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Welcome to Jaes Company’s YouTube channel! Today we’re going to explore a fundamental machine in many production settings: the overhead crane. Often, when we think of large industrial plants or complex factories, we overlook how many devices are necessary to move heavy materials safely. The overhead crane (or bridge crane) is one of those essential devices.
But what exactly is an overhead crane? What is it used for? How is it made? And above all, how does it work? In this video, we will answer all these questions, show you the structure of an overhead crane, and walk you through its main components and how they work.
________________________________________
Why Is the Overhead Crane So Important?
Imagine having to move loads of several tons inside a warehouse: doing so manually would be unthinkable, both for safety and productivity. This is where the overhead crane comes in—a highly versatile lifting system consisting of a horizontal structure (the bridge) running on two tracks placed on either side of the work area.
Its main purposes:
- Lifting and transporting very heavy loads (like metal sheets, coils, industrial components, containers, etc.).
- Reducing risks related to manual handling by using controlled lifting systems with safety features.
- Enhancing the efficiency of industrial processes by speeding up loading/unloading of raw materials and finished products.
________________________________________
Structure of an Overhead Crane
Although it may seem a complex machine, an overhead crane is composed of a few key components each of which plays a crucial role in the lifting process.
Let’s explore together the key components:
1. Runways
The runways are the supporting structures on which the overhead crane’s movement system is installed. These are typically beams fixed onto the load-bearing columns of the building or onto an independent structure.
The quality and maintenance of the runways are fundamental to ensuring the correct operation of the crane, preventing vibrations and abnormal wear.
Sliding rails are installed on these runways, allowing the crane to move along them.
2. Sliding Rails (Tracks)
The sliding rails are metal tracks fixed onto the runways. They serve as a guide for the crane’s wheels, allowing it to move smoothly and in a controlled manner along the work area.
The crane’s end carriages, which support the entire structure, run along these rails.
3. Conductor Line (Insulated Conductor Bar System)
The overhead crane requires a continuous supply of electric power to operate. The conductor line system consists of copper conductors enclosed in a protective casing, ensuring a stable, uninterrupted power supply along the entire length of the runway.
The conductor trolley, equipped with copper contact shoes, runs along these conductors and ensures the transmission of energy.
It powers the electrical panel that manages the control system and drives the motors.
4. End Carriages
The end carriages are structural components located at both ends of the crane. They house the motorized wheels that allow the crane to travel along the sliding rails.
They support the bridge and enable its movement along the runways.
5. Bridge or Main Girder
The bridge is the horizontal structural element that connects the two end carriages and spans the working area.
It can be made of a single girder (single girder crane) or two girders (double girder crane), depending on the load capacity and operational needs.
The hoisting trolley moves along the bridge, carrying the hoist or winch.
6. Hoisting Trolley
The hoisting trolley moves along the bridge and carries the hoist or winch, which is responsible for lifting the load.
It can be operated to position itself precisely above the lifting point.
7. The Hoist or the Winch
This is the heart of the lifting system. The hoist, or electric winch, is equipped with a motor that drives a drum around which a wire rope or chain is wound. At the end of this rope or chain is the lifting hook.
Thanks to this component, the load can be raised and lowered.
Hoist: Ideal for small to medium loads, it is designed with the motor, gearbox, and wire drum aligned along the same axis, ensuring a compact structure suitable for less demanding handling operations.
Winch: Used for heavier loads, it features a configuration where the motor, gearbox, and wire drum are arranged separately, in order to better distribute loads, reduce wear, and guarantee greater strength and long-term durability.
8. Brakes
Brakes are essential components for the safety of the overhead crane, as they ensure the stopping of movement and the holding of the load in position.
Braking can rely solely on electric motors through inverters (electronic brakes), or be supported by actual mechanical brakes (electromechanical brakes), to guarantee safe stopping and holding of the load.
