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Industrial Overhead Crane Condition Monitoring
A6.ConditionIndustrial overhead cranes

Industrial Overhead Crane Condition Monitoring

Which crane or critical motor should be checked first?

Case ID
PHM-01
Module
A6.Condition
Application
Industrial overhead cranes
Industry
Overhead cranes and motors at a metalworking plant
  • Overhead crane
  • Vibration
  • Equipment history
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SHEET 01 · Case story

Which crane or critical motor should be checked first?

A metalworking plant collects vibration, temperature and equipment-status data from its overhead cranes and motors, organizing them into health rankings, trends and alerts for the maintenance team to plan inspections. Results still need to be reviewed against on-site conditions.

SHEET 02 · Challenge and response

From the site problem to a system approach.

  1. 01The challenge

    An overhead crane or critical motor issue may only be noticed after a stop or during an inspection.

  2. 02The system approach

    Bring vibration, temperature and equipment status together in health rankings, trends and alert tracking.

  3. 03Reported outcome

    Help the maintenance team set inspection priorities using condition rankings and trends.

SHEET 03 · Architecture

System architecture and data flow.

Sensors collect data through a Condition Gateway; the platform maintains an equipment list, alert thresholds and maintenance clues. Source diagrams retain some original Traditional Chinese labels.

L4應用層Application
L3 → L4：REST API · WebSocket · LINE Webhook
L3雲端層Cloud
L2 → L3：TCP/IP over HTTPS
L2邊緣層Edge
L1 → L2：Modbus TCP / MQTT / API
L1感測層Sensing
Data flows upward
    • 設備 Dashboard
    • 預警推播
    • 維修建議
    • 報表匯出
    • CaseInspection planning
    REST API · WebSocket · LINE Webhook
    • Equipment Health
    • Spectrum Analysis
    • Trend Database
    • Alert Rules
    • Maintenance Reports
    • CaseHealth rankings and trends
    TCP/IP over HTTPS
    • PHM Gateway
    • 既有平台 Box
    • 本地異常暫存
    Modbus TCP / MQTT / API
    • 震動感測器
    • 溫度感測器
    • 電流 / 電表
    • 設備狀態
    • CaseCrane and motor vibration, temperature
SHEET 04 · Wiring and hardware

Wiring diagrams and hardware configuration.

The diagram outlines data flow between site signals, edge devices, the network and the platform. Confirm installation and connection scope before work begins.

Original diagram notes (Traditional Chinese)
  1. 01主機櫃 / Main equipment cabinet 內含 24VDC PSU、既有平台 Box、PHM Gateway
  2. 0224VDC PSU（100~240VAC, 單相 / DC 24V / 5A / 工業電源）以 24VDC 紅虛線供電給 既有平台 Box 與 PHM Gateway
  3. 03既有平台 Box（IPC / HMI / Switch、本地資料整理、斷網本地暫存）與 PHM Gateway（Sensor I/O / MQTT、設備測點採集）以 Modbus TCP / MQTT 藍線連接
  4. 04既有平台 Box 上行至 既有平台 Cloud（部署於雲端 / 台灣）：TCP/IP over HTTPS via customer LAN（綠線）
  5. 054× 現場訊號 / 表計 / 感測器資料以橙線接入 PHM Gateway：設備 A（震動 / 溫度，測點 1）；設備 B（震動 / 溫度，測點 2）；設備 C（電流 / 運轉，測點 3）；設備 D（健康狀態，測點 4）

TOTAL既有平台 Box + PHM Gateway + 現場點位 / 表計 / 感測器 = PHM 基準配置

Original diagram legend藍線 = Ethernet / Modbus TCP / TCP-IP；綠線 = HTTPS / TCP-IP (Cloud Uplink)；橙線 = 震動 / 溫度 / 電流 / 運轉狀態資料；紅虛線 = 24VDC Power / 低壓電源Planning reference with Traditional Chinese labels. Confirm wire colors, terminals, power and communications against site-approved documents.
SHEET 05 · Before implementation

What to confirm before work begins.

This material describes a planning direction. Confirm site points, installation, report definitions and alert rules against actual site conditions.

  1. 01Site points and signal sources
  2. 02Communication protocols and network conditions
  3. 03Power, panels and installation method
  4. 04Report fields and data definitions
  5. 05Alert rules and responsible people
  6. 06Equipment brands, models and quantities
SHEET 06 · Related cases

More examples from this module.

Explore A6.Condition →

END · Next step

What would you most like to solve on site?

An equipment list, a panel photo or a problem you face every day is enough to start.

  1. 01An equipment list
  2. 02A panel photo
  3. 03A problem you face every day
Discuss site needsView cases