Abstract:
To address low production efficiency and large property losses caused by stacker crane failures in the warehousing and logistics systems of tobacco enterprises, a stacker crane state monitoring system based on multi-sensor fusion was designed. Vibration/temperature sensors, inclination sensors, laser displacement sensors, and cameras were installed on the stacker cranes to monitor the stacker crane attitude and the positions of the forks and pallets in real time, and monitoring data were transmitted at high speed using wireless communication technology. Monitoring data from key sensors were selected as health status evaluation indicators, and the CRITIC weighting method was used to fuse and analyze multidimensional operating data, including stacker crane vibration, inclination, and fork height. A comprehensive health evaluation model for stacker cranes was established to quantify equipment health. A stacker crane operating state monitoring platform was developed to visualize the state and health information of key components, reminding workers to perform preventive maintenance and servicing in a timely manner. Field verification was carried out using the stacker cranes at the Golden Leaf Production and Manufacturing Center. The results showed that, after the monitoring system was put into operation, the stacker crane failure rate decreased from 0.63% to 0.45%, the average monthly downtime decreased from 230 min/unit to 168 min/unit, and five material drop incidents per month were effectively avoided. The system can provide technical support for improving the safety of warehousing operations.