How can I ensure safety when using spare remotes on my overhead crane?

An overhead crane that moves by itself! Scary, isn't it? 

Poor management of spare remote controls can lead to accidents. An overhead crane could even be activated without the operator's knowledge! Is this possible? Yes, but how often does it happen? More than you think… 

But what happened? Did a button get stuck on the control? Does a low battery cause the crane to move involuntarily? 

Have you encountered this problem before? If so, you've come to the right place. 

As a service technician, I have personally had to go on site for similar emergency calls. And now that I'm a technical representative, I've helped a number of customers to improve their remote control safety management. 

In this article, you'll discover the different types of remote controls available on the market, how to avoid using them simultaneously and, above all, what simple procedures to put in place to ensure maximum safety. 

But first, are overhead crane remote controls safe? 

Are overhead crane remote controls safe to use? 

In the past, most overhead cranes were equipped with wired controls. But times have changed! Today, wireless remote controls, also known as radio transmitters, are becoming increasingly common. Ergonomic and practical, they make life easier for operators.  

But it also offers a safety advantage, as the operator can stay away from the load during maneuvers. 

Of course, these devices are not immune to faults and breakdowns. For this reason, to ensure productivity in the event of a problem, a second transmitter is provided as back-up. And it's in these situations that there's an element of risk, as accidents can occur if two remotes are used simultaneously on the same overhead crane.  

That's why it's important to be familiar with the different types of remote control available, as they don't all work in the same way. Although there are many models on the market, let's take a look at the 2 main models and how they work.

2 types of radio systems, 2 different working methods 

The radio system market offers a variety of models to suit different needs. Its selection will depend on several factors, such as budget, required functionalities and even the environment in which it will be used (for example, if it will be used outdoors during the winter). 

However, no matter which model you choose, understanding how a radio system works is essential to setting up a safe working method, especially when working with spare transmitters. 

Here are the two main models of radio systems on the market, how they work, and the specific working methods for each. 

2-transmitter system: risks and solutions 

How does it work? 

Some systems allow several transmitters to be pre-configured for a single receiver (see the box "Transmitter and receiver"). If one main transmitter fails, the second can be activated immediately. However, these models present a risk: without additional safety measures, the transmitters can take over from each other. What does this mean? As mentioned in the introduction, someone other than the overhead crane's operator can take its control. So how do you ensure safe crane operation with this type of remote control? 

Pros and cons 

• No handling required before using the second transmitter. It is pre-configured by the manufacturer to connect to the receiver but is not designed for quick coupling to another receiver.  

• Requires a strict safety procedure.  

• The price of this solution is generally lower. 

Recommended specific working method

With this model of remote control, the first step is to identify all the transmitters, both main and spare. A simple label with the equipment number affixed to the transmitter will avoid errors by linking each transmitter to the overhead crane it controls. 

Secondly, spare transmitters must be padlocked to prevent unexpected use by another operator. What does this mean in concrete terms? 

It means establishing a clear, written procedure for the use of spare transmitters, involving the use of a locked bag, box or shelf. This prevents inadvertent use of the spare transmitter of this type. All workers concerned should be informed and trained in this method.

Single management system: enhanced safety 

How does it work? 

These models allow only one transmitter to be active at a time for each receiver. When you insert a new transmitter, it automatically deactivates the previous one. To activate a replacement, the operator must enter a sequence of buttons or perform a configuration from the ground, much like a universal remote control. 

Pros and cons 

• As replacement transmitters are not assigned to any specific receiver, they can be paired with any receiver. A single replacement transmitter can therefore be available for several pieces of equipment.  

• Although the procedure is straightforward, it does require some handling to couple the replacement transmitter with the receiver. This handling is carried out on the ground with the remote controls.  

• This system is generally more expensive than the previous one. 

Recommended specific working method 

Theoretically, there are none, since it's impossible for two transmitters to be used at the same time on the same lifting device. However transmitter identification remains good practice, and training in the use of transmitters is necessary to avoid other types of accidents.

Understanding how your remote control works: the key to avoiding accidents 

You're now familiar with the 2 main types of remote control and the safety implications of using a spare remote control. The danger is real - an overhead crane can start moving on its own! 

It doesn't actually move by itself, as someone has the spare transmitter in hand without your knowledge. Still, that's the impression you get when you witness the scene. And believe me, it can be unsettling! But there are worse things than the fear of an overhead crane moving by itself: an accident occurring because of a lack of understanding of a certain type of radio system. 

How can you eliminate the worry and fear of an accident caused by using spare remote controls?  

     1. Understand how the system works 

     2. Use a safe work method, such as padlocking if necessary. 

     3. Train operators according to the system in place.  

To find out more about operator training, see the article "Is operator training mandatory? Do you offer this service?". You'll find important information on the types of training offered by companies specializing in the field. 

If you would like advice on how to use radio systems safely, please don't hesitate to contact us. We can help you make your operations safer by helping you implement the safest working method for your product. Just click on the "Contact a specialist" button at the bottom of this page.