Portable geo-location and banksman positioning tracker for enhancing crane operation accuracy and safety

Abstract

The system comprises a crane-mounted device that is calibrated accordingly with the crane’s jib / boom positioning. This may include setting the position of the crane slew to 0 degrees when the crane bo

Description

Technical Field This invention relates to crane operations and aims to improve lifting precision, safety, and efficiency on construction sites. Specifically, it introduces a portable geo-location and slinger / banksman positioning tracker system designed to display a slinger / banksman's position relative to a calibrated reference point installed on the crane. The device installed on the crane is paired with a handheld device carried by a slinger / banksman. This pairing allows the slinger / banksman to visualise their position relative to the crane on their handheld device, as if the crane were directly overhead. The crane driver already uses a device installed in the cabin that displays the crane's live position, including slew angle, jib / trolley radius, and hook block height. The proposed device and invention is installed on the crane at the centre of the slew ring, and establishes a 0-degree reference point on the slinger / banksmans device (e.g., facing north). By sending this information to the slinger / banksman's hand-held device, the system provides the distance and angle of the slinger / banksman from the crane. This enables the on ground person to see their position relative to the crane in the same way the crane driver perceives the crane's position. When a slinger / banksman communicates these two coordinates (slew angle[°] and jib / trolley radius[m]) to the crane driver, the crane driver can then accurately position the crane directly above the slinger / banksman and lower the load into the location needed by the banksman. This proposed system greatly enhances communication between the ground crew and the crane operator by providing precise positional data of the slinger / banksman. Additionally, the system can integrate with smartphone applications and other portable devices in future versions, and it includes options for devices installed within the crane cabin or directly on the load. Background of the Invention Cranes are critical in construction, industrial, and logistical operations for moving heavy loads efficiently and safely. However, their operation poses significant challenges, especially on large construction sites where visibility is often obstructed, requiring crane operators to rely on external guidance from ground personnel. These situations, commonly referred to as “blind lifting,” demand precise coordination between the crane operator and the banksman or slinger signaller, who guides the load to its target location. The absence of direct visual contact with the load increases the potential for errors, decreases operational speed, heightens safety risks, and adds greater fatigue for the crane team. Various technologies have been developed to enhance crane operation efficiency and safety by providing real-time data on load positioning. These systems typically give the crane operator accurate information about the load’s position in relation to the crane and its surroundings. However, despite these advancements, there remains a need for a more flexible, portable solution that allows ground personnel to monitor and guide crane movements effectively, particularly in blind lifting scenarios. Several patents in this field address real-time crane load positioning, such as US9041595B2, which discloses a tower crane load location determiner. This system employs sensors, including long-range radar or laser measurement units, to calculate the load’s location and transmit this information to the crane operator through a user interface. Another example is EP2794456A1, which describes a crane load location system that utilises radar, laser, and satellite systems for load tracking. Both patents focus on advanced sensors that measure the load's position and provide the crane operator with continuous, real-time data through a display inside the crane cab. While effective at improving operator awareness, these systems rely on fixed installations integrated into the crane, limiting their flexibility in multi-crane environments or situations where rapid operational changes are required. The present invention, the Portable Geo-Location and Banksman Positioning Tracker, introduces a distinct approach. Instead of focusing solely on load positioning for the crane operator, this invention prioritises the coordination between crane operators and ground personnel. The system is designed to provide the banksman or slinger signaller with their own position relative to the crane’s slew angle (based on a fixed reference point, such as 0 degrees when the crane is facing north) and jib radius (determined by the distance between the crane and the banksman). This allows the banksman to communicate precise instructions to the crane operator, who already has access to live crane positioning data in the cabin. A key feature of this invention is that it does not track the crane’s live movements for the banksman. Instead, the system enables the banksman to understand their own position based on the crane's calibrated slew angle and jib radius, allowing for more efficient guidance during blind