Crane Safety Monitoring System: Technical Standards & Implementation
Why Your Crane Needs a Safety Monitoring and Management System
As special equipment, cranes directly impact personnel safety and asset protection. The Safety Technical Specification for Special Equipment (TSG 51—2024) issued by the State Administration for Market Regulation mandates that all newly manufactured bridge and gantry cranes must be equipped with a Safety Monitoring and Management System (SMS), with existing equipment required to complete retrofits by the end of 2026.
▲ Overall architecture of the crane Safety Monitoring and Management System
Core Technology Modules of a Safety Monitoring System
1. Load Limiting and Overload Protection
The lifting capacity limiter is the most fundamental—and most critical—safety device on any crane. Using tension load cells or pressure sensors mounted at the hoist wire rope termination, the system continuously monitors the suspended load. A pre-alarm is triggered when the load reaches 90% of the rated capacity, and at 105% the system automatically cuts the hoisting circuit and activates an audible and visual alarm.
2. Travel Limit Switches and Anti-Collision System
Travel limit protection covers hoisting height limiters, bridge travel limits, and trolley travel limits, available in three technology configurations: weight-type (pendant), cam-type, and non-contact (photoelectric or inductive proximity switch). For applications where multiple cranes operate on the same runway, the anti-collision system uses laser distance measurement or UWB positioning to monitor clearance between adjacent cranes in real time, with a three-stage deceleration and braking sequence to ensure safe operation.
3. Condition Monitoring and Fault Diagnosis
Key operating parameters—including motor current, brake status, gearbox temperature, and wire rope wear—are monitored online. An integrated fault diagnosis model identifies common failure modes (such as brake slippage, motor overload, and abnormal bearing temperature rise) and provides recommended maintenance actions.
▲ Real-time data display interface of the Safety Monitoring System
4. Black Box Data Recording
Similar to an aircraft flight recorder, the Safety Monitoring System incorporates a high-capacity storage module that continuously logs the most recent six months of operational data, including load curves, operator action sequences, alarm events, and fault codes. In the event of an incident, dedicated software can replay the full five minutes of operational data preceding and following the event.
How to Choose the Right Safety Monitoring System
- Sensor quality: Select imported or top-tier domestic sensors (e.g., HBM, Zemic) to ensure long-term stability
- Display terminal: 10-inch or larger industrial-grade touch screen with sunlight readability and glove-touch support
- Connectivity: 4G/5G remote data upload for centralized fleet monitoring across multiple sites
- Open interfaces: Standard protocols including OPC UA and Modbus TCP for seamless integration with plant MES systems
▲ On-site installation and commissioning of the Safety Monitoring System
Kelude Safety Monitoring Solutions
Kelude Heavy Industry offers a full range of Safety Monitoring Systems compliant with TSG 51—2024, covering two product lines: standard systems for cranes up to 100t rated capacity and custom-engineered solutions for heavy-lift applications. All products are certified by national special equipment inspection authorities, and we provide turnkey installation, commissioning, and operator training services.
