In the field of heavy industry, cranes are used as key equipment, and their safety is directly related to the smooth progress of the entire project and the safety of personnel's lives. According to statistics, more than 60% of the national lifting machinery accidents in 2022 will be caused by inadequate safety monitoring measures. The crane safety monitoring and management system is an intelligent solution born to meet this challenge. It integrates sensing technology, data analysis and real-time control to build a digital safety line of defense for lifting equipment.
The crane safety monitoring and management system is essentially an intelligent system that integrates data collection, condition monitoring, risk early warning and process management. This system is like installing a crane with a ”smart brain” and ”keen senses”, which can continuously guard the operation of the equipment 7×24 hours a day.
Its core functions include: real-time weight monitoring (accuracy up to 0.5%), height limit protection, amplitude detection, wind speed monitoring (early warning threshold can be set), tilt alarm, collision prevention, and data black box recording. Taking the WTM series developed by micro-technology as an example, the system also adds an AI learning function, which can predict potential risks by analyzing historical data, and truly realize the transition from passive protection to active prevention.
The installation of a safety monitoring system is not only a compliance requirement, but also a dual investment in economic efficiency and safety. According to the "Technical Regulations for the Safety of Lifting Machinery" (TSG 51-2023) promulgated by the State Administration for Market Supervision and Administration, cranes with a rated lifting weight greater than 50 tons must be installed with a safety monitoring system.
Practical application data show that after the installation of the system, the equipment accident rate decreased by an average of 85%, the equipment utilization rate increased by 30%, and the maintenance cost was reduced by 40%. After a port group installed the system on 32 of its door machines, the annual maintenance costs were reduced by 2.3 million yuan, and the indirect benefits from the reduction of downtime due to accidents exceeded 5 million yuan. More importantly, the operation data recording function provided by the system provides an indisputable basis for accident investigation and liability determination.
The working principle of the system is based on the closed-loop control logic of ”perception-analysis-execution”. Sensors distributed in key parts of the crane (including weight, angle, position, wind speed, etc.) collect operating data in real time and transmit it to the central processing unit through an industrial bus network. The processor adopts a multi-core architecture, processes security algorithms and logic control in parallel, and can make judgments within milliseconds.
When hazardous working conditions are detected, the system will initiate a three-level response: first, sound and light warnings are issued to remind the operator, then the range of hazardous operations is automatically limited, and finally the power source is cut off in an emergency. Real-time monitoring through 4G/5G wireless transmission technology, the data is transmitted synchronously to the local cab display and the remote monitoring center, supporting simultaneous access by multiple terminals.
At present, the market is mainly divided into two camps: international brands and domestic brands. International brands such as Liebherr in Germany and Crane Pro in the United States have advantages in the high-end market, but the price is higher; domestic brands such as Weite WTM series, Sany SYMC, Zhonglian ZPMC, etc. Are more cost-effective and more adapted to domestic working conditions. When choosing a product, you need to focus on: system accuracy (weight error≤1%, angle error≤0.2°), protection level (above IP67), certification qualification (special equipment manufacturing license), remote function and service support capabilities.
It is recommended to conduct a field trip to check the operation cases under similar working conditions. A central enterprise required suppliers to provide third-party inspection reports when purchasing, and conducted 72 hours of continuous testing on site, and finally selected an enhanced anti-corrosion system suitable for its tropical coastal environment.
Professional installation is a key part of ensuring system reliability. The standard installation process includes: preliminary survey → program design → sensor installation → wiring construction → system commissioning → acceptance training. Special attention needs to be paid when installing: the weight sensor should be installed at the end of the balance wheel or fixed pulley shaft to avoid cutting the main structure; the installation position of the inclination sensor should avoid vibration sources and high temperature areas; all cables must be shielded cables and laid separately through pipes.
Precise calibration is required on the calibration platform during the debugging phase. It is recommended to use a standard weight block for weight calibration and a digital level meter for angle calibration. After the installation is completed, a 72-hour trial operation should be carried out to verify the stability and reliability of the system.
The system price is affected by a variety of factors and usually fluctuates in the range of 80,000 to 500,000 yuan. The main influencing factors include: crane type (tower, gantry, automobile crane, etc.), the number of monitoring parameters (basic parameters or full-function configuration), sensor accuracy level, communication method (wired/wireless), brand value and after-sales service content.
The simple system meets the basic compliance requirements, about 80,000-150,000 yuan; the full-featured intelligent system includes predictive maintenance and remote diagnosis functions, usually more than 300,000 yuan. In addition, the difficulty of installation and special environmental requirements (such as explosion-proof and highly corrosive environments) will also increase costs. It is recommended not to simply compare prices when purchasing, but also to consider the whole life cycle cost. A logistics center once chose a cheap system, resulting in late maintenance costs that far exceeded the initial savings.
Operators need to undergo professional training to master the basic principles and operating procedures of the system. In daily use, attention should be paid to: self-inspection before each operation to confirm that the sensors are displayed normally; clean the sensor surface regularly to maintain the measurement accuracy; pay attention to the early warning information of the system, and deal with minor alarms in a timely manner to avoid the accumulation of serious diseases. In terms of maintenance, a three-level maintenance system needs to be established: operators conduct daily visual inspections and functional tests; maintenance workers conduct weekly data comparison and accuracy verification; professional engineers conduct comprehensive calibration and software upgrades every quarter.
The experience summarized by a large steel mill is: adhere to the ”three no principles”-do not adjust the parameters at will, do not shield the alarm function, and do not repair the core components without authorization. This set of principles has enabled their system to operate trouble-free for 5 consecutive years.
Common faults mainly include sensor drift, signal interruption, abnormal display and communication failure in four categories. Sensor drift is the most common problem, usually caused by vibration or temperature changes, which can be solved by recalibration; signal interruption is mostly due to loose wiring or oxidation of the interface, you need to check the connectors and clean the interface; the display abnormality may be a software problem, which can be solved by restarting the system or upgrading the software; communication failures need to check network equipment and network equipment.Signal strength.
It is recommended to establish a fault tree analysis diagram and investigate in the order from simple to complicated. The system is generally equipped with self-diagnosis functions. For example, the fault code base of the micro-special system contains 127 fault types, which can guide maintenance personnel to quickly locate the problem. For complex failures, the manufacturer should be contacted for technical support in time to avoid secondary damage caused by improper maintenance.
With the development of the Internet of Things and artificial intelligence technology, a new generation of crane safety monitoring and management system is developing in the direction of predictive maintenance and intelligent decision-making. Through big data analysis of equipment operation history, the system can predict the life and potential failures of parts and components, and truly realize the transition from ”post-mortem maintenance” to ”pre-prevention”.
Choosing a reliable monitoring system is not only to meet regulatory requirements, but also an important guarantee for personnel safety, equipment protection and return on investment.
It is recommended that users conduct a detailed demand analysis before purchasing, and choose a supplier with a good reputation and a perfect service system, so that the intelligent monitoring system can truly become the safety guardian of lifting operations.
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