Replacement method of reducer of bucket-wheel stacker-reclaimer

Abstract

The application relates to a reducer replacement method of a bucket-wheel stacker-reclaimer and relates to the technical field of reducer replacement. The reducer replacement method of the bucket-wheel stacker-reclaimer comprises the following operation steps: fixing and connecting a supporting seat and a mounting table, wherein the mounting table is provided with a reducer to be replaced; dismounting the reducer to be replaced from the mounting table; mounting a replaced reducer to the mounting table; disconnecting the supporting seat from the mounting table; and performing trial operation detection on the replaced reducer on the mounting table, and if the detection result is qualified, the replacement of the reducer is completed. The reducer replacement method of the bucket-wheel stacker-reclaimer can avoid the safety problems of equipment damage or personnel injury in the replacement process, avoid abnormal vibration and abnormal sound of the driving mechanism of the bucket-wheel stacker-reclaimer during work after the replacement of the reducer is completed, and improve the replacement efficiency of the reducer.

Description

Technical Field

[0001] This invention relates to the field of speed reducer replacement technology, and particularly to a method for replacing the speed reducer of a bucket wheel stacker-reclaimer. Background Technology

[0002] Bucket wheel stacker-reclaimers have many drive mechanism components and complex structures. Currently, the replacement methods for the reducers in the drive mechanism of bucket wheel stacker-reclaimers are not standardized and the steps are chaotic. During the replacement process, safety issues such as platform tilting leading to equipment damage or personnel injury may occur. Furthermore, the replacement of the reducer may cause abnormal vibration and abnormal noise in the drive mechanism of the bucket wheel stacker-reclaimer. Summary of the Invention

[0003] This invention provides a method for replacing the reducer of a bucket wheel stacker-reclaimer, which can avoid safety issues such as equipment damage or personal injury during the replacement process, and prevent abnormal vibration and noise from occurring in the drive mechanism of the bucket wheel stacker-reclaimer after the reducer is replaced.

[0004] This application provides a method for replacing the reducer of a bucket wheel stacker-reclaimer, including the following steps: fixing a support base and a mounting platform together, wherein the mounting platform has the reducer to be replaced; removing the reducer to be replaced from the mounting platform; installing the replaced reducer onto the mounting platform; disconnecting the support base from the mounting platform; and testing the replaced reducer on the mounting platform. If the test result is qualified, the reducer replacement is complete.

[0005] According to the above embodiments of this application, the support base and the mounting platform are fixedly connected by welding or fasteners.

[0006] According to any of the above embodiments of this application, the test test of the speed reducer replaced on the mounting platform includes the following sub-steps: keeping the speed reducer replaced on the mounting platform in working condition; detecting whether the speed reducer replaced on the mounting platform generates vibration or abnormal noise when in working condition; if no vibration or abnormal noise is detected, the test result is qualified and the speed reducer replacement is completed; if vibration or abnormal noise is detected, the step of removing the speed reducer to be replaced from the mounting platform is returned.

[0007] According to any of the above embodiments of this application, the replacement reducer is installed on the mounting platform, including the following sub-steps: adjusting the coaxiality between the replacement reducer and the hydraulic coupling until the coaxiality is less than or equal to a preset error; connecting the replacement reducer to the mounting platform, the brake, and the coupling respectively.

[0008] According to any of the above embodiments of this application, adjusting the coaxiality between the replaced reducer and the hydraulic coupling to make the coaxiality less than or equal to a preset error includes the following sub-steps: installing one end of a dial indicator on the hydraulic coupling, so that the pointer of the other end of the dial indicator is close to the brake drum; rotating the hydraulic coupling, and repeatedly measuring the coaxiality between the replaced reducer and the hydraulic coupling until the deviation of the coaxiality is less than or equal to 20 per thousand.

