Vibration monitoring and early warning system for quay crane rotating mechanism
By combining a multi-source sensor array with a wireless inspection device, along with an industrial control computer and a monitoring center, real-time monitoring and early warning of the quay crane's rotating mechanism were achieved. This solved the problems of accuracy and flexibility in existing monitoring systems, and improved the accuracy of fault diagnosis and the coverage of data acquisition.
Patent Information
- Application Number
- CN202520714794.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-16
- Publication Date
- 2026-02-17
- Estimated Expiration
- 2035-04-16
AI Technical Summary
The existing monitoring system for the quay crane rotation mechanism suffers from large human error, poor data accuracy, and high false alarm rate, making it unable to effectively monitor faults, especially in harsh environments where accurate fault diagnosis is difficult.
A combined solution is adopted, consisting of a multi-source sensor array, a wireless inspection device, a data acquisition cabinet, an industrial control computer, and a monitoring center. Data is collected by the wireless inspection device and the multi-source sensor array, the industrial control computer performs signal analysis and early warning, and the monitoring center transmits and displays the data, thereby realizing real-time monitoring and early warning of the quay crane's rotating mechanism.
It enables rapid and accurate fault early warning of the quay crane's rotating mechanism, improves the accuracy of fault diagnosis, reduces the false alarm rate, enhances the flexibility and coverage of data collection, and adapts to the needs of unmanned terminals.
Smart Images
Figure CN223920921U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a fault early warning system for quay crane equipment, and in particular discloses a vibration monitoring and early warning system for the rotating mechanism of a quay crane. Background Technology
[0002] Unmanned terminals are a future development trend, and China is already deploying and promoting unmanned terminal technology to reduce terminal staff and manual operations. Quay cranes (also known as quay cranes) are crucial process equipment in ports. Their main rotating mechanisms include the trolley traction mechanism, main hoisting mechanism, and front beam pitching mechanism. Common faults include motor electromagnetic failures, worn or broken gears in the gearbox, and worn or poorly lubricated bearings. To promptly detect equipment faults or potential problems and take appropriate repair or maintenance measures to ensure the safe and reliable operation of the quay cranes, it is necessary to monitor the key components of the rotating mechanism.
[0003] Currently, existing monitoring systems for quay crane operating mechanisms primarily use microphones and vibration acceleration sensors to collect sound or vibration waves, combined with visualization equipment for monitoring, and finally, the collected information is aggregated on an online platform. However, some quay cranes at wharves still suffer from incomplete network communication infrastructure, the need for data confidentiality (not leaving the factory), and considerations regarding the cost of deploying monitoring systems. Therefore, fault diagnosis of the motors and gearboxes of the main rotating mechanisms still mainly relies on on-site inspections. In industrial settings, the manual, timed inspection methods used for the main rotating mechanisms of quay cranes typically involve listening for abnormal noises or installing vibration or temperature sensors and evaluating the equipment's condition using simple vibration or overheat indicators. The first method requires experienced on-site personnel to obtain relatively accurate results, has a high rate of human error, and cannot effectively detect early anomalies. The second method lacks in-depth data mining and collection of vibration data, easily leading to missed or false alarms.
[0004] Because quay cranes are specifically designed for container handling and are located on the shore of port terminals, their working environment is less than ideal. Conventional alarm systems based on simple vibration and temperature indicators often have shortcomings and are not timely in providing feedback on certain faults. The rotating mechanism operates intermittently, with vibrations including start-stop and impact components. Under these harsh conditions, conventional signal acquisition and alarm methods yield inaccurate data and have a high false alarm rate.
[0005] Therefore, it is necessary to design a data acquisition and early warning device for the main rotating mechanism of the quay crane, which is in line with the current development of unmanned terminals, improves the accuracy of fault diagnosis, realizes the collection, analysis and judgment of effective data of the quay crane rotating mechanism and provides early warning, and meets the urgent practical needs. Summary of the Invention
[0006] The purpose of this invention is to address the shortcomings of existing technologies by designing a vibration monitoring and early warning system for the quay crane's rotating mechanism. This system employs suitable instruments and equipment, combining a wireless inspection device with a multi-source sensor array to collect working data. When the industrial control computer determines that the collected signal data exceeds a preset threshold, indicating a fault, the system uploads the collected raw data and early warning information to a monitoring center located at the dock. Furthermore, the system can utilize the wireless inspection device for multi-point on-site inspection and fault information verification, thereby achieving effective, real-time, and accurate monitoring of the quay crane's rotating mechanism.
