Deep hole oil cylinder intelligent lifting and turning over equipment and use method

Abstract

This invention discloses an intelligent lifting and turning device and its method for deep-hole hydraulic cylinders. It includes an upper clamping device that engages with the upper end of the hydraulic cylinder and a lower clamping device that engages with the lower end of the hydraulic cylinder. The upper clamping device includes an upper clamp, both sides of which are rotatably connected to both sides of the main support frame. An angle encoder is installed at the rotatable connection position. An upper lifting lug connected to the upper lifting rope of a crawler crane is located in the middle of the main support frame. The lower clamping device includes a lower clamp, and a lower lifting lug connected to the lower lifting rope of a gantry crane's slewing crane is located on its side. This invention features convenient installation, reliable turning action, and real-time alerts and multi-signal alarms based on changes in the hydraulic cylinder angle during the turning process. It also provides reliable data on the gantry crane's trolley speed and the gantry crane's slewing rope retraction speed based on the positional changes of the hydraulic cylinder during the turning process, thus making the turning process safer and more reliable.

Description

Technical Field

[0001] This invention relates to the field of deep-hole hydraulic cylinder turning technology, specifically to an intelligent lifting and turning equipment and method for using deep-hole hydraulic cylinders. Background Technology

[0002] Deep-hole hydraulic cylinders are crucial flood discharge equipment in hydropower stations. Water diversion and flood discharge primarily rely on the opening and closing force provided by these cylinders to open or close the deep-hole arc gates. According to relevant equipment maintenance standards, these cylinders must be overhauled annually. During overhaul, the cylinders must be hoisted in and out, turned over, loaded onto a truck, and returned to the factory for further maintenance—essential steps. The cylinder's height from its installation position to its final position at the orifice is approximately 76.5 meters. The current turning method primarily uses clamps; two circular steel wire ropes are secured to the four lifting lugs of the clamps with clips, and a 300T crawler crane is used to lift the cylinder in and out. During the turning operation, the steel wire ropes are spread out using support rods. A sling is then attached to the lower end cover of the cylinder, and the 300T crawler crane, in conjunction with a gantry crane, performs the turning maneuver.

[0003] The main drawbacks of existing deep-hole hydraulic cylinder turning methods are as follows:

[0004] (1) Cumbersome installation: The hoisting tool is complicated to install. The wire rope needs to be installed after the installation and the wire rope needs to be prevented from scratching the cylinder body. The wire rope must be kept symmetrical at all times. The support rod must be kept horizontal and under force at all times in order to fully open the wire rope so that it can be turned over.

[0005] (2) High risk: The upper support rod is in contact with the sling, which may squeeze or cut the sling, thus causing the risk of lifting; the lower sling cannot be effectively fixed, which may damage the upper cylinder of the hydraulic cylinder, thus causing the oil in the cylinder to leak out.

[0006] (3) High difficulty: After the 300T crawler crane is lifted out of the orifice, when the gantry crane and the slewing crane work together to turn the cylinder, the cylinder turning operation is mainly carried out by the travel speed of the gantry crane trolley. The travel speed of the trolley also directly affects the angle of the slewing crane wire rope, thus affecting the operation safety of the slewing crane. The turning process is carried out by the driver and the crane commander's vision and experience, which makes the operation difficult. Summary of the Invention

[0007] The purpose of this invention is to overcome the above-mentioned shortcomings and provide an intelligent lifting and turning equipment and method for using a deep-hole hydraulic cylinder, so as to solve the problems mentioned in the background art.

[0008] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: an intelligent hoisting and turning equipment for deep-hole hydraulic cylinders, comprising an upper clamping device that cooperates with the upper end of the hydraulic cylinder and a lower clamping device that cooperates with the lower end of the hydraulic cylinder. The upper clamping device includes an upper clamp, the two sides of which are rotatably connected to the two sides of the main body support. An angle encoder is provided at the rotatable connection position. An upper lifting lug connected to the upper lifting rope of the crawler crane is provided in the middle of the main body support. The lower clamping device includes a lower clamp, the side of which is provided with a lower lifting lug connected to the lower lifting rope of the gantry crane.

[0009] Preferably, the main support is a U-shaped frame structure, with its two ends hinged to one end of the rotating shaft, and the other end of the rotating shaft fixedly connected to the middle of the U-shaped clamp. The ear plates on both sides of the upper clamp are located inside the U-shaped clamp and connected by positioning pins.

[0010] Preferably, the end of the rotating shaft is connected to the input end of the angle encoder, and the mounting plate of the angle encoder is fixed to the side of the main support.

[0011] Preferably, the outer end of the rotating shaft is also provided with an oil injection nozzle.

[0012] Preferably, the upper clamp includes two semi-circular clamps, and the sides of the two semi-circular clamps are connected by a first bolt.

[0013] Preferably, the main support frame is also provided with a laser rangefinder and a power distribution box on its side.

[0014] Preferably, the lower clamp includes two semi-circular clamps, the sides of which are connected by a second bolt, and the ends of the semi-circular clamps are provided with a fixing ring, which is engaged with the bolts on the cylinder end cover.

[0015] In addition, the present invention also discloses a method for using the above-mentioned intelligent lifting and turning equipment with deep-hole hydraulic cylinders, which includes the following steps:

[0016] S1: Install the upper clamp device onto the upper end of the hydraulic cylinder, then connect the upper lifting rope of the crawler crane to the upper lifting lug, and lift the hydraulic cylinder to a certain positioning height through the rope winding process of the upper lifting rope;

[0017] S2: Install the lower clamp device to the lower end of the cylinder, and then connect the lower hoisting rope of the gantry crane to the lower hoisting lug, so that the gantry crane trolley of the gantry crane moves away from the cylinder and the lower hoisting rope is simultaneously wound up.

[0018] S3: The hydraulic cylinder is adjusted from a vertical to a horizontal position;

[0019] S4: The crawler crane's upper lifting rope and the gantry crane's lower lifting rope are released at the same speed, thereby placing the hydraulic cylinder behind the flatbed trailer to complete the entire lifting and turning process of the hydraulic cylinder.

[0020] Preferably, in step S2, the lifting rope of the crawler crane remains stationary, and the moving speed of the gantry crane trolley is controlled as follows:

[0021] v = d(L sinθ) / dt;

[0022] Where v is the gantry crane trolley moving speed, L is the distance between the corresponding lifting points of the upper and lower clamping devices of the hydraulic cylinder, and θ is the rotation angle of the angle encoder, which ranges from 0° to 90°.

[0023] The speed at which the lower hoist rope of the gantry crane is wound up is:

[0024]

[0025] Among them, V h α is the speed at which the lower rope is pulled up, α is the angle between the lower rope and the vertical direction, and α0 is the initial angle between the lower rope and the vertical direction after it is first connected to the lower lug.

[0026] Preferably, in step S2, the gantry crane trolley of the gantry crane moves away from the hydraulic cylinder, and the lower hoisting rope of the gantry crane and the upper hoisting rope of the crawler crane are simultaneously released; the height H between the top of the hydraulic cylinder and the ground is measured in real time using a laser rangefinder, wherein H is within the range of H... min —H max between.

[0027] The beneficial effects of this invention are:

[0028] This invention features convenient installation, reliable tilting action, and real-time alerts and multi-signal alarms based on changes in the cylinder angle during the tilting process. It also provides reliable data on the gantry crane's trolley speed and rope retraction speed based on the cylinder's positional changes during tilting, making the tilting process safer and more reliable. Once the cylinder tilts from a vertical to a horizontal position, the alarm device promptly alerts the crane operator. Compared to previous methods that relied on experience to determine cylinder level, this invention is more intelligent and reliable. Attached Figure Description

[0029] Figure 1 This is a schematic diagram showing the usage status of an intelligent lifting and turning equipment with a deep-hole hydraulic cylinder.

[0030] Figure 2 for Figure 1 A schematic diagram showing the connection between the middle hydraulic cylinder and the upper and lower clamping devices;

[0031] Figure 3 for Figure 2 Schematic diagram of the upper and middle clamping device;

[0032] Figure 4 for Figure 2 Schematic diagram of the middle and lower clamping device;

[0033] Figure 5 This is a schematic diagram of the electrical principle involved in the present invention. Detailed Implementation

[0034] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0035] like Figures 1 to 5 As shown, an intelligent hoisting and turning equipment for deep-hole hydraulic cylinders includes an upper clamping device 1 that cooperates with the upper end of the hydraulic cylinder 3 and a lower clamping device 2 that cooperates with the lower end of the hydraulic cylinder 3. The upper clamping device 1 includes an upper clamp 1-3, which is rotatably connected to the two sides of the main support 1-2. An angle encoder 1-9 is provided at the rotatable connection position. The middle part of the main support 1-2 is provided with an upper lifting lug 1-1 that is connected to the upper lifting rope 4-1 of the crawler crane 4. The lower clamping device 2 includes a lower clamp 2-1, and the side of the lower clamp 2-1 is provided with a lower lifting lug 2-2 that is connected to the lower lifting rope 5-1 of the gantry crane 5. In this embodiment, by setting up the upper clamp device 1 and the lower clamp device 2, the upper lifting rope 4-1 of the crawler crane 4 and the lower lifting rope 5-1 of the gantry crane 5 can be quickly connected to the upper and lower ends of the hydraulic cylinder 3, respectively. Furthermore, because the upper clamp 1-3 is rotatably connected to the two sides of the main support 1-2, the upper end of the hydraulic cylinder 3 can partially rotate relative to the lifting point, effectively preventing the lifting ropes from being squeezed or cut, thus avoiding lifting risks. The use of the angle encoder 1-9 can monitor the posture of the hydraulic cylinder 3; when it is in a horizontal posture, it can issue an early warning, reminding the worker to proceed with the next operation.

[0036] Preferably, the main support 1-2 is a U-shaped frame structure, with its two ends hinged to one end of the rotating shaft 1-6, and the other end of the rotating shaft 1-6 fixedly connected to the middle of the U-shaped clamp 1-4. The ear plates on both sides of the upper clamp 1-3 are located inside the U-shaped clamp 1-4 and connected by positioning pins 1-5. This design structure enables the rotational connection between the upper clamp 1-3 and the main support 1-2, and also facilitates the installation and disassembly of the upper clamp 1-3 and the main support 1-2, making it convenient to use.

[0037] Preferably, the end of the rotating shaft 1-6 is connected to the input end of the angle encoder 1-9, and the mounting plate of the angle encoder 1-9 is fixed to the side of the main support 1-2.

[0038] Preferably, the outer end of the rotating shaft 1-6 is also provided with an oil injection nozzle 1-7. By providing the oil injection nozzle 1-7, lubricating oil can be injected into the hinge position between the rotating shaft 1-6 and the main support 1-2, making the rotation process of the rotating shaft 1-6 smoother.

[0039] Preferably, the upper clamp 1-3 includes two semi-circular clamps, the sides of which are connected by a first bolt 1-8. This structure and bolt connection facilitate the installation and removal of the upper clamp 1-3 on the surface of the cylinder 3. The tightness of the upper clamp 1-3 on the surface of the cylinder 3 can also be adjusted by adjusting the degree of screwing in the first bolt 1-8.

[0040] Preferably, the main support frame 1-2 is further provided with a laser rangefinder 1-10 and a power distribution box 1-11 on its side. In this embodiment, the laser rangefinder 1-10 can measure the height H between the top of the hydraulic cylinder 3 and the ground in real time, wherein H ranges from H... min —H max Between these points, avoid the hydraulic cylinder 3 being adjusted to a horizontal position and its height being too high or too low.

[0041] Distribution boxes 1-11 mainly contain components such as a 24V battery, transmitter, PLC, and wireless communication terminal. The 24V battery primarily powers the angle encoder, laser rangefinder, transmitter, PLC, and wireless communication terminal. The angle encoder detects the real-time attitude of the hydraulic cylinder. The transmitter converts the voltage value from the angle encoder into a 4-20mA current value. The PLC converts the 4-20mA current signal output from the transmitter into an analog signal. The wireless communication terminal establishes communication with the gantry crane, transmitting the analog signal from the tilting equipment to the crane, which detects the hydraulic cylinder's attitude. Simultaneously, the signal is transmitted to a handheld manual display device, enabling dynamic monitoring of the hydraulic cylinder's rotation angle and position, and providing alarm signals to the crane operator and other equipment operators. The schematic diagram is shown below. Figure 5 As shown.

[0042] Furthermore, the early warning system of this device during the hoisting process is as follows:

[0043] 1. The process of the hydraulic cylinder being lifted out of the orifice by the crawler crane is a bottom-up lifting process. The rotation angle of the angle encoder on the lifting device is always 0°±θ° (θ° is the allowable error value); if the angle exceeds 0°±θ°, an alarm will be issued to the handheld display of the crane operator.

[0044] 2. After the hydraulic cylinder is fully extended, the initial angle α0 between the lower hoisting rope 5-1 of the gantry crane and the vertical direction should be within (-α). min —α max If α0 exceeds a certain range, the lower suspension rope 5-1 will interfere with the platform 5-2 on the gantry crane, affecting the safety of the gantry crane and triggering an alarm. During operation, the angle α between the lower suspension rope 5-1 and the vertical direction should always be maintained between (-α). min —α maxTo prevent interference between the lowering rope 5-1 and the platform 5-2 on the gantry crane during hoisting, an alarm will be triggered once the angle approaches the limit, and the travel speed of the gantry crane trolley will need to be adjusted.

[0045] 3. After the hydraulic cylinder is connected by the crawler crane and the gantry crane, when the cylinder is horizontal, the angle encoder displays an angle θ of 90°, indicating that the cylinder has been flipped and can be loaded onto the vehicle; when the cylinder is vertical, the angle encoder displays an angle θ of 0°, indicating that the cylinder can be reinstalled. In this embodiment, 0° is defined as the cylinder being in a vertical state, and 90° is defined as the cylinder being in a horizontal state.

[0046] 4. Based on the laser rangefinder H, the cylinder rotation angle, and the cylinder length, the vertical height from the lower end of the cylinder to the ground can be determined. If this height is too low, an alarm will be triggered, and the rope-laying speed of the crawler crane and the gantry crane will need to be adjusted.

[0047] Preferably, the lower clamp 2-1 includes two semi-circular clamps, the sides of which are connected by a second bolt 2-3. A fixing ring 2-4 is provided at the end of each semi-circular clamp, and the fixing ring 2-4 engages with a bolt on the end cap of the cylinder 3. This structure and bolt connection facilitate the installation and removal of the lower clamp 2-1 on the surface of the cylinder 3; and because the fixing ring 2-4 engages with the bolt on the end cap of the cylinder 3, axial slippage between the lower clamp 2-1 and the surface of the cylinder 3 is less likely to occur.

[0048] In addition, the present invention also discloses a method for using the above-mentioned intelligent lifting and turning equipment with deep-hole hydraulic cylinders, which includes the following steps:

[0049] S1: Install the upper clamp device 1 onto the upper end of the hydraulic cylinder 3, then connect the upper lifting rope 4-1 of the crawler crane 4 to the upper lifting lug 1-1, and lift the hydraulic cylinder 3 to a certain positioning height through the rope winding process of the upper lifting rope 4-1.

[0050] S2: Install the lower clamp device 2 onto the lower end of the cylinder 3, and then connect the lower hoisting rope 5-1 of the gantry crane 5 to the lower hoisting lug 2-2, so that the gantry crane trolley of the gantry crane 5 moves away from the cylinder 3, and at the same time, the lower hoisting rope 5-1 is wound up.

[0051] S3: Hydraulic cylinder 3 is adjusted from a vertical position to a horizontal position;

[0052] S4: The upper lifting rope 4-1 of the crawler crane 4 and the lower lifting rope 5-1 of the gantry crane 5 are released at the same speed, so that the hydraulic cylinder 3 is placed on the flatbed trailer 6 to complete the entire lifting and turning process of the hydraulic cylinder 3.

[0053] Preferably, the technical solutions corresponding to step S2 above include the following two:

[0054] Example 1: In step S2, the lifting rope 4-1 of the crawler crane 4 remains stationary, and the gantry crane trolley speed of the gantry crane 5 is controlled as follows:

[0055] v = d(L sinθ) / dt;

[0056] Where v is the moving speed of the gantry crane, L is the distance between the corresponding lifting points of the upper clamping device 1 and the lower clamping device 2 of the hydraulic cylinder 3, and θ is the rotation angle of the angle encoders 1-9, which ranges from 0° to 90°.

[0057] The speed at which the lower hoisting rope 5-1 of the gantry crane 5 is wound up is:

[0058]

[0059] Among them, V h α is the speed at which the lower rope 5-1 is pulled up, α is the angle between the lower rope 5-1 and the vertical direction, and α0 is the initial angle between the lower rope 5-1 and the vertical direction after it is first connected to the lower lifting lug 2-2.

[0060] Example 2: In step S2, the gantry crane 5 moves away from the hydraulic cylinder 3, and the lower hoisting rope 5-1 of the gantry crane 5 and the upper hoisting rope 4-1 of the crawler crane 4 are simultaneously released; the height H between the top of the hydraulic cylinder 3 and the ground is measured in real time using a laser rangefinder 1-10, where H is within the range of H... min —H max In this embodiment, the vertical height from the lower end of the hydraulic cylinder to the ground can also be obtained using a laser rangefinder H, the cylinder rotation angle θ, and the cylinder length L. If this height is too low, an alarm will be triggered, and the rope-laying speed of the crawler crane and the gantry crane will need to be adjusted.

[0061] The above embodiments 1 and 2 correspond to two hoisting methods, wherein the gantry crane trolley moving speed v and the gantry crane slewing and rope retraction speed v h All speeds are instantaneous. The gantry crane trolley travel speed is divided into four gears, and the gantry crane slewing rope retraction speed is divided into four gears. Based on the instantaneous speed, refer to different gear ranges to select the appropriate trolley travel and slewing rope retraction speed gears.

[0062] There are two methods for reinstalling the hydraulic cylinder. Method 1: First, two hoisting devices horizontally lift the cylinder to the hoisting height. Then, the gantry crane selects the pre-set cylinder reinstallation and turning parameters, and the lifting mechanism begins to descend. The gantry crane trolley, which assists the gantry crane trolley, follows the trolley and the gantry crane releases the rope. The reinstallation method is the reverse of the entire process corresponding to Example 1. Method 2: After lifting the cylinder to a certain height, the speed of the crawler crane (i.e., the lifting speed) must be greater than the rope releasing speed of the gantry crane trolley. After the gantry crane trolley moves synchronously, the cylinder is turned from a horizontal position to a vertical position. This is the reverse of the entire process corresponding to Example 2.

[0063] Once the cylinder is detected to be in a vertical position, the hoisting mechanism and the trolley mechanism stop their respective actions and issue a corresponding warning signal; disconnect the auxiliary hoisting equipment (gantry crane) from the cylinder's lower turning fixture (lower clamp device), and have the main hoisting equipment (crawler crane) lift the cylinder to the designated position.

[0064] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The embodiments and features described in these embodiments can be arbitrarily combined without conflict. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A method of using a deep-hole hydraulic cylinder intelligent hoisting and turning equipment, the deep-hole hydraulic cylinder intelligent hoisting and turning equipment includes an upper clamp device (1) that cooperates with the upper end of the hydraulic cylinder (3) and a lower clamp device (2) that cooperates with the lower end of the hydraulic cylinder (3), the upper clamp device (1) includes an upper clamp (1-3), the upper clamp (1-3) is rotatably connected to the two sides of the main body support (1-2), and an angle encoder (1-9) is provided at the rotatable connection position, and an upper lifting lug (1-1) is provided in the middle of the main body support (1-2) for connection with the upper lifting rope (4-1) of the crawler crane (4); the lower clamp device (2) includes a lower clamp (2-1), the upper clamp device (1-3) includes an upper clamp (1-3) that cooperates with the upper end of the hydraulic cylinder (3), the lower clamp device (2-3) includes an upper clamp (1-3) that cooperates with the upper end of the hydraulic cylinder (3), the upper clamp device (1-3) includes an upper clamp (1-3) that cooperates with the upper end of the hydraulic cylinder (3), the upper clamp device (1-3) includes an upper clamp (1-3) that cooperates with the upper end of the main body support (1-2), the lower clamp device (2-3) includes an upper clamp (2-1), the lower clamp device (2-3) includes an upper clamp (2-3) that cooperates with the upper end of the hydraulic cylinder (3), the upper clamp device (1-3) includes an upper clamp (1-3) that cooperates with the upper end of the main body support (1-2), the lower clamp device (2-3) includes an upper clamp (2 ... The lower clamp (2-1) has a lower lifting lug (2-2) on its side that connects to the lower lifting rope (5-1) of the gantry crane (5); the main support (1-2) is a U-shaped frame structure, with its two ends hinged to one end of the rotating shaft (1-6), and the other end of the rotating shaft (1-6) fixedly connected to the middle of the U-shaped clamp (1-4); the ear plates on both sides of the upper clamp (1-3) are located inside the U-shaped clamp (1-4) and connected by positioning pins (1-5); the end of the rotating shaft (1-6) is connected to the input end of the angle encoder (1-9), and the mounting plate of the angle encoder (1-9) is fixed to the side of the main support (1-2); its features are: The usage method includes the following steps: S1: Install the upper clamp device (1) onto the upper end of the cylinder (3), then connect the upper hoisting rope (4-1) of the crawler crane (4) to the upper hoisting lug (1-1), and lift the cylinder (3) to a certain positioning height through the rope winding process of the upper hoisting rope (4-1); S2: Install the lower clamp device (2) onto the lower end of the cylinder (3), and then connect the lower hoisting rope (5-1) of the gantry crane (5) to the lower hoisting lug (2-2), so that the gantry crane trolley of the gantry crane (5) moves away from the cylinder (3) and the lower hoisting rope (5-1) is simultaneously wound up. S3: The hydraulic cylinder (3) is adjusted from a vertical position to a horizontal position; S4: The upper lifting rope (4-1) of the crawler crane (4) and the lower lifting rope (5-1) of the gantry crane (5) are released at the same speed, so that the cylinder (3) is placed on the flatbed trailer (6) and the entire lifting and turning process of the cylinder (3) is completed. In step S2, the lifting rope (4-1) of the crawler crane (4) remains stationary, and the gantry crane trolley of the gantry crane slewing crane (5) is controlled to move at the following speed: ； Where v is the moving speed of the gantry crane, L is the distance between the corresponding lifting points of the upper clamp device (1) and the lower clamp device (2) of the hydraulic cylinder (3), and θ is the rotation angle of the angle encoder (1-9), which is in the range of 0° to 90°. The speed at which the lower hoisting rope (5-1) of the gantry crane (5) is wound up is: ； in, Let α be the speed at which the lower rope (5-1) is pulled up, and let α be the angle between the lower rope (5-1) and the vertical direction. The initial angle between the lower suspension rope (5-1) and the vertical direction after it is first connected to the lower suspension lug (2-2).

2. The method of using the intelligent lifting and turning equipment with deep-hole hydraulic cylinders according to claim 1, characterized in that: The outer end of the rotating shaft (1-6) is also provided with an oil injection nozzle (1-7).

3. The method of using the intelligent hoisting and turning equipment with deep-hole hydraulic cylinders according to claim 1, characterized in that: The upper clamp (1-3) includes two semi-circular clamps, and the sides of the two semi-circular clamps are connected by the first bolt (1-8).

4. The method of using the intelligent lifting and turning equipment with a deep-hole hydraulic cylinder according to claim 1, characterized in that: The main support (1-2) is also equipped with a laser rangefinder (1-10) and a power distribution box (1-11) on its side.

5. The method of using the intelligent hoisting and turning equipment with a deep-hole hydraulic cylinder according to claim 1, characterized in that: The lower clamp (2-1) includes two semi-circular clamps. The two semi-circular clamps are connected on the sides by a second bolt (2-3). The end of the semi-circular clamp is provided with a fixing ring (2-4), which is engaged with the bolt on the end cover of the oil cylinder (3).

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