ISO 24036:2020 Crane Monitoring Standard Guide
ISO 24036:2020, the new standard for intelligent monitoring systems on cranes, defines the functional architecture, parameter acquisition, data transmission, alarm interlocking, and remote management requirements that are driving the industry toward digitalized crane operations.
System Architecture and Core Functions
The intelligent monitoring system specified in ISO 24036:2020 follows a four-layer architecture. The sensing layer uses a suite of sensors—load sensors, working radius encoders, height encoders, anemometers, inclinometers, and GPS positioning modules—to capture real-time crane operating parameters. The network layer transmits data to the cloud platform over 4G/5G or WiFi using MQTT or HTTPS communication protocols with encrypted data transfer. The platform layer leverages cloud servers for data storage, processing, and analysis, including a digital twin model that mirrors the physical equipment in real time. The application layer provides PC-based management dashboards and mobile apps for remote monitoring, alarm push notifications, historical data retrieval, and statistical analysis. Core system functions include real-time parameter display (lifting capacity, working radius, torque percentage, height, wind speed), a three-level alarm system (pre-warning, limit alarm, and fault alarm), data recording for a minimum of 3 years, remote lockout, and permission management.
Alarm and Safety Interlocking
The system's three-level alarm mechanism works as follows. Pre-warning: when operating parameters reach 85% of rated values, an audible and visual alarm alerts the operator. Limit alarm: at 100% or 105% of rated values, the buzzer sounds continuously, the red indicator light flashes, and the affected mechanisms—hoisting and working radius movement—automatically stop. Fault alarm: in the event of a sensor wire break, communication failure, or abnormal self-check, maintenance personnel are notified immediately, and alerts are pushed to safety administrators via SMS or app notification. Alarm interlocking ensures that alarm information is simultaneously pushed to the remote management platform and designated phone numbers. The system also supports an electronic fence that restricts crane operation to a designated area, triggering an automatic alarm and speed limit if the crane moves beyond the boundary. Data recording runs at a sampling frequency of at least 1 Hz, capturing torque, lifting capacity, and working radius every second, with a minimum storage duration of 3 years and support for historical playback and export.
| Hierarchy | Composition | Function |
|---|---|---|
| Sensor Layer | Load/Working radius/Height/Wind Speed/Tilt Angle/GPS | Real-timeparameter acquisition |
| Network Layer | 4G/5G/Wi Fi | data upload Encryption |
| platform Sensor Layer | cloud server+Digital Twin | Storage & Analytics+Model Mapping |
| Application Layer | PCTerminal+Mobile Device APP | Remote Monitoring+alarm push notification |
Maintenance & Data-Driven Insights
The intelligent monitoring system requires monthly sensor calibration with a deviation tolerance of ≤±5%. Communication modules are inspected quarterly for signal strength, and SIM card renewals are handled as needed. System software is upgraded on demand, with security patches applied promptly. Data analytics cover overload event statistics and trend analysis, enabling Predictive Maintenance that detects sensor accuracy drift and mechanical performance attenuation early. Kelude's intelligent monitoring system is configured to ISO 24036:2020, supporting digitalized crane operations and maintenance management.
| maintenance item | Interval | Content |
|---|---|---|
| sensor calibration | Monthly | Load/Working radius/Height Deviation≤±5% |
| Communication Check | Quarterly | Signal Strength/SIMCard |
| Software Upgrade | On-demand | Security Patch+Feature Update |
| data backup | Monthly | Cloud+Local Dual Backup |
FAQ
Q: What is the four-layer architecture of the ISO 24036:2020 intelligent monitoring system?
A: The perception layer (six types of sensors collecting parameters), the network layer (4G/5G/WiFi encrypted transmission), the platform layer (cloud server + digital twin model), and the application layer (PC and mobile app for remote management).
Q: How does the three-level alarm mechanism work?
A: Pre-alarm at 85% triggers an audible and visual alarm; limit alarm between 100% and 105% stops the mechanism and continues alarming; fault alarm sensor wire break or communication interruption pushes SMS/APP notifications. Alarm information is simultaneously sent to the remote platform and mobile devices.
Q: What are the data recording requirements for the intelligent monitoring system?
A: Sampling frequency ≥1Hz (torque, lifting capacity, and working radius are recorded every second). Data is stored for at least 3 years with historical playback and export capabilities. Dual backup is maintained in the cloud and locally.
Q: What are the maintenance requirements?
A: Sensors require monthly calibration with deviation ≤±5%, communication systems are checked quarterly, and software security patches are upgraded as needed. Kelude Heavy Industry's intelligent monitoring system is configured according to the standard to support digitalized crane operations and maintenance.