[0009] According to any of the above embodiments of this application, when rotating the hydraulic coupling and repeatedly measuring the coaxiality between the replaced reducer and the hydraulic coupling, the coaxiality on both sides along the first direction and the coaxiality on both sides along the second direction are measured respectively until the coaxiality deviation on both sides along the first direction and the coaxiality deviation on both sides along the second direction are both less than or equal to 20 per thousand, and the first direction and the second direction intersect.

[0010] According to any of the above embodiments of this application, the replacement reducer is connected to the mounting platform, the brake, and the coupling, respectively, including the following sub-steps: connecting the base of the replacement reducer to the mounting platform; connecting the output shaft of the replacement reducer to the coupling; and connecting the input shaft of the replacement reducer to the brake.

[0011] According to any of the above embodiments of this application, removing the reducer to be replaced from the mounting platform includes the following sub-steps: disconnecting the reducer to be replaced from the coupling, brake and mounting platform respectively; and transferring the reducer to be replaced from the mounting position on the mounting platform to a designated position.

[0012] According to any of the above embodiments of this application, disconnecting the reducer to be replaced from the coupling, the brake, and the mounting platform includes the following sub-steps: disconnecting the output shaft of the reducer to be replaced from the coupling; disconnecting the input shaft of the reducer to be replaced from the brake; and disconnecting the base of the reducer to be replaced from the mounting platform.

[0013] According to any of the above embodiments of this application, when the input shaft of the reducer to be replaced is disconnected from the brake, the brake is moved axially towards the side closer to the hydraulic coupling by a predetermined distance.

[0014] The present application discloses a method for replacing the speed reducer of a bucket wheel stacker-reclaimer. A support base and a mounting platform are fixedly connected, thus securing the mounting platform and preventing platform tilting during the disassembly of the speed reducer to be replaced and the installation of the replaced speed reducer, which could cause damage to equipment and personnel. This allows for rapid replacement of subsequent speed reducers and avoids abnormal vibrations and noises in the drive mechanism of the bucket wheel stacker-reclaimer after speed reducer replacement due to platform tilting, thereby improving speed reducer replacement efficiency. Attached Figure Description

[0015] The invention will now be described in more detail with reference to embodiments and the accompanying drawings.

[0016] Figure 1 This is a schematic diagram of the steps of a method for replacing the reducer of a bucket wheel stacker-reclaimer in one embodiment of the present invention;

[0017] Figure 2 This is a schematic diagram of the steps of the method for replacing the reducer of the bucket wheel stacker-reclaimer in another embodiment of the present invention;

[0018] Figure 3 This is a schematic diagram of the drive mechanism in a bucket wheel stacker-reclaimer according to one embodiment of the present invention;

[0019] Figure 4 This is a schematic diagram of the drive mechanism in a bucket wheel stacker-reclaimer according to another perspective of an embodiment of the present invention.

[0020] Figure label:

[0021] 100-Drive mechanism; 10-Mounting platform; 20-Support base; 30-Drive motor; 40-Hydraulic coupling; 50-Brake; 60-Reducer; 70-Coupling; 80-Drum;

[0022] X - First direction; Y - Second direction; Z - Third direction. Detailed Implementation

[0023] The invention will now be further described with reference to the accompanying drawings.

[0024] Bucket wheel stacker-reclaimers consist of a bucket wheel mechanism, a slewing mechanism, a belt conveyor, a tail car, and a pitching and traveling mechanism. Currently, the replacement methods for the reducer in the drive mechanism of bucket wheel stacker-reclaimers are inconsistent and the procedures are chaotic. During the replacement process, safety issues such as platform tilting leading to equipment damage or personnel injury have even arisen. Furthermore, the replaced drive mechanism of the bucket wheel stacker-reclaimer may exhibit abnormal vibrations and noises during operation.

[0025] This invention provides a method for replacing the reducer of a bucket wheel stacker-reclaimer, which can avoid safety issues such as equipment damage or personal injury during the replacement process, and prevent abnormal vibration and noise from occurring in the drive mechanism of the bucket wheel stacker-reclaimer after the reducer replacement is completed.

