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Condition, usage and operating data for efficient maintenance planning
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TRUCONNECT is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity.
TRUCONNECT Remote Monitoring is an essential product for incorporating predictive maintenance elements as part of a maintenance program. Remote Monitoring provides valuable usage and operating data that can be used along with inspection and maintenance information for a comprehensive view of equipment maintenance needs and performance.
Analyzing and identifying anomalies, patterns and trends in TRUCONNECT data helps us make informed, component-specific predictions, and prioritize recommendations and actions.
TRUCONNECT Remote Monitoring
TRUCONNECT Remote Monitoring collects condition, usage and operating data from control systems and sensors on a crane and provides alerts of certain anomalies. Remote Monitoring data is used in maintenance planning and in predicting possible component or equipment failure.
Collected data varies depending on the make and model of your crane, but typically covers condition and expected service life of critical components, running time, lifted loads, motor starts, work cycles and emergency stops. Additional TRUCONNECT options allow certain cranes to be equipped with hoisting brake and/or inverter monitoring.
TRUCONNECT data is accessible on the yourKONECRANES customer portal and includes:
Safety-related occurrences, such as brake service life, over-temperatures, attempted overloads and emergency stops
Pareto analysis of critical alerts and faults
Operating statistics, such as load spectrum, monitoring of hoist jogging, overloads, emergency stops, work cycles and running hours
Estimates of remaining Design Working Period (DWP) of selected components, such as the hoist, hoist brake, contactors and trolley (SMARTON)
TRUCONNECT Remote Monitoring with alerts based on the equipment/application is required in order to effectively implement predictive maintenance. Remote Monitoring data combined with inspection and maintenance data provided by the maintenance program gives a comprehensive view of equipment maintenance needs and performance.
Safety alerts are delivered automatically by email or text message to notify designated contact personnel of selected safety risk events.
Benefits of Remote Monitoring
Supports predictive maintenance
Maintenance actions can be planned based on estimated component condition i.e. estimated remaining life
Provides knowledge of the remaining design working period (DWP) and remaining service life of selected components such as hoist, brakes, structures and contactors
Provides asset usage and operating information that is used to assess crane condition and safety
Notifies you of brake service life, hoist overloads, emergency-stops and over-temperature occurrences through text or email alerts, allowing for prompt response
Availability
TRUCONNECT Remote Monitoring can be delivered with new Konecranes cranes such as CXT hoists, CXT SMART, SMARTON / UNITON cranes, new waste to energy cranes and select engineered cranes, to sites where mobile network coverage is available.
The remote service hardware can be retrofitted on some existing cranes with:
A9 Modem retrofit if the crane is equipped with ControlPro
DemagModem retrofit for Demag hoists and cranes equipped with Safecontrol
TRUCONNECT retrofit for non-Konecranes brand hoists
Controlpro retrofit kit if there is no existing ControlPro and modem
Brake monitoring retrofit if the crane is equipped with electromagnetic disc brake
Continuous rope monitoring retrofit
Data security
Konecranes digital services have been awarded ISO/IEC 27001:2013 certification for information security management. The ISO/IEC 27001 certificate demonstrates a commitment to proactively manage the information security of Konecranes digital services and ensure compliance with legal and customer requirements. The certification applies to the development and delivery of the yourKONECRANES.com customer portal, CheckApp for Daily Inspections and the Slings and Accessories Inspection app and the TRUCONNECT suite of remote service products.
Get connected to your entire fleet
Add TRUCONNECT to an existing crane with a retrofit
TRUCONNECT Remote Monitoring hardware can be retrofitted on existing cranes including Konecranes equipment, non-Konecranes brand hoists and Demag hoists and cranes equipped with SafeControl. These retrofits can help give you a comprehensive fleet view of all your assets.
In addition to a condition monitoring unit and modem, component-specific sensors for the brake and rope can be retrofitted to provide more specific insights on the condition of these critical load-bearing components.
The hoist brake is one of the most critical wearing components in a crane. The brake is looked at during inspections, but with heavily used cranes, the service lifetime of brake wearing parts may end sooner than expected. Additional inspections also require crane shutdown and provide only a snapshot of the current condition of the brake.
TRUCONNECT Brake Monitoring uses a condition monitoring device to collect the status of brake air gap, mechanical and electrical faults from the electromagnetic disc brakes. The service provides visibility into current brake condition, estimates remaining service life and indicates brake faults. Brake Monitoring information is used in predictive maintenance and can also be used for brake maintenance planning.
