IoT in Cranes: Smart Monitoring for Better Efficiency and Safety

Intelligent technology has become a cornerstone of China’s national strategy.

02:30 16 November 2024

Intelligent technology has become a cornerstone of China’s national strategy. The 20th National Congress emphasized advancing high-end, intelligent, and green development in manufacturing. We are in an era where technology progresses rapidly, and the transformative impact of intelligence on life and work may exceed expectations. In particular, the integration of smart and connected technology is reshaping heavy machinery, including cranes, bringing unprecedented improvements in productivity, safety, and operational efficiency.

Intelligentization and Connectivity in the Crane Industry

Compared to traditional structures and hydraulic technology, intelligent and connected technologies are evolving rapidly and diversely, sometimes in leaps. A crane's essential function is to lift and transfer heavy materials. By analyzing each operational phase in construction projects, smart technology seeks to enhance crane performance, efficiency, and safety, ultimately benefiting construction and operations teams.

To optimize operations, cranes, as tools, must maximize value for users and minimize maintenance and management costs. Thus, a shift is taking place: from merely managing equipment to managing a crane as a complete service that enhances user operations.

Internet of Things (IoT) in Crane Applications

IoT-powered remote crane monitoring solutions combine cloud-based data analysis, mobile apps, and hardware sensors. These solutions can be integrated into various cranes, including EOT cranes, gantry cranes, tower cranes, mobile cranes, and more.

The IoT provides essential functions such as predictive maintenance, safety alerts, operational efficiency tracking, and motion monitoring, all of which are critical to keeping heavy-duty cranes at peak performance. IoT-based remote crane monitoring ensures continuous tracking and analysis of operations, wear, fault detection, and alarms.

Advantages of IoT in Crane Operations

• Customization: Solutions can be tailored to specific crane models.

• Predictive Maintenance: Supports life-cycle management to enhance quality and reduce warranty costs.

• Real-Time Usage and Safety Data: Allows easy, remote assessment of crane condition and safety.

• Reduced Downtime: Optimized maintenance scheduling helps reduce unplanned downtime, enhancing productivity and equipment value.

• Retrofit Capabilities: IoT solutions can be added to existing cranes, improving proactive service support for aging machinery.

• Alerts on Key Parameters: Email alerts notify of critical data, such as SWP, duty cycles, vibration, overloads, and emergency stops.

Monitoring Parameters for Indoor and Outdoor Cranes

Indoor Cranes

1. Motor Voltage and Current: Tracks hoist, cross-travel, and long-travel motor health using AI-based algorithms for preventive maintenance.

1. Motor Temperature: Alerts users before overheating, avoiding costly motor damage.

1. Hoist Motor Vibration: Long-term monitoring to identify wear and tear over months or years.

1. Operation Usage: Tracks crane movements across lifting, cross, and long travel motions to measure efficiency.

1. Overload and Load Monitoring: Utilizes load sensors to monitor actual load, ensuring safe operations.

1. Brake Faults: Monitors brake gaps to minimize risks associated with brake failure.

1. SCADA, VFD, and PLC Monitoring: Interacts with automation systems for enhanced crane operation insights.

1. SWP Tracking: Uses advanced algorithms to estimate remaining lifecycle.

1. Rope Faults: Slack rope alerts prevent load drop risks.

Outdoor Cranes

1. GPS Tracking: Monitors location and movement of mobile cranes.

1. Speed Tracking: Alerts users of over-speed conditions.

1. Operational Data: Records runtime data for optimized maintenance.

1. Safe Load Indicators: Ensures cranes operate within safety limits.

1. Angle and Tilt Monitoring: Alerts when crane inclination exceeds safe parameters.

1. Vibration Monitoring: Tracks external vibrations for accident prevention.

IoT Impact on Crane Data Analytics and Alerts

IoT-enabled cloud data analysis offers two main functionalities:

1. Dashboard Reporting: Provides daily and weekly reports for management.

1. Alerts: Notifies users of critical changes or maintenance needs via email, SMS, or app.

AI-based algorithms establish baseline conditions for motors and brakes. Deviations from these baselines trigger alerts, allowing for timely preventive measures.

IoT Hardware and Cloud Integration

The IoT monitoring system includes edge sensors, wireless communication hardware, cloud applications, and smartphone apps. Sensors, placed strategically on various crane parts, collect and transmit data to a nearby device that sends it to a cloud server. Through a browser or mobile app, users can access and monitor crane status remotely, allowing continuous oversight and proactive maintenance.

The integration of IoT and intelligent technology in the crane industry is not only a step forward in operational efficiency but also a means to extend the life cycle of machinery and enhance safety, aligning with China’s strategy of fostering high-end, intelligent, and green manufacturing.