Large oil cylinder disassembly and repair device and method for deep-hole arc-shaped working door of high-water-head power station

Abstract

A device and method for disassembling and repairing large hydraulic cylinders of deep-hole arc-shaped working gates in high-head power stations is disclosed. The device mainly includes a crane head disassembly and assembly device, a piston disassembly and assembly device, a lower cover disassembly and assembly device, and a roller support device. The crane head disassembly and assembly device includes a main frame, on which a main crane head support frame, an auxiliary crane head support frame, and a piston rod platform are mounted. A reducer is installed on the main crane head support frame, and a crane head fixing mechanism is installed at the output end of the reducer. A roller support device is installed on the auxiliary crane head support frame. A piston rod clamp is installed on the piston rod platform. The piston disassembly and assembly device includes a piston disassembly and assembly platform, on which a second roller is mounted. Baffles are provided before and after the second roller. The lower cover disassembly and assembly device includes a lower cover disassembly and assembly platform, with a lower cover clamp at the top. This invention provides a device and method for disassembling and repairing large hydraulic cylinders of deep-hole arc-shaped working gates in high-head power stations, improving repair efficiency and ensuring personnel safety during the repair process.

Description

Technical Field

[0001] This invention relates to hydraulic cylinders, and more particularly to a disassembly and repair device and method for large hydraulic cylinders of deep-hole arc-shaped working gates in high-head power stations. Background Technology

[0002] Deep-hole hydraulic cylinders are crucial flood discharge equipment at the Three Gorges Dam. Water diversion and flood discharge primarily rely on these cylinders to provide the opening and closing force for the deep-hole gates. According to relevant equipment maintenance standards, these cylinders must be overhauled annually, requiring complete disassembly and repair to replace cylinder bolts and seals, and to inspect the internal structure of the cylinder barrel and the piston rod surface. Therefore, cylinder disassembly and repair is an essential part of hydropower station equipment maintenance.

[0003] The current method mainly involves using a single-girder crane in the factory to transfer and support the hydraulic cylinder, then using a small tripod, slings, hand-operated hoists, and simple semi-circular support devices for positioning and fixing, and finally using wrenches and levers for disassembly. The existing maintenance method lacks dedicated equipment for disassembling and assembling the piston rod, lifting head, and lower end cover.

[0004] The parameters of each component of the deep-hole hydraulic cylinder are as follows:

[0005] Piston rod: 12t, diameter 380mm, length 13500mm;

[0006] Lifting head: 3t, length 1650mm, width 1000mm;

[0007] Lower end cap: 1.1t, large circle diameter 954mm, small circle diameter 600mm, height 480mm;

[0008] Piston: 830kg, 650mm in diameter, and 520mm in height, cylindrical structure.

[0009] The main drawbacks of existing methods are as follows:

[0010] (1) In terms of disassembly and assembly efficiency: Traditional disassembly and assembly operations are relatively inefficient. Cranes are required to assist in the disassembly and assembly of the crane head. However, cranes can easily cause the parts to sway, which will have a certain impact on the disassembly and assembly. Some parts (such as the crane head) do not have suitable leverage points when disassembling, so temporary welding is required, which affects the disassembly efficiency;

[0011] (2) Regarding the quality of components: It has a certain impact on the quality of the components themselves. They are prone to shaking when hoisted, which may cause collisions between components; some components do not have a point of leverage when disassembling and assembling, so they need to be welded before disassembly and assembly, which may cause damage to the components themselves; some components are easy to be violently disassembled, causing irreversible damage.

[0012] (3) Personnel safety: The shapes of the various parts of the hydraulic cylinder are different, and the center of gravity of the parts is constantly changing. The disassembly process requires a large number of personnel and workers must be highly familiar with the operation. The parts disassembled during hydraulic cylinder maintenance are all much larger than 1 ton. If the parts fall, the risk of injury is extremely high. Summary of the Invention

[0013] The technical problem to be solved by the present invention is to provide a device and method for disassembling and repairing large hydraulic cylinders of deep-hole arc working gates in high-head power stations. This device and method can greatly optimize the overall disassembly and repair process of large hydraulic cylinders, improve the repair efficiency of each link, ensure the safety of personnel during the repair process, shorten the repair period and save repair costs for enterprises.

[0014] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0015] A disassembly and maintenance device for a large hydraulic cylinder of a deep-hole arc-shaped working gate in a high-head power station, including a crane head disassembly and assembly device, a piston disassembly and assembly device, a lower cover disassembly and assembly device, and a roller support device.

[0016] The lifting head assembly / disassembly device includes a main frame, on which a main lifting head support frame, an auxiliary lifting head support frame, and a piston rod platform are sequentially mounted; the main lifting head support frame and the auxiliary lifting head support frame are slidably fitted with the main frame; the piston rod platform is fixedly connected to the main frame;

[0017] Among them, a reducer is installed on the main support frame of the lifting head, and a frame is installed on the output end of the reducer. The frame is equipped with an end face clamping mechanism, a hollow positioning mechanism and an end head clamping mechanism. The end face clamping mechanism, the hollow positioning mechanism and the end head clamping mechanism fix the lifting head of the oil cylinder.

[0018] The lifting head auxiliary support frame is equipped with a second worm gear screw lifting mechanism and a liftable V-shaped roller support device. The second worm gear screw lifting mechanism supports the end clamping mechanism, and the liftable V-shaped roller support device supports the lifting head end of the hydraulic cylinder.

[0019] A piston rod clamp is installed on the piston rod platform, and the piston rod clamp fixes the piston rod of the hydraulic cylinder.

[0020] The piston assembly / disassembly device includes a piston assembly / disassembly platform, on which multiple sets of second rollers are installed, and the second rollers support the piston of the hydraulic cylinder; baffles are provided in front and behind the second rollers, and the baffles limit the piston of the hydraulic cylinder in front and behind; the baffles are fixedly connected to the telescopic rod, and the telescopic rod is fixed on the piston assembly / disassembly platform.

[0021] The lower cover disassembly and assembly device includes a lower cover disassembly and assembly platform. The upper end of the lower cover disassembly and assembly platform is provided with a lower cover clamp that matches the lower cover of the lifting head. The lower cover clamp fixes the lower cover of the lifting head.

