A rapid on-site repair method for the cantilever bending of a stacker-reclaimer

Abstract

The present invention provides a method for quickly repairing the cantilever bending of a stacker-reclaimer on-site, belonging to the technical field of stacker-reclaimer repair. By setting a reasonable disassembly and assembly sequence, selecting appropriate lifting positions and lifting equipment, the technical problem of quickly repairing the cantilever bending of a stacker-reclaimer similar to the structure of the DQL9000 stacker-reclaimer on-site is solved, effectively ensuring the personal and property safety during the on-site quick repair of the cantilever bending of the stacker-reclaimer. In addition, the method of the present invention has obtained good practical verification effects in on-site maintenance and repair work, and each operation step is safe and reliable, worthy of promotion.

Description

Technical Field

[0001] The present invention belongs to the technical field of stacker-reclaimer repair, and particularly relates to a method for quickly repairing the cantilever bending of a stacker-reclaimer on site. Background Art

[0002] Stacker-reclaimers are indispensable large-scale machines and tools for raw material industries such as steel enterprises and port companies. The cantilever stacker-reclaimer is a continuous and efficient bulk material handling machine, which is widely used in ports, metallurgy, mines, power, coal chemical industry and other fields, and can realize the continuous operation of stacking and reclaiming bulk materials such as coal and ore. The upper metal structure of the cantilever stacker-reclaimer consists of a cantilever frame, portal columns, a counterweight frame, tie rods and a tail car, etc.; the cantilever frame, portal columns, counterweight frame, etc. are all structures with welded I-beams and box girders as the main load-bearing members; the portal is a box girder structure.

[0003] The cantilever stacker-reclaimer can be divided into two main parts: the main machine and the tail car according to the overall structure and function; among them, the main machine adopts an overall pitching (hydraulic pitching) structure, and the slewing mode is bearing-supported slewing.

[0004] Taking the DQL9000 stacker-reclaimer as an example, its stacking and reclaiming height is 13.5 meters, it runs bidirectionally, the slewing radius is 43.5 meters, the bucket wheel diameter is 7 meters, the stacking capacity is 9000T / h, the reclaiming capacity is 2500T / h, the total weight of the machine body is 962 tons, and the weights of each part are as follows: the tail counterweight is 190 tons, the cantilever frame weighs 70 tons, the bucket wheel body weighs 22 tons, and the tie rod weighs 15 tons. Its overall stress structure is triangular. If the disassembly and assembly sequence is incorrect, or the lifting position or lifting equipment is not selected appropriately, it will cause great personal and property safety during the construction process.

[0005] During the operation of the DQL9000 stacker-reclaimer, when the cantilever is affected by external forces due to improper operation, the cantilever beam will be bent and deformed. Due to the excessive weight of the whole machine and each component equipment of this large-scale machine and tool, and the relatively complex stress of each component, it brings certain difficulties to the maintenance work. Therefore, it is urgent to find a safe, fast and low-cost repair method. Summary of the Invention

[0006] The present invention provides a method for quickly repairing the cantilever bending of a stacker-reclaimer on site. By setting a reasonable disassembly and assembly sequence, selecting an appropriate lifting position and lifting equipment, it solves the technical problem of quickly repairing the cantilever bending of a stacker-reclaimer similar to the DQL9000 stacker-reclaimer structure, and effectively guarantees the personal and property safety during the quick repair process of the cantilever bending of the stacker-reclaimer on site.

[0007] In order to solve the above technical problems, the technical solution provided by the present invention is as follows:

[0008] A method for quickly repairing the cantilever bending of a stacker-reclaimer on site, comprising the following steps:

[0009] S1. Protectively remove cables and signal lines, disconnect and remove the cantilever belt, remove other non-structural accessories, clean the work site and fabricate support tooling offline;

[0010] The support tooling includes: bucket wheel support tooling, cantilever beam support tooling, gantry support tooling, slewing mechanism support tooling, front-section support steel bench for the cantilever beam, rear-section support steel bench for the cantilever beam, and bottom cushion plate for the tooling;

[0011] S2. Detect the parts of the stacker-reclaimer with large stress by flaw detection;

[0012] S3. Install the support tooling and remove the counterweight. Use a crane to lift and remove the tail counterweight, and use a wire rope for hoisting. During the hoisting process, use guy ropes to fix and stabilize the counterweight;

[0013] S4. Disassemble the expansion sleeve of the bucket wheel shaft and the bearing housing of the bucket wheel shaft connecting the bucket wheel body and the cantilever beam. Use a crane to lift and remove the bucket wheel body as a whole. Lock the wire rope on the side of the bearing housing of the bucket wheel shaft, and use a chain block to cooperate with the wire rope to lock the side of the bucket wheel body to keep the balance of the bucket wheel body during hoisting and remove the bucket wheel body as a whole;

