High-precision intelligent weighing system for electromagnetic crane in shipyard

1. Industry background: Safety bottleneck of electromagnetic hoisting operations in shipyards

In the process of ship construction, the use of bridge cranes (cranes) with electromagnetic spreaders to lift ultra-long marine steel plates, profiles and components is an extremely important core process. Due to the huge size and extremely heavy weight of the steel plate, and the deviation of the center of gravity during the lifting process, the traditional mode of operation mainly relies on the experience of the engineer and the crane driver for human eye judgment.

• Invisible security risks are prominent：In this extensive mode, dangerous conditions such as center of gravity partial load, single-point overload or overall overload can easily be ignored. Once the center of gravity shifts, the light weight will cause the steel plate to tilt and the spreader to be damaged, and the heavy weight will cause catastrophic safety accidents such as the falling of the steel plate and the destruction of the crane structure.
• Lack of digitization of operation, maintenance and management：The long-term lack of objective records of hoisting operation data on the production site makes it difficult to trace the source of accidents in the event of failures, fine-grained daily safety management, and preventive operation and maintenance of equipment.
• Production rhythm does not match specifications：Modern shipyards pursue fast-paced production, and the requirements for standardized and digitized lifting safety are increasing day by day. The traditional empirical judgment model has become a bottleneck restricting efficiency and safety.

In view of the pain points of these industries, micro-technology strives to create a high-precision intelligent weighing system for electromagnetic cranes. Through the organic combination of real-time monitoring, intelligent early warning, safety interlocking and data traceability, a one-stop digital safety protection system for shipyard lifting operations is built.

2. The wide range of applications of the system

This program is designed for in-depth customization of electromagnetic hoisting and hoisting conditions in shipyards, and is fully adapted to multiple types of high-frequency operating areas in the yard.：

• Steel plate pretreatment workshop：Mainly responsible for the daily lifting of marine steel plates with a length of 10 meters to 21 meters and a thickness of 6 mm to 40 mm, and the cutting and transportation operations of the cutting production line.
• Segmented assembly workshop：In the process of steel plate splicing and assembly of large hull components, it provides accurate hoisting alignment and positioning guarantee.
• Steel plate yard and logistics area：Responsible for the storage, inventory transfer, transshipment, and loading and hoisting of single or multiple steel plates.
• Suitable for a full range of equipment：It can perfectly match all kinds of bridge cranes (cranes) equipped with electromagnetic cranes or electric permanent magnet spreaders. The system can perform flexible and personalized parameter matching according to the specific tonnage of the equipment and the spacing of the lifting points.

3. Modular system architecture and core hardware

This solution adopts intelligent modular design, and there is no need to change the original structure of the existing crane or electromagnetic crane during the installation process. It has the advantages of simple installation, short construction cycle, and fast results. The complete system consists of two parts: a high-precision weighing sensor unit and an intelligent centralized control display terminal.

1. High-precision load cell unit (BH plate ring weight sensor）

• Full lifting point load collection：The sensors are deployed at the four key lifting points of the electromagnetic crane. The real-time load data of each lifting point is collected independently, which provides an accurate and reliable objective basis for the background partial load analysis and high-frequency calculation of the total weight.
• Excellent performance parameters：The weighing accuracy is ≤±0.5%, and the standard range of a single lifting point covers 0-10 tons (customizable), which fully meets the lifting needs of marine steel plates of different specifications.
• Adaptability to harsh environments：The full range of hardware has excellent protection performance, comprehensive waterproof and moisture-proof, anti-high salt spray, and anti-electromagnetic interference. It can adapt to complex and harsh working conditions such as high humidity, dust and oil pollution unique to shipyards for a long time. The stainless steel shell is equipped with a sturdy structure and impact resistance, which is suitable for heavy-duty continuous operation.
• Easy installation features：It is installed in the connection position of the spreader and the hook, and does not interfere with the original hoisting process, so as to achieve long-term stable and stable operation of a single installation.

