Overhead Crane Condition Monitoring System for Galvanizing Plant

Condition monitoring for double girder gantry crane

Galvanizing is a process that involves coating metal with zinc to protect it from corrosion. However, it also exposes the production equipment to harsh conditions, such as acidic fumes, high temperatures, and mechanical stress.

Levate has developed a new double girder overhead gantry crane (2*20.000 kg) for use in this extreme environment.

The control panel components are located on top of the crane and need to be robust to withstand these harsh conditions, vibrations, shocks, and voltage dips.

The crane is in continuous operation and any downtime stops production, which is very costly. A high degree of reliability is therefore required.

Condition monitoring

To ensure the reliability and safety of the new crane, a condition monitoring system was implemented. The system collects and analyzes data from the crane control systems. The data collected includes:

• Contactor operations
• Motor running currents
• Hoist-loading data
• Hoist vibration data
• Travel limits

The system uses this data to calculate the crane’s condition. For example, it can estimate the hoist’s safe working period (SWP) based on the load and operating state, using a load spectrum recorder function block.

The system also provides a WebUI that displays all the condition monitoring information on a web panel inside the cabinet, for easy access by maintenance or local personnel. Alternatively, the information can be viewed remotely via a web browser.

Preventive maintenance

The system flags when individual motors or components need servicing, based on running time for brakes, motor, ropes etc or according to the service schedule.

More importantly, the system can detect vibration and current anomalies that may indicate bearing or alignment problems on the hoist, allowing preventive maintenance.

Safe operations

The system also monitors lifting operations throughout tandem lifts, where both hoists are used, stopping any situations that may lead to an unsafe lift.

Configuration and Reporting

All information is logged and accessible from a WebUI that displays all condition monitoring information on a web panel or can be viewed remotely via a web browser.

In addition, all of the data is sent to a cloud reporting system where Levate engineers and the end customer can log in and see the state of the assets.

The webUI also provides a single point to configure the 2 hoist systems to alter parameters such as limit positions etc.

The solution

The condition monitoring system is a separate application from the 2 hoist control systems and is connected using Modbus TCP.

The system is running on a single RevolutionPi with 2 separate applications, a monitoring logic / logging app and a webUI app.

The application was developed using CDP Studio, mostly using no-code development and only using full-code option for the math calculations. The HMI was created using the CDP no-code design tool and using the included widgets and themes. In this way, the monitoring system with the UI and cloud connection was quite fast to develop.

About Levate Solutions

Levate Solutions: https://www.levate-solutions.com/

Levate delivers complete turnkey solutions for your engineering projects, from design to complete commissioning. They are specialists in material handling, cranes, and control systems.