[0014] S5. Use a crane combination to hoist and remove the cantilever beam tie rod;

[0015] S6. Remove the cantilever beam in sections. First, remove the front section of the cantilever beam, and then remove the rear section of the cantilever beam;

[0016] S7. Fabricate a supplementary section for the cantilever beam according to the dimensions of the trimmed front section and rear section of the cantilever beam, and assemble the cantilever beam offline. Butt-join the front section of the cantilever beam, the supplementary section of the cantilever beam, and the rear section of the cantilever beam by welding in sequence;

[0017] S8. Use a crane combination to hoist and reinstall the assembled cantilever beam;

[0018] S9. Use a crane combination to hoist and reinstall the cantilever beam tie rod;

[0019] S10. Restore the connection of the hydraulic part of the structural components to make the structural components return to the normal use state;

[0020] S11. Reinstall the bucket wheel body as a whole;

[0021] S12. Reinstall the counterweight;

[0022] S13. Reinstall the cantilever beam belt and other non-structural accessories, restore the connection of the remaining electrical auxiliary equipment, and remove the support tooling.

[0023] Further, in S2, UT + MT is used to detect the welds of the cantilever beam and the first cantilever beam tie rod where the two-side working beams are welded to the middle non-working support beam. The inspection and acceptance standard is no linear or non-linear defects;

[0024] In S2, detect the change in the distance between the articulated points of the portal frame and the cantilever beam, the portal column and the first cantilever beam tie rod, the portal column and the second cantilever beam tie rod, the portal column and the counterweight beam tie rod, the cantilever beam and the first cantilever beam tie rod, the cantilever beam and the second cantilever beam tie rod, and whether there is deformation in the structure.

[0025] In S2, use UT + MT to detect the welds on the upper part of the portal column, and the inspection and acceptance standard is no linear or non - linear defects.

[0026] Furthermore, in S3, use a forklift or a truck crane to separately insert the bucket wheel support tooling, the cantilever beam support tooling, and the slewing mechanism support tooling under the bucket wheel, under the cantilever beam, and under the slewing mechanism, and fix them by spot welding and stuff them tightly.

[0027] The specific installation positions of the support tooling are as follows: one bucket wheel support tooling is set on the side of the bucket wheel away from the portal column, one cantilever beam support tooling is set respectively under the front section and the rear section of the cantilever beam on both sides of the cantilever bending point, and one slewing mechanism support tooling is set under the slewing mechanism.

[0028] Furthermore, the specific operation method and steps in S4 are as follows:

[0029] Step (1): Hang the wire rope and the chain block on the hook head of the truck crane.

[0030] Step (2): After the wire rope is stressed and straightened, remove the bolts on the upper end cover of the bucket wheel shaft bearing seat, and lift out the upper end cover of the bucket wheel shaft bearing seat.

[0031] Step (3): Remove the connecting bolts between the electrical auxiliary equipment on the cantilever beam and the bucket wheel shaft expansion sleeve, weld a temporary jack for removing the bucket wheel shaft on the bucket wheel shaft expansion sleeve, and use a hydraulic jack to jack out the bucket wheel shaft.

[0032] Step (4): Use a 160t truck crane to lift the 25t bucket wheel body. When lifting, slowly lift the hook head of the truck crane. After the wire rope is tightened, observe the state of the cantilever beam, and adjust the balance position of the bucket wheel body by pulling the chain block through the trial - lifting method until the bucket wheel body is balanced, and then lift out the bucket wheel body.

[0033] Furthermore, in S5, use two truck cranes to separately lift the bottom and the top of the cantilever beam tie rod. First, remove the bottom pin shaft between the cantilever beam tie rod and the cantilever beam, and then remove the top pin shaft between the cantilever beam tie rod and the portal column. The two truck cranes lift simultaneously to place the cantilever beam tie rod on the ground.

[0034] Furthermore, the operation method and steps for removing the front section of the cantilever beam in S6 are as follows:

[0035] Step (1): Use a truck crane to lift the front section of the cantilever beam on the side away from the portal column. At the same time, use a truck crane to pull the rear section of the cantilever beam in the opposite direction on the side close to the portal column to maintain the overall balance of the stacker-reclaimer.

[0036] Step (2): Use chain hoists to pull the front section and the rear section of the cantilever beam respectively. The operator uses a scissor lift to move to the bending point of the cantilever, and cut the cantilever beam at the bending point to form an independent front section of the cantilever beam and a rear section of the cantilever beam still connected to the stacker-reclaimer.

[0037] Step (3): After lifting the front section of the cantilever beam away from the stacker-reclaimer body, gradually release the chain hoist, remove the front section of the cantilever beam and place it on four supporting steel stools for the front section of the cantilever beam, and start to shape and trim the front section of the cantilever beam, cutting off a part of the deformed cantilever beam at the bending point.

