- Apr 22, 2025
- Case Studies
Mexico BZ Floor‑Mounted Jib Crane With Vacuum Cups
Explore our detailed case study on the Mexico BZ Floor-Mounted Jib Crane equipped with vacuum cups. Discover its innovative design, efficiency, and impact on operational productivity.
Industry Profile And Customer Background
The customer is a sheet‑metal fabrication plant supplying automotive and construction components. Their workshop performs cutting, bending, and welding of metal plates up to 4mm thick. Before this project, handling large panels required manual effort and forklifts, causing workflow interruptions and ergonomic risks for operators.
Customer Needs And Operational Challenges
Safety And Ergonomic Requirements
Operators reported frequent back strains and musculoskeletal discomfort from lifting and positioning 1.5m × 3m steel sheets. Overexertion and bodily reaction accounted for 329150 lost‑workday cases in material‑moving occupations during 2021–22, half leading to one or more days away from work.
High‑Volume Sheet Metal Handling
The plant processes up to 200panels per week. Each panel weighs 80–120kg. Manual handling or forklift repositioning took 3–4minutes per panel, limiting throughput and creating a production bottleneck.
Space Constraints And Installation Requirements
The workshop has narrow aisles and a low ceiling (4m). The new lifting solution needed a compact footprint, minimal structural modifications, and unobstructed coverage of a 6m × 6m work zone.
Criteria For Selecting A Floor‑Mounted Jib Crane
Load Capacity And M4 Working Class
The required lifting capacity was 2tons to handle multiple panels simultaneously. The crane's working class is M4, suitable for regular workshop use with an expected 125000 cycles per year according to ISO4301‑1 classification :contentReference[oaicite:1]{index=1}.
Lifting And Slewing Speeds
The customer specified a lifting speed of 8m/min to align with production cycle timing and an operating (slewing) speed of 20m/min for quick repositioning of loads across the work cell.
Vacuum Cup System Specifications
The integrated vacuum‑cup attachment needed:
- A suction pump producing ≥550mbar differential pressure to grip smooth metal surfaces reliably.
- Multiple suction pads arranged to support 2tons with 2×SWL proof‑test safety factor.
- A vacuum reservoir capacity to hold loads for at least 5minutes during pump failure.
Product Overview And Technical Features
Structural Design And Installation
This BZ floor‑mounted jib crane features a 180° slewing radius on a 300mm diameter column. The 6m jib arm provides coverage of the target area without additional runway beams. Foundation requirements were limited to a single 1m ×1m concrete plinth, reducing installation time to one day.
Vacuum Cup Integration
A detachable vacuum lifter attaches to the crane hook. The system uses four 300mm diameter suction pads, each rated for 500kg at minimum vacuum. An electric vacuum pump maintains 600mbar differential, with an emergency reservoir and indicator alarm to signal if vacuum falls below 80% of setpoint.
Control And Safety Features
The crane is operated via a pendant control with switch. An overload protection limiter prevents lifting beyond 2tons. The vacuum system includes an audible and visual alarm for vacuum loss. The slewing brake engages automatically at end stops, and bumpers protect the column base.
Implementation Process And Performance Testing
Installation And Commissioning
In the pre-communication process, our technical team communicated with the customer about the floor strength to ensure smooth subsequent installation of the crane. The crane was anchored on the existing slab with chemical anchors. Electrical connections for the hoist motor and vacuum pump were completed in one day, followed by load testing and operator training.
Task Simulations And Load Testing
We conducted proof load tests at 2×SWL (4tons) for static proof per EN13155 guidelines. Vacuum lifter tests included dynamic proof at 2×SWL and drop tests to simulate sudden vacuum loss. Cycle simulations moved 120kg panels through typical pick‑up, slewing, and placement motions at full speed.
Impact And Results
Customers said that originally they need manual and forklift coordination to work to line, with the new crane, the original need for more people to cooperate with the work can be completed by only one person, greatly reducing the handling time of the plate. It is said that before the customer needs to move an average of 3 minutes per plate, now it only takes more than a minute. Their operator reported that the jib crane was easy to operate and that his spinal fatigue had improved considerably since using the new equipment.
Conclusion
This case study demonstrates how the Mexico BZ floor‑mounted jib crane with vacuum cups addressed the needs of a sheet‑metal fabrication plant. By meeting rigorous safety and performance requirements—ISO class M4, 2ton capacity, 8m/min lifting speed, and 20m/min slewing speed—the solution improved throughput, eliminated manual handling injuries, and reduced maintenance costs. If youa are looking for a reliable lifting solution for hamdling smooth‑surface loads, you can consider this configuration. For more information, visit our floor-mounted jib crane.
