Overhead cranes have been an integral part of material handling operations for decades, playing a vital role in various industries. These towering machines, including gantry cranes, have often been seen working the same way for years, with minimal changes to their original design and function. However, as technology continues to evolve, so does the crane industry. Today, we are witnessing significant advancements in crane technology, particularly in the integration of automation and smart features.
For many businesses, especially those operating older cranes, the traditional methods of operation remain unchanged. Yet, in other sectors, companies are increasingly recognising the benefits of upgrading their overhead cranes and gantry structures with new technology. These upgrades often include the installation of variable frequency drives and a suite of automated features designed to enhance operational efficiency, improve safety, and reduce the risk of downtime.
Key Features of Modern Overhead Cranes
Modern overhead crane technology is now equipped with a range of engineered features that have revolutionised the way these machines operate. These features are not only designed to make operations smoother but also to ensure the safety of the workplace. Some of the most notable advancements include:
- Falling Load Detection: This feature detects unexpected load dropping by monitoring the difference between the commanded direction and the actual motor rotation direction. It acts as an early warning system, preventing potential accidents and ensuring the safety of both the load and the workers.
- Anti-Sway Control: As crane speeds change during load handling, the load can sway, posing a risk to both the material and the surrounding area. Anti-sway control stabilises loads, reducing takt time (the cycle time per unit) and ensuring smooth and safe operation.
- Load Dependent Speed Control: The speed of the overhead crane automatically adjusts based on the load mass. For instance, with lighter loads, the crane will operate at a higher speed, increasing efficiency without compromising safety.
- Start/Stop Control: This feature ensures smooth acceleration and deceleration by automatically controlling torque. As a result, material tension remains consistent, reducing the risk of damage to the load.
- Brake Sequencing System: By shortening the time from startup to brake opening, this system improves response at low speeds and reduces wear on the brake lining, extending the lifespan of the brakes.
- Overload Detection: When the load exceeds the crane’s capacity, the system halts operation and alerts the operator, preventing potential damage to the overhead crane and the load, as well as avoiding accidents.
The Role of Automation in the Crane Industry
While these features have significantly improved overhead crane operations, the integration of automation into overhead crane technology is shaping the future of the industry. Businesses are increasingly looking to minimise downtime, and automated systems are becoming critical in achieving this goal. By connecting overhead cranes to back-office systems, companies can monitor component wear and perform predictive maintenance, thus avoiding unexpected breakdowns.
Automated systems provide real-time alerts about the condition of critical components, such as hoists, brakes, and structures. For instance, as components begin to wear, the system can notify operators of potential issues before they become major problems. This proactive approach not only helps in maintaining smooth operations but also enhances workplace safety by preventing accidents before they occur.
Moreover, these systems offer valuable insights into the remaining design working period (DWP) and the service life of selected components. They provide detailed asset usage and operating information, which is crucial for assessing the condition and safety of the overhead crane. Automated notifications, delivered through text or email, alert operators to critical events such as brake service life, hoist overloads, emergency stops, and over-temperature occurrences, enabling prompt and informed decision-making.
As the crane industry continues to evolve, the adoption of advanced technology and automation is becoming increasingly important. These innovations not only improve operational efficiency but also play a crucial role in maintaining safety and minimising downtime. For businesses looking to stay competitive in the market, investing in modern overhead crane technology is no longer a luxury but a necessity.
For more information on how Lifting Systems can help your business upgrade to the latest in overhead crane technology, please contact us at sales@lifting-systems.co.uk.
