To address defects in the support points of an explosion-proof lever hoist, a systematic approach focusing on design optimization, material selection, manufacturing quality control, and maintenance protocols is essential. Below is a structured solution:

1. Design Optimization

Structural Analysis: Use finite element analysis (FEA) to simulate stress distribution at support points under various load conditions. Identify areas prone to deformation or failure and reinforce them with additional material or ribbing.

Ergonomic Design: Ensure the support points are positioned to minimize operator fatigue and maximize leverage. The handle and support structure should be aligned to reduce torsional forces during operation.

Modular Design: Consider a modular approach where support points can be easily replaced or upgraded without dismantling the entire hoist.

2. Material Selection

High-Strength Alloys: Use corrosion-resistant, high-strength alloys (e.g., stainless steel or titanium alloys) for support points to withstand heavy loads and harsh environments.

Non-Sparking Materials: In explosive environments, ensure all materials are non-sparking (e.g., copper-beryllium or aluminum-bronze alloys) to comply with explosion-proof standards.

Surface Treatments: Apply anti-corrosion coatings (e.g., galvanizing or powder coating) to protect support points from environmental degradation.

3. Manufacturing Quality Control

Precision Machining: Ensure support points are machined to tight tolerances to prevent misalignment or premature wear.

Welding Standards: If welding is used, adhere to strict welding procedures (e.g., AWS D1.1) to avoid defects like cracks or porosity.

Non-Destructive Testing (NDT): Perform NDT (e.g., ultrasonic or magnetic particle inspection) on support points to detect internal flaws before assembly.

4. Load Testing and Certification

Proof Loading: Subject the hoist to a load test exceeding its rated capacity (e.g., 150% of rated load) to verify the integrity of support points.

Third-Party Certification: Obtain certification from recognized bodies (e.g., ATEX, IECEx) to ensure compliance with explosion-proof and safety standards.

5. Maintenance and Inspection

Regular Inspections: Schedule periodic inspections of support points for signs of wear, corrosion, or deformation.

Lubrication: Ensure proper lubrication of moving parts to reduce friction and prevent premature failure.

Replacement Parts: Keep spare support points readily available for quick replacement in case of damage.

6. Operator Training

Safe Usage Guidelines: Train operators on proper lifting techniques and load limits to avoid overloading the hoist.

Maintenance Awareness: Educate operators on recognizing early signs of wear or damage in support points.

7. Innovative Solutions

Self-Monitoring Sensors: Integrate load cells or strain gauges into support points to provide real-time feedback on stress levels.

Predictive Maintenance: Use IoT-enabled sensors to predict failures before they occur, allowing for proactive maintenance.

8. Compliance with Standards

Adhere to Relevant Standards: Ensure the hoist design complies with international standards such as:

ISO 4301 (Classification of Cranes)

EN 14492-1 (Powered Hoists for Lifting Loads)

NFPA 497 (Electrical Classification for Hazardous Locations)

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