A vertical loop mounting method

Abstract

The application discloses a vertical loop mounting method, steps are as follows: installing a base frame; installing a bottom section loop car track and a bottom section counterweight track; processing support piles and cushion piles and respectively installing the support piles and the cushion piles on the upper part of a bottom maintenance safety bolt mechanism and the upper surface of a center buffer seat; hoisting a half loop car and placing the half loop car above the support piles and the cushion piles; connecting two loop cars into a whole after repeating the above operation; hoisting a counterweight; installing an upper structure frame and installing an upper loop car track and an upper counterweight track on the upper structure frame; welding a plurality of main lifting lugs for hoisting by a main hook of a travelling crane and a plurality of auxiliary lifting lugs for hoisting by a small hook of the travelling crane on a top pulley block platform; hoisting and fixing the top pulley block platform; and completing installation and debugging of accessories. The method has good operation safety, high work efficiency and small labor intensity, and has a good application prospect.

Description

Technical Field

[0001] This invention relates to the field of mechanical equipment installation technology, and specifically to a vertical looper installation method. Background Technology

[0002] In metallurgical engineering projects, strip steel processing lines (cold rolling, galvanizing, continuous heat treatment lines, continuous annealing lines, pickling lines, etc.) often use loopers to store steel strips to ensure the continuity of the production process. For factories with limited floor space, vertical loopers are usually used. During the construction of such projects, the production line equipment is often installed after the factory structure is enclosed. Vertical loopers have a high structural body, require high precision, and are inherently dangerous to install. Specifically, the traditional installation sequence for vertical loopers is to install the looper trolley after the column structure and rails are installed. During this process, because the working distance between the looper trolley rails and the longest dimension between the outer edges of the looper wheels is almost the same, the hoisting position is at a height of tens of meters, and there is no platform nearby for traction, collisions between the looper trolley and the rails and structure are inevitable, potentially affecting precision and requiring secondary adjustments. The large top platform area of ​​the vertical looper results in poor stability when hoisted with a single hook; generally, a dual-crane lifting method is used for installation. The disadvantages are that the operation of the two cranes requires synchronization, high skill levels for operators, and... In some situations, due to the influence of the conductor rail and the overhead crane track, one side of the overhead crane cannot be driven to the hoisting position, making it impossible to complete the double-machine lifting. In addition, the installation position is tens of meters in the air, and there is no platform for traction around, which is quite dangerous, especially in the confined space of the factory. When installing the traditional counterweight wire rope, the wire rope is first laid on the top pulley block, and then the counterweight is hoisted. Personnel connect the rope end to the counterweight in mid-air and continue to lift the counterweight. The wire rope inside the platform is first subjected to external force and then slides down under the action of gravity, connecting the bottom looper together. This process requires very high skills from the operators and is very dangerous.

[0003] Therefore, developing a vertical looper installation method that offers good operational safety, high work efficiency, and low labor intensity is of great practical significance. Summary of the Invention

[0004] Due to the aforementioned deficiencies in existing technologies, this invention provides a vertical looper installation method that offers good operational safety, high work efficiency, and low labor intensity. This method can significantly improve the safety of the installation process of large vertical loopers, enhance the installation efficiency of large vertical loopers, increase the utilization rate of hoisting equipment, and reduce the labor intensity of operators. This overcomes the shortcomings of existing vertical looper installation methods, which place high demands on operators, are highly dangerous, and have low work efficiency.

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

[0006] A vertical loose-fitting installation method includes the following steps:

[0007] (1) Install the basic frame, and simultaneously install the central buffer seat, the bottom inspection safety pin mechanism and the loose bottom roller;

[0008] (2) Install the bottom section looper track and bottom section counterweight track on the basic frame;

[0009] (3) Process the support piles and pads and install the support piles on the upper part of the bottom maintenance safety pin mechanism and install the pads on the upper surface of the center buffer seat. The support piles and pads must ensure that the upper surface of the looper car is level when it is placed on the upper surface of the two. (Due to the manufacturing error of the looper car and the bottom maintenance safety pin mechanism, directly using the safety pin mechanism and the center buffer seat to keep a single looper car in the maintenance position may result in a large gap between its wheel flange and the track surface, which may cause the other half of the looper car to be unable to be positioned or to be inconvenient to be positioned. This is time-consuming and labor-intensive, so this method is not recommended.)

