A maintenance method for online replacement of crane end beam

Abstract

The invention provides an inspection and maintenance method for online replacement of a crane end beam, which relates to the technical field of bridge cranes and comprises the following steps: making a set of jacking tools according to the horizontal elevation of the crane main beam from the ground; collecting data to find out the longitudinal, transverse reference lines and vertical center lines of the crane inspection and maintenance, fixing the three reference lines with steel wires to form measurement standard data; obtaining the crane diagonal data, the parallelism data of the main beams on both sides of the end beams on both sides, and the end beam fixing angle data, moving the jacking tool to the opposite side of the replaced end beam, jacking up the main beam and leveling it; cutting off the end beam on one side of the main beam and hoisting it off the line; the invention uses the jacking tool and determines the longitudinal, transverse reference lines and vertical center lines during the inspection and maintenance process, and uses these references as references to determine the standard range of alignment of the new end beam, performs spot welding and fixation, and fully welds the end beam, thereby overcoming the difficulties of off-line replacement and inspection of the crane end beam, and achieving short crane maintenance time and low cost.

Description

Technical Field

[0001] The invention relates to the technical field of bridge cranes, and in particular to a maintenance method for online replacement of a crane end beam. Background Art

[0002] Bridge crane is a special equipment for heavy industry production. The main load-bearing parts of the crane are: main beam, end beam, crane wheels, etc., which form a load-bearing frame. Therefore, the inspection and replacement of the end beam is very important for the stable operation of the crane's load-bearing structure.

[0003] Traditional replacement technology is mainly offline replacement, which requires dismantling the factory roof, crane trolley mechanism, crane electrical control system, manufacturing tooling platform, dismantling the crane bearing system, etc. The maintenance time is long and there are many factors affecting the quality. Moreover, after the machine is offline, the maintenance environment and maintenance site requirements are relatively high. It is impossible to calibrate the vehicle diagonal horizontal data, wheel vertical center line, wheel parallelism, etc. in combination with the operating conditions of the crane. After maintenance, the crane needs to be dismantled again and transported in reverse. At the same time, it is easy to cause secondary errors in the maintenance data, which is not conducive to efficient and high-quality maintenance of the crane end beam. Therefore, the present invention proposes a maintenance method for online replacement of the crane end beam to solve the problems existing in the prior art. Summary of the invention

[0004] In view of the above problems, the present invention proposes a maintenance method for online replacement of crane end beams, which adjusts the main technical data of the crane, adopts corresponding auxiliary equipment and facilities, removes the old end beam of the crane and restores the factory data of the crane to ensure that the main parameter data of the crane is restored to within the qualified standard range after the new end beam is installed.

[0005] To achieve the purpose of the present invention, the present invention is implemented by the following technical scheme: a maintenance method for online replacement of a crane end beam, comprising the following steps:

[0006] Make a set of lifting tools according to the horizontal elevation of the crane main beam from the ground;

[0007] Collect data to find the longitudinal, transverse reference lines and vertical center line of the crane maintenance, fix the three reference lines with steel wires to form measurement standard data;

[0008] Obtain the crane diagonal data, the parallelism data of the main beams on both sides of the end beams, and the fixed angle data of the end beams, move the crane trolley to the opposite side of the replaced end beam, and use the lifting tool to lift the main beam and level it;

[0009] Cut off the end beam on one side of the main beam, hoist it off the line, put the new end beam on the line and align it within the standard range according to the reference, spot weld it and fix it, and fully weld the end beam;

[0010] Cut off the end beam on the other side of the main beam, hoist it off the line, put the new end beam on the line and align it within the standard range according to the reference, spot weld it, fully weld the end beam, and install the end beam connecting pin shaft;

[0011] After the replacement is completed, remove the lifting tooling and restore the main parameter data of the crane to the factory data standard.

[0012] Further improvement is: seamless steel pipe is selected for the jacking tooling, channel steel scissors struts are installed on the inner side of the seamless steel pipe to form the tooling, and then steel plates are used to seal the upper and lower surfaces of the tooling.

[0013] Further improvement lies in finding the longitudinal reference line for crane maintenance. Specifically, the crane is parked at a position where the track flatness is higher, and the track elevation is used as the reference point. The method of multi-point measurement and averaging is implemented to measure the track elevation as the longitudinal reference line for the maintenance measurement data, which is used as the reference standard for the crane main beam lifting and end beam fixing.

[0014] Further improvement lies in finding the horizontal reference line for crane maintenance, specifically: using a total station to measure the vertical intersection of the span between tracks and the longitudinal reference line, as the horizontal reference line for crane maintenance, which is used for measuring the diagonal data of the intersection of the main beam and the end beam.

[0015] Further improvement is to find the vertical center line of the crane, specifically: use a total station to measure the vertical center line of the longitudinal reference line and the horizontal reference line, which is used as a reference for the vertical and parallel installation of the crane end beam.

