解析起重机械存在的不安全因素
Analysis on unsafe factors of heavy machinery
随着中国起重机械制造水平的不断提高, 起重机械的效率和可靠性也在持续提高, 但起重机械在实际运用中出现故障的情况仍较多, 完善系统设计、做好定期维护、提高操作人员水平是提高起重机械可靠性的关键, 总结经验, 针对不同的故障采用针对性的方法对减少事故及提高工作效率也非常重要。
With the development of Chinese hoisting machinery manufacturing level unceasing enhancement, since the efficiency and reliability of heavy machinery continued to improve, but the hoisting machinery faults in practical application is more perfect, system design, complete the regular maintenance, improve the level of operating personnel is to improve the key, heavy mechanical reliability summary experience, in view of the different the fault using the targeted approach to reduce accidents and improve the work efficiency is also very important.
在企业里运用较为平凡的主要有电动葫芦、电动单梁起重机及通用桥式起重机。一般情况下生产型企业运用起重机械主要是在检
In the enterprise in the use of more ordinary mainly electric hoist, electric single girder crane and bridge crane. General production enterprise use of lifting machinery mainly in the examination
修的时候辅助使用, 且运行环境较恶劣, 使用率不高, 但是故障率较高, 据统计, 检修用起重机械每年平均的使用次数约为6次, 但是发生故障为1.2次, 从而影响检修进度、增加维修费用及成本, 且对检修时的安全埋下了极大的隐患。因此, 判断起重机械的故障原因并采取有效的的措施预防其故障的发生就显得尤为重要。 When repairing auxiliary use, and the operation environment is very bad, the utilization rate is not high, but the failure rate is high, according to statistics, the overhaul by use of hoisting machinery annual average number is about 6 times, but failure is 1.2 times, thus affecting the maintenance schedule, increasing repair costs and cost, and the repair of the safety buried the huge hidden trouble. Therefore, judge fault reason of lifting and take effective measures to prevent the fault is particularly important.
1. 起重机械的详细分类
A detailed classification of 1 hoisting machinery
目前, 国内已经正式使用的起重机设备种类多样, 从不同的角度对其进行分类的结果是不一样的。详细划分起重机的类别有助于了解各类设备的故障问题, 引导操作人员掌握相应的机械性能, 提高机械故障的故障防范意识, 实现安全故障率的降低。常用的分类方式是参照机械结构划分, 包括:
At present, the domestic has been officially used crane species diversity, the results of its classification from the different angle is not the same. The detailed division of crane categories helps to understand the problems of all kinds of equipment, guide the operating personnel to grasp the corresponding mechanical performance, improve the fault of machinery fault prevention awareness, reduce the safety failure rate. Classification of commonly used reference mechanical structure, including:
1、桥式起重机。桥式起重机属于一种大空间结构的机械设备, 其主要架设在企业
的大生产车间中。常用的桥式起重机包括:门式起重机、装卸桥、冶金桥式起重机等。
1, the bridge crane. Bridge crane is a kind of large space structures, machinery and equipment, the main building in the enterprise production workshop. Bridge crane used include: gantry crane, bridge crane, crane etc..
2、升降式起重机。升降式起重机即“施工升降机”, 这种起重机的运行空间相对较小。升降机在运行期间均是按照原先的轨道升降运动, 结构组合比较简单且运动形式也多数是垂直运动。
2, lifting crane. Lifting crane " lifts ", a relatively small operation space for such crane. Lift during operation are in accordance with the track lifting motion of the original, structure is simple and the motion form mostly vertical movement.
3、臂架式起重机。臂架式起重机常会架设在运输汽车上, 不仅达到了升降运动的要求, 且方便了起重机的运输需要。主要设备有:汽车式起重机、轮胎式起重机、塔式起重机等细石混凝土泵。
3, jib crane. Jib cranes often erected in the transport vehicles, not only to the lifting movement of the requirements, and facilitates the crane transportation need. Main equipment: truck crane, truck cranes, tower cranes.
4、小型起重机。小型起重机最大的特点在于机械结构简单, 没有过于复杂的机械运行形式。通常小型起重机只能完成简单的“升降运动”, 最具代表性的则是千斤顶、滑车、绞车等。
4, small crane. The characteristics of small crane is the most simple mechanical structure, no mechanical operation is too complex. Usually small crane can complete a simple " lifting movement ", the most representative is Jack, pulley, winch etc..
