Photo caption: Konecranes supplied a 1,600 kg KBK solution that adapts to the hall geometry and enables the safe, electrically operated transport of the engine components to the adjacent hall bay. (Image source: Konecranes GmbH)

Cummins Deutschland GmbH has expanded its large engine overhaul center at its Groß-Gerau site to include industrial component cleaning. For the safe transport of engine components within the work area – including transfer to an adjacent hall – Konecranes implemented a crane solution based on the modular Konecranes KBK workstation crane system with a lifting capacity of 1,600 kg. The system takes the existing building geometry into account, enables electrically driven load movements, and meets safety requirements through configurable travel speeds.

A crane system that, despite supports and installations, fully covers the area and can later be extended to the existing bridge cranes. (Image source: Konecranes GmbH)

Initial situation at Cummins Germany

At the service and repair center in Groß-Gerau, engines with outputs ranging from 13 to 2,600 kW are completely disassembled, overhauled, and rebuilt using original spare parts. The installation of a new washing machine for engine components necessitated a reorganization of the internal material flow, as cleaning is now integrated as a fixed process step.

Project requirements (technical specifications)

Since the relevant hall area contains static columns and permanently installed utility equipment, a crane system had to be developed that would allow access to the entire workspace without altering the building structure. All structural conditions were thoroughly considered when determining the column positions for the crane system.

Another key criterion was the later possibility of extending the KBK crane track into the adjacent hall, in order to transfer components directly to two existing Konecranes bridge cranes.

Bernd Böhringer, Konecranes GmbH, in front of the installed KBK system, which, thanks to its adapted steel construction and modular components, enables optimal area coverage despite structural constraints. (Image source: Konecranes GmbH)

For ergonomic reasons, only electrically driven axes were specified (lifting, trolley, and crane travel). Furthermore, the control system had to be designed to allow fine adjustment of travel speeds in order to permit only low speeds in safety-critical areas – particularly to minimize crushing and collision risks.

Other function-relevant criteria:

• Load capacity 1,600 kg across the entire working area
• Use of a freestanding steel superstructure
• The steel structure and KBK crane system can be flexibly expanded at any time.
• The modular crane system allows for the optional retrofitting of additional crane bridges.
• Fulfillment of all relevant design criteria for use in multi-shift operation.

Statement from the project management team

“The challenge was to cover the entire work area with crane technology, despite the existing hall structure, fixed installations, and a central support in the load path. Through a customized steel structure and the use of the modular Konecranes KBK system, we were able to implement a solution that took the existing building geometry into account while still ensuring the complete material flow between the washing machine and downstream processes.” Bernd Böhringer, Sales Engineer Light Lifting Equipment.

At the Groß-Gerau service center, the material flow has been reorganized, as a new component washing machine will now be a standard step in the overhaul process for the 13–2,600 kW motors. (Image source: Konecranes GmbH)

Technical implementation by Konecranes

Konecranes implemented the solution based on the modular KBK workstation crane system. The system consists of cold-rolled KBK II-H steel profiles with high inherent stiffness, capable of supporting loads of up to 2,000 kg even over larger spans. The steel structure’s supports were positioned asymmetrically to avoid any further disruption to the existing hall. This creates the largest possible, continuously usable work area.

The KBK crane runway was designed to allow for future load transfer to the adjacent hall, where it can be handled by the existing overhead cranes. All movements are electrically powered and controlled via an ergonomic control switch. During commissioning, the travel speeds were individually adjusted to meet customer requirements, which also enhances workplace safety.

Results and benefits for Cummins

With this system, Cummins has a reliable, user-friendly, and flexibly expandable crane system at its disposal, covering the entire material flow from dismantling and cleaning to subsequent processing steps. The high-quality components used ensure an ergonomic work environment with efficient operation and minimal noise. This allows the operator to maintain full control over the load at all times, work safely, and concentrate fully on the process without distractions.

Thanks to its modular design, the plant can also be easily expanded in the event of future process changes without any intervention in the building or foundation structure.

Konecranes GmbH