Overview
A manufacturing facility in Cedar Falls, Iowa, needed a VFD crane modernization for a 5-ton Robbins & Myers overhead bridge crane dating back to the 1950s. The crane remained an important part of a key production area. However, the customer wanted smoother, more controlled movement than the existing controls provided.
Budget was also an important consideration. Rather than replace the complete crane, the customer chose to modernize the existing system. AFE Crane developed a control package that added variable frequency drive (VFD) control to the hoist, trolley, and bridge motions. The project also included a new radio control system and backup pendant.
The modernization allowed the customer to retain the existing crane while improving operator control. It also provided an alternate control method to help limit downtime in this production-critical area.
Project Challenges
The existing 5-ton overhead crane had been in service for decades and used older control technology. The customer wanted greater control over crane movement, including smoother acceleration and deceleration. Easier load positioning was also an important goal.
Replacing the complete crane was not the preferred approach due to budget considerations. Instead, the project required integrating modern control technology with the existing crane while retaining equipment that could continue to serve the application.
Crane availability was another important consideration. The crane supported a key production area where extended downtime could disrupt operations. The new control system needed to improve crane operation while also providing an alternate control method if the radio became unavailable.
The AFE Crane Solution
AFE Crane developed a control modernization package for all three powered crane motions. The new system added Magnetek G+ Mini variable frequency drives to the hoist, trolley, and bridge motions. The VFDs provided programmable acceleration and deceleration for smoother crane movement and improved positioning.
AFE Crane also added a Magnetek Flex-6EX2Â radio control system, giving the operator greater freedom of movement while controlling the crane.
Because the crane served a key production area, the customer also wanted a backup method of operation. AFE Crane incorporated a pendant with a quick-connect arrangement. If the radio became unavailable, the operator could disconnect the radio receiver and connect the pendant to continue operating the crane. This redundancy helped reduce the risk of extended downtime caused by an inoperable radio control.
Project Execution
AFE Crane began by taking field measurements of the existing crane. The team also documented the existing equipment and electrical configuration before developing the new control package. The project required integrating current VFD and radio control technology with a crane originally manufactured decades earlier.
AFE Crane supplied the new bridge, trolley, and hoist control equipment and completed the field installation. The team coordinated the work around the customer’s production requirements. Installation took place during off-shift hours around the July 4th holiday period to reduce disruption to manufacturing operations.
The completed modernization retained the existing 5-ton crane while updating its control system to better meet the customer’s current operating requirements.
Conclusion
This VFD crane modernization demonstrates how an older overhead crane can sometimes be upgraded rather than completely replaced. The condition of the existing equipment, application requirements, and project budget all factor into that decision.
By adding VFD control to the hoist, trolley, and bridge motions, AFE Crane provided smoother acceleration and deceleration, improved operator control, and easier load positioning. The radio control gave the operator greater freedom of movement. A backup pendant also provided an alternate way to operate the crane if the radio became unavailable.
For this Cedar Falls manufacturer, modernization provided a practical way to update a crane dating back to the 1950s while working within budget constraints. The project retained the existing crane while updating the controls to better support a production-critical application.
Facilities with aging overhead cranes should evaluate each system individually when operating requirements change or controls become outdated. Depending on the condition and configuration of the equipment, modernization may provide a practical alternative to complete crane replacement.
Learn More About Crane Modernization & Upgrades
Contact AFE Crane
If your facility has an older overhead crane with outdated controls or changing operating requirements, AFE Crane can evaluate the existing equipment and help determine whether modernization is a practical alternative to replacement.
Our engineering and service teams can evaluate existing crane controls and operating requirements and develop modernization solutions incorporating VFDs, radio controls, control panels, hoists, electrification, anti-collision systems, and other upgrades when appropriate for the application.
Contact AFE Crane to discuss your overhead crane modernization project.