Enhancing Crane Safety: The Role of Advanced Collision Avoidance Sensors

The earliest documented use of cranes dates back to 2000 B.C. Ancient Egyptians are often credited as the inventors of cranes, who used them as rudimentary tools to carry out small-scale operations. However, cranes were perfected over time. Romans had a key role in modernizing crane designs. These cranes were crucial for them to build the marvels of the Roman Empire.?

Fast forward to this day, every manufacturing industry, warehouses, and shipping ports use cranes to lift heavy loads, making them indispensable for operations in high-risk environments.

However, this surge in usage is directly proportional to the risks associated with operating this machinery. According to the Census of Fatal Occupational Injuries (CFOI) report, from 2011 to 2017, there were 297 crane-related fatalities. That's an average of 42 deaths annually. 79 of these cases involved an object falling or being put in motion by cranes.

These numbers depict the need to invest in modern safety solutions, such as advanced collision avoidance sensors. It’s a worthy investment in dealing with financial and human crises.?

Evolution of Collision Avoidance Technology

Advanced collision avoidance sensors leverage technologies such as lasers, infrared, ultrasonic, and LiDARs today. The most recent addition is the integration of Artificial Intelligence (AI).

However, the early innovations were limited to collision warning systems, which used simple alarms and proximity detectors. Many industries, like automotive and manufacturing, still use these systems to warn operators of nearby obstacles. Therefore, their primary function is to inform the users. They aren’t capable of taking any action on their own.

On the contrary, modern technologies have helped convert these warning systems into avoidance systems. Therefore, a modern automated crane collision avoidance system can inform and initiate action to prevent mishaps.

The ultrasonic and infrared sensors have provided precise detection capabilities to the collision avoidance technology. Further, wireless communication and GPS integration enable real-time data sharing and management. This allows the coordination of multiple machines on complex worksites, like shipping yards.

The latest and most significant innovation is the integration of LiDAR and Artificial Intelligence. AI-based collision avoidance technology paired with LiDAR sensors provides three-dimensional mapping, predictive analytics, and automated decision-making capabilities to prevent potential collisions.

Furthermore, modern sensors equipped with plug-and-play technology help connect sensors seamlessly with crane control mechanisms. This instantaneous connection permits the sensors to provide adaptive responses like automated braking, emergency maneuvering, or load adjustment.

This evolution from providing warnings to avoiding collisions reflects a shift from reactive safety measures to proactive risk management in industrial environments.

Real-World Applications of Collision Avoidance Sensors

Advanced collision avoidance sensors can be used on most crane types under convoluted environments. Industries such as manufacturing, shipping yards, and warehouses use these sensors because the operations involve multiple stakeholders and machinery, including workers, other cranes, or equipment.

Distribution and Warehousing

Modern distribution centers and warehouses commonly feature densely packed shelving, narrow aisles, and high volumes of foot and equipment traffic. Overhead cranes, automated guided vehicles (AGVs), and forklifts constantly move heavy loads, often within inches of racks, pallets, and other machinery. These tight spaces can significantly increase the risk of collisions.

The best way to prevent such accidents is by utilizing a collision avoidance sensor such as Hokuyo’s KAD-300. It’s a best-in-class sensor for overhead cranes, equipped with three distance outputs that allow for precise slow-down and stop commands in case another crane is in close proximity.?

Automotive and Aerospace

Both the automotive and aerospace industries involve the assembly and transport of large, heavy components, ranging from car bodies and engine blocks to airplane fuselage sections and wings.?

In these high-stakes environments, cranes are often used in concert with other specialized handling equipment to safely and precisely position critical parts during assembly. Any misalignment or collision can result in costly production delays and potential damage to high-value components.

Hokuyo has built industry-leading solutions for this sector, and a notable mention is RSC-30LN. This sensor is designed to prevent collisions between high and low-bay cranes. It’s a programmable, laser-equipped, wide-detection-range sensor ideal for busy environments like automotive and aerospace assembly plants.

Ports and Terminals

Ports are among the busiest spaces. Cranes transport hundreds and thousands of cargo, transfer it to warehouses, and load it onto ships. In addition to overhead cranes, ports also have other factors, such as moving cranes, trucks, robots, shipping containers docked vertically, and, most importantly, personnel handling the operations.

In such situations, both RSC-30LN and KAD-300 can play a crucial role. These sensors can be deployed to monitor different operations and ensure the safety of the financial and human capital involved.?

For example, RSC-30LN can detect obstacles and initiate appropriate actions under high-traffic conditions. At the same time, KAD-300 can be mounted on crane bridges to detect fixed objects or moving cranes to prevent them from colliding.

Choose Hokuyo’s Collision Avoidance Sensors

Over the years, cranes have undergone a significant transformation, automating and accelerating operations to meet the growing demands. However, they also pose risks, making collision avoidance sensors a must.

At Hokuyo, we pioneered the development of reliable, durable, advanced, and rigorously tested sensor products designed for safe and efficient crane operations. Our infrared retro-reflective sensors and laser-based sensors can detect collisions before they happen, preventing accidents and costly shutdowns.

Contact us if you need help understanding which product best suits your requirements.

We’re here to help you make working with cranes efficient, faster, and, most importantly, safer.