Recognize. Reduce. Stop.
Railcar Lift Protection Without Additional Sensors
Our railcar lift protection system detects early on when a railcar is lifted during the handling of containers or semi-trailers. To do this, the system uses the load-sensing bolts that are already installed on your crane.
Unidentified load couplings endanger your crane operations
When handling containers and semi-trailers, all it takes is a single unlocked latch: The crane applies force, and the railcar lifts along with it. In the worst-case scenario, the wheel comes off the track.
This happens particularly often with pocket cars. The semi-trailer’s kingpin is positioned in the car’s mounting socket. If the lock on the kingpin is forgotten or not fully released, the grab will lift the car along with the semi-trailer during unloading.
It doesn’t stop at the raised railcar
Cost per incident:
€5,000–15,000
for the removal, inspection, and, if necessary, repair of the railcar alone.
Not included: delays in the track slot as well as delayed arrivals and departures of trains.
Limitations of Common Systems
Conventional systems use laser scanners, LiDAR, or cameras. While this approach works, it presents challenges, particularly along the tracks.
Unobstructed view required
Fences, loading units, and track geometry block the view. The kingpin is hidden beneath the semi-trailer, next to the flatbed trailer.
Weather and Dirt
Fog, snow, and dirty lenses impair detection.
Installation in the driving area
Sensors located near traffic are susceptible to damage.
Designed for trucks
Most solutions are designed for trucks at container terminals, not for railcars and flatcars.
Your crane with our lift protection
The solution is already installed on your crane at
When a railcar is lifted, the force curve in the Hoist changes.
The load-sensing pins in the overload protection system measure this anyway, and our ATL module evaluates the data.
Step 1
Load-measuring bolt
The load measurement sensors on both ends provide signals even when the load measurement pins are not calibrated.
Step 2
Cranium ATL Module
Our controller analyzes the force curve during lifting and detects the coupling with the railcar.
Step 3
Crane PLC
The PLC receives the signal and automatically reduces or stops the stroke.
Interested in a railcar anti-lift system without additional sensors?
Find out how we can help.
Our Railcar Lifting Protection in Day-to-Day Terminal Operations
Clear driving area
The load protection system works in conjunction with the crane’s load-measuring system. Nothing is installed in the travel area that could be struck or contaminated.
Ready to Go with Existing Load Cells
Even uncalibrated load cells are sufficient. Our controller evaluates the load signals during lifting and detects coupling with the railcar.
In any weather
Force measurement is not affected by visibility or weather conditions—whether it’s fog, rain, or snow.
Full handling capacity
The automatic, gentle lifting action mimics the operating style of experienced crane operators.
Spreader and Gripping Pliers
The car-lifting protection system operates in both pivot and gripping modes.
Quick to set up
Up and running in no more than one day per crane. A repeat of the process is generally not necessary.
A Comparison with
Conventional Sensor Systems
| Sensor Retrofit | Our Railcar Lifting Protection | |
|---|---|---|
| Additional Hardware on the Crane | Laser, LiDAR, or Camera | Only the Polarith control |
| Designed for | Primarily trucks at the container terminal | Railcars and flatcars in rail transshipment |
| Data Source | Newly Installed Sensors | Existing load-measuring bolts |
| Commissioning | Usually up to 3 days, including installation | No more than one day per crane |
On duty in Cologne-Eifeltor
Our technology is put to the test every day by Europe’s largest logistics and infrastructure companies. We don’t just deliver systems—we deliver measurable results.
Our railcar lift protection system is in use at the Intermodal Cranes operated by DSD Hilgers and DUSS in Cologne-Eifeltor as part of the Cranium platform, where it has been successfully tested.
The result: early detection of coupled loading units and smooth handling.
Request a quote for our lifting protection system for your crane
Optimize your logistics processes with our railcar lifting protection.
Martin Kirst
Geschäftsführer
Richard Herrmann
Prokurist
Uwe Ochs
Vertrieb
