Positioning tool for replacing reamer seat and positioning and replacing method of reamer seat

Abstract

The application discloses a positioning tool for replacing a reamer seat, which comprises a reference plate and eight positioning columns, four of which are divided into a group, and two groups of the positioning columns are installed on the two longitudinal sides of the reference plate according to the position coordinates provided in Table 1. a+1 and the reference reamer seat A a ; 2) cutting off the damaged reamer seat, and cleaning the installation surface of the new reamer seat; 3) positioning and fixing the new reamer seat by using the tool; 4) spot welding the new reamer seat A a+1 according to the finally determined installation position, removing the tool, and finally completing the overall welding of the new reamer seat according to the process requirement. The tool and the method solve the problems that the existing technology requires many devices, the on-site positioning is not accurate, and the on-site replacement is required to be high.

Description

Technical Field

[0001] This invention belongs to the field of dredging equipment technology, and relates to a positioning tool for replacing the cutterhead seat. This invention also relates to a method for positioning and replacing the cutterhead seat. Background Technology

[0002] The cutterhead system (including cutter teeth, cutterhead holder, and pins) on dredging equipment is the cutterhead component that directly contacts the dredging target. The welding position of the cutterhead holder determines all parameters related to dredging performance, such as the cutter's cutting radius, cutting angle, and clearance angle. Therefore, the welding position of the cutterhead holder directly affects the dredging performance of the cutterhead. During operation, due to the complex underwater environment, the cutterhead encounters hard objects such as hard rocks (Rc≥30MPa). Under the condition of rapid rotation of the cutterhead, the impact can cause the cutterhead holder to break, or the cutter teeth may be damaged and not replaced in time, leading to wear of the cutterhead holder. Wear and breakage of the cutterhead holder can easily cause two adverse consequences: firstly, reduced dredging performance; and secondly, reduced service life of the cutterhead. Without the protection of the cutter teeth and cutterhead holder, severe wear of the cutter arm will inevitably occur, eventually leading to the scrapping of the entire cutterhead. Therefore, the cutterhead holder must be repaired immediately after a certain degree of wear or breakage.

[0003] Because the arrangement of the reamer holders is a three-dimensional spiral structure with spatial twisting, the welding positioning of the reamer holders must be carried out in a spatial coordinate system, and the entire welding process requires positioning by specific auxiliary tooling. Existing dredging equipment cutter heads typically come with a special tooling for replacement in case of wear or breakage during operation. However, the drawbacks of using this special tooling include: 1) The tooling needs to be assembled on a large platform, and the precision of its assembly is crucial for ensuring the accuracy of positioning and welding of the cutter head to be replaced. This requires a large number of tooling and equipment components; 2) During cutter head replacement, the entire cutter head must first be disassembled and lifted to a large platform before the second step of assembling the tooling can begin. Due to the significant weight of the cutter head (the largest existing cutter head exceeds 40 tons), impact damage to the tooling and platform is inevitable during lifting and lowering, affecting their positioning accuracy and service life, resulting in lower safety; 3) The positioning process for replacing the cutter head requires specific conditions on the dredging vessel or at the construction site. If on-site repair is not possible, the cutter head must be returned to the factory for repair, which is time-consuming and labor-intensive. Summary of the Invention

[0004] The purpose of this invention is to provide a positioning fixture for replacing the cutter head, which solves the problems of the prior art, such as the need for a lot of equipment, inaccurate on-site positioning, and high requirements for on-site replacement when replacing the cutter head.

[0005] Another objective of this invention is to provide a method for positioning and replacing a cutter head.

[0006] The technical solution adopted in this invention is a positioning fixture for replacing the cutter head, which includes a reference plate and eight positioning posts. Every four positioning posts are divided into a group, and the two groups of positioning posts are installed on the longitudinal sides of the reference plate at intervals according to the position coordinates provided in Table 1.

[0007] Another technical solution adopted in this invention is a method for positioning and replacing a cutter head, which is implemented using the above-mentioned positioning fixture for replacing the cutter head according to the following steps:

[0008] Step 1) Determine to replace cutter head A a+1 and reference reamer seat A a ;

[0009] Step 2) Cut off the damaged cutter head and clean out the mounting surface of the new cutter head;

[0010] Step 3) Use the tooling of this invention to position and fix the new auger holder;

[0011] Step 4) Replace the cutter head A according to the final determined procedure. a+1 First, spot weld the installation position, then remove the tooling of this invention, and finally complete the overall welding of the new auger seat according to the process requirements.

