Crane hook proximity limiter

The IntelliSafe Crane Hook Proximity Limiter is an advanced, state-of-the-art safety system designed to prevent costly collisions and dangerous accidents by automatically monitoring and controlling the hook’s proximity to the crane’s boom tip or other critical structures. This system is the definitive solution for enhancing safety, protecting your infrastructure, and maximizing operational uptime.

A primary cause of crane-related damage and failure is the over-hoisting of the mobile crane hook block, leading to catastrophic “two-blocking” incidents. The IntelliSafe Proximity Limiter acts as an intelligent guardian, continuously measuring the distance between the hook and the boom tip. It provides clear warnings and, if necessary, automatically cuts hoist power to prevent contact, safeguarding your crane, load, and most importantly, your crew.

Crane Hook Proximity Limiter Key Features & Benefits

• 1. Automatic Collision Prevention: The system intervenes automatically by disengaging the hoist function when a dangerous proximity is detected, eliminating reliance solely on operator vigilance.
• 2. Two-Stage Warning System:
  • Stage 1 – Pre-Warning: An audible alarm and visual beacon activate at a pre-set safe distance, alerting the operator to slow down.
  • Stage 2 – Hard Shutdown: If hoisting continues, the system triggers an immediate and automatic cut-off of the hoist-up motion at the second, closer set-point, preventing impact.
• 3. Advanced Sensing Technology: Utilizes highly reliable non-contact sensors (e.g., ultrasonic, laser, or radar) immune to environmental factors like dust, moisture, and temperature fluctuations, ensuring consistent performance in harsh conditions.
• 4. Robust and Durable Design: Engineered with industrial-grade materials, the sensor and all components are built to withstand shock, vibration, and exposure, guaranteeing longevity and reliability on any job site.
• 5. Easy Installation & Calibration: Designed for retrofitting onto existing cranes of all types (mobile, tower, overhead) and seamless integration into new builds. The intuitive setup wizard allows for quick and precise calibration.
• 6. Self-Testing Diagnostics: The system continuously performs self-checks upon startup and during operation to confirm all components are functioning correctly, providing peace of mind and meeting safety compliance requirements.
• 7. Data Logging Capability (Optional): Records operational data and event history (e.g., near-misses, shutdowns), providing valuable insights for safety audits, maintenance planning, and operator training.

Crane Hook Proximity Limiter Technical Specifications

Parameter	Specification
Operating Range	Up to 15 meters (50 feet), customizable
Accuracy	± 2 cm (± 0.8 inches)
Outputs	2x Relay (N/O & N/C) for Warning & Shutdown
Power Supply	24V DC (Standard), 12V/110V/230V options
IP Rating	IP67 (Dust-tight and protected against immersion)
Operating Temp.	-40°C to +85°C (-40°F to +185°F)
Sensing Technology	Ultrasonic / Laser (LIDAR)
Compliance	Meets ANSI, ASME, ISO standards, CE Certified

How It Works

• 1. Sensing: A robust sensor is mounted on the crane’s boom tip, continuously measuring the exact distance to the hook block or ball.
• 2. Processing: The distance data is transmitted to the central processing unit (CPU) in the cab.
• 3. Alerting: The CPU compares the real-time distance to the pre-programmed setpoints.
• 4. Action: The system activates alarms and executes a controlled shutdown sequence if the hook approaches the danger zone, preventing a collision.

Crane Hook Proximity Limiter Application Scenarios

The IntelliSafe system is vital for any lifting operation, including:

Construction Sites	Protecting tower cranes and mobile cranes from boom damage.
Shipping Ports & Terminals	Preventing accidents on ship-to-shore gantry cranes and container handlers.
Manufacturing & Warehouses	Safeguarding overhead bridge cranes and gantry cranes.
Wind Energy	Essential for safe lifting operations during turbine construction and maintenance.
Mining and Heavy Industry	Providing reliable safety in the most demanding environments.

Why Choose the IntelliSafe Proximity Limiter?

• 1. Reduce Downtime: Avoid weeks of costly repairs and project delays caused by two-blocking incidents.
• 2. Lower Maintenance Costs: Prevent extensive damage to ropes, hooks, blocks, and the boom structure.
• 3. Enhance Safety Culture: Proactively protect your workforce and demonstrate a commitment to the highest safety standards.
• 4. Insurance Advantages: Many providers offer reduced premiums for equipment equipped with certified safety limiters.

Invest in certainty. Invest in safety.

Contact our technical sales team today for a consultation and to request a quote tailored to your specific crane fleet.