One-key hoisting system of smart bridge machine: Leading the new standard of intelligent hoisting of hydropower stations

In the maintenance and maintenance of large-scale hydropower stations, the bridge machine assumes the heavy responsibility of hoisting key components such as rotors and stators. Traditional bridge machine operation relies on manual experience, and there are challenges such as low positioning accuracy, high safety risks, and limited efficiency.One-key hoisting system of smart bridge machineIt came into being, and through intelligent upgrading, a revolutionary breakthrough from “manual control” to “intelligent operation” has been achieved.

1. System overview: Redefine the new standard for bridge intelligence operation

Based on the precise on-site surveying and mapping of the hydropower station plant, a complete spatial structure model is systematically constructed. Through the precise modeling of the walking trajectory and hook movement of the bridge and trolley, a complete spatial structure model is established.High-precision automatic positioning system。 The system integrates multiple types of sensors and real-time monitoring equipment to realize the automatic collection and analysis of bridge operation data to ensure that the positioning accuracy reachesMillimeter level, To provide a reliable guarantee for the hoisting of key components.

2. Core technology highlights: Four major innovations to build an intelligent closed loop

High-precision automatic positioning technology

• Based on the three-dimensional spatial modeling of the plant, an accurate coordinate reference system is established
• The positioning accuracy of large and small cars is ±1mm to meet the needs of precision hoisting
• Intelligent identification of key areas and environmental impact factors to ensure positioning reliability

One-click intelligent control system

• Integrated one-key start-stop and anti-swing control to simplify the operation process
• Automatically plan the optimal hoisting path to improve operational efficiency
• Intelligent anti-swing algorithm to ensure smooth and reliable hoisting process

Real-time operation monitoring network

• Multi-sensor collaborative collection of bridge machine position and operation data
• Real-time monitoring of system status, timely detection and early warning of abnormalities
• Data cloud storage and analysis, support remote diagnosis and decision-making

Gap monitoring and automatic correction

• Real-time monitoring of the air gap between the rotor and the stator, with an accuracy of millimeters
• Automatically correct the center position to avoid the risk of collision
• Multi-point video surveillance of thrust oil tank, large shaft flange, etc. to ensure safety in all directions

3. System architecture: multi-level collaborative intelligent control system

As shown in the system architecture diagram, the one-key hoisting system of the smart bridge adopts a layered design：

​Perception layer​: Sensor networks deployed at key locations in the plant to collect operating data in real time

​Control layer​: Integrate PLC and intelligent algorithms to achieve accurate motion control and decision-making

​Executive layer​: Large and small car drive system and hook mechanism, responding to control instructions

​Monitoring layer​: Human-computer interaction interface and remote monitoring platform, providing a full range of operational support

This architecture ensures that the system can monitor the stator rotor clearance in real time during key operations such as rotor hoisting in and out, automatically adjust the center position, and provide comprehensive information support for command personnel and operators.

Through precise positioning of the operation of large and small cars, anti-shake control of wire ropes, and automatic ultrasonic air gap monitoring, the plant bridge machine can be accurately positioned when hoisting the rotor, with a positioning accuracy of 1mm.

4. Application value: comprehensively improve the level of maintenance and maintenance of hydropower stations

The application of one-key hoisting system of smart bridge machine has brought significant benefits to hydropower stations：

​Safety performance doubled​

• Precise positioning at the millimeter level, effectively avoiding equipment collisions
• Real-time clearance monitoring to eliminate safety hazards in the hoisting process
• Intelligent anti-swing control to ensure stable and reliable hoisting of heavy objects

​Work efficiency improvement​

• One-click operation simplifies the process and reduces manual intervention
• Automatic path planning to optimize the efficiency of hoisting operations
• Multi-system collaboration to shorten maintenance downtime

​Management level upgrade​

• Intelligent transformation from empirical operation to data-driven
• Predictive maintenance support to extend the service life of equipment
• Lay a solid foundation for the digital management of power stations

The one-key hoisting system of smart bridge machine represents the development direction of intelligent large-scale hoisting equipment for hydropower stations. We will continue to deepen technological innovation in the hydropower industry, use smarter, safer and more efficient solutions to help hydropower stations realize the modernization and upgrading of operation and maintenance management, and contribute professional strength to ensure the safe and stable operation of “large heavy equipment”.