|
| Item description | Failure mode analysis | Failure effect analysis | Failure risk analysis |
| SN | FU | FM | FMT | FC | FP | FD | FS | RPN | CREV | CRPN | RMM |
| SE | EE | ECE | MCE | SR | ER | ECR | MCR |
| (1) | (2) | (3) | (4) | (5) | (6) | (7) | (8) | (9) | (10) | (11) | (12) | (13) | (14) | (15) | (16) | (17) | (18) |
|
| CRANE01020404 | Winding steel wire | Abrasion | Obvious potential type | Natural wear of long twisted wire rope | 3-7 years | Easily detected | No harm | Slight influence | ¥0.1∼1million | ¥0.1∼0.5million | 28 | 21 | 11 | 7 | 11664 | 16 | If it does not affect the use, there is no need for maintenance |
| Crackle | Obvious potential type | Material defects (especially castings) or welding defects constitute the cause of cracks and develop into cracks | 3-7 years | Normally detected | No harm | Slight influence | ¥0.1∼1million | ¥0.1∼0.5million | 19 | 6 | 2 | 2 | 59049 | 10 | Surfacing welding after punching |
|
| CRANE01020405 | Speed down and increase the output torque | Transmission failure | Obvious sudden type | Bond damage and planetary fracture | 0.5-2 years | Easily detected | Intermediate injury | Local influence | ¥0.1∼1million | ¥0.1∼0.5million | 2 | 1 | 3 | 3 | 331776 | 2 | Check whether the gearbox has any abnormal phenomena such as fever, vibration, oil leakage, and abnormal noise |
| Vibration | Obvious sudden type | Bearing frame and stagnation | 0.5-2 years | Easily detected | Intermediate injury | Local influence | ¥0.1∼1million | ¥0.1∼0.5million | 2 | 1 | 3 | 3 | 331776 | 2 | Disintegration examination |
| Abnormal sound | Obvious sudden type | Gear breakage, bearing falling, lack of lubrication, and severe wear on tooth surfaces | >0.5 years | Easily detected | No harm | Minor pollution | ¥20∼100 thousand | <¥50 thousand | 17 | 3 | 10 | 15 | 40000 | 11 | Check the oil level of the reducer, change the gear oil, and check the oil particle situation; check the fastener every 500 hours if necessary; torque wrench is fixed |
|
| CRANE01020406 | Stop moving and stay at rest | The breaks cannot open | Obvious sudden type | Overall aging failure | 0.5-2 years | Directly detected | Intermediate injury | Slight influence | ¥0.1∼1million | ¥50∼100 thousand | 16 | 23 | 17 | 17 | 4608 | 20 | Dismantling and repairing once a year |
| Great impact on braking | Obvious type | Friction strip wear out of limit (beyond the range of self-compensation) | 0.5-2 years | Easily detected | No harm | Slight influence | ⩽¥20 thousand | <¥50 thousand | 21 | 7 | 21 | 17 | 4096 | 23 | Replace the piston seal every 500 hours; replace all springs every 3000 hours |
| Insufficient power, leading to a decline | Obvious potential type | Brake oil or cylinder block | 0.5-2 years | Easily detected | Intermediate injury | Slight influence | ¥0.1∼1million | ¥50∼100 thousand | 2 | 7 | 3 | 8 | 73728 | 5 | It is recommended to change the form of the brake |
|
| CRANE010205 | Lift wire rope | Abrasion | Obvious potential type | Natural wear | 0.5-2 years | Easily detected | No harm | Slight influence | ⩽¥20 thousand | <¥50 thousand | 21 | 7 | 21 | 17 | 4096 | 23 | Check the degree of wear per month |
|
| CRANE010206 | Prevent the rope from jumping out of the pulley groove | Deformation | Obvious potential type | Improper operation | 0.5-2 years | Directly detected | Intermediate injury | Slight influence | ¥20∼100 thousand | <¥50 thousand | 16 | 23 | 21 | 29 | 1536 | 27 | Check state at any time |
|
| CRANE010207 | Transfer pulling force | Broken wire | Obvious potential type | Broken wires due to wear; rust and broken wires due to lack of daily oil and maintenance | 3-7 years | Directly detected | Intermediate injury | Slight influence | ¥0.1∼1million | ¥0.1∼0.5million | 19 | 29 | 20 | 16 | 2187 | 26 | Daily inspection, pay attention to check the steel rope that is subjected to the impact load, the steel rope section that often produces friction with the roller and pulley frame, and the steel rope section which can easily cause fatigue damage repeatedly through the pulley |
| Rust | Obvious potential type | Corrosion broken wire resulting from the lack of daily oil maintenance | 0.5-2 years | Directly detected | Primary injury | Slight influence | ¥20∼100 thousand | ¥0.5∼5million | 21 | 23 | 21 | 8 | 4096 | 23 | Add 1 protective lubricant a month |
| Abrasion | Obvious potential type | The steel rope is pulled up, resulting in natural wear and deterioration of lubrication condition | 0.5-2 years | Easily detected | Primary injury | Slight influence | ¥20∼100 thousand | ¥0.5∼5million | 8 | 7 | 12 | 1 | 65536 | 9 | Check the diameter of the wire rope with vernier caliper. If it is found that the diameter has been reduced by more than 10%, it should be replaced. For frequent use of cranes, there should exist mandatory replacement of wire rope every 3 years |
|
| CRANE010208 | Transfer the force and change the direction of the force | Slots wear | Obvious potential type | Repeated winding work in the work, natural wear; rope angle is too large and will cause severe wear and tear | 0.5-2 years | Directly detected | Primary injury | Slight influence | ¥0.1∼1million | ¥0.1∼0.5million | 21 | 23 | 17 | 12 | 4608 | 20 | Replacement of pulley when the wear is overlimited |
