HoistCam UK technical director Matt Hassock explains how the technology has evolved over the last ten years and affected the crane industry.
“The technology for crane cameras has really come from nothing to where we are now,” Hassock says. “I think that wireless transmission, LCD screens, advanced cameras and other technological developments have really turned crane safety cameras from a concept to reality”.
Hassock explains that HoistCam is a system that provides video monitoring and recording of tower crane operations for the improvement of safety and productivity.
HoistCam is manufactured in the USA by Netarus and founded in 2002. HoistCam UK acts as the UK and European distributor for Netarus providing HoistCam systems, spares and technical support for sales and rentals. HoistCam is supported in the UK by FLG Services who carry a wide range of stock and provide on-site technical expertise.
“HoistCam provides additional assurance for difficult lifts or lifts where the load is not in sight of the operator,” says Hassock. “HoistCam also offers LCD screens, which are easy to mount, bright and clear.”
HoistCam can be instrumental in the prevention of incidents or the evaluation of their cause.
HoistCam is an integrated, wireless video system with digital video recording and embedded sensors coupled with a custom, cloud-based software-monitoring platform. Crane operators can attach HoistCam to a crane’s hook block and additional cameras can monitor safety-critical systems such as the crane’s winch and motors.
HoistCam offers a number of systems, including the HC 190, the HC180 and the HC 140.
The HC180 is used for general crane applications including luffing and saddle jib and fl at-top tower cranes.
The HC180 comprises a rugged wireless camera unit, which fits simply and safely onto the hook block with quickly removable magnetic fixings and a safety lanyard. This is a weather-proof camera, with a built-in rechargeable battery, a 2.4GHz interference-resistant frequency-agile wireless transmitter and a polycarbonate armoured camera dome. Additional magnetically-mounted rechargeable battery packs can extend the duty cycle around the clock.
The HC180 transmits the signal wirelessly into the crane cab. A small receiver unit is fitted in the operator’s cab with a 9.7in LCD screen, which can be mounted, like a rear view mirror, to provide positive confirmation of a safe lift without obstructing the operator’s view.
“We also offer additional products like the HoistCam HC190 Pan-Tilt-Zoom wireless camera platform,” Hassock says. “The HC190 can provide the crane operators with positional control of the camera, allowing them to see anywhere on the job site, even inaccessible areas of the construction.”
Hassock continues, “We also have the low-profile HoistCam HC140. If you are working with very small lifting block or you need the cameras to go somewhere inaccessible, you can use this system.”
The main features of the HC 140 include the IP67 rated wide 90° angle, fixed lens camera, magnetic mount and safety lanyard. It also has infrared illuminators for night-time viewing.
Hassock adds, “These cameras have very good low light capability, so we can operate down lift shafts or in confined spaces. HoistCam is designed from the ground up to be a portable and modular system. For special projects, such as gantry cranes with multiple cameras, HoistCam systems can be quickly put together to precisely capture the users’ required viewpoints.
“HoistCam has been used to assist the rigger and crane operator with a blind lift of cold rolled steel from inside the hull of a cargo ship. The results of using the HoistCam increased the safety rating above 90% and the efficiency of the unloading was reduced from nine hours to four hours, an over 55% increase in productivity and efficiency.
With the HoistCam Director, Hassock explains, HoistCam video can be recorded in a number of different ways. For example, video and images can be recorded onto an SD-card that can continuously record days of crane operations, while overwriting the oldest recording as the card fills. Hassock says: “There is always a record of the lifts, so management can review procedures to analyse the lift strategies and make improvements on the way the crane is used.”
The HoistCam Director software employs a mobile digital video transmission system that allows supervisors and management to watch the operations as they occur from anywhere in the world. Optionally, HoistCam Director will record operations directly to a cloud-based server system for later viewing or analysis.
“HoistCam Director is used for an enterprise setup when a building or crane company wants to review and manage all the operations,” Hassock says. “From an internet connected device it is possible to look at a fleet of cranes with the position of each noted by GPS sensor on Google Maps and zoom remotely on the same view as the operator on the job site.
Each crane transmits video from up to four cameras, where this data can be captured and analysed to provide actionable data about the job site. All the information is stored in the server and it’s possible to see what each crane is doing in real time or on a particular date and time in the past.”
New developments
HoistCam has developed ‘SiteTrax.io’ to analyse imagery captured from the camera. Images and video are passed through HoistCam Director to the cloud based servers of SiteTrax.io. SiteTrax. io processes the data to produce actionable results such as high resolution stitched images of the job site, BIM compatible 3D site models, or digital surface maps. These data points can be used for checking actual construction against plans, for asset tracking or general site safety.
