Overview
A manufacturer needed an overhead lifting system to support robot maintenance within an assembly-line pit. However, the existing building conditions left very little room for a conventional crane system.
Only 10 inches of clearance were available between the bottom of the support steel and the underside of the crane bridges. In addition, workers performing maintenance in the pit required fall protection.
AFE Crane worked with Unified Industries to develop a compact low headroom workstation crane system. The system provided lifting capacity up to 2,000 pounds while also supporting the customer’s fall-protection requirements.
Project Challenges
Available headroom presented the primary engineering challenge. The existing overhead steel sat directly above the assembly area, leaving only 10 inches of clearance for the crane bridges. A power-and-free paint system above the assembly line further restricted the available space.
The customer also needed two different functions within the same limited area. Maintenance personnel needed fall protection while working around the pit. At the same time, they needed overhead lifting capability to remove and position robot components during maintenance.
Therefore, the crane system needed to maximize available vertical space without interfering with the surrounding equipment. A standard crane configuration would not provide the compact profile required for the application.
The AFE Crane Solution
AFE Crane selected a low headroom workstation crane system from Unified Industries. The system used Unified ETA-8 aluminum runway and bridge components, which provided a lightweight structure suited to the restricted installation area.
The design incorporated two crane bridges with separate functions. A single-girder bridge supported the fall-protection system. Meanwhile, a double-girder bridge provided the 2,000-pound lifting capacity needed for robot maintenance.
AFE Crane also incorporated a low headroom nested trolley with a CM Lodestar electric chain hoist. Nesting the trolley within the bridge structure reduced the vertical space required by the hoist and trolley assembly. As a result, the system could preserve more usable hook height within the limited clearance.
Project Execution
AFE Crane coordinated with Unified Industries to configure the workstation crane around the existing support steel, assembly-line equipment, and available headroom.
The project required careful coordination of the bridge, runway, trolley, and hoist components because the system had very little unused vertical space. The final configuration integrated the lifting and fall-protection functions within the existing facility constraints.
Conclusion
This project demonstrates how low headroom workstation cranes can provide overhead lifting capability when existing equipment and building conditions leave little room for a conventional crane system.
With only 10 inches of available clearance, component selection and crane configuration were critical. The combination of aluminum workstation crane components, low headroom end trucks, a nested trolley, and an electric chain hoist allowed the system to fit within the restricted area.
The project also addressed two needs within the same workspace: lifting robot components and supporting fall protection for maintenance personnel working around the assembly-line pit.
Learn More About Workstation Cranes
Contact AFE Crane
If your facility needs overhead lifting capability but limited headroom, existing equipment, or building obstructions make a conventional crane difficult to install, AFE Crane can help. Our engineering team can evaluate your available space, required capacity, hook coverage, and surrounding equipment to determine a practical crane configuration.
Whether your application requires a low headroom workstation crane, specialized hoist configuration, or a custom overhead lifting system, AFE Crane provides engineering, equipment integration, installation, startup, and long-term service support.
Contact AFE Crane to discuss your next workstation crane project.