Operation and maintenance management system for the whole life cycle of lifting equipment

1. Product R&D background and industry pain points

At this stage, all kinds of gantry cranes, bridge-mounted vehicles, and offshore lifting equipment in steel mills, shipyards, and ports generally follow the traditional operation and maintenance mode: relying on manual visual and auditory inspections, paper ledger records, and post-mortem emergency repairs + regular fixed repairs management methods. There are problems such as uneven personnel skills, lag in the discovery of hidden dangers, inability to identify fatigue cracks in steel structures in advance, concealment of transmission component failures, non-quantitative evaluation of equipment life, serious data silos, and high maintenance costs. In response to the intelligent upgrading of Industry 4.0 and the compliance requirements of the annual safety inspection of lifting equipment, Weite launched an integrated lifting equipment life cycle operation and maintenance management system, which integrates Internet of Things sensing, AI vision, thermal imaging, stress monitoring, and big data life analysis technologies to achieve safe use of lifting equipment+Dual digital control of essential safety.

Second, the overall design idea of the system

The system is based onEquipment life cycle managementAs the core, a three-layer architecture is built: on-site perception acquisition layer, 5G/optical fiber transport layer, and cloud three-dimensional operation and maintenance platform. Full coverage monitoring of metal steel structure, lifting transmission mechanism, wire rope, brake, motor reducer, electric control cabinet, cart track, load and wind speed multi-dimensional data, taking into account the five core capabilities of real-time safety alarm, fault pre-diagnosis, remaining life calculation, intelligent spot inspection, and maintenance work order closed loop, suitable forA full range of lifting equipment such as shipbuilding 800T gantry cranes, steel mill cranes, port gate cranes, offshore platform cranes, etc., meet CCS, special equipment testing, GB/T3811, GB/T41510 specifications and acceptance.

3. Full-dimensional online monitoring module (core hardware perception system)

1. Metal structure stress and arch monitoring

Micro-strain sensors are used to arrange the key welds and stress concentration points of the main beam to collect dynamic stress data in real time; with a liquid level arch monitoring device, the static/dynamic deflection of the main beam is continuously recorded. The system calculates the cumulative structural damage in real time based on the national standard algorithm, gives early warning of fatigue cracks and excessive deflection of the main beam, avoids major structural fracture accidents, supports the monitoring of wheel pressure imbalance on the cart platform, and prevents irreversible damage to the track and wheels.

2. Lifting mechanism fault pre-diagnosis system

Vibration + temperature dual sensors are deployed in motors, reducers, gear holders, and reel bearings to collect spectral data in real time, and AI algorithms to identify bearing wear, gear broken teeth, loose feet, and hidden dangers of oil shortage and high temperature; supporting brake laser ranging + infrared temperature sensor to monitor brake tile wear thickness and brake disc overtakingTemperature, hierarchical push replacement and maintenance reminders.

3. Non-destructive flaw detection and monitoring of wire rope

Based on the principle of magnetic memory detection, online identification of broken wires, broken strands, wear and corrosion defects inside and outside the wire rope, automatic generation of flaw detection and detection reports, accurate positioning of the damage site, instead of manual regular offline flaw detection, greatly reduce the safety risk of wire rope fracture, and the detection data is permanently archived for reference.

4. AI reel rope visual monitoring

The high-definition industrial camera is equipped with a visual recognition algorithm to monitor the arrangement of reel wire ropes in real time, automatically identify job changes, random ropes, extrusion and wear, capture abnormal pictures and push sound and light alarms to avoid wire rope cutting damage.

5. Thermal imaging fire monitoring of electric control cabinet

Infrared thermal imaging cameras monitor the temperature of power distribution cabinets, contactors, and cable connectors around the clock to identify local overheating and fire hazards, synchronize regional intrusion, and AI identification of personnel crossing boundaries, taking into account electrical fire prevention and on-site operation safety.

6. Safety monitoring of load, wind speed, and torque

Integrated multi-channel acquisition of weight, angle, oil pressure, and wind speed, real-time torque limit, overload interlock, and high wind prohibit lifting protection, record the load spectrum of each working cycle, and provide raw data support for the calculation of the remaining life of the whole machine.

7. Early warning of the life of electrical components

Connect to the crane PLC system, accumulate the number of contactor, relay, and limit switch actions, and automatically push the replacement plan against the standard theoretical life to prevent sudden failure and shutdown of electrical components.

4. The core functions of the cloud integrated operation and maintenance management platform

• 3D visualization overview: The 3D model of the whole machine can be viewed remotely, the real-time status of each monitoring point and the alarm pop-up window jump with one click, and the computer/mobile phone terminal can access it synchronously.；
• Real-time multi-level early warning push: Equipment over-temperature, stress over-limit, overload, wire rope damage, abnormal fire situation, platform pop-up window + SMS/WeChat message push, hierarchical risk control；
• Full life cycle life measurement: According to the national standard GB/T3811 and GB/T41510 algorithms, the working cycle and load damage are automatically counted, and the remaining service life of the main beam, mechanism, and wire rope is output. Report；
• Paperless intelligent inspection: Support PDA handheld terminal on-site inspection, the sensor automatically generates electronic inspection records, missing manual items are filled in online, and the inspection ledger is automatically generated；
• Closed-loop management of maintenance work orders: The system automatically generates maintenance and repair tasks, assigns the responsible person, uploads maintenance records, flaw detection reports, and maintenance pictures, and can be traced throughout the process.；
• Export of big data tables: Support Excel export of stress curve, vibration trend, load statistics, alarm record, maintenance ledger, suitable for safety supervision, ship inspection, and internal audit of enterprises；
• Equipment data archive: Unified storage of equipment drawings, certificates of conformity, flaw detection reports, and annual inspection data, and can be accessed online at any time；
• Multi-device cluster managementA single platform controls multiple gantry cranes, driving vehicles, and platform cranes at the same time, and statistical management of sub-factories and sub-equipment groups.

V. Core advantages of the system

• Double securitySynchronous control, operation and use safety + the essential structure safety of the equipment, taking into account the hidden dangers of hoisting overload and internal component fatigue；
• Predictive maintenance instead of urgent repairsPredict failures several months in advance, significantly reduce sudden downtime, and reduce maintenance costs by more than 40%；
• Unmanned automatic monitoringAll sensors in key parts are collected online to reduce the intensity of manual inspection and reduce the risk of personnel working at high altitude.；
• Standardized compliance outputA full set of monitoring data and reports meet the annual inspection of special equipment, CCS of shipyards, and safety reviews of steel mills；
• Compatible with old and new lifting equipmentSupporting new machines, old gantry cranes/vehicles can be retrofitted and installed, and 5G/wired dual transmission can be adapted to harsh environments in factories and offshore.；
• Integrated packageOne-stop delivery of sensor hardware + acquisition box + cloud platform + on-site construction calibration, supporting after-sales training.

6. Applicable equipment and industry scenarios

Suitable for 800T shipbuilding gantry crane, steel mill bridge crane, foundry metallurgical crane, port gantry crane, offshore drilling platform crane, container shore bridge, construction site beam lifting machine, hydropower station lifting equipment; covering shipbuilding heavy industry, metallurgical iron and steel, ports and terminals, offshore oil and gas, infrastructure bridges, hydropower major industries,It is an integrated complete solution for intelligent safety control and digital operation and maintenance of large-scale lifting equipment.