Some standard content:
National Standard of the People's Republic of China
Test method for reliability of tire rollers
Pneumalic tyre roller-Test method for rellability Subject content and scope of application
This standard specifies the reliability test method for tire rollers (hereinafter referred to as rollers). This standard applies to self-propelled pneumatic tire rollers. Towed tire rollers can also refer to it. 2 Reference standards
GB8507 Performance test method for tire rollers 3 Terminology
3.1 Reliability
The ability of a product to complete specified functions under specified conditions and within a specified time. 3.2 Failure
The loss of specified functions of a product.
3.3 Maintenance
UC 625. 084
:620.169.1
GB 8508-87
Technical measures carried out in accordance with a predetermined plan or the provisions of the corresponding technical conditions to prevent product performance degradation and reduce the probability of product failure.
3.4 Repair
Technical measures carried out to restore the product to the state where it can complete the specified function after a part of the product fails. 3.5 Operation time
The time it takes for a product to complete the specified function.
3.6 Repair time
The time required from the discovery of a fault to the restoration of the specified function of the product, that is, the sum of the time for fault diagnosis, repair preparation and repair implementation. The repair time in this standard only counts the repair implementation time. 3.7 Inspection batch
In reliability testing, the unit products collected for sampling inspection. 3.8 Random sampling
When sampling from the inspection batch, the sampling method in which all unit products in the batch have equal probability of being sampled. 4 Basic provisions of reliability test
4.1 Total test time
The total test time of the reliability of the road roller is set at 400h (only the effective working time is counted). 4.2 Basic conditions and time allocation
The basic working conditions and time allocation of the reliability test of the road roller shall be in accordance with the provisions of Table 1. 4.3 Periodic assessment
Approved by the Ministry of Urban and Rural Construction and Environmental Protection of the People's Republic of China on December 23, 1987, and implemented on July 1, 1988
GB 8508-87
While operating under the working conditions specified in 4.2, the performance of each item shall be assessed in accordance with the provisions of Table 2. Table
Basic working conditions
Road driving
Compacting operation
Cycle working time
Note: ()Road driving without reverse working conditions,
Test requirements
Drive on a flat road with maximum working mass and medium and high gear running speeds, and operate at working gear speeds in the test field or on site [Proportion of compaction operation in the total test time
②The forward and backward time of compaction operation each accounts for 50%, and the operation time at the first gear speed accounts for 65%. The operation time at the first gear speed accounts for 35%. Table 2
4.4 Sampling determination
Braking on flat ground
Stop and start on slope
Minimum turning
Every 8 hours of cumulative cycle operation
Every 50 hours of cumulative cycle operation
Every 20 hours of cumulative cycle operation
Assessment requirements
Braking at medium and high speeds for no less than 6 times, braking at low speeds for no less than 16 timesClimbing a slope for no less than 5 times
Stop and start on slope for no less than 3 times,
The slope is 20%, and the slope is longer than 10m
One left and right turn for forward and backward4.4.1The inspection batch submitted for reliability test must be the product that has passed the technical appraisal and has been put into batch production. 4.4.2The inspection batch submitted must be a continuous batch with stable quality produced within the past year. 4.4.3 When sampling in the finished product warehouse of the roller manufacturer, the number of inspection batches shall not be less than 5. 4.4.4 Sampling method
The prototypes for reliability test shall be randomly selected from the submitted inspection batches. The prototypes determined by sampling shall be recorded with the nameplate of the whole machine and the engine, and the sampled machines shall be sealed. 5 Test conditions
5.1 Test site
The reliability test of the roller shall be carried out at the test site or the construction site. 5.1.1 Test site
The site shape is circular or linear;
The ground of the site is not allowed to accumulate or soak.Www.bzxZ.net
5.1.2 Construction site
The reliability test of the roller shall be carried out at the construction site, which is not restricted by site conditions. 5.2 Compacting materials
5.2.1 Use materials that are not easy to compact or other elastic materials. 5.2.2 In the case of 5.2.1, sandy soil can be used instead. However, during the compaction operation of the reliability test, the soil should be loosened frequently.
5.2.3 The compaction materials inherent in or filled at the construction site are not limited by the above materials. 5.3 Test environment
5.3.1 The temperature should not be lower than 5℃
5.3.2 The reliability test should be conducted outdoors in rainless weather. If it has no impact on the human, machine system and test site, the test can also be conducted in light rain.
