US-based AFE Crane has modernised the control system of a 5t Robbins & Myers overhead bridge crane, originally installed in the 1950s, at a manufacturing facility in Cedar Falls, Iowa, rather than undertaking a full replacement.
The project focused on improving operator control and minimising production downtime, while taking into account budget limitations.
The crane remains a critical component in one of the plant’s key production areas.
AFE Crane was tasked with developing a solution to provide smoother, more precise movement than the older equipment could offer.
Rather than replacing the entire crane, the manufacturer opted for a modernisation strategy concentrating on its operational controls.
The modernisation package developed by AFE Crane introduced variable frequency drive (VFD) control to the hoist, trolley, and bridge motions.
The system used Magnetek G+ Mini VFDs, which enables programmable acceleration and deceleration for smoother load handling and improved positioning.
Additionally, a Magnetek Flex-6EX2 radio control system was added, allowing operators greater mobility while using the crane.
To address the risk of production interruptions, especially as the crane is central to manufacturing operations, AFE Crane incorporated a quick-connect backup pendant.
This device provides an alternate method for operating the crane in the event that the radio control becomes unavailable, reducing the likelihood of extended downtime.
Execution of the project involved initial field measurements and a review of the crane’s existing electrical setup before integrating the new control technology.
Installation was scheduled to take place during off-shift hours to minimise disruption to ongoing production.
AFE Crane completed the upgrades by supplying and installing the new controls for the bridge, trolley, and hoist, integrating them with the decades-old crane.
This approach allowed the manufacturer to continue using existing equipment while meeting updated operational needs and working within the required budget.
AFE Crane, established in 1983, supplies overhead bridge cranes, monorails, and hoisting equipment throughout Iowa and the Midwest.
The company, part of LAFORGE, provides both standard and customised overhead material handling systems, as well as below-the-hook lifting devices designed for specific applications.
In July 2025, AFE Crane installed a freestanding top-running single girder bridge crane in a new metrology laboratory at an existing facility in Des Moines, Iowa.
