Overview
Our customer required an overhead crane system specifically designed for an environment with extremely limited headroom. This system was essential to safely and effectively service robots located within an assembly line pit. Due to the unique positioning of the robots, personnel were mandated to use fall protection gear during maintenance operations. The system had to reliably lift loads up to 2,000 pounds to manage robot components.
Project Challenges
The primary challenge was the severe headroom restriction, with only 10 inches of available clearance from the bottom of the support steel to the underside of the crane bridges. The overhead steel structure’s low positioning was further complicated by the proximity of a power and free paint system installed above the assembly area. This configuration required an exceptionally compact and efficient crane solution to maximize operational space while ensuring safety and functionality.
The AFE Crane Solution
AFE Crane responded with a specialized low headroom crane system from Unified Industries, Inc. Employing Unified’s ETA-8 aluminum material for both runway and bridge structures, the design optimized weight, durability, and clearance. The system featured low headroom end trucks for both the single-girder bridge, designated for fall protection, and the double-girder bridge designed for the one-ton hoisting operations. A strategically selected low headroom nested trolley was paired with a CM Lodestar electric chain hoist, effectively maximizing the available vertical lifting space.
Project Execution
AFE Crane coordinated closely with Unified Industries to ensure precise installation within the customer’s stringent spatial requirements. The carefully engineered components were successfully integrated, delivering a crane system that provided robust lifting capability while maintaining critical clearances. The project execution emphasized safety, functionality, and minimal disruption to existing operations.
Conclusion
By implementing a tailored solution utilizing low headroom equipment and innovative engineering, AFE Crane effectively addressed the customer’s unique operational challenges. The completed system not only met the tight clearance constraints but also enhanced safety and maintenance efficiency for the assembly line robots. For future overhead crane system challenges, AFE Crane remains committed to providing custom solutions to meet specialized application requirements.
