JBT 4030.1-2000 汽车起重机和轮胎起重机试验规范 作业可靠性试验

ICS91.220J80JB/T4030.1－2000汽车起重机和轮胎起重机试验规范作业可靠性试验Testcodefortruckcraneandwheelcrane—Testofoperafingveliabilify2000-04-24发布2000-10-01实施国家机械工业局发布I前言1范围····················································································································································································································12引用标准·········································································································································································································13定义····················································································································································································································14试验样机与试验条件···············································································································································································25试验要求·········································································································································································································26试验结论·········································································································································································································47故障分类·········································································································································································································58变型起重机的作业可靠性试验方法················································································································································5附录A（标准的附录）作业可靠性试验故障模式及其分类表···························································································6附录B（提示的附录）作业可靠性试验记录表·························································································································20JB/T4030.1－2000目次II前言本标准是对JB4030.1—85《汽车起重机和轮胎起重机试验规范作业可靠性试验》的修改。本标准是汽车起重机和轮胎起重机整机试验规范之一，它与GB/T6068.1~6068.4、JB/T4030.2、JB/T4030.3组成汽车起重机和轮胎起重机整机试验的一套试验规范。本标准与JB4030.1—85相比，主要技术内容改变如下：——增加了可靠性考核时的抽样方法；——修改了对于不同吨位的作业可靠性试验的各工况循环次数；——增加了总作业时间的规定要求；——增加了故障分类及其当量故障数；——修改了可靠性指标计算公式；——增加了变型产品的可靠性试验方法。本标准自实施之日起代替JB4030.1—85。本标准的附录A是标准的附录。本标准的附录B是提示的附录。本标准由建设部长沙建设机械研究院提出并归口。本标准起草单位：建设部长沙建设机械研究院、国家工程机械质量监督检验中心。本标准主要起草人：冯桂英、曹仲梅。本标准于1985年7月1日首次发布。本标准委托建设部长沙建设机械研究院负责解释。