Brake Monitoring is delivered with new PLC controlled Konecranes SMARTON and UNITON (hoist brake) and RTG cranes (traveling/traversing machinery brakes). Retrofits are also available for most Konecranes hoist models.
Benefits of Brake Monitoring
Provides visibility to brake condition between normal inspection visits
Helps minimize the risk of load drop with the detection of brake faults
Helps you avoid unnecessary brake disassembly for inspection
Enables predictive brake maintenance
Assists in further optimization of maintenance activities to reduce unplanned downtime and to improve equipment safety, productivity and lifecycle value
Availability
TRUCONNECT Brake Monitoring is delivered with new Konecranes SMARTON and UNITON cranes.
It can be delivered as a retrofit kit to Konecranes CXT and S-series hoists, SMARTON and UNITON cranes, and selected engineered cranes with electromagnetic disc brakes, to sites where 3G or 4G mobile network coverage is available.
Brake Monitoring can also be retrofitted on existing cranes if the crane is equipped with electromagnetic disc brakes and the brake control current is under 2 amperes.
TRUCONNECT Wire Rope Monitoring
The wire rope is one of the fastest wearing load-bearing component on a crane. During a typical inspection of a wire rope, only the outer wires and strands can be visually inspected. Magnetic NDT measurements can be performed to analyze the condition of the internal wires, but this requires crane shutdown and a specialist to perform the inspection.
TRUCONNECT Wire Rope Monitoring provides a continuous view of rope condition through the use of sensors installed on the wire rope. It reveals both visible exterior defects as well as internal defects that are not detectable with a visual inspection.
An indication of defects on different parts of the rope helps you identify which parts of the wire rope have started to wear out and may need further attention.
Wire rope replacement limits are based on the ISO4309:2017 Standard (Annex C) and extensive test data and other statistical data from Konecranes.
Trend displays give you an aggregated view of rope condition over time. This information helps estimate the remaining wire rope lifetime and can aid in maintenance planning.
Know the condition of your wire ropes in an instant and at any time
Helps you discover defects that are not visible in periodic inspections
Assists in reducing the risk of load drop and other safety risks related to wire ropes
No shutdown needed to inspect rope condition
Offers potential to optimize rope change intervals – plan ahead to have the wire rope replaced during a planned shutdown
Less expensive than regular NDT tests
Rope safety can be monitored remotely without interrupting crane operations
Availability
TRUCONNECT Wire Rope Monitoring can be preinstalled with a new Konecranes engineered cranes.
Wire Rope Monitoring is available as a retrofit for SMARTON cranes.
Location needs 3G or 4G mobile network coverage.
TRUCONNECT Remote Support
TRUCONNECT Remote Support provides 24/7 access to a global network of crane experts and specialists, offering problem solving and troubleshooting to help reduce unplanned downtime. In controlled circumstances, two-way communication with the machines and their operators can be established in order to expedite corrective action. Remote Support is ideally suited for extremely remote locations.
Benefits of Remote Support
Short lead time to begin troubleshooting helps minimize downtime
Troubleshooting for problems that require high-level technical expertise
Quick response support for even extremely remote locations
Support 24/7 from one easy point of contact, available by phone
Helps identify the need for corrective on-site maintenance actions and spare parts which may eliminate unnecessary site visit
Availability
Select Programmable Logic Controlled (PLC) engineered industrial or standard cranes if the crane is equipped with Smart electrics, CMS (Engineered cranes), or MUI (Waste-to-Energy) in select regions.
Konecranes provides service, equipment and parts in a wide variety of industries around the world.
Don't see your country listed here? Find a location near you or contact us for availability.
TRUCONNECT Remote Monitoring collects condition, usage and operating data from control systems and sensors on a crane and provides alerts of certain anomalies. Remote Monitoring data is used in maintenance planning and in predicting possible component or equipment failure.
The hoist brake is one of the most critical wearing components in a crane. The brake is looked at during inspections, but with heavily used cranes, the service lifetime of brake wearing parts may end sooner than expected. Additional inspections also require crane shutdown and provide only a snapshot of the current condition of the brake.
The wire rope is one of the fastest wearing load-bearing component on a crane. During a typical inspection of a wire rope, only the outer wires and strands can be visually inspected. Magnetic NDT measurements can be performed to analyze the condition of the internal wires, but this requires crane shutdown and a specialist to perform the inspection.