INDUSTRIAL CRANE MODERNIZATION THE SMART . - Overhead Cranes
INDUSTRIAL CRANESNUCLEAR CRANESPORT CRANESHEAVY-DUTY LIFT TRUCKSSERVICEMACHINE TOOL SERVICECRANE MODERNIZATIONSINDUSTRIAL CRANE MODERNIZATIONTHE SMART WAY TO EXTENDOVERHEAD CRANE SERVICE LIFE
2KonecranesCranePortal ModernizationsCranesMAKE YESTERDAY’SCRANE WORK HARDFOR YOU TODAYAND TOMORROWMODERNIZATIONS CAN PROVIDE A COMPLETE TRANSFORMATIONOF YOUR EXISTING CRANE AS AN ALTERNATIVE TO REPLACING IT.As businesses evolve and grow, the technology theydepend on must adapt to support new and increaseddemands or be replaced with new equipment altogether.Depending on your crane application, you may need toincrease your crane’s speed and lifting capacity, enhanceergonomics and operator comfort, apply new safetyfeatures and positioning capabilities, or simply replacehigh-maintenance, obsolete components with newertechnology. Or, perhaps you need to modify or relocateyour crane to support an entirely new applicationor location.Whatever your need, a modernization may be your bestoption when it comes to achieving the benefits of newtechnology, without the cost of purchasing a new crane.Konecranes professionals are skilled and experiencedin modernizations, large and small. With completecustomization options available, Konecranes can help turnyour aging overhead crane into a specialized tool designedto meet your exact production needs.Common modernizations:Replacement of hoists, controls, trolleys and operatorcabins to achieve increased capacity, speed, duty,ergonomics and/or load control.GETTING STARTEDKonecranes will work with you to provide a detailed analysisof your crane in relationship to its application. We’ll evaluatethe structural integrity of the crane and the condition of allmechanical and electrical components. We’ll also studyload and duty requirements and maintenance records. Afteranalyzing all these factors against the required performanceneeds, we will identify the most appropriate system upgradeand corresponding modernization plan.REBUILDING PRODUCTIVITYRegaining top performance could mean nothing more thaninstalling a more efficient motor and self-adjusting brake.Perhaps a new remote control system is necessary. Or, aback-up limit switch for added safety. Many modernizationoptions are available, but we’ll recommend only those youneed. You’ll end up with a fully integrated system that isperfectly tailored to meet the needs of your operation.GET THE ADVANTAGES OF A NEWCRANE WHILE SAVING MONEYIf your needs for crane modernization extend beyond basicupgrades to improve safety, reliability and performance,we can virtually rebuild your old crane to meet your newdemands and today’s high technology standards, all at afraction of the cost of a new crane.GET THE GREATEST LIFECYCLE VALUE OF YOUR CRANEWITH CONTINUED SUPPORT FROM KONECRANESYou can depend on Konecranes well beyond installation.Upon completion of your modernization, we’ll providecomplete parts and maintenance manuals. Uponrequest, our network of expert technicians can alsoprovide comprehensive maintenance and repair servicesdesigned to achieve optimal safety and productivity withminimal downtime.MODERNIZATION:A SMART INVESTMENTWhen the purchase of new lifting equipment becomes too costly,crane modernization services by Konecranes can bring state-of-the-artcrane technology and performance within reach.
4KonecranesCrane ModernizationsTRUST THEMODERNIZATIONSLEADERKonecranes is a leading provider of overhead cranemodernizations with over 100 years of experience.As the world’s largest manufacturer of processcranes, with the most extensive overhead craneservice network in the world, Konecranes has thescale, expertise, technology and resources to repairany make or model of overhead crane.Color CodeType of ModernizationImprove performanceIncrease reliability andreduce maintenanceIncrease safety and ergnomicsChange of applicationIncrease reliability whilereducing maintenanceand improving performanceIncrease safety, ergnomicsand reliability while reducingmaintenanceImprove performance andchange of applicationMECHANICAL UPGRADESELECTRICAL UPGRADES1. MOTORSDC and AC long-life motors are designedand built for hard reversing and pluggingservice. Many options are availableincluding AC squirrel cage motor,external blower motor and DC mill motor.7. ERGONOMIC CAB AND ARM CHAIRAn open cab (on crane) or enclosedinsulated, air conditioned cab help providemaximum visibility. A deluxe console chairoffers optimum comfort to the operator.2. CONTROL SYSTEM UPGRADEIf your overhead crane uses an antiquated control system,upgrade to a more advanced control system, such as avariable frequency drive. Where severe applications demandit, we offer air conditioned E-house with variablefrequency controls, static stepless and DC controls.3. BRIDGE DRIVESDrives can be upgraded with heavy dutyfoot mounted gearboxes (on crane).Shaft mounted motor reducers canalso be applied to eliminate cross shaftmaintenance and alignment issues.4. FESTOON SYSTEMOR ENERGY CHAINSFestoon systems increase safety byreplacing wear-prone open conductorsand collectors. Energy Chain is analternative option that protects the powerand control cables from mechanical wearand reduces the risk of external damage.5. RADIO CONTROLFloor operated controls allow theoperator ease of mobility and agood