[0022] The roller support device is arranged in multiple groups side by side. Each group of roller support device includes a roller, which is mounted on the support body through a roller support.

[0023] The end face tightening mechanism is divided into multiple groups and fixed at the upper and lower ends of the frame; the end face tightening mechanism includes a tightening screw, which is threadedly connected to a threaded sleeve fixed on the frame, and a top plate is installed at the output end of the tightening screw, which tightens against the end face of the lifting head of the oil cylinder.

[0024] The hollow positioning mechanism includes a sleeve with a flange at the upper end and a threaded hole at the lower end. The sleeve passes longitudinally through the frame and the lifting head of the hydraulic cylinder and is then fixed by the top plate and bolts.

[0025] The main support frame of the lifting head includes a first base, and a plurality of first guide rods are circumferentially installed on the first base. The first guide rods slide in cooperation with the first mounting plate at the upper end. The first mounting plate is driven to move up and down by a first worm gear screw lifting mechanism on the first base.

[0026] The liftable V-shaped roller support device includes multiple sets of first rollers, which are mounted on a roller frame. The roller frame is mounted on a first lifting seat, which has the same structure as the main support frame of the hoist.

[0027] The piston assembly / disassembly platform, the lower cover assembly / disassembly platform and the piston rod platform have the same structure. The piston assembly / disassembly platform, the lower cover assembly / disassembly platform and the piston rod platform all include a second lifting seat. The second lifting seat has the same structure as the first lifting seat. The output end of the second lifting seat is equipped with a first ball screw mechanism. The output end of the first ball screw mechanism is equipped with a fixed frame. The fixed frame is equipped with a piston rod clamp.

[0028] The main frame, piston assembly / disassembly platform, and lower cover assembly / disassembly platform are all equipped with multiple sets of locking casters and multiple sets of adjustable feet.

[0029] The method for disassembling and overhauling the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station includes the following steps:

[0030] Step 1) Use a 100T truck crane to lift the hydraulic cylinder to the roller support device. Each hydraulic cylinder requires 2 sets of roller support devices. Each set of roller support devices consists of 2 rollers, for a total of 4 rollers. One set supports the cylinder barrel, and the other set supports the piston rod.

[0031] Step 2) Use a compressed air compressor to pump air into the upper chamber of the cylinder, causing the piston rod to extend approximately 1 meter. After stopping the pressurization, exhaust air from the upper chamber. Move the lifting head assembly / disassembly device to the lifting head at the piston rod end. Lower the adjustable V-roll support device and piston rod clamp so that they are below the lowest point of the piston rod. Remove the hollow positioning mechanism, open the end clamping mechanism, and move the main support frame and auxiliary support frame of the lifting head so that the lifting head extends into the frame, aligning the lifting head hole with the hole on the frame. Lock the casters and adjust the feet. Install the lifting head end of the cylinder into the clamp of the end clamping mechanism and lock the clamp. The hollow positioning mechanism passes through the lifting head hole and is installed, serving to stabilize the cylinder. The end face clamping mechanism rotates to hold the crane head in place, preventing it from moving up and down. Then, the liftable V-roll support device is adjusted so that the first roller of the liftable V-roll support device fully supports the end of the crane head. At the same time, the second worm gear screw lifting mechanism is adjusted. At this time, after the second worm gear screw lifting mechanism is lowered, it no longer serves as a support frame. Finally, the piston rod clamp is raised to fully support the piston rod and hold it in place. The wheel on the reducer is rotated counterclockwise. During the crane head rotation process, the main support frame and the auxiliary support frame of the crane head move outward at the same time until the crane head is completely separated from the piston rod. After the crane head is separated, the casters are opened and the feet are adjusted. The crane head is then transported to the maintenance area through the crane head disassembly and assembly device.

[0032] Step 3) After the lifting head is removed, continue to pump air into the upper chamber of the hydraulic cylinder, causing the piston rod to move slowly. At this time, the crane connected to one end of the piston rod moves at the same speed. After the piston rod extends 1 / 3 of its length, adjust and move one of the other set of idler roller support devices to provide some support for the piston rod. Then continue to pump air into the upper chamber of the hydraulic cylinder. After the piston rod extends 2 / 3 of its length, adjust and move one of the other set of idler roller support devices to the lower end of the piston rod. At this time, the set of idler roller support devices serves to support the piston rod and its components. Continue to add air until the piston rod is fully extended. The extension speed of the piston rod must be kept consistent with the speed of the crane. The idler roller support devices should keep the piston rod approximately 3-4 meters from both ends. The hydraulic oil in the lower chamber must ensure unobstructed return and have a waste oil storage tank. The crane's cooperation is for protection purposes and does not need to be subjected to significant force.

[0033] Step 4) After the piston rod is fully extended, release the gas in the upper chamber of the cylinder, move the lower cover removal and assembly device to the bottom of the lower cover, lock the casters and adjust the feet, and then fix the lower cover by finely adjusting the lower cover removal and assembly platform and fully supporting the lower cover with the lower cover clamp. Then remove the bolts between the lower cover and the cylinder, remove the lower cover, unlock the casters and support feet, and move the lower cover outward along the piston rod axis.

[0034] Step 5) Completely disengage the piston from the cylinder. Move the piston disassembly and assembly device directly below the piston. Lock the casters of the piston disassembly and assembly device and adjust the feet. Fine-tune the piston disassembly and assembly platform until the second roller fully supports the cylinder piston. At this point, remove the bolts between the piston and the piston rod. After the connecting bolts are completely removed, slowly adjust the telescopic rod until the baffle completely blocks the lower part of the piston. Adjust the feet and unlock the casters. Slowly pull the piston out of the piston rod. When the outer end face of the piston is completely separated from the piston, adjust the outer telescopic rod, raise the position of the outer baffle, and continue to move the piston outward. When the inner end face of the piston is completely separated from the piston, adjust the inner telescopic rod, raise the inner baffle, and move the piston disassembly and assembly device until the piston and piston rod are completely disengaged.

