Project D

Machine Upgrade 3 – Wireless Communication Upgrade for a 350-Foot Crane 

Project Overview  

This 350-foot crane is a critical part of our customer’s daily operations. It is used constantly, and any downtime has serious consequences. When the crane goes out of service, ships are forced to wait—resulting in costly delay charges—and in some cases, missed tidal windows, creating even larger logistical problems. 

The customer needed a reliable, modern solution to eliminate unexpected shutdowns and keep port operations running smoothly. 

The Challenge 

The crane’s communication system relied on a solid Profibus catenary cable running the full height of the structure. Over time, the cable became highly prone to damage due to: 

• Continuous movement  
• Exposure to wind, vibration, and weather
• Wear from general operation 

These issues caused frequent breakdowns, leaving the crane out of action and resulting in substantial financial penalties for vessel waiting time.

Replacing the Profibus cable was extremely difficult due to the crane’s height and physical layout. A more reliable, less maintenance-intensive solution was needed. 

Our Solution 

We replaced the vulnerable Profibus catenary system with a robust industrial Wi-Fi communication link, eliminating the need for the damaged cable altogether. 

1. Wireless Communication Link  

• A high-performance Wi-Fi bridge was installed on the operator’s movable cabin
• The second unit was mounted on the stationary control panel 
• The antennas were aligned to maintain a clear line of sight at all times, ensuring a stable, interference-free connection 

2. CPU Communication Upgrade 

We upgraded the PLC’s CPU port to support communication with the new wireless adapter, enabling seamless data exchange across the crane’s control system. 

3. Elimination of the Profibus Cable 

The wireless link now handles all communication previously carried by the Profibus cable.

This makes the old catenary cable fully redundant and removes the source of ongoing breakdowns. 

The Result 

The crane now operates with significantly improved reliability, providing: 

• Zero dependency on fragile catenary cables 
• Stable and continuous communication between the operator cabin and control panel 
• Reduced downtime, eliminating costly waiting charges for ships 
• Improved safety and maintainability, with no need for high-risk cable replacements at 350 feet 
• A modern, future-proof communication system suitable for demanding industrial environments