[0010] (4) Hoist the half-section of the looper car, slide one side wheel of the half-section looper car into the bottom section looper car track and place it above the support pile and pad pile;

[0011] (5) Repeat step (4) to complete the hoisting of the other half of the looper car and connect the two looper cars into a whole;

[0012] (6) The hoisting assembly of the counterweight causes the counterweight guide to slide into the bottom section counterweight track;

[0013] (7) Install the upper structural frame and install the upper looper track and upper counterweight track on the upper structural frame. Ensure that the upper looper track is aligned with the bottom looper track and the upper counterweight track is aligned with the bottom counterweight track. The upper structural frame is installed using conventional methods to adjust the structural columns to meet the requirements, connect them into a complete frame, weld them firmly, and re-measure the deformation to meet the requirements. The track is adjusted after the top pulley platform is installed to avoid the impact on the frame during the installation of the top pulley platform, which would affect the track accuracy.

[0014] (8) Weld multiple main lifting lugs for lifting the main hook of the crane and multiple auxiliary lifting lugs for lifting the small hook of the crane on the top pulley block platform. The main lifting lugs are evenly distributed around the central circumference of the top pulley block platform, and the auxiliary lifting lugs are located on the same side of the top pulley block platform.

[0015] (9) The top pulley platform is hoisted. The main lifting lug is used as the main lifting force point, and the auxiliary lifting lug is used as the auxiliary force point to adjust the attitude of the top pulley platform during the hoisting process. After hoisting into place, the top pulley platform is fixed to the upper structure frame (the wire rope used for hoisting needs to be wrapped around the corresponding hook head several times to avoid slippage of the ropes on both sides during the hoisting process, which would cause uneven force and lead to accidents; the selection of wire rope and lifting lug needs to consider extreme conditions to ensure that the bearing capacity meets all working conditions). This method does not require a traction rope, and all operators are far away from the hoisted object, eliminating the delay and instability of attitude control of extra-large volume components during high-altitude hoisting and ground traction, and effectively improving the safety of hoisting in narrow spaces.

[0016] (10) Fix one end of the counterweight wire rope to the counterweight, and then use the small winch to pull the other end of the counterweight wire rope along the pulley block. When the wire rope is almost vertical (do not fully tension it to avoid the small winch rope breaking), the crane lifts the counterweight at the same time. The wire rope continues to be pulled down using the small winch. When the other end of the counterweight wire rope reaches the connection point with the hook car, the crane stops lifting. After the counterweight wire rope is firmly fixed to the hook car, remove the small winch and use the lifting vehicle to send personnel to the counterweight. Disconnect the counterweight from the crane main hook.

[0017] (11) Use a small winch to wind the wire rope on the pulley block in the same way as the loop winch wire rope. Connect the small winch rope hook to the loop winch rope head. Use the small winch to wind the loop winch wire rope on the pulley block. Wind the excess part on the loop winch drum. Adjust the length of the wire rope on both sides and fix it to the drum.

[0018] (12) Use a loop winch to lift the loop car and perform debugging operations.

[0019] This installation method effectively avoids the dangers and difficulties in the installation process: ① After the foundation columns and bottom track sections are installed and adjusted, the installation sequence of first installing the hoisting trolley and then lifting the upper structure avoids the inevitable impact on the structure when the hoisting trolley is installed later; ② The vertical hoisting platform uses a main hook for lifting and an auxiliary hook for traction to control the stability of the large-volume, relatively lightweight platform during the hoisting process, replacing the method of manual traction rope control. This eliminates the delay and instability in controlling the attitude of extra-large components during high-altitude hoisting and ground traction, effectively improving the safety of hoisting in confined spaces; ③ A counterweight wire rope is installed at the low point. The trolley lifts the counterweight, and at the same time, the other end is pulled down into place by a small winch and fixed to the hoisting trolley. In the past, the wire rope was hung horizontally on the top pulley block. The trolley lifted the counterweight to the middle position, and personnel installed and fixed the wire rope in mid-air, which was very dangerous.

