Crane Networking
IntelliKran Wireless Bridge (WB)
IntelliKran Wireless Bridge creates a real-time data link between two EOT cranes, sharing live position, operational status, load data, and safety interlocks wirelessly. When cranes work in tandem to lift a single load, the WB ensures that a fault, overload, or limit trip on one crane is instantly communicated to the other — preventing uncoordinated motion, load drops, and structural overload accidents.
Real-Time Link
Live position, speed, and operational state shared wirelessly between cranes
Interlock Sharing
Overloads, limit switches, and E-stops propagated to the partner crane instantly
Load Summation
Combined hook load enforced against factory structural rated capacity in real time
No Cable Runs
Fully wireless — no inter-crane cabling between runways or overhead structures
Core Value Proposition
- Prevents accidents in tandem crane operations by sharing live interlock and fault states between crane partners in real time.
- Enforces safe load summation across two cranes — if combined lift exceeds the structural rated capacity, the system restricts the over-limit crane automatically.
- Eliminates the blind-spot between two independently controlled cranes lifting a single shared load.
- Automatic slow-down or stop command to the partner crane when the other detects an overload, limit switch trip, or any motion fault.
- Improves operational coordination in tandem lifts without requiring expensive hardwired interlock cabling between cranes.
- Built for heavy-duty industrial environments including steel plants, shipyards, and large-bay manufacturing facilities.
Tandem Operation Safety Scenarios
Every tandem crane lift carries a unique set of risks. IntelliKran WB addresses each scenario with a targeted wireless data response — turning a blind inter-crane gap into a coordinated safety network.
Overload Interlock Sharing
If Crane A trips its overload protection mid-lift, Crane B receives an immediate wireless signal and automatically reduces speed or stops to prevent an unbalanced load drop or structural shock.
Motion Limit Switch Propagation
End-of-travel, hoist-up, or cross-travel limit trips on one crane are wirelessly broadcast to the partner crane, synchronizing their motion boundaries during a coordinated lift.
Load Summation Enforcement
Each crane continuously broadcasts its live hook load. If the sum of both cranes' loads approaches or exceeds the building or girder's rated structural capacity, the crane closer to its individual limit is restricted from lifting further.
Emergency Stop Propagation
An E-stop triggered on either crane is relayed wirelessly to the partner within milliseconds, bringing both cranes to a safe synchronized stop during a tandem operation.
Load Summation — Worked Example
A factory has a 20 T EOT crane and a 10 T EOT crane on the same runway. The building structure has a rated combined load capacity of 20 T. Without the Wireless Bridge, both cranes can independently lift at their full rated loads simultaneously — creating a combined 30 T load that exceeds the structural limit and risks catastrophic failure.
With IntelliKran WB, both cranes share live hook load data. The system calculates the combined structural load in real time and dynamically limits the remaining allowance on the higher-capacity crane, enforcing a hard ceiling equal to the factory structural limit.
Safety Outcome
If the 10 T crane is carrying 6 T, the 20 T crane will be restricted to a maximum lift of 14 T — enforced by the WB relay output — regardless of what the operator commands.
Example Parameters
- Crane A Rated Capacity20 T
- Crane B Rated Capacity10 T
- Factory Structural Limit20 T
- Crane B Current Hook Load6 T
- Crane A Remaining Allowance14 T (enforced by WB)
- Crane A Max Permitted LiftLimited to 14 T dynamically
Integrated Applications
- Steel plants and rolling mills where multiple overhead cranes operate in the same bay, often sharing lifting duties on long structural members or coils.
- Shipyards and heavy fabrication yards using tandem gantry or overhead cranes to lift large hull sections, propeller shafts, or ship equipment.
- Large assembly halls and aerospace maintenance bays where wide-span EOT cranes work in coordinated lifts on aircraft structures or modules.
- Power plants and transformer stations with tandem lifting requirements for large rotating machines, transformers, or generator stators.
- Port and intermodal terminals where crane pairs are used for oversized container or bulk cargo operations.
- Heavy engineering workshops where two cranes on the same runway handle long press platens, moulds, or tooling assemblies.
Technical Data
Wireless data link between two EOT cranes on same or parallel runways
Real-time position sharing: cross-travel, hoist height, and speed data
Interlock I/O sharing: overload, limit switches, E-stop, and motion faults
Live hook load data exchange for structural load summation logic
Configurable capacity thresholds for individual crane and combined structural limits
Fail-safe output: relay outputs for slow-down and stop commands
Industrial-grade wireless communication — immune to crane EMI, motor noise, and RF interference
Supply voltage: 24 VDC
Compatible with IntelliKran PLC and third-party crane PLCs via digital I/O or RS485
Operating temperature: -25 °C to +70 °C
Rugged enclosure rated for industrial crane environments
Easy commissioning with no hardwired inter-crane cabling required
Ready to Connect Your Crane Fleet?
Contact the IntelliControl team to discuss your tandem crane setup, load summation requirements, and integration options for the IntelliKran Wireless Bridge.