view of the load in the hook.These controls can be equippedwith real time load data.6. LIMIT SWITCHESProvide hoist secondary limit switches protectionby preventing the bottom block from damagingthe drum. Bridge and trolley travel limit switchprotection. Collision avoidance systems, zonecontrol and automation.COMPLETE TROLLEY UPGRADE17. SMT TROLLEYThe SMARTON trolley is built for heavy processindustries and applications. The motor, gearbox andcontrol unit are designed and manufactured in-house,which allows for excellent lifting performance and longlife. The flange-mounted motors have integrated brakes,which support the proper alignment of the machinery.13. BRIDGE BUMPERSProtect the crane and the building by installing aspring, hydraulic or rubber bridge bumper that meetsOSHA, ASME and CMAA requirments.8. END TRUCKS AND WHEEL ASSEMBLIESAnti-friction bearings help meet increased productivity demands.Konecranes high capacity end trucks are designed to lengthenwheel life and improve crane tracking.14. BRIDGE BRAKESBrakes for cab/floor operation. Includes electricshoe, electric/hydaulic shoe, or DC spring set,electric release disc bake (OSHA, ASME or CMAA).UNITONTM TROLLEYThe UNITON trolley is available with multipleconfigurations and a wide range of hoisting speeds, loadcontrol features, and load and duty class options (CMAAClass A-F, up to FEM/ISO:M8). With a lifting capacity ofup to 160 tons on a single trolley (320 tons with twotrolleys), UNITON can be built to meet project-specificrequirements in almost any application. Its modulardesign and construction make maintenance and partreplacement easy.15. HOIST DRUMSRedesign drums for upgraded capacity andperformance.3241011615112CJ TROLLEYThe CJ trolley is designed for Class D or E use inindustrial applications. Its greatest attribute is itsease of maintenance. The foot-mounted gear case isintegrated into the trolley, which enables easy access tothe gears, shafts and pinions without needing to removethe entire trolley.917756119. SELF-ADJUSTING,BONDED NON-ABESTOS,SELF-ALIGNING BRAKESReduce maintenance by automaticallycompensating for lining wear. DC AISE spring set,electric release or AC impulse actuated shoe brakesare available.12. GIRDER MODIFICATIONS AND REINFORCEMENTSKonecranes can increase or decrease the length of the girderspan, which may be required during building expansions orwhen fitting a used crane into an existing building. Additionally,we can provide structurally improved end ties and end trucksfor severe applications to address fatigue and repair issues.Konecranes can also provide engineering studies for capacityincreases and hot metal conversions for the entire crane.81410. HOIST GEAR CASEUprating lift capacity. Shafts rotate on spherical bearingsencapsulated in machined retainers. Helical/spur gearing isprecision machined and heat treated for long life.11. PLATFORMSIncrease safety and maintenance accessibility by adding orimproving platforms, making them ASME/CMAA/FEM complaint.31SMARTON TROLLEY131616. BOTTOM BLOCKSKonecranes offers bottom blocks in a wide variety ofsizes and configurations, including rotating blocks orspeciality designed blocks for severe duty applications.We also offer common wear items such as hooks,frames, pins, sheaves, bearings and safety latches.6UNITON TROLLEYCJ TROLLEY
7KonecranesIndex8KonecranesCrane ModernizationsTECHNOLOGY FEATURESFOR A SAFER, SMARTER,MORE PRODUCTIVE WORKPLACESince your overhead crane was first built, safety regulations and production requirements have probablychanged. Konecranes can update your crane to help you meet production demands. A modernization willalso help you stay in compliance with current safety requirements and may reduce the risk of failure,helping you avoid costly downtime, injuries or damage to facilities, materials or products.SAVE ENERGY, ADD POWERWith regenerative braking, power is sent back to the powergrid during every downward or decel motion, instead ofbeing dissipated by resistors. With more energy returnedto the grid, less energy needs to be produced—leading toincreased cost-savings.SMART FEATURESKonecranes’ cranes are available with software-basedSmart Features that improve safety and productivity fromtwo perspectives, load control and positioning and areacontrol. Smart Features include Sway Control, ExtendedSpeed Range, Hook Centering, Snag Prevention, AssistedLoad Turning, Follow Me, Shock Load Prevention, Slack RopePrevention, Hoisting Synchronization, Inching, Microspeed,Target Positioning, End Positioning, Working Limits andProtected Areas. For example, we can add a GPS positioningsystem for collision avoidance with end stops, cranesor obstructions. You can upgrade your crane with SmartFeatures as your requirements change.AUTOMATION TECHNOLOGYAutomated features improve efficiency and precision whileallowing crane operators to pay increased attention tothe surrounding work environment, promoting safer andmore productive operation. Konecranes has engineeredapplication-specific, fully automated cranes, including cokercranes designed with traveling hoppers that deliver coke torail cars as well as automated paper storage cranes thatsignificantly increase storage capacity and available space.A SERVICE-MINDED TEAMWith the largest, most experienced service network inthe industry, Konecranes experts are