Large-Tonnage Electric Hoist Selection Guide

Large-Tonnage Electric Hoist Selection Guide

In heavy industry, port logistics, infrastructure projects, wind power installation, and other fields, large-tonnage electric hoists (typically those with a rated lifting capacity of 50 tons or more) are essential equipment for efficient heavy load handling. Their selection not only directly impacts operational efficiency and safety but also impacts overall lifecycle cost control. Choosing the right equipment can reduce downtime losses by over 30%, while choosing the wrong one can lead to equipment damage from overload, safety incidents, and even project delays. International professional buyers should systematically consider the following six dimensions to ensure the selection accurately matches their needs.

I. Pre-selection: Identify three core requirements to avoid blind benchmarking

The first step in selecting a model isn't to compare specifications, but to identify the "rigid requirements" of your specific application. This forms the foundation for all subsequent decisions:

Load requirements: Consider not only the "rated tonnage," but also the "dynamic load factor."

International buyers often overlook "dynamic load shock"—when a hoist lifts heavy objects, accelerates, or brakes, the actual load can far exceed the rated value (for example, the typical dynamic load factor in the crane industry is 1.2-1.5). For example, if a 100-ton steel structure needs to be moved, and the operation involves frequent starts and stops (such as in workshop assembly), a hoist with a rated capacity of 120 tons or higher (100 tons x 1.2 dynamic load factor) should be selected, rather than directly benchmarking against a 100-ton rating. This prevents motor burnout or wire rope breakage from prolonged overload.

Operating Conditions: Environmental Compatibility is Key to Longevity

Four key operating environment indicators should be clearly defined:

Temperature Range: High-temperature environments (such as steel mills) require a high-temperature-resistant motor (insulation grade F ≥). Low-temperature environments (such as cold ports) require low-temperature grease (suitable for -30°C to -10°C).

Corrosion: Coastal or chemical environments require a corrosion-resistant model (with epoxy zinc-rich paint applied to the body and motor protection grade ≥ IP55).

Dust Concentration: Mines or cement plants require dust shields to prevent dust from entering the gearbox's wear parts.

Explosion-Proof Requirements: Oil and gas or chemical plants require explosion-proof hoists that comply with ATEX (EU) and IECEx (international). The explosion-proof rating must match the hazardous area classification (e.g., Ex d IIB T4 for Zone 1).

Efficiency Requirements: Hoisting/Operating Speeds Must Be "Matched"
Speed ​​requirements vary significantly across different operations:

Precision assembly applications (e.g., wind turbine installation): require low-speed stability (Hoisting Speed ≤ 0.5 m/min). A variable frequency speed control system is recommended, enabling stepless adjustment from 0 to rated speed.

Batch handling applications (e.g., port unloading): require high speed and efficiency (hoisting speed ≥ 2 m/min). A dual-speed motor (high speed for no-load/light load, low speed for heavy-load positioning) can be selected to balance efficiency and safety.

II. Core Parameter Analysis: Four "Easily Confused Indicators" Determine Equipment Performance

The parameter markings for large-tonnage electric hoists in the international market vary significantly (for example, the imperial system is commonly used in Europe and the United States, while the metric system is widely used in Asia). It is important to clarify the following four key indicators:

Rated Capacity vs. Maximum Capacity

The rated capacity is the upper limit of the load for long-term safe operation of the equipment (in compliance with international standards such as EN 13000 and OSHA 1910.179), while the maximum capacity is a short-term emergency load (usually 1.1 times the rated capacity) and should not be used as a guide for daily operation. For example, a hoist labeled "100T (Max 110T)" should only be used at 100T in daily operation. Motor Protection Grade (IP) and Insulation Grade

Protection grade (IPXX): The first digit represents dustproofness (5 = dustproof), the second digit represents waterproofness (4 = splashproof, 5 = waterjetproof). For port and outdoor operations, IP55 or higher is recommended, while IP44 is acceptable for clean indoor environments.

Insulation grade (A/B/F/H): This represents the motor's upper temperature limit (F = 155°C, H = 180°C). Large-tonnage hoists, due to their heavy loads and high heat generation, are recommended to have at least F-grade insulation to prevent high-temperature burnout of the motor.

Braking System: "Dual Braking" is the Bottom Line

Large-tonnage hoists must be equipped with a dual system: "Service Brake + Safety Brake":

Service Brake: Synchronizes with the motor's start and stop (e.g., electromagnetic brake) and is used for routine deceleration and positioning.

Safety Brake: An emergency brake independent of the motor (e.g., hydraulic push rod brake). If the service brake fails or the power is lost, it engages within 0.5 seconds to prevent the load from falling. The braking distance must be confirmed (for example, the braking distance for a 100-ton hoist should be ≤0.3m), and a brake system life test report must be provided.

Wire Rope/Chain: The material determines the "load limit."

Wire Rope: Choose high-strength galvanized steel wire rope (e.g., 6×37+FC structure, with a breaking force ≥ 5 times the rated load). Pay attention to the wire rope diameter (e.g., a 100-ton hoist requires a wire rope with a diameter ≥32mm).

Chain: If choosing a chain hoist, select a high-strength alloy chain of Grade 80 or higher (e.g., 20Mn2) to prevent chain fatigue fracture. Also, confirm the chain lubrication method (automatic lubrication reduces maintenance costs).

III. Compliance and Safety: International Certifications + Mandatory Safety Devices: Neither is Necessary

For international buyers, compliance directly determines whether equipment can be imported and used, while safety devices are crucial for the safety of personnel and assets:

Three Must-See International Certifications

Regional Certifications: The EU requires CE certification (compliant with the EN 13000 crane standard), the US requires OSHA and UL certifications, the Middle East requires SASO certification, and Southeast Asia requires TISI certification.

