Automated vs semi-automated overhead crane: which one to choose?

Do you sometimes feel that your overhead crane operators are doing repetitive tasks? You might even be thinking: “We employ someone to systematically perform the same manipulations with our overhead cranes. If only we could automate this process!”

Indeed, whether it’s to save space, improve organization or speed up the production line, every strategy for improving a process should be analyzed. Otherwise, the company may unknowingly be spending resources that could be better invested.

Premium Industrial Group participated in the successful commissioning of overhead crane automation projects in Quebec. And since every need is different, we’ve been able to adapt each solution thanks to an experienced electrical design team. But I’ve noticed a confusion during my conversations about automation in the lifting industry: what exactly can be automated? Can a lifting cycle be fully automated? And what about safety?

For this reason, in this article, we will compare the following 2 types of overhead cranes :

1. Semi-automated overhead cranes
2. Automated overhead cranes

We’ll look at their key features and strengths, as well as application examples. After reading, you’ll be able to decide whether an automated or semi-automated overhead crane could be right for you to boost your productivity.

Semi-automated overhead cranes: operation, safety and strengths

An overhead crane is considered semi-automated when part of the lifting cycle, or a particular lifting sequence, is automated, while the rest of its operations are performed by a human operator with manual control. This is not a sub-feature (such as an anti-sway or zoning system), but the operation of the crane itself.

Let’s take an example: an operator manually moves the overhead crane to a location to hook a load. Then, using a special command available on his remote control, he automatically sends the crane to a starting location (also known as the “home” function). When the crane is at this point, another special command is used to automatically move it from point A to point B. The operator can then remove the load and, either manually or automatically, return the crane to its starting point. As you can see, not all overhead crane operations are automated, but only part of them.

The key features are much the same as those of a conventional manually operated overhead crane, with a few minor nuances.

Control

Manual, wired or wireless. In many cases, however, the control has additional pre-programmed buttons for switching to automated mode.

Safety

The operator is responsible for his load at all times, even when the equipment switches to automated mode. In fact, even if he is not in control of the operation in progress, he must be ready to intervene at any time by regaining control of the load. For example, in order to prevent an accident, they must be able to press the red stop-reset button (commonly referred to as the emergency stop), which will temporarily disable the automation.

What are the advantages of this type of automation?

The advantages of semi-automated overhead cranes

The semi-automated overhead crane offers significant advantages for certain applications.

1. Interesting for delicate but repetitive maneuvers. Increases safety.
2. Can speed up operations by reducing human-induced downtime.
3. Can help synchronize several pieces of equipment at the same time.
4. Useful for applications in confined spaces. For examples, when you need to estimate from the ground the height you need to reach to get over a high obstacle.

There are many possible applications where semi-automated lifting can be advantageous.
Let’s take a look at a few examples.

Examples of semi-automated overhead crane applications

Feeding a production machine

The example mentioned above can easily apply to feeding a production machine. If approaching the machine is tricky, it might be possible to create an automated sequence from point A – departure – to point B – the machine – while the rest of the maneuvers are performed by an operator.

Assembly plant

In some industries, such as assembly plants, the overhead crane may have to move slowly along a production line. It could be worthwhile installing an automated travel function. When the function is triggered, the semi-automated overhead crane moves along the production line at the right speed, without intervention. But during this movement, the system could offer the operator the option of moving up or down to align the part, in addition to usual interruption mechanisms.

Sandblasting chamber

In other applications, such as sandblasting chambers, it is even possible to automate travel in the same way as the previous option, while enabling you to go in the opposite direction at any time. In other words, when you activate automation to move the overhead crane into the sandblasting chamber, you can manually move the lifting device backwards (in the opposite direction) when necessary. However, once the travel button is released, the equipment automatically starts moving again.

These are only a few examples of possible applications, but there are many more. However, in the case of the automated overhead crane, there are some notable differences which we will examine.

Automated overhead cranes: operation, safety and strengths

An automated overhead crane is a lifting system that performs all these lifting cycles without the intervention of a human operator. It is completely autonomous, operated by a computerized management system. It only needs to be activated by a person with access to the system. It will then perform all the operations for which it was designed.

Here are the key features of this type of automation.

Control

No wired or wireless control. The control system is housed in a module with an interface. It’s a management system, or software solution, that processes commands according to an established program. A manual override is usually provided for maintenance purposes only.

