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SYNCHRONOUS DOUBLE PORTAL CRANE SYSTEMS – MAXIMUM SAFETY AND CONTROL UNDER HEAVY LOADS

SYNCHRONIZED DOUBLE GANTRY CRANE: ADVANCED ENGINEERING SOLUTION FOR SAFE, CONTROLLED, AND SIMULTANEOUS HEAVY LOAD HANDLING

In heavy industry, some loads are too large, wide, or asymmetrical to be handled by a single crane. In such cases, two gantry cranes operate simultaneously and fully synchronized to lift the same load together. This system is called a synchronized double gantry crane.

Synchronized systems are essential for the following types of loads:

• Steel structures 20–40 meters long

• Prefabricated concrete columns and trusses over 50 tons

• Giant machine bodies

• Large wind turbine components

• Wide marble or stone blocks

• Large modular units loaded onto trucks or ships

These systems require millisecond-precision synchronization, advanced automation, and full safety infrastructure, as coordination between two cranes is critical.

Eser Vinç Engineering is one of Turkey’s leading manufacturers of synchronized gantry crane systems, specializing in heavy tonnage and long-load applications.

This guide explains how synchronized gantry crane systems operate, where they are used, their technical specifications, and professional solutions offered by Eser Vinç.

1. What is a Synchronized Double Gantry Crane System?

A synchronized double gantry crane allows two separate gantry cranes to be controlled from a single center, moving simultaneously at the same speed and position.

Key points:

• The two cranes are not physically connected

• PLC-based automation ensures they behave as a single unit

• One operator controls both cranes simultaneously

• Purpose: lift and transport heavy or oversized loads safely and balanced

2. Why is a Synchronized Gantry Crane Required?

Some loads cannot be lifted by a single crane because:

✔ Too long – a single crane cannot lift one end, causing bending or imbalance
✔ Too heavy – exceeds single crane capacity
✔ Wide geometry – trusses, columns, long steel beams require synchronized movement
✔ Precise lifting required – uneven lifting risks damage and safety
✔ Needs two-point lift – e.g., a 30-meter concrete truss

Synchronized systems are the safest method for heavy load handling.

3. Industries Using Synchronized Double Gantry Cranes

Critical heavy industry operations:

• Precast Concrete Production – beams 20–40 m, giant columns, double truss elements

• Steel Construction – large trusses, wide column frames, giant steel profiles

• Machinery Manufacturing – wide machine bodies, 30–60 ton press molds

• Marble Yards – heavy and wide blocks, large slabs

• Shipyards & Ports – modular units, ship components, heavy containers

• Energy Sector – turbine bodies, large wind turbine components

Synchronized systems ensure safety and increase efficiency.

4. How Synchronized Gantry Cranes Work – PLC-Based Intelligent Control

The heart of synchronization is PLC automation.

• Each crane has its own motors and drives

• PLC monitors all movement parameters in real time

• Hoisting, travel, and braking are managed simultaneously

• Any deviation of 0.1 mm is corrected automatically

• Operator controls both cranes from a single console

Synchronized operations include:

• Lift synchronization

• Travel synchronization

• Lateral (left/right) synchronization

• Braking synchronization

• Load distribution balance

Without this system, operating two cranes together is extremely risky.

5. Technical Specifications (Eser Vinç Standard)

✔ PLC-based full synchronization control
✔ Dual-speed motor–reducer system
✔ Synchronized algorithms for lifting and traveling
✔ Anti-sway load stabilization
✔ Overload sensor
✔ Digital torque and speed feedback
✔ Remote control for dual crane operation
✔ Motor temperature and brake status monitoring
✔ Load balance sensors
✔ Emergency simultaneous stop

Designed for 99% accuracy even under heavy loads.

6. Safety Systems (Critical for Heavy Loads)

• Simultaneous braking in emergencies

• Torque and speed comparison sensors

• Automatic slip correction

• Real-time load distribution monitoring

• Limit switch synchronization

• End-of-rail buffer synchronization

• Brake safety systems

• Prevention of lifting beyond synchronized range

• Operator safety control interface

• Load balance verification

Essential for operator and load safety.

7. Construction Design for Synchronized Gantry Cranes

Eser Vinç uses heavy-duty constructions for synchronized gantry cranes.

Design features:

• Steel structure compliant with FEM 3m / FEM 4m

• High torsional rigidity girders

• Crane legs designed for 20–50 m spans

• Wind load-analyzed gantry legs

• Superior rigidity, low vibration

• Anti-derail systems

• Storm brakes and wind locks

For synchronized operation, both cranes must have identical rigidity.

8. Who Should Use a Synchronized Double Gantry Crane?

Required if any of the following apply:

• Load exceeds 10 meters

• Load geometry is wide

• Load exceeds 20 tons

• Load must be lifted at two points simultaneously

• Load rotation risk during lifting

• Load deformation risk exists

Synchronized systems should only be designed by expert engineering firms.

9. Factors Affecting the Price of Synchronized Gantry Cranes

Because they require advanced automation, pricing depends on:

• Load capacity of both cranes

• Span width

• Gantry leg height

• Automation level (PLC – VFD – Anti-sway)

• Load balancing system

• Wind load class

• Ground and rail conditions

• Installation site

• Process intensity

Pricing is entirely project-specific.

10. Eser Vinç – Turkey’s Expert in Synchronized Gantry Cranes

Key advantages:

• Expertise in heavy and long loads

• Advanced PLC synchronization software

• 20+ years experience in gantry construction

• Anti-sway + VFD + smart control technology

• Professional team for wind load and ground calculations

• Turkey’s fastest service and spare parts network

• Long-lasting heavy-duty design

• European-standard testing and commissioning

Eser Vinç is a trusted brand with dozens of synchronized gantry projects in Turkey.

11. Conclusion

For heavy, long, wide, or delicate loads, operating two gantry cranes simultaneously is mandatory. Only advanced PLC automation and strong engineering can ensure safe handling.

Eser Vinç synchronized gantry cranes provide:

• Simultaneous control

• High-level safety

• Heavy-duty construction

• High precision

• Minimal risk

• Long service life

• Continuous stable operation

They are the most reliable solution for heavy industry.

Contact us for a price quote today.