A sintering machine trolley wheel non-stop replacement system and replacement method

Abstract

The present application relates to sintering machine technical field, specifically disclose a kind of sintering machine trolley wheel non-stop replacement system and replacement method, including sintering machine trolley track, guide rail lifting platform, trolley wheel dismounting device, trolley wheel mounting device, lifting walking device, trolley running position detection equipment, trolley wheel position detection equipment, guide rail lifting platform detection equipment and equipment control system, bearing damage sintering machine trolley wheel runs to predetermined position, guide rail lifting platform drops, trolley wheel is suspended, hydraulic jack removes trolley wheel, removes installation position in the opposite direction of trolley movement, trolley wheel mounting device enters installation position, and trolley wheel is installed to trolley axle working position, by end cap mounting device installation end cap, guide rail lifting platform rises, and sintering machine normal operation;The present application is novel in structure design, realizes that bearing damage trolley wheel is replaced on line under the normal operating state of sintering machine, need not stop processing, ensure that sintering machine long-term stable operation.

Description

Technical Field

[0001] This invention relates to the field of sintering machine technology, specifically to a system and method for replacing sintering machine trolley wheels without stopping the machine. Background Technology

[0002] The sintering machine trolley is driven by the head drive mechanism, which lifts it from the lower track via the head bend to the upper horizontal track. This propels the trolley forward along the track towards the tail of the machine. The mixture moves towards the bellows area as the trolley moves, and upon reaching the igniter, ignition and ventilation occur simultaneously, marking the start of the sintering process. Near the tail end, the sinter reaches its final sintering point. The trolley then begins to tip over and unload at the tail bend, simultaneously being engaged by the rotating tail star wheel and moving onto the lower horizontal track. One complete rotation of the trolley completes one work cycle, which is then repeated.

[0003] The sintering machine trolley wheel assembly consists of the trolley wheel housing, double-row tapered rollers, washers, through-caps, through-cap oil seals, baffles, O-rings, U-rings, and spacer rings, among other spare parts, and its internal structure is complex. During prolonged operation of the sintering machine, a gap develops between the trolley wheel and the self-lubricating bushing due to long-term wear. This causes the mechanical labyrinth seal to fail, allowing dust and small particles of sintered ore to enter the seal through the gap. The trolley wheel's rear frameless oil seal opening faces to the right, and the thick-lip sealing surface is also on the right side, which is intended to partially prevent dust ingress. The original design used ordinary nitrile rubber, but after reaching 200°C at the machine tail, the nitrile rubber rapidly aged, the seals failed, and fine materials and other impurities frequently entered the bearing rollers, causing accelerated bearing wear and ultimately damaging the sintering machine trolley wheel.

[0004] With the increasing size of sintering equipment, the number and weight of the trolleys are gradually increasing. Taking a 500㎡ sintering machine as an example, the machine is equipped with 173 trolleys and 692 trolley wheels. If the bearing of even one trolley wheel fails, the entire sintering machine will have to be shut down to replace the trolley. If problems such as trolley wheels getting stuck at the machine head or the tail rail bending occur, it will lead to a long downtime, with equipment repair and restoration taking more than 4 hours, affecting both the output and quality of the sinter.

[0005] Therefore, it is necessary to design a non-stop replacement system and method for sintering machine trolley wheels to solve the problem of downtime and production stoppage caused by the current requirement to stop the machine to replace the trolley when a problem occurs. Summary of the Invention

[0006] To address the problems existing in the prior art, the present invention aims to provide a non-stop replacement system and method for sintering machine trolley wheels, enabling fully automatic online replacement of trolley wheels without stopping the sintering machine. The replacement process requires no manual intervention, has a high degree of automation, and the sintering machine operates normally throughout the entire replacement process without the need for production reduction or shutdown.

[0007] The technical solution adopted by this invention to solve its technical problem is: a sintering machine trolley wheel replacement system without stopping the machine, including a sintering machine trolley track, a guide rail lifting platform, a trolley wheel disassembly device, a trolley wheel installation device, a lifting and traveling device, a trolley running position detection device, a trolley wheel position detection device, a guide rail lifting platform detection device, and an equipment control system. The trolley wheels of the sintering machine trolley run on the sintering machine trolley track. A gap is provided on the sintering machine trolley track, and a guide rail lifting platform is installed in the gap. The guide rail lifting platform is provided with a lifting guide rail, a fork scissor, a locking mechanism, and a hydraulic power mechanism. The hydraulic power mechanism controls the lifting guide rail to move up and down through the fork scissor.

[0008] The lifting and walking device is equipped with a walking track, walking wheels and a walking support frame. The walking track is laid horizontally and parallel to the sintering machine trolley track. The walking wheels move on the walking track and are installed in the walking wheel guard plate. The walking support frame is installed on the upper part of the walking wheel guard plate through a lifting screw.

[0009] Both the trolley wheel disassembly device and the trolley wheel installation device are equipped with a trolley wheel clamp, an end cap disassembly and assembly mechanism, a trolley wheel replacement support frame, and a hydraulic jack. The trolley wheel clamp is a vertically divided cylindrical structure that clamps the trolley wheel. The trolley wheel clamp is installed on the trolley wheel replacement support frame. The bottom of the trolley wheel replacement support frame is connected to the traveling support frame through a sliding groove. The trolley wheel replacement support frame is also equipped with an end cap disassembly and assembly mechanism and a hydraulic jack. The piston cylinder of the hydraulic jack has a groove at the front, and the trolley wheel clamp is connected in the groove.