“So we can accurately model the job site and facilitate better and more informed decisions,” Hassock says. “HoistCam is important to manage not just safe lifting but complete site operations. We are expanding the operations of HoistCam beyond the standard crane safety camera. With HoistCam Director and SiteTrax. io, we provide solutions from basic load placement to comprehensive understanding of the entire job site with a direct monitoring solution for site operations and management.”
Virginia-based company HookCam manufactures a wireless camera system that attaches directly to the hook block of a crane and delivers a live video stream to the operator in the cab.
HookCam CEO, David Catanzaro says the company offers the Original HookCam, which is a three-part system with a camera on the hook block, a powered trolley box with encryption, radio, solar and antenna, and a monitor in the cab (100% wireless).
“We offer the HookCam Plus, which consists of a ‘dual camera’ with the Original HookCam featuring the camera on the hook block and a second camera mounted on the trolley. This wireless system includes two monitor displays.
“We provide a luffing system HookCam that is closely related to the Original HookCam. It is wireless from the hook block to the boom tip, but we use a wired solution from the boom tip to the monitor.”
HookCam provides four different lenses ranging from wide angle where jobs rely on moving long rebar; sewer lines, or for instance work around porches.
“We offer narrow field of views for the concrete companies, for instance, where they focus on the bucket or smaller diameters,” says Catanzaro.
“Our systems are built to allow the lenses to be easily switched in several minutes.
“HookCam was the first in 2004 to invent and patent a camera transmitting wireless video from the hook block of a tower crane. Today HookCam is the go-to safety camera for tower and luffing cranes.
“We provide the operator with a view from the hook block while fifteen years ago we provided a view from the trolley and that link had to be wired.
To offer a video from the hook with a moving trolley, wireless technology was required. Our patent was wireless transmission from the hook block.
Today, at the option of the user, we can provide both views. Most of our sales are the traditional HookCam, where camera placement is on the hook block.”
The HookCam Pro is a system with a camera on the hook and a direct wireless feed to the monitor. The HookCam Pro is used for crawlers and certain line of sight conditions.
HookCam needs power in two places: the hook block and the trolley. On the block a 12V DC, 11ah rechargeable battery is used, which provides between 12 and 14 hours of run time for 2,000 cycles.
Power has evolved with delivery of both direct current battery chemistry on the hook block where we use a re-chargeable battery on the hook block and the use of either solar or alternating current (AC) on the trolley.
“HookCam systems are shipped around the world,” says Catanzaro. “We have to ship under US Department of Transportation (DOT) and International Air Transport Association (IATA) regulations, and that places battery safety as our highest priority.
We have to be licensed to ship our systems.
“Solar technology is much more efficient today than the past but at best our solar can drive our trolley system for 12 or 14 hours between charges.
We developed a docking station for those sites that operate 24 hours per day or operate in extreme cold, which reduces battery life.”
“Older systems rely on a daisy chain of antenna wire to catch the signal from the hook,” says Catanzaro. “But with HookCam the relay is above the hook, which hangs from the trolley. That ensures the signal relay to the cab.
It is expensive and technically difficult to introduce a reliable wireless signal from the trolley to the cab because the trolley is constantly on the move. Overcoming the technical challenges to have that reliable signal relayed from the trolley assures the live video is immediate when a building blocks signal delivery from the block to the cab or when the HookCam is used in a deep shaft.”
Regarding the method of attachment, HookCam attaches to the block with use of a magnet, which has a handle that aligns the poles. With a quarter turn our magnet is engaged with 272kg of holding force.
Catanzaro explains their magnets are molybdenum and are wrapped in 1cm stainless steel and they will not shatter upon impact.
“We avoid the use of earth magnet because they are known to shatter shortly after the impact,” he adds.
“That would not be good for our customer or our industry.”
Talking about the range of the HookCam antenna and wireless video transmission, Catanzaro says it is “much greater today due to the use of new RF technology.”
HookCam has been field-tested at 1,700ft (roughly 518m) and HookCams have been installed on the Salesforce Tower in San Francisco that are working at 1,500ft. This requires a special antenna and a high voltage for signal strength. Catanzaro explains, “There are numerous sources of signal conflict, but the power and the proximity of the HookCam receiving antennas eliminate the risk of downtown interference.”
Catanzaro adds operators regularly email or text them, saying HookCam should be standard equipment on all tower cranes. With multiple languages, changes in rigger personnel, blind picks, fatigue, even weather, which presents fog or clouds at the operator level, the HookCam provides a reliable view.”
