Amplitude torque solution: The "Invisible Guardian" of Engineering Safety

The boom slowly extended, and the heavy object was suspended in mid-air. At this moment, the "pressure" that the crane bears not only comes from the load itself, but is also closely related to the length of the boom's extension - this is itAmplitude torqueA core parameter that determines the safety of lifting operations. How to tame this "invisible killer" that varies with amplitude? Professional amplitude torque solutions are the key!

Luffing moment: A "dynamic risk source" for Hoisting operations

• The magic of the lever arm: Imagine carrying a bucket of water in your hand. When the arm is fully extended (with a long lever arm), it feels more strenuous. When the arm is bent (the lever arm is short), it feels more relaxed. The same goes for cranes! When lifting heavy objects, the farther the boom extends (the greater the amplitude), the greater the overturning moment (risk) it generatesGeometric series growth! The same crane may not be able to lift even half the weight it can easily lift at a short distance at a long distance.

• "Invisible" overload trap Monitoring weight alone is far from enough! Amplitude change is the largest variable. If the operator relies solely on experience or only pays attention to the gauge, it is very likely that when the boom extendsAccidentally stepping into the danger zone of overloading. If the amplitude increases just a little bit, the safety margin may disappear instantly.

• Dynamic challenges intensify During the luffing action (retracting or extending the arm), the load and amplitude change in real time, making the calculation of torque more complex. Sudden wind loads and the shaking of the equipment itself have greatly increased the difficulty of risk control.

Solution: Intelligent amplitude torque limiting scheme

True security requires a set of capabilitiesReal-time perception, precise calculation, and intelligent decision-makingA systematic solution

1. High-precision "eyes" : Real-time capture of amplitude and weight

   • Amplitude measurement The core is to precisely know how far the boom "extends". Mainstream technologies

     • High-precision Angle sensor Install at the root or hinge point of the boom, directly measure the boom's elevation Angle, and calculate the amplitude in combination with the inherent length model of the boom. High precision and good reliability (such as the anti-interference Angle sensor adopted by Weite).

     • Pull wire type/laser distance sensor Directly measure the horizontal distance from the head of the hook or boom to the rotation center. It has strong applicability, but attention should be paid to protection and environmental interference.

   • Weight perception The actual load under the hook is obtained in real time through high-stability pressure sensors (oil pressure systems) or direct load cells. The accuracy and stability of sensors are the cornerstones.

2. Intelligent "Brain" : Dynamic Torque Calculation and Decision-making

   • Core algorithm The core of the system lies in the real-time acquisitionWeight (W withAmplitude (R The data is calculated at high speed and continuously based on the physical principle (torque = weight × lever arm) to obtain the current actual valueAmplitude torque value。

   • Dynamic compensation Advanced systems (such as the Weite WT series) will be integratedDynamic compensation algorithm. Taking into account real-time factors such as boom deflection deformation, equipment tilt Angle, and wind load influence, the calculation results are corrected to significantly improveCalculation accuracy under complex working conditionsReduce false alarms and missed alarms.

   • Safety threshold comparison The system has pre-set the device at different amplitudesSafety Workload Curve (SWL Curve That is, the safety torque threshold. Compare the real-time calculated torque with the threshold at the corresponding amplitude at the millisecond level.

3. Decisive "executors" : Graded early warning and hard protection

   • Early warning first When the real-time torque approaches the safety threshold (such as reaching 90%-95%), the system is triggered immediatelySound and light early warning. The alarm sounds in the operation room, and the display screen highlights the current status (amplitude, weight, torque percentage) and risk direction (such as "Do not extend the arm"), providing the operator with sufficient reaction time to make adjustments.

   • Hard protection is resolute: If the torque reaches or exceeds the safety limit of 100%, or if the operator fails to respond to the warning in a timely manner, the systemAutomatically trigger hard protection. Immediately cut off the control signals in the dangerous direction (usually by continuing to extend the arm or increasing the load), force the equipment to stop the dangerous actions, and lock the risk in its infancy. This is the last line of defense for ensuring safety.

4. Loyal "Recorder" : Data Traceability and Optimization

   • Black box function: The system records key operation data throughout the process: time, amplitude, weight, calculated torque, early warning/alarm events, operation instructions, etc.

