As an indispensable lifting equipment in the industrial field, the safety performance and operation efficiency of overhead cranes are directly related to the safety and efficiency of production operations.In 2019, with the continuous progress of technology and increasingly strict safety standards, the factory inspection regulations of overhead cranes have been comprehensively updated and upgraded. This procedure aims to ensure that every factory-issued overhead crane can meet the established safety requirements and performance indexes through a series of scientific and systematic inspection items and standards. It not only covers the basic knowledge of the structural characteristics and working principle of cranes, but also specifies the all-round inspection process from safety performance, mechanical performance to electrical system and appearance quality, which provides a solid guarantee for the safe use of overhead cranes.
As a key lifting equipment in the field of industrial production, the stability and safety of overhead travelling crane plays a decisive role in the safety and efficiency of the whole production operation. With the rapid change of industrial technology and the continuous improvement of safety standards, the factory inspection of overhead travelling crane has put forward more strict requirements. In order to ensure the safety and reliability of bridge cranes, in 2019, the industry has developed a comprehensive and detailed set of protocols for the factory inspection of bridge cranes. The introduction of this set of regulations is aimed at strictly controlling the quality of bridge cranes from the source, preventing safety accidents, and promoting the development of the entire industry in the direction of greater safety and efficiency. The formulation and implementation of the regulations is not only a positive response to the relevant national laws and regulations, but also a concrete embodiment of the responsibility to the production enterprises and the use of units. It helps to improve the quality consciousness and safety management level of the production enterprises, and also provides reliable equipment protection for the use units.
This regulation specifies in detail the various aspects and requirements of the factory inspection of overhead travelling crane, including but not limited to safety performance, mechanical performance, electrical system and appearance quality and so on. In order to ensure the safety and reliability of bridge cranes, this regulation is applicable to all kinds of bridge cranes manufacturers. Whether it is general-purpose bridge cranes or cranes for specific purposes, they need to be inspected strictly according to this regulation before leaving the factory. Through the inspection according to the regulations, it ensures that each crane can meet the predetermined safety standards and technical requirements when it is delivered for use, so as to provide more reliable and safer equipment for production operations.
Overview table of the content of the statute
| Statute section | Descriptive | Scope of application |
| Statutory background | Critical equipment for industrial production, where performance stability and safety are of paramount importance | Bridge Crane Manufacturer |
| Purpose of the statute | Ensure crane safety and reliability, prevent safety accidents and promote industry development | Various types of bridge cranes |
| Main Content | Safety performance, mechanical performance, electrical system, appearance quality, etc. | Bridge cranes for general and specific applications |
| Inspection process | Pre-shipment inspection in strict accordance with protocols | All bridge cranes that leave the factory |
| Safety standard | Meet predetermined safety standards and technical requirements | Bridge cranes delivered |
Details of Factory Inspection Regulations for Bridge Cranes
| Test items | Content of the test | Criteria for determination |
| Safety performance | Anti-tipping device, braking system, overload protection device, etc. | Comply with national and industry standards, no safety hazards |
| Mechanical property | Hooks, ropes, pulley blocks, winches, etc. | Smooth operation, no abnormal sound and wear |
| Electrical system | Control circuits, motors, electrical components, etc. | Good insulation, no short-circuit, broken phenomenon |
| Appearance quality | Painting, welding, bolting, etc. | Clean appearance, no corrosion, deformation, loose |
| Additional requirements | Special requirements for cranes for specific applications (e.g. explosion-proof, corrosion-proof, etc.) | Meets the requirements for use in specific environments |
As a kind of efficient and flexible lifting equipment, the structural design of bridge crane takes full consideration of the diversity and efficiency of operation. The bridge is the core load-bearing part of the bridge crane, which is usually made of box beam or truss structure welded or bolted with high-strength steel to ensure sufficient strength and rigidity when bearing vertical and horizontal loads. The bridge is usually equipped with rails inside, which are used to carry the large and small vehicle running mechanism.
The large vehicle running mechanism is a wheel-type structure installed in the lower part of the bridge, which makes the whole bridge move laterally along the workshop through the motor-driven reducer. The trolley running mechanism is located on top of the trolley and is also driven by a motor to move longitudinally along a track perpendicular to the direction of the trolley. This double-layer running structure greatly improves the operating efficiency of the crane.
