A method for installing a quantum electric furnace electrode lifting system

Abstract

The application discloses a kind of installation methods of quantum electric furnace electrode lifting system, including the adjustment range value of the eccentric shaft of guiding seat roller and zero point, upper rack leveling, upper and lower guiding seat installation correction, upper intermediate guiding seat disassembly, ground assembly electrode lifting support seat and its hoisting, upper intermediate guiding seat reset installation, ground assembly lifting column and lifting hydraulic cylinder and its hoisting correction 11 installation steps.Eccentric shaft of guiding seat roller is measured in advance in the installation method, can effectively eliminate the cumulative error generated in positioning and welding process, ensure the plumbness of electrode lifting column and the contact between guiding wheel and electrode lifting column in adjustable range;Multi-step ground assembly reduces installation height, facilitates measurement adjustment, effectively ensures installation precision, improves installation efficiency and construction safety;The installation and disassembly steps of intermediate guiding seat solve the problem that electrode lifting support is difficult to weld in conventional installation method.

Description

Technical Field

[0001] This invention relates to the field of metallurgical equipment construction technology, and more specifically, to an installation method for a quantum electric furnace electrode lifting system. Background Technology

[0002] The quantum electric arc furnace (QA) is a new type of smelting equipment used in large-scale steel enterprises to automate the steelmaking process. The QA features a scrap trough equipped with a lifting system, siphon-type slag-free discharge, flexible furnace shell installation, tilting, and replacement, and an innovative waste gas treatment system, reducing production costs by approximately 20%. Theoretically, the average smelting cycle of a QA is ≤40 minutes, with power consumption of 280 kWh / t and electrode consumption of 0.9 kg / t, shortening the smelting cycle by 30% compared to a conventional electric furnace. For the same specifications, a QA increases annual steel production by 53% and scrap steel consumption by 58% compared to a conventional electric furnace, while improving scrap steel recovery rate by 3-4%. The QA is a key piece of equipment in the short-process steelmaking production process, aligning with national industrial policy guidelines. However, the installation process for QA is currently in the exploratory stage, and the optimal installation method needs to be found.

[0003] like Figure 1 As shown, the electrode lifting system of a quantum electric furnace comprises numerous individual components, including the upper frame, electrode guide seats, rotary bearings, motor lifting supports, lifting columns, and lifting cylinders. The relative positions of these individual components are closely spaced, and the installation sequence must be determined based on on-site welding and ease of installation and adjustment. Conventional installation methods would prevent some components from being properly positioned, resulting in rework. Therefore, developing a precise positioning and installation method for the quantum electric furnace electrode lifting system, while also facilitating safe construction, has become a pressing technical challenge. Summary of the Invention

[0004] Due to the aforementioned defects in the existing technology, the present invention provides an installation method for a quantum electric furnace electrode lifting system to solve the problems of some equipment failing to be installed in place and easy rework caused by conventional installation methods.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A method for installing a quantum electric furnace electrode lifting system, characterized by comprising the following steps:

[0007] Step S1: Determine the adjustment range of the eccentric shafts of all guide seat rollers used for the guide electrode, and determine and mark the middle position of the roller eccentric shafts;

[0008] Step S2: Using the connection surface between the upper frame and the rotary bearing as a reference, level the upper frame on the ground, and set the center frame according to the geometric center of the frame, and weld it to the frame;

[0009] Step S3: Using the center frame, install and calibrate the three upper guide seats of the upper frame on the ground. The upper guide seats No. 1 and No. 3 on both sides are welded and fixed to the upper frame, and the upper guide seat No. 2 in the middle is positioned by a stop block.

[0010] Step S4: Install the lower guide seat corresponding to the upper guide seat on the ground, and after the rollers of the upper and lower guide seats are vertically aligned, weld and fix the lower guide seat to the frame.

