Tower crane safety monitoring system: Intelligent system for tower cranes and hoists

1. Industry pain points

​

​The fatal hidden dangers of tower cranes in high-altitude operations​

• ​Risk of overloading and overturningTower collapse accidents caused by excessive torque account for 68% of major accidents (mandatory control item in GB 12602-2009).
• ​Blind spot collision out of controlDuring high-altitude hoisting, the field of vision is limited, and the rotation may collide with surrounding structures or high-voltage lines.
• ​Data silo problemParameters such as lifting capacity, amplitude and height are displayed independently, lacking real-time correlation protection.
• ​It is difficult to trace illegal operationsAfter the accident, the operation records cannot be restored and the responsibility definition is ambiguous.

Note: The tower crane accident 90% was caused by torque over-limit, blind zone collision and limit failure (GB 5144-2006).

2. Solution​

​WTSM-T Tower Crane Intelligent Safety Monitoring System (National Standard Full Certification)​

​Four-layer protection closed-loop design​：

1. ​Dynamic interlocking of core parameters​

   → ​Lifting capacity + amplitude + height + turning AngleReal-time calculation of actual torque: warning when exceeding 95% and cutting off power when exceeding 105% (in compliance with GB/T 5031-2008).

2. ​Three-dimensional anti-collision system​

   The laser rangefinder can scan obstacles within the range, with dual response of sound and light alarm and automatic braking (accuracy ±0.5m).

3. ​Dual-channel braking redundancy​

   The main control PLC+ independent safety relay enables emergency shutdown in case of any fault.

4. ​Full-process black box​

   Store over 180 days of operation data and support accident traceability (with a resolution of 0.1 seconds).

3. Core technology​

​Hard-core barriers under the framework of national standards​

• ​Multi-sensor fusion algorithm​
  • The lifting capacity sensor (accuracy ±1%) + amplitude encoder (±0.1°) + altimeter (±1cm) are integrated in real time to resist strong wind interference.
• ​AI anti-collision model​
  • Based on the GIS map, a no-entry zone is constructed. When the hook enters a dangerous area with a radius of 10 meters, it automatically decelerates.
• ​Dual power supply disaster recovery design​
  • Dual power supply of 220VAC for civilian use and 24VDC for electric control, maintaining 30-minute safety monitoring even in case of power failure.

4. Core advantages​

​Six values derived from national standard certification​

​① All items are covered by national standards​

Strictly comply with five types of mandatory standards such as GB 5144/GB 6067.1, and pass the inspection at one time.

​② Millisecond-level dual protection​

The dual-channel processing of the main control system and independent safety relay results in a braking response of less than 100ms.

​③ Intelligent early warning in advance​

11 types of risks such as overloading prediction, wind speed exceeding limit, and wire rope hopping are warned 3 seconds in advance.

​④ Industrial-grade compatibility​

Directly read PLC data (supporting Ethernet /PROFIBUS) and seamlessly integrate with electronic control systems of various brands.

​⑤ Judicial traceability​

It encrypts and stores over 50,000 operation records and supports third-party authentication and retrieval.

​⑥ Simplified operation and maintenance​

Remote fault diagnosis +OTA program upgrade, maintenance efficiency improved 70%.

​5. Configuration List (Full Analysis of Image Parameters)​

​Full-domain protection of the hardware system​

​(For selection, the following must be provided: load curve table, arm length, ratio, center distance, and wire rope diameter.​

• ​Perception layer​
  • ​Lifting capacity sensorStrain bridge type, range 1-100t ±11T - 3T
  • ​Amplitude encoder(Photoelectric type, resolution 0.01°)
  • ​Height limiter(Magnetic induction, ±1cm accuracy)
  • ​Rotation Angle sensor(Absolute encoder, 360° omnidirectional monitoring)
  • ​Anemometer(Mechanical fan cup type, 0-60m/s)
• ​Control layer​
  • ​Security monitoring host(Industrial-grade CPU, IP65 protection
  • ​Dual braking relay module(Redundant Control loop
• ​Interaction layer​
  • ​10-inch touch screen(Real-time display of torque percentage and three-dimensional coordinates)
  • ​1080P anti-shake camera(Hook tracking + blind spot monitoring
• ​Expansion module (optional​
  • ​Laser anti-collision system(Effective radius: 30m
  • ​4G remote transmission terminal(Uploaded to the cloud platform in real time

6. Practical Case (Shanghai Electric Power Project​

​SceneHoisting of 132-meter super high-rise substation (QTZ250 tower crane)

​Configuration plan​：

• Optional6 Limit scheme(Lifting/Rotation/Amplitude/Height/Weight/wind speed)
• "IncreaseLaser anti-collision module(Protection against nearby high-voltage lines

  ​"Effectiveness"​：

• Three overloading operations were successfully intercepted (with a maximum load rate of 103.5%).
• The collision warning system was activated 17 times, with no safety incidents
• The data automatically generates inspection reports and passes the regular inspection by TSG Q7015

Customization Tip: Please specify the power supply type (220VAC/24VDC), cable length, and special interface requirements. The Weite technical team will provide a dedicated solution within 48 hours.