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Software-defined zones. Change them without touching a sensor.
Zone boundaries are configured in software — no moving hardware, no physical repositioning.
Part of the craneIQ platform — integrates with Core, Monitoring and Cloud.
Overview
Overhead crane collisions with buildings, equipment and other cranes are preventable — but they keep happening because traditional safety measures rely entirely on the operator. craneIQ Zoning removes that reliance. Using laser distance sensors combined with software-defined zone boundaries, the system automatically decelerates and stops the crane before it enters a restricted area. Zones are configured in software — add a new machine to the shop floor, change a pedestrian route, or add a new restricted area, and the zone boundary updates in software without physically moving any sensors or hardware. As part of the craneIQ platform, Zoning integrates directly with craneIQ Core and craneIQ Cloud — zone events are logged, visible remotely, and part of the complete crane data picture.
Common scenarios
Crane to crane — shared runways
Two or more cranes sharing the same runway. craneIQ Zoning prevents them getting too close — automatically decelerating the approaching crane before contact can occur. No reliance on operators watching each other.
Crane to building — structural protection
Keep the crane away from columns, end walls, roof steelwork and other structural elements. Particularly important where cranes operate close to the building fabric or where visibility is limited.
No-fly zones — floor level machinery
Restrict crane entry above sensitive equipment, machine centres, or areas where a swinging load would cause damage. Zone boundaries can be defined at any height — crane level, load level, or both.
Personnel protection — walkways and offices
Prevent crane operation above pedestrian routes, welfare areas, or in-plant offices. A zone boundary above these areas ensures automatic intervention before the crane can enter — without relying on operator awareness.
What it does for you
- Software-defined zones — change them without moving hardwareZone boundaries exist in software — update them as your facility changes without physically repositioning any sensors
- Multi-crane anti-collision on shared runwaysPrevents two cranes getting too close — automatically decelerates the approaching crane before contact
- Protects buildings, structures and steelworkKeeps the crane away from columns, walls and roof elements that would be damaged by impact
- Floor-level protection for machinery and personnelDefine restricted areas above sensitive equipment, walkways or in-plant offices
- Smooth automatic deceleration — no sudden stopsThe crane slows gradually as it approaches a boundary — no shock loads, no load swing from abrupt stops
- Warning before interventionOperator receives visual and audible warning approaching a zone boundary — system only intervenes if they continue
- Unlimited zones per craneNo practical limit on the number of zones — configure as many as your site requires
- Part of the craneIQ platformZone events logged and visible in craneIQ Cloud — integrates with Core and Monitoring for a complete picture
Compatibility & installation
| Works on | Any overhead crane |
| Zones | Unlimited, software configured |
| Detection | Laser, encoder, RFID |
| Response time | < 50ms |
| Output | Safe stop relay |
| Power supply | 24V DC |
| Platform | Integrates with craneIQ Core & Cloud |
| Available | Worldwide |
What it protects against
| Other cranes | Collision prevention |
| Buildings & steelwork | Impact prevention |
| Floor machinery | Access restriction |
| Pedestrian areas | Zone enforcement |
CEUKCARoHS
Who it's for
Plant Managers
Reduce downtime, protect equipment, keep cranes running safely and efficiently without disrupting production.
Engineering Managers
A system that integrates cleanly with existing controls, uses no proprietary hardware, and can be interrogated and maintained without specialist support.
Crane Partners
Add intelligent capability to any crane you supply or service — without being tied to a single manufacturer's ecosystem.
Talk to us about craneIQ Zoning
We work with plant managers, engineering teams and crane partners worldwide. Engineered in the West Midlands, UK — installed globally. Get in touch to discuss your application.