[0011] Step S5: Remove the No. 2 upper guide seat, and retain the positioning block (1120) for reinstallation and positioning of the No. 2 upper guide seat;

[0012] Step S6: The electrode lifting support (4) is temporarily placed and fixed under the frame according to the installation direction;

[0013] Step S7: After hoisting the upper frame, use connecting bolts to fasten the rotary bearing (3) and the upper frame (2); position and align the upper frame (2) and the electrode lifting support (4), and weld the upper frame (2) and the electrode lifting support (4);

[0014] Step S8: The No. 2 upper guide seat is reset and welded to the upper frame;

[0015] Step S9: Assemble the lifting column and lifting hydraulic cylinder on the ground;

[0016] Step S10: Adjust the eccentric shafts of all guide rollers so that the rollers move outward by 1 to 2 mm. The lifting column and lifting hydraulic cylinder are hoisted by passing through the guide seat as a whole.

[0017] Step S11: Adjust all guide rollers to make the lifting column vertical and in good contact with the guide rollers.

[0018] The installation method of the quantum electric furnace electrode lifting system provided by this invention pre-determines the adjustment range value of the eccentric shaft of the electrode guide seat roller and determines the intermediate position, which can effectively eliminate the cumulative error generated during positioning and welding, and ensure that the plumbness of the electrode lifting column and the contact between the guide wheel and the electrode lifting column are within the adjustable range; the multi-step ground assembly reduces the installation height of the equipment, facilitates measurement and adjustment, effectively ensures installation accuracy, and improves installation efficiency and construction safety; the installation and removal steps of the intermediate guide seat solve the problem of difficult welding of electrode lifting supports in conventional installation methods.

[0019] Preferably, in step S2, the levelness is adjusted by adding or removing the adjusting shims between the temporary support legs of the frame and the frame using the three-point alignment method, so as to ensure that the levelness deviation of the upper frame is less than or equal to 0.05 mm / m.

[0020] Preferably, the correction of the upper guide seat in step S3 includes center position correction and levelness correction, with a center position allowable deviation of 0.5 mm and a levelness deviation less than or equal to 0.1 mm / m.

[0021] Preferably, in step S3, the stop block is positioned in three directions near the electrode side and is made of 20mm×20mm×50mm square steel.

[0022] Preferably, during the hoisting process in step S7, lifting lugs are symmetrically welded above the longitudinal center of the electrode lifting columns on the steel tapping side and slag tapping side of the upper frame. The position of the lifting lugs welded on the electrode lifting support should be consistent with the center of the lifting lugs on the upper frame. This feature ensures accurate positioning when the manual hoist lifts the electrode lifting support.

[0023] Preferably, in step S7, the center correction of the electrode lifting support is based on the upper guide seat, with an allowable center deviation of ±2mm, and an allowable vertical deviation of 1mm / m in any direction, and the total height range is less than 2mm.

[0024] Preferably, in step S7, the connecting bolts are tightened in three stages: the first stage with 30% preload, the second stage with 60% preload, and the third stage with 100% preload.

[0025] Preferably, the bolt tightening sequence in step S7 is as follows: the first and second tightenings are cross-symmetrical, and the third tightening is a clockwise rotation to pre-tighten each bolt individually.

[0026] Preferably, the contact between all guide rollers and the lifting column in step S11 is determined by the standard that a 0.03mm feeler gauge cannot be inserted.

[0027] Preferably, in step S11, the allowable deviation of the plumbness of the lifting column is 0.1 mm / m tilt from the electrode side to the frame side and the total height does not exceed 0.2 mm.

[0028] Compared with the prior art, the above invention has the following advantages or beneficial effects:

[0029] (1) It can effectively eliminate the cumulative error generated during positioning and welding, and ensure that the verticality of the electrode lifting column and the contact between the guide wheel and the electrode lifting column are within the adjustable range.

[0030] (2) Multi-step ground assembly reduces the installation height of the equipment, facilitates measurement and adjustment, effectively ensures installation accuracy, and improves installation efficiency and construction safety;

[0031] (3) The installation and removal steps of the intermediate guide seat solve the problem of difficult welding of electrode lifting support in conventional installation methods;

[0032] (4) The complete installation method has been tested on site and is highly operable.

