Technical Support
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Revision Record
| Version Number | Description | Release Date |
| V1.0 | Initial Version | 2024/12/10 |
I. Installation Overview
The following diagram shows the installation schematic of a four-beam double trolley crane. If it is a single trolley crane, you can ignore the auxiliary trolley part.
Figure 1.1 Installation Schematic of Four-Beam Double Trolley Crane
II. Material and Tool Preparation
The following materials need to be prepared for the installation of the radar-assisted driving system:
| Type | List |
| Tools | Screwdriver, wire cutter, insulating tape, adjustable wrench, electric drill, network cable pliers, steel pipes, welding machine, etc. |
| Consumables | Network cable, crystal head, steel pipe, twisted pair, cable |
III. Product Installation
The steel pipes used for installation are generally selected with an outer diameter of 30-70mm (common steel pipes such as six-point pipes or inch pipes), and the length depends on the site conditions. The steel pipes and railings should be installed in a way that allows for easy disassembly for subsequent maintenance. A sleeve method can be used to fix the steel pipe for installation labels, by making a hole in a slightly larger outer diameter steel pipe, welding a nut to the hole, and tightening a bolt to fix the internal steel pipe, as shown in the figure below. However, it should be noted that considering overall stability, the length of the slightly larger outer diameter pipe should not be less than one-fourth of the length of the installation label steel pipe.
Double U-shaped cross buckles (for six-point and one-inch pipe sizes) can also be used to fix the steel pipe at the fence, as shown in the figure.
Figure 2.2 Installation Schematic of Double U-Shaped Cross Buckle
- Positioning Base Station
The base station is installed on both sides of the track facing the crane. The recommended installation height is 3-8m above the track plane or in an unobstructed position in the middle of the track, at least 1m away from the corridor columns.
The positioning base station is installed on the steel pipe using clamps and tightened with a screwdriver.
The directional antenna is installed above the positioning base station, using an L-shaped bracket and clamps for installation. The antenna signal emission surface (non-metallic surface) should be vertical and directly facing the large trolley label to reduce deviations up and down and left and right. It is necessary to ensure that the directional antennas on both sides of the track are at the same height. The antenna and base station need to be connected via N/F interface feed lines, and care should be taken to tighten the connections to avoid poor contact that could lead to RF signal transmission loss.
Note: The antenna above the positioning base station should be 0.2-1m higher than the same span large trolley label.
2. Large Trolley Label
The large trolley label is installed facing the positioning base station, and all large trolley labels on the crane should be kept at the same height as much as possible. The label is fixed to the steel pipe using clamps, and tightened with a screwdriver close to the large trolley label. The specific installation effect of the large trolley label is shown in the figure below.
Note: The height of the large trolley label steel pipe should not exceed this marked label.
3. Small Trolley Label
The small trolley label is directly fixed to the small trolley railing corresponding to the large trolley label using clamps, with the label installation accessory clamped onto the steel pipe, and tightened with a screwdriver close to the small trolley label.
If the crane on site is a double trolley structure, the small trolley label on the auxiliary trolley should be installed facing the corresponding large trolley label at the railing. Since the large trolley label corresponding to the auxiliary trolley does not need to measure the distance to the positioning base station, the power can be reduced during debugging, as shown in the figure.
4. Control Unit:
The control unit is generally installed in the electrical room and fixed to the wall with M4 installation screws. There are 5 M4 screw mounting holes on the back of the control unit, which can be used to fix it on the guide rail of the electrical screen cabinet. The project can choose the installation method according to specific conditions. The specific installation effect of the control unit is shown in the figure below.
5. Human-Machine Interaction Panel:
The interaction panel is installed in the driver's cabin of the crane, fixed to the wall of the cockpit using an L-shaped bracket. There are four M6 screw mounting holes on the back of the interaction panel, which can also be used to fix the interaction panel. The project can choose the installation method according to specific conditions. The specific installation effect of the interaction panel is shown in the figure below.
IV. Product Wiring
Figure 2.10 Wiring Schematic
1. Positioning Base Station
The base station is equipped with a power adapter and a quick-connect aviation plug. Due to the complex power supply scenarios on site, we have not connected the adapter and the quick-connect aviation plug together. Users can prepare a sufficiently long two-core cable according to the site environment.
2. Large Trolley Label
The large trolley label requires a power line, RS485 communication line, and network cable. Below are the connection methods and requirements for the three cables.
- The power line connection method is the same as that of the base station.
- The RS485 line is used for communication between the large trolley label and the control unit. The specification used on site is the national standard RVSP/RVVSP twisted pair shielded cable with 4 cores and 1 square millimeter, which should be connected to the 0.5m long 4-core RS485 twisted pair we provided according to the wire color and markings. If the length exceeds 100 meters, to ensure communication effectiveness, it is recommended to add an industrial-grade RS485 repeater in the middle of the cable or connect a terminal resistor with a power of 1W and a resistance of 120Ω at the control unit to reduce the error rate.
- For the network cable, users should prepare a sufficiently long Category 6 gigabit network cable. After crimping the crystal head, insert one end of the network cable into the waterproof connector and then plug the network cable into the port, tightening the waterproof connector.
3. Small Trolley Label
The small trolley label only needs to connect to the power line, and the method is the same as that of the base station.
4. Control Unit:
There are 4 control relays inside that connect to the control system using multi-core cables. Their output is a dry contact on/off signal, supporting a contact capacity of AC250V/3A and 30V/3A. After power on, the contact is normally closed; it becomes normally open after power off or triggering. These four relays can be used to control the vehicle.
It has two power/RS485 signal interfaces, which are for connecting tags and the interactive panel. The corresponding wire colors are red, black, blue, and yellow, which correspond to +24V positive, 0V negative, RS485-A, and RS485-B respectively. Users should check carefully after extending the RS485 signal line to avoid damaging the equipment.
5. Human-Machine Interaction Panel:
The interactive panel has one power/RS485 signal interface, connected to the control unit. The corresponding wire colors are red, black, blue, and yellow, which correspond to +24V positive, 0V negative, RS485-A, and RS485-B respectively. If users need to extend the wiring distance, they should check the wire order after extending to avoid damaging the equipment.
5. Precautions
- All tags on the vehicle should be kept at the same height as much as possible, and should be in the same vertical plane as the two side base stations. It is recommended to install the tags above the surrounding railings on the top of the vehicle, avoiding obstacles between the base station and the tags, as well as between the tags themselves.
- The external antenna of the base station and the internal antenna of the tags should maintain a distance of at least 0.2m from metal objects, and at least 1m away from corridor columns, to avoid multipath effects caused by the electromagnetic waves emitted by the antennas reflecting off nearby metal, which can affect positioning accuracy.
- The device can be powered using the supplied power adapter connected to AC220V power or directly connected to 24V power. It should not be directly connected to AC220V power to prevent damage to the device.
- The device should not be placed near high-power devices (full-band harmonics), such as high-power radio equipment, large machinery, fluorescent lights, etc. Since the wireless signals in this frequency band are close to noise levels, any high-power multiple harmonics will affect it.
- Keep away from liquids, as liquids absorb electromagnetic waves in this frequency band very significantly.
- The recommended working environment temperature is between -20℃ and 65℃ for optimal performance.
- Each cross radar positioning system can support the positioning of up to 6 vehicles simultaneously.