Implementing Data Logger Systems for Mobile Cranes-Its Purpose, Benefits and Specifications

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Lester Norton
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1 Implementing Data Logger Systems for Mobile Cranes-Its Purpose, Benefits and Specifications Presented by Mr Frank Beardsley Vice-President, Engineering, Rayco Wylie systems In conjunction with Load Control Systems, Singapore 1

2 Ceres Accident Show photo of crane accident 2

3 Ceres Accident 3

4 Ceres Accident 4

5 Ceres Accident 5

6 Ceres Accident Show photo of broken shaft due to fatigue 6

7 Ceres accident-records of 6493 total lifts 7

8 Causes of Crane Accident Fatalities According to the US Bureau of Labor Statistics the majority of crane accident fatalities in the US are caused by: Electrocutions Crane collapse Falling booms/jibs 8

9 EN13000 Requirements If the mobile crane is equipped with a set-up button and/or a bridging device, then a data recorder shall be available which meets the following criteria: 9

10 EN13000 Requirements the data shall be recorded automatically, independent of the crane operator; each actuation of the set-up button or the bridging device, which leads to an overloading of the crane (greater than 100% of the set load chart), shall be recorded. Here, the size of the overloading shall be recorded; in addition, if the set-up button, or the bridging device, is activated, all data shall be recorded which are relevant to reconstruct the last load case; 10

11 EN13000 Requirements a suitable interface to read out the data shall be available; suitable measures shall prevent the manipulation of the recorded data; the function of the data recorder shall be automatically checked each time the crane is put into operation. A data recorder malfunction shall be indicated to the crane operator. 11

12 What do you need for data logging? Download PC Cable Communication Interface Box Or Portable PC DL3000 Data Logger Analysis CD 12

13 Data logging Individual users log in using unique pass code on start up. Records a summary of every significant lift, also records bypass use and anti-two block operation. Every record is date and time stamped 13

14 Warning given when memory is nearly full. Data logging Operates invisibly Warning given if battery power is low. Note: battery is only required for clock power as data is stored in nonvolatile memory. 14

15 Data logging Supplied with data analysis tools for Windows PC Sequential downloads from the RCI are combined together to produce a life history for each machine Data can be filtered and reports printed in a wide variety of forms 15

16 Crane Parameters Logged Description of Event When logged System Power-Up Date and Time Crane Type as Recorded in the Chart Data Chip i3000 Operating System Version Approach Warning Threshold as % SWL Overload Warning Threshold as % SWL Cut Warning Threshold as % SWL Crane Identity Number Used (operator) Identity Start of Lift Date and Time Start of Lift Units of Measure for this Lift Start of Lift Current Duty Number Start of Lift Current Number of Falls Start of Lift Crane Configuration Table (CCT) Number Start of Lift Time when Approach Warning Set Actual Radius at Approach Warning Time when Approach Warning Cleared Time when Overload Warning Set Actual Radius at Overload Warning Time when Overload Warning Cleared System Power-Up System Power-Up System Power-Up System Power-Up System Power-Up System Power-Up System Power-Up System Power-Up (Load > 20%SWL) (Load > 20%SWL) (Load > 20%SWL) (Load > 20%SWL) (Load > 20%SWL) When Approach Threshold reached When Approach Threshold reached When return below Threshold When Overload Threshold reached When Overload Threshold reached When return below Threshold 16

17 Crane Parameters Logged Description of Event Time when Cut Warning Set Actual Radius at Cut Warning Time when Cut Warning Cleared End of Lift Date and Time End of Lift Maximum % SWL Reached During the Lift End of Lift Maximum Actual Load at Max % SWL End of Lift Radius at Max % SWL End of Lift Maximum Actual Radius reached during the Lift End of Lift Minimum Actual Radius reached during the Lift End of Lift Max. Main Boom Angle reached during the Lift End of Lift Min. Main Boom Angle reached during the Lift End of Lift SWL at Max % SWL End of Lift Boom Angle at Max % SWL End of Lift Maximum Moment (load x radius) End of Lift Static Load End of Lift Log Static Moment End of Lift Anti Two-Block Detected Time and Date Motion Cut Bypass Time and Date System Power-Down Date and Time When logged When Cut Threshold reached When Cut Threshold reached When return below Threshold (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) (Load < 20%SWL) When an ATB is Detected When a Bypass is Detected System Power-Down 17

18 Data Logger Minimum Recommendations Time and date of all lifts Crane configuration Operator and crane identification Maximum per cent of rated capacity during lift Load on hook, min/max radius, boom angle Anti-two-block warnings Overload warnings and occurrences Overrides and cutouts 18

19 Purpose and Benefits Accident investigation Maintenance Utilization Monitoring the usage of the crane for abuse Printed reports of data in useable format Operators will be more careful with awareness of the data logger 19

20 Data logger screen shot examples

21 Data logger screen shot examples

22 Data logger screen shot examples

23 Data logger screen shot examples

24 Fleet Management 24

25 Future Developments Rayco/Wylie i4500 coming in 2012 Transmission of data logged to remote location Recording of video images from boom tip cameras 25

26 Accurate and Reliable 26

27 2440, avenue Dalton Sainte-Foy (Québec) Canada G1P 3X1 Tel. : Fax : rayco@raycowylie.com Load Controls Systems Pte Ltd 8 Sungei Kadut Avenue Singapore Tel: (+65) Fax: (+65) lcs@tathong.com.sg Rayco-Wylie Systems Drury Lane St.Leonards-On-Sea, East Sussex TN38 9BA, United Kingdom Tel. : Fax : wylie@raycowylie.com 27

Requirement for installing Data Loggers in Mobile Cranes

Requirement for installing Data Loggers in Mobile Cranes A Great Workforce A Great Workplace Ian Teh Yi Tian Engineering Safety Branch OSH Specialists Department Occupational Safety and Health Division,