Executive Summary  

A manufacturing company specializing in black metal handling faced challenges in loading, unloading, and precision material handling. Their traditional hook-style system was inefficient, and the high temperatures of their materials demanded advanced solutions. By adopting an electromagnetic bridge crane with specialized design features, the company increased operational efficiency by 40%, achieved millimeter-level positioning accuracy, and successfully managed high-temperature black metal materials.  

The client, a prominent name in the black metal manufacturing industry, was seeking a solution to automate and optimize their material handling processes. With a diverse product line, including steel plates, ingots, and steel bars, their operations involved frequent loading, unloading, and assembly. Meeting market demands for precision, speed, and safety required innovative approaches in handling these heavy, magnetic, and often high-temperature materials.  

The Problem  

Before implementing the solution, the company faced three primary challenges:

1. Inefficient Material Handling

   Traditional hook-style lifting mechanisms were slowing down their loading and unloading processes. These inefficiencies created bottlenecks, affecting overall production timelines.  

1. High-Temperature Resistance Needs

   The facility regularly handled black metal materials heated up to 500℃. Their existing equipment was not equipped to safely manage such temperatures without compromising safety or durability, leading to frequent delays.  

1. Precision Requirements in Raw Material Warehousing and Assembly

   Certain processes in their raw material warehouse and assembly workshops demanded millimeter-level positioning accuracy. Their existing technology couldn’t meet the high level of precision required, impacting the quality of the final products.  

The client sought a robust solution to address these inefficiencies and maintain their competitive edge in the industry.  

The Solution  

To tackle these challenges, an electromagnetic bridge crane system was implemented with advanced structural features tailored to their operations. The solution included the following design enhancements:

1. Parallel Axis Lifting Mechanism

   The lifting mechanism was redesigned with a classic parallel axis arrangement, optimizing the crane’s performance for black metal handling.  

1. Centralized Drive Structure on Small Car Mechanism

   A low-speed shaft centralized drive structure was introduced, ensuring smoother and more controlled loading and unloading operations.  

1. Independent Drive System for Large Car Mechanism

   The large car mechanism employed independent drive systems on both sides, enabling better stability and efficient maneuverability.  

1. Customization for Various Scenarios
   1. The cranes were customized into hook-type and beam-type, depending on the type of material to be retrieved.  
   1. Hanging beams were arranged as parallel main beam type or vertical main beam type for enhanced adaptability.  
   1. Rotation systems were configured as upper rotation type or lower rotation type for greater control during material handling.  
   1. The operation modes included ground operation, air operation, and remote control operation, enabling safer and more flexible handling.  

This tailored approach allowed the client to address not only the inefficiencies in their prior system but also future-proof their infrastructure for greater scalability.  

Results  

The implementation of the electromagnetic bridge crane system led to remarkable improvements in the client’s operations, including:

• 40% Increase in Operational Efficiency

   Loading and unloading times for steel plates, ingots, and steel bars were reduced significantly, directly boosting productivity.  

• Millimeter-Level Positional Accuracy

   The assembly workshops and raw material warehouses achieved enhanced precision, ensuring consistency and high-quality manufacturing outputs.  

• Effective High-Temperature Handling

   Materials with temperatures below 500℃ were easily managed, improving safety and reliability while reducing delays.  

• Streamlined Processes for Magnetic Conductive Materials

   The electromagnetic system leveraged magnetic force for material retrieval, making the handling process seamless and efficient compared to traditional hook methods.