A special trolley tool for disassembling and assembling the seal of a water turbine governor servomotor

Abstract

This invention discloses a special pulley fixture for disassembling and replacing the seal of a turbine governor relay, belonging to the technical field of hydropower equipment maintenance tools. The fixture includes a track assembly, a pulley assembly, a relay, and a special lifting tool. The track assembly consists of two sets of parallel I-beam rails and channel steel connecting beams. The pulley assembly is slidably mounted on the track assembly via heavy-duty pulleys at the bottom. The relay is placed on top of the pulley assembly and fixed by the special lifting tool, which is rigidly connected to the pulley assembly. The pulley assembly is equipped with side guard plates and pads for auxiliary protection. This invention transforms traditional vertical lifting into horizontal sliding, eliminating the risk of lifting injuries at the source, simplifying maintenance procedures, improving work efficiency, and simultaneously providing comprehensive protection for the relay. It is easy to assemble and disassemble and is compatible with different models of relays, meeting the needs of safe, efficient, and low-damage maintenance in the turbine pit.

Description

Technical Field

[0001] This invention relates to the technical field of maintenance tools for hydropower equipment, specifically to a special pulley fixture for disassembling and replacing the seal of a turbine governor relay. Background Technology

[0002] The turbine governor relay is a core actuator of the speed control system. Its seals age and wear after long-term operation, requiring periodic replacement. Traditional relay seal replacement procedures have the following prominent problems: 1. Extremely high safety risks: In the narrow pit, multiple hand-operated hoists are required to lift the relay device weighing several tons, which poses a significant risk of lifting injuries. When the equipment cannot be lifted out of the pit, the lifting space is limited, further increasing the difficulty and risk of the operation.

[0003] 2. Low operational efficiency: Traditional processes rely on manual labor, the operation is complicated, and each seal replacement operation takes a long time, which seriously affects the unit's maintenance schedule.

[0004] 3. The equipment is susceptible to damage: During the hoisting process, the relay is prone to shaking and collisions, which can cause deformation of the shell and scratches on the sealing surface, increasing maintenance costs.

[0005] Currently, the industry lacks specialized sliding fixtures for replacing relay seals in machine pits, which fails to meet the needs for safe and efficient maintenance. Summary of the Invention

[0006] (a) Technical problems to be solved This invention addresses the shortcomings of existing technologies and aims to solve the problems of high risk, difficult operation in pits, low work efficiency, and easy damage to equipment in traditional operation methods.

[0007] (II) Technical Solution To achieve the above objectives, the technical solution adopted by the present invention is as follows: A special pulley fixture for disassembling and replacing the seal of a water turbine governor relay includes: The track assembly includes two sets of parallel I-beam rails, with a channel steel connecting beam fixedly connected between the two sets of I-beam rails. The trolley assembly slides on top of the track assembly; The relay unit is placed on top of the trolley assembly; Special lifting tools are fixedly installed on the outside of the relay.

[0008] Further details of the above technical solution: Four sets of mounting slots are symmetrically provided on the front and rear sides of the top of the trolley assembly. The inner cavity of the mounting slot is provided with threaded holes for the protective plate. The inner cavity of the mounting slot is provided with a side protective plate. The side protective plate is an L-shaped structure composed of a bottom horizontal plate and a top vertical plate. The horizontal plate is matched with the mounting slot. A stepped groove is provided on the top of the horizontal plate. The protective plate bolt is installed in the stepped groove and is screwed into the threaded hole of the protective plate. Heavy-duty pulleys that match the I-beam rail are installed at the four corners of the bottom of the trolley assembly. A lifting tool threaded hole is provided in the middle of the front and rear sides of the top of the trolley assembly.

[0009] Further details of the above technical solution: protective pads are placed at both the left and right ends of the top of the trolley assembly. The top of the protective pads is an arc shape that matches the relay, and the bottom of the protective pads is provided with an anti-slip rubber layer.

[0010] Further definition of the above technical solution: The special lifting tool includes two sets of symmetrically arranged support plates. The top and bottom of the support plates on the opposite side are symmetrically provided with clearance grooves. Lifting tool bolts that penetrate the two sets of support plates are installed in the clearance grooves. A lifting ring is fixedly installed on the top of one set of support plates.

