Safety solutions for locks and generator sets

In the field of water conservancy engineering, the reliable operation of key facilities such as locks and generator sets is directly related to the safety and economy of the entire water conservancy system. It is difficult for traditional monitoring methods to perceive inherent hidden dangers such as bolt preload attenuation and structural displacement changes in real time, resulting in long-term water conservancy machinery facing pain points such as high safety risks and low operation and maintenance efficiency. This article will introduce in detail a set of integrated solutions that integrate automatic decoupling, intelligent early warning and full life cycle management.

Industry pain points: Traditional monitoring methods face challenges

Traditional monitoring methods have obvious limitations and cannot meet the safety needs of modern water conservancy facilities：

​Bolt breaks without warning​: Bolt loosening and fatigue cannot be detected in time, and sudden fractures can easily cause chain structural accidents, resulting in serious consequences.

​Structural displacement is difficult to monitor​: There is a lack of real-time monitoring of the displacement changes of key structures such as guide vane arms and wind brakes, and timely warning of loosening and deformation is impossible, making it difficult to detect safety hazards.

​High risk of manual inspection​: Equipment detection in high-altitude, underwater, and high-speed operating environments is difficult, there are many blind spots, and safety risks are prominent, making it difficult to guarantee the safety of personnel.

​Overhaul relies on empirical decision-making​:Lack of data support, maintenance plans rely on regular maintenance and post-mortem disposal, predictive maintenance cannot be achieved, and operation and maintenance costs are high.

Automatic decoupling system for mooring ship piles

The automatic tripping floating bollard is a safe mooring device designed for multi-stage locks. It can automatically decouple when the water level drops abnormally and the tension of the cable exceeds the standard, effectively preventing the ship from capsizing and the structure of the gate body from being damaged.

Before automatically falling off

After automatically falling off

​Main monitoring functions​：

• Automatic decoupling protection: automatically release the cable when the tension is too large to avoid the ship being pulled over
• Adjustable tripping force value: the trigger threshold can be flexibly set according to the ship's tonnage and hydrological conditions
• Sound and light alarm reminder: An immediate warning is issued when decoupling, reminding the staff to deal with it in time
• Simple transformation: suitable for upgrading existing bollards, simple construction and low cost

Online monitoring system for bolt preload (loosening): prevention of structural failures

Based on ultrasonic monitoring technology, the axial stress changes of bolts are measured in real time, and the state of preload is accurately evaluated, so as to effectively prevent major safety accidents caused by bolt loosening or fracture.

​Core functions​：

• High-precision stress measurement: ultrasonic technology is used to directly measure the true preload of the bolt, with small errors and high reliability.
• Real-time monitoring and early warning: continuously track the trend of preload attenuation, and issue real-time alarms when abnormal
• In-service bolt diagnosis: evaluate the status of the bolt without disassembly and assist in maintenance decisions

Online monitoring system of the crank arm of the unit: to achieve predictive maintenance

Through real-time monitoring of the displacement changes of key parts of the turbine guide vane arm, the loose nuts and abnormal clearance are accurately identified, and the equipment status assessment and early warning are provided.

​Core functions​：

• Real-time displacement monitoring: high-precision detection of the displacement of the gap between the guide vane arm, timely detection of hidden dangers of loosening
• Multi-state intelligent judgment: automatically identify normal, critical and fault states, and issue hierarchical early warnings
• Trend analysis and prediction: generate fault trend reports based on long-term data to support predictive maintenance decisions

Online monitoring system of air brake displacement: to ensure braking safety

Monitor the displacement status of the air brake brakes of the hydroelectric generator set in real time to ensure that the brakes work within a safe range, and effectively prevent mechanical failures or safety accidents caused by abnormal displacement.

​Core functions​：

• Real-time displacement monitoring: accurately monitor the displacement of the air brake brake and find abnormalities in time
• Abnormal alarm function: Sound and light alarms are issued immediately when the displacement exceeds the limit to remind the operation and maintenance personnel to deal with it.
• Safety status judgment: automatically identify whether the displacement exceeds the limit, and provide three-level status reminders for normal, early warning, and fault.