Safety Technical Requirements for Crane Spreaders

As an indispensable equipment in modern industry, the safety and technical requirements of lifting machine spreaders are directly related to the safety and efficiency of production operations. The spreader not only carries the weight of goods, but also plays a vital role in the complex operating environment. From design to manufacture, to installation, use, maintenance and even end-of-life replacement, every step of the process needs to strictly comply with safety specifications. This is not only to prevent accidents, but also to protect the lives and properties of personnel safety, improve production efficiency. Therefore, in-depth discussion of lifting machine spreader safety technical requirements, to ensure the safe and stable operation of industrial production is of great significance.

Electro-permanent magnet spreader

Spreader design and manufacturing requirements

Material selection and strength requirements

Material selection is the cornerstone of spreader design and manufacture, and its rationality directly determines the safety performance and service life of the spreader. When selecting materials, the specific application scenario of the spreader, the characteristics of the working load and the environmental conditions in which it is located must be fully considered to ensure that the selected materials are able to withstand long-term stress loads without damage. For heavy load spreader, especially those need to work in high temperature, high humidity, corrosive environment spreader, should give priority to the selection of high-strength, excellent corrosion resistance and wear resistance of special alloy steel or stainless steel and other high-performance materials. These materials not only have excellent mechanical properties, can resist high strength load, but also has excellent fatigue resistance, can be in a long time under high load operation to maintain stable mechanical strength, effectively prevent the fatigue caused by crack expansion and fracture and other problems.

In terms of strength design, the key components of the spreader, such as lifting beams, lugs, hooks, etc., should be strictly calculated and verified according to the relevant national or industry standards. During the design process, it should be ensured that the safety coefficients of all components meet the specified requirements, e.g., according to the international common specification, for the important components of lifting machinery, their minimum safety coefficients are usually between 4:1 and 6:1. This means that under the design load, the actual load carrying capacity of the component should be at least 4 to 6 times of the design load, so as to ensure that the spreader will not be damaged under extreme conditions and to effectively prevent safety accidents caused by overloading.

Manufacturing process and quality control

The advantages and disadvantages of the manufacturing process directly affect the quality and service life of the spreader. In the manufacturing process, the quality of raw materials should be strictly controlled to ensure that there are no cracks, inclusions and other defects. During processing, advanced technology and equipment, such as precision casting, forging, welding, etc., should be used to ensure the dimensional accuracy and shape tolerance of the spreader. In addition, the finished products need to be strictly inspected and tested, including non-destructive testing, mechanical properties test, etc., to ensure that the quality of the spreader meets the design requirements. Non-destructive testing is a commonly used technical means to assess the internal structure and surface condition of materials. By adopting various methods, such as ultrasonic, magnetic particle and penetration, the key components of the spreader are comprehensively inspected in order to find out the possible existence of tiny cracks, inclusions or other potential defects. Mechanical performance test is to simulate the loading and stress state under actual working conditions, and conduct tensile, compression, bending and other mechanical performance tests on spreader materials or finished products to verify whether they meet the design requirements and national standards. These advanced processes and strict quality control measures can ensure that the spreader is not damaged during the manufacturing process and has sufficient strength and durability, thus providing a strong guarantee for the subsequent safe use.

Safety Protection Device Design

Safety protection devices are an important and indispensable part of spreader design, and their core objective is to prevent all kinds of potential safety risks and accidents. At the design stage, the designer needs to fully consider the various extreme conditions and risk factors that may be encountered in the actual application of the spreader, including but not limited to overloading, decoupling, collision, over-winding and other dangerous working conditions. In response to these risks, the designer will carefully set up a series of efficient and reliable safety protection devices. For example, the overload limiter is a key device that monitors the actual load weight of the spreader in real time and compares it with the preset rated load. Once the load is detected as exceeding the safety threshold, the overload limiter immediately triggers an alarm system and automatically cuts off the power supply source, thus effectively preventing mechanical damages or safety accidents triggered by overloading; and the anti-delinking device adopts advanced mechanical locking principle or intelligent sensor technology to ensure that the hook is not damaged during operation. The anti-dehooking device adopts advanced mechanical locking principle or intelligent induction technology to ensure that the hook is always reliably connected with the sling during operation to avoid accidental dislodgement leading to material fall or equipment damage.

In addition, for possible collision accidents, the designer will consider setting up anti-collision devices, such as infrared sensors or ultrasonic distance sensors and other equipment, to issue an early warning when the spreader is close to an obstacle and automatically adjust the trajectory or speed of operation; and for potential risks such as over-reeling of the winch or skidding, the designer will design protective measures such as limit switches and emergency braking systems. The use of these safety protection devices can greatly reduce the safety hazards and the possibility of accidents during the lifting operation.

Design framework of spreader safety protection device

Marking and Instruction Manuals

Spreader marking is an important way for users to recognize product information, usage and safety warnings. During the product design stage, the designer needs to carefully plan and determine the content, form and location of the markings. These markings should include, but are not limited to: basic information such as spreader model, specification, manufacturer's name and date of manufacture; key parameters such as maximum working load; and safety operation tips and warnings. To ensure that the user can quickly access the necessary information and follow the correct operating procedures, the designer also needs to provide a detailed instruction manual. This manual should cover the installation and commissioning steps, daily use precautions and maintenance methods of the spreader.

