Operational Data of Lifting Equipment as the Basis for the In-Service Performance Maintenance Method
Abstract
A method for maintaining the working condition of a crane is proposed, which involves a transition from a calendar to a rolling planning of maintenance and repairs based on an analysis of the intensity of operation. The implementation of the method is based on the processing of up-to-date, objective, reliable and complete information about the actual use of the crane and its mechanisms. It is proposed to use new-generation security devices as sources of information, the objectivity of which is achieved by jointly processing data from alternative sources, reliability is ensured by improving processing algorithms adapted to the specifics of the measured processes. To protect against destruction according to the strength criterion, it is proposed to use algorithms for predicting force factors that take into account the characteristics of the crane, operating conditions and possible control commands. To assess the technical condition of the crane and its mechanisms, it is proposed to use the criterion of drive energy. Examples of practice-oriented techniques and promising safety devices implementing the presented principles are described.
About the Authors
S. D. Ivanov
Bauman Moscow State Technical University
Russian Federation
Russian Federation
Sergey D. Ivanov, Associate Professor of the Department of Lifting and Transport Systems, Candidate of Technical Sciences
105005, Moscow, 2nd Bauman str., 5
A. N. Nazarov
Bauman Moscow State Technical University
Russian Federation
Russian Federation
Alexander N. Nazarov, Associate Professor of the Department of Lifting and Transport Systems, Candidate of Technical Sciences
105005, Moscow, 2nd Bauman str., 5
References
1. Zhukov, D., Valiev, D., Burganov, F., Medvedev, S. On the Criteria for Assessing Compliance with Industrial Safety Requirements for Overhead Electric Cranes. Reglament. 2015, no. 5(43), pp. 78-79. EDN VZXZDR.
2. Larochkina, N.M. The Current State of Industrial Safety of Cranes: Problems and Effective Solutions. Modern Equipment and Technologies. 2016, no. 3(55), pp. 123-125. EDN WANAUJ.
3. Korotkiy, A.A., Egelskaya, E.V., Sherstyuk, A.P. Justification of the Safety of Cranes. Bulletin of the Don State Technical University. 2017, vol. 17, no. 4(91), pp. 136-143. DOI 10.23947/1992-5980-2017-17-4-136-143. EDN YNOFPH.
4. Kaminsky, L.S., Kaminsky, F.L., Pyatnitsky, I.A., Fedorov, I.G. Improving the Efficiency of Using Safety Devices for Cranes. Scientific Perspective. 2016, no. 1, pp. 140-144. EDN VKJRHF.
5. Kozlov, V.S. On the Improvement of Crane Safety Devices. Lifting and Transport Engineering. 2011, no. 4(64), pp. 15-17. EDN ONPTDZ.
6. Karmanov, S., Boyanov, K., Gnibeda, I. Safety Devices and Sensors for Monitoring Overhead Cranes. Technical Supervision. 2015, no. 11(108), p. 164. EDN XHBASF.
7. Simonov, N.V., Syroezhkin, V.Yu., Razinkov, V.K. et al. The Role of Crane Data Recorders in Industrial Safety Expertise. Industrial Safety Expertise and Diagnostics of Hazardous Production Facilities. 2015, no. 5, pp. 88-89. EDN VZALGV.
8. Zaretsky, A.A., Kaminsky, L.S., Fedorov, I.G. Data Recorders for Cranes. Occupational Safety in Industry. 2001, no. 4, pp. 60-62. EDN JVVTZT.
9. Ageicheva, M.M. Accounting for Real Crane Operating Conditions in Residual Life Calculation Based on Data Recorder Information. In: Scientific Community of Students of the XXI Century. Technical Sciences: electronic collection of articles based on the materials of the CXXXI International Student Scientific and Practical Conference, Novosibirsk, November 09, 2023. Novosibirsk: Siberian Academic Book LLC, 2023, pp. 85-92. EDN ECQRWT.
10. Lyashenko, N.V., Lepikhova, V.A., Shestak, S.G. Analysis of the Causes of Emergency Situations in Metal Structure Failures. In: Ecology. Risk. Safety: Materials of the All-Russian Scientific and Practical Conference, Kurgan, October 29–30, 2020. Kurgan: Kurgan State University, 2020, pp. 254-255. EDN ORPAJW.
11. Kuzminov, A.L., Golubev, A.V., Zelenkov, N.N., Glazunov, A.E. Assessment of the Residual Life of a Portal Crane During Industrial Safety Expertise. European Science. 2015, no. 8(9), pp. 17-21. EDN UPTSWP.
12. Ermolenko, V.A., Vitchuk, P.V. Features of Calculating Reliability Indicators for Cranes. Nadezhnost. 2016, vol. 16, no. 2(57), pp. 20-25. EDN WHGDRJ.
