Maintenance and inspection cycle of electric hoists
Maintenance and inspection cycle of electric hoists: the key to ensuring safety and efficiency
In the process of industrial production and material handling, electric hoists, as a common lifting equipment, play a vital role. However, to ensure that the electric hoist always maintains a good operating condition, regular maintenance and inspection are essential. This article will explore in depth the maintenance and inspection cycle of electric hoists, as well as the key issues that should be focused on at different stages, aiming to help international wholesale buyers and related users understand how to scientifically and reasonably perform maintenance work on electric hoists to extend the service life of the equipment and ensure operational safety and efficiency.
1. The importance of maintenance and inspection of electric hoists
Ensure operational safety: Electric hoists carry a huge weight in lifting operations. Once a failure occurs, it may cause serious safety accidents. Through regular maintenance and inspection, safety hazards of equipment can be discovered in time, such as wear of the hook, breakage of the wire rope, failure of the brake, etc., and repair or replace them in time, so as to effectively prevent accidents and ensure the life safety of operators and the integrity of surrounding equipment and facilities.
Extend the service life of the equipment: Electric hoists that are in frequent use for a long time will suffer different degrees of wear and loss in various parts. Regular maintenance can repair, lubricate and adjust these parts in time, reduce friction and wear between parts, reduce the frequency of failures, keep the equipment in good operating condition, thereby extending the overall service life of the electric hoist and bringing greater economic benefits to users.
Improve work efficiency: An electric hoist in good operating condition can complete lifting tasks more stably and efficiently. Regular maintenance and inspection can ensure that the performance indicators of the equipment are in the best state, avoid operation interruptions and delays caused by equipment failure, improve production efficiency, ensure the continuity and stability of production, and help enterprises better arrange production plans and delivery schedules.
2. Factors affecting the maintenance and inspection cycle of electric hoists
Frequency of use: The frequency of use of electric hoists is one of the important factors in determining the maintenance and inspection cycle. For equipment with high frequency of use, such as electric hoists that run for a long time and high intensity every day in busy production workshops or logistics warehouses, the wear rate of its various parts is relatively fast, so more frequent maintenance and inspection are required. Generally speaking, some simple inspections and maintenance work are required every week or even every day, such as checking the wear of the wire rope, cleaning the surface of the equipment, lubricating the moving parts, etc., while more comprehensive and detailed inspections are required every month. On the contrary, for electric hoists with low frequency of use, the maintenance and inspection cycle can be appropriately extended, but regular inspections are still required to ensure their normal operation.
Working environment: The working environment has a significant impact on the performance and life of the electric hoist. If the equipment is in a harsh working environment for a long time, such as high temperature, humidity, dust, corrosive gas, etc., its metal parts are prone to rust and corrosion, and electrical components may also fail. Therefore, it is necessary to shorten the maintenance and inspection cycle, strengthen the protection and maintenance measures for the equipment, and clean the dust, oil and debris on the surface of the equipment in time to prevent it from causing damage to the equipment. For electric hoists used in a clean, tidy and well-ventilated environment, the maintenance and inspection cycle can be relatively extended.
Equipment type and specification: Different types of electric hoists differ in structure, performance and complexity, and the focus and cycle of their maintenance and inspection will also be different. For example, chain electric hoists and wire rope electric hoists differ in transmission systems, lifting media, etc., so they need to be inspected and maintained accordingly according to their respective characteristics during maintenance. Generally speaking, the maintenance and inspection cycle of small electric hoists is relatively long, while large electric hoists, due to their complex structure and large load-bearing capacity, involve more key components and higher safety requirements, and usually require more frequent and comprehensive maintenance and inspection work to ensure their safe and reliable operation.
Manufacturer's advice: When designing and manufacturing electric hoists, manufacturers will formulate corresponding maintenance and inspection guidelines based on the characteristics and use requirements of the products. These guidelines usually contain detailed maintenance cycles, inspection items and operating methods, and are important references for ensuring the normal operation of the equipment. Users should carefully read and strictly follow the manufacturer's advice, and formulate a reasonable maintenance plan based on actual conditions to give full play to the performance and service life of the equipment.