2. 起重机械使用过程中存在的不安全因素
Unsafe factors existing in the 2 hoisting machinery used in the process of
近几年, 国家对特种设备的安全很重视, 先后制定了《特种设备安全监察条例》、《起重机械安全监察规定》等多项法规、标准, 加强了对起重机械的监察管理工作, 有效地控制了事故发生。但由于种种原因, 起重机械仍然存在许多不安全因素, 起重机械存在的不安全因素主要有以下几点:
In recent years, the national security of special equipment very seriously, has formulated the " special equipment safety supervision regulations ", " crane safety supervision regulations " and other laws and regulations, standards, strengthen the monitoring and management of hoisting machinery, effective control of the accident. But due to various reasons, the hoisting machinery still exist many unsafe factors, lifting the unsafe factors mainly in the following points:
2.1人为因素
2.1 human factors
由人为因素引起的起重机械事故较多, 主要表现在:
Caused by human factors play a more heavy machinery accidents, mainly in:
(1)起重机械司机的失误。司机注意力不集中, 司机的能力、意识不足, 不熟悉所使用的起重机械, 不按安全操作规程作业, 易导致事故的发生。
( 1 ) crane driver errors. The driver can not concentrate, lack of driver's ability, consciousness, is not familiar with the use of lifting machinery, not according to the rules of safe operation, easy to cause accident occurred.
(2)起重机械监管的失误。起重机械进行危险性较大作业时, 不设专门监管人员旁站; 监管人员责任心不强, 疏于监护, 造成起重机械与周围物体碰撞。
( 2 ) the hoisting machinery regulatory failure. The hoisting machinery is very dangerous operation, no special supervision personnel supervision; supervision personnel responsibility heart is not strong, lack of care, resulting in hoisting machinery and the surrounding objects collision.
(3)起重机械指挥人员的失误。起重指挥人员技术水平差, 不了解起重机械的使用性能, 在指挥时站位不正确, 判断有误, 造成错误指挥而引发事故。
( 3 ) the hoisting machinery command personnel mistakes. Lifting the command level technical personnel, do not understand the performance of heavy machinery, in the command position is not correct, wrong judgment, causing the error caused the accident command.
2.2管理因素
2.2 management factors
(1)使用单位在执行国家有关起重机械的法规、标准、规范的同时, 也制定了自己的管理制度, 如进场验收制度、安全操作规程制度、日常定期检查制度、等, 明确了起重机械的使用要求, 但存在法规、标准、制度执行不彻底的现象。
( 1 ) the use of units in the implementation of the relevant state laws and regulations, the hoisting machinery standards, at the same time, also made their own management system, such as site acceptance system, safety operation rules, daily regular inspection system, and so on, clear the use of lifting machinery requirements, but there are laws and regulations, standards, system implementation is not thoroughly the phenomenon.
(2)重要零部件的质量直接影响起重机械的作业安全。如液压(电磁) 制动器、起重量限制器、力矩限制器等, 如果在采购时对其疏于监管, 就会给起重机械的安全使用带来隐患。
( 2 ) the important parts of the quality of a direct impact of lifting operation safety. Such as hydraulic ( electromagnetic ) brake, lifting weight limiter, moment limiter, if in the procurement of lax supervision, will give up using heavy machinery safety hidden dangers.
(3)起重机械的安装维修人员、操作人员等, 均应经有关部门培训、考核合格取得证件后方可上岗, 实际中存在培训过于形式化或无证上岗的现象。
( 3 ) the installation of lifting machinery repair personnel, operating personnel, should be the relevant departments of the training, pass the examination and obtain the certificate before induction, the existence of the training is too formal or without card mount guard phenomenon in practice.
(4)使用单位管理人员违章指挥, 也易造成起重机械事故。
( 4 ) use the unit management personnel illegal command, also easy to cause the crane accident.
(5)使用单位违规使用已经达到报废期限的起重机械。
( 5 ) the use of units of illegal use of retirement period of hoisting machinery has reached.
2.3技术因素
2.3 technical factors
(1)起重机械的安全技术档案不全, 造成技术数据无法查取或引用错误。
( 1 ) safety technical archives heavy machinery is not complete, the data can not search or reference error.
(2), 制定的吊装方案不完善; 对需更换的加工件选材错误或加工精度不符合要求; 对新使用的起重机械的性能不够了解; 对操作人员的作业指导不到位等。
( 2 ) technical personnel quality is low, poor, lifting scheme is not perfect; the need to replace the workpiece material error or machining accuracy can not meet the requirements of the new use; performance of lifting machinery and lack of understanding; to operating personnel work guidance is not in place.
(3)起重机械鉴定、检查存在问题, 不能正确判断已报废的部件而继续使用。 ( 3 ) the hoisting machinery, check the identification of problems, unable to correctly judge has scrapped parts and continue to use.
