A method for replacing a luffing wire rope of a bridge unloader

Abstract

The application is a kind of bridge ship unloader luffing wire rope replacement method, comprising the following steps: S1, limit removal and program sealing point; S2, arrangement of traction wire rope; S3, new wire rope traction to trapezoidal frame platform and old wire rope connection; S4, old wire rope traction new wire rope into machine room; S5, release old wire rope; S6, new wire rope connection reel and debugging; S7, set luffing zero and restore related limit. The application changes the complex mode of traditional wire rope replacement, optimizes the luffing wire rope replacement method, effectively reduces the maintenance time and maintenance personnel, improves the work efficiency and safety and reliability.

Description

Technical Field

[0001] This invention relates to the field of wire rope replacement technology, and in particular to a method for replacing the pitching wire rope of a bridge unloader. Background Technology

[0002] Ship loaders are common equipment used to load cargo onto ships in ports. Since pitching is the primary movement of the ship loader's boom, the pitching wire rope, which enables this movement, experiences relatively high stress and wear. After a period of use, the pitching wire rope will fatigue, exhibiting problems such as wear, broken wires, stranding, and exposed wires, threatening the safe operation of the ship loader. Therefore, to ensure the safe and reliable operation of the ship loader, the pitching wire rope needs to be replaced with a new one after a period of use. However, the traditional bridge-type ship unloader pitching wire rope replacement process is difficult, dangerous, time-consuming, and inefficient. Therefore, it is necessary to research a bridge-type ship unloader pitching wire rope replacement method to improve the safety and efficiency of wire rope replacement. Summary of the Invention

[0003] The present invention aims to address the shortcomings of the prior art by providing a method for replacing the pitching wire rope of a bridge unloader.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a method for replacing the pitching wire rope of a bridge-type ship unloader, comprising the following steps:

[0005] S1, Limiter removal and program sealing point;

[0006] S2. Arrange the traction steel wire rope;

[0007] S3. The new steel wire rope is pulled to the trapezoidal frame platform and connected to the old steel wire rope.

[0008] S4. The old steel wire rope pulls the new steel wire rope into the machine room;

[0009] S5. Release the old steel wire rope;

[0010] S6. Connect the new steel wire rope to the drum and adjust it;

[0011] S7. Set the pitch zero position and restore the relevant limits.

[0012] Specifically, S1 includes the following steps:

[0013] S11. The main trolley moves to a position 20m on the sea side of the front beam;

[0014] S12. By sealing the pitch limit switch and the main trolley interlock limit switch in the machine room, the pitch drum can rotate freely.

[0015] S13. Jog the pitch up. When the pitch angle is zero, remove the cam limit device of the pitch mechanism.

[0016] S14. Operate the pitch descent, and loosen the pitch wire rope until the last turn remains inside the drum;

[0017] S15. Remove the limit switch for releasing the drum and the limit switch for preventing slack rope and breaking rope detection on the trapezoidal frame platform.

[0018] Specifically, S2 includes the following steps:

[0019] S21. Prepare two traction winches on the ground and tie them to the foundation of the belt conveyor column using a hand-operated hoist and rope buckle.

[0020] S22. Hang the redirecting pulley on the lifting point of the trapezoidal frame platform lifting beam, pass the 170m hemp rope through the redirecting pulley and put it into the funnel platform, and then throw it from the funnel platform to the dock surface.

[0021] S23. One end of the hemp rope is connected to the forklift via a redirecting pulley on the land side, and the other end is connected to the traction wire rope of the winch.

[0022] S24. Raise the windshield to its upper limit position;

[0023] S25. The forklift pulls the rope, so that the winch's traction wire rope goes up to the redirecting pulley of the trapezoidal frame platform and then returns to the dock surface.

[0024] S26. Connect the end of the traction wire rope to the new pitching wire rope.

[0025] Specifically, S3 includes the following steps:

[0026] S31. Use a hand chain hoist to fix two pitching steel wire ropes on the trapezoidal frame platform and tighten them from the sea side so that the middle steel wire rope balance block is not under tension, and disengage the shaft pin to remove the wedge joint.