[0011] Further details of the above technical solution: mounting bases are fixedly installed on the left and right sides of the bottom of the two sets of support plates that are far apart from each other. The top of the mounting base has a through mounting hole, and a lifting device mounting bolt is installed in the mounting hole. The lifting device mounting bolt is screwed into the threaded hole of the lifting device.

[0012] Further definition of the above technical solution: the side of the two sets of support plates that are close to each other is an arc-shaped structure that matches the shell of the relay.

[0013] Further limitations on the above technical solution: anti-slip rubber pads are attached and fixed to the side of the two sets of support plates that are close to each other.

[0014] Further limitations on the above technical solution: the heavy-duty pulley is a double-row deep groove ball bearing pulley, and the wheel surface of the heavy-duty pulley is adapted to the lower flange of the I-beam rail.

[0015] (III) Beneficial Effects Compared with the prior art, the present invention provides a special pulley tooling for disassembling and replacing the seal of a turbine governor relay, which has the following beneficial effects: The inherent safety is significantly improved: the traditional vertical hoisting is replaced by horizontal sliding operation, eliminating the risk of lifting injuries in the pit from the source, and the operation process is stable and controllable.

[0016] Maintenance efficiency is greatly improved: a single person can complete the horizontal movement, alignment and disassembly of the relay, simplifying the process, significantly shortening the operation time, and effectively extending the maintenance period of the compressor unit.

[0017] Equipment protection is more reliable: the special lifting tool fits precisely with the relay housing, and the anti-slip rubber pads and protective pads provide cushioning support to avoid shaking, bumps and scratches, and prevent housing deformation and damage to the sealing surface.

[0018] Easy to assemble and disassemble, and highly adaptable: It adopts a segmented modular structure, which can be quickly assembled and disassembled in the machine pit, and is suitable for the seal replacement and disassembly maintenance of different models of speed controllers and relays. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention without the relay, special lifting tool and protective pad installed; Figure 3 This is a schematic diagram of the structure of the present invention without the relay and special lifting tool installed; Figure 4 This is a schematic diagram of the installation state of the relay and special lifting device of the present invention; Figure 5 This is a schematic diagram of the track assembly structure of the present invention.

[0020] Among them, 1. Track assembly; 101. I-beam track; 102. Channel steel connecting beam; 2. Trolley assembly; 201. Mounting groove; 202. Threaded hole of guard plate; 203. Side guard plate; 204. Clearance groove; 205. Guard plate bolt; 206. Heavy-duty pulley; 207. Threaded hole of lifting tool; 3. Relay device; 4. Special lifting tool; 401. Support plate; 402. Clearance groove; 403. Lifting tool bolt; 404. Lifting ring; 405. Mounting seat; 406. Mounting hole; 407. Lifting tool mounting bolt; 5. Protective pad. Detailed Implementation

[0021] The following is in conjunction with the appendix Figure 1-5 The present invention will be described in further detail below.

[0022] Example: Figure 1-5 As shown in the figure, this embodiment discloses a special pulley fixture for disassembling and replacing the seal of a turbine governor relay, which solves the problems of high risk of vertical hoisting, difficult operation in the turbine pit, low work efficiency, and easy damage to equipment in traditional operation methods. The fixture specifically includes a track assembly 1, a pulley assembly 2, a relay 3, and a special lifting tool 4. The components work together to achieve safe and efficient disassembly and maintenance of the relay. The specific structure is as follows: The track assembly 1 includes two sets of parallel I-beam rails 101. The two sets of I-beam rails 101 are fixedly connected by a channel steel connecting beam 102 by welding to form an integral rigid track structure, which can effectively ensure the load-bearing capacity and stability of the track and prevent the track from deforming or shifting during the sliding process.