[0020] The above installation method effectively reduces the operational risks of looper installation, improves equipment installation efficiency, reduces the labor intensity of operators, and has good repeatability and operability.

[0021] As a preferred technical solution:

[0022] As described above, in a vertical loose-fitting installation method, the installation sequence of the basic frame is as follows: after installing the basic columns, the basic columns are connected and fixed to the connectors to form the basic frame.

[0023] As described above, in a vertical looper installation method, a guide fixture I is installed inside the top of the bottom looper track to facilitate the smooth entry of the looper wheels into the track (especially the installation and matching of the clamping guide wheel and the track).

[0024] When hoisting the half-section looper car, one side wheel of the half-section looper car slides into the bottom section looper car track along the guide direction of guide tool I.

[0025] After connecting the two looper cars into a whole, remove guide fixture I to allow the upper structure and upper track to be properly positioned.

[0026] In the vertical looper installation method described above, in step (6), before hoisting and assembling the counterweight, guide fixture II is processed and guide fixture II is installed on the top of the bottom section counterweight rail;

[0027] When the counterweight is hoisted, the counterweight guide wheel slides into the bottom counterweight track along the guide direction of guide fixture II;

[0028] After the counterweight is hoisted, remove guide fixture II to allow the upper counterweight track to be properly positioned.

[0029] As described above, in this vertical slip-on installation method, before hoisting the top pulley platform, guide fixture III is fabricated and installed at the connection surface between the top of the upper structural frame and the top pulley platform. Multiple guide fixtures III are arranged around the top of the upper structural frame. An open guide device is installed at the top of the column to facilitate the positioning and installation of the top pulley platform, reducing the amount of misalignment adjustment and thus reducing the workload of platform adjustment. This improves the efficiency of high-altitude assembly of the slip-on platform. In conventional high-altitude assembly, workers work on bolt holes within a temporary platform at the top of the column, with a large steel platform suspended overhead, posing numerous safety risks. This device eliminates these risks. After the top pulley platform is hoisted to the predetermined height, it is slowly lowered. The relative position of the platform and guide fixture III is constantly monitored (by listening to sound). The crane is moved appropriately to adjust the relative position. Utilizing its guiding function, personnel can remotely control the hoisting and positioning of the top pulley platform, and then make minor adjustments and fixations to the platform.

[0030] As described above, in a vertical looper installation method, after fixing the top pulley block platform, measurement control points are placed above the platform, and the pulley block, upper looper track, and upper counterweight track are adjusted to meet the requirements and tightened.

[0031] As described above, in a vertical looper installation method, the support piles and pad piles are removed after the commissioning work is completed.

[0032] The above technical solution is only one feasible technical solution of the present invention. The scope of protection of the present invention is not limited thereto. Those skilled in the art can reasonably adjust the specific design according to actual needs.

[0033] The above invention has the following advantages or beneficial effects:

[0034] The vertical looper installation method of the present invention makes full use of the double hook lifting capacity of a single crane, optimizes the construction sequence, clarifies the reasonable installation sequence of each large component, effectively reduces the danger of high-altitude operation of large vertical looper installation, improves the utilization rate of lifting equipment, reduces the rigid requirements on operators, reduces the intensity of work, and improves installation efficiency. It has good repeatability, strong operability, and good application prospects. Attached Figure Description

[0035] The invention, its features, shape, and advantages will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings. Like reference numerals denote like parts throughout the drawings, the emphasis being on illustrating the gist of the invention.

[0036] Figure 1 This is a schematic diagram of a vertical looper structure.

