Method for replacing wire rope of winch-type gate hoist

Abstract

A method for replacing the wire rope of a winch-type gate hoist comprises the following steps: 1) removing a synchronous shaft; 2) installing a rope-collecting device and a rope-releasing device; 3) removing one end of the old wire rope; 4) welding one end of the new wire rope to one end of the old wire rope; 5) removing the other end of the old wire rope and pulling it onto the rope-collecting device; 6) starting the rope-collecting device and the rope-releasing device; 7) cutting off the connection point when the new and old wire ropes reach the rope outlet; 8) keeping the rope-collecting device running and retrieving the old wire rope; 9) keeping the wire rope drum rotating so that the tail end of the new wire rope is wound onto the wire rope drum; 10) debugging and testing the replaced new wire rope; and 11) reinstalling the gate hoist synchronous shaft. The present invention adopts the above method, which can effectively reduce the intermediate operation links in the wire rope replacement operation process, save labor cost investment, improve the safety of on-site operations, avoid the influence of human factors, and improve the efficiency and quality of the wire rope replacement operation.

Description

Technical Field

[0001] The invention relates to the technical field of maintenance of a winch-type gate hoist, and in particular to a method for replacing a steel wire rope of a winch-type gate hoist. Background Art

[0002] The wire rope of the winch-type gate hoist needs to be inspected and replaced regularly to avoid damage and rust on the wire rope, which may lead to a decrease in the mechanical properties of the wire rope, making it unable to meet the opening and closing needs of the arc gate and affecting the safety of flood discharge.

[0003] The existing wire rope replacement process mainly relies on manual replacement after the rope is collected. This method is inefficient and unsuitable for replacing large wire ropes. In addition, the existing technology also usually uses a single wire rope drum to collect the rope and then replace it with a new wire rope drum to pay out the rope. This process requires moving the old wire rope drum and then moving the new wire rope drum into place before the replacement operation. The entire process is labor-intensive and time-consuming, and it cannot achieve the purpose of continuous wire rope replacement. In addition, the wire rope replacement process is affected by interference factors, which has the problem of reduced replacement accuracy. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for replacing the wire rope of a winch-type gate hoist, which can effectively reduce the intermediate operation links in the wire rope replacement operation process, save labor cost investment and improve the safety of on-site operations, avoid the influence of human factors, and improve the efficiency and quality of the wire rope replacement operation.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: a method for replacing the wire rope of a winch-type hoist, comprising the following steps:

[0006] 1) Turn off the first and second gate hoists and remove the synchronization shaft so that the first and second gate hoists can operate independently;

[0007] 2) Install the rope collecting device and rope releasing device in place;

[0008] 3) Remove one end of the old wire rope from the wire rope drum of the winch-type hoist;

[0009] 4) Weld one end of the new wire rope to the removed end of the old wire rope;

[0010] 5) Remove the recovery end of the old wire rope from the wire rope drum and pull it to the rope collection device;

[0011] 6) Start the rope-collecting device and the rope-releasing device, and replace the wire rope in the manner of outputting three turns of old wire rope while inputting one turn of new wire rope;

[0012] 7) When the connection point of the new and old wire ropes reaches the rope outlet position on the wire rope drum, cut off the connection position of the new and old wire ropes;

[0013] 8) Keep the rope collecting device running and recycle the old wire rope to the rope collecting device;

[0014] 9) After fixing the end of the new wire rope at the cut position, continue to rotate the wire rope drum so that the tail end of the new wire rope is wound onto the wire rope drum;

[0015] 10) Carry out commissioning and testing of the new wire rope that has been replaced;

[0016] 11) Complete the wire rope replacement operation and reinstall the synchronization shaft between the first and second gate hoists.

[0017] In the preferred solution, in step 3), when removing the old wire rope, the pressure plate at one end of the old wire rope is first removed and fixed with a rope clamp, and then the end of the old wire rope is lifted by a bridge crane to prevent the wire rope from falling and sliding.

[0018] In a preferred solution, in step 4), after the end of the new steel wire rope pulled to the machine room is polished and smoothed, the new and old steel wire ropes are welded together using an iron chain, and a rubber belt is tied at the weld to prevent the connection from damaging the pulley.

[0019] In a preferred solution, in step 5), the pressure plate at one end of the old steel wire rope is first removed, and then the end of the old steel wire rope is pulled onto the rope-collecting device.

[0020] In a preferred embodiment, in step 6), while the old steel wire rope is being pulled and wound onto the rope-retracting device, lubricant is continuously sprayed on the portion of the old steel wire rope that is not stretched out to prevent it from rotating along with the steel wire rope drum.