[0023] The trolley assembly 2 is slidably mounted on top of the track assembly 1. Four sets of mounting slots 201 are symmetrically opened on the front and rear sides of the top of the trolley assembly 2. The inner cavity of the mounting slot 201 is provided with a guard plate threaded hole 202. An L-shaped side guard plate 203 is detachably installed in the mounting slot 201. The side guard plate 203 is integrally formed by a bottom horizontal plate and a top vertical plate. Its bottom horizontal plate is adapted to the inner cavity of the mounting slot 201. A stepped groove is opened on the top of the horizontal plate. A guard plate bolt 205 is installed in the stepped groove. The guard plate bolt 205 passes through the stepped groove and is threadedly connected to the guard plate threaded hole 202 to achieve a firm fixation of the side guard plate 203. Heavy-duty pulleys 206 adapted to the I-beam rail 101 are installed at the four corners of the bottom of the trolley assembly 2 by bolts. A lifting tool threaded hole 207 is opened at the middle of the front and rear sides of the top of the trolley assembly 2 for connecting and fixing with a special lifting tool 4.

[0024] Pads 5 are placed on both the left and right ends of the top of the trolley assembly 2. The top of the pads 5 is an arc shape that matches the shape of the relay 3, which can achieve close support for the relay 3. The bottom of the pads 5 is provided with an anti-slip rubber layer, which can increase the friction between the pads 5 and the trolley assembly 2, prevent the pads 5 from shifting, and further play a role in buffering and shock absorption, avoiding direct contact between the bottom of the relay 3 and the trolley assembly 2 and causing scratches.

[0025] The special lifting tool 4 includes two sets of symmetrically arranged support plates 401. The top and bottom of the support plates 401 on the opposite side are symmetrically provided with relief grooves 402. Lifting tool bolts 403 are installed in the relief grooves 402, passing through the two sets of support plates 401. The two sets of support plates 401 can be clamped relative to each other by tightening the lifting tool bolts 403. The top of one set of support plates 401 is fixedly installed with a lifting ring 404 by welding, which facilitates the movement of the trolley assembly 2 by maintenance personnel.

[0026] On the left and right sides of the bottom of the two sets of support plates 401 that are far apart from each other, there are mounting bases 405. The top of the mounting base 405 has a mounting hole 406 that passes through the mounting base 405. The lifting device mounting bolt 407 is installed in the mounting hole 406. The lifting device mounting bolt 407 passes through the mounting hole 406 and is threadedly connected to the lifting device threaded hole 207 on the trolley assembly 2, so as to realize the rigid connection between the special lifting device 4 and the trolley assembly 2 and ensure that the relay 3 and the trolley assembly 2 move synchronously.

[0027] The side of the two sets of support plates 401 that are close to each other has an arc-shaped structure that matches the housing of the relay 3, which can achieve a tight fit with the housing of the relay 3 and improve clamping stability. The side of the support plates 401 that are close to each other is attached with anti-slip rubber pads, which can increase the friction between the support plates 401 and the housing of the relay 3, prevent the relay 3 from slipping, and avoid scratching the housing of the relay 3 during clamping.

[0028] The heavy-duty pulley 206 adopts a double-row deep groove ball bearing pulley, whose wheel surface is adapted to the lower flange of the I-beam rail 101. It has the characteristics of strong load-bearing capacity, low frictional resistance and smooth operation, which can ensure that the trolley assembly 2 drives the relay 3 to slide smoothly along the rail assembly 1, reducing the operating intensity of maintenance personnel.

[0029] The core working principle of this tooling is to transform the vertical hoisting of the relay 3 into horizontal sliding, thereby enabling the safe movement and disassembly for maintenance of the relay 3 in the confined space of the pit. The specific working process is as follows: 1. Track positioning and foundation support: Two sets of parallel I-beam rails 101 are assembled into an integral track foundation by channel steel connecting beams 102. According to the actual size of the maintenance station in the pit, the track assembly 1 is laid and fixed in a suitable position in the pit to provide a straight and rigid sliding path for the trolley assembly 2, ensuring that the trolley assembly 2 does not deviate or get stuck during movement.

[0030] 2. Trolley load-bearing and horizontal sliding: The trolley assembly 2 is mounted on the I-beam rail 101 via the heavy-duty pulleys 206 at the bottom. The fit between the pulleys and the rail is checked to ensure smooth sliding. Then, the relay 3 is placed on the protective pad 5 on top of the trolley assembly 2. The trolley assembly 2 bears the entire weight of the relay 3, eliminating the need for high-altitude lifting operations and thus eliminating the risk of lifting injuries in the pit from the source.

