1、 Structural design defects and optimization

Problem manifestation: Key structural components (such as inclined beams) have insufficient strength and difficult processing, resulting in actual bearing capacity lower than the design value.

Solution:

Optimize the structural form: Remove the main reinforcement and board bending, inner board pasting, and reduce stress concentration points.

Enhance material strength: Replace the original design materials with high-strength plates (such as Q690 high-strength steel) to improve deformation resistance.

Theory combined with practice: Verify the rationality of the design through finite element analysis, ensure the feasibility of the processing technology, and avoid "empty talk on paper".

2、 Welding defects and improvements

Problem manifestation: Defects such as weld cracks and pores can lead to a decrease in structural strength, and even cause the support to tilt.

Root cause analysis:

Stress concentration in welds and improper operation.

Insufficient coverage of protective gas, contamination of welding wire/workpiece, and high arc voltage.

Solution:

Strict welding process:

Control the arc voltage and the distance between the nozzle and the workpiece to ensure sufficient coverage of the protective gas.

Select high-purity gas, regularly check the pressure reducing valve and gas transmission pipeline to prevent blockage or leakage.

Post weld treatment:

Perform non-destructive testing (such as ultrasonic testing) on key welds to promptly detect and repair cracks.

Adopting annealing or vibration aging treatment to eliminate residual stress and improve weld toughness.

3、 Hydraulic system faults and troubleshooting

Problem manifestations: Abnormal support movement caused by oil cylinder leakage, hose leakage, control valve failure, etc.

Root cause analysis:

Damaged seals, mismatched materials, and worn hydraulic cylinders.

Rubber hose aging, loose joint clamping, and hydraulic oil contamination.

Solution:

Seal management:

Choose high-pressure and wear-resistant sealing materials (such as polyurethane sealing rings), regularly inspect and replace aging seals.

Ensure the dimensional accuracy of the sealing groove to avoid assembly damage.

Rubber hose maintenance:

Regularly replace aging rubber hoses to avoid mixing high and low pressure hoses.

Use specialized tools during assembly to prevent loose or damaged joints.

Hydraulic oil management:

Regularly filter hydraulic oil to remove impurities and moisture, and prevent system blockage or corrosion.

Replace the hydraulic oil according to the recommended cycle to avoid the deterioration of the oil and the expansion or contraction of the seals.

4、 Interference and adjustment of supporting equipment

Problem manifestation: The bracket interferes with equipment such as scraper and coal mining machine, resulting in the bracket not functioning properly or equipment damage.

Reason analysis: Insufficient consideration was given to the spatial relationship of equipment during design, resulting in collisions or blockages during actual operation.

Solution:

3D dynamic simulation:

Use software such as Solidworks to establish a 3D model of "three machines and one frame" (coal mining machine, scraper, belt conveyor, hydraulic support), and combine it with the Simulation module for dynamic simulation.

By simulating the motion trajectory of equipment under different working conditions, optimizing the size and installation position of the support structure to avoid interference.

On site debugging:

Conduct joint debugging during the equipment installation phase to promptly identify and adjust interference points.

Adjust the length or angle of key components such as tail beams and insert plates to ensure coordinated operation with supporting equipment.

5、 Improper operation and maintenance and standardization

Problem manifestations: bracket tilting, column self lowering, accelerated wear of structural components, etc., often caused by improper operation or inadequate maintenance.

Root cause analysis:

Too many columns were lowered during the relocation, causing the base to sink due to soft bottom, and the bracket to tilt without timely adjustment.

Damaged seals were not replaced in a timely manner, and hydraulic oil contamination was not treated.

Solution:

Operation specification training:

Provide professional training for operators, emphasizing the control of column height during frame relocation (generally not exceeding 2/3 of the height of the adjacent frame side guard).

Use shims or adjust the posture of the bracket in the soft bottom area to prevent the base from sinking.

Regular maintenance and inspection:

Establish a daily inspection system, focusing on inspecting vulnerable parts such as seals, hoses, and welds.

Promptly address any issues discovered, such as replacing damaged seals, repairing cracked welds, etc.

Emergency plan formulation:

Develop emergency plans for serious malfunctions such as bracket tilting, clarify the handling procedures and responsible persons.

Regularly organize emergency drills to improve the ability of operators to respond to unexpected events.

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