Inspection and Test Plan

Material and manufacturing records, mechanism tests, load tests, accuracy checks, interface tests and document hold points.

Commercial Schedule

Price, Incoterm, milestones, delivery, erection, commissioning, acceptance, documentation, training, spares, warranty and exclusions.

Aircraft Load Matrix

Component names, mass, dimensions, center-of-gravity range, approved lifting points, allowable point loads, orientation and drawings.

Handling Sequence

Pickup and destination stations, route, required orientation, lift frequency, shifts, cycle, dwell, alignment steps and contingency.

Building and Layout

Span, lift, runway length, support layout, allowable reactions, building drawings, obstructions, installation access and power supply.

Controls and Environment

Synchronization, positioning, operating modes, plant interfaces, safety zones, clean-area or hazardous classification and ambient conditions.

Standards and Acceptance

Destination regulations, design standards, conformity route, FAT, SAT, representative loads, accuracy tests, documentation and training.

Commercial Boundary

Destination, Incoterm, runway or roof steel, freight, duties, erection, commissioning, test loads, spares, warranty and schedule.

Which crane is suitable for aircraft final assembly?

Large final-assembly bays commonly use multi-support underhung systems or bridge cranes with multiple synchronized hoists. The building, component load path, required coverage and positioning criteria determine the configuration.

Why are multiple lifting points used?

Multiple points distribute force across approved interfaces and stabilize long or flexible components. Point quantity and spacing follow aircraft structural and tooling data.

How is aircraft crane capacity calculated?

The rated requirement includes the component, spreader, fixtures, slings and accessories. Every hoist and structural element is checked for the governing load share, center of gravity and operating case.

Can an aircraft crane operate automatically?

Automatic or assisted operation can include target positions, synchronized motion, anti-sway, protected zones and plant interfaces. The operating sequence, exceptions and manual recovery are validated before production release.

Does every aircraft plant require an explosion-proof crane?

No. Explosion-protected construction is required only where the approved hazardous-area classification establishes the applicable zone, material group, temperature class and equipment protection requirements.

Can an existing hangar roof support an underhung crane?

Only after the roof framing, connections, foundations, condition, fatigue history, allowable reactions and deflection are verified for every crane and load position.

How much does an aircraft manufacturing crane cost?

Published standard-system prices are not valid for an aircraft project without the load interface, number of lifting points, span, structure, accuracy, controls, environment, installation and acceptance scope.

What should be tested with representative aircraft tooling?

Tests can verify engagement, point loads, synchronization, clearance, micro-speed, position, interlocks, abnormal stopping, restart and the approved handling sequence.

01 · Multi-Point Single-Girder Suspension Crane

Multiple suspended runway lines distribute crane and lifted-load reactions across the roof structure. The system preserves an unobstructed hangar floor and can cover wide bays where a conventional two-runway arrangement would impose excessive beam depth or concentrated roof loads.

02 · Multi-Support Double-Girder Underhung Crane

A double-girder suspended structure increases capacity, rigidity and trolley options for large components or long spans. Synchronized drives control the multiple support points, while the underhung arrangement keeps columns and runway legs away from aircraft circulation and docking equipment.

03 · Top-Running Bridge Crane

A top-running single- or double-girder crane is suitable when the hangar has dedicated runway beams and sufficient headroom. It provides high capacity and wide hook coverage but requires careful coordination of columns, runway elevations, door pockets, roof trusses and aircraft tail clearance.

04 · Ceiling-Mounted Workstation Crane

A lightweight enclosed-track or modular workstation crane supports localized maintenance tasks, benches and small-component handling. It is appropriate for lighter loads and shorter spans where low manual effort, responsive movement and clear floor space are priorities.

05 · Portable or Motorized Gantry Crane

A floor-running portable gantry provides temporary or movable coverage for engine shops, helicopter maintenance and changing service zones. Wheel loads, floor flatness, steering, stability, clear travel routes and safe movement around the aircraft must be confirmed for every operating position.

06 · Synchronized Multi-Hoist Crane

Two or more hoists can support long, flexible or offset-center components when the complete lifting fixture and control system are engineered as one system. Load sharing, position feedback, skew limits, individual-hoist overloads and safe recovery are defined before tandem lifting is permitted.