2. Intelligent centralized control display terminal (WTZ(L)-A700 smart meter）

• High-frequency data operation and visual display：Summarize the high-frequency data collected by the four sensors, automatically calculate the total lifting weight and the load difference of different lifting points, and flatten and visualize the center of gravity offset state through the high-definition LCD screen. All information is clear at a glance.
• Multi-level safety control：Integrated sound and light alarm, overload limit interlock control functions. When a risk is detected, the active intervention mechanism is triggered at the second level.
• Digital data management：The local system automatically stores the full amount of job data, and adopts data desensitization technology to support the query and one-click export of historical records to meet the needs of special inspection safety verification, accident traceability, and management operation and maintenance.
• Flexible deployment：It can be installed in the crane operation room or a centralized monitoring point on the ground according to the needs of the site, which is convenient for operators in different roles to monitor in real time.

4. Core functions: build a digital security protection network

• High-frequency weighing and status monitoring of all hanging points：The system collects load data from four hanging points at high frequencies, and the data transmission is stable without delay. Restore the real load deviation in a medium proportion in the digital world, and accurately calculate the overall lifting weight, the load difference at each point, and the center of gravity of the steel plate. Completely replace the human eye judgment mode, and realize the digital dynamic monitoring of the whole process of hoisting.
• Hierarchical warning and safety interlocking of partial load and overload：The system supports preset partial load thresholds and overload thresholds according to specific operating conditions. When the center of gravity is significantly offset, the single-point load is too large, the total weight exceeds the standard and other abnormal conditions occur, the equipment immediately triggers a hierarchical sound and light alarm at the second level, which can be used to remind the operator. At the same time, it can be linked to the crane PLC control system to perform emergency restricted operations, forcibly block the right to continue movement in the dangerous direction, and fundamentally avoid the safety hazards of safety accidents such as falling steel plates and damaged equipment.
• Online precipitation and refined management of job data：The system completely records and keeps information records such as the weight of each lifting point, total lifting weight, partial load data, alarm fault records, etc. for each hoisting. The data adopts tamper-proof technology, which supports intelligent query of historical data and export of custom reports. It can be used for accident cause traceability, equipment fatigue assessment, safety inspection and operation process optimization.
• One-key parameter independent adjustment and easy operation：The overall modular structure eliminates the need to change the original crane and electromagnetic crane structure for installation, and the construction cycle is short and the effect is fast. The interactive interface of the instrument is simple and intuitive, and the flat design allows all data to be displayed like a mobile phone APP. The parameter settings support one-click curing and backup. In case of accidental damage to components, the system settings can be restored in seconds after replacement. Operators only need simple training to get started and use it without disturbing the normal production rhythm.

5. Core application advantages of the system

• The scene is highly adapted to solve rigid pain points：Targeted research and development is specifically aimed at the exclusive needs of shipyards for electromagnetic cranes to transport ultra-long steel plates. Compared with weighing by weighing, the system can more deeply accurately calculate the spatial safety geometry of the equipment's trajectory, identify the sensitivity of partial load, and predict the safety threshold value in advance.
• A full range of industrial-grade high-weather-resistant hardware：The full range of hardware is waterproof, moisture-proof, salt spray-resistant, and electromagnetic interference-resistant. Aviation-grade material, the fuselage is made of strong and durable materials, and the high protection level can easily cope with complex and harsh environments such as high-concentration sand and dust on construction sites, mining areas, and open-air construction sites.
• Security systematization construction, build the whole process of data traceability：It integrates online condition monitoring of load torque limiter, hierarchical early warning, hard interlock interlock control, and data black box and black box recording. The data is traceable through the USB interface lossless, lossless and lossless.
• One-stop service, one machine, one case customization and support：The manufacturer's pre-sales on-site one-machine plan.

6. Application value value

Electromagnetic crane, electromagnetic crane, electromagnetic crane, partial load, difficult to identify, overload, overload tube, difficult data, no data, no data, four major industries, major, high-risk operations, safe operations, equipment, and goods are guaranteed. At the same time, it has improved the intelligent management of production. It is the choice of digitization, digitization, and digitization.