Multi-point Synchronised Hoisting System for Large Components | KLD Engineering Case Study

Case Study Overview

In renovation projects for large exhibition halls, theatre stages and assembly workshops, the hoisting of large-scale components---such as LED screens, conference table tops and stage lighting trusses---presents a key technical challenge: how to achieve fully synchronised lifting and lowering during multi-point hoisting operations.

Traditional solutions involving multiple independently controlled winches struggle to eliminate inconsistencies in lifting point heights caused by factors such as motor response delays and variations in wire rope elongation, posing risks of component tilting, jamming, or even damage.

Addressing this industry pain point, Beijing Tianheng Kairui (KLD Winch) has launched a four-rope synchronous hoisting winch system. This system employs a mechanical synchronisation solution featuring a single motor drive and a single drum with multiple rope grooves, providing reliable technical assurance for multi-point hoisting.

Issues and Pain Points

In typical multi-point hoisting applications, the main engineering challenges are as follows:

Synchronisation Challenges

As the four lifting points are driven by separate power sources, achieving fully synchronised response at the millisecond level is difficult even with sophisticated electronic control systems, resulting in height discrepancies between lifting points.

Uneven Load Distribution

Lack of synchronisation directly leads to uneven load distribution on the components. Localised overloading may cause structural deformation or damage, whilst also accelerating wire rope wear.

Limited Installation Space

The complex overhead structure and limited installation space make it difficult for traditional winch layouts to adapt to on-site conditions.

Operational Noise

Indoor installation environments impose strict requirements on equipment noise levels, which standard industrial winches struggle to meet.

Solution Overview

KLD has designed a four-rope synchronous hoisting winch system for this application, with the core solution outlined below:

Single-motor drive with gear reducer:

By utilising a single power source, synchronisation errors inherent in multi-motor coordinated control are fundamentally eliminated, ensuring stable and reliable power output.

Single-drum, multi-rope groove design:

The drum is machined with precision helical grooves. All four steel wires are wound simultaneously onto the same drum; as the drum rotates once, the length of wire taken up or let out is identical for all four wires---achieving mechanically enforced synchronisation.

Guide pulley assembly for distributed lifting points:

By altering the rope exit direction via guide pulleys, the four lifting points can be flexibly distributed to the required positions on the structure, adapting to different layout requirements.

Rope-pressing roller design to prevent rope slippage:

Equipped with rope-pressing rollers to prevent the steel wire ropes from slipping out of the grooves, ensuring safe and reliable operation.

Optional integrated steel structure frame

An integrated mounting frame can be designed according to the overhead structure, simplifying on-site installation and enhancing overall stability.

Core Technical Parameters

Design Highlights

Structural Design

✔ Single-drum, multi-rope groove structure with mechanical forced synchronisation for high reliability

✔ Rope guide roller design prevents wire rope from slipping out of the groove, ensuring safe operation

Drive System

✔ Driven by a single gear motor, ensuring stable power output and eliminating coordination errors associated with multiple motors

Protective Design

✔ Protective features can be customised to meet operational requirements, adapting to different environments

Control System

✔ Supports variable frequency speed control to meet speed requirements under various operating conditions

✔ Control methods can be customised according to customer requirements

Reliability

✔ High-quality materials combined with precision manufacturing processes ensure low operating noise and a long service life

Application Scenarios:

This system is suitable for the following typical scenarios:

• Multi-point suspension of large LED displays
• Height adjustment of large tabletops, such as conference tables and office desks
• Suspension of stage lighting trusses
• Lifting of large truss structures
• Height adjustment of exhibition items in showrooms
• Transportation of large components on industrial assembly lines

Project Benefits:

Upon implementation of this solution, the following benefits are achieved:

✓ Enhanced lifting stability: Four-rope synchronisation eliminates the risk of tilting, ensuring a smooth and safe lifting process

✓ Improved operational efficiency: Lifting into position in a single operation, eliminating the need for repeated adjustments and significantly boosting efficiency

✓ Reduced equipment risk: Mechanical synchronisation is far more reliable than electronic control, eliminating safety hazards

✓ Extended equipment lifespan: Evenly distributed load reduces wire rope wear, prolonging the service life of the equipment

Customisation Services

In addition to our standard products, we offer customisation services and various optional configurations.

Customers may customise the following aspects according to their specific operational requirements:

• Load capacity
• Hoisting speed
• Wire rope length
• Control method
• Installation method
• Rope discharge direction
• Equipment material

Furthermore, depending on specific requirements and operational scenarios, we can further consider design and configuration aspects such as product protection, durability and safety.

Customisation Enquiries

Company: Beijing Tianheng Kairui (KLD Winch)

Website: https://kldwinch.com

Customisation Services: We provide one-to-one technical solutions and bespoke quotations; please feel free to discuss your specific requirements

FAQ

Q1: Can the winch be customised?

A1: Yes. Comprehensive customisation is available based on load capacity, speed, rope length, control method, installation method, rope discharge direction, and materials.

Q2: What is the maximum lifting capacity?

A2: Standard models typically handle 300kg, but we can design four-rope synchronous systems with higher tonnages to meet specific requirements.

Q3: Is speed regulation available?

A3: Yes. Variable frequency drive systems can be fitted according to operational requirements.

Q4: In what environments is the equipment suitable for use?

A4: The standard model is suitable for dry indoor environments; however, we can enhance protection and durability to suit specific operating conditions upon request.

Q5: Does KLD provide technical support?

A5: Yes, we provide full-process technical support, from design to on-site commissioning.