How Are Our Tire Cranes Designed Using a Modular Approach?

The core of our tire crane's modular design lies in adhering to principles of functional independence, standardized interfaces, rapid assembly/disassembly, and expandability/replaceability. The entire machine is segmented into seven core modules—Structural, Traveling, Hoisting, Power, Electrical Control, Hydraulic, and Counterweight—thereby achieving high efficiency across the entire lifecycle, including manufacturing, transportation, installation, maintenance, and upgrading.

I. General Principles of Modular Design
Functional Independence: Each module performs a single core function, featuring clear boundaries and ensuring no mutual interference.
Standardized Interfaces: Mechanical, electrical, and hydraulic interfaces adhere to unified specifications, enabling "plug-and-play" functionality.
Transport Compliance: The dimensions and weight of individual modules are optimized to meet road and maritime transport standards (Width ≤ 3.5m, Height ≤ 4.5m, Weight ≤ 40t).
Rapid Assembly: Utilizing pins, bolts, and quick-connect couplings, on-site assembly can be completed within 4 hours.
Expandability & Replaceability: Supports the addition or removal of modules and component upgrades based on specific operating conditions, thereby reducing modification costs.
II. Segmentation and Design Highlights of the Seven Core Modules
1. Structural Module (The Machine's Skeleton)
Upper-structure Slewing Platform Module
Features an integrated welded and/or bolted structure, incorporating the slewing bearing mount, operator's cab, and counterweight mounting points.
Interfaces: Standard slewing bearing flange (connecting to the lower structure), crane/boom mounting points, and hydraulic/electrical cable routing ports.
Gantry / Outrigger Module (for RTG Cranes)
Comprises left and right gantry legs, a crossbeam, and a cantilever; constructed using high-strength steel (Q345B/Q960) via welding.
Modularity: The gantry legs are segmented into upper and lower sections; the crossbeam is segmented; and the cantilever is designed to be retractable or detachable.
Interfaces: Connected via high-strength bolts and pins; alignment pins combined with guide slots ensure precise coaxiality.
Boom Module (for Truck Cranes / RTG Cranes)
Telescopic Boom: Consists of segmented main and auxiliary boom sections; each section is independent, features internally mounted hydraulic cylinders, and utilizes quick-connect couplings.
Lattice Boom: Composed of standard segments (6m/8m lengths) connected via bolts, allowing the overall boom length to be configured as required. Lightweight Design: Q960 steel / carbon fiber composite construction, achieving a 20–30% weight reduction.
2. Traveling Chassis Module (Mobile Core)
Lower Frame Module
Integrated box-beam structure, incorporating the steering axle, drive axle, outriggers, and slewing bearing base.
Interfaces: Standardized slewing bearing mounting surface, outrigger connection mounts, and power/hydraulic installation points.
Drive / Steering Module
Drive: Permanent magnet synchronous motor + wheel-side reducer direct drive; modular assembly designed for rapid removal and replacement.
Steering: Full-hydraulic / electro-hydraulic steering; independent module supporting 90-degree and "crab-walk" modes.
Tires: Heavy-duty engineering tires; quick-release hubs with integrated tire pressure monitoring.
Outrigger Module
Comprises fixed outriggers, movable outriggers, and vertical hydraulic cylinders; designed as independent assemblies.
Interfaces: Pin-shaft connections + hydraulic quick-connects; independent control for horizontal and vertical extension.
3. Lifting Operation Module (Core Actuation)
Hoisting Mechanism Module
Integrates the winch, motor, brake, reducer, and wire rope spooler into a single, unified assembly.
Interfaces: Standard flange connection to the slewing platform; hydraulic/electrical quick-connects.
Trolley / Gantry Traveling Module (RTG)
Trolley: Modular drive wheel sets, rail wheels, guide wheels, and brakes; travels along the main girder.
Gantry: Four-wheel / eight-wheel drive configurations; independent drive modules with synchronized control.
Spreader / Grab Module
Independent modules for container spreaders, hooks, and grabs; designed for rapid interchangeability (within 10 minutes).
Interfaces: Standard connection pins + electrical/hydraulic quick-connects.
4. Power Module (Energy Source)
Diesel Generator Set Module
Integrates the engine, generator, radiator, fuel tank, and control system into a single unit for integral hoisting.
Interfaces: Standard power output flange, electrical control interface, and cooling system quick-connects.
Pure Electric / Hybrid Module
Lithium-ion battery / fuel cell pack modules with integrated BMS; designed for rapid replacement (within 30 minutes). Hybrid System: Diesel + Battery Common DC Bus, Energy Recovery, Independent Control Unit.
