WTSLSG-ROMS-HM Arc Gate Online Monitoring System

WTSLSG-ROMS-HM Arc Gate Online Monitoring SystemIt is the latest product developed by our company. It is mainly used in arc gates and hoists and belongs to hydraulic metal structure equipment. It is like installing a 24-hour online "health manager + early warning radar" for those huge "water gates" of hydropower stations.

Let's do a brief science popularization first: The water in a hydropower station rushes forward. There must be something to control the water volume, right? That arc-shaped iron gate, which can open and close like a large fan blade and block the water flow, isCurved gate. The strongman responsible for driving it on and off isHoist. They all belong to "hydraulic metal structures", which are constantly submerged in water, subjected to huge forces, exposed to wind and sun, and operate underwater, so they often break down.

The traditional method of managing these gates is actually quite simple, which is manual inspection. Therefore, there are many problems:

1. So inefficient that I'm crying The workers carried the instruments, climbing up and down, relying entirely on their experience to "observe, listen, ask and feel". When the gate is dozens of meters high or submerged in water, not only is it time-consuming and laborious to check it once, but it is also common to miss or misjudge it. The most outrageous misjudgment I've ever heard of was misting normal vibration for a major malfunction, which almost caused the power station to shut down, turning out to be a false alarm.

2. High security risk Just thinking about high-altitude work and underwater inspection makes my legs weak. This is no joke. I know an old master who had an accident while checking the hinges of a gate underwater back then. Fortunately, he was saved, but he never dared to go underwater again.

3. Hindsight: Zhuge Liang Manual inspection cannot be monitored 24 hours a day. Those fatal sudden problems, such as severe vibration caused by water flow (flow-induced vibration) or the "joint" that supports the rotation of the gate getting stuck (hinge jamming), often turn minor issues into major accidents by the time they are discovered. In mild cases, the machine stops for maintenance; in severe cases, the gate deforms or even collapses, resulting in huge losses.

4. "Short lifespan" of the equipment Without real-time data, maintenance relies entirely on "regular" or "deal with it when it breaks down". Many gates and hoists, which could still be used for a few more years, have retired prematurely due to internal fatigue and wear that were not detected in time. What's wasted is all the money!

So, we have developed this "WTSLSG-ROMS-HM Arc Gate Online Monitoring System" (the name is a bit long, just understand the engineers' meticulousness), precisely to address these pain points! Its core idea can be summed up in one sentenceUse sensors as eyes and ears, data as doctors, and let the gate "speak" by itself!

How does this system work? Simple, straightforward yet intelligent

1. Covered all over with "sensors" It's like giving a person a comprehensive physical examination.

   • Musculoskeletal (stress) : StickSurface strain gaugeMonitor whether the force on the steel structure is tensile or compressive, and neither static force (continuous compression) nor dynamic force (sudden impact) is overlooked. This is a combinationFinite element modelYou can understand it as making a super precise virtual anatomical diagram of the gate for analysis. It's very accurate.

   • Is there "trembling" (vibration) : installationThree-axis acceleration sensorEven the slightest tremors caused by water flow impact and mechanical loosening cannot escape its "sharp eyes". (By the way: This thing is so precise that it can detect even the slightest displacement changes of a human hair, and it's even more sensitive than the scale in my kitchen）。

   • Is the posture crooked (running posture) : upDual-axis tilt sensorIt will tell you in real time whether the opening and closing Angle of the gate is off and if you are "standing crooked".

   • "Joint" abnormal noise (abnormal hinge bearing) : UseAcoustic emission sensorJust like a stethoscope, it captures the "moaning" sound waves emitted by the tiny cracks, wear and jamming inside the bearing, enabling early detection and treatment.

2. The data "runs" : The massive amounts of data collected by these sensors, throughMulti-channel data acquisition box(Waterproof and dustproof, IP65 grade, not afraid of wind and rain) summarizedOn-site workstationIt can be understood as a local small computer beside the gate, and then transmitted to the cloud.

3. AI "brain" activated: This is the essence! The cloud has a powerful analysis system, not simply looking at the size of the numbers.

   • It will doSpectrum analysis(See which frequency is mainly causing trouble in the vibration)Trend predictionIs this vibration value gradually increasing? Danger!" .

   • Based onNB/T 10859-2021Industry standards should set scientific thresholds (for instance, an alarm should be triggered when the vibration displacement exceeds 0.5mm. This is not a decision made on a whim).

   • The most amazing thing is that it canIntegrate physical models and AI algorithmsWhile referring to the precise "virtual anatomy diagram" (finite element model) of the gate, use it simultaneouslyLSTM neural networkPredict how long the bearing can still be used (it is said that the error can be controlled within 31T to 3T!) "3D Convolutional networkIdentify the characteristics of microcracks in acoustic emission. When the results from both sides are combined, the diagnosis becomes more reliable (with a confidence level of ≥0.85, which is exactly what engineers pursue).

   • The threshold will still beDynamic adjustment! It is not a rigid number. It will automatically optimize the alarm line based on water level, gate opening degree, and even historical operation data, significantly reducing false alarms (the target is <2%).

What exactly can be brought by installing this thing? I summarize four points

1. Equipment "Life-prolonging" Master: From "real-time monitoring" to "predictive maintenance", say goodbye to "repair only when broken". Detect fatigue and wear in advance to extend the lifespan of the equipmentIt was forcibly extended by 20% or more! It's equivalent to giving an old car a new engine and it can still run for another 100,000 kilometers.

2. Warning "Divine Operator" Early warning based on standards and intelligent analysis is accurate! As mentioned earlier, when the vibration exceeds 0.5mm, the false alarm rate is extremely low (<2%).Real case After installation at a certain power station, the system captured abnormal acoustic emission signals from the hinge bearing and issued a warning of "early jamming risk". Upon disassembly and inspection, it was found that there was indeed slight wear and insufficient lubrication. Timely handling prevented an unplanned shutdown and possible structural damage. If this were to be inspected manually, it would probably require major repairs during the next check.

3. Money-saving and labor-saving expert The number of manual inspectionsSharply reduced 80%! Workers no longer have to take the risk of frequently climbing up and down and diving for work. Overall operation and maintenance costsReduce 30%What's not good to do with the saved manpower and material resources?

4. "Tough and durable 'tough guy' Those sensors, every one of themIP68 protection gradeA tough character. It means: Soaking in water? No problem! Damp and cold? Little trouble! Low temperature and severe cold? Just keep working as usual! Designed specifically for the harsh environment of hydropower.

Let me share some practical thoughts:

In the past, I always thought that for major infrastructure projects like hydropower, technological updates were slow. But the emergence of such online monitoring systems has shown me that traditional industries are also embracing intelligence. It solves not only technical problems, but alsoSafety issues and efficiency issues. One less accident, one less shutdown, one less worker injury, and several more years of equipment lifespan - this value is far beyond what cold parameters can fully reflect.

Of course, no matter how good the technology is, it still depends on its practical application. Our system, from sensor selection, data fusion algorithms to dynamic threshold management, strives to closely align with actual working conditions and comply with national standards (NB/T 10859 is the bottom line, not the upper limit!) . The goal is to make the operation of power stations safer, more worry-free and more cost-effective.

So, all the brothers engaged in water and electricity operation and maintenance, if you are still worried about gate inspections, troubled by sudden equipment breakdowns, and concerned about high maintenance costs, it's really time to get to know this kind of online monitoring system well. It may not be omnipotent, but it is definitely a powerful tool for ensuring safety, enhancing efficiency and reducing costs.