Daily maintenance of crane rails is essential to ensure the safe operation of the crane and extend the service life of the rails. Here are some key points for daily maintenance:
Clean the rails: Regularly use tools such as brooms, vacuum cleaners or high-pressure water guns to remove dust, oil, iron filings and other debris from the surface of the rails. Pay special attention to cleaning the sides and bottom of the rails, which are prone to accumulate debris and affect the operation of the crane. For stains that are difficult to remove, such as oil stains, you can use a special detergent to clean them and then wipe them dry with a clean cloth.
Check the wear: Regularly visually check the wear of the rail surface, focusing on the parts that the wheels often contact, such as the top and sides of the rails. To measure the wear of the rails, you can use a caliper or a special rail measuring tool to compare it with the original size. Generally speaking, when the side wear of the rail head exceeds 10% and the top wear exceeds 15%, it is necessary to consider repair or replacement. At the same time, pay attention to check whether the rails have damage such as peeling and falling blocks. If there is any damage, it should be handled in time to prevent the damage from expanding.
Check the flatness and straightness of the track: Use a level and wire pulling methods to regularly check the flatness and straightness of the track. The horizontal deviation of the track should be controlled within a range of no more than 2mm per meter, and the straightness deviation within the full length should not exceed 5mm. If the track is found to be deformed or uneven, the cause should be analyzed and adjusted in time. It may be caused by foundation settlement, loose installation or impact force during crane operation. Take corresponding measures for different reasons, such as strengthening the foundation, adjusting the track pad, etc.
Check the track connection parts: Carefully check whether the track connection parts such as fishplates, bolts, and nuts are loose, deformed or damaged. The fishplate and the rail should fit tightly. If there is a gap, it will affect the integrity and stability of the track. Bolts and nuts must be tightened. A torque wrench can be used to check whether the tightening torque meets the specified requirements. Loose bolts should be tightened in time, and damaged parts should be replaced immediately to prevent the track from shifting or shaking during operation.
Lubricate the track: Lubricate the rails regularly according to the frequency of use of the crane and the working environment. Generally, lubrication is performed every 100-200 working hours or at least once a week. Use special rail grease or lubricant and apply it evenly on the surface of the rail, especially the contact area between the wheel and the rail. Lubrication can reduce friction, reduce wear, and also help prevent rust. However, be careful to avoid applying too much lubricant to avoid making the track surface too smooth and affecting the braking performance of the crane.
Check the track foundation: Check whether the track foundation has cracks, sinking or damage. The stability of the foundation is directly related to the operation of the track. If there is a problem with the foundation, notify the professionals in time for evaluation and repair. For concrete foundations, check whether there are exposed steel bars, concrete peeling, etc.; for steel structure foundations, check whether the welds are cracked and whether the components are deformed. If necessary, ultrasonic detection, ground penetrating radar and other technical means can be used to detect the inside of the foundation to find potential problems.
Do a good job of rust prevention: If the crane works in a humid or corrosive gas environment, the rails are prone to rust. In addition to regular lubrication, the rails should also be regularly treated with rust prevention according to environmental conditions. You can use methods such as spraying anti-rust paint and applying anti-rust oil to protect the rail surface from corrosion. Before anti-rust treatment, clean the rail surface and remove impurities such as oil and rust to ensure that the anti-rust coating can adhere well.
Record maintenance: Establish a detailed maintenance record file to record the time, content, problems found, and treatment results of each maintenance. By analyzing the maintenance records, you can understand the use status and change trends of the rails, discover potential problems in time, and provide a basis for formulating reasonable maintenance plans and replacement cycles. At the same time, maintenance records are also important information for equipment management and safety inspections.