起重機製動器安全性能的探討

起重機製動器安全性能的探討

1
、起重機製動器失控造成人員傷亡

2003-03-09，dahuashuilifadianzongchangzaichengbaozuojiangdianchangjianxiugongchengdeshigongzuoyezhong，angongzuojihuajinxingzhuanlunhuizhuang。zhaokaibanqianhuihou，jinxingzuoyeqiandegongzuoanpaiheanquanjishujiaodi
，xiangguangongzuorenyuanzhunbeijiuxu
，kaishigongzuo。zaidiaozhuanghaoxieshuizhui，zhengtishidiaozhuanlunwuyihou

，10：28開始往機坑吊裝

，10：30當轉輪吊至機坑並下放約3m時shi，橋qiao機ji突tu然ran失shi控kong
，轉zhuan輪lun加jia速su下xia落luo。在zai此ci過guo程cheng中zhong，橋qiao機ji上shang製zhi動dong器qi發fa生sheng爆bao裂lie，減jian速su箱xiang齒chi輪lun崩beng裂lie，鋼gang絲si繩sheng拉la斷duan，轉zhuan輪lun落luo至zhi機ji坑keng。事shi故gu造zao成cheng在zai橋qiao機ji上shang負fu責ze監jian護hu的de工gong作zuo人ren員yuan1人死亡，2人受傷。

事故原因初步分析為橋機在吊物下放時脫檔，造成橋機失控。

2、起重機製動方式不合理

據了解，目前絕大多數起重機製動器，都是輪轂式製動器，當需要開閘或製動時，通過電磁鐵吸、放或油泵的起動、停ting止zhi
，將jiang製zhi動dong彈dan簧huang的de彈dan力li壓ya緊jin或huo釋shi放fang，使shi製zhi動dong瓦wa離li開kai製zhi動dong輪lun或huo貼tie合he夾jia在zai製zhi動dong輪lun上shang，達da到dao開kai閘zha或huo製zhi動dong的de要yao求qiu。而er現xian在zai的de起qi重zhong工gong作zuo，特te別bie是shi在zai起qi吊diao大da型xing重zhong物wu時shi，往wang往wang在zai起qi重zhong機ji上shang配pei備bei數shu名ming負fu責ze監jian護hu的de工gong作zuo人ren員yuan，其qi目mu的de是shi在zai起qi吊diao中zhong發fa生sheng脫tuo檔dang、溜鉤事故時，須用撬棍等工具加大製動瓦對製動輪的施壓，從而達到緊急製動的目的，以減少事故的損壞程度。在“3.9”事(shi)故(gu)中(zhong)，橋(qiao)機(ji)上(shang)負(fu)責(ze)監(jian)護(hu)的(de)工(gong)作(zuo)人(ren)員(yuan)也(ye)采(cai)取(qu)了(le)這(zhe)樣(yang)的(de)措(cuo)施(shi)，但(dan)沒(mei)有(you)取(qu)得(de)相(xiang)應(ying)的(de)作(zuo)用(yong)
，反(fan)而(er)卻(que)因(yin)為(wei)製(zhi)動(dong)器(qi)發(fa)生(sheng)崩(beng)裂(lie)
，製(zhi)動(dong)器(qi)碎(sui)片(pian)飛(fei)出(chu)致(zhi)使(shi)監(jian)護(hu)人(ren)員(yuan)傷(shang)亡(wang)的(de)重(zhong)大(da)事(shi)故(gu)。為(wei)什(shen)麼(me)付(fu)出(chu)了(le)人(ren)員(yuan)傷(shang)亡(wang)的(de)慘(can)痛(tong)代(dai)價(jia)卻(que)沒(mei)能(neng)減(jian)少(shao)事(shi)故(gu)的(de)損(sun)壞(huai)程(cheng)度(du)呢(ne)?

