Intelligent centralized lubricating system for portal crane

Abstract

The invention discloses an intelligent centralized lubricating system for a portal crane. The intelligent centralized lubricating system aims to overcome the defects that a traditional dry oil double-line system is low in lubricating precision, free of fault monitoring, poor in protection grade and high in comprehensive cost. The system comprises an intelligent fuel distribution tank module, a hierarchical control module and a fuel distribution tank control module, the main unit can take over and operate according to guaranteed parameters during partition failure), a double-sensor backup module (monitoring the lubrication state through cross validation), a dynamic threshold value alarm module (dynamically adjusting a threshold value based on a portal crane load and carrying out delayed confirmation), a temperature and humidity self-adaption module (adapting to a harbor severe environment), a visual operation and maintenance platform and a mobile terminal APP. Lubricating parameters can be accurately controlled, faults can be early warned in real time, the operation stability of equipment is improved, the annual cost of a single gantry crane is saved by more than 380,000 yuan, and the system is adaptive to port multi-working-condition large loading and unloading equipment and has the whole-port-area popularization value.

Description

Technical Field

[0001] This invention relates to the field of port gantry crane technology, specifically to an intelligent centralized lubrication system for gantry cranes. Background Technology

[0002] During the operation of port gantry cranes, the lubrication system is a core subsystem that ensures the normal operation of key components such as the hoisting mechanism, slewing mechanism, and luffing mechanism. Its performance is directly related to the reliability of the gantry crane's operation, maintenance costs, and service life.

[0003] Currently, the lubrication system used in port gantry cranes is a traditional dry oil dual-line system, which has the following technical defects in practical applications: Low lubrication control precision and poor adaptability: Traditional dry oil dual-line systems achieve unified oil supply for the entire machine through a single main pump station. They cannot differentiate the oil output and oil injection cycle according to the actual working conditions of different mechanisms and lubrication points of the gantry crane (such as high-load lifting mechanisms requiring high-frequency and precise lubrication, and low-load auxiliary mechanisms requiring low-frequency lubrication). This easily leads to problems such as "over-lubrication" (causing waste of lubricating grease and environmental pollution) or "under-lubrication" (accelerating component wear and increasing the risk of failure) at some lubrication points, resulting in unstable lubrication effect.

[0004] The system lacks monitoring and alarm functions, resulting in low fault handling efficiency: It is not equipped with lubrication point status monitoring components, making it unable to detect faults such as oil circuit blockage and grease leakage in real time, relying solely on regular manual inspections. Due to the wide distribution of lubrication points on the gantry crane, manual inspections are not only time-consuming and labor-intensive (averaging over 2 hours per day), but also fail to detect early, hidden faults (such as minor oil circuit blockages or trace grease leaks), often leading to the escalation of faults, causing gantry crane shutdowns, and impacting port loading and unloading efficiency.

[0005] Low protection level and easy aging of components: The core components of the traditional dry oil dual-line system (such as oil pipelines, seals and control components) have a protection level of only IP44. In the harsh environment of ports with dust, humidity and salt corrosion, they are prone to aging and leakage problems. At the same time, the system components are scattered and disorderly, without a unified integrated design, which not only increases the difficulty of equipment maintenance, but also causes pollution to the on-site working environment due to grease leakage, which is not conducive to on-site environmental management.

[0006] High overall operating costs: Due to unstable lubrication, the wear rate of key components of the gantry crane is accelerated, resulting in high annual maintenance costs; manual inspection and troubleshooting require a large amount of manpower, keeping labor costs high; in addition, the waste of lubricating grease caused by "extensive oil supply" makes the total annual lubrication-related loss cost of a single gantry crane significant, seriously affecting the economic efficiency of port operations.

[0007] Therefore, we propose an intelligent centralized lubrication system for gantry cranes. Summary of the Invention

