Tower Crane Safety Monitoring System — ZNAO-TG2 Black Box

▌ 01 PRODUCT OVERVIEW · ZNAQ-TJ2

Multi-crane anti-collision for tower cranes

Several tower cranes working one excavation is normal: they share the same footprint, their slewing envelopes overlap, and their jibs sweep the same sky.

From his cabin the driver cannot see when the next jib is coming round, and the other driver cannot see him either — each tower and the buildings between them block the view. ZNAQ-TJ2 turns that from something every driver has to watch out for into something the system handles: the angles of the machines are exchanged live, the zones are worked out from where the jibs are right now, and the warning comes before the contact, not after.

The system does not change the way the crane is driven and does not replace the safety devices already on it. It does two things:

▌ A WORKING-AREA PLAN the live angle of every neighbouring crane, always up to date

▌ A WARNING, THEN A LIMIT at three graded rings

Zones are set crane by crane and re-set whenever the site layout changes.

KEY POINTS

● Angles exchanged crane to crane over 4G wireless, up to 1000 m

● 3 graded zones per crane: slow-down / warning / stop

● Six collision cases covered: same way, opposite, from behind, over-swing, hook into a building, jib into an obstacle

● Site obstacles and overhead power lines drawn on the same plan

● Zones set on the platform, pushed to the cranes over the air

▌ 02 ON THE SITE · WHY ANTI-COLLISION COMES FIRST

Several towers working one sky

Put three, four or more tower cranes on the same excavation and their slewing envelopes will overlap.

Each machine works out its own working radius from where it stands, and where the next jib is at this moment is not something the driver can see from his cabin. That is the dangerous part of a group-tower site: not that the safety devices are missing, but that they do not know about each other.

Anti-collision is therefore not one more sensor on one crane — it is what happens between the cranes. Each unit shares its angle with the others, every working area is recalculated from where the neighbours are right now, and the margin is called out before it is crossed.

A sensor on a single machine can only see that machine; that is why stand-alone alarms do not solve a group-tower site.

KEY POINTS

● On one excavation, slewing envelopes overlap

● No line of sight to the next jib — talking to each other is not the same as the machines knowing

● Zones worked out from where every jib is now, not from a drawing

● No line of sight needed between the cranes — angles go over the air

● Add a crane or move the site: set the zones again and push them

▌ 03 GRADED ZONES · THREE RINGS

Slow-down, warning, stop — three graded rings

The anti-collision system goes beyond simple “maintain distance” commands.

It establishes three concentric zones around each crane relative to its neighbors:

▌ OUTER RING Deceleration zone a warning as the crane approaches another crane’s operating range, prompting the operator to slow down

▌ MIDDLE RING Pre-warning zone audible and visual alarms in the cab, ample reaction time for the operator

▌ INNER RING Stop zone any further slewing or movement of the crane strictly prohibited

The space between these zones provides operators with critical reaction time.

Buildings, roads, and overhead lines are all marked on the site plan — these are not merely background elements to be ignored; operations must cease immediately upon approaching these physical obstacles.

ZONE CONFIGURATION

▌ PER CRANE configured individually for each crane and adjustable as the site evolves

▌ REAL-TIME BOUNDARIES angular data exchanged over wireless modules up to 1,000 m away, so zone boundaries follow the cranes’ real-time positions

KEY POINTS

● Buildings, roads and overhead lines marked on the same site plan

● Configured per crane, adjustable as the site changes

● Wireless modules: angular data exchanged over up to 1,000 m

▌ 04 THE HARDWARE · ONE HOST, EVERY LIMIT

One screen, every dimension of the crane

The in-cab display serves as the system’s interactive interface, plotting the real-time positions of the host crane and surrounding cranes.

This allows the operator to instantly monitor the relative heights and jib slewing status of all cranes. A central processing unit located behind the display processes data — such as height, working radius, slewing angle, tilt angle, load, and wind speed — to generate a real-time operational status map, while simultaneously transmitting readings and warning alerts to the cloud via a 4G network.

SENSORS ON THE EXISTING STRUCTURE

▌ HEIGHT / AMPLITUDE Absolute encoders

▌ SLEWING / TILT Electronic compass module

▌ LOAD Load sensor installed on the hoist rope

▌ WIND Anemometer mounted at the top of the tower mast

These are standard mounting points requiring no drilling, structural modifications, or routine maintenance, and the system requires no additional operator training.

KEY DATA

▌ DISPLAY HD main display cab configuration · AC 220 V / 50 Hz

▌ HEIGHT / AMPLITUDE 0–300 m absolute encoders · 0.1 m resolution

▌ SLEWING / TILT 360° / 0–15° 1° and 0.01° resolution

▌ LOAD / WIND 0–10 t · 0–60 m/s ±5% on load

▌ PROTECTION IP65 sensors on existing structure, maintenance-free after fitting

▌ 05 THE PLATFORM · DATA & ALARMS

Data in the cloud, every alarm on record

Every crane’s readings and alarms reach the cloud platform over 4G.

The project office watches the whole crane group live on a computer or a phone — which machines are working, which one raised an alarm and at what time, kept one by one and ready for review.

For rental companies running several sites at once the benefit is the most direct: no more climbing tower after tower to collect data.

ZONES AND PLATFORM

▌ ZONES ON THE PLATFORM Slow-down, warning and stop rings drawn crane by crane and pushed to the machines over the air

▌ RE-SET ONCE when the site adds a crane or changes its layout, the zones are re-set once on the platform

▌ MULTI-LANGUAGE the interface ships in multiple languages and is tailored to the target market — ask for a remote demo any time

▌ SAME MAKER platform and host come from the same maker, supported from quotation to on-site commissioning

KEY POINTS

● Live readings and alarms in the cloud, on PC or phone

● Every alarm kept on record, reviewable by time

● Zones set per crane on the platform, pushed over the air

● Multi-language interface, tailored to the market

▌ CONTACT shandongzhinuo@outlook.com WhatsApp +86 176 6371 0314 · en.znaqkj.com