News

Design and implementation of crane hook overload protection system

1. System Design Principles

1. Multi-level protection mechanism

• Level 1 warning: 85% rated load sound and light alarm

• Second level intervention: automatic speed reduction at 95% rated load

• Level 3 protection: 105% rated load emergency braking

2. Core parameter calculation

F_{limit} = \frac{σ_y \cdot A}{n} 

Where: σ_y = material yield strength (MPa), A = minimum cross-sectional area (mm²), n = safety factor (≥4)

2. Hardware System Architecture

III. Key Technology Innovation

1. Dynamic load compensation algorithm

def dynamic_compensation(F_raw):
    # Eliminate vibration noise
    F_filtered = kalman_filter(F_raw) 
    # Impact coefficient correction
    K = 1 + 0.5*(a/g) # a is acceleration
    return K * F_filtered

2. 3D stress field reconstruction

• Adopt 16-channel strain gauge layout scheme

• Finite element real-time inversion calculation

• Visualize hot spots

4. Safety certification requirements

1. Functional safety certification

• SIL2 level (ISO 13849)

• Fault coverage>90%

2. Environmental adaptability

• IP67 protection level

• Immunity to electromagnetic interference (EN 61000-6-2)

V. Implementation Case (50t hook at a port)

1. Deployment Effect

• False alarm rate <0.1%

• Overload accidents reduced to 0

• Reduce maintenance costs by 35%

2. Economic Analysis
   | Project | Cost (RMB 10,000) | Revenue (RMB 10,000/year) |
   |------|------------|---------------|
   | Hardware | 8.5 | Reduced accidents (12) |
   | Software | 3.2 | Reduced downtime (25) |
   | Installation | 1.8 | Maintenance savings (8) |

6. Future upgrade direction

1. Digital Twin Integration

• Real-time life prediction

• Virtual commissioning function

2. AI autonomous decision making

• Load optimization based on historical data

• Adaptive control strategy

Note: The system requires monthly simulated overload testing to ensure the reliability of each module. It is recommended to deeply integrate with the crane PLC system to achieve linkage control.

F_{limit} = \frac{σ_y \cdot A}{n} 

def dynamic_compensation(F_raw):
    # Eliminate vibration noise
    F_filtered = kalman_filter(F_raw) 
    # Impact coefficient correction
    K = 1 + 0.5*(a/g) # a is acceleration
    return K * F_filtered

F_{limit} = \frac{σ_y \cdot A}{n} 

def dynamic_compensation(F_raw):
    # Eliminate vibration noise
    F_filtered = kalman_filter(F_raw) 
    # Impact coefficient correction
    K = 1 + 0.5*(a/g) # a is acceleration
    return K * F_filtered