Overhead Crane HMI System Guide: Interface, Protocols & Safety
Kelude KR-HMI overhead crane HMI system — three core technology pillars: Interface Design (three-zone layout at 60%/35%/5% + four-level fault color coding + 48px minimum touch target + three-tier access control), Communication Protocols (Profinet/EtherCAT/Modbus TCP with dual-port isolation between control and information networks), and Human-Machine Interaction (touch response ≤10ms + ≥4.5:1 color contrast ratio + IP65 rated, -20~60°C wide-temperature operation).KR-HMI is deployed on 200+ overhead cranes and integrates seamlessly with remote control cabins, big data platforms, and MES systems.
The crane HMI (Human-Machine Interface) serves as the primary interaction window between the operator and the crane, bridging the PLC control layer and the MES information layer. A well-designed HMI system must not only follow ergonomic interface principles but also support communication protocols compatible with different PLC brands and incorporate safety mechanisms that ensure reliable operation. This pillar page covers the three key areas of overhead crane HMI design — interface layout, communication protocols, and human-machine interaction — and introduces how KR-HMI integrates with remote control cabins and big data platforms.
1. HMI Screen Layout: Three-Zone Design with Four-Level Fault Alerts
The KR-HMI interface uses a proven three-zone layout: operating area at 60% (crane diagram + control buttons), status area at 35% (real-time parameters + alarm list), and a system status bar at 5%. Four-level fault color coding — green for normal, yellow for warning, red for alarm, and dark red for emergency stop — enables operators to assess equipment status at a glance. Touch buttons are a minimum of 48×48px to ensure reliable operation even with gloves, and critical actions (hoisting/lowering) require a 500ms long-press plus a confirmation dialog to prevent accidental activation.View the complete HMI design guide
2. Industrial Ethernet Protocols for Every PLC Brand
KR-HMI fully supports Profinet (preferred for Siemens PLCs, 1ms refresh rate), EtherCAT (preferred for Inovance and Beckhoff PLCs, ≤100μs cycle time), and Modbus TCP (ideal for retrofit projects, 20ms standard refresh rate). The HMI comes standard with dual network ports — the control port connects to the PLC for real-time operation, while the information port links to big data platforms and MES for non-real-time data collection. Physical network isolation ensures robust security.View the full protocol comparison
3. Ergonomic HMI Design: Three Rules for Safe and Efficient Operation
KR-HMI ergonomic design follows three non-negotiable rules: touch responsiveness (48px minimum target size, 200ms feedback, 500ms long-press anti-accident protection), visual hierarchy (four-level color semantics, standardized font sizing, ≥4.5:1 contrast ratio), and operational safety (three-tier access control, full audit logging, 5-minute auto screen lock, physical emergency stop override). The HMI is designed to never interfere with crane operation — the guiding principle is that the HMI serves as a monitoring window and does not participate in the safety interlock circuit.View the complete ergonomic design rules
4. Cloud Integration: Connecting HMI with Remote Cabins and Big Data Platforms
KR-HMI connects to the Kelude Heavy Industry big data platform via the information network port (Modbus TCP/OPC UA), streaming real-time crane operating data (load, temperature, current, energy consumption, alarms) to an InfluxDB time-series database. Data from the big data platform can also be pushed back to the HMI via MQTT — for example, when a predictive maintenance model detects abnormal bearing conditions, an alert is generated on the big data platform while a maintenance recommendation pops up on the corresponding crane's HMI. When integrated with a remote control cabin, HMI alarms are synchronized to the remote operator station; once the remote operator acknowledges an alarm, the HMI status updates accordingly. KR-HMI also supports data synchronization with the remote cabin's touch screen — remote operators can view local crane parameters through the HMI, while on-site operators can monitor remote control status from the same interface.Crane Big Data Analytics Platform · Remote Control Platform for Overhead Cranete Control Platform for Overhead Crane
200+Unit KR-HMIInstalled Base Steel/Chemical/Building Materials/Machineryery | 3 Type Communication Protocol Support Profinet/Ether CAT/Modbus | 50,000h MTBF (Mean Time Between Failures)MTBF) Design Life ≥8 Years |
IP65 Protection Rating -20~60°C · Dustproof Waterproof | 3Level Access Rights Grade Operator/Maintenance/Administrator | 7Days Free Trial Prototype / Demo Unit Installation to On-Site Commissioning |
5. Implementation Guide & Selection Tips
Selecting the right KR-HMI system is a straightforward four-step process. Start by identifying the PLC brand used on your overhead crane (Siemens, Inovance, Mitsubishi, or other). Next, choose the communication protocol that matches your setup (Profinet, EtherCAT, or Modbus TCP). Then, pick the screen size that fits your application: the 15-inch standard display, the 10-inch compact option, or the 7-inch economy model. Finally, confirm the environmental requirements—whether the unit will operate indoors, outdoors, in explosion-proof areas, or within a cleanroom. Kelude offers both standard and custom configurations. Standard units ship with a 7-working-day Delivery Time, while custom builds—which include interface layout modifications, LOGO customization, and special communication protocols—require 15 working days. Pricing for the complete HMI system (including the KR-HMI main unit, mounting bracket, power supply adapter, and communication cables) is as follows: approximately $740–$1,190 for the 15-inch standard model, $520–$820 for the 10-inch compact version, and $300–$520 for the 7-inch economy option. Volume orders of 10 or more units qualify for a 20% discount.