[0031] 3. Special lifting tool clamping and reliable fixation: Insert the two sets of arc-shaped support plates 401 of the special lifting tool 4 from both sides of the relay 3, so that the anti-slip rubber pads on the inner side of the support plates 401 are in close contact with the housing of the relay 3. Then tighten the lifting tool bolts 403 in the relief groove 402 so that the two sets of support plates 401 hug the housing of the relay 3. Then connect and fix the mounting base 405 of the special lifting tool 4 to the lifting tool threaded hole 207 of the trolley assembly 2 through the lifting tool mounting bolts 407, so that the relay 3, the special lifting tool 4 and the trolley assembly 2 form a whole, ensuring that the relay 3 does not shake, deviate or bump during the sliding process.

[0032] 4. Side guard plate and pad auxiliary protection: The side guard plate 203 is fixed in the mounting groove 201 of the trolley assembly 2 by the guard plate bolts 205. The top longitudinal plate of the side guard plate 203 forms a lateral limit, which can effectively prevent the relay 3 from accidentally shifting to the side during the sliding process. The arc-shaped pad 5 on the top of the trolley assembly 2 forms a flexible support for the bottom of the relay 3, further buffering and damping, avoiding direct contact between the sealing surface and flange surface of the relay 3 and the trolley assembly 2 to prevent scratches, and at the same time preventing the shell from deforming due to uneven force.

[0033] 5. Horizontal displacement and disassembly for maintenance: Maintenance personnel can use the lifting ring 404 on the special lifting tool 4 to pull or gently push the trolley assembly 2 and the relay 3 smoothly along the track assembly 1 to a position that is easy to disassemble and install the seal. During the entire process of seal replacement, end cover removal and piston extraction, the relay 3 is always in a horizontal support state, without the need for repeated lifting and flipping, which effectively simplifies the maintenance process, improves work efficiency, and at the same time achieves all-round protection for the relay 3 and reduces maintenance costs.

Claims

1. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay, characterized in that, include: The track assembly includes two sets of parallel I-beam rails, with a channel steel connecting beam fixedly connected between the two sets of I-beam rails. The trolley assembly slides on top of the track assembly; The relay unit is placed on top of the trolley assembly; Special lifting tools are fixedly installed on the outside of the relay.

2. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 1, characterized in that, The trolley assembly has four sets of mounting slots symmetrically opened on the front and rear sides of the top. The inner cavity of the mounting slot has threaded holes for the protective plate. The inner cavity of the mounting slot is equipped with a side protective plate. The side protective plate is an L-shaped structure composed of a bottom horizontal plate and a top vertical plate. The horizontal plate is matched with the mounting slot. The top of the horizontal plate has a stepped groove. The stepped groove is equipped with a protective plate bolt, and the protective plate bolt is screwed into the threaded hole of the protective plate. Heavy-duty pulleys that match the I-beam rail are installed at the four corners of the bottom of the trolley assembly. The middle of the front and rear sides of the top of the trolley assembly has threaded holes for the lifting device.

3. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 2, characterized in that, The top left and right ends of the trolley assembly are covered with pads. The top of the pads is an arc shape that matches the relay, and the bottom of the pads is covered with an anti-slip rubber layer.

4. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 3, characterized in that, The special lifting tool includes two sets of symmetrically arranged support plates. The top and bottom of the support plates on the opposite side are symmetrically provided with clearance grooves. Lifting tool bolts that pass through the two sets of support plates are installed in the clearance grooves. A lifting ring is fixedly installed on the top of one set of support plates.

5. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 4, characterized in that, On the left and right sides of the bottom of the two sets of support plates that are far apart from each other, there are mounting bases fixedly installed. The top of the mounting base has a through mounting hole, and the mounting bolt of the lifting device is installed in the mounting hole and screwed into the threaded hole of the lifting device.

6. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 5, characterized in that, The side of the two sets of support plates that are close to each other has an arc-shaped structure that matches the casing of the relay.

7. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 1, characterized in that, Anti-slip rubber pads are attached and fixed to the side of the two sets of support plates that are close to each other.

8. A special pulley fixture for disassembling and replacing the seal of a turbine governor relay unit according to claim 2, characterized in that, The heavy-duty pulley is a double-row deep groove ball bearing pulley, and the wheel surface of the heavy-duty pulley is adapted to the lower flange of the I-beam rail.

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