Catanzaro adds that the demand for these cameras has been so great, that HookCam recently introduced a full service-leasing program to fulfil some orders, which needed a HookCam for a period of critical lifts.
“We undertook a reliability study in Honolulu working closely with Hawaiian Dredging, Kobayashi, Nordic PCL and Layton Construction where HookCam studied the downtime over a period of 14,000 usage hours and found HookCam down time was less than 1% of those hours,” Catanzaro says.
“Every HookCam that is produced is encapsulated to protect from water intrusion, vibration, shock and temperature.”
Catanzaro explains that HookCam is designed as an aid to good safety practices. The hook traverses up and down and that gives the operator the contextual view. When the hook is up, the operator has a big picture: bone yard, new personnel, and moving vehicles. When the hook is down, the operator can see the rigging, personnel, hand signals, balance, load and more. “This outweighs the benefit of the zoom,” says Catanzaro. “The operator’s job requires both hands on crane controls. It is tempting to add zoom but HookCam is passive. Once installed the 10.4” sun readable monitor shows an image as if the operator was 30ft from the pick and there is no operator action required other than to occasionally confirm the radio information with a quick glance.”
The latest HookCam innovation is the remote viewing. HookCam has a system of 18 cranes within one company that have the ability to transmit the video to corporate.
“The subject of the remote viewing was a difficult choice for us,” explains Catanzaro. “Our customer is the operator and we did not focus on the use of Internet to deliver the video to the operator. We know from our studies that the use of internet, delays the delivery of the image to the operator and of course this is not good.
“When HookCam was asked to deliver video to both the operator and to a remote monitor, we had to review it with insurance and our own technical staff. The solution was a closed circuit with a direct feed to the operator and after the fact, milliseconds later, an independent feed to the internet to allow a remote viewing. This is the only way to offer to the operator a reliable and immediate signal.” Catanzaro adds that nowadays the remote viewing, recording, operating hours are options on the HookCam system.
Orlaco develops and produces high quality camera and monitor systems for several applications on a wide range of utility vehicles and vessels. Orlaco chief business development officer EMEA Miquel Boudin explains that the company is a camera and monitor specialist for utility vehicles with more than 27 years of experience.
“We design, test and produce the cameras and monitors in the Netherlands,” says Boudin. “We have a complete engineering team, who is constantly working to improve and develop new technologies and systems.”
US Stoneridge, designer and manufacturer of highly engineered electrical and electronic components, modules and systems acquired Orlaco on February 1. Boudin adds: “Stoneridge is a large company and we have been working together for a couple of years. This merger is good for both parties because working together can be helpful in terms of sharing the same customers and assistance.”
Talking about Orlaco vision systems, Boudin explains that hightech HMI are equipped in the cabin are becoming more regular in the crane market. These displays offer multiple functions to give plenty of information to the operator.
Orlaco introduced an Ethernet camera to be integrated in these HMI displays and also Ethernet networks. This is the EMOS Ethernet camera, which produces images in nearly real time with a lightning-fast 100 Mb/s connection.
“The sturdy camera is operational in the blink of an eye,” says Boudin. “This provides perspective to many industrial applications that require efficiency and safety. This camera is already successful in the mining and agricultural markets. With the current trend of digital information, the EMOS is a perfect match for the crane market. For the crane applications this camera suits perfectly jobs such as integrating camera feeds into radio remote controls and HMI, for vision solutions like winch view or side view.
This is made possible thanks to the compact and flexible design for mounting and to perform under the most extreme conditions.”
The camera is shock-resistant at 50 G, vibration-resistant at 15 GRMS at a frequency of 24 – 2,000Hz and can handle temperatures from minus 40ºC to plus 85ºC. The EMOS has an aluminium housing with 2k moulding and is completely waterproof (IP68/ IP69k). It can even be used underwater up to a depth of 10m.
“EMOS camera is small (55 x 60 x 24mm), light (150g) and energy efficient (<2W),” says Boudin. “The EMOS is available with viewing angles of 180°, 120°, 90°. The 60° and 30° viewing angles will be introduced to the market later this year. The camera’s maximum latency is 48ms at 30 FPS, and 31ms at 60 FPS. In combination with a common hardware processing platform, such as the IMX6 or ARM, the total latency of the camera-monitor system is less than 100ms.”
The EMOS carries CMOS chip technology and contains integrated corrections, such as automatic white balance, photometric and geometric lens correction, mirror imaging and the ability to rotate images 180°. Users can be assured of crystal clear images with a maximum camera output of 60 FPS at 720p SDR to 43 FPS at 960p HDR. Thanks to the sensor’s high degree of light sensitivity (0.05 Lux), the EMOS also offers superb night vision.