[0007] This utility model is implemented as follows: A vibration monitoring and early warning system for a quay crane rotation mechanism includes a wireless inspection device, a multi-source sensor group, a data acquisition cabinet, an industrial control computer, and a monitoring center. The multi-source sensor group is connected to the data acquisition cabinet via cables, the data acquisition cabinet is connected to the industrial control computer via a network cable, and the industrial control computer is connected to the monitoring center via a wireless network. The wireless inspection device is connected to a mobile APP client via Bluetooth, and the mobile APP client is connected to the industrial control computer via a wireless network set up inside the monitoring center. The multi-source sensor group includes temperature vibration sensors, stress wave acceleration sensors, and magnetic flux speed sensors correspondingly installed at the motor, gearbox, and roller of the rotation mechanism. The multi-source sensor group is connected to a signal acquisition card set in the data acquisition cabinet via cables. The acquisition card is connected to the industrial control computer via a switch and a network cable. The industrial control computer is equipped with a signal processing and analysis module, an early warning module, and a data transmission module for processing multi-source signal data acquired by the multi-source sensor group. The monitoring center is equipped with a human-machine interface device, which can remind on-site personnel to view and calibrate the early warning information in real time.
[0008] The multi-source sensor group is used to collect multi-source signal data of vibration, stress wave, temperature and rotation speed signals of the rotating mechanism. The signal processing and analysis module on the industrial control computer is used to analyze the multi-source signal data collected by the multi-source sensor group to obtain the real-time vibration index value and temperature value of the quay crane. The early warning module is used to generate corresponding early warning information when the real-time vibration index value and temperature value of the quay crane exceed the corresponding preset alarm threshold. The data transmission module is used to transmit the early warning information and the corresponding original multi-source signal data to the monitoring center through a wireless network. The human-machine interaction device in the monitoring center is used to view the early warning information in real time and calibrate the early warning information.
[0009] The temperature and vibration sensors are used to transmit real-time temperature and vibration acceleration signals of the quay crane's rotating mechanism to the data acquisition cabinet via cables. The temperature measurement range is -20 to 120°C, the vibration component is IEPE type, and the upper limit of the frequency response range is greater than or equal to 10 kHz. They are installed vertically at the motor drive end, vertically at key load-bearing positions on each shaft of the gearbox, and horizontally at the bearing seats of the rollers. The stress wave acceleration sensor is used to transmit the collected real-time stress wave signals of the quay crane's rotating mechanism to the data acquisition cabinet via cables, and is installed vertically on the intermediate shaft of the gearbox. The magnetic flux speed sensor is used to obtain the rotational speed by measuring changes in the motor's magnetic field and then transmit the real-time rotational speed signal of the quay crane's rotating mechanism to the data acquisition cabinet via cables. It is mounted on the motor using a tooling fixture.
[0010] The data acquisition cabinet is powered by a 220V AC power supply via an air switch and a 24V power supply to its signal acquisition card. The signal acquisition card has 8 or 16 acceleration channels, 8 or 12 slow-change channels, and 2 speed channels. Preferably, one 8-channel and one 16-channel acceleration channel are used simultaneously, which can basically cover the corresponding number of sensors. The signal acquisition card acquires the temperature, vibration acceleration, stress wave acceleration, and speed values of the rotating mechanism in real time based on the signals transmitted from the multi-source sensor group, and connects to a switch via a network cable. The switch is then connected to an industrial control computer via a network cable. The signal acquisition card is used to preset reasonable speed and vibration thresholds based on the rotational speed and vibration data of the rotating mechanism and associate them with the acquisition function. When the real-time vibration acceleration or speed value of the rotating mechanism exceeds the corresponding preset speed or vibration threshold, long-cycle waveform data acquisition is performed, with a waveform sampling frequency of at least 102.4 kHz and a duration of at least 10 seconds.
[0011] The wireless inspection device is used to collect the current vibration waveform of the rotating mechanism. The sampling frequency is set to 25.6KHz and the sampling time is 2s. The collected signal data is uploaded to the mobile APP client via Bluetooth. After the user enters the location of the inspection device and the rotation speed tag of the rotating mechanism through the mobile APP client, the data is uploaded to the industrial control computer through the wireless network set up inside the monitoring center.
