Industrial Safety
Multi-Level Crane Safety for Industry 5.0 Human-Centric Operations
Overview
Electric Overhead Traveling (EOT) cranes play a critical role in steel plants, warehouses, fabrication shops, casting houses, and manufacturing units. But operators often work from elevated cabins or remote stations with limited visibility, making it difficult to detect ground personnel, suspended loads, and dangerous lifting angles. Flagman's AI-Powered EOT Crane Safety System brings Industry 5.0 intelligence to crane operations by combining human detection, danger-zone mapping, multi-level alerting, machine interlocks, and advanced load-path analytics — including Cross-Pulling Detection, a critical safety enhancement for crane movement integrity. By using AI cameras installed at strategic vantage points, Flagman provides operators and supervisors with continuous situational awareness, reducing accidents and enabling safer, more informed crane movements.
The Challenge
Crane operations involve high-risk interactions between suspended loads, moving trolleys, ground workers, multi-level platforms, and obstructed visibility zones. Crane operators frequently face blind spots caused by:
Key Challenges
- Elevated operator cabins
- Machinery, pillars, racks, coils, and large materials
- Multiple floors and mezzanines
- Lighting variations (dust, glare, low light)
- Fast crane/trolley motion
Flagman Solution
Flagman transforms any EOT crane bay into a smart, self-enforcing safety environment using advanced AI vision systems. When a risk is detected, Flagman immediately alerts crane operators, activates audio/visual alarms on the shop floor, sends notifications to supervisors, sends stoppage/hold signals to the crane via PLC or Wi-Fi, and logs the incident with time-stamped evidence. Flagman ensures the crane only operates when all zones are clear and lifting conditions are safe.
Key Features
- Accurate human detection even when partially blocked by materials or machinery
- Custom danger-zone mapping for load paths, floors, and maintenance areas
- Multi-level alerts to operators, ground workers, and supervisors
- PLC/Wi-Fi based crane stoppage with industrial protocol support
- Cross-pulling detection to prevent unsafe diagonal pulls and rope damage
- Local and remote alerts via sirens, beacons, and mobile notifications
- Event logging with timestamps and video evidence for compliance
Benefits
Significantly Fewer Crane Accidents
AI-powered detection and automated stoppage prevent accidents by identifying personnel in danger zones and unsafe lifting conditions before incidents occur.
Better Operator Visibility
Real-time monitoring compensates for blind spots and obstructions across multiple floors and complex bay layouts, providing complete situational awareness.
Cross-Pulling Prevention
Unique capability to detect and prevent dangerous diagonal pulls that can cause structural stress, rope damage, load instability, and crane derailments.
Coordinated Multi-Level Communication
Synchronized alerts across floors ensure ground teams, crane operators, and supervisors receive immediate notifications for rapid response.
Improved Material Handling Efficiency
Operator confidence and reduced mental load enable safer, smarter, and more synchronized crane operations without unnecessary stops.
Comprehensive Compliance & Audit Readiness
Automated, unbiased safety enforcement with detailed event logs, video evidence, and analytics for ISO/OSHA compliance and root-cause analysis.
Frequently Asked Questions
AI cameras cover the bay and track humans even with crane movement.
Yes — via relay logic or PLC integration.
Yes — alerts reach ground teams and upstairs operators.
Yes — built to withstand harsh industrial environments.
Yes — configured via the dashboard.
Video evidence, timestamps, and event logs.
No — installation is quick and non-intrusive.
Ready to Transform Your Safety Operations?
See how Flagman can help you achieve zero-harm operations with AI-powered safety systems. Our team will show you how this solution fits your specific environment.
