The document describes several crane automation technologies from CAMotion, including Auto Move, Expert Operator, Crane Vision, and Safe Move. Auto Move allows complex crane move sequences to be automated, improving cycle times by 25% and ensuring precise payload placement within 1 inch. Expert Operator and Crane Vision help eliminate payload sway for safer, more precise lifting. Safe Move creates virtual safety walls to prevent cranes from colliding with equipment by smoothly stopping motion at boundaries. Case studies at manufacturing plants demonstrate reduced collisions and improved productivity with these technologies.

1. BENEFITS AT A GLANCE
PRODUCTIVITY Operator studies demonstrate that cycle
time can improve by 25% when move sequences are
automated
PRECISION Automatic and accurate load placement is
repeatable. Payload placement accuracy of 1-inch is
achievable
SERVICE LIFE Maintenance costs and downtime are
reduced by decreasing mechanical and structural stress
that can occur during manual operation
PERSONNEL Crane operation is transformed from a skill-
based task to a supervision-based task, reducing mental
fatigue, and enabling novice operators to complete
complex hoisting tasks
FEATURES AT A GLANCE
OBSTACLE AVOIDANCE Stationary obstacles
within the workspace are avoided during
automatic moves to prevent collisions
TIME OPTIMAL Motion paths are generated using
optimization routines that command the crane to
travel along the most time-efficient path
EXPANDABLE Automate a single move sequence,
or hundreds of move sequences over multiple
cranes
COMPATIBLE Auto Move is compatible with
existing VFDs, radio and tethered pendants with
continuous or multi-step functionality
PRINCIPLE OF OPERATION
Automatic Move
Commands
Sensory Information from
Bridge, Trolley, & Hoist
Manual Move
Commands
Auto Move builds on the foundation of
CAMotion’s proprietary anti-sway technology,
which permits cranes to move without payload
swing. This technology is combined with patented
positioning control that ensures the payload
closely follows prescribed trajectories.
Hundreds of complex move sequences can be
programmed into the system. Operators initiate
automatic moves by using a stationary operator
interface, or portable pendent.
Move commands and sensor information are used
by the control to generate reference signals that
are issued to the motor drives.
CASE STUDY
Automatic & precise payload positioning is possible
with CAMotion crane control. Automatic motion is
initiated and monitored by an operator. Placement
accuracy of 1-inch is typical.
AUTOMOVE
TM
M O T I O N C O N T R O L S O L U T I O N S F O R I N D U S T R I A L C R A N E S
Rev 102010
Novelis, a manufacture of aluminum sheet products,
implemented Auto Move in their scalping process, where
cranes are used for moving 25-ton ingots of aluminum.
By installing Auto Move, Novelis designed to reduce
equipment damage, and permit novice crane operators to
perform as well as their experienced couterparts.
“The crane operates much smoother and controlled then in
the past. New operators can better simulate movements
that used to be reserved for more experienced operators.
This is expected to reduce equipment damage and
excessive wear.”
-Tim Foster, Novelis Project Engineer

2. BENEFITS AT A GLANCE
PRINCIPLE OF OPERATION
VISION TM
CRANE
Vision-based crane manipulation increases
safety and simplifies precise positioning tasks.
CAMotion Crane Vision is the combination
of advanced motion control and machine
vision technologies.
TM
CRANE When Crane Vision is enabled, the crane smoothly,
automatically, and continuously positions itself directly over the
suspended load. This behavior reduces payload swing, eliminates
“side-pull” lifts, and enables an operator to move the crane simply by
pushing on the payload.
CAMERA Sensory information about hook position is obtained by
using an industrial machine-vision camera, together with robust hook-
tracking software. The camera is mounted on the trolley, near the
cable drum, and is oriented downward. In this configuration, the
hook is always visible to the camera. The camera captures and
analyzes 20 images of the hook each second. Hook position
information is issued to the Crane Vision controller.
HOOK To facilitate reliable hook tracking, a pattern of retro-
reflective fiducial markers are fastened to the hook. Fiducial markers
are easily discernable from the other features in the workspace. They
permit the camera to track the hook consistently and with a
positioning accuracy of less than an inch.
COMPATIBLE Crane Vision is compatible
with existing VFDs. Enabling & disabling
Crane Vision can be accomplished with
existing wired or radio pendants.
RETROFITABLE Integration onto existing
hardware platform is possible. 1-Day
installation time, typical.
MODULAR Crane Vision can be used stand-
alone, or in conjunction with CAMotion’s
other crane control technology: Expert
OperatorTM, Safe MoveTM, and Auto MoveTM.
PROVEN Crane Vision technology has a
proven industrial track record with
applications on heavy equipment
production cranes, primary metals coil
cranes, and general purpose single & double
girder bridge cranes.
DISTURBANCE REJECTION Payload swing
caused by an inexperienced operator, or
from external disturbances like wind, can
be quickly damped out by enabling Crane
Vision.
PUSH & PULL CONTROL Crane Vision
continually adjusts the position of the crane
over the load. This enables crane motions to be
made by simply pushing or pulling on the load.
This type of haptic control simplifies precise
load positioning.
AUTOMATIC LOAD CENTERING Crane Vision
prevents “side-pull” lifts by adjusting
bridge and trolley position so that the
crane is directly centered over the load.
Adjustments happen automatically during
hoisting.
M O T I O N C O N T R O L S O L U T I O N S F O R I N D U S T R I A L C R A N E S
Rev 102010

