Telematics can be described as “the integrated use of telecommunications and informatics”. Or more specifically as “the science of sending, receiving and storing information via telecommunication devices”.
For crane operators, it enables important information and operating data to be sent back from equipment working in the field for analysis and assessment to ensure equipment efficiency is maximised and operational downtime minimised.
The effective use of telematics is best evidenced by the technology’s central role in the modern automotive industry, particularly F1 motor racing, where engineers and pit crews are able to keep a close eye on the performance of their multi-million dollar cars as they hurtle around Silverstone, the Nürburgring or the streets of Monaco.
This data includes vital information about engine performance, aerodynamic efficiency, oil pressure, tyre grip and brake wear, as well as numerous measurements taken from the car regarding the driver’s progression on the track.
The use of telemetry is also evident in the commercial car market, where companies such as Toyota and General Motors (GM) use it as a safety and convenience features tool.
GM’s OnStar system produces a monthly diagnostic report that provides vehicle owners with information on key operating systems, such as the antilock brake system, air bag system and engine/transmission system; maintenance information to maximise vehicle performance; and notification information for recalls, services and account information.
Other features of OnStar include automatic crash response, which uses sensors to detect incidents and alert an advisor who checks on the vehicle and alerts the relevant emergency services; one-push button access to emergency services should a passenger require emergency help; and crisis assist, which during severe weather or natural disasters connects the vehicle to a crisis advisor who can provide information on evacuation routes, connect the driver to family and friends, and help find food, water, medical supplies or shelter locations.
Convenience features include remote door unlock, in case the driver becomes locked out of the vehicle; remote horn and lights, should the driver be unable to locate their vehicle; and built-in hands-free calling.
Toyota’s Safety Connect system will offer comparable features, including automatic collision notification, one-push button emergency assistance and stolen vehicle location.
Construction equipment
Other construction equipment sectors are advanced in their use of telematics in day-to-day operations.
MiX Telematics’ DataTrak system provides UK plant and construction equipment operators with a range of information on their equipment, such as location, speed, direction, position and status. It uses a GPRS locator and reports via a web-based application, DataTrak Online, which produces a range of reports useful for managing assets.
It can be employed on both mobile and static items with Kent, UK-based MEMS Power Generation using it for both tracking of mobile machines and telemetry on installed equipment, including as an early warning system for equipment malfunctions.
The crane-equipped heavy trucks and fuel tankers in MEMS’s delivery and collection fleet are all fitted with DataTrak, which is used to confirm locations, movements and secure its fleet, while telemetry on static items allows the company to provide an improved customer service.
“The primary service we provide is disaster recover, which means our generators are frequently used in business critical situations,” says Paul Knight, procurement director for MEMS.
“Once switched on our customers depend upon us for continuity, which in turn demands a rapid response from our engineers should any problems occur. DataTrak is excellent in this respect as it immediately alerts us to any potential issues that may arise.”
Taking the technology cross-continental, Komatsu uses its Komtrax OEM-developed system across its product range. Fitted as standard on most of the company’s machines, Komtrax lets managers monitor essential information about their equipment directly on a computer.
“Komtrax is a tool that helps you manage your whole fleet of Komatsu machines easily and cost effectively,” says Komatsu. “You can track them in the field and optimise their output through increased efficiency and proactive maintenance.”
The system was launched in Japan and the US in 2001, before being extended to European customers in 2006. Komatsu says the system is active on more than 130,000 machines worldwide, with more than 17,500 users in Europe.
The system works in any country where Komtrax transmission is allowed, and when the system is activated the data is downloaded regularly via satellite. The data is accessed through a standard web browser, with a variety of search parameters available to precisely determine the status of Komtrax-equipped machines.
“It’s the way to go forward, especially for larger companies,” says Wayne Burns, contracts controller at Marubeni-Komatsu, the sole distributor for Komatsu equipment in the UK.
“It’s available now on virtually every model. It can be retrofitted and we also offer a universal system that can be used on other manufacturers’ machinery, but this only uses the ignition circuit to monitor basic systems.”
Crane catch-up
The crane industry is moving to catch up with other construction equipment sectors with similar systems that allow a crane’s operation and performance to be remotely monitored.
REDIview, developed in the US by Remote Dynamics, is a GPS-enabled system that allows crane and hoist users to monitor a number of data streams in real-time. Customers are using it on Comedil, Liebherr, Potain, Wolff, Sun, and Peiner tower cranes, as well as Alimak, Hercules and Pecco hoists.
It produces a number of reports based on important data that is used in asset management, including trip reports, travel history, cost analysis, ignition, exceptions and time at shop.
This provides operators with information that they can use to check on the location of their cranes, audit customer invoices and time sheets, see how much trips are costing the company and monitor hour meters.
Data is transferred using the AT&T GSM network and Orbcomm and Globalstar satellite networks to maximise subscribers’ remote access to their equipment, which Remote Dynamics says helps them keep on top of maintenance operations and the service they offer their customers.
Next step
For Manitowoc, its CraneSTAR system is the next step in asset management for the crane industry; and refers to it as “the most extensive OEM-produced crane asset management system available today”.
“CraneSTAR came about from Manitowoc asking what can we do to be more proactive and provide better customer service and customer care,” says John Bittner, director of global marketing at Manitowoc Crane Care.
