• Jul 28, 2022
• Case Studies

3 Units 1-ton Electric Chain Hoist for United Arab Emirates

3 Units 1 ton Electric Chain Hoist with U type Track for United Arab Emirates. Let's take a look at the twists and turns of the transaction process.

The customer is an industrial maintenance and manufacturing facility located in the United Arab Emirates. Their operations involve heavy machinery, mechanical repairs, and periodic equipment upgrades. In such an environment, reliable material handling equipment—especially electric chain hoists—is vital. The plant previously used 0.5 ton capacity hoist cranes. Aging equipment and limited lifting capacity led to bottlenecks. The client needed to upgrade to 1 ton electric chain hoists to streamline maintenance, reduce manual labor, and improve safety.

Specific tasks include lifting motors, gearboxes, pumps, and tooling components within confined workshop areas. The facility's existing U shaped track (U track) rail system required hoists that could mount easily and move smoothly. With health and safety regulations in the UAE, the client demanded a solution that combined high lifting precision, dual-speed operation, and compact size to fit under low ceilings.

Customer's Initial Inquiry and Evolving Requirements

In the project's early stage, the client submitted an inquiry via Yuantai's website. They asked for a quote on a 1 ton, 5 meter lifting height, two-speed electric hoist. Within 30 minutes, Yuantai provided a detailed quotation for a single-speed electric wire rope hoist and suggested dual-speed options. However, the client disappeared without responding.

Revised Request After Three Months

Three months later, the customer reappeared with new requirements. They had replaced their 0.5 ton hoist cranes and needed to upgrade to 1 ton electric chain type hoists that could run on their existing U type track system. Their updated request included:

• Quantity: Three units of 1 ton hoist crane.
• Lifting Height: 5 meters required minimum space.
• Hoist Speeds: Slow speed 6 m/min; fast speed 12 m/min; CT speed 17 m/min.
• Track Compatibility: Must fit and travel on existing U type rails without modification.
• Hoist Dimensions: Low headroom, compact design to fit under existing gantry beams.

The addition of dual-speed lifting and dual braking became essential. They needed precise control when lowering heavy equipment and faster travel when moving empty hooks. The CT speed of 17 m/min would allow quick transit between workstations.

Client Concerns and Detailed Drawings

The customer provided drawings of their U type track profile and beam dimensions. They were concerned that the proposed hoist trolley would not properly fit or run smoothly. At this stage, they also increased the required lifting speed from 7 m/min to between 8–10 m/min. Yuantai's engineering team analyzed the U track cross-section and the beam flange profile. We confirmed the hoist trolley assembly could be modified to match the track rail width and curvature exactly. The team then prepared a customized electric chain hoist solution to meet all specs.

Challenges Faced Before Yuantai's Solution

1. Inadequate Lifting Capacity

Before consulting Yuantai, the facility used 0.5 ton hoist cranes. These underpowered hoists struggled with 800–900 kilogram pumps, often requiring two workers to operate, which reduced efficiency. The lack of a 1 ton hoist meant frequent use of forklifts or manual pulley systems, increasing downtime and safety risks.

2. Incompatible Rail and Hoist Systems

The existing U type track rails had a non-standard profile. Off-the-shelf hoist trolleys could not match the track width or curvature. This mismatch caused jerky trolley travel and increased wear on both track and wheels. The plant experienced frequent derailments and maintenance interventions, leading to project delays.

3. Lack of Dual-Speed Control and Safety Features

Previous single-speed hoists lacked precision when positioning heavy loads. Operators reported sudden jerks when approaching the final position. In confined areas, this caused collisions with nearby equipment and occasional minor injuries. There were no overload limiters or redundant braking systems to prevent accidental drops.

4. Limited Technical Support for Installation

Because the plant relied on outdated manual hoists, there was no experience with modern electric chain hoist installation. Any new equipment required a robust plan for commissioning. The facility lacked in-house expertise to install and test complex dual-speed electric hoisting systems. This uncertainty caused hesitation in finalizing the purchase.

