Mechanical upgrades extend life of crane

The useful life of mechanical parts such as wheels, gears, bearings, etc. is in excess of 20 years. However, even the availability of spare parts after 10 to 15 years can be problematic. Upgrading old, worn parts with modern and improved counterparts is just one advantage to modernization.

Technological advancements in engineering can extend the life of a modernized crane. For example, modern precision gearing with much closer tolerances can result in reduced vibration, less gear wear, lower maintenance, and notably quieter operation than gears common in older cranes. Utilizing modern Flux Vector Control and eliminating high-maintenance, inefficient hoist mechanical load brakes can improve performance, reduce wear on brake discs or pads, and allow gearing to run cooler.

One of the most important crane modernization, retrofit, or repair considerations is the replacement of outdated or unserviceable crane brakes with current modern industrial braking technology

Brake performance has improved, and brake linings last longer especially when brakes operate in conjunction with AC adjustable frequency controls or digital DC controls. In many cases, journal bearings in pivot arms have been replaced with self-lubricating composite bearings which are shock resistant, unaffected by dirt or other contaminants, and can operate in corrosive environments. Newer brake designs include features such as automatic adjustment that compensates for lining wear and automatic equalization, which provides balanced braking and assures equal brake pad wear. These features go a long way in reducing maintenance costs and prolonging brake life.

Old hydraulic brake systems tend to leak and create maintenance andenvironmental issues. They can be replaced with modern “brake-by-wire” packages with foot pedal operated AC Thruster Brakes that address these issues while still providing operators with the same “feel” they had with hydraulic brakes.

Complete modern-design “drop-in” brakes are available, which meet the performance and dimension characteristics of the original equipment brakes -- often at a cost less than that of a replacement component -- with significantly shorter lead times. They can operate with existing brake wheels and avoid costly brake-support modifications.

Heavy Duty Caliper Disc Brakes with ratings from 50 to 30,000 ft-lbs are availableas replacements for existing brakes in high duty cycle, high speed, or high torque stopping AC or DC applications.

Low cost AC Thruster Brakes are often used to replace aging DC drum brakes.These brakes eliminate the need for AC-DC rectifier panels, and have optional features, such as stepless externally adjustable time delays for both brake setting and release; external torque springs to permit maintenance personnel to “dial-in” just the right amount of stopping torque for traverse motions; and automatic adjustment and automatic equalization to reduce maintenance costs.

Motor-mounted brake-support bases can also be furnished -- greatly simplifying retrofits and avoiding costly brake-support modifications.

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