[0038] Further, the operation method and steps for removing the rear section of the cantilever beam in S6 are as follows:

[0039] Step (1): Set up a scaffolding at the bottom of the pin shaft position where the cantilever beam is connected to the stacker-reclaimer body to form an operating platform for the operator.

[0040] Step (2): Use a truck crane to lift the joint between the rear section of the cantilever beam and the stacker-reclaimer body, so that the joint of the rear section of the cantilever beam and the stacker-reclaimer is in a relaxed state. The operator uses the scaffolding to move to the joint of the rear section of the cantilever beam and the stacker-reclaimer body, and remove the pin shaft at the joint of the rear section of the cantilever beam and the stacker-reclaimer.

[0041] Step (3): Use a truck crane to lift off the rear section of the cantilever beam and place the rear section of the cantilever beam on two supporting steel stools for the rear section of the cantilever beam, and start to shape and trim the rear section of the cantilever beam, cutting off a part of the deformed cantilever beam at the bending point.

[0042] Further, the specific operation method and steps in S7 are as follows:

[0043] Step (1): After the supplementary section of the cantilever beam is manufactured, measure and confirm the dimensions offline, and make corrections according to the actual situation on site.

[0044] Step (2): Use a jack to adjust the positions of each section of the cantilever beam. After docking and spot welding the front section of the cantilever beam, the supplementary section of the cantilever beam, and the rear section of the cantilever beam one by one, perform full welding. The welding uses CO2 gas shielded welding, with an X-shaped 60° groove and double-sided welding.

[0045] Step (3): Perform flaw detection after docking each section of the cantilever beam.

[0046] Further, the specific operation method and steps in S8 are as follows:

[0047] Step (1): Before hoisting, place gantry support tools at the corresponding positions of the rear section and the front section of the original cantilever beam of the stacker-reclaimer, and place the assembled cantilever beam steadily.

[0048] Step (2): Use two truck cranes to lift the cantilever beam as a whole, and make the cantilever beam fall steadily on the gantry support tools.

[0049] Step (3): Use two chain blocks to adjust the position of the cantilever beam, and make the holes of the hinge points of the cantilever beam and the stacker-reclaimer opposite, and install the pin shafts.

[0050] Further, in S9, use two truck cranes to lift the bottom and top of the cantilever beam tie rod respectively. First, install the top pin shaft of the cantilever beam tie rod and the portal column, and then install the bottom pin shaft of the cantilever beam tie rod and the cantilever beam.

[0051] As can be seen from the above technical solutions, the present invention has the following advantages:

[0052] The present invention solves the technical problem of rapid on-site repair of the cantilever bending of a stacker-reclaimer similar in structure to the DQL9000 stacker-reclaimer by setting a reasonable disassembly and assembly sequence, selecting appropriate hoisting positions and hoisting equipment, and effectively guarantees the personal and property safety during the rapid on-site repair of the cantilever bending of the stacker-reclaimer.

[0053] In addition, the method of the present invention has obtained good practical verification effects in on-site maintenance and repair work. Each operation step is safe and reliable and is worthy of promotion.

[0054] Therefore, compared with the prior art, the present invention has prominent substantive features and significant progress, and the beneficial effects of its implementation are also obvious. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] In order to more clearly illustrate the technical solutions of the present invention, the drawings required to be used in the description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0056] Figure 1 It is a schematic diagram of the overall structure of the stacker-reclaimer.

[0057] Figure 2 It is a schematic diagram of the partial structure of the cantilever beam and the cantilever beam tie rod of the stacker-reclaimer and a schematic diagram of the working surface structure of the cantilever beam tie rod.

[0058] In the figure, 1, bucket wheel; 2, cantilever beam; 3, counterweight beam; 4, portal; 5, portal column; 6, counterweight beam tie rod; 7, first cantilever beam tie rod; 8, second cantilever beam tie rod; 9, working beam; 10, non-working support beam. Detailed implementation mode

[0059] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0060] Embodiment 1

[0061] A rapid on-site repair method for the cantilever bending of a stacker-reclaimer includes the following steps:

[0062] S1. Protectively remove the cables and signal lines, disconnect and remove the cantilever beam belt, remove other non-structural accessories, clean the operation site and fabricate the support tooling offline.

[0063] Specifically, make marks on the cables and signal lines for reinstallation.

[0064] Specifically, according to the position of the on-site crane, clean the side stockpile for the crane to stand and install the support tooling.

[0065] Specifically, the support tooling includes: bucket wheel support tooling, cantilever beam support tooling, gantry support tooling, slewing mechanism support tooling, front-section support steel bench for the cantilever beam, rear-section support steel bench for the cantilever beam, and bottom cushion plate for the tooling.

[0066] The front-section support steel bench for the cantilever beam has a specification of 1m * 1.5m * 1m.