[0010] The trolley running position detection equipment is installed on the outside of the sintering machine trolley track. The signal output terminal of the trolley running position detection equipment is connected to the control cabinet of the guide rail lifting platform, the control cabinet of the trolley wheel disassembly device, and the control cabinet of the trolley wheel installation device. The trolley running position detection equipment is used to detect online when the trolley that needs to disassemble and install the trolley wheel reaches the designated position, and sends the guide rail lifting signal, the trolley wheel disassembly signal, and the trolley wheel reinstallation preparation signal in sequence.

[0011] The wheel position detection device is installed on the wheel fixture. The wheel position detection device is used to detect when the wheel reaches the designated area and send a precise alignment signal to the wheel disassembly device control cabinet or the wheel installation device control cabinet.

[0012] The guide rail lifting platform detection equipment is installed at the highest and lowest points of the guide rail platform. The signal output terminal of the guide rail lifting platform detection equipment is connected to the platform hydraulic station control system. When the guide rail lifting platform is raised or lowered to the designated position, it sends a stop signal to the hydraulic station, and the lifting platform is locked in that position.

[0013] Specifically, the forklift is hinged in the middle by a pin, and the upper part of one side of the forklift is rotatably connected to the fixed block of the lifting platform by a pin. The lower part of one side of the forklift is rotatably connected to the fixed block of the fixed base by a pin. The fixed blocks are fixed to the bottom of the lifting platform and the upper part of the fixed base, respectively. The upper part of the other side of the forklift is rotatably connected to the movable slider of the lifting platform by a pin. The lower part of the other side of the forklift is rotatably connected to the movable slider of the fixed base by a pin. The movable slider is slidably connected in the grooves at the bottom of the lifting platform and the upper part of the fixed base. The bottom of one side of the forklift arm is connected to the piston rod of the hydraulic power mechanism. The hydraulic power mechanism controls the lifting of the forklift and drives the lifting guide rail to lift. The highest point of the lifting guide rail is at the same level as the sintering machine trolley track.

[0014] Specifically, the traveling track is constructed of I-beams and laid horizontally, parallel to the sintering machine trolley track, and the traveling wheels travel on the track. The top of the traveling support frame is connected to the bottom of the trolley wheel replacement support frame via a sliding groove, allowing the trolley wheel replacement support frame to slide within the groove, thereby driving the trolley wheel clamp and hydraulic jack to move axially back and forth. The lower part of the vertical frame of the traveling support frame is a lifting screw, the middle part of the traveling support frame is a screw slider, and the upper part of the traveling support frame is a hollow round tube or a hollow square tube. The inner diameter of the hollow round tube or hollow square tube is larger than that of the lifting screw. The outer diameter of the lever, the hollow round tube or the hollow square tube, is fixed to the lead screw slider by bolts, rivets or welding; each lifting lead screw is driven to rotate at the same speed by a motor and speed divider, the walking support frame is raised or lowered in the vertical direction, and the trolley wheel changes the vertical movement of the support frame; the bottom of the walking support frame is equipped with walking wheels, the sides of the walking wheels are equipped with semi-wedge-shaped walking wheel guards, the top of the walking wheel guards is installed on the walking support frame, and the bottom semi-wedge structure of the walking wheel guards is inserted into the I-beam groove of the walking track to form an anti-tipping protection for the whole.

[0015] Specifically, the trolley wheel clamp is cylindrical, hollow inside, and its internal dimensions are 0.1–5 mm larger than the diameter of the trolley wheel. The trolley wheel clamp is vertically divided into two halves, and its opening and closing actions are controlled by a hydraulic cylinder, pneumatic cylinder, or motor. Bearings are installed on the bottom edge of each half of the trolley wheel clamp, and the diameter of the bearings is equal to the bottom wall thickness of the trolley wheel clamp. The trolley wheel clamp has sidewalls on both sides, with one sidewall abutting the inner side of the trolley wheel and the other sidewall engaging with the outer ring groove of the hydraulic jack piston cylinder. The sidewall of the trolley wheel clamp holding the trolley wheel has a thickness of 5–20 mm and a length of 20–60 mm. The sidewall of the trolley wheel clamp engaging with the piston cylinder groove has a thickness of 5–20 mm and a length of 20–40 mm.

[0016] Specifically, the piston cylinder groove depth of the hydraulic jack is the length of the side wall of the trolley wheel clamp + 2 to 5 mm, and the width is the thickness of the side wall of the trolley wheel clamp + 1 to 3 mm. The hydraulic jack is connected to a hydraulic system, which provides a pressure of 0 to 10 MPa. The hydraulic jack is installed on the trolley wheel replacement support frame to form a relatively static moving whole.

[0017] Specifically, the trolley running position detection device includes a first photoelectric limit switch, which is installed along the vertical direction of the trolley wheel's movement, and is interlocked with the guide rail lifting platform control system;

[0018] The first photoelectric limit switch detection device receives the detection signal and sends a start signal for the guide rail lifting platform to the platform control cabinet. The hydraulic cylinder starts to retract, and the guide rail lifting platform descends, suspending the trolley wheel to be disassembled. At the same time, it sends a start signal to the trolley wheel disassembly device, which enters the disassembly position to prepare for disassembly. It also sends a trolley wheel reinstallation preparation signal to the trolley wheel installation device, which enters the installation preparation position. The sintering machine remains in normal operation.

