Advanced Diagnostics Services from Konecranes increase accuracy, safety, and efficiency of crane operations

Two innovative and unique devices have been introduced into the South African market by global crane giant Konecranes, prolonging the overall lifetime of the runways and the ropes through two unique solutions: RailQ Runway Survey and RopeQ Wire Rope Inspection.

RailQ Runway Survey saves time, increases safety, and improves reliability

RailQ is an alignment survey technology developed to provide faster, safer, and more accurate analysis than any other type of rail survey available worldwide. RailQ uses precise survey techniques with specific software to accurately measure straightness, elevation, rail-to-rail elevation, and the span of the rails. The result is a precise, reliable runway analysis that provides cost-effective solutions for any rail system and for all makes and models of cranes.  It also takes a fraction of the time to conduct as compared to traditional rail surveys.

For smooth and straight crane travel

Efficient crane operation requires a crane that runs straight and smooth on its runway. RailQ uses proprietary visualization technology and a remote-controlled robot trolley which runs along the rail collecting data via Bluetooth technology and transferring the data to a total station to determine tracking issues and misalignments — critical problems which can potentially lead to accelerated wear, higher costs, and even failure. At the total station, survey software processes the data for straightness, span, elevation, and rail-to-rail elevation. RailQ inspection methods can also verify the geometry of the crane structure and components, identifying problems that can result from geometric deficiencies. Supported by visualization software that produces accurate and dependable calculations, Konecranes’ engineers analyze all RailQ survey data and provide customers with proactive, cost-effective recommendations for corrective action.

Saving time

The RailQ testing method can reduce surveying time by more than 80 percent, as compared to other runway survey methods, by assessing all dimensions of the crane rail with one measurement — keeping downtime to a minimum. With RailQ, technicians navigate the runway just once to obtain all distinct measurement data, reducing surveying time and significantly decreasing the technician’s risk of fall and trip hazards.


Konecranes RailQ Runway Survey

RopeQ Wire Rope Inspection enables economical and safe rope operations

Combining engineering resources and years of research, Konecranes has developed RopeQ, the latest wire rope testing methods throughout the overall lifetime of the ropes. RopeQ Wire Rope Inspection is a visual and Non-Destructive (NDT) rope inspection service examines what is non-visible on the ropes. The service provides data on the current condition of the ropes leading to increased operator safety, while helping to lower the total operating costs of lifting equipment. RopeQ detects internal broken wires that are not visible to the eye and would be missed by traditional inspection methods. It provides a quick-to-read and easy-to-understand report on the real rope condition.

Detecting non-visible rope failures

Wire ropes contain up to 400 individual wires. Throughout a wire rope’s working life, the wires are subject to bending and abrasion wear. If too many of these wires are broken, the safety of the rope is jeopardized. Only the outer surface of a wire rope is checked during a visual inspection. It is impossible to inspect the inner core using standard methods of inspection. For this reason, many wire ropes are classified as safe even when they should be discarded because of heavy internal damage. It is also worthwhile knowing that the ISO4039 standard requires the ropes to be inspected if the lifting machinery has not been used in three months. RopeQ’s comprehensive inspection will fulfill all inspection requirements.

Increasing safety

RopeQ Wire Rope Inspection increases safe use of the equipment and the wire ropes since the condition of the inner wires is also measured. In applications with a higher safety risk, it is necessary to measure both the inner and outer surface of a wire rope. The magnetic-inductive method of inspection is a practical and reliable method of assessing the condition of a wire rope. The observations and results of the RopeQ inspections are demonstrated in a wide report with recommendations for the rope change schedule and next inspection.

“Service and maintenance are a very high priority for us”, says John MacDonald, Sales & Marketing Manager for Konecranes Southern Africa. “These new products put us at a huge advantage in terms of fulfilling our mandate to service and maintain all makes of cranes”.

For over 80 years, Konecranes has been dedicated to improving the value and productivity of customer operations in all types of industry and ports around the globe. Its worldwide presence makes it possible for customers to receive local know-how acquired on a global scale. A broad global service allows Konecranes to meet customers’ needs for increased uptime, reliability, safety, and productivity, while reducing the overall lifetime costs.

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