A Brief Discussion on Common Malfunctions Analysis and Improvement Suggestions of Explosion-proof Leverage Gourd

Abstract

Explosion-proof leverage gourds (electric hoists) are widely used in hazardous environments such as petrochemical, coal mining, and military industries. However, due to their complex structures and harsh operating conditions, they are prone to malfunctions, which may lead to safety accidents. This paper analyzes common malfunctions of explosion-proof leverage gourds, proposes corresponding improvement suggestions, and provides references for equipment maintenance and safety management.

1. Introduction

Explosion-proof leverage gourds are lifting devices designed for hazardous environments, featuring explosion-proof motors, controllers, and other components to prevent sparks or high temperatures from triggering explosions. Common types include wire rope electric hoists and chain electric hoists. Despite their explosion-proof design, malfunctions may still occur due to factors such as wear, aging, or improper operation.

2. Common Malfunctions Analysis

2.1 Electrical System Malfunctions

Motor Failure

Overheating: Caused by overload, poor ventilation, or bearing damage.

Insulation Breakdown: Due to aging or moisture ingress, leading to short circuits.

Rotor Locking: Caused by mechanical jamming or electrical faults.

Controller Failure

Contact Adhesion: Due to poor contact quality or overcurrent, leading to uncontrolled operation.

Relay Malfunction: Caused by coil burning or contact wear, resulting in failure to switch circuits.

Cable Damage

Breakage or Insulation Damage: Due to frequent bending or external forces, leading to short circuits or leakage.

2.2 Mechanical System Malfunctions

Brake System Failure

Brake Slipping: Due to brake pad wear or spring fatigue, leading to inability to hold loads.

Brake Not Releasing: Caused by mechanical jamming or hydraulic system failure.

Reducer Failure

Gear Wear or Breakage: Due to poor lubrication or overload, leading to noise or loss of transmission.

Oil Leakage: Caused by seal aging or improper assembly, resulting in lubrication failure.

Wire Rope or Chain Failure

Fracture or Deformation: Due to overload, wear, or corrosion, leading to safety hazards.

2.3 Explosion-proof Component Malfunctions

Explosion-proof Enclosure Damage

Cracks or Deformation: Due to impact or corrosion, compromising explosion-proof performance.

Explosion-proof Joint Loosening

Thread Wear or Loosening: Due to vibration or improper installation, leading to gas or dust ingress.

3. Improvement Suggestions

3.1 Strengthen Maintenance and Inspection

Regular Electrical Inspections

Check motor insulation resistance and contactor performance monthly.

Clean and tighten electrical connections to prevent overheating.

Mechanical System Lubrication and Adjustment

Lubricate reducers and bearings regularly according to the manual.

Adjust brake clearance and replace worn brake pads promptly.

Explosion-proof Component Inspection

Inspect explosion-proof enclosures and joints for damage quarterly.

Replace damaged gaskets or fasteners immediately.

3.2 Upgrade Components

Use High-reliability Electrical Components

Replace contactors and relays with explosion-proof types with longer lifespans.

Install motor overload protection devices to prevent overheating.

Improve Mechanical Design

Use high-strength wire ropes or chains and add wear indicators.

Optimize brake system design to enhance reliability.

3.3 Enhance Operator Training

Standardize Operation Procedures

Prohibit overloading and ensure even distribution of loads.

Require operators to inspect equipment before use.

Emergency Response Training

Conduct drills for scenarios such as brake failure or electrical faults.

3.4 Introduce Intelligent Monitoring

Install Condition Monitoring Systems

Use sensors to monitor motor temperature, vibration, and brake performance in real time.

Set up alarm thresholds for early warning of abnormalities.

Implement Predictive Maintenance

Analyze historical data to predict component failures and schedule maintenance proactively.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment