The industrialized production and construction process is inseparable from the control of the operation and use of equipment such as forklifts, which directly affects the cost and safety and reliability of facility transportation control. However, in the actual operation and use process, due to the long-term working state of the equipment and the harsh working environment, the heavy duty forklift mast is prone to oil leakage, abnormal steering wheel flexibility, and system operation noise and jitter problems. For this reason, the fault control personnel should start with the inspection and detection means, that is, on the basis of judging the cause of the fault, carry out targeted control of the fault, thereby shortening the time of fault handling and improving the efficiency of work. Therefore, the inspection and detection technicians should combine the fault generation phenomenon to improve the pertinence and reliability of the application of technology.
1. The practical significance of studying the common faults of forklift masts and their inspection and detection
At the current stage, in the development and construction of transportation, logistics and foreign trade industries, forklifts are the key to improving product flow and reducing labor costs. However, in the actual operation and use process, the forklift will cause the mast to wear due to the collision of the vehicle body, which reduces the safety and reliability of the forklift. To this end, relevant personnel should adopt inspection and detection technology to analyze the causes and effects of mast failures in order to improve the quality of maintenance work.
2. Common faults of 5 ton forklift masts
(I) Cylinder failure
The cylinder failures of forklift masts are mainly concentrated in two aspects: oil leakage of the lifting cylinder and the use of the piston rod. The location of the cylinder leakage is mostly concentrated in the return pipe of the lifting cylinder and the automatic descent problem. The reason is that there is a certain oil seal damage problem between the lifting cylinder and the piston rod, which reduces the safety and reliability of the forklift mast operation. The problem is caused by the position of the cylinder return pipe. The lifting problem of the piston rod, such as the shaking problem, can be judged that there is a problem with the hydraulic oil inside the tank, causing the pump pressure to be abnormal.
(II) Insufficient steering wheel flexibility
The heavy steering in place and the lack of heavy feeling during driving in this problem are mainly caused by the jamming of the diverter valve core and the poor pressure effect. To control it, it is necessary to start from the management perspective to strengthen the quality of forklift mast inspection and testing work.
(III) Noise and vibration problems of forklift mast system
The noise generated during the operation of the mast system is caused by the friction of various components. The system here refers to the traditional system, hydraulic system and engine. Taking the transmission system of the forklift mast as an example, under normal circumstances, the mast chain, gearbox and drive shaft and other components will vibrate, accompanied by certain noise. For the exhaust system, due to the air and pulsating intake sound, the operation process also generates certain noise.
The vibration problem of the forklift mast is that there is a certain gap between the inner and outer masts and the sliding steel plate of the forklift. Because the forklift mast is formed by a telescopic structure, the operating state will meet various needs. Under normal circumstances, the guide rail of the inner mast of the forklift is the outer mast, and its up and down running trajectory is telescopic. Once the gap between the steel plates of the inner and outer masts is too large, the fork will be in the process of rising, which will lead to the instability of the mast, that is, the vibration phenomenon.
3. Inspection, testing and control of forklift mast
(I) Inspection, testing and control of oil cylinder leakage
For oil cylinder leakage, the oil seal should be replaced and the treatment technology should be strengthened to eliminate the impact of oil leakage. In this process, the inspection and testing technicians should formulate the corresponding movable hard iron sheet fixing ring in combination with the design of the forklift mast. In addition, the oil seal sleeve should be used to treat it, and it should be clamped with pliers and then sent to the operating environment of the cylinder equipment. In this way, not only the waste phenomenon is avoided, but also the movable hard iron sheet can be used many times, thereby greatly improving the efficiency of resource utilization. For piston rod problems, the inspection and testing control personnel should control the hydraulic oil pressure by understanding whether there is an air problem in the hydraulic pipeline and the cylinder piston. If it still cannot operate normally, the return oil pipe of the lifting cylinder needs to be loosened. This process is to raise the cylinder to the top and then drop it to the bottom, and repeat the operation to discharge the air in the hydraulic pipeline, thereby completing the inspection and testing control of oil cylinder leakage.
(II) Inspection, testing and control of steering wheel flexibility
From a management perspective, the inspection and testing technicians should adjust the management direction and action pressure of the diverter valve. If the effect is obvious, the diverter valve can be disassembled and the valve core can be polished with water sandpaper. Then, apply a layer of hydraulic oil to enhance the smoothness of the equipment operation. In this way, problems such as jamming can be effectively avoided, so that the facility can act on the forklift's mast in normal operation.
(III) Inspection, testing and control of system noise and jitter
The control of noise should focus on the control of the sound source, that is, by optimizing the cam design structure and installing another cam device on the basis of the original equipment. In this way, not only can the gap problem between the forklift mast and the mast column be solved to avoid the negative impact of noise. In addition, a lifting cylinder can be set in the buffer zone to avoid vibration noise caused by abnormal lifting speed of the hydraulic cylinder. In this way, the stability of the forklift frame can be guaranteed.
For the vibration problem of the forklift mast system, the inspection and control should be carried out from a practical perspective, that is, the deformation and weld problems of the mast should be inspected and tested to improve the rationality of its numerical effect. At the same time, it is also necessary to ensure that the wear of the wheel groove is less than 10% of the original size. Only by comprehensively inspecting and analyzing the above-mentioned various aspects can the specific control measures be used to achieve twice the result with half the effort. For example, during the inspection of the chain, the tightness of the chain acting on the system operation needs to be adjusted to avoid deformation. That is, the pitch of the chain should be controlled below 4% of the overall length, and the overlong chain should be replaced in time to improve its flexibility. In this process, in order to ensure the tightness and flexibility of the connection between the lifting cylinder and the mast, the components with problems need to be replaced in time. In the process of strengthening the performance of the forklift mast oil, if the test results are realistic and there is a serious pollution problem, a more scientific method should be adopted to carry out system inspection and control so that the performance of the oil is not affected by the operation of the equipment.
IV. Conclusion
In summary, the problem of forklift gantry equipment failure should be solved from a fundamental perspective, that is, the source of the failure should be analyzed by using inspection and detection technology to make the treatment measures more efficient. Facts have proved that only in this way can the most effective control measures be applied to the forklift gantry failure control in the industrial production and construction process, thereby promoting the high stability and high efficiency development and construction process in all walks of life.