5.4 Drivers and maintenance personnel
GB 8508-87
5.4.1 The driver of the prototype for the test should be a skilled worker who has passed the training and assessment and obtained a roller driving license (operating license). 5.4.2 The maintenance personnel participating in the test should be skilled workers. 5.5 Test instruments and other
5.5.1 The test instruments, meters and measuring tools must be inspected and calibrated before use. 5.5.2 The tools and instruments used in the test should be intact and complete. 5.6 Measurement accuracy
The measurement accuracy should comply with the provisions of 4.3.2 of GB8507. 6 Steps and methods of reliability test
6.1 Test preparation
6.1.1 Before the test, prepare the test outline and test plan in accordance with the provisions of Chapter 4, and make detailed arrangements for the test schedule, site, personnel, and work shifts.
6.1.2 Technical data preparation
Related standards that must be implemented in the test;
Instructions for use of the roller;
Test record form;
Drawings required for retesting.
6.2 Initial test
Before the reliability test, the initial data of the main technical performance of the roller must be measured. The test items are as follows: the floating amount of the front and rear wheels;
the overlapping width of the front and rear wheels;
the average ground contact pressure of the tires of the front and rear axles;
the operating force of each control mechanism;
the driving speed of each gear;
the climbing ability;
the parking and starting performance on the slope;
the braking performance on the flat ground;
the minimum turning radius:
the noise of the whole machine.
6.2.2 The test method shall be carried out in accordance with GB8507. The test results shall be recorded in Table C1.6.3 Cyclic operation and test records
6.3.1 The reliability test shall be carried out in the form of continuous cyclic operation. The average daily working time shall not be less than one working shift. The cumulative working time of each working shift shall not be less than 5 hours.
6.3.2 After each continuous working time of 2 hours, the roller is allowed to stop for 15 minutes; after each cumulative working time of 4 hours, it is allowed to stop for 30 minutes. Within 30 minutes, it is allowed to add oil and water to the roller or perform routine maintenance according to the instructions. 6.3.3 Measure the temperature of the gearbox hydraulic oil and the tire pressure once every 50 hours. Before measuring the temperature, the roller should have at least 2 hours of continuous working time.
Record the test results in Table C2.
6.3.4 When conducting reliability tests under various working conditions, the test personnel should pay attention to observing the working conditions of each part, and record the test date, working environment, test conditions, cumulative working time, etc. in Table C3 on a monthly basis. 6.4 Maintenance and repair
6.4.1 Maintenance work should be carried out according to the content and time specified in the roller's manual, and the time used should be recorded in the cumulative maintenance time.
GB 8508—87
6.4.2 If maintenance is required during the specified working time, and the downtime is less than 30 minutes, follow-up maintenance shall be carried out, and the time used shall be included in the maintenance time; if it exceeds 30 minutes, fault repair shall be carried out, and 30 minutes shall be included in the maintenance time[i], and the time exceeding the time shall be included in the fault repair time.
6.4.3 If a roller fails during operation, it shall be stopped for inspection and repair in time. The machine shall not be allowed to operate with a fault, and the time of repair implementation shall be included in the fault handling time. 6.4.4 Fault repair shall not change its original technical performance. 6.4.5 The personnel participating in maintenance and fault repair should be two skilled people. If there are other personnel participating, the time will be converted into man-hours. That is, if three people participate in the repair, each hour spent will be converted into 1.5 hours; if four people participate in the repair, each hour spent will be converted into 2 hours. 6.4.6 The content, cause, repair situation and repair man-hours of maintenance and fault repair shall be recorded in Table C3. 7 Determination of the number of faults
7.1 Equivalent number of faults
According to the nature and degree of harm of the fault, it is stipulated that the faults shall be divided into three categories: A, B and C (see Appendix A (Supplement)). And the equivalent number of faults shall be used as the total number of faults.
The equivalent number of faults shall be calculated according to formula (1):
Equivalent number of faults;
Where: N
The harm coefficient of the i-th fault, see Table A1: E
n,—the number of i-th faults.
7.2 The replacement of expired wearing parts according to the routine maintenance system shall not be counted in the number of failures, but shall be recorded. 7.3 For failures occurring at the same time, only one failure shall be calculated, and the hazard coefficient shall be calculated according to the larger one. All failures occurring at the same time shall be recorded in Table C3.1)
7.4 Failures occurring due to accidents (not due to the roller itself) shall not be counted as the number of failures, and their repair time shall not be counted in the cumulative repair time.
