Messung's Smart Crane Monitoring
                     SMART CRANE MONITORING WITH XMPRO 
PLC AND IIOT: REAL-TIME INSIGHTS FOR 
SAFER AND SMARTER OPERATIONS
www.messungautomation.co.in 
Introduction
In modern industrial automation, efficiency and intelligence define success.
Messung’s NX-ERA PLCs empower industries with seamless control, connectivity, and 
real-time decision-making.
• Cranes power material movement across industries
• Safety, uptime, and efficiency remain key challenges
• Traditional monitoring is outdated and reactive
• XMPRO PLC with IIoT enables real-time, data-driven crane operations
www.messungautomation.co.in 
What is a Smart Crane IIoT System?
• Integration of sensors, PLCs, VFDs,
   and cloud connectivity
• Continuous monitoring of load,
  VFD status, and relay activity
• Data streamed to cloud platforms
   (AWS) via MQTT
• Enables predictive diagnostics,
   energy optimisation, and remote
   monitoring
www.messungautomation.co.in 
Common Challenges in Traditional Crane 
Monitoring
• Manual data logging → prone to 
errors
• Lack of real-time visibility → 
delayed
  detection
• No predictive maintenance → 
frequent
  breakdowns
• Overload risks and sudden 
www.messungautomation.co.in stoppages
Benefits of IIoT in Crane Automation
• Improved safety with real-time 
load
  and relay monitoring
• Reduced downtime through
  predictive maintenance
• Enhanced efficiency with
  energy-optimised VFD integration
• Remote monitoring and control
  from anywhere
• Significant cost savings in
ww w m.maesinsutnegnaautnocmea taionn.dco o.ipn erations
Architecture and System Components
• PLC & Modules – XMPRO-17-ADT
  main CPU + XM-DI16 expansion
• Sensor Integration – Load cells, 
relays,
  safety interlocks, VFDs via Modbus
• MQTT Communication – Live data
  streams to AWS for analytics
• Panel Setup – Stable power, 
mapped
  terminals, safety-compliant design
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PLC Programming & Data Mapping
• Application logic for real-time
  data acquisition
• Continuous load monitoring
  through load cells
• VFD Modbus registers for speed,
  voltage, frequency, power,
  and fault codes
• Enables predictive maintenance
   and energy optimisation
www.messungautomation.co.in 
Conclusion
• Transforms crane operations into a smart, connected ecosystem
• Real-time visibility → safer lifts and predictive maintenance
• Energy-optimised operations → lower costs and higher ROI
• Built for Industry 4.0 with Messung’s proven automation expertise
With NX-ERA PLCs, Messung enables industries to go beyond automation
and achieve true transformation.
The journey to smarter, future ready control begins here.
www.messungautomation.co.in 
THANK YOU.
Contact us
MESSUNG SYSTEMS PVT. LTD.
Office No.420, Tower -2,World Trade Center, Kharadi, Pune, India - 411 014.
T: +91 9561703619 | E: [email protected]
www.messungautomation.co.in