Fraunhofer Institute for Factory OperationIntelligent Assistance for Process Cranes
A New Research Project Will Boost Reliability and Efficiency in Industry
Tarakos GmbH, Kranbau Köthen GmbH and the Fraunhofer Institute for Factory Operation and Automation IFF have launched a research project to developed a skill-based assistance system for process cranes. The objective of the project is to use intelligent assistance systems to make complex crane operations safer, more efficient and easier to control for operators. This will establish an important technological basis for the automated manufacturer in which intelligent assistance systems assist people and complex manufacturing and material flow processes are automated flexibly and reliably.
Digital design meets real-world crane control
The project centers on an innovative approach to the semi-automation of crane movements in so-called enable mode. First, movements are modeled in a digital twin, replicated as a combination of individual, configurable crane movements, so-called skills. They establish the basis for complex target positioning that can subsequently be transferred to real-world crane systems and completed with assistance. The crane operator remains in charge at all times but is actively supported by the system when completing and evaluating movements.
A key technological component is the end-to-end combination of simulation, sensing and real-time analysis. Three-dimensional LiDAR sensors continuously scan the crane’s work zone and produce a high-resolution 3D point cloud. This makes it possible to display the current process situation in detail and continuously compare it with the crane movement planned in the digital twin. Deviations are detected instantly and presented transparently to the operator so they can respond promptly or the system provides assistance in critical situations.
More reliability and efficiency in demanding industrial processes
The particular technical innovation is the integrated crane work zone analysis based on an integrated real-time 3D dataset. It enables a contextual assessment of complex situations. Payload equilibrium, potential collisions or irregular movements can be reliably detected and assessed, for instance.
This opens new opportunities for industrial uses: High precision and safety standards for the transport of molten materials, bulk items or heavy bar stock contend with dynamic and frequently low-visibility work environments. Assisted crane positioning reduces operator errors and stabilizes processes while lowering operators’ workload. Continuous analysis of real-world motion data additionally improves the transparency and facilitates the optimization of operations.
The three project partners are pooling their respective expertise to implement this technological vision. While tarakos GmbH is in charge of designing the movements in the digital twin, Kranbau Köthen GmbH will be transferring them to real-world control functions. Fraunhofer IFF is developing the sensor-based analysis and the assistance functions building upon that, contributing substantially to reliable interpretation of the process situation.
The project will establish an important basis for the steady automation of crane systems. At the same time, it will contribute to refining Industry 4.0 application and boosting the manufacturing industry’s competitiveness. The technologies developed will facilitate the vision of the automated manufacturer by combining intelligent assistance, digital twins and real-time sensor-based analysis into one complete, reliable and efficient system.
The project will run for twenty-four months.
Funding: The project is being co-funded by the European Union (ZS/2026/01/210074)
