Intelligent Overhead Crane 80 Ton/32 Ton for Scrap Steel Handling

Intelligent overhead crane for steel mill. Customized overhead crane, with electromagnet for scrap steel handling, intelligent control, high efficiency.

For an unmanned steel industrial factory, Yuantai Crane produced an 80/32T overhead crane for metallurgical workshop for scrape steel handling.  The scrap crane spreader is a hook with a round electromagnetic disc lifter, and the bridge crane is built with a 24.6 m span and a 29.26 m lifting height. .

Features of 80 /32 ton overhead crane include:

• This scrap steel handling overhead crane has the best anti-sway automatic positioning system in the world, which allows for smooth operation, precise positioning, and dependable performance;
•  It has functions for 360-degree real-time monitoring and intelligent anti-collision to guarantee the on-site safety of people and equipment; and 3.
• To achieve all-encompassing data management and intelligent ordering, the software integrates the intelligent craneWMSv3.0 warehouse management system with the original digital twin 3D screen of the lifting industry;
• To guarantee precise and effective lifting operations, the intelligent 3D scanning system updates the on-site material data in real-time.
• The  80 ton /32 ton bridge crane uses a double hoisting mechanism design. The main hoist is used for ladle handling, and the production line for preheating scrap steel is fed by the deputy hoist, which is intelligently managed. The intelligent crane system operates the main and deputy lifts in order to achieve safety interlocking, autonomous control, and non-interference.
•  Multiple cranes operate in tandem at both high and low altitudes in the system, which is used in metallurgical workshops. The system's unique multi-level security protection system guarantees the safe and effective operation of cranes.
•  The overhead crane system can prevent accidental material leakage and magnetic discharge during crane operation and guarantee the safety of field personnel and equipment by using an efficient electromagnet control strategy.
• The intelligent crane system places numerous cameras in the crane and key workstations in the workshop, allowing for a 360-degree view of the scene without a dead angle. The video delay is less than 200 ms, effectively supporting the customer's remote manual operation.
• The overhead crane system has remote manual, semi-automatic, completely automatic, on-site remote control, and the ability to handle special operations in addition to regular automatic operation.

Currently, the intelligent crane system has been used and put into practice in many big steel factories for tasks like cold-rolling coils, storing bars, grabbing blast furnace slag, loading scrap, moving ladles, and others. The system functions effectively and dependably and is tightly integrated with production situations. It is helpful for heavy-duty logistics, aids in the modernization and transformation of traditional steel plants that produce smart steel, satisfies consumer demand for digitalization, networking, and intelligence, and receives high marks from clients.

Unmanned technology for intelligent overhead crane positioning

The three techniques listed below are typically used to determine the loads location of the crane and trolley of the overhead crane:

• 1. The absolute address information discovered through the discovery of the absolute coded scale location is accurate and trustworthy, free of error code and accumulation error. The absolute coded scale operates in a non-contact manner.
• 2. The absolute address within the overhead crane's travel range can be continuously and precisely detected using Gray bus position detection, with a detection precision of 5mm, fully satisfying the need for accurate positioning of the overhead crane.
• 3. The process from the laser transmitter transmitting laser pulses to the reflecting plate to the reflected light is received will be timed in the location detection through laser ranging, and then the distance between the laser and the target can be calculated.

There are many technological ways to determine where the overhead crane is when it is operating. The positioning technology used for a given project is determined by the real circumstances surrounding the warehouse area, including the working environment, warehouse size, the number and arrangement of overhead cranes, etc.

The unmanned intelligent overhead crane performs an essential function called anti-collision. The overhead crane's other control systems must not interfere with the anti-collision system's ability to function. By doing this, the anti-collision system can continue to function regularly even if there is a problem with the PLC system or positioning device, preventing collision accidents between overhead cranes.

Some of the most popular anti-collision devices include the ones listed below:

• Grating
• Laser
• Radio signals or radar (frequency 5.8GHz or 61GHz)

In most cases, aluminum foil manufacturing facilities can use optical (grating or laser) anti-collision devices for overhead cranes. The highly harsh working environment can be taken into consideration when using the radar anti-collision technology. The particular technical proposal must be carefully planned in accordance with the customers' actual requirements.

The most commonly used anti-collision system adopts grating technology. A grating transmitter is installed on one overhead crane, and a reflecting plate is installed on an adjacent overhead crane. The grating transmitter and the traveling track are adjusted to form a certain angle. When the distance between the two overhead cranes gets close to a certain level, the light transmitted from the grating will hit the reflecting plate of the adjacent overhead crane. After receiving the reflected signal, the system will send out an alarm signal. If the safety standard is high, two sets of grating anti-collision systems (adopting different communication channels) can be installed on each overhead crane of the unmanned overhead crane system.

Mechanical anti-swing

The most effective anti-swing is mechanical, but it must be implemented during the overhead crane's design and production phases. For mechanical anti-swing, it is very challenging to modify the supplied overhead cranes, and a poor modification could compromise the cranes' performance in terms of safety.

The mechanical anti-swing mechanism lessens clamp swinging brought on by the acceleration and deceleration of the overhead crane through the special design of lifting equipment or steel wire rope, and design specifics vary depending on the crane maker.

Electrical anti-swing

The lifting device will undoubtedly wing when the crane and trolley stop operating because of the flexibility of the steel wire rope used in the overhead crane. The swinging of the clamp cannot be completely avoided, but skilled operators can reduce it by anticipating the direction of swinging and properly adjusting the speed of the crane and trolley.

The inverter contains an integrated anti-swing control device that is simple to troubleshoot. More than 95% of swing can be eliminated by it, and it guarantees that the swing height is less than 30mm after two swing cycles. The  anti-swing system does not require the addition of a swing angle detection device because it is regulated by an electronic switch. To accomplish the goal of anti-swing, the inverter calculates and modifies the output speed and acceleration of the inverter in real time in accordance with the output speed and acceleration, anti-swing pendulum length, and the mathematical model of anti-swing. The inverter's real output speed curve is shown in the diagram below.

Equipment status monitoring system

The system receives information from key devices like electrical equipment, safety doors, clamps, and other overhead crane devices, monitors their status, understands their running status through monitoring parameters, and aids operators in determining when a device is failing. This ensures safe production, prevents unnecessarily stopping, and reduces unnecessarily costly downtime.

Video monitoring system

The intelligent storage system includes a crucial component called the unmanned overhead crane surveillance system. According to the real situation in the warehouse area, the monitoring system focuses on monitoring the operation of the overhead crane, incoming and outgoing steel coils, incoming and outgoing people, and incoming and outgoing vehicles. The camera positions will be set up in accordance with the stacking area where the steel coils are put and the overhead crane working area, per the warehouse area planning.

The walking beam area, the use of the overhead crane, and the lifting of steel coils by the lifting apparatus are all created in accordance with the project's system. The two main components of the monitoring system are the video monitoring part for overhead crane devices and the video monitoring part for ground warehouse status.