How To Improve Crane Life?
Jul 27, 2023
How To Improve Crane Life?
Cranes are more dangerous during use.
During the operation of the crane, the moving parts will inevitably produce wear, loose connections, oil deterioration, and corrosion of the metal structure, which will cause different degrees of reduction in the technical performance, economic performance and safety performance of the crane.
Therefore, in order to prevent and eliminate hidden dangers and ensure that the crane is always in good condition, the crane should be maintained and maintained before the wear and tear of the crane parts has not reached the level that affects the crane.
With the development of the economy and the increase of large-scale construction projects, cranes have become indispensable production equipment.
Hoisting machinery is the main component of special equipment stipulated by the state, and it is very dangerous during use. In order to prolong the service life of the equipment, reduce and eliminate the safety accidents of the crane, it is necessary to use and maintain it correctly.
At present, there are still problems such as poor management of cranes, drivers or operators who do not strictly overhaul and repair the equipment, making the equipment "sick", no strict operating procedures, improper storage and other problems, resulting in more crane failures.
This is all caused by the poor maintenance and maintenance of the crane. Over time, it will cause the crane to fail, require shutdown for maintenance, and even cause serious casualties.
1. The importance of good crane maintenance and maintenance
① Working characteristics and risk factors of cranes
A 5 ton overhead crane is a machine that can lift vertically and move objects horizontally within a certain range, and is characterized by intermittent movements and cyclical operations.
As a large-scale machinery, the working characteristics of the crane determine that there are great risk factors. In order to ensure the safe operation of the crane, the country lists it as special equipment for management, and many enterprises regard the management of lifting equipment as a key to safe production key link.
② It is very difficult to maintain a large-scale mechanical crane. Doing a good job in crane maintenance can increase the number of crane repairs to a certain extent.
Only by knowing how to maintain cranes, do the basic work of crane maintenance well, and prevent problems before they happen.
Doing a good job of maintenance in the early stage can better avoid the root cause of crane maintenance problems.
For example, there should be enough oil in the transmission part of the crane, and the vulnerable parts must be checked, repaired or replaced frequently. The bolts of the machine, especially the parts that often vibrate, such as the slewing ring and the connecting bolts of the boom, should be checked for looseness. If it is loose, it must be tightened or replaced immediately, so as to avoid major problems with the crane and save the trouble and loss of finding someone to repair.
③ Do a good job in the maintenance and maintenance of the 5 ton bridge crane, which can play the following roles.
a. To ensure that the cranes always have good technical performance, so that all institutions can work normally and reliably, and improve management indicators such as their integrity rate and utilization rate.
b. Ensure that the crane has good performance, strengthen the protection of structural parts, keep the connection firm, and the electro-hydraulic components operate and function normally, avoid abnormal vibration caused by electromechanical factors, and meet the normal use requirements of the crane.
c. Ensure the safe use of cranes.
d. Comply with the relevant environmental protection standards stipulated by the state and departments.
e. Prolong the service life of the crane reasonably and effectively. Through the maintenance of the crane, the repair interval of the crane or mechanism, including the overhaul period, can be effectively extended, thereby prolonging the service life of the crane.
④ The causes of crane accidents mainly include human factors and equipment factors. Among them, the human factors are mainly due to the irrational behavior of managers or users due to psychological reasons such as fluke, trouble-saving and rebellion, and the physical factors are mainly It is because the equipment is not designed, manufactured, installed, repaired and maintained according to the requirements, especially the inspection is not carried out according to the requirements, and it is operated with "sickness", thus burying potential safety hazards.
2. Crane maintenance and maintenance points
① Crane maintenance and maintenance time specification
Some daily maintenance should be carried out every day; after 1000 hours of work, minor repairs to the mechanical and electrical systems; after 4000 hours of work, medium repairs to the mechanical and electrical systems; after 8000 hours of work, major repairs to the mechanical and electrical systems.
