Some standard content:
National Standard of the People's Republic of China
Construction winch test code and procedures
Constriction wluch--Test code and proceduresUDC621.862:620
GB6947-86
This standard applies to the construction winch (hereinafter referred to as winch) specified in GB1955-86 "Construction winch", and stipulates the test specifications and methods for evaluating the performance of the winch. Types of tests
Winch tests are divided into qualification tests and type tests. 1.1: Qualification tests are acceptance and inspections conducted by the manufacturer on the winch before it is released. 1,2, Type tests are comprehensive inspections of the manufacturing quality, technical performance and reliability of the winch. Type tests should be carried out in the following cases: a. New products or transferred products developed: b. Products whose design, technology or material changes affect the performance of the winch: c. Products that have been stopped for more than two years and resumed production. 2 Test conditions
All working devices specified in the design should be installed. The ambient temperature during the test should be between -15 and 35 °C, and the wind speed should not exceed 8.3 m/s. 2.2
2.3 The height of the tower used in the test should not be less than 10m. 2.4 The tolerance of the power supply voltage relative to the rated voltage shall not exceed ± 5%. 2.5 The test load should be accurately calibrated, and the tolerance shall not exceed ± 1% of the actual weight. 2.6 When measuring noise, at the measuring point, the difference between the A sound level measured when the south source is working and the A sound level of the background noise should be greater than 10dB (A). The ideal acoustic environment should be no other reflective objects except a reflective surface (ground). 2. All required technical documents should be prepared before the type test. 2.8 For winches with special requirements, the test shall be carried out according to the conditions specified in the user contract. Test instruments and measuring tools
Power meter, voltmeter, ammeter. The accuracy of instruments shall not be less than Class 0.5: tension sensor (or tension meter),
contactless switch (or tachometer),
strain gauge;
oscilloscope ink
precision sound level i
temperature meter:
stopwatch,
travel switch.
, "Length tool!
National standard 1986-10-09 issued
1987-09-01 implementation
Wb weighing instrument.
A Test method
4.1 Qualification test
Winches should be subjected to qualification tests.
4.1.1 Visual inspection should be carried out before the test.
GB6917--86
4.1.2 After the commissioning and running-in of the winch, the forward and reverse rotations shall be tested for no less than 15 minutes each without load, and the operation and sound conditions shall be checked,
operating system, clutch, brake, stopper action conditions, $.
c.: Conditions of each fastening connection part
d. Lubrication and sealing conditions.
4.1.8 For winches produced in continuous batches, samples (except 4.2.2, 4.2.3.2, 4.2.4, and 4.2.5) shall be tested in accordance with GB2828-81 "Batch Inspection Count Sampling Procedure and Sampling Table", and a secondary sampling plan shall be adopted. Normal inspection sampling shall be adopted, level II shall be adopted, and sampling inspection transfer rules shall be implemented. The qualified quality level (AQL) of the whole machine shall be set at 2.5. 1. For the inspection of non-continuous batches, the inspection shall be carried out in the same way as for continuous batches, but it must start from the inspection of water light II. 4.2 Type test
Type test includes the content of qualified test. 4.2.2 Quality measurement and external dimension measuring
Weigh the quality of the whole machine (excluding wire rope ), and shall comply with the provisions of Article 3.15 of GB1955-86 b. Measure the overall dimensions of the electrical machine.
4.2.8 Load test
The load test method and device are shown in the figure. Various tests are carried out on the reference layer 1 with the rated tension of the wire rope. When the test is carried out on the non-reference layer, the added test load should make the torque produced by the winch equal to the torque produced by the rated tension of the wire rope acting on the reference layer. The wire rope speed should be converted to the value of the reference distance. Duration
Test load
4.2.3.1 Noise measurement
The noise is measured using the rectangular hexahedron method specified in GB3768-83 "Simple method for determining the sound power level of noise sources". Take five measuring points, namely, the front, rear, and Four points at a height of (H+1)2, 1m from the left and right outermost sides, and one point at (H+1) directly above (H is the height of the winch, m). If the difference between the highest and lowest sound levels measured does not exceed 5dB (A), take the arithmetic mean; if it is greater than dB (A), measure and calculate according to the requirements of Item 16.4.3.2 and 7.1 of GB376883111. The measured noise value shall comply with the provisions of Item 13.10 of G131955-861. 4.2.3.2 Measurement of overall efficiency Overall efficiency is the ratio of overall output power to motor input power, expressed as a fraction of a ton. Use a tension sensor (or tension meter) to measure the wire rope tension, use a contactless switch (or tachometer) to measure the speed of the drum, and record the actual radius of the drum. The formula for the actual output power of the winch is P.
