Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
11 February 2009
The tipping line on every complete crane load chart separates it into
two halves. On one side of the line, an overload will tip over the crane.
On the other side, an overload may damage the crane, but it will not tip
over the crane. Current European standards require rated capacity
indicators (RCIs) to prevent overloading on cranes over 1,000kg or
40kNm capacity (but not timber handling cranes). The planned revision
of knuckleboom crane design standard EN 12999 will require that RCIs
also monitor the crane’s stability, to also make sure it doesn’t tip. The
standard has been revised by an industry working group, and is
currently being translated, prior to being voted on by individual
European countries. The states can vote yes or no, but cannot make
further revisions. It is expected to be in force by 2010.
The convenor of the EN 12999 revision group was Lars Rydahl,
manager of structural mechanics at Hiab. He explains, “The standard
says that for cranes covered by the stabiliser supervision requirement,
‘the stability of the vehicle shall be included in the safety function of the
rated capacity limiter.’ So, the safety system must ensure the vehicle is
stable: how that is implemented is up to the manufacturer.
“Manufacturers are coming up with different solutions to meet the new
standard. Some are sticking with simple proximity sensors which
prevent the crane operating unless the stabilisers are deployed. Others
are using more sophisticated devices such as encoders or other digital
devices to monitor the position of the stabilisers and the slew angle of
the boom.”
Reasonably foreseeable
The standard has been revised partly because of changes to the
European Machinery Directive. The current version of the Machinery
Directive, which was launched in 1998, requires manufacturers to make
sure that their equipment is safe when used as intended. Manufacturers
indicate compliance with this by posting a CE-mark on the machinery.
To be sold in Europe, a crane or other piece of machinery must have a
CE-mark. A new version of the Machinery Directive is coming into effect
on 29 December 2009. It is based on a slightly different philosophy than
before: not only must machines be safe when used as intended, but
also when used in ways that could be reasonably foreseeable.
Rydahl says, “It’s reasonably foreseeable that an operator may use
stabilisers on one side only, if he intends to work on that side, and then
slew to the other side but forget the stabilisers aren’t extended.”
The standard was also revised because of pressure from the UK’s
safety regulator, the Health and Safety Executive, according to Lars
Rydahl. “The UK pushed quite hard to have stabiliser supervision
included.”
Ian Simpson, HSE principal specialist investigator (mechanical
engineering) says, “A few years ago, we pushed for interlocks on
stabilisers, but that was rejected.” Stabiliser interlocks use proximity
switches to tell if the stabilisers are fully extended, and stop the crane if
they are not. “This time, we went for having the rated capacity limiter
monitor the position of the stabilisers and limit the capacity according to
their deployment. This time it got passed.”
Alan Johnson, technical director of the UK Association of Lorry Loader
Manufacturers and Importers (ALLMI) and director of SJB Crane, says,
“Ultimately, the standard has evolved to this stage as a result of the
incorrect deployment and/or stowage of stabilisers being one of (if not
the) highest causes of accidents and sometimes fatalities. To fail to
address this issue is not an option.”
Danish loader manufacturer HMF already offers a stability supervision
system as an option. René Dahlkilde, HMF product manager for cranes
and a member of the CEN EN 12999 revision working group, says, “At
HMF, we came up with our own solution, the EVS system, about 10 or
11 years ago. At the time we thought it would only be a short time
before it was demanded by the standard. We were a bit surprised it
took so long, not coming into effect until 2010. But, now we have a lot of
units running, somewhere around 1,000–1,500. We look at the new
norm with calm; all of our workshops are prepared and used to the
system.”
The EVS system is a small box mounted on the crane. Once calibrated,
it provides a precise measure of the inclination of the vehicle. This
measure can be used to limit the crane’s capacity if risks becoming
unstable.
Dahlkilde says, “It was an expensive option for customers, but some
saw its possibilities. When the installer tests a crane’s stability, they
have to do it with an empty truck. [In use,] the EVS system allows you
to use the system with an [additional] stability load in the back of the
truck, increasing its capacity. The EVS system senses the inclination
angle of the vehicle. By putting weight on the body, you can keep the
vehicle more stable. That allows you to use more of the crane’s
capacity. We needed to put in that customer advantage, to make the
system attractive when it wasn’t mandatory.”
“With no stabilisers down, the vehicle can still move very fast; but with
the stabilisers extended only to 30cm [12in], using the EVS system, it is
very hard to make the vehicle unstable.
“We think there are advantages to measuring the angle of the vehicle
rather than, for example, the pressure on the stabiliser legs. We saw
measuring the angle of inclination as a better and safer parameter. The
installer can set the permitted inclination when the system is installed.
For example, the system can be set up to allow a stabiliser leg to lift by
no more than 5cm: that’s a very precise and defined measure of the
vehicle’s stability.”
Terex Atlas has also developed its own stability systems for some
cranes, but is working now on making them universal across its range,
in line with the revision. Terex Atlas engineering and technical manager
(and ALLMI representative at the CEN revision group) Bryan Flintham
says, “Most Terex loader cranes offered for the commercial market have
a stabiliser monitoring option available through the rated capacity
limiter. However, at the moment this option cannot be used in
combination with other options which monitor the slewing angle (such
as protection for a raised platform or an area of reduced stability over
the cab).
“Customers who required such combinations have been
accommodated using special designs. These tended to be based on
our 10.5t models, but due to the commonality of the base components,
the same package could be implemented on most models between 8.5t
and 12t. These designs were for specific contracts and have not been
not updated, in line with developments of the standard products.
Consequently they can only now be configured for use with remote
control.
“In order to meet the revision of EN 12999, stability monitoring needs to
become a core function of the control system rather than the add-on
option offered currently. Given that the stability of any given truck and
crane combination will be different from every other, our focus is to get
the most flexibility from the fewest number of common components.
This approach will give our customers the flexibility they require,
minimise the cost increase, and maintain productivity. We are well on
the way with development and are optimistic that the market will react
positively to what we will be offering in 2010.”
Other manufacturers, including Hiab and Fassi, say they are working on
new systems, but, like Terex Atlas, are not ready to announce the
specifics.
Understanding stability
Developing systems that meet the requirements of the standard are just
one step in the process. Dahlkilde points out that communication with
users is key: “In our experience it is complicated for users to deal with
stability. Even understanding how stability on a loader works can be
difficult. Operators are good at assessing risk, in a way that the stability
systems can’t. The operator can see the difference in risk between
lifting a load two metres off the ground close to the crane, and lifting it
20m in the air. The stability system might stop the crane in both
situations, depending on the load.
“The operator will need clear signals of what to do, and how to operate
cranes using the system. The operator might be seeing warnings for
different reasons: it may be overload or it may be stability; it may be
he’s slewed into an unsafe area, or he’s tried to pick a load that’s too
heavy for the crane. He has to know what the problem is, and what to
do about it.
“There will be a number of manufacturers offering different stability
systems. There will be a problem with operators needing to know each
of the systems they use. We need to look at how we put signs on the
loaders so the guy using it knows what he is doing, and that he can
trust the stabiliser system.