[0067] The rear-section support steel bench for the cantilever beam has a specification of 1m * 5m * 1m.

[0068] S2. Detect the parts of the stacker-reclaimer that are under large stress.

[0069] Since the bending of the cantilever beam 2 will cause damage to the overall structure of the vehicle, before repairing the cantilever beam 2, detect the parts of the stacker-reclaimer that are under large stress. If there is damage to any part, replace it in time to avoid deviation during the repair construction of the cantilever beam 2.

[0070] Specifically, the detection parts include the cantilever beam 2, the first cantilever beam tie rod 7, the portal column 5, and the hinge points of the portal base 4 with the cantilever beam 2, the first cantilever beam tie rod 7, the second cantilever beam tie rod 8, and the counterweight beam tie rod 6, as well as the hinge point of the cantilever beam 2 and the first cantilever beam tie rod 7.

[0071] Specifically, use UT + MT to detect the welds of the operation beams 9 and the intermediate non-operation support beams 10 on both sides of the cantilever beam 2 and the first cantilever beam tie rod 7. The detection and acceptance standard is no linear or non-linear defects.

[0072] Specifically, detect the distance changes at the hinge points of the slewing jib 4 and the cantilever beam 2, the portal column 5 and the first cantilever beam tie rod 7, the second cantilever beam tie rod 8, and the counterweight beam tie rod 6, as well as the hinge points of the cantilever beam 2 and the first cantilever beam tie rod 7 and the second cantilever beam tie rod 8, and check whether the structure is deformed.

[0073] Specifically, use UT + MT to detect the welds on the upper part of the portal column 5, and the inspection and acceptance standard is no linear or non-linear defects.

[0074] S3. Install the support tooling and remove the counterweight. Use a crane to lift the tail counterweight. Use a wire rope for hoisting, and fix and stabilize the counterweight with guy ropes during the hoisting process.

[0075] Specifically, use a forklift or a truck-mounted crane to insert the bucket wheel support tooling, the cantilever beam support tooling, and the slewing mechanism support tooling respectively under the bucket wheel 1, under the cantilever beam 2, and under the slewing mechanism, and fix them by spot welding and make them firm.

[0076] The specific installation positions of the support tooling are as follows: One bucket wheel support tooling is set on the side of the bucket wheel 1 away from the portal column 5; one cantilever beam support tooling is set respectively under the front section and the rear section of the cantilever beam on both sides of the cantilever bending point; one slewing mechanism support tooling is set under the slewing mechanism.

[0077] Use a truck-mounted crane to lift the entire tail counterweight.

[0078] Specifically, use a 160t truck-mounted crane to lift the 190t tail counterweight, use a wire rope of φ32mm * 6m for hoisting, and fix and stabilize the counterweight with guy ropes during the hoisting process.

[0079] S4. Disassemble the bucket wheel shaft expansion sleeve and the bucket wheel shaft bearing seat connecting the bucket wheel body and the cantilever beam 2, use a crane to lift the bucket wheel body as a whole, lock it with a wire rope on the side of the bucket wheel shaft bearing seat, use a chain block to cooperate with the wire rope to lock the side of the bucket wheel body, keep the balance of the bucket wheel body during hoisting, and remove the bucket wheel body as a whole.

[0080] The bucket wheel body includes: a bucket wheel drive system, a bucket wheel 1, on which a bucket wheel shaft, a bucket wheel shaft expansion sleeve, and a bucket wheel shaft bearing seat are provided; the bucket wheel body is fixed on the cantilever beam 2 through the bucket wheel shaft bearing seat, and a speed reducer is also fixed on the cantilever beam 2, and the speed reducer is connected to the bucket wheel body through the bucket wheel shaft expansion sleeve.

[0081] Specifically, disassemble the bucket wheel shaft expansion sleeve and the bucket wheel shaft bearing seat connecting the bucket wheel body and the cantilever beam 2, use a 160t truck-mounted crane to lift the 25t bucket wheel body, lock it with a φ32mm wire rope on the side of the bucket wheel shaft bearing seat, use a 10t chain block to cooperate with the φ32mm wire rope to lock the side of the bucket wheel body to keep the balance of the bucket wheel body during hoisting. The specific operation methods and steps are as follows:

[0082] Step (1): Hang the wire rope and the chain block on the head of the 160t truck crane hook.

[0083] Step (2): After the wire rope is stressed and straightened, remove the bolts on the upper end cover of the bucket wheel shaft bearing seat, and lift out the upper end cover of the bucket wheel shaft bearing seat.

[0084] Step (3): Remove the connecting bolts between the reduction gearbox and the expansion sleeve of the bucket wheel shaft, weld a temporary jack for removing the bucket wheel shaft on the expansion sleeve of the bucket wheel shaft, and use a hydraulic jack to push out the bucket wheel shaft.

[0085] Step (4): Use a 160t truck crane to lift and remove the 25t bucket wheel body. When lifting, slowly raise the head of the truck crane hook. After the wire rope is tightened, observe the state of the cantilever beam 2. Adjust the balance position of the bucket wheel body by pulling the chain block through the trial lifting method until the bucket wheel body is balanced, and then lift out the bucket wheel body.

[0086] S5. Use a crane combination to hoist and remove the cantilever beam tie rods. The cantilever beam tie rods include: the first cantilever beam tie rod 7 and the second cantilever beam tie rod 8. It can start from the side far away from the portal column 5 and remove the first cantilever beam tie rod 7 and the second cantilever beam tie rod 8 in sequence.

[0087] Specifically, use two truck cranes to lift and hold the bottom and top of the cantilever beam tie rod respectively. First, remove the pin shaft at the bottom of the cantilever beam tie rod to make the cantilever beam tie rod in a relaxed state, and then remove the pin shaft at the top of the cantilever beam tie rod. The two truck cranes lift simultaneously to place the cantilever beam tie rod on the ground.

[0088] After the cantilever beam tie rod is removed, measure and detect the flaw of the cantilever beam tie rod. If cracks are found at the welded structure of the cantilever beam tie rod, use an angle grinder to grind the crack until reaching the root of the crack, and then reinforce the crack.

[0089] Specifically, the reinforcement method can adopt the reinforcement method of welding a reinforcement piece at the crack of the cantilever beam tie rod.

[0090] S6. Remove the cantilever beam 2 in sections. First, remove the front section of the cantilever beam, and then remove the rear section of the cantilever beam.

[0091] The cantilever bending point divides the cantilever beam 2 into the front section of the cantilever beam far away from the portal column 5 and the rear section of the cantilever beam close to the portal column 5.

[0092] Use two 160t truck cranes to remove the front section of the cantilever beam. One is set at the front section of the cantilever beam far away from the portal column 5, and the other is set at the rear section of the cantilever beam close to the portal column 5.

[0093] The specific operation method and steps for removing the front section of the cantilever beam are as follows:

[0094] Step (1): Use a truck crane to lift the front section of the cantilever beam on the side away from the portal column 5. At the same time, use a truck crane to pull the rear section of the cantilever beam in the opposite direction on the side close to the portal column 5 to maintain the overall balance of the stacker-reclaimer.

[0095] Step (2): Use chain hoists to pull the front section and the rear section of the cantilever beam respectively. The operator moves to the cantilever bending point using a scissor lift and cuts the cantilever beam 2 at the cantilever bending point to form an independent front section of the cantilever beam and a rear section of the cantilever beam still connected to the stacker-reclaimer.

[0096] Step (3): After lifting the front section of the cantilever beam off the stacker-reclaimer body, gradually release the chain hoist, remove the front section of the cantilever beam and place it on four supporting steel stools for the front section of the cantilever beam, and start shaping and trimming the front section of the cantilever beam, cutting off a deformed part of the cantilever beam 2 at the cantilever bending point.

[0097] The specific operation methods and steps for removing the rear section of the cantilever beam are as follows:

[0098] Step (1): Before removing the rear section of the cantilever beam, set up a scaffolding at the bottom of the pin shaft position where the cantilever beam 2 is connected to the stacker-reclaimer body to form an operating platform for the operator.

[0099] The height of the scaffolding is 9 m, and the projected area of the scaffolding is 18 m 2 , and the rear section of the cantilever beam weighs 20 t. Use a 160 t truck crane for the removal operation.

[0100] Step (2): Use a truck crane to lift the articulated joint between the rear section of the cantilever beam and the stacker-reclaimer body to make the articulated point between the rear section of the cantilever beam and the stacker-reclaimer in a relaxed state. The operator moves to the articulated joint between the rear section of the cantilever beam and the stacker-reclaimer body using the scaffolding and removes the pin shaft connecting the rear section of the cantilever beam and the stacker-reclaimer.

[0101] Step (3): Use a truck crane to lift off the rear section of the cantilever beam and place the rear section of the cantilever beam on two supporting steel stools for the rear section of the cantilever beam, and start shaping and trimming the rear section of the cantilever beam, cutting off a deformed part of the cantilever beam 2 at the cantilever bending point.

[0102] S7. According to the dimensions of the trimmed front section and rear section of the cantilever beam, compare with the dimensions of the original cantilever beam 2, fabricate a supplementary section of the cantilever beam, and assemble the cantilever beam 2 offline. Butt the front section, the supplementary section, and the rear section of the cantilever beam section by section by welding.

[0103] The specific operation methods and steps are as follows:

[0104] Step (1): After the supplementary section of the cantilever beam is fabricated, measure and confirm the dimensions offline and make corrections according to the actual on-site situation.

