Safety monitoring and management system for bridge building machine

1. Introduction and purpose：

Bridge erection machine safety operation system(or:Safety monitoring device for special cranes used in prefabricated beam erectionIt is a customized large-scale lifting equipment specially designed and manufactured for the erection operation of prefabricated beam sections in bridge engineering. The lifting machinery specially designed and manufactured to meet the harsh working conditions such as high-altitude operations, precise alignment, and longitudinal upward movement of beam sections in bridge construction can safely and efficiently lift, transport and precisely place prefabricated beam sections at the designated positions on the bridge piers.

It is a reinforced key equipment for bridge construction specially designed and manufactured for different types of Bridges such as highway Bridges, conventional railway Bridges and passenger dedicated line railway Bridges. It features strong adaptability to working conditions, stable load and reliable longitudinal movement.

2. Basis for product development:

GB12602-1990 "Safety Technical Code for Overload Protection Devices of Lifting Machinery"
GB6067.1 "Safety Regulations for Lifting Machinery"
GB/T 28264-2017 "Safety Monitoring and Management System for Lifting Machinery"
GB/T 20776 "Classification of Lifting Machinery"

Three major pain points in the safety management of bridge erection machines:

The control system is backward.
Early equipment generally adopted traditional logic circuits and was not upgraded to PLC (Programmable Logic Controller), resulting in low control accuracy, high failure rate, and difficulty in achieving intelligent monitoring and data interaction.

The operating environment is rudimentary.
Single and double guide beam bridge erection machines lack dedicated operation rooms. They are only equipped with simple operation panels and open-air electrical cabinets. Operators are exposed to high altitudes, dust, and vibration environments, resulting in seriously insufficient safety and comfort during operations.

The safety protection device has failed
A large number of active equipment protection devices (such as limiters and overload alarms) are damaged or missing, and the protection circuit design is imperfect, making it impossible to monitor operational risks in real time (such as longitudinal deviation and load over-limit), and the accident prevention capability is weak.

Lack of standardization and insufficient maintenance
The lack of unified safety standards in the early design, coupled with the long-term lack of maintenance, led to the aging and failure of key components (such as sensors and braking systems), and the phenomenon of equipment operating while faulty was widespread.

An intelligent monitoring system is urgently needed
Traditional bridge erection machines lack real-time safety monitoring of the hoisting and longitudinal movement of beam sections. Installing an integrated safety monitoring and management system (such as load monitoring, displacement correction, and emergency braking) is a rigid demand to ensure construction safety.

4. Bridge erection Machine Safety Monitoring and Management System Solution:

Standardized compliance transformation
Developed strictly in accordance with the latest national standard "Safety Monitoring and Management System for Lifting Machinery", it is compulsorily compatible with railway laying and erection equipment (including in-service renovations and new machine installations), and simultaneously compatible with various types of lifting machinery for highways, municipal works, etc.

All-domain security protection system
Deploy multi-dimensional sensor networks (load/displacement/inclination Angle, etc.) + high-definition image terminals + video monitoring systems to achieve monitoring of beam section hoisting, longitudinal movement trajectories, and equipment statusFull-process real-time monitoringActively intercept human operational errors (such as over-limit operation, deviation and collision).

Industrial-grade intelligent technology integration
▶ Integration "Sensing - Embedded - Remote communication" triple technology stack：
- Sensor system: Millisecond collection of key parameters (load rate, longitudinal displacement, bridge pier alignment deviation)
- Edge computing unit: The embedded chip analyzes risks in real time and triggers local early warning/braking
- Remote Platform (optional) : Transmits data to the cloud via 4G/5G, supporting remote supervision on PC/ mobile devices

Highly adaptable hardware design
▶ Dual power supply redundancy architecture (220VAC industrial power + 24VDC emergency power), resistant to voltage fluctuations;
The protection level reaches IP65 (dust-proof and vibration-resistant), making it suitable for high-altitude open-air operation scenarios of bridge erection machines.

Cross-domain expansion capabilities
The core module can be quickly transplanted to heavy-duty equipment such as port gantry cranes, metallurgical cranes, and tower cranes, providing standardized safety monitoring interfaces.

The core value of the plan
▸ Accident reset to zeroBy using machines to replace "human judgment", eliminate overturning and falling accidents of over 90% caused by negligence
▸ Zero risk of complianceMeet the national mandatory standards and avoid regulatory penalties and losses from suspension
▸ Increase in lifespanReal-time diagnosis of equipment health status reduces maintenance costs caused by sudden malfunctions

"From passive Response to Active Defense - Enabling Bridge Erection Machines to Move longitudinally Safely with Millimeter-level accuracy"

5. Core Advantages:

Compliance monitoring, full data recording: Meet national standards, independently record and display all key safety parameters in real time.

Powerful compatibility, easy connection Equipped with a variety of commonly used interfaces (switch quantity, analog quantity, pulse quantity), it supports Modbus/Profibus communication, facilitating the connection of various sensors and devices.

Transparent operation and traceable analysis: Real-time viewing of operation records, the correctness of operations can be analyzed in the background, and all operation data is automatically uploaded to the server for storage.

Equipment positioning, clear at a glance: Remotely and in real time view the GPS location of the device to keep track of its dynamics.

Intelligent early warning, security upgrade Early warning of common faults, alarm and control when faults occur, automatically save fault information, and enhance safety and reliability.

Operation management, remote support Manage the historical operation records of the equipment. The remote module can be used to achieve remote diagnosis and repair of some faults.

Seamless connection, information visibility It provides a communication interface with the PLC to directly read and display various operation data of the equipment in real time.

6. Success Cases:

Hubei Road and Bridge

Wuhan Tonglian