Modular crane v.s. Process crane: Overhead crane & Gantry crane

Modular cranes and process crane, which is right for your application? After amount of engineering and fabrication, Dongqi crane will offer you the most suitable overhead crane, gantry crane, and jib crane or other workshop cranes either it is process crane or modular crane.

Is an overhead crane needed for to the workshop in your facility? What is the right overhead crane for your application, the modular crane or the process crane (also called the engineered crane)?

The main difference between a modular crane system and a process crane is the amount of engineering required to design and build the bridge crane system. Special consideration has to be given to:

• The lifting application
• Working environment
• Actual usage and runtime
• Budget
• Any additional features or add-ons required

What is an overhead modular crane system?

Single girder overhead crane v.s Double girder overhead crane  - Dongqi types of cranes for sale 

An overhead modular crane is a pre-engineered overhead crane system, including all the bridge crane components and parts, but without the excluding the bridge girder(s) and the paint system.

These pre-engineered process cranes do not need particular designs for a specific process but for the general purpose material handling. The modular cranes has the following typical features, such as

Low crane duty, low load handing capacity within 10 ton, with more standards span and runway ranges, low travelling speeds and operated in a low frequency.

What’s more, the crane components and parts of the modular cranes are off-the-shelf parts, which includes crane electrification, crane controls, electric hoist, crane motors, and drives, etc.

The off-the-shelf crane components and cranes parts can go match with the pre- specified ranges of crane capacity, crane span, and application, etc.

The modular cranes can be top running crane design or under running crane design. The crane bridge girders can be configured in a single girder crane design or double girder crane design and are manufactured to order according to the required span and capacity of the crane system.

When modular cranes are recommended?

Modular cranes are widely used in general industrial, and light manufacturing industries, maintenance and machine workshops, etc.

A modular crane systems are recommended when the following factors are fulfilled:

• Usage: For general material handling in a common facility. The crane system is not required for material handling work than average speed, average capacity, and basic controls.
• Application: Modular cranes I are widely used in general industry or light manufacturing/maintenance facilities.
• Price: Modular cranes are much more economical and short-term solution, which can be delivered quickly.
• Short production time: After all the confirmation of the crane order and drawing, a modular crane system can be manufactured and delivered in a very short time.

Modular + Engineering crane systems

“ Modular + engineering” crane system is between the modular crane system and a fully engineered process crane.

Features of modular + engineering crane system

The modular + engineering crane system is composed of off-the-shelf components, and engineering components designed based on the customer’s requirements and applications requirements.

• Durable working life of modular cranes.
• Prevent premature wear on crane components.
• Good return on the initial investment.
• Reduce vibration.
• Utilize a below-the-hook lifting device.

How to get the most out of modular crane system

Modular crane system is the most economical solution for many business owners. Once the modular crane system is fully fits your usage, application, budget and delivery requirements, then it would be a good crane system for you.

How to get your modular crane system a good return on your investment?

• Inspect and maintain your crane systems based on the plan recommended by the crane manufacturer.
• Make sure the crane system is precisely applied to the crane service duty classification.
• Operated the modular crane system as it is supposed to be used.

During overhead crane designing, special consideration is required for the future usage requirements, such as, the higher capacity lifts or an increase in the number of lifts per day in the future. )

Over-specify a crane system, the initial cost for the crane and runway system may be higher, but the maintenance cost will lowered in a long terms. , If your crane system is being over-used, or was under specified to begin with, the cost of the maintenance, service, and repair may cost more.

Since the off-the-shelf components are used in the modular crane system, the working life of the included parts will influence the performances of crane system. Then the sustainable supply of the crane components need to be guaranteed or it may cost longer breakdown time or cost much to purchase it which may not be worthy, comparing with buying a new crane system.

Attention: On the crane system buying, it should take the total cost of crane system in 3-5 years or even 10 years in the long run. If you have any doubt or question, please feel free to contact us. Or leave a message below.

What is an engineered / process crane?

Process crane for steel industry 

Process cranes are designed and fabricated, based on the specific requirements and applications. The process crane is highly engineered crane system, which is designed to withstand the rigors and high crane duty service in a critical lifting action over and over again.

Benefits of process cranes

• High efficiency and safety;
• Faster speed and more lifts within a production shift;
• High precision controls;
• High engineered components and systems with more durable life.

Features of process crane

• Higher capacity;
• Higher duty cycle;
• High requirement of material handling requirements;
• Handling materials at a fast working speed, with more precision compared with a modular crane;
• Automated drives to control the speed and motion of the crane;
• Collision avoidance systems when multiple cranes are in operation;
• Use of below-the-hook lifting devices;
• Remote monitoring and diagnostics;
• Overload sensors and read-outs;
• Brake slip detection;
• Less mechanical wear and maintenance.

Process cranes applications

For certain applications, the process cranes is required for heavy duty material handling, which usually are the following industries and workshops:

• Steel mills / steel processing facilities –such as, hot metal cranes, coil/bar/plate lifters, shipping and receiving cranes, magnetic scrap handling, etc.
• Die handling and automotive stamping facilities.
• Galvanizing facilities or other chemically active environments.
• Paper mills.
• Powerhouse and energy facilities.
• Explosion-proof environments.
• Bulk material handling or distribution.

Why need process crane system?

An engineered crane system is focused on the design which is individualized by a specific process or unique lifting application. One processed engineered crane system may highly differentiate with the other even though with the same specs or components as a similar capacity crane used in a steel mill or a paper mill.

When to process crane is highly required?

• Usage:The usage of process crane is various. Usually, the process crane is often used in in near-constant, or constant use, or will be operated at faster speeds, or fulfilla very precise and critical lift.
• Application:Process crane can be used in a wide range of applications. Usually, the process cranes are used in the applications such as, steel mills and related processing facilities, paper mills, power station, high-output manufacturing plant and factory, distribution centers, and bulk material handling applications and other industrial applications, etc.
• Price:The price of process crane or engineered cranes are much more expensive than a pre-engineered crane system because of the complexity of process crane design, estimating, engineering, and production and installation, etc.
• Lead Time:The lead time of process engineered crane will be longer than that of modular cranes for the sourcing of the individualized components, the designing, fabrication, and assembly of the engineered crane will take more times.

Engineered / Process Crane Components

On an engineered overhead crane system, each components of the process crane is given high consideration. On this occasion, each specialized and robust component is designed to meet the strict requirements of crane design and production.

Engineered cranes could offer these advantages to final users:

For variable speeds and strict load control, the encoders and flux vectors are used on the motors.

• More robust radio systems makes the diagnostics and multiple crane operation possible.
• High speed operation of the bridge, trolley and hoist is possible.
• Load control and placement is with high precision.
• Applied to specialized environments with features such as, corrosion resistance or spark resistance.