Operation & Maintenance Information Based Supporting Technology Of Manufacturing Optimization For Large-Scale Lifting Equipment

For adapting to the rapid development of China’s industrial economy,the lifting equipment is moving towards the direction of large-scale,complex and intelligent.Large complex lifting equipment has a numerous and jumbled structure,poor working environment,strong continuity of operation,because of which,the component failure and structural failure of it may resulting in a huge economic losses,even more,casualties and irreparable major accidents.The existing security measures such as early warning and fault maintenance for the safety guarantee of crane operation can not effectively eliminate the failure from the source.Therefore,based on the crane manufacturing process,in order to eliminate the potential failure risk,combined with the actual operation & maintenance information,this paper puts forward a set of supporting technical methods of crane manufacturing optimization,which is applied in the case of quayside container crane.The main research work of this paper is as follows:(1)Firstly,through a lot of investigation,the general manufacturing process of large lifting machinery steel structure is summed up.The fault cases of crane are collected and analyzed to determine several potential risk manufacturing process.And the relationship between the failure mode of steel structure and the potential risk manufacturing process is elaborated.(2)Secondly,the method of diagnosing failure mode by operation & maintenance information is studied.The supporting technologies such as PFMEA and SPC are introduced,which is for realizing the optimization and control of the crane’s potential risk process.(3)Thirdly,a case study of Shanghai port double 40-foot quay container crane is carried out.The failure mode and the failure location of key operation is diagnosed from the operation & maintenance information.Then,the potential risk process is determined,and PFMEA is applied to make risk assessment.Furthermore,the improvement measures and control plan related to the welding process,stress relieving process,assembly process of the key part of front girder are put forward.(4)Finally,Combined with SPC,PFMEA is applied to track and evaluate the optimized process.The process optimization effect is reflected from the data.Besides,a set of specific optimization scheme is formed,which consist of the PFMEA file,the welding and assembly process control plan,work instructions for adding local heat treatment and stress detection of the key parts of the front girder.