[0033] This invention discloses an installation method for a quantum electric furnace electrode lifting system, comprising 11 steps: determining the adjustment range and zero point of the eccentric shaft of the electrode guide seat rollers; leveling the upper frame; fabricating tooling such as the center frame; installing and correcting the upper and lower guide seats; disassembling the upper intermediate guide seat; hoisting the upper frame; assembling and hoisting the electrode lifting support seat on the ground; resetting and installing the upper intermediate guide seat; and assembling and hoisting and correcting the lifting column and lifting hydraulic cylinder on the ground. The installation method pre-determines the adjustment range of the eccentric shaft of the electrode guide seat rollers to determine the intermediate position, effectively eliminating accumulated errors during positioning and welding, ensuring the plumbness of the electrode lifting column and the contact between the guide wheel and the electrode lifting column are within the adjustable range; multi-step ground assembly reduces the installation height of the equipment, facilitates measurement and adjustment, effectively ensures installation accuracy, and improves installation efficiency and construction safety; the installation and removal steps of the intermediate guide seat solve the problem of difficult welding of the electrode lifting support in conventional installation methods. Attached Figure Description

[0034] The invention, its features, shape, and advantages will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings. Like reference numerals denote like parts throughout the drawings. The drawings are not drawn to scale; their focus is on illustrating the gist of the invention.

[0035] Figure 1 This is an overall structural diagram of the quantum electric furnace electrode lifting system of the present invention;

[0036] Figure 2 This is a schematic diagram of the upper frame and guide seat assembly of the present invention;

[0037] Figure 3 This is a schematic diagram showing the position of the positioning block of the No. 2 upper guide seat of the present invention;

[0038] Among them, 11 is the upper guide seat, 12 is the lower guide seat, 111 is the No. 1 upper guide seat, 112 is the No. 2 upper guide seat, 113 is the No. 3 upper guide seat, 121 is the No. 1 lower guide seat, 122 is the No. 2 lower guide seat, 123 is the No. 3 lower guide seat, 1120 is the stop block, 2 is the upper frame, 20 is the temporary support leg, 21 is the center line frame, 3 is the rotary bearing, 31 is the frame base, 4 is the electrode lifting support seat, 5 is the lifting column, and 6 is the lifting hydraulic cylinder. Detailed Implementation

[0039] The structure of the present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the present invention.

[0040] Example

[0041] One such Figure 1 The on-site installation method of the quantum electric furnace electrode lifting system shown includes the following installation steps. Step S1: Determine the adjustment range of the eccentric shafts of all guide seat rollers used for the guide electrodes, and determine and mark the middle position of the roller eccentric shafts; specifically, fix the dial indicator measuring point on the horizontal mid-plane of the roller using a magnetic base, rotate the eccentric shaft one revolution and read the maximum value a and minimum value b of the dial indicator. At this time, ab = the maximum horizontal movement of the roller c, and c / 2 is the middle value of the horizontal movement of the roller, which is the roller "zero" point; rotate the eccentric shaft to move the roller in the horizontal direction, and the dial indicator reading is the middle value, which is the roller "zero" position. Make corresponding "zero" position scale lines on the guide seat and eccentric shaft, mark the rotation direction of the eccentric shaft and the horizontal movement direction of the roller, tighten the eccentric shaft locking cap bolt to lock the eccentric shaft, and the roller "zero" point adjustment is completed.

[0042] Step S2: Using the connection surface between the upper frame 2 and the rotary bearing 3 as a reference, level the upper frame 2 on the ground, and set the center frame 21 according to the geometric center of the frame, and weld it to the frame; specifically, use the three-point alignment method to adjust the levelness by adding or removing the adjusting shims between the temporary support legs 20 of the frame and the frame, so as to ensure that the levelness deviation of the upper frame is less than or equal to 0.05mm / m.