[0008] The purpose of this invention is to provide an intelligent centralized lubrication system for gantry cranes to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a gantry crane intelligent centralized lubrication system, comprising an intelligent oil distribution tank module, a graded control module, a dual-sensor backup module, a dynamic threshold alarm module, and a temperature and humidity adaptive adjustment module; The intelligent oil distribution tank module is used to independently set the oil output of each oil outlet and to set differentiated oil injection cycles for the lubrication points of different mechanisms of the gantry crane. The hierarchical control module includes a main control unit and at least four partition control units. Each partition control unit corresponds to four to five lubrication points. The main control unit is used for global parameter management and data aggregation. The partition control units are used to execute the oil output and oil injection cycle control of the corresponding lubrication point. When any partition control unit fails, the main control unit can take over the basic lubrication task of the partition lubrication point and operate according to the preset minimum parameters. The dual-sensor backup module installs two pressure sensors and two flow sensors of the same model at key lubrication points such as the bearings and rotating gearbox of the gantry crane lifting mechanism. The lubrication status is judged by cross-validation logic. When the data of a single sensor is abnormal and the deviation exceeds 5%, it automatically switches to the backup sensor. If the data of the two sensors deviates significantly, a sensor calibration alarm is triggered. The dynamic threshold alarm module constructs a "equipment load-lubrication status" correlation model based on the real-time operation data of the gantry crane, dynamically adjusts the alarm threshold, and sets a 30-second delay confirmation mechanism for leakage alarms. The temperature and humidity adaptive adjustment module includes a miniature temperature and humidity sensor and a heating and dehumidification component. When the humidity in the intelligent oil separator exceeds 60% or the temperature is below -5℃, the dehumidification or heating function is automatically activated. It also includes a visual operation and maintenance management platform, which includes an equipment health dashboard, a cost accounting dashboard, and an alarm processing ledger module; The equipment health dashboard links lubrication data with equipment fault records to generate a health score for each lubrication point. The health score uses the lubrication compliance rate as the core indicator, with a full score of 95% or above. For every 5% decrease, 10 points are deducted. The cost accounting dashboard provides real-time statistics on the lubricating oil consumption, manual maintenance hours, and repair costs of a single gantry crane. It automatically compares the cost differences before and after the system upgrade and generates an annual return on investment calculation report. The alarm handling log module automatically records the alarm type, handling time, responsible person, and resolution result, forming a historical database. Preferably, the housing of the intelligent oil distribution tank module and the graded control module is made of 304 stainless steel and has an anti-corrosion coating, with a protection level of IP67; the wiring terminals of the intelligent oil distribution tank module are waterproof and sealed joints, and the oil pipeline is made of oil-resistant and weather-resistant polyurethane material.

[0010] Preferably, the dynamic threshold alarm module further includes a historical data learning unit, which is used to collect lubrication point wear records and grease viscosity change data in different seasons for the past 6 months of the gantry crane, and automatically optimize the oil output and oiling cycle based on the data; and the dynamic threshold alarm module supports manual triggering of "parameter learning mode", which can adjust lubrication parameters according to the input gantry crane load changes.

[0011] Preferably, the visual operation and maintenance management platform is also equipped with a mobile operation and maintenance APP. The mobile operation and maintenance APP has the functions of real-time alarm information push, automatic dispatch of maintenance tasks, and online filling of maintenance records, which can control the alarm response time within 30 minutes.

[0012] Preferably, the main control unit and the partition control unit of the hierarchical control module are connected via industrial Ethernet communication, with a communication rate of not less than 100Mbps and data encryption transmission function.

[0013] Preferably, the sensors of the dual-sensor backup module also have a periodic self-calibration function. The self-calibration cycle can be set by the main control unit of the hierarchical control module, and a calibration prompt is triggered when the calibration deviation exceeds 3%.

[0014] Preferably, the equipment health dashboard of the visual operation and maintenance management platform also supports custom health score weights. According to the differences in importance of different mechanisms of the gantry crane (such as hoisting mechanism, slewing mechanism, luffing mechanism), the operation and maintenance personnel can manually adjust the score weight ratio of the corresponding lubrication points of each mechanism, and the adjustment records are automatically saved to the historical database for easy traceability and auditing.

[0015] Preferably, the mobile maintenance APP also has a lubricating grease inventory management function, which can synchronize the inventory of different types of lubricating grease in the warehouse in real time. When the inventory of a certain type of grease is lower than a preset threshold (which can be set independently according to 1.5 times the monthly consumption of a single gantry crane), it will automatically push a replenishment reminder to the warehouse manager and display the consumption trend chart of that type of grease over the past 3 months to assist the manager in formulating a procurement plan.

[0016] Preferably, the industrial Ethernet communication link of the hierarchical control module also has an automatic link failure switching function. When the main communication link (based on industrial Ethernet) is disconnected, the packet loss rate exceeds 5%, or the delay exceeds 100ms, the system automatically switches to the backup 4G / 5G wireless communication link to ensure the communication continuity between the main control unit and the partition control unit. The lubrication task being executed is not interrupted during the link switching process, and the switching record is uploaded to the alarm processing ledger module of the visual operation and maintenance management platform in real time.