KR-HMI Industry Applications: Real-World Case Studies
| Industry | Customer Count | Number of Units | PLCBrand | Communication Protocol | Screen Size | Special Requirements |
|---|---|---|---|---|---|---|
| Steel & Metallurgy | 8 | 72 | Siemens S7-1500 | Profinet | 15Screen Size | High Temperature & High Dust |
| Chemical | 5 | 38 | Inovance AC800 | Ether CAT | 15Screen Size | Explosion-proof Ex db ⅡB T6 |
| Building Materials | 6 | 45 | Mitsubishi FX5U | Modbus TCP | 10Screen Size | Installed Base Retrofit |
| Machinery Manufacturing | 7 | 52 | Siemens S7-1200 | Profinet | 15Screen Size+10Screen Size | MESBarcode Scanning Integration |
Selection Decision Workflow: Step 1 — confirm the overhead crane working environment (standard ambient / high-temperature dust-laden steel mill / explosion-proof chemical / cleanroom electronics). Step 2 — confirm the PLC brand and communication protocol (Siemens Profinet, Inovance/Beckhoff EtherCAT, other/legacy Modbus TCP). Step 3 — confirm the screen size (15-inch for spacious operator stations, 10-inch for compact control cabinets, 7-inch for monitoring-only applications). Step 4 — determine whether integration with a remote control cabin or big-data platform is required (optional dual-Ethernet model). Kelude Heavy Industry offers the KR-HMI model selection chart covering the full specifications and pricing for 12 standard models. Customers can also submit selection requests online via the Kelude Heavy Industry WeChat official account, and the technical team will respond with a recommendation within 2 hours.
Three KR-HMI Standard Models for Quick Selection: KR-HMI-15S (15-inch standard model, ¥5,800, IP65 wide-temperature rating, supports Profinet/EtherCAT/Modbus TCP, dual Ethernet ports, suitable for ~90% of overhead crane applications — recommended first choice); KR-HMI-10S (10-inch compact model, ¥4,200, IP65 wide-temperature rating, Modbus TCP, ideal for space-constrained control cabinets); KR-HMI-15E (15-inch explosion-proof model, ¥18,500, Ex db ⅡB T6 Gb certified, Profinet + Modbus TCP, designed for chemical explosion-hazard zones). All three models are powered by the Rockchip RK3588 octa-core processor (4×Cortex-A76 + 4×Cortex-A55), 4GB RAM, 32GB storage, and run a Linux RT real-time kernel with the Qt 6.5 graphics framework. Every model comes standard with one gigabit control Ethernet port plus one 100Mbps information Ethernet port, with optional 4G/WiFi wireless expansion. The full product line carries a 2-year warranty and includes 7×24 remote technical support. For bulk orders (10 units or more), unit pricing is discounted by 20%, and a custom HMI interface package is included (customer logo + brand color scheme + custom boot screen).