[0021] In a preferred solution, in step 6), before the new wire rope enters the wire rope drum, the rope clamp part used to fix the old wire rope is removed, and a limiting mechanism is installed at the input end and the rope feeding position of the new wire rope to reduce the probability of the new and old wire ropes moving out of the groove.

[0022] In a preferred solution, in step 6), during the process of starting the rope-collecting device and the rope-releasing device and replacing the old and new wire ropes, the lubricant is continuously sprayed on the contact position between the new wire rope and the wire rope drum.

[0023] In a preferred solution, in step 6), during the wire rope replacement process, the number of wire rope windings at the rope outlet end of the wire rope drum is controlled to be three, and the number of wire rope windings at the rope inlet end is controlled to be two.

[0024] In a preferred embodiment, the step 6) further includes controlling the return of the wire rope, manually cooperating with the hook-returning device to pull the wire rope back, and further coordinating with the reverse rotation of the wire rope drum to allow the wire rope to gradually cross the rope groove, thereby preventing the wire rope from crossing significantly and causing damage to the wire rope and the rope groove.

[0025] In a preferred solution, during the return control process of the wire rope, the lubricant spraying is stopped at the wire rope entry end, and after the wire rope returns, the wire rope drum stops reversing and the hook return device is removed.

[0026] The present invention provides a method for replacing a wire rope of a winch-type gate hoist, which has the following beneficial effects by adopting the above method:

[0027] (1) It reduces the early and intermediate operation links in the conventional wire rope replacement process and speeds up the efficiency of wire rope replacement operation;

[0028] (2) It reduces the number of human intervention steps, improves on-site operation safety, and saves labor costs;

[0029] (3) The replacement tooling is combined with the gate hoist to form a wire rope operation circulation system, which avoids the problem of decreased wire rope replacement accuracy caused by human factors. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present invention will be further described below with reference to the accompanying drawings and examples:

[0031] Figure 1 It is a flowchart of the present invention.

[0032] Figure 2 This is a schematic structural diagram of the present invention when performing a wire rope replacement operation.

[0033] Figure 3 This is a schematic diagram of the wire rope drum structure during the wire rope replacement operation of the present invention.

[0034] In the figure: first gate hoist 1, second gate hoist 2, synchronous shaft 3, wire rope 4, guide device 5, rope collecting device 6, rope releasing device 7, gate chamber 8, fence 9, protective device 10, wire rope drum 11, old rope recovery direction 12, new rope entry direction 13. DETAILED DESCRIPTION

[0035] Example 1:

[0036] like Figure 1 The method for replacing the wire rope of the winch-type gate hoist includes the following steps:

[0037] 1) Turn off the first gate hoist 1 and the second gate hoist 2 and remove the synchronization shaft 3 so that the first gate hoist 1 and the second gate hoist 2 can operate independently;

[0038] 2) Install the rope collecting device 6 and the rope releasing device 7 in place;

[0039] 3) Remove one end of the old wire rope from the wire rope drum 11 of the winch-type hoist;

[0040] 4) Weld one end of the new wire rope to the removed end of the old wire rope;

[0041] 5) Remove the other end of the old wire rope from the wire rope drum 11 and pull it onto the rope collection device 6;

[0042] 6) Start the rope collecting device 6 and the rope releasing device 7, and replace the wire rope in such a way that every three turns of old wire rope are output and one turn of new wire rope is input;

[0043] 7) When the connection point of the new and old steel wire ropes reaches the rope outlet position on the wire rope drum 11, cut off the connection position of the new and old steel wire ropes;

[0044] 8) Continue to operate the rope collecting device 6 and recycle the old wire rope to the rope collecting device 6;

[0045] 9) After fixing the end of the new wire rope at the cut position, continue to rotate the wire rope drum 11 so that the tail end of the new wire rope is wound onto the wire rope drum 11;

[0046] 10) Carry out commissioning and testing of the new wire rope that has been replaced;

[0047] 11) Complete the wire rope replacement operation and reinstall the synchronization shaft 3 between the first gate hoist 1 and the second gate hoist 2.

[0048] Example 2:

[0049] by Figure 2 For example, in step 2), the rope collecting device 6 and the rope releasing device 7 are moved to the outside of the fence 9 of the lock chamber 8, and the method described in step embodiment 1 is implemented to pull the new and old wire ropes 3 and realize Figure 2 Shows the connection status.

[0050] Before completing the traction operation of the wire rope 3, a protective device 10 for the wire rope 4 is pre-installed on the fence 9, and a guide device 5 is installed on the dam retaining wall at the same time. During the entire replacement process, the overall structure of the operation area is as follows: Figure 2 shown.

