Konecranes KBK workstation lifting system supports large engine overhauls at Cummins Germany

At the service and overhaul center in Groß-Gerau, engines with power ratings from 13 to 2,600 kW are completely dismantled, overhauled and rebuilt using original spare parts. The installation of a new industrial parts washer for engine components made it necessary to reorganize the internal material flow, as cleaning is now integrated as a defined process step within the overhaul workflow.

Static columns and permanently installed utilities in the relevant hall area required a crane solution that could provide full coverage without any modification to the existing building structure. All column positions for the crane system were engineered to accommodate the on-site structural constraints.

Another key requirement was the option to extend the KBK runway in a later phase into the neighbouring hall, allowing engine components to be transferred directly to two existing Konecranes overhead bridge cranes.

From an ergonomic and safety perspective, all crane movements – hoisting, trolley travel and crane travel – were specified as electrically powered. In addition, the control system had to allow finely adjustable travel speeds, particularly to enable reduced speeds in safety-critical zones and minimize pinch and collision risks.

Additional functional requirements:

• 1,600 kg lifting capacity across the entire work area
• Use of a freestanding steel superstructure
• Flexible expansion of steelwork and Konecranes KBK workstation crane system at any time
• Modular system design allowing optional installation of additional crane bridges
• Compliance with all relevant design criteria for multi-shift operation