Overhead Crane Fleet for EV Plant: Stamping, Welding, Painting
Key Highlights An EV manufacturer purchased 20 Kelude cranes (12 overhead cranes + 8 jib cranes) for four workshops: stamping, welding, painting, and final assembly. The 32t QD cranes with VFD and micro-motion control achieve 3mm accuracy, the welding shop features three-crane linkage, and the painting shop includes anti-corrosion upgrades. Total contract value: approximately $101,000, with full delivery and acceptance completed in 90 days.
In July 2026, Kelude Heavy Industry completed the delivery of a crane fleet for a new factory of a leading NEV brand, totaling 12 overhead cranes + 8 jib cranes covering the stamping, welding, painting, and final assembly workshops as well as warehouse areas. The total contract value was approximately $101,000, with the entire process from solution design to final acceptance completed in 90 days.
Project Background
Located in East China, this NEV factory is planned for an annual output of 300,000 new energy passenger vehicles, placing stringent demands on the precision, reliability, and delivery time of the lifting equipment:
- Stamping workshop: Die handling (max. die weight approx. 25t) requiring micro-motion accuracy of ≤5mm
- Welding workshop: Lifting and transport of welding fixtures and body-in-white assemblies, requiring coordinated control for multi-crane linkage
- Painting workshop: Explosion-proof and anti-corrosion requirements, with an electrical system resistant to chemical corrosion
- Final assembly workshop: Hoisting of powertrains and battery packs (max. approx. 800kg) requiring precise positioning
Solution Configuration
| Workshop | Equipment Type | Quantity | Lifting Capacity | Span | Control Mode |
|---|---|---|---|---|---|
| Stamping Workshop | QD Type Double Girderoverhead type | 2Unit(s) | 32t/5t | 28.5m | Remote Control+Operator Cabin |
| Stamping Workshop | LD Typesingle girderoverhead type | 2Unit(s) | 10t | 22.5m | Remote Control |
| Welding Assembly Workshop | LH Type Hoist Double Girderoverhead type | 3Unit(s) | 16t | 25.5m | Remote Control+Variable Frequency Drive (VFD) |
| Painting Workshop | LD Type Anti-corrosionoverhead type | 2Unit(s) | 5t | 19.5m | Remote Control |
| Final Assembly Workshop | LD Typesingle girderoverhead type | 3Unit(s) | 3t | 16.5m | Remote Control |
| Plant-wide Workstations | BZDjib crane | 8Unit(s) | 0.5~2t | 3~5m | pendant |
Project Highlights
1. 32t QD Crane in Stamping Workshop Achieves 3mm Micro-Motion Accuracy
Kelude equipped two 32t QD-type cranes in the stamping workshop with VFD + closed-loop vector control systems, delivering a minimum stable speed of 0.5m/min and a measured micro-motion accuracy of 3mm—exceeding the customer's 5mm requirement.
2. Three-Crane Synchronization Control in the Welding Workshop
Three LH-type cranes operating on the same runway in the welding workshop are fitted with laser distance measurement anti-collision systems and wireless communication modules for synchronized operation. The cranes can work together to handle large body-in-white assemblies or run independently without interference.
3. Anti-Corrosion Upgrade for the Painting Workshop
Given the acidic/alkaline fumes and humid conditions in the painting workshop, Kelude's LD-type overhead cranes received a specialized anti-corrosion treatment: electrical cabinets upgraded to IP55 protection, motors coated with corrosion-resistant finishes, and conductor rails manufactured from stainless steel.
Delivery and Acceptance
The project was delivered in two phases: Phase 1 (stamping + welding workshops) was completed in 60 days, and Phase 2 (painting + final assembly + jib cranes) in 90 days. All 12 overhead cranes and 8 jib cranes passed the TSG load test on the first attempt.
FAQ
Q: How do crane requirements differ across the four workshops in an automotive plant?
A: The stamping workshop needs large tonnage with high-precision micro-motion (QD-type double girder + VFD); the welding workshop requires multi-crane coordination (LH-type with anti-collision interlock); the painting workshop demands corrosion resistance (IP55 protection); and the final assembly workshop uses smaller-capacity cranes in greater numbers (LD single girder with remote control).
Q: At what stage should cranes be procured when building a new factory?
A: We recommend finalizing the crane solution during the factory design phase. Crane rails, embedded parts, and corbel loads must be pre-planned into the civil works, which can shorten the overall schedule by approximately 20–30 days.
Q: How do multiple cranes operating in the same workshop avoid collisions?
A: We recommend a dual protection scheme combining laser distance measurement with zone interlocking. Cranes on the same runway are assigned work zones via PLC, and any cross-zone movement triggers an automatic stop.
Q: How do jib cranes and overhead cranes work together?
A: Overhead cranes handle workshop-level heavy lifting, while jib cranes cover workstation-level light hoisting. Pairing one overhead crane with 4–6 jib cranes can free up roughly 30–40% of the overhead crane's operating time.