首(shou)先(xian)，負(fu)責(ze)監(jian)護(hu)工(gong)作(zuo)的(de)機(ji)械(xie)工(gong)作(zuo)人(ren)員(yuan)使(shi)用(yong)撬(qiao)棍(gun)等(deng)工(gong)具(ju)加(jia)大(da)製(zhi)動(dong)瓦(wa)對(dui)製(zhi)動(dong)輪(lun)的(de)施(shi)壓(ya)，從(cong)而(er)達(da)到(dao)緊(jin)急(ji)製(zhi)動(dong)目(mu)的(de)的(de)工(gong)作(zuo)方(fang)法(fa)值(zhi)得(de)商(shang)榷(que)。當(dang)起(qi)重(zhong)機(ji)在(zai)起(qi)吊(diao)大(da)型(xing)重(zhong)物(wu)而(er)又(you)發(fa)生(sheng)脫(tuo)檔(dang)

、溜鉤事故時，起動電機、傳chuan動dong軸zhou會hui隨sui著zhe重zhong物wu的de加jia速su下xia滑hua產chan生sheng飛fei逸yi轉zhuan速su，傳chuan動dong軸zhou上shang的de製zhi動dong輪lun也ye隨sui之zhi產chan生sheng強qiang大da的de徑jing向xiang振zhen動dong力li。此ci時shi，起qi重zhong機ji製zhi動dong器qi動dong作zuo合he閘zha，製zhi動dong瓦wa會hui受shou到dao巨ju大da的de徑jing向xiang衝chong擊ji力li，若ruo再zai人ren為wei的de加jia大da製zhi動dong瓦wa對dui製zhi動dong輪lun的de施shi壓ya
，製zhi動dong瓦wa本ben身shen所suo受shou到dao的de巨ju大da衝chong擊ji力li也ye就jiu會hui更geng大da
，製zhi動dong瓦wa發fa生sheng崩beng裂lie的de危wei險xian性xing隨sui之zhi升sheng高gao，在zai製zhi動dong器qi前qian施shi壓ya的de工gong作zuo人ren員yuan的de危wei險xian性xing可ke想xiang而er知zhi。因yin此ci
，筆bi者zhe以yi為wei工gong作zuo人ren員yuan使shi用yong撬qiao棍gun等deng工gong具ju加jia大da製zhi動dong瓦wa對dui製zhi動dong輪lun的de施shi壓ya，從cong而er達da到dao緊jin急ji製zhi動dong目mu的de的de工gong作zuo方fang法fa不bu可ke取qu。其qi次ci，製zhi動dong器qi隻zhi設she置zhi在zai傳chuan動dong軸zhou上shang不bu夠gou完wan善shan。因yin為wei假jia如ru發fa生sheng脫tuo檔dang而er製zhi動dong器qi卻que又you機ji械xie性xing損sun壞huai的de時shi候hou，就jiu沒mei有you任ren何he辦ban法fa能neng減jian少shao事shi故gu的de損sun失shi了le。那na麼me應ying如ru何he減jian少shao起qi重zhong機ji因yin為wei脫tuo檔dang而er產chan生sheng的de事shi故gu損sun失shi呢ne?筆者認為升船機的製動方式可以借鑒。

3、改進起重機製動器安全性能的探討

以岩灘電廠垂直入水式升船機的製動方式為例
，其承船廂重1430t，配重混凝土重1100t，zhutishengjizhidongxingshiweiyeyapanshizhidongqi，baokuogongzuozhidongqiheanquanzhidongqiliangtaoxitong。shengchuanjimeicixuyaodongzuoshi