[0019] Specifically, the wheel position detection device includes a second photoelectric limit switch, which is installed on the wheel fixture. The wheel position detection device is used to detect when the center of the fixture is aligned with the wheel axle during the disassembly and installation of the wheel, and sends a precise alignment signal to the control cabinet of the wheel disassembly device or the wheel installation device.

[0020] Specifically, the trolley wheel disassembly device and the trolley wheel installation device adopt a four-axis or industrial robot. The trolley wheel disassembly device is used for longitudinal, lateral and vertical three-dimensional operation, wherein the maximum longitudinal operation speed is higher than the sintering machine operation speed; the trolley wheel installation device is used for longitudinal, lateral and vertical three-dimensional operation, wherein the longitudinal operation speed is the same as the sintering machine operation speed.

[0021] An automatic wheel replacement method for a sintering machine trolley wheel replacement system without stopping the machine includes the following steps:

[0022] S1. When the damaged trolley wheel reaches the initial disassembly position A, the guide rail lifting platform closes the locking mechanism and begins to descend. The trolley wheel disassembly device aligns the center of the trolley wheel clamp with the center of the trolley wheel axle. Its lifting and traveling device drives the trolley to move in the same direction and at the same speed, keeping the two centers always aligned.

[0023] S2. The guide rail lifting platform descends to the lower limit position, the table wheel clamp opens to both sides, the table wheel clamp moves along the table wheel axle until the inner side wall plane of the clamp coincides with the inner side wall plane of the table wheel, the table wheel clamp closes, clamps the damaged table wheel, one end of the inner side wall of the table wheel clamp contacts the inner side wall of the table wheel, and the other end of the table wheel clamp is inserted into the slot of the hydraulic jack.

[0024] S3. The end cover removal and assembly mechanism enters the trolley wheel clamp, the sleeve is aligned with the fastened bolts to perform disassembly, the end cover and bolts are removed, the end cover is removed from the disassembly position, and it is lifted up beyond the travel stroke of the trolley wheel clamp.

[0025] S4. The hydraulic jack starts working, the hydraulic rod presses against the axle of the trolley wheel, and the hydraulic cylinder drives the trolley wheel clamp that is stuck in the slot to move outward. The trolley wheel moves outward along the axis of the trolley wheel clamp and disengages from the axle of the trolley wheel.

[0026] S5. The lifting and traveling device of the trolley wheel dismantling device moves in the opposite direction of the trolley movement and exits the dismantling position A.

[0027] S6. The trolley wheel installation device clamps the new trolley wheel with the trolley wheel clamp. Its lifting and traveling device moves closer to the trolley axle and enters the installation position from the installation preparation position. The center of the new trolley wheel, that is, the center of the trolley wheel clamp, is aligned with the center of the trolley wheel axle. Its lifting and traveling device drives the trolley to move in the same direction and at the same speed, keeping the two centers always aligned.

[0028] S7. Install the new platform wheel to the working position of the platform wheel axle;

[0029] S8. The end cover removal and installation mechanism enters the trolley wheel clamp and presses the end cover to the outside of the trolley wheel. The bolt holes of the end cover are aligned with the bolt holes on the trolley axle. The end cover bolts in the sleeve are aligned with the bolt holes on the end cover for installation. After tightening the bolts, the end cover removal and installation mechanism exits the trolley wheel clamp and is lifted beyond the travel stroke of the trolley wheel clamp.

[0030] S9. The trolley wheel installation device exits the installation position, and the trolley wheel clamp is retracted to outside the trolley wheel working interface.

[0031] S10. The guide rail lifting platform rises until the lifting guide rail is level with the sintering machine trolley track, and the locking mechanism of the guide rail lifting platform is activated.

[0032] Specifically, the initial disassembly position A in step S1 is the trigger position of the first photoelectric limit switch of the sintering machine trolley running position detection device;

[0033] The wheel clamp is equipped with a laser rangefinder sensor, which is used to detect the distance from the laser rangefinder sensor to the wheel end face and send the distance data signal to the control cabinet of the wheel disassembly device and the control cabinet of the wheel installation device. The clamping and docking position of the wheel clamp is calculated by the control cabinet of the wheel disassembly device and the control cabinet of the wheel installation device based on the received distance from the laser rangefinder sensor to the wheel end face, the trolley running speed and the forward extension speed of the wheel clamp.

[0034] The present invention has the following beneficial effects:

[0035] The sintering machine trolley wheel replacement system and method designed in this invention replaces damaged sintering machine trolley wheels online, avoiding downtime for replacing the entire trolley. This reduces the operational risks and labor intensity of manual trolley replacement, and improves the automation and intelligence of on-site equipment operation. It has practical significance for promoting intelligent production in steel plants under Industry 4.0.

[0036] The sintering machine trolley wheel replacement system and method designed in this invention avoids sintering machine downtime exceeding 10 minutes, or even more than half an hour, caused by trolley replacement. The entire process of shutdown, trolley replacement, and restart operations poses significant safety risks to equipment operation and causes fluctuations in sinter output and quality. The invention enables automatic replacement of damaged trolley wheels without shutting down the machine, eliminating various risks. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the automatic wheel replacement system for the sintering machine without stopping the machine.

[0038] Figure 2 This is a schematic diagram of the installation structure of the lifting guide rail platform.

[0039] Figure 3 This is a structural schematic diagram of the lifting guide rail platform.

[0040] Figure 4 This is a schematic diagram of the installation structure of the forklift.

[0041] Figure 5 This is a schematic diagram of the structure of a wheel removal device or a wheel installation device. Figure 1 .

[0042] Figure 6 This is a schematic diagram of the structure of a wheel removal device or a wheel installation device. Figure 2 .