3. 起重机械发生安全事故的原因分析
Analysis of 3 accidents cause heavy machinery
(1)目前由于施工工期紧张, 承建单位在施工过程中采取加班、加点等措施, 易造成作业人员疲劳, 注意力不集中。同时经常因追赶工期的影响, 忽视了起重机械的大修、维护保养等工作, 造成起重机械带病工作、疲劳作业。
( 1) due to the current tight construction schedule, construction units to take to work overtime, overtime and other measures in the construction process, easy to cause the operator fatigue, attention is not centered. At the same time, often due to the impact of catch-up period, ignoring the overhaul, hoisting machinery maintenance, resulting in hoisting machinery in operation, fatigue.
(2)使用单位定期对 起重机械需持证人员进行安全技术培训, 但受种种因素影响, 培训往往难以达到预期效果。加上目前使用的劳务人员较多, 劳务人员大多文化水平低、接受能力差、培训难以到位, 导致作业人员技能达不到要求。 (3)使用单位管理人员的安全责任不能很好地落实, 管理人员对施工现场起重机械监管不力, 如起重机械的使用、维修、保养几
(2 ) the use of units to conduct regular safety technical training of hoisting machinery be certificated personnel, but subject to various factors, training are often difficult to achieve the desired effect. Many workers use and present, workers are mostly low cultural level, accept ability is poor, training hard to place, leading to operating personnel skill is not up to the requirements. ( 3 ) the use of management staff of the unit safety responsibility cannot be well implemented, management personnel to the construction site lifting machinery supervision, such as lifting machinery use, repair, maintenance of a few
方面的工作不能落到实处, 就容易引发事故。 (4)目前大多数使用单位没有配置专门的检测设备和工具, 对起重机械自检的能力较差, 这些问题往往导致事故发生。
Aspects of the work can not be implemented, it is easy to cause the accident. ( 4 ) most units is not configured to detect special equipment and tools, ability of hoisting machinery self-inspection of the poor, these problems often lead to accidents.
2. 机械故障的改进方法
2 improved methods of mechanical failure
安全生产是企业长期发展的先进理念, 为了保证起重机械的正常运行, 操作人员要
熟练掌握一些常见的起重机机械故障形式。根据起重机的功能结构分析, 大部分设备都配备了相应的安全装置, 控制好这些安全装置可保证起重机机械性能的发挥。
Safe production is advanced the concept of the long-term development of enterprises, in order to ensure the normal operation of heavy machinery, operating personnel should be familiar with some of the common crane machinery fault form. According to the functional structure of the crane, most devices are equipped with a corresponding safety device, control of the safety device can guarantee play crane mechanical properties.
2.1变幅装置。利用吊臂变幅安全装置可以在危险故障发生后, 及时中断起重机的机械运输活动。起重机发生异常情况时, 如:吊臂变幅油缸回路存在高压软管、油管爆裂、切断等情况, 液压回路中的平衡阀能立刻把油缸下腔的工作油锁闭, 防止吊臂下降造成的意外。
The 2.1 luffing device. The boom luffing safety device can occur in the dangerous fault, timely interrupt mechanical transport activity of crane. Crane abnormal conditions, such as: Boom luffing cylinder circuit has high pressure hose, pipe burst, cutting condition, balance valve in the hydraulic circuit can immediately put the lower cavity of the oil cylinder oil lock, prevent the boom caused by accident.
2.2限位装置。在吊钩上升到标准高度之后会接触限位重锤, 然后把行程开关打开, 立刻切断吊钩起升、吊臂伸出等状态。通过这样的紧急制动流程, 起重机会立刻停止运行, 待故障处理之后按下释放按钮, 则能恢复正常的升降或水平位移操作。 The 2.2 limiting device. After rising to the standard height in the hook will contact limit weight, then the travel switch is turned on, immediately cut off the hook lifting, hoisting arm extending state. Through the emergency braking process, lifting the opportunity to immediately stop running, after troubleshooting press the release button, lifting and horizontal displacement operation can resume normal.
2.3感应装置。感应装置主要是利用传感器接收信号, 再利用计算机系统判断信号的正常与否, 若信号发出异常警告则说明起重机发生故障。利用计算机技术、电子技术、机械技术等融合为一体, 为起重机运行设计安全防范系统, 这样可以有效防止机械故障的发生。
The 2.3 induction device. Induction device is receiving signal by sensor, then use computer systems to determine the signal is normal or not, if the signal abnormal warning that crane fault. Integrated with the use of computer technology, electronic technology, mechanical technology, design for crane operation safety and prevention system, it can effectively prevent the mechanical failure.