Due to the influence of materials, processes, parts aging and human factors, various failures inevitably occur in the use of construction machinery. However, if you can correctly analyze the causes of various faults, take effective and targeted precautions to minimize the damage speed of mechanical parts, it can effectively prevent mechanical failure and prolong the service life of the machine.
1. Minimize the impact of harmful factors
(1) Reduce the impact of mechanical impurities
Mechanical impurities generally refer to non-metallic substances such as dust and soil, and some metal chips and wear products produced by the construction machinery itself during use. Once these impurities enter the inside of the machine and reach the mating surface of the machine, the hazard is great. It not only causes the relative movement to block, accelerates the wear of the parts, but also scratches the mating surface, destroys the lubricating film, and raises the temperature of the parts. High, lubricating oil deteriorates. It is determined that when the mechanical impurities in the lubrication increase to 0.15%, the wear rate of the first piston ring of the engine will be 2.5 times larger than the normal value; when the rolling shaft enters the impurity particles, the life will be reduced by 80%-90%.
Therefore, for construction machinery working in a harsh environment and complex conditions, we must use high-quality, supporting parts and lubricants, grease to block the source of harmful impurities; second, we must do a good job in the mechanical protection of the work site. To ensure that the corresponding mechanism can work properly and prevent various impurities from entering the inside of the machine. For faulty machinery, try to repair it at a regular repair site. When repairing on site, protective measures should also be taken to prevent parts replaced during on-site repair from being contaminated by impurities such as dust before entering the machine.
(2) Reduce the impact of temperature
In the work, the temperature of each component has its own normal range. For example, the temperature of the general cooling water is 80-90 ° C, and the temperature of the hydraulic oil of the hydraulic transmission system is 30-60 ° C. Below or above this range will accelerate the wear of the parts, causing deterioration of the lubricating oil, resulting in changes in material properties and the like. Tests have shown that the main drive gears and bearings of various construction machinery operate in lubricating oil at -5 ° C than in lubricating oil at 3 ° C, and the wear is increased by 10-12 times.
However, when the temperature is too high, the deterioration of the lubricating oil will be accelerated. If the oil temperature exceeds 55-60 ° C, the oxidation rate of the oil will be doubled for every 5 ° C increase in the oil temperature. To this end, during the use of construction machinery, it is necessary to prevent overload operation at low temperatures, ensure normal operation in the low-speed pre-warming stage, and then drive or work after the machine reaches the specified temperature. Do not ignore the problem because there is no problem at that time. The important role; Second, to prevent the machine from running at high temperatures, the mechanical operation process should always check the values ​​on the various thermometers, find the problem immediately stop the inspection, and find that the fault is eliminated in time. For reasons that cannot be found for a while, it must not be treated without any treatment. In the usual work, pay attention to check the working condition of the cooling system. For water-cooled machinery, it must be checked before daily work to add cooling water. For air-cooled machinery, the dust on the air-cooled system should be cleaned regularly to ensure smooth air circulation.
(3) reduce various corrosive effects
The phenomenon that the metal surface is chemically or electrochemically affected by the surrounding medium and is destroyed is called corrosion. This corrosive effect not only affects the normal operation of the mechanical appearance equipment, but also corrodes the internal parts of the machine. For example, rainwater, chemical substances in the air enter the machine through external passages and gaps of mechanical parts, corrode the inside of mechanical parts, accelerate mechanical wear and increase mechanical failure. Because this kind of corrosion is sometimes invisible and intangible, it is easy to be ignored, so it is more harmful. In use, management and operators should take effective measures according to local weather conditions and air pollution at that time to reduce the impact of chemical corrosion on machinery, with the focus on preventing the intrusion of chemical components into the rainwater and air.
2, to ensure normal working load
The size and nature of the engineering machinery's working load have an important impact on the mechanical loss process. In general, the wear of the parts increases proportionally with the increase in load. When the part is subjected to a load higher than the average design load, its wear will increase. In addition, when the other conditions are the same, the stable load is less worn than the dynamic load, the failure is less, and the life is low. Tests have shown that the engine's wear under the unstable load will increase by 2 times compared with the work under stable load. Engines operating under normal load have a lower failure rate and a longer life. On the contrary, in the case of an overloaded engine, the failure rate is significantly increased, and the life expectancy is also reduced compared to the design index. The amount of mechanical wear that is often in a wide range of load changes is greater than that of a continuously stable machine. In general, engines used in generators have a longer life than engines used in bulldozers, excavators, and the like.