[0035] Step 6) Reassembly: First, install the upper end cover of the cylinder, then place the lower end cover onto the piston rod, then install the piston and remove the piston disassembly / reassembly device; next, move the piston rod containing the piston into the cylinder, install the lower end cover, then remove the lower end cover disassembly / reassembly device, inject hydraulic oil into the rod chamber of the cylinder, and when the piston rod moves to 1m from the extended end, install the lifting head, move the lifting head disassembly / reassembly device to the end of the piston rod, and adjust the lifting head main support frame and the liftable V-shaped roller support device until the external thread of the piston rod is fully engaged with the internal thread hole of the lifting head, lock the casters of the lifting head disassembly / reassembly device and adjust the feet, raise the piston rod clamp, and the piston rod clamp... The clamp fully supports the piston rod and holds it in place. Rotate the wheel on the reducer clockwise. During the rotation of the crane head, the main support frame and the liftable V-shaped roller support device move inward until the crane head and piston rod are installed. Rotate the end face tightening mechanism to completely release the crane head, pull out the hollow positioning mechanism, and open the end clamping mechanism. The crane head and the crane head disassembly and assembly device are completely separated. Adjust the second worm gear screw lifting mechanism and the second worm gear screw lifting mechanism support frame. After removing the casters and adjusting the feet, move the crane head disassembly and assembly device away. After the crane head is installed, continue to pump hydraulic oil until the cylinder is fully retracted.

[0036] The present invention relates to a device and method for disassembling and overhauling a large hydraulic cylinder in a deep-hole arc-shaped working gate of a high-head power station, which has the following technical advantages:

[0037] 1) After breaking down the disassembly and maintenance process of the hydraulic cylinder, special maintenance and disassembly devices for the lifting head, lower cover of the hydraulic cylinder, piston, and overall support device of the hydraulic cylinder are manufactured according to the different maintenance objects. This greatly improves the work efficiency of disassembling and maintaining large hydraulic cylinders of deep-hole arc working gates in high-head power stations; while saving maintenance time and manpower, it also protects the safety of operators.

[0038] 2) For the first time, special maintenance tools were used for the maintenance of large hydraulic cylinders in the deep-hole arc working gate of the high-head power station. They can be used frequently and many times, which greatly saves manpower and material resources and reduces the maintenance cost of the enterprise.

[0039] 3) Traditional dismantling methods involve directly removing the top cover and draining the oil. Using compressed air to extend the cylinder reduces oil contamination, and the returned oil in the cylinder can be directly collected into a waste oil drum. Traditionally, the lifting head is the last step because it's difficult to remove; the piston rod and lifting head need to be transported together to a lathe for dismantling with lathe assistance and welding of support points. This method, with its lifting head dismantling device, can directly complete the lifting head dismantling, significantly reducing the steps in the dismantling process and saving time and labor costs. Traditionally, lifting is done by crane, which can cause damage to parts due to crane swaying. In this application, a roller support device supports the piston rod and cylinder, and the crane's lifting rope pulls the piston rod horizontally, making it safer, more reliable, and effectively protecting the piston rod's surface coating.

[0040] 4) The lifting head assembly / disassembly device, piston assembly / disassembly device, and lower cover assembly / disassembly device in this application can all achieve effective lifting and forward / backward adjustment through a worm gear screw lifting mechanism, which facilitates matching with the height and position of the lifting head, piston, and lower end cover, thereby achieving effective fixation and support; among them, the lifting head assembly / disassembly device is equipped with a fixed piston rod platform and a sliding main support frame and auxiliary support frame for the lifting head, and uses a reducer, frame, and fixed components on the frame to drive the lifting head to rotate, quickly achieving the separation of the lifting head and piston rod (the lifting head and piston rod are threaded together), and ensuring stability in the process. Attached Figure Description

[0041] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0042] Figure 1 This is a schematic diagram of the structure of the present invention.

[0043] Figure 2 This is a structural schematic diagram (first view) of the lifting head assembly / disassembly device in this invention.

[0044] Figure 3 This is a schematic diagram (second perspective) of the lifting head assembly / disassembly device in this invention.

[0045] Figure 4 This is a structural schematic diagram (first view) of the main support frame of the hoisting head in this invention.

[0046] Figure 5 This is a structural schematic diagram (second perspective) of the main support frame of the hoisting head in this invention.

[0047] Figure 6 This is a schematic diagram of the end face clamping mechanism in this invention.

[0048] Figure 7 This is a schematic diagram of the hollow positioning mechanism in this invention.

[0049] Figure 8This is a schematic diagram of the liftable V-shaped roller support device in this invention.

[0050] Figure 9 This is a schematic diagram of the piston rod platform in this invention.

[0051] Figure 10 This is a schematic diagram of the piston assembly / disassembly device in this invention.

[0052] Figure 11 This is a partial structural schematic diagram (first view) of the piston assembly / disassembly device in this invention.

[0053] Figure 12 This is a partial structural schematic diagram (second view) of the piston assembly / disassembly device in this invention.

[0054] Figure 13 This is a schematic diagram of the lower cover disassembly and assembly device in this invention.

[0055] Figure 14 This is a schematic diagram of the roller support device in this invention.

[0056] In the diagram: 1. Lifting head disassembly / assembly device; 2. Piston disassembly / assembly device; 3. Lower cover disassembly / assembly device; 4. Roller support device; 1-1. Main frame; 1-2. Casters; 1-3. Foot cups; 1-4. Anti-collision buffers; 1-5. Longitudinal handles; 1-6. Lateral handrails; 1-7. Lifting head main support frame; 1-8. Reducer; 1-9. Support shaft; 1-10. End face clamping mechanism; 1-11. Hollow positioning mechanism; 1-12. End clamping mechanism; 1-13. Second worm gear screw lifting mechanism; 1-14. Lifting head auxiliary support frame; 1-15. Liftable V-shaped roller support device; 1-16. Piston rod clamp; 1-17. Piston rod platform; 1-18. Slide rail; 1-19. Frame; 1-10-1. Clamping screw; 1-10-2. Threaded sleeve; 1-10-3. Top plate; 1-10-3. Sleeve 1 -11-1, Flanged edge 1-11-2, Top plate 1-11-3, First roller 1-15-1, Roller frame 1-15-2, First lifting seat 1-15-3, First base 1-7-1, First guide rod 1-7-2, First mounting plate 1-7-3, First worm gear screw lifting mechanism 1-7-4, Second lifting seat 1-17-1, First ball screw mechanism 1-17-2, Fixed frame 1-17-3, Piston disassembly and assembly platform 2-1, Third lifting seat 2-2, Second bracket 2-3, Second ball screw mechanism 2-4, Support roller frame 2-5, Second roller 2-6, Baffle 2-7, Telescopic rod 2-8, Lower cover clamp 3-1, Lower cover disassembly and assembly platform 3-2, Support roller 4-1, Support roller support 4-2, Support body 4-3. Detailed Implementation

