KASTO , during the status analysis . These components are not expected to malfunction in the next few years . However , the system ’ s controls were severely outdated and could become a concern . The replacement of specific parts “ would not have worked because they were not compatible with the remaining components in the control chain ” Gekeler adds . Therefore , the experts from Swabia opted for a retrofit .
At the end of February 2022 , KASTO updated the complete control electronics at stations and crane bridge . “ We replaced the entire drive technology on the crane ,” Schwörer reports . This included switch components as well as motor and encoder cables . The existing measuring systems were replaced by an absolute encoder with integrated cable pull and an optical laser measuring system . In addition , the technicians updated the optical data light barrier and installed two climate control units in the control cabinets on the crane bridge . They also swapped out two frequency converters at the stations . The new components come with a service agreement to support the plant ’ s internal maintenance department . “ The retrofit not only eliminates the cause of many malfunctions , minimising the risk of downtime ,” Gekeler explains , comparing before and after . “ At the same time , the new technology equips us for the future .”
The retrofit at the beginning of the year was already the third project of this kind at SÜLZLE Hagmeyer .
Even the experienced automation expert from Achern rarely undertakes retrofit projects on stacking cradle systems . The project also faced challenges due to the physical conditions . “ Normally , we prefer to work with up to 15 employees on retrofit projects . This allows us to carry out several measures in tandem ,” explains Schwörer . “ Unfortunately , that was not so straightforward in Hall 9 .” The crane bridge did not provide nearly enough work space for the amount of personnel required . The KASTO team overcame the challenging conditions and limited space under the hall roof by using three articulated aerial platforms and a truck-mounted crane to transport loads efficiently . The safety of technicians was given utmost importance due to the significant working height . Protecting them from falling or other incidents
was the number one priority . “ For obvious reasons , work safety preceded maximum speed ,” Schwörer strongly emphasizes .
POSITIVE EXPERIENCE REPEATED TIME AND TIME AGAIN
The retrofit at the beginning of the year was already the third project of this kind at SÜLZLE Hagmeyer . In 2011 , KASTO upgraded a KASTO Unicompact 4000 honeycomb storage system , which was put into operation in 1993 . In 2010 , retrofit measures on a sheet metal storage system from a third-party supplier lead the way . The positive experience from previous interactions influenced the decision to place the new contract . Gekeler praised its project partner by saying “ KASTO always demonstrated exceptional project planning skills ”. “ Goals are defined for each day and met consistently . The resources provided are selected to meet the current challenges faced taking into consideration the team size and the required auxiliary equipment .” As a result , this project was also executed flawlessly as per schedule . “ The fast and dependable execution of projects like this helps us to better coordinate with customers and suppliers .,” reports the IT Director . KASTO completed the retrofit measures within three weeks and , most importantly , handed over a turnkey , reliable system in mid-March .
Left , SÜLZLE Hagmeyer ’ s treasure chest : In 2001 , the metal distributor built a hall for its high-quality steel and aluminium products . The storage system was updated in 2022 . Above , from the SÜLZLE Hagmeyer team ( from left ): Hans Gekeler , Director of IT , Gerhard Mehlmann , Maintenance Manager , and Ralf Thierer , Supervisor and Warehouse Manager .
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