[0037] Figure 2 A schematic diagram of guide fixture I installed on the base frame;

[0038] Figure 3 A schematic diagram showing the installation of support piles and pad piles on the foundation frame;

[0039] Figure 4 A schematic diagram of the installation of a half-set of the slingshot;

[0040] Figure 5 A schematic diagram showing the installation of guide fixture II;

[0041] Figure 6 Schematic diagram of the installation of guide fixture III;

[0042] Figure 7 A schematic diagram showing how guide fixture III guides the top pulley block platform;

[0043] Figure 8 A schematic diagram of the platform for hoisting the top pulley block;

[0044] Figure 9 This is a schematic diagram showing the completed installation of the top pulley block platform;

[0045] Figure 10 Schematic diagram for the installation of counterweight wire rope;

[0046] Figure 11 A schematic diagram showing the debugging status of a vertical looper;

[0047] The components include: 1. Basic frame; 11. Basic column; 12. Central buffer seat; 13. Bottom maintenance safety pin mechanism; 14. Loose bottom roller; 15. Bottom section loose carriage track; 16. Bottom section counterweight track; 17. Half-piece loose carriage I; 18. Half-piece loose carriage II; 19. Guide fixture I; 110. Support pile; 111. Pad pile; 112. Guide fixture II; 113. Counterweight; 2. Upper structure frame; 21. Guide fixture III; 22. Upper loose carriage track; 23. Upper counterweight track; 3. Top pulley block platform; 31. Main lifting lug; 32. Auxiliary lifting lug; 4. Main hook of the crane; 5. Small hook of the crane. Detailed Implementation

[0048] The structure of the present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the present invention.

[0049] Example 1

[0050] A vertical loose-fitting installation method includes the following steps:

[0051] Step 1: First, install the foundation column 11. After adjusting it to meet the dimensional accuracy requirements, connect and fix the foundation column 11 with the connector to form the foundation frame. The center buffer seat 12, the bottom maintenance safety pin mechanism 13, and the loose bottom roller 14 can be installed simultaneously.

[0052] Step 2: Install the bottom section looper track 15 and the bottom section counterweight track 16 on the basic frame 1, adjust the dimensions to meet the requirements, and fix them completely.

[0053] Step 3: Fabricate and install guide fixture I19 (e.g., on the upper end of the bottom section looper track 15) Figure 2 (As shown); A support pile 110 is fabricated and installed on the upper section of the safety pin mechanism 13, and a pad pile 111 is fabricated and installed at the central buffer seat 12. When the looper is placed on the upper surface of the support pile 110 and the pad pile 111, the upper surface of the looper is made to be horizontal (as shown). Figure 3 (As shown); the half-piece looper I17 is hoisted along the guide fixture I19 and placed above the support pile 110 and the pad pile 111 (as shown). Figure 4 As shown, the flange of the looper wheel is in contact with the rail surface.

[0054] Step 4: As described in Step 3, hoist the half-piece looper II18 along the other side guide fixture I19 and place it above the support pile 110 and the pad pile 111. Adjust the two looper pieces so that their dimensions and related accuracy meet the specifications and drawing requirements. After connecting the two looper pieces into a whole, remove the guide fixture I19.

[0055] Step 5: Fabricate guide fixture II112 (e.g., on the upper end of the bottom section counterweight track 16) Figure 5 (As shown), so that the counterweight guide wheel can smoothly slide into the counterweight track and complete the positioning of the counterweight 113. After completion, remove the guide fixture II112.

[0056] Step Six: Install the vertical looper upper structure frame 2, the upper looper track 22, and the upper counterweight track 23. First, use conventional methods to install and adjust the upper structure columns to meet the requirements, connect them to form a complete frame, weld and fix them firmly, and re-measure the deformation to ensure it meets the requirements.

