Modernisierung des Kabelwerks in Usbekistan: Sechs kundenspezifische Brückenkrane für die Nachrüstung des bestehenden Werks entwickelt

Dafang Crane recently successfully delivered and installed 6 customized overhead cranes (2 of 10 tons and 4 of 5 tons) for a cable factory in Uzbekistan. The project not only involves providing equipment for the customer’s new workshop, but also overcomes the complex technical problems of upgrading and transforming the original track of the old workshop.

This article will analyze the five core highlights of this case in depth and show how Dafang Crane can win the high trust of customers and promote continuous cooperation in gantry crane projects through accurate site survey, efficient full frequency conversion drive (VFD) technology, reliable dual control system, and excellent project execution (early production).

Customized Site Survey: Aligning Raw Data with Operational Realities

Project challenge: The customer’s old factory track has problems with old age and different standards. Any dimensional deviation may lead to installation failure or poor operation, resulting in a huge waste of time and cost.

Original Track Layout Fig.1

Original Track Layout Fig.3

Original Track Layout Fig.3

Generous solution-we are not just putting new machines on, we are ensuring that your old factory assets can be given a second life. Dafang Crane refuses to rely on the old drawings provided by customers but regards the old workshop as a “living ecosystem”, through detailed on-site investigation and research, to ensure the complex integration of new equipment and old infrastructure.：

• Basic Parameter Audit

Multi-point re-testing is carried out for the working level, actual span and lifting weight to ensure that the structural strength of the crane can perfectly match the real production load on the site, rather than the theoretical value.

• Rail System Mapping

Accurately measure the deviation, spacing and wear pattern of each section of track. Through the measured data, the end beam and connecting plate are customized to ensure that the new machine runs smoothly on the old track, and the phenomenon of “rail gnawing” is eliminated from the source.

• Headroom Verification

Without changing the original roof structure, the space margin on the beam is accurately verified, and the maximum lifting height is achieved for the 10-ton and 5-ton single-girder cranes, and the storage space is optimized.

• Electrical Stability Analysis

Comprehensively monitor the voltage fluctuations of the local industrial power grid. Based on data feedback, we have enhanced the anti-interference ability of the electrical system in a targeted manner and optimized the control algorithm to ensure that when hoisting precision cable trays, even if the power grid is unstable, the operation is still stable and jitter-free.

• Operator-Centric Review

We communicate directly with the on-site operation team and simulate the transfer path of the cable tray on the spot. By observing the operating habits, the response sensitivity and safety limit logic of the control handle are optimized to ensure that the equipment not only conforms to the operating intuition, but also can achieve accurate obstacle avoidance in busy operations.

This kind of early pursuit of data makes the entire installation process show extremely high certainty. At the construction site of the Uzbekistan cable plant, the 6 overhead cranes were not only installed in just 20 days, but also demonstrated a perfect physical fit during the first load operation.

Judging from the on-site feedback, the crane fits tightly to the side of the track, and there is no cant or offset even under high-speed operation. This ultimate pursuit of detail reflects Dafang Crane’s core strength as a high-end custom manufacturer and realizes its commitment to “one-time success” for customers.

Compatible with Existing Rails

Installation View1

Installation View2

Technical Customization: Advanced Drive Upgrades on Demand

In the Uzbekistan project, they generously demonstrated a high degree of flexibility. Considering the extremely high penetration rate and operating habits of LD single girder overhead cranes in the local market, customers hope to obtain a high-precision control experience that exceeds the standard because of retaining this classic and easy-to-maintain model. We have deeply responded to this demand and achieved the optimal balance of performance through a special upgrade of the advanced frequency conversion drive system (VFD)：

1. Frequency Conversion Drive System (VFD) with Smooth and Accurate Operation

Unlike the standard configuration of ordinary motors generally used in the industry, according to the strict requirements of customers for the smoothness of cable tray hoisting, we have customized an advanced frequency conversion control system for the whole line:

• Stability beyond the standard: customers require the complete elimination of the “instantaneous impact” when the traditional motor starts and stops. By upgrading the VFD power unit, we have achieved millisecond-level soft start and soft stop. This ensures that the cable tray, weighing several tons, is as stable as Mount Tai at the moment of lifting and operation, effectively protecting the wiring accuracy of high-value cables.

• Precise docking: Cable production has extremely high requirements for the stability of Pay-off loading. Thanks to the high-configuration VFD frequency conversion system specially upgraded by the customer, the crane has an excellent low-speed crawling function. The operator can control the precise placement of the cable tray at a very fine stepping speed to ensure that the tray is accurately docked with the shaft hole of the cable release frame, and the tooling damage or cable disorders caused by shaking and collision are completely avoided.