Required hook coverage = every approved pickup and set-down point + safe approach path + maintenance access

Crane design load = lifted load + lifting fixture + hoist/trolley effects + applicable dynamic and load-combination factors

Controlled Low-Speed Motion

VFD hoisting and travel, defined acceleration ramps, creep speed and controlled braking support final positioning. The required tolerance is established from the aircraft maintenance procedure, lifting fixture, load response and operator visibility rather than assumed from the drive system alone.

Hoist and Load Protection

Overload protection, upper and lower limits, service and emergency braking, rope monitoring, hook safety latches and defined emergency-stop functions protect the suspended load. Additional redundancy is selected from the load consequence and purchaser risk assessment.

Aircraft Exclusion Zones

Travel limits, protected zones, anti-collision devices, warning systems and operating permits prevent the crane or load from entering prohibited aircraft, dock, door or personnel areas. Limits are configured from the approved hangar layout and maintenance state.

Synchronized Drive Control

Multi-support cranes use coordinated travel drives with position or speed feedback and skew supervision. Control tolerances, correction behavior, braking sequence and the safe response to an encoder, motor or communication fault are documented in the functional design.

FOD and Clean Maintenance Practice

Fastener retention, enclosed electrics, cable management, drip control, accessible inspection points and controlled maintenance procedures reduce foreign-object and contamination risk. Cleanliness requirements are agreed for sensitive component and assembly areas.

Hazardous-Area Configuration

Painting, coating or fuel-related work may require classified-area equipment. Explosion protection is supplied only against the confirmed zone or division, gas or vapor group, temperature class, ambient conditions and destination certification requirements.

Design basis

Approved load and task schedule, aircraft and hangar envelopes, duty calculation, hook coverage, support reactions, clearances, control philosophy and code matrix.

Interface documents

General arrangement, suspension or runway plan, wheel or hanger reactions, power demand, lifting-device data, interlocks, installation tolerances and maintenance access.

Manufacturing records

Material traceability, welding procedures, welder qualifications, dimensional inspection, NDT reports and component certificates as contractually required.

Factory acceptance

Functional checks, brake and limit tests, VFD motion, synchronization, alarms, interlocks, simulated operating modes and witnessed inspection when included.

Before Manufacture

Complete the hangar survey, structural verification and coordinated layout. Confirm roof or runway geometry, clearances, doors, docks, services, aircraft protection zones, power supply, equipment access and the division of civil, structural and electrical work.

Erection and Commissioning

Coordinate unloading, temporary lifting, roof or runway installation, survey, electrical work, control setup, no-load testing, proof load, synchronization, protected zones, lifting-device trials and operator and maintenance training.

Planned Maintenance

Inspect brakes, ropes or chains, drums, hooks, wheels, end trucks, hangers, runway joints, synchronized drives, position feedback, limits, electrical panels, festoons and lifting fixtures under a documented preventive-maintenance program.

What is an aircraft maintenance crane?

It is an overhead, suspended, workstation or mobile crane configured to remove, transfer and install aircraft components and maintenance equipment inside an MRO hangar, airline base, engine shop or aerospace facility.

Which crane is suitable for a wide aircraft hangar?

A multi-point single- or double-girder suspended crane is often suitable where the roof can accept distributed loads and the floor must remain unobstructed. A top-running crane may be preferable when dedicated runway beams already exist.

How is the required crane capacity calculated?

Capacity includes the maximum aircraft component or maintenance load plus the complete lifting beam, fixture, adapter and rigging tare. Dynamic effects, load eccentricity, multiple-hoist sharing and the required design load combinations are then verified.

Can an aircraft maintenance crane remove an engine?

Yes, when the crane capacity, hook path, low-speed control, engine fixture, stand height, center of gravity and removal procedure are designed for the specific engine and aircraft. The approved maintenance procedure remains the governing basis.

Can the crane lift a complete aircraft?

Only if the complete-aircraft lift is explicitly engineered and approved. A crane designed for engines, landing gear or tooling must not be assumed suitable for a fuselage or full aircraft. Lifting points, load distribution, synchronization and airframe limits require separate verification.