[0043] Figure 7 This is a schematic diagram of the installation structure of a wheel clamp and a hydraulic jack.

[0044] Figure 8This is a schematic diagram of the installation structure of the walking support frame.

[0045] Figure 9 This is a schematic diagram of the installation structure of the walking wheels.

[0046] In the diagram: 1-Sintering machine trolley track; 2-Guide rail lifting platform; 3-Sintering machine trolley wheel and end cover; 4-Trolley wheel clamp; 5-Trolley wheel disassembly device; 6-Trolley wheel installation device; 7-Lifting and traveling device; 8-Lifting guide rail; 9-Lifting platform; 10-Fixing block; 11-Fixing base; 12-Forklift; 13-Moving slider; 14-End cover disassembly and assembly mechanism; 15-Trolley wheel replacement support frame; 16-Hydraulic jack; 17-Traveling support frame; 18-Lifting screw; 19-Traveling track; 20-Traveling wheel guard plate; 21-Traveling wheel. Detailed Implementation

[0047] The technical solutions of the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0048] Example 1:

[0049] like Figures 1-9 As shown, a non-stop wheel replacement system for a sintering machine trolley includes a sintering machine trolley track 1, a guide rail lifting platform 2, a trolley wheel disassembly device 5, a trolley wheel installation device 6, a lifting and traveling device 7, a trolley running position detection device, a trolley wheel position detection device, a guide rail lifting platform detection device, and an equipment control system. The trolley wheels of the sintering machine trolley run on the sintering machine trolley track 1. A gap is provided on the sintering machine trolley track 1, and the guide rail lifting platform 2 is installed in the gap. The guide rail lifting platform 2 is equipped with a lifting guide rail 8, a fork scissor 12, a locking mechanism, and a hydraulic power mechanism. The hydraulic power mechanism controls the lifting guide rail 8 to move up and down through the fork scissor 12.

[0050] The lifting and walking device 7 is equipped with a walking track 19, walking wheels 21 and a walking support frame 17. The walking track 19 is laid horizontally parallel to the sintering machine trolley track 1. The walking wheels 21 move on the walking track 19. The walking wheels 21 are installed inside the walking wheel guard plate 20. The walking support frame 17 is installed on the upper part of the walking wheel guard plate 20 through the lifting screw 18.

[0051] Both the wheel disassembly device 5 and the wheel installation device 6 are equipped with a wheel clamp 4, an end cap disassembly and assembly mechanism 14, a wheel replacement support frame 15, and a hydraulic jack 16. The wheel clamp 4 is a vertical cylindrical structure divided into two halves. The wheel clamp 4 clamps the wheel. The wheel clamp is installed on the wheel replacement support frame 15. The bottom of the wheel replacement support frame 15 is connected to the travel support frame 17 through a sliding groove. The end cap disassembly and assembly mechanism 14 and the hydraulic jack 16 are also installed on the wheel replacement support frame 15. The piston cylinder of the hydraulic jack 16 has a groove at the front, and the wheel clamp 4 is connected in the groove.

[0052] After the lifting platform 9 descends, the wheel disassembly device 5 is activated. The wheel position detection device sends a signal to align with the wheel to be replaced. One end of the wheel clamp 4 clamps the wheel, and the other end engages with the slot of the hydraulic jack 16. The end cap removal mechanism 14 enters the wheel clamp 4 and performs disassembly operations by aligning with the fastened bolts. After removing the end cap and bolts, it exits its position. The hydraulic jack 16 then activates, working in conjunction with the wheel clamp 4. The wheel moves axially backward along with the wheel clamp 4 and the hydraulic cylinder, removing the wheel. The lifting and traveling device 7 then moves in the opposite direction of the trolley's movement, moving it away from its installation position.

[0053] After receiving the start signal, the lifting and traveling device 7 of the trolley wheel installation device 6 begins to move from the trolley wheel reinstallation preparation position to the installation position, aligning with the trolley wheel axle to be reinstalled. The trolley wheel clamp 4 drives the trolley wheel to move simultaneously, and the trolley wheel follows the trolley wheel clamp 4 axially forward until the trolley wheel is reinstalled to the working position of the trolley axle. The end cover removal and installation mechanism 14 enters the trolley wheel clamp 4, installs the end cover and fastens the bolts. After installation, the trolley wheel clamp 4 and the end cover removal and installation mechanism 14 are removed from the installation position, and the lifting platform 9 is raised and reset.

[0054] The trolley position detection device is installed on the outside of the sintering machine trolley track 1. The signal output terminal of the trolley position detection device is connected to the control cabinet of the guide rail lifting platform 2, the control cabinet of the trolley wheel disassembly device 5, and the control cabinet of the trolley wheel installation device 6. The trolley position detection device is used to detect online when the trolley that needs to disassemble and install the trolley wheel reaches the designated position, and sends the guide rail lifting signal, the trolley wheel disassembly signal, and the trolley wheel reinstallation preparation signal in sequence.

[0055] The wheel position detection device is installed on the wheel fixture 4. The wheel position detection device is used to detect when the wheel reaches the designated area and send a precise alignment signal to the wheel disassembly device control cabinet or the wheel installation device control cabinet.

[0056] The inspection equipment for the guide rail lifting platform is installed at the highest and lowest points of the platform. The signal output of this equipment is connected to the platform's hydraulic control system. When the platform rises or falls to a designated position, it sends a stop signal to the hydraulic station, locking the platform in that position. The detection position at the lowest point needs to be confirmed based on the daily damage statistics of the sintering table wheels and the final descent height. This position requires continuous adjustment based on on-site operating conditions.