Requirements for spreader installation and commissioning

Preparation before installation

Before installing the spreader, it is necessary to read the product manual and installation drawings to understand the structure, performance and installation requirements of the spreader. This helps to provide necessary guidance and reference for the subsequent installation work. It is also necessary to investigate the installation site to ensure that the installation location meets the design requirements and to check whether the surrounding environment is safe and free of obstacles. At the same time, prepare the required installation tools, equipment and materials according to the installation requirements, and check whether their quality and quantity meet the requirements.

Installation process and requirements

During the installation process, it is important to operate in strict accordance with the product specification and installation drawings. This includes following the correct installation sequence and steps, as well as ensuring that the installation position, angle, height and other parameters of the spreader meet the design requirements. When installing key components, such as lifting beams and hooks, necessary checks and measurements need to be made to ensure their installation accuracy and reliability. In addition, attention needs to be paid to safety issues during installation. For example, it is necessary to prevent the occurrence of accidents such as falling from height and electric shock to ensure the safety of the staff.

Commissioning and inspection process

After the installation is completed, the spreader needs to be debugged and inspected. Debugging includes gradually loading to the rated load, observing the deformation and vibration of the spreader to ensure that it works smoothly and without abnormality. Inspection includes comprehensive testing of various performance indexes of the spreader, such as load carrying capacity, stability, safety, etc. Through these tests and verifications, it can be ensured that the spreader meets the design requirements and usage needs.

Spreader debugging and inspection process

Spreader use and maintenance requirements

Use and operation standardization

Before using the spreader, it must be ensured that the operator has fully understood and mastered the correct use of the spreader. This includes, but is not limited to, the structural design principles, functional characteristics and operating procedures of the spreader, etc. The operator not only needs to be familiar with the theoretical knowledge, but must also undergo professional skills training and assessment, and can only be formally put into operation after passing the strict training and obtaining the qualified certificate.

In the actual operation process, especially when performing lifting operations, operators must maintain a high degree of concentration and pay attention to the working condition and performance of the spreader at all times. This means that they have to closely observe whether key parameters such as the spreader's trajectory, speed control and load carrying capacity are within the normal range, and whether various safety protection devices such as overload protection and limit switches can function properly. Once any abnormal signs or potential risks are detected, such as unstable spreader operation, excessive wear and tear of components, alarms of electronic control systems, etc., they should stop the operation immediately to ensure the principle of safety first and report the problem to the relevant management personnel in a timely manner, so that professional overhaul and maintenance can be carried out.

Daily Maintenance

Daily maintenance of the spreader is the key to ensure its long-term stable operation. The spreader should be cleaned, lubricated and fastened regularly to eliminate potential safety hazards. Regular cleaning of the spreader removes dust, dirt and other debris and avoids wear and damage to the spreader from debris. Lubricating the spreader reduces friction, protects the mechanical equipment and bearings and other components of the spreader, and extends its service life. Fastening the spreader can ensure its structural stability and safety and avoid accidents caused by loosening. At the same time, it is also necessary to carry out regular inspection of the key parts of the spreader, such as wear, deformation, cracks, etc., and should be replaced or repaired in time once any abnormality is found. Periodic inspection of the key components of the spreader is an important measure to ensure its normal operation.

Periodic Inspection and Evaluation

In addition to routine maintenance, the spreader should be inspected and evaluated regularly. The inspection includes the structural integrity of the spreader, the stability of its performance, and the effectiveness of the safety protection devices. When assessing the spreader, it is necessary to make a comprehensive evaluation of the safety performance of the spreader according to the results of the inspection, in order to determine whether it meets the requirements for continued use. If a spreader is found to have hidden safety hazards or performance problems, timely measures should be taken to deal with them, including repair, replacement or scrapping. Periodic inspection and evaluation is an important means of ensuring the safe use of spreaders and must be strictly enforced.

Spreader Periodic Inspection and Maintenance Record Sheet

Check date	Check items	Check content	Check results	Maintenance measures	Responsible person
_	Structural design integrity	Whether the spreader structure is complete and free of deformation, cracks, etc.	_	_	_
_	Functional characteristics	Whether the spreader function is normal, such as lifting, rotating, etc.	_	_	_
_	Safety protection device	Are overload protection, limit switches, etc. working properly?	_	_	_
_	Wear of key components	Wear degree of wire ropes, pulleys, bearings and other components	_	_	_
_	Electrical system	Are cables, motors, controllers, etc. normal?	_	_	_
_	Cleanliness	Is the surface and interior of the spreader clean and free of debris?	_	Cleaning spreader	_
_	Lubrication condition	Whether each lubrication point is well lubricated and there is no dry grinding phenomenon	_	Lubricating spreader	_
_	Fastening situation	Whether the connection parts are tight, no loosening phenomenon	_	Fasten the connection part	_
_	Comprehensive assessment	Does the spreader meet the requirements for continued use?	_	Repair/replacement/scrap	_

Spreader Maintenance and Repair Record Sheet

Maintenance date	Maintenance items	Maintenance content	Maintenance results	Note	Responsible person
_	Cleaning and maintenance	Remove dust and dirt on the surface and inside of the spreader	_	_	_
_	Lubrication and maintenance	Lubricate each lubrication point and add lubricant	_	_	_
_	Fastening and maintenance	Check and tighten each connection part to ensure stability	_	_	_
_	Parts replacement	Replace severely worn parts, such as wire ropes, pulleys, etc.	_	_	_
_	Electrical system inspection	Check whether the cables, motors, controllers, etc. are working normally	_	_	_
_	Safety protection device inspection	Check whether overload protection, limit switches, etc. are working normally	_	_	_
_	Functional testing	Test whether the functions of lifting and rotating the spreader are normal	_	_	_
_	Overall assessment	Evaluate the overall performance of the spreader and make suggestions	_	_	_

Spreader End-of-Life and Replacement Criteria

End-of-life conditions and judgment

Spreaders will be affected by various factors such as wear and tear, aging, corrosion, etc., which will lead to the gradual deterioration of their performance during long-term use. When the spreader has the following defects such as serious wear, deformation, cracks, etc., or when it is found that its key performance indexes such as load carrying capacity, stability, etc. can no longer meet the use requirements, it should be judged as end-of-life. For spreaders exceeding the designed service life, they should also be considered for scrapping.

