System for diagnosing car cranes with automated processing of results using the example of the Kaluga region - diploma

Contents

1. Introduction

2. Mechanization

3. Design Part

4. Process Part

5. Calculation of hydraulic system

6. Research part

7. Safety devices

8. Organizational and Economic Part

9. Production and environmental safety

10. Literatures

11. Applications

1.1. Scope (use).

The 16t automobile crane on the KamAZ53213 chassis, hydraulic, is pre-assigned to perform loading, unloading and construction and installation work with conventional and discharge cargoes at dispersed facilities.

1.2. Purpose and purpose of development.

The automobile crane, with a carrying capacity of 16 tons, is created in connection with the replacement of the crane being removed from production.

1.3. Technical requirements.

1.3.1. Crane composition and requirements to its structural structure.

The designed valve is hydraulic, full-turn, with a rigid suspension of a telescopic boom, consists of the following components:

• non-rotating part: power take-off box, frame, remote supports, boom strut, suspension locking mechanism, car chassis, hydraulic equipment of non-rotating part, pneumatic equipment, lining.

• swivel part: cargo winch with pressure roller, turning mechanism, swivel frame, support-swivel device, cab, casing, heater, hydraulic equipment of swivel part.

• the crane is equipped with the load limiter of the OHC crane - 140 - 05.

• boom equipment: a rope of D = 16.5 mm, a hook pendant with a hook with a loading capacity of 16 tons, an arrow, a hydraulic cylinder of raising of an arrow.

• control drives: operation control drive, engine control engine.

• electrical equipment: single spares.

1.3.2. Required technical data:

• load capacity, tons, maximum:

on remote ports...................... 16

without externalities................... 3

when moving with a load on a hook.................................. 3

• hook lifting height, m, maximum........................ 21,7

• departure, m, maximum.......................... 18,5

• loading capacity at promotion of a telescopic arrow, maximum, tons....................................................................... 4

• maximum depth of hook lowering for boom 9, 7 m with load of 8 t at flight 5m, m..................................................................................................................................................................................................................................................................................................................................................................................... 12

• length, m.................. 9,7…21,7

• speed of lifting and lowering of nominal load, m/s. 0,14

• maximum speed of hook lifting-lowering without load, m/s. 0,3

• hook departure change rate, m/s:

when lifting (lowering) the wheel.................. 0,15

at extension (retraction) of boom........................ 0,13

• rotating speed of the rotary part, rpm. 1,75

• crane speed, km/h:

.. 50

working with load on hook...................... 5

• dimensions of the reference contour, m:

.. 3,85

• width: front ports................... 4,8

rear....................... 4,8

• rotation angle, deg:

without load on the hook with an arrow of 9.7 m..................... 360

with load on hook when working on supports........................ 240

with load on hook when operating without supports........................ 240

• total weight of the crane, kg...................... 21500

1.3.3. Reliability requirements.

The average life before the first overhaul must be at least 5000 hours. Time between failures must be at least 100 hours. Lubrication devices shall ensure operability of crane mechanisms without change of lubrication during the period between maintenance.

Maintenance activities shall include:

- control inspections;

- daily services;

- number maintenance;

- seasonal maintenance;

1.3.4. Requirements to the level of unification and standardization.

The main mechanisms and components of the crane are as unified as possible with the mechanisms and assemblies of car cranes mass-produced.

The applicability rate shall not be lower than 70%.

The repeatability must be at least 1.3.

1.3.5. Aesthetic requirements.

The crane in appearance and decoration must meet the modern requirements of technical aesthetics. Aesthetic index must not be lower than

9 points.

1.3.6. Requirements to initial materials of crane components.

The design of the designed crane uses materials modified for the manufacture of KS cranes - 3572, KS - 3571, KS - 3576, as well as

other materials. Crane load polyspast blocks are made of cast iron of grade SCH 18 - 36 GOST 1412 - 70 "Castings from gray cast iron."

1.3.7. Operating conditions.

The designed crane is designed for operation under the conditions established by GOST 22827-77 "Boom self-propelled cranes for general purpose. Specifications, "taking into account the requirements set by this specification.

1.3.8. Additional requirements.

• The crane shall be operable:

during operation at any time of the year and day at ambient temperature from + 40 to 40.

at slope - 3.

at crane inclination (inclination of structure to which boom is attached) relative to horizon:

on remote supports - 1.5.

without remote supports - 6.

with a corresponding 80% reduction in load characteristics.

• Crane deployment time (when the engine is running), from the trans-tailor position to the working or from the working to the transport, with a calculation of two people, no more than 5 minutes.

• Crane design shall provide:

prevention of damage of units;

possibility of operation in front of the cabin;

mechanized locking of LG trolley springs;

safety margin of load rope is not less than 6.

• The crane has to have protective coloring by the XB 518 vinyl chloride enamel on soil No. 138 or GF - 020.

• Hydraulic drive shall provide smooth, stepless control of crane operating mechanisms speeds.

• Boom sections shall be extended using hydraulic cylinders. Lifting capacity at extension of boom sections must be

within the cargo characteristic.

Valve hydraulic system arrangement.

Hydraulic drive of crane mechanisms is made according to open two-pump hydraulic circuit.

A feature of the crane hydraulic circuit is the use of an adjustable hydraulic motor for driving a cargo winch and the presence of a hydraulic drive for extending the supports beams. These features make it possible to use the crane more efficiently in construction, installation and loading and unloading operations in cramped conditions.

The use of a two-pump circuit and a hydraulic distributor with a special intermediate section in the hydraulic drive allows the following combination of working operations:

- lifting (lowering) of boom without load with rotation of turning part;

- lifting (lowering) of load with telescoping of boom sections;

- lifting (lowering) of boom with lifting (lowering) of cargo;

- boom lifting (lowering) with boom sections telescoping;

- rotation of the rotary part with lifting (lowering) of the load;

Two axial-piston pumps of type 210.26 and 210.10 are used as the working pressure source. A pump of lower capacity is used to drive hydraulic supports and lock the springs of the rear chassis trolley, as well as a group of working mechanisms: rotation of the rotating part; lifting (lowering) and telescoping boom sections.

A higher-capacity pump serves to drive the main winch. The manual pump is designed to bring the crane from the operating to the transport position, in case of failure of the main pumps drive.

The pump drive is designed to transmit torque from the chassis gear box to the crane unit pumps. The drive is carried out by means of a power take-off box mounted directly

together with the transmission of the car.

Controls of the main operations of the crane are located in the cockpit.

Installation of the crane on remote supports and control of the spring locking mechanism is performed from the panel.

Research part.

Task:

Analyze defects occurring on car cranes operating in the Kaluga region. Develop a system for classification and coding of car crane defects.

Detailed classification makes it possible to find the most common defects characteristic of each type of crane. And the analysis of the obtained results makes it possible to develop methods for preventing defects, for diagnosing the crane during its operation.

After the classification, the obtained defects are encoded. Defect coding facilitates the creation of an electronic data bank. The Data Bank allowed for the rational organization, compact storage and rapid use of a variety of information on all the faucets.