[0017] A control method for a gantry crane intelligent centralized lubrication system, characterized by comprising the following steps: S1: Set the oil output of each oil outlet and the oil injection cycle of different lubrication points through the intelligent oil distribution tank module, and at the same time start the dual sensor backup module to monitor the lubrication status. S2: The partition control unit of the hierarchical control module executes the lubrication control of the corresponding lubrication point, and the main control unit collects data from the partition control unit in real time and performs global management. S3: The dynamic threshold alarm module adjusts the alarm threshold based on the real-time operation data of the gantry crane. When a lubrication abnormality is detected, if it is a leakage abnormality, a 30-second delay is initiated for confirmation, and an alarm is triggered after confirmation; if it is a blockage abnormality, an alarm is triggered directly. S4: The temperature and humidity adaptive adjustment module monitors the temperature and humidity inside the intelligent oil tank in real time. When the humidity is greater than 60% or the temperature is less than -5℃, the corresponding dehumidification or heating operation is activated. S5: If any partition control unit fails, the main control unit will immediately take over the lubrication point of that partition, perform the lubrication task according to the preset minimum parameters, and trigger the fault partition location alarm.

[0018] Preferably, in step S3, the real-time operating data of the gantry crane includes the lifting capacity, running time and rotation speed of the gantry crane; when the gantry crane is running at full load, the dynamic threshold alarm module widens the normal range of lubrication point pressure by 10%-15%; when the gantry crane is running at no load, it tightens the normal range of lubrication point pressure by 8%-12%.

[0019] Preferably, step S6 is also included: generating equipment health scores, cost accounting reports and alarm handling ledgers through the visual operation and maintenance management platform, and pushing alarm information and dispatch tasks through the mobile operation and maintenance APP. After the maintenance personnel complete the maintenance, they upload the maintenance records through the APP.

[0020] Preferred, Intelligent oil distribution tank module: It has 8 independent oil outlets, and the oil output of each outlet can be set independently. Differentiated oil injection cycles are customized for the lubrication points of the gantry crane's lifting, rotating, and luffing mechanisms. Hierarchical control module: includes 1 main control unit and at least 4 partition control units (each unit corresponds to 4-5 lubrication points). The main unit is responsible for global parameter management and data aggregation, while the partition units perform local lubrication control. When a partition unit fails, the main unit automatically takes over and operates according to preset minimum parameters to avoid lubrication interruption. Dual sensor backup module: Two pressure and flow sensors are installed at each of the key lubrication points (lifting mechanism bearings and rotating gearbox). The lubrication status is determined by cross-validation. When the deviation of a single sensor data exceeds 5%, the backup sensor is switched. If the deviation is too large, a calibration alarm is triggered. Dynamic threshold alarm module: Based on the real-time operating data of the gantry crane (lifting weight, running time, speed), a load-lubrication correlation model is built to dynamically adjust the alarm threshold; the leakage alarm is equipped with a 30-second delay confirmation mechanism to reduce false alarms and missed alarms; Temperature and humidity adaptive adjustment module: Includes miniature temperature and humidity sensor and heating and dehumidification component. When the humidity in the oil tank is >60% or the temperature is <-5℃, the adaptive function is automatically activated to ensure the stability of the grease and the life of the components. Visualized operation and maintenance management platform: includes equipment health dashboard (lubrication compliance rate of 95% is full marks), cost accounting dashboard (real-time statistics of cost-saving data), alarm handling ledger, and supporting mobile APP to realize alarm push, task dispatch and maintenance record filling, with a response time of ≤30 minutes; Protective design: The core component housing is made of 304 stainless steel with anti-corrosion coating, with a protection level of IP67; the wiring terminals use waterproof sealed joints, and the oil pipeline is made of oil-resistant and weather-resistant polyurethane material, which is suitable for the harsh port environment. The control method includes the following steps: S1: After the system starts, the intelligent oil distribution tank module initializes and sets the oil output of each oil outlet and the oil injection cycle of the lubrication point. The dual sensor backup module starts to collect data. S2: The hierarchical control module is in operation, the partition control unit performs the lubrication task, and the main control unit collects partition data in real time; S3: The dynamic threshold alarm module loads real-time data from the door operator to determine the lubrication status: if leakage is abnormal, it will confirm after a 30-second delay; if blockage is abnormal, it will alarm directly. After the alarm, the fault point will be located and pushed to the platform and APP. S4: Temperature and humidity adaptive module monitors the environment and automatically starts dehumidification / heating when the temperature and humidity exceed the standard; S5: When a partition unit fails, the main control unit takes over and operates according to the backup parameters; S6: After maintenance personnel handle the fault, they upload the record, and the system continues to run; when the parameter update conditions are met (such as load changes), the historical data learning unit automatically optimizes the oil injection parameters.

