4-Rope Battery Swap Hoist for New Energy Stations PLC | KLD

A servo-controlled electric hoist developed for new-energy battery swap stations, mounted on double-girder overhead cranes for unmanned automated battery-swapping operations. A single main motor drives four ropes fully synchronized; four fixed rigging points prevent load offset; load sensor, PLC-programmable control and dual safety protection (mechanical height limiter + absolute encoder) support safe, repeatable operation.

Quick Specs

Rated load: ≥250 kg (per point / total)
Rope: 4 × Ø4 mm, 20 m
Lifting speed: ≥0.2 m/s (VFD adjustable)
Control: PLC-programmable, wireless remote
Power: AC 220V 50Hz, ≥500W
Protection: IP55

Application Scenarios and Applicable Boundaries

- New-energy battery swap stations — unmanned automated battery-swapping operations on double-girder overhead cranes.
- Automated material handling — servo-controlled lifting with PLC programming for repeatable, automated sequences.
- Precision multi-point lifting — four fixed rigging points in a 300 × 300 mm square support stable lifting without load offset.
- Industrial automation — integration into crane systems with wireless remote and programmable control.

Boundary: This is an engineered-to-order product for battery-swap station hoisting; confirm the load, rope arrangement, lifting height and interface requirements with our sales team before ordering. The standard configuration is not intended for personnel lifting.

Features Benefits

Synchronized four-rope operation — A single main motor drives all four ropes fully synchronized, keeping the four rope lengths consistent during lifting and lowering for stable platform motion.
Fixed rigging without load offset — Four rigging points are fixed in a 300 × 300 mm square arrangement, supporting even load distribution and preventing load offset.
Accurate load judgment — The load sensor supports accurate judgment of the lifted workpiece weight, feeding weight data to the control system.
Programmable drive with holding — The electromagnetic brake motor with internal encoder supports programmable control and reliable braking for automated sequences.

Complete Technical Specifications

Size Installation and System Interface

The hoist is designed for mounting on a double-girder overhead crane via the reserved fixing interface; the hoist and guide wheels form an integrated structure. The 4 rope outlet directions align with the 4 rigging directions. Overall dimensions and mounting details are confirmed on the design drawing after parameter confirmation.

Available interfaces include: AC 220V power input, PLC communication, wireless remote, load sensor signal, mechanical height limiter contacts and absolute encoder output. Electrical interfaces are defined in the final wiring diagram.

Control Safety and Protection

- Normal control: PLC-programmable smart control with wireless remote; supports start/stop, synchronized four-rope lifting and lowering sequences.
- Load monitoring: load sensor supports accurate judgment of the lifted workpiece weight.
- Travel protection: mechanical height limiter combined with absolute encoder provides dual safety protection.
- Cable limit: rope-length limiting function per the technical requirement.
- Braking: electromagnetic brake motor provides braking; holding behavior confirmed in the control scheme.
- Environment: IP55 protection; confirm site conditions before ordering.

Standard vs optional items are confirmed on the control scheme for each order.

Customization Options and Engineering Process

Configured around your operating conditions — Share the required line pull, rope travel, operating speed, duty cycle, power supply, installation envelope and environment. KLD will review the application and provide a proposed configuration, technical drawing and quotation for approval. Free design schematics are provided for different scenarios.

Requirements → Concept → Drawing & Quotation → Approval → Production & Test → Delivery

Standards Testing and Quality

The company operates an ISO 9001 quality management system. CE conformity documents (LVD, EMC) are available for applicable configurations on request.

Factory testing follows the approved technical specification for each configured unit and may include: no-load run, rated-load operation, rope-guide function and control verification. Available documentation may include dimensional drawings, electrical diagrams, inspection records and functional test results, depending on project scope.

Engineering Cases

Challenge: A new-energy battery swap station required an automated hoist for unmanned battery-swapping on a double-girder crane — four synchronized ropes, fixed rigging without load offset, load sensing and dual travel protection.
Solution: A servo-controlled 4-rope hoist with PLC-programmable control, electromagnetic brake motor with internal encoder, load sensor, double-row rope guide and dual safety protection (mechanical limiter + absolute encoder), configured per the technical requirement.
Outcome: The hoist passed the customer's functional acceptance procedure for the planned automated swapping duties.

Technical Data Download

Downloads:
- Product Datasheet (PDF)
- General Arrangement Drawing (PDF)
- Installation & Operation Manual (PDF)
- Request CAD / Electrical Drawing

Delivery Packaging and Lifecycle Support

Most winches are custom-made products; lead time is confirmed after technical approval and order review. Project support can include configuration review, drawing approval, factory testing, export packaging, remote commissioning support and recommended spare parts. On-site measurement and installation support are available for ap