Cranes are like the backbone of any industry. During the early period, mostly animals and humans used to lift all the heavy loads manually, which put immense physical stress on them. But the invention of cranes has made lifting heavy weights like a cakewalk. The loads which used to take hours or even days for lifting have become a matter of minutes. That is how cranes save time and money and also spares people from potential accidents in lifting heavy loads by themselves.
For all these reasons, almost all medium to heavy industries uses cranes. Unfortunately, there are plenty of reasons for which a crane often malfunctions. With precautions and necessary measurements, you can avoid the inconvenience of Crane failure.
Common causes of a crane failure:
In the industries, there are several types of cranes in use – Gantry Crane, Overhead EOT Crane, JIB Crane, etc. however, some common reasons can make them fail all equally. The causes can range from technical faults to manual faults. No matter what kind of failure it is, it always results in similar consequences, such as –
- Injuries to employees
- Damage to the equipment and floor
- Expensive repair
- Downtime
Any one of these can shut down all kinds of activities in any industry. Each of the components plays a critical role in every crane's functioning. Hence they serve as causes for a breakdown.
- Electrical faults – Most cranes rely on electrical power to operate, so this is one of the most regular reasons for failures. Wires and electrical components in poor condition can wear out and tear, leading to a short circuit. Most of them are often unpredictable. It can be caused by overheated electrical contacts. Faulty contacts become unable to cut off the power, leading to an issue. Sometimes, electrical components can fail and take down mechanical system components.
- Misused equipment – In most of the plants, cranes often work heavy schedules. If the components overwork due to lack of proper monitoring, that leads to bad consequences. The swinging of heavyweight can come down and injure floor workers and damage the crane. These can happen when:
- Handling of the components by lifting the weight at an angle (Side Pulling) rather than lifting vertically.
- Not programming crane routes beforehand to avoid a collision.
- Lifting more than the recommended weight (Overloading). This is one of the most usual scenarios.
- Lifting the weight faster than a recommended speed.
- Worn mechanical parts – The mechanical parts experience the most stress and tension. Overlooking them is certainly not the best idea.
- Brakes are a vital component when it comes to the smooth and precise operation of cranes. Failing of them can be disastrous.
- Gears and bearings function as tension erasers; while taking the load and rotating it. They lose lubrication soon and start taking damage.
- The hoist, hoist chains, and rope take the heaviest damage while directly pulling the load. The hook connects and holds the weight from the hoist. That’s why they are prone to erosive damage.
Furthermore, there are miscellaneous instances of damage and cause an accident.
What to do in case of crane failure?
Crane failure is definitely an unwelcome incident that can impact you in many ways. Although some mistakes are unavoidable, and if it happens then you should look after some things to prevent further damage.
- Sometimes, some operational errors happen due to the crane operator's lack of experience. The operator fails to stop the controller at zero during parking, resulting in a quick load drop even though the operator can mistake it as a brake failure. For this kind of event, incorrect methods of handling controllers are the primary cause of these incidents. To make the crane function optimally, only experienced and qualified personnel should handle the controller.
- Control panels often fail for faulty contactors. Due to that, the reverse brakes fail to close, which pushes the crane to activate regeneration downwards. While all these, the motor is not turned on, so the load drops freely on the ground. That is sometimes regarded as brake failure, too. However, the difference is the crane switches downwards. You should stop at the moment when you notice that the brakes are not closing. You have to set it right before using them.
In the matter of brake failures, performing any type of reverse operation is a good idea. It is vital not to let the crane drop the load. If the operation is closer to the ground, it is advisable to put the brake on the last block of descent and follow the normal commands for a safe operation.
However, it is always a wise choice to put your crane through frequent inspections. An inspection every month or week is ideal for pointing out and mending visible damages and replacing components. By doing so, you can avoid the minor defects turning into major disruptions and eventually crane failure. It increases your equipment's longevity and reduces expenses. Certified professionals inspect the machine by international standards, which is an assurance.
Conclusion
Because of cranes, our lives have become a lot easier. For that, keeping them in good condition is every owner’s priority. For that, preventive measures and regular maintenance is key to make every operation safe.
