Mobile crane safety monitoring system: Intelligent systems for crawler cranes and truck cranes

1. Industry pain points

​A safety vacuum enforced by regulations​

• ​Regulatory lagThe safety of traditional crawler cranes relies on manual inspection and cannot capture sudden risks in real time (such as instantaneous overloading and sudden changes in structural stress).
• ​Loss of control under harsh working conditionsWhen working in the field, there is a lack of a linked protection mechanism for dynamic risks such as strong winds, slopes, and blind spot obstacles.
• ​The predicament of accident traceabilityAfter a malfunction occurs, it is difficult to precisely trace back the operation process and equipment status.
• ​Transform compliance risks: Not selected to haveQualification for 342,000KN·m torque limiterFor service providers with the "Installation, Renovation and Maintenance License", the system may be declared invalid.

According to the new regulations of TSG51-2023, crawler cranes with a capacity of over 200 tons must be mandatorily equipped with safety monitoring systems.

2. Solution - Application Scenarios of Crawler Cranes

​WTSM-B system full-scenario protection closed loop​

• ​Dynamic monitoring layer​：
  • ​Weight sensorReal-time perception of lifting load, with an accuracy of ±0.5%;
  • ​Angle/orientation sensorLinkage calculation of boom attitude and operating radius;
  • ​Wind speed sensorMonitor wind speeds ranging from 0 to 60m/s and trigger the strong wind efficiency reduction protection.
• ​Intelligent control layer​：
  • ​CAN bus communicationIntegrate more than 32 sensor signals;
  • ​Passive switch quantity +4-20mA interfaceCompatible with all brands of PLCS.
• ​Visualized management​：
  • ​Anti-shake camera +DVRRecord blind spot operations and support AI recognition for hoist skipping rope.
  • ​Cab touch screenReal-time display of torque percentage and tilt Angle risk value.
• ​Cloud-based early warning layer​：
  • ​4G/5G remote transparent transmissionGPS location and working condition data are sent to the monitoring center.
  • ​Three-level alarm mechanismLocal sound and light → Automatic speed reduction → remote forced shutdown.

3. Core technology

​Triple composite protection architecture​

• ​High-precision perception technology​：
  • Dual-axis inclination compensation for anti-track vibration eliminates terrain inclination errors;
  • The pulse encoder monitors the hoist height with a resolution of up to 1mm.
• ​Edge computing core​：
  • Embedded host operating torque algorithm, supporting 2000T-level overload prediction;
  • Respond to the trend of the hook slip in milliseconds and trigger braking 2 seconds in advance.
• ​AI Visual Enhancement​：
  • The 1080P wide-angle lens intelligently recognizes abnormal hook trajectory.
  • The hard disk video recorder stores videos for over six months, meeting the requirements for accident traceability.

4. Core advantages

​The eight competitive advantages derived from the platform's characteristics​

• ​Full interface compatibilitySupports passive switch quantities, 4-20mA analog signals, pulse quantities and Can bus expansion, and can be directly connected to PLC control systems of various brands.
• ​National standard certification guaranteeCertified by GB/T 28264-2017, it complies with the mandatory requirements for 200t+ crawler cranes stipulated in TSG51-2023.
• ​Cloud-based dual-channel management​► ​Real-time monitoringRemotely view GPS location, working condition data and video streams;

  ► ​Record for future referenceThe operation logs and fault information are stored in the cloud for more than six months.

• ​Predictive maintenanceSelf-diagnose and issue early warnings for common faults (such as overheating of bearings and damage to steel wire ropes), and save analysis reports to guide maintenance.
• ​Contactless operation and maintenanceSupport remote parameter download, program upgrade and fault repair to reduce on-site downtime.
• ​Judicial-level securityIndependent password protects operation permissions, and automatic latching and alarm for data tampering.

5. Configuration list

​The system hardware covers the entire domain​

• ​Perception terminal​
  • Weight sensor (hook pulley block)
  • Angle sensor (boom root pin)
  • Super lift height encoder (drum shaft end)
  • Azimuth sensor (turntable center, GPS+ gyroscope
  • Wind speed sensor (top of the boom
• ​Control center​
  • Host control unit (dust-proof electrical control cabinet, IP65 protection)
  • I/O communication module (CAN bus expansion hub)
• ​Interactive storage​
  • Monitoring display instrument (cab touch screen, 65K true color)
  • Hard disk video recorder (storing video from 4 cameras)
  • Wide-angle anti-shake camera (middle arm/top of the cab)