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Overhead Crane Failures and Repair: Essential Solutions for Metal Structures and Travel Mechanisms
Table of Contents
Lifting machinery inevitably experiences aging and wear during use, leading to various failures. This article provides a comprehensive analysis of overhead crane failures and repairs, including fatigue cracks and deformations in the metal structure, as well as skewed travel and rail gnawing in the travel mechanism. By understanding these failures and their solutions, maintenance efficiency and overhead crane reliability can be significantly improved.
Failures and Repair of Overhead Crane Metal Structures
| Failures | Causes | Repair |
|---|---|---|
| Fatigue cracks in the main girder web or cover plate | Overload for long time | For cracks less than or equal to 0.1 mm, use a grinding wheel to smooth them out. For larger cracks, drill holes larger than Φ 8 mm at both ends of the crack, then create a 60° groove along both sides of the crack and perform welding repairs. For critical load-bearing components, reinforce the repaired area with additional plates to ensure strength. |
| Wave-like deformation in the main girder web | Overloading, causing local instability of the web plate | Use flame straightening to correct the deformation. Use hammering to relieve internal stresses. Strictly prohibit overloading in the future. |
| Side bending of the main girder | Combined working stresses, improper transportation, or storage | Use flame straightening by heating the convex side of the main girder, and apply appropriate jacks and pulling tools as needed. |
| Main girder sinking deformation | Structural stress in the main girder, wave-like deformation of the web plate, overloading, thermal effects, improper storage or transportation, and other factors | Use the prestressing method for correction. After flame straightening, reinforce the lower cover plate of the main girder with channel steel. |
Failures and Repair of Overhead Crane Travel Mechanism
Bridge Travel Mechanism
| Failures | Causes | Repair |
|---|---|---|
| Bridge girder skew and rail gnawing | Excessive diameter difference between the two drive wheels | Measure, machine and replace crane wheels |
| Driving wheels are not fully contact with rail | Balance rails and adjust the wheel | |
| Excessive horizontal deviation of the wheel | Check and eliminate excessive horizontal deviation of the wheel | |
| Deformation of metal structure | Rectify | |
| Excessive deviations in gauge, lateral straightness, and height difference between the two rails | Adjust rail and make rail installation satisfy technical requirements | |
| Oil or frost on the rail surface | Remove oil and frost |
Overhead Crane Trolley Travel Mechanism
| Failures | Causes | Repair |
|---|---|---|
| Roil skid | Oil on the rail | Clean |
| Wheel load is not even | Adjust wheel load | |
| Rail top height difference is too much at the same cross-section | Adjust rail till it meets technical requirements | |
| Start or brake too violently | Change the method of motor start, choose winding motor | |
| Trolley twists when starting | Uneven wheel pressure or one drive wheel lifting off. Rail gnawing. | Adjust the problem that only three wheels touch the rail. Resolve rail gnawing. |
Conclusion
The above outlines common overhead crane failures and repair methods during operation, addressing issues in both metal structures and travel mechanisms. By analyzing the causes of these failures and providing practical repair solutions, this guide aims to enhance your understanding of effective equipment maintenance and troubleshooting, ensuring safer operations, reduced downtime, improved productivity, extended equipment lifespan, and cost savings for industrial facilities.
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