Where F—wire rope tension, kN;
drum speed, r/mins
R—actual radius of the drum, mm.
F·R·n
The formula for measuring the input power of the motor using the two-watt method is: (kw)
P,= P,+ P, (kW)
Where: P, P,—the readings on the two power meters, respectively. Overall efficiency:
%
Mechanical efficiency:
—motor efficiency.
4.2.3.3 Determination of rated speed of wire rope (Vrated) Measure the displacement of the wire rope and the time required, then: V
wire rope displacement, ms
—the time required for the corresponding wire rope displacement, S. 60S
The tolerance between the result and the design value shall not exceed ±5% of the design value. 4.2.3.4 Load Sliding Determination
(m/min)
Install a travel switch linked to the brake at an appropriate position on the tower. When the load descends at the rated speed, the travel switch is triggered to close the brake. The distance from the point on the load that touches the travel switch to the travel open contact when the load is completely stationary is measured. The result must comply with the provisions of Article 3.12 of G81955-86. The winch that allows slipping can be visually inspected. 4.2.3.5 Reduced Voltage Starting Test
Hang the rated load in the air. When the test voltage is 90% of the rated voltage, it must be able to be lifted from this state. The test should be performed at least twice.
4.2.3.6 Static load test
The test load is 125% of the rated tension of the wire rope. The machine is lifted to a height of 200-300mm from the ground and stays there for no less than 10 minutes. After unloading, the machine shall not have cracks, permanent deformation, paint peeling, loose joints, or damage that affects performance and safety. 4.2.3.7 Dynamic load test
The test load is 110% of the rated tension of the wire rope. The test shall be conducted no less than twice, with the lifting height above 3m. Lifting, lowering and braking tests shall be conducted. Check the working condition of the brake and whether the components and connectors are loose or damaged. 4.2.3.8 Device inspection
: The limit device shall be safe and reliable.
b. The overload protection device shall be safe and reliable. Its safety margin is =10%. 4.2.3: 9 Temperature plate test
The machine shall be operated according to the designed load duration rate. The test operation time shall comply with the requirements of Table 1, and the temperature of each part of the machine shall not exceed the requirements of Table 2.
W.Duration of load, %
Time, min
Part name
Gearbox housing and bearing cover
Motor housing (measurement of lifting ring and screw)
Brake line
Brake wheel surface and brake band
GB $47-86
E-level insulation 65
B-level insulation 70
F-level insulation B5
E-level insulation B0
B-level insulation 90
F-level insulation 115
Maximum temperature
After the above tests, check the contact condition of the brake band, brake wheel and clutch joint surfaces. The distribution area of the contact spots should not be less than 81% of the contactable area. 4.2.4 Reliability Test
Through reliability test, evaluate whether the reliability characteristic quantity of the product reaches the required level, check the stability and reliability of the product's technical performance, and check the quality of parts and components. 4.2.4.1 Test conditions
Repeated lifting test with rated load, the lifting height is not less than 5m. 4.2.4.2 Reliability cycle number
When conducting reliability test, the basic cycle number N of repeated lifting is stipulated as follows: a. Fast winch N10 times;
Slow winch N6×10° times;
c. Speed-adjustable winch is recommended to have n kinds of working speeds, each gear is carried out N4 times respectively. 2. 4.3 Total working time
Before the test, the working time of each test cycle should be measured three times, and the average value is taken. The total working time required to complete the reliability test: In the formula; N-
-the specified number of reliability test cycles, times, N,
-the working time required for each test cycle (excluding rest time), S4.2.4.4 Operation and maintenance
.bzsoso:comGB 6947--86
Reliable. Operators should strictly follow the operating procedures according to the regulations and requirements in the product manual. b. Complete daily (shift) maintenance according to the regulations in the manual. During the test, the winch is not allowed to work with faults. 4.2.4.5 Test requirements
, the test is carried out according to the designed load duration rate, and the temperature of the reducer housing is measured every 4 hours. b. Within the specified number of cycles of the reliability test, except for the wear of the elastic ring and the wire rope positive belt, other parts are not allowed to be replaced. c During the test, the replacement of the wire rope due to normal wear is not considered a fault, but the time spent on replacing the wire rope should be counted as maintenance time.
