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Overhead Crane Detection
LiDAR for Overhead Crane
Detection, Anti-Collision & Safety Laser Scanner Selection
Compare YB industrial 2D LiDAR for non-safety detection and switching-output automation with SH27 safety laser scanners for safety-related protective sensing. Selection depends on the function the sensor must perform, required detection distance, control architecture and applicable machine-safety requirements.
Overhead crane anti-collision
Configurable detection zones
Standard PLC or safety control architecture
YB and SH27 selection
01
Application Fundamentals
Where LiDAR & Safety Laser Scanning Fit in Overhead Crane Applications
Laser scanning can support several different functions around an overhead crane, from simple distance and obstacle awareness to safety-related protective sensing. The important engineering question is therefore not simply “Can LiDAR detect the object?” but “What function must the detection perform?”
01
Distance Monitoring
Measure relative distance to another crane, runway structure, wall or other object so the control system can monitor approach conditions.
02
Object & Area Detection
Detect objects within a configured scan area and provide information that can be used for warning, sequencing or other automation logic.
03
Position & Approach Awareness
Use scan measurements to support positioning, docking, approach monitoring or host-side calculation where suitable for the application architecture.
04
Safety-Related Detection
Where detection is part of a required safety function, the sensing device and complete control architecture must satisfy the applicable safety requirements identified by the machine risk assessment.
Function-First Selection
Two Sensor Paths for Crane Applications
CCH offers both industrial 2D LiDAR and safety laser scanning. They may operate on similar laser-scanning principles, but they should not be treated as interchangeable devices.
Non-Safety Industrial Sensing
YB Industrial 2D LiDAR
Suitable for applications such as distance, object and configurable-area sensing where the required function does not require a safety-rated protective device.
Safety-Related Scanning
SH Safety Laser Scanner
Intended for applications where laser scanning forms part of a safety-related control function and the required design calls for Type 3 / PL d safety performance.
The sensor choice is determined by the required function, not simply by the fact that the equipment is an overhead crane. The same physical detection task may require a different sensing architecture depending on applicable standards, local requirements, machine risk assessment and the required safety performance.
02
Detection & Anti-Collision Tasks
Typical Overhead Crane Detection & Anti-Collision Applications
Bridge cranes, gantry cranes and other travelling crane systems may require awareness of nearby cranes, runway limits, fixed structures or objects within shared operating areas. Laser scanning can provide configurable detection zones and switching signals that the crane control system uses for warning, reduced-speed operation, motion inhibition or other defined responses.
Crane-to-Crane
Crane-to-Crane Approach Monitoring
When two travelling cranes operate on the same runway or within overlapping working areas, a scanner can monitor the approach of another crane or defined structure before the distance becomes critical.
Relative approach detection
Configurable warning or control zones
Switching signals for crane control logic
Runway Monitoring
End-of-Runway & Structure Detection
Laser scanning can monitor the crane travelling direction for runway-end structures, walls, columns or other fixed objects entering configured detection areas as the crane approaches.
Runway-end approach monitoring
Fixed-structure detection
Configurable detection distances and zones
Shared Operating Area
Obstacle & Shared-Zone Monitoring
In facilities where cranes, machinery or structures share operating space, 2D scanning can detect objects entering a defined scan plane or monitored area and provide switching information to the control system.
Configurable area monitoring
Object or presence detection
Warning and automation control signals
Multi-Zone Control
Multi-Zone Approach Control
Configurable detection zones can support staged crane approach logic, allowing different switching outputs to be associated with progressively closer monitored areas.
Configurable detection zones
Switching outputs for PLC or control-system logic
Support for staged warning, deceleration or stop strategies
Typical Control Concept
Detection Is Only One Part of the Anti-Collision Function
The scanner detects whether an object has entered a configured area. The resulting switching signal is then evaluated by the crane control system. The required control architecture depends on whether the function is ordinary automation or a safety-related function.
Step 01
Detect
The LiDAR or safety laser scanner monitors the configured detection or protective area.
