What Are The Overhead Crane Remote Control Systems?

By Author: Anand Enginnering
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What are the overhead crane remote control systems?
Crane wireless remote control is used for industrial purposes. The Overhead crane is also called a bridge crane. It is a machine that is used to lift and moves heavy equipment from one place to another place. In an overhead crane remote control hook and line mechanism are used. This mechanism runs along a horizontal beam.
Overhead cranes are used to transfer heavy equipment or materials over a long distance. Overhead crane remote covers a longer distance as compared to other cranes. The industries that usually use bridge cranes include the automobile industry, manufacturing, steel industry, warehousing industry, and construction industry. Applications typically include loading or unloading ships, transporting heavy materials on construction sites, and transporting components along assembly lines. Depending on the site, application, and travel distance, single beam, double beam, JIB or other types of overhead cranes can be used.

Safety requirements for overhead crane wireless remote control:
Three important crane remote control design considerations ...
... that have remained unchanged for centuries are: the crane must be able to lift heavy objects, the crane must not tilt when lifting loads and crane components, and the crane must not be damaged during operation. Another important consideration, especially during crane operation, is that no one should be injured.
OSHA records indicate that more than half of crane accidents are the direct result of inadvertent electrical contact. The metal part of the crane rubs against the power source, causing the crane to get an electric shock, causing physical injury to the operator, and injury to the personnel within the current range. Of the recorded deaths, most were crane operators. Further investigation revealed that inadequate safety planning, insufficient preventive safety measures, and insufficient operator training caused these accidents. Material overload is the second leading cause of bridge crane accidents. According to OSHA, 80% of crane accidents are directly caused by overload, which can cause irreparable damage to the crane and injury to the operator and other personnel on-site.
According to statistics, one overload accident occurs every 10,000 hours of work. Machine failure, skidding, and two locks are other causes of crane accidents. In 2012 alone, about 20 people died directly due to accidental falls of material. Most tow truck accidents occur due to negligence and lack of early warning; these two factors are easily remedied.

How Often Do Accidents Happen?
Crane accidents are not unique to modern cranes. For example, in 2006, there were 72 crane-related fatal injuries. Between 2003 and 2005, there were an average of 78 accidents each year. This includes fatalities directly attributable to overhead crane control operations, as well as secondary fatalities. Most of these accidents are related to mobile cranes, railway cranes, and bridge cranes. The above-mentioned deaths included workers, electricians, welders, cutters therefore, ground crews and operators were also affected. Industry-related statistics show that the death toll in the manufacturing industry far exceeds the death toll in the mining industry. Texas has the largest number of accidents, followed by Florida, California, and Louisiana.

The cause of the crane accident:
Usually, the hook and rope system of the crane is installed on the beam. The girders of the overhead crane remote run-on parallel rails. Mobile cranes are installed on trucks or tracks, while EOT cranes are stationary. Ground personnel guides the crane operator during operation. In any crane operating process, there are three major risk areas: accidental contact of metal parts with the power supply, accidental falling of materials, and overloading. The failure or malfunction of one or more components can also cause an accident. Other areas of risk include errors in judgment on the part of the operator or poor communication between the operator and ground personnel. OSHA (Occupational Safety and Health Administration) has identified the proximate causes of the following crane accidents –

• Overhead crane
• Gantry crane
• Monorail crane
• Cantilever crane
• Workstation crane

Although these are the proximate causes of accidents. These accidents can occur due to any or all of the following situations:

1. Crane is unstable
2. Load is unstable
3. Defective component
4. Near power source
5. Ground personnel near crane operating area
6. Space of communication between ground crew and crane control operator
7. Training space
8. Maintenance gap

All of this boils down to inadequate control of the conditions or environment surrounding crane operations, especially crane maintenance and crane components, the proximity of metal components to a power source, lack of replacement of component faulty or rapidly failing components, and ground personnel Lack of communication of generators between operators. Additionally, if ground crews stand too close to the crane, they will also be at risk, as shown in the statistics below. Close supervision of the crane and its operation can help reduce or even completely reduce the risk of accidents.

Guidelines for preventing crane accidents:

OSHA inspects a large number of overhead crane accidents and determines the precautions that must be taken.

1. Before each operation, a qualified inspector inspects the machine to check for mechanical failures
2. Routine comprehensive inspections in advance
3. Identify any faulty wiring, damaged components, or worn ropes or spools.
4. Repair by qualified and trained personnel.
5. By trained personnel who understand the rigging and load balance points.
6. Check the load as much as possible
7. Avoid working under a suspended load
8. Regularly check the load capacity and safety margin of the equipment
9. Use the equipment to mark the hazardous area when the capacity is slightly lower than (recommended radius is 90 feet) and do not work in this within the area.
10. Develop pre-work plans to determine hazards, sequence of events, and hazardous areas
11. Determine pinch points
12. Determine and follow removal procedures

In India, the Bureau of Standards of India (BIS) Act (1986) has issued a legal document detailing the standards for the manufacture, assembly, operation, and maintenance of cranes and crane components.
For more details about crane control equipment contact Anand Systems Engineering Pvt. Ltd.