[0057] like Figure 1As shown, the disassembly and maintenance device for the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station mainly consists of a lifting head disassembly and assembly device 1, a piston disassembly and assembly device 2, a lower cover disassembly and assembly device 3, and a roller support device 4. The lifting head disassembly and assembly device 1 is mainly used to remove the lifting head of the piston rod; the piston disassembly and assembly device 2 is mainly used to separate the piston from the piston rod; the lower cover disassembly and assembly device 3 is mainly used to remove the lower cover, separating it from the piston rod; and the roller support device 4 is mainly used to support the piston rod and other large components such as the cylinder.

[0058] like Figure 2-3 As shown, the lifting head assembly / disassembly device 1 includes a main frame 1-1. At the lower end of the main frame 1-1 are installed casters 1-2 with locking function and feet 1-3 that can be threadedly connected to the outriggers. The feet 1-3 are adjustable in height. The casters 1-2 and feet 1-3 work together to facilitate the movement and fixation of the device. A longitudinal handle 1-5 is installed at one end of the main frame 1-1, and a transverse handrail 1-6 is installed on one side of the main frame 1-1. The longitudinal handle 1-5 and the transverse handrail 1-6 mainly facilitate the longitudinal and transverse movement of the lifting head assembly / disassembly device 1.

[0059] like Figure 2-3 As shown, a main support frame 1-7, an auxiliary support frame 1-14, and a piston rod platform 1-17 are installed on the upper part of the main frame 1-1. The lower ends of the main support frame 1-7 and the auxiliary support frame 1-14 are slidably mounted on the slide rail 1-18 via sliders, and the two are hinged together on their left and right sides by a connecting rod to form a whole. The piston rod platform 1-17 is fixed to the main frame 1-1.

[0060] Here, the main support frame 1-7 and the auxiliary support frame 1-14 of the lifting head are connected together by a connecting rod. Because the lifting head is a deep-hole hydraulic cylinder lifting head, the lifting heads are of the same size. At the same time, the lifting head is removed by rotation and can be moved outward at the same time. After being completely separated from the piston rod, it can play a supporting role at the same time.

[0061] like Figure 2-3 As shown, a single-stage horizontal cycloidal pinwheel reducer 1-8 is installed on the upper end of the main support frame 1-7 of the lifting head. The output end of the single-stage horizontal cycloidal pinwheel reducer 1-8 is connected to the support shaft 1-9. A frame 1-19 is installed on the other end of the support shaft 1-9. An end face tightening mechanism 1-10, a hollow positioning mechanism 1-11, and an end head clamping mechanism 1-12 are fixed on the frame 1-19. The end face tightening mechanism 1-10, the hollow positioning mechanism 1-11, and the end head clamping mechanism 1-12 can be used to fix the lifting head of the hydraulic cylinder and prevent the lifting head of the hydraulic cylinder from moving. The single-stage horizontal cycloidal pinwheel reducer 1-8 can drive the frame 1-19 to rotate, thereby causing the lifting head on the frame 1-19 to separate from the piston rod.

[0062] The frame 1-19 here has an opening on one side and one end, which makes it easy for the lifting head to pass through and extend into the frame 1-19.

[0063] like Figure 2-3 As shown, a second worm gear screw lifting mechanism 1-13 is installed on one side of the lifting head auxiliary support frame 1-14, and a liftable V-shaped roller support device 1-15 is installed on the other side. The second worm gear screw lifting mechanism 1-13 is used for the frame 1-19, especially providing support before installation.

[0064] The frame 1-19 on the main support frame 1-7 of the hoist is in a cantilever state. The weight of the frame 1-19 cannot be fully supported by the support shaft 1-9 alone, which will damage the connecting parts over time. However, the second worm gear screw lifting mechanism 1-13 raises the support when not under maintenance, so that both ends of the frame 1-19 are under load, preventing damage to the support shaft 1-9 due to uneven load distribution. The second worm gear screw lifting mechanism 1-13 needs to be lowered when the frame 1-19 rotates and raised when the frame 1-19 is not rotating.

[0065] The liftable V-shaped roller support device 1-15 is mainly used to provide support during the disassembly and installation of the piston rod, primarily supporting the end of the lifting head.

[0066] like Figure 2-3 As shown, a piston rod clamp 1-16 is installed on the piston rod platform 1-17. The piston rod clamp 1-16 is mainly used to fix the piston rod and prevent the piston rod and the lifting head from rotating at the same time.

[0067] Specifically, such as Figure 5-6 As shown, the end face tightening mechanism 1-10 is fixed in multiple groups at the upper and lower ends of the frame 1-19. The end face tightening mechanism 1-10 includes a tightening screw 1-10-1, which is threadedly connected to a threaded sleeve 1-10-2 fixed on the frame 1-19. A top plate 1-10-3 is installed at the output end of the tightening screw 1-10-1. Rotating the handwheel at the end of the tightening screw 1-10-1 causes the top plate 1-10-3 to extend or retract, thus tightening the end face of the hydraulic cylinder's lifting head. For ease of installation, the clamp of the end head clamping mechanism 1-12 is slightly larger than the lifting head size, therefore it is not in a fully tightened state. By setting the end face tightening mechanism 1-10, the lifting head's vertical movement during assembly and disassembly can be prevented.

[0068] Specifically, such as Figure 5 , Figure 7As shown, the hollow positioning mechanism 1-11 includes a sleeve 1-11-1 with a flange 1-11-2 at its upper end. The upper end of the sleeve 1-11-1 is limited by the flange 1-11-2 after passing through the frame 1-19. The lower end of the sleeve 1-11-1 is fixed to the frame 1-19 by a top plate 1-11-3 and bolts. During installation, when the lifting head of the hydraulic cylinder enters the frame 1-19, the center hole of the lifting head is aligned with the hole on the frame 1-19. Then, the sleeve 1-11-1 is passed through the center hole of the lifting head, and the top plate 1-11-3 is placed against the lower end face of the frame 1-19. Bolts are screwed into the threaded holes of the top plate 1-11-3 and the sleeve 1-11-1 to lock them in place, thus completing the center positioning of the lifting head. The diameter of the sleeve 1-11-1 is approximately the same as, but slightly larger than, the diameter of the through hole on the lifting head.