[0105] Step (2): Use a jack to adjust the positions of each section of the cantilever beam 2. After butt-joining and spot-welding the front section, supplementary section, and rear section of the cantilever beam one by one for positioning, perform welding using the full-welding method. The installation tolerance is ±3 mm. CO2 gas shielded welding is used for welding. The welding wire is selected as E501T-2 * 1.2 mm. An X-shaped 60° groove is used, and the gap tolerance is ±3 mm. Double-sided welding is performed.

[0106] Step (3): After butt-joining each section of the cantilever beam 2, perform welding flaw detection.

[0107] The on-site welding method and requirements are as follows:

[0108] Step (1): Before welding, check whether the groove angle, root face, gap, and misalignment amount meet the welding requirements, and clean the rust, oil stain, mill scale, etc. inside and on both sides of the groove.

[0109] Step (2): Re-check the welding preheating temperature. If the temperature is insufficient, reheat it to meet the requirements.

[0110] Step (3): Install the welding backing plate and the arc striking plate, and check whether the surface cleanliness of the welding backing plate and the arc striking plate meets the requirements. The surface cleanliness requirements of the welding backing plate and the arc striking plate are the same as those of the groove surface. The welding backing plate is pressed tightly against the base metal, and the arc striking plate is firmly welded to the base metal. During welding, arc striking is not allowed on the base metal outside the groove.

[0111] Step (4): After welding one side, use carbon arc air gouging to clear the root. Select an 8-mm carbon rod and grind it. Then weld the other side. After welding on both sides is completed, remove the welding slag and spatter. If welding defects occur, grind them off in time and repair them.

[0112] Step (5): Let the welded steel member of the cantilever beam 2 cool naturally. After it reaches room temperature, perform weld flaw detection inspection.

[0113] Step (6): After the weld flaw detection inspection is qualified, touch up the paint in time.

[0114] S8. Use a crane combination to hoist and reinstall the assembled cantilever beam 2.

[0115] After the cantilever beam 2 is assembled, the overall weight is 50 t. Use two 160-t truck cranes for combined hoisting.

[0116] The specific operation method and steps are as follows:

[0117] Step (1): Before hoisting, place portal support tooling at the corresponding positions of the rear section and the front section of the original cantilever beam of the stacker-reclaimer respectively to ensure that the assembled cantilever beam 2 is placed stably.

[0118] Step (2): Use two 160t truck cranes to lift the cantilever beam 2 as a whole, and gently place the cantilever beam 2 onto the gantry support tooling.

[0119] Step (3): Use two 10-ton chain hoists to adjust the position of the cantilever beam 2, and align the hole positions of the cantilever beam 2 with the hinge points of the stacker-reclaimer. Install the pin shafts.

[0120] The methods and precautions for combined lifting by multiple cranes are as follows:

[0121] (1). The hoisting site and the road must be flat and solid. Backfilled soil and soft soil layers should be compacted and a bottom plate should be laid. The crane should not be parked on a slope.

[0122] (2). For the cranes participating in the combined lifting, the load capacity shall not exceed 75% of the rated lifting capacity of a single crane; ensure that the comprehensive safety factor k for the combined lifting by the cranes is ≥ 1.5.

[0123] (3). Designate a on-site commander at the hoisting site. The on-site commander should stand where all the crane drivers can see, and the command signals must be unified. Closely observe and monitor the situation of the lifted object during the lifting process.

[0124] (4). One crane should not operate two mechanisms simultaneously. When two cranes operate simultaneously, they should perform the same type of actions, and the actions should be kept steady; and the hook pulley blocks of both cranes should be kept in a vertical state.

[0125] S9. Use the combined crane lifting to reinstall the cantilever beam tie rod.

[0126] Specifically, use two truck cranes to lift simultaneously, and respectively lift the bottom and top of the cantilever beam tie rod. First, install the top pin shaft of the cantilever beam tie rod and the portal column 5; after the installation of the top pin shaft is completed, then install the bottom pin shaft of the cantilever beam tie rod and the cantilever beam 2.

[0127] S10. Restore the connection of the hydraulic parts of the structural components to make the structural components return to the normal operating state.

[0128] Specifically, after the installation of the cantilever beam 2 and the cantilever beam tie rod, connect and install the cables and automated signal lines of the electrical auxiliary equipment and the hydraulic drive device to make the equipment except the cantilever beam belt conveyor and the bucket wheel body return to the normal operating state.

[0129] S11. Reinstall the bucket wheel body as a whole.

[0130] The bucket wheel body weighs 25t and is reinstalled using a 160t truck crane.

[0131] Specifically, before reinstalling the bucket wheel body, lower the cantilever beam 2 to facilitate the installation of the bucket wheel body.

