The safety issues and solutions for operating electric hoists are as follows:

1、 Core security issues

Overload risk

Problem: Exceeding the rated load can lead to wire rope breakage, brake failure, or structural deformation, causing heavy objects to fall.

Case: A factory caused a steel wire rope to break due to overloading of lifting equipment, resulting in heavy objects damaging the equipment and almost injuring people.

Solution:

Install overload limiter to automatically cut off power when the load exceeds the rated value.

Clearly define the lifting capacity limit before operation and strictly prohibit overloading operation.

Before the first use of the new equipment, a static load test at 125% of the rated load should be conducted (hovering 100mm off the ground for 10 minutes).

Brake system failure

Problem: Insufficient sensitivity of the braking device may cause heavy objects to lose control and fall.

Case: Due to brake failure, a heavy object suddenly slid down during lifting in a warehouse, causing equipment damage.

Solution:

Regularly check the wear of the brake and replace faulty components in a timely manner.

Adjust the braking sliding amount to ensure that the braking sliding amount under rated load is ≤ V/100 (V is the stable lifting distance within 1 minute under load).

Equipped with a dual braking system (if the first brake fails, the second brake will immediately activate).

Broken or tangled steel wire rope

Problem: Worn, broken or tangled steel wire ropes may cause heavy objects to fall.

Case: A construction site caused a heavy object to fall and injure people due to the failure to replace the broken strands of the steel wire rope in a timely manner.

Solution:

Check the wear and breakage of the steel wire rope daily, and replace it immediately if the single strand breakage exceeds 10% or the wear exceeds the standard.

A single-layer winding drum needs to be equipped with a rope guide to prevent tangled ropes.

The fixed end of the steel wire rope uses a reliable rope pressing plate to ensure that no less than 2 safety rings are retained on the drum.

Improper operation (inclined pulling and lifting, emergency stop and start)

Problem: Violation of regulations can result in heavy objects shaking, equipment damage, or personal injury.

Case: A factory lost control of heavy objects and crashed equipment due to diagonal pulling and lifting, resulting in injuries to operators.

Solution:

Strictly lift vertically, and do not pull or lift diagonally or stop or start abruptly.

Before lifting, conduct a trial lift to confirm the balance of the heavy object before officially lifting.

Operators need to undergo professional training, hold certificates, and be familiar with equipment performance and safety regulations.

Electrical faults (leakage, short circuit)

Problem: Insulation failure or short circuit in the electrical system may cause electric shock or fire.

Case: A warehouse experienced a short circuit due to aging electrical circuits, resulting in equipment burning out and causing a fire.

Solution:

Use low voltage control (such as 36V safe voltage) and equip with short-circuit protection and grounding protection.

Regularly check the insulation performance of power cords and control buttons, and ensure that the cold resistance is greater than 5M Ω.

Avoid use in damp, high temperature, or corrosive environments, and the equipment protection level should reach IP54 (dustproof and splash proof).

Limit device failure

Problem: Failure of the limiter may result in heavy objects hitting or excessively lowering, causing equipment damage.

Case: Due to the failure to adjust the upper and lower limit blocks, a heavy object collided with the drum shell, causing the steel wire rope to break.

Solution:

Install upper and lower limit position switches to automatically cut off power when the limiter fails.

Regularly test the sensitivity of the limit device to ensure that it can automatically stop when the heavy object reaches its limit position.

Do not repeatedly use the limiter as a travel switch.

2、 General safety regulations

Pre operation inspection

Check whether the steel wire rope, hook, brake, limiter, electrical system and other components are intact.

Clean up obstacles in the work area to ensure that the track is flat and free of foreign objects.

Test the no-load operation and confirm that the buttons, brakes, and rope guides are sensitive and effective.

Requirements during operation

Overloading, inclined pulling and lifting, or emergency stop and start are strictly prohibited.

No one is allowed to stand under the suspended object, and personnel are prohibited from lifting or descending with the suspended object.

When multiple people are working, a dedicated person needs to command and unify the operation signal.

Outdoor operations require the installation of rain shelters to prevent electrical components from getting damp.

Post operation maintenance

Raise the hook to a safe position, cut off the power, and prohibit heavy objects from hanging in the air.

Regularly lubricate the chain/wire rope, clean the equipment of dust and debris.

Conduct a full machine inspection every quarter, including gearbox, electrical system, limiters, etc.

3、 Special scenario security measures

High temperature/mining environment

Choose explosion-proof or high-temperature resistant electric hoists to shorten the single operation time.

Regularly check the insulation performance of the motor to prevent overheating and fire hazards.

Mobile electric hoist

Ensure a smooth track and avoid colliding with obstacles while moving.

Set up baffles at both ends of the track to prevent the hoist from derailing.

Stage/Aerial Operations

Adopting dual track synchronous control to prevent heavy objects from tilting.

Equip with safety nets, guardrails, and other protective equipment to ensure the safety of operators.

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