What positioning accuracy is available?

VFD drives, creep speed, encoders, controlled braking and anti-sway can support precise handling. The guaranteed tolerance is project-specific and depends on the structure, hoist, lifting fixture, load behavior, sensing and acceptance method.

Can two hoists lift one aircraft component together?

Yes, when tandem operation is part of the engineered design. The system requires defined lifting points, load sharing, synchronized motion, individual overload protection, skew or attitude limits and a safe response to loss of one drive or feedback channel.

Is an explosion-proof crane required in an aircraft hangar?

Not in every hangar. It may be required in paint, coating, fuel or other classified areas. The equipment must be selected against the confirmed zone or division, substance group, temperature class, ambient condition and destination certification rules.

How much does an aircraft maintenance crane cost?

Public benchmarks range from approximately US$18,000–US$30,000 for a light 2 t ceiling workstation system and US$19,000–US$30,000 for a standard 5 t crane kit to US$25,000–US$100,000 for standard 10–20 t bridge equipment. A long-span multi-point hangar system requires a project quotation.

What information is needed for a quotation?

Provide the aircraft and component schedule, masses and lifting points, hangar and structural drawings, hook coverage, capacity, lift height, duty, speeds, positioning, controls, maintenance stands, environment, applicable code, destination and supply and installation boundary.

PRIMARY SYSTEM

Underhung & Low-Headroom Cranes

CAPACITY RANGE

0.5 t – 50 t

CRITICAL DIMENSION

Hook Height Under Roof

CONTROL OPTIONS

Micro-Speed, Sync & Anti-Sway

Engine Removal and Installation

Engines travel with cradles, QEC kits and transport stands, so the rated load is the full assembly. Micro-speed hoisting, stable holding and shock-free set-down onto the pylon decide both the schedule and the risk of the engine change.

Landing Gear and Flight Controls

Gear assemblies, flap tracks, elevator and rudder components are heavy, long or cantilevered. Synchronised two-point lifting with controlled speed keeps them straight and unstressed through the whole removal path.

Component Backshops

Wheels, brakes, APUs, seats, galleys and test equipment move through repair cells and benches. Workstation and suspended systems place these loads exactly where the work stands needs them, at ergonomic heights.

Dock-Side Structural Work

Fuselage panels, doors and wing components are handled beside docking towers that occupy the hook’s natural path. Coverage, reach around docks and clearance planning matter as much as capacity in these bays.

Paint and Composite Hangars

Paint and composite shops add atmosphere and cleanliness constraints to every crane operating inside them. Enclosure class, surface finish and absence of dripping or contamination are specified with the environment in mind.

GSE and Material Logistics

Ground support equipment, tooling, containers and consumables flow between stores, staging areas and the aircraft. General bay cranes keep this logistics stream moving around the maintenance schedule.

Where the roof steel allows it, underhung and European-style suspended cranes are the backbone of aviation lifting. They hang from the building structure with no elevated runway steel, run at low height directly over the work, and place the hook in the station instead of above it. Multi-point suspension extends the same principle across wide or irregular bays, and multi-support double girder underhung systems carry one crane line along long production and hangar runs.

Where a runway exists or heavier loads demand it, low-headroom single girder cranes recover hook height that standard designs lose to the hoist trolley — critical under hangar roofs — and double girder cranes take the heaviest assemblies, gear units and special tooling. Intelligent hoist cranes add closed-loop positioning, monitored lifting and dual braking for the highest-value loads in the facility.

Whatever the platform, the aviation build centres on control quality: frequency inverter travel and hoisting with micro-speed steps for engine and component set-down, anti-sway behaviour for long lifts across the bay, and synchronised two-point handling for gear, tracks and long parts.

01 · Aircraft and Component Weights

List every lift with its complete suspended weight — engine with cradle or QEC kit, gear assemblies, tooling. A large turbofan that weighs six tonnes bare can impose well over ten tonnes on the hook by the time it is rigged.

