Enerpac Introduces Intelli Lift 2.0 Wireless Gantry Controller

30 Second Takeaway

Enerpac Heavy Lifting Technology has introduced the Intelli Lift 2.0 Wireless Gantry Controller for its SL Series and SBL Series hydraulic gantries. The system can synchronously control up to eight gantries and allows operators to establish limits based on the load and maximum lift height. Dual joysticks, proportional speed control, automatic data logging, remote diagnostics and a seven inch touchscreen provide greater visibility and control during complex lifting operations.

New Control System for Enerpac Hydraulic Gantries

Enerpac Heavy Lifting Technology has expanded its hydraulic gantry control technology with the introduction of the Intelli Lift 2.0 Wireless Gantry Controller.

Developed for use with Enerpac’s SL Series and SBL Series hydraulic gantries, the new controller combines operating controls, lift monitoring, data recording and diagnostic functions within a single wireless unit.

The system is designed to give operators a clearer view of the gantry configuration and lifting status while allowing multiple units to move synchronously.

Before beginning an operation, users can define permitted operating limits according to the weight of the load and the maximum planned lift height. These parameters provide an additional control layer by establishing the boundaries within which the gantry system is intended to operate.

Synchronous Control of Up to Eight Gantries

A central feature of Intelli Lift 2.0 is its ability to control up to eight hydraulic gantries synchronously. Using more gantries can allow lifting contractors to distribute a large or complex load across additional lifting points. This can be important when handling long, flexible or irregularly shaped structures that cannot be supported effectively by a conventional four tower arrangement.

Coordinating additional lifting points also increases the importance of accurate control. If one gantry advances more quickly than another, the resulting difference in elevation can alter the distribution of forces through the load and lifting system.

Synchronous control is intended to keep the connected gantries working together while providing the operator with information on load, stroke and system status.

Carsten Daft, senior product manager at Enerpac Heavy Lifting Technology, said: 

“It gives Enerpac gantry users the opportunity to handle more challenging projects, involving up to eight gantries operating synchronously, with enhanced safety, improved reliability and efficiency.”

Dual Joysticks Provide Proportional Control

The new controller features two ergonomically designed joysticks with proportional speed control. Rather than limiting the operator to a basic start and stop command, proportional control allows movement speed to correspond with joystick input. This supports slower, more deliberate movements as the load approaches its final position.

Operators can use the controller to switch between three principal gantry functions:

• Vertical lifting and lowering

• Powered side shift

• Horizontal travel

Bringing these functions together on one controller allows the operator to manage the principal stages of a gantry operation without changing between separate control devices.

The ability to reduce movement speed can be particularly valuable during final positioning, when a heavy component must be aligned with foundations, supports, bearings or machinery connections.

Operating Limits Can Be Defined Before the Lift

Intelli Lift 2.0 allows users to establish operating limits based on the load and maximum lift height. These limits help align the control system with the engineered lift plan and selected gantry configuration. Hydraulic gantry capacity can change as the lifting towers extend. The maximum load that can be supported at a lower stage is not necessarily available when the gantries approach their full lifting height.

Entering the planned limits gives the operator an additional reference during the lift and helps prevent the system from being operated outside the defined parameters.

The controller supports the lift plan, but it does not replace the need for engineering calculations, equipment inspection, suitable ground preparation or trained personnel.

Seven Inch Touchscreen Displays Lift Data

A seven inch full colour HD touchscreen provides the primary information display.

Enerpac describes the screen as sunlight readable, allowing it to remain visible during outdoor operations and in changing light conditions.

The display provides information covering:

• Current lift status

• Load information

• Gantry stroke

• System condition

• Operating mode

• Defined limits

• Connected equipment

Colour coded status bands allow the operator to assess key system information without navigating through several menu screens. An integrated selector dial provides another method of moving through the controller’s menus. This can be useful when wearing work gloves or operating in conditions where touchscreen navigation is less convenient.

The combination of visual information, physical controls and colour coding is intended to reduce the time required to interpret gantry status during an operation.

Dual Wireless Technology Addresses Signal Interference

Wireless communication is provided through a combination of dual 2.4 GHz and Ultra Wideband technology. Industrial facilities and construction sites can contain numerous wireless devices, electrical systems, steel structures and operating machines. These can contribute to radio frequency interference or obstruct direct communication between equipment.

Enerpac designed the dual wireless arrangement to maintain communication in environments with high levels of radio frequency activity. A wireless controller also allows the operator to select a suitable viewing position rather than remaining beside a fixed control station.

This can improve visibility of the load, lifting points and surrounding work area. The operator must still remain within the approved operating zone and maintain communication with the lift supervisor and other personnel.

Automatic Data Logging Creates a Lift Record

The controller automatically records operating data, removing the need for users to document every stage manually.Automatic data logging can provide a digital record of the gantry operation for later review. This information can assist with project documentation, technical assessment and troubleshooting.

For contractors completing repetitive lifts or working under formal quality assurance requirements, stored operating information can also support comparisons between planned and completed movements. The available data must still be interpreted in the context of the approved lift plan, equipment configuration and site conditions.

The user manual can also be accessed directly through the controller, giving operators an onsite reference without requiring a separate printed copy.

Remote Diagnostics Designed to Reduce Downtime

Intelli Lift 2.0 supports remote diagnostics, allowing Enerpac service engineers to connect to the system and carry out checks in real time. Over the air access can help technicians identify control, communication or configuration issues without first travelling to the project site.

