Truck-mounted cranes: the core engineering equipment for mobile heavy-duty operations

I. Core Definition of Truck-Mounted Cranes Truck-mounted cranes (commonly known as "mobile cranes") are mobile engineering machines that integrate lifting devices (boom, hook, hydraulic system) onto a truck chassis (or a specially modified chassis). Their core components include four main modules: chassis system, lifting device, hydraulic transmission system, and electrical control system. Rated lifting capacity ranges from 3.2 tons to over 1200 tons, with a working radius of 10-120 meters. Their core value lies in "mobility and flexibility + heavy-duty efficiency + multi-scenario adaptability." They can achieve rapid road transport via truck chassis (up to 80 km/h) and perform precise operations such as lifting, slewing, and luffing of heavy objects through hydraulic drive. They are core heavy-duty equipment connecting engineering construction, logistics handling, and emergency rescue, widely adaptable to the demands of "fast-paced, highly mobile" operations. II. Development History The industrialization of truck-mounted cranes began in the early 20th century. In 1915, Germany first combined lifting devices with truck chassis, introducing the first generation of mechanically driven truck-mounted cranes, initially mainly used for port cargo handling. From the 1950s to the 1970s, breakthroughs in hydraulic technology propelled industry upgrades, shifting from mechanical to hydraulic transmission, significantly improving lifting capacity and operational stability. Simultaneously, American and Japanese companies introduced specialized chassis models suitable for heavy-duty scenarios. China achieved domestic production breakthroughs in the 1960s (e.g., the first 5-ton truck-mounted crane from Xuzhou Construction Machinery Plant), and entered a period of rapid development in the 1990s, gradually achieving large-scale production of medium and large tonnage products through technology import and independent research and development. Since the beginning of the 21st century, "intelligentization + new energy" has become the direction of transformation. Companies such as XCMG, Sany, and Zoomlion have made breakthroughs in core technologies such as ultra-large tonnage (1200-ton class), intelligent control (remote operation, load monitoring), and new energy chassis (hybrid and pure electric). China has become the world's largest producer and consumer, with products exported to more than 100 countries around the world. III. Core Characteristics Analysis

(I) Core Functional Characteristics

The core advantages of the truck-mounted crane lie in its "dual balance of mobility and heavy load": In terms of mobility, relying on the truck chassis, it can directly reach the work site by road, and the transfer efficiency is more than 60% higher than that of crawler cranes, without the need for special transportation equipment; In terms of heavy load performance, through the design of multi-section telescopic boom (3~8 sections) and multi-axle drive chassis (4~12 axles), the maximum lifting capacity can reach 1200 tons, and the working radius covers 10~120 meters, which can meet the needs of all scenarios from light lifting (equipment installation) to ultra-heavy lifting (wind turbine blades); In terms of precise control, the hydraulic proportional control and electric control collaborative system can achieve millimeter-level lifting and positioning, and the load fluctuation is controlled within ±3%, which is suitable for precision equipment lifting scenarios. (II) Structural and Performance Characteristics The vehicle adopts a modular design of "chassis + superstructure". The chassis is mostly a heavy-duty truck chassis (such as Dongfeng and Sinotruk) or a self-made special chassis, which has strong load-bearing capacity and off-road passability (minimum ground clearance ≥250mm). The boom material is mainly high-strength alloy steel (such as Q690 and Q960 grade), and some ultra-large tonnage products use titanium alloy and aluminum alloy composite materials to achieve a balance between lightweight and high strength (boom weight reduction of 15%~20%). The hydraulic system adopts a combination of high-pressure variable pump and multi-way valve, with a working pressure of 35~45MPa, fast response speed and low energy consumption. The safety protection system is complete, equipped with overload protection, anti-tipping alarm, torque limiter and other multiple devices, with an operational safety factor ≥1.3. (III) Scene Adaptability Features Different attachments (hooks, grabs, electromagnetic chucks, aerial work platforms) can be configured to adapt to diverse scenarios: small and medium tonnage (3.2~25 tons) are suitable for urban infrastructure construction, logistics loading and unloading, and equipment installation; medium and large tonnage (50~300 tons) are suitable for bridge erection, factory construction, and wind turbine tower hoisting; and extra-large tonnage (500~1200 tons) are suitable for offshore wind power, nuclear power equipment, and heavy equipment transportation. In addition, some products have off-road capabilities (four-wheel drive/six-wheel drive), making them suitable for unpaved road operations in mines and other outdoor environments, demonstrating strong environmental adaptability. IV. Mainstream Production Processes

