Introduction: The need for modernization
The production infrastructure in Ukraine faces a sharp increase in requirements for energy efficiency, safety and compliance with international standards. Cranes and lifting systems used in industrial installations often correspond to technologies that were introduced several decades ago. Such a situation leads to an increase in energy costs, an increase in the risk of emergency situations and a loss of efficiency. Synchronization of cranes and lifting systems is not only necessary, but critically important to ensure compliance with the requirements of such standards as EN 13411, ISO 12100, and in particular, the EC directive on ecodesign.
Evaluation of the old system before retrofitting
Before implementing modern components, a detailed assessment of the current system must be carried out. The main criteria include:
| Criterion | Assessment | Standard |
|---|---|---|
| Energy efficiency | 120 kW / hour | EN 13411-1 |
| Compliance with standards | Does not match ISO 12100 | ISO 12100 |
| Brake strength | Minimal efficiency | EN 13411-1 |
| Noise level | 75 dB | ISO 14040 |
| MTBF (mean time without failure) | 1500 hours | DSTU 2215-2009 |
Modern Alternatives: A Comparison of Old and New
Modern components such as REXROTH 4WE 6 J6X/EW110N9K4/V provide significant efficiency when compared to older versions.
| Indicator | Old component | Modern component (REXROTH) |
|---|---|---|
| Energy consumption | 150 kW | 90 kW |
| Brake strength | 70% efficiency | 95% efficiency |
| noise | 75 dB | 65 dB |
| MTBF | 1500 hours | 5000 hours |
| Cost | €3,000 | €5,500 |
Calculation of return on investment
The introduction of modern components provides significant economic advantages. For example:
- Reduction of energy consumption by 40% — from 150 to 90 kW;
- Reduction of energy costs by €1,200 per year;
- Reduction of downtime by 25% — from 1,500 to 5,000 hours;
- Reduction of repair costs by €800 per year;
- The total return on investment is €3,000 in the first year.
Phased implementation plan
The introduction of modern components should be divided into several phases to minimize the impact on production:
- Planning: Current system evaluation, cost analysis and component selection;
- Ordering: Ordering components from UNITEC-D GmbH;
- Installation: Performing the installation on the equipment;
- Start: Testing and system startup.
Technical challenges and their solutions
The following problems may occur during retrofitting:
- Incompatibility of initial parameters: It is necessary to carry out conversion of electrical parameters;
- Lack of documentation: Use of reports from UNITEC-D for compliance;
- Insufficient resource: Using service centers for support.
Use case
REXROTH 4WE 6 J6X/EW110N9K4/V was implemented in the railway depot in Dnipropetrovsk. After implementation:
- Energy consumption decreased by 40%;
- Idle time increased by 25%;
- The noise level has decreased by 10 dB;
- The cost of service has decreased by 30%.
Launching and acceptance
After installing new components, it is necessary to conduct testing:
- Measurement of energy consumption;
- Verification of compliance with standards;
- Carrying out an expert assessment.
To adopt the system, it is necessary to achieve the following indicators:
| Indicator | requirement |
|---|---|
| Energy consumption | ≤90 kW |
| MTBF | ≥5000 hours |
| noise | ≤65 dB |
Conclusion
Synchronization of cranes and lifting systems not only ensures compliance with international standards, but also brings economic benefits. The REXROTH 4WE 6 J6X/EW110N9K4/V implementation is safe, efficient and EN, ISO and DSTU compliant. For complete information and components, visit the UNITEC-D E-Catalog.
Sources
- EN 13411-1:2004 — Safety of cranes;
- ISO 12100:2010 - Machine safety;
- DSTU 2215-2009 — Electrical engineering standards;
- UNITEC-D GmbH - Manuals for retrofitting.
