Update crane and lifting equipment systems: modern drivers, braking systems and safety

Introduction: The need for modernization

Modern requirements for energy efficiency, safety and compliance with regulatory standards necessarily require the modernization of crane systems and lifting devices. Although older systems may function, they often do not meet modern standards, resulting in increased energy consumption, repair costs and the risk of production stoppages. Modernization provides increased efficiency, reduced costs and increased safety.

Evaluation of the old system before modernization

Before starting the modernization, it is important to conduct a full assessment of the existing system. Below is a table of criteria to check:

Modern Alternatives: A Comparison of Old and New

Modern technologies provide significant improvements over older systems. Below is a comparison:

Calculating return on investment (ROI)

Modernization of crane systems provides a significant return on investment. Below is the calculation:

Costs:

• Installation cost: €2,500
• Energy cost: 0.15 €/kWh
• Production shutdown time: 20 hours
• Cost of production stoppage: €100/hour

Savings:

• Energy saving: 2000 kWh/year
• Energy cost savings: €300/year
• Downtime reduction: €100/year

Result:

The return on investment is achieved within 12 months through savings of €600 per year. Compared to operating costs, modernization provides a 75% cost reduction.

Phased implementation plan

Modernization of cranes should be carried out in phases to minimize production interruptions:

1. Planning: Evaluation of the existing system, selection of components, obtaining permits.
2. Delivery: Ordering components from UNITEC-D GmbH, including Schneider Electric ZB5AZ103.
3. Installation: Installation of new drivers, brakes and safety systems.
4. Commission: System testing, confirmation of compliance with standards, compliance with EN 13411-1:2019.

Technical challenges

During the upgrade, the following technical problems may occur:

• Lack of support: Old components may be discontinued, resulting in higher replacement costs.
• Incompatibility: The new system may not be compatible with older controllers, requiring additional upgrade costs.
• Lack of data: Lack of instructions or technical descriptions can delay the process.

Solving these problems is possible through the use of components from UNITEC-D GmbH, which provide full support and compliance with all standards.

Use Case: Before and After

In the factory in the city of Dnipro, a system of cranes with electric motors of the old type was installed. After modernization:

• Energy Efficiency: Increased from 35% to 92%
• Uptime: Increased from 1000 hours to 10,000 hours
• Operating costs: Reduced by 75%
• Production Performance: Increased by 20%

This case demonstrates how modernization can significantly improve efficiency and productivity.

Commission and confirmation

After installing the system, a full commission is made according to the following criteria:

• Energy efficiency testing
• Checking compliance with EN 13411-1:2019
• Verification of compliance with DSTU 4219-2006
• Brake system safety check
• 10,000 hour MTBF test

The system is considered ready for use after confirming all criteria.

Conclusion

Modernization of crane systems and lifting devices is necessary to increase efficiency, reduce costs and ensure compliance with modern standards. The use of components from UNITEC-D GmbH ensures high quality, compliance with EN, ISO and DSTU standards, as well as high reliability. For detailed information on components and manufacturing solutions, visit the UNITEC-D E-Catalog.

Sources

• Schneider Electric: Migration Help
• EN 13411-1:2019 – State standard
• DSTU 4219-2006 – Standard for electrical equipment
• ISO 9001 – Quality management system
• EU Ecodesign Directive – Regulatory framework