，anquanzhidongqishouxiankaizha，kaizhadaoweihouzhutishengdianjichulidadaoyidingdeniujuhougongzuozhidongqikaizha，shengchuanjikaishiyunxing;需要停機時，工作製動器配合主提升電機先合閘製動，延時6s後(hou)安(an)全(quan)製(zhi)動(dong)器(qi)合(he)閘(zha)製(zhi)動(dong)
，完(wan)成(cheng)運(yun)行(xing)過(guo)程(cheng)。發(fa)生(sheng)故(gu)障(zhang)和(he)事(shi)故(gu)時(shi)，還(hai)能(neng)按(an)照(zhao)編(bian)製(zhi)的(de)製(zhi)動(dong)動(dong)作(zuo)程(cheng)序(xu)，安(an)全(quan)地(di)緊(jin)急(ji)製(zhi)動(dong)停(ting)機(ji)。整(zheng)個(ge)過(guo)程(cheng)可(ke)靠(kao)安(an)全(quan)
，在(zai)升(sheng)船(chuan)機(ji)的(de)安(an)裝(zhuang)調(tiao)試(shi)及(ji)這(zhe)幾(ji)年(nian)的(de)運(yun)行(xing)中(zhong)得(de)到(dao)可(ke)靠(kao)的(de)驗(yan)證(zheng)。因(yin)此(ci)，如(ru)果(guo)起(qi)重(zhong)機(ji)采(cai)用(yong)以(yi)下(xia)製(zhi)動(dong)方(fang)式(shi)，可(ke)以(yi)達(da)到(dao)安(an)全(quan)可(ke)靠(kao)的(de)效(xiao)果(guo)。

3.1采用液壓盤式製動器

helungushizhidongqixiangbi
，yeyapanshizhidongqijuyouzhidongyuanlijianjiekekao

，hezhaxiangyingkuaidengtedian。zaihezhazhidongshi，zhidongwaduizhidongpandezuoyonglishizhouxiangdeerbushijingxiangde，shizhidongpanchengshoudechongjilifeichangxiao
，rangzhidongshixiaogailvjiangzhizuidi。

3.2增加安全製動器

這(zhe)裏(li)所(suo)要(yao)增(zeng)加(jia)的(de)安(an)全(quan)製(zhi)動(dong)器(qi)
，是(shi)指(zhi)參(can)照(zhao)垂(chui)直(zhi)升(sheng)船(chuan)機(ji)的(de)製(zhi)動(dong)設(she)置(zhi)，在(zai)卷(juan)筒(tong)部(bu)分(fen)增(zeng)加(jia)製(zhi)動(dong)盤(pan)並(bing)在(zai)相(xiang)應(ying)合(he)適(shi)的(de)位(wei)置(zhi)放(fang)置(zhi)數(shu)組(zu)盤(pan)式(shi)製(zhi)動(dong)器(qi)，使(shi)它(ta)們(men)成(cheng)為(wei)完(wan)全(quan)獨(du)立(li)的(de)一(yi)套(tao)安(an)全(quan)製(zhi)動(dong)係(xi)統(tong)。這(zhe)樣(yang)做(zuo)的(de)優(you)點(dian)是(shi)顯(xian)而(er)易(yi)見(jian)的(de)。

(1)解放了監護人員的人力操作，減少被傷害的危險性;

(2)增強了起重機運行的安全可靠性，當起重機發生事故時能有效防止事故的擴大。通俗說就是假如起重機發生脫檔、溜鉤事故
，即使是在起動電機、傳動軸、工作製動器、減速箱都損壞的情況下
，卷筒部分的安全製動器都能有效地合閘製動，製止吊鉤繼續下滑，防止事故進一步擴大;

(3)zaimouxiexuyaoyoubiansuxiangjinxingjixieqiehuangaodisudangdeteshuqiaoshiqizhongjishang，zhixujianganquanzhidongqihezhazhidong，quebaojuantongbeianquanzhidongqibaojinhou
，zuohaoxiangyingdefangzhianquanzhidongqiwudongcuoshi，jiukeyigenjuxuyao，songkaigongzuozhidongqijinxinggaosudangyudisudangdehuhuangongzuo。

