This article provides a brief overview of the maintenance and upkeep of the hydraulic system in the Duobeimaya detachment cableway. It deeply analyzes the importance of identifying hidden dangers in the hydraulic system and provides a comprehensive analysis of its significance in the operation system. The article aims to strengthen the identification of hidden dangers in the hydraulic system, enhance technical training, strengthen fault diagnosis, and strengthen hidden danger control.
Keywords: management philosophy; Technical training; case analysis
1. Preface
The establishment of the safety management concept for Jinsha Cableway equipment is also achieved through continuous exploration and practice, and innovation. Timely optimization. We believe that device security management needs to highlight the center of "people-oriented", and develop the infiltration of security concepts and the cultivation of security behaviors as two basic points. Internalize thoughts, externalize behaviors. Continuously improve employees' safety awareness and sense of safety responsibility. Make 'safety first' a conscious behavior of every employee. The concept of safety determines safety awareness, and safety awareness determines safety behavior. The three complement each other, forming a trinity. Therefore, we have put in a lot of effort to instill safety concepts and cultivate safe behaviors among our employees. We identify the characteristics of safety work in different periods. Continuously instill safety knowledge in employees and turn safety culture into their conscious spirit. Transforming the safety concept into a code of conduct for employees in the process of safe production.
The company leaders attach great importance to the cultivation of technical personnel and have invested a large amount of manpower, material resources, and financial resources to strengthen the comprehensive quality of technical personnel. Strengthen the improvement of vocational skills. By establishing a case database and using various channels to collect and simulate equipment failure cases, we hope to reduce troubleshooting time and narrow the scope of troubleshooting in the future when similar problems arise. Effectively ensure the safe operation of equipment.
Improving the hydraulic technology level of cableway technicians, analyzing and identifying various problems existing in cableways, strictly implementing hydraulic technology standards and passenger cableway safety regulations, and eliminating accident hazards are important tasks to ensure the safe operation of passenger cableways. In conjunction with this year's "Cableway Association's Safety Hazard Investigation" activity, in accordance with the provisions of the "Regulations on Supervision, Inspection and Regular Inspection of Passenger Cableways", we will inspect, maintain, manage and test the problems and hazards in each link item by item, resolutely rectify them, and never let them go. Ensure good performance and stable operation of hydraulic systems and components, laying a solid foundation for the safe operation of passenger ropeways. Below is a brief analysis of two typical hydraulic issues that have occurred with the Jinsha Cableway.
2. Hydraulic Case - Sealing Dust Ring Deformation
(1) The sealing dust ring inside the emergency brake cylinder body is deformed
In daily inspections, in addition to paying attention to whether there is oil leakage, scratches, and relative friction damage in the oil pipes, it is important to replace the aging pipe joint seals and oil pipes in a timely manner, inspect and maintain them thoroughly, and strictly follow the operating instructions and methods to ensure safety. During the routine half month inspection, we found that the emergency brake seal ring was deformed (Figure 1).
Figure 1
(2) Possible hazards include dust and metal shavings falling into the hydraulic cylinder body, causing blockage. Once the hydraulic emergency braking system malfunctions, whether it is a brake system failure or a brake system misoperation, it often poses a significant safety hazard. The principle of our cableway technicians is to immediately deal with the problem. Below, we will talk about the process of replacing the emergency brake hydraulic cylinder seal ring.
(3) Tool preparation
① Firstly, open the shut-off valve of hydraulic system 38 to completely relieve the pressure in the hydraulic system. After confirming that there is no pressure, use a 19 open-end wrench to remove the pipeline. Use a protective cover at the pipeline interface to ensure dust protection.
② Use a 55 open-end wrench to remove the disc spring, and remove the end with the radial thrust ball bearing. To remove all disc springs, it is necessary to clean them with kerosene or gasoline and carefully inspect for cracks and damage (simultaneously cleaning and inspecting the disc springs).
③ Remove all four M12 screws that fix the hydraulic cylinder, and remove the cylinder body from the brake. Before removing it, pay attention to the angle, otherwise the hydraulic cylinder cannot be removed.
