Levate Solutions and fortop develop CraneIQ intelligent safety system for overhead crane operations
Working with automation specialist fortop Automation & Energy Control (fortop UK), Levate Solutions has developed CraneIQ, a retrofittable safety system that prevents collisions and unsafe scenarios on overhead and gantry cranes. The system combines laser distance sensors and intelligent control technology to enhance operator safety across industrial environments, with particular interest from the automotive manufacturing sector.
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Addressing Critical Safety Challenges
Overhead crane operations in busy manufacturing facilities carry significant risks, and it’s here that Levate Solutions identified recurring safety issues that traditional crane systems failed to prevent. These include operators inadvertently guiding cranes into walls, lifting loads at dangerous angles that collide with building structures, and cranes entering restricted zones where personnel work below.
Explaining the catalyst for developing CraneIQ Joe Davies at Levate Solutions says: "Customers approached us because they'd experienced fatalities and wanted to improve operator safety fundamentally. They needed a system that would make it impossible for unsafe scenarios to occur, not just rely on operator vigilance."
And the challenge extended beyond new installations. Some manufacturers are operating crane fleets spanning decades, with equipment from multiple suppliers dating back to the 1980s, needed a solution that could retrofit to any system 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. Here, fortop UK provided automation expertise and sensor technology to create a solution that functions as an intelligent middleman between operator and machine.
At the heart of the system, Dimetix D-Series laser distance sensors provide absolute position measurement, with the sensors monitoring the crane's proximity to walls, other cranes, and the position of the trolley running along the rail. Using Profinet communication, the Dimetix units connect directly to a Siemens PLC that processes sensor data in real time.
Commenting for fortop UK, business development manager Carrick Hill says: " The crane won't 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, so when an operator attempts to move a crane into a restricted area or towards a collision, CraneIQ simply blocks the command. "
The system incorporates multiple 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 work, and load angle detection prevents picks that could strike building structures.
Levate Solutions designed the control system around rapid installation. The patented CraneIQ control box uses Escha Profinet cables for communication and Escha receptacles to connect power and data cables, with ILME bulkhead connectors providing robust interconnection. This plug-and-play approach, specified and supplied by fortop UK, allows installation teams to commission systems quickly without extensive on-site termination work.
Retrofittable Safety Across Any Fleet
CraneIQ's design allows installation on overhead cranes from any manufacturer and any era, with Levate Solutions having successfully retrofitted the system to equipment spanning four decades of service, demonstrating the platform's adaptability.
As Joe explains, the automotive manufacturing sector has shown particular interest in the technology: "Automotive manufacturers operate complex facilities with multiple crane systems working in close proximity. They're highly conscious of safety requirements and this technology addresses their specific operational challenges." says Joe.
The system works independently of existing crane controls, which eliminates the need to modify or replace legacy equipment. For facilities managing mixed fleets with cranes from different suppliers and different decades, this interoperability delivers consistent safety standards across all lifting operations.
Beyond preventing accidents, CraneIQ provides operational benefits. The system allows safe operation of multiple heavy-capacity cranes in shared spaces. "We've seen interest from facilities running two thirty-tonne cranes that can't be in the same bay simultaneously, or situations with cranes operating at different heights where collision risks exist." says Joe.
Evolving Technology Platform
Levate Solutions has developed CraneIQ over several years, progressively integrating proven safety features into a unified package. The modular architecture allows the company to add new capabilities as sensor technology and customer requirements evolve.
Working with fortop UK's automation expertise and access to industrial sensor technology has enabled Levate Solutions to create a scalable safety platform. The system now represents a practical response to the cultural shift towards enhanced workplace safety in industrial environments.
