To extend the service life of electric winches, a systematic maintenance system needs to be constructed from five dimensions: daily inspection, regular maintenance, operational norms, environmental management, and spare parts management. Specific measures are as follows:

1、 Daily check: prevent problems before they happen

Pre startup inspection

Electrical system: Check whether the power cord, controller, and remote control (if any) are intact, without damage or aging; Test whether the emergency stop button and safety interlock device are sensitive.

Mechanical components: Check the temperature of key components such as brake belts, bearings, gears, etc. (not exceeding 70 ℃), and confirm that there is no excessive wear or jamming; Check whether the brake device is flexible and reliable, and whether the gap between the brake wheel and the brake shoe meets the standard (usually 1-2mm).

Rope and fixing points: Check whether the steel wire rope or synthetic rope has broken wires, wear or distortion, and ensure that the fixed end is firm and reliable; If using trees as anchor points, tree ties should be used to protect the bark.

Monitoring during operation

Instrument monitoring: Pay close attention to instruments such as ammeters, oil pressure gauges, and depth indicators. If the pointer swings violently or shows abnormal values (such as current exceeding the set value by 20%), immediately stop the vehicle for inspection.

Abnormal response: If you hear abnormal noises, smell strange odors, or find that the ropes are arranged in a disorderly manner, immediately stop and troubleshoot; In case of emergency (such as sudden power outage), emergency braking can be used, but a comprehensive inspection of the equipment is required afterwards.

2、 Regular maintenance: precise maintenance

Monthly maintenance

Lubrication and maintenance:

Motor bearings: Add lithium based grease (such as No.2 lithium based grease) every 3 months, with an amount not exceeding 2/3 of the bearing chamber.

Reducer: Replace the gear oil (such as N220 industrial gear oil) every 6 months, and the oil level should be between the upper and lower limits of the oil gauge.

Wire rope: Apply wire rope lubricating grease (such as calcium based grease) to reduce wear and corrosion.

Component tightening: Check and tighten all bolts and nuts, especially key connection parts such as motor base and reducer bracket, with torque that meets design requirements (such as M16 bolt torque of 180-220N · m).

Braking system: Adjust the brake clearance to ensure that the contact area between the brake shoe and the brake wheel is not less than 70%; Clean the brake oil circuit and replace the aging sealing ring.

annual maintenance

Comprehensive disassembly and inspection: Disassemble core components such as motors, reducers, and brakes, check gear wear, bearing clearance, and brake pad thickness (the remaining thickness of the brake pads must not be less than 50% of the original thickness).

Load test: Conduct a static load test at 1.25 times the rated load and a dynamic load test at 1.1 times the rated load for 10 minutes without any abnormalities before continuing to use.

Anti corrosion treatment: Remove rust from metal components (such as rollers and brackets) and apply anti rust paint (such as epoxy zinc rich primer+polyurethane topcoat) with a thickness of not less than 80 μ m.

3、 Operating standards: Scientific use

load control

Overloading is strictly prohibited: The load weight must not exceed 80% of the rated load of the winch to avoid prolonged full load operation. For example, a winch with a rated load of 5 tons should be controlled within 4 tons in actual use.

Uniform loading: When lifting or lowering a load, it is necessary to start and stop slowly to avoid sudden acceleration or braking that may cause impact loads. Experiments have shown that impact loads can shorten gear life by more than 50%.

Speed Management

Low speed start: When starting, run at low speed (such as 30% of rated speed) for 1-2 minutes, and then accelerate to working speed after the equipment is preheated.

Graded speed regulation: Achieving stepless speed regulation through a frequency converter or controller to avoid mechanical wear caused by frequent gear shifting.

Shutdown specifications

Idle shutdown: After completing the task, first lower the load to the ground, then run it idle for 5 minutes to dissipate heat, and finally cut off the power.

Brake release: When the machine is stopped for a long time, the brake should be released and the drum should be rotated regularly (such as manually turning 1-2 times a week) to prevent the brake pads from sticking.

4、 Environmental Management: Optimizing Operating Conditions

Temperature and Humidity Control

Temperature range: The operating environment temperature of the equipment should be between -20 ℃ and+40 ℃. If it exceeds this range, cooling measures (such as installing fans) or insulation measures (such as wrapping insulation cotton) should be taken.

Humidity control: The relative humidity should not exceed 85%, otherwise a dehumidification device or a moisture-proof motor (such as IP55 protection level) should be installed.

Dust and corrosion prevention

Sealing protection: In dusty environments, dust covers (such as stainless steel mesh covers) should be installed on components such as motors and reducers, with a porosity of no more than 0.5mm.

Cleaning cycle: Use a high-pressure air gun to clean the dust on the surface of the equipment every quarter, and thoroughly clean it once a year with a neutral cleaning agent (such as an industrial cleaning agent with pH=7).

Anti shock and anti tilt

Foundation reinforcement: The equipment installation foundation must be flat and solid, with a tilt angle not exceeding 0.5 °. Otherwise, shock absorbers (such as rubber shock absorbers) or adjusting the height of the support legs must be added.

Fixed device: Mobile winches need to be equipped with anti slip devices (such as ground anchors or anti slip chains) to prevent displacement during operation.

5、 Spare parts management: ensuring maintenance efficiency

Key spare parts reserve

List of vulnerable parts: Establish inventory of vulnerable parts such as brake pads, gears, bearings, and wire ropes, with inventory levels sufficient to meet the demand for 3 months of use. For example, the inventory of brake pads must not be less than 5 sets.

Quality of spare parts: Select original or third-party spare parts certified by ISO 9001 to avoid equipment damage caused by the use of inferior products.

Spare parts replacement cycle

Preventive replacement: Develop a replacement plan based on the wear curve, such as replacing brake pads every 2 years and steel wire ropes every 3 years (even if they do not meet the scrap standard).

Condition monitoring: dynamically adjust the replacement cycle of spare parts through vibration analysis, oil detection and other technical means. For example, when the iron chip content in gear oil exceeds 0.1%, it is necessary to change the oil in advance.

6、 Maintain records and analyze data

Maintenance Log

Record content: Detailed record of each maintenance time, project, replaced spare parts, discovered problems, and handling measures. For example, on October 5, 2023, 12 M16 bolts were replaced, and the drum made abnormal noise due to loose bolts.

Data analysis: Optimize maintenance strategies by analyzing data such as failure frequency (such as monthly brake pad wear), spare parts consumption (such as annual wire rope replacement), etc. For example, if the average lifespan of a certain type of gear is 2 years, a major overhaul can be scheduled 3 months in advance.

digital management

Maintenance system: Introduce CMMS (Computerized Maintenance Management System) to achieve automatic reminders of maintenance plans, real-time monitoring of spare parts inventory, and rapid diagnosis of fault codes.

Remote monitoring: Real time collection of device operation data (such as temperature, vibration, current) through IoT sensors, automatically triggering alarms and pushing maintenance suggestions when parameters are abnormal.

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