Electric power maintenance 200KG large load transport aircraft: high-altitude equipment lifting technology tutorial

1. Tutorial Overview

1.1 Scope of application

This tutorial is applicable to special transport aircraft for electric power maintenance with a rated load of 200KG. It is aimed at the lifting operations of high-altitude transmission line tower materials, insulators, maintenance tools and other materials. It covers the standard operating procedures in different terrain conditions such as plains, hills, and mountainous areas. It can be learned and used by certified operators, on-site commanders and safety monitoring personnel.

1.2 Core Objectives

By standardizing operating procedures, clarifying safety requirements, and explaining troubleshooting methods, we ensure that high-altitude lifting operations are carried out safely and efficiently, reduce personnel safety risks, improve the efficiency of power maintenance material transportation, and ensure that maintenance work is completed on schedule with high quality.

1.3 Prerequisites

1. Operators must hold corresponding special operation qualification certificates and be familiar with the basic performance, operating specifications and safety protection requirements of this type of transport aircraft.； 2. On-site commanders and rope handlers must hold certificates to work and have the ability to command and coordinate power maintenance and lifting operations. ； 3. A safety technical briefing must be completed before the operation and written records must be formed to ensure that all participants understand the operation tasks, risk points and prevention and control measures.

2. Basic understanding of equipment

2.1 Core technical parameters

Taking a common 200KG electric maintenance transport aircraft as an example, the core parameters are as follows: - Rated load capacity: 200KG (overload operation is strictly prohibited) ； - Maximum lifting height: adapted to the conventional maintenance height of power pole towers (specifically, please refer to the equipment manual) ； - Power parameters: usually 12V/60Ah maintenance-free battery, power 0.8KW (different models vary slightly) ； - Safety protection: Equipped with overload protector, limit switch, low voltage alarm and other devices ； - Applicable environment: It can operate at an altitude of ≤6000 meters and without strong winds above level 6 (operating is prohibited in bad weather).

2.2 Key components and functions

1. Main frame: carries heavy objects and the weight of the equipment itself. It must be ensured that the connections are tight and there is no deformation or damage.； 2. Lifting system: including motor, wire rope/insulated sling, drum, pulley, etc., responsible for lifting and lowering heavy objects. The motor must have stable start and stop performance, and the wire rope must comply with GB/T5972 standard ； 3. Control system: including operating buttons, remote controls, and limit switches to control the lifting and movement of equipment. The buttons must be sensitive and reliable, and the limit switches must be calibrated regularly. ； 4. Walking system: It adopts PU wheel or crawler design to ensure the stability of traffic in different terrains. The minimum turning radius is usually 1200mm. ； 5. Braking system: To ensure the stable parking of heavy objects and prevent sliding, the braking gap must be maintained at 0.3-0.5mm.

3. High-altitude lifting operation process

3.1 Preparation before operation

1. Plan preparation and approval: Prepare a special hoisting operation plan based on the weight, specifications, operating height and on-site terrain of the lifted materials. Unconventional operations require expert demonstration and can only be implemented after approval.； 2. On-site survey: Check the terrain bearing capacity of the working area, the smoothness of the access road, check for surrounding obstacles, and focus on confirming the safe distance from overhead transmission lines (the minimum safe distance for 1-35KV lines is not less than 3 meters, and the 110KV line is not less than 4.1 meters) ； 3. Equipment inspection:   - Mechanical components: Check the tightening of the frame bolts, the wire rope is not broken or worn, the pulley rotates flexibly, and the thickness of the brake pad meets the requirements (the wear does not exceed 50%) ；   - Electrical system: Use a multimeter to measure the power supply voltage (needs to be within ±10% of the rated voltage), check that the line insulation resistance is ≥0.5MΩ, that the wiring is not loose, aged or damaged, and that the contactor operates normally ；   - Safety devices: Test whether the overload protector, limit switch, and low-voltage alarm functions are sensitive and reliable ； 4. Preparation of materials and tools: Check the weight of the materials to be lifted to ensure that the rated load is not exceeded, prepare qualified binding rigging, padding, communication tools (such as walkie-talkies), and emergency rescue equipment.

