How do you prevent motors and control cabinets from overheating during the production of road safety systems?

In the production of road infrastructure components, the reliability of crane systems is crucial - any failure can lead to road hazards and costly downtime. One of the main challenges is the overheating of motors and control cabinets, which can result in damage, loss of productivity and even failure of safety systems.

To prevent this, the customer needed a solution to continuously monitor temperature and react quickly to temperature increases. The implementation of JUMO Wtrans wireless sensors, the JUMO variTRON 300 controller and the JUMO Cloud platform allowed for ongoing monitoring, automatic alerts and optimised maintenance.

What challenges did the customer face and what benefits did the implementation bring? Read on!

Why is temperature control crucial for the safe production of road infrastructure components?

Reliable operation of crane motors and control cabinets is crucial in the production of road safety infrastructure components such as safety barriers or energy guards. They are responsible for the control of the safety mechanisms, and their failure can lead to serious consequences - from downtime to damage to infrastructure to danger to road users.

Excessive temperature is one of the main risk factors. Overheating electrical components can cause a drop in performance, accelerated wear and tear of parts and, in extreme cases, even fires. In addition, it can put strain on the drive, leading to a drop in performance and accelerated component wear. Prolonged overheating also affects the performance characteristics of the motor, causing changes in current draw and power system load. Traditional inspection methods, based on periodic inspections, do not allow for ongoing detection of problems, increasing the risk of unexpected failures and costly repairs.

The solution is real-time preventive temperature monitoring, which enables a rapid response to any anomalies. This not only minimises the risk of failure, but also extends the life of the equipment and optimises the maintenance schedule, preventing unplanned downtime. What specific challenges did our client face? This is discussed in the next chapter.

Why does crane engine overheating pose a risk to road infrastructure? The customer's problem

The client, involved in the design and installation of road safety systems, was faced with the challenge of ensuring reliable temperature control in crane motors and control cabinets. High temperatures could lead to failures, which in road infrastructure meant not only downtime, but also a real threat to the safety of road users.

Existing temperature control methods were insufficient. The client needed a solution that would enable continuous real-time monitoring of the temperature and, if the limit values were exceeded, would immediately generate automatic alerts. The response had to be fast to avoid major breakdowns and costly repairs.

An additional challenge was to implement a wireless system that would allow remote access to data and optimise maintenance, eliminating the need for manual temperature readings and on-site inspections. The new solution also had to interface with existing control systems, ensuring full integration with the road safety management infrastructure.

How have wireless temperature sensors improved crane motor monitoring? Our solution

To provide the customer with a reliable and efficient temperature monitoring system, JUMO Wtrans wireless sensors were implemented. Their use allowed the precise measurement of the temperature of crane motors and control cabinets without the need to install complex cabling, which was crucial in road infrastructures where access to some system components is difficult.

The collected data was analysed in real time thanks to the JUMO variTRON 300 controller, a compact PLC that enables automatic detection of temperature rise and immediate system response. When safety thresholds were exceeded, the controller activated the relevant alerts, informing operators to take preventive action.

In addition, the system was integrated with JUMO Cloud, which enabled remote access to data, trend analysis and the generation of real-time notifications. This enabled technical staff to monitor the condition of equipment without the need for site visits, while proactive maintenance management reduced downtime and extended equipment life.

The implemented solution provided the client with full control over the temperature of key components, improving the safety and reliability of road infrastructure systems.

How has the elimination of the risk of engine overheating affected system reliability? Customer benefits

The new temperature monitoring system has significantly increased operational safety by eliminating the risk of overheating of motors and control cabinets. Real-time alerts enabled technical staff to respond quickly to abnormalities, reducing downtime and optimising maintenance.

Wireless sensors have eliminated the need for costly cable installation, making monitoring easier even in hard-to-reach areas. Data is now available remotely, giving full control over the condition of the equipment and allowing quick service decisions to be made.

As a result, the client has not only protected key components, but also reduced maintenance costs and increased operational efficiency.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

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