Safety monitoring and management system solution for bridge crane in metallurgical industry
Application of wt-sms safety monitoring management system in metallurgical crane
1、 Background and current situation
Metallurgical Bridge The crane is a kind of bridge crane, which has the widest range of use and the largest number
Hoisting machinery
。 With the development of industrial construction, bridge cranes are used more and more frequently, and overturning accidents occur from time to time. Derailment and overturning often lead to major accidents in which aircraft are destroyed and people are killed.
Especially in the metallurgical industry, such as the steel plant, if the crane overturns, the consequences are unimaginable.
In July 2010, the State Council issued a notice on the mandatory implementation of the monitoring and management system for the installation of large cranes.In July 2012, the General Administration of quality supervision, inspection and Quarantine of the people's Republic of China and the National Standardization Administration of China issued GB / T 28264-2012 safety monitoring and management system for cranes.Weite Technology Co., Ltd. participated in the revision and drafting of GB / T 28264-2017 safety monitoring and management system for lifting appliances implemented in May 2018.Circular No. 375 of the General Administration of quality supervision, inspection and Quarantine of the people's Republic of China on the relevant opinions on the rectification of metallurgical cranes points out that metallurgical cranes are manufactured as casting cranes for lifting molten metals, so they meet the requirements for installing safety monitoring systems for hoisting machinery。 Safety production is an insurmountable red line. It is necessary to increase the input of safety supervision equipment to prevent accidents in production
Weite Technology Co., Ltd. has the experience and type test qualification in designing, manufacturing and installing overload limiter, torque limiter and safety monitoring management system. It is a national high-tech enterprise integrating the provision of solutions, design, R & D, production and installation services.
The safety monitoring and management system for metallurgical cranes designed and produced by the company is a customized product that applies modern Internet of things information transmission technology, takes the user as the main body, and is equipped with cranes for metallurgical enterprises such as professional steel mills.
2、 Safety monitoring system of metallurgical suspension bridge crane
design requirement
The system is implemented according to the latest national standard safety monitoring and management system for lifting appliances (GB / T 28264-2017), and needs to meet the following basic functional requirements. Hereinafter referred to as "system"① The system shall meet all signals required to be monitored by metallurgical lifting machinery.② The system has the function of playing back and tracing back the operation status and fault information of the lifting machinery.③ The system has the function of fault self diagnosis, and the fault of the system does not affect the normal use of the crane equipment.④ The system shall be able to display the data and status of lifting machinery operation in real time in the form of numbers, words, diagrams, etc., and send out danger alarm to the operator in the form of sound, light and text prompt.⑤ The system alarm device shall be able to give a clear alarm to the personnel in the dangerous area.⑥ The communication protocol of the system shall be open to the outside world.1. Due to the particularity of working environment, working condition and structure, metallurgical crane shall also meet the following hard core requirements when designing safety monitoring products:
① The working environment temperature of casting crane is high. When it is close to the top of the furnace mouth, the processes such as molten iron mixing and feeding will lead to high-temperature flue gas of more than 100 ° C in the end beam area of the bridge crane, and even the burning flame will flash onto the end beam of the crane. Therefore, the safety monitoring system shall be designed to meet the environmental temperature of the site.② The dust in the foundry workshop is very large, including a large number of harmful corrosive gases and substances that affect the normal use of the monitoring system equipment, such as metal scrap, metal oxide scale and soot. Therefore, the dust prevention of the safety monitoring system shall meet the site requirements.③ Long working hours. Among the lifting equipment of all steel plants, the lifting equipment of casting process is in the middle of the production chain, which is especially busy (most plants are designed with three shift system, with no change of personnel and vehicles). The product quality of the safety monitoring system shall meet the stable work of long-term high load.
2. Metallurgical crane safety monitoring management system monitors specific parameters
The items to be monitored by the system can be found by referring to the three tables of GB / T 28264-2017 safety monitoring and management system for lifting appliances, which will not be described here.
3、 Safety monitoring system of wt-sms-yj metallurgical crane
Hard core applications
The metallurgical crane safety monitoring system designed and produced by Weite Technology Co., Ltd. not only meets the requirements of the national standard for the monitoring system, but also greatly improves the products according to the particularity of the metallurgical industry, which is mainly reflected in the following aspects.1. Hard core optimization of structural layout
A set of good products, especially the electronic equipment suitable for the metallurgical environment of the steel plant, must have a reasonable system structure to ensure the stable transmission of equipment signals.The system adopts distributed signal acquisition, and transmits data by communication after processing. There is no hidden danger of transmission attenuation of analog signals.The system is equipped with communication isolation equipment to make the impedance between lines of the system more matched.On the carrier of communication signal transmission, oxygen free copper double screen twisted pair special communication flexible streamer is used, which is resistant to temperature and folding and can isolate external signal interference.
