In the construction of modern smart water conservancy，Gate remote control systemIt has become the standard configuration for flood control and flood control of small and medium-sized reservoirs. Traditional reservoirs have heavy rains during the flood season, and management personnel must rush to the top of the dam in the rain to manually open and close the gates. Not only is the response slow, but there is also a great risk of personal safety. Nowadays, there is no need to spend a lot of money to build a physical central control room, just a set of Internet of Things transformation plan, you can directly use a computer website or mobile phone WeChat to remotely control the reservoir gate.
so，How much does it cost to retrofit a remote control system for reservoir gates? What equipment is included? This article will take the common "3-hole single-point hoist spillway" as an example to disassemble a set of renovation plans and detailed quotation lists that take into account high safety and high cost performance.
1. How much does it cost to retrofit a 3-hole single-point hoist gate? (With detailed quotation form)
Many reservoir managers are most concerned when setting up projects
Gate remote control systemprice。 If the mechanical structure of the reservoir's original gate and hoist hoist is intact, and there is already a 380V power supply and network signal at the top of the dam, eliminating the need for independent power supply and the renovation of the central control room, the overall renovation cost of the 3-hole gate is usually in the range of
85,000 yuan to 135,000 yuan between.
The following are the equipment configuration and budget details that can be directly used for procurement inquiries：
| Cost composition module |
Core hardware and software configuration |
3-hole total budget |
Selection logic and function description |
| 1. On-site control cabinet (LCU) |
304 stainless steel outdoor rainproof cabinet (IP65), industrial PLC, 7-inch touch screen, contactor and lightning protector |
35,000-55,000 yuan |
Independent control of “one gate and one cabinet” is adopted, and when a single hole is repaired or fails, it will not affect the normal flood discharge of the remaining two holes. |
| 2. Opening and load sensor |
Multi-turn absolute encoder (3 sets), wire rope tension/load sensor (3 sets) |
15,000-25,000 yuan |
The encoder does not lose the zero point if it is powered off; the load sensor prevents the gate from getting stuck or the rope from loosening at the bottom. |
| 3. Water level and video surveillance |
80G high frequency radar water level meter (2 sets), 4 million pixel infrared with wiper ball machine (3 sets) and video recorder |
15,000-24,000 yuan |
The water level is measured at each place before and after the gate; the video is used to confirm that no personnel are staying downstream before the gate is opened. |
| 4. Communications, UPS and cloud platform |
Wired+4G dual-link industrial router, industrial-grade UPS power supply, water conservancy cloud platform access authorization |
10,000-18,000 yuan |
UPS guarantees that data will continue to be returned after a power failure; it reuses a mature cloud platform, eliminating the need for software customization fees. |
| 5. Auxiliary materials and installation and commissioning |
Flame-retardant control cable, galvanized threading pipe, coupling customization, lightning protection grounding and 72-hour joint adjustment |
10,000-13,000 yuan |
It includes the removal of aging and old electronic control boxes, the installation of sensor mechanical brackets, and on-site debugging labor. |
2. In the mode of no central control room, how does the gate remote control system realize mobile phone and computer monitoring?
For reservoirs that do not have an independent central control room，Automatic transformation of reservoir gateMainly through the “end—management—cloud” three-layer lightweight architecture to achieve remote unattended：
- On-site execution and data collection (end)
Install an outdoor waterproof on-site control cabinet next to each hoist type hoist. Real-time acquisition of reel shaft end by PLC in the cabinetAbsolute encoder(Accurately calculate the height of the gate opening), on the wire ropeLoad sensor(Monitoring the lifting tension) and the front and rear of the damRadar water level meterdata.
- Wired + wireless dual-link transmission (tube)
Using the existing broadband network at the top of the dam, it is equipped with an industrial-grade 4G/5G dual-link router. Usually, wired broadband is used to transmit high-definition video and control instructions; once the wired network is damaged during the flood season, the system automatically switches to a 4G wireless network to ensure that the signal is not interrupted.
- Collaborative control of computer web pages and mobile phones (cloud)
Directly access the mature water conservancy Internet of Things cloud platform without the need to build your own server. Managers can open a computer browser or a mobile phone WeChat mini program to view the opening of the 3-hole gate, the reservoir water level curve and the live high-definition video in real time, and issue “rise, stop, fall” or “Set the opening to run automatically” commands with one click.
3. The 4 safety standards that must be met for the automatic transformation of reservoir spillway gates
The spillway of the reservoir is related to the safety of the downstream.Gate remote control systemWhen, manufacturers must be required to implement the following four safety lines of defense in the design：
- On-site manual has the highest priority: The control cabinet panel must retain the physical emergency stop button and the ”local/remote" hard-wire transfer switch. At any time, as long as the on-site personnel press the emergency stop or switch to the on-site mode, the remote command will immediately expire to ensure the safety of maintenance personnel.
- Dual protection of anti-loosening rope and anti-blocking: If the single-hoisting point hoist continues to be lowered after the bottom is set, it is very likely that the wire rope will be tangled. The system needs to combine the “soft limit of the encoder” with the “hard limit of the mechanical hammer”, and activate the load sensor-once the tension suddenly increases (stuck resistance) or drops sharply (the bottom loosens the rope), the PLC will automatically stop within 0.5 seconds and alarm the mobile phone.
- Video with the same screen and two-time password security lock: When opening the gate remotely on the mobile phone or computer, the software interface must force a real-time video screen of the corresponding gate hole to pop up (to confirm the downstream safety), and after the operator's hierarchical authority and dynamic password are confirmed twice, it can be operated to completely eliminate accidental contact.
- Emergency protection for power failure and battery life: The control cabinet is equipped with industrial-grade UPS uninterruptible power supply as standard (backup power supply is not less than 2 hours). Even if the heavy rain causes the MAINS to trip, the water level meter, encoder, router and camera can still work normally and report a power failure alarm.
4. Frequently Asked Questions (FREQUENTLY Asked Questions)
Q1: Does the hoist type hoist of the old reservoir need to be replaced with the machinery during the renovation?
No need. As long as the original hoist gears, wire ropes, brakes and three-phase motors can operate normally, the automation upgrade can be completed by removing the aging old electric control box and installing the local control cabinet and sensors, greatly saving the budget.
Q2: The motor power of the opener and closer is large. What should I pay attention to when retrofitting?
You need to check the hoist motor nameplate before purchasing. If the power of a single motor is greater than or equal to 15kW, It is recommended to install it in the control cabinetSoft starter, Reduce the mechanical impact of high-current start-up on the power grid and gearbox; at the same time, it is necessary to match the load sensor of the corresponding range according to the rated tonnage of the opener (such as 10t, 16t or 25t).
