Crane canbus Safety System enabled-Klug Avalon

CanBus System

wireless crane controller-Crane System -Klug Avalon

Wireless System

Crane Safety analog System enabled-Klug Avalon

Analog System

Telescopic Crane Safety Solution

Telescopic boom cranes are getting longer, reaching big heights, and able to pick very heavy loads. The crane operation has become more complex and the lifting capacity is not merely depending on crane lifting radius but also on other parameters viz. wind speed, outriggers position, slew angle, and many more. 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 telescopic 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, outrigger position, slew angle, counterweight and other. The system displays these parameters on its HMI and also annunciates the crane operator by audible and visual alarm.

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Specifications- Telescopic Crane Solution

Load measurement using two methods to suits crane model and customer’s requirement:

Pressure Sensor, measuring luff pressure in the lift cylinder. The lifted load is calculated based on the pressure output. No welding on the boom.

Dynamometer mounted in the hoist wire rope. Measures the force in the wire rope by deflecting the wire rope..

Sunlight readable backlit LCD Display, UV stabilized with antiglare coating

Clear & easy to understand Audio & Visual Annunciation for exceptional conditions

Robust-built, sealed components designed to operate in rough & rugged conditions. Water ingress protection on all outdoor components.

Easy to use, operator-friendly & trouble-free operation.

Operates on 10V to 30V battery supply

Simple, easy to do wiring using waterproof connectors

Serial port output to integrate telematics device to transmit lift data to the cloud.

Output available to drive a hydraulic dump valve for implementing motion cut-off function, protecting the crane from an accident.

Protection against overloading:

Overloading causes structural failure, breaking of wire rope may lead 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 activates the cut-off device to stop further movement of the crane in dangerous conditions.

Protection against toppling:

Telescopic cranes have different duty cycles for lifting from the front- back- side of the crane. Using a slew sensor the KOPS will automatically select the correct load chart and monitor the lifted load accordingly, avoiding stability loss leading to an accident.

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 leading to an accident. The KOPS system uses an A2B switch with a dead weight 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.

Fail Safe:

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 an 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 cutoff 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.

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 an unsafe condition. This is for alerting personnel working close to the crane so as they could move away from the vicinity of the crane.

We keep on adding many more safety features to our system periodically. For more information please contact our sales team.

Coming Soon….

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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.

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Telescopic Crane Solution

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On-Site Environment

No matter you are a Crane Owner. A Crane Service Provider, or an Orignal Equipment Manufacturer(OEM), we have a solution for you all.


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.

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