Replacement Procedures and Requirements

When replacing the spreader, it should be operated in strict accordance with relevant regulations and procedures. First of all, the new spreader should be accepted and inspected to ensure that its quality meets the design requirements. During the acceptance and inspection process, attention should be paid to the material, size, connection method and other key parameters of the spreader to ensure that it meets the design requirements and safety standards. Secondly, during the replacement process, it should be ensured that the connection methods and sizes of the new and old spreaders are matched to avoid safety accidents caused by improper connection. At the same time, it should be ensured that the operation standardization in the replacement process, to avoid the safety hidden danger caused by improper operation. Finally, after the replacement is completed, the new spreader should be debugged and inspected to ensure that it can work normally and meet the use requirements. In the commissioning and inspection process, attention should be paid to the stability of the spreader, load capacity and other key performance indicators to ensure that it meets the safety standards and use requirements.

Disposal of end-of-life spreaders

For the end-of-life spreader, it should be handled properly. First, it should be removed from the work site and transported to a designated place for storage. During the dismantling process, the safety of the operators should be ensured to avoid injuries caused by improper operation. At the same time, the end-of-life spreader should be transported to the designated location for storage, in order to avoid it being misused or causing environmental pollution. Secondly, the end-of-life spreader should be dismantled or crushed to prevent it from being misused or causing environmental pollution. In the process of disintegration or crushing, corresponding safety measures should be taken to avoid safety accidents caused by improper operation. Finally, the disposal process of end-of-life spreaders should be recorded and archived for subsequent review and audit. The records should include the name, specification, quantity, disposal time and location of the end-of-life spreader for subsequent review and audit. At the same time, the records should be archived for subsequent inspection and audit.

In summary, the safety technical requirements of lifting machine spreaders cover various aspects such as design, manufacture, installation, use, maintenance and scrapping. Only in strict accordance with these requirements for operation and management, in order to ensure that the spreader in a variety of working conditions can be stable and reliable operation, so as to protect the safety of operators and production efficiency. At the same time, it should also strengthen the maintenance and repair work of the spreader to prolong its service life and improve the safety of use.

Safety Technical Requirements for Crane Spreaders

Safety precautions for overhead cranes lifting operations

 As an indispensable heavy equipment in the industrial field, the safety of bridge crane hoisting operations is directly related to production efficiency and personnel safety. In a complex operating environment, how to ensure that the hoisting operation of bridge cranes is foolproof is a question that every practitioner must think deeply about. Hoisting operations not only require the equipment itself to be in good condition, but also require a comprehensive consideration of the operating environment, operator qualifications and safety operating procedures. From safety preparations before the operation, to a detailed inspection of the crane equipment, to a comprehensive assessment of the operating environment, every detail is crucial. At the same time, the professional skills and safety awareness of the operator are also the key to preventing accidents. This article will explore in depth the safety precautions in bridge crane hoisting operations, aiming to provide a set of scientific and comprehensive safety management guidelines for related industries.

Safety preparation before operation

Before carrying out the hoisting operation of a bridge crane, a series of detailed and comprehensive safety preparations need to be carried out to ensure the safety, efficiency and smooth progress of the entire hoisting process. A careful and rigorous review of the operation plan is a crucial first step. In this process, it is necessary to conduct a comprehensive assessment of the feasibility and safety of the lifting task, and fully consider the performance parameters of the bridge crane, such as rated lifting weight, span, lifting height, etc., to ensure that all parameters of the lifting operation are within the design range of the crane, and avoid mechanical failures or even safety accidents caused by overload operation or improper operation.

Safety environment improvement at the operation site is also an indispensable part. Before the lifting operation, the site must be thoroughly cleaned and all obstacles that may affect the operation of the crane and the lifting operation must be removed, including but not limited to scattered objects, sharp objects, temporary stacking objects, etc. At the same time, it is necessary to ensure that the operation path of the crane is unobstructed and no personnel or equipment is stranded to prevent accidental collisions or squeezing incidents during the lifting process.

The establishment of a clear and definite command and coordination mechanism is a key link in safeguarding the safety of lifting operations. Before the operation, special commanders should be set up, and strict command signals and communication rules should be formulated to ensure that all personnel involved in the operation can understand the command intention accurately and correctly, and the information transmission of each link should be timely and effective. In addition, emergency plans and liaison mechanisms should be established to deal with possible emergencies and improve operational efficiency while ensuring safety.

Pre-operation safety check list

Crane equipment safety inspection

Equipment appearance and structure inspection

The safety of the equipment appearance and structure is the basis for ensuring the normal operation of the crane and the personal safety of the operator. Before each operation, a comprehensive and detailed inspection should be carried out to ensure that the equipment is in good condition. First of all, the metal structure of the bridge crane should be checked, including the bridge frame, end beam, trolley frame and other parts, to ensure that there are no cracks, slag inclusions, leaks and other phenomena in the welds, and the bolted joints should be tightened without looseness to avoid structural instability or deformation due to connection problems. At the same time, it is also necessary to pay attention to the wear of various parts of the crane, such as pulleys, pulley blocks, wire ropes and other wearing parts, check the wear of the pulley grooves to see if they meet the use requirements; check the wear and broken wires of the wire rope to ensure that its load-bearing capacity meets the standards to prevent safety accidents such as breakage during use.

