Home / Cases / Custom QCL Rotary Electromagnetic Overhead Crane Officially Put into Operation for Ship Steel Production Line of Samsung Heavy Industries Shipyard
Custom QCL Rotary Electromagnetic Overhead Crane Officially Put into Operation for Ship Steel Production Line of Samsung Heavy Industries Shipyard
Nation: Samsung Heavy Industries Shipyard
The steel plate processing workshop of Samsung Heavy Industries’ ship production base is mainly responsible for the warehousing, transportation, blanking and cutting of marine thick steel plates, profiles and hull components.
The steel plate processing workshop of Samsung Heavy Industries’ ship production base is mainly responsible for the warehousing, transportation, blanking and cutting of marine thick steel plates, profiles and hull components. Marine steel plates feature heavy single-piece weight and smooth surfaces that are prone to sliding. Traditional hook sling binding has low efficiency and potential safety hazards caused by manual auxiliary operation. The workshop adopts 24-hour continuous mass production, which puts forward strict requirements on the crane’s synchronous rotation, electromagnetic adsorption and high-frequency heavy-duty operation performance. After multiple rounds of technical comparison and on-site working condition investigation, Samsung Heavy Industries customized the QCL rotary electromagnetic hanging beam double-girder overhead crane from Henan Dafang Heavy Machinery. Integrated with a 360° rotatable electromagnetic sucker hanging beam, the equipment requires no sling binding, can adsorb multiple steel plates at one time and freely adjust plate angles, perfectly matching the operation rhythm of shipyard cutting production lines. Dafang’s technical team optimized the overall structure and electric control system targeting the shipyard’s humid, dusty and high-frequency heavy-duty working conditions. The whole manufacturing cycle of the large non-standard shipbuilding crane lasted 90 days. The equipment passed load testing and safety acceptance in one single pass after on-site arrival and has been stably put into marine steel plate transportation operation.
Project Execution & Solution Overview
Samsung Heavy Industries ultimately selected Henan Dafang Heavy Machinery Co., Ltd. to customize a QCL electromagnetic rotating gantry crane with dual-beam design. Key project milestones and engineering solutions included:
Shipyard Working Condition Targeted Customization
Targeting the complex working conditions of 24-hour continuous production, slippery steel plates, high humidity and dense metal dust in shipyards, the equipment is specially optimized in electromagnetic adsorption stability, heavy-load anti-fatigue structure and dust-proof & moisture-proof electric control system, thoroughly solving the industry pain points of low efficiency and poor safety of traditional sling binding operation.
Rotary Electromagnetic Intelligent Lifting
Equipped with self-developed QCL rotary electromagnetic hanging beam, the crane supports stepless angle adjustment and independent magnetic control of multiple suckers. It is suitable for batch grabbing of marine steel plates of different thicknesses without manual binding. The automatic magnetic retention function prevents plate falling, greatly improving the efficiency of blanking, positioning and transportation on production lines.
Strict Non-standard Manufacturing & Quality Control
As a special non-standard lifting equipment for large shipyards, the crane adopts high-strength steel structure and full weld non-destructive testing technology. After 90 days of refined manufacturing, full-load testing, electromagnetic safety inspection and overall linkage commissioning are completed before delivery, fully meeting the high-frequency heavy-duty production standards of shipbuilding industry.
One-time Acceptance & Stable Mass Production
The equipment passed load detection and safety acceptance in one single pass after arrival. Dual operation modes adapt to shipyard assembly line operation with stable running and precise positioning. Complete safety interlocks ensure continuous and stable production of the whole process of marine steel plate blanking, cutting and transportation.
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 high-toughness Q355 low-alloy structural steel with A7 high working class designed for 24-hour uninterrupted shipyard hoisting. All load-bearing welds pass 100% ultrasonic non-destructive testing. Featuring high bearing rigidity, the crane shows no obvious deflection during synchronous lifting of multiple thick steel plates and can withstand long-term alternating heavy loads, adapting to mass continuous transportation of marine plates. The whole machine adopts Dafang’s signature industrial yellow topcoat and three-layer epoxy anti-rust coating to resist corrosion caused by workshop moisture and metal dust.
360° Rotary Electromagnetic Hanging Beam System
The core is equipped with Dafang self-developed QCL rotary electromagnetic hanging beam, which realizes stable 360° stepless rotation to accurately adjust steel plate angles for accurate blanking on CNC cutting tables. Multiple high-strength electromagnetic suckers adopt zoned independent control, supporting single-sucker light lifting for thin plates and multi-sucker synchronous grabbing for multiple thick marine plates. It eliminates manual steel wire rope binding, greatly reducing labor costs and plate collision & scratch risks. Equipped with a power-off magnetic retention device, the suckers can maintain magnetism for 15 minutes in case of sudden power failure, completely avoiding high-altitude steel plate falling accidents.
Moisture-proof and Dust-proof Variable-frequency Electrical System
The ship processing workshop features high humidity and dense iron powder dust. The complete electrical system is specially upgraded for shipyard protection. The IP65-grade control cabinet is built with dehumidifying and heating modules to prevent condensation and short circuits. Travelling, hoisting and rotating mechanisms adopt variable-frequency speed regulation for smooth start and stop without impact. Full sets of safety interlock devices including overload protection, power-off magnetic retention, height limit, travel limit, emergency stop and wind speed monitoring are equipped. Dual operation modes of cab control and wireless remote control comply with shipbuilding safety specifications. The matched sliding cable towing system moves synchronously with the rotating beam to avoid cable pulling and winding, extending the service life of electrical accessories.
Modular Detachable Hanging Beam for Multi-specification Handling
The electromagnetic hanging beam adopts a detachable modular structure with adjustable sucker spacing, suitable for transporting wide hull steel plates as well as narrow marine section steels, flat steels and flange components. Buffer anti-collision devices are installed on both sides of the beam to avoid collision with workshop columns and cutting equipment during operation. The travelling and hoisting speeds have two gears (fast and slow). The fine adjustment mode realizes precise positioning for cutting tables, greatly improving the overall production capacity of the shipyard plate processing line.
On-Site Delivery & After-Sales
The complete QCL electromagnetic overhead crane is divided into multiple modules including main girder, hoisting trolley, rotary electromagnetic hanging beam and electric control system for transportation to Samsung Heavy Industries’ factory. Our professional installation team completed full on-site construction procedures including main girder splicing, track calibration, sucker wiring, synchronous rotation commissioning and full-load pressure testing. Complete sets of inspection documents such as steel material reports, non-destructive testing certificates, third-party electromagnetic safety test reports and factory qualification certificates were delivered for safety filing.
Special on-site training was provided for crane operators and maintenance teams, covering magnetic retention operation specifications, daily maintenance in humid and dusty environments, and rotating mechanism maintenance guidelines. 7×24-hour full-cycle remote technical support and sufficient original core accessories (suckers, frequency converters, cables, etc.) ensure uninterrupted operation of the shipyard plate processing workshop.
Summary
The QCL rotary electromagnetic overhead crane delivered to Samsung Heavy Industries is a special heavy-duty lifting equipment developed by Dafang Heavy Machinery for shipbuilding and steel plate processing industries. Integrating three core advantages of 360° rotary electromagnetic suction, high-frequency heavy-duty structure and moisture-proof & dust-proof electric control, it effectively solves the industry pain points of low thick steel plate transportation efficiency and high manual binding risks in shipyards.
Dafang Heavy Machinery can customize 5t~120t electromagnetic hanging beam overhead cranes, grab cranes and metallurgical overhead cranes for shipbuilding and steel structure processing 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 lifting equipment demands in plate processing and shipbuilding industries.
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