13. Ganshkevich, A.Yu., Rozov, V.V., Chernyak, O.A. Approaches to Forecasting the Technical Condition of Lifting Equipment Based on Monitoring. Science and Business: Development Paths. 2025, no. 3(165), pp. 106-111. EDN SJWSKU.
14. Ivanov S.D., Ivanova N.Yu. Technical and Economic Indicators of the Efficiency of Lifting and Transport Operations. Mechanization of Construction. 2016, no. 6, pp. 15-21.
15. Ivanov, S.D., Ivanova, N.Yu. Formation of an Information Base for Refining the Calculation of Residual Life and Improving the Maintenance Planning Methodology for Lifting and Transport Equipment Using Safety Devices - Data Recorders (Case Study of Cranes). In: Digital Economy: Technologies, Management, Human Capital: Materials of the All-Russian Scientific and Practical Conference, Moscow, May 28, 2019. Moscow: Moscow State Technological University "STANKIN", 2019, pp. 236-241. EDN OAZGZT.
16. Ivanova, N.Yu., Ivanov, S.D., Nadezhenkov, S.A., Nazarov, A.N. Objective Information on the Operation of Lifting and Transport Machines as a Basis for Improving the Quality of Information Systems at Cargo Handling Enterprises. Machines and Installations: Design, Development and Operation. 2023, no. 2, pp. 81-96. EDN MRGIFW.
17. Nazarov, A.N. Research and Development of the Department "Lifting and Transport Systems" for Creating Modern Safety Devices for Lifting Equipment. Machines and Installations: Design, Development and Operation. 2024, no. 4, pp. 34-40. EDN JIIQKE.
18. Timin, Yu.F., Sushinsky, V.A. Experience in Using Data Recorders in Overhead Cranes. Lifting and Transport Engineering. 2009, no. 3(53), pp. 12-14. EDN NDIICZ.
19. Orlov, Yu.A., Orlov, D.Yu., Stolyarov, D.P., Kahiev, R.N. Data Recorder for Overhead Cranes. Mechanization of Construction. 2015, no. 8(854), pp. 30-31. EDN UDOSVD.
20. Ageicheva, M.M., Ivanov, S.D. Assessment of Container Crane Utilization Intensity Based on Remote Monitoring System Data Processing. In: The Seventy-Sixth All-Russian Scientific and Technical Conference of Students, Masters, and Postgraduates with International Participation, Yaroslavl, April 19–20, 2022. Part 76. Yaroslavl: Yaroslavl State Technical University, 2023, pp. 417-420. EDN VEJJLX.
21. Vasiliev, V.V. Innovative Technologies in the Work of the Labor Protection and Industrial Safety Service. Quality Management. 2025, no. 10(260), pp. 74-78. DOI 10.33920/pro-01-2510-11. EDN MVLKSZ.
22. Konovalov, D. Remote Registration and Assessment of Crane Utilization. A System for Monitoring and Managing Port Lifting Equipment. River Transport (XXI Century). 2007, no. 4(28), pp. 64-65. EDN IBIKVV.
23. Orlov, Yu.A., Dementiev, Yu.N., Odnokopylov, G.I. et al. A Bridge Crane Protection System Based on Monitoring the Parameters of the Hoisting Mechanism Electric Drive. Bulletin of the Tomsk Polytechnic University. 2008, vol. 312, no. 4, pp. 119-124. EDN JRGNRR.
24. Nazarov, A.N. The Driving Force of the Hoisting Mechanism Motor of Overhead Cranes in Real Operating Conditions. Bulletin of the Siberian State Automobile and Highway University. 2023, vol. 20, no. 1(89), pp. 34-50. DOI 10.26518/2071-7296-2023-20-1-34-50. EDN DJBHGB.
25. Ivanov, S.D., Nazarov, A.N. Assessment of the Applicability of Electric Drive Parameters for Determining the Load on the Hoisting Mechanism of Overhead Cranes. Bulletin of the Siberian State Automobile and Highway University. 2022, vol. 19, no. 1(83), pp. 36-47. DOI 10.26518/2071-7296-2022-19-1-36-47. EDN XZSFJQ.
26. Lutkin, A.R. Reliability of Determining Crane Operational Parameters. In: Lifting and Transport, Construction, Road, Railway, Land Reclamation Machines and Robotic Systems: Proceedings of the XXIII Moscow International Interuniversity Scientific and Technical Conference, Moscow, April 04, 2019. Moscow: National Research Moscow State University of Civil Engineering, 2019, pp. 520-525. EDN UQZEMN.
27. Ageicheva, M.M. Assessment of the Residual Life of a Gantry Crane Based on High- Quality Preparation of Initial Data on Its Actual Operating Conditions. In: Lifting and Transport, Construction, Road, Railway, Land Reclamation Machines and Robotic Systems (Young Engineer): Materials of the XXVIII Moscow International Interuniversity Scientific and Technical Conference, Moscow, April 24–26, 2024. Moscow: Publishing House of the Bauman Moscow State Technical University, 2024, pp. 11-14. EDN FDJFOU.