[0021] A control method for an intelligent centralized lubrication system for port gantry cranes includes the following steps: S1: Set the oil output of each oil outlet and the oil injection cycle of different lubrication points through the intelligent oil distribution tank module, and at the same time start the dual sensor backup module to monitor the lubrication status. S2: The partition control unit of the hierarchical control module executes the lubrication control of the corresponding lubrication point, and the main control unit collects data from the partition control unit in real time and performs global management. S3: The dynamic threshold alarm module adjusts the alarm threshold based on the real-time operation data of the gantry crane. When a lubrication abnormality is detected, if it is a leakage abnormality, a 30-second delay is initiated for confirmation, and an alarm is triggered after confirmation; if it is a blockage abnormality, an alarm is triggered directly. S4: The temperature and humidity adaptive adjustment module monitors the temperature and humidity inside the intelligent oil tank in real time. When the humidity is greater than 60% or the temperature is less than -5℃, the corresponding dehumidification or heating operation is activated. S5: If any partition control unit fails, the main control unit will immediately take over the lubrication point of that partition, perform the lubrication task according to the preset minimum parameters, and trigger the fault partition location alarm.

[0022] Preferably, in step S3, the real-time operating data of the gantry crane includes the lifting capacity, running time and rotation speed of the gantry crane; when the gantry crane is running at full load, the dynamic threshold alarm module widens the normal range of lubrication point pressure by 10%-15%; when the gantry crane is running at no load, it tightens the normal range of lubrication point pressure by 8%-12%.

[0023] Preferably, step S6 is also included: generating equipment health scores, cost accounting reports and alarm handling ledgers through the visual operation and maintenance management platform, and pushing alarm information and dispatch tasks through the mobile operation and maintenance APP. After the maintenance personnel complete the maintenance, they upload the maintenance records through the APP.

[0024] Compared with the prior art, the beneficial effects of the present invention are: Improve lubrication control precision to ensure the stability of gantry crane operation. This system, through its intelligent oil distribution tank module, allows for independent setting of the oil output at each outlet. It also precisely customizes the lubrication cycle for different mechanisms of the gantry crane, such as lifting, rotating, and luffing (e.g., the lubrication cycle for the high-load lifting mechanism can be set to 1.5 hours / cycle, while the lubrication cycle for the low-load auxiliary mechanism can be set to 4 hours / cycle), completely resolving the lubrication imbalance problem caused by the traditional system's "uniform oil supply." After the upgrade, the number of lubrication point failures on the gantry crane decreased from an average of 12-15 times per year to 1-3 times, and the number of lubrication-related shutdowns decreased from an average of 4-6 times per year to 0-1 times, significantly improving the operational stability of the gantry crane.

[0025] The system is equipped with a temperature and humidity adaptive adjustment module, which can monitor the temperature and humidity inside the intelligent oil tank in real time. When the humidity exceeds 60% or the temperature is below -5℃, the dehumidification or heating function will be automatically activated to avoid the lubrication effect being affected by changes in temperature and humidity in the port environment (such as the solidification of grease due to low temperature in winter and accelerated aging of parts due to humidity in summer), and further ensure the reliable operation of the gantry crane under harsh working conditions.

[0026] Real-time fault monitoring and alarms reduce maintenance difficulty and cost. The system is equipped with a dual-sensor backup module, installing two identical pressure and flow sensors at each of the gantry crane's key lubrication points (such as the lifting mechanism bearings and rotating gearbox). Through cross-validation logic, it monitors lubrication status in real time, accurately identifying faults such as oil circuit blockages and grease leaks. Simultaneously, the dynamic threshold alarm module dynamically adjusts alarm thresholds based on real-time gantry crane operating data (such as lifting capacity, running time, and rotational speed), and implements a 30-second delay confirmation mechanism for leakage alarms, reducing false alarms and missed alarms. When a fault occurs, the system can quickly locate the fault point and trigger an alarm, reducing fault response time from over one hour to within 30 minutes, improving maintenance efficiency by more than 50%.

