metalworkingmag.com
06
'26
Written on Modified on
Automated Hydraulic Rotation Systems Optimize Heavy Steel Fabrication
To safely rotate asymmetrical flame-cut steel parts during tower crane production, Liebherr has deployed a specialized hydraulic material handling system developed by Teqram.
teqram.com
The EasyFlipper can be operated simply and safely from a distance at the press of a button.
Liebherr-Werk Biberach GmbH has partnered with Teqram to integrate hydraulic rotation equipment that automates the handling of heavy oxy-fuel-cut steel components. By deploying this specialized material handling infrastructure, the manufacturer mitigates workplace hazards and accelerates workflow within the heavy crane production and steel fabrication sectors.
Industrial Context and Operational Challenges
At its facility in Biberach, Germany, Liebherr develops and manufactures tower cranes and mobile construction cranes. The production process requires the manipulation of massive steel components, many of which are fabricated from heavy flame-cut parts. These oxy-fuel-cut components present distinct material handling challenges due to their extreme weight, complex geometries, and asymmetrical centers of gravity.
During subsequent manufacturing stages, these parts must be turned multiple times. Traditionally, operators utilized standard factory cranes and lifting equipment to rotate the steel components. Because the balance points of the asymmetrical parts shift constantly during rotation, the manual rigging and lifting procedures were time-consuming, highly dependent on operator experience, and introduced significant workplace safety risks.
Goals for Process Improvement
To address these workflow bottlenecks, Liebherr sought to upgrade its industrial automation capabilities. The primary objectives for the facility were to improve workplace ergonomics by eliminating physically demanding manual handling methods and to enhance operational safety. Additionally, the engineering team aimed to reduce the time spent securing and positioning heavy parts to increase overall manufacturing productivity.
The hydraulic EasyFlipper turns components weighing up to 5,000 kg within one minute.
Technical Solution Selected
To achieve these operational goals, Liebherr selected the hydraulic EasyFlipper system developed by Teqram. Rather than relying on overhead single-point crane lifting, the EasyFlipper utilizes a controlled, dual-table mechanical design to securely clamp and rotate heavy workpieces.
Liebherr opted for the high-capacity hydraulic variant of the system, which is engineered to handle and turn steel components weighing up to 5,000 kilograms. The facility selected this specific solution because it replaces variable manual rigging with a standardized, repeatable mechanical process, safely accommodating the unpredictable center of gravity inherent to irregular flame-cut parts.
Deployment Results and Process Optimization
Following the integration of the hydraulic system at the Biberach plant, operators now position the heavy workpieces directly onto the machine's tables for automated rotation. By eliminating complex lifting and securing procedures, the facility has significantly reduced the risk of hazardous load-shifting situations. The process is now standardized and no longer relies heavily on individual handling techniques.
The deployment has objectively improved process efficiency. Workers no longer expend time adjusting rigging for asymmetrical parts, ensuring a smoother flow through the production line. This incremental time savings per component yields a measurable increase in total line output. Furthermore, the system successfully addresses the facility's ergonomic goals by removing the need for manual component manipulation.
Robert Piesche, Manufacturing Technology Engineer at Liebherr-Werk Biberach GmbH, outlined the impact of the deployment: "Automation relieves our employees of a monotonous and physically demanding task. It has also enabled us to significantly improve workplace safety."
Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.
www.teqram.com
Liebherr-Werk Biberach GmbH has partnered with Teqram to integrate hydraulic rotation equipment that automates the handling of heavy oxy-fuel-cut steel components. By deploying this specialized material handling infrastructure, the manufacturer mitigates workplace hazards and accelerates workflow within the heavy crane production and steel fabrication sectors.
Industrial Context and Operational Challenges
At its facility in Biberach, Germany, Liebherr develops and manufactures tower cranes and mobile construction cranes. The production process requires the manipulation of massive steel components, many of which are fabricated from heavy flame-cut parts. These oxy-fuel-cut components present distinct material handling challenges due to their extreme weight, complex geometries, and asymmetrical centers of gravity.
During subsequent manufacturing stages, these parts must be turned multiple times. Traditionally, operators utilized standard factory cranes and lifting equipment to rotate the steel components. Because the balance points of the asymmetrical parts shift constantly during rotation, the manual rigging and lifting procedures were time-consuming, highly dependent on operator experience, and introduced significant workplace safety risks.
Goals for Process Improvement
To address these workflow bottlenecks, Liebherr sought to upgrade its industrial automation capabilities. The primary objectives for the facility were to improve workplace ergonomics by eliminating physically demanding manual handling methods and to enhance operational safety. Additionally, the engineering team aimed to reduce the time spent securing and positioning heavy parts to increase overall manufacturing productivity.
The hydraulic EasyFlipper turns components weighing up to 5,000 kg within one minute.
Technical Solution Selected
To achieve these operational goals, Liebherr selected the hydraulic EasyFlipper system developed by Teqram. Rather than relying on overhead single-point crane lifting, the EasyFlipper utilizes a controlled, dual-table mechanical design to securely clamp and rotate heavy workpieces.
Liebherr opted for the high-capacity hydraulic variant of the system, which is engineered to handle and turn steel components weighing up to 5,000 kilograms. The facility selected this specific solution because it replaces variable manual rigging with a standardized, repeatable mechanical process, safely accommodating the unpredictable center of gravity inherent to irregular flame-cut parts.
Deployment Results and Process Optimization
Following the integration of the hydraulic system at the Biberach plant, operators now position the heavy workpieces directly onto the machine's tables for automated rotation. By eliminating complex lifting and securing procedures, the facility has significantly reduced the risk of hazardous load-shifting situations. The process is now standardized and no longer relies heavily on individual handling techniques.
The deployment has objectively improved process efficiency. Workers no longer expend time adjusting rigging for asymmetrical parts, ensuring a smoother flow through the production line. This incremental time savings per component yields a measurable increase in total line output. Furthermore, the system successfully addresses the facility's ergonomic goals by removing the need for manual component manipulation.
Robert Piesche, Manufacturing Technology Engineer at Liebherr-Werk Biberach GmbH, outlined the impact of the deployment: "Automation relieves our employees of a monotonous and physically demanding task. It has also enabled us to significantly improve workplace safety."
Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.
www.teqram.com
