Crane Intelligent Dispatching System with Multi-Crane Path Planning
Core capabilities of the intelligent crane dispatching system include task assignment (optimized via genetic algorithms), path planning (A* algorithm with obstacle avoidance), multi-crane coordination (priority-based yielding plus time-window scheduling) yielding plus time-window scheduling), and real-time dispatching. The system manages 8–20 cranes simultaneously, boosting daily throughput by 30%–50% and reducing idle travel by 20%.
In large workshops and storage yards, coordinating multiple cranes across shared or adjacent bays is a common requirement—yet collision risks, task conflicts, and inefficiency remain persistent pain points. Kelude Heavy Industry's intelligent crane dispatching system leverages operations research optimization algorithms to automate task assignment, path planning, and multi-crane coordination.
An intelligent dispatching system is a key enabler for unmanned material handling. For more on IoT platforms for remote vehicle monitoring, see IoT Platform for Remote Crane Monitoring.
Core Technology Modules
Task Assignment Algorithm. An improved genetic algorithm solves the multi-objective optimization problem. Encoding uses priority-based real-number representation, with a fitness function that balances four indicators: shortest path distance, task priority, equipment load balancing, and urgent order insertion. Tournament selection (size 3) is used for the selection operator, while the crossover operator dynamically switches between PMX and OX. Mutation probability adapts between 0.05 and 0.15. In a typical scenario, assigning 20 tasks to 5 overhead cranes completes in under 5 seconds.
Path Planning Algorithm. A hierarchical A* approach is employed: the global layer plans a coarse path on a workshop grid map (1 m resolution), while the local layer refines it in dynamic environments (0.1 m resolution). The cost function incorporates three factors: path length, collision risk, and current equipment occupancy zones. Dynamic obstacle detection runs on a 200 ms cycle, and local path replanning takes less than 50 ms when obstacles are encountered.
Multi-Crane Coordination Strategy. A dual mechanism combines a priority-based yielding protocol with time-window scheduling. Each crane is assigned a dynamic priority (based on task urgency), and lower-priority cranes yield to higher-priority ones. Time-window scheduling prevents deadlocks: each crane's trajectory locks zone resources for specific time slots, and when requests conflict, arbitration follows a priority-plus-earliest-completion-time policy. Kelude Heavy Industry implements a hybrid architecture in the field—centralized dispatching with distributed execution: the dispatching server handles task assignment and global path planning, while each overhead crane's local controller manages path tracking and obstacle avoidance.
System Performance Comparison
| Indicator | Manual Dispatching | Intelligent Dispatching | Improvement Ratio |
|---|---|---|---|
| Daily Lifting Cycles | 150~200cycles | 240~300cycles | +50%~60% |
| Equipment Idle Rate | 35%~45% | 15%~25% | -20% |
| Average Waiting Time | 8~15min | 3~5min | -60%~70% |
| Collision Risk | High(Operator Experience Dependency) | Low(Algorithmic Assurance) | Significant Reduction |
| Task Response Time 10~20min 2~5min -75% |
| Genetic Algorithm 20Task5Trolley Solution Time <5s | A*Path Planning Dynamic Replanning <50ms | Multi-Crane Coordination Priority+Time-Window Dual Mechanismime-Window Mechanism |
| Throughput Increase Daily Lifting Cycles Increase 50% or More |
The intelligent dispatching system is designed and manufactured in compliance with GB/T 37651 and T/CPARK 4 standards. Before leaving the Kelude factory, every dispatching system undergoes 2,000 hours of continuous operation testing to guarantee 7×24 stable performance.
Intelligent Dispatching System FAQ: Capacity, PLC Integration & Safety
Q: How many cranes can the intelligent dispatching system coordinate?
A: In standard configuration, the Kelude dispatching system supports up to 20 cranes operating collaboratively in the same zone. For deployments exceeding 20 cranes, a multi-level dispatching architecture is required: cranes are divided into groups of 8–12 units, with each group managed by its own dispatching server and a master server arbitrating between groups.
Q: How does the dispatching system interface with the PLC?
A: The dispatching server communicates with each overhead crane's PLC via OPC UA or Modbus TCP. It sends task commands (target position, lifting height, travel speed) and reads equipment status (current position, load, operating mode, fault information) on a 200 ms communication cycle. Dispatching commands always take priority over local manual operation.
Q: How does the system respond to unexpected equipment failures?
A: When an overhead crane fails, the dispatching engine automatically reassigns its unfinished tasks to the nearest available crane within 3 seconds. The affected zone is flagged as restricted, and all other cranes automatically re-route to avoid it. The system maintains over 90% throughput even with a single equipment failure.
Q: What safety measures are built into the unmanned overhead crane dispatching system?
A: Three layers of protection: ① zone interlock logic (hard-wired to the PLC, independent of network connectivity), ② sensor-level obstacle avoidance (dual detection via LiDAR and millimeter-wave radar), and ③ dispatching-level safety (dynamic safety distance and speed limiting). The safety level complies with ISO 13849 PLd for machinery safety.