④ Before disassembling the cylinder block, it is necessary to make proper markings on the scale.
(4) Several precautions during disassembly and replacement process
① The storage time for preparing to replace the sealing ring should not exceed 4 years. During the replacement process, it is forbidden to damage the hydraulic cylinder by gravity tapping. We use a special tool for replacing the filter element for disassembly.
Figure 2
② Before installation, it is necessary to ensure the cleanliness of the equipment and the site environment. The installation of the sealing ring must ensure sufficient lubrication with new hydraulic oil and internal cleaning
③ There are three sealing rings inside the cylinder. During installation, the sealing rings should be rolled into an 8-shaped shape and placed into the groove. The direction of the green sealing ring should not be wrong, and the notch should be downward to ensure that the hydraulic cylinder can lock the pressure under pressure. During the installation process, it is prohibited to use sharp devices to touch the sealing ring.
Before installation, it is necessary to check whether there is any metal damage in the groove, otherwise it will hinder the installation effect of the sealing strip. Ensure that the sealing strip is installed without deformation.
④ After all installations are completed, place the hydraulic column into the cylinder body first, and directly screw the lubrication sleeve into the cylinder body, ensuring sufficient lubrication of the hydraulic oil throughout the entire process.
⑤ Lock it with a chain specific tool?, It must be marked on the original prepared label.
⑥ Connect the hydraulic cylinder body to the hydraulic pipeline, pressurize to 100 bar, and conduct a 5-minute pressure test.
Figure 3
3. Wear of the coupling and buffer pad of the hydraulic motor coupling
(1) Fault phenomenon: In the morning of 2013, when the system was turned on, the system pressure reached 138 bar. By the afternoon, the system pressure was only 130 bar, and sometimes even 129 bar (not reaching the critical value causing parking).
(2) Technical analysis: The normal situation for system pressure drop is pipeline leakage and valve damage with internal leakage. During inspection, a manual pump was first used to pressurize 140 bar, and it was found that the system pressure gauge value did not decrease, indicating that the pipeline and valve are in good condition. Also, it is possible that there is a problem with the hydraulic oil. After opening the inspection and filtering the hydraulic oil, it was found that the pressure was still decreasing,? After identifying other possible fault points, it was determined that there was a problem with the hydraulic system motor (power component). When we connected a pressure gauge to the pressure outlet of the motor gear pump, the pressure displayed was equivalent to the system pressure, indicating that there was a problem with the integration of the power component. After opening the brake hydraulic system motor, it was found that the coupling and buffer rubber block between the motor and the pump were severely damaged (half of the coupling was worn, the bottom of the base was covered in aluminum ash, and the rubber buffer block was torn apart). After replacing the rubber buffer block and filtering the hydraulic oil, they returned to normal.
Fault summary: Firstly, the inspection of the motor module was not specified in the operation manual, and the technical personnel's carelessness caused the missing inspection of this component. We included the inspection of the coupling in our monthly equipment inspection project, and since then, this phenomenon has not occurred.
Figure 4
The pressure drop in the hydraulic system may not only be caused by pipeline leaks and valve damage, but also by electrical transmission component failures. When troubleshooting the hydraulic brake system, the principle of executing first and then controlling should be followed as much as possible based on the specific occurrence of the fault, that is, starting from the execution end of the hydraulic system device to identify whether the fault is caused by the execution component or the control component.
4. Summary
Only by optimizing the system of equipment maintenance work, establishing a sound maintenance system, elevating safety thinking into concepts, safety practices into systems, and safety requirements into habits. By implementing refined equipment management and assigning responsibility to individuals, we continuously explore the static and dynamic operating conditions of equipment, focus on analyzing the technical parameters of equipment during its lifespan, and continuously implement reliable maintenance decisions throughout the entire process of safety production while ensuring safety. This enables all employees to fully participate in the company's safety production work, cultivate a sense of ownership, extend the investigation of equipment safety hazards, make the system more perfect, make the system meet operational needs, and align the concept with the company's sustainable development.
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