Low-cost IoT-Based sensors dashboard for monitoring the state of health of mobile harbor cranes: Hardware and software description

A cost-effective IoT-based real-time data acquisition and analysis hardware system was developed to enhance the performance of the mobile harbor cranes using a combination of a cost-effective quality control monitoring sensor dashboard (proximity sensors, angle position sensor, weight sensor, vibration sensor, and wind sensor), embedded microcontroller (Arduino), and embedded computer (Raspberry Pi). Hardware was operated using a specially developed novel Quality Control and Data Acquisition Multiprocessing software (QC-DAS). The QC-DAS can automatically collect and save real-time data of the sensors in a large-capacity SD card, monitor the state of health of the hardware, and transmit the real-time data of the sensors and the working state of the crane to an IoT server. The novelty of the QC-DAS design is that each function is encapsulated in a predefined module that is "immersed" in a message transmission medium. Modules interact by sending and receiving various signals through this medium. Modularity makes system design simpler, faster, and flexible. Thanks to modularity, users may incorporate their data processing modules when new sensors are added to match the system's needs. Thanks to modularity the DC-DAS can operate quality control hardware for any mobile cranes. There are several constraints in the quality control data acquisition system used by the Damietta Port Authority in Damietta, Egypt, SESCO TRANS company which cause the loading and unloading process to be slowed down. As a result, the SESCO TRANS company upgraded its quality control data acquisition system using the QC-DAS. The hardware was deployed for six months, during which the collected data was used to verify the crane's performance. The vibration produced by the slewing of the crane was monitored and compared with the bearing fault frequency limits, during the operation the wind speed was monitored and compared with the critical wind speed to stop the crane operation automatically, and the payloads data of the six months was collected and was used to calculate the working efficiency of the load and unload process of the crane. The results demonstrated that while maintenance costs were decreased, the crane load/unload procedure was improved. The SESCO TRANS company crane operators approved the developed approach and appreciated the achieved results.