[0012] The industrial control computer is located in the electrical room of the quay crane and is equipped with a wireless network card. It connects to the monitoring center via the wireless network on the quay crane. The industrial control computer is the FXTS10 model developed by Frequency Exploration Intelligent Technology Jiangsu Co., Ltd., which comes with AI device guardian software. The data storage module on the industrial control computer is configured with 300G or more of storage space to store multi-source signal data collected in the past 3 months. The main tasks of the signal processing and analysis module on the industrial control computer include multi-source signal data information analysis, vibration index calculation, alarm threshold determination, and data comparison.
[0013] The signal processing and analysis module on the industrial control computer is preset with multiple vibration index alarm thresholds at different levels selected according to the real-time operating conditions of the rotating mechanism. The AI device guardian software, through the signal processing and analysis module, analyzes and calculates the real-time vibration index and temperature values of the quay crane based on multi-source signal data collected by the multi-source sensor group. The alarm thresholds are determined as follows: The corresponding rotational speed and temperature values are obtained by using the timestamps of the vibration waveform and stress wave acceleration waveform constructed from the multi-source signal data. The rotational speed is divided into multiple regions, and the index values obtained from the waveform within a stable rotational speed period are used as the vibration index of the quay crane. Alarm thresholds for the temperature index and multiple vibration index levels are preset based on the rotational speed range of the quay crane's rotating mechanism. The regions corresponding to the rotational speed values are used as signal tags. When the real-time vibration index or temperature value of the quay crane, obtained by the signal processing module based on the real-time operating conditions of the rotating mechanism or through inspection, exceeds the preset alarm threshold corresponding to the rotational speed range of the current real-time rotational speed, the early warning module in the industrial control computer generates corresponding early warning information. The data transmission module transmits the early warning information and the corresponding original multi-source signal data to the monitoring center via a wireless network. Signals without warning are only stored on the industrial control computer.
[0014] The monitoring center is a local server located in the port's computer room, equipped with a human-machine interface (HMI) and accessed via an intranet. The HMI interface includes vibration trend graphs, early warning information, and a tagging system. The monitoring center can push early warning information to users in real time. Users manually input tags to interpret the early warning information via the HMI. After transmission to the industrial control computer, the computer saves the calibrated original multi-source signal data and corresponding indicators. When a user accesses the monitoring center, early warning information is displayed via pop-up windows and sound alerts. The early warning information mainly includes the monitoring points, their health status, and real-time vibration and temperature values. The tagging system is synchronized with the early warning information, recording the original data that generated the early warning, displaying signal spectra, equipment status, and real-time vibration and temperature values. The industrial control computer periodically cleans up data that has not triggered alarms or has not been calibrated.
[0015] The beneficial effects of this utility model are:
[0016] This invention utilizes a multi-source sensor array triggered by the rotational speed of the quay crane's rotating mechanism to collect vibration waveforms and stress wave acceleration waveforms. It also incorporates a wireless inspection device for manual inspection, collecting vibration waveforms and verifying faults. An industrial control computer selects fault-mode-sensitive index values from the multi-source sensor array, determining the vibration index of the quay crane based on data from the stable rotational speed phase. Multiple alarm thresholds are set based on the rotational speed range of the quay crane's rotating mechanism, and a tagging system is established for subsequent optimization and iteration of alarm thresholds. This invention can quickly and accurately provide early warning of faults in the main rotating mechanism of the quay crane. The multi-source sensor array design also plays a role in classifying quay crane fault conditions, demonstrating significant practical and engineering value.
[0017] This invention acquires vibration, stress wave acceleration, temperature, and rotational speed signals of the main rotating mechanism of the quay crane using a multi-source sensor array. Based on the common failure characteristics of the quay crane, it selects vibration and stress wave acceleration indicators sensitive to fault diagnosis for monitoring, and sets appropriate alarm thresholds for tiered alarm levels. Simultaneously, it uploads the raw alarm data and early warning information to the monitoring center, achieving timely and effective data acquisition, analysis, judgment, and early warning for the quay crane's rotating mechanism. The wireless inspection device equipped in this invention not only verifies faults and improves the accuracy of fault alarms and maintenance location, but also allows for inspection and data collection on quay crane equipment without sensors, increasing the range of multi-source signal data acquisition and improving data acquisition flexibility. This meets the current practical needs of container terminals and has significant application value. Attached Figure Description
[0018] Figure 1 This is a schematic block diagram of the composition structure of this utility model.
[0019] In the diagram: 1. Multi-source sensor array; 2. Data acquisition cabinet; 3. Wireless inspection device; 4. Industrial control computer; 5. Monitoring center. Detailed Implementation
[0020] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.
