Cone of Safety around
a Crane Hook
Presented by Team 5
Xue Cheng
Samuel Falabi
Charlie Nguyen
Richard Szink
Lanea Williamson
The Team
Project Management
Richard
Szink
Samuel
Falabi
Charlie
Nguyen
Xue
Cheng
Lanea
Williamson
• Proximity Sensors
• Overall design and Hardware Implementation
Documents Preparer
• Power supply
• Alarm system
Web Designer
• Safety cone design
• Software implementation
Presentation
• Sensor Research
• Data Logging
Lab
• Alarm system
• Cost estimating and Purchasing
Faculty
Dr. Hayder Radha
Professor and Associate Chair for Research
Study in coding and communications; image and video
compression; image processing; multimedia
communications over packet networks; video coding
and communications over the Internet and wireless
networks; modeling and analysis of the stochastic
behavior of communication networks; wavelet,
subband, and multiresolution coding
Sponsor
• ArcelorMittal USA
-World’s leading steel and mining
company
• James Lang
-Coordinator, Finish and Coating
Background and Objectives
ArcelorMittal Company Background
• World’s leading steel and mining company
• Annual production capacity of 115 million tons
and operating in 60 countries
• Produce safe and sustainable steel
• Provide conductive and a safe work
environment for its employees
Safety Issues
• Suspended steel coil loads hang from
the overhead cranes and are
potential safety risks to the
operators.
• Over fifty accidents have caused
deaths in the past 15 years in the
northwest Indiana Steel Industry.
Our Mission
• The system will be able to detect any operator within a certain
distance from a working crane.
• The system will be turned on when the load is within 8ft above
ground.
• The system will sound an alarm and warn the operator when the
operator is in the danger zone.
• Data will be recorded so ArcelorMittal can constantly improve their
safety measures and prevent future occurrences.
Exploring a Solution
Design Schematic diagram
How do we build this?
• Sensors
• Alarm
• Data Recording
• Processing all the information
• Protective Casing
Research Techniques
• What are the industry standards?
• Opportunity to advance field?
• Has a similar project been completed
before?
• What was the outcome?
• What type of sensors would fulfill our
needs?
• What are our design constraints?
• How can we overcome them?
Ranking of Conceptual Designs
Cost
Cone
Shape/Cha
nging
Radius
Feasibility
Score
Option
Detect
Human
Suitable
Range
Sense
Through
Objects
Industry Standard Design
0
100
0
90
25
85
46
|||||||||||||||||||||||||||||||||||||||||||||
Thermal Imaging Design
100
85
90
80
95
95
92
|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Motion Sensor Design
100
90
90
80
50
95
86
|||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Image Processing Design
80
90
0
95
90
60
66
||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
Ultrasonic Sensor Design
0
90
0
75
60
80
47
||||||||||||||||||||||||||||||||||||||||||||||
Programming Flowchart
• Detect load
distance
• Detect humans
• If a human is
detected:
• Turn on an alarm
• Record data
Microcontroller
• Arduino
• Cheap
• Popular
• Lots of Documentation
• Libraries with easy functions
Final Design
Overall Design
Adjusting size of Safety Cone
• When the load gets closer to
ground, we need to adjust the
angle of sensor to shrink the
safety cone
Detect Distance of the Load
• Mount sensor on the trolley of crane
to sense distance from load to
ground
• HC-SR04 Ultrasonic Sensor
• Takes advantage of the piezoelectric
effect to send waves and record the
time it takes that same wave to
return.
𝑫𝒊𝒔𝒕𝒂𝒏𝒄𝒆 𝒕𝒐 𝑮𝒓𝒐𝒖𝒏𝒅 = 𝑺𝒆𝒏𝒔𝒐𝒓 𝑯𝒆𝒊𝒈𝒉𝒕 − 𝑫𝒊𝒔𝒕𝒂𝒏𝒄𝒆 𝒕𝒐 𝑳𝒐𝒂𝒅
However…
• Proximity Sensors can
neither differentiate
human body from the
load
D6T Thermal Sensor
• Uses infrared technology to sense its
surrounding and create a 4x4 matrix
of surrounding temperatures.
• The 4x4 matrix can be manipulated to
successfully create a cone shape.
Selecting Thermal Angle
• With thermal imaging sensor,
we can select the range we
need to measure. Therefore,
we can adjust the safety cone
with the height of the load.
Alarm System
• Circuit takes advantage of a
transistor, high-wattage
resistors, and a voltage input
from both the power supply and
the Arduino board.
• Properly output the 80+ db
sound
Data Logging
• SD card shield combines a SD
card slot with a 3.3V – 5V level
shifter and a 3.3V voltage
regulator. This enables direct
hookup to the Arduino’s SPI
pins.
Protective Casing
• Designed with NX
• 3D printed
• Material
Testing and Proof of Design
Testing
A scaled version of an overhead
crane was created using PVC pipe,
wood, a pulley system, and a
simulated load.
Testing of Thermal Sensor
Data Logging
Budget
Table 2: Estimated Cost per Unit
Table 1: Actual Cost of Prototype
Final Cost
• According the Pi-Chart
based on cost per unit,
main cost for this project
is D6T Thermal Sensor
and Arduino Mega ADK
board
• Cost of design would be
greatly reduced when
putting in massproduction
Suggestions for Future Work
• Panasonic Thermal Sensor – Product Liability
• Improvement in System Housing – Product Safety
• Power Supply - Standards
Summary
• Safety is top priority at ArcelorMittal
• Using effective design techniques leads to best results
• Opportunity for industry to use new methods to enhance safety
• First recognizable project of its kind