Tower crane

The company has developed a range of related technologies, including teach-free automatic positioning and welding systems, multi-layer multi-pass welding systems, automatic cutting systems, and omnidirectional welding positioning systems. Furthermore, by optimizing existing client production processes and integrating the automatic positioning and welding systems, the company has successfully achieved automated welding operations.

Flexibility

Staff will make a production analysis of the customer’s future production needs and goals. Material flow analysis and planning define the optimal configuration and layout for your site.
Rhythmicization

Remote repair service enables instant visual connection to the machine despite its geographical location.
Intelligentization

Full range of spare and wear parts, including original spare parts, retrofit parts, and approved replacement OEM parts, all meeting the strictest quality criteria.

The welding production line for tower cranes is mainly designed for key steel structures such as tower sections, lifting arms, balancing arms, tower caps, slewing bearing supports, chassis, and attachment frames of tower cranes. It adopts a combined process layout of automation and semi-automation, and is the core manufacturing process that ensures the bearing capacity, structural rigidity, anti-fatigue performance, and operational safety of tower cranes. The entire production line adheres to the standards for heavy-load, high-strength and high-precision construction machinery manufacturing, while also taking into account the requirements of large-scale production and flexible switching.

Overall Layout and Flow of the Production Line

The typical process flow is as follows

01 Raw Material Pretreatment
02 Part Cutting and Beveling
03 Alignment and Positioning
04 Robotic / Manual Welding
05 Post-Weld Slag Removal and Correction
06 Nondestructive Testing
07 Shot Blasting for Rust Removal
08 Proceed to Machining / Painting

Overview of the Standard Section Welding Production Line

The automatic welding production line for tower crane standard sections is an intelligent, full-process welding manufacturing system specifically designed for the core load-bearing components (standard sections) of tower cranes. It integrates robot welding, precision fixtures, automatic logistics, intelligent detection and information management technologies, enabling the automatic assembly, welding and circulation of standard sections from the main chord members, diagonal members, connection sleeves to the assembly. It addresses the problems of low efficiency, unstable quality and high labor intensity in traditional manual welding, and is the core equipment for tower crane intelligent manufacturing.

The production lines mostly adopt linear or U-shaped streamlined layouts, ensuring smooth logistics and compact workstations.

The automated welding production line aims for high quality, high efficiency, low consumption and flexibility, and achieves the following:

• Stable quality: The robot welding trajectory is precise, the weld seam consistency is good, and the one-time qualification rate can reach over 99%.

• Efficiency improvement: The entire process is automated, significantly shortening the single production cycle, and suitable for large-scale production.

• Cost reduction and efficiency increase: Reducing reliance on human labor, reducing welding deformation, rework, and labor costs.

• Intelligent traceability: Real-time collection of production data, achieving full-process traceability of welding parameters, equipment status, and quality information.

Overview of the Chip-Type Main String Rod Robot Welding Workstation

Automated welding for the main tension rods of the plate-type standard sections

01
Process advantages

The special centering fixture provides precise positioning, effectively controlling the bending and twisting deformation of the main string rod, and ensuring that the total length and coaxiality meet the standards.
02
Automatic Fixture

The fixture utilizes an automatic design—specifically, a pneumatically and electrically controlled system—to reduce the operator's physical workload.
03
Modular Design

The equipment has strong compatibility and can quickly switch between different cross-sections and lengths of main string rods. The degree of flexible production is high.

Overview of Automated Welding of Upper and Lower Supports

The main task is to precisely assemble and conduct automated welding for components such as the base plate of the support, the cylinder body, the flange plate, the reinforcing ribs, the hinged ear plate, and the connection seat. This ensures the bearing strength, connection accuracy, and rotational stability of the support. It is a key manufacturing position that ensures the force connection of the entire tower crane.

1. Integrated Assembly and Welding Fixture

By using a dedicated hydraulic positioning tool, the positions of each component are precisely locked. The flatness, coaxiality and installation hole position accuracy are strictly controlled to ensure the interchangeability of the entire machine assembly.
2. Improve production efficiency

Using the rotary machine, the workpiece can be rotated at multiple angles, enabling fully automatic welding in all positions (flat welding, corner welding, and vertical welding), thereby eliminating the quality variations caused by manual welding.
3. Flexible Design

The production line has strong flexibility and can be adapted to switch between different tonnage and different specification tower crane upper and lower supports for production, and is suitable for batch standardized manufacturing.
4. Lean Control of Welding Cycle Time

By using the multi-layer and multi-pass welding process with carbon dioxide gas protection, the weld seam has sufficient penetration depth and regular shape, and exhibits excellent resistance to impact and fatigue.

Lifting Arm Overview

Automated welding production line for tower crane boom

Core advantages of the process

The position of the components is fixed by using a dedicated positioning tool, which effectively prevents the arm frame from twisting, bending or deforming. This ensures uniform product dimensions and high interchangeability.
Robotic Welding Station

Single-Station Manual Component Assembly (Manual Part Placement, Robotic Spot Welding)
Improve production efficiency

Welding data is fully retained throughout the process, with stable and controllable process parameters, enabling quality traceability throughout the production process.
Flexible Platform Design

The welding fixture features a flexible platform design, enabling compatibility with various machine models for the welding workpieces.