[0043] Step S3, as follows Figure 2 and Figure 3 As shown, using the center frame 21, three upper guide seats 11 of the upper frame are installed and aligned on the ground. Upper guide seats 1 and 3 on both sides are welded and fixed to the upper frame, while the middle upper guide seat 2 is positioned using a stop block 1120. Specifically, a reference center line is laid, and the center line is calibrated using the geometric center of the frame. A plumb line and oil cup are used for plumb line support, and a steel ruler is used to measure the tangent point and end face dimensions of the guide seat rollers. The guide seat positions are adjusted to meet the planar positions of the longitudinal and transverse centers of the guide seats, with an allowable deviation of 0.5mm. The levelness of the guide seats is adjusted by adding or removing shims between the guide seats 11 and the upper frame 2. The levelness is controlled within 0.1mm / m, with the upper surface of the guide seat as the reference. After the center and level of the guide seats meet the requirements, guide seats 111 and 313 are spot-welded to the frame. Guide seat 212 is fixed in place with a stop block 1120 to facilitate the removal of guide seat 112. The stop block is positioned on three sides of the electrode side. The stop block is made of 20×20×50mm square steel.

[0044] Step S4: Install the lower guide seat 12 on the ground, corresponding to the upper guide seat 11, and after the rollers of the upper and lower guide seats are vertical, weld and fix the lower guide seat 12 to the frame 2.

[0045] Step S5: After all six guide seats have been inspected and accepted, remove the No. 2 upper guide seat and retain the positioning block 1120 for reinstallation and positioning of the No. 2 upper guide seat.

[0046] Step S6: The electrode lifting support 4 is temporarily placed and fixed under the frame according to the installation direction;

[0047] Step S7: Clean the mating surfaces of the upper frame and the rotating bearing, remove burrs, and position according to the center mark. After hoisting the upper frame 2, use connecting bolts to tighten the rotating bearing 3 and the upper frame 2. Tighten the connecting bolts in three stages: first, 30% preload; second, 60% preload; third, 100% preload. The bolt tightening sequence is as follows: the first and second tightenings are symmetrical and cross-tightening, and the third tightening is clockwise rotation, tightening each bolt individually. After all bolts are preloaded to 60%, take one bolt and apply 80% preload to check if the bolt fails. If the bolt is fine, then all bolts can be preloaded to 100%. The electrode lifting support base 4 is aligned, and the upper frame 2 is welded to it. Specifically, after the upper frame 2 is hoisted and installed, lifting lugs are symmetrically welded above the longitudinal center of the electrode lifting columns 5 on the steel discharge side and slag discharge side of the upper frame. The position of the lifting lugs welded on the electrode lifting support base 4 should be consistent with the center of the lifting lugs on the upper frame. A 5t hand-operated hoist is installed on each side of the frame's lifting lugs for lifting the electrode lifting support base 4. After the electrode lifting support base 4 is in place, the center of the support base is aligned with the plumb bob using tools such as jacks, hand-operated hoists, and plumb bobs. Once the alignment meets the requirements, it is spot-welded firmly to the frame. The hand-operated hoists and other alignment measures are removed, and the installation accuracy is re-measured. After the alignment meets the requirements, it is welded according to the design requirements. The center alignment of the electrode lifting support base 4 is based on the upper guide seat 11 of the frame. The allowable center deviation is ±2mm, and the allowable deviation of the plumb bob in any direction is 1mm / m, with a total height range of less than 2mm.

[0048] Step S8: The No. 2 upper guide seat 112 is reset and welded to the upper frame 2; specifically, after the upper frame 2 is welded to the electrode lifting support seat 4 and passes the ultrasonic non-destructive testing, the No. 2 upper guide seat 112 is reset according to the original ground assembly and correction position. After checking that the contact condition of the stop block is the same as that of the ground assembly and correction, the No. 2 upper guide seat 112 is welded.