Step 02
Switch
Detection produces the applicable switching output or safety-rated OSSD state.
Step 03
Control
The control system applies the configured response such as warning, reduced speed, motion inhibition or stopping.
Step 04
Validate
The complete function is verified against the application, stopping behaviour and applicable safety requirements.
“Anti-collision” describes the application objective, not the safety classification of the sensing device. YB switching-output 2D LiDAR can be used for non-safety crane detection and automation logic. Where the detection function is safety-related, the required safety performance must be determined from the applicable standards, local requirements and machine risk assessment, with an appropriate safety-rated sensing and control architecture used where required.
03
Sensor & Model Selection
Recommended CCH Sensors for Overhead Crane Applications
For typical overhead-crane approach and anti-collision applications, the primary requirement is often a switching signal that can be integrated into the crane control system. CCH provides two distinct routes: YB industrial 2D LiDAR for non-safety detection and SH27 S-series safety laser scanners when the required function needs safety-rated protective sensing.
Industrial Switching Output
YB Switching Output 2D LiDAR
For non-safety crane detection, configurable monitoring areas and PLC-based automation logic. Switching output can be configured as PNP or NPN.
Available Switching Output Models
YB27-15CS
15 m
@ 70% reflectivity
YB27-25CS
25 m
@ 70% reflectivity
YB27-25HS
25 m
@ 70% reflectivity
YB27-35HS
35 m
@ 70% reflectivity
YB27-40HS
40 m
@ 70% reflectivity
Scanning Angle
Up to 270°, configurable active scan angle
Switching Output
PNP / NPN configurable
Angular Resolution
Default 0.3°
Scan Frequency
Default 30 Hz; model-dependent configurable rates
Zone Groups
Up to 16 selectable zone groups
Response Time
67–536 ms, configuration-dependent
Supply Voltage
DC 9–28 V
Power Consumption
< 2 W
Protection Rating
IP65
Application Role
Use YB switching-output models when the crane requires non-safety distance, object or configurable-area detection and the resulting PNP / NPN signal will be processed by a standard PLC or automation controller.
Safety-Rated Switching Output
SH27 S-Series Safety Laser Scanner
For crane applications where the scanning function is part of a safety-related control system and the required design calls for Type 3 / PL d protective sensing.
Recommended S-Series Models
Safety Classification
Type 3 · SIL 2 · Category 3 · PL d
Safety Output
PNP OSSD
Scanning Angle
276°
Angular Resolution
0.1°
Scan Frequency
30 Hz
Response Time
100 ms default, configurable
Object Resolution
70 mm at maximum protective radius
Zone Sets
Up to 64 configurable zone sets
Supply Voltage
DC 24 V ±20%
Power Consumption
< 5 W
Protection Rating
IP65
Application Role
Use the SH27 S-series when detection is required as part of a safety-related protective function. The protective field acts through the safety-rated OSSD output. The larger warning field is available for non-safety warning or preliminary control functions.
Quick Selection
Start With the Required Control Function
Need raw scan data as well? Selected YB configurations provide raw scan data for host-side processing. SH27-03D and SH27-05D retain the SH27 safety functions and additionally provide non-safety Ethernet raw distance, angle and echo-intensity data. Raw scan data does not replace the safety-rated OSSD function.
04
Multi-Zone Control Logic
How Multi-Zone Crane Anti-Collision Control Works
A single detection point is often not enough for a travelling crane. Multiple monitored zones can provide progressively earlier responses as the crane approaches another crane, runway structure or obstacle. The exact zone distances and control actions must be engineered for the actual crane speed, braking behaviour and required function.
Example Approach Strategy
Far Zone → Intermediate Zone → Near Zone
The following is a conceptual example rather than a fixed factory setting. Actual field geometry, distances and responses should be defined during machine design and commissioning.
Far Zone
Early Warning
The first monitored area detects an approaching crane or obstacle while sufficient separation still remains.
