Overhead Crane Solutions for Logistics & Automation
Material handling equipment manufacturing (conveyors: 500 kg–5 t/h per line; stackers: 5–15 t per unit; AGVs: 500 kg–2 t per unit; sorting machines: 3–8 t per unit) involves a mix of light- and heavy-duty assembly, where station-level lifting and end-of-line logistics are the critical factors. Recommended configuration: KBK 500 kg + QD double-girder 10–20 t + LD single-girder 5 t. Kelude's material handling equipment solutions are tailored by product category and line takt time.
Material handling equipment manufacturing spans four main product categories: conveyors, stackers, AGVs, and sorting machines. Production lines are primarily assembly-focused, with structural component welding as a secondary operation. Conveyor assembly lines typically run 10–50 m in length and require KBK multi-point coverage; stackers stand 6–30 m tall and need large-span QD bridge cranes; AGVs follow a production rhythm of 4–8 hours per unit; sorting machine guide rails demand high assembly accuracy with straightness of ≤±2 mm/10 m. This article presents differentiated lifting solutions for the assembly of all four equipment types.
Conveyor Assembly: Roller, Belt & Chain Plate Lines
Conveyor assembly (roller, belt, or chain plate) centers on the frame (steel profile welding, 200–800 kg per section), drive unit (motor + gearbox + drum, 100–500 kg), and conveying surface installation. With line lengths of 10–50 m, multi-point lifting coverage along the line is essential. Delivery lead time for a single conveyor is 15–30 days.
Recommended model: KBK flexible combination crane, 500 kg capacity, arranged along the line (one column every 6–8 m), with an independent trolley at each workstation. The frame welding zone is equipped with a column-mounted jib crane (250 kg) for profile loading and unloading. Drive unit installation uses a pneumatic balancer (100 kg) for precise positioning.
Price reference: KBK 500 kg units run approximately 20,000–40,000 CNY per set, with 2–4 sets required depending on line length. Kelude Heavy Industry customizes KBK rail lengths and column spacing for conveyor assembly lines based on workstation layout.
Stacker Vertical Assembly: Columns, Load Platforms & Rails
Stackers (5–15 t per unit, 6–30 m high) require vertical assembly within the workshop, covering column installation (H-beam welded, 2–5 t, 6–30 m long), load platform assembly (1–3 t), and top/bottom rail installation. Multiple lifting operations, fine adjustments (perpendicularity ≤ H/2000), and measurements are required throughout. Workshop clear height must be at least stacker height + 2 m.
Recommended model: QD-type double-girder bridge crane, 10–20 t capacity with an 18–24 m span, and lifting height of at least stacker height + 3 m. Variable frequency speed control (creep speed ≤ 0.5 m/min) enables precise column perpendicularity adjustment. A rotating lifting beam (5 t capacity) facilitates column flipping and upright positioning.
Price reference: QD double-girder 10 t/20 m units run approximately 120,000–200,000 CNY each. Kelude Heavy Industry's stacker solution includes a dedicated column-erection lifting spreader plus laser-assisted perpendicularity measurement.
AGV Production Lines: Chassis Welding & Navigation Calibration
AGV assembly (500 kg–2 t per unit) centers on chassis welding (≤800 kg), drive/steering wheel installation (50–200 kg), battery mounting (100–300 kg), and navigation system setup. Production rhythm runs 4–8 hours per unit, with batch sizes of 10–50 units. The assembly sequence is: chassis frame welding → chassis assembly → electrical wiring → navigation calibration → full machine testing.
Recommended model: KBK flexible suspension rail (250 kg) covering the chassis welding and chassis assembly zones. Drive wheel installation uses a pneumatic balancer (50 kg). Finished units are transferred off-line via AGV automatic docking, with an electric hoist (250 kg) in the maintenance bay for battery removal assistance.
Price reference: KBK 250 kg units run approximately 15,000–30,000 CNY per set. Kelude Heavy Industry's AGV solution includes automatic off-line AGV transfer, maintenance lifting support, and a navigation calibration platform.
Long Sorting Conveyor Assembly: Cross-Belt & Sliding Shoe Systems
Cross-belt and sliding shoe sorters (3–8 t per unit, 20–60 m line length) involve guide rail installation (aluminum rails, 2–3 m/50–100 kg per section), carriage/slider mounting (hundreds to thousands of units), and drive/tensioning system setup. Guide rail straightness must be ≤±2 mm/10 m, with sorting chute positioning accuracy of ≤±5 mm.