3. Daily maintenance and inspection of electric hoists
Inspection before each use: Before using the electric hoist each time, the operator should perform some simple inspections. First, check whether there are obstacles around the work site to ensure that there is sufficient and unobstructed space for the equipment to operate. Secondly, observe whether there are any abnormal conditions on the running track, such as whether the track is deformed, debris is accumulated or damaged, etc., to ensure that the electric hoist can run smoothly. In addition, it is necessary to check whether the button device (flashlight) is sensitive and reliable, whether the lifting, lowering, left and right running actions are accurate, and the electric hoist should not move when a group of buttons are pressed at the same time to prevent accidents caused by misoperation. For the hook device, it is necessary to ensure that the hook can rotate flexibly within the circumference of 360° and the vertical range of 180°, there is no jamming and collision when the pulley rotates, the hook nut anti-loosening device is normal, and the hook mouth locking device is effective. For wire ropes, daily observations should be carried out in accordance with the relevant provisions of GB5972 to check whether the wire ropes are broken, deformed, worn, etc., to ensure that they meet the requirements for safe use. The inspection of the brake should not be ignored. The lifting, lowering and running brakes should be sensitive and reliable, and can stop accurately at the predetermined position. Finally, check whether the rope guide and other safety devices are operating normally, safely and reliably.
Cleaning and maintenance after use: After each use of the electric hoist, cleaning should be carried out in time. Remove dust, oil, debris, etc. from the surface of the equipment, especially key parts such as hooks, wire ropes, pulleys, etc., to prevent debris accumulation from affecting the normal operation and service life of the equipment. At the same time, lubricate the equipment as necessary, and add an appropriate amount of lubricating oil or grease to the appropriate parts according to the manufacturer's recommendations to reduce friction and wear between components and ensure that the equipment can run smoothly the next time it is used.
4. Regular maintenance and inspection
Monthly inspection: Conduct a comprehensive inspection of the electric hoist at least once a month, and the inspection content includes but is not limited to the following items. Check the wear of key components such as hooks, wire ropes, chains, etc., check whether there are cracks, deformations, broken wires, etc., measure whether the degree of wear exceeds the specified standards, and replace them in time if necessary. Check whether the friction plate of the brake is severely worn, whether the brake is sensitive and reliable, and adjust the brake clearance of the brake to ensure that it can provide sufficient braking torque. Conduct a comprehensive inspection of the electrical control system, including checking whether the wires and cables are worn, aged, damaged, etc., and check whether the operation of electrical components such as relays, contactors, buttons, etc. is flexible and reliable, and whether the wiring is firm, to ensure the safe and stable operation of the electrical system. Check whether the lubricating oil in the gearbox is sufficient and clean, and whether the oil quality has deteriorated. If it is insufficient or deteriorated, it should be added or replaced in time. At the same time, check the wear of transmission parts such as gears and bearings, and check whether there are abnormal phenomena such as abnormal noise and overheating. In addition, it is necessary to check whether the safety protection devices such as the limit device and the lifting weight limiter of the electric hoist are accurate and reliable, and can function normally to prevent accidents such as equipment overload and offside.
Quarterly inspection: A more detailed inspection and maintenance work is carried out every quarter. In addition to all the items included in the monthly inspection, it is also necessary to focus on some parts that are easily overlooked but have a greater impact on the performance and life of the equipment. Carry out a comprehensive inspection of the metal structure of the electric hoist to check whether there are cracks, deformation, rust, etc., check whether the connecting bolts and welds are firm and reliable, and ensure the overall structural stability of the equipment. Carry out detailed inspection and maintenance of the reducer of the lifting mechanism and the operating mechanism, including checking the meshing condition, wear degree, lubrication condition of the gears, etc., and clean, change oil and adjust them when necessary. Perform performance tests on the motor to check whether its insulation resistance meets the requirements, whether there are abnormal vibrations, overheating, noise, etc. during operation, to ensure that the motor can work normally. In addition, the control system of the electric hoist needs to be functionally tested to check whether its various control modes and protection functions are normal, such as remote control, automatic control, overload protection, short-circuit protection, etc., to ensure the safe and reliable operation of the equipment under various working conditions.
Annual inspection: It is very important to conduct a comprehensive and thorough inspection and maintenance of the electric hoist every year. In addition to covering all the contents of the monthly inspection and quarterly inspection, the annual inspection pays more attention to the evaluation of the overall performance of the equipment and comprehensive maintenance. All parts of the electric hoist are disassembled, inspected and repaired in detail, including non-destructive testing of lifting parts such as hooks, pulleys, wire ropes, chains, etc., comprehensive inspection and commissioning of key parts such as motors, reducers, brakes, etc., in-depth inspection and maintenance of the electrical control system, and replacement of aging wires, cables, electrical components, etc. The metal structure of the equipment is rust-proofed, anti-corrosive, and repainted to extend its service life. Carry out load test, static load and dynamic load test according to the rated lifting capacity of the equipment, check the performance and stability of the equipment during lifting, lowering, operation, etc., and verify whether the equipment can meet the design requirements and safety standards. At the same time, check whether the nameplate, logo, instruction manual, etc. of the electric hoist are complete and clear. If there is any missing or damaged, it should be supplemented and repaired in time.
