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Fast cranes for heavy loads

Neuman Aluminum modernized their material flows in the extrusion plant in Marktl, Austria, during the Christmas holidays. At the core is a new automatic crane system by Vollert with 21 interchangeable cycles for loads of up to 3 tons. It replaces two existing transport cranes and is one of the fastest automatic cranes ever used in the extrusion industry.

The new automatic crane in the Neuman Aluminum extrusion plant in Marktl, Austria, is significantly more efficient and faster than its two predecessors. The new transport crane carries cassettes with aluminum profiles of more than 3 tons of up to 7.5 m in length, and stores, and transports them for post-heat treatment. It stacks up to five cassettes with the utmost precision and, with its four-wheel drive, achieves driving speeds of 4 m/s on the crane runway of around 60 m long. The 8.5 m wide overhead crane hoist has a weighing function with a tolerance of only 0.5 percent and leading centering for correct positioning of the stackable profile cassettes. Owing to limited space, cassettes in the warehouse are stacked only 90 mm apart. Special gripping tongs therefore grab the cassettes from above while the anticipatory centering allows precision stacking. When accessing the lowest pallet level near the ground, the centering guide is automatically retracted.

Make one out of two in 14 days

For Neuman Aluminum, it was not only Vollerts expertise in the extrusion industry, but also its many years of expertise in dealing with complex modernization projects that clinched the deal. Vollert has modernized several facilities during public holidays and while continuing production. As general contractor, the experts from Weinsberg took over the entire engineering and coordination of the assembly - from the mechanics and the control technology to commissioning. "Accurate project management is crucial in these conversions pressed for time - otherwise such narrow time frames would be impossible," says Andreas Pyzalski, Project Manager at Vollert. Only 14 days were available during the Christmas holidays for dismantling the two old cranes and assembling the new crane. Since the existing plant engineering was not designed for the new loads and speeds, the crane runway and the rails had to be replaced. In addition, the entire support structure had to be reinforced, while the new crane with guide rail and distance measuring system had to be installed exactly according to the existing conveyor engineering.

Better safe than sorry

Prior to installation, the crane was completely set up and tested - also so that the position measuring systems could be pre-adjusted. The crane's high precision is a special feature: Neuman Aluminum's two laser measuring systems ensure exact positioning information, which is also important for the safety of the processes. Overall, the crane will be integrated into ten security areas with passenger transport. "The engineering and coordination of those involved in this project were extremely complex," says Andreas Pyzalski. However, the total duration of the project, including planning, took only about a year. With around 2,400 staff at ten locations in Europe, North America and Asia, the Neuman Aluminum Group manufactures aluminum solutions for the automotive, construction, electrical and security industries.

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