always nearby andready to help. Our approach to service is simple—helpyour business achieve maximum lifecycle value for itscranes with minimum total cost of ownership. Throughregular preventive maintenance and timely repairs, yourcranes will be lifting your business for years to come.REMOTE MONITORING AND REPORTINGTRUCONNECT Remote Monitoring provides youwith usage data that enables you to optimize maintenanceactivities and give visibility to maintenance and applicationcompliance. The data gives you confidence to planyour actions and make informed decisions regardingmaintenance investments and productivity.SAFETY FIRST, LAST AND ALWAYSWhen it comes to safety, we believe that any accidentis one too many. Our commitment to safety starts withR&D and continues for the lifetime of your crane. A majorfocus of our R&D is on feasibility studies and the humaninterface. One of the best ways to improve safety is tomake the equipment logical and straightforward to use.MAINTENANCEMaintenance done right is not an expense. It is aninvestment that pays a measurable return. We havemore than 430,000 pieces of equipment undermaintenance contracts and more than 80 yearsof experience behind us. If you would like to keepyour crane working reliably with regular preventivemaintenance, please get in touch.SPARE PARTSWith a global spare parts network and a partsorganization that is the OEM for more than 40 brandsof cranes and hoists, we offer quick delivery of spareparts for any crane, anywhere. If we don’t have whatyou need and can’t get it through our extensivesupplier network, our engineers can quickly designparts to your exact specifications. And when anoriginal equipment manufacturer goes out of business,we can manufacture original spare parts.TRAININGAt our respected Training Institute, we train craneoperators and technicians from around the world. Thistraining includes crane operator and safety training,emergency procedures, OSHA and ANSI regulationsand other relevant information that operators need topromote a safe and productive work environment.LIFECYCLECARELIFECYCLE CARE – OUR APPROACH TO MAINTENANCELifecycle Care provides the highest lifecycle value for yourlifting equipment—maximizing the productivity of uptimeand minimizing the cost of downtime. Our crane expertsapply a systematic Risk and Recommendation Methodand a consultative, planning and review process to drivecontinuous improvement in safety and productivity. Inspections and Preventive Maintenance identifycertain areas of risk and improvement opportunitiesand support compliance. Corrective Maintenance and Retrofits address specificsafety and productivity issues and capitalize onimprovement opportunities. Consultation Services guide decision-making, uncovercritical issues and maximize your return on investment. Modernizations economically prolong the service lifeof your lifting equipment. New Lifting Equipment for new facilities or to replaceold lifting equipment.This publication is for general informational purposes only. Konecranes reserves the right at any time, without notice, to alter or discontinue the productsand/or specifications referenced herein. This publication creates no warranty on the part of Konecranes, express or implied, including but not limited to anyimplied warranty or merchantability or fitness for a particular purpose.
SHEAVY-DUTY SERVICELIFT TRUCKSMACHINETOOLSERVICEKonecranes is a world-leading group of Lifting Businesses offering lifting equipment andservices that improve productivity in a wide variety of industries. The company is listed onNASDAQ OMX Helsinki Ltd (symbol: KCR1V). With over 12,000 employees at more than 600locations in almost 50 countries we have the resources, technology and determination todeliver on the promise of Lifting Businesses . 2015 Konecranes Plc. All rights reserved. ‘Konecranes’, ‘Lifting Businesses’ andtrademarks of Konecranes Plc.KONECRANES ISTHE ORIGINALEQUIPMENTMANUFACTURER OFOVER 40 BRANDSare either registered trademarks orKONECRANES BRANDS2015 619KWDNo matter the type of crane,Konecranes has the expertiseand parts available to keepyour lifting equipmentrunning at optimalperformance.Konecranes Modernizations5306 S. Emmer Dr.New Berlin, WI 53151P: 262.207.1870konecranesUSA.comen.konecranes.ca
Since your overhead crane was first built, safety regulations and production requirements have probably changed. Konecranes can update your crane to help you meet production demands. A modernization will also help you stay in compliance with current safety requirements and may reduce the risk of failure,
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Double Girder Overhead Traveling Crane Double Beam EOT Crane P r o d u c t s & S e r v i c e s. MATERIAL HANDLING CRANES Material Lifting Crane Heavy Duty Crane Electric Overhead Travel Crane Single Beam Crane P r o d u c t s & S e r v i c e s. GANTRY CRANE Portable Gantry Crane Heavy Duty Gantry Crane Semi
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o 3.3.9 Bulk-handling crane o 3.3.10 Loader crane Overhead crane: An overhead crane, also known as a bridge crane, is a type of crane where the hook-and-line mechanism runs along a horizontal beam that it self runs along two widely separated rails. Often it is in a long factory building and runs along rails along the building's two long walls .
