Method for dismounting and mounting hydro-pneumatic spring of full balance rack and pinion climbing vertical ship lift

Abstract

The application discloses a full-balanced gear and rack climbing type vertical ship lift liquid gas spring dismounting method, which comprises the following steps: S1, removing the hydraulic cylinder oil pipe of the liquid gas spring; S2, removing the connecting bolt of the top of the hydraulic cylinder and the adjustable support on the ceiling; S3, lifting the section on the ceiling by hoisting equipment; S4, supporting and fixing the displacement adaptation mechanism and the lower flange of the liquid gas spring; S5, removing the connecting pull rod of the liquid gas spring; S6, lifting out the hydraulic cylinder; S7, measuring the shaft, dismounting and replacing, and reinstalling the lower flange; S8, reinstalling the new hydraulic cylinder; S9, reinstalling the connecting pull rod of the liquid gas spring; S10, connecting the top of the hydraulic cylinder with the adjustable support and debugging the hydraulic system; and S11, reinstalling the section on the ceiling. The method can greatly reduce the construction workload, improve the efficiency of the ship lift liquid gas spring mechanism maintenance, and is convenient for subsequent daily maintenance of the liquid gas spring mechanism, guarantees the operation reliability of the liquid gas spring mechanism, and thus guarantees the safe and stable operation of the ship lift.

Description

Technical Field

[0001] This invention relates to the field of vertical ship lift technology, and in particular to a method for disassembling and assembling the hydropneumatic spring of a fully balanced rack and pinion climbing vertical ship lift. Background Technology

[0002] The fully balanced rack and pinion vertical ship lift has a safety function that locks the ship compartment in case of imbalance. The hydraulic-pneumatic spring device in the drive mechanism is the key equipment for switching the support from the open rack and pinion transmission pair of the drive mechanism to the threaded contact pair of the rotating screw and nut column of the safety mechanism during lifting, thus achieving overload locking of the ship compartment. The hydraulic-pneumatic spring mechanism consists of a double-piston hydraulic cylinder, a support seat, a connecting rod, an accumulator, hydraulic lines, and valves. The upper piston rod end of the cylinder is threaded to the upper flange, and the lower piston rod is fitted with the mounting hole of the lower flange through a guide slider with a clearance fit; the upper and lower flanges are connected by a connecting rod. The bottom measuring shaft is mounted in the self-aligning rolling bearing in the shaft hole of the lower flange and in the hinge hole at the end of the bottom beam, and is axially positioned by the shaft end baffle and connecting screws installed at the end of the bottom beam. The hinge shaft in the middle of the cylinder is supported on the support seat by a self-lubricating bearing, and the support seat is bolted to the ship compartment structure. Based on the structural design of the pull rod and piston rod head, when the hydraulic spring load is downward, the load is transmitted through the upper piston rod, and the lower piston rod is not subjected to force; when the hydraulic spring load is upward, the load is transmitted through the lower piston rod, and the upper piston rod is not subjected to force.

[0003] The Three Gorges Dam ship lift operates 24 hours a day, year-round, with only about 35 days allocated for equipment maintenance annually. Due to the inherent layout of the equipment, the maintenance space is limited, and the placement of maintenance tools is restricted, affecting maintenance efficiency. Achieving rapid maintenance of key equipment is currently a challenge. The hydropneumatic spring mechanism is a crucial component of the ship lift's drive mechanism; therefore, this application proposes a method for disassembling and assembling the hydropneumatic springs of a fully balanced gear and rack climbing vertical ship lift, for the maintenance and repair of the ship lift's hydropneumatic spring mechanism. Summary of the Invention

