Mast crane safety monitoring system solution

1. Industry Pain Points

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​Inherent defects and safety challenges of mast cranes​

• ​High-risk control of guy ropes8 to 16 guy ropes need to be set up. Manual adjustment is inefficient and uneven force distribution can easily cause overturning (accounting for 35%+ of accident rates).
• ​Dynamic blind spot riskWhen hoisting large components, the field of vision is limited, making it easy to collide with obstacles or misjudge the moment (especially in narrow Spaces).
• ​Low migration efficiencyThe disassembly and reinstallation of the guy ropes take 2 to 3 days, which delays the construction period.
• ​National standard compliance gapMost of the equipment failed to meet the mandatory requirements for real-time monitoring as stipulated in JT/T 1277-2019.

Note: Although mast cranes have a large lifting capacity, they are only limited to specific scenarios due to their poor flexibility. Technical measures are needed to compensate for their shortcomings.

2. Solution​

​Weite WISP Intelligent Monitoring System (Exclusively designed by the drafting unit of the national standard)

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​A fully closed-loop protection system​：

• ​Intelligent stable control of guy ropesThe high-precision force measurement ring monitors the tension of each rope in real time. When the deviation exceeds 15%, an audible and visual alarm is triggered. The tilt sensor is linked to calculate the balance state of the mast to prevent the risk of foundation settlement.
• ​Three-dimensional job protectionThe laser rangefinder can scan obstacles within a radius of 20 meters (with an accuracy of ±10cm). The main/auxiliary hook independent overload cut-off module, with dual-channel guarantee.
• ​Ultra-fast relocation and loading technologyPre-integrated sensor group, disassembled for reuse without calibration (migration time < 4 hours).
• ​National standard data cloud archivingThe operation records are encrypted and stored for more than 5 years, meeting the inspection requirements of JT/T 1277-2019.

3. Core technology​

​The three technical barriers under the framework of national standards​

• ​Dynamic load compensation algorithm​
  • Real-time calibration of inclination-moment based on ANSYS model, resistant to strong wind interference (accuracy 99.5%).
• ​Multi-rope cooperative control system​
  • 16-channel parallel cable tension analysis, generating heat maps to warn of imbalance risks.
• ​Contactless operation and maintenance of the kernel​
  • OTA remote program upgrade, automatic fault diagnosis and push repair solutions.

4. Core advantages​

​The seven core competencies of micro and Special systems​

​① National standard compliance certification​

It fully complies with the requirements of "JT/T 1277-2019", independently records 48 parameters and displays them in real time.

​② Full interface compatibility​

It is standardly equipped with passive switch quantities, 4-20mA analog quantities, and pulse interfaces, and supports Modbus/Profibus expansion.

​③ Judicial traceability​

The cloud stores operation records, and the background analyzes the compliance of operations (with an accuracy of 0.1 seconds).

​④ Full-domain visual management​

Remotely view the GPS location of the equipment and real-time working condition data (4G transparent transmission).

​⑤ Predictive Protection​

Warn of common faults (such as wire rope overload) and save the fault feature library.

​⑥ Digital operation and maintenance​

Remotely repair system malfunctions and manage historical operation reports.

​⑦ Seamless integration with PLC​

Read the PLC data directly and display it dynamically on the monitoring terminal.

5. Configuration list​

​Full coverage of core hardware

​Perception layer terminal group​

• ​anemometerMonitor wind speed from 0 to 60m/s (installed at the top of the boom)
• ​Angle sensorDual-axis inclinometer (±0.1° accuracy, mast base)
• ​Weight sensorMain hook force measurement unit (range 50-2000t)Control layer equipment​
• ​Monitoring display instrument10-inch touch screen (cab, 65K color dynamic display)
• ​Hard Disk Video Recorder (DVRStore 4 channels of 1080P video for over 30 days
• ​Anti-shake camera120° wide-angle night vision (covering the hook operation area)Interaction layer components​
• ​Video displayReal-time monitoring screen of the command center

 6. Installation diagram