For those customers who simply cannot wait for a service technician to come troubleshoot a crane fault, much less send the crane to a service centre, crane manufacturers and third parties have developed remote diagnosis systems that link the crane to service personnel who are not physically present.
Since 1999, Liebherr Ehingen has offered a remote diagnosis service for its all-terrain cranes. If the user’s service tech cannot solve a problem, service representatives at the Ehingen factory, or in Liebherr’s national offices in the main European markets, can access the crane computer themselves. They can interrogate the crane’s computer, check inputs and outputs, currents and sensors, and even operate the crane remotely.
At the least, the technology can help service engineers feel confident to skip the call-out visit. “In many cases, the service engineer need not travel, because he can tell the crane operator to do this or that to solve the problem. In other cases, he knows he will have to change a part, and he can go to the crane and have the correct spare with him,” he says.
The remote diagnosis system consists of an optional cellular network modem module that connects to the Liebherr LICCON crane computer. Some training is required to set up and operate a connection with the Ehingen service department, although the firm says it is simple. Users pay for the telephone calls, but not for the technician’s time, a spokesman says.
Liebherr Biberach, its German tower crane factory, offers a similar service for its products. In addition to being able to view faults, the teleservice system makes contact with the crane’s data logger and data analysis system, so that engineers can understand exactly how the crane is being used, and what aspect of its use might have contributed to the fault.
German tower crane manufacturer Wolffkran launched a teleservice function on its towers in 2006 that allows its service engineers to view ‘all relevant crane data’ on a computer screen, the company says, enabling fault diagnosis from afar.
A further sign of the rising importance of remote diagnostics functions in the industry comes from product launches from third-party electronics manufacturers. Definitely not do-it-yourself solutions, these products need to be wired into cranes in the factory. Still, their very existence suggests that manufacturers have been asking for them.
Australian control systems manufacturer Robway has launched E-Log, a standalone remote control device and data logger. The machine records crane lifts and configurations through eight digital inputs and two analogue inputs, and keeps an eye on the crane’s location with on-board GPS location tracking. The device can also access and control the crane remotely through an internal modem. It can send text messages with fault codes in case of a fault, and can also start up and shut down a crane remotely upon receipt of a text message.
German crane electronics firm PAT is also standardising a remote diagnostics option in its forthcoming refresh of its iFlex computer platform, due out early next year. Previously, PAT would source components on a case-by-case basis for customers requiring the ability for remote access.
Product manager Gregor Leuschen says that PAT is looking at cellular network and VPN technology (secure access to a private network via the internet), although the specification is not yet finished. It will standardise the components used in the option. “At Bauma we presented ourselves as a system integrator, and this is a step more into the system world,” Leuschen says. “We have a piece of hardware, and LMI and control tasks are just different tasks in the hardware. Remote functionality has to be considered as one part of the system.”
“Steve Filipov, president, Terex Cranes” |
My opinion is that diagnostics works in developed countries. The question is how to offer it into the machines so that it doesn’t deteriorate other markets that don’t want it or don’t need it |
This month Danish loader crane manufacturer HMF is refreshing its crane computer for loader cranes above 4tm. The new version includes support for remote access. The remote control on the RCL 5300 shows faults with a three-digit display. A separate hand terminal, called a controller gateway, connects to the crane by a wire. It can be connected to a laptop computer for set-up and diagnostics.
If the laptop has a Wi-Fi wireless internet card installed, and is in range, then the HMF service department can control the crane control panels as if they were physically present, examining data logs, error readouts, and installing software upgrades.
“We want our cranes to run 24 hours a day, and we want our customers to have confidence in our electronics,” says René Dahlkilde, HMF product manager. “If there are doubts, we want to show that we have efficient back-up. We do a lot more from home, although of course we are still travelling if it is bad. Before we had to go to Holland, France, Germany. Remote diagnosis allows the possibility of fast and competent help at once.”
The service would make a technician’s life easier if he or she has to travel to the crane, says Alan Johnson, managing director of UK loader crane maintenance company SJB Crane. Forewarned is forearmed—with the right tools, documentation and parts, they can fix a greater proportion of breakdowns the first time. “The opportunities for first-time fix would be greatly enhanced,” he says. “Apart from anything else, it would eliminate a lack of clarity in communication following a breakdown. The amount of duff information that you can get prior to attending any form of breakdown or service repair issue can be quite high.”
Non-remote diagnostics
Many crane manufacturers do not currently offer remote diagnostics. But that does not mean that crane faults cannot be rectified without needing a technician call-out.
If there is a fault, modern cranes display error codes that help narrow down where the fault has occurred. If a crane operator can make a call on a mobile phone, he might be able to follow the instructions of a service engineer to diagnose and even repair the fault.
For example, tower crane manufacturer Jost has integrated the control cabinet in its new CACON crane cab to avoid the need for remote diagnostics, says Frank Crombe of Dutch manufacturing partner and Benelux dealer Kranenbouw.
“In case this is not a mechanical problem, he can reach the electrical cabinet easily in the room behind him, follow the instruction of the service engineer and manipulate the controls. He can read the messages written on the display and give them to the service engineer at the other end of the line. Basically, we believe that an audio communication with the crane’s operator is the key of a remote diagnosis system.”
Crombe continues: “All electronic systems have a limit: they rely on data which can be either present or not available or erroneous. A crane driver is far more flexible and can test locally until he has found the breakdown, following the instructions of the service engineer.”
“Crawler crane product manager Randy Harris of USA crane rental firm All Erection” |
We are not currently using it, but we should be – the technology is there |
Crombe adds that in case the operator cannot resolve the issue, a service technician will visit the crane.