[0004] To address the existing technical problems, the main objective of this invention is to provide a method for disassembling and assembling the hydropneumatic spring of a fully balanced gear and rack climbing vertical ship lift, which is used for the inspection and maintenance of the hydropneumatic spring mechanism of the ship lift.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a method for disassembling and assembling the hydropneumatic spring of a fully balanced gear and rack climbing vertical ship lift, comprising the following steps: S1. Disconnect the hydraulic cylinder oil pipe of the hydropneumatic spring and mark the oil pipe. Remove the sensor and its wiring. Before disconnecting the oil pipe, confirm that the hydraulic cylinder is in a depressurized state. S2. Remove the connecting bolts between the top of the hydraulic cylinder and the adjustable bracket on the ceiling; S3. Use lifting equipment to lift open the upper sections of the roof; S4. Fix the lower flange of the displacement adaptation mechanism and the hydraulic spring; S5. Remove the connecting rod of the hydraulic spring; S6. Lift out the hydraulic cylinder; S7. Remove and replace the measuring shaft, then reinstall the lower flange; S8. Reinstall the new hydraulic cylinder; S9, connecting rod for reinstalling the hydraulic spring; S10. Connect the top of the hydraulic cylinder to the adjustable bracket, reinstall the sensor, reinstall the oil pipe, and debug the hydraulic system. S11, Reinstall the upper section of the roof.

[0006] In S1, the method for relieving pressure in the hydraulic cylinder is as follows: In maintenance mode, the hydraulic cylinder is pressurized, causing the piston rods at both ends of the hydraulic cylinder to extend and discharge the oil in the rod chamber to the high-level oil tank. Open the drain ball valve at the bottom of the high-level oil tank, use a clean container to collect the oil, drain all the hydraulic oil from the high-level oil tank, and then remove the air filter at the top of the high-level oil tank. Adjust the system relief valve in the hydraulic system pressure regulating valve block to the fully relaxed state, then disconnect the power to the two proportional pump motors and close the oil supply high-pressure ball valve in the main pressure oil pipe. The accumulator and hydraulic cylinder are depressurized; the cylinder depressurization solenoid valve is energized to start depressurizing the rodless chamber of the hydraulic cylinder. After observing that the pressure gauge pointer is zero, loosen all the overflow valve adjusting screws in the safety shut-off valve block of each accumulator, open the manual pressure relief valve, and observe that the pressure gauge pointer is zero. Loosen all the adjusting screws of the two overflow valves in the cylinder side block of the hydraulic cylinder. Then, use the pressure measuring point between the hydraulic cylinder and the cylinder side block to measure the pressure. Only after the pressure gauge shows zero can the oil pipe connected to the hydraulic cylinder and the cylinder side block be disconnected.

[0007] S3 also includes the steps for ceiling renovation: The oil cylinder and its accessories are protected with asbestos cloth inside the ceiling. Draw a circular cutting line on the side wall of the ceiling; Use lifting equipment to lift the top of the ceiling, cut the ceiling along the cutting line to form a lower ceiling section and an upper ceiling section, lift the lower ceiling section apart, and polish the cut positions of the lower ceiling section and the upper ceiling section smooth. The first flange and the second flange are connected and fixed into a whole using bolts; Hoist the flange to the top of the lower section of the roof and position it there. Then hoist the upper section of the roof to the top of the flange and position it there. Weld the first flange to the lower section of the roof and weld the second flange to the upper section of the roof. After welding, remove the connecting bolts of the first and second flanges, and then lift the sections of the ceiling apart.

[0008] In S4, a rigid support and a jack are arranged below the tube bearing of the displacement adaptation mechanism. The jack is placed on the rigid support, and the displacement adaptation mechanism is connected and fixed to the ground by the support. The lower flange of the hydro-pneumatic spring is fixed and supported by the tooling support.

[0009] In S6, the steps for lifting the hydraulic cylinder are as follows: Secure the sling to the hydraulic cylinder, and hang the other end of the sling on the main hook of the bridge crane. Remove the connecting bolts between the support seat and the support plates on both sides of the cylinder; After the main hook of the bridge crane is lifted and the support plates on both sides of the hydraulic cylinder are separated from the support seat, the support plates on both sides are fixed to the hydraulic cylinder with wire. Then lift the main hook to hoist the hydraulic cylinder out of the machine room; Use lifting equipment in conjunction with a bridge crane to adjust the hydraulic cylinder to a horizontal position and place it on the cylinder support fixture.