[0027] S32. Cut the pitching wire rope at the root of the wedge joint;

[0028] S33. Start the winch to pull the new wire rope to the trapezoidal frame platform and secure it with a hand hoist.

[0029] S34. Connect the new and old steel wire ropes together by electric welding, and then remove the hand chain hoists from the new and old steel wire ropes.

[0030] S35. The forklift pulls the rope and pulls the end of the traction wire rope back to the dock surface.

[0031] Specifically, S4 includes the following steps:

[0032] S41. Operate the pitch drum to rise, and the old wire rope will pull the new wire rope upward.

[0033] S42. When there are 5 turns of the new steel wire rope remaining on the ground, stop traction and release the steel wire rope connection wedge joint on the reel.

[0034] S43. Connect the two prepared wedge joints with two traction steel wire ropes of the winch respectively. Operate the pitch drum to continue rising, and release the traction steel wire ropes of the winch at the same time to prevent the wedge joints from rising too fast due to the weight of the ropes.

[0035] S44. When the wedge joint rises to the trapezoidal frame platform, stop the pitching and rising.

[0036] S45. Use a hand chain hoist to secure the new wire rope, connect the wedge joint to the balance block, and remove the corresponding hand chain hoist.

[0037] S46. Lower the old wedge joint to the dock surface using a towing rope, and gradually remove the towing rope, hemp rope and guide pulley;

[0038] S47. Operate the pitching and raising mechanism to allow the new wire rope to enter the pitching drum until the new pitching wire rope on the front beam is just slightly slack, then stop raising.

[0039] S48. Use a hand chain hoist to secure the new wire rope. Calculate the length of the new wire rope after leaving only 5 turns on the drum and mark it. The length of the wire rope left on the drum on both sides should be the same.

[0040] S49. During the pitching and lowering operation, the new wire rope is released from the drum and cut off at the excess mark on the new wire rope, thus separating the old and new wire ropes.

[0041] Specifically, S5 includes the following steps:

[0042] S51. Open the landside hoisting hole of the pitch drum, operate the pitch descent, and lower the old wire rope from the hoisting hole into the wire rope cage on the dock surface.

[0043] S52. When there are two turns of the old wire rope remaining, stop the descent, secure the old wire rope with rope clamps, and then hoist it with the overhead crane in the machine room.

[0044] S53. Remove the wire rope pressure plate from the drum and use an overhead crane to lower the remaining old wire rope onto the dock surface.

[0045] Specifically, S6 includes the following steps:

[0046] S61. The new wire rope enters the drum groove and is fixed with a pressure plate. Remove the corresponding hand chain hoist.

[0047] S62. Operate the pitching and ascending motion, and stop ascending when one side of the wire rope is just taut.

[0048] S63. Observe the slack of the wire rope on the other side. If it is too slack, adjust it by winding the wire rope on that side separately. The specific steps are as follows:

[0049] S631. Record the number of turns of the wire rope on the tensioned side, operate the pitching and lowering mechanism, use a hand chain hoist to fix the wire rope on the tensioned side, remove the pressure plate on that side, and detach the wire rope from the drum.

[0050] S632. Operate the pitching and ascending motion. Stop ascending when the wire rope on the slack side is tightened. Calculate the excess wire rope length.

[0051] S633. Operate the pitch and descent operation again, use a hand chain hoist to secure the wire rope, then remove the pressure plate and cut off the excess wire rope.

[0052] S634. Connect the wire ropes on both sides to the drum and tighten the pressure plate, then operate the pitching and lifting mechanism.

[0053] S64. Observe whether the balance block of the trapezoidal frame platform is in the middle position. If it is not in the middle position, make adjustments. The specific steps are as follows:

[0054] S641. Operate the pitch descent to slack the wire rope;

[0055] S642. Loosen the wire rope on the side that needs to be tightened using the method in the previous step, adjust the length of the rope end extending out of the drum pressure plate, and then operate the pitching and raising operation again.

[0056] S643. When the counterweight is in the middle position, the wire ropes on both sides are in a balanced state.

[0057] Specifically, S7 includes the following steps:

[0058] S71. Keep the front beam flat and operate the pitch upward. Stop when the wire rope is just taut. At this time, confirm that the front beam is still in a horizontal state and restore the cam limit device.

[0059] S72. Restore the anti-slip limit of the drum and the anti-slack rope limit and rope breakage detection limit of the trapezoidal frame platform;

[0060] S73. Release all blockages in the procedure;

[0061] S74. Zero the pitch position;

[0062] S75. Automatic pitch control confirms that the automatic pitch hook function is working properly.

[0063] The beneficial effects of this invention are as follows: This invention changes the traditional process of replacing the pitching wire rope of a ship unloader, optimizes the wire rope replacement process, and closely integrates it with related process equipment; This invention adopts a new and old rope traction method, which reduces the cumbersome procedures of maintenance work. Compared with the traditional process of replacing the pitching wire rope of a ship unloader, it reduces the number of maintenance personnel and the requirements for the use of auxiliary machinery, and improves work efficiency and safety reliability. Attached Figure Description

[0064] Figure 1 This is a schematic diagram of the workflow of the present invention;

[0065] The following will describe in detail, with reference to the accompanying drawings, embodiments of the present invention. Detailed Implementation

[0066] The present invention will be further described below with reference to embodiments:

[0067] like Figure 1 As shown, a method for replacing the pitching wire rope of a bridge-type ship unloader includes the following steps:

[0068] S1, Limiter removal and program sealing point;

[0069] S11. The main trolley moves to a position 20m on the sea side of the front beam;

[0070] S12. By sealing the pitch limit switch and the main trolley interlock limit switch in the machine room, the pitch drum can rotate freely.

[0071] Table 1 Replacement of Pitching Wire Rope Sealing Points for Ship Unloaders

[0072]

[0073] S13. Jog the pitch up. When the pitch angle is zero, remove the cam limit device of the pitch mechanism.

[0074] S14. Operate the pitch descent, and loosen the pitch wire rope until the last turn remains inside the drum;

[0075] S15. Remove the limit switch for releasing the drum and the limit switch for preventing slack rope and breaking rope detection on the trapezoidal frame platform.

[0076] S2. Arrange the traction steel wire rope;

[0077] S21. Prepare two traction winches (2t) on the ground and tie them to the foundation of the belt conveyor column with hand-operated hoists and ropes;

[0078] S22. Hang the redirecting pulley on the lifting point of the trapezoidal frame platform lifting beam, pass the 170m hemp rope through the redirecting pulley and put it into the funnel platform, and then throw it from the funnel platform to the dock surface.

[0079] S23. One end of the hemp rope is connected to the forklift via a redirecting pulley on the land side, and the other end is connected to the traction wire rope of the winch.

[0080] S24. Raise the windshield to its upper limit position;

[0081] S25. The forklift pulls the rope, so that the winch's traction wire rope goes up to the redirecting pulley of the trapezoidal frame platform and then returns to the dock surface.

[0082] S26. Connect the end of the traction wire rope to the new pitching wire rope (at this time, do not disconnect the connection between the hemp rope and the traction wire rope).

[0083] S3. The new steel wire rope is pulled to the trapezoidal frame platform and connected to the old steel wire rope.

[0084] S31. Use a hand-operated hoist (3t) on the trapezoidal frame platform to fix two pitching steel wire ropes respectively and pull them taut from the sea side so that the middle steel wire rope balance block is not under tension, and disengage the shaft pin to remove the wedge joint.

[0085] S32. Cut the pitching wire rope at the root of the wedge joint;

[0086] S33. Start the winch to pull the new wire rope to the trapezoidal frame platform and secure it with a hand-operated hoist (1t);

[0087] S34. Connect the new and old steel wire ropes together by electric welding, and then remove the hand chain hoists from the new and old steel wire ropes.

[0088] S35. The forklift pulls the rope and pulls the end of the traction wire rope back to the dock surface.

[0089] S4. The old steel wire rope pulls the new steel wire rope into the machine room;

[0090] S41. Operate the pitch drum to rise, and the old wire rope will pull the new wire rope upward.

[0091] S42. When there are 5 turns of the new steel wire rope remaining on the ground, stop traction and release the steel wire rope connection wedge joint on the reel.

[0092] S43. Connect the two prepared wedge joints with two traction steel wire ropes of the winch respectively. Operate the pitch drum to continue rising, and release the traction steel wire ropes of the winch at the same time to prevent the wedge joints from rising too fast due to the weight of the ropes.

[0093] S44. When the wedge joint rises to the trapezoidal frame platform, stop the pitching and rising (the wedge joint needs to contact the hand chain hoist when passing through the trapezoidal frame platform).

[0094] S45. Use a 3t hand chain hoist to secure the new wire rope, connect the wedge joint to the balance block, and remove the corresponding hand chain hoist.

[0095] S46. Lower the old wedge joint to the dock surface using a towing rope, and gradually remove the towing rope, hemp rope and guide pulley;

[0096] S47. Operate the pitching and raising mechanism to allow the new wire rope to enter the pitching drum until the new pitching wire rope on the front beam is just slightly slack, then stop raising.

[0097] S48. Use a hand-operated hoist (3t) to fix the new wire rope. Calculate the length of the new wire rope after leaving only 5 turns on the drum and mark it. The length of the wire rope left on the drum on both sides should be the same.

[0098] S49. During the pitching and lowering operation, the new wire rope is released from the drum and cut off at the excess mark on the new wire rope, thus separating the old and new wire ropes.

[0099] S5. Release the old steel wire rope;

[0100] S51. Open the landside hoisting hole of the pitch drum, operate the pitch descent, and lower the old wire rope from the hoisting hole into the wire rope cage on the dock surface.

[0101] S52. When there are two turns of the old wire rope remaining, stop the descent, secure the old wire rope with rope clamps, and then hoist it with the overhead crane in the machine room.

[0102] S53. Remove the wire rope pressure plate from the drum and use an overhead crane to lower the remaining old wire rope onto the dock surface.

[0103] S6. Connect the new steel wire rope to the drum and adjust it;

[0104] S61. The new wire rope enters the drum groove and is fixed with a pressure plate. Remove the corresponding hand chain hoist (3t).

[0105] S62. Operate the pitching and ascending motion, and stop ascending when one side of the wire rope is just taut.

[0106] S63. Observe the slack of the wire rope on the other side. If it is too slack, adjust it by winding the wire rope on that side separately. The specific steps are as follows:

[0107] S631. Record the number of turns of the wire rope on the tensioned side, operate the pitching and lowering mechanism, use a hand chain hoist to fix the wire rope on the tensioned side, remove the pressure plate on that side, and detach the wire rope from the drum.

[0108] S632. Operate the pitching and ascending motion. Stop ascending when the wire rope on the slack side is tightened. Calculate the excess wire rope length.

[0109] S633. Operate the pitch and descent operation again, use a hand chain hoist to secure the wire rope, then remove the pressure plate and cut off the excess wire rope.

[0110] S634. Connect the wire ropes on both sides to the drum and tighten the pressure plate. Operate the pitching and raising operation (the wire ropes need to be fixed by hand hoist before removing the pressure plate, and the fixing on the wire ropes should be removed before pitching and raising).

[0111] S64. Observe whether the balance block of the trapezoidal frame platform is in the middle position. If it is not in the middle position, make adjustments. The specific steps are as follows:

[0112] S641. Operate the pitch descent to slack the wire rope;

[0113] S642. Loosen the wire rope on the side that needs to be tightened using the method in the previous step, adjust the length of the rope end extending out of the drum pressure plate, and then operate the pitching and raising operation again.

[0114] S643. When the counterweight is in the middle position, the wire ropes on both sides are in a balanced state.

[0115] S7. Set the pitch zero position and restore the relevant limits.

[0116] S71. Keep the front beam flat and operate the pitch upward. Stop when the wire rope is just taut. At this time, confirm that the front beam is still in a horizontal state and restore the cam limit device.

[0117] S72. Restore the anti-slip limit of the drum and the anti-slack rope limit and rope breakage detection limit of the trapezoidal frame platform;

[0118] S73. Release all blockages in the procedure;

[0119] S74. Zero the pitch position;

[0120] S75. Automatic pitch control confirms that the automatic pitch hook function is working properly.

[0121] The key point in the construction of this invention is the pitching wire rope traction process. Before this process, a 2t winch should be used to hoist two 170m hemp ropes to the second-floor platform using an overhead crane. One end of the rope is pulled onto the upper redirecting pulley platform, and the other end is placed on the dock surface. At the same time, the rope is connected to the winch traction rope. The traction wire rope is then pulled onto the upper redirecting pulley platform, passed through the redirecting pulley of the tooling, and the end of the traction rope is placed on the dock surface and connected to the new pitching wire rope.

[0122] This invention changes the traditional process of replacing the pitching wire rope of a ship unloader, optimizes the replacement process, and closely integrates it with related process equipment. This invention adopts a new and old rope traction method, which reduces the cumbersome procedures of maintenance work. Compared with the traditional process of replacing the pitching wire rope of a ship unloader, it reduces the number of maintenance personnel and the requirements for the use of auxiliary machinery, and improves work efficiency and safety reliability.

[0123] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0124] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0125] The present invention has been described above by way of example. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made by adopting the inventive concept and technical solution of the present invention, or direct application to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A method for replacing the pitching wire rope of a bridge-type ship unloader, characterized in that, Includes the following steps: S1, Limiter removal and program sealing point; S2. Arrange the traction wire rope, including the following steps: S21. Prepare two traction winches on the ground and tie them to the foundation of the belt conveyor column using a hand-operated hoist and rope buckle. S22. Hang the redirecting pulley on the lifting point of the trapezoidal frame platform lifting beam, pass the 170m hemp rope through the redirecting pulley and put it into the funnel platform, and then throw it from the funnel platform to the dock surface. S23. One end of the hemp rope is connected to the forklift via a redirecting pulley on the land side, and the other end is connected to the traction wire rope of the winch. S24. Raise the windshield to its upper limit position; S25. The forklift pulls the rope, so that the winch's traction wire rope goes up to the redirecting pulley of the trapezoidal frame platform and then returns to the dock surface. S26. Connect the end of the traction wire rope to the new pitching wire rope; S3. The new steel wire rope is pulled to the trapezoidal frame platform and connected to the old steel wire rope. S4. The old steel wire rope pulls the new steel wire rope into the machine room, including the following steps: S41. Operate the pitch drum to rise, and the old wire rope will pull the new wire rope upward. S42. When there are 5 turns of the new steel wire rope remaining on the ground, stop traction and release the steel wire rope connection wedge joint on the reel. S43. Connect the two prepared wedge joints with two traction steel wire ropes of the winch respectively. Operate the pitch drum to continue rising, and release the traction steel wire ropes of the winch at the same time to prevent the wedge joints from rising too fast due to the weight of the ropes. S44. When the wedge joint rises to the trapezoidal frame platform, stop the pitching and rising. S45. Use a hand chain hoist to secure the new wire rope, connect the wedge joint to the balance block, and remove the corresponding hand chain hoist. S46. Lower the old wedge joint to the dock surface using a towing rope, and gradually remove the towing rope, hemp rope and guide pulley; S47. Operate the pitching and raising mechanism to allow the new wire rope to enter the pitching drum until the new pitching wire rope on the front beam is just slightly slack, then stop raising. S48. Use a hand chain hoist to secure the new wire rope. Calculate the length of the new wire rope after leaving only 5 turns on the drum and mark it. The length of the wire rope left on the drum on both sides should be the same. S49. During the pitching and lowering operation, the new wire rope is released from the drum and cut off at the excess mark on the new wire rope to separate the old and new wire ropes. S5. Release the old steel wire rope; S6. Connect the new wire rope to the drum and adjust it, including the following steps: S61. The new wire rope enters the drum groove and is fixed with a pressure plate. Remove the corresponding hand chain hoist. S62. Operate the pitching and ascending motion, and stop ascending when one side of the wire rope is just taut. S63. Observe the slack of the wire rope on the other side. If it is too slack, adjust it by winding the wire rope on that side separately. The specific steps are as follows: S631. Record the number of turns of the wire rope on the tensioned side, operate the pitching and lowering mechanism, use a hand chain hoist to fix the wire rope on the tensioned side, remove the pressure plate on that side, and detach the wire rope from the drum. S632. Operate the pitching and ascending motion. Stop ascending when the wire rope on the slack side is tightened. Calculate the excess wire rope length. S633. Operate the pitch and descent operation again, use a hand chain hoist to secure the wire rope, then remove the pressure plate and cut off the excess wire rope. S634. Connect the wire ropes on both sides to the drum and tighten the pressure plate, then operate the pitching and lifting mechanism. S64. Observe whether the balance block of the trapezoidal frame platform is in the middle position. If it is not in the middle position, make adjustments. The specific steps are as follows: S641. Operate the pitch descent to slack the wire rope; S642. Loosen the wire rope on the side that needs to be tightened using the method in the previous step, adjust the length of the rope end extending out of the drum pressure plate, and then operate the pitching and raising operation again. S643. When the balance block is in the middle position, the wire ropes on both sides reach a balanced state. S7. Set the pitch zero position and restore the relevant limits.