lifts. The crane operator can then adjust the crane's movements according to the banksman’s instructions. The major advantages of this system over those described in US9041595B2 and EP2794456A1 include: 1. Portability and Flexibility: Unlike fixed systems integrated into the crane structure, this invention features portable devices that can be easily carried by personnel. The crane-mounted device is magnetically attached to the slew ring, jib, or mast and is equipped with replaceable batteries. Ground personnel can monitor their own position relative to the crane’s calibrated slew angle and jib radius without needing live crane tracking data. 2. Use of Smartphone or App (Optional): Although smartphone use is generally restricted on construction sites, the invention can optionally pair with a smartphone via an app. The app allows users to drop a point on a virtual map, which calculates the slew angle and radius relative to that location, providing an alternative to the handheld device in certain environments. 3. Driver Cabin Pairing: Another innovative feature involves pairing a device in the driver's cabin with the banksman's portable device. This pairing enables the crane driver to view the banksman / slinger's location and coordinates (slew angle in degrees and jib / trolley radius in metres) on a screen within the cabin. 4. Device on a Tag Line: An additional improvement involves installing a device on a tag line attached to the load. This device communicates with the portable device, transmitting “y” height information to the crane operator’s cabin, allowing for more precise load handling or when personnel are waiting for the crane to come with crane chains for a banksman / slinger to attach a load. 5. Enhanced Communication: The invention improves communication between crane operators and ground personnel. In its initial version, the banksman communicates their position, based on slew angle and jib radius, verbally over the radio to the crane operator. This manual interaction differs from automated systems and may better suit certain operational preferences, particularly in environments where human judgement is critical. 6. Point-and-Click Laser Add-On: For future iterations, the system may include a point-and-click laser add-on for the portable device. This would allow ground personnel to point the laser at distant or lower-level locations to calculate the slew angle and radius of a point, determining whether the crane can reach it without requiring personnel to physically walk to the target. 7. Adaptability to Multi-Crane Operations: The system enables ground personnel to switch between cranes by adjusting settings on their portable devices, similar to changing channels on a two-way radio. This adaptability is particularly beneficial in multi-crane construction sites, a feature not emphasised in prior art systems that typically focus on single-crane setups. Despite advancements in prior technologies, such as those disclosed in US9041595B2 and EP2794456A1, there remains a gap for a flexible, portable solution that enhances communication between crane operators and ground personnel (banksman / slinger). This invention fills that gap by empowering ground personnel to take control of their real time positioning data, improving coordination and safety during blind lifting operations. Additionally, the ability to seamlessly switch between cranes and easily transfer devices across the site adds a level of versatility not found in fixed systems. Statement of Invention The present invention provides a portable geo-location and banksman positioning tracking system designed to improve the accuracy, speed, and safety of crane operations, particularly in environments where crane operators are unable to directly see the load they are handling (commonly referred to as "blind lifting" operations). The system comprises a portable device used by ground personnel, such as a banksman or slinger signaller, to determine their own position relative to the crane's slew angle (calibrated from a 0-degree reference point) and jib radius (which corresponds to the distance from the crane). This positional information is then communicated to the crane operator, who uses it to adjust crane movements accurately. The system enhances communication and coordination between crane operators and ground personnel by providing the banksman with their precise position in relation to the crane’s fixed slew angle and radius, allowing for more effective guidance of the crane operator. The portable nature of the device allows for greater operational flexibility, enabling personnel to switch between different cranes easily. This flexibility is especially valuable on construction sites where multiple cranes are in use. Additionally, multiple devices can be paired with the same crane, providing synchronised real-time updates to various members of the lifting team. In the initial version of the system, the banksman communicates their position data to the crane operator via radio. Future iterations of the system may include: • A display installed in the crane cabin, showing the banksman’s position in real-time, thus eliminating the need for verbal communication. • Integration with a device in the crane cabin, which could use the crane’s internal data to show the ground operative’s position without needing a separate geo-location device mounted on the