28. Fedotov, A.V., Medvedeva, Yu.N. Comparison of Foreign and Domestic Approaches to the Design of Overhead Crane Trolleys. Machines and Installations: Design, Development and Operation. 2024, no. 4, pp. 41-55. EDN FPVXAO.
29. Fedotov, A.V. Research on the Possibility of Import Substitution of Trolleys of a Promising Design for Overhead Cranes. In: Lifting and Transport, Construction, Road, Railway, Land Reclamation Machines and Robotic Systems: Proceedings of the 29th Moscow International Interuniversity Scientific and Technical Conference, Moscow, April 23, 2025. Moscow: "Strategy of Unification", 2025, pp. 42-44. EDN ZSLEMW.
30. Yilmaz, M.Yu., Ivanov, S.D. Analysis of Transient Processes in Asynchronous Motors of Crane Drives for Diagnosing Mechanical Faults. Bulletin of the Siberian State Automobile and Highway University. 2025, vol. 22, no. 4(104), pp. 512-523. DOI 10.26518/2071-7296-2025-22-4-512-523. EDN NDLRWQ.
31. Yilmaz, M.Yu., Ivanov, S.D. Experimental Assessment of the Use of an Encoder of Various Resolutions to Obtain Information about Transient Processes in a Crane Electric Drive. In: Scientific Research of the SCO Countries: Synergy and Integration: Proceedings of the International Conference, Beijing, January 17, 2024. Beijing: "Infinity" LLC, 2024, pp. 143-147. DOI 10.34660/INF.2024.11.22.136. EDN QGHMZI.
32. Nazarov, A.N., Ivanov, S.D. Investigation of the Influence of a Load Limiter with Intermediate Thresholds on the Safety of Overhead Cranes. Machines and Installations: Design, Development and Operation. 2023, no. 1, pp. 41-52. EDN SZRVVB.
33. Ivanov, S.D. Development of the "Industrial Safety of Lifting Equipment" Research Direction at the Department "Lifting and Transport Systems". Machines and Installations: Design, Development and Operation. 2024, no. 4, pp. 11-24. EDN GACZBH.
34. Nazarov, A., Ivanov, S., Yilmaz, M. Configuring the Algorithm of the Load Limiter with Intermediate Threshold. E3S Web of Conferences. 2024, vol. 515, p. 02015. DOI 10.1051/e3sconf/202451502015. EDN NGQCHM.
35. Nazarov, A.N., Ivanov, S.D. Development of a Promising Safety Device for Overhead Cranes. Bulletin of the Siberian State Automobile and Highway University. 2024, vol. 21, no. 6(100), pp. 826-843. DOI 10.26518/2071-7296-2024-21-6-826-843. EDN TYGGUV.
36. Roshchin, V.A., Ivanov, S.D., Nazarov, A.N. Application of Hazard Factor Forecasting Methods in Crane Safety Devices Using the Example of a Crane Anemometer. Bulletin of the Siberian State Automobile and Highway University. 2020, vol. 17, no. 5(75), pp. 584-597. DOI 10.26518/2071-7296-2020-17-5-584-597. EDN VAFCGT.
37. Potapov, V.A., Roshchin, V.A., Ivanov, S.D. Development of a Wind Protection System for Rail Cranes. Machines and Installations: Design, Development and Operation. 2024, no. 4, pp. 25-33. EDN AHFIVF.
38. Ivanov, S.D., Nazarov, A.N., Mikhalchik, N.L. Selection of a Rational Algorithm for Data Processing of the Weight Measuring System of a Hoisting Crane. Journal of Physics: Conference Series. 2021, vol. 1926, p. 012047. DOI 10.1088/1742-6596/1926/1/012047. EDN JIUUGG.
39. Nazarov, A.N., Ivanov, S.D. Using a Moving Average Filter-Based Weighing Algorithm in the Data Recorder of an Overhead Crane. Bulletin of the Siberian State Automobile and Highway University. 2023, vol. 20, no. 4(92), pp. 418-431. DOI 10.26518/2071-7296-2023-20-4-418-431. EDN CBIJMP.
40. Mikhalev, A.V., Nazarov, A.N. Application of the Moving Average Algorithm for the Task of Determining the Mass of a Load. Machines and Installations: Design, Development and Operation. 2023, no. 2, pp. 44-57. EDN XLXJRI.
Review
For citations:
Ivanov S.D., Nazarov A.N. Operational Data of Lifting Equipment as the Basis for the In-Service Performance Maintenance Method. Machines and Plants: Design and Exploiting. 2025;(4):27 - 44. (In Russ.)
Views:
32
Email this article 