4.2..8 Performance retest
After the reliability test, a performance retest should be carried out if necessary, and the results should be compared. 4.2.4.7 Disassembly and inspection
After the reliability test, the whole machine is disassembled and inspected, and the disassembly and inspection situation is recorded in detail. The problems found should be studied and analyzed in time to determine the cause. The recording method can be text, photography or video recording. *, Cleanliness inspection: Use cleaning fluid to clean the internal parts of the reducer and the inner wall of the box, filter the used lubricating oil (grease) and cleaning fluid with a 1-centimeter self-sieve, dry the filtered debris and weigh the debris. b. See Table 3 for the names and inspection items of dismantling parts and components. Table 3
Name of parts and components
·Gear
Brake, clutch
4.2.4.8 Reliability test record
Reliability test should be filled in according to the requirements of Appendix A. 4.2. Element, 9 Reliability feature increase and its evaluation a. Reliability time index
Reliability time index is calculated as follows:
ATI(%)
Formula: T. 1. Total operation time for reliability test, h; T—Total maintenance and repair time, h.
Reliability time index is stipulated as follows:
Fast winch 4T1 is not less than 86%;
Slow winch ATI is not less than 90%;
Speed winch ATI is not less than 83%.
b. Repair time rate
Liaoning oil, damage, crack
Tooth surface contact marks, pitting, puncture
Cracks, plastic deformation, elastic seam non-cracks
Burns, rolling element or raceway wear, pitting contact spots, wear conditions
W. (7)
Repair time rate (RTR) is calculated as follows: Where: T, repair time, h.
c. Mean trouble-free working time
GB6947—86
RTR (%)
The mean time between failures (MTBF) is calculated as follows:MTBF
Where: Ni—Total number of failures during the reliability test period. N
+（(8)
（9）
If the winch does not fail during the reliability test period, the MTBF value is the total working time of the test. 4.2.4.10 For the provisions on the calculation method of failures (faults), the number of failures (faults), the explanation of the repair time, the total time for maintenance and repair, the maintenance implementation time, etc., see Appendix B.
4.2.5 Industrial Test
|Newly developed winches must be subjected to industrial tests. The test time should be no less than 300h. 5 Test report
After completing the above test contents, write a test report. For performance that does not meet the requirements, an analysis should be made in the report, a clear conclusion should be drawn, and the technical performance of the winch should be evaluated. W.bzsoso.coD Product model
Test location
Working timeh
Failure (fault)
Occurrence time
Speed box
Result when the fault occurs
Counted number of test cycles
GB 4,47-86
·Appendix A
Record sheet of odor resistance test
(supplement)
Factory date
Tester
Battery A
Failure (malfunction)
Brief description of the situation
Note: Voltage, current and noise are measured values for 4 hours per shift. Repair measures
Test date
Recorder
Number of completed cycles
Noise dB (A)
Failure elimination time h
WB.1 Failure (malfunction)
Failure includes:
GB 614T-86
Appendix B
Description of failure and repair time
(reference)
, B. Damage or abnormal operation of the winch during the test b. Damage caused by failure to comply with the operating and maintenance procedures specified in the instruction manual. Provisions on the calculation method of the number of failures (failures) in data collation. B.2
Failures that occur simultaneously are only counted as one failure, a.
b. Another failure that occurs during the repair implementation time is only counted as one failure together with the failure being eliminated. B.3 Repair time
. Failure diagnosis time (i.e. time to find the fault), b. Repair implementation time (i.e. time to eliminate the fault and time to adjust and check). The following time is not included in the data processing and reliability characteristic calculation:. The time used for damage caused by unexpected accidents or operating errors rather than improper product design and manufacturing,
b. Time wasted due to damage to auxiliary equipment during the test; time used for specialized technical research and inspection to analyze the cause of the failure. C
Total time for maintenance and repair
Repair time is the total time to eliminate faults,
maintenance implementation time;
The time it takes to replace the wire rope due to normal wear. c.
