INDUSTRY INSIGHT
All three mechanisms communicate via signal transmission and operate simultaneously within rated capacity limits.
Operation modes A remote-control device and host computer are configured in the automated brewing area to execute automatic operation commands through instruction input. When unloading from the cellar is required, the operator in the automated brewing area selects the target cellar (for example, Cell B3) on the remote control and confirms startup. The crane will then proceed as follows when no other operations are in progress. During the preparation phase, this
automatically raises the grab bucket and material hopper to safety height and activates the bridge/trolley travelling mechanisms based on cellar position, moving towards the target. In the unloading process, when positioned above the target cellar area the automated control programme lowers the grab bucket. Radar equipment on the hoisting mechanism detects grabbing depth and the grab bucket collects the distiller’s grains. After successful collection, the grab
bucket automatically raises to preset height, moves the trolley to position above the hopper and releases grains into the hopper. For the completion protocol, the system
returns to the cellar position and descends to a predetermined height and sounds a completion alert (single load cycle finished). As part of the crane’s capacity management, total loading cycles can be preset according to hopper capacity. When reaching preset cycles, it sounds full-load alert; it raises the grab bucket and hopper to safety height; returns automatically to the brewing area; and positions/empties hopper into the transfer equipment. When loading the cellar is required, it will necessitate the following: Initiation phase: The brewing equipment fills the charging hopper and the operator
A remote-control device and host computer are configured in the automated brewing area to execute automatic operation commands through instruction input.
confirms startup command. Automated positioning: The crane automatically elevates grab bucket and hopper to safety height. It activates bridge/ trolley mechanisms based on target cellar coordinates and transports to the specified cellar position. Position verification: Upon reaching target cellar, an audible alert signals crane arrival. The ‘loading’ indicator light activates and the cellar operator verifies hopper alignment. Precise discharge: There is then a controlled release of the distillers’ grains, simultaneous hopper movement and discharge. Progressive unloading ensures even material distribution.
Position coding system All fermentation cellars are assigned alphanumeric identifiers (for example, A1, A2, A3 through A7; B1, B2, B3 through B7, and so on) with corresponding numbered plates physically mounted at each cellar location for clear visual identification. The automated brewing zone and cellar zone are precisely demarcated to establish unambiguous positional references throughout the facility.
Intelligent positioning system The crane’s bridge travel and hoisting mechanisms utilise absolute encoders for precise positioning. The bridge encoder is installed on the idler wheel, which maintains constant contact with the rail to prevent measurement errors caused by slippage. The hoisting encoder is mounted on either the hoist motor or the drum. For the trolley, a linear scale positioning
system is employed to ensure accurate alignment between the lifting apparatus and brewing equipment. To eliminate cumulative errors in the
absolute encoders during prolonged operation, reference zero points are installed every 30–50m along the bridge travel rails. A master reference point is positioned at the centre of the main girder. Each time the trolley passes this point, its position data is automatically recalibrated to the absolute reference value. The hoisting mechanism performs
automatic position calibration after every 20 operating cycles by returning to a dedicated calibration point. Through the implemented intelligent positioning system, the crane achieves the following operational tolerances: Bridge travel: ±10mm positioning accuracy. Hoisting mechanism: ±10mm vertical positioning. Trolley mechanism: ±5mm lateral positioning.
The hoisting encoder is mounted on either the hoist motor or the drum.
12 | July 2025 |
www.hoistmagazine.com
Obstacle avoidance The crane’s laser detection system is set to monitor obstacles at a height of 6m. During automated operation, if an obstacle exceeding this height is detected within 15m, the crane immediately triggers an alarm and begins deceleration. Should the obstacle
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