[0057] Example 2: Working principle using the structure of Example 1.

[0058] The forklift 12 is hinged in the middle by a pin. The upper part of one side of the forklift 12 is rotatably connected to the fixed block of the lifting platform 9 by a pin, and the lower part of one side of the forklift 12 is rotatably connected to the fixed block of the fixed base 11 by a pin. The fixed blocks 10 are fixed to the bottom of the lifting platform 9 and the upper part of the fixed base 11, respectively. The upper part of the other side of the forklift 12 is rotatably connected to the movable slider 13 of the lifting platform 9 by a pin, and the lower part of the other side of the forklift 12 is rotatably connected to the movable slider 13 of the fixed base 11 by a pin. The movable slider 13 is slidably connected to the bottom of the lifting platform 9. Inside the groove on the upper part of the fixed base 11, the bottom of one side arm of the fork scissor 12 is connected to the piston rod of the hydraulic power mechanism. The hydraulic power mechanism controls the lifting of the fork scissor 12 and drives the lifting guide rail 8 to lift. The hydraulic power mechanism drives the piston rod to extend or retract, so that the guide rail lifting platform 2 rises or falls in the grooves of the guide rails on both sides. After reaching the highest or lowest point of the platform's lifting stroke, the piston rod stops moving and holds pressure, the locking device opens, the lifting platform position is locked, and the highest point of the lifting guide rail 8 is at the same level as the sintering machine trolley track 1.

[0059] The guide rail lifting platform 2 is one of the key components of the automatic replacement system for the sintering machine trolley wheels without stopping. The guide rail lifting platform 2 must descend a certain distance beyond the outer edge of the trolley wheel so that the trolley wheel is completely suspended in the air, in order to ensure that the trolley wheel can be taken out or reinstalled.

[0060] The traveling track 19 is made of I-beams and laid horizontally, parallel to the sintering machine trolley track 1. The traveling wheels travel on the traveling track 19. The top of the traveling support frame 17 is connected to the bottom of the trolley wheel replacement support frame 15 by a sliding groove. The trolley wheel replacement support frame 15 slides in the sliding groove, driving the trolley wheel clamp 4 and the hydraulic jack 16 to move axially back and forth. The lower part of the vertical frame of the traveling support frame 17 is a lifting screw 18, the middle part of the traveling support frame 17 is a screw slider, and the upper part of the traveling support frame 17 is a hollow round tube or a hollow square tube. The inner diameter of the hollow round tube or hollow square tube is larger than that of the lifting screw. The hollow round or square tube with an outer diameter of 18 is connected to the lead screw and slider by bolts, rivets, or welding. Each lifting lead screw 18 is driven to rotate at the same speed by a motor and a speed divider. The walking support frame 17 is raised or lowered in the vertical direction, which drives the trolley wheel to change the vertical movement of the support frame 15. The bottom of the walking support frame 17 is equipped with a walking wheel, and the sides of the walking wheel are equipped with semi-wedge-shaped walking wheel guards 20. The top of the walking wheel guards 20 is installed on the walking support frame 17, and the bottom semi-wedge structure of the walking wheel guards 20 is inserted into the I-beam groove of the walking track 19 to form an anti-tipping protection for the whole.

[0061] The trolley wheel clamp 4 is cylindrical, hollow inside, and its internal dimensions are 1mm larger than the diameter of the trolley wheel. The trolley wheel clamp 4 is vertically divided into two halves, and its opening and closing actions are controlled by a hydraulic cylinder, air cylinder, or motor. Bearings are installed on the bottom edge of each half of the trolley wheel clamp 4, and the diameter of the bearings is equal to the bottom wall thickness of the trolley wheel clamp 4. The trolley wheel clamp 4 has side walls on both sides. One side wall is attached to the inner side of the trolley wheel, and the other side wall is inserted into the outer ring groove of the hydraulic jack piston cylinder. The side wall of the trolley wheel clamp 4 holding the trolley wheel has a thickness of 10mm and a length of 40mm. The side wall of the trolley wheel clamp 4 inserted into the piston cylinder groove has a thickness of 10mm and a length of 30mm.

[0062] The piston cylinder groove depth of the hydraulic jack 16 is 13mm as long as the side wall of the trolley wheel clamp 4, and the width is 12mm as thick as the side wall of the trolley wheel clamp. The hydraulic jack 16 is connected to the hydraulic system, which provides a pressure of 10MPa. The hydraulic jack is installed on the trolley wheel replacement support frame to form a relatively static moving whole.

[0063] The trolley running position detection equipment includes a first photoelectric limit switch, which is installed along the vertical direction of the trolley wheel's movement and is interlocked with the control system of the guide rail lifting platform 2.

[0064] The first photoelectric limit switch detection device receives the detection signal and sends a start signal to the platform control cabinet for the guide rail lifting platform 2. The hydraulic cylinder starts to retract, and the guide rail lifting platform 2 descends, suspending the trolley wheel to be disassembled. At the same time, it sends a start signal to the trolley wheel disassembly device 5, which enters the disassembly position to prepare for disassembly. It also sends a trolley wheel reinstallation preparation signal to the trolley wheel installation device 6, which enters the installation preparation position. The sintering machine is still in normal operation.