02 · Hangar Geometry and Headroom

Roof height, tail heights of the largest aircraft type, dock and platform positions, and the vertical distance from hook to hangar steel define which configurations are even possible. In aviation, headroom eliminates options before price does.

03 · Coverage and Dock Interference

Map every pick-up and set-down position against docks, scaffolding and the aircraft envelope. Wide or irregular bays are covered with multi-point suspension or multi-support runs instead of losing coverage to runway steel.

04 · Precision and Micro-Speed

Define the required creep speed for engine set-down, the holding behaviour under load, and the positioning tolerance at each station. These select between standard dual-speed and frequency-controlled hoisting with defined micro-speed ratios.

05 · Cleanliness and FOD Prevention

Loads destined for open engine bays and composite work demand drip-free hoists, enclosed components, controlled surface finishes and wheels that run clean. Cleanliness is a specification item, not a housekeeping outcome.

06 · Duty and Dependability

Cycles are moderate but the cost of failure is extreme — a crane out of service can hold an aircraft in the hangar. Mechanism classifications, brake redundancy and maintenance access are set for availability, not just load.

07 · Control and Safety Functions

Radio control for sight-line management, overload protection, limit functions, anti-sway and synchronised two-point lifting are specified per station. Where engines are involved, dual braking on the hoist belongs in the base specification.

08 · Certification and Project Boundary

Load tests, documentation and acceptance criteria for the operator’s QA system, plus the suspension or runway interface, installation, commissioning and training scope — all assigned in writing before offers are compared.

Roof Steel Capacity

Suspended systems hang the full crane and load from the hangar roof structure. Truss capacity, bracing positions and allowable deflection are verified before any suspension layout is fixed.

Clearance to Aircraft and Docks

Hook paths are mapped against the tallest aircraft tail, docking towers and platforms in the bay. The crane must reach every working position without crossing protected volumes.

Runway Rails on Hangar Steel

Top-running cranes need rails, wheel load verification and often local reinforcement of the hangar structure — work that belongs in the project scope, not in a surprise during installation.

Power Feed and Control Positions

Conductor or festoon systems are routed with isolation points and maintenance positions that do not interfere with dock movement or floor traffic, and control stations are placed for sight-line management.

An aviation lifting project typically combines several systems in one facility: suspended and workstation cranes through the backshops and line stations, low-headroom or multi-support cranes covering the hangar bays, and a double girder crane for the heaviest assemblies and tooling. Henan Mine Crane plans these projects around a common engineering baseline — one control behaviour, one spare parts standard and one documentation set across every crane family in the facility.

A complete supply definition states the crane platform and hoist specification, the control and precision functions required at each station, the suspension or runway interface to the hangar structure, the safety functions with their acceptance criteria, the overload and load test regime, and the delivery, installation, commissioning and training responsibilities. Documentation is aligned with the operator’s maintenance and quality system so every acceptance step is evidenced.

Standard configurations are typically delivered within 30 to 45 days after drawing approval. Engineered systems with synchronisation, anti-sway or multi-support runs are delivered on confirmed project schedules agreed before production starts.

Aircraft and Load Data

Aircraft types, engine and component weights with cradles and QEC kits, landing gear assemblies, and the heaviest complete suspended load in the facility.

Hangar and Geometry Data

Roof height and steel capacity, bay spans, dock and platform positions, tail heights, travel lengths and every pick-up and set-down position the cranes must cover.

Precision and Function Data

Required creep speeds, holding behaviour, positioning tolerances, synchronised handling needs and the safety functions required for engine and component work.

Commercial and Site Data

Voltage and frequency, destination and Incoterm, installation responsibility, required certifications and documentation, spares level and requested delivery schedule.

What crane is used for aircraft maintenance?

Suspended and underhung cranes for backshops and line stations, low-headroom single girder cranes for height-restricted hangar bays, multi-support runs for wide or long coverage, and double girder cranes for engines, gear and heavy tooling — with micro-speed control wherever components are set down precisely.

What capacity does an engine change need?

The rating follows the complete suspended assembly, not the bare engine. A large turbofan of around six tonnes can impose well over ten tonnes on the hook once its cradle, QEC kit or transport stand is rigged, so the crane is rated to that total.