   • Value manifestation Provide solid evidence during the accident analysis; Daily management can optimize operational habits. Potential hidden dangers in equipment maintenance can be traced. Provide a complete basis for security audits.

Technical highlights: The core strength of the micro and special amplitude torque solution

Facing the challenge of amplitude torque, Weite Solution stands out with its profound technical accumulation:

• Dual-core redundancy, double security

  • The high-end WT series adoptsDual cpus independently and in parallel processingArchitecture.

  • The two systems simultaneously sample sensor data, calculate torque and determine safety status.

  • Real-time cross-checkingAs a result, ensure that the calculation is absolutely reliable.

  • If any CPU malfunctions, another CPU will take over seamlessly in an instantSafety protection is never interrupted。

• Intelligent algorithm, precise adaptation

  • Advanced dynamic compensation modelSignificantly enhance the accuracy of torque calculation under complex working conditions such as amplitude variation processes, wind load disturbances, and structural deformations.

  • Effectively distinguish between real danger and temporary fluctuations (such as slight tremors of the boom)Significantly reduce the rate of misoperationImprove the fluency of homework.

• Core sensing, stable and reliable

  • Industrial-grade high-precision Angle/distance measurement sensorDesigned specifically for the harsh environments of construction machinery (wide temperature range, high humidity, strong vibration, and electromagnetic interference).

  • Special protective treatment(Such as IP67 high-protection grade enclosure, anti-salt spray coating), ensuring long-term stable operation in harsh environments such as ports, at sea, and in mines.

• Module design, convenient and worry-free

  • Sensors, hosts, display unitsModular designInterface standardization.

  • It is easy to install and debug, and the cost and efficiency of later maintenance, upgrade or replacement of components are low.

Core application scenario: Where is it most necessary to "keep a close eye on" the amplitude torque?

• Telescopic boom crane (truck crane, all-terrain crane) Frequent amplitude variation is its core operational feature. The amplitude range is large and the torque changes dramatically. It is the amplitude torque protection schemePrimary application fields. The Weite solution is widely applied in mobile cranes of major brands both at home and abroad.

• Tower crane (tower hoist The working range is large, especially when operating in the arm tip area, torque control is of vital importance. The plan ensures the safety of high-rise building construction.

• Large crawler crane It undertakes the hoisting of overweight and oversized items and often operates at the limit range. Precise control of amplitude torque is the cornerstone for the safe completion of wind power hoisting and petrochemical construction.

• Port Marine cranes (such as ship cranes, crane cranes) : The intensification of ship sway and the dynamic changes in load. The solution needs to have a stronger anti-sway algorithm and corrosion resistance.

• Special working condition crane Such as wind power maintenance cranes and railway rescue cranes, the working space is limited, and the luffing operation needs to be extremely precise and safe.

Value summary: Dual guarantee of safety and efficiency

Investing in professional amplitude torque solutions is not a cost, but ratherHigh-return security guarantee and efficiency foundation：

• Prevent overturning accidents Fundamentally prevent the risk of overturning due to amplitude changes and protect the lives of personnel and the safety of huge assets.

• Maximize equipment capacity Within the safety threshold, the intelligent system enables operators to make more full use of the lifting capacity of the equipment at different amplitudes.Improve work efficiency。

• Reduce equipment damage Avoid long-term overload of the structure, extend the service life of the equipment and reduce maintenance costs.

• Optimize operation management Data recording promotes the standardization of operations and provides quantitative basis for safety management.

• Enhance industry competitiveness Comply with increasingly strict safety regulations and enhance the enterprise's safety image and market reputation.

Since installing this (Micro Variable amplitude torque) system on our main vehicles, the operators have felt more at ease and dare to work more efficiently within a safe range. The management can also see the data reports more clearly, and the safety investment is tangible and visible." -- Remarks by the equipment manager of a large hoisting company

Choose the Weite variable amplitude torque solution to equip your lifting equipment with a smart "safety rein". Precisely control every degree of change to ensure that every amplitude adjustment operation is as stable as a rock, achieving both safety and efficiency!