[0026] like Figure 1 As shown, and see also Figure 3-4This application provides a method for replacing the reducer of a bucket wheel stacker-reclaimer, including the following steps: S10: Fixing the support base 20 and the mounting platform 10 together, wherein the reducer to be replaced is mounted on the mounting platform 10; S20: Removing the reducer to be replaced from the mounting platform 10; S30: Installing the replaced reducer onto the mounting platform 10; S40: Disconnecting the support base 20 from the mounting platform 10; S50: Testing the replaced reducer on the mounting platform 10. If the test result is qualified, the reducer replacement is complete.

[0027] It is understandable that the gearbox to be replaced refers to the gearbox that needs to be removed from the mounting platform, while the gearbox to be replaced refers to the gearbox that needs to be installed on the mounting platform.

[0028] In this embodiment, the drive mechanism 100 of the bucket wheel stacker-reclaimer consists of a mounting platform 10, a support base 20, a drive motor 30, a hydraulic coupler 40, a brake 50, a reducer 60, a coupling 70, and a drum 80. The support base 20 is disposed at the bottom of the mounting platform 10 to support the mounting platform 10. The drive motor 30, the hydraulic coupler 40, the brake 50, and the reducer to be replaced are sequentially connected along the first direction X and coaxially disposed on the mounting platform 10. The coupling 70 and the drum 80 are sequentially connected to the reducer to be replaced along the third direction Y, wherein the first direction X, the second direction Y, and the third direction Z are perpendicular to each other.

[0029] It should be noted that the drive mechanism 100 should be de-energized before connecting the support base 20 and the mounting platform 10. Since there is a gap between the support base 20 and the mounting platform 10, and the mounting platform 10 is movable relative to the support base 20, the support base 20 and the mounting platform 10 are fixedly connected as a single unit by welding, snap-fitting, or fasteners. This ensures that the mounting platform 10 is secured, preventing tilting during the disassembly of the gearbox to be replaced and the installation of the replaced gearbox, thus facilitating the subsequent disassembly of the gearbox to be replaced and the installation of the replaced gearbox.

[0030] It should be noted that the drive mechanism 100 should be de-energized before connecting the support base 20 and the mounting platform 10. Since there is a gap between the support base 20 and the mounting platform 10, and the mounting platform 10 is movable relative to the support base 20, the support base 20 and the mounting platform 10 are fixedly connected as a single unit by welding, snap-fitting, or fasteners. This ensures that the mounting platform 10 is secured, preventing tilting during the disassembly of the gearbox to be replaced and the installation of the replaced gearbox, thus facilitating the subsequent disassembly of the gearbox to be replaced and the installation of the replaced gearbox.

[0031] The method for replacing the speed reducer of a bucket wheel stacker-reclaimer according to an embodiment of this application involves: A support base 20 and a mounting platform 10 are fixedly connected. The speed reducer to be replaced is then removed from the mounting platform 10, allowing it to be moved from its installation position to a designated location. After removing the speed reducer and moving it from its installation position to the designated location, the replacement speed reducer is installed in its original installation position. The support base 20 is then disconnected from the mounting platform 10, and the replaced speed reducer is tested. If the test results are satisfactory when the replaced speed reducer is in operation, the speed reducer replacement is complete. In this embodiment, the support base 20 and the mounting platform 10 are connected as one unit, so that the mounting platform 10 is fixed, avoiding damage to the equipment and personnel caused by the platform tilting during the process of disassembling the reducer to be replaced and installing the replaced reducer. This allows the reducer to be replaced to be quickly removed and the replaced reducer to be quickly installed, avoiding abnormal vibration and abnormal noise when the drive mechanism 100 of the bucket wheel stacker-reclaimer is working after the reducer to be replaced is installed due to the platform tilting problem, thus improving the replacement efficiency of the reducer to be replaced.

[0032] In some embodiments, the support base 20 and the mounting platform 10 are fixedly connected by welding or fasteners.

