This case study examines the implementation of a specialized, bespoke control interface designed and programmed by IPU Group for a heavy-lift FASSI knuckle boom crane operated by the Charles Russell Transport Group. The system is engineered to manage auxiliary power from a rear-mounted Deutz diesel engine, ensuring seamless integration, high-level operator safety, and precise control over high-capacity lifting operations.
The Challenge
Operating high-capacity equipment requires more than raw hydraulic power; it demands sophisticated, intelligent management. When an auxiliary power unit such as the rear diesel Deutz engine is used to drive the crane independently of the truck’s main engine, the control architecture must bridge the gap between the power unit, the crane’s native electronic systems, and the complex safety requirements of the vehicle assembly.
IPU Group was tasked with engineering a bespoke solution that functions not merely as a central controller, but as a robust safety backbone and power distribution center for the entire lifting setup. By serving as this foundational infrastructure, the system orchestrates the auxiliary engine’s power output while simultaneously enforcing the critical interlocks and diagnostic monitoring required for safe operation.
Integrated Control Features
The solution developed by IPU Group centers on a custom control panel that provides the operator with total command while enforcing rigorous safety protocols.
1. Advanced Safety Interlocks
The system utilizes sophisticated interlocks to prevent unsafe operation. These are programmed to ensure that specific conditions are met before the auxiliary engine can be engaged or the crane can be operated:
• Cab/Counterweight Connection: The crane’s auxiliary engine will not start or engage the hydraulic pump unless the system verifies that the crane is correctly connected to the main cab or that necessary counterweight configurations are
secured. This prevents accidental instability or operation without the required support structure.
• Lighting System Interlocks: To ensure visibility and compliance with road and site safety regulations, the control system is hard-wired into the vehicle’s lighting
systems. Crane functions are locked if critical lighting circuits are not active or if an error is detected in the vehicle’s warning light network.
• Operational Drive-Away Protection: The system incorporates logic that prevents the operator from driving the vehicle while high-intensity work lights remain active. Upon detecting “Work Light” status while the vehicle is in a driving state, the controller triggers visual warnings and automatically shuts off the work lighting circuits.
2. Seamless Interface with FASSI Remote Control
The IPU control panel acts as a bridge to the crane’s native electronic ecosystem. By directly interfacing with the FASSI radio remote control (RRC) unit, the system achieves:
• Unified Start/Stop: The operator can control the auxiliary engine’s ignition state directly from their remote control, removing the need to return to the vehicle.
• On-Demand Speed Management: The system automatically throttles the Deutz engine based on crane demand. When a function is called via the remote control, the IPU controller increases engine RPM to meet hydraulic flow requirements, then returns the engine to an idle state when the function is complete, improving fuel efficiency and reducing mechanical wear.
Hardware Analysis: Enovation Controls MPC-10
The Enovation (Murphy) PowerCore MPC-10 controller was an ideal choice due to its balance of rugged durability and flexible connectivity. It is IP67-rated for environmental protection, supports CAN protocols, and provides precise, configurable I/O and logic to handle the necessary safety interlocks and engine management.
Operational Impact
By integrating PLC-based control logic with high-performance hydraulics, IPU Group has transformed a potentially complex, multi-component task into a streamlined, safe, and intuitive process, elevating the performance and safety of heavy machinery.
Special thank you to Jay Pinn & Louise Hazel from WASP IPU for this case study.
