Overhead Crane Failures and Repair: Essential Solutions for Metal Structures and Travel Mechanisms

2月 15, 2025

Lifting machinery inevitably experiences aging and wear during use, leading to various failures. This article provides a comprehensive analysis of overhead crane failures and repairs, including fatigue cracks and deformations in the metal structure, as well as skewed travel and rail gnawing in the travel mechanism. By understanding these failures and their solutions, maintenance efficiency and overhead crane reliability can be significantly improved.

Overhead Crane Metal Structures and Travel Mechanism Failures and Repair

Failures and Repair of Overhead Crane Metal Structures

失败	原因	维修
Fatigue cracks in the main girder web or cover plate	Overload for long time	For cracks less than or equal to 0.1 mm, use a grinding wheel to smooth them out. For larger cracks, drill holes larger than Φ 8 mm at both ends of the crack, then create a 60° groove along both sides of the crack and perform welding repairs. For critical load-bearing components, reinforce the repaired area with additional plates to ensure strength.
Wave-like deformation in the main girder web	Overloading, causing local instability of the web plate	Use flame straightening to correct the deformation. Use hammering to relieve internal stresses. Strictly prohibit overloading in the future.
Side bending of the main girder	Combined working stresses, improper transportation, or storage	Use flame straightening by heating the convex side of the main girder, and apply appropriate jacks and pulling tools as needed.
Main girder sinking deformation	Structural stress in the main girder, wave-like deformation of the web plate, overloading, thermal effects, improper storage or transportation, and other factors	Use the prestressing method for correction. After flame straightening, reinforce the lower cover plate of the main girder with channel steel.

Failures and Repair of Overhead Crane Metal Structures

Failures and Repair of Overhead Crane Travel Mechanism

Bridge Travel Mechanism

失败	原因	维修
Bridge girder skew and rail gnawing	Excessive diameter difference between the two drive wheels	Measure, machine and replace 起重机车轮
	Driving wheels are not fully contact with rail	Balance rails and adjust the wheel
	Excessive horizontal deviation of the wheel	Check and eliminate excessive horizontal deviation of the wheel
	Deformation of metal structure	Rectify
	Excessive deviations in gauge, lateral straightness, and height difference between the two rails	Adjust rail and make rail installation satisfy technical requirements
	Oil or frost on the rail surface	Remove oil and frost

Failures and Repair of Overhead Crane Bridge Travel Mechanism

Overhead Crane Trolley Travel Mechanism

失败	原因	维修
Roil skid	Oil on the rail	干净的
	Wheel load is not even	Adjust wheel load
	Rail top height difference is too much at the same cross-section	Adjust rail till it meets technical requirements
	Start or brake too violently	Change the method of motor start, choose winding motor
Trolley twists when starting	Uneven wheel pressure or one drive wheel lifting off. Rail gnawing.	Adjust the problem that only three wheels touch the rail. Resolve rail gnawing.

Failures and Repair of Overhead Crane Trolley Travel Mechanism

结论

The above outlines common overhead crane failures and repair methods during operation, addressing issues in both metal structures and travel mechanisms. By analyzing the causes of these failures and providing practical repair solutions, this guide aims to enhance your understanding of effective equipment maintenance and troubleshooting, ensuring safer operations, reduced downtime, improved productivity, extended equipment lifespan, and cost savings for industrial facilities.

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