JB/T 5242-1991 Test specifications for slewing mechanisms of truck cranes and tire cranes
Some standard content:
Machinery Industry Standards of the People's Republic of China
Test specifications for slewing mechanisms of truck cranes and tire cranes
Question content and scope of application
JB/T5242—91
This standard stipulates Test contents, conditions and methods for the slewing mechanism of truck cranes and tire cranes (hereinafter referred to as "cranes"). This standard applies to factory testing and type testing of crane slewing mechanism products. 2 Reference standards
GB2828 Batch-by-batch inspection and counting sampling procedures and sampling tables (applicable to continuous batch inspections) GB3768 Simple method for determination of sound power level of noise sources JB4030.1 Truck crane and tire crane test specification Operation reliability test 3 Slewing mechanism and test content of slewing mechanism 3.1 Slewing mechanism generally includes the following components: a.
power components (such as hydraulic motors, electric motors, etc.); b.
reducer (including hydraulic torque converter device, hydraulic coupling, etc.); c.bzxz.net
d.
e.
f.
rotary pinion;
braking device;
Speed ??control device;
Control device (only for slewing mechanisms with independent control devices). 3.2 The slewing mechanism test is divided into factory test and type test. The factory test is an acceptance inspection test that must be carried out for each slewing mechanism before leaving the factory. It includes the following content: 3.2.11
a.
.
d.
3.2.2
Appearance inspection;
empty Load running test;
Lubrication and sealing condition inspection:
Braking capacity test of brakes (brakes controlled by hydraulic pressure also include brake opening pressure testing). Type testing is a comprehensive inspection of the technical performance, manufacturing quality and reliability of the slewing mechanism. Products that fall under one of the following circumstances should undergo type inspection: newly developed products or products produced by factory transfers; b. Products that have been resumed production for more than 10 years; d.
Products that are sampled in accordance with the provisions of GB2828 when the mass production exceeds 1,000 units. 3.2.2.1 In addition to the factory test content, type inspection also includes the following items: a.
b.
c.
Determination of the weight and center of gravity of the mechanism:
Measurement of dimensions (including installation dimensions): load operation test;
Ministry of Mechanical and Electronic Industry of the People's Republic of China approved 894 on 1991-07-01
Implemented on 1992-07-01
Organizational efficiency Measurement;
d.
e.
f.
Noise measurement;
braking performance test;
reliability test;
g.
h． Industrial assessment.
JB/T 5242—91
Note: Product type inspections belonging to items c and d in 3.2.2 only carry out four items: c, e, and fg. 3.2.2.2 Quality supervision inspection, except that the test content specified in item h in Article 3.2.2.1 can be exempted, the rest shall be carried out according to the content in type inspection.
4 Test conditions and instruments and equipment
4.1 Test conditions of the rotary mechanism
4.1.1 The rotary mechanism submitted for testing shall comply with the provisions of Article 3.1 and shall have all the required technologies document. The test environment temperature should be between -20 and +40C. 4.1.2
4.1.3 The deviation of power supply voltage or hydraulic system oil pressure is ±5% of the rated value. The total error between the calibration error of the test load and the loading error is ±1%. 4. 1. 4
4.1.5 When measuring noise, the background noise of the measuring point must be at least 3dB (A) lower than the working noise value of the working mechanism being measured, and its acoustic environment should comply with the provisions of GB3768||tt ||4.1.6 Rotary mechanisms with special requirements shall be tested according to the conditions required by the user in the contract. 4.2 Test equipment and instruments:
a.
b.
c.
d.
e.
f.|| tt||g.
h.
i.
j.
k.
1.
m.||tt ||n.
o.
Slewing mechanism test bench (a similar crane or load device can also be used instead of the test bench); dynamic strain gauge;
tachometer;|| tt||torque measuring instrument;
oscilloscope;
timer (stopwatch);
point thermometer;
sound level meter:
galvanometer ;
Voltmeter:
Wattmeter;
Pressure gauge;
Flow meter:
Length measuring instrument;
Weighing instrument.
Test method and detection content
5
Dehiro test method and detection content
5.1
5.1.1 The appearance of the slewing mechanism should be inspected before the test Inspect, and adjust the parts that need to be adjusted according to the design requirements and run-in according to the "General Technical Conditions for Assembly of Engineering Machinery" to ensure that it is in normal technical condition. 5.1.2 No-load operation test
The slewing mechanism operates in the forward and reverse directions at the rated speed for 30 minutes each. During the no-load operation, change the operating actions appropriately and check:
a.
Motion stability;
895
t
b.
c.
d.
e.| |tt||The operation conditions of brakes, clutches, etc.; JB/T 524291
Whether the fastening and connecting parts are loose or abnormal; the sealing condition of each sealing part:
After the dry operation, each Heat generation at the bearing seat. 5.1.3 Braking capacity test of the brake
With the brake fully braking, gradually apply 1~~1.25 times the rated output torque to the rotating pinion, and check whether the rotating pinion rotates.
The applied torque should be smooth and not violent. The braking capacity test is not required for the slewing mechanism driven by the worm gear with self-locking function. 5.1.4 Brake opening pressure test
With the brake fully braking, apply the rated output torque smoothly on the rotating pinion, gradually increase the brake opening oil pressure, and record the brake opening oil pressure when the rotating pinion starts to rotate. pressure value. 5.2 Type test methods and test contents
5.2.1 For the test items in the type test that are the same as those in the Iduhiro test, the test methods and test contents shall be carried out in accordance with the provisions in Article 5.1. 5.2.2 Measuring the weight of the mechanism and determining the center of gravity position of the mechanism. The center of gravity position is calibrated by the coordinate values ??of the spatial coordinate system (see figure) formed by the output axis and two mutually perpendicular straight lines in the end plane perpendicular to the axis. The two mutually perpendicular straight lines in the plane are the X-axis and the Y-axis respectively, the output axis is the Z-axis, and upward is positive. A direction
x
5.2.3 Measure the following parameters:
a.
overall dimensions (total length, total width, total height); b.||tt| |Connection installation dimensions;
c.
test items of rotary pinion.
5.2.4 Load test
z
Output shaft
Install the slewing mechanism on the test bench, and apply the rated output on the slewing pinion in the form of gear mesh Torque. Run forward and reverse for 30 minutes each. Carry out the following inspections during the test: whether each fastening part is loose or abnormal; a.
b. The sealing condition of each sealing part.
5.2.5 Mechanism efficiency determination
Mechanism efficiency is the output power of the rotary pinion and the input power of the electric motor, or the input power of the hydraulic motor, or the input power of the power input coupling Power ratio expressed as a percentage. 896
JB/T 5242-91
5.2.5.1 Use a torque measuring instrument to measure the torque on the rotating pinion; use a tachometer to measure the speed of the rotating pinion, then the actual output power of the rotating mechanism is Formula (1) calculation:
P
Mn
9.55
where: P. -Output power of the slewing mechanism, kW; M——--Torque outside the slewing pinion, kN·m - Rotating speed of the slewing pinion, r/min.
(1)
5.2.5.2 For a rotary mechanism with a motor as the driving element, use the two wattmeter measurement method to measure the input power. The input power P is calculated according to formula (2): | |tt||P,=P,+P2
Where: P1, P, - are the readings on the wattmeter, kW respectively. (2)
5.2.5.3 The slewing mechanism with a hydraulic motor as the driving element measures the flow and pressure values ??at the oil inlet of the hydraulic motor respectively. The input power P is calculated according to formula (3): ||tt ||Pl=1. 667X 10-°pQ
where;--
pressure of hydraulic motor inlet, MPa;
Q
hydraulic motor inlet Flow rate of oil port, L/min. (3)
5.2.5.4 For rotary mechanisms that can be connected to other power sources through couplings to obtain input power, use a torque meter and a tachometer to measure the torque and rotational speed values ??on the input coupling. Finally, the input power P is calculated according to formula (4): Mng
P,= 9.55
where: M—input torque value, kN·m#
ne —Input the rotation speed, r/min.
5.2.5.5 Mechanism efficiency n is calculated according to formula (5): Pe×100%
5.2.6 Noise measurement
(4)
(5))| |tt||Measure the noise value of the rotary mechanism according to the rectangular hexahedron method specified in GB3768. In the rectangular hexahedron composed of parallel planes 1m away from the front, rear, left, right and top of the slewing mechanism and the chassis plane, the centroid points of the first five sides are the measurement points; the slewing mechanism works at the maximum Rated load and corresponding rated speed state: Use the A weighting gear to measure, and read the stable maximum value of the meter at each point (excluding instantaneous interference values) as the measured value of that point. If the difference between the highest sound level and the lowest sound level at each measured point is greater than 5dB (A), a supplementary test shall be carried out in accordance with the provisions of Article 6.4.3.2 of GB3768. The measured value of each measuring point is corrected according to the provisions of Article 6.5 of GB3768 according to the background noise.
The noise value of the slewing mechanism is expressed by the sound power level (Lw^) of the noise source and is calculated according to the provisions of Article 7 of GB3768 5.2.7 Braking performance test
The purpose is to determine The braking capacity and braking smoothness of the brakes. 5.2.7.1 The braking performance test is carried out on the slewing mechanism test bench. Use a torque meter to measure the maximum braking torque value of the brake (referring to the torque value when the brake begins to slip); apply the maximum braking force on the slewing pinion of the slewing mechanism. Rated torque, brake at rated speed; open the brake, use a loading device to keep the rotating pinion running at the rated speed. Brake the brake. Use a light recorder, etc. to record the torque changes during the braking process (the braking torque is determined by Zero reaches the maximum value) is recorded. 5.2.7.2 Use the following two coefficient tables to express the technical characteristics of braking performance: a.
The braking capacity coefficient Kp+ is calculated according to formula (6): Kp=Mx/M.
where: Mijmax
The maximum braking torque value that the brake can generate, kN·m; (6)
897
JB/T 5242-91
M. —The resistance torque value of the slewing mechanism transmitted to the shaft where the brake is located under the rated load, kN·m. b. Braking torque change rate a; calculated according to formula (7): a, -M'inax /t
where: Mimax - the maximum braking torque of the brake during actual working process, - is generally equal to M, kN·m;..(7)
-braking torque growth time, the time required for the braking torque to reach M\inax from zero during the braking process, s. 5.2.8 Reliability test
The purpose of the reliability test is to evaluate whether the reliability characteristics of the slewing mechanism have reached the required level; to check the stability and reliability of product technical performance; to check the quality of parts. 5.2.8.1 See Table 1 for reliability test conditions. Table 1 Reliability test conditions
Serial number
1
2
3
Load type
Light
Load
Rated load
Dynamic
Load
Working condition
Load at rated speed and 50% of the rated load at the rotating pinion· Forward and reverse operation of 40 to 60 times each constitutes a working cycle at rated speed, and the interrotating pinion is loaded according to the rated load. Forward and reverse operation of 40 to 60 times each constitutes a working cycle. At rated speed, the interrotating pinion is loaded with rated load. The load is 1.1 times of the rated load, and each working cycle is 40 to 60 seconds in the forward and reverse directions. Note: Braking is required twice in each working cycle (braking once in the forward and reverse rotations). 5.2.8.2 The number of reliability test cycles is distributed according to Table 2. In the absence of special provisions, the working level of the slewing mechanism shall be tested according to the number of cycles and distribution plan specified in Table 2. ||tt ||Sequence
2
3
No.
Load type
Light load
Rated load
Dynamic load| | tt |
1000
5.2.8.4 After completing the specified number of cycles of the reliability test, perform a performance retest according to the contents of 5.1.3.5.1.4 and 5.2.5 in this chapter
5.2. .8.5
Table 3.
After the retest, the tested prototype shall be dismantled and inspected. The disassembly and inspection shall be recorded in detail. The disassembly and inspection items and inspection contents are shown in Table 3. Requirements
serial number" assembly
reduce
speed
unit
make
movement
unit||tt| |898
Parts
Tooth
Wheel
Bearing
Body
Box
Lubricating oil
Wear elements
brake wheel or
item
item
gear surface
limit degree
none for closed transmission gear tooth surface Crushing and peeling. The number of pitting corrosion points per tooth surface shall not exceed 3 points per square meter. The pitting corrosion point diameter shall not be greater than 1mm and the depth shall be less than 0.2mm. The weight of contaminants on the rolling element surface
and the raceway surface
Degree of wear
Elasticity of pressure plate
Component
Degree of wear
For split transmission gears, the tooth thickness wear should be less than 10% of the original teeth None Overheating burns. The surface of the rolling element and the raceway are the same as the surface of the closed transmission gear teeth. There are no cracks and no deformation
Drain all the lubricating oil in the box, measure the volume of the lubricating oil, and then clean the inside of the box , use a 120 self-filter to filter out the contaminants in the lubricating oil and cleaning fluid, dry and weigh them, and weigh them separately according to the metal and non-metal components. The contaminants are ≤50mg/1. The metal component is less than 60% and the wear is less than the original thickness. 50%, no breakage, no burns, no cracks, surface wear less than 1.5nin. No damage, no fatigue cracks 5.2.8.6
Industrial Assessment
JB/T 5242
2 —91
The purpose of the industrial assessment is to assess the matching of the rotary mechanism on the host machine. All belong to 3.2.The products specified in items a and b in Article 2 must be installed on a crane for industrial assessment, but this does not need to be carried out on the same prototype used for reliability inspection. The industrial assessment time shall not be less than 300 hours.
The manufacturer and the user are jointly responsible for the industrial assessment, and record the working conditions, load conditions, and total operation time of the operation. The record format can be recorded with reference to the reliability assessment record form. Any abnormal phenomena and conditions of the slewing mechanism that occur during the assessment period should be recorded in detail, and analysis and handling opinions should be provided. After the industrial assessment is completed, an industrial assessment report should be compiled. 6 Test report
After the type test, organize the test record [see Appendix A (reference part) for the record form], prepare the test report, and make the test report according to the corresponding standards for the acceptance conditions of the truck crane and tire crane slewing mechanism. Conclusion, 899
Product Model:
Test Date
Month
End
Day
On
Product Model:
Date of manufacture:
Product number:
Appearance quality
No-load operation test
Lubrication and sealing inspection
Brake braking Capability test
Brake opening pressure test
Product number:
Tester:
Item
Outline dimensions (length × width × height) ||tt ||Installation size value
Mechanism weight
Center of gravity position (X, YZ)
Rotation speed of the rotary pinion
Rated output torque of the rotary pinion||tt| |Rotating pinion speed
efficiency
rate
measurement
determined
JB/T 5242-91
Appendix A||tt ||Test record
Table
(reference part)
Table A1
Slewing mechanism factory test record table
Manufacturer:
Test content
Appearance quality
Motion stability
Brake action
Clutch action
Manufacturing date:
Each sealing part The sealing condition: the heating condition (temperature rise) of each bearing seat
After braking, the drag torque exerted on the rotating pinion is at least! When the rated output torque is 1 to 1.25 times, does the rotating pinion rotate
Apply the rated torque to the rotating pinion after braking. Then slowly increase the oil pressure and observe the oil pressure value when the rotating pinion starts to rotate ( Passed/unqualified)
Signature of person in charge:
Table A2 Rotary Mechanism Test Data Record Form
Manufacturer:
Test Date:
Day| |tt||Motor input power (wattmeter reading PP,) Hydraulic motor inlet throttle pressure
Hydraulic motor inlet flow
Input shaft torque
Input shaft speed| |tt||M
「Environmental noise value at measuring point
900
mm
tmm
kg
mm||tt| |r/min
N
I
r/min
kw
MPa
L/min
kN ·m
r/min
dB(A)
result notes
year
design (nominal) value
test value| |tt||Test person
Month
Day
Remarks
Effect
Rate
Test
Defined|| tt | Environmental noise value at the measuring point
V Environmental noise value at the measuring point
Environmental noise value at the measuring point
V
Correction value
Working noise value at the measuring point| |tt||Working noise value of measuring point
Working noise value of II measuring point
Working noise value of NV measuring point
Working noise value of V measuring point
Item|| tt||Rectangular hexahedral parameter value (length × width × height) The maximum braking torque of the brake Mima
The maximum resistance torque M acting on the brake The maximum actual braking torque M\mux braking torque growth time. :
Brake opening oil pressure
Table A3
Prototype model:
Test period:
Start-up time
Stop time|| tt||Test time
Manufacturing area:
Test location:
h
Imin
h
min
h
Time of failure (fault)
Recovery test time
Working
Condition
min
min
Failure (fault). Brief description of the failure (fault) situation:
Repair measures:
Maintenance time:
h
Additional instructions:||tt ||min
JB/T 5242-91
Cont. Table A2
dB(A)
dB(A)
dB(A)| |tt||dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dR (A)
mm
kNi·m
kN·m
kN·m
MPa
slewing mechanism reliability test record Table
Factory number:
Tester:
Export period:
Number of cycles completed in this class
Cumulative test time
Cumulative completion Number of cycles
Cumulative number of failures
Cumulative maintenance time:
min
This standard is proposed by the Ministry of Construction and is under the jurisdiction of the Ministry of Construction Changsha Construction Machinery Research Institute was responsible for drafting. The main drafters of this standard are Zhan Chunxin and Xiao Yang. Design (nominal) value! Test value
Remarks
Year
Month
min
Forced to stop operation due to failure and troubleshooting
Stop operation time||tt| |Cumulative chased stop running time
min
min
901
Then slowly increase the oil pressure and observe the oil pressure value when the rotary pinion starts to rotate (passed/unqualified)
Signature of the person in charge:
Table A2 Rotary Mechanism Test Data Record Form||tt| |Manufacturer:
Test date:
Day
Motor input power (wattmeter reading PP,) Hydraulic motor inlet throttle pressure
Hydraulic motor inlet flow
Input shaft torque
Input shaft speed
M
