Sany Heavy Industry insists on zero defect quality management, pursues lean manufacturing and pays attention to every detail control in the production process. Every piece of equipment assembled from the production line has to undergo strict machine debugging, and after everything is confirmed to be correct, it is painted, put into storage and finally delivered to customers. The design and manufacturing concept of "no looseness, no oil leakage, no cracking and high reliability" and strict quality management system ensure that customers enjoy high-quality products. Sany Heavy Industry Equipment Quality Assurance System has 132 quality management and inspection personnel, including 12 quality experts and 20 engineers. It consists of quality management department, product inspection department, testing center and quality assurance department of subsidiaries such as fully mechanized mining, fully mechanized mining, mine car and hydraulic support. There are 4 large and medium-sized test sites, more than 20 kinds of test equipment and more than 2,000 pieces of testing instruments. Able to carry out material analysis, metallographic structure analysis, physical performance detection and flaw detection on metal materials; Carry out high and low temperature wet and hot life test, power frequency withstand voltage test, insulation performance test, cabinet vibration test, cabinet sealing test and mine electrical test on electrical devices; Carry out cylinder pressure test, reducer loading test, hydraulic component test and seal reliability test on equipment components; Walking, climbing, spraying, three-level load, cutting load and power detection were carried out on the assembled machine. Strict incoming inspection and parts testing ensure the quality of products, not only put an end to the phenomenon of unqualified product installation, but also greatly improve the reliability and safety of products. Perfect testing system and rigorous work style have become important means to ensure product quality. Let's introduce several major experiments. 1, vibration test of electric control cabinet Let's first know about the vibration test-bed of electric control cabinet: the test-bed of electric control cabinet consists of two AC variable frequency motors, frequency converters, anchoring clamps and vibration-damping bottom plates; Vibration tests can be carried out on various types of electric cabinets to eliminate the early looseness of electrical connectors and wiring bolts. So as to ensure the stability of the power system under actual industrial and mining conditions. This test can simulate extremely harsh working environment, such as great resistance and external impact when the equipment is running, so as to ensure that the electric control cabinet can work normally under various extreme conditions and its service life can meet the needs of customers. At the beginning of the test, install the electric cabinet on the vibration test bench, and there are at least three mounting bolts on the left and right doors of the electric cabinet, which are not in the same line, so as to ensure that the doors and the box body vibrate together; Adjust two motors and set the vibration frequency to 10~ 15Hz and the acceleration value to 15~20m/s2. The two motors run in reverse, and the vibration time shall not be less than one hour. After the test is completed, open the door to check the inside of the electrical cabinet: the electrical appliances on the guide rail should be installed firmly without looseness; All terminals must ensure that the connector is tight and the spring pad is horizontal. Check that the wiring shall not be loose or dropped; Check whether all wiring screws and bolts are loose. Electrical control cabinets that do not meet the above requirements will be reassembled and are not allowed to enter the next assembly line. 2. The withstand voltage test of the electric cabinet can detect the sealing performance of the cover plate, the left and right door panels, the air tightness of the weld and the withstand voltage of the box, and finally ensure that the explosion-proof performance of the electric cabinet meets the requirements of coal mine safety standards. The pressure test bench injects water into the box through the water pump, pressurizes and maintains the pressure according to the standard requirements, and observes whether there is any leakage in the box. Before pressing, check whether the weld has obvious defects such as porosity, slag inclusion and cracks. Then tighten all sealing surfaces, introduce water into the box, observe the water pressure gauge, keep the pressure at 65438±0.0 MPa, and keep the pressure for 65438 0 minutes, and observe all parts of the box to ensure no water seepage. 3. Cylinder pressing test The cylinder pressing test includes size detection, pressure resistance detection and flaw detection. 1. dimension detection: operate the test device, adjust the oil cylinder to the maximum stroke and minimum stroke respectively, and measure the maximum and minimum installation distance of the oil cylinder with vernier caliper. Calculate the cylinder stroke, compare it with the design requirements, and enter the next process only if it meets the standard. 2. Pressure test: stop the oil cylinder piston at the limit position, adjust the test pressure to 32Mpa, and keep the pressure for at least 3 minutes. Observe that the oil cylinder must not have any abnormal phenomena, such as leakage and permanent deformation. 3. Carry out flaw detection inspection on the piston rod and weld to see whether the material and weld are defective. 4. The three-level load test of roadheader is affected by the working environment, the running load of equipment will change, and the normal running equipment will also produce noise and temperature rise. Three-level load test can be used to test the stability of equipment under different loads. Connect the cutting spindle of the cutting part with the hydraulic dynamometer, and load the whole machine to 50% rated power for 2 hours, 75% 1 hour and 100% for half an hour respectively through the loading device. Observe the noise, oil tank temperature, cutting reducer temperature and sealing conditions. During the test, measure the temperature at the designated position every half hour. When 100% power is loaded, it should be recorded every 10 minute. During the test, the detected temperature should rise steadily, and the temperature rise should be calculated after each measurement. Once the allowable value is exceeded, the test shall be stopped immediately for inspection. 5. Climbing test of roadheader The underground roadway environment is complex, and the terrain conditions such as slope and curve will be encountered when the machine is driving. In order to test the stability of roadheader climbing on site, the whole machine climbing test was carried out. At present, our company has two roadheader climbing test sites, one of which is a slope changing test site, which can adjust the slope according to the actual requirements, monitor the temperature changes of various parts of roadheader climbing in real time through thermal imaging devices, and automatically collect and generate test data for technicians to analyze. The indoor rock climbing experimental field is designed to be 25m long, with a maximum slope of 26 degrees, and the surface is covered with ordinary soil, with a thickness of1.5m.. According to the requirements higher than the design, start the machine to move back and forth for 40 times in the climbing test site, and start the star wheel, the first transport and the cutting part to sweep left and right at the same time, and the height from the ground will increase by100-200mm each time; Record the temperature change during the test, and there is no leakage in the hydraulic system after the test. 6. Spray test sprayer of roadheader is an important part of dust removal system. Whether the work is normal or not affects the dust removal effect, and then directly affects the tunneling efficiency. So every machine has to go through the dust collector inspection. Start the machine, adjust the external spray pressure to 1.5Mpa, adjust the internal spray pressure to 3Mpa, and rotate the cutting head for spraying. Observe the water mist sprayed by water mist and nozzles. Should be greater than 1.5m, the nozzle is not blocked and sprayed evenly.