Yuantai's Tailored Electric Chain Hoist Solution

Yuantai proposed a 1 ton electric chain hoist with U type track trolley assembly. The design addressed every client concern and provided a robust, efficient solution. Specific features included:

Customized U Type Track Trolley Design

• Exact Track Profile Matching: The trolley wheels and flanges were machined to precisely match the client's U track dimensions (45 mm inner width, 20 mm rail thickness).
• High-Strength Steel Wheels: Heat-treated 65Mn steel wheels with a hardness of HRC58–62. Ensures minimal wear on the track and long service life.
• Sealed Roller Bearings: Each wheel features double-sealed bearings (SKF standard) to prevent dust ingress. Ideal for dusty workshop environments.
• Adjustable Beam Clamps: Allows fine-tuning of trolley width by ±5 mm to accommodate minor variances in rail spacing.

Electric Chain Hoist Design

• Lifting Capacity: 1 ton at 5 meter lift height, ensuring safe handling of medium-weight machinery and tooling.
• Dual Hoist Speeds: 0–6 m/min for slow, precise positioning and 0–12 m/min for rapid lifts. Incorporates variable frequency drive (VFD) control for smooth acceleration and deceleration.
• CT Speed 17 m/min: High-speed trolley travel for efficient load transit between workstations.
• Motor and Gearbox: Schneider electric motor (1.5 kW) with IP55 protection rating for dust and splash resistance. Helical gearbox with 94% efficiency and low noise.
• Load Chain: G80 FEC alloy steel chain rated for 50 kN tensile strength. Corrosion-resistant plating for long life in humid environments.
• Hook Assembly: Drop-forged high-tensile steel hook with 360° swivel and safety latch. Load test certified at 1.25 times rated capacity.
• Brake System: Dual braking mechanism with mechanical load brake and friction disc brake. Ensures load holds at any position even in power loss.
• Control Options: Pendant station with IP65 rating. Wireless remote control with 50 m range. Both feature ergonomic designs and clear, tactile buttons.

Design Adaptations for COVID-19 Constraints

• Extended Lead Time Planning: Accounted for shipping delays and quarantine requirements. Delivered within 60 days despite global logistics disruptions.
• Remote Commissioning Tools: Included detailed installation manuals, step-by-step assembly videos, and remote video conferencing support. This reduced on-site engineer visits by 50%.
• Local Installation Team Coordination: In areas where there is a lack of regular Yuantai staff, Yuantai will send installers to the local area to participate in the installation and ensure that everything goes smoothly.

Implementation and Commissioning

Once the electric chain hoist with U type track units arrived in the UAE, Yuantai coordinated the following steps:

Site Survey and Preparation

Yuantai engineers reviewed the client's existing U track installation. They measured beam depths, flange widths, and track alignment. Minor welding repairs were done on worn sections of the track before hoist installation.

Trolley and Hoist Assembly

• Mounted the trolley assembly on each U track. Adjusted wheel spacing to fit the 45 mm track width.
• Secured beam clamps and tested trolley travel. Ensured smooth motion with no binding.
• Suspended the electric chain hoist from the trolley. Verified that the hook-to-rail distance did not exceed 4.2 meters, fitting under low overhead obstacles.

Electrical Hookup and Control Testing

• Connected Schneider motor to the 415 V, 50 Hz, three-phase power supply. Checked motor rotation and direction switches in the pendant control.
• Paired the wireless remote transmitter with hoist receiver. Verified that commands for slow/fast lift and trolley travel were responsive up to a 50 m range.
• Performed functional tests of dual-speed hoisting (6 m/min and 12 m/min) and dual trolley speeds (6 m/min low, 17 m/min CT). Fine-tuned VFD parameters to minimize load sway.

Load Testing and Certification

• Conducted no-load travel tests across the 10 m span. Ensured no binding or misalignment.
• Performed incremental load tests: 0.5 ton, 1 ton, and 1.25 ton (overload) to verify mechanical brake performance and overload limiter tripping.
• Inspected limit switch accuracy by lowering the hook until it activated. Verified that the hoist stopped 10 cm above the floor.
• Issued Factory Acceptance Test (FAT) reports. Provided certificates for chain, motor, brake, and safety devices.

