What are the causes of crane wheel flange wear?
4 Answers
The causes of crane wheel flange wear are as follows: Wheel factors: Wheel installation deviation, including horizontal and vertical deviations. Significant diameter deviation between two driving wheels. Car body factors: The camber of the girder does not meet requirements. Excessive diagonal deviation. Track factors: Excessive track installation deviation, such as span deviation, uneven height, bending deformation, etc. Other factors: Asynchronous movement of wheels on both sides during crane travel, such as motor asynchrony, inconsistent brake tightness, or wheel slippage and deviation caused by oil stains on tracks or wheels, leading to flange wear.
I have been operating overhead cranes in factories for over 20 years and frequently encounter wheel rail gnawing issues, mainly caused by misaligned track installation or wheel misalignment. For example, tracks may deform and bend due to thermal expansion and contraction, or workshop ground settlement may cause track tilt, leading to wheel deviation during operation. Additionally, when the crane load is uneven, causing one side to be heavier than the other, the wheels experience uneven force, eventually gnawing the rail edges over time. Furthermore, severe wheel wear, especially in older equipment, reduces flange thickness, leading to improper sliding. Untreated, these issues accelerate wear and may even cause accidents. Regular maintenance should include using a level to check track straightness and adjusting wheel clearance properly.
After years in this maintenance job, I've noticed that crane wheel flange wear mostly stems from improper daily operations, like operators driving too fast or overloading. Rapid starts and stops cause wheels to impact rail edges, grinding grooves; unbalanced heavy lifting creates skewed pulling that increases friction. Another issue is severe dust accumulation on rails and inadequate lubrication, causing wheels to slide poorly and scrape rails during forced operation. I recommend maintaining steady speeds with light loads, regularly cleaning rails and applying grease – this prevents most problems.
From installation experience, crane wheel rail gnawing is usually caused by initial setup errors. For example, significant horizontal deviation during rail laying, misaligned joints; skewed installation of wheel sets leading to non-parallel wheel axes with the rails; or unstable and loose foundations. If there are design flaws, excessive rail gaps can cause wheel slippage. Professional calibration tools should be used to prevent early wear.
