Crane Components Solutions customization galore

Crane manufacturers are offering a wealth of solutions for facilitating higher levels of efficiency and reliability so that the end-users enjoy more productivity and better profit margins

Cranes are undergoing large-scale engineering transformations that involve customization as per the application requirements, and upgradation of the components. Cranes are now required to have superior lifting capabilities, along with high stability to ensure reliable performance, and there is increasing demand for control systems, and greater safety features.

Affirms Mr. Rajesh Bhandari, MD, Gates India, “There is demand for hoses that optimally support faster duty cycles along with reliability. We are offering customized solutions based on an evaluation of the pressure cycle and oil flow rates by our application engineers. We technically support the OEMs and the end-customers by providing design support through right routing of the hoses and couplings.”

He adds, “Our hoses and couplers are manufactured as per Gates tested ‘Stamped’ product development strategy, which takes into account the required size of the hoses, ambient temperatures, applications, materials to be moved, ends, and delivery. Specifications of the hoses and couplings are based on critical simulation tests of actual site conditions, conducted at our Lalru Punjab and Faridabad manufacturing facilities. They include impulse tests, ozone tests, volumetric tests, and for oil spillage, based on which, the polyurethane or additional tough cover is given to the hoses.”

He informs that the company is promoting its ‘Pro-Series’ value line of hoses for the price-conscious Indian buyer. These hoses can accommodate pressure at 5000 psi and can be easily replaced.

Gates India has contracts with leading mobile and tower crane manufacturing companies for supplying hoses for the mobile cranes. We are exploring opportunities for high pressure tubing as well with these OEMs.

Intelligence building & machinery optimization

"Component manufacturers are developing solutions to enhance performance and reliability of the cranes. Says Mr. Wahan, Murphy by Enovation Controls, GM-Sales & Marketing India, “We offer total integrated solutions such as control systems for the hydraulics, engines and transmission; monitoring systems for hydraulic oil pressure, engine temperature and speed levels; safety systems to monitor the operation of the load moment indicators; and systems efficiency solution (a combination of the control, monitoring and safety systems) to enable the crane operator to do predictive analysis by monitoring oil pressure, filter clogging etc., and derive optimum efficiency and safe working of the cranes.”

He adds, “Our systems help deliver cost effectiveness and product reliability by controlling redundancies in operation. Our safety systems are based on our software, which we customize and co-engineer with our major customer OEMs. The company also renders comprehensive training support to OEM engineers through its training programs."
Co-engineering for product development is also undertaken by Bonfiglioli for its gear boxes and drives for all forms of lifting equipment including reach stackers, crawler cranes, truck mounted cranes, rough terrain cranes and tower cranes. Says Mr. Kennady. V. Kaippally, Country Manager, Mobile and Wind Solutions, Bonfiglioli India, “Based on the critical performance criteria of crane manufacturers to ensure speed, gradients, lift capacities, compliance with duty cycles and braking requirements etc., our R&D team in Chennai develops the gear boxes and drives to meet these requirements. This team is part of the global platform, which collates knowledge from our R&D centres in Italy, Germany, and China. In case of customer specific requirements, we validate our designs by carrying out accelerated life tests in the laboratory and under real jobsite conditions.”

The gear boxes are manufactured at the company’s two facilities in Chennai (Mannur and Thirumudivakkam) and one in Pune. To further strengthen its R&D and manufacturing capabilities, it is expanding its Thirumudivakkam facility.

Bonfiglioli supplies swing, travel and winch drives for most of the OEM’s making lifting equipment in India, including, Potain, Liebherr, ACE, TIL, ECEL, Anupam Industries etc. It also provides refurbishment and retrofitting of its gear boxes and drives. Bonfiglioli India, a fully-owned subsidiary of Bonfiglioli Italy, is also exporting a fair volume of its products.

Legislation is necessary

It is important that the Indian government lays down certain rules and regulations for the safety of the cranes during operation, taking into account factors like load limiters, outriggers spread, and monitoring, as prevalent in the advanced countries. Crane manufacturers should disseminate information on a regular basis on factors like load calculation as per lifting requirement, and have their products certified.

A joint effort by OEMs and crane owners on the critical aspects of safety and efficient performance of their products will make development of the right components by manufacturers more effective.

Lifting & Specialized Transport — October - December 2017