[0057] Step 7: Fabricate and install guide fixture III21 (e.g., at the connection surface between the top of the upper structural column and the top pulley platform) Figure 6 , Figure 7 As shown in the figure, this facilitates the positioning and installation of the top pulley block platform 3, reducing the amount of misalignment adjustment between the two and reducing the workload of platform adjustment.

[0058] Step 8: Weld four main lifting lugs 31 onto the top pulley platform 3. Use the main hook 4 of the crane for lifting, serving as the main lifting force points. Simultaneously weld two auxiliary lifting lugs 32, using the small hook 5 of the crane for lifting, serving as auxiliary force points to ensure the stability of the large platform during the lifting process (e.g., ...). Figure 8 As shown), (the wire rope used for hoisting needs to be wrapped around the corresponding hook head several times to avoid uneven force caused by slippage of the ropes on both sides during hoisting, which may lead to accidents; the selection of wire rope and lifting lugs should take extreme conditions into consideration to ensure that the load-bearing capacity meets all working conditions). During hoisting, the wire rope on the auxiliary lifting lug should be kept almost taut. Excessive force may cause the small hook to be overloaded.

[0059] Step Nine: After the top pulley platform 3 is hoisted to the predetermined height, it is slowly lowered. Constant monitoring of the relative position between the platform and guide fixture III21 is necessary (this can be determined by listening to the sound). The crane is moved appropriately to adjust the relative position. Utilizing its guiding function, personnel can remotely control the hoisting and positioning of the top pulley platform (e.g., ...). Figure 9 (As shown).

[0060] Step 10: The operators make minor adjustments and secure the platform. Once it is fully secured, the hoisting wire ropes are removed.

[0061] Step 11: Place the measurement control points on the platform, then adjust the top pulley block, the upper looper track 22 and the upper counterweight track 23 to meet the requirements and tighten them.

[0062] Step Twelve: First, fix one end of the counterweight wire rope to the counterweight. Then, use a small winch to pull the other end of the counterweight wire rope along the pulley block. Once the wire rope is nearly vertical (do not fully tension it to avoid the small winch rope breaking), simultaneously lift the counterweight with the crane. Continue pulling the wire rope down using the small winch. When the other end of the counterweight wire rope reaches the connection point with the looper, stop lifting and fix the counterweight wire rope to the looper (e.g., ...). Figure 10 , Figure 11 (As shown), remove the small winch; use a lifting vehicle to transport personnel to the counterweight and disconnect the counterweight from the main hook of the crane.

[0063] Step 13: Use a small winch to wind the wire rope on the pulley block in the same way as the slip-on winch. Connect the small winch hook to the slip-on winch rope head. Use the small winch to wind the slip-on winch wire rope onto the pulley block, with the excess part wound onto the slip-on winch drum. Adjust the length of the wire rope on both sides and fix it to the drum.

[0064] Step Fourteen: Use a looper winch to lift the looper car. If the lifting and lowering action is normal, remove the support piles and pad piles to complete the installation of the vertical looper equipment.

[0065] Verification has shown that the vertical looper installation method of the present invention fully utilizes the double-hook lifting capacity of a single overhead crane, optimizes the construction sequence, clarifies the reasonable installation sequence of each large component, effectively reduces the danger of high-altitude operations for large vertical looper installations, improves the utilization rate of lifting equipment, reduces the rigid requirements for operators, reduces the intensity of work, and improves installation efficiency. It has good repeatability, strong operability, and good application prospects.

[0066] Those skilled in the art should understand that variations can be implemented by combining existing technology with the above embodiments, which will not be elaborated here. Such variations do not affect the essence of the present invention, and will not be elaborated here either.

[0067] The preferred embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and the devices and structures not described in detail should be understood as being implemented in a conventional manner in the art. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the present invention. This does not affect the essential content of the present invention. Therefore, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the present invention's technical solutions still fall within the protection scope of the present invention.