2. Upgrading of hard core for host and acquisition equipment
Display:The system host adopts imported true color 65536 color TFT-LCD display screen, which can display parameters and status in numbers, Chinese characters and graphics. It can also reflect the monitoring status through color changes, and the picture is true.
Operation:Touch operation is adopted to prevent dust from entering the key gap or the key film from being broken after long-term use. Optimized keyboard input mode, fast and convenient operation, prompt sound operation confirmation, backlight adjustment.
Storage:Super large storage capacity for more than 6 months.
Interface:It has multi-channel rs232rs485 serial port and network port, and 2-channel USB interface. It can download data and upload upgrade programs through the U port.
Software:Professional software customized for metallurgical bridge crane equipment, which can quickly and automatically correct data and query fault alarm records with one key.
3. Hard core protection upgrade of signal acquisition equipment
The signal acquisition equipment is installed in a sealed dust-proof protective box. The dust-proof box is designed with a dust-proof sealing strip, and the inlet hole is equipped with a sealing ring and a stuffing box to isolate the metal dust, metal oxide film and smoke on the site and ensure that the signal acquisition equipment is not affected by the environment.The signal acquisition main board circuit adopts military grade electronic components to ensure stable operation in long-time, high-temperature and extreme environment. Before leaving the factory, the circuit board shall be sprayed with three times of three anti-corrosion paint, put into the high and low temperature box for aging, and tested on the shaking table.
4. Hard core multi-element upgrade of signal acquisition means
Most of the metallurgical crane equipment are equipped with load monitoring instruments, and some are equipped with external display screens, and the instruments have no load data signal output interface. Most enterprises are unwilling to replace the instruments when they operate well. The safety monitoring system needs to collect load data for storage. Our company uses special equipment to separate signals from the original overload equipment and retain the original system, without affecting the normal use of the original system.
5. Hard core upgrade of travel data accuracy
Type selection promotion:It is necessary to install a distance sensor to monitor the height of the hook and the position of the trolley. The accuracy of the traditional potentiometer is not high, and the laser is not suitable for temperature and dust. Our company adopts imported absolute value encoder with power-off memory function. Even if the system is powered off and the crane is shifted, the accuracy of data will not be affected.Software and hardware improvement:In actual use, mechanical structure clearance, start-up buffer and other factors will lead to accumulated error of travel data during long-time operation. Our company solved the problem by adopting the automatic correction method, that is, when the software detects the added correction point position signal, it automatically synchronizes the display value.Safety protection lifting:The installed encoders are equipped with dust covers to reduce the corrosion of dust and metal chips on the sensors. The connection mode between the sensor and the transition wheel is upgraded, and the split pin and screw are used for double protection to prevent the roller from falling off.
After the safety monitoring system of our company was installed in a steel plant in Jiangsu Province, the market supervisor visited the customer and feedback that there was no frequent alarm due to travel error.
6. Hard core improvement of product applicability
At present, most of the lifting equipment in the metallurgical industry has been used for a long time. The electrical control configuration of the equipment is different. Some models do not have PLC controllers, and some have.In view of this market phenomenon, Weite company has developed two kinds of signal acquisition equipment, which fully meet the current online operation of metallurgical cranes.1) Develop a dedicated IO signal detection module.
Most of the equipment of WISCO group are cranes produced in the Soviet Union decades ago. Most of the electrical controls are not PLC controllers. The IO module of our company is used to reduce the potential trouble caused by too many lines.2) Integrate modules that can read multiple PLC protocols
The monitoring system host reads the status of each IO point of the PLC through the module, such as Siemens s7-200s7-300s7-400 PLC and ab PLC, which have been successfully used.
7. Video monitoring hard core configuration
The minimum requirements of the national standard for video system stipulate that the lifting point area of the bridge crane shall be recorded for no less than 72 hours, and the historical data can be retrieved and queried at any time.Configuration upgrade:In combination with the special working conditions and crane structure of metallurgical crane, the video viewpoint scheme provided by our company not only meets the basic requirements of the national standard for the lifting point area, but also can clearly track and photograph the whole working process of the hook, unhooking and ladle displacement of gantry hook and small hook. The camera adopts high-temperature and high-temperature dust-proof products.Cable upgrade:High temperature resistant, fire-resistant and flame-retardant Teflon sheathed cables are used for cables in high-temperature areas, and the temperature resistance is greater than 180 degrees.Storage capacity upgrade:The storage device is equipped with 2T high-capacity professional monitoring hard disk, and is equipped with 8-channel controller to make redundancy for the later configuration upgrade of the device.Display:HD resolution 1920x1080p, with HDMI, VGA synchronous video interface, standard adaptive, standby low power consumption.