(I) Core Production Process (Mainstream Processes)

The production of truck-mounted cranes is based on "modular integration + precision manufacturing". Key processes include:
1) Chassis selection and modification: Selecting a special chassis according to tonnage requirements, reinforcing the frame, optimizing bridge load distribution, and installing hydraulic oil tanks and outriggers;
2) Boom manufacturing: High-strength steel plates are CNC cut and bent, then submerged arc welding and robotic welding (weld pass rate ≥99.5%) are used. Subsequent processes include shot blasting for rust removal and protective coating. Some products undergo heat treatment (quenching + tempering) to improve strength;
3) Hydraulic and electrical control system assembly: Integrating core components such as high-pressure pumps, multi-way valves, and hydraulic cylinders, and conducting pipeline connection and sealing tests (pressure resistance test pressure is 1.5 times the working pressure);
4) Overall debugging and testing: Verifying lifting performance, safety performance, and reliability through no-load tests, load tests (125% rated load), and driving tests, ultimately obtaining CE, ISO, and other certifications before leaving the factory. This process is highly automated, with a production cycle of approximately 30-60 days for medium to large tonnage products. (II) Process Technology Upgrade Directions With the upgrading of high-end manufacturing and "dual-carbon" requirements, the industry is accelerating process innovation: First, lightweight manufacturing, using high-strength aluminum alloy and titanium alloy booms, applying topology optimization design, reducing vehicle weight by 10%-15% and fuel consumption by 8%-12%; Second, intelligent upgrading, integrating GPS positioning, remote monitoring, automatic obstacle avoidance, and remote control operation systems, with some products achieving L2-level assisted lifting (automatic leveling, precise alignment); Third, new energy transformation, developing hybrid (fuel + electric), pure electric, and hydrogen fuel cell chassis models, with pure electric models achieving a range of 100-200km, suitable for low-emission operations in urban areas; Fourth, precision manufacturing upgrade, adopting laser welding and 3D printing (for some structural parts) technologies to improve boom strength and manufacturing precision, extending service life. (III) Core Component Manufacturing Processes Key component manufacturing technologies have become a core competitive advantage: 1) Hydraulic System: High-pressure multi-way valves are precision cast and machined on five axes, with valve core clearance ≤0.005mm, ensuring control accuracy; 2) Telescopic Boom: Utilizing "synchronous telescopic technology," multi-section booms are telescopically extended and retracted through wire rope and hydraulic cylinder linkage, improving work efficiency by 30%; 3) Electrical Control System: A dedicated controller (ECU) has been developed, integrating load sensing and attitude perception functions, with a response time ≤0.1 seconds. V. Core Application Areas