3.2 On-site layout and debugging

1. Park the equipment: Park the transport aircraft on a flat, solid ground. Wheeled equipment needs to be firmly adjusted with outriggers. Tracked equipment needs to ensure stable grounding and avoid tilting during operation.； 2. Safety warning: Set up cordons and warning signs in the work area to prohibit unauthorized persons from entering. A red light warning must be hung for night operations. ； 3. Equipment debugging: Test the lifting and moving functions of the equipment under no-load conditions, check the reliability of the braking system, adjust the signal strength of the remote control, and ensure timely operation response. ； 4. Personnel in place: Clear division of responsibilities among operators, commanders, and guardians. Commanders should stand in a safe position upwind to ensure clear lines of sight and clear communication with operators.

3.3 Bundling and lifting operations

1. Material bundling:   - Choose the appropriate binding method according to the shape and weight of the materials. Angular objects need to be padded to prevent damage to the rigging. ；   - The angle of the rigging should not exceed 120°, and the binding must be firm to avoid loosening and slipping during lifting. A special bucket must be used for bulk materials. ；   - Ensure that the binding point is above the center of gravity of the material to ensure a balanced lifting process without the risk of tilting ； 2. Trial lifting inspection:   - Instruct the operator to slowly lift the heavy object and stop when it reaches 10-20cm above the ground. Check the stress of the rigging, the braking performance of the equipment, and the balance status of the materials. ；   - After confirming that there is no abnormality, the commander will send a lifting signal, and the operator will operate the equipment smoothly to lift. ； 3. High-altitude lifting:   - The lifting process is uniform and slow to avoid emergency stops and sudden rises to prevent impact loads from damaging equipment or materials. ； - During the lifting process, the height of heavy objects from the ground should not be too high, and it is strictly prohibited to pass over people. Monitoring personnel should observe the operating status throughout the process. ；   - Lifting is carried out according to the predetermined route, avoiding obstacles and dangerous areas, and the commander coordinates in real time through flags or walkie-talkies.

3.4 Accurate delivery and uninstallation

1. Drop point positioning: When the heavy object is transported above the target position, it slowly descends, and the commander accurately guides it to ensure the accurate drop point.； 2. Unload smoothly: After the heavy object touches the ground, check whether it is stable. If you need to adjust the position, do so gently to avoid hitting the tower or other equipment. ； 3. Rigging removal: After confirming that the heavy object is completely stable and the load-bearing weight is relieved, a dedicated person will remove the binding rigging. The removal process must be slow and orderly to prevent the rigging from bouncing and injuring people.

3.5 Cleaning up after work

1. Equipment reset: Move the transporter to a safe parking area, turn off the power, organize the wire ropes and rigging, and ensure that the equipment is in standby mode； 2. On-site cleaning: Clean tools, padding, etc. in the working area, and remove cordons and warning signs. ； 3. Record and archive: Fill in the operation record form, record the operation time, material weight, equipment operating status, fault conditions, etc. in detail, and organize and archive it for retention.

4. Safety operating regulations

4.1 General safety requirements

1. Strictly implement the "Ten Don'ts" regulations for lifting: Do not lift if the command signal is unclear, do not tie up tightly, do not lift if the safety device is faulty, do not lift if the line of sight is unclear, do not lift angular objects without protection, do not lift if they are overloaded, do not lift if there are people on the hook, do not lift if the object is unknown to be buried, do not lift obliquely pulled objects, do not lift in bad weather (heavy rain, heavy snow, heavy fog, strong winds above Level 6)； 2. During the operation, no personnel are allowed to stay or walk under heavy objects, and no heavy objects are allowed to be suspended in the air for a long time. ； 3. It is strictly forbidden to directly correct the tensioned rigging with your hands. If you find any abnormality in the rigging or abnormal noise in the equipment during lifting, stop immediately for inspection. ； 4. When multiple pieces of equipment are working together, they need to be led by a professional and technical person in charge to ensure that the distance between the equipment is reasonable and to avoid collisions.

4.2 Special requirements for working at heights

1. Lifting materials must keep a safe distance from overhead transmission lines. It is strictly prohibited to work directly under the lines. The lifting arm must be lowered when the equipment passes near the lines.； 2. When operating in mountainous areas, attention should be paid to the slope of the terrain to avoid equipment rollover, and temporary support platforms should be built if necessary. ； 3. When dropping materials at high altitude, make sure there are no people around the drop point, and set up protective measures below the drop area to prevent materials from falling and injuring people.

