Crane Safety Control System with Person Detection
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Solution Overview
Problem
Gantry cranes pose safety risks due to potential snagging and uncontrolled movement of loads, especially during initial lifting operations, which can result in hazardous situations for operators and equipment.
Innovation Solution
A crane control system equipped with sensors, such as cameras and motion detection systems, that inhibit lifting operations when a person is detected within the safety region, ensuring safe operation by preventing lifting until the area is clear, and allowing only controlled movements to prevent load swing and collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of the crane is maintained, then operational flexibility and ease of use are preserved, but safety risks increase due to potential human error and inability to respond quickly to hazardous situations
Solution Approach 1:
The patent replaces manual mechanical control with an automated control system that uses sensors (optical, thermal, motion detection) to detect persons in safety regions and automatically inhibits lifting operations. This substitution of manual operation with sensor-based automated control resolves the contradiction by improving safety through continuous monitoring while managing complexity through integrated control logic.
Solution Approach 2:
The control system performs self-monitoring and self-protection by automatically detecting hazardous conditions (persons in safety regions) and taking corrective action (inhibiting lifting operations) without human intervention. This self-service capability improves safety while the automated nature manages operational complexity.
2Reliability
If lifting operations are continuously monitored and inhibited when persons are detected, then safety is improved, but operational efficiency and productivity decrease due to frequent interruptions
Solution Approach 1:
The system performs preliminary detection of persons in safety regions before lifting operations commence or continue. By detecting hazards in advance and preventing them before they result in accidents, the system improves safety while minimizing interruptions to legitimate operations. The preliminary action allows operators to clear the area proactively rather than experiencing reactive stoppages.
Solution Approach 2:
The control system continuously monitors the safety region and provides real-time feedback on the presence of persons. This feedback mechanism allows for dynamic adjustment of lifting operations, improving safety through continuous awareness while optimizing productivity by only inhibiting operations when actually necessary. The feedback loop enables operators to make informed decisions about area clearance and operation resumption.
3Reliability
If the safety region is defined broadly to maximize protection, then safety coverage is improved, but the frequency of false alarms and unnecessary operation inhibitions increases
Solution Approach 1:
The patent applies different detection methods and sensitivity levels to different zones within or around the safety region. By using multiple sensor types (optical, thermal, motion detection) with different characteristics, the system achieves comprehensive safety coverage while reducing false alarms through multi-parameter verification. This local differentiation of detection quality optimizes both safety and operational continuity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces the risk of accidents by ensuring that operators are not in the danger zone during critical lifting phases and prevents load collisions, enhancing overall safety and operational precision.
Implementation Method 1
the at least one sensor can be a thermal imaging camera suitable for detecting the body heat of a person entering the safety region
Implementation Method 2
Alternatively, the at least one sensor can be a motion detection sensor
Data Source
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AI summary
The present invention relates to a crane (101).The crane (101) has a hoist (113) for performing a lifting operation and a controller (125) for controlling operation of the crane. At least one sensor (127) is provided for detecting the presence of a person in a safety region (129). The controller (125) is configured to inhibit operation of the crane (127) when the sensor (127) detects a person in the safety region (129).The present invention also relates to a crane control system and a method of operating a crane (101).