[0065] The trolley wheel position detection device includes a second photoelectric limit switch, which is installed on the trolley wheel clamp 4. The trolley wheel position detection device is used to detect when the center of the trolley wheel clamp 4 is aligned with the trolley wheel axle during the trolley wheel disassembly and installation process, and sends a precise alignment signal to the control cabinet of the trolley wheel disassembly device 5 or the control cabinet of the trolley wheel installation device 6.

[0066] To ensure the safe operation of the trolley, the time taken for the guide rail lifting platform 2 to rise from its initial descent to its final position is less than or equal to the time taken by a single wheel of the sintering machine. The guide rail lifting platform 2 has sliding groove devices on both sides to ensure that the lifting platform 9 can withstand a certain axial force. During normal operation, the lifting guide rail 8 remains in a straight line with the sintering machine trolley track 1.

[0067] The trolley wheel disassembly device 5 and the trolley wheel installation device 6 are equipped with a four-axis or industrial robot. The trolley wheel disassembly device 5 is used for longitudinal, lateral and vertical three-dimensional movement, with the maximum longitudinal movement speed being higher than the sintering machine's operating speed. The trolley wheel installation device 6 is used for longitudinal, lateral and vertical three-dimensional movement, with the longitudinal movement speed being the same as the sintering machine's operating speed.

[0068] Example 3:

[0069] An automatic wheel replacement method for a sintering machine trolley wheel replacement system without stopping the machine includes the following steps:

[0070] 1. When the damaged trolley wheel reaches the initial disassembly position A, the guide rail lifting platform 2 closes the locking mechanism and begins to descend. The trolley wheel disassembly device 5 aligns the center of the trolley wheel clamp 4 with the center of the trolley wheel axle. Its lifting and traveling device 7 drives the trolley to move in the same direction and at the same speed, keeping the two centers always aligned.

[0071] 2. The guide rail lifting platform 2 descends to the lower limit position, the table wheel clamp 4 opens to both sides, the table wheel clamp 4 moves along the table wheel axle direction until the inner side wall plane of the clamp coincides with the inner side wall plane of the table wheel, the table wheel clamp 4 closes, clamping the damaged table wheel, one end of the inner side wall of the table wheel clamp 4 contacts the inner side wall of the table wheel, and the other end of the table wheel clamp 4 is inserted into the slot of the hydraulic jack 16.

[0072] 3. The end cover removal and installation mechanism 14 enters the trolley wheel clamp 4, the sleeve is aligned with the fastened bolts to perform the disassembly operation, the end cover and bolts are taken out, the end cover is removed from the disassembly position, and it is lifted up to the outside of the travel range of the trolley wheel clamp 4.

[0073] 4. When the hydraulic jack 16 starts working, the hydraulic rod presses against the axle of the trolley wheel, and the hydraulic cylinder drives the trolley wheel clamp 4, which is stuck in the groove, to move outward. The trolley wheel moves outward along with the trolley wheel clamp 4 and disengages from the trolley wheel axle.

[0074] 5. The lifting and traveling device 7 of the trolley wheel dismantling device 5 moves in the opposite direction of the trolley movement and exits the dismantling position A.

[0075] 6. The new trolley wheel installation device 6 clamps the new trolley wheel with the trolley wheel clamp 4. Its lifting and traveling device 7 moves closer to the trolley axle and enters the installation position from the installation preparation position. The center of the new trolley wheel, that is, the center of the trolley wheel clamp 4, is aligned with the center of the trolley wheel axle. Its lifting and traveling device 7 drives the trolley to move in the same direction and at the same speed, keeping the two centers always aligned.

[0076] 7. Install the new trolley wheel into the working position of the trolley wheel axle.

[0077] 8. The end cover removal and installation mechanism 14 enters the trolley wheel clamp 4, presses the end cover to the outside of the trolley wheel, aligns the bolt holes of the end cover with the bolt holes on the trolley axle, aligns the end cover bolts in the sleeve with the bolt holes on the end cover for installation, tightens the bolts and then the end cover removal and installation mechanism 14 exits the trolley wheel clamp 4 and is lifted beyond the travel stroke of the trolley wheel clamp 4.

[0078] 9. The trolley wheel installation device is removed from the installation position, and the trolley wheel clamp 4 is retracted to outside the trolley wheel working interface.

[0079] 10. The guide rail lifting platform 2 rises until the lifting guide rail 8 is level with the sintering machine trolley track 1, and the locking mechanism of the guide rail lifting platform 9 is activated.

[0080] The initial disassembly position A is the trigger position of the first photoelectric limit switch of the sintering machine trolley running position detection equipment.

[0081] The wheel clamp 4 is equipped with a laser rangefinder sensor. The laser rangefinder sensor is used to detect the distance from the laser rangefinder sensor to the end face of the wheel and sends the distance data signal to the control cabinet of the wheel disassembly device 5 and the control cabinet of the wheel installation device 6. The clamping and docking position of the wheel clamp 4 is calculated by the control cabinet of the wheel disassembly device 5 and the control cabinet of the wheel installation device 6 based on the received distance from the laser rangefinder sensor to the end face of the wheel, the trolley running speed and the forward extension speed of the wheel clamp 4.

[0082] This invention is not limited to the above-described embodiments. Anyone should know that any structural changes made under the guidance of this invention, and any technical solutions that are the same as or similar to this invention, fall within the protection scope of this invention.

[0083] The technologies, shapes, and structures not described in detail in this invention are all known technologies.