2. The method for replacing the pitching wire rope of a bridge-type ship unloader according to claim 1, characterized in that, S1 includes the following steps: S11. The main trolley moves to a position 20m on the sea side of the front beam; S12. By sealing the pitch limit switch and the main trolley interlock limit switch in the machine room, the pitch drum can rotate freely. S13. Jog the pitch up. When the pitch angle is zero, remove the cam limit device of the pitch mechanism. S14. Operate the pitch descent, and loosen the pitch wire rope until the last turn remains inside the drum; S15. Remove the limit switch for releasing the drum and the limit switch for preventing slack rope and breaking rope detection on the trapezoidal frame platform.

3. The method for replacing the pitching wire rope of a bridge-type ship unloader according to claim 2, characterized in that, S3 includes the following steps: S31. Use a hand chain hoist to fix two pitching steel wire ropes on the trapezoidal frame platform and tighten them from the sea side so that the middle steel wire rope balance block is not under tension, and disengage the shaft pin to remove the wedge joint. S32. Cut the pitching wire rope at the root of the wedge joint; S33. Start the winch to pull the new wire rope to the trapezoidal frame platform and secure it with a hand hoist. S34. Connect the new and old steel wire ropes together by electric welding, and then remove the hand chain hoists from the new and old steel wire ropes. S35. The forklift pulls the rope and pulls the end of the traction wire rope back to the dock surface.

4. The method for replacing the pitching wire rope of a bridge-type ship unloader according to claim 3, characterized in that, S5 includes the following steps: S51. Open the landside hoisting hole of the pitch drum, operate the pitch descent, and lower the old wire rope from the hoisting hole into the wire rope cage on the dock surface. S52. When there are two turns of the old wire rope remaining, stop the descent, secure the old wire rope with rope clamps, and then hoist it with the overhead crane in the machine room. S53. Remove the wire rope pressure plate from the drum and use an overhead crane to lower the remaining old wire rope onto the dock surface.

5. The method for replacing the pitching wire rope of a bridge-type ship unloader according to claim 4, characterized in that, S7 includes the following steps: S71. Keep the front beam flat and operate the pitch upward. Stop when the wire rope is just taut. At this time, confirm that the front beam is still in a horizontal state and restore the cam limit device. S72. Restore the anti-slip limit of the drum and the anti-slack rope limit and rope breakage detection limit of the trapezoidal frame platform; S73. Release all blockages in the procedure; S74. Zero the pitch position; S75. Automatic pitch control confirms that the automatic pitch hook function is working properly.

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