2. High-end Options for Central Asian Working Conditions

To meet the customer’s long-term plan for the durability of the equipment, we have also carried out advanced configuration upgrades simultaneously on the mechanical side:

• High-level protective power: A specially equipped F-class insulated motor with stronger sealing is specially equipped to ensure excellent thermal stability under long-term high-frequency operation.

• Low-noise transmission system: The use of a high-precision gear grinding reducer not only has higher transmission efficiency, but also significantly reduces the operating noise of the workshop, creating a better working environment for front-line employees.

3. Dual Control System to Ensure Safety

To avoid any risk of downtime in the busy production rhythm, we are equipped with a redundant control scheme of “wireless remote control + industrial wired handle” for each overhead cranes:

• Flexibility upgrade: The operator can avoid material stacking through the wireless remote control and command at the best line of sight, greatly improving ground safety.

• Operation continuity guarantee: In response to the customer’s pursuit of “zero unplanned downtime”, the backup wired handle can be switched in seconds. Even in the face of a complex electromagnetic interference environment, production will never be interrupted.

The successful delivery of these 6 LD overhead cranes is a concentrated demonstration of Dafang Crane’s customized strength. We not only provide standardized products, but also transform every high-end configuration upgrade into real productivity through in-depth disassembly of customer-specific working conditions. This comprehensive evolution from the drive system to the control logic reflects our solemn commitment to the “long-term operational benefits” of our customers.

Rapid Execution: 6 Overhead Cranes Commissioned in 20 Days

Overhead Cranes in Operation

Overhead Cranes in Operation

Overhead Cranes in Operation

The customer’s production plan is tight and there are requirements for the delivery cycle. After receiving the order, Dafang Crane handed over a satisfactory answer sheet through the closed-loop collaboration of  “efficient production (50 days) + cross-border speed (14 days) + fast integration (20 days)”:

• Compliance production (50 days): Under the premise of strictly following ISO and EAC international certification standards, we completed the manufacture and rigorous quality inspection of 6 customized cranes within 50 days.

• Cross-border logistics (14 days): Relying on mature central asian logistics channels, the equipment arrived at the Uzbekistan site safely in just 14 days.

• Seamless installation (20 days): This is the core highlight of the entire project. Thanks to the early five rounds of on-site surveys that eliminated all hidden dangers of track integration, the 6 overhead cranes completed the whole process from hoisting to load testing in just 20 days after they arrived.

The delivery speed of these 20 days is direct proof of Dafang’s comprehensive strength. We have optimized every node from design to installation to ensure that the equipment can be “plug and play”, helping customers minimize downtime and quickly release production capacity. This kind of response speed to deliver high-quality customized products within a tight deadline has not only won high praise from customers, but also laid a solid foundation for subsequent strategic repurchases.

Securing Future Partnerships: The Ultimate Testament to Customer Satisfaction

After the overhead cranes successfully passed the strict acceptance of the customer and was put into smooth operation, the customer highly praised our product quality, professional service, and project execution.

Based on the deep trust established by this project, the customer has decided to continue to cooperate with Dafang Crane on its next gantry crane project. This marks the upgrade of the two sides from one-time equipment procurement to a long-term strategic partnership. The best marketing is the customer’s reputation. The intention of this follow-up project is the most direct and powerful market return brought about by Dafang Crane’s “customer-centered” service concept and excellent product capabilities.

From precise survey to customized design, from efficient configuration to fast delivery, Dafang Crane’s outstanding performance in tc project systematically demonstrates our core competitiveness as a manufacturer of high-end lifting equipment. What we deliver is not only cranes, but also comprehensive solutions to ensure efficient, safe and reliable production for customers.

If your factory is also facing the challenges of equipment upgrading, renovation of old factories or new production lines, please feel free to contact us. Let us use the same professional engineering strength to tailor lifting equipment suitable for you.

Cindy

WhatsApp: +86 191 3738 6654

Email: cindywang@hndfcrane.com

Ich bin Cindy, habe 10 Jahre Berufserfahrung in der Kranbranche und eine Fülle an Fachwissen angesammelt. Ich habe für über 500 Kunden die zufriedenstellendsten Kräne ausgewählt. Wenn Sie irgendwelche Bedürfnisse oder Fragen zu Kränen haben, können Sie sich gerne an mich wenden. Ich werde mein Fachwissen und meine praktische Erfahrung nutzen, um Ihnen bei der Lösung des Problems zu helfen!