Introduction to wireless remote controls and pendant cable control
Wired pendant controls
This cable connects directly to the control box. All signals are sent through the wires, reducing the chance of signal interference. It's cost-effective; however, the cable length is limited.
Components: Housing of the pendant station, Emergency Stop (mushroom-head button), Directional buttons (Up/Down), Bridge/Long travel Forward/Backward/Trolley/Cross Travel Left/Right, Start button. Cable sheath. Suspension ring.
Control functions: Hoisting and bridge travel. Dual-speed versions feature high- and low-speed settings.
The advantages of this product include: strong resistance to interference from electromagnetic sources, no battery issues, low cost, and easy maintenance.
Cables age quickly on outdoor cranes due to wind exposure and sunlight.
Wireless Remote Control
It consists of two components: a transmitter, which is a hand-held unit, and a receiving unit (which is mounted on the electrical cabinet of the crane). It uses radio frequency signal transmission to allow the operator to move freely and avoid dangerous areas.
Components for the transmitter include: housing with red emergency stop buttons, power key, start button, directional buttons, status light, battery compartment, and antenna.
Receiver components: receiver board, relay module, antenna, and power fuse. The unit should be mounted on top of the crane electrical cabinet.
Compare the wireless remote control to pendant cable controls
|
Item |
Pendant cable control |
Wireless remote control |
|
Connection Method |
Cables are used to connect the crane control panel. |
Signal transmission by radio waves (e.g., 433 MHz, 315MHz, 2.4GHz ) |
|
Operational freedom |
The operator has to walk next to the crane,e and this limits their mobility. |
The operator can freely move within the effective range, which is typically a 100-meter circle. They can also choose a safe view angle. |
|
Safety Risks |
Safety of the operator when operating in hazardous conditions (e. g., where suspended loads pass overhead). |
Safety is enhanced when operators stay away from the danger zone. |
|
Applicable Scenarios |
Small or simple cranes such as bridge cranes and gantry cranes |
Various types of cranes, especially for harsh, complex, and large-scale operating conditions |
|
Typical Configuration |
A handheld controller attached to a box of controls, which usually has a limited set of buttons |
Composed of a transmitter unit (handheld) and receiver (mounted to the equipment). |
Standard operating procedure (Applicable to Bridge Cranes and Gantry Cranes).
Follow these guidelines to ensure safety: Conduct pre-operation checks. To ensure safety, inspect the remote control or handheld unit. Confirm that all buttons work smoothly and that signal transmission is stable. Wireless controllers should have sufficient battery power. Check that the equipment is in good working order: make sure the controller handles are all in the neutral position before turning it on.
Wire Pendant Cable Operation Procedures
1. Connect the main electrical supply.
2. If you find any damage, inspect the pendant and its cable.
3. Test the movements in all directions and reset the emergency stopping device.
4. Upon completion, hang the pendant at its designated spot. Do NOT drag the cable.
Wireless Remote Control: Operating Procedures
1. The main power supply should be switched on.
2. Plug the transmitter with a fully charged battery into the key switch.
3. Press the Start key; the indicator should normally flash green.
4. Test each feature to confirm that the limit switch, emergency stop function, and other functions are functioning correctly.
5. During operation: Stop operations immediately if signal quality deteriorates or the battery light flashes red (indicating low power).
6. After operation: Remove the batteries and key, press the emergency Stop button, then remove the remote control from the storage unit.
7. When there is an emergency: press the red button with a mushroom shape to halt any mechanical movements. You may also need to shut down the main power supply of the crane.
Repair Precautions For Crane Controls
1. Remote Control: Do not attempt to repair your main circuit board. Replace the entire transmitter/receiver set for most problems. This will ensure that the safety circuit is reliable.
2. Replacement remote controls require pairing (code matching).
3. Comprehensive testing is required after repairs have been completed. Checks should be made for the movement of all mechanisms, emergency stopping function, limit switch operation, and automatic shutdown on signal loss.
4. Short-circuiting or bypassing safety devices such as key switches or emergency stops is prohibited.
Maintenance tips on crane controls
Daily Inspection
Examine the housing. Check for the emergency stop button. Look at the batteries/cables. Check out the indicator lights.
Weekly Maintenance
If you have a wireless remote control, clean the housing and antenna of dust and oil/grease. Also inspect the battery compartment contact springs.
Check the cable for wear. Also, make sure to check that the suspension ring is attached securely.
Monthly Maintenance
Test the remote control range, inspect the receiver terminals, and look for signs such as arcing or burnt contacts on relay contacts.
The batteries should be replaced periodically, rather than waiting for them to completely drain.
Annual inspection
Check all safety functions on the remote; check the receiver antenna. Test the signal loss shut-down function.
Test the integrity of safety circuits and calibrate the joystick-style remote control to zero.
Criteria to Scrap
If the mainboard is burned out, or if there is severe corrosion in the internal wiring, you should replace it. Replace the pendant/remote controller unit. Do not continue using it.
Finally Words
Dejun has over 30 years of experience in the crane industry and is an expert in providing customized service. We are confident that we can provide you with top-quality equipment and a suitable solution. Please contact us if you have any further questions.