The EMOS is connected through a M12 D-coded connector for data. A shielded cable with sprayed-on connector provides excellent EMC performance (100V/m). The camera can be directly connected to the vehicle’s power supply (8 – 32V) and the power supply is protected from peak voltage, overvoltage, jump-starts, spikes and ripples.
Via the RTP and AVB protocols, the camera is able to stream MJPEG or H.264. The ISO17215 protocol is used to communicate with the camera.
This includes setting the resolution, mirroring the image and starting/ stopping streaming. For extra safety and ease of use, it is also possible to display overlays (text, arc, line, image and safety ticker) as desired.
Other products for cranes include the zoom camera. This can be used for a Load View solution to provide a view on the top of the hook and the load, and the working area. The advantage of a Load View camera is that the crane operator can immediately see whether a lifting operation could possibly become dangerous. “Thus, the operator can make the right decisions without delay and prevent accidents on site,” Boudin says. “The zoom camera can be extended with a tower crane package to completely benefit from the zoom camera. With the solar panel, battery pack and our spectrum scanner for wireless applications, our set is one of a kind when it comes to performance in the most extreme conditions.”
The Orlaco compact HMOS camera is a digital digicoax camera, which provides real time images with a 50G resistance. Boudin adds: “The HMOS camera is also used as part of our CornerEye camera system and provides a 270° field of vision. This is ideal for mobile cranes or crawler cranes, to get an excellent view on the front and side area around the vehicle with only one camera in real time.
The compact camera FAMOS is built for heavy-duty applications under the most extreme conditions. The shock and vibration resistance and the watertight housing provide a clear image without fail.
“Orlaco camera and monitor systems have been the solution for Dakar trucks for years,” Boudin says.
“The Dakar rally is known for its extreme conditions. During the race on rough land, trucks have to withstand strong impacts that wheels come off the ground. This requires materials that can handle this kind of impacts. Even in muddy and sandy areas, the smart camera lens with anti-dust and -dirt coating can provide a perfect image.”
Orlaco also offers the Spectrum Scanner, a wireless 2.4GHz video transmitter and receiver that can be used for several vision systems, such as making wired cameras wireless. The Spectrum scanner has a maximum range of 300m, it depends on surroundings and the type of Spectrum Scanner.
The receiver receives power supply directly from the Orlaco monitor, and the transmitter receives power supply from the included power cable from the machine or from the vehicle supply. Boudin adds that Orlaco’s next development will be the WiFi solution for Ethernet cameras.
Orlaco’s Load View has been used by one of the biggest crane owners in the Netherlands, Kuiphuis, to lift construction material over a 60m tall building with a telescopic crane.
“Orlaco’s Load View system is essential for that”, crane driver Wim Goorman says. “Using this system I can directly see the hook and the load and I can check pedestrians and the position of my load in the cabin’s monitor. I can also get everything in sight when I have to put the load on a roof or to lift it over a building.”
Boudin explains that Orlaco developed these cameras to improve safety and to secure workplaces all over the world. “But cameras can’t replace the worker on the floor who check the work progress on site,” Boudin adds. “We believe that the best combination is to have camera in the cabin and the colleague on the floor.” RaycoWylie integrates cameras from suppliers including HoistCam, Orlaco and others in its crane vision solutions.
RaycoWylie technical sales and customer support Chris Cartwright explains the reason why they developed a crane monitoring system, which can incorporate multi options in one unit.
“Crane operators usually have to manage multiple and separate screens to monitor the wind speed, load conditions, and camera system, but it’s not easy to concentrate properly during lifting operations. Thus, our cameras are generally built into our monitoring system,” says Cartwright.
“Our aim is to supply one complete crane monitoring system rather than having a lot of separate systems. This increases reliability, reduces the amount of cab space required and keeps the information clear and easy for the operator.
If the crane camera is connected to the RaycoWylie system both the camera and load critical information can be displayed at the same time. This results in the operator not needing to monitor different screens while carrying out operations.
Cartwright says the availability to high definition, good quality heavy duty colour screens has opened up the use of them in cranes, the advantages of which include the use of different colours to warn operators producing an interactive and intuitive system.
“Boom tip cameras or hook mounted cameras can increase the operators vision during blind lift operations, while rear or 360° view systems are generally used while the crane is traveling or slewing,” Cartwright says.
RaycoWylie offers the i4500 series of systems, which include the i4500, i4507 and i4510. They have been developed to meet demanding regulations and standards of the crane and lifting industry.
