Discover the crucial components of an overhead crane
An overhead crane is a sophisticated assembly of mechanical and electronic components. For engineers and safety coordinators, understanding this composition is essential for both safety and efficiency. This article analyzes the full anatomy of the crane: from the basic structure (girders) and the hoisting mechanism to the indispensable infrastructure (power supply) and controls. Mennens combines technical depth with practical maintenance advice.
Key insights
- The Backbone: Crane girders and end carriages form the basic structure and determine the range.
- Hoisting Mechanism: Hoists, winch units, and trolleys ensure the actual movement of the load.
- The Infrastructure: Power supply (conductor bars) and crane runways are essential for the system's operation.
- The Brain: The control panel coordinates all electronic components and monitors safety.
- Operation: Radio remote control is the new standard (90% of cases) for safety and flexibility.
1. The basic structure
1.1. Crane girders and end carriages
The basic structure of an overhead crane consists of the crane girders and the end carriages that guarantee stability. These are the largest physical parts of the installation.
1.2. The crane girders (the backbone)
The crane girders form the absolute backbone of the overhead crane. A crane can consist of one or two girders, depending on the required lifting capacity. The length of these girders is what we call the span. The hoists that perform the heavy lifting move along these girders.
1.3. The end carriages
The crane girders are connected at the ends to robust end carriages (also known as end trucks). These end carriages ensure that the entire crane construction can travel smoothly along the crane runway. Without properly functioning end carriages, the horizontal movement (long travel) of the overhead crane is impossible.
2. The hoisting components
2.1. Hoists, Winch Units, and Trolleys
The hoisting components are the primary mechanisms that actually lift and position the load. These technical modules determine the operational capacity of the installation.
- Hoists and Winch Units: These components deliver the lifting force. They are equipped with a hook block or bottom block to safely rig the load.
- The Trolley: The trolley ensures transverse movement (cross travel). This mechanism enables the hoist or winch unit to travel along the length of the crane girder(s).
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3. The infrastructure
3.1. Power supply and crane runway
An overhead crane never functions in isolation; it is part of an integrated system. To fully understand its operation, we must look at the energy supply and the track on which the components move.
- Power Supply: The energy supply to the crane and the trolley is typically handled via a conductor bar system (safety power rail) or a C-rail system with cable trolleys (festoon system). This guarantees a constant and safe power supply to the electrical components during travel.
- The Crane Runway: The end carriages move over specific crane rails mounted on the runway girders. The choice of rail type and its precise alignment are decisive factors in crane wheel wear and travel behavior.
4. Controls and safety
4.1. The control panel
The control panel acts as the electronic brain of the overhead crane. This switch cabinet controls all individual crane components.
The cabinet contains high-quality electronic components and wiring to coordinate movements with precision. Additionally, crucial safety mechanisms are built in here. Modern control systems from Mennens significantly increase the precision of the lifting job. Furthermore, these systems minimize risks for the operator on the shop floor.
5. Operating the overhead crane
The method of operation determines how flexibly and safely the operator can work with the overhead crane. The major advantage of an overhead crane is its range: the hoist hook can be moved in almost all directions (X, Y, and Z axes).
We distinguish between two main forms of operation:
| Type of operation | Characteristics | Advantage |
| Pendant control | Wired connection (the "pendant station"). | Robust and directly connected. |
| Radio Remote Control (RRC) | Wireless remote operation. | Maximum freedom of movement and safety. |
The Mennens standard
Mennens sees a clear shift in the market. Approximately 90% of the new cranes delivered by Mennens are now operated via Radio Remote Control. This allows the operator to always choose a safe position with a clear view relative to the load.
6. Maintenance and inspection
Guarantee continuity
Regular maintenance is vital to ensure the efficiency and safety of the overhead crane. Cranes often play a key role in business operations. Downtime costs money immediately.
A well-maintained overhead crane offers three concrete benefits:
- Longer lifespan of the installation.
- Minimal downtime through preventive detection of defects in critical parts.
- Maximum safety and reduced risk of accidents.
As an EKH-certified company, Mennens ensures that your installations meet the strictest legal requirements.
Conclusion
The various parts of an overhead crane work together integrally to safely move heavy loads. Knowledge of these components—from girder and conductor bar to control panel—contributes to more effective use. This directly increases productivity and safety in your industrial environment.
Does your crane need inspection, or are you looking for advice on a new installation? Contact your nearest Mennens branch. Our experts are ready with technical advice and decisive support.
Frequently asked questions (FAQ)
What is the difference between a single and double girder overhead crane?
A single-girder crane is lighter and more compact, suitable for lighter loads. A double-girder construction offers more stability, a higher lifting capacity, and a greater lifting height, making it ideal for heavy industrial applications.
How often must an overhead crane be inspected?
According to the Working Conditions Decree (Arbobesluit) and EKH guidelines, an overhead crane must be fully mechanically inspected and tested by an expert at least once a year. Additionally, a test with a test load of 125% of the working load limit (WLL) is mandatory upon commissioning or after major repairs or modifications.
Why do most companies choose radio remote control?
Radio remote control offers the crane operator the freedom to choose the safest position with the best overview while lifting and moving the load. The operator does not have to walk right next to the load, which improves visibility and reduces the risk of entrapment or collision.
Can I equip my existing overhead crane with radio remote control?
Yes, it is possible to install radio remote control on your existing crane. For this so-called "Retrofit," a receiver is installed on the existing control panel, and the transmitter used by the operator can be equipped with push buttons or joysticks. Specific technical knowledge of electricity is required for installation, and a re-inspection of the crane may be necessary afterward. We therefore recommend having this performed by an expert or specialist. Mennens can handle the conversion for you so that you can be sure your crane complies with the latest laws and regulations.
