Radio remote controls for crane and conveyor technology

Industrial radio remote controls enable wireless and mobile control of machines, vehicles and apparatus. Range, safety and reliability of the frequency, as well as the ergonomics of the buttons, joysticks and housings are therefore crucial for safe and efficient remote control. Likewise, the components of the remote controls must be very robust against water, oils, gases and extreme temperatures. But how does all this work exactly?

The principle is actually very simple: the transmitter sends encrypted data packets by pressing a button, a switch or turning a potentiometer. We work here with a 48-bit key for an individually encrypted connection between transmitter and receiver. Then the data packets are first checked for the security code by the radio module in the receiver and then evaluated differently. In this case, a predefined task is carried out by the receiver as soon as it receives a signal from an enabled transmitter. With bidirectional remote control, the remote control also has a receiver for common fieldbus networks and can thus receive information from the machine itself. Information can now be read on the 24-digit alphanumeric LCD display. Our remote controls work with the common operating frequency of 433 MHz (433.05 – 434.790 MHz).

The frequencies required for industrial radio remote controls may be used free of charge. However, not all of them are. Exactly which ones are free can vary from country to country. Within the EU, most industrial radio remote controls operate in the 433 MHz or 868 MHz frequency ranges. However, many other radio waves travel on these frequencies, for example from mobile phones, W-LAN or communication for emergency services such as the police or fire brigade. Here, interference must be prevented at all costs, because it would severely affect everyone involved. For this reason, a binding decision was made that a certain frequency range may be used for each application and within this frequency range, one can in turn use a certain channel, for example 433.05 MHz. In this way, the transmission range is further limited. In addition, radio remote controls are equipped with a unique code and key so that the receiver only evaluates signals sent by an associated transmitter.

Does this also apply to JoyPLUSor does it work with 868 MHz? As far as I know, 433 MHz is often very simple by nature due to the lack of bidirectional communication and encryption in the area of protocols.

In crane systems, any type of movement can be controlled with the pendant stations  or radio remote controls from our range. Due to the modular structure of the product range in the field of radio technology, the remote control can be individually tailored to almost any machine. The same can be realised even more easily for the pendant control.

In many places, the days of the complicated cab control, still familiar from the driver’s cab of an old crane, have long been numbered. Numerous levers were necessary for the various types of movement in order to be able to control each individual drive of the crane. Those who were perhaps already fascinated by the toy crane as a small child were especially enthusiastic about the numerous joints and the high degree of mobility. With the real crane, the operation is even more versatile and correspondingly even more complicated because the control levers can be moved in different directions. You therefore always had to know exactly which of the many joints had to be operated in which order, for example, to lower, lift or maneuver a load in a certain direction.

Fortunately, digitalization is also making its way into traditional machines such as cranes. Intuitive and ergonomic joysticks make it much easier to move loads today.

The control of the individual drive units, for example, works via radio remote control. The crane operator will therefore be seen sitting in the cabin less and less. With the remote control in his hand, he can stand next to the crane and follow the movements from outside. This way he keeps a better overview.

The whole thing becomes even more efficient and simple with joystick control. Because even with many remote controls, the principle has remained the same up to now. The crane operator had to master the assignment of the control levers and their interaction, similar to the cabin control.

Radio remote controls with joystick consists of a module with up to two joysticks, which can be extended with further switches and components. Joystick 1 is intended to carry out the movements of the crane in the horizontal plane, while joystick 2 raises or lowers the load. The crane operator does not have to think much about this. If the joystick is pressed forward to the right, the end of the crane also moves in the same direction, i.e. forward to the right. With the second joystick, the load can then be raised or lowered by the user pushing the lever away (upwards) or pulling it towards him (downwards). The decisive advantage: all crane drives are moved simultaneously and the individual joints no longer have to be controlled directly by the crane operator.

The radio remote control of the JOYsys series can be used for many applications due to its good compatibility and small dimensions.

The handheld transmitter can be equipped with up to 2 joysticks, 1- or 2-axis, and 6 function keys to operate several motors simultaneously. A variety of functionalities have been implemented in the handheld transmitter to increase flexibility in operation. For example, the operating frequency, the passive emergency stop time and the power-saving mode can be programmed directly on the hand-held transmitter. Individual switches or push-buttons for additional functions can also be added later. The components have IP65 protection, can be used at operating temperatures of 10°C…+55°C and are available in 1-4 speeds. The range is 80 metres.

Handheld transmitter

• Transmitting power: 10mW
• Antenna: in housing
• Power supply: 3.6V DC
• Power consumption: 65mA max.
• Batteries: Ni-Mh battery pack
• Operating time: > 8 hours
• Material: GRP plastic
• Protection class: IP 65
• Weight: approx. 1.1kg

The receiving section contains 20 relays and is available with AC or DC power supply. Dip switches can be used to ­program different command sequences for ­maximum flexibility in operation. The receiver is supplied in an ABS housing. Appropriate mounting options for surface mounting are provided.

Receiving unit (with or without housing)

• Sensitivity: -110dBm
• Antenna: inside
• Power supply AC: 48V ~ 50-60Hz 5VA
• Power supply CC: 12V – 5W
• Switching capacity relay/stop: 8A/4A 250V~
• Protection class: IP 65
• Material housing: ABS

For easy maintenance or in case of service, the ­entire system is ­modular and can be replaced in individual parts.

All radio remote control systems from B-COMMAND are subjected to careful testing before delivery.

Safety aspects

Safety is at the forefront of every B-COMMAND product. All radio remote controls are therefore ­equipped with ­dual control channels operated by dual microprocessors.­ Each individual microprocessor performs a permanent function test during operation. The ­output relays have been equipped with 2 safety relays for the stop function. These guarantee a safe shutdown of the machine even in the event of a failure of any kind.

In addition, a 48-bit key ensures an individually encrypted connection between sender and receiver.

The JOYplus series from our radio remote control programme is equipped with the possibility of bidirectional communication. The hand-held transmitter can not only send commands to the receiver, but also receive and process feedback from the receiver. The hand-held transmitter can be equipped with up to 2 joysticks, 1- or 2-axis, and with up to 6 function keys to operate several motors simultaneously. It is also equipped with an LCD display with a 24-digit alphanumeric display, which can also show small function symbols. This means that urgently needed information such as weight, distance, working conditions, error messages, etc. can be made directly visible to the user. If the machine is equipped with an intelligent serial interface (CANopen, Profibus and Profinet), the type and number of feedbacks is almost unlimited. In this case, the generation of messages can be taken over directly by the machine with the help of a small program. If no serial interface is available, various ON/OFF inputs can be visualized on the display. The different states of the inputs can also lead to the display of predefined text modules. The components have IP65 protection, can be used at operating temperatures of 10°C…+55°C and are available in 1 and 2 speeds. The range is 80 meters.

One of the main applications here is the remote control of the forestry winch to pull felled trees out of the forest by remote control. However, other machines in the field of timber harvesting are also suitable for radio remote control. For example, the control of logging trucks or the typical crane control. Especially the use on the forestry winch offers a decisive advantage: you can follow the movement of the tree trunk and at the same time keep a safe distance. In this way, one can react faster and is safe at the same time.