[0069] Specifically, such as Figure 5 As shown, the end clamping mechanism 1-12 is a clamp, which is longitudinally divided into left and right semi-circular rings. The two semi-circular rings can be fixed by upper and lower bolts. The end clamping mechanism 1-12 can fix the cylindrical part of the end of the lifting head. The end clamping mechanism 1-12 can prevent the lifting head from swaying up and down and left and right during disassembly and assembly, and can better fix the lifting head.

[0070] Specifically, such as Figure 8 As shown, the liftable V-shaped roller support device 1-15 includes multiple sets of first rollers 1-15-1. These first rollers 1-15-1 are mounted on a roller frame 1-15-2 and are arranged in a V-shape. The first rollers 1-15-1 can be used to support the lifting head end of the hydraulic cylinder. The roller frame 1-15-2 is fixedly mounted on a first lifting seat 1-15-3. The first lifting seat 1-15-3 has the same structure as the main support frame 1-7 of the lifting head and can adjust the height of the multiple sets of first rollers 1-15-1.

[0071] Specifically, such as Figure 4 As shown, the main support frame 1-7 of the lifting head includes a first base 1-7-1, on which a first guide rod 1-7-2 is mounted. The first guide rod 1-7-2 is slidably engaged with a first mounting plate 1-7-3 at its upper end. The first mounting plate 1-7-3 is driven to move up and down via a first worm gear screw lifting mechanism 1-7-4 on the first base 1-7-1. When the handwheel of the first worm gear screw lifting mechanism 1-7-4 is rotated, the first mounting plate 1-7-3 can be driven to move up and down via the first worm gear screw lifting mechanism 1-7-4.

[0072] Specifically, such as Figure 9As shown, the piston rod platform 1-17 includes a second lifting seat 1-17-1, which has the same structure as the first lifting seat 1-15-3 and has a lifting function. A first ball screw mechanism 1-17-2 is installed on the upper end of the second lifting seat 1-17-1. The ball nut of the first ball screw mechanism 1-17-2 is fixedly connected to the fixed frame 1-17-3. By rotating the handwheel at one end of the screw of the first ball screw mechanism 1-17-2, the piston rod clamp 1-16 on the fixed frame 1-17-3 can be driven to move left and right. The piston rod platform 1-17 has lifting and left / right movement functions, facilitating the adjustment of the position of the piston rod clamp 1-16.

[0073] Preferably, the piston rod clamp 1-16 has a rubber pad on its inner side, which can prevent damage to the piston rod body after the clamp rotates relative to the piston rod.

[0074] Preferably, anti-collision buffers 1-4 are fixed at the end of the main frame 1-1 and inside the piston rod platform 1-17, so that when the main support frame 1-7 and the auxiliary support frame 1-14 of the hoist head move to their extreme positions, they can be limited and buffered.

[0075] Here, the piston rod platform 1-17 is fixedly installed, and the piston rod clamp 1-16 can hold the piston rod in place, keeping the piston rod stationary. The main support frame 1-7 and the auxiliary support frame 1-14 of the lifting head are slidably installed, so that the lifting head is disassembled after rotation and moves away from the piston rod with the sliding of the main support frame 1-7 and the auxiliary support frame 1-14 of the lifting head, thereby achieving the purpose of disassembling the lifting head.

[0076] like Figure 10-12 As shown, the piston assembly / disassembly device 2 includes a piston assembly / disassembly platform 2-1, the structure of which is the same as that of the piston rod platform 1-17. It includes a third lifting seat 2-2, the lower end of which is fixed to a second bracket 2-3. The bottom of the second bracket 2-3 is also equipped with locking casters and adjustable feet. The locking casters and adjustable feet work together to facilitate the movement and fixation of the device. A second ball screw mechanism 2-4 is fixed to the mounting plate at the upper end of the third lifting seat 2-2. The ball nuts of the second ball screw mechanism 2-4 are fixed to a roller support frame 2-5. Multiple sets of second rollers 2-6 are mounted on the roller support frame 2-5, arranged in a V-shape to support the cylinder piston.

[0077] The second roller 2-6 is equipped with baffles 2-7 at its front and rear. The baffles 2-7 are fixedly connected to the telescopic rod 2-8, which is welded to the left and right sides of the mounting plate of the third lifting seat 2-2. The telescopic rod 2-8 consists of two sleeved rods screwed together and secured with bolts. The distance between the two baffles 2-7 is consistent with the length of the hydraulic cylinder piston, thus limiting the piston's position at both ends and preventing it from tipping over. During adjustment, the length of the telescopic rod 2-8 can be adjusted according to the piston's center of gravity, thereby adjusting the height of the baffles 2-7.

[0078] In addition, horizontal handrails are fixed at both ends of the piston assembly / disassembly platform 2-1, which facilitate manual movement of the piston assembly / disassembly device 2.

[0079] like Figure 13 As shown, the lower structure of the lower cover disassembly and assembly device 3 is the same as that of the piston disassembly and assembly device 2. The difference is that the roller assembly in the piston disassembly and assembly device 2 is replaced with a lower cover clamp 3-1. The lower cover clamp 3-1 has a rubber pad inside to prevent damage to the lower cover. The lower cover disassembly and assembly device 3 is mainly used to fix the lower cover of the lifting head for removal and transfer.

[0080] like Figure 14 As shown, the roller support device 4 mainly consists of a PTFE roller 4-1, a roller support 4-2, and a support body 4-3. The roller support 4-2 can realize lifting (using the worm gear screw lifting mechanism as described above, not shown in the figure) and left and right movement (using the ball screw mechanism as described above). The roller support device 4 is mainly used for supporting the piston rod and cylinder, effectively protecting the paint film on the piston rod surface and facilitating disassembly.

[0081] The overall disassembly of the deep hole hydraulic cylinder mainly involves disassembling the upper end cover, lifting head, lower end cover, and piston one by one. After cleaning the main components, replacing the seals and screws, the cylinder is reassembled. After reassembly, the cylinder undergoes a full-stroke operation inspection, internal and external leakage test, and pressure test. Once the inspection and test are passed, the cylinder meets the factory acceptance standards and will be ready for standby.