3. Expert crane operators skillfully time crane maneuvers in
order to quickly eliminate sway. Expert Operator is a
hardware module that intercepts pendent commands –
converts them into expert commands – and then issues the
modified commands to motor drives. Cable sway is
eliminated, permitting all operators to perform like experts.
Download the Expert Operator crane simulator for a virtual
test drive at www.camotion.com.
PRINCIPLE OF OPERATION
Manipulate payloads in a swing-
free manner. Expert Operator
permits both novice and expert
operators to reduce payload
swing by 85-95%.
EXPERTOPERATOR
TM
TM
FEATURES AT A GLANCE
SWAY SUPPRESSION over entire hoist range, even
with complicated rigging configurations
SENSORLESS technology does not require
encoders, zone sensors, or other length
measurement
SEAMLESS integration into existing hardware
platform. 1-Day installation time, typical
SIMPLE graphical configuration software aids
setup and commissioning
COMPATIBLE with existing VFDs, radio and
tethered pendants with continuous or multi-step
functionality
BENEFITS AT A GLANCE
PRODUCTIVITY Hundreds of operator studies demonstrate
that cycle time improves by 10% to 40%
PRECISION Accurate load placement is simple because
operators focus on positioning rather than swing
correction
SAFETY Load sway prevention reduces risk of equipment
damage and personal injury
SERVICE LIFE Maintenance costs and downtime are
reduced by decreasing mechanical and structural stress
PERSONNEL Novice operators perform as well as
experienced counter parts, reducing the need for
extensive training
SPECIFICATIONS
Boeing, a world-wide manufacturer of aircrafts, imple-
mented Expert Operator technology at their St. Louis
assembly plant, where cranes are used extensively for
production.
Boeing conducted an independent study to assess the
benefits of the technology. Four operators drove cranes
with and without the technology installed.
Expert Operator reduced payload collisions by 94%.
“made it a lot easier”
-operator 1 (experienced)
“it was easier to anticipate stopping”
-operator 2 (novice)
“incredible, quickly builds confidence”
-operator 3 (crane operator trainer)
“it felt much safer”
-operator 4 (novice)
CASE STUDY
Control Input 2-5 Speed multi-step, discrete*
Control Output
Uni-polar analog. 0 – 10 VDC. 2x discrete, direction
Uni-polar analog. 4 – 20 mA. 2x discrete, direction
Uni-polar analog. 0 – 20 mA. 2x discrete, direction
Bi-polar analog. ±10 VDC. 1x discrete, run
Temperature Range 0º – 60º Celsius**
Relitive Humidity
Electrical Supply
Enclosure
10% – 95% ***
120/230 VAC, 50 Hz or 60-Hz
NEMA 12. Hinged wall mount. 14x12x6 (in), 305x356x152
(mm), (HxWxD)
* Discrete input signal accommodation: 120/230 VAC, 24 VDC, or 48 VDC
** -25º – 60º Celsius available upon request
Auxiliary Input Req. 2x discrete*
*** 5%º – 95% available upon request
EO-0311-12 (120/230 VAC Control Input)
EO-0311-24 (24 VDC Control Input)
EO-0311-48 (48 VDC Control Input)
Order Description
M O T I O N C O N T R O L S O L U T I O N S F O R I N D U S T R I A L C R A N E S
Rev 102010

4. BENEFITS AT A GLANCE
PERSONNEL Operators can manipulate payloads more
quickly and confidently when safety walls are erected
around costly and sensitive equipment
PRECISION AT PAYLOAD Safe Move can be used in
conjunction with CAMotion’s anti-sway technology. This
combination prevents both the crane structure and the
crane hook from penetrating a safety wall
SMOOTH & PRECISE STOPPING Safe move does not
abruptly stop crane motion when a safety wall is crossed.
Instead, sophisticated motion control slows, and then stops
crane motion at the safety boundary, not after
SAFETY Safety boundaries can enclose equipment,
product, and personnel to prevent the crane and payload
from penetrating into these regions
FEATURES AT A GLANCE
MINIMAL HARDWARE Safe Move utilizes crane-
mounted laser sensors for position measurement, This
eliminates runway-mounted limit switches, simplifies
wiring, and enables quick commissioning
VERSATILE Safety walls can enclose arbitrarily
shaped regions within the workspace. This means
that the safety walls do not have to be aligned
with the bridge and trolley travel directions
EXPANDABLE Hundreds of safety walls can be
erected in the workspace. They can be enabled
and disabled together or in configurable sets
COMPATIBLE Safe Move is compatible with
existing VFDs, radio and tethered pendants with
continuous or multi-step functionality
CASE STUDY
Logan Aluminum is a manufacture of aluminum sheet
products. At the manufacturing headquarters in Russellville,
KY, cranes are used extensively for production and
maintenance.
One such crane is used to transfer massive steel rolls from
holding areas to grinding machines. Occasional collisions
with the machines motivated Logan to implement Safe
Move.
During operation with Safe Move, payload-to-grinding
machine collisions are eliminated.
PRINCIPLE OF OPERATION
Safe Move can limit crane motion in multiple regions
throughout the workspace. This is accomplished by
erecting virtual safety walls that can surround equipment,
walk ways, work stations, or other safety-critical regions.
Virtual safety walls are specified by using a portable HMI
that displays real-time information about the crane and its
position in the workspace.
Once enabled, Safe Move prevents the crane, and crane
hook from penetrating into regions surrounded by safety
walls. This is because Safe Move slows and stops the crane
before it crosses a safety wall, not after.
M O T I O N C O N T R O L S O L U T I O N S F O R I N D U S T R I A L C R A N E S
Rev 102010
CAMotion Safe Move prevents collisions
between payloads and surrounding
equipment by erecting virtual safety
walls. Walls are easily configured,
and can be quickly
enabled & disabled.
SAFE MOVE
TM
TM