Common failures and analysis of forklift mast
Aug 30 , 2021
The industrialized production and construction process is inseparable from the control of the operation and use of forklifts and other equipment, 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 condition of the equipment and the harsh working environment, the forklift mast is prone to oil cylinder leakage, steering wheel flexibility, and system operation noise and jitters. To this end, fault control personnel should start with inspection and detection methods, that is, based on judging the cause of the fault, carry out targeted control of the fault, so as to shorten the time of fault handling and improve the efficiency of work development. Therefore, inspection and testing technicians should combine the occurrence of faults to improve the pertinence and reliability of technical application.
1. Study the common faults of forklift mast and the practical significance of inspection and detection
At the current stage, during the development and construction of the transportation, logistics and foreign trade industries, forklifts are the key to increasing product flow rates and reducing labor costs. However, in the actual operation and use process, the forklift will cause wear and tear on the mast due to the collision of the vehicle body, which reduces the safety and reliability of the forklift. For this reason, relevant personnel should adopt inspection and detection technology to analyze the causes and effects of mast failures to improve the quality of maintenance work.
2. Common faults of forklift mast
(1) Cylinder failure
The failure of the oil cylinder of the forklift mast is mainly concentrated in two aspects: the oil leakage of the lifting oil cylinder and the use of the piston rod. The oil leakage position of the oil cylinder is mostly concentrated on the oil return pipe of the lifting oil cylinder and the problem of automatic descent. The reason is that there is a certain oil seal damage 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 oil return pipe of the oil cylinder. The lifting problem of the piston rod, if there is a jitter problem, it can be judged that there is a problem with the hydraulic oil in the oil tank, which makes the pressure of the hydraulic pump abnormal.
(2) Insufficient steering wheel flexibility
In this problem, the situation of heavy steering and no feeling of heaviness in driving is mainly caused by the issue of the diverter valve spool and the poor pressure effect. To control it, it is necessary to start from a management perspective to strengthen the quality of the inspection and testing of the forklift mast.
(3) Forklift mast system noise and jitter issues
The noise generated during the operation of the mast system is caused by the frictional operation of various components. The system here refers to traditional systems, hydraulic systems, and engines. Take the transmission system of a forklift mast as an example. Under normal circumstances, the original parts such as the chain, gearbox, and drive shaft of the mast will have vibration problems with certain noise. For the exhaust system, due to the air and pulsating intake sound, a certain amount of noise is also generated during the operation.
The jitter problem of the forklift mast is that there is a gap between the inner and outer mast of the forklift and the sliding steel plate. And because the forklift mast is formed by a telescopic structure, the running state will meet the needs of all aspects. Normally, the guide rail of the inner main frame of the forklift is the outer main frame, and its up and down track is telescopic. Once the gap between the steel plates of the inner and outer masts is too large, the fork will be in the ascending process, which will lead to the instability of the mast, which is the phenomenon of shaking.
3. Inspection and control of forklift mast
(1) Inspection and control of oil cylinder leakage inspection
If the oil cylinder leaks, the oil seal should be replaced, and the treatment technology should be strengthened to prevent the influence of the oil leak. In this process, the inspection and testing technicians should combine the design of the forklift mast to work out the corresponding live-mouth hard iron fixing ring. In addition, it should be treated with an oil seal sleeve, clamped with pliers, and then sent to the operating environment of the cylinder equipment. In this way, not only the occurrence of waste is avoided, but also the live hard iron sheet can be used multiple times, thereby greatly improving the efficiency of resource utilization. For piston rod problems, the inspection and control personnel should be aware of whether there is an air problem in the hydraulic pipeline and cylinder piston to control the pressure of the hydraulic oil. If it still fails to operate normally, the oil return pipe of the lifting cylinder needs to be loosened. In this process, the oil cylinder is raised to the top and then dropped to the bottom, and repeated operations are performed to exhaust the air in the hydraulic pipeline, thereby completing the inspection, detection and control of oil leakage in the oil cylinder.
(2) Inspection and control of steering wheel flexibility
From a management perspective, inspection and testing technicians should adjust the management direction and operating pressure of the diverter valve. If the effect is obvious, the diverter valve can be disassembled, and then sandpaper can be used to polish the valve core. Then, apply a layer of hydraulic oil to enhance the smooth operation of the equipment. In this way, problems such as jamming can be efficiently avoided, and the facility can act on the mast of the forklift in a normal operating state.
(3) System noise and jitter inspection, detection and control
Noise control should focus on sound source control, that is, by optimizing the cam design structure, and installing another cam device on the basis of the original device. In this way, it can not only solve the problem of the gap between the forklift mast and the mast column, but also avoid the negative impact caused by noise. In addition, a lifting cylinder can be installed in the buffer zone to avoid vibration and noise caused by the abnormal lifting speed of the hydraulic cylinder. In this way, the stability of the forklift frame can be guaranteed.
For the jitter problem of the forklift mast system, the inspection and control of the mast system should be started from a practical perspective, that is, the deformation of the mast and the welding seam problem should be inspected to improve the rationality of its numerical effect. At the same time, it is also necessary to ensure that the degree of wear of the wheel groove is less than 10% of the original size. The inspection and analysis of the above-mentioned various aspects can make the application of specific control measures have a multiplier effect. For example, in the process of testing the chain, it is necessary to adjust the tightness that it acts on the operation of the system to avoid the influence of deformation. That is, the pitch of the chain should be controlled below 4% of the overall length, and the excessively long chain should be replaced in time to improve its flexibility. In this process, in order to ensure the tightness and flexibility of the connection position between the lifting cylinder and the mast, the problematic components need to be replaced in time. In the process of strengthening the oil performance of the forklift mast, if the test results are realistic and there are serious pollution problems, a more scientific method should be adopted for system inspection and control, so that the oil performance is not affected by the operation of the equipment.
Four, concluding remarks
In summary, the use of forklift mast equipment failure problems should be based on a fundamental point of view, that is, the use of inspection and detection technology to analyze the source of the failure problem, so that the use of treatment measures are efficient. Facts have proved that only in this way can the most effective control measures be applied to the failure control of the forklift mast in the industrial production and construction process, and then promote the development and construction process of various industries with high stability and high efficiency.
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