[0010] In S7, the steps for removing the measuring shaft are as follows: Hang a hoist on the main hook of the lifting equipment. The hoist is connected to the lower flange. Tighten the hoist to make it strong. Remove the support supporting the lower flange. The measuring shaft is protected with sheet metal on the inside of the support base. A hole is made in the web of the support base with a cutting tool, and the inner wall of the hole is polished smooth. Remove the end baffle of the fixed measuring shaft, use a jack to push the measuring shaft out of the shaft hole from the side, and then lift out the lower flange.

[0011] Install a reinforcing ring at the opening location, weld the reinforcing ring to the web, grind the weld smooth after welding, and repair the paint. Replace the slider inside the support seat and lift the lower flange back to its original position; Reinstall the new measuring axis; Secure and support the lower flange, then unload using the hoist.

[0012] In S8, the steps for reinstalling a new hydraulic cylinder are as follows: Use lifting equipment in conjunction with a bridge crane to lift the new hydraulic cylinder horizontally from the bracket, and then adjust the hydraulic cylinder to a vertical position. The lifting equipment is fitted with support plates on both sides, and the support plates are fixed to the hydraulic cylinder with wire; The hydraulic cylinder is hoisted into the machine room by a bridge crane. When the hydraulic cylinder is hoisted to a certain distance above the support seat, it is stopped. The distance between the two support plates is adjusted to ensure that the distance between the two support plates matches the distance between the clamping plates at the top of the support seat. Slowly lower the main hook of the bridge crane so that the guide slider at the lower end of the hydraulic cylinder enters the groove of the lower flange. Then slowly lower the main hook and adjust its position so that the support plate enters the clamping plate of the support seat. After the support plate is aligned with the bolt holes of the support seat, connect and tighten the support plate and the support seat with bolts.

[0013] In S10, the hydraulic system commissioning steps are as follows: After energizing the two proportional pump motors, first start the control pump, then start one of the proportional pumps, and adjust the system overflow valve in the pressure regulating valve block to be energized. After the system pressure is adjusted to 20MPa, the system overflow valve is repeatedly energized and de-energized three times to verify the system pressure. When the system overflow valve is energized, the system pressure is always displayed as 20MPa, and when the system overflow valve is de-energized, the system pressure is always displayed as zero. Close all manual pressure relief valves and oil inlet valves in the safety shut-off valve block of each accumulator, close the plate-type high-pressure ball valve in the hydraulic cylinder side valve block, and tighten the overflow valve adjusting screw to the correct position and then turn it back one and a half to two turns. Start the control pump. After starting one proportional pump, open the high-pressure ball valve in the main pressure oil pipe. The system overflow valve and the ball-type solenoid directional valve will be energized. After observing that the pressure gauge shows 20MPa, start opening the accumulator inlet valve one by one to fill the oil. Adjust the overflow valve in the accumulator safety shut-off valve block to the actual value measured. Then close the accumulator inlet valve and start the next accumulator. Repeat the above steps to adjust the overflow valve in the safety shut-off valve block of all four accumulators. Open the oil supply ball valve of the high-position oil tank in the rod chamber of the hydraulic cylinder to inject hydraulic oil into the rod chamber of the hydraulic cylinder; After all the inlet valves in the accumulator safety shut-off valve block are closed, start adjusting the overflow valve in the hydraulic cylinder side valve block to the actual measured value before opening the plate-type high-pressure ball valve in the side valve block to start pressurizing the rodless chamber of the hydraulic cylinder. When the pressure gauge reading is the same as the overflow valve adjustment value, the ball-type solenoid directional valve is de-energized and the cylinder pressure relief solenoid valve is energized to start depressurizing the rodless chamber of the hydraulic cylinder. After observing that the pressure gauge pointer is zero, the ball-type solenoid directional valve is energized and the cylinder pressure relief solenoid valve is de-energized. Repeat this process multiple times to exhaust air from the cylinder. After the hydraulic cylinder body is vented, the relief valve is adjusted. First, tighten the relief valve adjusting screw to the correct position and then turn it back one and a half to two turns. Then, pressurize the hydraulic cylinder. After the ball solenoid directional valve is energized, observe the pressure gauge reading. When the pressure reaches 20MPa, energize the cylinder pressure relief solenoid valve to begin depressurizing the rodless chamber of the hydraulic cylinder. Observe the pressure gauge reading. If it is higher than 2MPa, adjust the relief valve in the cylinder side block to 2MPa. Then, connect the pressure gauge to the pressure measurement point between the hydraulic cylinder and the cylinder side block, and slowly loosen the relief valve again to adjust the pressure to the actual measured value. Repeat this process several times, energizing the ball solenoid directional valve and de-energizing the cylinder pressure relief solenoid valve, to verify whether the relief valve pressure is consistent with the actual measured value. After all the oil inlet valves in the accumulator safety shut-off valve block are in the open state, the local station linkage test is carried out. The first five local station linkage tests need to be further checked and verified to see if the overflow valve pressure is consistent with the actual value measured. The local station's hydraulic cylinder operates normally, the pressure remains normal, the accumulator pressure replenishment is normal, there is no jamming, and there is no oil leakage.

