A modular installation method for large scale stacker reclaimers

Abstract

The application discloses a modular installation method for a large-scale stacker-reclaimer, which comprises the following steps: S1, modular design: the structure of the stacker-reclaimer is divided into several module units, and the size and weight of each module unit are suitable for the road and hoisting equipment on site; S2, factory manufacturing and pre-assembly: the module units are divided according to the division of the module units in a factory or a pre-assembly site; S3, module splitting and transportation, and the components transported to the site are assembled according to the modules; S4, module hoisting; S5, three-dimensional measurement and installation adjustment: a large-scale stacker-reclaimer installation construction process is monitored by using a drone, a three-dimensional installation model is established, and the spatial dimensions of the stacker-reclaimer are detected through the model; the module units after hoisting are checked and adjusted to ensure the consistency and stability of the module units and the whole structure; the method provided by the application improves construction efficiency, reduces construction period, reduces cost, increases flexibility, and provides maintainability and upgradability.

Description

Technical Field

[0001] This invention relates to the field of stacker-reclaimer technology, specifically a modular installation method for large stacker-reclaimers. Background Technology

[0002] Stacker-reclaimers are mainly used for loading operations in large material storage yards such as mines and ports. In material storage yard scenarios, stacker-reclaimers are typically installed on fixed tracks and operated from a control console to perform actions such as flipping and grabbing, excavating and stacking large materials such as bulk materials and ores. To meet the needs of use, stacker-reclaimers adopt a steel structure, are large in size and heavy in weight.

[0003] In addition, given the limited space in the construction environment, it is of great significance to assemble the massive stacker-reclaimer quickly and safely. Summary of the Invention

[0004] The modular installation method for large stacker-reclaimers provided by this invention improves construction efficiency, reduces construction time, lowers costs, increases flexibility, and provides maintainability and upgradeability. This installation method has significant application value in large material yard projects.

[0005] To achieve this objective, the present invention provides the following technical solution:

[0006] This invention provides a modular installation method for a large stacker-reclaimer, comprising the following steps:

[0007] S1. Modular design: The stacker-reclaimer is structured into several modular units, and the size and weight of each modular unit must be suitable for the on-site roads and lifting equipment;

[0008] S2. Factory manufacturing and pre-assembly: In the factory or on-site prefabrication site, each component is processed, inspected, marked and stacked according to the division of modular units to ensure that the quality and size of the components meet the design requirements.

[0009] S3. Modules are disassembled and transported, and the components delivered to the site are assembled in modules;

[0010] S4. Module hoisting;

[0011] S5. Three-dimensional measurement and installation adjustment: UAVs are used to monitor the installation process of the large stacker-reclaimer, creating a three-dimensional model of the installation. The model is then used to check the various spatial dimensions of the stacker-reclaimer. The hoisted modular units are inspected and adjusted to ensure their consistency and stability with the overall structure.

[0012] In this invention, modular assembly and hoisting of the stacker-reclaimer are performed on-site to effectively simplify the installation process. Modular assembly involves manufacturing the various components and parts of the stacker-reclaimer in a modular manner, pre-assembling them in the factory, and then disassembling and transporting them to the site for assembly. This means that in the manufacturing plant, each component is prefabricated and assembled according to standardized modules. Each module undergoes rigorous quality control and testing to ensure its performance and reliability. Modular assembly reduces the workload of on-site customization and assembly, lowering human resource and time costs. Modular hoisting uses hoisting equipment to install the pre-assembled stacker-reclaimer modules on-site. The hoisting equipment can be a crane. Through reasonable hoisting planning and operation, each module can be accurately installed in the predetermined position and connected and secured as necessary. Modular hoisting transforms the construction process, which previously required extensive assembly at heights, into a safer environment on the ground, significantly reducing the risks and uncertainties during on-site construction and improving construction efficiency and safety.

[0013] Preferably, in step S1, the stacker-reclaimer structure is divided into 8 modular units, namely, traveling mechanism, slewing steel structure, pitching steel structure, cantilever beam device, counterweight device, tail car, power distribution room, and safety protection device.

[0014] Preferably, in step S2, appropriate equipment, tools and materials should be used during the processing to avoid damage or deformation of the components.

[0015] Preferably, in step S2, during the inspection process, accurate instruments, methods and standards should be used to ensure that the dimensions, shape, strength and surface quality of the components meet the design requirements.

[0016] Preferably, in step S2, during the marking process, clear markings, colors, and codes should be used to facilitate the identification and transportation of components.

[0017] Preferably, in step S2, during the stacking process, sturdy supports, pads, and ropes should be used to prevent the components from sliding or tipping over.

