Crane vibration monitoring system: The AI Guardian of Safe operation in Heavy Industry

1. Product Introduction

The Weite crane vibration monitoring system is an intelligent diagnostic device specially designed for industrial scenarios. It has completely transformed the traditional "fire-fighting" maintenance mode that relies on manual inspection. This system is composed of portable sensors, high-speed collectors and diagnostic industrial control computers. It can continuously collect vibration, temperature and stress data of key components of cranes (such as motors, reducers and bearings) for 24 hours, and analyze the health status of the equipment in real time through AI algorithms.

For instance, in the metallurgical workshop of Xianggang, the system operates continuously under the high-temperature and dusty environment, giving early warnings of the wear of the reducer bearings, thus avoiding production line shutdowns caused by sudden malfunctions and directly cutting the maintenance costs by more than half.

2. Technical principles

Its core isMulti-sensor fusion + edge computingThe vibration sensor captures the high-frequency impact signals of the equipment (with a frequency range of 20Hz-20kHz), the temperature sensor tracks the risk of overheating, and the stress sensor keeps an eye on the fatigue of the metal structure. After these raw data are filtered and denoised, the system will extract themOver 40 characteristic parametersFor instance, root square amplitude, kurtosis index, envelope spectrum frequency center of gravity - and then throw them into the fault model library for matching.

Take a hardcore example: When there are fine cracks in the gears of a reducer, traditional methods cannot detect them at all, but the micro system can pass throughResonance demodulation technologyAmplify the fault frequency submerged in noise by 100 times, and even the spalling of the tooth surface cannot escape. What's even more ruthless is that it even usedOptical fiber sensing technologyAnti-electromagnetic interference, in the strong electromagnetic environment of port ship unloaders, the vibration monitoring error is reduced to a lower level, which is much more stable than traditional electrical sensors.

3. Scope of application

From steel mills to docks, this system is almost applicable to all heavy-load scenarios:

• ​Metallurgical industryOn the 200-ton casting crane of Xianggang, the system operates under the radiation of molten steel at 1600℃. The dust-proof box sealing strip and military-grade circuit board firmly withstand the high-temperature iron oxide dust.
• ​Port machineryFor instance, the hoisting mechanism of a ship unloader monitors the vibration spectrum of the steel wire rope in real time. While warning of the risk of broken wires, it also manages to correct the deviation of the large vehicle to prevent the entire machine from overturning due to resonance during unloading.
• ​Automobile manufacturingIn the workshop, it is connected to the bridge crane. Through the UWB positioning hook, the accident rate of hoisting is reduced to a lower level.
• ​Energy infrastructureStress monitoring of the main beam of the gantry crane in hydropower stations, predicting the structural life based on historical data, and warning of metal fatigue several weeks in advance under extreme working conditions.

4. Product display

The hardware configuration is directly customized for industrial violent environments:

• ​SensorThe three-axis vibration sensor is wrapped in an alloy aluminum housing, which can withstand temperatures up to 150℃ and has an IP66 protection rating against spray. It is directly bolted to the equipment housing, and even cleaning agents cannot loosen it.

• ​Host: 65,536-color TFT touch screen, dual display mode of digital curves, 6-month ultra-long storage - In the Jingjiang Special Steel project, workers can directly swipe the screen to retrieve the three-year vibration trend chart of the reducer.

5. Product advantages

The most valuable aspect of this system is that it transforms "post-failure repair" into "pre-failure interception" :

• ​Save on downtime costsA certain car factory has made statistics and found that unplanned downtime has decreased.
• ​Extend the service life of the equipmentThe mold crane of a certain automobile factory has extended the scrapping cycle of steel wire ropes from six months to 15 months by means of vibration early warning.
• ​Remote diagnosis and treatmentWith a 5G transmission delay of less than 100ms, engineers at Xiangtan Steel Plant can access the real-time spectrum of cranes from their ground offices, remotely diagnose faults in the inner rings of bearings, and accelerate maintenance response. 40%.

6. Typical applications

Yangtze River BridgeAfter the R4300 tower crane was installed with the micro and special system, a precursor to the rotor breakage of the hoisting motor was detected once. At that time, the vibration kurtosis index suddenly soared to 8.2 (safety value <4), and the system triggered an audible and visual alarm within seconds to prevent a thousand-ton hoisting accident.

​Intelligent operation and maintenance of port ship unloadersAt the Ningbo-Zhoushan Port, the system conducts a "full physical examination" on 12 ship unloaders. Once, a packet was detected that the high-speed shaft of the reducer was misaligned. After comparing 100,000 sets of historical data, the AI directly pushed a maintenance plan - adjusting the base gasket by 0.5mm. As a result, the vibration value dropped from 12mm/s to 1.8mm/s, and the maintenance time was compressed from 8 hours to 90 minutes.

7Conclusion​

From predictive maintenance to life cycle management, this system of Weite is becoming the "mechanical doctor" of heavy industry. In the future, it will also integrate digital twins - for instance, a certain power grid project has piloted mapping vibration data to a 3D model, allowing for the simulation of the critical point for bearing scrapping with just a click of the mouse. In the battlefield of Industry 4.0, identifying potential risks earlier means earning millions more in profits.