[0014] During the reinstallation of the hydraulic cylinder, mark the direction of the arrow on the oil window cover of the high-level oil tank of the hydraulic cylinder. After removing the oil window cover and cleaning out the remaining oil, use kneaded dough to stick the inner wall of the high-level oil tank. After the inner wall of the high-level oil tank is clean and free of impurities, reinstall the oil window cover and air filter, and close the drain ball valve at the bottom of the high-level oil tank and the oil supply ball valve of the rod chamber of the hydraulic cylinder. After the hydraulic cylinder is reinstalled, tighten the connection to the cylinder interface according to the markings when the oil pipe was removed; when reinstalling, make sure the combination gasket and sealing ring are intact, and apply grease evenly to the sealing ring; After filtering the new hydraulic oil, use the refueling trolley to add the hydraulic oil to the high-level oil tank. During the refueling process, pay close attention to whether there is any oil leakage at the oil window cover seal.

[0015] The present invention has the following beneficial effects: Due to the inherent layout characteristics of ship lifts, the maintenance space for their gas spring mechanisms is narrow, and the arrangement of maintenance tools and fixtures is limited, affecting maintenance efficiency. Achieving rapid maintenance of key equipment on ship lifts remains a challenge. This invention, a method for disassembling and assembling the hydropneumatic springs of a ship lift, significantly reduces workload and saves manpower. By drilling holes in the support base, the disassembly and assembly efficiency of the measuring shaft can be effectively improved, reducing safety risks during hoisting operations. Furthermore, the simple operation method not only enhances the efficiency of maintaining the hydropneumatic spring mechanism but also facilitates routine maintenance of the measuring shaft, ensuring the reliability of the hydropneumatic spring mechanism and thus guaranteeing the safe and stable operation of the ship lift. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Figure 1 This is a schematic diagram of the overall hydraulic-pneumatic spring device of the ship lift.

[0018] Figure 2 This is a schematic diagram of the crane equipment layout.

[0019] Figure 3 This is a schematic diagram of the displacement adaptation mechanism support.

[0020] Figure 4 This is a schematic diagram of the scene when the hydraulic cylinder is lifted out.

[0021] Figure 5 This is a diagram showing the state of the hydraulic cylinder lifting the cylinder out.

[0022] Figure 6 This is a schematic diagram of the existing structure of the support.

[0023] Figure 7 This is a schematic diagram of the structure after the support seat has been drilled.

[0024] Figure 8 This is a schematic diagram of the site when the lower flange is lifted out.

[0025] Figure 9 This is a diagram showing the state of the hydraulic cylinder during installation.

[0026] Figure 10 Draw a schematic diagram of the cutting lines on the ceiling.

[0027] Figure 11 This is a schematic diagram showing the division of the ceiling into lower and upper sections.

