Modernisation of a casting crane
Our client:
NEUE HALBERG-GUSS GMBH
NEUE HALBERG-GUSS GmbH is a company belonging to H.T.P. Automotive GmbH. NEUE HALBERG-GUSS GmbH's position as one of Europe's leading foundries in the development and production of cylinder blocks, cylinder heads for industrial engines made of cast iron and cast crankshafts is based on decades of experience. The product range includes delicate three-cylinder blocks for passenger car engines as well as large-volume V8 engines for commercial vehicles and aluminium bedplates.
The task
The electrical control system for the crane is designed as a thyristor control (cut-in control) for slip ring motors. The control system was getting on in years, and some spare parts from the original manufacturer were no longer available. It also did not comply with BGV-A3 safety regulations. For this reason, the control system needed to be modernised in order to ensure operational safety.
The performance
The existing electrical control system, including cabling and power supply to the trolley, was replaced. As with the existing system, a thyristor control system was used for all drives. The control system now complies with the Low Voltage Directive 2006/95/EC.
To increase the functional safety of the control system, all safety-related parts of the control system were upgraded to the state of the art. They were selected in accordance with performance level PLd and category 3 in accordance with EN ISO 13849-1. Sensors and safety modules suitable for the respective application were used.
All changes were examined for new hazards and risks in accordance with DIN EN ISO 12100. A final inspection of the crane system in accordance with BGV D6 was carried out by an independent crane expert.
Additional services:
- Project planning for the entire conversion work
- Creation of electronic documentation in EPLAN
- Construction of the electrical control system
- Dismantling of the old system and old cabling
- Conversion of tender to a heavy-duty energy chainInstallation of the new control system, including installation of new system components (load measuring bolts, limit switches, etc.)
- Recabling of the entire crane
- Commissioning of the new system
- Expert acceptance
Facts and figures
The crane:
- 20t main hoist: drive power 26kW, lifting speed
- 6.3m/min6.3t auxiliary hoist: drive power 20kW, lifting speed 12.5m/min
- Trolley travel: drive power 3.3kW, travel speed 20m/min
- Crane travel: Drive power 2x8.5 kW, travel speed 80 m/min
- Control type: Radio-controlled crane, the existing cabin control system has been decommissioned
Renewal or new installation of the following essential plant components
Lifting mechanisms:
- New installation of a redundant overload protection device in performance level PLd
- Installation of a lifting gear limit switch with emergency stop in performance level PLd
- Installation of a new stator cut-off control for speed control of slip ring motors
- New installation of a safety control in performance level PLd for the following functional safety functions:
- Emergency limit switch ‘Lift’ with test function
- Overspeed monitoring of hoist
- Overload shutdown, only the ‘Lower’ direction of travel is possible
Chassis:
- Installation of dual-channel snap-action magnetic limit switches with additional evaluation device
- Installation of a new stator cut-off control for speed regulation of slip ring motors