Typical response: warning indication or preliminary control action.
Intermediate Zone
Reduced Speed
A closer monitored area can trigger a second control stage when the crane continues to approach the detected object.
Typical response: reduced travel speed or restricted motion.
Near Zone
Stop or Motion Inhibit
The closest zone can be associated with the final configured control response before the available separation becomes unacceptable.
Typical response: configured stop command or motion inhibition.
Where this action is safety-related, a validated safety-rated
sensing and control architecture is required.
Scanner monitors configured zones
→
Applicable switching output changes state
→
Crane control system applies the defined response
Standard Automation Route
YB Switching Output Control
YB switching-output LiDAR can monitor configured detection zones and provide PNP / NPN switching signals to a standard PLC or crane automation controller for non-safety industrial detection.
1
Configure Detection Areas
Define the required monitoring geometry according to the crane
approach direction, target and installation position.
2
Generate PNP / NPN Switching Signals
Detection within the configured area changes the applicable
switching-output state.
3
Standard PLC Executes Automation Logic
The controller may use the signal for warning, reduced speed,
motion restriction or other defined non-safety control
behaviour.
Safety-Related Route
SH27 Safety Scanner Control
Where the sensing function is safety-related, SH27 provides a safety-rated protective field and PNP OSSD outputs for integration into the applicable safety control architecture.
1
Configure Warning & Protective Fields
Warning areas may support preliminary non-safety actions.
The protective field performs the safety-related detection
function.
2
Protective-Field Infringement Changes OSSD State
When the protective field is infringed, the safety-rated
PNP OSSD outputs change state according to the configured
safety function.
3
Safety Control Architecture Responds
The OSSD signal is evaluated by the applicable safety
controller, safety relay or machine safety circuit as part
of the complete safety function.
Important Safety Distinction
Warning, Deceleration and Safety Stop Are Not Automatically the Same Function
With YB, switching outputs are intended for industrial automation and non-safety detection. A PLC may use those signals for configured warning, speed-reduction or stopping logic, but this does not make the sensing function safety-rated.
With SH27, the safety-related sensing function is provided through the protective field and safety-rated PNP OSSD outputs. SH warning fields can support preliminary warning or other non-safety switching functions, but the warning field itself must not be used as the safety-rated protective field.
Zone distances should never be selected from a generic template alone. Crane travel speed, sensor response time, controller and drive response, braking behaviour, load condition, installation geometry and the required safety performance all influence the final field design. These factors are addressed in the following engineering section.
05
Detection Distance Engineering
How to Determine the Required Crane Detection Distance
The required scanning distance should be derived from the actual motion of the crane rather than selected from sensor range alone. Travel speed, sensor response, controller and drive response, braking behaviour, load condition and engineering margin all influence how early an approaching crane or obstacle needs to be detected.
Conceptual Engineering Relationship
Start From the Crane, Not From the Sensor Catalogue
First determine how much distance the moving crane needs to detect, process and respond to an obstacle. Then select a sensor capable of reliably covering that requirement under the actual installation conditions.
Required Distance ≈
Travel During Response
+
Braking Distance
+
Engineering Margin
This relationship is a conceptual engineering aid only. It is not
a substitute for a safety-distance calculation required by an
applicable machine-safety standard.
01
Crane Travel Speed
A faster travelling crane covers more distance during the same sensor and control-system response time. Maximum operating speed should therefore be considered when defining detection zones.
02
Sensor Response Time
Detection is not instantaneous. YB switching-output response time depends on scan-count configuration, while SH27 response time is configurable around the required safety-scanner operating mode.
03
Controller & Drive Response
PLC scan time, safety controller response, drive-command delay and other control-system behaviour add to the total time before the crane begins to decelerate or stop.
04
Mechanical Braking Distance
The crane continues moving after the stop command is issued. Brake condition, drive system, travel speed and mechanical characteristics influence the actual stopping distance.