Additional notes:
This standard is proposed by the Ministry of Urban and Rural Construction and Environmental Protection of the People's Republic of China. This standard is under the jurisdiction of Changsha Construction Machinery Research Institute. This standard was drafted by Changsha Construction Machinery Research Institute, Fuxin Mining Machinery Factory, Xuzhou Mining Equipment Manufacturing!, and Shanxi Machinery. The main drafters of this standard are Zhuo Xianwei, Lv Haifeng, Sun Shitian, and Liang Changrong.7 Disassembly and inspection
After the reliability test, the whole machine shall be disassembled and inspected, and the disassembly and inspection shall be recorded in detail. Any problems found shall be studied and analyzed in time to determine the causes. The recording method may be text, photo or video. *, Cleanliness inspection: Use cleaning fluid to clean the internal parts of the reducer and the inner wall of the box, filter the used lubricating oil (grease) and cleaning fluid with a 1-centimeter self-sieve, dry the filtered debris and weigh the debris. b The names of the disassembly and inspection parts and components and the inspection items are shown in Table 3. Table 3
Name of parts and components
·Gear
Brake, clutch
4.2.4.8 Reliability test record
The reliability test shall be filled in according to the requirements of Appendix A. 4.2. Element, 9 Reliability feature increase and its evaluation a Reliability time index
The reliability time index is calculated as follows:
ATI(%)
Formula: T. 1. Total operation time for reliability test, h; T—Total maintenance and repair time, h.
Reliability time index is stipulated as follows:
Fast winch 4T1 is not less than 86%;
Slow winch ATI is not less than 90%;
Speed winch ATI is not less than 83%.
b. Repair time rate
Liaoning oil, damage, crack
Tooth surface contact marks, pitting, puncture
Cracks, plastic deformation, elastic seam non-cracks
Burns, rolling element or raceway wear, pitting contact spots, wear conditions
W. (7)
Repair time rate (RTR) is calculated as follows: Where: T, repair time, h.
c. Mean trouble-free working time
GB6947—86
RTR (%)
The mean time between failures (MTBF) is calculated as follows:MTBF
Where: Ni—Total number of failures during the reliability test period. N
+（(8)
（9）
If the winch does not fail during the reliability test period, the MTBF value is the total working time of the test. 4.2.4.10 For the provisions on the calculation method of failures (faults), the number of failures (faults), the explanation of the repair time, the total time for maintenance and repair, the maintenance implementation time, etc., see Appendix B.
4.2.5 Industrial Test
|Newly developed winches must be subjected to industrial tests. The test time should be no less than 300h. 5 Test report
After completing the above test contents, write a test report. For performance that does not meet the requirements, an analysis should be made in the report, a clear conclusion should be drawn, and the technical performance of the winch should be evaluated. W.bzsoso.coD Product model
Test location
Working timeh
Failure (fault)
Occurrence time
Speed box
Result when the fault occurs
Counted number of test cycles
GB 4,47-86
·Appendix A
Record sheet of odor resistance test
(supplement)
Factory date
Tester
Battery A
Failure (malfunction)
Brief description of the situation
Note: Voltage, current and noise are measured values for 4 hours per shift. Repair measures
Test date
Recorder
Number of completed cycles
Noise dB (A)
Failure elimination time h
WB.1 Failure (malfunction)
Failure includes:
GB 614T-86
Appendix B
Description of failure and repair time
(reference)
, B. Damage or abnormal operation of the winch during the test b. Damage caused by failure to comply with the operating and maintenance procedures specified in the instruction manual. Provisions on the calculation method of the number of failures (failures) in data collation. B.2
Failures that occur simultaneously are only counted as one failure, a.
b. Another failure that occurs during the repair implementation time is only counted as one failure together with the failure being eliminated. B.3 Repair time
. Failure diagnosis time (i.e. time to find the fault), b. Repair implementation time (i.e. time to eliminate the fault and time to adjust and check). The following time is not included in the data processing and reliability characteristic calculation:. The time used for damage caused by unexpected accidents or operating errors rather than improper product design and manufacturing,
b. Time wasted due to damage to auxiliary equipment during the test; time used for specialized technical research and inspection to analyze the cause of the failure. C
Total time for maintenance and repair
Repair time is the total time to eliminate faults,
maintenance implementation time;
The time it takes to replace the wire rope due to normal wear. c.