Crane function test

Function test is an important part of ensuring the normal operation of the crane and the personal safety of the operator. Before the operation, test the various functions of the crane to check whether it runs smoothly and whether there are abnormal sounds or vibrations. First, test the lifting function of the crane to observe whether it runs smoothly and whether there are any abnormal sounds or vibrations. The performance of the brake should also be checked to ensure that it can stop and decelerate reliably. Secondly, test the operation function of the crane to check whether the trolley and the car are running smoothly and whether there are any abnormal sounds or vibrations. In particular, pay attention to the connection and coordination between the components to see if there are problems such as looseness or wear. In addition, for cranes with variable amplitude function, it is also necessary to check whether its variable amplitude function is normal, observe the working condition of the variable amplitude mechanism, and ensure that it can accurately control the variable amplitude speed and position. Through functional testing, potential faults can be discovered and eliminated in time, providing reliable equipment guarantee for hoisting operations.

Safety device verification

Safety devices are an important part of cranes, including limiters, buffers, anti-unhooking devices, etc. The role of these safety devices is to play a role at critical moments to prevent safety accidents caused by loss of control or misoperation of the crane. Before operation, check the various safety devices of the crane to ensure that they can play a role at critical moments. First, check the limiters of the crane, including travel limiters, lifting limiters, etc. Ensure that these limiters can reliably function when the equipment runs to the limit position to avoid damage caused by overload or collision. Secondly, check the buffer. The function of the buffer is to absorb the impact force generated by the equipment during operation to prevent the equipment from being damaged. By checking the performance of the buffer, ensure that it can effectively absorb the impact force. Finally, check the anti-unhooking device. The function of the anti-unhooking device is to prevent the hook from accidentally falling off and causing safety accidents. By checking the reliability of the anti-unhooking device, ensure that it can play a role at the critical moment.

Safety device verification record sheet

Safety device name	Verify content	Verification result	Checker	Verification date
Travel limiter	Can the equipment stop reliably when it reaches the limit position?	Pass/Fail	_	_
Lifting limiter	Can the equipment stop reliably when it reaches the limit position?	Pass/Fail	_	_
Buffer	Is the impact absorption performance good?	Pass/Fail	_	_
Anti-unhooking device	Reliability to prevent the hook from accidentally falling off	Pass/Fail	_	_
Other safety devices	_	Pass/Fail	_	_
Remark	Problems found during the calibration process and their solutions	_	_	_

Crane function test record sheet

Test items	Test content	Test Results	Tester	Test Date
Lifting function test	Is the operation smooth? Are there any abnormal sounds or vibrations?	Pass/Fail	_	_
Brake performance test	Can it stop and slow down reliably?	Pass/Fail	_	_
Crane operation test	Is the operation smooth? Are there any abnormal sounds or vibrations?	Pass/Fail	_	_
Trolley running test	Is the operation smooth? Are there any abnormal sounds or vibrations?	Pass/Fail	_	_
Amplitude function test	Can the luffing speed and position be accurately controlled (if applicable)	Pass/Fail	_	_
Pulley and wire rope inspection	Check whether the pulley groove wear, wire rope wear and wire breakage meet the standards.	Pass/Fail	_	_
Remark	Problems found during testing and solutions	_	_	_

Lifting operation environment assessment

Operation area division and identification

The lifting operation area should be scientifically and reasonably divided according to the scope, scale and degree of danger of the operation, and clear and eye-catching safety warning signs and isolation facilities should be set up. The signs should include but are not limited to the key positions such as the lifting operation area boundary, lifting path, and lifting operation point to clearly indicate the specific area of ​​the lifting operation. At the same time, key parts in the operation area, such as lifting points, supporting structures, important pipelines, etc., should also be clearly marked so that operators can accurately identify them.

Ground bearing capacity assessment

Ground bearing capacity is an important guarantee for the safety of lifting operations. Before lifting operations, a detailed bearing capacity assessment of the ground in the operation area must be carried out. The assessment work should take into account factors such as soil properties, geological conditions, humidity, etc., and refer to previous data and experience to ensure that the ground can withstand the weight of the crane and the hoisted objects. If the ground bearing capacity is insufficient, reinforcement measures should be taken, such as increasing the foundation, laying steel plates, etc., to increase the bearing capacity of the ground. The reinforcement measures should be calculated and confirmed by professionals to ensure their reliability and safety.

Meteorological conditions and lighting requirements

Meteorological conditions have an important impact on the safety of lifting operations. Before lifting operations, pay close attention to meteorological conditions and avoid operating in bad weather. Lifting operations should be suspended in bad weather such as strong winds, heavy rain, and thunder and lightning. At the same time, lighting at the work site is also very important. Adequate light can ensure that operators can clearly observe the hoisted objects and the surrounding environment, avoiding safety accidents caused by poor vision. Lighting equipment should be set in appropriate locations to ensure that the lighting in the work area is sufficient and uniform. In addition, lighting equipment should also have windproof and waterproof properties to ensure normal use in bad weather.

Operator training and qualifications

Operation skills training

The skill level of operators plays a vital role in hoisting operations and directly affects the safety and efficiency of operations. In order to ensure that operators are competent for their work, they must be systematically trained in operation skills. The training content should cover the operating principles, operation procedures and troubleshooting of cranes. Through in-depth theoretical learning and practical operations, the skill level of operators can be improved so that they can master the various functions and usage methods of cranes, thereby ensuring safety and efficiency during operations.