[0018] Preferably, step S4 includes:

[0019] S41. Perform basic on-site treatment and calibrate the module installation reference points and center lines;

[0020] S42. Erect temporary fixed supports for placing the traveling mechanism of the stacker-reclaimer;

[0021] S43. Erect temporary safety supports for placing the cantilever beam device of the stacker-reclaimer;

[0022] S44. Using specialized hoisting equipment, the assembled modular units are hoisted to the designated location and connected to other modular units;

[0023] S45. Remove temporary fixed supports and temporary safety supports.

[0024] Preferably, the procedure also includes the following steps: conducting non-destructive testing and various inspections to determine whether the bolted joints meet the requirements for safety and stability, and that no loosening is allowed. Performing ultrasonic or X-ray testing on the welded connections to clearly show the weld morphology and defects. Strictly treating the welded surfaces, corners, and necking joints according to specifications to ensure that the post-weld mechanical properties fully meet the design requirements.

[0025] Compared with the prior art, the beneficial effects and significant progress of the present invention are as follows:

[0026] 1. This invention provides a modular installation method for a large stacker-reclaimer. The method involves designing and manufacturing the various components and parts of the stacker-reclaimer in a modular fashion. After the components are transported to the site, they are modularly assembled, and then hoisted onto the site in modules. Pre-assembly and testing are performed in the manufacturing plant. To facilitate transportation, the components are disassembled and transported to the site in batches for modular assembly. This reduces the difficulty and danger of high-altitude operations on site, minimizing risks during construction. Simultaneously, on-site modular hoisting simplifies the installation process, improves construction efficiency, and reduces human resources and time costs. Furthermore, the modular design increases the maintainability and upgradeability of the system, facilitating future maintenance and improvements.

[0027] 2. This invention provides a modular installation method for large stacker-reclaimers. For large material yard projects, modular installation of stacker-reclaimers can lead to faster construction periods and less disruption. Because modular components are prefabricated and tested in the manufacturing plant, downtime at the construction site can be reduced, and interference with existing stockpiles and facilities can be minimized. This allows projects to be completed faster, reducing production interruptions and economic losses.

[0028] 3. This invention provides a modular installation method for large stacker-reclaimers, which offers greater flexibility and adjustability. Depending on specific project requirements, one or more stacker-reclaimers can be installed. By combining and adjusting the number and position of modules, different site conditions and material handling needs can be accommodated. This flexibility allows the stacker-reclaimer to better adapt to potential future expansion or modification needs. Attached Figure Description

[0029] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the embodiments of the present invention will be briefly introduced below.

[0030] Obviously, the accompanying drawings described below are only some of the drawings of the embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort, but these other drawings are also within the scope of the drawings required for the embodiments of the present invention.

[0031] Figure 1 This is a flowchart of a modular installation method for a large stacker-reclaimer according to Embodiment 1 of the present invention;

[0032] Figure 2 This is an installation diagram of a modular installation method for a large stacker-reclaimer according to Embodiment 1 of the present invention;

[0033] Figure 3 This is an installation process diagram of a modular installation method for a large stacker-reclaimer according to Embodiment 1 of the present invention;

[0034] Figure 4 This is an installation process diagram of a modular installation method for a large stacker-reclaimer according to Embodiment 1 of the present invention;

[0035] In the diagram, 1 is the traveling mechanism, 2 is the slewing steel structure, 3 is the pitching steel structure, 4 is the cantilever beam device, 5 is the counterweight device, 6 is the tail car, 7 is the power distribution room, 8 is the safety protection device, 9 is the temporary fixed support, and 10 is the temporary safety support. Detailed Implementation

[0036] To make the objectives, technical solutions, beneficial effects and significant advancements of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below.

[0037] Obviously, all the embodiments described are only some embodiments of the present invention, and not all embodiments; based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] It should be noted that the terms "first," "second," and "third" (if present), etc., in the specification, claims, and embodiments of this invention are merely used to distinguish different objects and not to describe a specific order. Furthermore, the term "comprising" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0039] What needs to be understood is:

[0040] In this invention, unless otherwise explicitly specified and limited, the terms "installation", "connection", "fixation" and the like should be interpreted broadly. For example, it can be a fixed connection, a detachable connection or a movable connection, or it can be an integral part; it can be a direct connection, an indirect connection through an intermediate medium, or an invisible signal connection, or even an optical connection; it can be the internal connection of two elements or the interaction between two elements, unless otherwise explicitly limited.

[0041] Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] It should also be noted that the following specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments.

[0043] The technical solution of the present invention will now be described in detail with reference to specific embodiments.

[0044] Example 1

[0045] like Figure 1 As shown, a modular installation method for a large stacker-reclaimer includes the following steps:

[0046] S1. Modular design: The stacker-reclaimer is structured into several modular units, and the size and weight of each modular unit must be suitable for the on-site roads and lifting equipment;

[0047] S2. Factory manufacturing and pre-assembly: In the factory or on-site prefabrication site, each component is processed, inspected, marked and stacked according to the division of modular units to ensure that the quality and size of the components meet the design requirements.

[0048] S3. Modules are disassembled and transported, and the components delivered to the site are assembled in modules;

[0049] S4. Module hoisting;

[0050] S5. Three-dimensional measurement and installation adjustment: UAVs are used to monitor the installation process of the large stacker-reclaimer, creating a three-dimensional model of the installation. The model is then used to check the various spatial dimensions of the stacker-reclaimer. The hoisted modular units are inspected and adjusted to ensure their consistency and stability with the overall structure.

[0051] like Figure 2 As shown, in step S1, the stacker-reclaimer structure is divided into 8 modular units: 1. traveling mechanism, 2. slewing steel structure, 3. pitching steel structure, 4. cantilever beam device, 5. counterweight device, 6. tail car, 7. power distribution room, and 8. safety protection device.

[0052] In this embodiment, during step S2, appropriate equipment, tools and materials should be used to avoid damage or deformation of the components.

[0053] In this embodiment, during step S2, accurate instruments, methods, and standards should be used during the inspection process to ensure that the dimensions, shape, strength, and surface quality of the components meet the design requirements.

[0054] In this embodiment, during step S2, clear marking, colors, and codes should be used to facilitate the identification and transportation of components.

[0055] In this embodiment, during step S2, sturdy supports, pads, and ropes should be used to prevent the components from sliding or tipping over during the stacking process.

[0056] like Figure 3-4 As shown, step S4 includes:

[0057] S41. Perform basic on-site treatment and calibrate the module installation reference points and center lines;

[0058] S42. Erect temporary fixed supports 9 for placing the walking mechanism of the stacker-reclaimer;

[0059] S43. Erect temporary safety supports 10 for placing the cantilever beam device of the stacker-reclaimer;

[0060] S44. Using specialized hoisting equipment, the assembled modular units are hoisted to the designated location and connected to other modular units;

[0061] S45. Remove temporary fixed support 9 and temporary safety support 10.

[0062] This embodiment also includes the following steps: performing non-destructive testing and various inspections to determine whether the bolted joint meets the requirements for safety and stability, and that no loosening is allowed. Performing ultrasonic or X-ray testing on the welded connection to clearly show the weld morphology and defects. Strictly treating the weld surface, corners, and necking according to specifications to ensure that the post-weld mechanical properties fully meet the design requirements.

[0063] Example 2

[0064] like Figure 2-4 As shown, during the installation of two DQL700 / 800.51 boom bucket wheel stacker-reclaimers manufactured by Northern Heavy Industries Group in the centralized coal yard project of Wuhan Iron and Steel Co., Ltd., modular installation was carried out using the method described in Example 1. The specific installation steps are as follows.

[0065] Step 1: On-site measurement is the first step in designing the stacker-reclaimer, based on site conditions, transportation conditions, and lifting requirements for the final module hoisting. For ease of transport and installation, the stacker-reclaimer structure is divided into several modular units. The dimensions and weight of each modular unit must be suitable for the site's roads and lifting equipment. When designing the modular units, the strength and rigidity of the structure, as well as the reliability and ease of connection, must be considered. Generally, modular units can be connected by bolts or welding; the specific choice depends on site conditions and customer requirements. The structural design of the stacker-reclaimer should comply with relevant standards and specifications to ensure safe and stable operation. The design is modular, including the traveling mechanism, slewing steel structure, pitching steel structure, cantilever beam device, counterweight device, tail carriage, power distribution room, and safety protection devices. Each module is designed with component breakdown according to on-site hoisting and transportation requirements, and a suitable connection method is designed.

[0066] Step 2: At the factory or on-site prefabrication site, process, inspect, mark, and stack each component according to the modular unit division to ensure that the quality and dimensions of the components meet the design requirements. A crucial step in modular construction is the processing and pre-assembly of components at the factory or on-site prefabrication site. To guarantee the quality and dimensions of the modular units, each component needs to be rigorously inspected, marked, and stacked according to the design drawings and specifications. During processing, appropriate equipment, tools, and materials should be used to avoid damage or deformation of the components. During inspection, accurate instruments, methods, and standards should be used to ensure that the dimensions, shape, strength, and surface quality of the components meet the design requirements. During marking, clear labels, colors, and codes should be used to facilitate component identification and transportation. During stacking, stable supports, pads, and ropes should be used to prevent the components from sliding or tipping over.

