Professional IoT solution equipment supplier 
Solution Overview
The positioning control and anti-collision systems for overhead cranes, bridge cranes, and gantry cranes utilize wireless pulse ranging technology to achieve high-precision positioning. By monitoring distances in real-time for early warning and automatically adjusting status to prevent collisions, they are widely used in industries such as logistics, warehousing, manufacturing, metallurgy, and power. Particularly in scenarios requiring frequent movement and positioning of cranes (e.g., automated warehouses, production lines), these systems can significantly enhance operational safety and stability, reducing the likelihood of accidents. The positioning control and anti-collision systems for overhead cranes, bridge cranes, and gantry cranes are crucial equipment for ensuring industrial production safety. By employing advanced wireless pulse ranging technology, high-precision sensors, and intelligent control algorithms, these systems enable real-time crane positioning and anti-collision warnings, providing reliable safeguards for industrial production.
Application Areas: Can be used for overhead crane positioning, bucket wheel machine positioning, rail-mounted equipment positioning, gantry crane positioning, etc.
Solution Features
- Positioning accuracy of 10 cm, with no cumulative error;
- 24/7 continuous operation, 365 days a year;
- Quick and simple installation, operational upon power-up;
- Industrial-grade design with IP67 protection rating;
- Unaffected by dust, moisture, rain, or snow.
System Architecture
The overhead crane positioning system primarily consists of an origin ranging terminal and ranging terminals installed on the crane. Data is transmitted to the server or PLC via 485 or RJ45 interfaces.
Typically, to position the trolley of an overhead crane, three ranging base stations need to be installed. For positioning only the bridge (girder), two stations are sufficient. Generally, one station is installed at the starting point of the crane rail as the zero point (origin). Another station is installed on the bridge. The distance measured between the station on the bridge and the origin station gives the bridge's position along the rail, which we can denote as X. A third station is installed on the trolley. The distance measured between this station and the one on the bridge gives the trolley's position along the bridge rail, which we denote as Y. Thus, we obtain the real-time XY coordinates of the crane.
Introduction to Overhead Crane Positioning Principle
Overhead Crane Hook Positioning Principle
How do we proceed if we need to position the overhead crane hook?
The crane hook moves with the trolley, making it impractical to install a directly powered device. In this case, we use our battery-powered ranging tag. By installing this tag on the hook and performing real-time ranging between the tag and the terminal on the trolley, we can obtain the real-time height of the hook.
As shown in the figure, this is our ranging tag. It is powered by a 750mAh rechargeable lithium battery, can operate continuously for over one month at a 1Hz frequency, and features an IP67 waterproof and dustproof design. The back of the tag can be equipped with strong magnets for direct attachment and fixation to metal surfaces.
Installation Notes for Overhead Crane Positioning Terminals
First, before going to the site for installation, prepare mounting brackets, power cables, electrical tape, installation tools such as screwdrivers, wrenches, pliers, and a laptop for debugging.
Second, prepare antenna mounting bracket poles in advance. These poles are used to install directional antennas, and a pole height of at least 0.5 meters is recommended.
Third, requirements for terminal antenna installation: Directional antennas that measure distance to each other should ideally be at the same horizontal height. Since the measured distance is from antenna to antenna, the centerlines of the ranging antennas should be aligned opposite each other.
Fourth, there must be a clear line of sight between antennas that measure distance to each other, with no obstructions in between.
Fifth, to ensure optimal positioning performance, antennas should be spaced at least 40 cm away from walls or metal surfaces.
The installation requires antennas that measure distance to each other to be on the same horizontal plane. Directional Antenna 2 on the bridge should face Origin Directional Antenna 1; Directional Antenna 3 on the bridge should face Trolley Directional Antenna 4. Origin Directional Antenna 1 should face Bridge Directional Antenna 2, and Trolley Directional Antenna 4 should face Bridge Directional Antenna 3.
Content Reviewer: YAO Pinggui (Jimme Yao)