Why is low headroom so important in hangars?

Hangar roof heights are fixed, and docks, platforms and aircraft tails consume the volume below them. Every centimetre the hoist takes above the hook is a centimetre the maintenance process loses, so underhung and low-headroom designs exist to give it back.

How much does an aircraft maintenance crane cost?

Workstation and suspended systems for component work typically run from about US$2,000 for light stations to US$60,000 for long underhung runs. Low-headroom single girder cranes span roughly US$3,000–70,000, and double girder cranes for engine and heavy assembly work from about US$5,000 to 110,000 depending on span, duty and control scope. Freight, duty and installation typically add 20–50 % on top.

Can one crane system cover the whole hangar bay?

Wide and irregular bays are covered with multi-point suspension or multi-support underhung runs, where one crane line travels along the bay on several suspension points. The layout is engineered against the roof steel and the dock positions, not against a catalogue span.

What is the delivery time?

Standard configurations are typically delivered within 30 to 45 days after drawing approval. Systems with synchronised handling, anti-sway or multi-support runs run on confirmed project schedules agreed before production starts.

PRIMARY DUTY

Aircraft Maintenance, Repair and Overhaul

TYPICAL LOADS

Engines, Landing Gear, Tooling and Components

SYSTEM OPTIONS

Underhung, Bridge, Monorail and Multi-Point

PROJECT PRIORITIES

Clear Floor, Low Sway and Aircraft Protection

The crane schedule should follow the actual maintenance work package and aircraft fleet. A narrow-body engine-change bay, wide-body heavy-maintenance hangar, military depot, business-jet facility and helicopter maintenance workshop can require different spans, service loads, access arrangements and restricted zones.

Separate lifting arrangements can be assigned to high-value aircraft components, general tooling and elevated maintenance access so that each duty receives the appropriate control, attachment and inspection regime.

Engine Removal and Installation

Controlled vertical movement, accurate lateral positioning and a compatible engine cradle support disconnection, lowering, transfer and reinstallation without uncontrolled sway.

Landing-Gear Service

Load control and fine positioning help maintain component orientation during removal, overhaul support, replacement and alignment with approved fixtures.

Flight-Control and Airframe Parts

Flaps, rudders, elevators, fairings, doors and structural panels may require long spreaders, protected contact surfaces and several balanced support points.

Cabin and Interior Modules

Monorails, light suspension cranes or service hoists can move seats, monuments, galleys, test equipment and maintenance materials along defined routes.

Maintenance Docks and Tooling

The crane can reposition calibrated fixtures, engine stands, access-dock sections and maintenance equipment while preserving clear marked routes around the aircraft.

Overhead Maintenance Access

A purpose-engineered telescopic platform can provide stable access to upper fuselage, tail and wing areas when platform duty, personnel protection and emergency recovery are included in the system design.

Aircraft Fleet and Work Scope

Aircraft models, parking positions, maintenance checks, removable components, approved procedures and future fleet changes define the required coverage.

Rated and Net Hook Load

The heaviest component, fixture, spreader, sling, powered attachment and credible center-of-gravity position are included in the load schedule.

Coverage and Hook Approach

Plan and elevation drawings verify service around the nose, wings, engines and tail, including door pockets, roof trusses, docks and parked equipment.

Motion Quality

Low-speed range, acceleration, braking, sway control, travel accuracy and radio-control ergonomics are defined for the most sensitive maintenance task.

Hangar Structure

Roof capacity, runway beams, support spacing, deflection, fatigue, connection details, seismic criteria and erection access govern the structural arrangement.

Maintenance Environment

Temperature, humidity, washing, coatings, lighting, fire systems, paint or solvent areas and required enclosure protection are documented by bay.

Henan Mine Crane publishes a multi-support double-girder underhung platform for aircraft manufacturing plants and aircraft maintenance hangars. The crane is suspended from several support rails to distribute reactions and preserve an unobstructed floor.

The ranges below define available product boundaries rather than one standard hangar model. Final ratings, motion speeds, number of supports, clearances and structural reactions are selected from the aircraft maintenance duty and verified building data.

