1、 Common fault types and case analysis

1. Electrical system malfunction

Fuel injector blockage

Case: There are many impurities in diesel fuel in mining environments, leading to frequent malfunctions of fuel injectors and high maintenance costs.

Reason: Insufficient diesel filtration and poor sealing of explosion-proof motors.

Abnormal fuel consumption during engine idling

Phenomenon: Fuel consumption is higher at idle than in driving mode, and long-term operation increases costs.

Root cause: Improper calibration of the engine control unit (ECU) or aging of sensors.

Short circuit/poor grounding of electrical components

Case: A fire broke out in a certain explosion-proof vehicle due to a short circuit caused by aging wiring.

Cause: Lack of regular maintenance and corrosion of explosion-proof surfaces leading to insulation failure.

2. Mechanical structural failure

Abnormal wear and lagging

Case: Long term overload operation leads to bearing damage and chain looseness.

Reason: Insufficient lubrication and poor material wear resistance.

Brake/steering failure

Case: A mining company's explosion-proof vehicle overturned due to brake failure, resulting in 1 death and 3 injuries.

Direct cause: Lack of maintenance of the braking system and excessive tire wear.

Interference of plug-in mechanism

Problem: The explosion-proof car plug-in bracket interferes with the container palletizer, affecting compatibility.

Technical bottleneck: The structural design did not reserve avoidance space.

3. Operational errors and environmental impacts

Check for negligence and fatigue driving

Case: The driver failed to check the condition of the vehicle and applied emergency brakes during operation, resulting in the cargo tipping over.

Management loopholes: lack of standardized inspection procedures and lack of fatigue driving monitoring.

Insufficient environmental adaptability

Phenomenon: The humid environment causes condensation and corrosion on the explosion-proof surface, reducing its explosion-proof performance.

Technical defects: The explosion-proof surface coating process does not meet the standards, and there is a lack of dehumidification devices.

2、 Improvement suggestions

1. Electrical system optimization

Upgrade filtering and sealing

Adopting high-precision diesel filter element (filtration accuracy ≤ 5 μ m) and adding oil-water separator.

Improve the sealing structure of explosion-proof motors and add breathing valves to prevent internal condensation.

Intelligent monitoring

Deploy engine ECU self-learning module to optimize fuel consumption and idle control in real-time.

Adding insulation monitoring and warning for electrical systems can reduce the failure rate by over 40%.

2. Mechanical structure strengthening

Material upgrade and lubrication management

Key components such as bearings and chains are coated with ceramic or self-lubricating materials.

Design an automatic lubrication reminder system to replenish lubricating grease as needed.

Reconstruction of plug-in mechanism

Referring to the patent design, add an "L" - shaped support plate and avoidance port to solve the interference problem.

Adopting modular plug-in brackets, compatibility is improved by 30%.

3. Operational standards and management upgrades

Standardized process

Develop a daily inspection checklist for explosion-proof vehicles, covering 12 key nodes such as braking, tires, and electrical connectors.

Introduce driver fatigue monitoring system (such as facial recognition) and enforce mandatory rest for continuous driving exceeding 4 hours.

Training and Safety Culture

Develop VR simulation operation training, covering emergency braking, slope operation and other scenarios.

Establish a "no accident reward" mechanism to incentivize proactive reporting of hidden dangers.

4. Improvement of environmental adaptability

Explosion proof surface protection

Adopting nano coating technology, the rust prevention performance is improved by 5 times.

Add a humidity sensor inside the explosion-proof chamber and automatically activate the linked dehumidification device.

Structural design optimization

Expand the ground clearance to 450mm to enhance passability.

Improve tire tread design to meet the grip requirements of muddy roads

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment