Gather Information for Discussion with Your Dealer
You know your business best. Gathering some basic information in preparation to work with your dealer will assist the process. If you are replacing or enhancing an existing enclosed rail system, like a Demag KBK modular crane system, you may have many of these answers at your fingertips. If you need to quote a new system, you may have more unknown information the dealer or manufacturer can help you with, but having as much information as possible upfront is crucial.
Looking for industry standards is an important part of your research for the discussion. Not only do these standards keep your workforce safe, but they also create a foundation for safer products. The Monorail Manufacturers Association (MMA), an industry group of the Material Handling Institute (MHI), has the MMA Certified program. This program allows enclosed rail crane and monorail manufacturers to become certified by meeting specific product safety and design requirements.
1. Identify the Processes to be Used with an Enclosed Rail System
As you start your purchase journey for an enclosed rail crane, freestanding workstation crane, or jib crane, the first step is understanding your processes. You know what lifting and material handling needs to happen in the manufacturing processes within your facility. There may be a special way you want to move a component or new ways you want to grip the component as it moves to enhance your assembly processes. There is no one better than you and your workforce to understand the positives and negatives of the processes you currently perform.
Along with this, you’ll be considering critical inputs like capacity and location of the system. These factors may ultimately dictate the crane configuration required and the location of the solution. A properly sized and configured solution will optimize your lifting and handling processes while ensuring workforce safety. Don’t forget, manufacturers who are MMA Certified must meet specific product design and safety standards to further promote safety.
2. Crane Configurations to Meet Your Requirements
There are many overhead lifting solutions that may meet your requirements. Ceiling-mounted enclosed rail crane systems attach to the superstructure of your building and allow lifting, positioning, and movement on the X, Y, Z axis. These systems can be located throughout your facility to optimize your assembly and manufacturing processes. If you consider a ceiling-mounted system, always verify the structural details of your building.
Monorail systems allow lifting and transportation of loads directly beneath the monorail. These systems can be equipped with a lifting device or specialized tooling on a trolley to enhance the flow of components through your factory. Monorail systems can be routed around corners and curves, and be enhanced with different accessories like turntables, track switches, and automation for efficient material flow throughout your facility.
Freestanding workstation cranes allow you to add a material handling and lifting area with an X, Y, Z axis nearly anywhere within your existing floor space. The crane is supported with a support system of columns attached to the concrete floor of the building. Workstation cranes can create optimized assembly and manufacturing areas, retool an underused area of your production facility, or add lifting and material handling capabilities to buildings without robust superstructures.
Jib cranes are found in nearly every industry. These cranes can be wall-mounted or pillar-mounted, allowing for lifting within an area under the jib arm up to 360 degrees. The jib arm reaches out from the wall or pillar mount, allowing for lifting and handling in a circular-shaped area. These cranes can fit nearly anywhere within a facility to build a new cell for manufacturing in unused space or replacing manual lifting in an existing area of the facility.
3. Comparing the Benefits of Aluminum or Steel Runway and Bridges
Demag offers enclosed rail track in both steel and aluminum. Each type of rail brings benefits to your application. Generally speaking, aluminum rail is more ergonomic for manual push/ pull applications. Steel rail can support heavier loads on bridges and runways. Both types of track can be used in a KBK crane to meet the specific requirements of your lifting needs.
Budget is an important detail when adding a crane or monorail system to your operations. There are ways to optimize your budget with enclosed rail cranes and monorail systems. Using standard track lengths is more economical than a customized length. This means the final system designed may be slightly shorter or longer than originally planned. When you work with your authorized Demag dealer to create your solution, they can help you navigate standardized rail lengths to optimize your budget.
4. Measuring Dimensions for Lifting and Handling
A critical measurement to understand is height—height under the beam, floor to trolley saddle height, and lift height for the hoist. These measurements assure your system gives you the proper amount of space to work within the area and lift and move materials. Height under the beam for your enclosed rail crane or monorail assures that lifting and moving process can be accomplished between the bridge and floor on a ceiling-mounted system. Floor to trolley saddle height assures the same on a freestanding workstation crane, giving you the support beam height necessary. Lift height is a critical measurement, measuring the distance from the floor to the saddle of the lifting device hook when the hook would be in the uppermost position.
5. Electrical Requirements & Powering Your System
Every geographic area has specific electrical requirements. In the USA and Canada, we typically handle 3-phase power, 230V, 480V or 575V with 60Hz. Regardless of your location, assuring your crane system will work with the local electrical requirements is critical.
In addition to the geographic electrical requirements, there are different ways to deliver reliable power within the crane or monorail system. Demag KBK track can be equipped with an integrated conductor line, potentially eliminating the need for festooning. Festooning is a flexible option for electrical and compressed air-powered applications.
6. Lifting Device & Travel
Choosing a lifting device and trolley is just as important as the crane or monorail configuration. Demag lifting devices are designed to seamlessly integrate into a KBK crane or monorail system with the right trolley solution to meet your requirements. DC chain hoists allow you to lift loads traditionally with a pendant or with the Manulift handle with one hand on the control handle above the hook and the other hand on the load.
Balancers are found in assembly and manufacturing operations for intelligent lifting with float mode. Available as electric or pneumatic balancers, both allow an operator to float the load and maneuver it into place with two hands on the load. Demag offers the DCBS Electric Balancer, based on our DC chain hoist product line, easily programmed to your exacting needs.
In addition to lifting a load, moving a load on the crane or monorail system is accomplished with a trolley. Trolleys can be manual push or electric. Many factors can dictate whether you are required to use one or the other, for instance, weight of the load or the travel path. Manual push trolleys are appropriate for certain applications and need to be ergonomic to keep your workforce safe. Electric trolleys have a travel drive attached that moves the load. The operator controls the trolley and lifting device with one pendant or radio. Less commonly, trolleys can be powered with clean air, pneumatic power.
Choosing the Demag KBK Crane or Monorail Solution to Meet Your Requirements
Demag KBK modular crane and monorail systems are an industry standard. Trusted in OEM automotive manufacturing facilities and production lines for complex handling, Demag KBK crane and monorail systems are flexible, customizable, and safe for your workforce and work processes. Even in simple crane applications, KBK delivers a reliable, efficient, and safe solution for your workforce and your operations.
KBK makes load handling precise and ergonomic, making work safer and more efficient. Adding a Demag lifting device like a DC chain hoist or DCBS electric balancer seamlessly integrates to customize your solution.
Optimized for Safety & Ergonomics
The most demanding industries trust Demag KBK Systems and Components to contribute to a safe, ergonomic work environment. KBK is MMA Certified, meeting the industry standard in product design and safety. Trolleys move smoothly and quietly with minimized rolling resistance over the entire service life.
KBK bridge trolleys are designed to be precise and smooth-running to reduce or eliminate binding due to articulation. Unlike rigid crane systems, KBK crane system components articulate and skew with hanger joints, eliminating binding, making movement smooth and easy even on the extreme ends of bridges and runways. Articulating cranes, make handling more ergonomic.
When you’re ready to get a quote for an enclosed rail crane or monorail system, contact us. Learn more about Demag KBK Modular Crane and Monorail Systems and contact us to be match with a Demag Dealer in the US or Canada.