Engine and landing-gear work requires a defined lifting method, not only a hook over the work area. The technical schedule identifies component mass, center of gravity, approved attachment points, fixture deadweight, extraction direction, required orientation and every temporary support state.

Variable-frequency motions provide controlled acceleration and low-speed adjustment. Load monitoring can identify overload or unequal load share. Where two or more hoists lift one component or fixture, encoder feedback, synchronization limits and a safe fault response keep the points within the permitted relative-height window.

The aircraft multi-point lifting solution covers hangar maintenance, engine handling, landing-gear work and specialized maintenance tooling.

Attachment
Approved fixture, spreader, sling geometry, positive engagement and protected contact surfaces.

Load Control
Net hook load, point-load range, overload limit and center-of-gravity envelope.

Fine Motion
Defined low speed, acceleration, braking, inching and permissible sway.

Acceptance
Representative load, fixture interface, clearance, positioning and recovery tests.

Service Trolley

A hoist trolley supports engines, components and tooling. Capacity, hook approach, power transfer and bridge compatibility are coordinated across every approved route.

Telescopic Platform

A rigid telescopic mast can reduce platform sway and reach upper aircraft zones. Rated occupancy, tools, rescue, emergency lowering and personnel-lifting compliance form part of the design basis.

Bridge Locking and Transfer

Mechanical alignment, positive locking, position confirmation, motion inhibition and load-state logic prevent transfer until both bridge paths are safely connected.

Zoned Motion

Position monitoring can impose slow zones, no-go areas, height limits and defined parking positions around aircraft tails, doors, docks and other cranes.

Power and Communications

Busbars, festoons, cable management, radio control and data communications are arranged to avoid snagging and maintain service across transfer interfaces.

Maintenance and Rescue Access

Inspection platforms, isolation points, retrieval provisions and manual or powered recovery routes are included for bridges, hoists and personnel-access units.

Hangar geometry is developed in plan and elevation using the aircraft envelope, towing route, maintenance docks, tail position, wing-tip clearance, hangar doors, roof trusses and all overhead services. The crane must reach the maintenance point without creating a conflict elsewhere in the bay.

The structural interface schedule states maximum and minimum vertical reactions, transverse and longitudinal forces, buffer loads, simultaneous crane positions, fatigue cycles, support tolerances, runway or roof deflection, seismic actions where applicable, and erection loads. Existing hangars require verified drawings and a condition assessment before support capacity is accepted.

Lighting, sprinklers, smoke extraction, ventilation ducts, door drives, antennas and maintenance walkways are included in the coordinated model. Isolation access and component-removal routes remain available after the aircraft and docking system occupy the bay.

Protective Functions

Overload and overtravel protection, emergency stop, motion limits, anti-collision, restricted zones, warning devices, brake supervision where specified and safe electrical isolation.

Aircraft Surface Protection

Low-sway travel, padded or approved attachments, controlled approach speed, protected hooks, positive fixture locking and exclusion of loose objects from lifting equipment.

Factory Acceptance Test

Mechanisms, controls, alarms, limits, interfaces, simulated faults, load-monitoring functions, synchronized motion and contracted document hold points.

Site Acceptance Test

Runway geometry, travel clearances, electrification, rated and proof loads, zone functions, representative routes, accuracy, recovery, training and handover records.

Maintenance-Task Validation

Approved fixture engagement, engine or component clearance, low-speed placement, route access and defined abnormal-state recovery are verified with a representative load.

Lifecycle Records

Inspection schedules, lifting-accessory records, calibration where required, rope and brake checks, critical spares, software backups, maintenance logs and change control.

A general maintenance hangar does not automatically require explosion-protected construction. Paint, solvent, fuel-system or battery work may create a classified zone only after the facility’s hazardous-area study defines the substance, zone or division, gas or vapor group, temperature class, ventilation basis and equipment category.

Where classification is confirmed, motors, brakes, enclosures, controls, cable systems, limit devices and operating procedures are selected for the declared environment. A crane crossing classified and unclassified bays requires clear equipment boundaries and an approved operating philosophy.