Safety knowledge education

Safety knowledge education is an important way to cultivate operators' safety awareness. During the training process, emphasis should be placed on safety precautions in hoisting operations, including operating specifications, hazard warnings and emergency response. In addition, operators should also be taught how to respond in emergency situations, such as how to avoid accidents, how to save themselves and how to save others. Through safety knowledge education, operators can fully realize the importance of safety and have basic safety awareness and self-rescue capabilities.

Operation qualification review

Operation qualification is an important basis for ensuring that operators have legal operating qualifications. After the training, the qualifications of operators should be reviewed. The audit process should strictly follow relevant regulations and standards, including the assessment and testing of operating skills and safety knowledge. Only operators who pass the qualification review can obtain legal operating qualifications and be allowed to perform hoisting operations. Those who fail the review need to continue to participate in training or study until they meet the qualification standards.

Safety operating procedures for hoisting operations

Lifting operation process specification

Lifting operation is a high-risk operation and must be carried out strictly in accordance with the standardized process. Before the operation, a detailed lifting plan should be formulated to clarify the weight, size, lifting point location and other information of the lifting object. The lifting plan should include details such as the pretreatment of the lifting object, the lifting sequence, the lifting route, and the lifting height to ensure the smooth progress of the lifting operation. When formulating the lifting plan, the characteristics, weight, size and other factors of the lifting object, as well as the environment and equipment at the lifting site should be fully considered. The operator should operate strictly in accordance with the lifting plan and shall not change the operation process without authorization. During the operation, a special person should be designated to command and supervise to ensure the coordination and safety of the lifting operation.

Requirements for the use of slings and rigging

Slings and rigging are indispensable tools in lifting operations. Before use, the slings and rigging should be inspected to ensure that they are in good working condition. The inspection content should include: the integrity of the slings and rigging, wear and tear, cracks and other defects, and whether the connectors and fasteners are loose. For the slings and riggings with problems, they should be repaired or replaced in time to ensure their safety and reliability. Appropriate slings and riggings should be selected according to the weight and size of the hoisted objects to avoid safety accidents caused by improper selection. When selecting slings and riggings, factors such as the characteristics, weight, size and other factors of the hoisted objects, as well as the environment and equipment at the hoisting site should be fully considered. For special types of hoisted objects, such as those in high temperature and corrosive environments, high temperature and corrosion resistant slings and riggings should be selected to ensure that they will not be damaged or fail during use.

Response measures in emergency situations

In hoisting operations, emergencies occur from time to time. In order to ensure that operators can respond quickly in emergency situations, detailed response measures should be formulated. This includes the use of emergency stop buttons, planning of escape routes, and the provision of fire-fighting equipment. Emergency measures should clarify the responsibilities and actions of operators to ensure that measures can be taken quickly and accurately in emergency situations. For possible emergencies, simulation drills and training should be conducted to familiarize operators with the implementation methods of emergency measures. Emergency measures should take into account various possible emergency situations, such as equipment failure, operational errors, natural disasters, etc. Different response measures should be formulated for different emergency situations to ensure that effective response measures can be taken quickly in emergency situations.

Emergency response procedures for lifting operations

Safety precautions for overhead cranes lifting operations

Safety Requirements for Lifting Operations and Lifting Machinery

 In the field of modern industry and construction, lifting operations and lifting machinery play a pivotal role, they not only greatly improve the efficiency of work, but also expand the boundaries of construction and production. However, as the complexity of lifting operations and lifting machinery to enhance the diversity of the types of safety issues have become increasingly prominent. Lifting operations involve working at height, heavy lifting and other high-risk aspects, once improper operation or equipment failure, it may cause serious accidents, posing a huge threat to the safety of personnel and production order. Therefore, in-depth discussion of lifting operations and lifting machinery safety requirements, not only to follow the industry norms, but also to respect and protect the safety of life.

Basic requirements for lifting operations

Definition and classification of lifting operations

Lifting operations refers to the use of a variety of lifting machinery and equipment, through vertical or horizontal movement of materials to achieve loading and unloading, installation, handling and other operational processes. According to the mode of operation, material characteristics and the use of different scenes, lifting operations can be divided into lifting operations, handling operations, loading and unloading operations and other types. Each type has its own specific safety requirements and operational standards. For example, lifting operations require the use of cranes and other lifting machinery, heavy lifting and installation or movement; handling operations require the use of forklifts and other equipment, the material will be moved in the horizontal direction; loading and unloading operations need to be in ports, yards and other places, the use of various loading and unloading machinery will be loaded or unloaded into or out of the vehicle, warehouse and other places.

Safety risk assessment of lifting operations

Before carrying out lifting operations, a comprehensive assessment of factors such as the working environment, equipment conditions, and material characteristics must be conducted to determine potential safety risks. The assessment content includes but is not limited to equipment carrying capacity, working space restrictions, material stability, etc. Through risk assessment, targeted safety precautions can be formulated to reduce the probability of accidents. For example, for lifting operations, it is necessary to assess whether the crane's carrying capacity meets the requirements, whether the lifting plan is reasonable, whether the lifting equipment is safe and reliable, etc.; for handling operations, it is necessary to assess whether the passage is unobstructed, whether the forklift is stable, etc.; for loading and unloading operations, it is necessary to assess whether the stability of the cargo is good, whether the operation of the loading and unloading machinery is standardized, etc.

