Crane fatigue early warning monitoring system: All-weather protection for operation safety

1. Product Introduction

The crane fatigue early warning monitoring system is an intelligent safety protection solution specially developed for the field of special equipment. In high-altitude operation scenarios such as ports, metallurgy, and construction, operators are under high pressure for long periods of time, which can easily lead to problems such as fatigue, distraction, and operational errors. According to accident statistics,On average, each tower crane accident causes 1.66 deathsThe economic loss exceeded 1.9 million yuan, far higher than that of an ordinary engineering accident. Traditional contact monitoring equipment not only affects operation but also has limited accuracy. The new generation of systems has passedNon-contact monitoring technologyReal-time capture of the driver's physiological state and behavioral abnormalities, combined with fatigue analysis of key equipment components, to build a dual protection system. For example, the system of Micro and Special Technology has been implementedThe alarm response delay is only 3 to 5 secondsSignificantly reduce safety accidents caused by human error.

2. Technical principles

The system integrates multi-dimensional perception technology to achieve full-time domain monitoring

• ​Analysis of Driver BehaviorIt adopts infrared cameras and lightweight convolutional neural networks to capture facial features (closing eyes, yawning), body posture shifts in real time, and identify dangerous behaviors such as smoking and making phone calls. When abnormal actions last for more than 3 seconds, a hierarchical alarm will be triggered immediately
• ​Physiological state monitoringSome high-end systems (such as Jiangzhi solutions) are equipped with biosensors that establish fatigue coefficient models based on data like heart rate and eye movement trajectories. The formula is:

  PL=γ×∑[βi×αi×arctan(ti/dt)]

  Among them, the dynamic weight coefficient, in combination with different states such as lifting, driving and resting, precisely quantifies the fatigue threshold

• ​Equipment fatigue diagnosisAccumulate the number of actions and conduct stress analysis on key components such as brakes and steel wire ropes. For example, when monitoring the wear of the brake shoes, throughMeasure the braking coasting distance with millimeter-level accuracyPredict the maintenance cycle in combination with the over-limit algorithm

3. Scope of application

The system has been adapted to various heavy-duty equipment scenarios

• ​Port machineryWhen the portal crane is operating in areas prone to typhoons, the system synchronously monitors the wind speed and the lifting height through a formulaZh=Lh×exp(-(α1×(W/Dw)^β+α2×(F/Df)^β)Dynamically calculate the safety height threshold to prevent the loss of control of the lifted object caused by wind force
• ​Metallurgical craneFor the scenario of hoisting molten steel at high temperatures, a thermal imaging module is added. When it detects that the operator becomes confused due to high temperatures, the hook will be automatically activated to limit the speed
• ​Construction tower craneIn areas with dense construction, AI vision can identify intruders within a 50-meter radius and trigger sound and light alarms to drive them away
• ​Railway and crawler cranesThe built-in GPS module records the movement trajectory of the device and combines the vibration spectrum to analyze the wear status of the gearbox

4. Product display

​Hardware configuration​：

• Wide-angle infrared camera: 120° field of view covering the cab, supporting extreme environments ranging from -30℃ to 70℃
• Three-proof industrial host: IP67 protection grade, integrated stress sensor interface
• Intelligent alarm terminal: Equipped with dual-frequency buzzer (intermittent buzzer when 90% is under load and continuous buzzer when 104%)

​Software platform​：

• Digital twin interface: Real-time display of driver heart rate fluctuations and equipment stress cloud maps (see the example below)
• Black box system: Military-grade storage chips record the operation video 20 seconds before the accident
• Operation and maintenance dashboard: Automatically generate component life prediction reports, such as the calculation of the remaining service life of steel wire ropes

5. Product advantages

1. ​Safety efficiency doubles​

   After the deployment of Jiangzhi System at Ningbo Zhoushan Port,The collision accident decreased by 76%The response time for overload operations has been increased to 0.3 seconds

2. ​Optimization of operation and maintenance costs​
   • Predictive maintenance reduces the downtime of 70%. For instance, hub wear monitoring can warn of replacement nodes 30 days in advance
   • The online detection accuracy rate of steel wire ropes reaches 98%, avoiding excessive replacement. A single device saves 120,000 yuan in material costs annually
3. ​Human-machine collaborative upgrade​
   • The driver identity authentication system records the operation trajectory, and the efficiency of tracing violations has been improved by 90%
   • The voice assistant provides real-time alerts for wind speed changes: "Northeast wind at level 6. It is recommended to reduce the load by 15%."
4. ​Expand flexibility​

   Modular design supports functional combination

   • Basic version: Fatigue monitoring + Load alarm
   • Flagship Edition: Added stress Diagnosis + Personnel intrusion recognition

     Users can select and configure as needed, and then carry out secondary development through the SDK later

6. Typical applications

​Automated terminal of Qingdao Port​

Deploy a multi-sensor fusion system on 40 door machines:

• The ultrasonic matrix monitors the distance between adjacent machines and automatically decelerates when it approaches the 10-meter threshold
• A total of 12,000 fatigue driving warnings have been issued, with a false alarm rate of less than 0.8%
• The equipment lifespan has been extended by 30%, and the maintenance cost has been reduced by 50%

​Baosteel metallurgical crane​

Integrate the monitoring of key components

1. Brake action counter: Push maintenance notifications after accumulating 500,000 actions
2. Main beam stress monitoring: Detect a 3mm crack trend to prevent major accidents
3. Driver status analysis: The accuracy rate of smoking recognition is 99.3%, with an average reduction of 47 violations per month

​Hydropower Station Project in Southeast Asia​

Customized for tropical rainstorm environments:

• The lens defogging mode is activated when the humidity exceeds 85%
• When a red alert for heavy rain is issued, the lifting height will be automatically restricted
• The accident rate dropped to zero in the first year of deployment and it won the owner's Safety Innovation Award

​Industry futureWith the implementation of the new standard GB/T 28264-202X, the system will integrate 5G+ Beidou positioning to achieve centimeter-level anti-sway control. A certain test data shows that the new generation of products can increase the hoisting accuracy from ±50cm to ±5cm and further reduce labor costs by 40%. When dusk falls at the port, the green dots flickering on the monitoring screen are precisely the solemn protection of life by technology.