B Characteristics and their calculation methods
B.1 Reliability characteristics
8.1.1 Average trouble-free working time
The ratio of the accumulated actual working time to the total number of failures of the roller during the reliability test is called the average trouble-free working time.
The mean trouble-free working time is calculated according to formula (2): MTBF
Where: MTBF-
-mean trouble-free working time, h
tu——accumulated actual working time, h;
N-equivalent number of failures. When N1, take N=1. 8.1.2 First trouble-free working time
The working time of the roller from the start of the test to the first failure (i.e. n1) is called the trouble-free working time. The first trouble-free working time is represented by t, unit h. 8.2 Effectiveness characteristic quantity
The effective characteristic quantity of the roller is represented by the effectiveness (i.e. operating rate). 8.2.1 Effectiveness
GB 8508-87
During the reliability test period of the roller, the ratio of the cumulative time to the total time of normal operation is called effectiveness. The effectiveness is calculated according to formula (3) and expressed as a percentage: A
Where: A—effectiveness:
—accumulated fault repair time, h;
accumulated maintenance time, h.
8.3 Maintainability characteristic quantity
×100%
to+t+t?
The maintainability characteristic quantity of the roller is expressed by the average repair time. 8.3.1 Average repair time
During the reliability test period of the roller, the ratio of the cumulative repair time to the number of repairs is called the average repair time. The average repair time is calculated according to formula (4):
Where t.—average repair time, h
repair soft number.
9 Retest and disassembly inspection
9.1 Retest
After the roller has completed the reliability test, retest the items specified in 6.2.1 and record the retest results in Table C1. If the function of any item is reduced, the fault judgment shall be made in accordance with the provisions of Article 7.1. 9.2 Disassembly inspection
After the retest is completed, disassembly inspection can be carried out in accordance with the following requirements. . (3)
9.2.1 Carry out inspection according to the inspection items specified in Table B1 and refer to the technical requirements of the corresponding component working drawings. The inspection results shall be recorded in Table C4.
9.2.2 Compare the measured values of the inspection items with the actual processing values of the corresponding components, conduct failure analysis on the components with loss or defects, and make evaluation opinions.
10 Data collation and test report
10.1 Test data management
10.1.1 According to the contents of the test record table in Appendix C, the data obtained from the test shall be collated and counted. 10.1.2 According to formulas (2), (3) and (4) in Chapter 8, calculate the values of characteristic quantities such as mean time between failures (MTBF), first time between failures (t), effectiveness (A), and mean time to repair (t). 10.2 Test report
After the test, write a reliability test report. The contents of the reliability test report are as follows: the name of the test report,
The source of the test task:
Test purpose and basis:
Model, factory number and factory date of the road locomotive; main technical performance parameters of the road locomotive;
Test overview (including the start and end time, location, climate, environment, site of the test; an overview of the cyclic operation under each basic working condition; the nature and cause of the failure, etc.):
Test records and test results;
The calculation results of the numerical values of each characteristic quantity;
Evaluation opinions on the test results;
Other contents that need to be stated:
GB 8508-87
Name of the test person in charge and test participants: Name and signature date of the person who writes, proofreads, reviews and approves the test report. Therefore, the following are the reasons for the failure: a. Danger to personal and equipment safety b. Major parts are damaged: r. The wearing parts and tools provided with the machine cannot be used to restore the machine. a. The working performance of the roller is significantly reduced or the roller stops; b. The replacement of wearing parts and the use of tools provided with the machine cannot eliminate the problem within 2 hours, which has a slight impact on the working performance of the roller. GB 850B-87 Appendix A Fault Classification Table (Supplement) Fault Content 1. Engine failure 2. The clutch, gearbox, differential, and reversing and steering mechanisms are damaged;
3. The brake system loses its braking ability
4. The main parts such as the transmission gears, transmission shafts, front wheel vertical shafts, fork feet, etc. are damaged
5. The drive chain and sprocket are broken or chipped; 6. The filter pressure pump, hydraulic motor, valve and hydraulic cylinder are damaged 1. When the temperature is above 5C, the engine cannot be started for three consecutive times,
