What exactly is the difference between a torque limiter and an overload limiter? After reading this, you will understand

In construction sites, port terminals or industrial plants, the stable operation of heavy equipment cannot do without the support of safety protection devices. Torque limiters and overload limiters, as two types of core safety devices, are often confused with the same function, but their actual effects are significantly different. This article will analyze the differences between the two through specific cases and principle analysis, and introduce the technical applications of Weite in related fields.

1. Different working principles: lever principle and weight monitoring

The working principle of the torque limiter is based on the lever principle. By comprehensively monitoring parameters such as the lifting Angle, arm length, and load weight of the equipment, the torque value is calculated in real time. For instance, the crane torque limiting system designed by Weite for a certain bridge project will automatically cut off the power when the boom elevation Angle is lower than the preset safety range, even if the load does not reach the rated weight, to prevent the risk of overturning caused by torque imbalance.

The overload limiter focuses on monitoring the total weight that the equipment bears. Its principle is similar to that of an electronic scale, directly measuring the load data through sensors. The intelligent forklift system developed by Weite for a certain logistics center will automatically lock the hydraulic system when the forklift load exceeds the set threshold, and display warning information on the operation interface to prevent structural damage caused by overloading.

Second, the protected objects are different: structural safety and load-bearing capacity

The core function of a torque limiter is to protect the mechanical structural integrity of the equipment. In the installation scenario of wind turbine generators, Micro's torque-limiting system will monitor the dynamic load distribution during the hoisting of the tower in real time. During a certain hoisting operation, the system detected a sudden change in wind speed, causing the swing amplitude of the boom to exceed the limit. The operation was promptly terminated. After the operation, it was found that stress cracks had appeared in the key connecting parts, thus avoiding a major accident.

The overload limiter mainly prevents the bearing components of the equipment from being damaged due to overload. Take the elevator safety system designed by Weite for commercial buildings as an example. When the load of the car exceeds the design value, the system will not only issue an audible and visual alarm but also prohibit the elevator from starting and operating. This design significantly reduces the fatigue loss of the traction machine and the steel wire rope, and prolongs the service life of the equipment.

Three. Different application scenarios: dynamic operations and static carrying

Torque limiters are widely used in hoisting equipment that requires dynamic adjustment. In the operation of gantry cranes in shipyards, the micro and special system will dynamically adjust the safety threshold based on parameters such as the weight of the lifted object, the extension length of the boom, and the rotation Angle. For instance, when hoisting sections of the hull, the system automatically reduces the maximum load limit by 201t to 3T upon detecting that the boom elevation Angle exceeds 75 degrees, ensuring stability under complex working conditions.

Torque limiter ‌：It is mainly used for boom cranesEspecially luffing cranes, such as tower cranes. It prevents cranes from overloading ‌ by limiting the load and amplitude.

Overload limiters are widely used in fixed-load equipment. After a certain chemical enterprise's reaction vessel transport vehicle was equipped with a micro-special overload protection device, once the vehicle was overloaded during the loading process, the instrument panel immediately displayed the specific overload value and locked the transmission output. This measure has reduced the enterprise's average annual tire wear cost by 371 tons and the frequency of major chassis overhauls by 451 tons.

‌Overload limiter ‌A safety protection device mainly used to prevent cranes from overloading.It is widely used in bridge-type cranes and elevatorsSome boom-type cranes, such as tower cranes and portal cranes, use overload limiters in conjunction with moment limiters ‌.

Four. Different trigger conditions: composite parameters and a single threshold

The triggering mechanism of the torque limiter relies on the comprehensive judgment of multiple parameters. The torque protection system for excavators designed by Weite for a certain mine will only trigger protection when the three sets of data - the hydraulic pressure of the boom, the Angle of the boom, and the load of the bucket - all reach the critical values simultaneously. This design avoids the misjudgment of a single parameter. In a recent ore loading and unloading operation, the system accurately identified the potential risks caused by abnormal vibration of the bucket rod.

The overload limiter triggers protection based on the preset weight threshold. The micro-special overload protection system of the port container quay crane equipment adopts a hierarchical early warning mechanism: a warning will be issued when the load reaches the rated value of 951 to 3t, and the operation will be forcibly stopped when it exceeds 1001 to 3t. This strategy has reduced the failure rate of key structural components by 62% while ensuring operational efficiency.

Five. Different system complexities: Multi-dimensional perception and single-point monitoring

The torque limiter needs to integrate multiple types of sensors. The latest intelligent tower crane safety system developed by Weite includes 6 sets of Angle sensors, 4 pressure sensors and 2 sets of GPS positioning modules, and analyzes 32 working condition parameters in real time through edge computing. In the construction of a certain super high-rise building, this system successfully warned of the risk of steel structure deformation caused by the temperature difference of sunlight.

The sensor configuration of the overload limiter is relatively simple. The standard overload protection device designed by Weite for the warehousing and logistics industry only requires the installation of 2 to 4 strain gauge sensors on the load-bearing beam. Combined with the core algorithm, it can achieve a measurement accuracy of ±1%. This minimalist design reduces equipment maintenance costs by 58%, making it particularly suitable for technological transformation in small and medium-sized enterprises.

Vi. Collaborative Protection: Weite's Systematic Security Solution

The safety protection of modern industrial equipment requires the collaborative work of torque limiters and overload limiters. In the dual-system integration solution designed by Weite for a certain offshore wind power project, the moment limiter is responsible for dynamic protection during the hoisting process, while the overload limiter monitors the static load during the tower transportation. The data of the two are exchanged in real time through the Internet of Things platform. During the recent typhoon's passage, the system predicted the hoisting risks three hours in advance and automatically entered the safety protection mode.

The intelligent safety management system of Weite has achieved data visualization and predictive maintenance. By analyzing historical operation data, the system can automatically optimize the safety parameter Settings of the equipment. In a certain bridge construction project, this function increased the equipment utilization rate by 24% and reduced the safety accident rate by 81%.

Vii. Conclusion

Torque limiters and overload limiters, as key components of the equipment safety protection system, respectively construct safety guarantees from two dimensions: dynamic torque balance and static load-bearing capacity. Through continuous technological innovation, Weite has elevated the protective efficiency of the two types of systems to a new level. With the in-depth application of intelligent sensing technology and big data analysis, the safety protection of industrial equipment is developing towards a more precise and intelligent direction. Understanding the differences and coordination principles of these safety devices is of great practical value for improving equipment management levels and preventing major accidents.