This is particularly relevant for gantry systems operating at remote industrial facilities or on projects with tightly controlled lifting schedules. Remote support does not remove the need for onsite inspection or repair when a physical equipment issue is identified. It can, however, help establish the likely cause of a problem and determine which service action, component or technical specialist is required. Reducing diagnostic time can limit disruption during projects where the gantry system is part of a larger installation sequence.

Greater Visibility for Complex Gantry Operations

Hydraulic gantries are frequently used where available space or overhead clearance makes the use of a large mobile or crawler crane difficult.

Typical applications include:

• Machinery installation and removal

• Transformer handling

• Generator installation

• Press relocation

• Tunnel boring machine assembly

• Bridge component handling

• Power station maintenance

• Industrial plant construction

• Rail vehicle lifting

• Vessel and module positioning

These operations can involve substantial loads moving within buildings or beneath existing structures. Precise control is therefore essential throughout lifting, travelling and side shifting.

The expanded synchronization capability of Intelli Lift 2.0 is particularly relevant for projects requiring more than four lifting points or coordinated control across several gantry systems.

How a Hydraulic Gantry System Works

A hydraulic gantry generally consists of telescopic lifting towers positioned on tracks. Header beams span between the towers and support the load through lifting links, slings or other rigging equipment. The hydraulic system raises or lowers the towers, while powered travel units allow the loaded gantry to move along its tracks. A powered side shift system can reposition the load laterally along the header beams.

This combination provides movement in several directions:

• Vertical movement through telescopic lifting stages

• Horizontal movement along the gantry tracks

• Lateral movement through the side shift system

Because the load is supported from below or from a relatively low overhead structure, hydraulic gantries can operate inside factories, power plants and other locations where crane boom clearance is unavailable. Every gantry operation still requires confirmation of capacity, lift height, track support, ground loading, load distribution and structural stability.

Compatibility With SL and SBL Gantries

Intelli Lift 2.0 has been introduced for Enerpac’s SL Series Super Lift and SBL Series Super Boom Lift hydraulic gantries. The SL range is designed for heavy lifting and machinery moving applications requiring a compact, modular gantry system.

The larger SBL range extends Enerpac’s gantry offering into higher capacity applications. Models within the series include the SBL1100, which has a stated maximum first stage capacity of approximately 1,178 US tons, or 10,484 kN, depending on the model and regional configuration.

Available capacity varies according to the gantry model, lifting stage, header beam arrangement and complete system configuration.

Compatibility with a particular gantry and accessory package should be confirmed through Enerpac before the controller is deployed.

About Enerpac Heavy Lifting Technology

Enerpac Heavy Lifting Technology develops equipment for the controlled lifting, lowering, moving and positioning of heavy loads. Its product portfolio includes hydraulic gantries, strand jacks, skidding systems, jack up systems, turntables, self propelled transport systems, synchronous lifting systems and specialised hydraulic equipment.

The systems are used across infrastructure, power generation, manufacturing, industrial maintenance, mining, offshore, shipbuilding and civil engineering projects.

Enerpac Heavy Lifting Technology supports projects where load control and precise positioning are required, including the installation of transformers, generators, turbines, presses, tunnel boring machines and other large industrial components.

Heavy lifting solutions website: Enerpac Heavy Lifting Technology

About Enerpac

Enerpac is a global manufacturer of high pressure hydraulic tools, controlled force products and equipment for lifting and positioning heavy loads. Its range includes hydraulic cylinders, pumps, torque tools, presses, bolting equipment, lifting systems and heavy load transport solutions. Enerpac serves customers in manufacturing, construction, infrastructure, energy, mining, maintenance and industrial service markets.

The brand forms part of Enerpac Tool Group, which was founded in 1910 and is headquartered in Milwaukee, Wisconsin. The group serves customers in more than 100 countries and is publicly traded on the New York Stock Exchange under the symbol EPAC.

Enerpac website: www.enerpac.com

Corporate website: www.enerpactoolgroup.com

Frequently Asked Questions

What is Intelli Lift 2.0?

Intelli Lift 2.0 is a wireless controller for Enerpac hydraulic gantries that combines movement control, lift monitoring, operating limits, data logging and remote diagnostic functions.

How many gantries can it control?

The system can synchronously control up to eight gantries.

Which Enerpac gantries are compatible?

Intelli Lift 2.0 is designed for Enerpac SL Series and SBL Series hydraulic gantries.

What movements can the controller manage?

Operators can switch between lifting, powered side shift and horizontal travel.

Does it provide proportional speed control?

Yes. Its dual joysticks provide proportional control, allowing the operator to regulate movement speed according to the required level of precision.

What information appears on the screen?

The seven inch touchscreen displays information including lift status, load and stroke data. Colour coded bands provide a visual indication of the system’s operating condition.

What wireless technology does the controller use?

The system combines dual 2.4 GHz and Ultra Wideband communication to support connectivity in environments with radio frequency interference.

Does the controller record lift information?

Yes. Automatic data logging creates an operating record without requiring the operator to document the information manually.

Can Enerpac diagnose problems remotely?

Yes. Enerpac service engineers can connect to the controller remotely for real time checks and troubleshooting.

Does the controller replace an engineered lift plan?

No. Intelli Lift 2.0 provides control and monitoring functions, but every operation still requires an approved lift plan, appropriate equipment configuration and qualified personnel.