Applications
Truck-mounted hydraulic cranes are machines designed for lifting and handling loads. Thanks to their ability to combine vehicle mobility and lifting functions , they are a versatile solution for operating in different work contexts. Depending on the configuration, they can be equipped with articulated or telescopic arms and, in some applications, with a jib to increase the operating reach.
The crane’s operation is based on the integration of mechanical systems, hydraulic systems, and control electronics that manage the extension of the stabilizers, the rotation of the upper structure, the lifting of the arm, and the telescopic extension of the arm. In this context, the use of linear position sensors, rotation sensors, tiltsensors, and pressure sensors allows the main operating variables of the machine to be monitored, improving movement precision, stability, and safety during work operations.
Requirements:
Stabilizers horizontal extension adjustment
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Stabilizers vertical position adjustment
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Vehicle tilt monitoring
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Main boom lift control
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Crane rotation angle measuring
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Telescopic boom length control
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Boom and jib angular position control
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Requirement:
Stabilizers horizontal extension adjustment
In truck-mounted hydraulic cranes, side stabilizers are extended to increase the machine’s support surface and transfer part of the weight of the crane and load to the ground. This operation stabilizes the vehicle before lifting operations begin, reducing the risk of tipping and improving operational safety.
Precise monitoring of the position of the stabilizers allows the crane control system to verify that the extension is correct and that the machine is operating under adequate stability conditions. Accurate measurement of the linear position also allows for more effective management of crane setup operations and supports electronic safety systems during operation.
Draw wire sensor for linear position measurement with range from 1.8 to 8.3 m, available with analog and digital outputs.
Solution:
To monitor the horizontal extension of the stabilizers, Gefran offers the GSH-S draw wire sensor, designed for applications on mobile machines and harsh operating environments.
Main features:
- Non-contact Hall effect magnetic technology, which guarantees measurement stability and long operating life
- Compact and versatile solution, suitable for integration into stabilizer extension systems
- Available with digital and analog interfaces
Thanks to these features, the GSH-S sensor allows precise monitoring of the position of the stabilizers, helping to improve machine stability, operational safety, and the reliability of lifting operations.
Requirement:
Stabilizers vertical position adjustment
In truck-mounted hydraulic cranes, the stabilizers are equipped with hydraulic jacks that allow the vehicle to be lifted slightly off the ground and distribute the weight of the machine over a larger surface area. This operation stabilizes the crane before work begins and compensates for any unevenness in the ground.
Monitoring the vertical position of the jacks allows the control system to verify the correct configuration of the stabilizers and keep the vehicle stable while lifting the load. At the same time, monitoring the pressure in the hydraulic circuit allows the operating conditions of the system to be checked, overloads to be prevented, and any anomalies in the operation of the jacks to be detected.
To monitor the position of the stabilizer jacks, Gefran offers the RK-5 magnetostrictive linear position sensor and the KM series pressure sensors , designed for hydraulic applications on mobile machines.
RK-5 magnetostrictive linear position sensor
Main features:
- Non-contact magnetostrictive technology, which guarantees high precision and long operating life
- Direct installation inside the hydraulic cylinder, without external bulk
- High resistance to shocks and vibrations typical of mobile machine applications
KM / KMC pressure sensors
Main features:
- Compact size, ideal for integration into hydraulic circuits
- High resistance to shock, vibration, and harsh environmental conditions
- Available with analog and digital outputs, also in configurations suitable for safety applications
Thanks to these features, Gefran sensors allow reliable monitoring of the position of the jacks and the pressure of the stabilizer hydraulic circuit, improving stability, operational safety, and machine control during lifting operations.
Requirement:
Vehicle tilt monitoring
During lifting operations, the stability of the crane depends not only on the correct extension of the stabilizers, but also on the leveling of the vehicle with respect to the ground. Uneven surfaces or slight slopes can affect the machine’s attitude and alter the load distribution during operation.
Continuous monitoring of the vehicle’s inclination allows the crane control system to verify that the machine is operating within safe stability conditions. Measuring the angle of inclination also supports electronic safety systems and improves control of lifting operations, helping to prevent potentially critical situations during work.
Solution:
For vehicle tilt monitoring, Gefran offers the GIG tilt sensor, designed for applications on mobile machines and harsh operating environments.
Main features:
- Single or redundant output to meet different safety requirements
- Sealed resin-coated structure, offering protection against dust, water, and external agents
- High resistance to shock and vibration, ensuring measurement stability over time
Continuous monitoring of the vehicle’s inclination allows the crane control system to verify that the machine is operating within safe stability conditions. Measuring the angle of inclination also supports electronic safety systems and improves control of lifting operations, helping to prevent potentially critical situations during work.
Requirement:
Main boom lift control
In truck-mounted hydraulic cranes, the main boom is lifted by one or more hydraulic cylinders that adjust its angle relative to the crane structure. This movement, known as luffing, allows the height and operating reach of the machine to be varied, enabling it to reach the desired working point.
Precise monitoring of the position of the lifting cylinder allows the crane control system to accurately determine the angle of the boom during work operations. At the same time, measuring the inclination of the boom allows its angle relative to gravity to be monitored directly. Combining this information improves control of the crane’s movements, supports electronic safety systems, and ensures more stable and precise lifting operations.
