Journal of Auto-vehicle Safety Association ISSN:2005-9396(Print) 자동차안전학회지

Crane tip-over accidents lead to severe casualties, property damage, productivity loss, and significant socioeconomic impacts. The primary causes of such accidents include operator error, ground subsidence, and overload lifting operations. To prevent them, a variety of actions are being implemented, including safety training, increased on-site supervision, strengthened safety regulations, and overload prevention devices such as automatic moment limiting devices (AML). The allowable lifting capacity of a crane should be determined by considering multiple operational factors, including crane inclination, boom length, and boom angle. However, conventional AML systems often rely primarily on manufacturer-provided data due to limited availability of real-time operating information, which can result in overly conservative lifting capacity limits. Therefore, accurate estimation of allowable lifting capacity requires experimentally measured operational state information. In this study, a dynamic analysis model was developed to evaluate crane safety devices in a laboratory environment. A Hardware-in-the-Loop Simulation (HILS) platform was established by integrating the dynamic model with an AML device in real time. Using this platform, the safety factor of the overload prevention device was evaluated under various conditions, including boom length, boom angle, lifting load, and crane inclination. The proposed HILS-based evaluation framework provides a practical approach for performance assessment of overload safety devices and can be applied to various types of cranes.