JB/T4030.1－200011范围本标准规定了汽车起重机和轮胎起重机（以下简称起重机）作业可靠性试验方法、故障分类及其特征量的计算方法。是评定起重机在规定的条件和预定的时间内强化作业状态下的工作能力，考察起重机在起重作业时整机和零部件的作业可靠性、主要零部件的耐磨性以及基本性能的稳定程度。本标准适用于JB/T1375规定的起重机，按GB/T6068.2规定，完成合格试验后进行的试验，作为新产品型式试验的组成部分，也是定型后批量生产的产品可靠性考核的试验。2引用标准下列标准所包含的条文，通过在本标准中引用而构成为本标准的条文。本标准出版时，所示版本均为有效。所有标准都会被修订，使用本标准的各方应探讨使用下列标准昀新版本的可能性。GB/T6068.1—1985汽车起重机和轮胎起重机试验规范一般要求GB/T6068.2—1985汽车起重机和轮胎起重机试验规范合格试验JB/T1375—1992汽车起重机和轮胎起重机分类JB/T9738—2000汽车起重机和轮胎起重机技术要求JB/T51060—2000汽车起重机和轮胎起重机产品质量分等3定义本标准采用下列定义。3.1故障起重机整机或零部件不能完成其规定功能，或其性能指标恶化至规定范围以外的一切现象。3.2基本故障起重机整机零部件本身内在缺陷或不满足使用条件而引起的故障。3.3从属故障由于操作人员违章操作，未按规定使用条件所造成的，或明显人为因素造成的故障。3.4致命故障危及作业安全，导致人身伤亡，引起主要总成报废，造成重大经济损失或对周围环境造成严重危害。3.5严重故障影响作业安全，导致主要总成零部件损坏或性能显著降低，且不能用随机工具及易损备件在短时国家机械工业局2000-04-24批准中华人民共和国机械行业标准汽车起重机和轮胎起重机试验规范作业可靠性试验Testcodefortruckcraneandwheelcrane—TestofoperafingveliabilifyJB/T4030.1－2000代替JB4030.1—852000-10-01实施JB/T4030.1－20002间（30min）内修复，修理费用高。3.6一般故障造成作业中断或性能下降，但不会导致主要零件损坏，并可用随机工具和易损备件在短时间（30min）内能够排除。3.7轻微故障暂时不会导致作业中断，不需更换零件，用随机工具在短时间（5min）内能轻易排除。3.8故障排除时间出现故障开始到排除故障恢复正常工作为止。它包括：故障诊断、检修设备、修理、更换、调整、试运转等时间。不包括由于人为或自然等因素而耽误的时间，也不包括等备件时间。4试验样机与试验条件4.1按照GB/T6068.2的规定完成合格试验后进行本标准试验。4.2起重作业可靠性试验的条件应符合GB/T6068.1的规定。4.3供可靠性试验的起重机应从当季正常生产入库的合格产品中随机抽取1台作为试验样机（以下简称样机），抽样基数不少于5台（大于40t的起重机抽样基数可以为2~5台）。若在用户处抽取样机时，则抽样基数不限。（对新产品的型式试验不执行本条）5试验要求5.1作业可靠性试验的循环次数和基本工况作业可靠性试验的循环次数和基本工况见表1。表1循环次数和基本工况表循环次数序号循环名称试验工况一次循环的内容3t~32t40t~80t≥100t1基本臂起升、回转循环基本臂；昀大额定起重量；相应的工作幅度；吊臂在正侧方重物由地面起升到昀大高度—下降到能回转的昀低高度—180°范围内左右回转—重物下降到地面300016005002中长臂起升、变幅回转循环中长臂1），2）中长臂时昀大额定起重量的1/3；相应的工作幅度；吊臂在正侧方重物起升离地200mm—起臂到昀小工作幅度后再落臂到原位—180°范围内左右回转—起升到昀大高度—下降到地面150010007003昀长主臂起升、回转循环昀长主臂；昀长主臂时昀大额定起重量；相应的工作幅度；吊臂在正侧方重物起升离地200mm—180°范围内左右回转—起升到昀大高度—下降到地面15001000400JB/T4030.1－20003表1（完）循环次数序号循环名称试验工况一次循环的内容3t~32t40t~80t≥100t4空载吊臂伸缩循环3）吊臂仰角50°；空载；吊臂在正侧方空载状态下，吊臂从基本臂状态全部伸出再缩回到基本臂状态4002001005副臂起升、回转循环各节副臂同序号1同序号15003003×1004）6支腿收放样机呈行驶状态支腿连续收放1001）中长臂无吊重性能的起重机，序号2的循环次数及工况按昀长主臂工况进行。2）多级中长臂的起重机按序号2的循环次数平均进行。3）有带载伸缩能力的起重机，按制造厂确定的带载伸缩能力和工况，在序号4工况中做不少于50次带载伸缩试验。4）起重量≥100t的起重机，副臂起升、回转循环，副臂长度不变的做100次循环，可变长度的副臂，试验工况中副臂长度按昀短副臂长、中间副臂长，昀长副臂长各做100次循环。5.2作业可靠性试验总作业时间根据表1的循环次数，作业可靠性试验须在表2规定的总作业时间内完成。表2作业可靠性试验总作业时间T0起重量t812162025321）40506580100125160200时间h300330350380400450350380400450140150170220注1起重量为30t或35t的参照32t。2有副臂的起重机，副臂装拆时间除外。5.3操作和保养5.3.1操作人员应严格执行操作规程，保证安全，操作应平稳。5.3.2按使用说明书的要求完成每日（班）的正常保养，起重作业时，不允许进行保养工作。5.3.3试验期间不允许带故障作业。5.3.4每天样机作业工作的时间一般不少于8h。5.4试验记录按日（班）分类记录：各工况的作业循环数、作业时间、燃油消耗量等。对有不正常的响声、紧固、轻微渗漏等故障的现场情况，及诊断、准备、修复、调试等时间均按要求做详细原始记录。记录要准确、真实。5.5性能复试可靠性试验后按GB/T6068.2规定复测性能。5.6拆检可靠性试验后，整机拆检，详细记录拆检的情况