crane. • Optional smartphone app support, offering additional control and flexibility. • The potential to install a device on the load or a tagline, which would communicate height and load information to the crane operator, providing even greater precision in load handling. Advantages The Portable Geo-Location and Banksman Positioning Tracker offers several key advantages over existing crane load location systems: 1. Portability and Flexibility: Unlike traditional systems that rely on fixed installations within the crane structure, this portable device can be easily carried by ground personnel. It uses a magnetic attachment system, allowing it to be securely placed on different parts of the crane (e.g., the slew ring, mast, or cabin), and is powered by a replaceable battery. This design enables quick deployment, easy transfer between cranes, and adaptability in dynamic work environments, such as multi-crane construction sites. 2. Enhanced Communication in Blind Lifting: The system significantly improves coordination between the crane operator and the banksman (or slinger signaller) by showing the banksman’s position relative to the crane’s fixed slew angle and jib radius. This enables precise verbal guidance, particularly in blind lifting situations where the operator cannot see the load. The crane operator, equipped with live crane positioning data, can adjust movements based on the banksman’s instructions. 3. Increased Operational Speed and Efficiency: By providing accurate real-time positioning data based on the crane’s fixed parameters, the system reduces the time required to execute lifts and minimises the number of corrections needed during load placement. This results in a reduction of crane downtime, an increase in productivity on site, and decreased fatigue for the lifting team. 4. Improved Safety: The system enhances safety by reducing communication errors between the crane operator and the ground team, particularly in hazardous or obstructed environments. With the banksman's ability to accurately view their position relative to the crane’s movement, the risk of accidents, injuries, and equipment damage is significantly reduced. 5. Multi-Device Pairing and Multi-Crane Operation: The system supports pairing multiple devices to the same crane, allowing several banksmen or signallers to receive synchronised real-time updates simultaneously. This is especially useful on large construction sites where multiple teams may be monitoring crane operations. Additionally, personnel can switch between cranes by adjusting device settings, similar to changing channels on a radio, offering flexibility in multi-crane setups. 6. Scalability: The system is designed for easy scalability. Starting with a minimum viable product (MVP) that relies on verbal communication over radio, future iterations could include: A display device installed in the crane cabin to provide real-time banksman positioning data directly to the operator. Integration of devices within the cabin that can sync with crane data systems, eliminating the need for a separate geo-location device mounted on the crane. An optional point-and-click laser add-on for the portable device, allowing the calculation of slew angle and radius for remote or hard-to-reach locations. 7. Cost-Effective Solution: By focusing on essential metrics such as slew angle and jib radius, the system avoids the need for expensive sensors like long-range radar or laser measurement units. This makes it an affordable solution for improving crane operations without compromising safety or precision. Detailed Description The Portable Geo-Location and Banksman Positioning Tracker is designed to enhance the precision, safety, and efficiency of crane lifting operations, particularly during "blind lifts" where crane operators lack direct visual contact with the load. By utilising portable devices, the system allows ground personnel, such as the banksman or slinger signaller, to determine their own position relative to the crane’s fixed slew angle and jib radius. This provides precise, real-time information to guide crane operators effectively, even when visibility is restricted. The invention comprises multiple components that work together to offer a flexible, scalable, and portable solution for crane operation management. The system is adaptable to various types of cranes, including tower cranes, mobile cranes, and crawler cranes, ensuring operational flexibility in multi-crane environments. System Components The system consists of the following key components: 1. Crane-Mounted Device 2. Portable Handheld Device 3. Display and Communication System 4. Pairing and Signal Amplification Unit (Optional) 1. Crane-Mounted Device This device is magnetically attached to the crane, typically installed near the slew ring, on the crane base, or inside the operator’s cabin. It is responsible for determining the banksman’s position relative to the crane, based on fixed crane parameters: • Calibration of Slew Angle: The device is calibrated to 0 degrees when the crane boom is facing a reference direction (e.g., north). As the crane moves, the banksman’s position is determined based on the angle from this fixed reference point. • Calculation of Jib Radius: The banksman’s distance from the crane is measured based on their distance from the device (jib radius). For trolley or luffing jib cranes, this measurement dynamically changes based on the jib or trolley's extension or retraction. • Transmission of Data: The device transmits the banksman’s position, including the slew angle and jib radius, to the portable handheld devices wirelessly, using radio-frequency (RF) communication or Bluetooth. The device is designed to withstand harsh construction environments, including dust, vibrations, and weather conditions. 