Overload Limiter

Safety Device

The crane overload limiter is a safety device that prevents the crane from lifting loads exceeding its rated capacity during operation.

Key Functions

Ensures the safety of lifting operations

Prevents crane damage or accidents caused by overloading

Components

The overload limiter generally consists of three parts:

Control instrument

Junction box

Load sensor

Types by Sensor Configuration

Based on the sensor type, overload limiters are mainly divided into three categories:

Bearing seat overload limiter

Pressure‑side overload limiter

Shaft pin overload limiter

Bearing seat overload limiters

Pressure-side overload limiters

Shaft pin overload limiters

Overload Limiter for Cranes with Winch Trolley

• Action error: ≤±3%F.S.
• Comprehensive error: ≤±5%F.S.
• Environmental temperature: -20~+60℃, ≤90%RH.
• Protection level: Load sensor: lP65
• Control instrument: lP44
• Alarm point:
• Warning when load reaches 90% of rated lifting capacity.
• Alarm when load capacity reaches 105% of rated lifting capacity and power off after 2S.
• Immediate disconnection when load capacity reaches 110% of rated lifting capacity.
• Installation position: Non-transferring side of the hoisting drum

Applications

Suitable for overhead cranes and gantry cranes

Applicable to various industry types of overhead cranes and gantry cranes

Features

Single sensor signal input – Simple configuration

Single relay contact output – Easy integration

Simple and lightweight – Easy to install, stable performance

Simple debugging – Easy to use and calibrate on‑site

High measurement precision and accuracy – Agile response with system self‑test

Strong anti‑magnetic interference capability – Reliable operation in industrial environments

Expandable functionality – Convenient for integration with other industrial control instruments or monitoring systems, allowing easy follow‑up processing

Applications

Suitable for main and auxiliary hook cranes

Suitable for multiple types of main and auxiliary hook cranes, gate hoists, and other double‑hook combination cranes

Features

Dual sensor signal input – Displays both main hoist and auxiliary hoist readings

Two sets of relay contact output – Independent control for each hook

Simple and lightweight – Easy to install with strong stability

Simple debugging – Easy to use and calibrate on‑site

High precision and accuracy – Quick response, system self‑check

Strong anti‑electromagnetic interference capability – Reliable performance in industrial environments

Expandable functionality – Convenient for integration with other industrial instruments or monitoring systems, allowing easy follow‑up processing

Applications

Suitable for grab overhead cranes and grab gantry cranes

Features

Two sensor signal combined input – Total load display and total control

Simple and lightweight – Easy to install with stable performance

Simple debugging – Easy to use and calibrate on‑site

High measurement precision and accuracy – Agile response with system self‑test

Strong resistance to electromagnetic interference – Reliable operation in industrial environments

Applications

Suitable for overhead and gantry double hook cranes of the same tonnage

Applicable to many types of overhead cranes and gantry cranes with same‑tonnage double hooks, including:

Electromagnetic disk cranes

Electromagnetic hanging beam cranes

Clamp cranes

Features

Dual sensor signal input – Total load display and total control

Applications

Suitable for many types of remote‑controlled overhead cranes and remote‑controlled gantry cranes

Additional Features

High‑power external crane warning devices – Enhanced safety alerts

Optional large screen display – Easy‑to‑read real‑time data

Applications

Suitable for lifting equipment requiring an underload control output

Mainly applicable to gantry cranes on dam crests and other hoisting equipment that requires underload control output

Features

Overload and underload control output functions

Underload setpoint can be arbitrarily adjusted

Applications

Suitable for main and auxiliary hook cranes

Provides sub‑display / sub‑control and total display / total control functions

Controls the lifting capacity of both main and auxiliary hooks

Features

Single‑chip intelligent digital circuit

Dual‑channel high‑bit AD chip acquisition inputs

Stable and reliable performance

Easy to use

High precision

Applications

Suitable for overhead cranes and gantry cranes

Based on the standard lifting capacity limitation function, this device adds real‑time recording of crane operating conditions.

Features

Real‑time recording of crane loading process data, including:

Load weight

Overload times

Load duration

Weight magnitude

End time

Crane operation frequency

Data Visualization

All recorded data can be viewed through computer software, providing:

Detailed records of crane work

Workload record charts

Work frequency and subcontracting frequency charts

Applications

Suitable for situations where connecting a cable line is inconvenient

Features

Wireless remote control

Wireless data transmission

Sensor Compatibility

The control instruments described above can also be used with other types of sensors, including:

Side pressure sensors

Shaft pin sensors

Overload Limiter for Wire Rope Electric Hoist

•   Action error: ≤±3%F.S.
•    Comprehensive error: ≤±5%F.S.
•    Environmental temperature: -20~+60℃, ≤90%RH.
•    Protection level: Load sensor: lP65
•    Control instrument: lP44
•    Alarm point:
•    Warning when load reaches 90% of rated lifting capacity.
•    Alarm when load capacity reaches 105% of rated lifting capacity and power off after 2S.
•    Immediate disconnection when load capacity reaches 110% of rated lifting capacity.

    Installation position: Fixed-end wire rope

Application

Suitable for electric wire rope hoists operating in environments with strong electromagnetic interference, such as:

Non‑ferrous metal smelting workshops

Features

High protection level – Reliable operation in demanding conditions

Anti‑electromagnetic interference design – ensures accurate performance in high‑interference environments

Wide voltage tolerance – Adaptable to unstable power supplies

Suitable for harsh industrial environments

Application

Suitable for various types of electric wire rope hoists.

Features

Wide model compatibility – Applicable to a broad range of hoist models

Stable performance – Reliable operation across different applications

Overload Limiter for European Crane and Hoist

• Application: European cranes, European hoists, port crane, chain hoists and where other types of sensors cannot be installed.
• Action error: ≤±3%F.S.
• Comprehensive error: ≤±5%F.S.
• Environmental temperature: -20~+60℃, ≤90%RH.
• Protection level: Load sensor: lP65
• Control instrument: lP42
• Alarm point:
  • Warning when load reaches 90% of rated lifting capacity.
  • Alarm when load capacity reaches 105% of rated lifting capacity and power off after 2S.
  • Immediate disconnection when load capacity reaches 130% of rated lifting capacity.
• Installation position: The position of the shaft pin in the pulley

Application

Suitable for European cranes and hoists.

Features

0.8‑inch LED display – Clear data readout

45° display angle – Optimized for easy viewing by ground operators

Overload Limiter for Explosion-proof Industry

Application

Suitable for explosion-proof double girder overhead cranes and explosion-proof double girder gantry cranes.

Features

Main components include:

Explosion-proof control box

Digital display instrument

Explosion-proof junction box

Load cell

Compatible with various types of intrinsically safe load cells

Application

Suitable for explosion-proof electric hoists.

Features

Compact size – Space‑saving design

Easy installation – Simple setup process

Simple commissioning – Quick and straightforward calibration

Low failure rate – Reliable long‑term operation