Many find themselves today with aging overhead cranes, originally designed to perform and survive in the tough environments of steel and manufacturing plants but operating with the previous generation of high-maintenance DC motors and controls. There are some 3,000 active cranes running in North América with traditional DC controls that could be retrofitted over time.
Most of these older cranes rely on traditional electromechanical DC Constant Potential (DCCP) systems which use contactors to switch regenerative load currents to resistor banks in order to dissipate the energy. DCCP systems are maintenance intensive due to their many moving and wearing parts which must operate under severe duty and in harsh environments. Rather than scrap an outdated crane, which is still structurally and mechanically sound, it is more economical to upgrade or modernize these cranes with state-of-the art electronic controls, designed to meet current operational needs.
AC is becoming the power source of choice, especially for new installations in paper mills, steel mills, bulk materials handling, shipyards, and many more areas. However, DC motors are both efficient and robust and offer year upon year of service, providing acceptable performance for the most demanding applications. Retaining an existing DC motor and upgrading the crane with solid-state controls is more environmentally friendly and – from a commercial perspective – provides an opportunity to enhance overall system performance and reliability while minimizing the risk to production and the required capital investment, an attractive proposal in today’s economic environment
Three main control options are available for modernizing existing DC Cranes:Retain existing power source, dc-motors and control wiring and replace traditional contactor control or obsolete static controls with Digital DC Controls.
These microprocessor based, solid-state, four-quadrant DC-to-DC controls are designed for series, shunt, and compound wound motors and are a perfect drop-in replacement for traditional contactor control since they easily interface with existing power and control circuitry and use the same connection points while having a smaller footprint. This is the least costly option of the three, since existing motors, brakes, and wiring can often be utilized. In addition, energy savings can be significant, since these Digital DC Controls recover energy from the load and return it to the DC power supply.
Convert crane to operate on AC power retaining existing shunt-wound dc-motors and control wiring, replacing existing controls with DC Digital Static Drives.
These drives are microprocessor digital logic controllers, which deliver precise,repeatable AC-in/DC-out control of shunt-wound bridge, trolley, and hoist motors -- with reliable, energy-efficient performance -- while significantly reducing operating and maintenance costs. This control has performance characteristics and many of the same advanced features of AC Adjustable Frequency Control. It can be an economical drop-in replacement for those cranes already equipped with shunt-wound dc-motors.
Convert crane to operate on AC power with low cost, efficient ac-motors and Variable Frequency Drives.
Variable Frequency Drives have revolutionized the market for high performance AC Crane Controls -- now surpassing the torque control and speed regulation capabilities of DC shunt motor control.
Upgrading an aging DC crane with modern, robust and reliable DC or AC Digital Controls results in increased up-time, improved performance, reduced maintenance costs plus energy savings, which all translate into a significant return on investment.
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