Project Information
- Client: Fujian Kaicheng Machinery Manufacturing Co., Ltd.
- Location: Fujian Province, China
- Equipment Supplied: 300-Ton New Chinese-Style Double Girder Overhead Crane
- Scope: Engineering, Manufacturing, Installation, Commissioning, Operator Training
Heavy lifting upgrades inside an active fabrication workshop always bring tight constraints. Fujian Kaicheng Machinery Manufacturing Co., Ltd. needed to handle components close to 300 tons more efficiently.
At the same time, the plant could not stop normal production. In addition, the existing building structure limited major reconstruction work. Therefore, the customer needed a solution that improved lifting capacity without changing the overall workshop layout.
Weihua Group delivered a 300-ton New Chinese-style double girder overhead crane to meet these requirements.
Upgrading Heavy Lifting Within Existing Workshop Limits
Before the upgrade, the factory used older resistance-controlled cranes. These cranes required frequent maintenance and also struggled with precise load positioning during heavy operations.
As production demands increased, the customer needed better lifting accuracy and more stable performance under full load.
To solve these issues, Weihua engineers redesigned the lifting system using a New Chinese-style overhead crane platform. The structure uses optimized stress distribution and high-strength steel design. As a result, the crane reduces overall dead weight by about 15%.
Because of this reduction, the existing runway beams remained in use with only minor reinforcement. Therefore, the customer avoided large-scale civil reconstruction and saved significant installation time.
Installation Planned Around Production Schedule
Weihua and the customer coordinated installation work during a planned weekend shutdown. This approach helped avoid disruption to daily production.
During installation, the team completed rail alignment, electrical connection, and load testing in sequence. Meanwhile, engineers closely monitored site conditions to ensure stable integration with existing equipment.
Since the plant operates in Fujian’s coastal environment, humidity and salt exposure require additional protection. Therefore, Weihua applied marine-grade sealing for hoist motors, VFD cabinets, and limit switches before delivery.
In addition, all key components received high-build epoxy coating to improve corrosion resistance. On-site, technicians checked every connection and adjusted control parameters based on actual operating conditions.
Precision Control for Heavy Load Operation
After installation, the commissioning process focused on control performance and load stability rather than speed alone.
Heavy fabrication work requires smooth movement and accurate positioning, especially under maximum load conditions. Therefore, Weihua engineers adjusted the variable-frequency drive system to improve low-speed control and reduce load swing.
At the same time, the team tested the redundant braking system to confirm safe stopping performance under full load.
Operators then completed trial runs using both pendant and wireless control systems. In addition, they practiced repeated lifting cycles under simulated working conditions.
Within two days, the crane entered stable daily operation without unexpected interruptions.
Improved Efficiency and Lower Maintenance Demand
After commissioning, the production team quickly noticed several operational improvements.
First, maintenance work decreased compared with the previous crane system. Second, energy consumption per lifting cycle dropped due to improved drive efficiency and reduced mechanical resistance.
In addition, the workshop gained more usable floor space after removing outdated support structures. This change improved material staging and internal workflow organization.
Most importantly, operators reported greater confidence during heavy lifting tasks. Real-time monitoring systems and overload protection now support daily operation and reduce safety risks.
Supporting Heavy-Lift Upgrades in Existing Facilities
Many manufacturing plants face similar challenges when upgrading heavy lifting systems inside existing buildings. In most cases, the main difficulty is not only load capacity, but also space limitation and production continuity.
Therefore, modular and optimized crane structures have become a practical choice for many heavy industry users.
Weihua continues to provide customized overhead crane solutions for steel plants, fabrication workshops, machinery manufacturers, and large industrial facilities. The company also supports layout planning, structural verification, installation management, and long-term service support to ensure stable operation after commissioning.ct scheduling.