Safety Certifications: Prefer brands certified to ISO 4871 (Crane Safety) and ISO 12100 (Machinery Safety Design).

Explosion-Proof Certifications: Hazardous environments require ATEX (EU), IECEx (International), or CSA (North America) certifications. The certificate must include the specific explosion-proof level and applicable media (e.g., Class IIB gas, T4 temperature group).​

5 "Mandatory Safety Devices" You Can't Skip

Even with a limited budget, the following safety devices must be standard:

Overload Limiter: Automatically cuts off the hoist power supply when the load exceeds 10% of the rated value to prevent overloading;

Up/Down Limiter: Prevents the hook from hitting the top or bottom, protecting the wire rope and motor;

Emergency Stop Button: The machine must be equipped with two or more red mushroom-shaped emergency stop buttons (on the operating handle and the machine body) for easy emergency operation;

Buffers: Polyurethane or spring buffers must be installed at both ends of the running track to reduce the impact of the hoist collision;

Acoustic and Visual Alarm: Automatically emits audible and visual signals during hoisting/operation to alert nearby personnel to move out of the way.​

IV. Adaptation and Integration: Ensuring Equipment Integration into Existing Systems

Large-tonnage electric hoists are not designed for standalone use. They must be compatible with the crane's main beam, rails, and control system to avoid the situation of "affordable but inoperable."

Compatibility with the Crane Main Beam

Three main beam data items are required: main beam span (determines the length of the hoist's running rails), main beam web thickness (determines compatibility with the hoist's trolley wheel pressure), and main beam load rating (must be ≥ hoist weight + 1.2 times rated load). For example, a 100-ton hoist weighs approximately 15 tons, and the main beam must be able to withstand a concentrated load of at least 138 tons (15 + 100 × 1.2).

Track Compatibility

The track model (e.g., QU120, P43) must match the hoist trolley wheel diameter. Also, ensure track straightness (deviation ≤ 1mm per meter) and curvature radius (when operating on a curve, the radius must be ≥ 10 times the hoist trolley wheelbase) to prevent the trolley from jamming or excessive track wear.

Control System Integration

If integration with a factory automation system (e.g., PLC, MES) is required, confirm whether the hoist supports 485 communication (Modbus protocol) or Profinet protocol. A control interface manual should also be provided to facilitate subsequent commissioning. Furthermore, for remote control requirements (e.g., operation from 100 meters away), select a wireless remote control (e.g., F21-E1B, with an anti-interference rating of ≥ Level 3) to avoid the wiring limitations of wired control systems.

V. Lifecycle Cost: Don't Just Look at the "Purchase Price," Calculate the "Long-Term Cost"

International buyers often fall into the "low-price trap." Instead, they should focus on the combined "purchase price + operating cost + maintenance cost + failure cost."

Purchase Cost: Beware of "Reduced Specifications for Lower Prices"

Low-price hoists may skimp on key components, such as replacing a 6-pole motor with a 4-pole motor (which speeds up and increases braking risk) or replacing high-strength wire rope with ordinary wire rope (which reduces lifespan by 50%). It's recommended to choose suppliers who provide transparent pricing. Require suppliers to list the brand and model of core components such as motors, brakes, and wire ropes (e.g., Siemens motors, ABB drives) to facilitate price comparison.

Operation Cost: Energy Consumption is a "Hidden Expense"

Variable frequency motors use over 30% less electricity than conventional motors. For example, a 100-ton hoist (75kW motor) operating 8 hours per day with an electricity price of $0.80 per kWh can save approximately $52,000 annually (75 x 8 x 365 x 30% x 0.8). Furthermore, an automatic lubrication system reduces grease consumption, saving approximately $2,000 annually in maintenance material costs.

Maintenance Cost: Ease of Replacement is More Important Than Affordability for Consumable Parts

Consumable parts (such as brake pads, wire ropes, and bearings) must be readily available and have a reasonable procurement cycle. International brands must offer global delivery (e.g., delivery within 48 hours) to avoid downtime due to shortages. For example, a project was shut down for a week due to a brake pad shortage, resulting in $200,000 in lost time alone, far exceeding the cost of the brake pads themselves. Failure Cost: Reliability Determines "Downtime Losses"

Choose brands with low failure rates (e.g., MTBF ≥ 5000 hours). Require suppliers to provide overseas after-sales service outlets (e.g., service centers in Europe, North America, and Southeast Asia) to ensure on-site repairs within 24 hours of a failure to minimize downtime.

VI. Selection Mistakes: Avoiding Four Common Pitfalls

Mistake 1: "The Bigger the Tonnage, the Better"

Selecting a hoist larger than required (e.g., selecting a 100-ton hoist when 80 tons is actually required) will result in an excessively low motor load factor (constantly below 50%), increasing energy consumption and motor heat. Furthermore, the hoist's increased weight will place additional strain on the main beam.

Mistake 2: Ignoring "Installation Space"

Failure to measure the plant height (the lifting height must be ≥ the maximum distance from the hook to the ground + a 1-meter safety distance) or failing to consider the minimum turning radius of the hoist trolley can result in equipment installation problems upon arrival. Misconception 3: Not considering "after-sales service"

Some suppliers don't offer overseas after-sales service. Failures require dispatching engineers from China, and repair cycles can take up to a month. It's recommended to choose brands with established after-sales teams in your target market and to ensure they offer a warranty of at least one year (two years for core components).

Misconception 4: Skipping "trial lift tests"

Upon arrival, equipment is put directly into operation without undergoing a trial lift test (e.g., running it unloaded for 30 minutes and then running it fully loaded 10 times). A trial lift can reveal problems like abnormal brake noise and trolley jamming, preventing accidents during full operation.