[0012] The beneficial effects of the present invention include the following aspects:

[0013] 1) The method of the present invention can replace the reamer seat without disassembling the entire reamer. According to the screw height data and positioning column position data listed in Table 1, the position of the reamer seat to be replaced is determined by the assembly relationship of the standard teeth of the reamer teeth.

[0014] Traditional methods require disassembling the entire cutter head and placing it on a large platform before the cutter head seat can be positioned and replaced. This is time-consuming and labor-intensive. Furthermore, traditional tooling requires adjustments to the position and assembly relationship with the cutter arm during installation, making the process complex and requiring experienced workers. This is the essence of the difference between the method of this invention and traditional specialized tooling.

[0015] 2) The tooling of this invention, by adjusting the position and height of the positioning column, can be used for the positioning and replacement of cutter heads of various types of cutter heads (only the data required in Table 1 needs to be provided in advance), which improves the adaptability of the tooling and reduces maintenance costs. Traditional positioning tooling is only applicable to a specific cutter head and is a dedicated tooling. However, a dredger is often equipped with multiple cutter heads of different specifications, so multiple positioning tooling must be prepared.

[0016] 3) The tooling of this invention is small in size, has few parts, and is easy to store and transport.

[0017] 4) The reference plate used in the tooling of this invention is made of carbon tool steel with high hardness and a thickness δ of 15-25mm. It is not easily deformed during use, ensuring that the position of the new auger seat does not deviate.

[0018] 5) The lead screw in the positioning column used in the tooling of this invention has a fine thread and the dimensional error is within ±0.1mm, ensuring the accurate implementation of the data provided in Table 1. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the installation structure of traditional tooling when replacing the cutter head;

[0020] Figure 2 This is a schematic diagram showing the positional relationship between the tooling of the present invention and the cutterhead during the tooling replacement process;

[0021] Figure 3 This is a schematic diagram showing the positional relationship of the positioning pins on the reference plate in the tooling of this invention;

[0022] Figure 4 This is a schematic diagram showing the correspondence between the cutter head, the standard teeth of the cutter teeth, and the positioning plate in the tooling of this invention;

[0023] Figure 5 This is a schematic diagram showing the height of the positioning column when the positioning state is completed using the method of the present invention;

[0024] Figure 6 This is a schematic diagram showing the position coordinates of the positioning pins used in the method of this invention on the reference plate;

[0025] Figure 7 This is a schematic diagram showing the fit between the steel ball on the positioning post and the ball socket on the positioning plate used in the method of this invention.

[0026] In the diagram, 1. reference plate, 2. positioning post, 21. magnet, 22. shock-absorbing rubber ring, 23. magnet protective sleeve, 24. sleeve, 25. locking screw, 26. lead screw, 3. standard tooth of auger, 31. positioning plate, 4. auger seat, 5. auger arm. Detailed Implementation

[0027] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0028] Reference Figure 1 This is a specialized tooling typically included with existing reamers. Due to its relatively rigid structure and insufficient adaptability, its performance in field applications is unsatisfactory.

[0029] Reference Figure 2 , Figure 3 , Figure 5The tooling of the present invention consists of a reference plate 1 and eight positioning posts 2. Every four positioning posts 2 are divided into a group, and the two groups of positioning posts 2 are installed on the longitudinal sides of the reference plate 1 at intervals according to the position coordinates provided in Table 1.

[0030] Reference Figure 4 Corresponding to the two sets of positioning posts 2, there are also two positioning plates 31. Each positioning plate 31 is welded to a standard tooth 3 of a reamer tooth to determine the installation angle of the standard tooth 3 of the reamer tooth and its reamer seat 4. Each positioning plate 31 has a ball socket near the four corners of its support surface. The top steel balls of the four positioning posts 2 of the same set are respectively fitted into the four ball sockets of the support surface of the positioning plate 31.

[0031] Reference Figure 7 Each positioning post 2 has the following structure: a magnet 21 is attached to the reference plate 1 according to the selected coordinate position. A magnet protective sleeve 23 with a cover is fitted on the magnet 21. A shock-absorbing rubber ring 22 is provided between the magnet protective sleeve 23 and the magnet 21. A sleeve 24 is coaxially fixed (welded) to the upper surface of the magnet protective sleeve 23. A lead screw 26 is threaded in the sleeve 24. A steel ball is welded to the top of the lead screw 26. A locking screw 25 is provided between the lead screw 26 and the sleeve 24. The locking screw 25 is used to limit the circumferential rotation and axial movement of the lead screw 26 after the extension height of the lead screw 26 is adjusted to the correct position.

