Condition monitoring turns crane brake maintenance from reactive to preventive. Common monitoring tools include brake-open limit switches (confirm full release before motion), lining wear switches (early warning before torque drops), air gap monitoring (disc brakes), and temperature sensing to detect dragging and overheating. For electro-hydraulic systems, monitoring thruster current, stroke, and oil condition can reveal degradation before failure.
These signals can feed PLC/SCADA systems to trigger alarms, inhibit unsafe operation, and guide maintenance scheduling. The biggest safety benefit is early detection of failure modes that develop silently—lining wear, spring fatigue, partial release, or overheating. This is especially valuable for high-duty hoists and outdoor gantry cranes where environmental stress accelerates wear.
Condition monitoring does not replace inspection, but it dramatically improves response time and audit readiness. When implemented correctly, it reduces downtime, prevents catastrophic load incidents, and supports compliance with modern crane safety expectations.