[0021] According to the appendix Figure 1This utility model relates to a vibration monitoring and early warning system for the rotating mechanism of a quay crane. It collects data on vibration, stress wave acceleration, temperature, and rotational speed signals of the rotating mechanism and compares these data with alarm thresholds for temperature and vibration indices constructed based on signals from stable operation phases. This enables automatic early warning and display of the equipment's movement trends. The system includes a wireless inspection device 3, a multi-source sensor group 1, a data acquisition cabinet 2, an industrial control computer 4, and a monitoring center 5. The multi-source sensor group 1, located at key positions in the rotating mechanism within the quay crane's engine room, includes a motor, gearbox, and rollers, and is connected to the data acquisition cabinet 2 in the engine room's electrical room via cables. The data acquisition cabinet 2 contains signal... The acquisition card is used to trigger the acquisition of multi-source signals to obtain vibration and stress wave acceleration waveforms. The multi-source signals are transmitted via network cable to a switch, and then from the switch to the industrial control computer 4 in the engine room's electrical room via network cable. The signal processing and analysis module on the industrial control computer 4 determines the data used as vibration indicators and whether the currently acquired real-time multi-source signals and inspection data exceed limits. If limits are exceeded, the warning information and the corresponding original multi-source signal data are transmitted wirelessly to the monitoring center 5 via the warning module and data transmission module on the industrial control computer 4. The monitoring center 5 is equipped with a human-machine interface device, through which warning information can be viewed in real time and calibrated. The wireless inspection instrument 3 acquires the vibration waveforms of the rotating mechanism and uploads them to a mobile APP client via Bluetooth. The mobile APP client then uploads the corresponding data to the industrial control computer 4 via the wireless network set up inside the monitoring center 5.
[0022] Based on the failure modes of the quay crane's rotating mechanism, the multi-source sensor group 1 in this embodiment employs a temperature vibration sensor, a stress wave acceleration sensor, and a magnetic flux speed sensor. The temperature vibration sensor has a temperature measurement range of -20 to 120°C, and its vibration component is of the IEPE type. The selection requirement is that the upper limit of the frequency response range is greater than or equal to 10kHz, enabling it to capture vibration signals in the high-frequency range and more accurately reveal early bearing and rubbing failures. The stress wave acceleration sensor can effectively detect early bearing failures within the gearbox. The magnetic flux speed sensor obtains the rotational speed by measuring changes in the motor's magnetic field, and is easy to install and maintain. According to the structural design and main load-bearing positions of the quay crane's rotating mechanism, the temperature vibration sensor is installed vertically at the motor drive end, vertically at the key load-bearing positions of each shaft in the gearbox, and horizontally in the bearing housing of the roller. The stress wave acceleration sensor is installed vertically on the intermediate shaft of the gearbox, achieving a balance between monitoring vulnerable components and a moderate number of sensors. This can be adjusted according to the actual structure, while maintaining the overall installation requirements. The magnetic flux speed sensor is installed on the motor using a tooling fixture. The multi-source sensor group 1 transmits the real-time temperature signal, vibration acceleration signal, stress wave acceleration signal and rotation speed signal of the quay crane rotation mechanism to the data acquisition cabinet 2 via cables.
[0023] The data acquisition cabinet 2 is powered by a 220V AC power supply via an air switch and a 24V power supply to its signal acquisition card. Depending on the number of sensors, the signal acquisition card can select 8 or 16 acceleration channels, 8 or 12 slow-change channels, and 2 speed channels for acquisition. Preferably, it uses one 8-channel and one 16-channel acceleration channel simultaneously, which can basically cover the corresponding number of sensors. After receiving signals from the multi-source sensor group 1, the signal acquisition card performs real-time acquisition, obtaining the temperature, vibration acceleration, stress wave acceleration, and rotational speed values of the rotating mechanism. The signal acquisition card presets reasonable speed and vibration thresholds based on the rotational speed and vibration data of the rotating mechanism and associates them with the acquisition function. When the real-time acquired rotational speed or vibration acceleration value exceeds the set speed or vibration threshold, it quickly performs long-cycle waveform data acquisition, setting the waveform sampling frequency to 102.4 kHz and the time to at least 10 seconds. When using one 8-channel and one 16-channel acceleration channel simultaneously, the two signal acquisition cards are connected to the switch via network cables, and the switch is connected to the industrial control computer 4 via network cables to realize the transmission of multi-source signal data of the rotating mechanism's operating conditions.