KR-HMI vs. Third-Party HMIs: Key Advantages
Compared with general-purpose HMIs on the market (such as Siemens WinCC, Weinview, Kunlun Tongtai, etc.), the KR-HMI delivers the following differentiators in overhead crane applications: ① Crane-specific interface templates — preloaded hoisting/long-travel/trolley three-axis operation screens, a four-level fault color coding system, and crane schematic widgets that are ready to use out of the box (general-purpose HMIs require 3–7 days to design a crane-specific interface); ② Built-in crane communication protocol stack — direct support for Profinet/EtherCAT/Modbus TCP configurations for common crane PLCs, eliminating the need to learn protocol-specific configuration parameters (general-purpose HMIs require engineers to be familiar with each protocol's detailed configuration); ③ Native remote control cabin integration — the KR-HMI communicates with the Kelude remote control cabin platform via a proprietary MQTT protocol without any intermediate gateway, achieving end-to-end alarm and control signaling latency of <20ms (general-purpose HMIs require an additional OPC UA gateway, pushing latency above >100ms); ④ Explosion-proof certification — the KR-HMI explosion-proof model is Ex db ⅡB T6 Gb certified for Zone 1/Zone 2 chemical hazardous areas (explosion-proof versions of general-purpose HMIs require custom engineering with unpredictable cost and lead time). The KR-HMI is best suited for standardized deployment by overhead crane manufacturers producing in volume, while general-purpose HMIs are more appropriate for single-crane projects with highly customized interface requirements. The Kelude Heavy Industry KR-HMI system fully covers all aspects of this topic — for HMI interface design details, refer to Three HMI Interface Design Optimization Tips; for hands-on communication protocol configuration, see Communication Protocol Comparison: Choosing Among Three; for human-machine interaction guidelines, refer to Three Ergonomic Rules for HMI Design.
KR-HMI Frequently Asked Questions
Q: Is the KR-HMI developed in-house or rebranded from a third-party product?
A: The KR-HMI is a complete solution from Kelude Heavy Industry built on a domestically manufactured industrial touch panel PC (based on the Rockchip RK3588 or Allwinner T507 main control chip) combined with our self-developed HMI software system. The hardware is produced by a leading domestic industrial touch screen manufacturer (2-year warranty), while the HMI software — including interface logic, communication protocol stack, and safety mechanisms — is 100% developed in-house by the Kelude embedded engineering team (built on Linux RT + Qt framework). The advantage of in-house development is deep customization of crane-specific features (such as hoisting long-press anti-misoperation logic, four-quadrant energy consumption display, and protocol integration with the remote control cabin) that third-party general-purpose HMIs cannot offer.
Q: Can one HMI control multiple overhead cranes?
A: Yes. The KR-HMI can monitor up to 4 overhead cranes simultaneously from a single unit, switching between cranes via tab navigation. However, only one crane can be actively controlled at a time (control authority is exclusive — when switching, the currently controlled crane automatically pauses). Multi-crane monitoring mode is well suited for floor supervisors or maintenance personnel, but not for crane operators — for operator use, a 1:1 configuration (one HMI per crane) is recommended. Multi-crane monitoring requires higher processing power and a larger screen — a 15-inch or larger configuration is recommended.
Q: Is the KR-HMI suitable for explosion-proof environments?
A: Yes. The KR-HMI explosion-proof model is Ex db ⅡB T6 Gb certified for Zone 1/Zone 2 hazardous areas, including chemical plants, gas stations, and paint workshops. The explosion-proof HMI features a flameproof enclosure (cast aluminum) with an intrinsically safe touch circuit (explosion-proof touch glass thickness ≥6mm). It is approximately twice the thickness and weight of the standard model (about 5kg for the 15-inch version). The explosion-proof model is priced at approximately ¥15,000–25,000 (2–3 times the standard model) with an extended delivery time of 20 working days. For non-hazardous environments, the standard model is recommended — lighter, faster response, and lower cost.
Q: How are KR-HMI software updates handled?
A: The KR-HMI supports both over-the-air (OTA) updates (firmware pushed remotely via 4G/WiFi) and local USB updates. Firmware update packages range from approximately 50–200MB (including drivers, interface, and communication protocol stack). The upgrade process is fully automatic (verification, flashing, and reboot) and takes 3–5 minutes. During the upgrade, the HMI is temporarily unavailable, but crane operation continues normally without interruption. Kelude Heavy Industry releases firmware updates quarterly (new features + security patches), and all sold HMIs receive lifetime free upgrades. Critical security updates (such as emergency vulnerability patches) are pushed within 48 hours of discovery.
From interface design and communication protocols to ergonomics, the KR-HMI system delivers a complete human-machine interaction solution for overhead cranes. Kelude Heavy Industry has deployed 200+ KR-HMI units on overhead cranes, with compatibility across Profinet, EtherCAT, and Modbus TCP protocols, and seamless integration with remote control cabins, big-data platforms, and MES systems. To request the KR-HMI Technical Specification or apply for a free 7-day prototype trial, contact the Kelude Heavy Industry technical team.
