Loading crane

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We love problems – yours, for example

Loading crane.

Situation.

There are many companies who upgrade trucks with mobile cranes resulting in an enormous number of variations in terms of individual customer requirements. These customers require a wide variety of solutions when it comes to weight class, control type, motion sequence and attachment location. To meet these requirements, the cranes have to be custom designed and manufactured.

Problem.

The custom equipment increases manufacturing times and storage costs. Every order has to be examined and analysed in detail. The control units must be custom-built, order picking for individual parts has to be conducted, and the wiring must be done according to the wiring diagram. It is only possible to identify installation errors after successful installation of the control system and the peripherals (sensors and actuators). Commissioning of the vehicle is delayed, and the technology team must implement adjustments under ergonomically unfavourable conditions. Installation on the vehicle takes up to six hours, with much of the time taken up with searching for parts and getting oriented.

Solution.

The large number of variants is analysed with regard to the control properties to find where there are overlaps. This area of overlap is expanded with common equipment options. Additional installation space is taken into account for the requirements of exotic add-ons. A jumper module takes over the wiring tasks. Variants can be consolidated with a pre-installed housing with populated circuit board and connected cable set. Despite minor additional costs for installed-but-unused options, the savings clearly prevail. The pre-installed and pre-tested control modules are in stock and installed within 90 minutes. The commissioning phase is shortened by 120 minutes on average, because there are fewer delays caused by errors.

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Wind Energy

We`ve got the hang of it.

Situation.

Renewable energy production is becoming increasingly important, especially wind turbines. With a hub height of 60 meters and 1.5 megawatts of power, wind turbines that were originally considered to be enormous are now standard and built worldwide using German technology. In order for the turbines to work perfectly as well as cost-effectively, the optimum balance between torque and speed must be found. For this, it is necessary to be able to adjust the rotor blades. It’s not enough to turn the head of the turbine into or out of the wind. In case of high wind speeds, rotor blade adjustment is an additional way to apply the brakes effectively and an important safety aspect.

PROBLEM.

All three rotor blades must always be aligned synchronously, because excessive forces can otherwise act on a single blade. This means the rotor blade adjustment must have a central control system that is also guaranteed to function even in case of power failure. To make the task even more difficult, the hub is only accessible from the outside. On the shaft of the rotor, only a few contacts are available on the slip ring for establishing a connection. A control system via the hub and accommodation of rotor blade technology in the nacelle are therefore not possible. On-site installation in the hub is not practical and economical due to the height and difficult accessibility.

SOLUTION.

The entire rotor blade adjustment system is supplied with electrical power just through the slip rings, so only a few contacts of the slip ring are necessary. A central control box coordinates the rotor blade positions, which are each adjusted by their own drive control. This includes a battery pack to maintain control capability in case of power failure. Everything is modular and ready to plug in. All connections are pre-tested on a specially designed test station with contact force monitoring, eliminating errors and ensuring fast commissioning.

The central control module connects the individual drive controls with a single connector kit in each case. These align the rotor blade with a servomotor. The pre-fabricated installation can be quickly incorporated into the hub on the ground. Supply, signals and bus are consolidated in a single robust plug connector. The rotor blade is completely installed electrically in no time.