ISO 21858:2020 Crane Intelligent Safety System Requirements
ISO 21858:2020, "Requirements for Intelligent Safety Systems of Cranes," is the new international standard governing intelligent crane safety. It defines the functional architecture, safety monitoring parameters, three-level alarm mechanisms, and remote management requirements for intelligent safety systems. The standard covers safety functions such as torque limiting, lifting capacity limitation, height limit, and working area monitoring, leveraging Internet of Things (IoT) technology for real-time data acquisition, transmission, analysis, and early warning.
System Architecture and Safety Monitoring
The intelligent safety system is built on a four-layer architecture: perception, network, platform, and application. The perception layer uses six types of sensors—Load Sensors, working radius encoders, height encoders, anemometers, inclinometers, and working area LiDAR—to capture real-time operating parameters and safety status of the crane. The network layer transmits data to the cloud platform in real time via 4G/5G or WiFi with encrypted data transmission. The platform layer handles data storage, analysis, and alarm decision-making, including a Digital Twin model that maps physical equipment status in real time. The application layer provides a PC-based management platform and a mobile app for Remote Monitoring, alarm push notifications, and historical data retrieval. Core system functions include real-time parameter display—Lifting Capacity, working radius, torque percentage, height, wind speed—and electronic fence management for the working area. Kelude's intelligent safety system is configured in accordance with ISO 21858:2020.
Three-Level Alarm and Safety Interlocking
Pre-alarm: When operating parameters reach 85% of rated values, an audible and visual alarm alerts the operator. Limit alarm: At 100% or 105%, the system automatically stops related mechanisms—hoisting and luffing operations cease. Fault alarm: In the event of sensor wire break, communication interruption, or abnormal system self-check, maintenance personnel are notified. The alarm interlocking function pushes alarm information simultaneously to the remote management platform and designated mobile numbers. The system supports electronic fence configuration to restrict crane movement within designated areas, triggering automatic alarms and speed limiting beyond boundaries. Safety PLCs meet SIL2 for general protection and SIL3 for critical safety functions. Data recording operates at a sampling frequency of ≥1 Hz, logging key parameters every second with a storage duration of ≥3 years.
| Hierarchy | Composition | Function |
|---|---|---|
| Perception Layer | 6Category Sensor | Real-timeparameter acquisition |
| Network Layer | 4G/5G/Wi Fi | data encryption Upload |
| platform Perception Layer | cloud server+Model | Storage & Analytics+Decision-making |
| Application Layer | PC+Mobile Device APP | Remote Monitoring+Push Notification |
Maintenance & Data-Driven Insights
Sensor calibration is verified monthly to keep deviation within ±5%, while communication modules undergo quarterly inspections. Data analytics cover overload event logging and trend analysis, enabling predictive maintenance that detects sensor accuracy drift and mechanical performance attenuation early. Kelude's intelligent safety system supports digitalized crane safety management.
| maintenance | Interval | Content |
|---|---|---|
| sensor calibration | Monthly | Deviation≤±5% |
| Communication Inspection | Quarterly | Signal Strength |
| Software Upgrade | On-demand | Security Patch |
| data backup | Monthly | Cloud+On-premise |
FAQ
Q: What is the four-layer architecture of the intelligent safety system?
A: The perception layer (six types of sensors), the network layer (4G/5G/WiFi), the platform layer (cloud server plus Digital Twin model), and the application layer (PC client plus 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 at 100%–105% automatically stops the mechanism; fault alarm sensor wire break or communication loss pushes a notification. Alerts are simultaneously sent to the remote platform and mobile device.
Q: What are the safety PLC requirements?
A: SIL2 for general protection (failure rate ≤1×10⁻⁷/h) and SIL3 for critical safety functions (≤1×10⁻⁸/h). Redundancy architecture is 1oo2 or 2oo3.
Q: What does the Kelude intelligent safety system configuration include?
A: It is configured per ISO 21858:2020 with six types of sensors, three-level alarms, a safety PLC, and cloud-based data storage. It supports Predictive Maintenance and remote safety management.
