AI and Cranes

Many industries are increasingly turning to artificial intelligence (AI), with 78% of organizations using AI in 2024, according to the Stanford HAI AI Index Report 2025. Automated material handling solutions can help warehouses, maintenance plants, and manufacturing facilities boost productivity, efficiency, and safety. 

Some aspects of AI and cranes are still in their early stages, such as fully autonomous models. The near future of material handling requires high-quality, cost-effective crane systems that teams can rely on to enhance safety and productivity when moving heavy loads — AI complements these goals.

How Cranes Use AI

Currently, the main applications of AI for cranes are maintenance, data collection, and supporting automated crane systems. The key technologies that enable AI use in cranes include:

• Internet of Things (IoT) describes how devices like cranes can be equipped with sensors and software to form an interconnected network with each other to exchange information. 
• Machine learning (ML) is a subset of AI that adapts and improves performance using neural networks without being specifically programmed to do a task.

Using sensors, operational logs, and GPS, AI through the IoT gathers information about crane performance. This is because the data can be fed back and analyzed in real time to ensure operations are as efficient as possible. 

Over time, through machine learning, AI can begin to classify the items lifted by weight and the time taken to complete lifts. As a result, AI can predict how long a particular material may take to load. AI-powered cameras can set a grid to move a load to a target position. You can also set up no-go zones to ensure the safe movement of loads. The cameras also help the crane work around human operatives.

Through cameras and sensors, maintenance devices can support cranes by performing regular inspections. Through the IoT, they can be preloaded with data to help them detect faults, and through machine learning, these parameters can be refined over time. 

AI crane automation integrates into various components, including hoists and controls. Machine learning ensures the crane’s lifting speeds are optimized for the specific conditions of every lift. At the same time, the sensors monitor for wear and tear on various parts, feed that back to a central source, and compare it to the patterns in its dataset. 

Benefits of AI in the Crane Industry

Below are key advantages of integrating artificial intelligence-powered technologies into the crane industry.

Safety

AI enhances crane safety technology, offering benefits for workers on the floor, including:

• Avoiding collisions: Using cameras and sensors, AI crane systems can recognise a human worker or another obstacle and automatically stop or change paths to prevent collisions. 
• Loading prediction: AI can predict the weight of loads before any lifting takes place. This can help prevent overloading the crane and calculate how a load might be shared between two hoists and their respective weight limits, for example. 
• Improving machine control: Over time, cranes can use machine learning to find the fastest ways to move a load from A to B, replicating how crane operatives handle sway to move loads into place.
• Conducting safer inspections: Fixed cameras or drones can inspect cranes remotely, eliminating the need for inspectors to work at height. 

Efficiency and Productivity 

Using AI in overhead crane technology increases the efficiency and productivity of facilities with several benefits, such as:

• Proactive repairs: Another advantage of using AI-powered drones or cameras for maintenance is that AI predicts when a part is due to be replaced. This allows for timely servicing, preventing damage to loads or the crane itself, while maintaining uptime. In the long term, this can save money and resources by servicing the crane exactly when needed rather than traditional, fixed maintenance schedules. 
• Optimal pathfinding: AI can find the most efficient lifting path through machine learning. To do this, AI analyzes factors like obstacles, environmental factors like wind speed or temperature and the load’s center of mass.
• Industrial crane automation: For repetitive, routine tasks, AI can quickly learn the most efficient way of completing lifts, freeing up operators for the more complex aspects of the job. AI does not suffer from fatigue, so it can replicate these tasks with the same efficiency, maximising output.
• Energy-saving measures: By gathering real-time data, AI can reduce the amount of energy required by minimizing movements and prioritizing efficient flow in handling. In addition, it can automatically shut down equipment that isn’t in use.
• Reduce wastage: With increased ability to handle and control loads, AI cranes can help reduce wastage with targeted placement.

The Future of Smart Cranes

Many cranes now come with various in-built automation tools that benefit manual operatives. The future of smart cranes will be in making fully AI-integrated autonomous systems that require zero human intervention. As a step toward creating smart factories in Industry 4.0, some of the following measures could be possible in the next decade:

• Humanlike thinking: Instead of being reactive or limited to set pathways, cranes could use a strong AI model that thinks more like a human. This would mean autonomous cranes could perform new tasks even in unfamiliar contexts. It could also handle maintenance and setup without any human intervention.
• Autonomous systems: Through advances in the IoT, multiple AI cranes and supporting robotics could work together as part of a larger system, which could increase their flexibility in use. 
• Digital twinning: By creating an emulation of the crane, you can perform virtual tests and determine the most efficient operating methods. This can save your company money and resources. Additionally, it enables cranes to be used more sustainably by minimizing energy consumption. 

For now, AI capabilities are best suited to supporting material handling. Skilled operators and quality cranes are the vital driving forces. 

Find a High-Quality Crane System at Spanco

With the innovations in AI technology, smart cranes are more efficient than ever. With AI, it is easier to preventively maintain cranes and carry out repetitive tasks without fatigue, while gathering data to help make informed decisions to streamline your operations. The reliability of any crane system, even with AI, still depends on quality equipment that performs exactly as you expect.

Choose Spanco for crane systems you can depend on. We have a vast inventory of material handling solutions, including overhead gantry cranes, jib cranes, and more — all built to last. With over 40 years of experience, Spanco can provide you with the expert advice you need to create custom crane solutions for even the most complex of needs. 

Are you ready to get started with Spanco? Contact us today to learn more about our products. Our representatives are happy to help!