[0049] Step S9: Assemble the lifting column 5 and lifting hydraulic cylinder 6 on the ground. Specifically, place the electrode lifting column 5 flat on the storage bracket, with anti-slip rubber between the bracket and the electrode lifting column 5. When hoisting the lifting hydraulic cylinder 6, install two independently anchored hand-operated hoists between the two binding steel wire ropes and the crane hook. Each independent hand-operated hoist's lifting point bears the entire weight of the hydraulic cylinder. During binding, the two steel wire ropes are at a 30° angle. Use the hand-operated hoists to level the hydraulic cylinder, align it with the opening of the electrode lifting column, and insert it into the hydraulic cylinder. When the binding steel wire rope on the column side approaches the column, release the steel wire rope and hand-operated hoist, pulling the hydraulic cylinder piston rod outward. The change in the length of the piston rod pull causes a corresponding change in the lifting center of gravity of the hydraulic cylinder. The two binding steel wire ropes are alternately replaced, and the hydraulic cylinder is smoothly inserted into the electrode lifting column. Install the suspension device, and finally push the hydraulic cylinder piston rod in. After completion, install anti-slip devices at the ends of the electrode lifting column and the hydraulic cylinder piston rod.

[0050] Step S10: Adjust the eccentric shafts of all guide rollers to move the rollers outward by 1 to 2 mm. The lifting column 5 and the lifting hydraulic cylinder 6 are hoisted by passing through the guide seats as a whole. Specifically, after the electrode lifting column 5 and the hydraulic cylinder 6 are assembled on the ground, the eccentric shafts of the guide seat electrode rollers are adjusted before installation to move the rollers outward by 1 to 2 mm, so that the electrode lifting column can be smoothly inserted. Then, the main and auxiliary hooks of the workshop crane are used to simultaneously flip and erect the lifting column assembly in the air. The whole assembly is installed in the electrode support part by passing through the guide seat. The main hook is hoisted into place. A hand-operated hoist is set between the main hook and the steel wire rope binding the lifting column for adjusting the column plumbness. The auxiliary hook is used for the flipping auxiliary operation. An angle wrapping and anti-slip hand-operated hoist is set at the steel wire rope binding point of the auxiliary hook to prevent the steel wire rope from slipping when flipping and erecting.

[0051] Step S11: Adjust all guide rollers to ensure the lifting column 5 is vertical and in good contact with the guide rollers. Specifically, adjust the eccentric shaft of the electrode-side rollers to move the rollers towards the column. Use a 0.03mm feeler gauge to check the contact between all guide rollers and the column. If the feeler gauge cannot be inserted, it meets the standard. Use a 0.02mm / m frame-type horizontal guide rail to check the verticality of the lifting column. The allowable deviation is an inclination of 0.1mm / m from the electrode side to the frame side and a total height not exceeding 0.2mm to ensure the verticality of the electrode.

[0052] In summary, this application provides an installation method for a quantum electric furnace electrode lifting system, comprising 11 steps: determining the adjustment range and zero point of the electrode guide roller eccentric shaft; leveling the upper frame; fabricating tooling such as the center frame; installing and correcting the upper and lower guide seats; disassembling the upper intermediate guide seat; hoisting the upper frame; assembling and hoisting the electrode lifting support seat on the ground; resetting and installing the upper intermediate guide seat; and assembling and hoisting the lifting column and lifting hydraulic cylinder on the ground. This installation method pre-determines the adjustment range of the electrode guide roller eccentric shaft to determine the intermediate position, effectively eliminating accumulated errors during positioning and welding, ensuring the plumbness of the electrode lifting column and the contact between the guide wheel and the electrode lifting column are within the adjustable range; multi-step ground assembly reduces the installation height of the equipment, facilitates measurement and adjustment, effectively ensures installation accuracy, and improves installation efficiency and construction safety; the installation and removal steps of the intermediate guide seat solve the problem of difficult welding of the electrode lifting support in conventional installation methods. The entire installation method has been practically tested in the field and is highly operable.

[0053] Those skilled in the art should understand that variations can be implemented by combining existing technology with the above embodiments, which will not be elaborated here. Such variations do not affect the essence of the present invention, and will not be elaborated here either.

