How can I ensure safety when using a spare remote control on my overhead crane?

In the past, most overhead cranes were equipped with wired remote 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. What’s more, it 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 kept as a back-up.

However, this solution is not without risks. Accidents can happen if two remotes are used simultaneously on the same overhead crane. On one occasion, users of a certain type of remote control contacted me for support; the overhead crane had activated itself! In fact, it was another employee testing the spare transmitter. It’s certainly scary! This danger raises a crucial question: how can I ensure the safe use of spare radio transmitters on my overhead crane? After reading this article, you’ll be familiar with the different remote control models available and how they work in conjunction with the spare transmitter. This will help you choose the system that best suits your needs. You’ll also know what safety solutions to put in place so you don’t have to worry about this issue anymore.

First, let’s take a look at the methods you can use to secure your spare transmitter.

Work methods that ensure the safety of spare remote control

No matter what type of wireless remote control system you use, it’s recommended to use good working practices if you want to avoid accidents. The first step is to identify your remotes, whether they’re the main ones or replacements. A simple label with the equipment number affixed to the transmitter will help avoir errors by linking each transmitter to the overhead crane it controls.

Next, we can set up a remote control operating procedure tailored to your operations, limiting access to the spare transmitter to authorized people only, and only at the right time. Padlocking is an effective method, as is the use of a keyed bag, box or shelf. A clear, written procedure, including padlocking steps, should be communicated to all workers concerned.

But this strategy can be adapted according to the type of radio system used, as we shall now see.

The two main types of radio systems on the market and their safe use

The radio systems market offers various models that require different approaches to safety when using a second transmitter. Here are the two main models and how they work, as well as the recommended safety procedures for each.

1. Two-transmitter systems: the fast entry-level and the safety challenge

How does it work? Some systems allow several transmitters to be pre-configured for a single receiver (see “Transmitter and receiver” box). If one main transmitter fails, the second can be activated immediately. However, these models present a risk: the transmitters can take over from each other without any further safety action. What does this mean? As mentioned in the introduction, someone other than the overhead crane operator can take control of the overhead crane. So how do you ensure safe operations 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 strict safety procedures.

Recommended safety solution : padlocking. With this model of remote control, it’s essential to padlock spare transmitters to prevent them being used unexpectedly by another operator.

 

Transmitter and receiver

A radio system consists of 2 essential components: the transmitter, i.e. the remote control used by the operator to maneuver the overhead crane, and the receiver, i.e. the electronic module connected to the overhead crane which receives the commands.

The transmitter transmits the signal to the receiver by radio wave, on a predetermined frequency. The receiver, connected by cable to the overhead crane’s electrical system, transmits the commands for the overhead crane to execute.

The remote control is coupled to the receiver, either through a configuration made in advance by the manufacturer, or through a code entered by the operator.

 

2. Single transmitter management systems: a safe in-between solution

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 PIN code or perform a configuration from the ground, in the manner of a universal remote control.

Pros and cons : Since transmitters are not assigned to a specific receiver, they can be paired with any receiver. A spare transmitter can therefore be available for several pieces of equipment. All you have to do is carry out the simple replacement procedure on the ground. There is, however, some handling involved in pairing.

Recommended safety solution : none, as it is impossible for two transmitters to be used simultaneously on the same lifting equipment.

How do you choose the right solution?

Choosing the right radio transmitter depends not only on your security management, but also on a number of other factors, such as budget, required functionality and even the environment. For example, if you need to use remote controls outdoors, in temperatures that can drop to -20°C, the system’s robustness is essential.

That’s why a specialist analysis of your needs will help you see things more clearly and select the right system from the outset. The notion of safety when using the spare remote control will be part of this analysis. But in any case, this aspect is part of a whole set of criteria affecting your lifting equipment. That’s why we recommend reading the article “I need an overhead crane!” What information do I need to pass on to my supplier?

Avoid accidents with the right solution

Integrating spare radio transmitters can greatly simplify your operations, but it must be accompanied by a safety procedure adapted to the chosen model. Whether you opt for a padlock procedure or a single transmitter management system, the objective is the same: to avoid accidents and guarantee the safety of your workers. Now you can eliminate the worry and fear of an accident caused by the use of spare remotes. Do you have any questions about choosing a system or the options available?

Fill in the form at the bottom of the page, and a specialist will advise you according to your environment and security management.