Recommended model: LD-type single-girder electric bridge crane, 3–5 t capacity with a 12–18 m span, covering the sorting machine assembly area. Rail installation uses a measuring platform with a dedicated lifting spreader. The drive unit (motor + gearbox, 500–2000 kg) is handled by an independent jib crane.
Price reference: LD single-girder 3 t/15 m units run approximately 30,000–60,000 CNY each. Kelude Heavy Industry's sorting machine solution includes guide rail straightness inspection tools, drive lifting spreaders, and sorting chute positioning fixtures.
Material Handling Lifting Configuration Comparison
| Category | recommended model | Capacity | installation Features | reference price |
|---|---|---|---|---|
| conveyor | KBK+jib crane+Airdynamic balancing | 0.25~0.5t | Cable Length10~50m/Multi-point Hoisting | 2~810K/Set |
| Stacker | QDDouble Girder Variable Frequency Drive (VFD)+rotating lifting beam | 10~20t | Column H/2000Perpendicularity | 12~2010K |
| AGV | KBK+Airdynamic balancing+Electric Hoist | 0.25t | Takt Time4~8h/Unit | 1.5~410K |
| sorting machine | LDsingle girder+jib crane | 3~5t | Guide rail±2mm/10m | 3~610K |
Service Advantages for Logistics Equipment Manufacturing
Kelude Heavy Industry's logistics equipment solutions cover assembly lines for four equipment types — conveyors, stackers, AGVs, and sorting machines — with KBK, QD, and LD crane models matched to the specific production line characteristics of each category.
Category-Specific Configuration
Long conveyor lines use KBK (conveyors/sorting machines), vertical assembly uses QD (stackers), and assembly lines use KBK with automatic offloading (AGVs) — no one-size-fits-all approach.
Full-Line Layout Planning
We provide complete workshop layout plans for logistics equipment assembly — including crane type, capacity, span, and workstation density for each assembly area — ensuring multi-model co-production without interference.
Frequently Asked Questions (FAQ)
Q: Why recommend a KBK multi-point coverage system over a single LD overhead crane for conveyor assembly lines?
A: Conveyor assembly lines typically span 10–50 m. A single LD overhead crane can only serve one lifting point area, requiring repeated start-stop cycles (20–40 seconds each) to move loads along the line. A KBK flexible system runs the full length of the line, with an independent trolley at each workstation — operators can position loads in just 1–2 seconds, improving overall line efficiency by over 40%. Kelude Heavy Industry recommends installing a KBK support column every 6–8 m along conveyor lines.
Q: What is the inspection method for stacker column perpendicularity?
A: Stacker columns (6–30 m) must meet a perpendicularity requirement of ≤H/2000 (e.g., a 15 m column allows a permissible deviation of ≤7.5 mm). Inspection method: ① Coarse adjustment — use a laser plummet (accuracy ±0.5 mm/100 m) on two adjacent faces of the column; ② Fine adjustment — verify all four corners with a frame spirit level (accuracy 0.02 mm/m); ③ Adjustment — add or remove shims (0.5–2 mm) under the column base, re-checking after each adjustment. Kelude Heavy Industry offers laser-based perpendicularity measurement services.
Q: How do the KBK rails and AGV offloading coordinate on an AGV assembly line?
A: At the end of the AGV assembly line, the KBK system lifts the finished AGV (500 kg–2 t) down to the ground-level service bay for navigation calibration and load testing. From there, the AGV drives itself onto the test track via an automatic docking station. The KBK lowering position must align with the center of the service bay (deviation ≤20 mm). Kelude's solution includes an integrated KBK + service bay + automatic docking station system.
Q: How is guide rail straightness ensured for sorting machines?
A: To guarantee guide rail straightness of ≤±2mm/10m: ① Pre-adjust each rail section on the platform before installation (straightness ≤±1mm); ② During installation, use a laser alignment system (accuracy ±0.5mm) to establish a reference line from the infeed end to the discharge end; ③ After each rail section is installed, measure deviation and make immediate adjustments (via shimming or lateral pushing); ④ After all sections are installed, re-measure the full line. Kelude Heavy Industry's sorting machine solution includes a laser alignment system and rail fine-adjustment tooling.
