Project Overview
Client
- A premium German-owned automotive stamping and tooling manufacturer in Silesia, Poland
Location
- Newly built climate-controlled clean workshop, Katowice, Poland
Crane Type
- HD Type European Single Girder Overhead Crane (Low Headroom, Maintenance-Free)
Quantity
Key Specifications
Capacity
Span
Lifting Height
Duty Class
- FEM 2M (equivalent to ISO A5)
Drive Components
- Original German ABM three-in-one hoisting motor + German SEW travel drives + Schneider VFD electrical system
Customer Challenges & Environmental Demands
Severely Restricted Headroom
- To minimize overall construction and winter heating costs, the client designed a highly compact steel-structure workshop where the clearance from the crane runway rail to the lowest roof truss is only 900mm. A traditional Chinese single-girder crane would leave less than 4.8m of hook height, which is insufficient for lifting and flipping the client's 4.5-meter-tall stamping dies.
Vibration & Noise Restrictions
- The workshop houses high-precision CNC machining centers and coordinate measuring machines (CMM). Any mechanical vibration from the crane would ruin the machining accuracy. Additionally, European labor standards strictly limit workshop noise to under 65 dB.
Regulatory Compliance
- The cranes had to pass the strict on-site inspection of the Polish Office of Technical Inspection (UDT) and carry full CE certification.
Customized Solutions by Yixing Crane
Ultra-Low Headroom Design
- Using finite element analysis (FEA) to optimize the box girder, we paired it with a side-hanging compact wire rope hoist. This successfully compressed the vertical profile of the crane above the rails to just 710mm, leaving a safe 190mm clearance below the roof. This design achieved an effective hook height of 6.5m—reclaiming 1.7 meters of vertical workspace.
German Premium Drives & Quiet Operation
- The hoist is powered by a
German ABM three-in-one gearmotor
(IP55, Class H insulation, electromagnetic brake), and the travel carriages utilize
German SEW drives
. Controlled by Schneider VFDs with custom S-curve acceleration (4.5-second ramp time), the cranes start and stop with zero shock or sway. Running noise is kept under 58.5 dB, ensuring a quiet, vibration-free environment.
EU Standard Electrical Integration
- The control panels are wired with flame-retardant, double-shielded flexible flat cables. They include multi-stage safety interlocks, over-travel limits, and overload protection. Grounding resistance measures at just 0.08Ω, far exceeding EU safety codes.
Results & Long-Term Value
Hassle-Free Certification
- The cranes successfully passed all dynamic (110%) and static (125%) load tests during the UDT on-site audit, receiving operating permits with zero non-conformances.
Significant Structural Savings
- By adopting Yixing’s low-headroom design, the client was able to lower the entire factory building's column height by 1.5 meters during the design phase. This saved over 48,000 EUR in raw steel construction costs and reduced annual workshop HVAC energy consumption by 12%.
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