[0027] The automated operation of the system replaces traditional manual inspections, reducing the average daily manual maintenance time for a single gantry crane from 2-2.2 hours to 0.4-0.5 hours, resulting in an average annual saving of 20,160 yuan in labor costs. The fault early warning function reduces the workload caused by the expansion of faults, saving an average of 15,000 yuan in annual maintenance costs for a single gantry crane, significantly reducing maintenance costs.

[0028] Optimize protective design and component layout to extend equipment lifespan. The core components of the system (intelligent oil distribution tank, graded control module, and sensors) are made of 304 stainless steel with an added anti-corrosion coating, and the protection level is upgraded to IP67. The wiring terminals use waterproof and sealed joints, and the oil pipelines are made of oil-resistant and weather-resistant polyurethane material, which effectively resists the dust, humidity, and salt corrosion of the port. The problem of component aging and leakage is fundamentally solved, and the overall service life of the system is extended from the original 3 years to more than 5 years.

[0029] The system integrates the previously scattered lubrication components into a unified layout design, and plans the installation locations in a unified manner. This not only eliminates the pollution of the on-site environment caused by grease leakage, but also reduces the difficulty of daily maintenance operations and improves equipment management efficiency.

[0030] Reduce overall operating costs and improve port economics After the renovation, each gantry crane saves an average of 20,160 yuan in labor costs, 3,000 yuan in lubricating oil consumption costs, and 15,000 yuan in equipment maintenance costs annually, for a total annual cost saving of 38,160 yuan. The four gantry cranes at Sheyang Port No. 7-10 save a total of 152,640 yuan annually, and the long-term cost savings are even more significant as the equipment's service life extends.

[0031] Fewer gantry crane malfunctions and shorter downtime ensured the continuity of loading and unloading operations. Taking the No. 8 gantry crane, which operates under high load, as an example, the average number of crane trips per day increased after the upgrade, improving the efficiency of port loading and unloading operations and indirectly creating higher operating revenue for the port.

[0032] It has broad application value and helps upgrade port equipment. The technical solution of this intelligent centralized lubrication system is designed based on the actual working conditions of the Sheyang Port gantry crane. It adopts a modular and hierarchical control architecture and can be adapted to large port loading and unloading equipment (such as cranes and conveyors) with different loads (normal load, high load) and different operating modes (single machine operation, dual machine collaborative operation). It can be promoted and applied without major adjustments, providing a replicable technical solution for the intelligent upgrading of the lubrication system in the entire port area and promoting the transformation of port equipment management towards intelligence and low cost. Attached Figure Description

[0033] Figure 1 This is one of the control flowcharts for the intelligent centralized lubrication system of the present invention; Figure 2 This is the second control flowchart of the intelligent centralized lubrication system of the present invention; Figure 3 This is one of the data flow flowcharts for the visual operation and maintenance management platform of this invention; Figure 4 This is the second data flow flowchart of the visual operation and maintenance management platform of the present invention; Figure 5 This is a flowchart of the dual-sensor backup and self-calibration process of the present invention. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1: (Basic Adaptation Type) System configuration: The system adopts the intelligent oil distribution tank module (each tank has 6 independent oil outlets), the basic graded control module (1 main control unit + 4 zone control units, corresponding to 20 lubrication points), the dual sensor backup module (two pressure sensors are installed at each of the two key lubrication points, the hoisting mechanism bearing and the rotating gearbox), and the simplified dynamic threshold alarm module (only supports load-related threshold adjustment, without historical data learning function), and the hardware protection level is upgraded to IP65.

[0036] Operating parameter settings: Based on the daily workload of No. 7 gantry crane (an average of 80 truckloads of goods are lifted per day, mainly bulk goods), the lubrication cycle of the hoisting mechanism is set to 2 hours / time, with a single oil output of 0.8mL; the lubrication cycle of the rotating mechanism is set to 4 hours / time, with a single oil output of 0.5mL.

[0037] Operational results: Within one year after the renovation, the number of lubrication point failures of No. 7 gantry crane decreased from 12 times / year to 3 times / year, the manual inspection time was shortened from 2 hours / day to 0.5 hours, the monthly consumption of lubricating grease decreased from 15kg to 12kg, and the annual cost savings per unit (labor + grease + maintenance) reached 36,000 yuan.