[0024] The wireless inspection device 3 is set to a sampling frequency of 25.6 kHz and a sampling time of 2 seconds. Data is uploaded to a mobile app client via Bluetooth. Manual inspections are typically performed when the equipment is running stably. The mobile app client allows input of the inspection device's location and the equipment's rotation speed tag, and uploads data to the industrial control computer 4 via the wireless network set up within the monitoring center 5. Many wireless inspection devices are available on the market; this embodiment uses the FXP11M-B wireless inspection device manufactured by Frequency Exploration Jiangsu Co., Ltd., which can simultaneously collect vibration and temperature data.
[0025] The industrial control computer 4 is located in the electrical room of the quay crane and is equipped with a wireless network card, enabling communication with the monitoring center 5 via the internal wireless network of the quay crane. In this embodiment, the industrial control computer 4 is an FXTS10 model developed by Frequency Exploration Intelligent Technology Jiangsu Co., Ltd., equipped with AI Equipment Guardian software. The data storage module on the industrial control computer 4 has at least 300GB of storage space, capable of storing multi-source signal data collected within the last three months. The main functions of the signal processing and analysis module on the industrial control computer 4 include multi-source signal data information analysis, vibration index calculation, alarm threshold determination, and data comparison. The AI Equipment Guardian software, through the signal processing and analysis module, analyzes the multi-source signal data collected by the multi-source sensor group to obtain the real-time vibration index and temperature values of the quay crane. Specifically, the "Diagnostic Analysis" module of the AI Equipment Guardian software is used to select indicators such as rotor imbalance, rotor misalignment, rolling bearing damage, mechanical loosening, poor bearing lubrication, poor gear meshing, root mean square vibration velocity, root mean square acceleration, peak acceleration, steady-state impact intensity, and optimized kurtosis based on data obtained from stable rotational speed values over a period of time. These indicator values are used as vibration indicators for the quay crane. The AI Equipment Guardian software uses the area corresponding to the rotational speed value as a signal label and presets alarm thresholds for vibration and temperature indicators. The alarm thresholds for vibration indicators are preset to multiple levels based on the rotational speed range of the rotating mechanism. When the real-time vibration indicator value obtained by the signal processing and analysis module from the real-time operating condition data of the rotating mechanism or from inspection data exceeds the preset alarm threshold corresponding to the current real-time rotational speed value, the early warning module in the industrial control computer 4 generates corresponding early warning information. The data transmission module transmits the early warning information and the corresponding original multi-source signal data (i.e., real-time vibration indicator value and corresponding waveform and temperature value) to the monitoring center 5 via a wireless network. Data without warning is only stored on the industrial control computer 4. The AI device guardian software on the industrial control computer can also be replaced by other software with calculation index functions. The AI device guardian software described in this embodiment is copyrighted by Frequency Exploration Intelligent Technology Jiangsu Co., Ltd., registered on October 28, 2021, registration number 2021SR1587687. Further details are omitted here.
[0026] The monitoring center 5 is a local server located in the port's computer room, equipped with a human-machine interface (HMI). Users can access it via the intranet. The HMI interface includes vibration trend charts, early warning information, and a tagging system. Monitoring center 5 pushes early warning information to users in real time. When users access the local monitoring center, early warning information will trigger pop-up windows and sound alerts. Early warning information includes the monitoring point, its health status, real-time vibration and temperature values, etc., assisting in manual fault diagnosis. When an early warning is issued, the tagging system records the corresponding real-time vibration, stress wave acceleration values, displayed signal spectrum, equipment status, vibration values, and the tags entered by the user through the HMI. This tag information is then transmitted to the industrial control computer 4. The original data and corresponding indicators of calibrated tags are continuously saved for adjusting vibration alarm thresholds. The industrial control computer 4 periodically cleans up non-alarm or uncalibrated data.
[0027] Based on the installation and operation of the quay crane's rotating mechanism and the development of sensor technology, the aforementioned temperature vibration sensor can be replaced by a vibration sensor and a temperature sensor; the stress wave acceleration sensor can be replaced by an impact pulse sensor; and the magnetic flux speed sensor can be replaced by a photoelectric speed sensor or an electromagnetic speed sensor. The vibration indices to be monitored, such as stable impact intensity, optimized kurtosis, and optimized peak value, can be replaced by kurtosis factor, margin factor, impulse factor, peak-to-peak value, and cross-KL divergence.
