System basic structure

At the base of SED lies a module endowed with a microprocessor that administers the GSM modem’s resources. This module is named "gsm_manager" and has its own functioning algorithm (source code) and communication protocol with the GSM modem and the PLC module (automate programmable on base of the microprocessor).

Between the gsm_manager module and the application module (PLC) there is a parallel communication system called data base line. On this data base line, the order and importance of the events are established. If necessary, the audio/video modules may be connected to the "gsm_manager" module.

Power unit

The SED deivce may be supplied from various usual power supply units (220Va.c./380Va.c./24Vc.c./12Vc.c/5Vc.c), the main power unit being the storage cell, that allows a permanently functioning (in the capacity limits) of the system. The SED device transmits notes regarding the storage cell’s status in various situations, in capacity percentage. Virtually, the storage cell may have a voltage of more then 3.7 V a.c. and an amperage of minimum 1.5 A.

The external power supplies may by of any type and value, the minimum and necessary condition is the possibility to ensure the charging capacity of the battery, in the limits of its parameters given in the battery manufacturer’s catalogue.

The software and the application interface

The application algorithm (software/binary code) that specifies the handling of the monitored information may be found in the program memory of the application module (PLC). These signals are transformed in binary codes that will be send in the future on the parallel data base line to the "gsm_manager" module. SED is compatible through standard communication using the RS232/USB/TCP/IP protocols with the Windows (XP, 7-8-10) operating systems, both for data emission and reception.

It was also recently developed an interface for Android operating system installed on smartphone and / or tablet. The communication program allows a direct connection with the radio modules for adjusting the reception/emission parameters, needed as a quality characteristic for data interchange. At the monitored results reception, an electronic block, called “gsm_dispatcher”, may be found. This module communicates with the PC through one of its ports.

The information received by the computer (PC) may be stored in a data base (server). These may be subsequently listed in order to obtain a physical evidence of the events, for example, to prepare a service report.

The system advantages

The System for Distance Supervision of Industrial Equipment (SED) presents the following advantages:

- an exact perception upon the nature of the defaults appeared at the equipment
- high reliability in operation for the industrial equipments
- safety in application because of the equipment’s monitoring
- a reduced intervention time for service team
- reduced service costs for industrial equipments equipped with SED device.

Elevators monitoring

SED device may be connected to an electric/hydraulic elevator installation. The basic function for this application is to realize a vocal link between the person(s) blocked in the elevator’s cabin and the dispatcher system, in the situation of a default caused by the elevator or external of it. It is known that elevators are compulsory endowed with intercommunication systems (interphones) between the cabin and the elevator’s room where the control is placed.

On this panel, the voltage battery (usually, 12 V) is placed and it supplies the communication interphone between the elevator’s cabin and an intervention point from a limiting area and for the alarm system. The alarm system is driven by the persons blocked in the cabin by means of an alarm switch in case of a drop in tension in the power distribution net.

In this case, SED is equipped with an audio module and a card reader. This reader is needed to monitor the maintenance and repair interventions of the supervised elevator. The existing installation (interphone/alarm) remains in the elevator’s configuration. SED will be connected to this and the alarm switch placed in the elevator’s cabin will have a double function: usual alarm and emergency appeal of a phone number or phone numbers of the company responsible for the elevator’s repair. These phone numbers exist in a dispatcher type switchboard with a permanent service routine. The emergency appeal has a permanent effect or only in case of a default that may appear in the elevator’s operation. The defaults’ monitoring will be done by means of the PLC module attached to the control panel of the elevator, that validates the command for the phone appeal.

Overhead travelling cranes monitoring

Motor voltage and current monitoring

This information is used to monitor the health of the engines. Using advanced analysis based on specific algorithms, anomalies and deteriorations in engine operation are detected. This notifies the user in advance to carry out preventive maintenance and thus avoid costly breakdowns.

Motor temperature monitoring

This information is important to prevent the motors from overheating, which could lead to their failure and expensive replacement. The system sends timely warnings when the temperature exceeds a safety limit to prevent damage.

Hoist motor vibration

This is a long-term monitoring solution that tracks engine wear over a long period of time - months or years. The algorithm informs the user when it is time for general preventive maintenance of the engine mechanics. For example, higher vibration could be a symptom that precedes an impending failure.

Usage monitoring

Monitoring the use of the crane or elevator travel. The operating data is recorded via the contacts of the travel buttons and the travel limiters. This is necessary to keep track of the duration and the different types of movements. This information is then consolidated to measure operational efficiency and remaining lifespan.

CDF (Cyclic Duration Factor) for motor

“Motor CDF” is calculated based on operating parameters related to work cycles, which include the frequency and duration of typical operations. This includes starting, running time with or without load, electrical braking and idle time. It is used to alert the user when CDF usage exceeds set limits.

Motor overload and load monitoring

Motor overload and actual load are monitored using a combination of current and load sensors. This information is used to track equipment usage under specific loading conditions.

Motor brake failure monitoring

The air gap of the brake is monitored by sensors. Brake fault alerts are sent when the air gap exceeds safe limits. This helps to minimize by detecting brake faults.

SCADA, VFD and PLC monitoring

The monitoring system interfaces with automation systems with customized protocols for monitoring control parameters, errors, status, etc. This allows detailed analysis of the operating conditions of the elevators and cranes, errors, faults etc.

Safe Design Working Period (SWP) monitoring

The long-term safe operating life of the elevators and cranes is calculated using advanced algorithms and operating history, CDF and loading conditions. This provides information about the calculated duration of use and the actual service life of the equipment.

Crane cable faults

Loose cable faults are monitored and alerts are issued immediately to prevent cable failures and other safety risks.

Features of the overhead travelling crane monitoring preventive maintenance system

The system is fitted with remote firmware upgrade. There is no need to visit the website to update the firmware with new features or bug fixes. Instead, it can be done right from your office. It has a small built-in battery, which indicates tampering with the device, such as power off, box opening, etc. This warning is sent to the server (within minutes) before the electronic parts run out of power. This will discourage malicious manipulation of the device. External devices such as VFDs, PLCs, data loggers can be connected to the system. The communication protocol of these devices must be known so that it can be implemented into the system to work with the existing electronic devices. In the event of a GSM signal failure, the system saves the data locally. This data is then uploaded to the server once connection to the server is restored. So, even in case of connectivity loss, there is no data loss. Since the hardware and software are designed and developed by ELMAS SRL, we can make changes, add functions and customize software screens, sensors and functions. This offers the user the unique advantage of receiving a customized system.

Industrial equipment’s monitoring

The system for distance survey of the equipment (SED) may also be fit on industrial installations, such as: industrial cranes, escalators, forklfit trucks, automatic storage systems, automatic auto-parking systems, etc. The minimum and necessary condition is for the device to be situated in the covered area of the signal delivered by the GSM operator. This is a very important condition especially in case of mobile applications, that is those that are moving with the SED device inside or outside the covering area of the signal.

In this case, SED is able to memorize the events that took place and couldn’t be transmitted to the place where monitoring is interpreted by scanning the electromagnetic field and finding the timely moment for the transmission. In this case, the information time may increase appreciably. For each industrial application type, the PLC module must be reprogrammed, depending on the requirements for the monitored data. This requires realizing the application software for the PLC micro-controller.