Qualification requirements for lifting operators

Lifting operators must have corresponding professional knowledge and skills and hold valid operating certificates. They should be familiar with the performance, structure, safety devices and operating methods of lifting machinery, and master basic first aid knowledge and emergency response skills. In addition, operators need to receive regular training and assessments to continuously improve their safety awareness and operating skills. At the same time, operators also need to understand relevant safety regulations and operating procedures to ensure the safety of themselves and others.

Safety management of lifting operation sites

A sound safety management system should be established at the lifting operation site to clarify the safety responsibilities and operating specifications of personnel at all levels. Obvious safety warning signs should be set up on site and necessary safety protection facilities should be equipped. At the same time, the monitoring and management of the operation process should be strengthened to ensure that various safety measures are effectively implemented. For example, at the lifting operation site, safety signs such as cordons and warning lights should be set up to remind passers-by and vehicles to pay attention to safety; at the handling operation site, the passage should be kept unobstructed to avoid the stacking of debris and obstacles; at the loading and unloading operation site, the cargo stacking and transportation routes should be reasonably arranged to avoid cross-operation and collision accidents.

Safety management form for Lifting operation site

Security management project	Concrete content	Person in charge	Note
Type of assignment	Lifting operations/handling operations/loading and unloading operations	_	Fill in according to the actual situation
Security risk assessment	Equipment carrying capacity, operating space limitations, material stability, etc.	Safety management personnel	Risk assessment reports
Operator qualifications	Operational certificates, professional knowledge and skills, first aid knowledge and emergency response skills	Human resources department	Photocopies of qualification certificates
Safety management system	Safety responsibilities and operating specifications for personnel at all levels	Safety management department	Management system documentation
Safety Warning Signs	Cordons, warning lights, safety signs, etc.	Site managers	Regular inspection and maintenance
Safety protection facilities	Safety nets, protective barriers, protective pads, etc.	On-site management personnel	Regular inspection and maintenance
Operation process monitoring	Monitor and record the operation process in real time	On-site management personnel	Monitoring Record Sheet
Emergency response measures	Emergency plans, emergency equipment, emergency drills, etc.	Safety management department	Emergency plan documents
Safety education and training	Organize safety training and assessment regularly	Human resources department	Training record sheet
Safety hazard investigation	Regularly inspect and rectify potential safety hazards	Safety management department	Hidden danger investigation record sheet

Table of Safety Precautions for Lifting Operations

Preventive measures	Concrete content	Person in charge	Note
Equipment inspection and maintenance	Regularly check equipment performance, structure, safety devices, etc.	Equipment maintenance personnel	Maintenance record sheet
Operating environment management	Keep the work site clean and orderly, and avoid debris stacking	On-site management personnel	Environmental inspection record sheet
Material Stability Management	Ensure that the materials are stacked stably to avoid collapsing or slipping	On-site management personnel	Material Inspection Record Sheet
Execution of operating specifications	Operate in strict accordance with operating procedures, and illegal operations are prohibited	Operators	Operation Record Sheet
Communication guarantee	Ensure smooth on-site communication and communicate operation information in a timely manner	On-site management personnel	Communication equipment inspection records
Personnel protective equipment	Protective equipment inspection records	Operators	Protective equipment inspection records
Cross-job management	Reasonably arrange the work sequence to avoid collision accidents caused by cross-work	On-site management personnel	Work schedule
Weather condition monitoring	Pay attention to weather changes and avoid operating in bad weather	Operators	Weather forecast record
Safety inspection	Conduct regular safety inspections of the work site to identify problems and rectify them in a timely manner	Safety management personnel	Inspection record sheet
Accident reporting and handling	Report accidents immediately and handle them in accordance with emergency plans	Safety management personnel	Accident Reporting Record Sheet

Basic structure and principle of lifting machinery

Classification and characteristics of lifting machinery

Lifting machinery is an indispensable and important equipment in modern industrial production. There are many types of lifting machinery. According to different structural forms, functions and application scenarios, lifting machinery can be divided into tower cranes, bridge cranes, gantry cranes, mobile cranes and other types.

1. Tower crane: Tower crane is a kind of lifting machinery with high lifting capacity and large working range, mainly used in the construction of large projects such as high-rise buildings, bridges, docks, etc. The structure of the tower crane mainly includes the tower body, boom, slewing mechanism and other parts. The lifting mechanism inside the tower body and the telescopic mechanism of the boom are used to realize the lifting and horizontal movement of materials.
2. Bridge crane: Bridge crane is a kind of lifting machinery widely used in workshops, warehouses and other places, with high work efficiency and flexibility. The structure of the bridge crane mainly includes the bridge frame, trolley running mechanism, trolley running mechanism and other parts. The trolley running mechanism and trolley running mechanism are driven by the motor to realize the horizontal and vertical movement of materials.
3. Gantry crane: Gantry crane is a kind of lifting machinery with a large span and high working intensity, mainly used in ports, docks and other places. The structure of a gantry crane mainly includes the gantry, the trolley running mechanism, the trolley running mechanism and other parts. The motor drives the trolley running mechanism and the trolley running mechanism to achieve the horizontal and vertical movement of materials.
4. Mobile crane: A mobile crane is a kind of lifting machinery with strong mobility and flexibility, which is widely used in construction sites, docks, bridges and other places. The structure of a mobile crane mainly includes the chassis, slewing mechanism, boom and other parts. The motor drives the slewing mechanism and boom to achieve the lifting and horizontal movement of materials.

Main structural components of lifting machinery

The main structural components of lifting machinery include lifting mechanism, operating mechanism, metal structure, electrical system, etc. These components cooperate with each other to complete the handling and lifting of materials.