05
Load & Operating Condition
A crane may not stop identically under every operating condition. Validation should consider relevant load, travel direction, operating mode and expected worst-case conditions.
06
Engineering Margin
Allow additional distance for measurement uncertainty, installation tolerance, environmental variation and other factors identified during system design and commissioning.
Practical Selection Workflow
From Crane Motion to Sensor Model
A useful selection process works backwards from the required control response rather than beginning with the longest available LiDAR range.
Step 01
Define Maximum Travel Speed
Establish the operating condition used for the detection design.
Step 02
Measure System Response
Include sensor, controller, drive and related response delays.
Step 03
Determine Braking Behaviour
Establish actual stopping performance under relevant conditions.
Step 04
Define Zone Distances
Set warning, speed-reduction and final intervention areas.
Step 05
Select & Validate Sensor
Confirm range, reflectivity, geometry and control architecture on the real crane.
Industrial Detection Range
YB Switching Output LiDAR
15 m to 40 m @ 70% Reflectivity
Available working range depends on the selected YB model. These distances describe industrial LiDAR detection capability under the stated target-reflectivity condition and should be validated using representative crane targets and installation geometry.
Safety-Rated Protective Range
SH27 S-Series Safety Laser Scanner
3 m or 5 m @ 1.8% Reflectivity
SH27 protective range is specified at low target reflectivity for its safety-related protective function. SH27-03S provides a 3 m protective radius and SH27-05S provides a 5 m protective radius, with larger non-safety warning fields available by model.
Target Reflectivity Matters
Do not compare sensor range values without checking the stated reflectivity condition. A YB range such as 40 m @ 70% reflectivity and an SH protective range such as 5 m @ 1.8% reflectivity describe different performance conditions and different application purposes. Real crane structures may include painted steel, dark surfaces, reflective panels, openings and complex geometry, so representative target testing is recommended during commissioning.
Safety-Related Applications
A Generic Distance Formula Is Not a Safety Validation
When the scanner is part of a safety-related crane function, protective-field dimensions must be determined using the applicable regulations, standards, machine risk assessment and the validated response and stopping characteristics of the complete system. The simplified relationship shown above is useful for understanding the engineering factors, but it must not be treated as a universal safety-distance formula.
06
Installation & Environment
Installation Considerations for Overhead Crane LiDAR & Safety Scanners
Reliable crane detection depends on more than sensor range. Mounting position, scan-plane geometry, vibration, target reflectivity, contamination and the direction of crane travel all influence whether the configured detection zones work as intended. Final validation should always be performed on the actual crane and representative targets.
01
Mounting Position
Mount the scanner where it has a stable and unobstructed view of the intended approach path. Structural members, cable carriers, hoist components or other moving parts should not repeatedly enter the monitored plane unless they are intentionally included in the detection logic.
02
Scan-Plane Geometry
The 2D scan plane must intersect the part of the opposing crane, wall, runway structure or obstacle that should be detected. A long nominal sensor range is not useful if the scan plane passes above, below or through an open section of the target.
03
Travel Direction
A crane may require monitoring in one or both travelling directions. Sensor quantity and mounting position should be chosen so that the relevant approach direction remains covered throughout the required operating area.
04
Vibration & Mechanical Stability
Crane travel, acceleration and braking can introduce vibration. Use a rigid bracket and verify that the sensor does not shift or rotate enough to move the configured detection field away from the intended target area.
05
Dust, Dirt & Window Condition
Industrial crane environments may contain dust, oil mist or other contamination. Keep the optical window accessible for inspection and maintenance and establish a cleaning interval appropriate to the operating environment.
06
Reflectivity & Ambient Conditions
Painted steel, dark surfaces, reflective markings and changing background conditions can produce different return levels. Commission the system using representative targets and verify reliable operation under the expected lighting and environmental conditions.
Scan Geometry
Make the Scan Plane Intersect a Reliable Target
Overhead cranes contain beams, wheels, rail structures, gaps and moving components. The scanner should be positioned so the monitored plane consistently intersects a suitable target surface throughout the required approach path.