The above picture is the picture of a steel plant in Shaanxi after installing our video monitoring system. The operator feedback that the picture is clear. Through the video picture, you can hook it alone and clearly know whether it is hung in the ladle lifting lug.
8. Signal transmission hard core protection
Cable protection upgrade:The metallurgical crane is used in a special environment. It is also necessary to pay attention to the use of signal lines for the signal transmission of each sensor. High temperature resistance is the most basic requirement. The high-temperature cable configured in this system is specially made of Teflon with external belt, which can withstand 200 ℃ high temperature and is fire-resistant and flame retardant.Cable specification upgrade:In order to ensure the stability of the signal, all signal cables are equipped with a full oxygen free copper 96 mesh shielding layer, the core diameter strictly meets the national standard, and the material is oxygen free copper.Cable construction upgrade:Steel pipes and metal hoses are used as protective layers for the cable layout, and the equipment shell is designed with discharge grounding to eliminate electrostatic interference.
4、 Some engineering cases
1. Xingcheng Special Steel
Jiangyin Xingcheng Special Steel Co., Ltd. is a CITIC Taifu special steel group subordinate to CITIC Co., Ltd Of the company. It has an annual production capacity of more than 13 million special steel, and has the world's advanced technology and equipment.
The metallurgical crane of Xingcheng Special Steel is wtsm-a metallurgical crane manufactured by Weite Technology Co., Ltd The machine safety monitoring and management system, after installation and operation, has greatly improved the efficiency of safe production of each branch plant and provided a strong guarantee for the safe production of equipment.
Wuhan Iron and Steel Group Co., Ltd. is the first super large iron and steel complex built after the founding of new China It began construction in 1955. After the joint reorganization, it became a large-scale enterprise group with a production scale of nearly 40 million tons, ranking the fourth in the world steel industry. The safety monitoring and management system of metallurgical crane of WISCO has passed the acceptance of the local geological supervision department and has been praised by the owner.
Founded in 1954, Baotou Iron and Steel Group Co., Ltd. is one of 156 key projects built by the state during the first five year Plan Period First, it is the first large-scale iron and steel enterprise built by new China in ethnic minority areas. It has the largest iron ore in Northwest China, the first rare earth reserves and the second niobium reserves in the world.
The metallurgical crane safety monitoring and management system of Baotou Iron and steel works has passed the acceptance of the local geological supervision department and has been approved by the owner Favorable comments.
5、 Redundancy upgrade of the system
Weite Technology Co., Ltd. has accumulated nearly 20 years of experience in the design, production and installation of overload limiter, torque limiter and safety monitoring management system, and has type test certificates for various products. It is a national high-tech enterprise integrating the provision of solutions, design, R & D, production and installation services.Weite Technology Co., Ltd. has long been committed to the design, manufacturing and service of safety protection products in the metallurgical industry. It can upgrade the installed safety monitoring and management system products to achieve remote centralized monitoring, and can also undertake the transformation of plant level equipment intelligent management system.Weite Technology Co., Ltd. takes advantage of its own technical advantages and rapid customized reaction ability, and has long been devoted to the development of lifting equipment safety products in the metallurgical industry. The products that have been put into operation include:1. Overload protection device of metallurgical crane
2. Space anti-collision system of metallurgical crane
3. Remote monitoring system of metallurgical crane
4. Intelligent management system of hoisting equipment in steel plant
5. Equipment spot check management system
6. On line monitoring system for key components of metallurgical crane equipment
7. Life evaluation system of metallurgical crane
The national standard GB / t36697-2018 casting crane scrapping conditions has been published in September 2018 On April 17, the State Administration of market supervision and administration and the National Standardization Administration of China officially approved the release and officially implemented it on April 1, 2019. In the future, the scrapping conditions and life evaluation of various cranes will be the general trend. The crane stress monitoring system is to provide important data support for the crane life monitoring and evaluation, and is the necessary technical monitoring means for large cranes in the future. The safety monitoring system for metallurgical cranes described above, coupled with the stress monitoring system specially designed for metallurgical cranes, and combined with big data technology and cloud platform technology, can provide remote stress data monitoring and analysis for the structural life of metallurgical cranes, providing a forward-looking research and solution for the industry.