The normal working load is guaranteed mainly by the operator's use of the construction machine. First, be careful not to work at the maximum load that the machine can withstand, and use the machine as far as it can. As the construction machinery management personnel, when designating the operator, the engineering machinery random data and operation manual should be handed over to the operator so that the mechanical performance and operation procedures can be mastered normally, and the relevant data should not be deducted at will. Second, we should try to ensure the uniform addition and subtraction of the mechanical load, so that the machine is in a relatively gentle load change. Specifically, it is necessary to increase and decrease the throttle more evenly to prevent the ups and downs of the engine and the working device.
3, to ensure the proper lubrication of the machine
The wear of the working face of the part, the corrosion of the surface of the part and the aging of the material are the three main forms of replacement of the mechanical parts under normal use conditions, and the failure caused by the wear of the working face of the part accounts for the largest proportion. That is to say, mechanical wear is one of the main reasons for the various components to go to the limit state of technology. Then, solve the wear problem of mechanical parts. In addition to using excellent materials, selecting advanced manufacturing processes, and designing a reasonable mechanical structure, an important task to be done during use is to ensure proper lubrication of the machine. According to statistics, more than half of the failures of construction machinery are caused by poor lubrication. Due to the precision of the various components of the construction machinery, good lubrication can maintain the normal working gap and the appropriate working temperature, thus reducing the wear of the parts and reducing mechanical failure.
Normal and reasonable lubrication is one of the effective measures to reduce mechanical failure. To this end, the first is to use lubricants reasonably. According to the type of machinery and the application structure, the normal lubricant category should be selected. According to the requirements of the machinery, select the appropriate quality group, and select the appropriate quality grade according to the requirements of the machine. Choose the right lubricant grade for the mechanical working environment and different seasons. In use, neither low-grade lubricant nor other types of lubricants can be used, and inferior products should not be used. The second is to check the quantity and quality of lubricants frequently. Insufficient quantity should be replenished in time, and quality should be replaced in time. Under different emergency conditions, use different types and grades of lubricant substitutes. Afterwards, the lubrication system must be cleaned and the normal lubricant replaced in time.
4, timely maintenance
Machinery will inevitably have various failures during use. Among these failures, the impact of some faults on mechanical equipment may be very small, some of which are more serious, and even cause serious accidents. Experience has shown that severe mechanical failures are often caused by smaller failures. The reason is to ignore the timely disposal of glitch. Therefore, for mechanical failures, regardless of size, it should be eliminated in time to maintain the normal performance of the machine and reduce the possibility of causing more failures.
In a sense, timely processing of faults is an effective measure to reduce and prevent faults. The so-called timely processing is to carry out regular maintenance and repair of the machinery in accordance with the maintenance and repair procedures. Maintenance and repair of various groups must be carried out as required. The existing maintenance and repair specifications are summaries of many years of practical experience, and they are scientific and reasonable. In the absence of major technological advancements and innovations, these procedures are absolutely instructive for the maintenance and repair of construction machinery. Sexuality must be followed. Second, in the process of use, it is necessary to strengthen the regular and irregular inspection of construction machinery, timely understand the operation of the machinery, and deal with temporary failures in a timely manner. Do not delay the maintenance time due to small failures and no impact on use. Into a bigger failure.
5. Adopt correct technical measures and organizational management measures
With the development of materials science and design and manufacturing technology, many new technologies, new materials and new structures have been adopted in construction machinery, which requires the technical support and management of machinery to be more scientific and perfect.
To this end, as the organization management personnel and operators of construction machinery, we must pay attention to ensure that machinery damage, deformation, corrosion, etc. during transportation and storage. Second, we must strictly control the daily maintenance of machinery, so that the machinery is in a good state of technology. The third is to educate operators to properly use and operate various construction machinery to reduce and prevent mechanical failure caused by human error. Fourth, we must carefully maintain the machinery, do the correct and regular regular and irregular maintenance, keep the machinery clean and clean, regularly check the technical state of the machine, find abnormal handling in time, and timely tighten and adjust the loose and misaligned parts. , preventive replacement of some consumables, etc.
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