2. Portable Handheld Device The portable handheld device, used by the banksman or slinger signaller, receives real-time positioning data and displays it, allowing ground personnel to guide crane operations accurately. • Real-Time Display: The handheld device features a display screen showing the banksman’s position relative to the crane’s fixed slew angle and jib radius in real time. This allows ground personnel to understand their position concerning the crane, even when the operator’s view is obstructed. • User Interface: The interface is simple and user-friendly, designed to help ground personnel quickly interpret the data in stressful or time-sensitive situations. It may display graphical or numerical representations of the crane's angle and radius for easier comprehension. • Manual Communication Feature: In the initial version, the banksman verbally communicates the data displayed on the handheld device to the crane operator via radio. This manual communication ensures that ground personnel maintain control over crane operations, even in environments where automated systems might fail. • Portability: The handheld device is lightweight and rugged, designed to withstand rough handling, rain, dust, and impacts. Multiple handheld devices can be paired with the same crane, allowing different team members to access synchronised real-time data. • Device Pairing: The handheld device can switch between cranes by adjusting settings, similar to changing radio channels. This feature is essential for multi-crane construction sites where personnel need flexibility in managing different cranes.3. Display and Communication System The communication system facilitates real-time data exchange between the crane-mounted device and the handheld devices, consisting of: • Wireless Transmission: The system uses RF or Bluetooth protocols to ensure quick and accurate data transmission between the crane and portable devices. Even in large construction sites with multiple obstacles, the system maintains robust signal integrity. • Display in Crane Cabin (Future Iterations): Future versions of the system may include a display installed in the crane cabin, allowing the crane operator to monitor the slew angle and jib radius data directly. This enhances operational efficiency and safety by providing the operator with real-time information without relying on verbal communication. • Multiple Device Synchronisation: The system allows multiple handheld devices to be connected to the same crane, ensuring that all users receive synchronised real-time updates. This feature is especially useful when coordinating large lifting teams or during blind lifts involving multiple banksmen. 4. Pairing and Signal Amplification Unit (Optional) In cases where signal strength is an issue due to large site areas or radio interference, an optional signal amplification unit can be used: • Signal Strengthening: The amplification unit boosts signal strength to overcome potential interference or long-range communication challenges, ensuring data reaches the handheld devices without delay or interruption. • Optional Use: The amplification unit is typically used only when the wireless signal is weak, such as in extensive construction sites or environments where multiple structures obstruct communication. Under most conditions, the system operates effectively without the need for signal amplification. Operational Workflow The system operates as follows during crane activities: 1. Crane Setup: The crane-mounted device is securely attached near the slew ring or inside the crane cabin. Once powered on, the device is calibrated to a 0-degree slew angle (e.g., facing north) and begins transmitting real-time data regarding the banksman’s position. 2. Banksman Guidance: The banksman uses the portable handheld device to monitor their position relative to the crane’s slew angle and jib radius. In blind lifting operations where the crane operator cannot see the load, the banksman provides verbal instructions via a two-way radio, guiding the operator based on the displayed data. 3. Real-Time Adjustment: The crane operator adjusts the crane’s movements in response to the banksman’s guidance. This process is repeated until the load reaches its destination, with continuous monitoring of the crane’s position. 4. Multi-Crane Environment: In sites where multiple cranes are in operation, the banksman can switch between cranes by adjusting the handheld device’s pairing settings. Each crane is associated with a unique communication channel, allowing seamless transitions between cranes as required. While the current version requires manual communication between the banksman and the crane operator, future iterations may include a direct communication system to the crane cabin. In these advanced versions, the operator would receive real-time slew angle and jib radius data directly, reducing reliance on verbal instructions and minimising human error, further improving operational efficiency.

Claims

1. A portable geo-location and banksman positioning tracking system for improving crane operation accuracy and safety in real time, comprising:a crane-mounted device working as an anchor point that is calibrated accordingly with crane jib / boom positioning. E.g: when both the crane boom and the device are facing north, the position of the crane slew angle is 0 degrees, and the device is configured according to which side the crane is rotating; clockwise or anti-clockwise.a portable handheld device used by ground personnel such as a banksman / slinger; said device displays real-time monitoring of the slingers position relative to the crane’s fixed parameters. Eg. it will show where the banksman is currently on site (in x and y coordinates), in relation to the crane slew angle and jib / trolley radius. With those two metrics (slew angle[°] and jib / trolley radius[m]) given to the crane driver, the crane driver, having his own display in his cabin, can position the crane precisely in this x / y location where the banksman is situated in real time.a wireless communication system enabling real-time data transmission between the crane-mounted device and the portable handheld device;a system for enabling multiple handheld devices to be paired to a single crane, wherein each device can display synchronised real-time data; and a mechanism allowing the handheld device to switch between different cranes, enabling personnelto monitor and guide multiple cranes in a multi-crane environment efficiently.

2. The portable geo-location and banksman positioning tracking system of Claim 1, wherein the crane-mounted device is attached near the crane's slew ring, on the crane mast, or within the crane operator’s cabin, providing real-time measurement of the crane’s slew angle and jib radius.

3. The portable geo-location and banksman positioning tracking system of Claim 1, wherein the portable handheld device comprises:a display screen configured to show real-time values for slew angle and jib radius relative to the crane’s fixed base;a user interface that enables switching between multiple cranes based on the selected radio frequency or communication channel;a durable and portable form factor, designed for use in harsh construction environments, including dust, rain, and impact resistance.

4. The portable geo-location and banksman positioning tracking system of Claim 1, further comprising a signal amplification unit designed to boost communication signals between the crane-mounted device and the portable handheld device in cases of long-range operation or significant signal interference.

5. The portable geo-location and banksman positioning tracking system of Claim 1, wherein the wireless communication system is configured to use radio frequency (RF) transmission, Bluetooth, or other short-range communication technologies to ensure robust data transmission in challenging construction environments.

6. The portable geo-location and banksman positioning tracking system of Claim 1, wherein the handheld device is capable of receiving real-time data from multiple cranes by switching between designated communication channels, similar to a two-way radio system, allowing personnel to manage multi-crane operations effectively.

7. The portable geo-location and banksman positioning tracking system of Claim 1, wherein the crane-mounted device acts as an anchor point, enabling ground personnel to visualise their own location on the site using crane coordinates (slew angle and jib / trolley radius in metres). This simplified approach eliminates the need for complex load position determination technologies like radar, laser, or GPS, as disclosed in US9041595B2 and EP2794456A1.

8. The portable geo-location and banksman / slinger positioning tracking system of Claim 1, further comprising an option to install a display screen within the crane operator’s cabin, showing real-time banksman / slinger positioning on site.

9. A method for improving crane operation accuracy and safety using a portable geo-location and banksman / slinger positioning tracking system, the methodcomprising:attaching a crane-mounted device to measure banksman / slinger positioning on site, according to crane’s slew angle and jib / trolley radius;transmitting the measured slew angle and jib / trolley radius data wirelessly to a portable handheld device used by ground personnel;displaying the real-time slew angle and jib / trolley radius data on the portable handheld device,displaying the real-time banksman / slinger positioning on site according to crane’s slew angle and jib radius data on the portable handheld device allowing ground personnel to determine their position relative to the crane and guide the crane operator during lifting operations;enabling multiple portable handheld devices to be paired to a single crane, with each device displaying synchronised real-time data; andallowing the portable handheld device to switch between cranes by changing communication channels, enabling efficient management of multiple cranes in a multi-crane construction site.

10. The method of Claim 9, wherein the crane-mounted device measures the slew angle by detecting the rotational position of the crane’s jib relative to the base.

11. The method of Claim 9, wherein the portable handheld device allows ground personnel to communicate the crane's slew angle and jib radius to the operatorverbally, particularly during blind lifting operations where the operator cannot see the load.

12. The method of Claim 9, wherein the system operates without complex load measurement technologies such as long-range radar, laser distance measuring, or GPS, distinguishing it from systems disclosed in US9041595B2 and EP2794456A1, which focus on full load position tracking.

13. The method of Claim 9, wherein the system operates by simplifying crane movement data to slew angle and jib / trolley radius, enhancing operational safety without requiring precise load position tracking as claimed in other patents.

14. A crane operation management system, comprising:a method for switching the portable handheld device between different cranes operating on a construction site, allowing ground personnel to guide multiple cranes using a single device by selecting different communication channels; anda wireless communication protocol that supports multiple devices receiving synchronised real-time data from the same crane, improving coordination in multi-crane operations.21