[0067] Step 3: Assemble the components delivered to the site according to modules.

[0068] Sufficient space should be reserved on site, and temporary processing and pre-assembly stations should be set up according to the order of the modular units to assemble each component into a complete hoisting modular unit. During the assembly process, attention should be paid to controlling the geometric dimensions and shape of the modular unit to ensure its docking accuracy with other modular units.

[0069] A spacious assembly area should be planned and reserved in advance at the construction site to ensure sufficient operating space for modular assembly. The area and height of the site should meet the size requirements of the largest module and consider transportation and lifting needs. Each component should be transported to the installation site in the designed modular unit sequence and precisely placed in the designated position. The position and tilt angle of the components should be controlled to facilitate subsequent positioning and docking. Based on the modular design drawings, the key structural positions should be accurately measured and marked. Modular assembly should be carried out step by step according to the assembly sequence, while monitoring key dimensions in real time to ensure they meet design requirements. Assembly joints must be strictly controlled to ensure the positioning accuracy of the center and connections. After assembling each module, its geometry and dimensions should be checked immediately, measuring the module's length, width, height, etc., and verifying that they are within tolerances. The mating surfaces must be kept clean, and no sand or other debris should be allowed to affect flatness. Connecting bolts must be of uniform specification and in the correct quantity. After modular assembly is completed, the connection accuracy and overall dimensions of each module should be thoroughly checked to ensure precise docking with other modules without gaps.

[0070] Step 4: Module hoisting

[0071] 4.1. On-site foundation treatment is carried out, and the installation reference points and center lines of the modules are calibrated.

[0072] 4.2. Using specialized hoisting equipment, the assembled modular units are hoisted to the designated positions and connected to other modular units. During hoisting, care should be taken to control the hoisting speed and angle to avoid damage or deformation to the modular units. Before the installation of the upper rotating steel structure, the stacker-reclaimer's traveling mechanism consists of three independent small units, each standing on the foundation rails. Since these units cannot maintain balance independently, temporary fixed supports are required to ensure their installation stability and the relative positions of the three independent small units, guaranteeing smooth installation of the rotating steel structure later. The temporary fixed supports should be designed and selected appropriately based on the weight and dimensions of the traveling mechanism. The material must have sufficient strength and rigidity. The connection points of the support supports must be compatible with the structural characteristics of the mechanism body to ensure a firm and reliable connection. After the mechanism is installed on the rail foundation, the support and fixing devices need to be erected promptly. Before fixing, the levelness of each small unit must be strictly controlled. The temporary support and fixing devices must reliably restrict the free displacement of each independent small unit of the traveling mechanism to prevent relative movement or tipping. Simultaneously, the relative positional relationship of each small unit in the horizontal plane must be strictly measured and controlled to ensure complete consistency with the structural design. After the upper part of the slewing assembly is installed, an inspection is conducted, and the temporary support fixing device is removed only after confirming that everything is correct. For the hoisting of the cantilever beam device, temporary safety supports must be used for support. Throughout the installation process, the temporary safety supports ensure the stability of the entire stacker-reclaimer, so the temporary support frame can only be removed after construction is completed.

[0073] 4.3 Use professional lifting equipment with a lifting capacity that meets the requirements. The selection of lifting equipment should be based on the module weight to ensure a sufficient safety factor. Before lifting, a comprehensive inspection of the lifting equipment and lifting tools must be conducted to ensure they are functioning properly. Work can only commence after qualified personnel have approved the operation. Connect the lifting tools to the lifting points on the module. The lifting points must be designed and calculated to prevent uneven loading. The connections must be reliable and secure. Before lifting operations, a lifting plan must be developed, specifying the path, height, and angle, and potential risk points must be assessed.

[0074] 4.4 During lifting, a designated person must direct and coordinate the signals. The lifting speed must be slow, with pauses between each action. The lifting path direction must be strictly controlled to prevent tilting or collisions. The lifting angle must not exceed the design limits. After the module is positioned and firmly on the ground, the position must be rechecked for consistency with the design before any connection is made.

[0075] Step 5: Use drones to monitor the installation process of the large stacker-reclaimer, establish a 3D model of the installation, and use the model to check the spatial dimensions of the stacker-reclaimer. Inspect and adjust the hoisted module units to ensure their consistency and stability with the overall structure. For bolted connections, tighten and inspect according to specifications. For welded connections, inspect and treat the welds according to specifications. After the modules are hoisted into place, immediately check the levelness and verticality, and compare the measurement data with the design requirements. Use a laser level or total station to measure the elevation of the top surface of the module and check whether the height difference is within the allowable tolerance range. Check the connection between each module and the overall main structure to ensure that the fit is completely in accordance with the design drawings. Tighten the bolts between modules one by one according to the specifications, controlling the torque to reach the reasonable design value. Check the connection rigidity after tightening.

