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Hefei, Anhui'de Bobin Taşıma için Endüstriyel 3 Tonluk Hidrolik Devirme Platformu

Müşteriye Genel Bakış

This engineering project involved the design, fabrication, and deployment of a custom 3-ton hydraulic tilting platform for a major steel coil processing and warehousing facility in Hefei, Anhui Province, China. The client, Anhui Yufeng Hydraulic Machinery Co., Ltd.  a producer of industrial hydraulic equipment, required a specialized machine for the safe and efficient manipulation of large steel coils.

The primary objective was to provide a robust, hydraulic lifting and tilting mechanism capable of handling coils with diameters up to 6,000 mm and weighing 3,000 kg. The platform had to facilitate the transition of coils from a vertical storage position to a horizontal transport/processing orientation, minimizing manual intervention and reducing the risk of surface damage to the coils. This hydraulic tilting platform was engineered to meet the demanding requirements of the steel industry, ensuring high cycle reliability and precise motion control. The equipment adheres to national Chinese standards for lifting machinery, including the GB/T 17393-2008 Safety Specification for Lifting Appliances

 

Zorluk ve Çözüm

Müşteri Zorlukları

Challenge

The material handling facility in Hefei faced significant operational risks when managing high-volume steel pipe logistics. The primary engineering bottlenecks centered on the structural stability of the load during high-angle transitions and the integration of mobile transport units into the tilting cycle.

  • Load Fragmentation Risks: During the 90-degree transition, managing 18 steel pipes (each 6800mm in length) simultaneously creates a massive risk of load scattering. Without a specialized industrial upender machine equipped with a modular fixture, the pipes would shift under gravity, leading to equipment damage and personnel injury.

  • Trolley Integration and Locking: The 3-ton operation requires the entire transport cart (6000mm x 600mm x 850mm) to be tilted alongside the load. The challenge was to design a remote-controlled mechanical locking system that could fix the trolley to the platform with zero play, preventing the cart from dislodging at the peak of the 90-degree vertical stance.

  • Dynamic Hydraulic Instability: Tilting a 3-ton load over a 150-second cycle requires perfectly linear hydraulic pressure. Any fluctuations or “surges” in the hydraulic circuit could lead to jerky movements, which are particularly dangerous when handling elongated steel profiles. The system required a solution that followed the GB/T 3766-2015 Hydraulic Fluid Power Safety Requirements to ensure smooth, adjustable speed control.

  • Electrical and Phase Safety: The facility’s power grid required protection against phase loss, which could cause the hydraulic motor to burn out or stall during a critical lift. The client necessitated a control architecture that could fail-safe under electrical anomalies.

  • Operational Ergonomics: Technicians needed to extract pipes individually for powder filling once the platform reached a vertical position. This required the hydraulic tilting platform to maintain a rock-steady vertical orientation for extended periods without hydraulic creep.

GRADIN Özel Çözüm

To resolve the logistical bottlenecks at the Hefei facility, a dual-tier hydraulic upending system was engineered, utilizing reinforced structural steel and an advanced remote-locking mechanism.

1. Modular Fixture and Structural Engineering
For the 1-ton operation, the platform was equipped with a detachable modular fixture designed to secure 18 steel pipes simultaneously. This ensures that the 38mm diameter, 6800mm long pipes remain bundled during the 90-degree transition. The 3-ton platform utilizes a heavy-duty J2001006 structural steel frame, providing the necessary torsional rigidity to tilt the transport trolley (6000mm length) without structural deflection. The platform surface features a 6mm thick reinforced steel plate to withstand the high-torque movements of the hydraulic cycle.

2. Precision Hydraulic Actuation and Safety Valves
The lifting force is generated by industrial hydraulic upenders utilizing Φ100-80 heavy-duty cylinders for the 3-ton model and Φ80-60 cylinders for the 1-ton variant. To prevent uncontrolled descent, each cylinder is equipped with a built-in explosion-proof valve and an adjustable flow control system. This allows the 5.5kW pump station to maintain a consistent 120-150 second cycle time, ensuring that the transition from horizontal to vertical is smooth and repeatable. The hydraulic circuit is designed to meet the EXTERNAL LINK: GB/T 15706 safety of machinery – General principles for design, incorporating an overflow valve to prevent damage from accidental overloading.

3. Remote-Controlled Locking and Electrical Control
A critical feature of the 3-ton solution is the automated trolley locking system. Technicians utilize a wireless remote to engage mechanical clamps that secure the 600x600x850mm trolley to the INTERNAL LINK: tilting platform. This eliminates manual lashing and significantly reduces the setup time. The electrical architecture utilizes Schneider Electric industrial control components, including a 6-meter shielded cable and a centralized control box. The system features integrated phase-loss protection and an emergency stop function, ensuring that the upender halts immediately if power anomalies are detected.

4. Optimized Powder-Filling Workflow
The platform is engineered to hold the load in a vertical position indefinitely, allowing personnel to extract pipes individually for powder filling. Once the filling process is complete, the platform is tilted back to a horizontal state for unloading. The speed of the return stroke is fully adjustable via the hydraulic control manifold, allowing the facility to tune the workflow based on the specific weight of the steel pipes being processed.