Additional notes:
This standard is proposed by the Ministry of Urban and Rural Construction and Environmental Protection of the People's Republic of China. This standard is under the jurisdiction of Changsha Construction Machinery Research Institute. This standard was drafted by Changsha Construction Machinery Research Institute, Fuxin Mining Machinery Factory, Xuzhou Mining Equipment Manufacturing!, and Shanxi Machinery. The main drafters of this standard are Zhuo Xianwei, Lv Haifeng, Sun Shitian, and Liang Changrong.7 Disassembly and inspection
After the reliability test, the whole machine shall be disassembled and inspected, and the disassembly and inspection shall be recorded in detail. Any problems found shall be studied and analyzed in time to determine the causes. The recording method may be text, photo or video. *, Cleanliness inspection: Use cleaning fluid to clean the internal parts of the reducer and the inner wall of the box, filter the used lubricating oil (grease) and cleaning fluid with a 1-centimeter self-sieve, dry the filtered debris and weigh the debris. b The names of the disassembly and inspection parts and components and the inspection items are shown in Table 3. Table 3
Name of parts and components
·Gear
Brake, clutch
4.2.4.8 Reliability test record
The reliability test shall be filled in according to the requirements of Appendix A. 4.2. Element, 9 Reliability feature increase and its evaluation a Reliability time indexwww.bzxz.net
The reliability time index is calculated as follows:
ATI(%)
Formula: T. 1. Total operation time for reliability test, h; T—Total maintenance and repair time, h.
Reliability time index is stipulated as follows:
Fast winch 4T1 is not less than 86%;
Slow winch ATI is not less than 90%;
Speed winch ATI is not less than 83%.
b. Repair time rate
Liaoning oil, damage, crack
Tooth surface contact marks, pitting, puncture
Cracks, plastic deformation, elastic seam non-cracks
Burns, rolling element or raceway wear, pitting contact spots, wear conditions
W. (7)
Repair time rate (RTR) is calculated as follows: Where: T, repair time, h.
c. Mean trouble-free working time
GB6947—86
RTR (%)
The mean time between failures (MTBF) is calculated as follows:MTBF
Where: Ni—Total number of failures during the reliability test period. N
+（(8)
（9）
If the winch does not fail during the reliability test period, the MTBF value is the total working time of the test. 4.2.4.10 For the provisions on the calculation method of failures (faults), the number of failures (faults), the explanation of the repair time, the total time for maintenance and repair, the maintenance implementation time, etc., see Appendix B.
4.2.5 Industrial Test
|Newly developed winches must be subjected to industrial tests. The test time should be no less than 300h. 5 Test report
After completing the above test contents, write a test report. For performance that does not meet the requirements, an analysis should be made in the report, a clear conclusion should be drawn, and the technical performance of the winch should be evaluated. W.bzsoso.coD Product model
Test location
Working timeh
Failure (fault)
Occurrence time
Speed box
Result when the fault occurs
Counted number of test cycles
GB 4,47-86
·Appendix A
Record sheet of odor resistance test
(supplement)
Factory date
Tester
Battery A
Failure (malfunction)
Brief description of the situation
Note: Voltage, current and noise are measured values for 4 hours per shift. Repair measures
Test date
Recorder
Number of completed cycles
Noise dB (A)
Failure elimination time h
WB.1 Failure (malfunction)
Failure includes:
GB 614T-86
Appendix B
Description of failure and repair time
(reference)
, B. Damage or abnormal operation of the winch during the test b. Damage caused by failure to comply with the operating and maintenance procedures specified in the instruction manual. Provisions on the calculation method of the number of failures (failures) in data collation. B.2
Failures that occur simultaneously are only counted as one failure, a.
b. Another failure that occurs during the repair implementation time is only counted as one failure together with the failure being eliminated. B.3 Repair time
. Failure diagnosis time (i.e. time to find the fault), b. Repair implementation time (i.e. time to eliminate the fault and time to adjust and check). The following time is not included in the data processing and reliability characteristic calculation:. The time used for damage caused by unexpected accidents or operating errors rather than improper product design and manufacturing,
b. Time wasted due to damage to auxiliary equipment during the test; time used for specialized technical research and inspection to analyze the cause of the failure. C
Total time for maintenance and repair
Repair time is the total time to eliminate faults,
maintenance implementation time;
The time it takes to replace the wire rope due to normal wear. c.