[0032] Reference Figure 3 , Figure 6 The eight positioning posts 2 are attached to the reference plate 1 by their respective magnets 21. The specific coordinate positions are shown in Table 1. After the steel ball at the top of the lead screw 26 in each positioning post 2 is adjusted to the predetermined height, the lead screw 26 is locked with the locking screw 25. The specific height values ​​are shown in Table 1.

[0033] Reference Figure 5 , Figure 6 The cutter heads are numbered from bottom to top as A1, A2, A3...A a+1 Naming in order, if using the reamer seat A a The reference is called the reference reamer holder A. a Using the tooling of this invention and the spatial positional relationships given in Table 1, the auger holder A to be replaced can be determined. a+1 The spatial location. Each set of data is based on the position data of the reference cutterhead, and the height and position data of the positioning column 2 of the cutterhead being replaced are calculated. Table 1 shows the data from A1, A2, A3...A a The height data and position of the positioning pins 2 of each cutterhead seat;

[0034] Table 1. Reference Area Holder a With the replaced cutter head A a+1 Spatial position relationship

[0035]

[0036] Explanation of symbols in Table 1:

[0037] 'a' represents the sequence number of the cutter head on a certain cutter arm 5, where a = 1, 2, 3...n;

[0038] h a1 h a2 h a3 h a4 These represent the reference reamer holder A. a The corresponding heights of the four positioning posts 2;

[0039] h (a+1)1 h (a+1)2 h (a+1)3 h (a+1)4 These represent the replaced cutterhead A. a+1 The corresponding heights of the four positioning posts 2;

[0040] (x a1 y a1 ), (x a2 y a2 ), (x a3 y a3 ), (x a4 y a4 () respectively represent the reference reamer holder A a The corresponding position coordinates of the four positioning posts 2 on the reference plate 1;

[0041] (x (a+1)1 y (a+1)1 ), (x (a+1)2 y (a+1)2 ), (x (a+1)3 y (a+1)3 ), (x (a+1)4 y (a+1)4 () respectively represent the replaced cutterhead A a+1 The corresponding position coordinates of the four positioning posts 2 on the reference plate 1.

[0042] h in Table 1 a1 h a2 h a3 h a4 With h' a1 ,h' a2 ,h' a3 ,h' a4 This indicates that the two sets of data are different and there is no reference relationship between them.

[0043] The specific values ​​of all data in Table 1 were determined based on the original parameters of each reamer holder for different models provided by the manufacturer.

[0044] The working process of this invention is carried out according to the following steps:

[0045] Step 1) Determine to replace cutter head A a+1 and reference reamer seat A a ,

[0046] When a cutter head 4 on a cutter arm 5 is found to be damaged and must be replaced, see Figure 2 Starting from the bottom zero position, count counterclockwise to confirm which cutter head 4 is the damaged one (generally, the original drawings provided by the manufacturer will indicate a specific cutter head as the zero position on each cutter arm). This is called replacing cutter head A. a+1 Then, the adjacent preceding cutterhead 4 is called the reference cutterhead A. a Selected reference reamer holder A a The assembly relationship with the standard tooth 3 of the reamer must be in the correct assembly mode;

[0047] Step 2) Cut off the damaged cutter head 4 and clean out the mounting surface of the new cutter head;

[0048] Step 3) Use the tooling of this invention to position and fix the new auger holder.

[0049] 3.1) According to the position coordinates provided in Table 1, attach the eight positioning posts 2 to the reference plate 1 using magnets 21. Then, screw the steel balls of the lead screws 26 in the eight positioning posts 2 to the corresponding heights given in Table 1, and lock each post with locking screws 25. (See table 1 for details.) Figure 4 and Figure 5 ;

[0050] 3.2) Fit the steel balls at the top of the lead screws 26 of the four corresponding positioning columns 2 on the reference plate 1 into the ball sockets at the four corners of the support surface of the first positioning plate 31. The first positioning plate 31 is located at the reference reamer seat A. a Standard tooth 3 of the reamer (i.e.) Figure 5 On one of the standard teeth 3) of the lower reamer tooth, three steel balls are used to determine the planar position of the first positioning plate 31, and another steel ball is used for positioning to ensure that the reference plate 1 of the tooling of the present invention is aligned with the reference reamer seat A. a The position of the standard tooth 3 of the upper auger does not change during the extrusion contact; then the tooling of the present invention in this state is securely fixed.

[0051] 3.3) First, place a new cutter head 4 on the mounting surface of the new cutter head (the installation angle is not precise at this time), which is called replacing the cutter head A. a+1 (Right now Figure 5 (A cutter head above); then, the four steel balls on the second set of four positioning posts 2 on the other side of the tooling reference plate 1 of the present invention are completely aligned with the four ball sockets of the second positioning plate 31 and securely fitted together. The second positioning plate 31 is located at the cutter head replacement A. a+1 The standard tooth 3 of the cutter head determines the need to replace the cutter head A. a+1 The spatial position of the standard tooth 3 of the cutter head and its matching cutter head is the original design position of the new cutter head 4, and also the position of the cutter head A to be replaced. a+1 The installation location.

[0052] Step 4) Replace the cutter head A according to the final determined procedure. a+1 First, spot weld the installation position, then remove the tooling of this invention, and finally complete the overall welding of the new auger seat 4 according to the process requirements.

[0053] Example 1

[0054] Taking a certain type of cutter head as an example, assuming that the fifth cutter head 4 is determined to be damaged due to excessive wear, and that the cutter head A5 must be replaced, the tooling of this invention is used to determine the position of the cutter head A5 to be replaced and to complete the replacement.

[0055] Positioning welding is performed according to the above steps of the method of the present invention. Table 2 shows the position data on the tooling of the present invention corresponding to the theoretical positions of the reference reamer seat A4 and the replacement reamer seat A5 on a certain reamer arm of the reamer.

[0056] Table 2. Theoretical position data of the reference cutterhead A4 and the replacement cutterhead A5 in Example 1.

[0057]

[0058] The newly welded cutterhead 4 was tested by a shape measurement device, and the spatial fixing error of the replaced cutterhead 4 was within the allowable range.

[0059] Example 2

[0060] Taking a certain type of auger as an example, assuming that the third auger holder 4 is damaged due to collision with a hard object, and it is determined that the auger holder A3 must be replaced, the tooling of the present invention is used to determine the position of the auger holder A3 to be replaced and the replacement is completed.

[0061] Following the procedure of Example 1, the tooling of the present invention is used to replace the new cutter head A3. The theoretical positions of the reference cutter head A2 and the replaced cutter head A3 in Example 2 are shown in Table 3 below:

[0062] Table 3. Theoretical position data of the reference cutterhead A2 and the replacement cutterhead A3 in Example 2.

[0063]

[0064] The installation error of the new cutter head 4, which was replaced using the method of this invention, was found to be within the allowable range by the test equipment.

[0065] Example 3

[0066] Taking a certain type of cutter head as an example, assuming that the fourth cutter head 4 is damaged due to cracks and must be replaced, the tooling of this invention is used to determine the position of the cutter head A4 to be replaced and to complete the replacement.

[0067] Following the procedure of Example 1, the tooling of the present invention is used to replace the new cutter head A4. The theoretical positions of the reference cutter head A3 and the replaced cutter head A4 in Example 2 are shown in Table 4 below:

[0068] Table 4. Theoretical position data of the reference cutterhead A3 and the replacement cutterhead A4 in Example 3.

[0069]

[0070] The installation error of the new cutter head 4, which was replaced using the method of this invention, was found to be within the allowable range by the test equipment.

[0071] In summary, the tooling and method of the present invention effectively solve the problems of existing technologies requiring numerous devices, inaccurate on-site positioning, and high requirements for on-site replacement when changing the cutter head.

Claims

1. A positioning tool for replacing a reamer seat, characterized by: It includes a reference plate (1) and eight positioning columns (2), every four positioning columns (2) are divided into a group, two groups of positioning columns (2) are installed on the longitudinal two sides of the reference plate (1) according to the position coordinates provided in table 1; The structure of each positioning column (2) is that it includes a magnet (21), the magnet (21) is adsorbed on the reference plate (1) according to the selected coordinate position, a magnet protection sleeve (23) with a cover is sleeved on the magnet (21), a damping rubber ring (22) is arranged between the magnet protection sleeve (23) and the magnet (21), a sleeve (24) is coaxially fixedly installed on the upper surface of the magnet protection sleeve (23), a lead screw (26) is threadedly sleeved in the sleeve (24), a steel ball is welded at the top end of the lead screw (26), and a locking screw (25) is arranged between the lead screw (26) and the sleeve (24); Eight positioning columns (2) are adsorbed on the reference plate (1) through respective magnets (21), and the specific coordinate positions are shown in table 1; the steel ball at the top of the lead screw (26) in each positioning column (2) is locked by the locking screw (25) after being adjusted to a predetermined height, and the specific height value is shown in table 1; the specific values of all data in table 1 are determined according to the original parameters of each reamer seat of different models of reamers provided by the manufacturer; Each group of positioning columns (2) is further provided with a positioning plate (31), and two positioning plates (31) are welded on the corresponding two reamer tooth standard teeth (3); the support surface of each positioning plate (31) is provided with a ball socket near each corner, and the top steel balls of the four positioning columns (2) in the same group are respectively sleeved in the four ball sockets of the support surface of the positioning plate (31); The table 1 is a reference reamer seat A a and the space position relationship of the replaced reamer seat A a+1 is expressed as follows: The symbol in table 1 is explained as follows: A represents the arrangement serial number of the reamer seat on a reamer arm (5), a=1, 2, 3…n; h a1 , h a2 , h a3 , h a4 respectively represent the height of the reference reamer seat A a corresponding to a set of four positioning posts (2) h (a+1)1 , h (a+1)2 , h (a+1)3 , h (a+1)4 respectively represent the height of the other group of four positioning columns (2) corresponding to the replaced reamer seat A a+1 ​ (x a1， y a1 ), (x a2， y a2 ), (x a3， y a3 ), (x a4， y a4 ) represent the reference reamer holder A respectively. a The corresponding coordinates of the four positioning posts (2) on the reference plate (1); (x (a+1)1 , y (a+1)1 ), (x (a+1)2 , y (a+1)2 ), (x (a+1)3 , y (a+1)3 ), (x (a+1)4 , y (a+1)4 ) respectively represent the position coordinates of the other group of four positioning columns (2) on the reference plate (1) corresponding to the replaced reamer seat A a+1 ​ h in Table 1 a1 h a2 h a3 h a4 with h ＇ a1 h ＇ a2 h ＇ a3 h ＇ a4 This indicates that the two sets of data are different and there is no reference relationship between them.

2. A method for positioning and replacing a reamer seat using the positioning tool for replacing a reamer seat according to claim 1, characterized in that, The following steps are implemented: Step 1) Determining replacement reamer seat A a+1 and reference reamer seat A a ; Step 2) cutting and removing the damaged reamer seat (4), and cleaning the installation surface of the new reamer seat; Step 3) using the tooling of the application to complete the positioning and fixing of the new reamer seat; Step 4) Replace the cutter head A according to the final determined procedure. a+1 First, spot weld the installation position, then remove the tooling of this invention, and finally complete the overall welding of the new auger holder (4) according to the process requirements.

3. The method of claim 2, wherein, In the step 1), the specific process is: when it is found that one of the reamer seats (4) on the reamer arm (5) is damaged and it is determined that it must be replaced, count the damaged reamer seat (4) from the bottom zero position counterclockwise upwards to determine which one it is, and call it reamer seat A to be replaced a+1 , and call the adjacent previous reamer seat (4) reference reamer seat A a .

4. The method of claim 2, wherein, In step 3), the specific process is as follows: 3.1) eight positioning columns (2) are respectively adsorbed on the reference plate (1) through the magnets (21) according to the position coordinates provided in table 1, and the steel balls of the lead screws (26) in the eight positioning columns (2) are respectively rotated to the corresponding height given in table 1, and are respectively locked by the locking screws (25). 3.2) the steel ball on the top of the screw rod (26) of the corresponding first group of four positioning columns (2) on the reference plate (1) is fitted into each ball socket on the four corners of the supporting surface of the first positioning plate (31), which is located on the standard tooth (3) of the reamer tooth on the reference reamer seat A a , wherein three steel balls are used to determine the planar position of the first positioning plate (31), and the other steel ball is used for positioning; then the tooling of the present application in this state is fixed firmly; 3.3) First, place a new reamer seat (4) on the mounting surface of the new reamer seat, called the replacement reamer seat A a+1 Then, the four steel balls on the second set of four positioning columns (2) on the other side of the tool reference plate (1) of the present application are completely matched and fastened with the four ball sockets of the second positioning plate (31), which is located on the replacement reamer seat A a+1 The standard teeth (3) of the reamer on the replacement reamer seat A a+1 and the space position of the standard teeth (3) of the reamer provided therefor are determined, and the position is the installation position of the replacement reamer seat A a+1 .

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