Crane safety system for overhead and gantry cranes
Working with automation specialist fortop Automation & Energy Control (fortop UK), Levate Solutions has developed CraneIQ, a retrofittable safety system designed to prevent collisions and unsafe scenarios on overhead and gantry cranes.
The system combines laser distance sensors with intelligent control technology to improve operational safety in industrial crane environments.
Addressing critical safety challenges
Overhead crane operations in busy manufacturing facilities involve significant risks. Levate Solutions repeatedly encountered situations where traditional crane systems did not prevent unsafe behaviour. Examples include operators guiding cranes into walls, lifting loads at unsafe angles that collide with building structures, or cranes entering restricted zones where personnel are working below.
Real-world incidents as a starting point
Explaining the catalyst for developing CraneIQ, Joe Davies of Levate Solutions says: “Customers approached us because they had experienced serious incidents and wanted to fundamentally improve operator safety. They needed a system that makes unsafe scenarios impossible, rather than relying solely on operator vigilance.”
Retrofit requirements for mixed crane fleets
The challenge extended beyond new installations. Many manufacturers operate crane fleets that span decades, often with equipment from multiple suppliers dating back to the 1980s. This required a solution that could be retrofitted to existing cranes, regardless of age or manufacturer.
An intelligent intervention system
Levate Solutions developed CraneIQ as a comprehensive safety platform that intercepts operator commands before they reach the crane’s control system. fortop UK provided automation expertise and sensor technology to create a solution that acts as an intelligent interface between operator and machine.
Sensor-based position monitoring
At the heart of the system, Dimetix D-Series laser distance sensors provide absolute position measurement. The sensors monitor the crane’s proximity to walls, other cranes and the position of the trolley running along the rail.
Using Profinet communication, the Dimetix sensors connect directly to a Siemens PLC that processes the sensor data in real-time.
Virtual safety zones and command blocking
Commenting for fortop UK, business development manager Carrick Hill says: “The crane will not physically respond to instructions that would create an unsafe situation. The system creates virtual no-fly zones throughout the factory and calculates safe stopping distances. When an operator attempts to move a crane into a restricted area or towards a collision, CraneIQ simply blocks the command.”
Integrated safety functions
The system incorporates several safety features:
- Anti-sway technology prevents loads from swinging dangerously
- Anti-collision monitoring stops cranes before impact
- Configurable no-fly zones protect areas where personnel are working
- Load angle detection prevents lifts that could strike building structures
Plug-and-play installation concept
Levate Solutions designed the control system for rapid installation. The patented CraneIQ control box uses ESCHA Profinet cables for communication and ESCHA receptacles to connect power and data cables. ILME bulkhead connectors provide robust industrial interconnection.
This plug-and-play concept, specified and supplied by fortop UK, allows installation teams to commission systems quickly without extensive on-site termination work.
Retrofittable safety across mixed crane fleets
CraneIQ can be installed on overhead cranes from virtually any manufacturer and era. Levate Solutions has successfully retrofitted the system to cranes spanning over four decades of service.
The system operates independently of the existing crane controls, eliminating the need to modify or replace legacy equipment. For facilities operating mixed crane fleets from different suppliers and generations, this allows consistent safety functionality across all lifting operations.
Particular interest from automotive manufacturers
As Joe Davies of Levate Solutions explains: “Automotive manufacturers operate complex facilities with multiple crane systems working in close proximity. They are highly conscious of safety requirements and this technology addresses their specific operational challenges.”
Safer operation of multiple cranes in shared spaces
Beyond preventing accidents, CraneIQ also enables safer operation of multiple heavy-capacity cranes within the same working area.
“We have seen interest from facilities running two thirty-tonne cranes that cannot operate in the same bay simultaneously, or from sites where cranes operate at different heights and collision risks exist,” says Joe Davies.
Evolving technology platform
Levate Solutions has developed CraneIQ over several years, integrating multiple safety functions into a single platform. The modular system architecture allows new capabilities to be added as sensor technology and operational requirements evolve.
Working with fortop UK’s automation expertise and access to industrial sensor technology has enabled Levate Solutions to build a scalable safety platform for overhead crane operations.