[0082] The dismantling process of the large hydraulic cylinder of the deep-hole arc-shaped working gate of the high-head power station is as follows:

[0083] Step 1) Use a 100T truck crane to lift the hydraulic cylinder to the roller support device 4. Each hydraulic cylinder requires 2 sets of roller support devices 4. Each set of roller support devices 4 consists of 2 units, for a total of 4 units. One set supports the cylinder barrel, and the other set supports the piston rod.

[0084] Step 2) Use a compressed air compressor to pump air into the upper chamber of the cylinder, causing the piston rod to extend approximately 1 meter. After stopping the pressurization, exhaust air from the upper chamber. Move the lifting head disassembly and assembly device 1 to the lifting head at the piston rod end. Lower the liftable V-shaped roller support device 1-15 and piston rod clamp 1-16 so that they are below the lowest point of the piston rod. Remove the hollow positioning mechanism 1-11 and open the end clamping mechanism. Mechanism 1-12: Move the main support frame 1-7 and auxiliary support frame 1-14 of the lifting head so that the lifting head extends into the frame 1-19, aligning the lifting head hole with the hole on the frame 1-19; lock the casters and adjust the feet; install the lifting head end of the hydraulic cylinder into the clamp of the end clamping mechanism 1-12 and lock the clamp; the hollow positioning mechanism 1-11 passes through the lifting head hole and is installed to provide positioning; the end face pressing mechanism 1-10 rotates to press against the lifting head, preventing... The crane head moves up and down; then the liftable V-shaped roller support device 1-15 is adjusted so that the first roller 1-15-1 of the liftable V-shaped roller support device 1-15 fully supports the end of the crane head. At the same time, the second worm gear screw lifting mechanism 1-13 is adjusted. At this time, after the second worm gear screw lifting mechanism 1-13 is lowered, it no longer serves as a support frame 1-19. Finally, the piston rod clamp 1-16 is raised to fully support the piston rod and hold the piston rod through the clamp. The wheel on the reducer 1-8 is rotated counterclockwise, and the crane head rotates accordingly. Since the crane head and the piston rod are connected by threads, during the rotation of the crane head, the main support frame 1-7 and the auxiliary support frame 1-14 of the crane head move outward at the same time until the crane head and the piston rod are completely separated. After the crane head is separated, the lifting piston rod clamp 1-16 is opened, the casters of the crane head disassembly and assembly device 1 are opened, and the feet are adjusted. Then, the crane head is transported to the maintenance area through the crane head disassembly and assembly device 1.

[0085] Step 3) After the lifting head is removed, continue to pump air into the upper chamber of the hydraulic cylinder, causing the piston rod to move slowly. At this time, the crane connected to one end of the piston rod moves at the same speed. After the piston rod extends 1 / 3 of its length, adjust and move one of the other set of roller support devices 4 to provide some support for the piston rod. Then continue to pump air into the upper chamber of the hydraulic cylinder. After the piston rod extends 2 / 3 of its length, adjust and move one of the other set of roller support devices to the lower end of the piston rod. At this time, the set of roller support devices 4 serves to support the piston rod and its components. Continue to add air until the piston rod is fully extended. The extension speed of the piston rod must be kept consistent with the speed of the crane. The roller support devices 4 should keep the piston rod approximately 3-4 meters from both ends. The hydraulic oil in the lower chamber must ensure smooth return and have a waste oil storage tank. The crane's cooperation is a protective measure and does not need to bear significant force.

[0086] Step 4) After the piston rod is fully extended, release the gas in the upper chamber of the cylinder, move the lower cover removal and assembly device 3 to directly below the lower cover, lock the casters and adjust the feet, and then, by fine-tuning the lower cover removal and assembly platform 3-2, fully support the lower end cover with the lower cover clamp 3-1 and fix the lower end cover with the lower cover clamp 3-1. Then, remove the bolts between the lower end cover and the cylinder, remove the bolts of the lower cover from the cylinder, unlock the casters and support feet, and move the lower end cover outward along the piston rod axis. After the piston is removed and moved away, remove the lower cover removal and assembly device 3 along with the lower end cover.

[0087] Step 5) Completely detach the piston from the cylinder. Move the piston disassembly and assembly device 2 directly below the piston. Lock the casters of the piston disassembly and assembly device 2 and adjust the feet. Fine-tune the piston disassembly and assembly platform 2-1 until the second roller 2-6 fully supports the cylinder piston. At this point, remove the bolts between the piston and the piston rod. After the connecting bolts are completely removed, slowly adjust the telescopic rod 2-8 until the baffle 2-7 completely blocks the lower part of the piston. Adjust the feet and unlock the casters. Slowly pull the piston out of the piston rod. When the outer end face of the piston is completely separated from the piston, adjust the outer telescopic rod 2-8, raise the position of the outer baffle 2-7, and continue to move the piston outward. When the inner end face of the piston is completely separated from the piston, adjust the inner telescopic rod 2-8, raise the inner baffle 2-7, and move the piston disassembly and assembly device 2 until the piston and piston rod are completely disengaged.

[0088] Step 6) Reassembly: First, install the upper end cover of the cylinder, then put the lower end cover onto the piston rod, then install the piston and remove the piston disassembly / reassembly device 2; then move the piston rod containing the piston into the cylinder, install the lower end cover, and then remove the lower end cover disassembly / reassembly device 3. Pour hydraulic oil (minimum starting pressure) into the rod chamber of the cylinder. When the piston rod moves to 1m from the extended end, install the lifting head. Move the lifting head disassembly / reassembly device 1 to the end of the piston rod. By adjusting the main support frame 1-7 of the lifting head and the liftable V-shaped roller support device 1-15, the external thread of the piston rod is fully engaged with the internal thread hole of the lifting head. Lock the casters of the lifting head disassembly / reassembly device 1 and adjust the feet. Raise the piston rod clamp 1-16 until the piston rod clamp 1-16 is fully supported. Support the piston rod and hold it with the clamp. Rotate the wheel on the reducer 1-8 clockwise. During the rotation of the crane head, the main support frame 1-7 and the liftable V-shaped roller support device 1-15 move inward until the crane head and piston rod are installed. Rotate the end face clamping mechanism 1-10 to completely release the crane head. Pull out the hollow positioning mechanism 1-11 and open the end clamping mechanism 1-12. The crane head and the crane head disassembly and assembly device 1 are completely separated. Adjust the second worm gear screw lifting mechanism 1-13 and the second worm gear screw lifting mechanism 1-13 support frame 1-19. After removing the casters and adjusting the feet, move the crane head disassembly and assembly device 1 away. After the crane head is installed, continue to pump hydraulic oil until the cylinder is fully retracted.

