A complete analysis of common problems with crane wheels
Crane wheels are core equipment for industrial transportation and heavy lifting, and wheels, as their key load-bearing and operating components, directly affect the safety and service life of the equipment. However, due to long-term high-load operation, installation errors or improper maintenance, crane wheels often have problems such as rail gnawing, wear, deformation, and even derailment accidents in severe cases. This article will deeply analyze the common failures, causes and solutions of crane wheels to help equipment managers optimize maintenance strategies and extend the life of wheels.
一、Common problems with crane wheels 1、Rail biting Rail biting refers to the friction between the wheel flange and the side of the track when the crane wheels are running on the track, resulting in abnormal wear and noise. Rail biting is extremely harmful, including:
（1）Increased wheel and track wear: Under normal circumstances, the wheels can be used for more than 5 years, but when the rail biting is serious, the life span may be shortened to 1 year.
（2）Increased running resistance: Cause motor overload and even drive shaft deformation.
（3）Cause derailment risk: In severe cases, the wheels may climb onto the track and cause the equipment to overturn.
Main causes of rail biting:
（1）Horizontal/vertical wheel deviation: Installation error or bridge deformation causes the wheel to be non-parallel to the track.
（2）Transmission system asynchrony: For example, the motor speeds on both sides are inconsistent or the brakes are not adjusted evenly.
（3）Rail installation deviation: Track spacing, height or straightness is out of tolerance
2、Wheel wear Crane wheels are subjected to heavy loads for a long time, and the main forms of wear include:
（1）Tread wear: If the original thickness exceeds 15%, it needs to be replaced or repaired.
(2）Rim wear: If the wear reaches 50% or there is a break, it needs to be scrapped.
（3）Crushing of hardened layer: Insufficient depth of quenching layer (should be ≥20mm) leads to surface peeling.
（4）Wheel cracks: If cracks are found, it must be replaced immediately, otherwise it may break and cause an accident.
二、Solutions and maintenance tips (1) Adjust the wheel unit Correction of horizontal deflection: adjust the bearing support or add or remove shims to ensure that the deflection is ≤D/400 (D is the wheel diameter).
Correction of vertical deflection: adopt an "eight" layout (the top of the wheel faces outward) to reduce the impact of deflection.
Span and diagonal adjustment: the span error of the trolley is ≤±7mm, and the trolley is ≤±3mm.
(2) Optimize the transmission system Synchronous drive motor: ensure that the motor model and parameters at both ends are consistent to avoid speed difference.
Braker balance adjustment: the braking torque on both sides must be the same to prevent asynchronous braking.
(3) Track maintenance and wheel replacement Regularly check the track: measure the track gauge and levelness every 6 months, and clean oil and frost.
Replace worn wheels: the diameter deviation of the driving wheel is ≤0.1%, and the driven wheel is ≤0.2%.
