GRIP - Geared Rope Integrity Prediction

Project objective

GRIP (Geared Rope Integrity Prediction) aims to modernize manual rope inspections on port cranes (gantry cranes and container cranes) by introducing an AI-powered, fully digital solution. Conventional inspections are manual, time-consuming, and labor-intensive, with only about 25% of the rope surface visible due to its curvature. Rope maintenance is a significant cost factor—accounting for up to 1 million euros per year per terminal for crane maintenance—and inspections contribute significantly to downtime and losses. GRIP uses a compact inspection device with three cameras to achieve full surface coverage while the cable runs through the center, e.g. in maintenance mode. The video footage is analyzed by intelligent algorithms that detect damage such as wire breaks, strand protrusions, external wear, and corrosion; the results are displayed on a user-friendly dashboard. Data and results are stored for traceability.

Project goals

The project aims to fully digitize cable inspections by implementing an AI-powered real-time assessment system that can reduce downtime, labor, and costs while simultaneously improving inspection accuracy and traceability. Key objectives include automated damage detection, real-time monitoring with live display of defects, configurable environment-specific parameters, and the generation of corresponding inspection reports. The solution aims for end-to-end digitization and enables rapid analysis, offline operation, an integrated power supply, and adaptable deployment in port terminals and related industries.

Fraunhofer CML's role within the project

Fraunhofer CML is leading the GRIP project and developing the AI-based pipeline for defect detection, the processing of data from multiple cameras, and the end-to-end inspection workflow. Its tasks include the hardware integration of the compact inspection device, on-device processing, and offline operation without internet access. CML is also working on the data pipeline, temporal defect tracking, threshold-based severity assessment, and the generation of traceable reports. In addition, it is focusing on system calibration, user interface design, and compliance with safety and regulatory standards.

Funding and Project Duration

The development of GRIP in 2025 was funded by an internal Fraunhofer program.