"Environmental noise value at the measuring point
900
mm||tt ||tmm
kg
mm
r/min
N
I
r/min
kw| |tt||MPa
L/min
kN·m
r/min
dB(A)
Result Notes
Year
Design (nominal) value
Test value
Test person
Month
Day
Remarks
Effect| |tt||rate
test
definition
make
dynamic
performance
test||tt ||Verification
Environmental noise value of measuring point
Environmental noise value of positive measuring point
Environmental noise value of V measuring point
Environmental noise value of measuring point
V
Correction value
Measuring point working noise value
Measuring point working noise value
II measuring point working noise value
NV measuring point working noise value
V measuring point working noise value
item
rectangular hexahedron parameter value (length × width × height) maximum braking torque Mima of the brake
acting on the brake Maximum resistance torque M. Maximum actual braking torque M\mux braking torque growth time:
Brake opening oil pressure
Table A3
Prototype model:
Test Hundreds of issues:
Start-up time
Stop time
Test time
Manufacturing area:
Test location:
h||tt| |Imin
h
min
h
Time of failure (fault)
Recovery test time
Work
Situation
min
min
Accumulated number of completed cycles when failure (fault) Failure (fault) brief description:
Repair measures:
Maintenance Time:
h
Additional notes:
min
JB/T 5242-91
Continuation Table A2
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dR(A)
mm
kNi·m
kN·m
kN ·m
MPa
Slewing mechanism reliability test record sheet
Factory number:
Tester:
Export period:
This Number of completed cycles per shift
Cumulative test time
Cumulative number of completed cycles
Cumulative number of failures
Cumulative maintenance time:
min||tt| |This standard was proposed and administered by the Shasha Construction Machinery Research Institute of the Ministry of Construction. This standard is drafted by the Shasha Construction Machinery Research Institute of the Ministry of Construction. The main drafters of this standard are Zhan Chunxin and Xiao Yang. Design (nominal) value! Test value
Remarks
Year
Month
min
Forced to stop operation due to failure and troubleshooting
Stop operation time||tt| |Cumulative chased stop running time
min
min
901
Then slowly increase the oil pressure and observe the oil pressure value when the rotary pinion starts to rotate (passed/unqualified)
Signature of the person in charge:
Table A2 Rotary Mechanism Test Data Record Form||tt| |Manufacturer:
Test date:
Day
Motor input power (wattmeter reading PP,) Hydraulic motor inlet throttle pressure
Hydraulic motor inlet flow
Input shaft torque
Input shaft speed
M
"Environmental noise value at the measuring point
900
mm||tt ||tmm
kg
mm
r/min
N
I
r/min
kw| |tt||MPa
L/min
kN·m
r/min
dB(A)
Result Notes
Year
Design (nominal) value
Test value
Test person
Month
Day
Remarks
Effect| |tt||rate
test
definition
make
dynamic
performance
test||tt ||Verification
Environmental noise value of measuring point
Environmental noise value of positive measuring point
Environmental noise value of V measuring point
Environmental noise value of measuring point
V
Correction value
Measuring point working noise value
Measuring point working noise value
II measuring point working noise value
NV measuring point working noise value
V measuring point working noise value
item
rectangular hexahedral parameter value (length × width × height) maximum braking torque Mima of the brake
acting on the brake Maximum resistance torque M. Maximum actual braking torque M\mux braking torque growth time:
Brake opening oil pressure
Table A3
Prototype model:
Test Hundreds of issues:
Start-up time
Stop time
Test time
Manufacturing area:
Test location:
h||tt| |Imin
h
min
h
Time of failure (fault)
Recovery test time
Work
Situation
min
min
Accumulated number of completed cycles when failure (fault) Failure (fault) brief description:
Repair measures:
Maintenance Time:
h
Additional notes:
min
JB/T 5242-91
Continuation Table A2
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dB(A)
dR(A)
mm
kNi·m
kN·m
kN ·m
MPa
Slewing mechanism reliability test record sheet
Factory number:
Tester:
Export period:
This Number of completed cycles per shift
Cumulative test time
Cumulative number of completed cycles
Cumulative number of failures
Cumulative maintenance time:
min||tt| |This standard was proposed and administered by the Shasha Construction Machinery Research Institute of the Ministry of Construction. This standard was drafted by the Shasha Construction Machinery Research Institute of the Ministry of Construction. The main drafters of this standard are Zhan Chunxin and Xiao Yang. Design (nominal) value! Test value
Remarks
Year
Month
min
Forced to stop operation due to failure and troubleshooting
Stop operation time||tt| |Cumulative chased stop running time
min
min
901
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