Select the intended detection target
Define which part of the other crane or fixed structure must
reliably enter the scanning plane.
Check the full travel path
Confirm that the target remains visible as crane position,
alignment and operating conditions change.
Avoid unintended obstructions
Ensure ropes, hooks, cable systems or structural elements do
not create nuisance switching unless intentionally accounted
for.
Lock and verify the mounting angle
After mechanical installation, verify the actual field position
before final commissioning.
One-Direction Monitoring
One Scanner May Be Sufficient
If the application only needs detection in one defined approach direction and the required scan plane remains unobstructed, a single scanner may cover the required monitoring task.
Bidirectional Monitoring
Two-Sided Coverage May Be Required
Where the crane can approach hazards or other cranes from both travel directions, separate sensing positions may be required. The final quantity should be determined from the actual mechanical layout and required coverage rather than assuming one scanner can always monitor both directions.
Commissioning Checklist
Validate the Installation Before Putting It Into Service
Configuration software can define detection fields, but real-world commissioning is required to confirm that the fields match the intended crane geometry and control behaviour.
Step 01
Confirm Sensor Alignment
Verify mounting position, angle and scan-plane height.
Step 02
Test Representative Targets
Use the actual crane structure or equivalent target surfaces.
Step 03
Verify Every Zone
Confirm switching behaviour at the intended field boundaries.
Step 04
Test Crane Response
Verify warning, speed reduction and stopping behaviour as used.
Step 05
Repeat Under Real Conditions
Check relevant travel speeds, load conditions and environment.
Installation quality is part of sensing performance. A correctly selected LiDAR or safety laser scanner can still produce unreliable results if its scan plane misses the intended target, the bracket moves under vibration or contamination is allowed to accumulate on the optical window. Mechanical installation, configuration and functional validation should therefore be treated as one engineering process.
07
Safety Standards & Regional Requirements
When Does an Overhead Crane Need Safety-Rated Scanning?
There is no single global rule stating that every overhead crane anti-collision application must use the same sensor classification. The required sensing architecture depends on the safety function, machine risk assessment, applicable legislation, crane-specific standards, control-system requirements and local project specifications.
Function Before Product
Determine the Required Safety Function First
A sensor should not be selected as “safety” or “non-safety” simply because it is installed on a crane. First establish what the detection function must achieve and what risk reduction the complete control system is required to provide.
Step 01
Assess the Risk
Identify collision hazards, operating conditions and possible consequences.
Step 02
Define the Required Function
Determine whether detection is ordinary automation or part of required safety-related risk reduction.
Step 03
Select & Validate the Architecture
Select sensing and control components suitable for the required performance and validate the complete function.
European Union
Machinery & Crane Safety Requirements Are Risk-Based
For EU projects, the applicable machinery legislation should be considered together with crane-specific and functional-safety standards. The required Performance Level or scanner architecture should be derived from the application rather than assumed solely from the fact that the machine is an overhead crane.
Current Framework
Machinery Directive 2006/42/EC
Remains applicable until 19 January 2027 and requires machinery manufacturers to carry out risk assessment and apply the relevant essential health and safety requirements.
From 20 January 2027
Regulation (EU) 2023/1230
Replaces Directive 2006/42/EC and continues the EU machinery framework with risk assessment and risk-reduction requirements.
EN 15011:2020 — Cranes · Bridge and Gantry Cranes
Crane-specific safety standard relevant to bridge and gantry
cranes travelling on rails, runways or roadway surfaces.
ISO 12100:2010 — Risk Assessment & Risk Reduction
Provides the general machinery risk-assessment methodology.
ISO 13849-1:2023 — Safety-Related Control Systems
Provides the methodology for safety-related control-system
design. It does not itself prescribe one universal PLr for
overhead cranes.
IEC 61496-3:2025 — AOPDDR Protective Devices
Defines requirements for diffuse-reflection electro-sensitive
protective equipment used as part of safety-related systems,
including 2D protective scanning technology.
