Introduction

The client, a prominent player in the shipbuilding industry, is renowned for constructing modular vessels, including aircraft carriers and large-scale industrial ships. Modular shipbuilding requires advanced precision and robust lifting infrastructure to handle massive ship sections. However, this competitive sector demands continuous innovation to overcome operational constraints and meet industry standards.

The Problem

Before implementing the solution, the client faced several critical challenges, including:

• Limited Lifting Capability: The client’s existing infrastructure lacked segmented lifting capabilities for hull sections ranging from 100 to 2500 tons.
• Inefficient Modular Processes: Ship segments often required precise lifting and turning operations to enable modular assembly. The absence of such capability frequently disrupted production workflows, resulting in delays and increased costs.
• Higher Costs and Reduced Precision: Without proper lifting mechanisms, the client resorted to expensive segmented transportation solutions, while the accuracy of ship closures suffered, with welding errors exceeding the industry-standard limit of 2mm. This hindered structural strength and ship performance.
• Impact on Major Projects: Projects like assembling 21 modules on the Liaoning aircraft carrier relied on advanced lifting infrastructure. The challenges forced the client to confront inefficiencies that directly threatened the success and competitiveness of such landmark projects.

The Solution

To address these challenges, a shipbuilding gantry crane was developed and implemented as a custom solution specifically designed for the client’s needs. These highly specialized cranes bring unparalleled segmented lifting and turning functionalities to shipbuilding operations. Key aspects of the solution include:

1. Advanced Design and Engineering 

The gantry crane features a unique design to maximize operational flexibility:

• Rigid & Flexible Support Legs: One rigid leg is fixed securely to the main beam, while the other flexible leg uses a hinged connection to facilitate superior weight distribution on large-span operations.
• Single & Double Main Beam Options: Depending on the modular shipbuilding requirements, the crane supports both single and double main beam configurations to achieve precision operations.

2. Comprehensive Functionality 

The shipyard gantry crane is equipped with advanced capabilities, including:

• Single-Hook and Multi-Hook Operations: Enable single-hook lifts or synchronously controlled multi-hook lifts for efficient handling of ship sections.
• Airborne Flipping & Rotation: Allows precise flipping and micro-adjustments of ship segments in mid-air to meet modular assembly demands.
• Dual Trolley System: The crane uses upper and lower trolleys operating on separate tracks to ensure seamless mobility. The lower trolley can even pass under the upper trolley for added flexibility.

Results

By adopting the shipbuilding gantry crane, the client achieved transformational results:

• Enhanced Precision: Welding error margins were reduced to below industry-standard limits, greatly improving the structural integrity and accuracy of ship closures.
• Streamlined Processes: Modular assembly workflows became smoother and more efficient, avoiding unnecessary production interruptions.
• Cost Efficiency: Eliminated the need for costly segmented transportation solutions, generating significant savings over time.
• Improved Competitiveness: The client was able to meet the complex demands of high-profile projects like the Liaoning aircraft carrier assembly, solidifying their position as a leading innovator in the shipbuilding industry.

“Now, we can efficiently lift and assemble ship sections with precision never thought possible. The gantry crane has elevated not only our production capacity but also our reputation in the industry,” said a representative from the client’s engineering division.