In industrial environments where heavy machinery and equipment are constantly moved, safety and efficiency are paramount. Overhead cranes, integral to such operations, often share tracks, posing significant collision risks if not managed. This blog post delves into a solution we developed to mitigate these risks using advanced safety lidar sensor technology, ensuring seamless operation and enhanced safety.

The Challenge : Collision Risk in Shared Tracks

In our latest project, we encountered a setup where two overhead cranes operated on the same track. Each crane, controlled independently via a wireless pendant by operators stationed at opposite ends of a 150-meter factory.

The key objectives were:

• Detection of Overhead Crane within 20 meters: Implement a system that can detect the presence of the opposite crane within a 20-meter range.
• Stop Crane when within 9 meters: Ensure the crane stops automatically if it comes within 9 meters of the other crane.
• Utilize Safety Devices and Components: Where available, incorporate safety-rated devices and components to enhance system reliability.

The Solution : Leveraging Lidar Technology

To achieve these objectives, we evaluated various detection technologies. While radar was considered, discussions with the customer highlighted a preference for a more precisely defined detection target. This led us to select lidar (Light Detection and Ranging) technology, which offers superior accuracy and precision for this application.

Components and Functionality

Safety Lidar Sensor (CAT3):

• Detection Range: The lidar sensor continuously scans the track for the opposite crane within a 20-meter range.
• Warning Field: If a crane enters this field, it automatically slows down, giving operators time to react.

Safety Controller (CAT4):

• Integration with Emergency Stop Circuit: The safety controller interfaces with the existing emergency stop circuit to halt the crane if necessary.
• Stop Field Engagement: When a crane enters the stop field at a 9-meter distance, the controller immediately stops its movement to prevent collision.
• Manual Reset and Override: After engaging the stop field, a manual reset is required to resume operations. Additionally, a manual override is needed to move the crane out of the stop field, ensuring controlled and safe movement.

Benefits and Achievements

Implementing this lidar-based safety system brought several significant benefits:

• Enhanced Precision: Lidar technology provided accurate detection and positioning, ensuring reliable crane operations.
• Automated Safety Measures: Automated speed reduction and stop mechanisms minimized the risk of human error.
• Fail-Safe Design: The integration of a manual reset and override ensured that the system could only be reset deliberately, enhancing safety.
• Reduced Downtime and Equipment Damage: By preventing collisions, the system reduced operational downtime and potential damage to expensive machinery.
• Achieving CAT3 Safety Rating: The use of safety-rated components and devices led to the successful achievement of a Category 3 safety rating, highlighting the system’s reliability and effectiveness.

This solution not only protects valuable equipment and minimizes downtime but also ensures a safer working environment for operators.

With Remtron’s team of dedicated product Managers in addition to our technical team we can work on any project and help in improving efficiencies.  By offering a range of customised solutions to make sure it’s the best possible outcome for your application.