Tuesday 12th September 2023
A team of three engineers from our service division, (Ciaran Clarke, Shane Horan, Shane Butler) undertook this intricate project to fulfill the unique requirements of our client. What set this project apart was the need to construct the cranes entirely from scratch on-site, an evidence to our commitment to tailored solutions. From the intricate festoon systems to the essential lead trolley arms, everything was meticulously crafted to perfection right where it was needed. Below details about the project will take you through the journey, step by step, to understand the complexities and nuances of this remarkable project.
Building from Scratch: Bespoke Crane Fabrication
The foundation of this project lies in the specialised need of our client from the construction sector. To meet these unique requirements, we embarked on the task of constructing two overhead cranes entirely from scratch, right on the customer's site. This approach allowed us to ensure that every aspect of the cranes, from design to execution, was tailored to the precise specifications provided by the client.
On-Site Fabrication: From Festoon Systems to Lead Trolley Arms
One of the standout features of this project was the comprehensive on-site fabrication process. It's essential to understand the critical components that made this project a success:
Festoon Systems: These systems were crafted on-site to ensure uninterrupted power and control signal supply to the moving components of the cranes. Festoon systems are vital for mobile equipment like overhead cranes as they enable seamless power transmission while the equipment is in motion.
Talking more about festoon system : They crucial components in the operation of overhead cranes and other mobile equipment that require the continuous supply of electrical power, control signals, or pneumatic lines while in motion. It is essentially a system of cables or hoses that are suspended in a loop or festooned fashion between a fixed point (often a trolley or bridge) and a moving component, such as the hoist or trolley of an overhead crane.
Lead Trolley Arms: Lead trolley arms, also known as conductor bars or conductor rails, were meticulously manufactured on the customer's site. These essential components play a crucial role in delivering electrical power to the moving parts of the crane, such as the hoist and trolley. ensuring smooth and precise motion. Lead trolley arms are typically installed along the runway or crane bridge and are in direct contact with the trolley or moving carriage.
Comprehensive On-Site Wiring
Wiring is the lifeblood of any electrical system, and in crane operations, it's no different. Recognising the critical role of electrical connections, our team executed a complete hard-wiring process on-site. This approach not only guaranteed a secure and reliable electrical connection but also simplified future maintenance and troubleshooting. It's worth noting that hard-wiring provides greater durability and reduces the risk of loose connections compared to alternative methods.
Rigorous Load Testing for Safety and Reliability
Safety is paramount in crane installation. Before the cranes were put into active service, our team conducted rigorous load testing to ensure their reliability and safety. Load testing involves subjecting the crane to loads that simulate real-world operating conditions. This testing process helps identify any potential issues and ensures that the crane can handle its designated capacities without compromising safety.
Project Components:
- Crane Kit,
- Electricity Panel,
- Enclosed Busbar System,
- Low Headroom Monorail Hoist,
- C Rail Kit
Each component used in this project played a critical role in the overall success of the crane installation. Let's dive deeper into each of these components:
Crane Kit: The crane kit formed the backbone of the project. It included essential components such as the hoist, trolley, and bridge. These components were carefully selected to meet the specific requirements of the project, ensuring optimal performance and reliability.
Electricity Panel for the Crane: A customized electricity panel was designed and installed to manage the power supply to the cranes. This panel serves as the nerve center of the crane's electrical system, providing a stable and reliable source of electricity to power the crane's motors and equipment.
Enclosed Busbar System: The enclosed busbar system was a crucial part of the electrical infrastructure. It provided a safe and efficient means of delivering power to the crane. The enclosed design protects against environmental factors, reducing the risk of electrical issues.
Low Headroom Monorail Hoist: The hoist used in this project was a low headroom monorail hoist with a remarkable capacity of 3200 kg and a height of lift reaching 7 meters. Its tapered rotor and conical motor type ensure smooth and precise operations, making it a key component for heavy-duty lifting.
C Rail Kit: The C rail kit provided the necessary guidance and stability for crane movement along the rails. This component is essential for ensuring that the crane operates smoothly and safely.