To prevent fatigue damage to electric winches, comprehensive measures need to be taken from multiple aspects such as design optimization, material selection, manufacturing process, usage standards, maintenance, and monitoring management. Here is the specific plan:

1、 Design optimization

Structural rationality:

Ensure that the overall structural design of the winch is reasonable and avoid stress concentration. By using modern design methods such as finite element analysis, stress analysis and optimization design of key components of the winch are carried out to improve the fatigue resistance performance of the structure.

Optimize the transmission system of the winch, reduce impact and vibration during the transmission process, and minimize fatigue damage to components.

Load analysis:

Conduct a detailed analysis of the working load of the winch, including static and dynamic loads, to ensure that the design load covers the actual working conditions.

Consider the load changes of the winch during start-up, braking, and operation, and design a reasonable safety factor to cope with possible overload situations.

2、 Material selection

High strength materials:

Select high-strength and high toughness materials to manufacture key components of the winch, such as wire ropes, drums, gears, etc. These materials have better fatigue resistance and can withstand greater loads and cyclic stresses.

Considering the fatigue limit and fatigue life of materials, choose materials with longer fatigue life to extend the service life of the winch.

Material handling:

Proper heat treatment of materials, such as quenching, tempering, etc., can improve their hardness and toughness, and enhance their fatigue resistance.

Using surface treatment techniques such as shot peening, carburizing, etc., to increase the residual compressive stress on the material surface and improve its resistance to fatigue crack propagation.

3、 Manufacturing process

Precision machining:

Adopting precision machining technology to ensure the dimensional accuracy and surface quality of winch components. Reduce defects and stress concentration during the processing, and lower the risk of fatigue damage.

Perform non-destructive testing on key components, such as ultrasonic testing, magnetic particle testing, etc., to ensure that there are no defects inside the components and improve their reliability.

Assembly quality:

Strictly control the assembly quality of the winch to ensure the accuracy of the fit and reasonable clearance between each component. Reduce stress concentration and friction during the assembly process, and lower the likelihood of fatigue damage.

Perform dynamic balance testing on the assembled winch to ensure that it operates smoothly and without vibration, reducing fatigue damage to components.

4、 Usage standards

Avoid overloading:

Strictly use the winch according to its rated load to avoid overloading operation. Overloading can cause excessive stress on winch components, accelerating the occurrence of fatigue damage.

During the start-up and braking process of the winch, avoid sudden loading or unloading to reduce impact and vibration on the components.

Smooth operation:

Operators should receive professional training and be familiar with the operating procedures and precautions of the winch. Maintain stability during operation, avoiding sudden acceleration, deceleration, and frequent start stop.

Regularly assess and train operators to improve their operational skills and safety awareness, and reduce fatigue damage caused by improper operation.

Environmental adaptation:

Take corresponding protective measures according to the operating environment of the winch. When used in humid and corrosive environments, the winch should be treated with anti-corrosion measures to reduce corrosion and fatigue damage to components caused by environmental factors.

When used in high-temperature environments, cooling measures should be taken, such as installing cooling fans and using high-temperature resistant materials, to prevent the winch components from reducing their fatigue resistance due to overheating.

5、 Maintenance and upkeep

Regular inspection:

Establish a regular inspection system to regularly inspect and maintain key components of the winch. The inspection content includes the wear, cracks, deformation, etc. of the components, and timely detection and handling of potential safety hazards.

Regularly inspect and replace steel wire ropes to ensure their strength and safety. The steel wire rope is one of the most vulnerable components of the winch, and its fatigue damage will directly affect the safe operation of the winch.

Lubrication and maintenance:

Regularly lubricate and maintain the transmission components of the winch to reduce friction and wear. Choose the appropriate lubricant and lubricate according to the specified lubrication cycle and amount.

Regularly inspect and maintain the lubrication system to ensure its normal operation. Poor lubrication can lead to increased component wear and accelerate the occurrence of fatigue damage.

Replace vulnerable parts:

Regularly replace vulnerable parts of the winch, such as brake friction plates, bearings, etc. The wear of vulnerable parts can lead to a decrease in winch performance and increase the risk of fatigue damage.

Establish a vulnerable parts inventory management system to ensure timely supply and replacement of vulnerable parts.

6、 Monitoring and Management

Status monitoring:

Real time monitoring of the operation status of the winch using state monitoring technology. By installing sensors and collecting data, monitor the vibration, temperature, stress and other parameters of the winch, promptly detect abnormal situations and take measures.

Using big data analysis and artificial intelligence technology to process and analyze monitoring data, predict the fatigue damage trend of winches, and provide a basis for maintenance.

Life assessment:

Regularly evaluate the service life of the winch, assess the remaining service life and fatigue damage level of the winch based on its usage history, load conditions, maintenance records, etc.

Based on the life assessment results, develop a reasonable maintenance plan and replacement cycle to ensure the safe operation of the winch.

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