9. Control System
The control system includes the command interfaces (pendant control, radio remote control, or operator cabin), frequency converters (inverters), and other devices that ensure safe and reliable operation.
It allows the operator to control speeds and movements safely and precisely.
The system manages all crane movements: bridge travel, trolley movement, and load lifting.
But what exactly is an overhead crane? What is it used for? How is it made? And above all, how does it work? In this video, we will answer all these questions, show you the structure of an overhead crane, and walk you through its main components and how they work.
________________________________________
Why Is the Overhead Crane So Important?
Imagine having to move loads of several tons inside a warehouse: doing so manually would be unthinkable, both for safety and productivity. This is where the overhead crane comes in—a highly versatile lifting system consisting of a horizontal structure (the bridge) running on two tracks placed on either side of the work area.
Its main purposes:
- Lifting and transporting very heavy loads (like metal sheets, coils, industrial components, containers, etc.).
- Reducing risks related to manual handling by using controlled lifting systems with safety features.
- Enhancing the efficiency of industrial processes by speeding up loading/unloading of raw materials and finished products.
________________________________________
Structure of an Overhead Crane
Although it may seem a complex machine, an overhead crane is composed of a few key components each of which plays a crucial role in the lifting process.
Let’s explore together the key components:
1. Runways
The runways are the supporting structures on which the overhead crane’s movement system is installed. These are typically beams fixed onto the load-bearing columns of the building or onto an independent structure.
The quality and maintenance of the runways are fundamental to ensuring the correct operation of the crane, preventing vibrations and abnormal wear.
Sliding rails are installed on these runways, allowing the crane to move along them.
2. Sliding Rails (Tracks)
The sliding rails are metal tracks fixed onto the runways. They serve as a guide for the crane’s wheels, allowing it to move smoothly and in a controlled manner along the work area.
The crane’s end carriages, which support the entire structure, run along these rails.
3. Conductor Line (Insulated Conductor Bar System)
The overhead crane requires a continuous supply of electric power to operate. The conductor line system consists of copper conductors enclosed in a protective casing, ensuring a stable, uninterrupted power supply along the entire length of the runway.
The conductor trolley, equipped with copper contact shoes, runs along these conductors and ensures the transmission of energy.
It powers the electrical panel that manages the control system and drives the motors.
4. End Carriages
The end carriages are structural components located at both ends of the crane. They house the motorized wheels that allow the crane to travel along the sliding rails.
They support the bridge and enable its movement along the runways.
5. Bridge or Main Girder
The bridge is the horizontal structural element that connects the two end carriages and spans the working area.
It can be made of a single girder (single girder crane) or two girders (double girder crane), depending on the load capacity and operational needs.
The hoisting trolley moves along the bridge, carrying the hoist or winch.
6. Hoisting Trolley
The hoisting trolley moves along the bridge and carries the hoist or winch, which is responsible for lifting the load.
It can be operated to position itself precisely above the lifting point.
7. The Hoist or the Winch
This is the heart of the lifting system. The hoist, or electric winch, is equipped with a motor that drives a drum around which a wire rope or chain is wound. At the end of this rope or chain is the lifting hook.
Thanks to this component, the load can be raised and lowered.
Hoist: Ideal for small to medium loads, it is designed with the motor, gearbox, and wire drum aligned along the same axis, ensuring a compact structure suitable for less demanding handling operations.
Winch: Used for heavier loads, it features a configuration where the motor, gearbox, and wire drum are arranged separately, in order to better distribute loads, reduce wear, and guarantee greater strength and long-term durability.
8. Brakes
Brakes are essential components for the safety of the overhead crane, as they ensure the stopping of movement and the holding of the load in position.
Braking can rely solely on electric motors through inverters (electronic brakes), or be supported by actual mechanical brakes (electromechanical brakes), to guarantee safe stopping and holding of the load.
9. Control System
The control system includes the command interfaces (pendant control, radio remote control, or operator cabin), frequency converters (inverters), and other devices that ensure safe and reliable operation.