[0033] In this embodiment, the support base and the mounting platform are fixedly connected by welding or fasteners. It is preferable to fix the support base and the mounting platform together by welding, which makes it safer and more reliable to remove the reducer to be replaced from the mounting platform and to install the replacement reducer, thereby improving the efficiency of reducer replacement.

[0034] like Figure 2 As shown, and see also Figure 3-4 In some embodiments, the replacement reducer on the mounting platform 10 is tested, including the following sub-steps: S51: Keep the replacement reducer on the mounting platform 10 in working condition; S52: Check whether the replacement reducer on the mounting platform 10 produces vibration or abnormal noise when in working condition; S53: If no vibration or abnormal noise is detected, the test result is qualified and the reducer replacement is completed; S54: If vibration or abnormal noise is detected, return to the step of removing the reducer to be replaced from the mounting platform 10.

[0035] It should be noted that checking whether the replaced reducer produces vibration or abnormal noise during operation means that the drive mechanism 100 in the bucket wheel stacker-reclaimer will not produce vibration or abnormal noise when the replaced reducer is in operation.

[0036] In this embodiment, after the replacement reducer is installed and the support base 20 is disconnected from the mounting platform 10, the drive motor 30 in the drive mechanism 100 of the bucket wheel stacker-reclaimer is energized. The engagement of the hydraulic coupling 40, brake 50, and coupling 70 with the replacement reducer in the working state is checked. If the drive mechanism 100 does not vibrate or make abnormal noise when the replacement reducer is in the working state, the test result is qualified, and the replacement reducer is completed. If the drive mechanism 100 vibrates or makes abnormal noise, the process returns to the step of removing the replacement reducer from the mounting platform.

[0037] It is understandable that returning to the step of removing the reducer to be replaced from the mounting platform 10 specifically means removing the replaced reducer from the mounting platform 10 and reinstalling it, and then repeating the testing process until it passes the test. At this point, the replaced reducer and the reducer to be replaced refer to the same reducer.

[0038] In some embodiments, installing the replaced reducer onto the mounting platform 10 includes the following sub-steps: adjusting the coaxiality between the replaced reducer and the hydraulic coupling 40 until the coaxiality is less than or equal to a preset error; connecting the replaced reducer to the mounting platform 10, the brake 50, and the coupling 70 respectively.

[0039] In this embodiment, before connecting the replaced reducer to the mounting platform 10, brake 50, and coupling 70 respectively, the coaxiality between the replaced reducer and the hydraulic coupling 40 is adjusted so that the coaxiality is less than or equal to the preset error. This avoids the drive mechanism 100 vibrating or making abnormal noise when the replaced reducer is tested due to the coaxiality being greater than the preset error, thus preventing the replacement reducer from being reinstalled.

[0040] In some embodiments, adjusting the coaxiality between the replaced reducer and the hydraulic coupling 40 to make the coaxiality less than or equal to a preset error includes the following sub-steps: installing one end of a dial indicator on the hydraulic coupling 40, and making the pointer of the other end of the dial indicator close to the brake drum; rotating the hydraulic coupling 40, and repeatedly measuring the coaxiality between the replaced reducer and the hydraulic coupling 40 until the deviation of the coaxiality is less than or equal to 20 per thousand.

[0041] In this embodiment, based on repeated measurements of the replaced reducer and hydraulic coupling 40 at different positions and directions using a dial indicator, the coaxiality between the replaced reducer and the hydraulic coupling 40 is adjusted to be less than or equal to 20 per thousand. After ensuring the coaxiality requirement, the replaced reducer is installed. The replaced reducer is then connected to the mounting platform 10, brake 50, and coupling 70. This avoids vibration and abnormal noise in the drive mechanism 100 during test runs of the replaced reducer due to coaxiality errors, thus avoiding repeated disassembly and assembly of the replaced reducer due to failure to pass the test, and improving the replacement efficiency of the reducer.