Claims

1. A vertical loose-fitting installation method, characterized in that: Includes the following steps: (1) Install the basic frame, and simultaneously install the central buffer seat, the bottom inspection safety pin mechanism and the loose bottom roller; (2) Install the bottom section looper track and bottom section counterweight track on the basic frame; (3) Process the support piles and pads and install the support piles on the upper part of the bottom maintenance safety pin mechanism and install the pads on the upper surface of the central buffer seat. The support piles and pads must ensure that the upper surface of the looper car is horizontal when the looper car is placed on the upper surface of the two. (4) Hoist the half-section of the looper car, slide one side wheel of the half-section looper car into the bottom section looper car track and place it above the support pile and pad pile; (5) Repeat step (4) to complete the hoisting of the other half of the looper car and connect the two looper cars into a whole; (6) The hoisting assembly of the counterweight causes the counterweight guide to slide into the bottom section counterweight track; (7) Install the upper structure frame and install the upper looper rail and upper counterweight rail on the upper structure frame, ensuring that the upper looper rail is aligned with the bottom looper rail and the upper counterweight rail is aligned with the bottom counterweight rail. (8) Weld multiple main lifting lugs for lifting the main hook of the crane and multiple auxiliary lifting lugs for lifting the small hook of the crane on the top pulley block platform. The main lifting lugs are evenly distributed around the central circumference of the top pulley block platform, and the auxiliary lifting lugs are located on the same side of the top pulley block platform. (9) Hoist the top pulley platform, with the main lifting lug as the main lifting force point and the auxiliary lifting lug as the auxiliary force point to adjust the attitude of the top pulley platform during the hoisting process. After hoisting into place, fix the top pulley platform to the upper structure frame. (10) Fix one end of the counterweight wire rope to the counterweight, and then use a small winch to pull the other end of the counterweight wire rope along the pulley block. When the wire rope is almost vertical, the crane lifts the counterweight in sync. The wire rope continues to be pulled down using the small winch. When the other end of the counterweight wire rope reaches the connection point with the hoist car, the crane stops lifting. After the counterweight wire rope is firmly fixed to the hoist car, remove the small winch and use the lifting vehicle to send personnel to the counterweight. Disconnect the counterweight from the crane main hook. (11) Use a small winch to wind the wire rope on the pulley block in the same way as the loop winch wire rope. Connect the small winch rope hook to the loop winch rope head. Use the small winch to wind the loop winch wire rope on the pulley block. Wind the excess part on the loop winch drum. Adjust the length of the wire rope on both sides and fix it to the drum. (12) Use a loop winch to lift the loop car and perform debugging operations.

2. The vertical loose-fitting installation method according to claim 1, characterized in that, The installation sequence of the basic frame is as follows: after installing the basic columns, connect and fix the basic columns to the connectors to form the basic frame.

3. The vertical loose-fitting installation method according to claim 1, characterized in that, The bottom section of the sliding car track is equipped with a guide fixture I inside the top; When hoisting the half-section looper car, one side wheel of the half-section looper car slides into the bottom section looper car track along the guide direction of guide tool I. After connecting the two loose-fitting carriages into a whole, remove the guide tool I.

4. The vertical loose-fitting installation method according to claim 1, characterized in that, In step (6), guide fixture II is processed before hoisting and assembling the counterweight, and guide fixture II is installed on top of the bottom section counterweight rail; When the counterweight is hoisted, the counterweight guide wheel slides into the bottom counterweight track along the guide direction of guide fixture II; After the counterweight is installed, remove guide fixture II.

5. A vertical loose-fitting installation method according to claim 1, characterized in that, Before hoisting the top pulley block platform, process guide fixture III and install it on the connection surface between the top of the upper structural frame and the top pulley block platform. There are multiple guide fixtures III, which are arranged around the top of the upper structural frame.

6. The vertical loose-fitting installation method according to claim 1, characterized in that, After fixing the top pulley block platform, place the measurement control points above the platform, adjust the pulley block, the upper looper track and the upper counterweight track to meet the requirements and tighten them.

7. The vertical loose-fitting installation method according to claim 1, characterized in that, After the commissioning work is completed, the support piles and pad piles are removed.

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