Claims

1. A non-stop wheel replacement system for a sintering machine, characterized in that, The system includes a sintering machine trolley track, a guide rail lifting platform, a trolley wheel disassembly device, a trolley wheel installation device, a lifting and traveling device, a trolley running position detection device, a trolley wheel position detection device, a guide rail lifting platform detection device, and an equipment control system. The trolley wheels of the sintering machine trolley run on the sintering machine trolley track. A gap is provided on the sintering machine trolley track, and a guide rail lifting platform is installed in the gap. The guide rail lifting platform is equipped with a lifting guide rail, a fork scissor, a locking mechanism, and a hydraulic power mechanism. The hydraulic power mechanism controls the lifting guide rail to move up and down through the fork scissor. The lifting and walking device is equipped with a walking track, walking wheels and a walking support frame. The walking track is laid horizontally and parallel to the sintering machine trolley track. The walking wheels move on the walking track and are installed in the walking wheel guard plate. The walking support frame is installed on the upper part of the walking wheel guard plate through a lifting screw. Both the trolley wheel disassembly device and the trolley wheel installation device are equipped with a trolley wheel clamp, an end cap disassembly and assembly mechanism, a trolley wheel replacement support frame, and a hydraulic jack. The trolley wheel clamp is a vertically divided cylindrical structure that clamps the trolley wheel. The trolley wheel clamp is installed on the trolley wheel replacement support frame. The bottom of the trolley wheel replacement support frame is connected to the traveling support frame through a sliding groove. The trolley wheel replacement support frame is also equipped with an end cap disassembly and assembly mechanism and a hydraulic jack. The piston cylinder of the hydraulic jack has a groove at the front, and the trolley wheel clamp is connected in the groove. The trolley running position detection equipment is installed on the outside of the sintering machine trolley track. The signal output terminal of the trolley running position detection equipment is connected to the control cabinet of the guide rail lifting platform, the control cabinet of the trolley wheel disassembly device, and the control cabinet of the trolley wheel installation device. The trolley running position detection equipment is used to detect online when the trolley that needs to disassemble and install the trolley wheel reaches the designated position, and sends the guide rail lifting signal, the trolley wheel disassembly signal, and the trolley wheel reinstallation preparation signal in sequence. The wheel position detection device is installed on the wheel fixture. The wheel position detection device is used to detect when the wheel reaches the designated area and send a precise alignment signal to the wheel disassembly device control cabinet or the wheel installation device control cabinet. The guide rail lifting platform detection equipment is installed at the highest and lowest points of the guide rail platform. The signal output terminal of the guide rail lifting platform detection equipment is connected to the platform hydraulic station control system. When the guide rail lifting platform is raised or lowered to the designated position, it sends a stop signal to the hydraulic station, and the lifting platform is locked in that position.

2. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The forklift is hinged in the middle by a pin. The upper part of one side of the forklift is rotatably connected to the fixed block of the lifting platform by a pin, and the lower part of one side of the forklift is rotatably connected to the fixed block of the fixed base by a pin. The fixed blocks are fixed to the bottom of the lifting platform and the upper part of the fixed base, respectively. The upper part of the other side of the forklift is rotatably connected to the movable slider of the lifting platform by a pin, and the lower part of the other side of the forklift is rotatably connected to the movable slider of the fixed base by a pin. The movable slider is slidably connected in the grooves at the bottom of the lifting platform and the upper part of the fixed base. The bottom of one side of the forklift arm is connected to the piston rod of the hydraulic power mechanism. The hydraulic power mechanism controls the lifting of the forklift and drives the lifting guide rail to lift. The highest point of the lifting guide rail is at the same level as the sintering machine trolley track.

3. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The traveling track is constructed of I-beams and laid horizontally, parallel to the sintering machine trolley track. The traveling wheels travel on the traveling track. The top of the traveling support frame is connected to the bottom of the trolley wheel replacement support frame via a sliding groove. The trolley wheel replacement support frame slides within the groove, driving the trolley wheel clamp and hydraulic jack to move axially back and forth. The lower part of the vertical frame of the traveling support frame is a lifting screw, the middle part is a screw slider, and the upper part is a hollow round tube or a hollow square tube. The inner diameter of the hollow round tube or hollow square tube is larger than the outer diameter of the lifting screw. The hollow round or square tube is fixed to the lead screw and slider by bolts, rivets, or welding. Each lifting lead screw is driven to rotate at the same speed by a motor and speed divider. The walking support frame is raised or lowered in the vertical direction, which drives the trolley wheel to change the vertical movement of the support frame. The bottom of the walking support frame is equipped with walking wheels, and semi-wedge-shaped walking wheel guards are installed on both sides of the walking wheels. The top of the walking wheel guards is installed on the walking support frame, and the semi-wedge structure at the bottom of the walking wheel guards is inserted into the I-beam groove of the walking track to form an anti-tipping protection for the whole.

4. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The trolley wheel clamp is cylindrical, hollow inside, and its internal dimensions are 0.1–5 mm larger than the diameter of the trolley wheel. The trolley wheel clamp is vertically divided into two halves, and its opening and closing actions are controlled by a hydraulic cylinder, pneumatic cylinder, or motor. Each half of the trolley wheel clamp has a bearing installed at its bottom edge, and the bearing diameter is equal to the bottom wall thickness of the trolley wheel clamp. The trolley wheel clamp has sidewalls on both sides, with one sidewall abutting the inner side of the trolley wheel and the other sidewall engaging with the outer ring groove of the hydraulic jack piston cylinder. The sidewall of the trolley wheel clamp holding the trolley wheel has a thickness of 5–20 mm and a length of 20–60 mm. The sidewall of the trolley wheel clamp engaging with the piston cylinder groove has a thickness of 5–20 mm and a length of 20–40 mm.

5. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The piston cylinder groove depth of the hydraulic jack is the length of the side wall of the trolley wheel clamp + 2 to 5 mm, and the width is the thickness of the side wall of the trolley wheel clamp + 1 to 3 mm. The hydraulic jack is connected to the hydraulic system, which provides a pressure of 0 to 10 MPa. The hydraulic jack is installed on the trolley wheel replacement support frame to form a relatively static moving whole.

6. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The trolley running position detection device includes a first photoelectric limit switch, which is installed along the vertical direction of the trolley wheel's movement and is interlocked with the guide rail lifting platform control system. The first photoelectric limit switch detection device receives the detection signal and sends a start signal for the guide rail lifting platform to the platform control cabinet. The hydraulic cylinder starts to retract, and the guide rail lifting platform descends, suspending the trolley wheel to be disassembled. At the same time, it sends a start signal to the trolley wheel disassembly device, which enters the disassembly position to prepare for disassembly. It also sends a trolley wheel reinstallation preparation signal to the trolley wheel installation device, which enters the installation preparation position. The sintering machine remains in normal operation.

7. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The wheel position detection device includes a second photoelectric limit switch, which is installed on the wheel fixture. The wheel position detection device is used to detect when the center of the fixture is aligned with the wheel axle during the disassembly and installation of the wheel, and sends a precise alignment signal to the control cabinet of the wheel disassembly device or the wheel installation device.

8. The sintering machine trolley wheel replacement system according to claim 1, characterized in that, The sintering wheel disassembly device and the sintering wheel installation device are equipped with a four-axis or industrial robot. The sintering wheel disassembly device is used for longitudinal, lateral and vertical three-dimensional movement, wherein the maximum longitudinal movement speed is higher than the sintering machine's operating speed; the sintering wheel installation device is used for longitudinal, lateral and vertical three-dimensional movement, wherein the longitudinal movement speed is the same as the sintering machine's operating speed.

9. The automatic replacement method for the sintering machine trolley wheel of the non-stop replacement system according to any one of claims 1-8, characterized in that, Includes the following steps: S1. When the damaged trolley wheel reaches the initial disassembly position A, the guide rail lifting platform closes the locking mechanism and begins to descend. The trolley wheel disassembly device aligns the center of the trolley wheel clamp with the center of the trolley wheel axle. Its lifting and traveling device drives the trolley to move in the same direction and at the same speed, keeping the two centers always aligned. S2. The guide rail lifting platform descends to the lower limit position, the table wheel clamp opens to both sides, the table wheel clamp moves along the table wheel axle until the inner side wall plane of the clamp coincides with the inner side wall plane of the table wheel, the table wheel clamp closes, clamps the damaged table wheel, one end of the inner side wall of the table wheel clamp contacts the inner side wall of the table wheel, and the other end of the table wheel clamp is inserted into the slot of the hydraulic jack. S3. The end cover removal and assembly mechanism enters the trolley wheel clamp, the sleeve is aligned with the fastened bolts to perform disassembly, the end cover and bolts are removed, the end cover is removed from the disassembly position, and it is lifted up beyond the travel stroke of the trolley wheel clamp. S4. The hydraulic jack starts working, the hydraulic rod presses against the axle of the trolley wheel, and the hydraulic cylinder drives the trolley wheel clamp that is stuck in the slot to move outward. The trolley wheel moves outward along the axis of the trolley wheel clamp and disengages from the axle of the trolley wheel. S5. The lifting and traveling device of the trolley wheel dismantling device moves in the opposite direction of the trolley movement and exits the dismantling position A. S6. The trolley wheel installation device clamps the new trolley wheel with the trolley wheel clamp. Its lifting and traveling device moves closer to the trolley axle and enters the installation position from the installation preparation position. The center of the new trolley wheel, that is, the center of the trolley wheel clamp, is aligned with the center of the trolley wheel axle. Its lifting and traveling device drives the trolley to move in the same direction and at the same speed, keeping the two centers always aligned. S7. Install the new platform wheel to the working position of the platform wheel axle; S8. The end cover removal and installation mechanism enters the trolley wheel clamp and presses the end cover to the outside of the trolley wheel. The bolt holes of the end cover are aligned with the bolt holes on the trolley axle. The end cover bolts in the sleeve are aligned with the bolt holes on the end cover for installation. After tightening the bolts, the end cover removal and installation mechanism exits the trolley wheel clamp and is lifted beyond the travel stroke of the trolley wheel clamp. S9. The trolley wheel installation device exits the installation position, and the trolley wheel clamp is retracted to outside the trolley wheel working interface. S10. The guide rail lifting platform rises until the lifting guide rail is level with the sintering machine trolley track, and the locking mechanism of the guide rail lifting platform is activated.

10. The automatic replacement method for the sintering machine trolley wheel of the non-stop replacement system according to claim 9, characterized in that, The initial disassembly position A in step S1 is the trigger position of the first photoelectric limit switch of the sintering machine trolley running position detection device. The wheel clamp is equipped with a laser rangefinder sensor, which is used to detect the distance from the laser rangefinder sensor to the wheel end face and send the distance data signal to the control cabinet of the wheel disassembly device and the control cabinet of the wheel installation device. The clamping and docking position of the wheel clamp is calculated by the control cabinet of the wheel disassembly device and the control cabinet of the wheel installation device based on the received distance from the laser rangefinder sensor to the wheel end face, the trolley running speed and the forward extension speed of the wheel clamp.

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