[0038] Example 2: (High-efficiency optimized version) System configuration: The system is equipped with the core modules of the retrofit plan, including an intelligent oil distribution tank module (each tank has 8 independent oil outlets), a complete graded control module (1 main control unit + 5 zone control units, corresponding to 25 lubrication points), a dual-sensor backup module (fully covering key lubrication points, including pressure and flow dual-type sensors), a dynamic threshold alarm module with historical data learning function, and a temperature and humidity adaptive adjustment module. The hardware protection level is upgraded to IP67.

[0039] Operating parameter settings: Considering the high-load operation characteristics of the No. 8 gantry crane (average 120 cargo trips per day, including heavy container cargo), the system automatically optimizes parameters through historical data learning: the lubrication cycle of the lifting mechanism is dynamically adjusted (1.5 hours / time when fully loaded, 2.5 hours / time when unloaded), and the single oil output adapts to the load fluctuation between 0.7-0.9mL; at the same time, the temperature and humidity adjustment function is enabled, and the corresponding components are automatically activated when the humidity is set to >60% or the temperature is <-5℃.

[0040] Operational results: Within one year after the renovation, the number of lubrication point failures of No. 8 gantry crane decreased from 15 times / year before the renovation to 1 time / year. There were no downtime events caused by insufficient lubrication. The monthly consumption of lubricating grease decreased from 18kg to 11kg. The labor maintenance cost was reduced by 22,000 yuan / year, and the total annual cost saving per unit reached 41,000 yuan.

[0041] Example 3: (Dual-machine collaborative type) System configuration: The No. 9 and No. 10 gate machines adopt the architecture of "shared main control unit + independent partition control unit". They share one main control unit with visualization operation and maintenance function (which can monitor the lubrication data of the two gate machines at the same time). Each gate machine is equipped with an independent intelligent oil distribution tank module (each with 7 oil outlets), a dual sensor backup module, and a temperature and humidity adaptive adjustment module. The hardware protection level is IP67.

[0042] Operating parameter settings: Based on the scenario of two gantry cranes working together (often jointly lifting large equipment, with the working load changing in tandem), the main control unit uniformly sets the linkage parameters: when one of the gantry cranes enters the heavy load mode (lifting capacity > 50 tons), the other gantry crane simultaneously shortens the lubrication cycle by 10%; the lubrication points of the rotating mechanism of the two gantry cranes share a set of temperature and humidity adjustment parameters to avoid repeated calibration.

[0043] Operational results: Within one year after the upgrade, the lubrication coordination failure rate of gantry cranes No. 9 and No. 10 during joint operation was 0. The monthly consumption of lubricating grease for a single gantry crane decreased from 16kg before the upgrade to 11.5kg. The total annual cost savings for both cranes reached 78,000 yuan. Maintenance personnel can manage both gantry cranes simultaneously through a visualization platform, and the average maintenance efficiency per person has increased by 50%.

[0044] II. Comparative Example Group (based on the original traditional dry-oil dual-line system) Comparative Example 1: Before the modification of gantry crane No. 7 (original dry oil dual-line system) System configuration: It adopts a traditional dry oil dual-line system with no independent oil output control unit. It achieves unified oil supply through only one main pump station, has no sensor monitoring module, no fault alarm function, the component protection level is IP44, and the oil pipeline is ordinary steel pipe.

[0045] Operating parameter settings: All lubrication points of the machine adopt a uniform oil injection cycle (3 hours / time) and a uniform single oil output (1.0mL). There is no load-related adjustment function. When the temperature and humidity change, the pump station pressure needs to be manually adjusted.

[0046] Operational results: In the year before the renovation, No. 7 gantry crane experienced 8 bearing wear failures due to insufficient lubrication and 4 leakage failures due to excessive grease. Manual inspection was carried out for 2 hours every day (requiring point-by-point inspection). The monthly consumption of lubricating grease was 15kg, the annual maintenance cost was 18,000 yuan, the labor cost was 25,000 yuan, and the total annual loss cost per unit (labor + grease + maintenance) reached 52,000 yuan.

[0047] Comparative Example 2: (High-load operating condition of the original dry oil dual-line system) System configuration: Same as Comparative Example 1, adopts traditional dry oil dual-line system, no monitoring, no alarm, component protection level IP44, oil pipeline is ordinary steel pipe, no load adaptation function.

[0048] Operating parameter settings: The entire machine has a uniform oiling cycle of 3 hours / time and a uniform single oil output of 1.0mL. There is no parameter adjustment when operating under high load (lifting capacity > 50 tons). In winter and low temperature, the oil circuit needs to be manually checked every 2 days to see if it has solidified.