[0042] See Figure 3-4 As shown, in some embodiments, when rotating the hydraulic coupling 40 and repeatedly measuring the coaxiality between the replaced reducer and the hydraulic coupling 40, the coaxiality on both sides along the first direction X and the coaxiality on both sides along the second direction Y are measured respectively until the coaxiality deviation on both sides along the first direction X and the coaxiality deviation on both sides along the second direction Y are both less than or equal to 20 per thousand, and the first direction X and the second direction Y intersect.

[0043] It should be noted that in this embodiment, the first direction X and the second direction Y are orthogonal. Specifically, the first direction X is the horizontal direction and the second direction Y is the vertical direction. The two sides of the first direction X and the two sides of the second direction Y specifically refer to the four directions of the hydraulic coupler 40: up, down, left, and right.

[0044] Understandably, after any adjustments are made to the replaced reducer, measurements should be taken again in all four directions (up, down, left, and right) to ensure that the coaxiality deviation is less than or equal to 20 per thousand.

[0045] In this embodiment, based on the measurement results of the dial indicator in the four directions of the hydraulic coupler 40 (up, down, left, and right), the coaxiality deviation between the replaced reducer and the hydraulic coupler 40 is adjusted to be less than or equal to 20 per thousand, so as to improve the measurement efficiency and accuracy.

[0046] See Figure 3-4 As shown, in some embodiments, the replaced reducer is connected to the mounting platform 10, the brake 50, and the coupling 70 respectively, including the following sub-steps: connecting the base of the replaced reducer to the mounting platform 10; connecting the output shaft of the replaced reducer to the coupling 70; and connecting the input shaft of the replaced reducer to the brake 50.

[0047] In this embodiment, the base of the replaced reducer is first fixed to the mounting platform 10 by bolts, then the output shaft of the replaced reducer is connected to the coupling 70 by bolts, and then the brake 50 is connected to the input shaft of the replaced reducer.

[0048] Furthermore, connecting the brake 50 to the input shaft of the replaced reducer specifically includes: first, fixing the brake 50 to the mounting platform 10 with bolts; then, electrically connecting the reducer to be replaced to the drive motor 30 via wiring, and energizing the drive motor 30 to connect the brake 50 to the replaced reducer.

[0049] See Figure 3-4 As shown, in some embodiments, removing the gearbox to be replaced from the mounting platform 10 includes the following sub-steps: disconnecting the gearbox to be replaced from the coupling 70, the brake 50 and the mounting platform 10 respectively; and transferring the gearbox to be replaced from the mounting position of the mounting platform 10 to a designated position.

[0050] In this embodiment, the reducer to be replaced is first disconnected from the coupling 70, the brake 50 and the mounting platform 10 respectively, and then the reducer to be replaced is transferred from the mounting position of the mounting platform 10 to the designated position.

[0051] In some alternative embodiments, moving the gearbox to be replaced from the mounting position of the mounting platform 10 includes using a crane to lift the gearbox to be replaced from the mounting position of the mounting platform 10, so as to facilitate the subsequent installation of the replaced gearbox.

[0052] See Figure 3-4 As shown, in some embodiments, disconnecting the reducer to be replaced from the coupling 70, the brake 50, and the mounting platform 10 includes the following sub-steps: disconnecting the output shaft of the reducer to be replaced from the coupling 70; disconnecting the input shaft of the reducer to be replaced from the brake 50; and disconnecting the base of the reducer to be replaced from the mounting platform 10.

[0053] In this embodiment, the connecting bolts between the output shaft of the reducer to be replaced and the coupling 70 are first removed, disconnecting the reducer from the coupling 70. Then, the input shaft of the reducer to be replaced is disconnected from the brake 50. Finally, the connecting bolts between the base of the reducer to be replaced and the mounting platform 10 are removed. This avoids disconnecting the reducer from the brake 50 or mounting platform 10 while the coupling 70 is still connected to the reducer, which could cause the reducer or mounting platform 10 to tilt during the removal of the connecting bolts. This prevents safety issues for workers or equipment damage caused by tilting of the mounting platform 10, reduces the risk of equipment damage, and improves the replacement efficiency of the reducer.

