Power construction transportation ropeway monitoring system

1. Product Introduction

In the lofty mountains of the 500-kilovolt main grid project in Hainan, a ropeway is operating in a brand-new way - when workers mistakenly enter the dangerous area, a shrill whistle immediately rings out on the spot. When the material transport trolley is 20 meters away from the finish line, the operation console automatically lights up a red indicator light. When the force on the load-bearing cable approaches the critical value, the management personnel receive a warning text message simultaneously on their mobile phones. This is precisely the product jointly developed by Weite and State Grid Hubei Electric PowerIntelligent monitoring and management system for ropewaysIt has solved the long-standing problem of "invisible, uncontrollable and unmanageable" cableway transportation in mountainous areas through three core modules: data monitoring, video monitoring and AI anti-intrusion. At present, this system has been put into use in multiple national-level power grid projects. The accident rate has dropped by 90%, and the transportation efficiency has increased by 35%, making the transportation of materials in high mountains and deep valleys as orderly and controllable as the operation of a subway.

2. Technical principles

The intelligent core of the entire system lies inThree-layer protective netConstruction
The mechanical sensors installed at the key nodes of the ropeway are like sensitive nerve endings, sensing every inch of tension and relaxation of the traction cable 24 hours a day. These coin-sized devices are equipped with military-grade MEMS chips, and even a 0.1-ton force fluctuation cannot escape their monitoring. Even more amazing is that they do not require wiring. They are powered by solar panels and wirelessly transmit data to the control center three kilometers away.

The AI camera suspended on the door frame is like an indefatigable night watchman. The built-in intelligent chip can instantly identify the color of safety helmets and the reflective strips of work clothes. When a person without safety equipment enters the loading and unloading area, the system can lock onto the target and trigger the sound and light alarm within 0.8 seconds. There was once a real case: In the Shennongjia power transmission Project in Hubei Province, the system successfully intercepted local villagers who were attempting to take a shortcut, thus avoiding a possible tragedy.

The positioning device installed on the car is an accurate navigator. Through dual-mode positioning of Beidou and GPS, combined with millimeter-wave radar speed measurement, the position of each car can be accurately grasped. When the transport vehicle is still 15 meters away from the finish line, the control screen in the operation room will pop up a slow-moving prompt. After reaching the station, the power will be automatically cut off, completely eliminating the collision accidents caused by human operational errors.

3. Scope of application

This system is particularly good at conquestTransportation challenges in extreme environments​：

• In the tropical rainforest of Hainan, the system has been operating continuously for 120 days without any malfunction in the humid and muggy environment
• In the power transmission project on the Qinghai Plateau, the positioning accuracy remains within 20 centimeters in the severe cold of minus 25 degrees Celsius
• When transporting large transformers for the Three Gorges Reservoir Area relocation project, the precise operation of a single hoisting of 80 tons was successfully controlled
  From the erection of cross-river high-voltage lines to the hoisting of wind farm blades, from the transportation of mining equipment to the delivery of emergency supplies, wherever there are steel wire ropes shuttling, it is its main battlefield.

4. Product display

Entering the operation room, the first thing that catches the eye is the large electronic screen that occupies an entire wall. On the left side, the load-bearing bar charts of 8 groups of gantries are dynamically displayed. When a certain set of data turns red, the 3D model will automatically zoom in on that area. In the middle are the moving light spots of 12 small cars, flowing slowly like a starry river on the cable car simulation diagram. The picture-in-picture on the right side is showing real-time surveillance footage of each loading and unloading point.

The tablet computers held by the on-site workers are mobile command consoles. Just tap the screen to bring up the speed curve of any small car and view the tension change graph of the past two hours. The most practical feature is the loading and unloading reminder function - when the materials reach the designated position, the equipment will automatically vibrate to give a prompt, avoiding the embarrassment of Shouting at the top of one's voice in the past. During the power grid renovation in Guizhou last year, Li, an elder of the construction team, said with a smile, "Now we can command the entire area just by staring at the tablet. We no longer have to run around with walkie-talkies."

5. Product advantages

The four value points of this system that most impressed the engineering party
​All-weather combat capabilityCommendable. The equipment casing adopts submarine-level sealing technology and can still operate normally in heavy rain. The dual power supply system can maintain a 15-day battery life during continuous rainy days. During the passage of Typhoon Mangkhut last year, the system of the Hainan project department provided uninterrupted protection throughout the process.

​A leap in management efficiencyEven more surprising. The ropeway that used to require three people to take turns on duty can now be easily managed by one person. In the Jiangxi ultra-high Voltage project, the project department accurately calculated the transportation cost per ton of materials and accordingly optimized the hoisting plan, saving 470,000 yuan in fuel costs for a single project.

​Active defense systemChanged the rules of the safety game. The system not only prevents dangers from occurring but also learns independently. In a certain project in Yunnan, it analyzed historical data and found that overloading occurred frequently in the afternoon. Therefore, it automatically added an enhanced monitoring mode from 14:00 to 16:00.

​Flexible adaptation featureLet different projects be customized. A certain project in Xizang has raised the warning volume by 30% to adapt to the wind sound environment. The Changbai Mountain Project has installed temperature compensation modules to eliminate measurement errors caused by the thermal expansion and contraction of steel.

6. Core Functions

​Safety protection functionIt's like equipping the ropeway with a smart armor:
When a car fully loaded with building materials passes through the canyon vent, the system will sense the changes in wind force in real time. If the lateral wind force exceeds level 5, operate at a reduced speed immediately. When loading and unloading workers forget to fasten the safety rope and enter the dangerous area, the AI camera can capture the movement at the moment they lift their feet and trigger the equipment to cut off the power for protection. The most ingenious part is overload prediction - by analyzing the force curves of the first three gantries, a graded alarm is issued before the fourth gantry reaches the critical value.

​Efficiency Engine functionThen the transportation management process was restructured:
The intelligent shift scheduling system dynamically plans the departure intervals of trolleys based on the load-bearing limit of the mast. In the offshore wind power project in Yangjiang, Guangdong Province, the system has reduced the waiting time for individual vehicles from 45 minutes to 12 minutes. The automatically generated transportation ledger is accurate to the time consumption, transportation distance and energy consumption of each hook of materials. Based on this, the project department optimizes the cable layout and shortens the overall construction period by 18 days.

7. Typical applications

The 500-kilovolt main grid structure project in Hainan can be regarded as a textbook-level case
During the eight-month construction period, this 12-kilometer cableway that traverses the tropical rainforest set a record of zero accidents. The system has cumulatively intercepted 27 personnel intrusions, prevented 13 overloading accidents, and corrected 89 violations of operation rules. What's even more remarkable is that it makes the transportation process transparent and controllable

• The chief commander of the project can view the real-time images from the headquarters in Wuhan
• The safety director can randomly check the operation records of any time period through his mobile phone at any time
• The operator precisely controls the loading and unloading rhythm according to the prompts on the tablet
  Wang Jianjun, the chief engineer of the project, said with emotion, "In the past, we were constantly on tenterhooks, staring at the walkie-talkie every day. Now, the system has become the most reliable safety officer, and we can finally sleep soundly." After calculation, the system has created a comprehensive benefit of over 3 million yuan for a single project. State Grid has listed it as a standard equipment for ultra-high voltage projects.