Operator Training and Handover

Yuantai's team trained the local maintenance crew on:

• Safe hoist operation: Slow approach mode, load positioning, and emergency stop usage.
• Routine lubrication: Chain lubrication points, gearbox oil check, and trolley wheel inspection.
• Troubleshooting: Interpreting overload limiter warnings, replacing a worn chain link, and resetting limit switches.

After satisfactory trials, Yuantai handed over the cranes with signed completion certificates. The client expressed confidence in the new hoist system.

Advantages of Yuantai's Electric Chain Hoist with U Type Track

1. Compatibility with Existing Infrastructure

Matching the U type track rail profile ensured seamless integration. No need for major modifications to existing beams or rails. This preserved structural integrity and saved installation time.

2. Enhanced Safety and Precision

Dual-speed operation (6 m/min slow and 12 m/min fast) and CT travel speed (17 m/min) allowed smooth load control. Operators could use slow mode for precise part placement. The dual braking system prevented accidental drops and ensured safe load holding during power outages.

3. Compact Low Headroom Design

The hoist's overall height of 3.2 meters fit under low ceilings and service pipes. This was critical in cramped workshop areas. It enabled lifting tasks without removing light fixtures or ducts.

4. Reduced Downtime and Maintenance Costs

Sealed roller bearings in trolleys and the high-strength G80 alloy chain minimized wear from dust and moisture. Schneider motors with IP55 protection required less frequent maintenance. The robust design extended service intervals from monthly to quarterly.

5. Cost-Effectiveness Compared to Custom Solutions

Instead of bespoke European-style hoists with long lead times and high costs, the electric chain hoist with U type track offered similar performance at 20–30% lower cost. Shorter delivery (60 days versus 70 days) aligned with the client's tight project schedule.

Broader Applications for the 1 Ton Electric Chain Hoist with U Type Track

The design and features of these hoists make them suitable beyond the UAE industrial plant. They can serve in multiple sectors:

1. Small and Medium Manufacturing Workshops

For lifting machine tools, die sets, and production molds. The 1 ton capacity handles medium-weight parts, while the dual-speed feature offers precise positioning on assembly lines.

2. Automotive Repair Shops

For hoisting engines, transmissions, and heavy subassemblies. The compact headroom design fits under low shop ceilings. Dual controls allow technicians to stand clear of moving loads.

3. Warehouse and Distribution Centers

For moving palletized goods and bulk items. The CT travel speed of 17 m/min improves workflow by reducing load cycle times across 10–20 meter aisles. U type track cranes can run on mezzanine-level rails for vertical storage handling.

4. Electrical and HVAC Equipment Installation

For lifting heavy air handling units, transformers, and switchgear into position. The 1 ton hoist can handle individual heavy components, while the 5 meter lift height covers raised floor or loft installations.

5. Food and Beverage Processing Facilities

In plants with limited overhead clearance, the low headroom electric chain hoist lifts stainless steel tanks and mixers. Sealed bearings and IP55 motors ensure washdown compatibility in hygienic environments.

Customer Feedback and Outcomes

Yuantai understood our U track constraints and provided a perfect 1 ton chain hoist solution. The dual-speed and dual-control features make our maintenance work faster and safer.

Yuantai Electric Chain Hoist

Yuantai's electric chain hoist has an electric motor, a transmission mechanism, and a sprocket. It lifts loads from 0.3 to 35 tons and reaches heights from 3 to 50 meters. It works in workshops, warehouses, wind power sites, logistics centers, terminals, and building sites with single or double beam cranes, jib cranes, and gantry cranes. The hoist has a sealed shell for tough environments. It stops if wired wrong thanks to reverse phase protection. Limit switches prevent over-lifting. A low-voltage handle switch reduces electrical risks. Braking uses a disc-type DC electromagnetic mechanism. The Grade 80 alloy steel chain stays strong and durable. Operators use a pendant or remote control.