Brazil · NR-11 & NR-12
Crane Requirements Meet Machine-Safety Requirements
In Brazil, NR-11 addresses transport, movement and handling of materials, including lifting equipment, while NR-12 establishes a broader framework for machinery safeguards and safety-related control systems.
Consider NR-11 requirements applicable to the crane and
material-handling operation.
Apply the NR-12 machinery-safety framework where the detection
function forms part of a safety system.
Determine protective measures through the applicable risk
assessment and technical standards.
Where a Type 3 / PL d protective scanner is appropriate for the
required function, SH27 provides that sensor classification.
NR-11 Revision · Public Consultation
A Brazilian government proposal for revision of NR-11 has included safety approach sensing concepts for bridge cranes, gantry cranes and semi-gantry cranes operating on the same rail. This is a proposed revision and must not be treated as currently effective NR-11 text. Always verify the current published requirements for the actual project.
China & Other Markets
Do Not Assume One Global Requirement
Requirements can differ by country, crane type, industry, customer specification and the role assigned to the collision detection function.
Check applicable national and industry standards.
Review end-user and project-specific safety requirements.
Establish whether collision detection is an automation function
or a safety-related protective function.
Confirm the required control-system performance with the
responsible machine or safety engineer.
Do not automatically transfer a safety classification from one
jurisdiction or project to another.
CCH Sensor Selection
How Safety Requirements Affect YB vs SH Selection
The same physical crane application can use different sensing architectures depending on whether the scanner is performing a standard automation function or a required safety-related protective function.
Non-Safety Industrial Function
YB Switching Output 2D LiDAR
Consider YB where the scanner provides configurable-zone, object or distance detection for standard crane automation and the project does not require the sensor itself to perform a safety-rated protective function.
Safety-Related Protective Function
SH27 Type 3 / PL d Safety Laser Scanner
Consider SH27 where laser scanning forms part of a safety-related protective function and the applicable risk assessment and control-system design require performance compatible with Type 3 / PL d protective sensing.
Safety Performance Is a System Property
A Type 3 / PL d Scanner Does Not Automatically Make the Crane System PL d
SH27 provides safety-rated sensing and OSSD outputs, but the performance of the complete crane safety function also depends on the safety controller or relay, drive or contactor architecture, diagnostics, wiring, response time, braking behaviour, fault handling and final validation. Sensor classification is therefore one element of the complete safety-related control system.
Regulatory note: This section provides general engineering guidance and is not a legal compliance determination for a specific crane. Regulations and standards can change, and requirements vary by jurisdiction, machine design and intended use. Confirm the current applicable legislation, standards and project requirements with the responsible machine designer, safety engineer, end user or local conformity professional before final system design.
08
FAQ & Project Selection
Overhead Crane LiDAR & Anti-Collision FAQ
The following questions cover the most common issues when selecting industrial LiDAR or safety laser scanning for bridge cranes, gantry cranes and other travelling crane systems.
What type of LiDAR is suitable for overhead crane anti-collision?
For many non-safety crane detection applications, a 2D LiDAR with configurable detection zones and switching outputs is suitable because the crane PLC normally needs a discrete signal when an object enters a defined area.
CCH YB switching-output models provide configurable PNP / NPN outputs for this type of industrial detection.
Can YB 2D LiDAR be used for crane collision avoidance?
Yes, YB switching-output models can be used for non-safety collision-avoidance, approach monitoring and configurable-zone detection where a standard industrial sensing function is appropriate.
YB is not a safety-rated protective device. If the detection function is required to provide safety-related risk reduction, the applicable safety architecture must be determined separately.
When should an overhead crane use a safety laser scanner instead?
A safety laser scanner should be considered when the scanning function is part of a safety-related control function and the machine risk assessment, applicable standards or project requirements call for safety-rated protective sensing.
SH27 provides Type 3 / SIL 2 / Category 3 / PL d sensing with safety-rated OSSD outputs.
