In the current wave of smart manufacturing driven by Industry 4.0, traditional industrial machinery is undergoing a profound transformation. For heavy lifting equipment, the intelligent upgrade of their core control systems is key to enhancing overall operational efficiency and safety. Beyond mere feature additions, true innovation lies in the redesign of the core architecture.
The WORLDHOISTS Ever Control System exemplifies this technological trend. The system integrates all electrical components onto a single circuit board, controlled by IGBT modules, providing intelligent features like soft start and variable frequency control, enabling a “plug-and-play” experience. It offers a simpler, smarter, and integrated control platform for various crane types (0.8–80 tons).
How a Fully Integrated PCB Control Technology Changes Crane Remote Control Operation
- Traditional crane remote control systems are often composed of multiple bulky, separate electrical cabinets, such as the hoist control cabinet and the bridge travel control cabinet. This decentralized design increases wiring complexity and occupies valuable installation space.
- The core innovation of the Ever Control System is the integration of all essential control logic and components—including the receiver for the crane remote control systems—onto a single, compact, and sophisticated PCB (Printed Circuit Board). This board serves as the single brain for the entire crane control.
By utilizing advanced IGBT (Insulated Gate Bipolar Transistor) modules, this PCB control board enables comprehensive variable speed control for all 3 crane mechanisms: hoisting, long travel (bridge), and cross travel (trolley).
IGBT technology perfectly combines the advantages of high input impedance and low on-state voltage drop, making it an ideal choice for high-efficiency inverter systems. This technology allows all movements to be precisely driven by a variable speed controller, providing the crane operator with unparalleled smoothness and accuracy, ensuring micro-level fine control of the load and significantly reducing mechanical wear.
Further Breakdown: How an Advanced PCB Solves Traditional Control Challenges
The electrical control systems of traditional crane lifting equipment have numerous challenges that directly affect installation, maintenance, and operational efficiency. The fully integrated PCB design of the Ever Control System provides a systematic solution to these core issues:
Traditional Challenges | Benefits of a Fully Integrated PCB |
Bulky and Complex Electrical Cabinets | Simplified Electrical Architecture: The Ever Control System merges the hoist and long travel cabinets into a single, minimalist control box for the entire crane. This significantly reduces wiring, lowers costs, and makes installation much more convenient. |
High Maintenance Costs | Modular Design, Precise Maintenance: The entire circuit board is composed of 7 main integrated circuit modules, each of which can be individually disassembled and replaced. This means that during crane service, technicians only need to replace a faulty module, saving substantial time and cost. |
Long Spare Parts Lead Time | Ample Spare Parts, High-Efficiency Response: Unlike the industry standard of waiting 3 months or more for spare parts, WORLDHOISTS maintains a sufficient stock of modular components. This ensures a quick replacement in case of a fault, minimizing productivity loss due to downtime. |
Extra Remote System Costs | Integrated Remote Control, No Extra Cost: The Ever Control System’s control board comes with an integrated receiver. The crane remote control transmitter is included as a standard feature at no extra cost. |
Top 4 Advantages of an Advanced Crane Control System
Intelligent Safety Monitoring: Self-diagnosis, Overload Protection, Overheat Protection, Lifting Rotation L/S, Bridge Infra L/S, Trolley Slow/down L/S, Over-Current/Voltage Protection, Lack of Phase Protection, Operation Data Recording, Fault Log
Meets IP55 protection and Class H insulation standards
1. Energy Savings and Cost Reduction
The Ever Control System’s control board, based on full-frequency IGBT technology, enables smooth power output, avoiding the current surges that occur during traditional starts and stops, thereby significantly reducing the motor’s energy consumption.
By consolidating hoist and bridge travel control onto a single board, it also optimizes the costs of the electrical cabinet and the associated cables. These design optimizations directly translate into significant energy savings and a lower total cost of ownership.
2. Efficient Operation and Precise Control
With full-frequency crane remote control, the Ever Control System ensures the smooth operation of hoisting, cross travel, and long travel. This not only reduces load sway and enhances the crane operator’s control accuracy but also makes lifting and positioning actions faster and more efficient. Whether handling everyday materials or using lifting attachments for cranes for specialized loads, this precise hoist control greatly improves overall work efficiency and contributes to higher productivity.
3. Simplified Maintenance and Enhanced Reliability
The core advantage of the Ever Control System lies in its modular PCB design. When any function module fails, crane service personnel can quickly locate and replace it, greatly shortening repair time. This ease of maintenance not only reduces downtime but also enhances the reliability of the entire crane remote control system.
At the same time, ample spare parts inventory ensures the immediate availability of crane remote control components, keeping the equipment in optimal condition.
4. Empowering Industry 4.0 and Smart Management
As an advanced electrical control system, the Ever Control System is a gateway to a smarter future. Its highly integrated design provides a solid foundation for future functional expansion, such as data acquisition and remote monitoring. Through the crane APP functionality (optional Bluetooth), managers can remotely monitor the operational data of the lifting equipment, conduct performance analysis, and predict faults.
This makes the crane remote control more than just an operating tool; it’s a data hub that elevates the operational management of crane lifting equipment to a new, data-driven level.
Ever Control System — Opening a New Chapter in the Hoisting Industry
The Ever Control System by WORLDHOISTS discards cumbersome architectures and uses a single, highly integrated smart control board to achieve comprehensive optimization of core crane functions. From the core IGBT technology to the modular maintenance design, every detail is aimed at simplifying processes, enhancing efficiency, and reducing costs.
Experience the future of hoisting. Contact us today to learn how the Ever Control System can revolutionize your operations.
