Automated Crane Modernization for Steel Coil Handling

Reference case: Full-scale electrical and automation upgrade of a bridge crane in a cold rolling mill

Initial Situation: A Critical Process Crane at the End of Its Life Cycle

An automated bridge crane operating in a cold rolling mill had reached the end of its lifecycle — particularly in terms of its electrical and automation systems. Spare parts were no longer available, the control systems were outdated, and the reliability of the crane was beginning to decline.

The crane was classified as a criticality class 1 unit, meaning its continuous and safe operation was essential for uninterrupted production. It operated both as a fully automated crane for steel coil handling and as a maintenance crane when needed.

Solution Design: A Thorough Modernization with Reliability as Priority

The customer initiated the project with a request for quotation. Satateräs responded with a comprehensive modernization plan focused on renewing all electrical and automation systems.

The scope included:

Complete electrical system renewal: all electrical cabinets, cabling, junction boxes, and lighting were replaced.
New frequency converters: all crane movements were equipped with regenerative drives optimized for crane use, including backup inverters.
PLC and control system: all functions were migrated to a new Siemens TIA platform (S7-1500).
New HMI panel: an intuitive and informative interface improves crane operation and diagnostics.
New safety systems: updated sensors, anti-collision, anti-sway protection and emergency shutdown features.

Additional upgrades:

Electrification of the automatic lubrication system
Replacement of cooling units
Integration of an automatic extinguishing system
Full integration with the existing warehouse management system
Dual camera monitoring system for lifting operations

All cable routing, critical components, and safety features were updated to meet current industrial standards. Manual operation was also preserved as a backup feature.

Project Execution: Close Collaboration and Timely Delivery

The project was carried out in seamless collaboration with the customer. Bi-weekly site visits and meetings ensured that the work progressed as planned. Ultimately, the crane was handed over to production ahead of schedule.

Smooth commissioning process – Factory acceptance tests and on-site commissioning included:
Full I/O and inverter testing
Wireless radio control verification

Operator training and system handover – Detailed documentation all operational, maintenance and automation documentation — including commented logic code — was delivered as part of the package.

Ensuring Spare Part Availability

Due to lack of original spare parts, Satateräs designed and manufactured the required mechanical components in-house. Electrical components were sourced from trusted manufacturers. This ensured long-term crane reliability without dependence on obsolete parts.

Maintenance Agreement Option

In this case, the customer opted to maintain the crane in-house. However, Satateräs also offers a comprehensive maintenance contract that includes:

Predictive maintenance and statutory inspections
Fast delivery of critical spare parts
Remote monitoring and fault diagnostics
Camera integration and IBA analytics for proactive performance tracking

Results: A Future-Proof, High-Reliability Crane

The modernization project was a technical and scheduling success. The crane’s performance, precision, and reliability were significantly improved. Maintenance intervals were extended, and downtime risks were minimized.

With integrated remote monitoring, potential issues can now be identified before they affect production.

The success of this project laid the foundation for long-term lifecycle cooperation — ensuring efficient and secure steel coil handling for years to come.