Claims

1. A disassembly and maintenance device for a large hydraulic cylinder in a deep-hole arc-shaped working gate of a high-head power station, characterized in that: It includes a lifting head disassembly and assembly device (1), a piston disassembly and assembly device (2), a lower cover disassembly and assembly device (3), and a roller support device (4). The lifting head assembly / disassembly device (1) includes a main frame (1-1), on which a main lifting head support frame (1-7), a lifting head auxiliary support frame (1-14), and a piston rod platform (1-17) are sequentially arranged; the main lifting head support frame (1-7) and the lifting head auxiliary support frame (1-14) are slidably engaged with the main frame (1-1); the piston rod platform (1-17) is fixedly connected to the main frame (1-1); Among them, a reducer (1-8) is installed on the main support frame (1-7) of the lifting head, and a frame (1-19) is installed on the output end of the reducer (1-8). An end face clamping mechanism (1-10), a hollow positioning mechanism (1-11) and an end head clamping mechanism (1-12) are provided on the frame (1-19). The end face clamping mechanism (1-10), the hollow positioning mechanism (1-11) and the end head clamping mechanism (1-12) fix the lifting head of the oil cylinder. The lifting head auxiliary support frame (1-14) is equipped with a second worm gear screw lifting mechanism (1-13) and a liftable V-shaped roller support device (1-15). The second worm gear screw lifting mechanism (1-13) supports the frame (1-19); the liftable V-shaped roller support device (1-15) supports the lifting head end of the hydraulic cylinder. A piston rod clamp (1-16) is installed on the piston rod platform (1-17), and the piston rod clamp (1-16) fixes the piston rod of the oil cylinder. The piston assembly / disassembly device (2) includes a piston assembly / disassembly platform (2-1), on which multiple sets of second rollers (2-6) are installed. The second rollers (2-6) support the piston of the oil cylinder. The second rollers (2-6) are provided with baffles (2-7) at the front and rear, which limit the piston of the oil cylinder. The baffles (2-7) are fixedly connected to the telescopic rod (2-8), which is fixed on the piston assembly / disassembly platform (2-1). The lower cover disassembly and assembly device (3) includes a lower cover disassembly and assembly platform (3-2), and the upper end of the lower cover disassembly and assembly platform is provided with a lower cover clamp (3-1) that matches the lower cover of the lifting head. The lower cover clamp (3-1) fixes the lower cover of the lifting head. The roller support device (4) is arranged in multiple groups side by side. Each group of roller support device (4) includes a roller (4-1), which is mounted on the support body (4-3) through a roller support (4-2).

2. The large-scale oil cylinder disassembly and repair device for the deep hole arc-shaped working door of a high water head power station according to claim 1, characterized in that: The end face tightening mechanism (1-10) is fixed in multiple groups at the upper and lower ends of the frame (1-19); the end face tightening mechanism (1-10) includes a tightening screw (1-10-1), the tightening screw (1-10-1) is threadedly connected to the threaded sleeve (1-10-2) fixed on the frame (1-19), and a top plate (1-10-3) is installed at the output end of the tightening screw (1-10-1), and the top plate (1-10-3) tightens the end face of the lifting head of the oil cylinder.

3. The disassembly and maintenance device for the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station according to claim 1, characterized in that: The hollow positioning mechanism (1-11) includes a sleeve (1-11-1), the upper end of the sleeve (1-11-1) is provided with a flange (1-11-2), the lower end of the sleeve (1-11-1) is provided with a threaded hole, and the sleeve (1-11-1) passes longitudinally through the frame (1-19) and the lifting head of the oil cylinder and is then fixed by the top plate (1-11-3) and bolts.

4. The disassembly and maintenance device for the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station according to claim 1, characterized in that: The main support frame (1-7) of the lifting head includes a first base (1-7-1). Multiple first guide rods (1-7-2) are circumferentially installed on the first base (1-7-1). The first guide rods (1-7-2) are slidably engaged with the first mounting plate (1-7-3) at the upper end. The first mounting plate (1-7-3) is driven to move up and down through the first worm gear screw lifting mechanism (1-7-4) on the first base (1-7-1).

5. The large oil cylinder disassembly and repair device for the deep hole sector gate of the high water head power station according to claim 4, characterized in that: The liftable V-shaped roller support device (1-15) includes multiple sets of first rollers (1-15-1), which are mounted on a roller frame (1-15-2). The roller frame (1-15-2) is mounted on a first lifting seat (1-15-3), and the first lifting seat (1-15-3) has the same structure as the main support frame (1-7) of the hoisting head.

6. The disassembly and maintenance device for the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station according to claim 5, characterized in that: The piston assembly / disassembly platform (2-1), the lower cover assembly / disassembly platform (3-2), and the piston rod platform (1-17) have the same structure. The piston assembly / disassembly platform (2-1), the lower cover assembly / disassembly platform (3-2), and the piston rod platform (1-17) all include a second lifting seat (1-17-1). The second lifting seat (1-17-1) has the same structure as the first lifting seat (1-15-3). The output end of the second lifting seat (1-17-1) is equipped with a first ball screw mechanism (1-17-2). The output end of the first ball screw mechanism (1-17-2) is equipped with a fixed frame (1-17-3). The fixed frame (1-17-3) is equipped with a piston rod clamp (1-16).

7. The disassembly and maintenance device for the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station according to claim 6, characterized in that: The main frame (1-1), piston assembly / disassembly platform (2-1), and lower cover assembly / disassembly platform (3-2) are all equipped with multiple sets of locking casters (1-2) and multiple sets of adjustable feet (1-3).

