SPOTLIGHT
The use of AI in overhead cranes and hoists could mean a reduction in accidents, less downtime and smoother operations.
human intervention during operation will keep people out of potentially hazardous areas more often, again reducing risk to life and limb. Enhanced safety stems from intrusion and collision prevention, enabled by computer vision and sensor arrays that can detect personnel and objects in high-risk zones, enabling the AI solution to trigger alerts and prevent collisions with other machinery or loads.
“AI means fewer accidents, less downtime and smoother operations,” says Rouse. “It automates routine decisions, provides early warnings before breakdowns and turns data into real, usable insight.”
AI in play
While much that is said about the capability of AI in industrial settings is still hypothetical and based on an extrapolation of current applications in those sectors that are leading the way – manufacturing, healthcare, finance, retail and technology. AI is driving a sea change in areas like customer service, fraud detection, personalised customer experiences, operational efficiency and advanced diagnostics across these industries, and is changing the game in cybersecurity, marketing, entertainment, agriculture and government services. Yet the crane and hoist sector is not one to
lag behind when it comes to new advances in technology, and AI is already making its mark. Some operators are already moving on from the old ways of managing sway, for example,
46 Fall 2025 |
ochmagazine.com
recognising that the traditional computational approach results in slow adjustments in how the load is managed. With the prevision AI offers, sway can even be turned into a positive, rather than something to be eliminated. With the precise measurement and
real-time adjustment in load management that AI can offer, sway can be predicted in such a way that it can be incorporated into the way in which the load is handled, so outward sway that takes the load over the setting- down point can be used to deliver it to its final destination faster, rather than needing to counteract any sway before lowering the load. Such incremental gains can, over time, result in significant time savings. Rather than pre-programming mathematical algorithms, which then need to be adjusted to factor in the realities of the environment, AI-powered algorithms can adjust performance in real-time, taking into account all of the current environmental factors. This is the same capability to adjust to real-time conditions that allows AI to improve safety, predictive maintenance and a whole host of other factors that impact efficiency, cost and performance. “AI can spot obstacles, prevent collisions,
reduce load sway and plan the quickest, safest route every time,” says Rouse. “It makes better use of floor space and keeps production flowing smoothly across every shift.” “Predictive maintenance, collision avoidance
and autonomous load handling are the big three,” he adds. “They directly cut accidents,
downtime and repair costs, all of which make AI pay for itself. It keeps cranes running longer, with fewer surprises and helps managers plan with precision. Every avoided breakdown and every smoother workflow is money back in the bank.” The enormous potential for AI to improve performance is leading manufacturers to build it into their equipment, both responding to customer demand and leading operators to consider more advanced solutions. The adaptive control features that enable cranes to make real-time adjustments in speed and movement based on changing conditions is one of the most compelling advantages that AI offers.
“Manufacturers are building ‘smart’ cranes with sensors and connectivity from day one,” Rouse remarks. “Service providers are investing in data platforms that watch performance 24/7 and make remote diagnostics routine.” AI is powering smart drive systems that can
handle torque adjustment, greatly enhance the precision of load handling, monitor loads in real time and limit downtime for maintenance. Yet there is another key benefit that AI can bring to improve safety and performance – automated inspections. AI-driven inspection reports rank any potential issue in order of severity, helping operators to prioritise repairs and schedule maintenance during planned periods of downtime. Embedded sensors that enable condition-based maintenance and minimise the need for manual
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