3.3控製係統的要求

考kao慮lv到dao起qi重zhong機ji升sheng降jiang需xu要yao頻pin繁fan動dong作zuo，並bing有you點dian動dong的de動dong作zuo要yao求qiu，如ru果guo安an全quan製zhi動dong器qi也ye頻pin繁fan動dong作zuo，就jiu會hui影ying響xiang到dao升sheng降jiang的de動dong作zuo要yao求qiu，因yin此ci，控kong製zhi係xi統tong的de設she計ji應ying滿man足zu以yi下xia工gong作zuo狀zhuang態tai的de要yao求qiu：

(1)正(zheng)常(chang)工(gong)作(zuo)狀(zhuang)態(tai)。每(mei)次(ci)啟(qi)動(dong)起(qi)重(zhong)機(ji)前(qian)，起(qi)重(zhong)機(ji)司(si)機(ji)按(an)下(xia)啟(qi)動(dong)按(an)扭(niu)，安(an)全(quan)製(zhi)動(dong)器(qi)自(zi)動(dong)開(kai)閘(zha)，開(kai)閘(zha)到(dao)位(wei)後(hou)發(fa)信(xin)號(hao)到(dao)操(cao)作(zuo)台(tai)允(yun)許(xu)起(qi)重(zhong)機(ji)工(gong)作(zuo)。起(qi)重(zhong)機(ji)工(gong)作(zuo)期(qi)間(jian)，升(sheng)降(jiang)的(de)製(zhi)動(dong)工(gong)作(zuo)由(you)工(gong)作(zuo)製(zhi)動(dong)器(qi)完(wan)成(cheng)，安(an)全(quan)製(zhi)動(dong)器(qi)保(bao)持(chi)常(chang)開(kai)狀(zhuang)態(tai)。起(qi)重(zhong)作(zuo)業(ye)結(jie)束(shu)
，工(gong)作(zuo)製(zhi)動(dong)器(qi)合(he)閘(zha)製(zhi)動(dong)，起(qi)重(zhong)機(ji)司(si)機(ji)檢(jian)查(zha)無(wu)異(yi)後(hou)，在(zai)離(li)開(kai)操(cao)作(zuo)台(tai)前(qian)，斷(duan)掉(diao)起(qi)重(zhong)機(ji)電(dian)源(yuan)，安(an)全(quan)製(zhi)動(dong)器(qi)合(he)閘(zha)鎖(suo)定(ding)，工(gong)作(zuo)結(jie)束(shu);

(2)起重機發生故障時的工作狀態。發生故障時
，起重機司機按應急製動按扭，工作製動器立即合閘製動
，安全製動器延遲2～5s合閘製動，防止發生事故;

(3)起qi重zhong機ji發fa生sheng破po壞huai事shi故gu時shi的de工gong作zuo狀zhuang態tai。發fa生sheng事shi故gu時shi
，起qi重zhong機ji司si機ji按an緊jin急ji製zhi動dong按an扭niu，起qi重zhong機ji控kong製zhi電dian源yuan斷duan開kai，工gong作zuo製zhi動dong器qi和he安an全quan製zhi動dong器qi立li即ji失shi電dian合he閘zha製zhi動dong，防fang止zhi發fa生sheng事shi故gu;

(4)在特殊情況下(如起重機突然係統失電)，工作製動器和安全製動器也應同時進行緊急合閘製動。

huozhejianganquanzhidongqishezhiweichangkaishianquanzhidongqi，pingshianquanzhidongqishizhongbaochiquankaizhuangtai，qizhongjishengjiangdezhidonggongzuoyougongzuozhidongqiwancheng
，anquanzhidongqizuoweiyizhongbaohubeiyong。dangqizhongjifashengguzhangheshiguhuogongzuozhidongqixuyaojianxiu


、需要鬆開工作製動器進行切換高速檔與低速檔的時候，安全製動器才投入使用。

其他的工況還可以根據要求，通過電氣部分的設定而另行調整。