Successful start of productive operation: Demag process crane for Swedish iron foundry
- Handling rates for scrap increased five-fold
- Maximum functional reliability in continuous operation
The Swedish iron foundry Arvika Gjuteri AB commissioned a new Demag process crane with an integrated weighing and position measuring system. With the investment in modern Demag crane technology, the manufacturer with a long tradition of producing castings for commercial and off-road vehicles pursued the goal of considerably increasing the handling rates for scrap in line with its increased production capacities. For the company, this is an important step to consolidate and further expand their competitive position on international markets.
“In order to meet the growing requirements of our customers, speed and precision are the decisive factors when collecting the material”, reports Anders Nilsson, Project Manager at Arvika. “We achieved this through implementation of the new crane installation. While the old crane needed up to 60 minutes for a single operating cycle, the new crane manages this work in only 12 minutes.”
At the headquarters of Arvika in the town of the same name in the Värmland province, the Demag ZKKW double-girder process crane has replaced an older crane model and is responsible for fast and reliable collection of scrap material, also known as charge make-up, and its transfer to the induction smelting furnace. With the old crane, the Arvika employees had to work 24 hours a day in the scrap yard and melting shop, now the new crane can handle the same weight of scrap in less than two shifts.
So the charging crane is also designed for future increases in capacity. “The start of productive operation already confirmed our decision to trust Demag Cranes as a solution provider to supply us with tailored technology”, continues Anders Nilsson.
“Our in-depth know-how of the foundry industry and the related development of customer-specific charging cranes was a great advantage for our customer Arvika”, adds Lutz Dowy, Senior Vice President Process Cranes at Demag Cranes. “The excellent co-operation with our Swedish agent Dematek also contributed to the successful processing of the project.”
Charging crane: integrated weighing and evaluation system saves time and costs
At Arvika Gjuteri AB, the scrap is prepared and correctly sorted in nine boxes. Orders for material pick-up are transmitted to the crane staff in the control station. The orders include information about the quantities to be removed from each of the individual boxes. These quantities are specified in formulations so that the resulting cast material contains exactly the desired properties.
The crane, which works five days a week in two-shift operations, first takes the material with the largest quantity from a box and, at the same time, determines the weight via calibrated crane scales integrated in the open winch crab. On the basis of this data, the quantities for further material are determined, transmitted to the cab by radio and displayed there. As soon as the desired final formulation is complete, the mixture is then tipped onto a heap of scrap from where it is conveyed to the smelting furnace. The more precisely the respective mixture is produced by the crane, the fewer high-cost alloys are required.
Magnet holds the load safely
The Demag ZKKW double-girder crane has a span dimension of 22.65 metres and travels on a 40-metre-long crane runway. It is equipped with a multi-purpose MPW open winch, characterised by its compact and maintenance-friendly design. The load is picked up using a round magnet connected to the hoist by a 4/2 reeving arrangement.
Top efficiency without restriction required
High handling rates require high speeds. With up to 80 m/min in long travel, cross travel from up to 60 m/min and load-dependent hoist speeds up to 66 m/min, the crane corresponds exactly to this requirement profile. Infinitely variable motions in three axes are regulated via frequency inverters, thus contributing to safe operation in two shifts, five days per week.
The crab and crane are equipped with cameras via which the process is permanently monitored in detail from the control station. This control station is installed as a cab. Demag Cranes has equipped the control panel inside with ergonomically arranged operating elements.
About Arvika Gjuteri AB
Arvika Gjuteri produces high-grade castings, primarily for the commercial vehicle industry. The components and solutions of the company are supplied mainly to global companies that produce commercial and off-road vehicles. Arvika Gjuteri has been owned by the Sixth AP Fund since 2009. The Sixth AP Fund manages general pension funds and invests its capital primarily in small and medium-sized Swedish companies.
About Demag Cranes
The Demag Cranes Group is one of the world’s leading suppliers of industrial cranes and crane components, harbour cranes and terminal automation technology. Services, in particular maintenance and refurbishment, are another key element of the Group’s business activities. The Group is divided into the business segments Industrial Cranes, Port Technology and Services and has strong and well-established Demag and Gottwald brands. Demag Cranes sees its core competence in the development and construction of technically sophisticated cranes and hoists as well as automated transport and logistics systems in ports and terminals, the provision of services for these products and the manufacture of high-quality components.
As a global supplier, Demag Cranes manufactures in 16 countries on five continents and operates a worldwide sales and service network that is present in over 60 countries through its subsidiaries such as Demag Cranes & Components GmbH and Gottwald Port Technology GmbH, agencies and a joint venture. In financial year 2010/2011, the Group, with its 6,115 employees, generated revenue of EUR 1,062.3 million. Since August 2011, the Terex Group in the United States (www.terex.com) has held a majority share in the company.
Demag Cranes AG. We Can Handle It.
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