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Reliable collision avoidance systems for cranes are essential wherever overhead, gantry, bridge, portal or container cranes share the same runway, travel close to one another or operate near fixed structures. As crane operations grow more complex, a single uncontrolled contact between two cranes, or between a crane and an end stop, can cause expensive downtime, damaged equipment and serious injuries.
A dependable crane anti-collision system continuously monitors the distance to the next obstacle, warns the operator, slows the crane down in defined zones and triggers a stop before any impact occurs. At Consult-IMPEX, we supply rugged, maintenance-free radar sensors that deliver this protection reliably, both indoors and outdoors and in the harshest port and industrial environments.
Modern crane collision avoidance relies on contact-free sensing between a sensor and a target, obstacle or second crane. As the gap drops below a defined safety margin, the system reacts in graduated stages: an alarm first, then a controlled speed reduction, and finally a stop inside the safety zone. The right detection range, from a few metres up to 40 metres or more, depends on the size of the workspace and the speed of the crane. Programmable switch points let you tailor each zone precisely to your application.
While laser, infrared and optical sensors are common, radar offers decisive advantages for collision avoidance on cranes operating outdoors or in dirty conditions. Our RadarRanger FMCW radar sensors work in the 24 GHz band (24.000 to 24.250 GHz) and reliably detect any obstacle that reflects radar waves, even through dust, dirt, smoke, fog, rain, snow, cold, heat and strong light reflections. With no moving parts and an IP 67 rating, they are virtually service-free and a cost-effective, weather-independent alternative to 2D laser scanners. Made in Germany, they are a proven drop-in replacement for many existing Banner or Sick sensor installations.
These anti-collision systems for cranes are in service on harbour cranes, industrial cranes, STS (ship-to-shore) cranes, RTG and RMG container cranes, straddle carriers and many other machines and vehicles. Typical tasks include crane-to-crane separation, end-stop protection, working-area limitation and boom-ship anti-collision on STS crane booms, as well as protecting the sideways travel of RTGs. The same robust radar technology also performs reliably in tunnel construction and other heavy-duty civil engineering sites where dust, humidity and vibration are constant.
We offer several radar models so you can match the horizontal detection angle and range to your application:
| Model | Range | Detection angle | Best for |
| CRAT20-150/11ST | up to 25 m | Extra-wide horizontal field | Capturing as many obstacles as possible, for example boom-ship anti-collision on STS cranes and booms, or sideways RTG travel |
| CRAT20-11/11ST | up to 40 m | Balanced horizontal field | General crane anti-collision and obstacle detection over longer ranges |
| CRAT20-5/14ST | up to 40 m | Narrow horizontal field | Long range with reduced interference where unwanted signals must be minimised |
All three share the same rugged specification: 24 GHz FMCW radar, IP 67 protection, 24 V DC supply, M12 connectors and a simple 4-hole screw mounting. Switch points are easily set with the configuration tool, and the variable antenna range can be adapted to the sensor position and task profile.
A well-specified crane anti-collision system protects three things at once: your people, your equipment and your output. By preventing crane-to-crane and crane-to-end-stop collisions, it reduces accident-related costs, avoids unplanned downtime and extends the service life of your lifting equipment. Contact-free radar keeps maintenance minimal, while precise, weather-independent detection allows fast crane movements without sacrificing safety, so loading and unloading stay both quick and secure.
When selecting a collision avoidance system for your cranes, match the detection range and opening angle to your workspace and crane speed, confirm the environmental rating for outdoor or tunnel use, and check compatibility with your existing control and braking system. Our team is happy to advise on the right RadarRanger model for your setup.
As a specialist supplier of industrial radar sensors and anti-collision technology for cranes and demanding sites, Consult-IMPEX helps you build a crane anti-collision system that fits your equipment and environment. Contact us for advice and a tailored quote. Simply add your preferred products to the catalogue request and we will send you a written offer.