5. Maintenance and inspection of electric hoists under special circumstances
Newly installed or overhauled electric hoists: Newly installed or overhauled electric hoists must be strictly tested before being put into use. First, according to the equipment's installation instructions and relevant standards, conduct a comprehensive inspection of the equipment's installation quality to ensure that all components are installed correctly and tightened reliably. Then, conduct a no-load test run to check whether the equipment's lifting, lowering, operation and other actions are normal, whether the various mechanisms operate smoothly and flexibly, whether the electrical control system is accurate, and whether the brake is sensitive and reliable. Next, the rated load test and overload test are carried out. The lifting, lowering and running tests are carried out according to the rated lifting weight of the equipment and the weight exceeding a certain proportion of the rated lifting weight, respectively, to check the performance of the equipment under different loads and ensure that it can operate safely and reliably. During the test run, if any abnormal situation is found, the equipment should be stopped immediately for inspection and adjustment and repair until the equipment fully meets the use requirements.
Electric hoist after long-term idleness: If the electric hoist is idle for a long time, it is also necessary to carry out comprehensive inspection and maintenance before it is used again. Due to long-term idleness, the equipment may be affected by factors such as dust and moisture, resulting in rust, corrosion of parts, aging of electrical components and other problems. The inspection content includes comprehensive cleaning and rust removal of the equipment, checking whether the lubricating oil is deteriorated or dried up, and replacing and lubricating it if necessary. Carry out a comprehensive inspection and test of the electrical system to ensure that the wires, cables, electrical components, etc. are not damaged, aged, short-circuited, etc., and the insulation resistance meets the requirements. Carry out a detailed inspection of the lifting components such as hooks, wire ropes, chains, etc. to check for rust, wear, deformation and other problems to ensure their safety and reliability. Carry out no-load test run and observe the operation of the equipment. If abnormal sound, vibration, jamming and other problems are found, the equipment should be stopped for inspection and repair in time. After comprehensive inspection and test run, confirm that the equipment has no problems before it can be officially put into use.
6. Record and management of maintenance and inspection
Establish maintenance files: It is very important to establish detailed maintenance files for each electric hoist, recording the basic information of the equipment, purchase time, installation and commissioning, instruction manual and other relevant information. At the same time, the time, content, problems found and treatment measures of each maintenance and inspection are recorded in detail to form a complete equipment maintenance history record. This not only helps users to fully understand the operation status and maintenance history of the equipment, and provide a basis for formulating a reasonable maintenance plan, but also provides valuable information for maintenance personnel when the equipment fails or needs to be overhauled, helping them to diagnose and solve problems quickly and accurately.
Data analysis and management: By regularly analyzing the data of maintenance and inspection records, potential problems and patterns in the operation of the equipment can be discovered. For example, by analyzing the frequency, location, and cause of failures, the weak links of the equipment can be identified, maintenance measures can be strengthened in a targeted manner, maintenance plans can be optimized, and the reliability and stability of the equipment can be improved. In addition, data analysis can also provide decision-making support for equipment upgrades. When the maintenance cost of the equipment is too high, the failure frequency increases, and the performance decreases significantly, the equipment should be updated in a timely manner to ensure production efficiency and safety.
7. Summary
The maintenance and inspection cycle of the electric hoist is determined based on a variety of factors, including frequency of use, working environment, equipment type and specifications, and manufacturer's recommendations. Daily maintenance and inspection work is the basis for ensuring the normal operation of the equipment. Simple inspections before each use and cleaning and lubrication after use cannot be ignored. Regular monthly, quarterly, and annual inspections, as well as inspections under special circumstances such as new installations, overhauls, and long-term idleness, are key measures to fully and deeply understand the equipment status, promptly discover and solve problems, and ensure the safe and reliable operation of the equipment. By formulating maintenance plans scientifically and rationally, strictly implementing maintenance and inspection standards, and establishing a complete maintenance file and data analysis system, we can effectively extend the service life of the electric hoist, improve its work efficiency, reduce the maintenance cost of the equipment, and provide strong support and guarantee for industrial production and material handling.