Crane safety monitoring and management system｜Full explanation of national standard specifications, composition, configuration, and installation standards

1. National standard basis for crane safety monitoring and management system (national standards and latest regulations)

1. Core national standards

2. Hard and fast requirements of the latest national regulations

1. All bridge and gantry cranes, mobile cranes, tower cranes, and gantry cranes with a rated lifting weight greater than or equal to 3t must be equipped with a complete set of safety monitoring and management systems in accordance with specifications; metallurgical lifting molten metal cranes are the mandatory highest level of control, and the monitoring function must not be simplified.
2. The system must have a local storage function that cannot be tampered with, and the operating records must be kept for a period of not less than 30 days; alarm records such as overload, limit actions, and illegal operations must be archived separately and cannot be deleted manually.
3. The monitoring circuit needs to be independent of the lifting main control circuit, and cannot rely on the driving main control PLC to complete the protection to ensure that the monitoring is still effective in the event of a failure of the main control.
4. Cranes that are not installed in accordance with standards, have missing system functions, or have failed storage will all be judged to be unqualified for annual inspection and required to be shut down for rectification.

2. What is included in the crane safety monitoring and management system (complete system composition)

(1) Front-end sensor acquisition hardware

1. Load monitoring component: Weight sensor, real-time monitoring of lifting load, identification of overload and partial load；
2. Travel limit sensor: Lifting upper and lower limits, travel limits for carts and trolleys, rotation limits, prevention and control of topping and collision of the whole machine；
3. Attitude angle sensing: Luffing angle and inclination sensors, suitable for tower cranes and automobile cranes to calculate torque to prevent overturning；
4. Brake and mechanism monitoring: Brake opening and closing detection, motor speed, reel operation monitoring, early warning of slip hook and brake failure；
5. Wire rope flaw detection sensor: Optional, online detection of broken wire, wear, rust, and loose strands of wire rope；
6. Environmental sensor: Wind speed sensor, mostly used for tower cranes and port cranes, high wind warning is prohibited for hoisting；
7. Video camera: High-definition video recording of the cab, hook, and cart walking area, and full video recording.

(2) Local on-board control cabinet

(3) Lifting machinery safety monitoring platform (remote cloud)

3. Mainstream classification: What are the adaptable models of crane safety monitoring and management system?

1. Special monitoring system for bridge gantry crane: Focus on load, stroke, anti-collision, and lifting mechanism monitoring, which is suitable for ordinary driving in factories; metallurgical models add high temperature resistance, anti-high temperature cables, and motor temperature monitoring.
2. Tower crane monitoring system: Standard torque, wind speed, rotation angle, and hook height monitoring to meet the compliance requirements of construction site tower cranes.
3. Mobile crane (car crane, crawler crane) monitoring system: With torque limiting, luffing, and arm length monitoring as the core, it is suitable for multi-road hoisting in the wild.
4. Port gate crane and container shore crane monitoring system: Increase moisture-proof and salt spray-proof hardware, increase anti-collision and monitoring of large vehicles, and adapt to the high-corrosion environment by the sea.

4. Crane safety monitoring and management system installation specifications and landing rules

1. The sensor point is firmly and reliably installed

   The tension sensor is installed in the hook group and the lifting reel to set the position of the pulley; the angle sensor is fixed at the root of the boom; the limit switch is fixed at the end of the cart, trolley track, and lifting reel; all brackets are welded and fastened, and the sensor shall not be loose and displaced due to long-term vibration of the vehicle. The sensors in the metallurgical workshop are equipped with thermal insulation protection to resist thermal radiation.

2. Wiring protection compliance

   The signal line is made of shielded oil-resistant cables, which are routed along the bridge and through bellows. The cables avoid high temperature, friction, and heavy objects rolling areas; the terminal blocks are fastened and waterproof to reduce data transitions caused by electromagnetic interference. Multiple cables are classified and labeled to facilitate later maintenance.

3. The installation location of the control cabinet is reasonable

   The local monitoring host is installed in the cab with the driver's line of sight and the vibration is too small to facilitate the driver to view the data in real time; the protection level of the open-air and outdoor control cabinets is not lower than IP54, and the waterproof and dustproof cabinets of IP65 and above are selected for seaside and metallurgical environments.

4. The wiring loops are independent and separated

   The safety alarm, limit shutdown circuit and the driving main control circuit are physically isolated, and the sharing of lines is prohibited to prevent the main control failure from being connected to the monitoring failure.

5. The installation is complete, the whole machine is calibrated and debugged

   Use standard weights to calibrate the weight accuracy, and test the limit alarm, overload shutdown, and wind speed warning functions one by one; verify that the local storage and video recording functions are normal, and keep the debugging record table for special inspection and reporting.

5. The core points of inspection of crane monitoring system standards

1. There are no defects in the full set of monitoring functions, and all monitoring items corresponding to the requirements of the national standard are fully equipped.；
2. The weight and torque errors are within the allowable range of the national standard, and the calibration can be traced；
3. The data is stored completely, the storage time is up to the target, and the records cannot be deleted or tampered with.；
4. The logic of the alarm action is accurate, and the overload and limit do not rely on cutting off dangerous actions.；
5. The wiring, protection, and installation are in line with on-site working conditions, and there are hidden dangers of wireless circuit aging and sensor bumps.

6. The multiple values of deploying a crane safety monitoring and management system

1. Meet mandatory compliance and successfully pass the annual inspection

   Keep up with the national standards for crane safety monitoring systems and the latest national regulations, and complete a complete set of systems can pass regular inspections of special equipment at once to avoid safety supervision penalties and the risk of shutdown and rectification.

2. Front prevention and control of lifting safety accidents

   All-dimensional monitoring of various risks such as overload, slip hooks, collisions, and high wind operations, early warning and active locking of dangerous operations, greatly reducing the probability of hoisting falling objects, equipment overturning, and labor injuries.

3. Realize job traceability and standardize personnel operations

   Hoisting data and videos are kept throughout the process, and all overloading, savage cable-stayed pulling, and illegal limit shielding are all recorded to facilitate management personnel to hold them accountable and rectify them, and restrain drivers from operating irregularly. In the event of an accident, a complete record can be used as an important certificate for the traceability of the accident.

4. Intelligent centralized management to reduce operation and maintenance costs

   Multiple cranes are connected to the lifting machinery safety monitoring platform, so managers do not need to travel to and from various workshops for on-site inspections, and remotely grasp the operating status of all equipment; rely on fault data to accurately locate aging parts, planned maintenance, and reduce sudden failures and shutdowns.

7, summary