The hoisting mechanism is the main part of the bridge crane used for lifting goods, which contains tools such as the winch system, pulley sets, hooks or grabs. The electric motor drives the reel to rotate through the reducer, thus realizing the lifting and lowering operation of the goods. The electrical control system, on the other hand, is composed of various sensors, controllers, protection devices, etc., to realize the automatic control of the crane, and at the same time, ensure the coordination and cooperation between the various institutions, so as to ensure the safe and efficient completion of various lifting tasks.
The working principle of bridge crane is mainly based on the motor drive, through the reducer, coupling, brake and other transmission components will be the motor's rotary motion into the linear or rotary motion of each mechanism. Under the control of the electrical control system, each mechanism carries out coordinated operation according to the predetermined procedures and instructions to complete the cargo handling and stacking tasks. The working process usually includes the following steps: firstly, the operator sends out the instruction through the control room or on-site console; then, the electrical control system receives the instruction, and monitors the running status of each organization in real time through the sensors and detecting devices; then, the electric motor starts and rotates according to the instruction and transmits the power to the winch system or other actuators through the transmission of the speed reducer and the coupler; finally, these actuators drive the goods to lift, level and stack. Finally, these actuators drive the goods to lift, pan and other actions to complete the handling task. In the whole process, the electrical control system continuously makes feedback adjustment to ensure the coordinated action between each organization, so as to ensure the efficient, stable and safe operation of the overhead travelling crane.
Safety performance inspection is a key part of the factory inspection of overhead cranes, and its core objective is to ensure the safe operation of cranes under various working conditions. Specific inspection items cover a number of safety protection and functional control parts, including but not limited to the reliability test of the brake, the sensitivity check of the limit switch, the validity verification of the overload protection device, and the determination of the reaction speed of the emergency stop device, etc. For the brake, it needs to be repeatedly tested. For the brake, static and dynamic performance tests need to be repeated to confirm that the braking efficiency meets the design requirements and that all moving parts of the crane can be stopped quickly and effectively in an emergency to prevent accidents.
Mechanical performance test mainly focuses on the structural strength of the crane and the flexibility of the moving parts. Engineers will accurately measure the deflection of the bridge through professional measuring instruments to ensure that it will not be permanently deformed due to excessive force during use, thus affecting the stability and safety of the crane. Regularly check the wear and tear of transmission parts such as gears, bearings, chains, etc. The degree of wear and tear of these parts directly affects the operational efficiency and reliability of the crane. In order to meet the design requirements, technicians will use high-precision equipment to strictly test the operating speed and acceleration of each mechanism, to ensure that in actual use, whether light or heavy load conditions, the crane can efficiently and accurately complete the various operational tasks in accordance with the preset parameters.
Electrical system inspection is an important guarantee to ensure the intelligent and automatic operation of overhead cranes. The inspection includes the insulation resistance measurement of electrical components, whether the wiring is firm and correct, the validity verification of the grounding protection system, and the verification of the logical relationship of the electrical control system, etc. The electrical performance inspection can ensure that the crane can operate efficiently and accurately according to the preset parameters. Through the electrical performance inspection, potential electrical faults are detected and eliminated in time to ensure the stable operation of the crane under various complex working conditions.
Appearance quality inspection mainly focuses on the overall appearance of the crane and painting quality. Check whether the crane parts are intact, whether the coating is even without flaking, whether the marking is clear and complete, and whether the connection and fastening of the parts are normal. Good appearance quality not only reflects the craftsmanship of the manufacturer, but also improves the overall aesthetics and service life of the crane.