It allows the operator to control speeds and movements safely and precisely.
The system manages all crane movements: bridge travel, trolley movement, and load lifting.
How Does an Overhead Crane Work?
An overhead crane operates through three key movements:
1. Bridge Travel
The bridge moves horizontally along the tracks installed at the top of the facility’s structure.
This movement allows the crane to cover the entire length of the working area, enabling wide-range positioning over the space below.
2. Trolley Traversing
Mounted on the bridge girder, the trolley—which supports the hoist—can move from one end to the other.
This motion allows the lifting hook to be positioned precisely where it’s needed, ensuring accurate and efficient load handling.
3. Lifting and Lowering the Load
The electric hoist (or winch) raises and lowers the load attached to the hook, allowing the operator to move the heavy object vertically.
Thanks to this movement, items can be lifted from the ground and carefully placed at their destination.
By combining these, the crane can reach any point within its working area, ensuring accuracy and speed.
________________________________________
Safety and Maintenance
Like any industrial machinery designed for handling heavy loads, the overhead crane must comply with strict safety standards—both during installation and throughout its operation.
Let’s take a look at some of the key aspects:
• Regular Inspections
Routine checks and testing of ropes, chains, hooks, and locking systems are essential to prevent mechanical failures or structural breakdowns.
• Non-Destructive Testing (NDT)
Techniques such as ultrasonic testing, magnetic particle inspection, or dye penetrant testing are employed to detect internal or surface defects without damaging the components. These tests also help estimate the remaining lifespan of the crane, supporting maintenance planning and preventing unexpected failures.
• Load Limiting Devices
These safety systems prevent the crane from lifting weights beyond its maximum rated capacity, thereby avoiding hazardous and damaging overloads.
• Limit Switches and Safety Sensors
These devices intervene to stop movement when a limit position is reached or when a hazardous condition arises, significantly reducing the risk of accidents.
• Operator Training
Personnel must be trained in the correct use of the crane, in reporting any anomalies, and in the proper use of personal protective equipment to ensure maximum safety during operations.
In addition, the ongoing maintenance of motors, hoists, ropes, bearings, and control systems is vital to guarantee long-term efficiency and operational safety.
________________________________________
Crane Duty Classes
Overhead cranes are classified according to their intended usage intensity and expected operational lifespan.
This classification—ranging from A1/M1 to A8/M8 (based on FEM and ISO standards, which are often used together but follow different criteria)—helps determine which crane best suits specific industrial requirements:
• A1/M1: Designed for very occasional use, such as rare load movements (e.g., once per year).
• A4/M4: Ideal for mechanical workshops and general industrial environments with moderate use, where the crane is operated regularly but without extreme loading.
• A8/M8: Intended for highly demanding sectors, such as steel mills, where the crane must operate intensively and handle heavy loads continuously.
Over time, due to natural wear and tear, cranes can be reclassified into a lower duty class.
This process makes it possible to extend its operational life at the expense of maximum capacity or frequency of use, while still ensuring safe operation of the machinery in compliance with current regulations.
________________________________________
Types of Overhead Cranes
Depending on the application, there are several types of overhead cranes available:
• Single Girder Crane: Ideal for light to medium loads, featuring a simpler structure and lower cost.
• Double Girder Crane: Suitable for higher capacities, offering greater stability and the ability to handle very heavy loads.
• Suspended Crane: The bridge runs on tracks mounted to the ceiling, optimizing the use of floor space.
• Jib Crane: While not strictly an overhead crane, it is a similar lifting solution, featuring a rotating arm mounted on a column.
The choice of crane depends on the size of the facility, the required load capacity, available headroom, and specific production needs.
________________________________________
The overhead crane is truly essential in many industries—from steelworks to logistics, from refineries to the food industry. Its ability to safely lift enormous loads and move them precisely within a defined area makes it an indispensable partner in any medium or large industrial plant.