Both Bittner and Scott Blair, Manitowoc’s director of global telematics, laud the advance of technology and electronics for the development of telematics and systems like CraneSTAR.
“Technology got to a point where these things were possible,” says Blair.
“I like to describe it as the sun and moon aligning,” says Bittner. “We couldn’t have done this kind of thing ten years ago for a number of reasons.
“There weren’t the electronic systems in place to handle it as it was all hydraulic. And cell service providers realised they could make a lot of money from the transmission of data. The technology has come around to allow us to transmit data with bandwidths growing to supply more data. The technology is also now portable.”
Manitowoc models equipped with CraneSTAR are fitted with a terminal control unit (TCU) that monitors the crane’s electronic systems and transmits the required information back to a secure data bank (“back office”), much like Komtrax and REDIview.
“It’s a way to see what’s going on with the crane remotely,” says Blair. “It uses the existing data that is produced by the crane’s systems and picks out certain bits of data and sends it to us. This can be done periodically or with a trigger that starts a countdown to something.”
“It is an asset management tool for end users,” says Bittner. ”We distribute products through dealers so we really look at it as a tool for the end user who can download the information and use it as they wish.”
What sets CraneSTAR apart from other systems like REDIview, according to Manitowoc, is the use of a global, quad-band SIM that allows it to work across the world. According to Manitowoc, this is “a feature no other system in the construction equipment industry currently offers”.
This opens up CraneSTAR to working on a range of local GSM networks and, coupled with connection to Orbcomm’s satellite network, provides comprehensive dual-mode global communications coverage.
Maps on the CraneSTAR website shows Orbcomm’s satellite network is authorised in North and South America, Europe, South Africa, parts of the Middle East, Australia and Japan. It also reports Orbcomm has filed an application to use its network in China and the Asia-Pacific region, and is extending its system to cover Russia and Greenland. Research is still in progress for much of the African continent. GSM and 3GSM coverage is prominent in North America, parts of South America, Europe, South Africa, India, China, Japan, the east coast of Australia and other areas around the world.
“It is the only global OEM system available,” says Blair. “There are other OEM telematics systems but what we’re doing differently is offering a dual-mode system that can transmit through both GSM networks and satellites. It is a hybrid solution; the TCU will connect via satellite if after a few attempts it cannot connect through GSM.
“We’re also the first people in the construction equipment industry to have a global SIM that allows the crane to be deployed anywhere in the world and the CraneSTAR system will still operate as normal.”
Data selected for transmission is fully definable by the end user in order to maximise their experience with the system, and this selection process can be carried out remotely. However, the system doesn’t transmit every piece of data if operating across a satellite connection as this increases the cost. Instead, it transmits priority information in order to reduce its use of bandwidth and the cost of transmission.
“Cost is a factor, as is transmission speed, “ says Blair. “Transmissions aren’t instantaneous despite what you see on TV shows like CSI. The system is only as good as the data. Networks aren’t good enough yet to handle instantaneous communications.”
Once transmitted, the data is available for access by authorised personnel via a web-based interface. It can be exported into a number of file formats allowing users to integrate the information into their own business systems and make the most of the information.
Manitowoc also has access to certain parts of the data as part of its service agreement with crane operators. The intention is that its customer service team will be able to use this limited information.
“Manitowoc’s access to the data allows our customer service team to use some information that brings another level to their service,” says Blair. “Like where the crane is and what it’s doing. It allows them to investigate some elements and issues with the cranes.”
Blair says the information stored as part of the CraneSTAR system is covered by the same US standards that cover storing corporate information, so there is no need for concern over the data being lost, misplaced or falling into a rival’s hands.
Equally as important as what it can do is what CraneSTAR can’t, add Bittner and Blair.
“It’s important that it’s not seen as a safety item,” says Bittner. “We want to make it very clear that the operator is still 100% responsible for the operation. It doesn’t allow live updates that let you look over their shoulder and give them directions or recommendations.”
“It’s not a real-time system,” adds Blair. “It uses historical data as an information point.” Blair says it can’t be used to directly record maintenance operations but records information that can be used to extrapolate the service life of components. “For instance if a crane operator replaces tyres, which is a big maintenance factor, it doesn’t measure the tyres themselves but can measure the distance the crane has travelled so can be used to work out the service life.”
CraneSTAR will be introduced on Manitowoc’s cranes in the third quarter of 2009, and will be available across most models within nine months. Blair says some crane types will be omitted from the rollout of the technology, most notably those that aren’t equipped with digital sensors and transmitters or those using hydraulics.
“The plan for CraneSTAR is that on cranes with higher-end electronic systems it will be delivered as standard,” adds Bittner. “The owners will get access to the system for three years. After then I imagine there will be some kind of renewal system in place. Costs depend on the state of technology then but what I can say is that it will be competitive and offer our customers best value.”
Blair says the role of telematics will undoubtedly become an increasingly important part of everyday business, as well as our everyday lives.
“It is a major step for the crane industry,” he says. “In five years, I’m sure all manufacturers will offer telematics. It’ll be a bigger part of our daily lives. It’s not about Big Brother but about how you manage your business and your fleet.”
