Home / Cases / 25-ton Multi-functional Stacking Overhead Crane Officially Put into Operation for Profile Warehouse Workshop
25-ton Multi-functional Stacking Overhead Crane Officially Put into Operation for Profile Warehouse Workshop
Address:Profile Warehouse Workshop
A large metal profile processing enterprise built a three-dimensional finished product warehouse for storing and handling massive steel billets, square steel and profile components.
A large metal profile processing enterprise built a three-dimensional finished product warehouse for storing and handling massive steel billets, square steel and profile components. The workshop requires cranes to complete multi-layer dense stacking, warehousing and outbound transportation operations. Traditional ordinary overhead cranes feature single lifting tools, failing to realize precise layered stacking. Manual auxiliary positioning leads to low efficiency, while high-level stacking faces risks of lifting inclination and profile scratching. After on-site inspections of multiple crane manufacturers, the customer customized a 25-ton multi-functional stacking double-girder overhead crane from Henan Dafang Heavy Machinery. Equipped with multiple synchronous telescopic clamping jaws and dedicated telescopic auxiliary beams, the crane can grab multiple profiles at one time and realize precise multi-layer stacking on three-dimensional shelves. Dafang’s technical team surveyed warehouse span, shelf height and profile specifications on-site, and optimized the telescopic lifting tool, variable-frequency synchronous control system and heavy-duty main beam structure. The whole non-standard stacking crane was manufactured within 65 days. After on-site delivery, the equipment passed full-load testing and safety interlock verification in one pass and was officially put into three-dimensional profile warehouse transportation operation.
Project Execution & Solution Overview
Dafang customized a 25-ton multi-functional stacking double-girder overhead crane for the project. Key project milestones and engineering solutions are listed below:
After inspecting the production strength of multiple crane manufacturers, the customer finally selected Henan Dafang Heavy Machinery to customize the 25-ton multi-functional stacking overhead crane, specially designed for three-dimensional profile warehouse stacking and transportation.
Multi-functional Telescopic Clamping Stacking System
Equipped with sets of synchronous telescopic clamping grabs and dedicated telescopic auxiliary beam, the crane can grab multiple profiles at one time and realize accurate multi-layer stacking on three-dimensional shelves, solving the limitations of traditional single-point lifting.
Dafang’s technical team surveyed the warehouse span, shelf height and profile specifications on-site. Targeted optimizations were carried out on the heavy-load main beam, telescopic spreader and variable-frequency synchronous control system to ensure high-precision and high-stability stacking operation.
65-day Fast Production & One-time Commissioning
The whole non-standard warehouse stacking crane was completed within 65 days. After full-load testing and safety interlock calibration, the equipment passed acceptance in one go and was officially put into continuous three-dimensional profile warehouse operation.
Core Technical Features & Advantages
Reinforced Heavy-duty Double-girder Structure
The crane adopts a thickened box-type double-girder structure. Main girders and end carriages are made of Q355 high-strength low-alloy steel plates with A6 high working class design, meeting the demands of 24-hour high-frequency hoisting and multi-layer heavy-duty stacking in warehouse workshops. All load-bearing welds pass 100% ultrasonic non-destructive testing, ensuring high rigidity and no obvious deflection under full load. The whole machine adopts Dafang’s signature red anti-corrosion topcoat and three-layer epoxy zinc-rich coating technology to resist corrosion caused by workshop metal dust and humid moisture, avoiding rusting and peeling during long-term indoor operation. Complete maintenance walkways and protective guardrails on the main beam top ensure the safety of staff working at height.
The core is equipped with self-developed multi-functional telescopic stacking auxiliary beams with multiple groups of independently adjustable clamping jaws evenly arranged at the bottom. The jaw spacing can be flexibly adjusted according to profile width to clamp multiple square steels and steel billets synchronously. Fitted with a hydraulic telescopic adjustment mechanism, the lifting tool can penetrate high-level and narrow shelf positions for material picking and stacking, replacing manual positioning and greatly improving warehouse space utilization. Wear-resistant buffer gaskets inside the jaws prevent hard profile scratching and ensure intact finished product appearance. The lifting tool supports overall lifting and transverse fine adjustment, with stacking alignment accuracy controlled within ±3mm.
Variable-frequency Synchronous Safety Electrical Control System
The full electrical system adopts full variable-frequency speed regulation, realizing synchronous linkage of hoisting, travelling and lifting tool telescopic movement with stable and impact-free start and stop. The IP65-grade electric control cabinet with built-in dehumidification modules prevents condensation and short circuits, adapting to dusty and humid warehouse environments. The crane is equipped with complete safety interlock devices including overload limit, lifting height limit, travel limit, shelf anti-collision limit, jaw clamping pressure monitoring and emergency stop button. Dual operation modes of cab centralized control and wireless remote control ensure safer high-level stacking operation.
Three-dimensional Warehouse Exclusive Anti-collision Limit System
Aiming at the dense shelf layout of the workshop, infrared anti-collision sensors are installed on the front and rear of the crane and both sides of the lifting tool, enabling automatic deceleration and forced shutdown at limit distances when approaching shelves. The travelling mechanism adopts layered height interlock logic to automatically limit high-speed travelling during high-level stacking, eliminating shelf and stacking collision risks caused by operational errors. The wear-resistant cable trolley moves synchronously with the telescopic lifting tool without cable pulling or winding, extending the service life of electrical accessories.
On-Site Delivery & After-Sales
The complete stacking overhead crane is divided into multiple modules including main girder, hoisting trolley, telescopic stacking lifting tool and electric control unit for batch transportation to the profile warehouse. Our professional installation team completed full on-site construction procedures including main girder splicing, track calibration, hydraulic pipeline connection of clamping jaws, synchronous system commissioning and multi-layer full-load stacking pressure testing. Complete documents such as material non-destructive testing reports, factory load inspection certificates and overall safety acceptance data were delivered for equipment safety filing.
Special on-site training was provided for warehouse operation and maintenance teams, covering multi-layer stacking operation specifications, daily jaw maintenance and equipment maintenance guidelines in dusty environments. 7×24-hour full-cycle remote technical support and sufficient original core accessories (jaws, frequency converters, hydraulic cylinders, etc.) ensure uninterrupted warehousing and outbound operations of the workshop.
Summary
The delivered 25-ton multi-functional stacking overhead crane is a special stacking lifting equipment developed by Dafang Heavy Machinery for the steel profile three-dimensional warehousing industry. Integrating multi-jaw synchronous telescopic lifting tool, high-precision variable-frequency control system and shelf anti-collision safety system, it perfectly solves the industry pain points of traditional cranes incapable of multi-layer dense stacking and easy profile scratching.
Dafang Heavy Machinery can customize 10t~50t multi-functional stacking overhead cranes, electromagnetic overhead cranes and gantry cranes for steel processing, profile warehousing and steel billet yard enterprises, providing one-stop services including on-site survey, non-standard scheme design, production & manufacturing, on-site installation & commissioning and operator training. Customized solutions and quotations are available for all special lifting equipment demands of three-dimensional warehousing.
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