A full colour display is available in 4.3in, 7in and 10.4in models in addition to self-diagnostics, operator usability, and ease of calibration.
The systems use the CANbus J1939 protocol to communicate with each interface, constantly monitoring all the cranes sensors to give clear accurate information to the operator, the CANbus network also allows huge amounts of flexibility allowing you to add or remove sensors when required at any time throughout the life of the equipment.
The i4500 series can be used whether with a 1te telescopic mobile, 100te crawler, 80m luffing tower, 10te flat top tower, swan-neck tower, port crane, barge crane, rail crane and custom specialist applications.
The software has been developed to make operation, calibration and fault finding as fast and simple as possible, the company says.
This is done through listening to the needs and recommendations of our customers, from flexible calibration points, centre of gravity calculations for attachments, USB connectivity.
Tower cranes are the newest application for the i4500 series. RaycoWylie has worked extensively with tower crane specialists and invested heavily to develop a flexible and versatile system that is perfectly suited to the tower crane market.
The software has been developed to work with luffers, flat-tops or swan necks.
Cartwright adds: “The main interest is to use the boom tip or hook mounted camera on the crane this is not only to aid the operator, but with the ability to record can be used for post job analysis, accident prevention and more.
“The availability to use wireless cameras can reduce the cost of installation and open up the option for temporary installations for specific lifts.”
UK-based company BlokCam manufactures a wireless system that can be deployed to the hook block or boom tip of a crane. The sound and view from below the camera is then transmitted and received wirelessly via the antenna systems to a screen in the cab. This allows the operator to see and hear the load and surroundings, giving an unobstructed, live, audio-visual feed of the critical areas that working in the blind would never allow.
BlokCam joint managing director Ben Windass explains the company offers a single product, the BlokCam Model X, which is compatible across all types of cranes. It is a modular system that can be built to suit our customer’s needs.
Windass says: “BlokCam is the first and only high definition, audio-visual, fully modular system compatible with telescopic cranes. BlokCam is the only crane camera system that records as a standard feature in addition to be the only crane camera system that supports audio (patent pending). BlokCam’s recessed, down facing lens does not get obscured when it rains. BlokCam is the lowest profile block mounted camera in the world and it can be used 24 hours a day.”
Windass adds that with BlokCam’s audio-visual data logging the customer can quickly investigate incidents. “It’s not about pointing the finger, crane camera footage can also be used for training and to address and improve procedures,” he says. “This technology has already reduced accidents, saved lives, time, money and jobs.”
BlokCam has been adopted and installed on sites across Crossrail, Europe’s largest infrastructure project. BlokCam worked closely with H&S Advisors and the site lifting teams comprising of the appointed persons, supervisors, operators and slinger signallers.
Windass says that slingers and operators considered BlokCam as an “extra pair of eyes and ears”. “It speeds up and clarifies radio communication by visualisation,” he adds. London Tower Cranes, managing director, Martin Harvey says: “BlokCam is one of the best investments London Tower Cranes have made. The quality, ability and value of their camera system are second to none.”
CMOS sensors
Steve Hearn, sales director at IDS Imaging Development Systems, explains that IDS has been a “pioneer” in the use of CMOS sensors in industrial cameras.
“Cameras are available using high performance sensors from a number of manufacturers and with a choice of GigE, USB2.0 and USB3.0 interfaces,” says Hearn. “All IDS cameras are supplied with the IDS software suite, which offers the same control functionality regardless of the interface type. The IDS range includes the LE series of board level cameras that are ideally suited to crane applications.”
He adds: “The compact, low cost UI-3881LE USB 3.1 Gen 1 board level colour or monochrome cameras can easily be incorporated into a weatherproof housing by the customer and use S-mount lenses to keep the cost down. This camera features a high resolution 6.4 megapixel (3088 x 2076) Sony IMX174 CMOS sensor with frame rates up to 60 fps.”
Costs
Talking about the crane cameras price, which is much more affordable than the past years but still a bit expensive, Boudin explains why the price shouldn’t be an issue.
“An acciden would require a larger amount of money to replace or repair the crane and additional costs of damages for example on the building site than buying this kind of camera systems,” Boudin says.
Cartwright adds: “Prices of cameras vary depending on type of camera, specification and manufacturer, RaycoWylie Systems are open to work with all compatible camera systems.”
Catanzaro also says HookCam monitors are not “inexpensive”, but that the delivery system, like other HookCam components are the finest made.
“We had one of our monitors fall from the window and dangle out the cab in an earthquake,” Catanzaro says. “We asked if it needed to be replaced and the operator said it still worked.”
