Sensor technology and safety control systems for modern crane systems

When you look at a mobile crane or gantry crane, the first things you see are steel structures, hydraulics and heavy loads. Less visible are the systems that, working in the background, detect positions, monitor movements and ensure safe operation.

With increasing automation in particular, sensor technology, data transmission and intelligent control systems are becoming increasingly important. At bauma, it became clear just how closely these technologies are now linked to modern construction machinery and crane systems. Machines are becoming not only more powerful but also more connected. For manufacturers, this means providing components that deliver precise data whilst meeting high standards of safety and availability. It is precisely in this context that Kübler positions itself with a portfolio of sensor technology, transmission technology, displays and safety solutions for mobile automation.

Kübler develops sensor technology for mobile construction machinery

Kübler develops and manufactures its products exclusively in Germany. The company offers solutions for position and motion detection, slip rings, transmission technology, as well as displays and process visualisation. At the bauma, the focus was on mobile machinery, particularly crane applications. Numerous sensors are used there to monitor various movements and conditions. The requirements are high: the systems must operate reliably under changing weather conditions, vibrations and heavy mechanical loads.

A mobile crane is a good example of just how extensively modern sensor technology is now used. Encoders, for example, detect lifting movements and the rotation of the upper carriage. Wire-pull sensors measure the extension length of telescopic booms or the position of outriggers. Tilt sensors monitor the horizontal alignment of the vehicle and the angle of the crane boom. This creates a digital representation of the machine’s movements, which has become indispensable for both operation and safety functions.

Rotary encoders and wire-pull sensors monitor every movement

The increasing automation of cranes is fundamentally changing the role of sensor technology. Whereas previously the machine operator had to make all decisions alone, today assistance systems support the work. To do this, the control systems require precise information on the current position and movement of all components. Sensors provide this data in real time, thereby forming the basis for automatic functions and safety monitoring.

Typical tasks for sensor technology include:

• Lift measurement and load monitoring
• Detection of the upper carriage rotation
• Measurement of outrigger positions
• Determination of the telescopic length
• Monitoring of tilt angles
• Position detection for gantry cranes
• Speed and motion monitoring

Slip rings connect sensors and controllers

In addition to data acquisition, data transmission plays a central role. Slip rings are of particular importance here, and Kübler presented them as a new solution at the trade fair. In mobile cranes, slip rings are used to transmit electrical power, sensor signals and communication data between the upper and lower carriages. Without these components, a continuous exchange of information between the various machine parts would not be possible.

This is no longer just about individual Signals. Modern cranes transmit large volumes of operational data. Sensor information, control commands and fieldbus communication all converge via the same systems. The demands on reliability and fault tolerance are rising accordingly. For operators, this means that all relevant information is available at all times wherever it is needed for control and monitoring.

Safety control systems for cranes and industrial plants

Another key focus is on safety control systems. Whilst sensors collect data, these systems ensure that machines are operated within defined safety limits. Kübler offers compact safety control modules with the relevant certifications for this purpose. Various sensors can be connected to these systems to safely monitor positions, speeds and motion sequences. This plays a particularly important role in crane systems. Movements must be precisely controlled to prevent collisions or malfunctions. The combination of sensor technology and safety control makes it possible to meet high safety requirements whilst supporting automated processes. Particularly noteworthy is the close integration of the individual components. Whilst many suppliers provide either sensors or controllers, the company takes the approach of providing both areas in a coordinated manner from a single source.

Connectivity and Industry 4.0 are transforming automation

Developments in recent years clearly show the direction in which the industry is moving. Machines are increasingly becoming part of connected systems. Sensors no longer supply data exclusively to the local machine control system, but frequently also to higher-level operational and fleet management systems. In the context of Industry 4.0, standardised interfaces and reliable communication between different systems are therefore becoming increasingly important. Sensors must provide information that is not only precise but also usable in complex digital environments. This opens up new possibilities for operators of cranes, construction machinery and industrial plants. Maintenance intervals can be planned more effectively, operating conditions continuously monitored and processes controlled more efficiently. The solutions presented at bauma demonstrate that modern automation today extends far beyond individual sensors. The key lies in the interplay between data acquisition, transmission, safety functions and intelligent networking. It is precisely this integration that will determine how efficiently and safely machines operate in daily use in the future.