Case study: Implementation of a positioning system for overhead cranes and personnel in a workshop

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Customer's task:

НA large machine-building enterprise operates several overhead cranes in a single production workshop. Due to the fast pace of work and limited visibility for operators, there was a risk of personnel entering the cranes' movement zones. The customer needed to:

• Ensure the safety of personnel in the crane operating area.

• Create a digital twin of the workshop with an accurate visualization of equipment and personnel movement.

• Collect and analyze movement history and potentially dangerous events.

• Use a solution with high real-time positioning accuracy.

Project objectives:

• Improve safety by eliminating cases of employees in dangerous crane movement zones.

• Create a digital twin to ensure a real-time display of equipment and personnel movements on an interactive 3D/2D workshop diagram.

• Ensure high-precision positioning to determine object coordinates with an accuracy of 10–30 cm.

• Collect detailed statistics on movements and events to optimize production processes with analytics and reporting.

RealTrac Solution:

A positioning system based on UWB technology was implemented for the project.

• PROD TAG 210 - Personal tags for employees that can be worn on a helmet, belt, or work clothes.

• PROD VTAG 210 - Transport tags for installation on overhead cranes.

• PROD POINT 520 - Stationary access points that form a UWB network for positioning.

• The RealTrac software provides movement display, zone configuration, statistics collection, and digital twin creation.

How it works:

1. Personnel are equipped with PROD TAG 210 tags and cranes are equipped with PROD VTAG 210 tags.

2. The PROD POINT 520 receives signals from the tags and calculates the coordinates of the objects with an accuracy of 10–30 cm.

3. The digital twin of the workshop in RealTrac displays the current location of each employee and crane.

4. When an employee enters a dangerous zone under a crane, the system emits audible and visual signals to the operator and employee.

5. All events are recorded for subsequent analysis and reporting.

Implementation results:

• A digital twin of the enterprise has been created, providing an accurate map of equipment and personnel movements.

• There have been zero incidents of people entering the danger zone since the system was launched.

• Process transparency — control of personnel movements, analysis of location zones, and work completion times.

• There is the possibility of integration with access control and ERP/SCADA systems.

Additionally:

The system can easily be scaled to other workshops and production sites. Integration with a collision prevention module and a staff working hours recording function is possible.

If you are interested in implementation details or you have a similar task, we are ready to help you with its solution.

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