Which SH27 models are suitable for switching-output crane applications?
The primary models for this application are SH27-03S and SH27-05S.
SH27-03S provides a 3 m protective radius at 1.8% reflectivity and a 10 m warning radius. SH27-05S provides a 5 m protective radius at 1.8% reflectivity and a 20 m warning radius.
Both use PNP safety-rated OSSD outputs for the protective function.
How far should an overhead crane anti-collision sensor detect?
There is no universal distance. The required distance should be determined from crane travel speed, sensing and control response time, drive response, braking distance, operating condition and engineering margin.
Sensor working range should then be selected and validated against that requirement using representative targets and the actual installation geometry.
Can one LiDAR provide warning, slow-down and stop zones?
Configurable monitored zones can support staged control logic. For example, a farther area may trigger warning, an intermediate area may initiate speed reduction, and a closer area may be associated with stop or motion inhibition.
The exact behaviour depends on the selected sensor and control architecture. With YB these are non-safety industrial switching functions. With SH27, only the protective field and safety-rated OSSD should be relied upon for the defined safety-related protective function.
Can the SH safety scanner warning field be used as the safety stop field?
No. The SH warning field is intended for preliminary non-safety functions such as warning or other simple switching actions.
The safety-related function is based on the configured protective field and OSSD safety output.
Does Brazil NR-12 require every overhead crane to use a Type 3 safety scanner?
NR-12 should not be interpreted as a universal statement that every overhead crane must use one particular scanner model or classification.
The appropriate protective measures and safety-system performance depend on the machine risk assessment, required safety function and applicable standards. NR-11 should also be considered for crane and material-handling requirements.
What is the difference between NR-11 and NR-12 for overhead cranes?
In Brazil, NR-11 addresses transport, movement, storage and handling of materials, including lifting equipment. NR-12 provides the broader machinery-safety framework, including safeguarding and safety-related control measures.
A crane project may therefore need to consider both, together with the applicable technical standards and project-specific risk assessment.
Can one scanner monitor both directions of crane travel?
Sometimes, but it should not be assumed. A 2D scanner only monitors its actual scan plane and field of view.
If hazards or other cranes can be approached from opposite ends, two mounting positions or two scanners may be required to achieve reliable coverage. The mechanical layout should determine the final sensor quantity.
What output should be used for overhead crane PLC integration?
For the typical detection applications covered on this page, switching outputs are the primary interface.
YB switching models provide configurable PNP / NPN outputs for standard PLC integration. SH27 S-series uses PNP OSSD outputs for its safety-related protective function.
Do overhead crane applications need raw LiDAR data?
Usually not for a conventional multi-zone anti-collision application because the PLC typically only needs switching information.
If the host system also needs individual scan measurements for custom software processing, selected YB models provide raw scan data. SH27-03D and SH27-05D add Ethernet raw distance, angle and echo-intensity data while retaining the SH safety functions.
Quick Selection
YB or SH27?
Standard Crane Automation
YB Switching Output LiDAR
Choose for non-safety configurable-zone detection using PNP / NPN outputs to a standard PLC.
Safety-Related Protective Function
SH27 Safety Laser Scanner
Choose where the required design calls for Type 3 / PL d protective sensing and safety-rated OSSD outputs.
Overhead Crane Project Support
Need Help Selecting YB or SH27 for Your Crane?
Tell us how the crane moves, the required detection distance, the expected control response and whether the function is safety-related. We can help narrow the appropriate switching-output model and sensing architecture.
Helpful Project Information
Crane type and travel arrangement
Maximum travel speed
Expected warning / slow-down / stop distances
Target structure and approximate reflectivity
PNP / NPN or safety OSSD requirement
Installation country or destination market
Whether the detection function is safety-related
Final sensor selection should be based on the complete crane application. Detection range alone does not determine suitability. Output type, target reflectivity, scan geometry, response and braking behaviour, environmental conditions, local requirements and the role of the sensing function should all be considered before commissioning.