Claims
1. A vibration monitoring and early warning system for a quay crane rotation mechanism, characterized in that: The vibration monitoring and early warning system includes a wireless inspection device, a multi-source sensor group, a data acquisition cabinet, an industrial control computer, and a monitoring center. The multi-source sensor group is connected to the data acquisition cabinet via cables, the data acquisition cabinet is connected to the industrial control computer via a network cable, and the industrial control computer is connected to the monitoring center via a wireless network. The wireless inspection device connects to a mobile APP client via Bluetooth, and the mobile APP client connects to the industrial control computer via the wireless network set up inside the monitoring center. The multi-source sensor group includes temperature vibration sensors, stress wave acceleration sensors, and magnetic flux speed sensors correspondingly installed at the motor, gearbox, and roller of the rotating mechanism. The multi-source sensor group is connected to a signal acquisition card set up in the data acquisition cabinet via cables. The acquisition card is connected to the industrial control computer via a switch and a network cable. The industrial control computer is equipped with a signal processing and analysis module, an early warning module, and a data transmission module for processing multi-source signal data acquired by the multi-source sensor group. The monitoring center is equipped with a human-machine interaction device.
2. The vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1, characterized in that: The multi-source sensor group is used to collect multi-source signal data of vibration, stress wave, temperature and rotation speed signals of the rotating mechanism. The signal processing and analysis module on the industrial control computer is used to analyze the multi-source signal data collected by the multi-source sensor group to obtain the real-time vibration index value and temperature value of the quay crane. The early warning module is used to generate corresponding early warning information when the real-time vibration index value and temperature value of the quay crane exceed the corresponding preset alarm threshold. The data transmission module is used to transmit the early warning information and the corresponding original multi-source signal data to the monitoring center through a wireless network. The human-machine interaction device in the monitoring center is used to view the early warning information in real time and calibrate the early warning information.
3. The vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1, characterized in that: The temperature and vibration sensor is used to transmit the real-time temperature and vibration acceleration signals of the quay crane's rotating mechanism to the data acquisition cabinet via cable. Its temperature measurement range is -20 to 120℃, and the vibration part is of type IEPE with an upper limit of frequency response greater than or equal to 10KHz. It is installed vertically at the motor drive end, vertically at the key load-bearing positions of each shaft of the gearbox, and horizontally at the bearing seat of the roller. The stress wave acceleration sensor is used to transmit the collected real-time stress wave signals of the quay crane's rotating mechanism to the data acquisition cabinet via cable. It is installed vertically on the intermediate shaft of the gearbox. The magnetic flux speed sensor is used to obtain the rotation speed by measuring the change of the motor's magnetic field and then transmit the real-time speed signal of the quay crane's rotating mechanism to the data acquisition cabinet via cable. It is installed on the motor using a tooling fixture.
4. A vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1, characterized in that: The data acquisition cabinet is powered by a 220V AC power supply via an air switch and a 24V power supply to the signal acquisition card. The signal acquisition card has 8 or 16 acceleration channels, 8 or 12 slow variable channels, and 2 speed channels. The signal acquisition card is used to acquire the temperature, vibration acceleration, stress wave acceleration, and speed of the rotating mechanism based on the real-time signal data from the multi-source sensor group. The data is then connected to a switch via a network cable, and the switch is connected to an industrial control computer via a network cable.
5. A vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1 or 4, characterized in that: The signal acquisition card is used to preset speed thresholds and vibration thresholds based on the rotation speed and vibration data of the rotating mechanism and associate them with the acquisition function. When the real-time vibration acceleration value or speed value of the rotating mechanism exceeds the corresponding preset speed threshold or vibration threshold, long-cycle waveform data acquisition is performed. The waveform sampling frequency is at least 102.4KHz and the time is at least 10s.
6. A vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1, characterized in that: The wireless inspection device is used to collect the current vibration waveform of the rotating mechanism. The sampling frequency is set to 25.6KHz and the sampling time is 2s. The collected signal data is uploaded to the mobile APP client via Bluetooth. After the user enters the location of the inspection device and the rotation speed tag of the rotating mechanism through the mobile APP client, the data is uploaded to the industrial control computer through the wireless network set up inside the monitoring center.
7. A vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1, characterized in that: The industrial control computer is located in the electrical room of the quay crane and is equipped with a wireless network card. It connects to the monitoring center through the wireless network on the quay crane. The data storage module on the industrial control computer is configured with 300G or more of storage space to store multi-source signal data collected in the past 3 months.
8. A vibration monitoring and early warning system for a quay crane rotation mechanism according to claim 1 or 2, characterized in that: The signal processing and analysis module on the industrial control computer has multiple preset vibration index alarm thresholds for different gears selected according to the real-time operating conditions of the rotating mechanism.