Maximizing Safety with Advanced Crane Collision Avoidance Sensors

Every country is pushing forward the Industry 4.0 revolution, which focuses on cementing rules for safer worksites using technological advancements. The need for it is crucial because, as per OSHA, there were 5,283 fatal work injuries in 2023. This means a worker died every 99 minutes from a work-related injury in the USA in 2023.

The causes of fatalities differed, but this alarming figure can not hide that safety is still a concern among most workers, especially those operating heavy machinery. Therefore, the need for advanced technologies, such as LED and LiDAR-based collision avoidance sensors, increases in such an environment.

These sensors are installed on cranes operating in different environments, such as warehouses, ports, manufacturing plants, etc. They support safety initiatives worldwide by helping humans avoid making fatal errors.

The global collision avoidance sensors industry is projected to reach USD 14.0 billion by 2031. It’s growing at a CAGR of 11.9%, showing its critical role in keeping the workforce safe globally.

Use KAD-300 and RSC-30LN to Prevent Crane Collisions

At Hokuyo, we’ve developed two industry-leading crane collision avoidance sensors, KAD-300 and RSC-30LN. Both are engineered for multiple purposes and focus on the same goal - to provide absolute safety. Let’s look at how they can make your organization’s worksite safer.

KAD-300

The KAD-300 is a retro-reflective infrared sensor with a primary function to prevent collisions between overhead cranes, monorail systems, and fixed obstructions. It is engineered to trigger slow-down and stop commands at adjustable distances up to 100 feet.
It is equipped with an integral FAULT output that provides an alert in real time if the sensor malfunctions.

Applications and Safety Benefits of KAD-300

It’s built specifically to prevent crane-to-crane and crane-to-wall collisions on the same runway. You can install the sensor on the crane bridge and mount a reflective target on the opposite wall or crane. The sensor will detect the reflective target within a set range and trigger a slow-down or stop command.

The industries which can use KAD-300 are:

Distribution and Warehousing - It can prevent overhead cranes from colliding with one another or the end walls where inventory racks are located.
Material Handling & Packaging - The sensor allows cranes to make safer automated movements by detecting runway obstacles early.
Automotive and Aerospace - The assembly line cranes can move freely without colliding with each other or fixed objects.
Overhead and Gantry Cranes - It prevents collision between two cranes deployed in the same working area.
Metal and Steel - It enhances safer operations for crane lifting, shifting, loading, and unloading heavy material. It detects other overhead cranes in the same bay at a set distance and stops movement until the path is clear.

Specification Table

Feature	Specification
Sensor Type	Retro-reflective infrared
Power Source	100-240VAC (50/60hz)
Detection Range	1 to 30 meters (100 feet)
Outputs	Three relay outputs for distance settings; one FAULT relay output
Response Time	≤50 milliseconds
Detectable Object	2 ft. x 2 ft. Retro-reflective Target (diamond-grade reflective surface)
Protective Structure	Rugged metal housing
Operating Temperature	-10 to +55 degrees C (14 degrees F to 130 degrees F)
Vibration Resistance	10 to 55 Hz, Double Amplitude: 1.5mm (X, Y, Z directions)
Impact Resistance	490 m/s2 (50G), 10 times in each direction (X, Y, Z)

Learn More About the KAD-300

RSC-30LN

The RSC-30LN is a scanning laser rangefinder designed and programmed for obstacle detection and collision prevention, especially for Rubber Tired Gantry cranes (RTG) and multi-level overhead cranes. Two sensor models are offered with a mounting bracket and an optional relay control box:

RSC-30LN-UP-DW (flush-mount bracket)
RSC-30LN-FR (horizontal-mount bracket)
RSC-C (control box)

Unlike the KAD-300, which operates on a fixed beam principle, the RSC-30LN uses a 190° scanning angle. It offers a similar detection range of 30 meters (100 feet), ideal for dynamic and high-bay to low-bay applications.

It is equipped with three configurable detection zones. Based on detection programming, it can gradually slow down or stop the crane movement.

Specification Table

Feature	Specification
Sensor Type	Scanning laser rangefinder
Power Source	10-30VDC (Sensor) / 100-240VAC (Control Box)
Detection Range	0.1 to 30 meters (black surface) / 100 feet max.
Scanning Angle	190°
Step Angle	0.25°
Detection Outputs	Three Configurable output zones
Detectable Object	Minimal detectable object: 65mm at 5m, 130mm at 10m, 400mm at 30m
Protective Structure	IP67
Distance Accuracy	+/-100mm (with 10% reflectance at 10m, with white Sheet at 30m)
Operating Temperature	-10 to +50℃ 85%RH (not condensing and icing)
Vibration Resistance	10 to 55Hz Double Amplitude 1.5mm, in each X, Y, and Z axis for 2 hours, 55 to 200 Hz 196 m/s2 sweep of 2 min. in each X, Y, and Z axis for 1 hour
Impact Resistance	196 m/s2 10 times in each X, Y, and Z axis
Interface	USB2.0 Full Speed, 12Mbps (for configuration of detection zone)

Applications and Safety Benefits of RSC-30LN

RSC-30LN is designed to excel at dynamic and static object detection. It is ideal for use in environments where multi-level overhead cranes or gantry cranes must operate in shared space or near other objects.
It helps cranes adapt their movements by providing real-time obstacle detection data and decreasing the chances of running into objects within the travel path.

Key industries, work sites, and cranes where it can deployed:

Distribution and Warehousing - It detects close-range objects and stops the crane from moving until the obstacle is removed.
Metal and Steel - It can detect potential obstructions on production lines and prevent damage.
Ports and Terminals - Shipping docks have numerous moving objects that can cause a collision with a moving crane. However, with RSC-30LN, the moving obstacles are detected early and save the crane from a collision.
Rubber Tired Gantry (RTG) Cranes - RSC-30LN ensures safety during container handling applications by stopping the crane from crashing into other infrastructure.

Learn More About the RSC-30LN

Adapt Advanced Crane Safety With Collision Avoidance Sensors

The safety of workers, equipment, and infrastructure is no longer an option. All three are essential for successfully scaling your business, and there’s no better way to start than by deploying crane safety measures. KAD-300 and RSC-30LN are equipped with the latest technology, such as LiDAR, and have superior detection capabilities to make your organization’s worksites safer.

You can choose any sensor based on your requirements and provide workers with a safe work environment. Besides, you will protect the workers and avoid federal scrutiny, as your company will already be following advanced safety measures.

At Hokuyo, we remain committed to research and developing flagship-level laser sensor solutions that make every industry safer, more efficient, and confident.

Have questions? Let’s talk.

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