2. The clutch cannot be engaged and disengaged normally. 3. The gearbox gear or reversing and differential gear cannot be meshed normally, resulting in gear skipping or failure to engage in gear. 4. The gearbox, clutch chain drive and oil pump have abnormal belt noise +
5. The floating tire is stuck or the floating wall is insufficient; 6. The engine suddenly stalls and stops:
7. Overheating of bearings, bearing outer fillings, brake housings and other parts:
8. Oil leakage, water leakage, air leakage;
9. Hydraulic oil deterioration;
10. The temperature of the oil in the gearbox exceeds 80 C, and the oil temperature in the hydraulic system is higher than 80 ℃;
11. The pipelines and joint seals in the filter pressure system are damaged: 12. The climbing performance is reduced (compared with the design value); 13. The braking distance is increased by 15% (compared with the initial measurement value); 14. The noise of the whole machine increases by 3 dB(A)(Compare with the initial measurement value);15.Cracks in important welding parts, the length is greater than 5% of the length of the part;
16. Keys and pins are damaged, but no serious consequences are caused;17. Various devices and instruments are out of order or damaged,
18. Fasteners in important parts are loose
1.Still oil, fresh water,
2. Uneven water in the water device:
3. Fasteners in non-important parts are loose
4. The scraper device cannot remove the attachments on the wheel surface;5. The lighting and turn signal lights are not on;
6.Cracks in general welding parts, the length is less than 5% of the length of the weld core of the part;
7.Other minor faults
Hazard coefficient
Use the random tools
to remove the weld metal in 2 h Internal
eliminated, otherwise
downgraded to level
components or systems
transmission system
hydraulic system
brake
suspension device
safety indicator device
GB 8508—87
Appendix B
disassembly inspection items list
(supplement)
main parts or components
shaft and spline shaft
hydraulic oil cleanliness
brake band or brake shoe
frame. tire
instruments, indicator lights, alarms
1. tooth surface pitting area;
2. the condition of the fusion zone along the tooth height and tooth width;3.circular chain gear: indexing chord tooth thickness and its tolerance,4.Cylindrical gear: Check the length of the normal line and its variation to see if there are cracks or other abnormal phenomena.
1. Check if there are cracks.
2. Cleanliness of lubricating oil in the box
The degree of contamination of hydraulic oil shall be in accordance with JJ 37-86 and JI 38—86 for inspection
1. Wear condition;
2. Whether there is any burning phenomenon
Whether there is any crack, breakage, distortion, local instability or aging, etc. Whether there is any failure or loss of heat
Roller model:
Factory number:
Upper and lower floating amount
Floating amount
Average ground pressure
Reselection width, mm
Operating force of operating mechanism, V
Driving speed km/h
Average braking distance, m
Minimum turning radius, m
Slope 20%,
Shift leader>10m
Noise, dB(A)
Forward and right turn
GB 8508—87
Appendix ℃
Test record
(supplement)
Initial test and retest record table
Test time:
Test location:
Steering wheel
Time.min
Timemin
Beside the driver's ears
Turn left
Test personnel:
Recorder:
Transmission gear lever
Back and turn right
Distance m
Distance m
15 m away, 1. 5 m above the ground
Note: The data above the slash\/\ are the initial test record data, and the data below are the retest record data. 3
Hand brake handle
Back and turn left
Power, kw
Power, kw
Road roller model:
Factory number
Driver,
Test items
Transmission oil temperature
GB8508—87
Table C2 Oil temperature, air pressure record
Weather, air temperature:
Test location:||tt ||Recording person:
Hydraulic oil temperature
Tire pressure
Road machine model:
Production number:
Manufacturing unit:
Manufacturing date:
Test period
Road machine model:
Factory number:
Testing location:
Seven major parts
Or component name
Additional instructions:
GB 8508—87
Table C3 Reliability test record
Test location:
Road conditions:
Driver:
Recorder:
Cumulative working time
Maintenance
Content and
Repair hours
Repair situation
Disassembly inspection record
Disassembly personnel:
Inspection personnel:
Recorder:
Inspection item date
Measured value or
Observation situation
Design value or corresponding standard deduction,
Kaifan’s specified value
Initial fault analysis
Evaluation conclusion
This standard is the responsibility of the Beijing Institute of Construction Machinery, Ministry of Urban and Rural Construction and Environmental Protection of the People’s Republic of China. This standard is drafted by Changsha Construction Machinery Research Institute of Urban and Rural Construction and Environmental Protection.
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