| Local rupture of the pulley | Obvious sudden type | The gap between bearing and bearing room is too large | 0.5-2 years | Directly detected | Primary injury | Slight influence | ¥0.1∼1million | ¥0.1∼0.5million | 21 | 23 | 17 | 12 | 4608 | 20 | One decomposition check every two years |
| Bearing rash or stagnation | Obvious sudden type | Poor lubrication; to reach the life span of bearing | 0.5-2 years | Easily detected | Primary injury | Slight influence | ¥0.1∼1million | ¥0.1∼0.5million | 8 | 7 | 3 | 3 | 73728 | 5 | Add lubricating grease and replace the bearings regularly |
|
| CRANE01030101 | Loading cargo carrying capacity | Hook twist | Obvious potential type | Hook deformation: open opening, distortion | 0.5-2 years | Easily detected | Intermediate injury | Slight influence | ¥0.1∼1million | ¥50∼100 thousand | 2 | 7 | 3 | 8 | 73728 | 5 | The dangerous section area should be reduced by 10%, which should be scrapped. The opening will increase by 15% or the distortion will reach 10 degrees |
| Hook wear | Obvious potential type | The main hook's dangerous section has been rubbed by the wire rope for a long time, and there is a deep groove | 0.5-2 years | Easily detected | Intermediate injury | Slight influence | ¥0.1∼1million | ¥50∼100 thousand | 2 | 7 | 3 | 8 | 73728 | 5 | Nondestructive testing of hook surface |
| A crack in the hook | Obvious potential type | Misuse | 0.5-2 years | Normally detected | Intermediate injury | Slight influence | ¥0.1∼1million | ¥50∼100 thousand | 1 | 4 | 1 | 3 | 373248 | 1 | Visual inspection of the hook before each use |
|
| CRANE01030102 | Connection and fixation | Bolt breaking; thread slipping | Obvious potential type | The transition tightened, causing thread slipping and even breaking | 0.5-2 years | Directly detected | Primary injury | Slight influence | ⩽¥20 thousand | <¥50 thousand | 21 | 23 | 29 | 28 | 512 | 29 | Use torque wrench to tighten rope nut |
| Corrosion failure | Obvious potential type | External environment | 0.5-2 years | Easily detected | Primary injury | Slight influence | ⩽¥20 thousand | <¥50 thousand | 8 | 7 | 21 | 17 | 8192 | 17 | Strengthen rust prevention and maintenance; check once a month |
|
| CRANE01030103 | Prevent decoupling | The opening of the hook cannot be completely covered | Obvious potential type | Use long time to deform | 0.5-2 years | Easily detected | Primary injury | Slight influence | ⩽¥20 thousand | <¥50 thousand | 8 | 7 | 21 | 17 | 8192 | 17 | Replace the spring and pin, and check the condition every time the rope is hung |
| Distortion | Obvious sudden type | External force deformation | 0.5-2 years | Easily detected | Primary injury | Slight influence | ⩽¥20 thousand | <¥50 thousand | 8 | 7 | 21 | 17 | 8192 | 17 | Operation specification; check the state every time the rope is hung |
|
| CRANE01030104 | Connecting drive | Abrasion | Obvious potential type | The fatigue damage of the wheel body or the impacting defect on the edge of the wheel | 0.5-2 years | Easily detected | Primary injury | Slight influence | ¥20∼100 thousand | <¥50 thousand | 8 | 7 | 12 | 17 | 16384 | 12 | Replacement of pulley after partial crushing; standard assembly during failure maintenance |
| Inflexible rotation | Obvious type | The damage of the pulley bearing; the wear and tear between the ropes | 0.5-2 years | Easily detected | Primary injury | Slight influence | ¥20∼100 thousand | <¥50 thousand | 8 | 7 | 12 | 17 | 16384 | 12 | Lubricate the pulley bearing regularly; check the deflection angle of the wire rope in and out of the pulley |
|
| CRANE01030105 | Circumferential rotation | Hook rotation is not flexible | Obvious type | Lack of lubrication or dust particles enter, resulting in early wear and tear of bearings and broken raceway breakage | 0.5-2 years | Easily detected | Primary injury | Slight influence | ¥20∼100 thousand | <¥50 thousand | 8 | 7 | 12 | 17 | 16384 | 12 | Regular refuel lubrication for hook bearing |
| The axial location of the hook is ineffective and the axial movement is large | Obvious sudden type | Bearing wear caused by impact load | 0.5-2 years | Normally detected | Primary injury | Slight influence | ¥20∼100 thousand | <¥50 thousand | 2 | 4 | 3 | 12 | 82944 | 4 | Strengthen daily inspection and remove inspection if necessary |
| The hook fell off because of the damage of the bearing | Obvious sudden type | The lifespan of the hook bearing has reached its service life | 0.5-2 years | Easily detected | Primary injury | Slight influence | ¥20∼100 thousand | <¥50 thousand | 8 | 7 | 12 | 17 | 16384 | 12 | Replace |
|
| CRANE01030106 | Fixed hook and pulley | Abrasion | Obvious potential type | Loosening of shaft end positioning component | 3-7 years | Easily detected | No injury | Slight influence | ⩽¥20 thousand | <¥50 thousand | 28 | 21 | 28 | 27 | 1296 | 28 | Check lock block and lock nut for each class |
|
