North America, June 2013
Challenge: Automotive supplier’s hoist brakes and hoist motors wearing out at a rapid pace
Solution: Training cuts the number of hoist starts by half
In June 2013, an automotive supplier in the US had a recurring issue of having to frequently replace the hoist brakes on their cranes. The company was mystified as to why they were going through hoist motors and brakes so quickly.
After replacing their equipment with a Konecranes CXT crane the company got access to the usage data and remote monitoring where they saw a significant number of hoist motor starts and emergency stops. In the first month that the crane was in operation it had an average of four emergency stops per day, adding up to about 20 per week, or 80 per month. In addition to that, there were 20,000 hoist motor starts per week, mounting up to around 80,000 each month.
“Every emergency stop burdens the brake 50 times more than a normal braking situation. Every hoist motor start, on the other hand, directly affects the hoist brake itself, the contactors, the control equipment and the hoist motor,” says Jim Skowron, Regional Vice President of Sales for Konecranes’ Service division in the Americas.
Hoist motors for a normal service duty class are designed to perform 25,000 to 30,000 starts a month over a 10 year life. In order to extend the life to 30 years, the design limit for the same duty class is 10,000 starts per month.
“This customer was on pace to replace the hoist motor every two to three years based on the current operating habits. It was discovered that the operators were pressing the up and down controls repeatedly to set their product instead of using the speed controls provided in the hoist.”
- With TRUCONNECT, you can follow equipment usage in real time and can track down particular alerts or incidents. Plus, the TRUCONNECT portal provides information on causes that the management should be aware of. It also recommends actions that can be taken, such as training or identifying power supply quality issues.
- Data is secure. Konecranes uses data security systems in remote monitoring that are similar to those used in online banking.