Provide users with intelligent winch and machine torque application technology
Smart Reducer Monitoring System
The intelligent reducer monitoring system developed by the SuGong team displays the reducer’s dynamic speed and load torque on the control system’s touchscreen. Based on the magnitude of the load torque and the trend of load resistance, the system autonomously determines the current load condition: light load, pre-emptive overload, overload, or tendency toward jamming.
Based on the current load status and combined with the user’s selections, the system can provide corresponding autonomous responses: In light-load conditions, it will initiate autonomous alarms, automatically adjust the gear ratio, and delay shutdown; when the load exceeds the predicted threshold or surpasses the rated capacity, it will trigger autonomous alarms, reduce speed automatically, and delay shutdown; if a jamming trend is detected, the system will proactively shut down within 100 milliseconds; during obstacle crossing, the system will autonomously identify the obstacle and proactively reduce speed to safely navigate it, then automatically resume normal speed once the obstacle has been cleared.
Users can test the drive torque of the gearbox under no-load conditions. If the no-load drive torque of the gearbox exceeds the factory-set no-load drive torque, the system will trigger an alarm, prompting the user to inspect or maintain the gearbox (e.g., damage to the transmission chain, lubrication failure, severe contamination, structural deformation, etc.).
The system displays the lubricant oil temperature and oil quality of the gearbox, as well as the bearing temperatures and the operational status of the lubrication oil lines, on the touchscreen. If any abnormality is detected, the system will prompt the user to take appropriate action.
The system automatically detects whether the motor is experiencing overcurrent or phase failure. In the event of a phase failure, the system will proactively shut down within 50 milliseconds. In the case of overcurrent, the system will either issue an alarm automatically or initiate a countdown shutdown (the approaching time for shutdown is correlated with the degree of overcurrent).
The system automatically generates and stores graphs of the reducer’s dynamic load torque and dynamic speed curves.
| Basic Features | Function Description | ||||||||||||||||||||||||||||||||||||||||||||
| Dynamic Torque Load Display | The system dynamically displays the reducer’s dynamic load torque on the touchscreen in the form of bar graphs, trend charts, and numerical values, enabling users to intuitively understand the reducer’s current load-bearing status. | ||||||||||||||||||||||||||||||||||||||||||||
| Dynamic Speed Display | The system dynamically displays the reducer’s current output speed in the form of bar graphs, trend charts, and numerical values on the touchscreen, enabling users to intuitively grasp the reducer’s current rotational speed. | ||||||||||||||||||||||||||||||||||||||||||||
| Light-load judgment | Once the torque load of the reducer falls below the user-defined light-load threshold, the system will automatically determine that the operating condition is a light-load state. | ||||||||||||||||||||||||||||||||||||||||||||
| Light-load autonomous response | In light-load conditions, the system can respond autonomously based on the user’s selection: issuing alarm notifications, automatically switching to low-speed or high-speed operation, or delaying shutdown. | ||||||||||||||||||||||||||||||||||||||||||||
| Judgment of Super-Predictive Load Blocking | Once the reducer’s load torque exceeds the predefined threshold for known load resistance set by the user, the system will automatically determine that the load has surpassed the pre-defined resistance level. | ||||||||||||||||||||||||||||||||||||||||||||
| Autonomous Response to Over-Prediction and Load Blocking | In the event of an over-prediction blockage condition, the system can respond autonomously based on the user’s selection: issuing an alarm notification, automatically switching to low-speed or high-speed operation, or delaying shutdown. | ||||||||||||||||||||||||||||||||||||||||||||
| Overload Detection | Once the load torque of the reducer exceeds its rated overload limit, the system will automatically determine that an overload condition has been reached. | ||||||||||||||||||||||||||||||||||||||||||||
| Overloaded Autonomous Response | In an overload condition, the system can respond autonomously according to the user’s choice: issuing an alarm, automatically switching to low-speed operation, performing an immediate shutdown, or initiating a countdown shutdown (with the approach time for shutdown being correlated with the degree of overload). | ||||||||||||||||||||||||||||||||||||||||||||
