en.Wedoany.com Reported - Germany – Dresden Krane + Industrie Service (DKS) has modernized the master-slave tandem crane system at the DB Bahnbau Group's Dresden bridge workshop using lifting components from STAHL CraneSystems, enhancing heavy assembly operations under continuous operation.
The DB Bahnbau Group's Dresden bridge workshop is responsible for the repair and construction of critical railway bridges. Its 100 employees manage complex infrastructure projects, including the historic restoration of the protected Chemnitz Viaduct. Due to prolonged high-load usage in the main welding workshop, equipment showed signs of wear and reduced availability. To eliminate operational safety risks, DKS was commissioned to perform a comprehensive overhaul of the system.
The retrofit project began in November 2024, with dismantling and installation carried out in August 2025. The entire modernization was integrated into ongoing production operations, and commissioning was completed in October 2025.
The upgraded system comprises two double-rail trolleys, each equipped with an ASF7063 main wire rope hoist capable of lifting 35 tons. The main hoist's lifting speed is adjustable, ranging from 0.08 m/min to 4.20 m/min. The system also features an SHF4012 auxiliary hoist, handling 5-ton loads at a speed of 8 m/min. Control technology includes an SMC22 multi-controller, a central programmable logic controller (PLC), and an HBC master-slave radio system.
The new master-slave tandem crane system operates within a span of 22 meters and a lifting height of 10 meters. To ensure stable data transmission and power supply while avoiding the risk of wear on sliding contacts, the hoists use drag chains with protected Profinet and Profisafe cables. The system features distance-controlled tandem operation and electronic load summation. An integrated PLC continuously monitors operating conditions; for example, when the cranes operate within a trolley travel range of 4 meters, the total combined load is electronically limited to 30 tons. When supporting full load capacity, the control system ensures the cranes maintain a minimum distance of 11 meters. The safety system complies with performance level d (PL d), category 2, and performs a safe shutdown in the event of overload.
The new system optimizes modular construction and assembly processes across four dedicated work zones in the workshop. Zone 1 handles initial fabrication such as cutting, drilling, and milling. Zone 2 uses two master-slave tandem cranes to assemble steel components and heavy T-beams, controlled by operators via HBC-radiomatic 'technos' radio control transmitters. Zone 3 performs shot blasting and anti-corrosion coating on welded structures. Zone 4 pairs completed bridge segments with storage components, preparing them for transport to construction sites.
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