In order to ensure the safety of the explosion-proof electric single-girder suspension crane , a test run must be carried out before it is put into use. The editor will share the test run outline of the explosion-proof electric single-girder suspension crane for your reference.
Before leaving the factory or putting into production, the crane must be tested with no load, rated load and overload to verify the correctness of the crane design, manufacture and installation, to verify the safety and reliability of the crane’s work, and to verify the crane’s experience in the actual operation process. Self-protection ability of accidents.
1.1 No-load test run
No-load test run is to confirm the correctness of each mechanism and transmission system movement, check the accuracy of the movement of each moving component, and verify the accuracy and reliability of various safety facilities.
1.2 Rated load test run
The rated load test run is to verify that the crane is capable of actual operations, including verifying the individual or combined working capacity of each mechanism, verifying the load-bearing capacity of the metal structure, and verifying the correctness of the crane's operating parameters.
1.3 Overload dynamic test run
The dynamic test of overload is mainly to consider the most unfavorable load combination that the crane may encounter during the operation. In this case, the crane can work normally. But it does not mean that the crane that has passed the overload dynamic test can be overloaded.
1.4 Overload static test run
The overload static test run shows that the crane itself can cope with the overload without difficulty. The crane has sufficient static strength and overall stability. The crane passes the overload static test run, which does not mean that it can be overloaded.
The crane must meet the following conditions before it is allowed to be tested
2.1 All cranes must be installed, all safety devices are in a normal state, and all the mechanisms and electrical parts that should be adjusted and tuned must be adjusted and tuned.
2.2 Each lubrication point and reducer should be filled with sufficient grease or lubricating oil in accordance with regulations.
2.3 The brakes of each mechanism are in good condition.
2.4 The electrical main circuit and control circuit of the crane are all consistent with the design drawings, the insulation resistance value of each part meets the requirements, and the main circuit is not less than 0.5 megohm. The control circuit should not be less than 1 megohm, the non-live shells of electrical components must be well grounded, and the grounding resistance of the crane should not be greater than 10 ohms.
2.5 The crane power supply voltage is normal and the phase sequence is correct.
2.6 The test environment should meet the following requirements.
(1) The temperature should be -15?-40?.
(2) The wind speed in the test environment does not exceed 8.3m/s.
(3) The track is in good condition.
(4) Set up safety isolation in the operating area of the crane trolley.
2.7 Various measuring instruments should be prepared before commissioning, including rulers, tape measures, stopwatches, tachometers and various electrical measuring instruments. In addition, various specifications of test weights are required (required to meet the requirements of 3t, 3.3t, 3.75t, and three tonnage combinations).
2.8 Fire extinguishers and other emergency equipment to ensure safety should be prepared before the test run.
2.9 Responsibilities and composition of the test team.
2.9.1 Responsibilities
The test team personnel must be fully familiar with the basis of crane technical performance, contracts, instructions, test items, and test run safety knowledge, and according to the requirements of each stage of the test run, measure and record various technical data, and instruct the inspectors to fill in the inspection report. The entire test run process must follow the unified command of the commander; all personnel should be on the scene at the same time during the test run.
2.9.2 Composition
One skilled driver
Several skilled fitters
Several skilled lifting workers
Several skilled cold work and welders
Personnel and supervision of the owner unit
Several electrical, mechanical, inspection, design, and technical personnel.
3.1 Visually inspect all working devices and safety devices of the whole machine to meet the design requirements; each working mechanism should be debugged and be able to operate normally; the whole machine has no abnormal phenomena.
3.2 Check the installation of metal structures, especially important welds and high-strength bolt connections.
3.3 Check that the installation of the transmission parts and fasteners should be reliable, the connection parts should be firm, the lubrication and sealing should be good; the joint parts should be unblocked.
3.4 Check the winding condition of the wire rope, and check the tightness of the wire rope joints and the bolts of the fixed pressure plate.
3.5 Check that each lubrication part is filled with lubricating oil or grease according to the lubrication requirements.
3.6 Check that the operating directions of the crane are consistent with the requirements of the operating direction of the handle.
3.7 Check that the buffers, gears, strokes, etc. should be installed correctly, act sensitively, and be safe and reliable.
3.8 Measure the insulation resistance of cables, motors, electrical components, and transformers. Measure the grounding resistance of the whole machine.
3.9 Check electrical protection functions, including power supply short-circuit protection, voltage loss protection, and phase loss protection.
3.10 When the power supply is suddenly cut off , check the working conditions of each mechanism, especially the brake.
4.1 Stroke limit test run
4.1.1 The travel switch of the hoisting mechanism is adjusted to 400mm below the center of the hook and the main body of the hoist. 100mm above the ground, if it is difficult to measure the stroke, you can calculate the number of turns of the hoisting rope on the drum.
4.1.2 The adjustment and setting of the traveling stroke of the cart are sensitive, and the block of the cart is safe and firm.
4.1.3 The trolley running buffer car block protects the safety and firmness.
4.2 Run test run
4.3 The overload limiter protects the test run (to be carried out after the overload dynamic test run).
When the specified lifting capacity corresponds to lifting 100% of the rated load, the alarm facility of the crane should function, and the lifting mechanism shall automatically cut off the power and stop.
4.4 Tuning of electrical components
The setting of electrical components refers to the manual and electrical diagrams.
The trip of each agency during the test run is determined by the commander, at least the full trip of the cart and the trolley, the full trip of the ascent and descent, and one run.
5.1 The organization operates independently.
5.2 Hoisting-trolley, hoisting-trolley, trolley-trolley joint action.
5.3 Do the combined actions of lifting, trolley, and trolley.
5.4 Record during the no-load test run: voltage, current, power, and measure the speed of the mechanism at the same time.
7.1 Under the premise of normal no-load test run, it can be used for rated load test run.
7.2 Lifting the rated load is to first lift 1 times the rated load (3t), the crane span is 0.2m above the ground, and it stops for 10 minutes.
7.3 The organization operates independently,
7.4 Combined actions of lifting-trolley, lifting-trolley, and trolley-trolley.
7.5 Perform combined actions of lifting, trolley, and trolley.
7.6 Record during the rated load test: voltage, current, motor speed, power, and measure the speed of the mechanism at the same time.
8.1 During the overload dynamic test, it is allowed to remove the overload limiter, but after the overload test, it should be restored to its original normal state.
8.2 The load of the overload dynamic test run is 110% of the rated load, namely: 3.3t.
9.1 During the overload static test, it is allowed to remove the overload limiter, but after the overload test, it should be restored to its original normal state.
9..2 The load of the overload static test run is taken as 125% of the rated load, namely: 3.75t.
9.3 The overloaded static test run is the maximum load under the corresponding lifting capacity, only the lifting mechanism is activated, and the lifting height is the weight off the ground (not greater than 0.2m), and hang for 10 minutes.
9.4 Perform weight load alarm test
When the crane is operating, without the interference of external noise, the decibel meter is placed 6 meters away from the equipment in the workshop, and the noise value of the crane is not more than 85dB(A).
Experimental Management Leading Group
Team Leader: Xiao Fenghua
Deputy Team Leader: Huang Yeguo
Member: He Dalong
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