Cranes are a major investment for any firm, from the largest rental fleets to the one-crane owner operators. A crane that is not working to its full potential is a major expense, the trouble is that sometimes the information that demonstrates a crane is not being utilised to the fullest often will not be readily available to the owner.
This is where asset management systems come into play. By monitoring a machines control system or location data an owner can track to see whether a crane is being used to its fullest potential. These systems typically come in the form of a small box connected to the onboard control system and using cellular GSM or satellite communication links to send system information to the owner. These systems can be used to assist in the accurate calculation of utilisation rates and help crane maintenance.
One system offering both maintenance benefits and utilisation improvements is Manitowoc’s CraneSTAR as its global integrated technical communications & CraneSTAR product director John M Alexander explains: "CraneSTAR is particularly useful for rental fleet owners who want to monitor their assets remotely. The system provides a total SMR (Service Meter Reading) that can feed into a maintenance program whereby the data can be used to help schedule maintenance work on the machine. The product is very much for the equipment manager that is responsible for the maintenance and efficient utilisation of crane equipment. The system monitors virtually all parts of the crane operational conditions, hydraulics and so on. This data is acquired using the internal computer or control system on the crane."
Not all asset management systems are the same. They all provide different levels of information in contrasting formats and as with many new technologies terms aren’t ubiquitous as of yet. Manitowoc define their system as an event recorder, Alexander continues: "I would classify CraneSTAR as an event recorder rather than a data logger. A data logger records every single second of operation on a crane. CraneSTAR is an event recorder that takes snapshots of operational data throughout the day. Every 30 minutes CraneSTAR monitors the control system outputs, hydraulics, the position of the boom and so on".
"CraneSTAR also monitors specific operation conditions like overloads, engine faults and excessive wind speed. Whenever these events occur CraneSTAR will report the operational conditions at the time of the event and send the data to the website. It’s not a safety device but an event recorder that monitors crane activity and sends it to the website/owner. It records hours of operation and fuel usage."
"There are a couple of different ways in which customers can interact with the data. Firstly, we have the website which allows users to view data from the current day or in the past. Another method is through the automated emails that contain the information from the device. These can be tailored to provide the information which the customer requires particularly."
Manitowoc aren’t the only manufacturer offering a telematics package, Japanese comany Kobeclo has its own Kobelco Cranes Remote Satellite System (KCROSS). This allows users to view the operational status of a crane and has location management functions. The system can also provide warnings in case of any unusual activity and has a trouble management features. The system can be set up for maintenance management also.
Tadano’s offering HELLO-NET works using GPS and communications satellite in order to take information from the job site and send it to a server. This can then be fed into the computer systems of the manufacturer, of the distributor or the owner. This provides a range of information to assist the various parties in using the crane more efficiently.
Other offerings
Alongside manufacturers asset management systems are those offered by companies specialising in telematics and machine monitoring systems. One such firm is Masternaut, who deploy telematics for the remote monitoring of commercial cranes and heavy lifting equipment. Its new service uses contactless CANbus connectivity to stream live from the vehicle or crane unit. Fully integrated with Masternaut’s core fleet product, the service enables fleet and construction plant managers to access real time utilisation and productivity data.
Cranes are installed with Masternaut’s MuxyGPS hardware streams data in real time and aggregated into tailored customer reports. This consists of asset details including temperature, water and oil levels, pressure values and weight carried. Through live alerts, equipment operators have the ability to monitor the condition of the crane remotely, facilitating predictive maintenance scheduling and the proactive deployment of engineers help address malfunctions. The firm offers telematics deployment on manufacturers including the Leibherr and Terex ranges, as well as equipment with Mercedes and Iveco ECUs.
Another system in the dockside sector is the Crane Data System (CDS) from Harbor Telematics. The system is an on board, cloud based computer system which gives users a direct, real time window into the operation of their cranes that provides information to every level within a CDS enabled equipment user’s organization, such as Operations, Maintenance, Logistics, Sales and Upper Management.
Managers can see production data in real time such as job tonnages, tons per hour, seconds per cycle, and overall efficiency performance information. The system allows operators to see individual equipment production with the capability to affect the outcome of the movement. They can also monitor overall job performance.
Harbor Telematics believe that CDS offers crane owners a real time view of customer use patterns. As well as allowing them to monitor incidents of misuse, identifying the difference between mechanical errors and poor usecan which can be used to reduce or prove warranty claims. The system allows the customer to track problematic parts or vendors.
Terex/Gottwald has adopted the use of CDS as an option on its new cranes and marketed the system to existing users. CDS can be adapted to other equipment and programmed to interface with existing terminal operating systems.
Fleet Manager from MiX Telematics solution captures information from the vehicle or engine’s CANbus system. Parameters such as fuel consumption, driver performance, the use of lorry-mounted-cranes and other equipment, running hours and safety factors can all be measured and reported back to the operator by way of web-based or mobile application reports and using email or text alerts. Fleet also Manager offers track and trace functionality to ensure the whereabouts of assets are visible.
One example involves Bristolbased independent builders’ merchant, Kellaway Building Supplies Limited, which invested in a customised Fleet Manager solution.
Describing the how the firm had benfited from the Fleet Manager system Kellaway building supplies operations and commercial director, Sean Morgan said: "In terms of safety, we were looking to minimise instances of the unsafe practice of trucks moving with their cranes up. MiX Telematics was able to incorporate the appropriate functionality into its solution. Now, should a driver move off without his crane stowed securely, a warning siren sounds in the cab and I receive automatically triggered email alert. This has had a marked effect in reducing the number of occurrences recorded."
Fleetilla has two products relating to asset management systems. The FL950 is a self-contained asset tracking device that can be used to remotely monitor equipment. The FL1260 is a compact GPS tracking/remote monitoring device.
FL950 has 50 channel GPS, capable of working in poor signal conditions using assisted GPS technology. The FL950 measures equipment movement, utilisation, orientation changes and other usage parameters using built-in 3- axis accelerometer. The device can be used with the Fleet Orb 9 asset management application, this allows a crane owner to view the lastest locations and usage information. As well as perform daily yard checks and viewing asset usage history.
The FL1260 has a built-in three-axis accelerometer to detect movement, orientation, crash and towing conditions. A driver key fob interface identifies drivers and authorizes who may drive each vehicle as well as creating information for payroll. The FL1260 also has the option to integrate a variety of temperature, humidity, pressure, level, voltage and current sensors. An incident buffer option provides detailed vehicle positions and acceleration or deceleration to assist with accident investigations.
