3 Commonly Overlooked Overhead Crane Safety Tips
Observing proper overhead crane safety protocols is crucial for preventing accidents and maintaining a smooth and productive work environment. While many safety protocols are well-known and widely practised, some lesser-known crane safety tips are commonly overlooked when it comes to overhead cranes—namely the implementation of a cross travel and long travel limit switch and proper load weight estimation techniques.
1. Implementation of Cross Travel & Long Travel Limit Switches
Installing cross travel and long travel limit switches on a crane is a crucial safety measure, highly recommended by crane repair companies and mandated by regulations. This system is designed to prevent over-travelling and potential collisions with the end stopper. These limit switches function by progressively controlling the crane’s speed as it approaches the end of its travel path.
Initially, when the crane reaches a predetermined point, the limit switch cuts off the fast-speed travel, ensuring that the crane begins to decelerate. This transition from high speed to a controlled, slower speed is vital for reducing the kinetic energy of the moving load, thus minimising the risk of abrupt stops that can cause mechanical stress or load instability.
As the crane continues to approach the end stopper, a secondary limit switch arm engages, causing the crane to come to a complete stop before colliding with the end stopper.
This multi-step deceleration process not only prevents mechanical damage to the crane but also enhances operational safety by reducing the chances of sudden impacts, thereby protecting both the equipment and the operators.
2. Proper Load Weight Estimation
Accurately estimating the weight of the load being lifted is fundamental to safe crane operation. However, without the proper techniques, this could lead to overloading and potential crane failure.
Load Weight Estimation Techniques
Overloading an overhead crane can lead to catastrophic failures, including structural damage to the crane and serious accidents. Proper load weight estimation involves knowing the exact weight of the load before lifting and ensuring it is within the crane’s rated capacity. There are several techniques and tools available to help operators gauge more accurately:
– Crane Load Display: These are integrated into the lifting system and provide precise weight readings. Crane scales ensure that operators are always aware of the load weight. A good example of this is our HoistSense+ electric hoist monitor, an industry 4.0 application that can be connected to a generic industrial WiFi or a mobile data router to securely feed information to CMAK cloud servers. This provides operators with real-time monitoring and data reporting.
– Extended Load Cells: These devices measure the weight of the load directly and provide real-time data to the operator. Installing load cells on the overhead crane hoist can help ensure accurate weight measurements and prevent overloading.
– Pre-lift Calculations: For loads that are assembled or combined on-site, pre-lift calculations using known weights of individual components can help estimate the total load weight accurately.
Proper training in load estimation techniques and the use of appropriate tools are essential for safe crane operations. Companies should prioritise the implementation of these practices to avoid overloading and ensure the longevity and safety of their crane systems.
Overhead cranes are massive, complex machines that require operators to exercise a great deal of caution and meticulousness to safely operate them. By diligently practising the above measures, you can significantly improve the safety and efficiency of your work site. Furthermore, crane service companies like Shin Guan can provide the necessary expertise and parts to help implement some of these safety measures, ensuring that they are properly installed.
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