If you found this video useful, let us know with a like and a comment, share it, and don’t forget to subscribe to our channel.
An overhead crane operates through three key movements:
1. Bridge Travel
The bridge moves horizontally along the tracks installed at the top of the facility’s structure.
This movement allows the crane to cover the entire length of the working area, enabling wide-range positioning over the space below.
2. Trolley Traversing
Mounted on the bridge girder, the trolley—which supports the hoist—can move from one end to the other.
This motion allows the lifting hook to be positioned precisely where it’s needed, ensuring accurate and efficient load handling.
3. Lifting and Lowering the Load
The electric hoist (or winch) raises and lowers the load attached to the hook, allowing the operator to move the heavy object vertically.
Thanks to this movement, items can be lifted from the ground and carefully placed at their destination.
By combining these, the crane can reach any point within its working area, ensuring accuracy and speed.
________________________________________
Safety and Maintenance
Like any industrial machinery designed for handling heavy loads, the overhead crane must comply with strict safety standards—both during installation and throughout its operation.
Let’s take a look at some of the key aspects:
• Regular Inspections
Routine checks and testing of ropes, chains, hooks, and locking systems are essential to prevent mechanical failures or structural breakdowns.
• Non-Destructive Testing (NDT)
Techniques such as ultrasonic testing, magnetic particle inspection, or dye penetrant testing are employed to detect internal or surface defects without damaging the components. These tests also help estimate the remaining lifespan of the crane, supporting maintenance planning and preventing unexpected failures.
• Load Limiting Devices
These safety systems prevent the crane from lifting weights beyond its maximum rated capacity, thereby avoiding hazardous and damaging overloads.
• Limit Switches and Safety Sensors
These devices intervene to stop movement when a limit position is reached or when a hazardous condition arises, significantly reducing the risk of accidents.
• Operator Training
Personnel must be trained in the correct use of the crane, in reporting any anomalies, and in the proper use of personal protective equipment to ensure maximum safety during operations.
In addition, the ongoing maintenance of motors, hoists, ropes, bearings, and control systems is vital to guarantee long-term efficiency and operational safety.
________________________________________
Crane Duty Classes
Overhead cranes are classified according to their intended usage intensity and expected operational lifespan.
This classification—ranging from A1/M1 to A8/M8 (based on FEM and ISO standards, which are often used together but follow different criteria)—helps determine which crane best suits specific industrial requirements:
• A1/M1: Designed for very occasional use, such as rare load movements (e.g., once per year).
• A4/M4: Ideal for mechanical workshops and general industrial environments with moderate use, where the crane is operated regularly but without extreme loading.
• A8/M8: Intended for highly demanding sectors, such as steel mills, where the crane must operate intensively and handle heavy loads continuously.
Over time, due to natural wear and tear, cranes can be reclassified into a lower duty class.
This process makes it possible to extend its operational life at the expense of maximum capacity or frequency of use, while still ensuring safe operation of the machinery in compliance with current regulations.
________________________________________
Types of Overhead Cranes
Depending on the application, there are several types of overhead cranes available:
• Single Girder Crane: Ideal for light to medium loads, featuring a simpler structure and lower cost.
• Double Girder Crane: Suitable for higher capacities, offering greater stability and the ability to handle very heavy loads.
• Suspended Crane: The bridge runs on tracks mounted to the ceiling, optimizing the use of floor space.
• Jib Crane: While not strictly an overhead crane, it is a similar lifting solution, featuring a rotating arm mounted on a column.
The choice of crane depends on the size of the facility, the required load capacity, available headroom, and specific production needs.
________________________________________
The overhead crane is truly essential in many industries—from steelworks to logistics, from refineries to the food industry. Its ability to safely lift enormous loads and move them precisely within a defined area makes it an indispensable partner in any medium or large industrial plant.
If you found this video useful, let us know with a like and a comment, share it, and don’t forget to subscribe to our channel.