Use Case — Industrial Automation

Crane Systems – High-Precision and Reliable Crane Control via Radio

R3 Solutions provides the wireless technology that connects crane systems to the central control system with precision and fail-safe operation. Deterministic, secure, and reliable even in industrial facilities with challenging electromagnetic conditions.

Industrial Crane

Overview

Crane systems move heavy loads over long distances and heights, often with millimeter precision and with people in the work area. This places high demands on the control system: positioning, load control, and safety functions must operate precisely and without delay at all times.

End-to-end cabling along the long travel paths of bridge, gantry, or overhead cranes is complex and subject to mechanical wear, such as via trailing cables or busbars. A wireless connection circumvents these problems. However, it must achieve the deterministic reliability of a wired connection—especially in industrial facilities where large motors, variable-frequency drives, and metal structures create an electromagnetically challenging environment. This requires wireless technology that remains stable under precisely these conditions.

Typical Challenges in the Industry

Precise control over long travel distances

Cranes move over long distances and across multiple axes. The control connection must remain precise and uninterrupted throughout the entire operating range.

Electromagnetically challenging environment

Large drives, inverters, and metal hall structures generate interference that can cause standard wireless solutions to fail.

Safety for Loads and People

Where heavy loads are moved and people are working in the vicinity, safety functions such as the emergency stop must be reliably transmitted at all times.

Wear on the mechanical power supply

Tow cables and sliding contacts along the crane runway wear out, leading to maintenance costs and downtime.

How R3 Solves the Challenges

R3 Solutions connects the crane control system to the central PLC deterministically via a dedicated radio link. The solution is designed to operate precisely and reliably even under the challenging electromagnetic conditions found in an industrial facility.

Bridge E

For safety and control applications with real-time requirements and high synchronization.

  • Determinism: Time-slot-based signal transmission, packet loss rate of 0.000000001 %.
  • Real-time communication: Latencies of up to 2 milliseconds are possible.
  • Safety-compliant: PROFIsafe, CIP Safety, and others are transmitted transparently.
  • Proven in practice: Years of use by European and American OEMs.

Typical Project Workflow

Project Assessment

Project analysis, functional safety requirements, protocol selection.

Network Solution Plan

Traffic analysis, channel planning, configuration details.

Deployment

Installation, functional safety testing, acceptance testing.

Support & Maintenance

Monitoring, firmware updates, and enhancements.

Success Stories

Maintenance-free wireless control of turntables for hose production

Turntables are a special case in automated production. Due to their rotational movements, the use of cable connections is virtually impossible. Sliding contacts are an alternative, but they often result in downtime. The obvious solution is therefore control via a wireless network.

Read Success Story

Secure Wireless Connection for Manual Emergency Stop Switches on AMRs

In the manufacturing facility of a Japanese automotive supplier, autonomous mobile robots (AMRs) handle material supply directly to the workstations. This saves employees a significant amount of walking and makes the production process more efficient.

Read Success Story

Wireless Robot Control for Auto Body Shops

In auto body manufacturing, robots equipped with grippers perform key work steps. The gripper control system relies on cables and connectors that are subject to regular wear and tear. If these fail during continuous operation, the system comes to a standstill, resulting in enormous follow-up costs.

Read Success Story

Daniel Thiel

Wireless Solutions Expert

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