[0051] Example 3:

[0052] by Figure 1 、 3 For example, during the replacement of the wire rope 3, the wire rope 3 needs to be in a relaxed and unstressed state, and all the wire ropes 3 wound on the wire rope drum 11 should be unwound. Figure 3As shown, the drum rotates counterclockwise. The left side of the drum is where the old wire rope is retrieved (arrow 12 indicates the direction of old rope retrieval), and the right side is where the new rope enters (arrow 13 indicates the direction of new rope entry). During the replacement process, three turns of the old wire rope are left on the left side to ensure sufficient friction between the wire rope 3 and the wire rope drum 11 to prevent relative sliding. The principle for wire rope replacement is: three turns of old rope out, one turn of new rope in.

[0053] In the preferred solution, in step 3), when removing the old wire rope, the pressure plate at one end of the old wire rope is first removed and fixed with a rope clamp, and then the end of the old wire rope is lifted by a bridge crane to prevent the wire rope from falling and sliding.

[0054] In a preferred solution, in step 4), after the end of the new steel wire rope pulled to the machine room is polished and smoothed, the new and old steel wire ropes are welded together using an iron chain, and a rubber belt is tied at the weld to prevent the connection from damaging the pulley.

[0055] In a preferred embodiment, in step 5), the pressure plate at one end of the old steel wire rope is first removed, and then the end of the old steel wire rope is pulled onto the rope collecting device 6;

[0056] During the process of the old steel wire rope being pulled and wound onto the rope taking-up device 6 , the lubricant is continuously sprayed on the portion of the old steel wire rope that is not shown to prevent it from rotating along with the rotation of the steel wire rope drum 11 .

[0057] In a preferred solution, in step 6), before the new wire rope enters the wire rope drum 11, the rope clamp part used to fix the old wire rope is removed, and a limiting mechanism is installed at the input end and the rope feeding position of the new wire rope to reduce the probability of the new and old wire ropes moving out of the groove.

[0058] In a preferred solution, in step 6), when the rope collecting device 6 and the rope releasing device 7 are started and the old wire rope is replaced with the new wire rope, the lubricant is continuously sprayed on the contact position between the new wire rope and the wire rope drum 11.

[0059] In a preferred solution, in step 6), during the wire rope replacement process, the number of wire rope windings at the rope outlet end of the wire rope drum 11 is controlled to be three, and the number of wire rope windings at the rope inlet end is controlled to be two.

[0060] Example 4:

[0061] Based on Example 1, during the replacement process, the wire rope lacks the tightening effect of the pressure plate, and the combined force of the friction between the wire rope and the drum and the tension applied by the replacement tool is biased toward the middle of the drum. Therefore, as the replacement proceeds, the wire rope will move closer to the middle of the drum.

[0062] Therefore, step 6) also includes the return control of the wire rope, which relies on manual cooperation with the hook return device to pull the wire rope back, and further cooperates with the reverse rotation of the wire rope drum 11 to make the wire rope gradually cross the rope groove, avoiding the wire rope from crossing significantly and causing damage to the wire rope and the rope groove.

[0063] In a preferred solution, during the return control process of the wire rope, the lubricant spraying is stopped at the wire rope entry end, and after the wire rope returns, the wire rope drum 11 stops reversing and the hook return device is removed.

[0064] Example 5:

[0065] On the basis of Example 1, during the disconnection operation of the new and old steel wire ropes described in step 7), when the connection reaches the rope outlet at the left end of the wire rope drum 11, rope clamps are installed at both ends of the connection to fix it, the rubber belt protection of the connection is removed, and the weld points of the connection are inspected. Then, the connection between the new and old steel wire ropes is cut off. Finally, the results of the two weld point inspections are analyzed and compared to determine whether the process during the replacement process is correct.

[0066] Example 6:

[0067] On the basis of Example 1, the rope collecting device 6 is operated. Under the action of the traction rope, the old wire rope is recovered to the replacement rope collecting device 6. A single pressure plate is installed and fixed at the left end of the new wire rope, leaving 20 cm at the end. The single pressure plate can quickly position and fix the new wire rope.

[0068] After completing the above operations, the wire rope drum 11 continues to rotate and the new wire rope continues to be wound until all the new wire rope is wound onto the wire rope drum 11 (the wire rope 3 is completely wound onto the left end of the wire rope drum 11, and the number of turns of the wire rope on the right end remains two turns). When the other end of the new wire rope reaches the right end of the wire rope drum 11, the rope clamp is fixed to the new wire rope on the right end, and the wire rope 3 on the right end is slightly hoisted by the bridge crane.

[0069] Example 7:

[0070] The new steel wire rope commissioning and testing described in step 11) of Example 1 is specifically as follows:

[0071] A single pressure plate is installed at the right end of the new wire rope to secure it. The wire rope drum 11 is then reversed, and the left wire rope is removed from the drum. The right wire rope is sprayed with lubricant to allow it to slide on the drum. A loop of wire rope is left on each end of the drum to ensure that the forces on the ropes are equal. The drum 11 is then rotated forward, and after the wire rope 3 is adjusted to the operating state, the double pressure plate is installed. The balance of the wire ropes 3 at both ends is manually adjusted, and the pulleys are measured to determine whether they rotate simultaneously. This is used to preliminarily determine whether the ropes are balanced.

Claims

1. A method for replacing the wire rope of a winch-type hoist, characterized in that The following steps are involved: 1) Turn off the first gate hoist (1) and the second gate hoist (2) and remove the synchronization shaft (3) so that the first gate hoist (1) and the second gate hoist (2) can operate independently; 2) Install the rope collecting device (6) and the rope releasing device (7) in place; 3) Remove one end of the old wire rope from the wire rope drum (11) of the winch-type hoist; 4) Weld one end of the new wire rope to the removed end of the old wire rope; 5) Remove the other end of the old wire rope from the wire rope drum (11) and pull it onto the rope collection device (6); 6) starting the rope collecting device (6) and the rope releasing device (7) to replace the wire rope in a manner that three turns of old wire rope are output while one turn of new wire rope is input; 7) When the connection point between the new and old wire ropes reaches the rope outlet position on the wire rope drum (11), cut off the connection position between the new and old wire ropes; 8) Continue to operate the rope collecting device (6) and recycle the old wire rope to the rope collecting device (6); 9) After fixing the end of the new wire rope at the cut position, continue to rotate the wire rope drum (11) so that the tail end of the new wire rope is wound onto the wire rope drum (11); 10) Carry out commissioning and testing of the new wire rope that has been replaced; 11) Complete the wire rope replacement operation and reinstall the synchronization shaft (3) between the first gate hoist (1) and the second gate hoist (2).

2. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, characterized in that: In the step 3), when removing the old wire rope, the pressure plate at one end of the old wire rope is first removed and fixed with a rope clamp, and then the end of the old wire rope is lifted by the bridge crane to prevent the wire rope from falling and sliding.

3. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, characterized in that: In step 4), after the end of the new wire rope pulled to the machine room is polished and smoothed, the new and old wire ropes are welded together using an iron chain, and a rubber belt is tied at the weld to prevent the joint from damaging the pulley.

4. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, wherein: In the step 5), the pressure plate at one end of the old steel wire rope is first removed, and then the end of the old steel wire rope is pulled onto the rope collecting device (6).

5. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, characterized in that: In the step 6), during the process of the old steel wire rope being pulled and wound onto the rope-receiving device (6), the portion of the old steel wire rope that is not drawn out is continuously sprayed with lubricant to prevent it from rotating along with the rotation of the steel wire rope drum (11).

6. The method for replacing a wire rope of a winch-type gate hoist according to claim 2, wherein: In the step 6), before the new steel wire rope enters the steel wire rope drum (11), the rope clamp portion for fixing the old steel wire rope is removed, and a limiting mechanism is installed at the input end and the rope feeding position of the new steel wire rope to reduce the probability of the new and old steel wire ropes moving out of the groove.

7. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, characterized in that: In the step 6), during the process of starting the rope-collecting device (6) and the rope-releasing device (7) and performing the replacement operation of the old and new steel ropes, the new steel rope enters and is continuously sprayed with lubricant at the contact position with the steel rope drum (11).

8. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, wherein: In the step 6), during the wire rope replacement process, the number of wire rope windings at the rope outlet end of the wire rope drum (11) is controlled to be three, and the number of wire rope windings at the rope inlet end is controlled to be two.

9. The method for replacing a wire rope of a winch-type gate hoist according to claim 1, characterized in that: The step 6) also includes the return control of the wire rope, which relies on manual cooperation with the hook-returning device to pull the wire rope back, and further cooperates with the reversal of the wire rope drum (11) to make the wire rope gradually cross the rope groove, so as to avoid the wire rope crossing a large distance and causing damage to the wire rope and the rope groove.

10. The method for replacing a wire rope of a winch-type gate hoist according to claim 9, characterized in that: During the return control process of the wire rope, the lubricant spraying is stopped at the wire rope entry end, and after the wire rope is returned, the wire rope drum (11) stops reversing and the hook return device is removed.

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