Integrated monitoring system of marine crane

1. System overview

The intelligent monitoring system for hydraulic and lifting safety of offshore platforms is a digital safety control solution specially designed for offshore drilling platforms, ship deck cranes and various types of offshore engineering lifting equipment. The system is based onReal-time online monitoring of multi-channel hydraulic oil pressure and oil temperatureAs the core, it integrates multi-dimensional modules such as torque load analysis, boom luffing angle measurement, and environmental wind speed monitoring.

In view of the extremely harsh working conditions of high salt spray, high humidity and easy oil pollution in the ocean, the hardware of this system adopts a high-protection design, which can dynamically collect the lifting weight of the main and auxiliary hooks, the angle of the lifting arm, the hydraulic pressure of the hoist, the oil temperature of the system and the real-time wind speed around the clock. When encountering abnormal working conditions such as hydraulic overpressure, oil temperature overheating, overload or strong winds, the system will automatically trigger sound and light alarms and perform safety interlock control, effectively meeting the strict requirements of maritime supervision, platform safety supervision and special equipment compliance annual inspection.

2. Core functional characteristics

• Multi-channel dynamic monitoring of oil pressure and oil temperature：The system can independently collect the pressure of the core hoist pipeline such as the main hook, auxiliary hook, luffing and rotation (0~60MPa) and the overall oil temperature of the hydraulic system (0~150℃). Users can independently set multi-level early warning and alarm thresholds to issue alarms before pipeline leakage, valve overload, hydraulic oil aging or seal burning, greatly reducing high offshore maintenance costs.
• Integrated multi-parameter same-screen display：The oil pressure, oil temperature, current lifting weight, operating range, boom angle, and wind speed data are centrally presented on one interface, and multiple oil pressure independent pagination and detailed viewing are supported, and the status is clear at a glance.
• Intelligent hierarchical security warning and interlocking：Hierarchical reminders are given for different working conditions and the degree of danger. When the secondary hazard threshold is reached, the system will automatically cut off the movement in the hazardous direction, eliminating hoisting accidents and mechanical damage from the source.
• Multi-sea condition load curve management：Built-in database of rated loads suitable for in-ship, out-of-ship, and under different wave height conditions, supports one-click switching of corresponding hoisting safety specifications according to actual sea conditions.
• High-precision multi-point independent calibration：The oil pressure, oil temperature, load and angle modules all support independent zeroing and multi-point calibration, which can effectively eliminate errors caused by individual differences in pipeline installation and sensors, and ensure accurate and reliable monitoring results.
• One-click backup and quick recovery of parameters：It supports archiving data such as the configuration parameters, oil pressure thresholds, and temperature limits of the whole machine. It can be quickly restored after routine maintenance or replacement of sensors, minimizing the time for equipment shutdown and commissioning.
• Large-capacity historical data storage：The system records the oil pressure, oil temperature, and load data during the operation process throughout the process, providing a solid data support for digital inspection and safety accident traceability.
• Marine-grade high-standard protection system：The protection level of key sensors is above IP67, and the core hardware module adopts double-layer waterproof and salt spray-proof sealing technology, which is perfectly adapted to the harsh environment of the sea surface.

3. System standard hardware configuration

1. Industrial-grade touch master display

It adopts a high-definition touch screen suitable for cockpit installation, provides an intuitive graphical interactive interface, and supports multi-language switching. There is a special hydraulic monitoring page, which displays the load, arm length, angle, wind speed and eight-way hydraulic status of the main and auxiliary hooks on the same screen, and integrates functions such as threshold setting, multi-point calibration, and historical record query.

2. Composite oil pressure and oil temperature sensor

As the core tentacles of the entire monitoring system, the pressure sensor is usually connected in series in a non-destructive manner in each hoist hydraulic pipeline; the temperature sensor is deployed close to the hydraulic manifold or fuel tank. It outputs a standard two-wire signal, has the ability to resist oil pollution and high humidity, and can keenly capture small pressure fluctuations and abnormal temperature rises in the system.

3. High-precision load cell

According to the structural form of the crane, it is specially used to collect the real-time load of the main hook and the auxiliary hook. The appearance of the sensor and the joints are both double-layer waterproof and anticorrosive treatment, which can withstand long-term immersion in seawater and oil erosion.

4. Inclination/boom angle sensor

Installed at the bottom of the crane boom, it is used to accurately measure the real-time luffing angle of the boom. The measured angle is combined with the lifting weight data, and the rated lifting weight in the current state is calculated in real time by the main controller.

5. Digital wind speed sensor

It is usually arranged at the highest point on top of the crane to monitor high winds in offshore operations in real time. Timely warning when there is a sudden strong wind or the ambient wind speed exceeds the standard to prevent the crane from overturning, and the anticorrosive structure of the whole machine is not afraid of sea breeze erosion.

6. Stainless steel integrated control box and sound and light alarm

The control box is responsible for aggregating the analog and digital signals of all sensors (pressure, temperature, weight, angle, wind speed), and performing centralized processing and communication transmission. The supporting sound and light alarm device is installed in an eye-catching position in the cab to provide priority sound and light warnings for high-risk states such as hydraulic overrun and overload. The whole set of cables is made of marine-grade flame-retardant shielded cables, which are oil-resistant and seawater-resistant.

4. Applicable scenarios and industry applications

This system is widely used inOffshore oil drilling platform crane, FPSO floating storage tanker crane, offshore engineering ship crane, port terminal deck lifting equipmentetc. It can be used as the original supporting safety system for newly built marine cranes, and it is also very suitable for the digitization and intelligent transformation of hydraulic safety of old marine cranes. It is an integrated professional system that takes into account the health monitoring of hydraulic systems and the safety control of torque loads.