Client Background
A UK manufacturing facility approached London Electronics to develop a custom load indication system for a 25 tonne overhead crane featuring both main and auxiliary hoists.
The customer required a solution capable of displaying live hoist loads whilst ensuring the crane’s total Safe Working Load (SWL) could never be exceeded.
The Challenge
The crane operated within a busy production environment where operators needed clear real-time visibility of both hoist loads.
The system needed to:
- Display live loads for both hoists
- Continuously calculate combined crane load
- Prevent overload conditions
- Automatically inhibit the auxiliary hoist if required
- Integrate with existing crane load cells
- Provide reliable long-term operation
Safety and rapid operator visibility were critical to the project.
The Solution
London Electronics designed and supplied a custom dual-hoist load indication system using high-brightness LED displays and intelligent RS485 communication.
Each display provides a live load reading for the:
- Main Hoist
- Auxiliary Hoist
The two units communicate continuously via RS485, allowing the system to monitor the combined crane load in real time.
If the main hoist approaches the crane’s SWL limit, the system can automatically inhibit or “park” the auxiliary hoist to prevent overload conditions and protect both operators and equipment.
Key features included:
- Real-time dual hoist load indication
- Automatic total load calculation
- Dynamic SWL protection
- High-brightness LED displays
- Direct load cell integration
- Industrial RS485 communication
- Long-distance visibility
- Pre-configured rapid installation
The Results
The completed system delivered improved operational safety and greater confidence for crane operators.
Benefits included:
- Automatic overload prevention
- Improved visibility of live loads
- Reduced risk of equipment damage
- Enhanced compliance with SWL requirements
- Reliable long-term operation
- Minimal installation disruption
Conclusion
London Electronics delivered a robust and intelligent crane load monitoring system tailored to the customer’s exact lifting requirements.
By combining real-time load indication with dynamic overload protection, the solution provides safe, dependable operation within a demanding industrial environment.
Need a Custom Load Indication System?
Contact London Electronics to discuss crane load displays, SWL monitoring systems and custom industrial process displays for your application.