[0049] Operational results: In the year before the renovation, No. 8 gantry crane experienced 6 gearbox failures due to insufficient lubrication under high load, 4 shutdowns due to solidification of oil circuits at low temperature, and environmental pollution treatment costs of 0.3 million yuan / year due to grease leakage. The monthly consumption of lubricating grease was 18 kg, the annual maintenance cost was 2.2 million yuan, the labor cost was 2.8 million yuan, and the total annual loss cost per unit reached 6.3 million yuan.

[0050] Example 1 (Basic Adaptation Type): Corresponds to the intelligent oil distribution tank module, basic version graded control module (1 main and 4 sub-modules), simplified dual-sensor backup module (pressure sensor only), simplified dynamic threshold alarm module (no historical data learning) in claim 1, and the technical features of protection level IP65 in claim 2.

[0051] Example 2 (High-efficiency optimized type): It fully covers the technical features of claims 1-7, including an intelligent oil distribution tank module (8 oil outlets), a complete graded control module (1 main and 5 sub-controls), a dual-sensor backup module (pressure + flow sensor), a dynamic threshold alarm module with historical data learning, a temperature and humidity adaptive adjustment module, and the technical features of claim 2, such as IP67 protection level, 304 stainless steel shell + anti-corrosion coating, waterproof sealing joint, and polyurethane oil pipeline. It also integrates the visual operation and maintenance management platform and mobile APP function of claims 4-5.

[0052] Example 3 (Dual-machine collaborative type): Corresponding to the core module in claim 1, it is superimposed with the industrial Ethernet communication (100Mbps+ encrypted transmission) of claim 6 and the visual operation and maintenance management platform (shared main control unit) of claim 4, and the protection level meets the IP67 of claim 2.

[0053] Comparative Examples 1-2 (Traditional Dry Oil Dual-Line System): It does not employ any of the technical features defined in claims 1-10, and only supplies oil through a single main pump station. There is no sensor monitoring, no fault alarm, no graded control, and the protection level is IP44. The oil pipeline is made of ordinary steel pipe.

[0054] Based on the above comparison, Example 2 (High-Efficiency Optimized) is the optimal solution among the three sets of examples, specifically based on the following: Technical completeness: Embodiment 2 fully covers all the technical features of claims 1-10, realizing full-link technical innovation of "precise control-fault monitoring-environmental adaptation-operation and maintenance management" without any missing functions; Embodiment 1 lacks technical features such as historical data learning and flow sensor, and Embodiment 3 lacks technical features such as temperature and humidity adaptive adjustment, both of which have functional shortcomings.

[0055] Optimal performance: Example 2 outperforms Examples 1 and 3 in four core indicators: fault control (fewest occurrences, no downtime), cost savings (highest amount), environmental adaptability (highest protection level), and promotion adaptability (widest coverage of working conditions). Compared with Comparative Examples 1-2, it completely solves the core pain points of traditional systems, and the technical effect is significant.

[0056] Supporting claim: The technical solution of Embodiment 2 corresponds completely to the technical features of claims 1-10. Its optimal effect directly proves that the technical solution defined by the claims has inventiveness and practicality, providing the strongest implementation verification for the scope of protection of the claims.

[0057] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0058] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A gantry crane intelligent centralized lubrication system, characterized in that, It includes an intelligent fuel tank module, a graded control module, a dual-sensor backup module, a dynamic threshold alarm module, and a temperature and humidity adaptive adjustment module; The intelligent oil distribution tank module is used to independently set the oil output of each oil outlet and to set differentiated oil injection cycles for the lubrication points of different mechanisms of the gantry crane. The hierarchical control module includes a main control unit and at least four partition control units. Each partition control unit corresponds to four to five lubrication points. The main control unit is used for global parameter management and data aggregation. The partition control units are used to execute the oil output and oil injection cycle control of the corresponding lubrication point. When any partition control unit fails, the main control unit can take over the basic lubrication task of the partition lubrication point and operate according to the preset minimum parameters. The dual-sensor backup module installs two pressure sensors and two flow sensors of the same model at key lubrication points such as the bearings and rotating gearbox of the gantry crane lifting mechanism. The lubrication status is judged by cross-validation logic. When the data of a single sensor is abnormal and the deviation exceeds 5%, it automatically switches to the backup sensor. If the data of the two sensors deviates significantly, a sensor calibration alarm is triggered. The dynamic threshold alarm module constructs a "equipment load-lubrication status" correlation model based on the real-time operation data of the gantry crane, dynamically adjusts the alarm threshold, and sets a 30-second delay confirmation mechanism for leakage alarms. The temperature and humidity adaptive adjustment module includes a miniature temperature and humidity sensor and a heating and dehumidification component. When the humidity in the intelligent oil separator exceeds 60% or the temperature is below -5℃, the dehumidification or heating function is automatically activated.