② Daily maintenance and maintenance of crane parts
a. Maintenance of motor and reducer
Always check the temperature of the motor casing and bearing parts, the noise and vibration of the motor for abnormal phenomena.
In the case of frequent starts, the ventilation and cooling capacity is reduced due to the low speed, and the current is large, and the temperature rise of the motor will increase quickly, so attention should be paid to the temperature rise of the motor not exceeding the upper limit specified in its manual. Adjust the brake according to the requirements of the motor instruction manual.
The daily maintenance of the reducer can refer to the instruction manual of the manufacturer. And the anchor bolts of the reducer should be checked frequently, and the connection must not be loose.
b. of the running gear
When using for the first time, you should open the vent cap of the reducer first to ensure good ventilation and reduce internal pressure. Before work, check whether the oil level of the reducer meets the requirements. If it is lower than the normal oil level, add the same type of oil in time.
The bearings of each wheel of the traveling mechanism have been filled with sufficient grease (calcium-based grease) during assembly, and do not need to be refueled daily. The grease can be replenished once every two months through the oil injection hole or by opening the bearing cap, and disassembled every year. Clean and replace - secondary grease.
Grease the meshing parts of each open gear once a week.
c. Maintenance and maintenance of hoist unit
Always observe the oil window of the gearbox to check whether the oil level is within the specified range. When it is lower than the specified oil level, replenish oil in time.
When the crane is not used very frequently and the sealing condition and the use environment are good, the oil in the reduction box should be replaced every six months, and when the use environment is bad, it should be replaced every quarter. When it is found that there is always foam in the tank or the oil surface and it is determined that the oil has deteriorated, the oil should be changed immediately. When changing the oil, the oil should be replaced strictly according to the instruction manual of the reducer, and the mixed use of oil should not be avoided.
The bearing seats at both ends of the reel should be filled with grease every two days, and the surface of the reel and the wire rope should be greased according to the situation. The rolling bearings of the fixed and movable pulley blocks should be replenished with grease once a month.
③ Maintenance and maintenance of the metal structure of the 20 ton overhead crane, which is an important aspect of crane maintenance:
a. Try to prevent component deformation and collision damage during transportation.
b. During the period of use, it must be inspected and maintained regularly to prevent corrosion.
c. Frequently check structural connection bolts, welds, and components for damage, deformation, and looseness.
d. Spray the paint once every 1-2 years.
④ Maintenance and maintenance of crane mechanical equipment to avoid "trauma" to the crane.
a. The brakes of each mechanism should be checked frequently and the gap between the brake shoe and the brake wheel should be adjusted to ensure flexibility and reliability. There should be no dirt on the friction surface, and if there is dirt, it must be washed off with gasoline or thinner.
b. The oil and hydraulic oil of various parts such as reduction box, gearbox, external meshing gear, etc. shall be in accordance with the requirements in the table.
c. Pay attention to check whether there are any broken wires and loose strands in each part of the wire rope. If it exceeds the relevant regulations, it must be replaced immediately. The maintenance of the wire rope should be strictly in accordance with the provisions of GB5144-85.
d. Frequently check the connection of each part, and tighten it if it is loose. The tightness of the connecting bolts of the body should be checked when the body is under pressure (the method of rotating the arm can be used to cause the state of compression), and all connecting shafts must have cotter pins and must be fully opened.
e. Frequently check whether each mechanism is operating normally and whether there is any noise. If any fault is found, it must be eliminated in time.
To use the crane safely and prevent accidents, it is necessary to control the human factor and prevent abnormal damage caused by man.
This requires the user unit to improve scientific and reasonable rules and regulations, strictly implement technical regulations, and take strict precautions against various possible failures.
It is even more necessary to strengthen the management of lifting equipment, do a good job in the daily maintenance and maintenance of cranes in accordance with the maintenance procedures, and ensure the integrity, utilization and utilization of lifting equipment.
