Lattice Boom/ Crawler Crane Safety Solution
Lattice boom cranes are getting longer, reaching big heights and able to pick very heavy loads. The crane operations have become more complex and the lifting capacity is not merely depending on crane lifting radius but also on other parameters viz. Wind speed, different crane configurations such as – ringer or sky horse or tower configuration. Lifting heavy loads on the operator’s judgment alone may lead to an accident. A smart comprehensive safety solution is a must for these cranes.
Klug avalon has a deep knowledge and experience in offering solutions to its customers. We have a team of field experts who constantly keep innovating to make crane operations safer and productive. One of the major reasons all major OEMs prefer working with us because we add value to their business.
Klug Avalon specifically designed a system for lattice boom cranes. The system measures the lifted load and compares it with the working capacity of the crane. The working capacity is calculated on various parameters viz. Crane boom length, boom angle, radius, wind speed, counterweight and other. The system displays these parameters on its HMI and also annunciates the crane operator by audible and visual alarm.
Specifications- Lattice Boom/ Crawler Crane Solution
Load measurement using three methods to suits crane model and customer’s requirement:
1.Load Plate, mounted at the end of the hoist wire rope in line with wedge socket arrangement. No welding on the boom. Also no deadweights required for load calibration. The load plates are pre-calibrated.
2.Three/Five Pulley dynamometer mounted in the hoist wire rope. Measures the force in the wire rope by deflecting the wire rope using three/five pulleys.
3.Load Plate, mounted at the end of the luffing wire rope in line with wedge socket arrangement. No welding on the boom. This method measures the luff force and using algorithm calculates lifted load.
Sunlight readable backlit LCD Display, UV stabilized with antiglare coating
Clear & easy to understand Audio & Visual Annunciation for exceptional conditions
Simple, easy to do wiring using waterproof connectors
Output available to drive a hydraulic dump valve for implementing motion cut-off function, protecting the crane from an accident.
Robust built, sealed components designed to operate in rough & rugged conditions. Water ingress protection on all outdoor components.
Simple, easy to do wiring using waterproof connectors
Operates on 10V to 30V battery supply
Easy to use, operator-friendly & trouble-free operation.
Serial port output to integrate telematics device to transmit lift data to the cloud.
Protection against overloading:
Overloading causes structural failure, breaking of wire rope leading to an accident. The KOPS prevents this by monitoring the load lifted by all the hooks and displays it on the display unit. On overload, the systems provide an audible and visual alarm to alert the operator and further activate the cut-off device to stop further movement of the crane in dangerous conditions.
Protection against over hoisting of hook:
For long boom cranes and lifting at full boom length, the crane operator is not able to clearly see the hook block. If the head pulley block collides with the hook block, it may cause wire rope breakage leads to an accident. The KOPS system uses an A2B switch with a deadweight suspended to it, to monitor over-hoisting avoiding an accident.
Protection against load lifting when the boom angle is in No Lift Zone (NLZ):
The load chart provided by the crane manufacture mentions the working boom angle for lifting the load. For lower boom angles the load chart specifies no lifting of any load to avoid toppling of the crane. The KOPS monitors the boom angle and annunciates the operator with distinct audile and visual alarm preventing an accident.
This function of KOPS, when configured by the supervisor; will ensure that the crane will not operate, if the safety system is bypassed or not functional. This ensures full safety at the site.
Voice alert the surrounding, using high pitch Hooter and Visual alert using a Tower Lamp:
As per the international safety standard, the crane surrounding needs to be annunciated, when the crane is in unsafe condition. This is for alerting personnel working close to the crane so as they could move away from the vicinity of the crane.
User settable set-points:
The KOPS system has five programmable set points. Based upon the %SWL the KOPS activates various alarms, both visual & audible. These setpoints can be settable by the user (thru password-protected supervisor settings) depending on the site requirements. E.g. Sites where safety is much needed like a petrochemical plant/ nuclear plan the setpoints %value can be reduced to make crane operation safer.
Safe and selective bypass:
By adding a cut-off function to the standard system, KOPS will auto bypass only the unsafe motion of the crane instead of completely freezing all motions. The operator can operate only those motions which will bring the crane to a safe condition. Thus ensuring complete safety.
Auto Hook Selection:
For cranes with Main and whip (aux) hook, the system automatically switches to the hook to monitor. If the operator lifts any heavy load on the Aux hook (wrongly selecting the Main hook), it may lead to an accident. The system is smart to select the right hook thus avoiding an accident.
Ensuring crane operator does not continue operating the crane when its overload:
The KOPS on overload condition activates a motion cut-off dump valve to stop the crane from further moving in a dangerous condition. The dump valve is connected in the crane hydraulic line. When activated the hydraulic oil is sent to the tank stopping the crane operation. The crane operator then needs to press the BYPASS key; responsibly; to bring the crane to safe condition by taking corrective action.
Ensuring the Bypass function is not misused by the crane operator:
When in an overload condition, if the operator misuses the BYPASS key to operate the crane (instead of taking corrective action to bring the crane to safe condition), then a BYPASS inhibit function proves very helpful. The KOPS has a fifth set-point, wherein if the %SWL crosses the set-point 5 it will freeze all crane functions, and even pressing the BYPASS key won’t help. The operator then needs to contact the crane supervisor for help. The crane supervisor using his password can ask him to get the crane in a safe condition. This facility proves very useful in avoiding an accident.
We keep on adding many more safety features to our system periodically. For more information please contact our sales team.
Solutions – Casestudy
SLI System for Crawler Crane
Other Crane Safety Solutions
Lorry Loader Crane
Pick and Carry Crane
View All Solutions
Comprehensive Operator’s Training – where operators can practice with the equipment they will use each day. Worldwide we provide on site and in house training facilities, educating them about the safety of the cranes.
Check Schedule at Training Center
Schedule On-Site Training Session
On Demand Training Video
Solution Information Video
Lattice Boom / Crawler Crane Solution
Let’s Create a Safe
What is an SLI system?
Safe load indicator is a safety control unit mounted in the crane’s cabin to alert the operator if the lift is exceeding the safe operating range of the machinery
Is it necessary to install SLI system in our crane?
Yes, it’s necessary and important to avoid any future accidents while working with materials without knowing the actual load and rated crane capacity.
What if we have old crane dose your SLI system support our crane operation?
Yes off course, as per your crane capacity chart we will make a custom SLI system that matches your crane and its operation
We have pre-installed SLI system, still its need to update?
Yes, sometimes pre fitted safety system are inadequate to protect hence we recommend to talk our Crane safety system officer and know the best suited solution for your crane.
What is an anti-two block switch?
Over-hoist switch measures the distance between the lifting hook block & the head of the boom crane, which avoids the collision between them and alerts the operator by sending signals via the SLI.