| Judgment of the jamming trend | When the load torque of the reducer exceeds the blocking torque threshold and the rotational speed shows a tendency toward stalling, the system will autonomously determine that a blocking trend is occurring. | ||||||||||||||||||||||||||||||||||||||||||||
| Autonomous Response to Jamming | When a jamming trend is detected, the system will automatically shut down within 100 milliseconds. | ||||||||||||||||||||||||||||||||||||||||||||
| Self-responsive to overcoming obstacles | When the reducer’s load torque reaches a critical threshold, if the user has enabled the self-responsive “over-hump” function, the reducer will autonomously detect and proactively reduce its speed to safely navigate the hump. After successfully passing the hump, it will automatically resume its original speed. | ||||||||||||||||||||||||||||||||||||||||||||
| Super-fast autonomous response | This function is designed to enhance the chain-break protection of the hoist’s drive system. When the drum speed of the hoist exceeds its rated speed, the system will automatically shut down and activate the disc brake on the hoist’s drum. | ||||||||||||||||||||||||||||||||||||||||||||
| Oil Product Alert | Once the lubricant oil in the reducer reaches the contamination threshold, the system will automatically trigger an alarm and prompt the user to change the oil. | ||||||||||||||||||||||||||||||||||||||||||||
| Oil temperature warning | Once the lubricant oil temperature of the reducer reaches the alarm threshold, the system will automatically trigger an alarm and prompt the user to take action. | ||||||||||||||||||||||||||||||||||||||||||||
| Oil Level Warning | When the lubricant oil level in the reducer is too low, the system will automatically sound an alarm and prompt the user to take action. | ||||||||||||||||||||||||||||||||||||||||||||
| Oil circuit alert | After the lubrication oil passage in the reducer becomes blocked or oil supply is interrupted, the system automatically triggers an alarm and prompts the user to take action. | ||||||||||||||||||||||||||||||||||||||||||||
| Bearing Temperature Alert | Once the bearing temperature of the reducer reaches the warning threshold, the system automatically triggers an alarm and prompts the user to take action. | ||||||||||||||||||||||||||||||||||||||||||||
| The measured internal resistance value of the reducer | The user can disconnect the coupling between the gearbox and the machine, then test the gearbox’s drive torque and compare it with the drive torque specified at the factory to determine whether there is any internal jamming or malfunction in the gearbox. | ||||||||||||||||||||||||||||||||||||||||||||
| Internal resistance self-check upon machine出厂 | When the machine leaves the factory, the manufacturer can self-learn and memorize the no-load drive torque at the time of出厂. During machine inspections or maintenance, this data can serve as a reference or basis for comparison. | ||||||||||||||||||||||||||||||||||||||||||||
| Machine internal resistance self-test | Users can run the machinery equipment at no load to test the drive torque under no-load conditions and compare it with the drive torque specified at the time of factory delivery, thereby determining whether there is any internal jamming or malfunction in the machine. | ||||||||||||||||||||||||||||||||||||||||||||
| Machine Internal Resistance Alert | If the machine’s no-load drive torque exceeds the no-load drive torque at the time of manufacture, the system will trigger an alarm, prompting the user to inspect or maintain the machine (e.g., damaged transmission chain, lubrication failure, severe contamination, structural deformation...). | ||||||||||||||||||||||||||||||||||||||||||||
| Remote communication of the machine | The system supports remote monitoring functionality, enabling gearbox manufacturers and machine manufacturers to remotely monitor the dynamic operating conditions of equipment and promptly notify equipment operators to take appropriate action. | ||||||||||||||||||||||||||||||||||||||||||||
| Motor overcurrent protection | The system displays the three-phase dynamic currents of the motor on the touchscreen. After the motor experiences overcurrent, the system can, according to the user’s selection, either trigger an automatic alarm or initiate a countdown shutdown (the approach time for shutdown is correlated with the degree of overcurrent). | ||||||||||||||||||||||||||||||||||||||||||||
| Motor phase-loss protection | Once the motor enters a phase-loss condition, the system will automatically shut down within 50 milliseconds. | ||||||||||||||||||||||||||||||||||||||||||||
Online Application Consultation(Key elements: Rated tensile force, rated rope speed, maximum rope capacity, operating conditions, control functions, display parameters...)
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Email: kefu@jssugong.com
Address: No. 1 Zhongshan West Road, Rucheng Town, Rugao City, Jiangsu Province, China.
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