Views: 0 Author: Site Editor Publish Time: 2026-08-07 Origin: Site
Inductively coupled coded cable laid along the track. Vehicle‑mounted antenna reads absolute position via electromagnetic coupling. No contact, no moving parts, no accumulated error. Absolute position available immediately at power‑on – no homing.
Encoder | Laser | FORWARD Gray Code Bus | |
|---|---|---|---|
Principle | Counts wheel rotations | Laser rangefinding | Electromagnetic induction on coded cable |
Advantages | Low cost, quick install | High static accuracy | No wear, maintenance‑free, immune to dust/heat/vibration, ±1mm, shared by multiple cranes |
Disadvantages | Slippage/drift, needs calibration, not for long‑span/high‑precision | Optics get dirty, high maintenance, poor in heat/vibration | Requires professional initial laying (then maintenance‑free) |
Conclusion: FORWARD delivers the best overall performance and lowest lifecycle cost, especially for unmanned cranes in harsh industrial environments.
Stable position data directly supports anti‑sway algorithms. At Shagang hot rolled coil plant, retrofitted cranes achieved ±25mm coil placement, over 95% sway reduction, and cycle time under 4 minutes per coil.
For multi‑crane coordination, all cranes share the same Gray Code Bus and receive real‑time positions of every other crane. When distance falls below safety threshold, the system automatically slows down and stops. Zero collisions reported across all deployed sites.
Item | Encoder | Laser | FORWARD |
|---|---|---|---|
Calibration/Cleaning | Monthly | Per shift | None |
Service Life | 3–5 years | 5–8 years | 10+ years |
Environmental Tolerance | Average | Poor | Excellent |
Zero maintenance and longer life result in the lowest annual cost over the plant lifecycle.
JISCO (hot rolling galvanized line): Continuous full‑automatic operation in extreme heat and dust – no position‑related interruptions.
WISCO (bar plant dust removal): Corrosive gas and particulates – sealed Gray Code Bus blocks contaminants, hardware runs maintenance‑free.
Shunde Factory: Multiple cranes retrofitted for unmanned operation – automatic inbound, outbound, and scheduling, with positioning errors well within tolerance.
Shagang Plant 2: 99.99% coil handling accuracy, cycle time consistently under 4 minutes.
The FORWARD system includes Gray Code Bus cable, antenna box, decoder, mounting hardware, and commissioning services.
Bridge (X‑axis) positioning: Vehicle‑mounted decoder connects directly to onboard PLC via ProfiNET – no protocol converter needed.
Trolley (Y‑axis) positioning: Ground‑based decoder, combined with hoist Z‑axis encoder, forms a complete 3D coordinate system.
Turnkey delivery: Full hardware and commissioning ensure system compatibility and immediate operation.
The system features an open architecture, compatible with Siemens, Rockwell, and other major PLC brands – no proprietary lock‑in, easy integration with existing infrastructure and future upgrades.
Ideal for overhead cranes in dusty, hot, wet, or high‑vibration environments, especially for automation retrofits or new unmanned systems. Retrofitting involves laying cable along existing track and connecting the decoder to the existing control panel. Commissioning takes 1–2 days per crane. Not the cheapest upfront, but stays working long‑term, delivering the best overall value.
