WELLD TOWER CRANE
FACTORY TOUR
WELLD tower crane production combines engineering design, steel fabrication, welding, machining, surface treatment, assembly and quality inspection. This process encompasses several key stages, from initial design and engineering to final assembly and testing, each demanding precision and adherence to stringent quality control measures.
Design and Engineering
The foundation of any WELLD tower crane lies in its design. This crucial phase begins with understanding the specific requirements of the crane, including its lifting capacity, reach, and operational environment.
WELLD engineers use 3D CAD tools to develop tower crane structures and mechanical components. Finite Element Analysis (FEA) is used to evaluate stress distribution and structural behavior under specified load conditions, helping engineers identify critical areas and optimize the design before it is released for production.
Design and Engineering
The foundation of any WELLD tower crane lies in its design. This crucial phase begins with understanding the specific requirements of the crane, including its lifting capacity, reach, and operational environment.
WELLD engineers use 3D CAD tools to develop tower crane structures and mechanical components. Finite Element Analysis (FEA) is used to evaluate stress distribution and structural behavior under specified load conditions, helping engineers identify critical areas and optimize the design before it is released for production.
WELLD adheres to international standards, such as Sa2.5, for material selection and preparation.
Material Selection and Preparation
The selection of high-quality materials is crucial for the structural integrity and longevity of WELLD tower cranes. WELLD uses Q345B and Q420 high-strength steel for applicable structural components. Before coating, fabricated steel surfaces undergo abrasive blasting to achieve the specified surface cleanliness, such as Sa 2½ where applicable. This standard ensures that the steel surface is free from rust, scale, and other contaminants, providing an optimal base for subsequent coating and welding processes.
Before fabrication, the steel undergoes a series of preparation processes. This includes cutting, bending, and machining to achieve the precise shapes and dimensions specified in the engineering designs. Plasma laser cutting technology is employed to ensure clean and accurate cuts, minimizing material waste and improving the quality of the finished components.
The selection of high-quality materials is crucial for the structural integrity and longevity of WELLD tower cranes. WELLD uses Q345B and Q420 high-strength steel for applicable structural components. Before coating, fabricated steel surfaces undergo abrasive blasting to achieve the specified surface cleanliness, such as Sa 2½ where applicable. This standard ensures that the steel surface is free from rust, scale, and other contaminants, providing an optimal base for subsequent coating and welding processes.
Before fabrication, the steel undergoes a series of preparation processes. This includes cutting, bending, and machining to achieve the precise shapes and dimensions specified in the engineering designs. Plasma laser cutting technology is employed to ensure clean and accurate cuts, minimizing material waste and improving the quality of the finished components.
Robot welding
Fabrication and Welding
The fabrication process involves cutting, bending, and welding steel components to form the crane's structural elements, such as the tower sections, jib, and counter-jib. WELLD employs advanced technologies to ensure precision and quality:
Plasma Laser Cutting: Utilizing plasma laser cutting machines to precisely cut steel plates into the required shapes and sizes. This technology ensures clean and accurate cuts with minimal material waste.
Robot Welding Technology: Implementing robotic welding systems to automate the welding process. Robots provide consistent and high-quality welds, reducing the risk of human error and improving production efficiency.
Manual Welding: Skilled welders perform manual welding for complex joints and areas inaccessible to robots, adhering to AWS D1.1 standards.
CNC Machining Centers: These centers are used to machine critical components such as slewing rings, gearboxes, and pin connections with high precision.
Tooling Application: Using precise jigs and fixtures to hold components in place during welding, ensuring dimensional accuracy and minimizing distortion.
The fabrication process involves cutting, bending, and welding steel components to form the crane's structural elements, such as the tower sections, jib, and counter-jib. WELLD employs advanced technologies to ensure precision and quality:
Plasma Laser Cutting: Utilizing plasma laser cutting machines to precisely cut steel plates into the required shapes and sizes. This technology ensures clean and accurate cuts with minimal material waste.
Robot Welding Technology: Implementing robotic welding systems to automate the welding process. Robots provide consistent and high-quality welds, reducing the risk of human error and improving production efficiency.
Manual Welding: Skilled welders perform manual welding for complex joints and areas inaccessible to robots, adhering to AWS D1.1 standards.
CNC Machining Centers: These centers are used to machine critical components such as slewing rings, gearboxes, and pin connections with high precision.
Tooling Application: Using precise jigs and fixtures to hold components in place during welding, ensuring dimensional accuracy and minimizing distortion.
Automatic Coating Line for production of WELLD tower cranes
Surface Treatment and Coating
Surface treatment and coating are essential for protecting the crane against corrosion and environmental degradation. WELLD utilizes advanced coating technologies to ensure long-term durability of its tower cranes.
Automatic Shot Blasting: Components undergo a thorough surface preparation process, including 360-degree shop blasting. This removes mill scale, rust, and other contaminants, creating a clean, uniform surface for coating. The material meets the international standard Sa2.5, ensuring a high degree of cleanliness.
Automatic Coating Line: An automatic coating line applies multiple layers of protective coatings. This typically includes an epoxy primer paint followed by a weatherproofing PU top finish.
Epoxy Primer Paint: The epoxy primer provides excellent corrosion resistance and adhesion, creating a strong bond between the steel and the topcoat.
Weatherproofing PU Top Finish: The polyurethane (PU) topcoat offers exceptional resistance to UV radiation, chemicals, and abrasion, ensuring long-term protection against the elements.
Surface treatment and coating are essential for protecting the crane against corrosion and environmental degradation. WELLD utilizes advanced coating technologies to ensure long-term durability of its tower cranes.
Automatic Shot Blasting: Components undergo a thorough surface preparation process, including 360-degree shop blasting. This removes mill scale, rust, and other contaminants, creating a clean, uniform surface for coating. The material meets the international standard Sa2.5, ensuring a high degree of cleanliness.
Automatic Coating Line: An automatic coating line applies multiple layers of protective coatings. This typically includes an epoxy primer paint followed by a weatherproofing PU top finish.
Epoxy Primer Paint: The epoxy primer provides excellent corrosion resistance and adhesion, creating a strong bond between the steel and the topcoat.
Weatherproofing PU Top Finish: The polyurethane (PU) topcoat offers exceptional resistance to UV radiation, chemicals, and abrasion, ensuring long-term protection against the elements.
Mechanical and Electrical Assembly
After structural components have completed fabrication and surface treatment, mechanical and electrical systems are installed and assembled. Hoisting, trolleying and slewing mechanisms are fitted together with the corresponding drive and control components.
Motors, control panels, wiring and applicable safety devices are installed and checked to verify correct connection and operation before final inspection.
After structural components have completed fabrication and surface treatment, mechanical and electrical systems are installed and assembled. Hoisting, trolleying and slewing mechanisms are fitted together with the corresponding drive and control components.
Motors, control panels, wiring and applicable safety devices are installed and checked to verify correct connection and operation before final inspection.
Quality control is an integral part of the WELLD tower crane production process. Each stage, from design to assembly and delivery, is subject to rigorous inspection and testing.