The Manufacturing Process of 25 Ton Overhead Cranes

April 15, 2025

Overhead cranes are integral to various industries, from manufacturing to construction, due to their ability to lift heavy loads with precision and safety. Among these cranes, the 25-ton overhead crane is one of the most commonly used for medium-duty lifting applications. The manufacturing process of a 25-ton overhead crane involves several critical steps, each designed to ensure the crane’s durability, efficiency, and compliance with safety standards. In this article, we will delve into the step-by-step process involved in the creation of a 25-ton overhead crane.

1. Design and Engineering Phase

The manufacturing process begins with the design and engineering phase, where a customized solution is developed based on the customer’s specific requirements. This stage is crucial as it sets the foundation for the entire manufacturing process. The design team works closely with the client to understand their lifting needs, the working environment, and any special requirements for the 25 ton overhead crane.

Key considerations in the design phase include:

Load capacity: In this case, the crane is designed to lift loads up to 25 tons, with attention to safety factors.
Span and lifting height: The crane’s span (the distance between its runway beams) and lifting height (the maximum height the hook can reach) are customized based on the customer’s facility.
Work duty: The duty cycle (how often the crane will be used, e.g., heavy or light duty) is taken into account to determine the type of components and materials required.
Safety features: These include features such as overload protection, emergency stop systems, and limit switches.
Materials selection: The appropriate materials for various components, such as steel for the structure and specialized alloys for load-bearing parts, are chosen.

The design phase concludes with the approval of engineering drawings, including detailed specifications for every aspect of the crane, from the structure to the electrical systems.

2. Procurement of Materials

Once the design is finalized, the next step is procuring the materials required for manufacturing. This process involves sourcing high-quality steel, electrical components, motors, gears, and other specialized materials. The materials are selected to ensure the crane's longevity, reliability, and compliance with industry standards.

Structural steel: The frame of the crane is made from high-strength structural steel, which is welded or bolted together to form the main body. Steel is chosen for its excellent strength-to-weight ratio, which makes it capable of handling the heavy loads while being light enough to allow for efficient lifting.
Electrical components: Motors, drives, controllers, and wiring are carefully selected to match the crane's specifications and ensure efficient and safe operation. The electrical components must also comply with local safety standards and regulations.
Other materials: Other materials such as bearings, hooks, cables, and pulleys are also procured at this stage.

The procurement team works with suppliers to ensure timely delivery of all materials, keeping in mind the manufacturing schedule and any customer-specific needs.

3. Fabrication of Structural Components

The fabrication stage involves transforming raw materials into the crane’s structural components. This is a critical step in the manufacturing process, as the quality of these components directly impacts the crane's strength, stability, and overall performance.

Key steps in the fabrication process include:

Cutting and welding: Large steel plates and beams are cut to the required dimensions using CNC cutting machines. The pieces are then welded together using advanced welding techniques to form the main framework of the crane. The quality of welding is vital to ensure the crane can safely handle its intended load.
Assembly of the crane frame: The crane's frame consists of the main girder, end trucks, and cross beams. These components are assembled with high precision to ensure they fit together correctly and can support the heavy lifting capacity of the crane.
Painting and corrosion protection: After the components are fabricated and assembled, they are thoroughly cleaned and coated with a protective paint or corrosion-resistant coating. This step not only improves the crane's appearance but also ensures its durability, especially in harsh environments.

The fabrication process is carried out in a controlled environment, where skilled welders and fabricators work to meet the exacting standards set out in the engineering drawings.

4. Manufacture of the Hoisting Mechanism

The hoisting mechanism is the heart of the overhead crane, responsible for lifting and lowering loads. For a 25-ton crane, the hoisting mechanism must be robust and capable of withstanding heavy-duty use.

Motor and gearbox: The hoisting mechanism is powered by an electric motor, typically an induction motor, which is coupled with a gearbox to provide the necessary torque to lift heavy loads. The gearbox is designed to reduce the speed of the motor and increase the lifting capacity.
Drum and wire rope: The wire rope is wound around a drum, which is rotated by the motor and gearbox. The drum is typically made of steel to handle the friction and tension exerted during the lifting process. The wire rope is carefully selected based on its strength and durability to ensure safe operation.
Hook and trolley system: The hook is suspended from the hoist and is used to attach the load. The trolley, which is mounted on the crane’s runway beams, allows the hook to move horizontally. This movement is powered by a separate motor and drive system.

The hoisting mechanism is assembled and tested separately to ensure it functions smoothly and can handle the full 25-ton load capacity.

5. Electrical System Installation

The electrical system is responsible for controlling the crane’s movements, including lifting, lowering, and horizontal travel. For a 25-ton overhead crane, the electrical system is complex and must be integrated with the crane's mechanical components for smooth operation.

Control panel: The control panel is installed, where operators can control the crane’s movements. It includes buttons for starting and stopping the motor, as well as emergency stop functions.
Wiring and cabling: The electrical components are wired together, including motors, limit switches, and sensors. High-quality cables and connectors are used to ensure reliable performance, even under heavy-duty conditions.
Safety systems: Safety systems, such as overload protection, emergency stop buttons, and limit switches, are integrated into the electrical system. These systems ensure that the crane operates safely and within its load limits.

The electrical system is carefully tested to ensure it operates correctly and complies with local electrical codes and safety standards.

6. Final Assembly and Testing

Once all the individual components—structural parts, hoisting mechanism, and electrical system—are ready, the final assembly takes place. The crane is carefully assembled on-site or in a dedicated assembly area, with each part being connected and calibrated for optimal performance.

Assembly of the crane: The crane’s structure is assembled, and the hoisting mechanism, trolley, and electrical system are integrated into the frame. The entire crane is then carefully aligned and tested to ensure smooth operation.
Load testing: Before the crane is dispatched to the customer, a load test is performed to verify its lifting capacity. The crane is loaded with a test weight equivalent to 25 tons, and the lifting, lowering, and horizontal movements are closely monitored for any issues.

This final testing phase is essential for ensuring that the crane meets all performance and safety standards.

7. Delivery and Installation

Once the crane passes all the tests, it is disassembled (if necessary) and prepared for delivery. The overhead eot crane is carefully packed and shipped to the customer’s site, where it is reassembled and installed.

On-site installation: Technicians from the manufacturing company are typically sent to the installation site to ensure the crane is set up correctly and safely. This includes verifying the alignment of the runway, connecting the electrical system, and ensuring all safety features are operational.
Final inspection: Once the installation is complete, the crane undergoes a final inspection to confirm it operates smoothly and safely. The customer is trained on how to operate the crane, and the final documentation is handed over.

Conclusion

The manufacturing process of a 25-ton overhead crane is a detailed and precise operation that involves careful design, material procurement, fabrication, hoist assembly, electrical installation, testing, and installation. Each step is aimed at ensuring the crane’s performance, durability, and safety in demanding industrial environments. By following a meticulous and structured manufacturing process, manufacturers can deliver overhead cranes that provide reliable service, enhance productivity, and meet the unique needs of their customers.

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