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

Tower Crane Safety Solution

Tower cranes are now common sites at all major construction sites. These cranes are reaching higher heights and each site often has multiple cranes operating together. As the load-carrying capacities of these cranes are increasing, the crane operation is also getting more complex. Apart from the lifted load and radius, the operator has to know the wind speed and hook height also to carry out the crane operations safely. 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 is because we add value to their business.

Klug Avalon specifically designed a system for Tower cranes. The system using various sensors measures the lifted load, Trolley position (radius), Wind-Speed, Slew Angle and Hook Height and calculates the safe lifting capacity of the crane. The system displays these parameters on its HMI and also annunciates the crane operator by audible and visual alarm. A set of Potential-free relays connected to the crane electrical stops the crane from moving towards a dangerous condition.

Specifications- Tower Crane Solution

Load measurement using three methods to suits crane model and customer’s requirement:
1. Load Pin mounted on one of the pulleys in hoist line, it measures the force exerted by the hoist line on the pulley. Using calibration, the force on Pulley is used to calculate the value of the lifted load. No welding on the crane is required.
2. Three Pulley dynamometer mounted in the hoist wire rope. Measures the force in the wire rope by deflecting the wire rope using three pulleys. This method is only used when data of the load Pin is unavailable or lead time for delivery is not available.
3. Load Plate mounted at the end of the hoist wire rope in line with wedge socket arrangement. No welding on the boom.

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

Four Relay Output is available to integrate with the crane electrical system 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.

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

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

AC Power Supply (AC to DC converter) unit to interface with the crane electrical. The system works from 90VAC to 260VAC. An optional transformer is provided in the input Ac power line to protect the system from surge voltage; usually found if the supply is from a generator.

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 cutoff device to stop further movement of the crane in a dangerous conditions.

Protection crane operations during high wind speed:

High wind exerts pressure on the crane structure and also oscillates the load, making the crane operations unsafe. Wind speed measurement is mandatory for such high height operations. The system displays the wind speed on the display unit and annunciates the crane operator, by visual and audible alarm, alerting him to stop or carefully operate the crane.

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 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.

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.

Protection against the hoisting Hook colliding with any structure:

The system displays the hook height of the hook to the crane operator. With this he can then carefully operate the crane, avoiding any accident.

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.

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.

Training Schedule at Klug Avalon

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On Demand Training Videos from Klug Avalon

On Demand Training Video

Solution Information Video

Tower Crane Solution

Let’s Create a Safe
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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