[0054] See Figure 3-4As shown, in some embodiments, when the input shaft of the reducer to be replaced is disconnected from the brake 50, the brake 50 is disconnected from the mounting platform 10 and moved axially a predetermined distance toward the side closer to the hydraulic coupler 40.

[0055] In this embodiment, after disconnecting the input shaft of the reducer to be replaced from the brake 50, the connecting bolts between the brake 50 and the mounting platform 10 are removed. Then, the brake 50 is moved axially towards the side closer to the hydraulic coupling 40 by a preset distance, making it easier to remove the reducer in the subsequent lifting process. At the same time, after the brake 50 is moved, the brake drum can be exposed, which is convenient for subsequent coaxiality testing.

[0056] Although the invention has been described with reference to preferred embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, the technical features mentioned in the various embodiments can be combined in any manner as long as there is no structural conflict. The invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A method for replacing the reducer of a bucket wheel stacker-reclaimer, characterized in that, The following steps are included: The support base and the mounting platform are fixedly connected, wherein the mounting platform has the reducer to be replaced; Remove the gearbox to be replaced from the mounting platform; Install the replaced speed reducer onto the mounting platform; Disconnect the support base from the mounting platform; The replaced reducer on the mounting platform is tested. If the test result is qualified, the reducer replacement is complete. Removing the gearbox to be replaced from the mounting platform includes: Disconnect the reducer to be replaced from the coupling, brake, and mounting platform respectively; Move the reducer to be replaced from its mounting position on the mounting platform to the designated position; When disconnecting the input shaft of the reducer to be replaced from the brake, move the brake axially towards the side closer to the hydraulic coupling by a preset distance; The step of installing the replaced speed reducer onto the mounting platform includes adjusting the coaxiality between the replaced speed reducer and the hydraulic coupling until the coaxiality is less than or equal to a preset error. Adjusting the coaxiality between the replaced reducer and the hydraulic coupling to ensure that the coaxiality is less than or equal to a preset error includes the following sub-steps: Install one end of the dial indicator on the hydraulic coupling, and make the pointer of the other end of the dial indicator close to the brake drum; When rotating the hydraulic coupling, repeatedly measuring the coaxiality between the replaced reducer and the hydraulic coupling, measure the coaxiality on both sides along the first direction and the coaxiality on both sides along the second direction, until the coaxiality deviation on both sides along the first direction and the coaxiality deviation on both sides along the second direction are both less than or equal to 20 per thousand, and the first direction and the second direction intersect. The replaced reducer is then connected to the mounting platform, brake, and coupling, respectively.

2. The method for replacing the reducer of the bucket wheel stacker-reclaimer according to claim 1, characterized in that, The support base and the mounting platform are fixedly connected by welding or fasteners.

3. The method for replacing the reducer of the bucket wheel stacker-reclaimer according to claim 1, characterized in that, The replacement reducer on the mounting platform is subjected to a test run, including the following sub-steps: To keep the replaced reducer on the mounting platform in working condition; Test whether the replaced speed reducer on the mounting platform produces vibration or abnormal noise during operation; If no vibration or abnormal noise is detected, the test result is qualified, and the speed reducer replacement is complete. If vibration or abnormal noise is detected, return to the step of removing the gearbox to be replaced from the mounting platform.

4. The method for replacing the reducer of the bucket wheel stacker-reclaimer according to claim 1, characterized in that, The replaced reducer is connected to the mounting platform, brake, and coupling respectively, including the following sub-steps: Connect the base of the replaced reducer to the mounting platform; Connect the output shaft of the replaced reducer to the coupling; Connect the input shaft of the replaced reducer to the brake.

5. The method for replacing the reducer of the bucket wheel stacker-reclaimer according to claim 1, characterized in that, Disconnect the reducer to be replaced from the coupling, brake, and mounting platform, respectively, including the following sub-steps: Disconnect the output shaft of the reducer to be replaced from the coupling; Disconnect the input shaft of the reducer to be replaced from the brake; Disconnect the base of the reducer to be replaced from the mounting platform.

Images