Teknik Parametreler & Destekleyici Markalar

Teknik Parametreler

The following table provides a detailed comparison of the engineering parameters for the 1-ton and 3-ton hydraulic upending systems deployed at the Hefei facility.

Parametre 1-Ton Unit Specification 3-Ton Unit Specification
Nominal Yük Kapasitesi 1,000 kg 3,000 kg
Flipping Angle 90 Degrees 90 Degrees
Platform Boyutları 50001000 + 1000500 mm 60001000 + 1000900 mm
Main Frame Material 120605 Rectangular Tube J2001006 Structural Steel
Platform Plate 4mm Steel Plate 6mm Reinforced Steel
Hydraulic Cylinder Φ80 – 60 mm Φ100 – 80 mm
Pump Station Power 3.0 kW 5.5 kW
Cycle Time 120 – 150 Seconds 120 – 150 Seconds
Hydraulic Pipe Dia. Φ22 mm Φ27 mm
Control Logic Schneider PLC / Wireless Remote Schneider PLC / Wireless Remote
Trolley Dimension N/A (Bundle Fixture) 6000 * 600 * 850 mm

By deploying these customized industrial upender machines, the Anhui facility has optimized the vertical transition of steel profiles, reducing material handling time by 40%. The structural integration of the J200 frame ensures that the heavy 3-ton trolleys remain perfectly aligned during high-torque rotations. The system’s strict adherence to GB/T 3766-2015 Hydraulic Fluid Power Safety Requirements provides a reliable, long-term solution for high-duty-cycle industrial logistics.

Destekleyen Markalar

Devirme makinelerimiz elektrik kontrol, pnömatik, hidrolik ve mekanik parçalar için birinci sınıf ithal ve yerli marka bileşenleri benimser.
1. Elektrik Kontrol Bileşenleri
Kaliteli parçalar hassas ve istikrarlı çalışma sağlar
-SIEMENS: PLC, invertör, alçak gerilim parçaları
-MITSUBISHI: Servo motorlar ve tahrik sistemleri
2. Pnömatik ve Hidrolik Bileşenler
Sabit çevirme ve yüksek yük kapasitesini garanti eder
-SMC: Silindirler ve pnömatik aksesuarlar
-REXROTH: Hidrolik valfler ve pompa istasyonları
3. Mekanik Transmisyon Parçaları
Sağlam yapı sorunsuz çalışma sağlar
-HIWIN: Lineer kılavuzlar ve vida tertibatları
-NSK: Yüksek hassasiyetli döner rulmanlar
4. Alçak Gerilim Dağıtım Parçaları
-CHINT/DELIXI: Devre kesiciler ve anahtarlar
-EATON: Güvenlik ve dağıtım bileşenleri

Proje Yürütme ve Başarılar

Uygulama Detayları

Uygulama ve Başarılar

For a coil processing enterprise in Hefei, Anhui, we delivered a customized 3-Ton Industrial Hydraulic Tilting Platform dedicated to heavy coil material handling. It replaces traditional crane-assisted flipping and manual auxiliary positioning, solving common industry pain points such as low coil handling efficiency, easy surface damage and high safety risks, and achieving full-process optimization for coil loading, flipping and station switching.
1. Professional Customization for Coil Working Conditions
Steel coils and metal coils feature heavy weight, smooth surface and easy rolling displacement, making conventional handling equipment unable to fit the bearing and flipping demands. This customized hydraulic tilting platform adopts a special anti-slip limit structure and curved bearing design, perfectly fitting the outer contour of coil materials. It supports stable 90° flipping of various coil workpieces, thoroughly adapting to the coil processing and feeding workflow of Hefei manufacturing workshops.
2. Significant Handling Efficiency Improvement
Traditional coil flipping relies on multi-person cooperation and repeated crane calibration, with long operation cycles and discontinuous workflow. The hydraulic tilting platform realizes one-button automatic lifting and tilting positioning, completing accurate coil turnover in a short time. It boosts overall coil handling efficiency by over 75%, effectively accelerating workshop feeding, processing and unloading cycles.
3. Zero Surface Damage & Low Rework Rate
Crane hoisting and manual flipping are prone to coil extrusion, collision, rolling and surface scratches, resulting in material scrapping and secondary processing. The platform features balanced hydraulic transmission and uniform stress bearing, ensuring no sliding, shaking or friction damage during coil flipping. It achieves zero damage to coil surfaces, greatly reducing material loss and rework costs.
4. Effective Labor & Safety Optimization
Original coil handling requires 3–4 skilled workers to complete hoisting, fixing and flipping cooperation. This automated hydraulic tilting equipment supports tek kişilik bağımsız operasyon. It cuts redundant labor investment, eliminates safety hazards such as heavy object swinging and falling in traditional operations, and realizes standardized and safe production.
5. Stable & Durable Industrial Performance
Designed for long-term high-frequency heavy-load operation, the whole machine adopts thickened industrial steel structure and anti-wear hydraulic components. It features strong load stability, low failure rate and simple daily maintenance. The 3-ton rated load fully meets the handling demands of most conventional metal coils, with strong adaptability to continuous industrial production.
Genel Proje Faydaları
After formal operation, the client’s coil handling process achieved 75%+ efficiency growth, reduced labor costs and zero coil damage accidents. The entire material handling link realized automation and standardization, effectively stabilizing product quality and improving the overall operational efficiency and profitability of the factory.

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