Flexible load handling
Integrated intralogistics concept on three levels
Strong cranes for heavy loads
For its new heavy-load bay, the plant engineering company SMS Meer developed an intralogistics concept for the handling and in-house transport of components that weigh up to 180 tonnes. To meet these requirements, we supplied five overhead and wall-traveling cranes that were installed on three operating levels.
From goods-in to goods-out
The logistics concept developed for the heavy-load bay includes supply of the unfinished parts and removal of the assembled installation elements by heavy-lift units to the ends of the bay, as well as the in-house material flow with cranes.
- Heavy-load level: Demag process crane with open winch units
- Transport level: two Demag universal cranes with rope hoists
- Assembly workplaces: two wall-mounted traveling cranes operating on a 98 m-long crane runway
SMS Meer assembly bay
Integrated planning as the key for success
SMS Meer already involved us in planning the cranes at an early stage. This enabled any optimum design of the interfaces to be defined and achieved. The result is an integrated intralogistics solution on three levels which exactly meets the requirements for handling the different loads during the various steps in the process.
SMS Meer: advanced crane engineering for a leading manufacturer
SMS Meer is a part of the SMS Group, a world market leader in the construction of plant and machinery for the industrial processing of steel, aluminum and non-ferrous metals. SMS Meer was established as a machine factory in 1872 and is now a full-range supplier in the metal forming sector.
Everything under one roof
The new building complex at SMS Meer interfaces direct with the existing buildings. Measuring 181 meters in length and 24 meters wide, the heavy-load bay offers sufficient space for the machining centers and assembly stations.
First crane level: transport of heavy loads
A Demag process crane fitted with two Multi-Purpose Winch (MPW) units is used to transport the heavy loads on a runway installed at a height of 14.15 m. The crane primarily serves a gantry milling center, where SMS Meer machines unfinished parts. The two open winch units have load capacities of 180 t and 90 t and operate at variable speeds that depend on the load. For handling particularly large components, the two MPW open winch units can also be employed in tandem. The compact design of the crabs enable them to approach each other with a hook center distance of 3.05 m.
- Convenient handling and precise positioning thanks to frequency inverter-fed drives
- Safe distance to the load thanks to radio control
- Load-dependent lifting speeds
- Workpieces can be turned safely and precisely for machining on both sides
To avoid any collisions between the crane installation and the gantry milling machine, sensors continuously measure the distance between the crane girder and the carriage of the milling machine. At distances of less than six meters, the crane travel speed is automatically reduced and a warning message appears on the operating panel of the milling machine. At a distance of three meters, crane travel is brought to a standstill.
Second crane level: transport of unfinished and assembly parts
On the second crane runway level, two standard overhead traveling cranes operate over the entire length of the bay. The first crane is fitted with an EKDR-Pro monorail traveling hoist and has a load capacity of 10 t. The second one is a double-girder overhead traveling crane which is equipped with a main hoist for loads weighing up to 32.5 tonnes and a 10 t auxiliary hoist unit. A hook center distance of just 1,288 mm was achieved by installing both hoist units on one crab.
Third crane level: serving workplaces
Two identical wall-mounted traveling cranes fitted with 5-tonne DR-Pro rope hoists operate on a 98 m-long crane runway along one side of the bay. They are used to transport material to the individual workstations. In addition, they are employed for positioning tasks at the assembly stations.
Cranes for mechanical engineering
|Crane type||MPW open winch units||DR-Pro rope hoists||Span|
|Load capacity [kg]||[mm]|
|Level 1: heavy load handling (at a height of 14.5 m)|
|ZKKW process crane||180||90||23,000|
|Level 2: transporting material (at a height of 10.28 m)|
|ZKKE standard crane||32||12.5||20,320|
|EKKE standard crane||10||20,320|
|Level 3: for assembly workplaces (at a height of 6.24 m)|
|2 wall-mounted travelling cranes||5||7,000*)|
*) Jib length