Wash areas and humid coastal hangars can require higher enclosure protection, corrosion-resistant components, compatible coatings, drainage control and a revised inspection schedule. Ambient temperature, altitude and outdoor exposure at the hangar door are included in the equipment data sheet.

5 Suspension Bridges
Overhead coverage distributed across the MRO work area.

2 Teleplatforms · 500 kg
Elevated aircraft access carried by the crane network.

2 Service Trolleys · Up to 10 t
Component and tooling lifting across approved routes.

Cross-Bay Transfer
Bridge locking connects service routes between hangar sections.

24 Equipment Sets for an Aerospace Research Institute

Henan Mine Crane reports delivering 24 equipment sets to an aerospace research institute, including six lower-rotating girder bridge cranes placed into operation. The published application covers precision transfer of aerospace power components and structural parts.

The equipment uses PLC and inverter closed-loop vector control, remote, manual and tablet operating modes, and a servo-controlled attachment with extension and rotation. Published performance includes positioning accuracy of ±2 mm and attachment rotation accuracy of ±0.5° for the project configuration.

The delivery passed acceptance by the Xi’an Institute of Special Equipment Inspection and Testing. This record demonstrates adjacent aerospace precision-handling capability; an aircraft MRO hangar system is engineered from its separate fleet, building and maintenance requirements.

View Published Aerospace Project →

Coverage and Structure
Bay dimensions, span, lift, support lines, runway length, headroom and building reinforcement.

Lifting Equipment
Capacity, number of hoists, load monitoring, synchronization, attachments and service trolleys.

MRO Functions
Interlocking bridges, transfer routes, teleplatforms, restricted zones and aircraft-protection logic.

Project Services
Freight, erection, commissioning, load tests, representative-task validation, training and spares.

Design Basis

Aircraft fleet, maintenance tasks, loads, fixtures, duty, environment, standards, operating modes and supply exclusions.

General Arrangement

Plan, elevation, aircraft envelope, hook approaches, transfer routes, parking positions, maintenance access and electrification.

Structural Interface

Support coordinates, vertical and horizontal reactions, buffers, simultaneous positions, tolerances, deflection and erection loads.

Control Description

Speed modes, interlocks, zones, anti-collision, bridge transfer, load monitoring, alarms, communications and recovery logic.

Inspection and Test Plan

Manufacturing records, mechanism tests, load tests, safety-function checks, transfer tests, task validation and document hold points.

Commercial Schedule

Price, Incoterm, milestones, delivery, site services, acceptance, documentation, training, spares, warranty and exclusions.

Which crane type is suitable for a large clear-floor hangar?

A multi-support underhung crane is frequently considered where roof or runway support can carry the required load and floor columns would obstruct aircraft or maintenance traffic. A top-running bridge crane remains practical when dedicated columns and runways are available.

Can one crane serve several hangar bays?

Yes. Interlocking suspension bridges can transfer compatible service trolleys or platforms between bays. Bridge alignment, locking, power continuity, transfer interlocks and route clearances must be engineered as one system.

How is capacity selected for aircraft engine handling?

Capacity includes the heaviest approved engine or component, cradle, spreader, slings, attachments and applicable dynamic or eccentric load conditions. The maintenance method also defines hook approach, low speed and required orientation.

Can an aircraft hangar crane carry personnel?

Only a purpose-engineered personnel-access system should perform that duty. A teleplatform requires its own rated load, fall protection, control hierarchy, collision prevention, emergency lowering, rescue plan and compliance assessment. A standard cargo hook does not establish personnel-lifting suitability.

Can a crane be installed in an existing aircraft hangar?

Yes, subject to verified building geometry and structural capacity. Retrofit engineering covers roof or column condition, reactions, reinforcement, access for erection, electrical supply, fire systems and continuing hangar operations.

Does every hangar require an explosion-proof crane?

No. Explosion-protected equipment is selected from the formal hazardous-area classification for a specific paint, solvent, fuel or process zone. The general aviation application alone does not determine explosion-protection requirements.

What determines aircraft hangar crane lead time?

Engineering approval, structural coordination, customized steelwork, hoists and controls, teleplatform or transfer equipment, conformity documentation, factory testing, ocean freight, site readiness and commissioning all affect the schedule.