2. The intelligent centralized lubrication system for a gantry crane according to claim 1, characterized in that: The outer shell of the intelligent oil distribution tank module and the graded control module is made of 304 stainless steel and has an anti-corrosion coating, with a protection level of IP67. The wiring terminals of the intelligent oil distribution tank module are waterproof and sealed, and the oil pipeline is made of oil-resistant and weather-resistant polyurethane material.

3. The intelligent centralized lubrication system for a gantry crane according to claim 2, characterized in that: The dynamic threshold alarm module also includes a historical data learning unit, which is used to collect lubrication point wear records and grease viscosity change data in different seasons for the past 6 months of the gantry crane, and automatically optimize the oil output and oiling cycle based on the data; and the dynamic threshold alarm module supports manual triggering of "parameter learning mode", which can adjust lubrication parameters according to the input gantry crane load changes.

4. The intelligent centralized lubrication system for a gantry crane according to claim 3, characterized in that: It also includes a visual operation and maintenance management platform, which includes an equipment health dashboard, a cost accounting dashboard, and an alarm processing ledger module; The equipment health dashboard links lubrication data with equipment fault records to generate a health score for each lubrication point. The health score uses the lubrication compliance rate as the core indicator, with a full score of 95% or above. For every 5% decrease, 10 points are deducted. The cost accounting dashboard provides real-time statistics on the lubricating oil consumption, manual maintenance hours, and repair costs of a single gantry crane. It automatically compares the cost differences before and after the system upgrade and generates an annual return on investment calculation report. The alarm processing log module automatically records the alarm type, processing time, responsible person, and resolution result, forming a historical database.

5. The intelligent centralized lubrication system for a gantry crane according to claim 3, characterized in that: The visual operation and maintenance management platform is also equipped with a mobile operation and maintenance APP. The mobile operation and maintenance APP has the functions of real-time alarm information push, automatic dispatch of maintenance tasks, and online filling of maintenance records, which can control the alarm response time within 30 minutes.

6. The intelligent centralized lubrication system for a gantry crane according to claim 2, characterized in that: The main control unit and the partition control unit of the hierarchical control module are connected via industrial Ethernet communication, with a communication rate of not less than 100Mbps and data encryption transmission function.

7. The intelligent centralized lubrication system for a gantry crane according to claim 2, characterized in that: The sensors in the dual-sensor backup module also have a periodic self-calibration function. The self-calibration cycle can be set by the main control unit of the hierarchical control module. A calibration prompt is triggered when the calibration deviation exceeds 3%.

8. The intelligent centralized lubrication system for a gantry crane according to claim 4, characterized in that: The equipment health dashboard of the visual operation and maintenance management platform also supports custom health score weights. Based on the differences in importance of different mechanisms of the gantry crane (such as hoisting mechanism, slewing mechanism, luffing mechanism), operation and maintenance personnel can manually adjust the score weight ratio of the corresponding lubrication points of each mechanism. The adjustment records are automatically saved to the historical database for easy traceability and auditing.

9. The intelligent centralized lubrication system for a gantry crane according to claim 5, characterized in that: The mobile maintenance APP also has a lubricating grease inventory management function, which can synchronize the inventory of different types of lubricating grease in the warehouse in real time. When the inventory of a certain type of grease is lower than a preset threshold (which can be set independently according to 1.5 times the monthly consumption of a single gantry crane), it will automatically push a replenishment reminder to the warehouse administrator and display the consumption trend chart of that type of grease over the past 3 months to assist the administrator in formulating a procurement plan.

10. The intelligent centralized lubrication system for a gantry crane according to claim 6, characterized in that: The industrial Ethernet communication link of the hierarchical control module also has an automatic link failure switching function. When the main communication link (based on industrial Ethernet) is disconnected, the packet loss rate exceeds 5%, or the delay exceeds 100ms, the system automatically switches to the backup 4G / 5G wireless communication link to ensure the communication continuity between the main control unit and the partition control unit. The lubrication task being executed is not interrupted during the link switching process, and the switching record is uploaded to the alarm processing ledger module of the visual operation and maintenance management platform in real time.

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