[0054] The preferred embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and the devices and structures not described in detail should be understood as being implemented in a conventional manner in the art. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the present invention. This does not affect the essential content of the present invention. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the present invention's technical solutions still fall within the protection scope of the present invention.

Claims

1. A method for installing a quantum electric furnace electrode lifting system, characterized in that, Includes the following steps: Step S1: Determine the adjustment range of the eccentric shafts of all guide seat rollers used for the guide electrode, and determine and mark the middle position of the roller eccentric shafts; Step S2: Using the connection surface between the upper frame (2) and the rotary bearing (3) as a reference, level the upper frame (2) on the ground, and set the center frame (21) according to the geometric center of the frame, and weld it to the frame; Step S3: Using the center frame (21), install and correct the three upper guide seats (11) of the upper frame on the ground. The upper guide seats No. 1 and No. 3 on both sides are welded and fixed to the upper frame, and the upper guide seat No. 2 in the middle is positioned by a stop block (1120). Step S4: Install the lower guide seat (12) corresponding to the upper guide seat on the ground, and after the rollers of the upper and lower guide seats are vertical, weld and fix the lower guide seat to the frame. Step S5: Remove the No. 2 upper guide seat, and retain the positioning block (1120) for reinstallation and positioning of the No. 2 upper guide seat; Step S6: The electrode lifting support (4) is temporarily placed and fixed under the frame according to the installation direction; Step S7: After hoisting the upper frame, use connecting bolts to fasten the rotary bearing (3) and the upper frame (2); position and align the upper frame (2) and the electrode lifting support (4), and weld the upper frame (2) and the electrode lifting support (4); Step S8: The No. 2 upper guide seat is reset and welded to the upper frame (2); Step S9: Assemble the lifting column (5) and lifting hydraulic cylinder (6) on the ground; Step S10: Adjust the eccentric shafts of all guide rollers so that the rollers move outward by 1 to 2 mm. The lifting column and lifting hydraulic cylinder are hoisted by passing through the guide seat as a whole. Step S11: Adjust all guide rollers so that the lifting column (5) is vertical and in good contact with the guide rollers.

2. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, In step S2, the levelness is adjusted by adding or removing the adjustment shims between the temporary support legs (20) and the frame using the three-point alignment method, so as to ensure that the levelness deviation of the upper frame is less than or equal to 0.05 mm / m.

3. The installation method of the quantum electric furnace electrode lifting system according to claim 1, characterized in that, The correction of the upper guide seat in step S3 includes center position correction and levelness correction. The allowable deviation of the center position is 0.5 mm, and the levelness deviation is less than or equal to 0.1 mm / m.

4. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, The stop block (1120) in step S3 is positioned in three directions near the electrode side and is made of square steel with a diameter of 20mm × 20mm × 50mm.

5. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, During the hoisting process in step S7, lifting lugs are symmetrically welded above the longitudinal center of the electrode lifting columns on the steel discharge side and slag discharge side of the upper frame (2). The position of the lifting lugs welded on the electrode lifting support seat (4) should be consistent with the center of the lifting lugs on the upper frame.

6. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, In step S7, the center correction of the electrode lifting support is based on the upper guide seat, with a center deviation allowable value of ±2mm, and a vertical deviation allowable value of 1mm / m in any direction, and the total height range is less than 2mm.

7. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, In step S7, the connecting bolts are tightened in three stages: the first stage is 30% preload, the second stage is 60% preload, and the third stage is 100% preload.

8. The installation method of a quantum electric furnace electrode lifting system according to claim 7, characterized in that, The bolt tightening sequence in step S7 is as follows: the first and second tightenings are cross-symmetrical, and the third tightening is a clockwise rotation to pre-tighten each bolt individually.

9. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, In step S11, the contact between all guide rollers and the lifting column is determined by the standard that a 0.03mm feeler gauge cannot be inserted.

10. The installation method of a quantum electric furnace electrode lifting system according to claim 1, characterized in that, In step S11, the allowable deviation of the verticality of the lifting column is that the electrode side tilts towards the frame side by 0.1 mm / m and the total height does not exceed 0.2 mm.

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