Intelligent solution for bridge of hydropower station

Introduction: The importance of safe operation of hydraulic metal structures

As the key lifting equipment, the bridge machine of the hydropower station is directly related to the production efficiency and safety of the entire power station for its safe and stable operation. Traditional monitoring methods rely on manual inspections and regular maintenance, which have pain points such as low efficiency, high safety risks, and inability to monitor in real time. This article will introduce in detail the comprehensive solutions of bridge condition monitoring and intelligent operation and maintenance of hydropower stations, and provide technical support for the safe operation of water conservancy and power generation.

Industry pain points: the dilemma of traditional monitoring methods

There are obvious limitations in the monitoring methods of traditional hydraulic metal structure equipment (such as door machines, bridge machines, gates, etc.).：

​Inefficient​: Manual testing has a large workload and relies on empirical judgment, which is prone to missed inspections and misjudgments, which affect the normal operation of the equipment.

​High security risk​: The high-altitude and underwater operating environment is dangerous, the inspectors are vulnerable to injury, and there is a lack of effective safety protection measures.

​Cannot be monitored in real time​: It is difficult to capture the early signs of sudden failures, and it is often only discovered after the problem is serious, which increases the difficulty and cost of maintenance.

​Short equipment life​: Lack of data support, unable to achieve predictive maintenance, resulting in shortened equipment life and increased operation and maintenance costs.

Bridge safety monitoring system: safety guarantee that meets national standards

WTSM-Special equipment safety monitoring and management system is a new type of monitoring system developed by micro-technology in accordance with the national "GB/T28264-2017" standard. It is not only suitable for the transformation of various special equipment and the enforcement of new standards, but also can be used for various construction equipment in other fields.

​Main functions​：

• ​Real-time security monitoring​: Continuously monitor the operating status of the equipment to ensure job safety
• ​Hazard warning​: Can identify and alert all kinds of hazards that may occur in the equipment in advance
• ​Fault self-diagnosis​: The system can automatically perform intelligent diagnosis and analysis of faults that occur
• ​Remote diagnosis and repair​: Relying on historical data, it supports remote diagnosis and repair of faulty equipment
• ​Operational data recording​: Complete record of equipment operation information, provide data support for analysis and maintenance

Localization transformation of bridge electrical system

The electrical equipment transformation of the water gate machine mainly includes key components such as control cabinets, electrical control components, cables, automation components (encoders, load sensors, stroke limiters, etc.), and linkage operation consoles.

​Core components​：

• ​Control cabinet​: Stainless steel or carbon steel spray material can be used according to customer requirements. The recommended material thickness is 1.5mm stainless steel and 2mm carbon steel. The size of the control cabinet can be customized according to on-site conditions
• ​Electrical control components​: It mainly includes PLC, circuit breakers, contactors, relays, etc., mainly using imported brands such as Siemens and Schneider, and can also be replaced with well-known domestic brands according to customer requirements.
• ​cable​: Including the replacement of power cables and communication cables, the erection of cable trays and the laying of cables
• ​Linkage console​: Provide a reliable operating platform for crane operators. Each console is equipped with a seat that can be adjusted up and down, front and rear

One-key hoisting system of smart bridge machine: a new standard for intelligent hoisting

The intelligent control system for one-key hoisting of large-scale bridge machines establishes a high-precision automatic positioning system through on-site surveying and mapping of the spatial structure of the plant. The system integrates sensors and real-time monitoring to realize automatic acquisition and precise control of the walking of large and small cars and the position of the hook, with one-key start and stop and anti-swing functions.

​Technological innovation points​：

• ​High-precision automatic positioning​: Based on the spatial modeling of the plant, the precise positioning of large, small cars and hooks is realized
• ​One-click intelligent control​: Integrated one-key start-stop and anti-swing control to ensure stable and efficient hoisting
• ​Real-time operation monitoring​: Collect the position and operation data of the bridge machine in real time through the sensor
• ​Gap monitoring and automatic adjustment​: Real-time monitoring of the gap between the rotor and the stator, and automatic correction of the center position
• ​Multi-scene video surveillance​: Video monitoring of key locations such as thrust oil tanks and large shaft flanges to assist in command and operation