UWB Positioning Solutions for Overhead Cranes, Gantry Cranes, Bucket Wheel Stackers, and Portal Cranes

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, these systems provide early warnings and automatically adjust operational statuses to prevent collisions. They are widely used in industries such as logistics, warehousing, manufacturing, metallurgy, and power generation. Particularly in scenarios requiring frequent movement and positioning of cranes (e.g., automated warehouses, production lines), these systems significantly enhance operational safety and stability while reducing the likelihood of accidents. The positioning control and anti-collision systems for overhead cranes, bridge cranes, and gantry cranes are essential 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 collision avoidance warnings, providing reliable protection for industrial operations.

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 (main girder), two stations suffice. Generally, one station is installed at the starting point of the crane rail as the zero point, and one is installed on the bridge. The distance measured between the station on the bridge and the origin station determines the bridge's position along the rail, which we denote as X. Another station installed on the trolley measures the distance relative to the station on the bridge, providing the trolley's position along the bridge rail, denoted as Y. Thus, we obtain the real-time XY coordinates of the overhead crane.

Overhead Crane Positioning Principle

Overhead Crane Hook Positioning Principle

How do we position the overhead crane hook when needed?

The crane hook moves with the trolley and cannot have devices installed via direct power supply. In this case, we use battery-powered ranging tags installed on the hook. Real-time ranging between this tag and the terminal on the trolley provides the hook's real-time height.

As shown in the figure, this is our ranging tag. It is powered by a 750 mAh rechargeable lithium battery and can operate continuously for over one month at a 1 Hz frequency. Designed with an IP67 waterproof and dustproof rating, the tag's back can be equipped with strong magnets for direct adsorption and fixation onto 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, and pliers, and a laptop for debugging.

Second, prepare antenna mounting bracket poles in advance. These poles are used for installing directional antennas, and the recommended pole height is no less than 0.5 meters.

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 central axes 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; no obstructions should be present in between.

Fifth, to ensure optimal positioning performance, antennas should be spaced at least 40 cm away from walls or metal surfaces.

Installation requires that antennas measuring distance to each other are 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.