09
References & Standards
Technical & Regulatory References
The following sources provide background for the crane-safety, risk-assessment, safety-control and protective-scanner principles discussed on this page. Applicable editions and legal requirements should always be verified for the specific project and destination market.
European Machinery & Crane Framework
Current EU Framework
Machinery Directive 2006/42/EC
Current EU machinery framework applicable before the general application date of Regulation (EU) 2023/1230. It establishes essential health and safety requirements and a risk-based machinery-safety approach.
EUR-Lex · European Union ↗
Applies From 20 Jan 2027
Regulation (EU) 2023/1230
The new EU Machinery Regulation replaces Directive 2006/42/EC and continues the machinery framework for risk assessment, essential requirements and conformity assessment.
EUR-Lex · European Union ↗
Crane-Specific Standard
EN 15011:2020
Cranes — Bridge and gantry cranes. A crane-specific European standard covering significant hazards and safety requirements for bridge and gantry crane machinery within its scope.
BSI · Standards Information ↗
Legislative Transition
Do Not Treat the Machinery Regulation as Fully Replacing the Directive Yet
As of 2026, Directive 2006/42/EC remains the principal current EU machinery framework until 19 January 2027. Regulation (EU) 2023/1230 generally applies from 20 January 2027, although certain individual provisions have earlier application dates.
International Machine-Safety Standards
Current Published Standard
ISO 12100:2010
Safety of machinery — General principles for design — Risk assessment and risk reduction. Provides the fundamental methodology for identifying hazards, estimating and evaluating risk and applying risk-reduction measures.
International Organization for Standardization ↗
Current Published Standard
ISO 13849-1:2023
Provides methodology and requirements for the design and integration of safety-related parts of control systems. It does not itself specify the safety function or PLr required for a particular crane application.
International Organization for Standardization ↗
Edition 4 · 2025
IEC 61496-3:2025
Particular requirements for active opto-electronic protective devices responsive to diffuse reflection (AOPDDR), covering the protective-device technology associated with safety laser scanning.
International Electrotechnical Commission ↗
Brazil · NR-11 & NR-12
Brazil · Current NR
NR-11
Brazilian regulatory standard addressing transport, movement, storage and handling of materials, including requirements relevant to lifting and material-handling operations.
Ministério do Trabalho e Emprego ↗
Brazil · Current NR
NR-12
Brazilian machinery-safety regulation defining fundamental principles, technical references and protective requirements for machines and equipment. The current official page identifies its latest modification as March 2024.
Ministério do Trabalho e Emprego ↗
Public Consultation
Proposed Revision of NR-11
Published consultation text for revision of NR-11. The proposal includes specific approach-sensing provisions for certain bridge, gantry and semi-gantry cranes travelling on the same rail.
Participa + Brasil · Federal Government ↗
Proposal Only · Not Current NR-11 Text
Keep the NR-11 Revision Separate From the Current Regulation
The public-consultation proposal includes safety approach sensors monitored by a safety interface for bridge cranes, gantry cranes and semi-gantry cranes moving on the same rail, with the proposed objective of achieving a safe stop and avoiding impacts. This proposed wording must not be represented as an already effective NR-11 requirement.
View NR-11 Public Consultation →
Engineering Interpretation
Standards Help Determine the Required Function — They Do Not Turn Every Crane Into the Same Application
References such as ISO 12100, EN 15011 and applicable regional legislation help identify hazards and establish required risk-reduction measures. ISO 13849-1 provides a methodology for safety-related control systems, while IEC 61496-3 addresses the protective-device technology. The required PLr, field dimensions and final sensing architecture must still be determined for the specific machine and safety function.
Reference note: Standards and regulations are revised over time. Always verify the currently applicable published edition, national adoption, harmonized-standard status and project-specific requirements before final machine design or conformity assessment. Product certification claims should be checked against the actual documentation for the specific CCH model rather than inferred from the latest edition of a referenced standard.