8. The method for disassembling and repairing the large hydraulic cylinder of the deep-hole arc-shaped working gate in a high-head power station according to claim 7, comprising the following steps: Step 1) The hydraulic cylinder is lifted to the roller support device (4) by a 100T truck crane. Each hydraulic cylinder requires two sets of roller support devices (4). There are two roller support devices (4) in one set, and a total of four in two sets. One set supports the cylinder and the other set supports the piston rod. Step 2) Use a compressed air compressor to pump air into the upper chamber of the cylinder, causing the piston rod to extend about 1m. After stopping the pressurization, exhaust air from the upper chamber. Move the lifting head disassembly and assembly device (1) to the lifting head at the piston rod end, and lower the liftable V-shaped roller support device (1-15) and piston rod clamp (1-16) so that the liftable V-shaped roller support device (1-15) and piston rod clamp (1-16) are lower than the lowest point of the piston rod. Pull out the hollow positioning mechanism (1- 11) Open the end clamping mechanism (1-12), move the main support frame (1-7) and auxiliary support frame (1-14) of the lifting head so that the lifting head extends into the frame (1-19) and the lifting head hole is aligned with the hole on the frame (1-19); lock the casters and adjust the feet, install the lifting head end of the hydraulic cylinder into the clamp of the end clamping mechanism (1-12) and lock the clamp. The hollow positioning mechanism (1-11) passes through the lifting head hole and is installed. To achieve the positioning function, the end face clamping mechanism (1-10) rotates and holds the crane head to prevent it from moving up and down. Then, the liftable V-shaped roller support device (1-15) is adjusted so that the first roller (1-15-1) of the liftable V-shaped roller support device (1-15) fully supports the end of the crane head. At the same time, the second worm gear screw lifting mechanism (1-13) is adjusted. At this time, the second worm gear screw lifting mechanism (1-13) no longer plays the role of supporting the frame (1-19) after it descends. Finally, the piston rod clamp (1-16) is raised to fully support the piston rod and hold the piston rod through the clamp. The wheel on the reducer (1-8) is rotated counterclockwise. During the crane head rotation process, the main support frame (1-7) and the auxiliary support frame (1-14) of the crane head move outward at the same time until the crane head and the piston rod are completely separated. After the crane head is separated, the casters are opened and the feet are adjusted. The crane head is then transported to the maintenance area through the crane head disassembly and assembly device (1). Step 3) After the lifting head is removed, the upper chamber of the cylinder continues to pump air, causing the piston rod to move slowly. At this time, the crane connected to one end of the piston rod moves at the same speed. After the piston rod of the cylinder extends 1 / 3, adjust and move one of the other set of roller support devices (4) to provide some support for the piston rod. Then continue to pump air into the upper chamber of the cylinder. After the piston rod extends 2 / 3, adjust and move one of the other set of roller support devices to the lower end of the piston rod. At this time, the set of roller support devices (4) plays the role of supporting the piston rod and its components. Continue to replenish air until the piston rod is fully extended. The extension speed of the piston rod must be kept consistent with the speed of the crane. The roller support device (4) keeps the piston rod 3-4m from both ends. The hydraulic oil in the lower chamber must be able to return smoothly and there is a waste oil storage tank. The crane is used as a protective measure and does not need to be subjected to obvious force. Step 4) After the piston rod is fully extended, release the gas in the upper chamber of the cylinder, move the lower cover disassembly and assembly device (3) to the bottom of the lower cover, lock the caster wheel and adjust the foot cup, and after finely adjusting the lower cover disassembly and assembly platform (3-2), fully support the lower cover with the lower cover clamp (3-1) and fix the lower cover with the lower cover clamp (3-1). Then remove the bolts between the lower cover and the cylinder, remove the lower cover, unlock the caster wheel and support foot cup, and move the lower cover outward along the piston rod axis. Step 5) Completely separate the piston from the cylinder. Move the piston disassembly and assembly device (2) directly below the piston. Lock the universal wheel of the piston disassembly and assembly device (2) and adjust the foot cup. By fine-tuning the piston disassembly and assembly platform (2-1), until the second roller (2-6) fully supports the cylinder piston. At this time, remove the bolt between the piston and the piston rod. After the connecting bolt is completely removed, slowly adjust the telescopic rod (2-8). The baffle (2-7) completely blocks the lower part of the piston. Adjust the foot cup and unlock the universal wheel. Slowly pull the piston out of the piston rod. When the outer end face of the piston is completely separated from the piston rod, adjust the outer telescopic rod (2-8), raise the position of the outer baffle (2-7), and continue to move the piston outward. When the inner end face of the piston is completely separated from the piston rod, adjust the inner telescopic rod (2-8), raise the inner baffle (2-7), and move the piston disassembly and assembly device (2) until the piston and the piston rod are completely separated. Step 6) Reassembly: First, install the upper end cover of the cylinder, then put the lower cover onto the piston rod, then install the piston and remove the piston disassembly device (2); then move the piston rod containing the piston into the cylinder, install the lower cover, and then remove the lower cover disassembly device (3). Pour hydraulic oil into the rod chamber of the cylinder. When the piston rod moves to 1m from the extended end, install the lifting head. Move the lifting head disassembly device (1) to the end of the piston rod. By adjusting the main support frame (1-7) of the lifting head and the liftable V-shaped roller support device (1-15), the external thread of the piston rod is fully engaged with the internal thread hole of the lifting head. Lock the universal wheel of the lifting head disassembly device (1) and adjust the foot cup. Raise the piston rod clamp (1-16). The piston rod clamp (1-16) fully supports the piston rod and passes through the clamp. Clamp the piston rod and rotate the wheel on the reducer (1-8) clockwise. During the rotation of the crane head, the main support frame (1-7) and the liftable V-shaped roller support device (1-15) of the crane head move inward until the crane head and piston rod are installed. Rotate the end face clamping mechanism (1-10) to completely release the crane head, pull out the hollow positioning mechanism (1-11), open the end clamping mechanism (1-12), and the crane head and the crane head disassembly and assembly device (1) are completely separated. Adjust the second worm gear screw lifting mechanism (1-13), the second worm gear screw lifting mechanism (1-13) support frame (1-19), untie the casters and adjust the feet, and then move the crane head disassembly and assembly device (1). After the crane head is installed, continue to pump hydraulic oil until the cylinder is completely retracted.

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