Additional notes:
This standard is proposed by the Ministry of Urban and Rural Construction and Environmental Protection of the People's Republic of China. This standard is under the jurisdiction of Changsha Construction Machinery Research Institute. This standard was drafted by Changsha Construction Machinery Research Institute, Fuxin Mining Machinery Factory, Xuzhou Mining Equipment Manufacturing!, and Shanxi Machinery. The main drafters of this standard are Zhuo Xianwei, Lv Haifeng, Sun Shitian, and Liang Changrong.1 Failure (fault)
Failure includes:
GB 614T-86
Appendix B
Explanation of failure and repair time
(reference)
, damage or abnormal operation of the winch during the test b. Damage caused by failure to comply with the operation and maintenance procedures specified in the instruction manual. Provisions on the calculation method of the number of failures (faults) in data collation. B.2
Failures that occur simultaneously are only counted as one failure, a.
b. Another failure that occurs within the repair implementation time is only counted as one failure together with the failure being eliminated. B.3 Repair time
. Failure diagnosis time (i.e. time to find the fault), b. Repair implementation time (i.e. time to eliminate the fault and time to adjust and calibrate). The following time is not included in the data processing and reliability characteristic calculation:. The time taken to deal with damage caused by accident or operation error rather than product design or improper manufacturing. b. The time wasted due to the damage of auxiliary equipment during the test; the time used for specialized technical research and inspection to analyze the cause of the failure. C. The total time for maintenance and repair. The repair time is the total time to eliminate the failure, maintenance implementation time; the time taken to replace the wire rope due to normal wear. c. Additional remarks: This standard was proposed by the Ministry of Urban and Rural Construction and Environmental Protection of the People's Republic of China. This standard is under the jurisdiction of Changsha Construction Machinery Research Institute. This standard was drafted by Changsha Construction Machinery Research Institute, Fuxin Mining Machinery Factory, Xuzhou Mining Equipment Manufacturing Co., Ltd., and Shanxi Machinery Co., Ltd. The main drafters of this standard are Zhuo Xianwei, Lv Haifeng, Sun Shitian, and Liang Changrong.1 Failure (fault)
Failure includes:
GB 614T-86
Appendix B
Explanation of failure and repair time
(reference)
, damage or abnormal operation of the winch during the test b. Damage caused by failure to comply with the operation and maintenance procedures specified in the instruction manual. Provisions on the calculation method of the number of failures (faults) in data collation. B.2
Failures that occur simultaneously are only counted as one failure, a.
b. Another failure that occurs within the repair implementation time is only counted as one failure together with the failure being eliminated. B.3 Repair time
. Failure diagnosis time (i.e. time to find the fault), b. Repair implementation time (i.e. time to eliminate the fault and time to adjust and calibrate). The following time is not included in the data processing and reliability characteristic calculation:. The time taken to deal with damage caused by accident or operation error rather than product design or improper manufacturing. b. The time wasted due to the damage of auxiliary equipment during the test; the time used for specialized technical research and inspection to analyze the cause of the failure. C. The total time for maintenance and repair. The repair time is the total time to eliminate the failure, maintenance implementation time; the time taken to replace the wire rope due to normal wear. c. Additional remarks: This standard was proposed by the Ministry of Urban and Rural Construction and Environmental Protection of the People's Republic of China. This standard is under the jurisdiction of Changsha Construction Machinery Research Institute. This standard was drafted by Changsha Construction Machinery Research Institute, Fuxin Mining Machinery Factory, Xuzhou Mining Equipment Manufacturing Co., Ltd., and Shanxi Machinery Co., Ltd. The main drafters of this standard are Zhuo Xianwei, Lv Haifeng, Sun Shitian, and Liang Changrong.
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