Cone of Safety around a Crane Hook Sam Presented by Team 5 Xue Cheng Samuel Falabi Charlie Nguyen Richard Szink Lanea Williamson

The Team Project Management Richard Szink Documents Preparer Samuel Falabi Charlie Nguyen Xue Cheng Lanea Williamson Project Management 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 Cost estimating and Purchasing Everyone says name

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. Sam

Exploring a Solution Matt

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

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 Charlie

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. Charlie

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 Caitlyn

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.

Caitlyn

Testing of Thermal Sensor Lanea

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 mass- production

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

Thank you! Lanea