• Lifting mechanism: The lifting mechanism is one of the core components of lifting machinery and is responsible for the vertical movement of materials. The lifting mechanism mainly includes motors, reducers, drums and other parts. The motor drives the reducer, and then the reducer drives the drum to achieve the lifting and lowering of materials.
• Operating mechanism: The operating mechanism is another important component of lifting machinery and is responsible for the horizontal movement of materials. The operating mechanism mainly includes two types: trolley operating mechanism and trolley operating mechanism. The trolley operating mechanism is mainly responsible for the horizontal movement of the bridge or gantry, while the trolley operating mechanism is mainly responsible for the horizontal movement of the trolley.
• Metal structure: The metal structure is the supporting and force-bearing component of the lifting machinery, mainly including the bridge, gantry, boom and other parts. These metal structures are connected together by welding or bolting to form a stable overall structure. At the same time, the metal structure also has sufficient strength and stability to withstand the weight of materials and various external forces.
• Electrical system: The electrical system provides power and control signals for lifting machinery, mainly including motors, controllers, sensors and other parts. The electrical system precisely controls the motor through the controller to realize various actions of the lifting machinery. At the same time, the sensor can also monitor the weight and position of the material in real time, providing accurate data support for the operator.

Working principle of lifting machinery

The working principle of lifting machinery is based on mechanical principles and electric traction technology. During work, the motor drives the actuator such as the drum or boom through the reducer to carry out material handling or lifting operations. At the same time, the control system precisely controls the operation of the motor to realize various actions of the lifting machinery. The control system monitors the weight and position of the material in real time through the sensor, and controls the motor accordingly according to the monitoring results to ensure the accuracy and safety of material handling or lifting operations.

The working principle of lifting machinery

Safety devices and protective measures for lifting machinery

Setting and function of overload limiter

The overload limiter is one of the core safety devices of lifting machinery, and its setting and function are crucial. First, according to the design parameters and working requirements of the lifting machinery, the overload limit value is set scientifically and reasonably. This value is usually lower than the actual load-bearing capacity of the lifting machinery to ensure that the limiter is not frequently triggered under normal working conditions. Once the actual load of the lifting machinery exceeds the preset limit value, the overload limiter will respond immediately, and prevent the equipment from continuing to overload by cutting off the power supply or issuing an audible and visual alarm signal, thereby preventing serious safety accidents such as equipment damage, structural instability, and wire rope breakage caused by overload.

Types and functions of limiters

The limiter is an important part of the lifting machinery. According to its different functions, it can be divided into various types such as travel limiter, height limiter, and weight limiter. These limiters accurately control the range of motion of the lifting machinery by mechanical or electrical means to ensure that it is always in a safe and controllable state during the working process. The travel limiter is usually installed on the running track or hanging beam of the crane to limit the maximum moving distance of the crane in a specific direction. The height limiter is used to limit the maximum lifting height of the hoist or hoisted objects in the vertical direction to prevent accidents caused by excessive lifting.

Configuration of buffers and stop devices

Buffers and stop devices are indispensable safety configurations in lifting machinery. Buffers are usually made of materials such as springs, hydraulics or rubber, which can effectively absorb the impact energy generated by the lifting machinery during movement, thereby reducing the degree of damage to the equipment during impact. The stop device is fixed on the movement trajectory of the equipment to achieve precise control of the movement range of the lifting machinery through mechanical or electrical means.

Requirements for the setting of protective covers and guardrails

In order to ensure the safety of personnel, protective covers or guardrails must be set in dangerous areas such as rotating parts and moving parts of the lifting machinery. Protective covers and guardrails should be firm and reliable, and can effectively prevent people from entering or contacting dangerous areas by mistake. At the same time, these devices should also be easy to observe and repair, and should not affect the operator's monitoring of the equipment status and daily maintenance work. In addition, the design of protective covers and guardrails should also take into account factors such as heat dissipation, maintenance and maintenance of the equipment, and the operator's line of sight.

Safety inspection and maintenance of lifting machinery

Content and cycle of regular inspection

Regular inspection is a key link to ensure the safe operation of lifting machinery, and its content covers many aspects. Appearance inspection includes careful observation of the structural parts, connectors and safety protection facilities of the lifting machinery to find possible cracks, deformation, wear, corrosion and other problems. Functional testing involves comprehensive inspection of various actions and performance indicators of the lifting machinery, such as lifting capacity, operating stability, braking performance, etc., to ensure the reliability and safety of the equipment under normal operation. Safety device calibration is an important link to ensure that the lifting machinery can act promptly and effectively when encountering abnormal conditions, including but not limited to overload protection devices, limit devices, alarm devices, etc. The accuracy and reliability of these safety devices directly affect the safety performance of the lifting machinery.

When determining the period of regular inspection, multiple factors need to be considered comprehensively. The frequency of use of the equipment is one of the key factors. Frequently used lifting machinery obviously requires a shorter inspection cycle to ensure that it always maintains a good operating state and safety. The working environment is also an important consideration. Harsh working environments such as high temperature, high humidity, high dust and other conditions may accelerate equipment wear and aging, so the inspection cycle needs to be shortened appropriately. The manufacturer's recommendations are also an important reference for determining the inspection cycle. Following the recommendations and standards provided by the manufacturer can ensure that the requirements of the equipment during the design and manufacturing process are met.

By strictly implementing the regular inspection system, potential safety hazards can be effectively discovered and eliminated, the safety of the working environment and the safety of personnel can be guaranteed, and the service life of the lifting machinery can be effectively extended, and the economic benefits and efficiency of the equipment can be improved.

