Secure collision avoidance of cranes on multiple levels with integrated communication

The advantages at a glance

  • Increased operational safety and optimal monitoring of operational processes through continuous tracking of the crane position
  • Possibility of mounting on cranes and rail-bound transfer carriages
  • Flexible blocking areas and independent definition of warning and stop times
  • Position determination and data transmission are combined in one device. All measurement data of a crane are transmitted with only one radio sensor


How it works

The position of a crane is determined dynamically via continuous distance measurements - e.g. to adjacent walls or cranes - with Symeo radio sensors of the type LPR®-1D24. The basis of the radio-based distance measurement is the patented Symeo radar technology LPR®, which measures in the freely available ISM band at 24 GHz. Because the measuring antenna is already built into the 1D24 housing, a rough alignment of the radio sensors is sufficient to obtain accurate measurement results.

All measurement data of a crane can be read out at any 1D24 station and forwarded wirelessly. Other raw data, such as crane movement data, can be flexibly integrated and output as well.

Direct relay switching allows the system to be implemented without an additional control system (PLC / PLC). The 1D24 units can be easily commissioned via the Collision Control Center - detailed programming knowledge or the installation of separate software is not required.

The Collision Control Center (CCC), a modular assistance system, takes over central management tasks and offers interaction with the user. Configuration, updates and monitoring of all units are carried out with the help of the CCC. The Collision Control Center can be called up easily via a web interface in the browser without installing any special software.

Source: SYMEO

Typical applications based on our reference projects

1. Collision warning despite lack of visual contact

Crane 168 and crane 169 have no direct visual contact with cranes 165 and 166. They need a collision warning with each other because the crane trolleys of cranes 165 & 166 could cause a crash with cranes 168 & 169.

ABF solution

Symeo antennas were installed to locate the cranes in the hall. By means of a PLC installed on each crane, the position measurement is sent via WLAN to a higher-level system. This system evaluates the position and the individual cranes are displayed in a 3D visualisation (once in the crane PC and once in the central visualisation in the office PC). In critical situations, an acoustic and a visual signal are passed on. This enables horns or warning lights to be triggered.


2. Collision warning including machine connection

Crane 1 is operated by a crane operator directly at the crane. Crane 2 is operated from an operating cassette. The cranes must be secured against each other to avoid collisions. Another safety-relevant point is that the neighbouring machine has different working heights and must therefore also be integrated into the collision warning system.

ABF solution

Symeo antennas were installed to locate the cranes in the hall. Thanks to the Symeo antenna, the antennas on crane 1 and crane 2 have a relay function that performs the following functions::

• move slowly when the crane is in the warning area
• stop when the crane is in the stop area

To cover the different working heights of the machine, an external PLC was set up. This has a connection to the machine on the one hand and a connection to the crane location via the wall antenna on the other. This means that the external PLC knows the current crane positions and the working height of the machine. It can therefore inform the Symeo antennas of the current position of the cranes by means of a telegram.

3. Communication of the crane trolley load weight

The load weight from the crane is needed for the purpose of verifying the load picked up. It is to be displayed in an external visualisation independent of the manufacturer.

ABF solution

The measured weight from the scales is transmitted to the crane PLC via Profinet. The data is transmitted from the crane to the external station via a WLAN network. The measured data is visualised on a touch panel.