To control the lifting of the main arm, Gefran offers the RK-5 magnetostrictive linear position sensor and the GIB , two measurement technologies that allow the position and angle of the arm to be detected accurately.
RK-5 magnetostrictive linear position sensor
Main features:
- Non-contact magnetostrictive technology, which guarantees high precision and long operating life
- Direct installation inside the hydraulic cylinder, without external bulk
- High resistance to shock and vibration, typical of mobile machine applications
GIB inclination sensor
Main features:
- Available with analog and digital outputs;
- Compact dimensions that facilitate integration on the crane arm
- High signal stability even in the presence of vibrations
Thanks to these features, Gefran sensors allow for precise monitoring of the main boom’s lifting movement, improving motion control, machine stability, and safety during lifting operations.
Requirement:
Crane rotation angle measuring
In truck-mounted hydraulic cranes, the upper structure of the machine can rotate relative to the vehicle chassis to orient the boom and position the load in the work area. This movement, known as slewing, allows the crane to operate over a wide operating range without moving the vehicle.
Monitoring the crane’s angle of rotation allows the control system to accurately determine the orientation of the boom relative to the vehicle. This information is useful for improving control of the machine’s movements and supporting the electronic systems that manage lifting operations and load positioning.
Solution:
To monitor the crane’s rotation angle, Gefran offers the GRA rotary sensor with shaft, designed for applications on mobile machines and harsh operating environments.
Main features:
- Non-contact Hall effect magnetic technology, which guarantees measurement stability and long operating life
- Robust design, suitable for integration on rotating kinematics and mechanical systems subject to vibrations
- Available with analog and digital outputs, also in redundant configuration
Thanks to these features, the GRA sensor allows the crane’s rotation angle to be accurately detected, improving movement control and load positioning accuracy.
Requirement:
Telescopic boom length control
On truck-mounted hydraulic cranes, the telescopic boom consists of several sections that slide into each other, allowingthe machine’s operatingreachand rangeto be progressively increased. The extension of the boom allows the desired working point to be reached while keeping the vehicle in its starting position.
Accurate monitoring of the telescopic boom length allows the crane control system to know the machine’s operating configuration in real time. This information is essential for precise control of the boom movements and to support the safety systems that monitor working conditions during lifting operations.
Draw wire sensor for linear position and inclination angle measurement with range from 1.8 to 8.3 m, available with digital outputs.
To control the length of the telescopic arm, Gefran offers the GSH-A draw wire sensor with tilt angle measurement, designed for applications on mobile machines and in harsh operating environments.
Main features:
- Non-contact Hall effect magnetic technology , which guarantees measurement stability and long operating life
- Robust and compact structure, suitable for both internal and external installation on the crane arm
- Available with analog and digital outputs for easy integration into control systems
Thanks to these features, the GSH-A sensor allows for precise monitoring of the telescopic boom length, improving movement control and safety during lifting operations.
Requirement:
Boom and jib angular position control
In truck-mounted hydraulic cranes, the main boom and any jib determine the reach and final position of the load in the working area. Precise monitoring of the angle of these elements allows accurate control of the crane configuration during lifting and positioning operations.
Measuring the angular position allows the machine control system to determine the operating geometry of the boom and manage the crane’s movements more precisely. This helps improve load positioning accuracy and supports the electronic systems that control the machine’s operating conditions.
Solution:
For monitoring the angular position of the boom and jib, Gefran offers the GRA rotary sensor with shaft, designed for applications on mobile machines and harsh operating environments.
Main features:
- Non-contact Hall effect magnetic technology, which guarantees measurement stability and long operating life
- Robust and compact design, suitable for integration on rotating kinematics and boom joints
- Available with analog and digital outputs, single or redundant signal
Thanks to these features, the GRA sensor allows for accurate detection of the angular position of the boom and jib, improving control of crane movements and precision in load lifting and positioning operations.
Operating principle:
Truck-mounted hydraulic cranes consist of a lifting structure installed on the vehicle chassis and an articulated or telescopic boom used to lift and position loads. Before starting work, the machine is stabilized by side stabilizers, which transfer part of the crane’s weight to the ground, ensuring the vehicle’s stability during lifting.
The crane’s movement is generated by hydraulic cylinders that control the lifting of the boom,the telescopic extension and the rotation of the upper structure. During operation, linear position sensors, rotary sensors, tilt sensors, and pressure sensors monitor key parameters such as the position of the stabilizers, the tilt of the vehicle, the angle of the boom, and the length of the telescopic boom.
Requirements and technology:
Truck-mounted hydraulic cranes operate in environments characterized by high loads, dynamic boom movements, and harsh environmental conditions typical of construction sites. Under these conditions, precise control of crane movements, vehicle stability during lifting and monitoring of key operating parameters are essential to ensure operational safety, maneuvering precision, and work cycle efficiency. For this reason, reliable measurement systems are required that can provide accurate data in real time and support the control and safety functions of the machine.
The main technological requirements include:
- Stabilizers horizontal extension adjustment
- Stabilizers vertical position adjustment
- Vehicle tilt monitoring
- Main boom lift control
- Crane rotation angle measuring
- Telescopic boom length control
- Boom and jib angular position control
Gefran meets these requirements with a complete range of linear, rotary, tilt , and pressure sensors designed to ensure measurement accuracy, reliability, and resistance to the operating conditions typical of mobile machines.