Safety

In the case of a fully automated overhead crane, safety is managed in a very different way. The environment itself has to be made completely safe. This means that no one will be able to circulate in the area of the automated crane while it is in operation. In fact, when someone enters the area, the entire system stops and doesn’t restart until the person has left.

The advantages of automated overhead cranes

This type of lifting equipment works much like an autonomous robot. Here are the advantages of this system.

1. Can operate 24/7 with minimal supervision.
2. Can make a major contribution to optimizing space by reducing or even eliminating traffic areas (for pedestrians or forklifts, for example), while maximizing overhead space.
3. Productivity is enhanced thanks to algorithms that systematically establish the shortest paths, thus increasing part circulation speed.
4. Allows reallocation of manpower to value-added jobs.

What applications are suitable for this type of lifting equipment?

Examples of automated overhead crane applications

Warehousing

Material handling

Who leads the overhead crane automation project, and what determines its success?

Essentially, the overhead crane supplier specializes in lifting. That’s why, as a general rule, this kind of solution will involve another company specializing in process automation. Let’s take a closer look at how an automation project works, depending on whether it’s partially or fully automated.

The semi-automated overhead crane

Who leads the automation project?

The overhead crane manufacturer

Most lifting equipment suppliers can work with you on a semi-automated overhead crane project. But naturally, it’s important to check with them whether they can handle your project, depending on its complexity.

Decisive factor in project success

The electrical design team

This team must have the knowledge and experience for this type of project. When an experienced electrical team is in place, it can take charge of the project, involving technology partners who offer solutions that match your needs.

The automated overhead crane

Who leads the automation project?

The company specializing in process automation

Overhead crane companies in general don’t do process automation. Instead, it’s specialized companies that should be involved, as they have cutting-edge expertise in the field. In fact, it’s not uncommon, on a project of this kind, for other machinery to be automated as well.

Decisive factor in project success

Preparing the lifting equipment, especially the manipulator

The most important role your overhead crane supplier will play in the success of the project is to prepare the lifting equipment for integration into the automation solution. This may include adding sensors or other technological mechanisms. What’s more, these projects often require a special manipulator instead of the traditional hook on the hoist. This may be a claw, a grapple or a magnet system. In all cases, the overhead crane needs to be adapted to this special accessory.

Overhead crane automation project : leader and success factors

In short, it’s a matter of close collaboration between various specialized players who combine their efforts to ensure the project’s success. Their professionalism and ability to work in synergy will make the difference in the success of this type of project.

And what about you? How do you approach such a challenge?

Where to start for a successful automation project?

To find which solution is best suited to your needs, it’s important to determine whether certain operations would benefit from automation. If so, partial or complete automation could well increase your productivity and profitability. On the other hand, sticking to traditional methods could well slow down your growth. Automation could therefore be a way of standing out in an increasingly competitive world.

So if you find that your lifting operations are repetitive, and you see a potential for automation, why not evaluate it? But where do you start with such a complex project?

First, determine what needs to be automated. Establish the critical points. Draw a diagram of the production stages involving the overhead crane, for example, identifying points A, B and C. Then contact your lifting specialist to see if the project is feasible.

Key differences between semi-automated and automated overhead cranes

A few key points before starting your automation project

Here are a few key points to check before contacting your specialist :

1. Does the project involve existing or new equipment?
   
   
2. If it’s existing equipment, is it suitable for special lifting accessories (plan to provide electrical drawings)?
   
   
3. How do you plan to manage the safety aspect of this project?
• Will the operator be able to maintain contact with the load at all times (semi-automated overhead crane)?
• Can a section of your plant be an area where no one will have access when your lifting equipment is in operation (automated overhead crane)?
  
  
4. Within what budget could such a solution be considered interesting for you (return on investment)?

By determining your needs and these few key points, you’ll already have the elements you need to determine the feasibility of your project.

Once you’re ready to start

Having seen the differences between the three types of overhead crane, you’re now better equipped to analyze your operations. If certain repetitive maneuvers are slowing down your production, it may be time to consider partial or complete automation.

Premium Industrial Group holds the experience and a skilled electrical team to help you realize your automation project. Contact one of our specialists by filling in the form at the bottom of the page, and we’ll get back to you promptly to help you develop your automated lifting project.