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Mechanical structure inspection is a key link to ensure the safe operation of the equipment. Operators need to use a combination of visual inspection and tool inspection to fully confirm the structural integrity of the support legs, focusing on whether there are deformations, cracks and other damage. At the same time, the surface of the hydraulic cylinder should be kept free of rust and oil accumulation to ensure its normal function. Taking a well-known brand of equipment as an example, the preload of its support legs needs to be accurately adjusted to 200N·m by a torque wrench to ensure that it can still maintain a reliable rigid connection when carrying a rated load of 300kg. The inspection of the tire status should focus on the air pressure (usually between 0.6-0.8MPa) and the degree of wear. When the tread depth is less than 1.6mm, it should be replaced in time. The locking mechanism of the platform guardrail must be verified by a dynamic loading test. Under the simulated lateral impact force of 50kg, the deformation of the guardrail shall not exceed 5mm to ensure its safety.
The detection of the electrical system requires the establishment of a multi-level protection mechanism. The battery pack should be inspected using a professional internal resistance tester to ensure that the internal resistance value of each single battery is within the range of 1.5-3mΩ. When the voltage of any single cell is lower than 12V, it must be charged evenly. The self-test of the control system needs to cover 28 core functions such as PLC logic, sensor signal, emergency stop button response, etc., especially to verify whether the limit switch can quickly trigger the brake when it is 0.3m away from the obstacle. A case in a certain industry shows that the equipment crossing accident caused by the limit switch signal delay of 0.2 seconds has caused damage to precision equipment worth millions, which fully demonstrates the importance of this detection link.
The inspection of the hydraulic system needs to focus on the dual verification of dynamic and static performance. The oil level detection should be carried out by combining the oil level gauge with the telescopic test of the hydraulic cylinder. When the equipment is in an unloaded state, if the platform cannot be completely landed, ISO VG46 hydraulic oil must be added immediately. Oil temperature monitoring should be carried out for 10 minutes before the equipment is started. When the ambient temperature is lower than -10℃, the heating device must be started to ensure that the oil temperature rises to above 15℃. In addition, the pressure test should be carried out under the rated load. If the system pressure exceeds 18MPa, the safety valve must be depressurized within 0.5 seconds to prevent potential safety hazards.
A redundant verification system needs to be established for the inspection of safety protection devices. The fall arrester must be verified through a simulated fall test. When the platform descends at a speed of 0.5m/s, the fall arrester must be locked within 0.1 seconds. The function of the emergency stop button needs to be verified through a continuous press test to ensure that the braking distance does not exceed 0.2m. The inspection of safety signs needs to cover 8 key locations such as the equipment body, the operating area, and the control panel. When the reflective coefficient of the sign is lower than 0.3, it needs to be replaced in time to ensure visibility in various operating environments.
Environmental adaptability inspection needs to be carried out in combination with specific operating scenarios. In a low temperature environment (-20℃), the heating efficiency of the battery insulation device needs to be verified to ensure that the battery pack temperature is not lower than -10℃; in a humid environment (relative humidity exceeds 80%), the sealing of the electrical cabinet needs to be checked, and when the insulation resistance is lower than 50MΩ, it must be dried. The application case of a port warehouse shows that through environmental adaptability transformation, the equipment failure rate has dropped from 12% in winter to 3%, which fully proves the importance of environmental adaptability inspection in improving equipment reliability.
