The 1,600 kg Konecranes KBK workstation lifting system was adapted to the hall geometry, enabling the safe and electrically powered transport of engine components into the neighboring hall. (Image source: Konecranes)
Full area coverage despite columns and fixed installations, with the option to extend the system to the existing overhead bridge cranes.
Bernd Böhringer, Konecranes GmbH, in front of the installed KBK workstation lifting system, which provides optimal area coverage despite structural constraints
The service center in Groß-Gerau reorganized its material flow after integrating a new parts washer as a fixed process step in the overhaul of engines rated from 13 to 2,600 kW.
Cummins Deutschland GmbH has expanded its large engine overhaul center in Groß-Gerau with an industrial parts washing unit. To support the safe handling and transport of engine components within the work area-including transfers to a neighboring hall - Konecranes delivered a customized solution based on the modular Konecranes KBK workstation lifting system with a lifting capacity of 1,600 kg. The system has been adapted to the existing building geometry, providing electrically powered movements and supporting safety requirements through finely adjustable travel speeds.
Initial situation at Cummins Germany
At the service and overhaul center in Groß-Gerau, engines with power ratings from 13 to 2,600 kW are completely dismantled, overhauled, and rebuilt using original spare parts. The installation of a new industrial parts washer for engine components made it necessary to reorganize the internal material flow, as cleaning is now integrated as a defined process step within the overhaul workflow.
Project Requirements (Technical Specification)
Static columns and permanently installed utilities in the relevant hall area required a crane solution that could provide full coverage without any modification to the existing building structure. All column positions for the crane system were engineered to accommodate the on-site structural constraints.
Another key requirement was the option to extend the KBK runway in a later phase into the neighboring hall, allowing engine components to be transferred directly to two existing Konecranes overhead bridge cranes.
From an ergonomic and safety perspective, all crane movements-hoisting, trolley travel and crane travel-were specified as electrically powered. In addition, the control system had to allow finely adjustable travel speeds, particularly to enable reduced speeds in safety-critical zones and minimize pinch and collision risks.
Additional functional requirements:
- 1,600 kg lifting capacity across the entire work area
- Use of a freestanding steel superstructure
- Flexible expansion of steelwork and Konecranes KBK workstation crane system at any time
- Modular system design allowing optional installation of additional crane bridges
- Compliance with all relevant design criteria for multi-shift operation.
"The challenge was to provide crane coverage for the entire work area given the existing hall structure, fixed installations and central support located directly in the load path. With an adapted steel structure and the modular Konecranes KBK workstation lifting system, we were able to realize a solution that supports complete material flow between the parts washer and downstream processes, all within the given building geometry," said Bernd Böhringer, Sales Engineer, Light Lifting Equipment, Konecranes Germany.
Technical Implementation by Konecranes
Konecranes implemented the solution using the modular KBK workstation lifting system. The system is based on cold-rolled KBK II-H enclosed steel profiles with high inherent stiffness, capable of handling loads of up to 2,000 kg over long spans. The freestanding steel columns were positioned asymmetrically to avoid creating new obstructions within the hall and to maximize the usable floor area.
The KBK runway was designed to allow future extension into the neighboring hall, where existing Konecranes overhead bridge cranes can carry over load handling. All crane movements are electrically powered and operated via an ergonomic pendant control. During commissioning, travel speeds were individually configured to meet customer requirements and further enhance operational safety.
Results and Benefits for Cummins
Cummins now operates a process-safe, user-friendly and scalable workstation lifting system that supports complete material flow from disassembly through cleaning and subsequent process steps. High-quality components create an ergonomic working environment with efficient powered travel and low noise levels. Operators retain full control of the load at all times, work safely and can remain fully focused on the task at hand.
Due to the modular design, the system can be expanded in the future to accommodate changing process requirements without any modifications to the building structure or foundations.
For more information contact:
Konecranes, Inc.
4401 Gateway Blvd.
Springfield, OH 45502
937-525-5533
www.konecranesusa.com