[0076] Step 6: Conduct non-destructive testing and various inspections to determine if the bolted joints meet the requirements for safety and stability, and that no loosening is allowed. Perform ultrasonic or X-ray testing on welded connections to clearly show the weld morphology and defects. Strictly follow the specifications to treat weld surfaces, corners, and necking joints to ensure that the post-weld mechanical properties fully meet the design requirements.

[0077] In conclusion, the choice of modular assembly and hoisting of the stacker-reclaimer in the Wuhan Iron and Steel Co., Ltd. raw material yard project not only demonstrates the advanced nature and feasibility of the technology but also provides a reliable solution for the smooth progress of the project. This technical approach has significant application value in large material yard projects and can provide reference and guidance for the installation work of other similar projects.

[0078] In the description process of the above instruction manual:

[0079] The terms "this embodiment," "an embodiment of the present invention," "as shown," "further," and "further improved technical solutions," etc., indicate that the specific features, structures, materials, or characteristics described in the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms are not necessarily directed at the same embodiment or example, and the specific features, structures, materials, or characteristics described can be combined or combined in any suitable manner in one or more embodiments or examples. Furthermore, without causing contradiction, those skilled in the art can combine or combine the different embodiments or examples described in this specification and the features of the different embodiments or examples.

[0080] Finally, it should be noted that:

[0081] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them;

[0082] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. Non-essential improvements, adjustments or substitutions made by those skilled in the art based on the content of this specification are all within the scope of protection claimed by the present invention.

Claims

1. A modular installation method for a large stacker-reclaimer, characterized in that, Includes the following steps: S1. Modular design: The stacker-reclaimer is structured into several modular units, and the size and weight of each modular unit must be suitable for the on-site roads and lifting equipment; S2. Factory manufacturing and pre-assembly: In the factory or on-site prefabrication site, each component is processed, inspected, marked and stacked according to the division of modular units to ensure that the quality and size of the components meet the design requirements. S3. Modules are disassembled and transported, and the components delivered to the site are assembled in modules; S4. Module hoisting; S5. Three-dimensional measurement and installation adjustment: UAVs are used to monitor the installation process of large stacker-reclaimers, a three-dimensional model of the installation is established, and the spatial dimensions of the stacker-reclaimer are detected through the model. The module units after hoisting are checked and adjusted to ensure their consistency and stability with the overall structure. In step S1, the stacker-reclaimer structure is divided into 8 modular units, namely, traveling mechanism, slewing steel structure, pitching steel structure, cantilever beam device, counterweight device, tail car, power distribution room, and safety protection device. Step S4 includes: S41. Perform basic on-site treatment and calibrate the module installation reference points and center lines; S42. Erect temporary fixed supports for placing the traveling mechanism of the stacker-reclaimer; S43. Erect temporary safety supports for placing the cantilever beam device of the stacker-reclaimer; S44. Using specialized hoisting equipment, the assembled modular units are hoisted to the designated location and connected to other modular units; S45. Remove temporary fixed supports and temporary safety supports.

2. The modular installation method for a large stacker-reclaimer as described in claim 1, characterized in that, In step S2, appropriate equipment, tools and materials should be used during the processing to avoid damage or deformation of the components.

3. The modular installation method for a large stacker-reclaimer as described in claim 1, characterized in that, In step S2, during the inspection process, accurate instruments, methods, and standards should be used to ensure that the dimensions, shape, strength, and surface quality of the components meet the design requirements.

4. The modular installation method for a large stacker-reclaimer as described in claim 1, characterized in that, In step S2, during the marking process, clear markings, colors, and codes should be used to facilitate the identification and transportation of components.

5. A modular installation method for a large stacker-reclaimer as described in claim 1, characterized in that, In step S2, during the stacking process, sturdy supports, pads, and ropes should be used to prevent the components from sliding or tipping over.

6. A modular installation method for a large stacker-reclaimer as described in claim 1, characterized in that, It also includes the following steps: Non-destructive testing and various inspections are conducted to determine whether bolted joints meet the requirements for safety and stability, and no loosening is allowed; ultrasonic or X-ray testing is performed on welded connections to clearly show the weld morphology and defects; welded surfaces, corners, and constrictions are treated strictly according to specifications to ensure that the mechanical properties after welding fully meet the design requirements.

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