[0016] Further improvement lies in: looking up the crane factory manual, determining the crane diagonal data, the parallelism data of the main beams on both sides of the end beams, and the end beam fixing angle data.

[0017] Further improvement is to move the jacking tool to the opposite side of the replacement end beam, jack up the main beam and level it. Before that, the ground under the jacking tool is compacted and then paved with steel plates.

[0018] A further improvement is that the full welding of the end beam adopts opposite reverse section welding to prevent stress from being generated during the welding process.

[0019] The beneficial effects of the present invention are:

[0020] 1. The present invention uses the jacking tooling and determines the longitudinal, transverse reference lines and vertical center lines during the maintenance process. This reference is used as a reference to determine the standard range for aligning the new end beam, and spot welding and full welding of the end beam are performed, thereby overcoming the difficulties in replacing and overhauling the crane end beam offline, and achieving short crane maintenance time and low cost.

[0021] 2. The present invention solves the problems of dismantling the roof, reversing the crane offline, dismantling the electrical control system, secondary errors in the crane body data caused by reversing, and secondary assembly after the end beam is replaced, and reduces the risk of secondary damage to the crane beam caused by the reversing process, thereby ensuring the quality of maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a flow chart of the present invention;

[0023] Figure 2 It is a schematic diagram of the jacking tooling of the present invention. DETAILED DESCRIPTION

[0024] In order to deepen the understanding of the present invention, the present invention will be further described in detail below in conjunction with examples. The examples are only used to explain the present invention and do not constitute a limitation on the protection scope of the present invention.

[0025] Embodiment 1

[0026] according to Figure 1 , 2 As shown, this embodiment proposes a maintenance method for online replacement of a crane end beam, comprising the following steps:

[0027] Make a set of lifting tools according to the horizontal elevation of the crane main beam from the ground;

[0028] Collect data to find the longitudinal, transverse reference lines and vertical center line of the crane maintenance, fix the three reference lines with steel wires to form measurement standard data;

[0029] Obtain the crane diagonal data, the parallelism data of the main beams on both sides of the end beams, and the fixed angle data of the end beams, move the crane trolley to the opposite side of the replaced end beam, and use the lifting tool to lift the main beam and level it;

[0030] Cut off the end beam on one side of the main beam, hoist it off the line, put the new end beam on the line and align it within the standard range according to the reference, spot weld it and fix it, and fully weld the end beam;

[0031] Cut off the end beam on the other side of the main beam, hoist it off the line, put the new end beam on the line and align it within the standard range according to the reference, spot weld it, fully weld the end beam, and install the end beam connecting pin shaft;

[0032] After the replacement is completed, remove the lifting tooling and restore the main parameter data of the crane to the factory data standard.

[0033] Embodiment 2

[0034] according to Figure 1 , 2 As shown, this embodiment proposes a maintenance method for online replacement of a crane end beam, comprising the following steps:

[0035] The jacking tooling is made of seamless steel pipes, and channel steel scissor braces are installed inside the seamless steel pipes to form the tooling, and then steel plates are used to seal the upper and lower surfaces of the tooling. Specifically: DN350 seamless steel pipes, selected according to the height of the crane, with a screw jack below to adjust the height; 5# channel steel scissor braces; 500mm*500mm*10mm steel plates.

[0036] Find out the longitudinal reference line for crane maintenance, specifically: park the crane at a location where the track is relatively flat, use the track elevation as the reference point, and measure the track elevation by taking the average value at multiple points. This will serve as the longitudinal reference line for the maintenance measurement data, which will be used as a reference standard for lifting the crane's main beam and fixing the end beam.

[0037] Find out the horizontal reference line for crane maintenance. Specifically, use a total station to measure the vertical intersection of the span between the tracks and the longitudinal reference line, which is used as the horizontal reference line for crane maintenance and is used to measure the diagonal data of the intersection of the main beam and the end beam.

[0038] Find the vertical center line of the crane, specifically: use a total station to measure the vertical center line of the longitudinal reference line and the transverse reference line, which will be used as a reference for the vertical and parallel installation of the crane end beam.

[0039] Taking a double-beam bridge crane as an example, look up the crane's factory manual to determine the crane's diagonal data, the parallelism data of the main beams on both sides of the end beams, and the end beam fixing angle data.

[0040] Move the crane trolley to the opposite side of the replaced end beam, use the jacking tool to jack up the main beam and level it. Before that, the ground under the jacking tool is compacted and then paved with steel plates.

[0041] Divide the end beams on each end of the main beam into ① and ② sides. First cut off the end beam on ① side of the main beam and hoist it off the line. Put the new end beam on the line and align it within the standard range with reference to the benchmark, fix it with spot welding, and fully weld the end beam (weld it with the opposite reverse section to prevent stress during welding). Then cut off the end beam on ② side of the main beam and hoist it off the line. Put the new end beam on the line and align it within the standard range with reference to the benchmark, fix it with spot welding, and fully weld the end beam (weld it with the opposite reverse section to prevent stress during welding). Install the end beam connecting pin. Replace the end beam at the other end in the same way.