(I) Engineering Construction Field (Traditional Core Area) Over 60% of truck-mounted cranes worldwide are used in engineering construction, making them indispensable equipment for infrastructure construction. In road and bridge construction, these products are used for box girder hoisting, pier pouring, and guardrail installation. Medium and large tonnage products can achieve overall hoisting of bridges with spans of 50 meters or more. In the building construction field, they are used for hoisting steel bars, formwork, and tower crane components. Small and medium tonnage products are flexibly adapted to urban building complex operations. In municipal engineering, they are used for street light installation, pipeline laying, and sewage treatment equipment hoisting. Some products are equipped with aerial work platforms to achieve integrated "lifting + aerial work". (II) Logistics and Heavy Equipment (Important Application Scenarios) In the logistics and handling sector, it is used for loading and unloading heavy cargo (such as steel coils, containers, and equipment units) in ports, steel mills, and chemical industrial parks. Ultra-large tonnage products can realize the transfer of heavy equipment with a single piece weight of over 500 tons. In the manufacturing sector, it is used for the production and assembly of automobiles, machinery, and nuclear power equipment, and for the precise hoisting of key components such as engines, machine tools, and reactor pressure vessels to ensure production efficiency and assembly accuracy. In the wind power and new energy sector, it is used for the hoisting of wind turbine towers, blades, and generators. Products with a tonnage of over 300 tons are suitable for onshore wind power (1.5~5MW), and products with a tonnage of 1200 tons are suitable for offshore wind power (over 10MW). (III) Emergency Rescue and Specialized Fields (Growth Drivers) In the emergency rescue field, these cranes are used for personnel rescue and material transfer in earthquakes, floods, and collapses. Some specialized models are equipped with anti-skid chains and emergency power supplies to adapt to complex rescue environments. In the firefighting field, specialized vehicle-mounted cranes integrating fire monitors and aerial platforms enable high-altitude firefighting and rescue. In the military industry, they are used for the transportation and hoisting of military equipment (such as missiles and radar), requiring high reliability and off-road capability. In the agricultural field, they are used for the installation of agricultural machinery and the transfer of crops; small and medium-tonnage products are suitable for operations in rural areas. VI. Market Development Trends (I) Steady Demand Growth, with Significant Increase in Large-Scale and High-End Products In 2024, China's vehicle-mounted crane production capacity was approximately 350,000 units, accounting for 75% of the global market, with a market size exceeding 50 billion yuan. The average annual compound growth rate is expected to remain between 7.5% and 9.0% over the next five years. Among them, the demand for large-tonnage (over 50 tons), intelligent, and new energy products is growing the fastest, with its share increasing from 28% in 2024 to over 45% in 2029. Currently, there is still a technological gap in ultra-large products of 1000 tons and above, and the import dependence of core components (high-end hydraulic valves, electronic control systems) is about 25%, mainly relying on imports from Germany and Japan. New energy infrastructure, offshore wind power, and emergency rescue are becoming the core driving forces for demand. (II) Concentrated production capacity and intensified regional and enterprise differentiation Global truck crane production capacity is mainly concentrated in China (XCMG, Sany, Zoomlion), Germany (Liebherr), and Japan (Kato, Tadano), while domestic production capacity is mainly distributed in engineering machinery industrial clusters such as Jiangsu (Xuzhou), Hunan (Changsha), and Shandong (Jining). The industry concentration continues to increase, with the top three companies accounting for 68.5% of the production capacity. XCMG and Sany dominate the market due to their technological R&D and scale advantages, while small and medium-sized enterprises focus on small and medium tonnage or niche special models. (III) Technological Innovation Driven, Green and Intelligent Development Becomes the Core Direction The "dual-carbon" strategy and the demand for high-end manufacturing are driving industry transformation, with new energy and intelligentization becoming core competitiveness. Policy requires that the penetration rate of new energy in urban construction machinery reach 30% by 2025, forcing companies to increase R&D investment in pure electric and hydrogen fuel cell vehicles. In terms of intelligentization, 5G + remote control, AI-assisted hoisting, and digital twin technology are gradually becoming widespread, and it is expected that the proportion of intelligent products will exceed 50% by 2027. In the medium to long term, breakthroughs in core technologies for ultra-large tonnage products, the localization of core components, and the improvement of the new energy industry chain will reshape the industry landscape. (IV) Price Fluctuations and Strategic Layout The price of truck-mounted cranes is affected by multiple factors: fluctuations in the prices of upstream raw materials (high-strength steel plates saw an average price increase of 12% in 2024, and hydraulic components increased by 15%) and core components (imported hydraulic valves account for 20%~25% of costs) directly impact production costs; downstream infrastructure investment scale, new energy project construction progress, and logistics industry demand influence the demand side; environmental policies (National VI emission standards) and new energy subsidy policies affect the supply structure. Due to its irreplaceable role in the infrastructure and new energy industry chains, truck-mounted cranes have become a strategic sub-segment of the construction machinery industry. Companies are strengthening R&D of core components (such as XCMG's independently developed high-pressure multi-way valve), new energy technology layout, and overseas market expansion to enhance their global industry chain influence.