Crane Construction of the Future: Requirements and Developments

DigiMessenger #11

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Ulrich Nieschalk | Professor of History of Architecture | LinkedIn | 6.1. 2023

Introduction

A crane is a device that can be used for vertical lifting and lowering of large loads. In addition to the possible vertical movements, the loads can also be moved horizontally in different directions with a crane. The combination of vertical and horizontal movements and their high lifting capacity makes cranes ideal for loading goods. The future design and construction of industrial cranes faces a number of challenges, which are explained below:

Energy efficiency

(energy-saving motors, brake energy recovery, compact gearboxes and geared motors, hybrid technology, hydrogen technology),

Process optimization and automation

(tablet operation, information management, load-dependent control, remote control technology, overload detection systems, intelligent kinematic, parameterization instead of programming, load pendulum damping, synchronized movement, load-dependent speed, 5G mobile radio standard)

Condition monitoring and predictive maintenance

(condition monitoring, acquisition of transmission data, endoscopy and oil check, vibration monitoring, intelligent service, artificial intelligence)

Services

(Life Cycle Services, Knowledge Transfer, Augmented Reality, 3D Printing, Easy Service Access, Lifetime Lubrication, Global Service Network, Standardized documentation and detailed diagnostics, targeted troubleshooting, worldwide provider catalog for services

1. Drives

The functional heart of crane systems is the drive technology with its components,  motors, gearboxes, geared motors, driving and wheel systems. It is important that all drive elements are precisely matched to each other. Leading manufacturers already offer modular systems for complete driving units. With energy-saving electric motors and components tailored as required, drives can be adapted specifically and optimally to the respective requirements. Modern transmissions make their contribution through ever more compact designs and weight savings.

2. Alternative energy

Global oil reserves for the production of diesel and gasoline are limited. Alternative drive systems will therefore play a relevant role in the future in order to remain mobile and at the same time take environmental and climate protection into account. Electric drive (high-voltage battery), hydrogen drive, hybrid drive, LPG, natural gas, bioethanol, biodiesel, vegetable oil. Electric vehicles are powered purely electrically. Instead of a combustion engine, high-voltage vehicles have a HV battery (also called traction battery), which is charged via the socket. The alternative drive technology hydrogen with fuel cells is regarded by experts as the future in the field of mobility. There are already commercial vehicles, public transport fleets and logistics vehicles powered by hydrogen. In this technology, the hydrogen in the fuel cell reacts with the oxygen to form water. The energy released is converted into electricity and drives the motor. No pollutants are produced during this process. For this reason, hydrogen-powered vehicles are also referred to as zero-emission vehicles. For Ainscough Metals company, the clear interim solution is HVO – a fuel that works like diesel, but does not use fossil energy, but purely vegetable energy from food waste, vegetable fats or vegetable waste. For this purpose, the vegetable oil obtained is converted into hydrocarbons in a catalytic reaction with the addition of hydrogen, which can drive an internal combustion engine and reduce CO₂ emissions by around 90 percent.

3. Safety

In the case of crane drives, safety will play a major role in the future. The machines are exposed to high loads and must react correctly and reliably in an emergency. This is only possible if all drive components work together perfectly, i.e. engine, transmission, control, brakes and clutches. To avoid boom collisions, electronic sensors detect potential hazards and warn the crane operator. If the signal is ignored, the crane stops fully automatically. Modern tracking systems track the movements of ground staff and stop the crane immediately if danger threatens. The measurement of wind speed with its warning system and an anemometer on the crane warns early when the maximum wind force is reached for safe operation. Overload warning systems detect overloading of the crane, give acoustic and visual warning signals and automatically prevent the lifting of the load. Controlled emergency braking in the event of hoist failure, special brake control systems and clutches automatically intervene at peak torques and thus largely prevent major damage to machines and material.

4. Automation and digitalization

The developments of motors, brakes or wire rope hoists in crane technology are supplemented by innovative hardware and software in the associated controls as well as modern communication technology with new operating, monitoring and maintenance concepts. Digitalization in crane construction will ever lead to new innovations: They include, for example, modular, intelligent crane controls, advanced sensor technology, remote systems, control and documentation platforms, artificial intelligence and telematics. With the help of the telematics function, the actual driving, idle and working hours of the crane can be analyzed. On this basis, the deployment planning of the machines can be optimized. In addition, the current position data of the crane can be permanently retrieved, which, among other things, simplifies scheduling and minimizes downtimes. In the event of acute technical problems, the repair service can be informed in advance about required spare parts.

5. User-friendliness

The future generation of cranes must become more user-friendly, easy to assemble and easy to maintain. Against the background of demographic development and the shortage of skilled workers, this user request is becoming a necessity. Because where there is a lack of qualified personnel, other concepts are required. While the technology required to create efficient, powerful and flexible machines is becoming more and more complex, competence and qualification on the user and operator side are declining. At least that's what more than half, namely 56%, of the approximately 1,800 members surveyed in the German Engineering Federation (VDMA) fear.

6. Sustainability

For industry, the transition to resource-efficient, low-emission and climate-friendly production is both a challenge and an opportunity. In addition to many new and smaller companies, industrial companies also develop innovative products and processes that serve sustainable development under suitable conditions. The production of a crane produces CO2 emissions. These are mainly caused by the production of steel and other components of the crane, but also by the required energy such as electricity, oil or natural gas, as well as by the necessary transports. By refurbishing used cranes, these CO2 emissions can be prevented or greatly reduced. New, more compact drive machines save energy and use energy generation through brake force compensation.

7. Conclusion

In the presentations of many national and international manufacturers, it becomes clear: The innovative strength in crane construction is greater than ever before. Digitalization in particular opens up new possibilities. There are still many stand-alone solutions that only consider and optimize individual areas of the crane or crane drive. The biggest challenge of the next few years will be to bring these areas together on a common platform so that all data and functions are bundled in one place and interact optimally. The most important trends in mechanical engineering currently include the acceleration of innovation cycles, a growing variety and complexity as well as increasingly tight time budgets for the development of new models: the crane has a future!

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