AI Early Warning System for Preventing Rope Drum Hopping

Industry pain point: Safety hazards of wire rope hopping

In key operations such as load lifting and boom luffing, cranes rely on wire rope hoisting mechanisms, and the neat arrangement of wire ropes on the drum is the core guarantee of safety. In the event of a job-hopping incident

• ​"Safety hazard"Uneven force on the steel wire rope may cause it to break, leading to serious safety accidents
• ​Economic lossAbnormal wear causes the steel wire rope to be replaced prematurely, with a single cost as high as tens of thousands of yuan
• ​Equipment riskJob-hopping can cause a chain of damages such as drum deformation and reducer failure
• ​Low efficiencyThe difficulty in manual monitoring leads to frequent shutdowns for maintenance, which affects production efficiency

Root cause analysis of the problem

The job-hopping of steel wire ropes is mainly caused by four factors:

1. ​The deflection Angle is too largeThe deflection Angle of the steel wire rope when entering and exiting the drum exceeds the design range
2. ​Insufficient preloadInsufficient tension of the steel wire rope leads to loose arrangement
3. ​Deviation in drum processingInsufficient precision of the rope groove hinders normal entry into the groove
4. ​Installation issueThe deviation in the position of the guide pulley causes abnormal rope arrangement angles

Technical principle: AI visual intelligent recognition

​Triple technical guarantee system reliability​：

1. ​High-definition video capture​
   • Industrial-grade cameras capture high-definition images of the drum and pulley areas in real time
2. ​AI intelligent analysis​
   • Deep learning algorithms accurately identify the arrangement status of steel wire ropes
3. ​Multi-level early warning mechanism​
   • Level three response: Early warning → Level One alarm → Emergency shutdown

​Innovative detection technology​：

• 24-hour non-stop video surveillance covers all key points
• The intelligent image recognition algorithm ADAPTS to complex working conditions such as rain, fog and changes in lighting
• Historical data storage supports event playback and analysis

Core function

System advantages

1. ​Upgraded safety protection​
   • Early warning of job-hopping risks reduces the safety accident rate by 80%
   • The three-level response mechanism blocks the accident chain
2. ​The economic benefits are remarkable​
   • The service life of the steel wire rope has been extended by more than 501T to 3T
   • Maintenance costs have been reduced by 40%
3. ​Improvement in operational efficiency​
   • Reduce unplanned downtime and increase equipment utilization by 30%
   • Automated monitoring replaces high-intensity manual inspection

Application scenarios

Covering six major industrial fields:

1. ​Port machineryQuay container crane
2. ​Metallurgical industryCasting/steel rolling crane
3. ​Construction engineeringHigh-rise construction tower cranes
4. ​Mining equipmentMine hoist
5. ​Wind power installationFan installation crane
6. ​Bridge constructionBridge erection machine/cable crane

Success case: Container crane at a certain port

​Implementation effect​：

• Three successful job-hopping risks were warned, preventing steel wire rope breakage accidents
• The service life of the steel wire rope is extended by 40%
• The annual maintenance cost has been reduced by 45%

​Performance data​：

Customize your security solution

​Consult a professional engineer immediately​：
☎️ ​13972023522(Same number for wechat

​Service Commitment​：
✅ Free technical consultation ✅ on-site working condition survey ✅ customized solution design

This system complies with the national safety standards for lifting machinery

​Let AI be your guardian of steel wire rope safety
One second earlier warning, save millions of losses! ​​