4.3 Equipment safety maintenance requirements

1. Check key components such as wire ropes, brakes, and motors regularly every month. Replace them immediately if the wire ropes are broken or severely worn.； 2. Add grease to bearings, gears, chains and other components according to the equipment manual period to keep the components running flexibly. ； 3. Regularly check the insulation performance of electrical circuits to avoid leakage caused by moisture and aging. The battery needs to be charged and maintained regularly to maintain sufficient power.

5. Common faults and solutions

5.1 Electrical system failure

1. The motor does not start or runs weakly:   - Possible reasons: power supply phase loss, unstable voltage, incorrect wiring, burned motor windings or damaged bearings, overload protection triggered ；   - Treatment method: Use a multimeter to measure the voltage and line continuity, repair the broken line or correct the wiring. ； Test the motor insulation resistance. If the winding is burned out, the motor needs to be replaced. ； Check the overload protector and restart after reset ； 2. Equipment trips frequently:   - Possible reasons: line leakage, short circuit, excessive voltage fluctuation, improper selection or aging of the air switch ；   - Treatment method: Use a megger to check the insulation performance of the line and repair leakage or short circuit points. ； Measure the stability of the power supply voltage and equip with voltage stabilizing equipment if necessary ； Check the switch specifications and replace the aging switch.

5.2 Mechanical system failure

1. Braking system failure (heavy object slides down): - Possible reasons: excessive brake pad wear, spring failure, excessive brake clearance, and oil stains on the brake wheel ；   - Treatment method: Replace the brake pad or spring, adjust the brake gap to the standard value, and clean the oil on the surface of the brake wheel. ； 2. The wire rope is worn or changed:   - Possible reasons: metal fatigue, insufficient lubrication, pulley deflection, overload operation ；   - Treatment method: Replace the excessive wire rope and add special grease regularly ； Correct pulley position to ensure wire rope alignment ； Verify the load, overloading is strictly prohibited ； 3. The drum or pulley is stuck:   - Possible reasons: bearing damage, wire rope winding disorder, rusty components ；   - Treatment method: Replace the damaged bearing and rearrange the wire rope ； Clean parts of dirt and add grease.

5.3 Operation process failure

1. Tilt of heavy object:   - Possible reasons: The binding point deviates from the center of gravity and the length of the rigging is uneven. ； - Treatment method: Stop lifting immediately, lower the heavy object slowly, readjust the binding point, and ensure the center of gravity is balanced before working again ； 2. The remote control signal is interrupted:   - Possible reasons: signal interference, too far distance, low battery power ；   - Treatment method: Stop working immediately and put down the heavy objects smoothly ； Replace the battery of the remote control, adjust the working position to avoid interference sources, and shorten the operating distance.

6. Emergency measures

1. Equipment failure causes heavy objects to hover: immediately activate the emergency plan, set up a warning area, and strictly prohibit people from approaching； Organize professional maintenance personnel to troubleshoot the fault. If on-site repair cannot be performed, use backup equipment for rescue and slowly transfer heavy objects. ； 2. Risk of equipment rollover or material falling: Operators should stop operating immediately and evacuate to a safe area ； Commanders organize the evacuation of surrounding people and set up a warning range ； Activate emergency rescue equipment according to the situation to avoid accident expansion ； 3. In case of personal injury: Stop work immediately and call emergency number ； Provide preliminary treatment to the injured, protect the accident scene, investigate the cause of the accident, and avoid secondary injuries.

7. Supplementary Provisions

1. For matters not covered in this tutorial, you must strictly abide by relevant national standards such as "Safety Code for Hoisting Machinery" and "Safety Work Procedures for Electric Power Construction"； 2. Equipment operation must be based on the instructions of the corresponding model. This tutorial is a general guide. If equipment from different manufacturers has special requirements, priority should be given to following the manufacturer's specifications. ； 3. This tutorial needs to be regularly improved based on equipment updates, standard revisions and operating experience to ensure guidance and timeliness.