[0132] Lift the pre-assembled bucket wheel body to the installation position of the bucket wheel shaft bearing seat on the cantilever beam 2, reinstall the upper end cover of the bucket wheel shaft bearing seat, and use the bucket wheel shaft expansion sleeve to fixedly connect the bucket wheel body with the cantilever beam 2.

[0133] When reinstalling the bucket wheel body, ensure that the contact surface between the bucket wheel body and the cantilever beam 2 is thoroughly cleaned, and do not apply grease on the contact surface. When fixing the bucket wheel shaft expansion sleeve, the torque used shall be in accordance with the torque specified for tightening the bucket wheel shaft expansion sleeve, and tighten the bolts.

[0134] S12. Reinstall the counterweight.

[0135] Before reinstalling the counterweight, weigh the counterweight again. When installing the counterweight, the pressure ratio between the counterweight and the pitching hydraulic cylinder shall be calibrated.

[0136] S13. Reinstall the cantilever beam belt and other non-structural accessories, restore the connection of the remaining electrical auxiliary equipment, and remove the support tooling.

[0137] Before installing the cantilever beam belt, vulcanize the joint of the cantilever beam belt.

[0138] Install the speed reducers, motors and other electrical auxiliary equipment of the remaining mechanisms such as the cantilever beam belt conveyor and the bucket wheel body, and restore the signal connection of the remaining electrical auxiliary equipment such as the cantilever beam belt conveyor and the bucket wheel body.

[0139] The terms "first", "second", "third", "fourth", etc. (if any) in the description and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and do not have to be used to describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion.

[0140] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for quickly repairing the cantilever bending of a stacker-reclaimer on-site, characterized in that, It includes the following steps: S1. Protectively remove cables and signal lines, disconnect and remove the cantilever belt, remove other non-structural accessories, clean the operation site and fabricate support tooling offline; The support tooling includes: bucket wheel support tooling, cantilever beam support tooling, gantry support tooling, slewing mechanism support tooling, front-section support steel bench for the cantilever beam, rear-section support steel bench for the cantilever beam, and bottom cushion plate for the tooling; S2. Detect the parts of the stacker-reclaimer with large stress; S3. Install the support tooling, and remove the counterweight. Use a crane to lift the tail counterweight, and use wire ropes for hoisting. During the hoisting process, use guy ropes to fix and stabilize the counterweight; S4. Disassemble the expansion sleeve of the bucket wheel shaft and the bearing seat of the bucket wheel shaft connecting the bucket wheel body and the cantilever beam. Use a crane to lift the bucket wheel body as a whole. Lock it with a wire rope on the side of the bearing seat of the bucket wheel shaft, and use a chain block to cooperate with the wire rope to lock the side of the bucket wheel body to keep the balance of the bucket wheel body during hoisting and remove the bucket wheel body as a whole; S5. Use a combination of cranes to hoist and remove the cantilever beam tie rod; S6. Demolish the cantilever beam in sections. First, remove the front section of the cantilever beam, and then remove the rear section of the cantilever beam; S7. Fabricate a supplementary section of the cantilever beam according to the dimensions of the trimmed front section and rear section of the cantilever beam, and assemble the cantilever beam offline. Butt the front section, supplementary section, and rear section of the cantilever beam section by section by welding; S8. Use a combination of cranes to hoist and reinstall the assembled cantilever beam; S9. Use a combination of cranes to hoist and reinstall the cantilever beam tie rod; S10. Restore the connection of the hydraulic part of the structural components to make the structural components return to the normal use state; S11. Reinstall the bucket wheel body as a whole; S12. Reinstall the counterweight; S13. Reinstall the cantilever belt and other non-structural accessories, restore the connection of the remaining electrical auxiliary equipment, and remove the support tooling.

2. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that, In S2, use UT+MT to detect the welds of the cantilever beam and the welds of the two-side working beams and the middle non-working support beam on the first cantilever beam tie rod. The inspection and acceptance standard is no linear or non-linear defects; In S2, detect the distance change of the hinge points of the portal frame and the cantilever beam, the portal column and the first cantilever beam tie rod, the portal column and the second cantilever beam tie rod, the portal column and the counterweight beam tie rod, the cantilever beam and the first cantilever beam tie rod, the cantilever beam and the second cantilever beam tie rod, and whether the structure is deformed; In S2, use UT+MT to detect the welds of the upper half of the portal column. The inspection and acceptance standard is no linear or non-linear defects.

3. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that In S3, use a forklift or a truck crane to respectively insert the bucket wheel support tooling, the cantilever beam support tooling, and the slewing mechanism support tooling under the bucket wheel, under the cantilever beam, and under the slewing mechanism, and fix them by spot welding and stuff them firmly; The specific installation positions of the support tooling are as follows: one bucket wheel support tooling is set on the side of the bucket wheel far from the portal column, one cantilever beam support tooling is respectively set under the front section and rear section of the cantilever beam on both sides of the cantilever bending point, and one slewing mechanism support tooling is set under the slewing mechanism.

4. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that, The specific operation method and steps in S4 are as follows: Step (1): Hang the wire rope and the chain block on the hook head of the vehicle hoist; Step (2): After the wire rope is stressed and straightened, remove the bolts of the upper end cover of the bearing seat of the bucket wheel shaft and lift out the upper end cover of the bearing seat of the bucket wheel shaft; Step (3): Remove the connecting bolts between the electrical auxiliary equipment on the cantilever beam and the expansion sleeve of the bucket wheel shaft. Weld a temporary jack for removing the bucket wheel shaft on the expansion sleeve of the bucket wheel shaft, and use a hydraulic jack to jack out the bucket wheel shaft. Step (4): Use a 160t truck crane to lift the 25t bucket wheel body. When lifting, slowly raise the hook head of the truck crane. After the steel wire rope is tightened, observe the state of the cantilever beam. Adjust the balance position of the bucket wheel body by pulling the chain block through the trial lifting method until the bucket wheel body is balanced, and then lift out the bucket wheel body.

5. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that In S5, use two truck cranes to lift the bottom and top of the cantilever beam tie rod respectively. First, remove the bottom pin shaft between the cantilever beam tie rod and the cantilever beam, and then remove the top pin shaft between the cantilever beam tie rod and the portal column. The two truck cranes lift simultaneously to place the cantilever beam tie rod on the ground.

6. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that The operation method and steps in S6 are as follows: Step (1): Use a truck crane to lift the front section of the cantilever beam on the side far from the portal column. At the same time, use a truck crane to pull the rear section of the cantilever beam in the opposite direction on the side close to the portal column to maintain the overall balance of the stacker-reclaimer. Step (2): Use chain blocks to pull the front section and the rear section of the cantilever beam respectively. The operator uses a scissor lift to move to the bending point of the cantilever beam and cut the cantilever beam at the bending point to form an independent front section of the cantilever beam and a rear section of the cantilever beam still connected to the stacker-reclaimer. Step (3): After lifting the front section of the cantilever beam away from the stacker-reclaimer body, gradually release the chain block, remove the front section of the cantilever beam and place it on four supporting steel stools for the front section of the cantilever beam. Start to shape and trim the front section of the cantilever beam, and cut off a part of the deformed cantilever beam at the bending point.

7. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that The operation method and steps in S6 for removing the rear section of the cantilever beam are as follows: Step (1): Build a scaffolding at the bottom of the pin shaft position where the cantilever beam is connected to the stacker-reclaimer body. Step (2): Use a truck crane to lift the articulated part of the rear section of the cantilever beam and the stacker-reclaimer body, so that the articulated point of the rear section of the cantilever beam and the stacker-reclaimer is in a relaxed state, and remove the pin shaft at the articulated point of the rear section of the cantilever beam and the stacker-reclaimer. Step (3): Use a truck crane to lift the rear section of the cantilever beam and place it on two supporting steel stools for the rear section of the cantilever beam. Start to shape and trim the rear section of the cantilever beam, and cut off a part of the deformed cantilever beam at the bending point.

8. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that, The specific operation method and steps in S7 are as follows: Step (1): After the supplementary section of the cantilever beam is manufactured, measure and confirm the dimensions offline and correct them according to the actual situation on site. Step (2): Use a jack to adjust the positions of each section of the cantilever beam. After butt-jointing and spot-welding the front section of the cantilever beam, the supplementary section of the cantilever beam, and the rear section of the cantilever beam one by one and positioning them, carry out welding by full welding. CO2 gas shielded welding is used for welding, with an X-shaped 60° groove and double-sided welding. Step (3): Conduct flaw detection after butt-jointing each section of the cantilever beam.

9. The on-site rapid repair method for the cantilever bending of a stacker-reclaimer according to claim 1, characterized in that, The specific operation method and steps in S8 are as follows: Step (1): Before hoisting, place portal support tools at the corresponding positions of the original rear section and the front section of the cantilever beam of the stacker-reclaimer respectively, and place the assembled cantilever beam stably. Step (2): Use two truck cranes to lift the cantilever beam as a whole, so that the cantilever beam falls stably on the portal support tools. Step (3): Use two chain hoists to adjust the position of the cantilever beam, and align the hole positions of the hinge points of the cantilever beam with the stacker-reclaimer, then install the pin shaft.

10. The on-site rapid repair method for the cantilever bending of the stacker-reclaimer according to claim 1, characterized in that, In S9, use two truck cranes to lift the bottom and top of the cantilever beam tie rod respectively. First, install the top pin shaft of the cantilever beam tie rod and the portal column, and then install the bottom pin shaft of the cantilever beam tie rod and the cantilever beam.

Images