Comparison table of factory inspection items and standards (safety performance)
| Test items | Content of the test | Inspection Standards |
| Brake Reliability | Static and dynamic performance testing | Designed to stop all moving parts quickly and efficiently. |
| Limit switch sensitivity | Trigger and reset test | Capable of triggering and resetting accurately at defined positions |
| Overload protection device | Load Test | Effective stopping of the crane in case of overload |
| Emergency stop | Measurement of reaction rate | Ability to stop the crane quickly in case of emergency |
Comparison table of factory inspection items and standards (mechanical, electrical, appearance)
| Test items | Content of the test | Inspection Standards |
| Mechanical property | Bridge Deflection Measurement | No permanent deformation, meets stability requirements |
| Wear inspection of transmission parts | Running speed and acceleration tests | |
| Running speed and acceleration tests | Conforms to preset parameters for efficient and accurate job completion | |
| Electrical system | Insulation resistance measurement | Electrical component insulation resistance up to standard |
| Wiring Inspection | The wiring is firm, correct and error free | |
| Grounding protection system validation | Grounding protection systems are effective | |
| Verification of logical relationships | Electrical control system logic is correct | |
| Appearance quality | Component integrity check | Components are intact and undamaged |
| Paint Quality Inspection | Uniform coating without flaking | |
| Marking inspection | Clear and complete labeling | |
| Connections and fastening | Parts are connected and fastened properly |
Before the field inspection, the relevant information of the crane needs to be reviewed. These data include design drawings, manufacturing process documents, quality inspection records and certificates of compliance. Through the data audit, you can understand the design principle of the crane, manufacturing process and quality control, for the subsequent field inspection to provide the necessary reference basis. At the same time can also find some potential problems, such as design defects, manufacturing process problems, etc., timely solution to avoid subsequent use of safety issues.
Field inspection is the core of the factory inspection. The inspectors need to have professional knowledge and skills to inspect each part of the crane one by one in accordance with the requirements of the regulations. These parts include, but are not limited to, the bridge structure, operating mechanism, hoisting mechanism, electrical control system and safety protection devices. In the field inspection, it is necessary to use professional testing equipment and tools, such as measuring instruments, electrical testing equipment, etc., to ensure the accuracy and reliability of the inspection results. At the same time, we should also pay attention to safety, comply with the relevant operating procedures to avoid accidents.
After completing the field test, the inspector needs to prepare a detailed test report based on the test results. The content of the report should include inspection items, inspection methods, inspection results and processing opinions. This report will serve as one of the important documents of the crane factory, and needs to be carefully prepared and reviewed. In the preparation process, each inspection item needs to be described in detail, including the purpose of the inspection, methods, steps and results. At the same time, it is also necessary to summarize and evaluate the overall inspection situation, and put forward the corresponding processing opinions and recommendations. The inspection report needs to be reviewed at multiple levels to ensure the accuracy of the data and the objectivity of the conclusions. Eventually, qualified cranes will obtain the factory certificate of conformity and be allowed to leave the factory for use.
As an indispensable lifting equipment in industrial production, the reliability of the bridge crane's safety performance is crucial. Before the bridge crane leaves the factory, it is strictly inspected, covering a comprehensive inspection of its structure, electrical, hydraulic, safety protection and other aspects. This strict factory inspection system can ensure that the bridge cranes strictly comply with the relevant national and industry standards during the design and manufacturing process, eliminating potential safety hazards from the source. Through this inspection mechanism, it can effectively reduce the risk of safety accidents during the use of cranes, protect the lives of operators, but also maintain the normal production order of the enterprise, to ensure the continuity and stability of the production process.
Qualified overhead cranes are able to operate stably and reduce faulty downtime after being put into use. At the same time, its efficient operation ability also brings higher production efficiency for the enterprise. In the fierce market competition, the improvement of production efficiency means the enhancement of enterprise competitiveness. By improving production efficiency, enterprises can shorten the product production cycle, reduce production costs, and improve product quality and stability. Therefore, strict factory inspection is of great significance to improve the productivity and competitiveness of overhead cranes.
By carrying out strict inspection before leaving the factory, quality problems existing in the manufacturing process of overhead cranes can be found and dealt with in time. This helps to avoid later repair and replacement costs caused by quality problems, thus reducing maintenance costs. In addition, through the feedback of the inspection report, the manufacturer can continuously improve the manufacturing process and quality control process, enhance product quality and reliability, and further reduce maintenance costs. This not only helps to improve the economic efficiency of the enterprise, but also helps to enhance the market competitiveness of the bridge crane.
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