KritiKal Solutions Inc. is a premier technology services firm with a global footprint and over 22 years of experience. It excels in product engineering, R&D, and cutting-edge innovation and has catered to its clients through over 500 projects with its deep expertise across AI-driven vision systems, embedded technologies, and cloud and mobile software solutions.

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Digital Rated Capacity Indicator (DRCI): Ensuring Safety and Operational Efficiency in Crane Systems

Digital Rated Capacity Indicator (DRCI): Ensuring Safety and Operational Efficiency in Crane Systems
Category:
Hardware / Automotive (Manufacturing)

The Problem Statement

The client required a robust, intelligent, and user-friendly device to monitor load conditions in real-time on cranes and lifting systems, ensuring compliance with safety regulations and preventing overloading accidents. Existing systems lacked integration, intuitive interfaces, and flexibility to adapt across different crane types. There was a need for: 

  • Real-time, visual and audio feedback for crane operators. 
  • Seamless integration with different sensors and actuators. 
  • Local configuration and diagnostics without specialized tools. 
  • Enhanced connectivity for industrial environments (CAN, RS485, Bluetooth). 

The Solution

KritiKal Solutions developed the Digital Rated Capacity Indicator (DRCI) – a compact, embedded system providing real-time load monitoring, alerts, and advanced control interfaces. The DRCI device supports: 

  • A 5″ RGB display for real-time operational feedback. 
  • Dual CAN, RS232/485, isolated UART, and Bluetooth for diverse communication needs. 
  • Configurable analog/digital I/Os, relay output, and camera input support. 
  • Onboard memory, RTC, and FOTA support for upgradeability and historical data logging. 
  • Rugged design suited for industrial crane environments. 

The Digital Rated Capacity Indicator (DRCI) is a transformative solution for the crane and lifting industry. By combining real-time monitoring, advanced connectivity, and intuitive user interaction, DRCI enhances both safety and productivity on-site. Its modular design and field-configurable features make it adaptable for a wide range of crane types and operational needs. Already in field trials with promising feedback, DRCI positions KritiKal Solutions as a forward-thinking partner in embedded safety systems for industrial automation. 

Architecture:

Hardware Components: 

  • STM32-based MCU at the core for deterministic and reliable processing. 
  • 5″ RGB screen + 8 tactile keys for HMI. 
  • CAN, RS485/RS232, Bluetooth (FC41D) for industrial and local communication. 
  • Sensor and actuator interface via: 
    • 6 analog/digital inputs 
    • 3 configurable high/low-side digital outputs 
    • 1 relay output (short-circuit protected) 
  • Real-time audio/visual alerts via buzzer and multi-LEDs. 
  • Dual camera input via video decoder for operator view or event recording. 

Connectivity & Expansion: 

  • Bluetooth for mobile diagnostics or SSID setup. 
  • Flash & EEPROM for firmware and settings storage. 
  • RTC for timestamping logs and alarms. 

Automation & Data Flow: 

  1. Sensor Data Acquisition 
    1. Analog/digital input channels capture strain, load cell, or tilt data. 
    2. Camera input provides visual stream for reference or alerts. 
  2. Real-Time Processing & Display 
    1. MCU processes sensor data continuously. 
    2. Live readings and safety indicators are shown on the RGB screen. 
  3. Alert & Feedback 
    1. Audible (buzzer) and visual (LED) alerts on overloading or unsafe operations. 
    2. Relay output triggers mechanical interlocks if needed. 
  4. Data Logging & Communication 
    1. Stores operational logs in flash with RTC timestamp. 
    2. Sends data via CAN or RS485 to a central safety system or PLC. 
  5. Local Setup via Bluetooth 
    1. Operators configure systems via mobile app using a secure BLE interface. 
    2. No need for PC or serial tools in the field. 

Benefits Delivered

  • Real-Time Feedback: 
    Live display and alerts increase operator responsiveness and safety. 
  • Flexible Integration: 
    Compatible with multiple sensor types and industrial protocols. 
  • Simplified Configuration: 
    Wireless local configuration reduces commissioning time. 
  • Enhanced Safety Compliance: 
    Prevents overloading and ensures adherence to operational standards. 
  • Future-Ready: 
    Supports firmware upgrades and flexible I/O for long-term scalability.