The key points of daily maintenance and maintenance

The daily maintenance and maintenance of lifting machinery is an important part of ensuring its safe and stable operation. This work involves many aspects. First, keep the surface of the equipment clean and clean the surface of the lifting machinery regularly to prevent dust accumulation, oil stains, etc. from affecting the appearance and performance of the equipment. Secondly, lubricating parts are an important part of ensuring the normal operation of lifting machinery. According to the lubrication requirements of the equipment and the actual working conditions, each lubrication point should be regularly inspected and lubricated to reduce component wear and maintain the stable operation of the equipment. In addition, checking fasteners is also an important part of daily maintenance and maintenance. Loose fasteners are one of the common causes of lifting machinery failures. Therefore, it is necessary to regularly inspect each connection part, promptly detect and tighten loose bolts, nuts and other fasteners to prevent equipment failures or safety accidents caused by loose fasteners.

In daily maintenance work, relevant personnel should keep regular maintenance records, record maintenance dates, maintenance content, replacement parts and other information, so as to establish a complete equipment maintenance file and provide strong support for subsequent equipment management. Through the implementation of these measures, the safety and stability of lifting machinery in daily use can be ensured, and accidents and equipment damage caused by improper maintenance can be effectively avoided.

Criteria for judging repair and replacement

When a lifting machinery fails or is damaged, it needs to be evaluated according to the criteria for judging repair and replacement. In the evaluation process, the nature and extent of the failure must first be comprehensively and carefully analyzed and judged. For those failures that can restore the original performance of the equipment after repair and will not have much impact on the overall operation, a decisive decision should be made to repair them. This can not only save cost resources, but also maintain the original performance of the equipment and extend the service life of the equipment. However, for those failures that cannot be effectively repaired by maintenance means, or for those damage conditions that still have safety hazards and affect the overall performance of the equipment after repair, replacement measures should be resolutely taken. By replacing the faulty parts or the whole machine, the problem can be completely solved, potential safety hazards can be eliminated, and the safe and stable operation of the lifting machinery can be ensured.

Inspection and rectification of safety hazards

In the process of using lifting machinery, the inspection and rectification of safety hazards are extremely important. In order to ensure the safe operation of the equipment, a comprehensive and detailed inspection of hidden dangers must be carried out. This work involves all aspects of the equipment, including but not limited to the degree of aging of structural parts, the looseness of connectors, the integrity of the electrical system, and the effectiveness of safety protection facilities. In the process of inspection, it is necessary to not miss any details and links that may have hidden dangers. For the safety hazards found, effective rectification measures must be taken immediately. The rectification measures should be targeted and operational to ensure that the safety hazards can be completely eliminated. At the same time, during the rectification process, attention should be paid to the relevant record work, so as to provide a strong basis for subsequent tracking and management. By strictly implementing the inspection and rectification system of safety hazards, the safe operation of lifting machinery can be effectively guaranteed, the probability of safety accidents can be reduced, and the safety of personnel and the integrity of equipment can be ensured.

Safety operating procedures for lifting machinery

Preparation before operation

Before operating lifting machinery, a series of preparations need to be carried out to ensure the normal operation of the equipment and the safety of personnel. First, check the appearance of the lifting machinery, including checking whether there are cracks, deformations and other damages on the surface of the equipment, and whether the connections of various components are firm. At the same time, it is also necessary to check the performance of the equipment, such as checking whether the braking system, hydraulic system, electrical system, etc. are normal. It is also necessary to confirm the effectiveness of safety devices, such as limiters, overload protectors, emergency stop buttons, etc., to ensure that the equipment can be stopped in time in dangerous situations. It is also very important to understand the working environment. Operators need to master the material characteristics, such as weight, size, shape, etc., in order to choose appropriate slings and lifting methods. In addition, it is also necessary to wear personal protective equipment, such as safety helmets, protective glasses, gloves, etc., to prevent injuries in the event of accidents.

Precautions during operation

During the operation of lifting machinery, safety operating procedures must be strictly followed. First of all, it is very important to operate the control handle correctly to ensure stable operation and precise position control. It is also essential to pay attention to the operating status of the equipment, observe whether the operating status of each component is stable, and deal with any abnormalities in a timely manner. It is also very important to maintain communication with the operating personnel to ensure the safety of collaborative operations. At the same time, dangerous operations such as overspeeding and overloading should be avoided during operation to ensure the safe operation of the equipment.

Response measures in emergency situations

In emergency situations, such as equipment failure and personal injury, the operator should take response measures immediately. First, cut off the power supply to avoid accidental startup of the equipment or aggravate the consequences of the accident; start the emergency shutdown device to quickly stop the operation of the equipment; evacuate personnel to avoid the expansion of the accident; report to relevant departments and personnel in a timely manner to quickly handle the accident. In the process of handling the accident, you should remain calm and take scientific and reasonable measures to minimize casualties and property losses.

Finishing work after the operation

After the operation, the finishing work should be done well. First, turn off the power of the equipment to save energy and avoid overheating or damage caused by long-term operation of the equipment; clean up the work site to keep it tidy and avoid safety hazards; return the tools to avoid loss or abuse; it is also necessary to inspect and maintain the equipment, such as checking whether the connections of each component are firm and whether the lubrication system is in good condition, to ensure that the equipment is in good operating condition. Strict finishing work can provide safety guarantee for the next operation and extend the service life of the equipment.

Safety Requirements for Lifting Operations and Lifting Machinery