[0042] After the end beam is replaced, the jacking tooling is removed, and the main parameter data of the crane is restored to the factory data standard according to the diagonal data of the crane, the parallelism data of the main beams on both sides of the end beams, and the fixed angle data of the end beams to meet the on-site use requirements.

[0043] Verification example:

[0044] The main data of the QL20-28A7 double-beam bridge crane before the end beam was replaced: the crane had rail gnawing, the main beam span difference was 7mm, the bridge frame diagonal deviation was 18mm, the height difference at the trolley track joint was 2mm, the end beam horizontal lateral bending was 13mm, and the wheel diagonal deviation was 16mm. After the inspection, the data was restored to the standard data: the rail gnawing phenomenon was eliminated, the beam span difference was 2mm, the bridge frame diagonal deviation was 2mm, the height difference at the trolley track joint was 0mm, the end beam horizontal lateral bending was 1mm, and the wheel diagonal deviation was 3mm.

[0045] The maintenance method for online replacement of the crane end beam uses the jacking tooling and determines the longitudinal, transverse reference lines and vertical center lines during the maintenance process. This reference is used as a reference to determine the standard range for aligning the new end beam, and spot welding and full welding of the end beam are performed. This overcomes the difficulties in offline replacement and maintenance of the crane end beam, reduces the auxiliary work such as electrical construction, large-scale transportation, dismantling and installation caused by the maintenance of the crane end beam, and achieves short time and low cost for crane maintenance, ensuring that the main force parameter indicators of the crane are restored to the standard range after the end beam is replaced, and meet the new vehicle use standards; at the same time, the implementation of online maintenance through this plan solves the problems of roof removal, offline transportation of the crane, removal of the electrical control system, secondary errors in the crane body data caused by transportation, and secondary assembly after the end beam is replaced, and reduces the risk of secondary damage to the crane beam caused by the transportation process, thereby ensuring the maintenance quality.

[0046] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A maintenance method for online replacement of crane end beams, characterized in that: The following steps are involved: Make a set of lifting tools according to the horizontal elevation of the crane main beam from the ground; Collect data to find the longitudinal, transverse reference lines and vertical center lines of the crane maintenance, and fix the longitudinal, transverse reference lines and vertical center lines of the crane maintenance with steel wires to form measurement standard data; Obtain the crane diagonal data, the parallelism data of the main beams on both sides of the end beams, and the fixed angle data of the end beams, move the crane trolley to the opposite side of the replaced end beam, and use the lifting tool to lift the main beam and level it; Cut off the end beam on one side of the main beam, hoist it off the line, put the new end beam on the line and refer to the measurement standard data to find it within the standard range, spot weld it and fix it, and fully weld the end beam; Cut off the end beam on the other side of the main beam, hoist it off the line, put the new end beam on the line and refer to the measurement standard data to align it within the standard range, spot weld it, fully weld the end beam, and install the end beam connecting pin shaft; After the replacement is completed, remove the lifting tooling and restore the main parameter data of the crane to the factory data standard.

2. The maintenance method for online replacement of a crane end beam according to claim 1 is characterized in that: The jacking tooling is made of seamless steel pipes, and channel steel scissors struts are installed on the inside of the seamless steel pipes to form the tooling, and then steel plates are used to seal the upper and lower surfaces of the tooling.

3. A maintenance method for online replacement of a crane end beam according to claim 2, characterized in that: Find out the longitudinal reference line for crane maintenance, specifically: park the crane at a location where the track is relatively flat, use the track elevation as the reference point, and measure the track elevation by taking the average value at multiple points. This will serve as the longitudinal reference line for the maintenance measurement data, which will be used as a reference standard for lifting the crane's main beam and fixing the end beam.

4. A maintenance method for online replacement of a crane end beam according to claim 3, characterized in that: Find out the horizontal reference line for crane maintenance. Specifically, use a total station to measure the vertical intersection of the span between the tracks and the longitudinal reference line, which is used as the horizontal reference line for crane maintenance and is used to measure the diagonal data of the intersection of the main beam and the end beam.

5. A maintenance method for online replacement of a crane end beam according to claim 4, characterized in that: Find the vertical center line of the crane, specifically: use a total station to measure the vertical center line of the longitudinal reference line and the transverse reference line, which will be used as a reference for the vertical and parallel installation of the crane end beam.

6. A maintenance method for online replacement of a crane end beam according to claim 5, characterized in that: Find the crane's factory manual to determine the crane's diagonal data, the parallelism data of the main beams on both sides of the end beams, and the end beam fixing angle data.

7. A maintenance method for online replacement of a crane end beam according to claim 6, characterized in that: Move the lifting device to the opposite side of the replaced end beam, lift the main beam and level it. Before that, the ground under the lifting device is compacted and then paved with steel plates.

8. A maintenance method for online replacement of a crane end beam according to claim 7, characterized in that: The full welding of the end beam adopts opposite reverse section welding to prevent stress from being generated during the welding process.

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