Terex Cranes president Steve Filipov says that subsidiary Demag is currently investigating a remote diagnosis system, but adds that his main priority is having people local to support crane users.
“We still need to study remote diagnostics and how it can help our industry. My opinion is that diagnostics works in developed countries. The question is how to offer it into the machines so that it doesn’t deteriorate other markets that don’t want it or don’t need it,” Filipov says.
“In Europe or North America, you can give people an opportunity to access the crane on line. You still need manpower behind to be able to fix the problem—we do that today,” Filipov says.
Filipov stresses that his focus is having repair people at least in the region. “If there’s a breakdown, engineers in Zweibruecken [Germany] or Waverly [Iowa, USA] can’t get on a plane and be there tomorrow. It is critical to have knowledge in the region to repair machines.”
He adds that it is often the biggest and most complicated cranes that are out of useful range of a remote diagnostics system. “Today we can do telematics and repair by GSM to a certain extent, but it’s a little difficult for larger companies like Mammoet or Sarens, who operate big machines all over the world, to use that kind of technology if they are in the middle of Russia or Africa. There is a trade-off to keep machines simple for those kinds of applications.”
Dahlkilde, at loader manufacturer HMF, admits that it is requiring a certain level of IT ability in its 100-150 dealers across Europe and in the USA, and says that not every crane owning-company is going to have the IT skills to be able to set up the system correctly so that they can be helped.
“We are not at the same level all over Europe. We may only get one or two guys in a company, in the office, who know about computers and how to download software. That has to be part of the education of service people. If they want to be helped, they have to bring someone with computer knowledge. We have some service partners very skilled with computers, and others who we want to raise to the next level so they can receive remote assistance.”
For some customers, getting these new systems to work is simply not a big enough priority. Alex Lowe is the managing director of UK-based Wolffkran customer and dealer HTC. The firm has a fleet of 200 Wolff tower cranes, according to Cranes Today Fleet File. But HTC has yet to install the remote diagnosis system on its cranes. “We’ve not gotten around to fitting it,” admits Lowe. “As it is, we’re flat out, going at 100 miles per hour. It’s something we keep discussing. I’m no computer expert. I need someone to say, ‘this is the software you want.’ At the moment, the driver rings the office and reads information off the computer in the cab to my engineer here, who knows what the codes mean.”
Managing the fleet
“product manager Gregor Leuschen, electronic manufacturer PAT” |
Remote functionality has to be considered as one part of the system |
For some rental companies aspire not to use a manufacturer’s remote diagnosis service, but to manage this service themselves.
“We are not currently using it, but we should be—the technology is there,” says Randy Harris, crawler crane manager at the USA’s All Erection.
“We tried one system four years ago by Micrologic, which had satellite tracking, GPS, and tracked crane overloads, and run-time. We ran it on a Manitowoc Model 2250, and after 200 run hours the indicator would go yellow, at 225 it would go red, so you know that it is almost ready for a service at 250 hours.”
This system would be useful for bare crane hire (without operator), Harris says, because it would help keep track of cranes out of the depots for long-term rental contracts. “Somebody in our service department could call up the customer where the crane is, maybe 900 miles away, and say, ‘Your crane is due for a service. Are you taking care of it, shall we set it up and help, and bill you?'”
Teething problems with the system prevented the twenty-machine trial being rolled out fleet-wide. The company is currently testing a barcode system for component tracking instead, Harris says.
AmQuip’s head of tower cranes, vice president Dennis Bates, also says that he has been investigating remote diagnosis systems. “Real time communication has been our biggest issue. The ideal system would notify us immediately if the data sensed a possible failure in the system. We could also get daily downloads from other data sources for time and load information.”
Bates says he is looking for a system that can adapt to different brands of crane, so it can be standardised across the fleet. Although he has not yet decided, he recommends Potain’s system and that of construction hoist brand Alimak, which he says could be adapted to tower cranes.
In Europe, Belgian tower crane rental company Arcomet ended a recent trial without a firm committment.
“It’s useful,” says Arcomet chief engineer David Jansson. “It is very important to get the information. But it is a lot of work to get that information on a rental fleet,” an exercise that is simply too expensive and too time consuming to currently justify it for Arcomet, he says.
Crane remote diagnosis aims to reduce the time that cranes are not working by providing data from cranes on a job site Service staff overhaul an all-terrain at Liebherr’s Houston, Texas service centre Transmission manufacturer ZF has launched TestmanPro diagnostic software for its latest electronically-controlled transmissions. The ZF transmission control unit records transmission faults and other parameters such as oil temperature and pressure, as weZF’s TestmanPro UK distribution software integrator IDC is marketing a service package using handheld computers for service staff. The computers hold the daily call schedules for each field engineer. They have integral bar-code readers, telephone and GPS unit. IDC launches service operation through handheld computers Remote diagnosis allows the possibility of fast and competent help at once Rene Dahlkilde, HMF
product manager Rene Dahlkilde of HMF
My opinion is that diagnostics works in developed countries. The question is how to offer it into the machines so that it doesn’t deteriorate other markets that don’t want it or don’t need it Steve Filipov, Terex CranesSteve Filipov, president, Terex Cranes
We are not currently using it, but we should be – the technology is there Randy Harris, All ErectionCrawler crane product manager Randy Harris of USA crane rental firm All Erection
Remote functionality has to be considered as one part of the system Gregor Leuschen, PATproduct manager Gregor Leuschen, electronic manufacturer PAT
Liebherr LICCON remote software Liebherr LICCON remote software Support personnel back in the office Support personnel back in the office Crane driver speaks on his mobile phone Crane driver speaks on his mobile phone