Wireless Data Monitoring System for Crane Application

Client: One of the India’s largest Aluminum Manufacturing Company

Operational Importance:

Crane monitoring is a critical operation within a steel or cement plant as multiple cranes separated in different areas, operated individually from the operator’s cabin are used for multiple tasks like removing anode and cathode from the pot, filling the pot with bath at open places whilst traveling a distance of about 1.2 km to handle all the pots in a room or for removing broken pieces from the pots.

Project Requirement:

Being most important part of a metal industry down time for the crane machine amounts to huge losses.  As the cranes are operated individually, maintenance engineers require considerable time to pinpoint faults, troubleshoot on the acknowledged fault and restart operations. The reduced operating hour affects the production drastically and hence the solution is required to reduce the machine breakdown time.

The  breakdown of crane can be eased with a central monitor which allows maintenance engineers to monitor and check for breakdowns. The  challenge is to provide connectivity among all moving cranes in high EMC area, dusty environment, closed Structure etc

Solution Features, Differentiators & Role of Masibus:

  • Online monitoring of all cranes and their tools’ operation
  • Reduce breakdown/downtime with preventive maintenance
  • Instant alarm messages for critical condition
  • High connectivity of all the wireless modules with turbo roaming technology
  • Wireless download/ upload of PLC program
  • Alarm and Faults observation from control room
  • Analysis of frequent alarm and faults through Historian Reports
  • Fiber optic connectivity for longer distance & highly EMC area
  • Masibus designed the solution
  • Masibus executed the successful supply of hardware and software
  • Installation and commissioning of complete system

Customer Advantage:

  • Continuous monitoring of all cranes from centralized SCADA reduces the time for notifying the fault condition from an operator to a maintenance engineer and hence reduced MTTR
  • Monthly analysis of historical data is useful to preempt and reduce future faults
  • Frequent alarm of particular tool/part can be used to prevent future failure of a tool/part with preventive action
  • Operator skills are evaluated with real time animation of crane operation
  • With prior information about motor run time and maintenance schedule, an emergency breakdown can be prevented
  • Direct sending of critical alarms to senior management via SMS
  • Maintaining log book with specific pattern and category is useful for training & learning from historic information