Hydraulic Power Unit (HPU)
Integrates oil pump, electric motor, oil tank, valve block, and cooler; constitutes an independent module.
Interfaces: High-pressure hydraulic quick-connects, electrical control interfaces.
5. Electrical & Control Module (The Central Brain)
Main Controller Module (PLC/MCU)
Industrial-grade PLC; integrates I/O, communication, and safety circuits; housed in an independent cabinet.
Interfaces: Standard fieldbuses (Profinet/EtherCAT), quick-connects for sensors/actuators.
Drive Control Module
Inverter modules for Hoisting / Long Travel / Cross Travel; features a common DC bus and energy regeneration capabilities.
Interfaces: Power cable quick-connects, control signal interfaces.
Sensor & Safety Module
Integrates torque limiter, height/radius sensors, anemometer, anti-collision system, and cameras.
Modularity: Safety PLC + sensor array; "Plug-and-Play" functionality.
Operator Cab Module
Integrates operator seat, control joysticks, display screens, HVAC system, and control console; designed for single-lift installation.
Interfaces: Quick-connects for electrical/hydraulic/communication lines, vibration-dampening mounts.
6. Hydraulic System Module (Actuation & Drive)
Main Valve Block Module
Integrates multi-way valves, relief valves, check valves, and counterbalance valves; features sub-plate mounting connections.
Interfaces: High-pressure hydraulic quick-connects, control signal interfaces.
Actuator Module
Hydraulic cylinders for Hoisting / Luffing / Telescoping / Outriggers; each constitutes an independent assembly with quick-mount connections.
Interfaces: Cylinder trunnion pins, hydraulic quick-connects.
Cooling & Filtration Module
Independent cooler, filter, and accumulator units; designed for individual replacement during maintenance.
7. Counterweight Module (Balance & Stability)
Segmented Counterweight
Standardized weight blocks (5t/10t units); constructed from cast iron or concrete; designed for stacking.
Interfaces: Locating pins, connecting bolts; quantity can be increased or decreased as required.
Movable Counterweight Module
Hydraulically driven system for fore-and-aft counterweight movement; constitutes an independent module for adjusting the center of gravity. III. Standardized Interface Design (Key Aspect)
1. Mechanical Interfaces
Connection Methods: High-strength bolts (Grade 10.9), pins, quick-release flanges.
Positioning: Locating pins + guide slots, ensuring repeatable installation accuracy (≤0.5 mm).
Identification: Unique numbering for each module and interface to prevent incorrect assembly.
2. Electrical Interfaces
Power Cables: Quick-disconnect connectors (IP67 rating), standardized wire gauges and colors.
Control Signals: Standardized bus terminals, plug-and-play functionality.
Communication: Unified protocols (Profinet/EtherCAT), module self-identification capability.
3. Hydraulic Interfaces
Hydraulic Hoses: Quick-connect couplings (ISO standard), leak-proof and rapid connection.
Identification: Clear labeling of pressure, flow rate, and flow direction to prevent incorrect connections.
IV. Implementation Steps for Modular Design
Functional Decomposition: Deconstruction into distinct categories—"Structure - Mobility - Lifting - Power - Control - Hydraulics - Counterweight"—to clearly define module boundaries.
Interface Definition: Standardization of mechanical, electrical, and hydraulic interface specifications; creation of a comprehensive interface master plan.
Module Design: Independent design for each module, ensuring compliance with requirements for structural strength, rigidity, transportability, and maintainability.
Simulation and Verification: Finite Element Analysis (for strength and fatigue) and motion simulation (to check for interference and verify accuracy).
Factory Pre-assembly: Workshop-based assembly and commissioning of individual modules; disassembly for shipment following full-machine integrated testing.
Rapid On-site Assembly: Assembly performed according to numerical sequence, allowing for complete machine commissioning within 4 hours.
V. Advantages of Modular Design
Production Efficiency: Parallel production of modules shortens the final assembly cycle by 50%.
Convenient Transport: Individual modules comply with transport regulations, reducing shipping costs by 30%.
Rapid Installation: On-site assembly takes **≤4 hours**, significantly boosting site-to-site transfer efficiency.
Simplified Maintenance: Faulty modules can be replaced individually, reducing downtime by 80%.
Flexible Configuration: Modules can be added or removed based on specific operating conditions, lowering customization costs.
Easy Upgrading: Replacement of older modules extends the overall service life of the equipment.