Crane
Predictive crane maintenance with IoT focuses on the cable carrier, which guides power and data cables to the trolley. Sensors report overload or breakage before the crane comes to a standstill and give maintenance and replacement recommendations.
Crane at a glance
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Verified projects featuring Crane
Private 5G brings reliable connectivity to harsh environments
Crane operators work under harsh conditions in ports and steel mills. With Private 5G, Siemens provides a stable, low-latency link for operating cranes remotely.
Extending the service life of energy chains in RMG cranes – with condition monitoring and predictive maintenance
Energy chains ensure continuous operation of container cranes under extreme conditions
Scalable HSE (Health Safety Environment) – through central IoT monitoring instead of additional personnel
Complete indoor crane automation thanks to the i.Sense monitoring system
Recording of all sensor data on a port data platform in Antwerp
Predictive crane maintenance with sensors on the cable carrier
In the igus solution examples, three measuring systems are built into the energy supply: i.Sense EC.P measures push and pull forces on the chain, i.Sense CF.P the tensile force on the cables, and i.Sense EC.B detects a broken chain link. If a guide trough is bent, a foreign object gets in or the chain is blocked, the crane operator is notified, and the system can stop the crane immediately if required. An additional predictive maintenance system recommends when the chain or cables should be replaced. On construction sites, platforms such as Cumulocity also combine sensor data on the load, angle and vibration of the crane boom and warn when wind, for example, deflects the crane too far.
The examples come mainly from ports and logistics. At the Port of Hamburg, EUROGATE relies on igus cable carrier systems and sensors for its rail loading cranes, which are almost 30 metres high and move containers weighing up to 40 tonnes around the clock. On a rail-mounted gantry crane (RMG) with a travel distance of 113 metres, sensors monitor two cable carriers mounted in opposite directions. Furniture manufacturer Nowy Styl monitors the energy supply of the automatic crane in its panel warehouse in real time, significantly reducing the risk of failure.
Podcast episodes featuring Crane
Condition monitoring in the crane industry: efficient cable routing and less downtime with energy chains
Sensor2Cloud integration – how to save costs in engineering and product development
Industrial Wireless Communication - Real-time communication via 5G with Profinet
Crane maintenance with IoT: frequently asked questions
How does IoT support crane maintenance?
IoT makes crane maintenance predictive: sensors continuously report the condition of wear-prone parts instead of damage only being noticed at the next inspection or during operation. In the solution examples, sensors on the cable carrier measure push and pull forces, the tensile force on the cables and chain breaks. A maintenance system uses this data to recommend when the chain or cables should be replaced, so unplanned stops become less frequent.
Why monitor the cable carrier of a crane?
On the crane bridge, the cable carrier guides the power and data cables of the trolley. If it fails, the entire crane stops. On outdoor cranes in particular, wind, weather and the heavy load of many cables wear the material. Sensors detect a bent guide trough, foreign objects, blockages or a broken chain link and notify the crane operator. If required, the system stops immediately, before more serious damage occurs.
How do port cranes stay available in continuous operation?
Port cranes stay available when wear-prone components are designed to be robust and are continuously monitored. At the Port of Hamburg, EUROGATE operates seven rail loading cranes that move containers of up to 40 tonnes around the clock. For the energy supply of the trolleys, the company relies on durable igus cable carrier systems with sensors. There, the cranes handle trains on eleven tracks of the combined transport rail terminal.
Can an automated overhead crane be monitored with IoT?
Yes, monitoring the energy supply is especially important for fully automated overhead cranes without an operator. Furniture manufacturer Nowy Styl runs an automated warehouse for wooden panels in Poland, where a crane travels more than 60 metres. A push-pull force sensor from igus monitors the cable carrier in real time. The result is continuous control over the condition of the energy supply and a significantly lower risk of failure.
More assets in “Conveying and Handling Technology”
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Forklift truck
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High-bay warehouse
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Welding robot
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