[0028] In the picture: Hydraulic cylinder 100, connecting rod 101, guide slider 102, lower flange 103; 200 for the ceiling, 201 for the adjustable bracket, 202 for the cutting line, 203 for the lower section of the ceiling, 204 for the upper section of the ceiling, 205 for the first flange, and 206 for the second flange. Support base 300, support plate 301, measuring shaft 302, web plate 303, reinforcing ring 304, slider 305. 400 lifting equipment Displacement adaptation mechanism 600, rigid support 601, jack 602, support 603, tooling support 604. Detailed Implementation

[0029] See Figure 1-11 As shown, a method for disassembling and assembling the hydropneumatic spring of a fully balanced rack and pinion climbing vertical ship lift includes the following steps: S1. Disconnect the hydraulic cylinder 100 oil pipe of the hydropneumatic spring, mark the oil pipe, and disconnect the sensor and its wiring; before disconnecting the oil pipe, confirm that the hydraulic cylinder 100 is in a depressurized state. S2. Remove the connecting bolts between the top of the hydraulic cylinder 100 and the adjustable bracket 201 on the ceiling 200; S3. Use lifting equipment 400 to lift open the upper section 204 of the roof 200; S4. Support and fix the displacement adaptation mechanism 600 and the lower flange 103 of the hydraulic spring; S5. Remove the connecting rod 101 of the hydraulic spring; S6. Lift out hydraulic cylinder 100; S7. Measuring shaft 302 is removed and replaced, and lower flange 103 is reinstalled. S8. Reinstall the new hydraulic cylinder 100; S9, connecting rod 101 for reinstalling the hydraulic spring; S10. Connect the top of the hydraulic cylinder 100 to the adjustable bracket 201, reinstall the sensor, reinstall the oil pipe, and debug the hydraulic system. S11, Reinstall the upper section of the roof 204.

[0030] The above structure enables the replacement of the hydraulic cylinder and measuring shaft of the hydraulic spring mechanism of the elevator, thus facilitating the inspection and maintenance of the hydraulic spring mechanism of the elevator.

[0031] It should be noted that the self-lubricating bearings of the hinged components can also be replaced during this process. For example, the self-lubricating bearing at the hinge between the support plate 301 and the hydraulic cylinder 100, and the self-lubricating bearing at the hinge between the hydraulic cylinder 100 and the measuring shaft 302.

[0032] In S1, the method for relieving pressure in hydraulic cylinder 100 is as follows: In maintenance mode, the hydraulic cylinder 100 is pressurized, causing the piston rods at both ends of the hydraulic cylinder 100 to extend and discharge the oil in the rod chamber to the high-level oil tank. Open the drain ball valve at the bottom of the high-level oil tank, use a clean container to collect the oil, drain all the hydraulic oil from the high-level oil tank, and then remove the air filter at the top of the high-level oil tank. Adjust the system relief valve in the hydraulic system pressure regulating valve block to the fully relaxed state, then disconnect the power to the two proportional pump motors and close the oil supply high-pressure ball valve in the main pressure oil pipe. The accumulator and hydraulic cylinder 100 are depressurized; the cylinder depressurization solenoid valve is energized to start depressurizing the rodless chamber of hydraulic cylinder 100. After observing that the pressure gauge pointer is zero, all the overflow valve adjusting screws in the safety shut-off valve block of each accumulator are loosened, and the manual pressure relief valve is opened. After observing that the pressure gauge pointer is zero, all the adjusting screws of the two overflow valves in the cylinder side block of hydraulic cylinder 100 are also loosened. Then, the pressure is measured using the pressure measuring point between hydraulic cylinder 100 and cylinder side block. Only after the pressure gauge shows zero can the oil pipe connected to hydraulic cylinder 100 and cylinder side block be disconnected.

[0033] In S1, clearly mark the oil pipes and corresponding interfaces at the inlet and outlet of the hydraulic cylinder. Use durable labels to mark the hydraulic hoses and corresponding interfaces on each hydraulic cylinder for easy reinstallation. Disconnect the hoses from the hydraulic cylinders. After disconnection, wrap the hose connectors and cylinder connectors with plastic bags to prevent foreign objects from entering the connectors.

[0034] Through the above steps, the pressure of the hydraulic cylinder 100 is released, ensuring the safe disassembly of the hydraulic cylinder 100 oil pipe and facilitating the reinstallation of the oil pipe.

[0035] In S2, see Figure 1 Remove the connecting bolts between the top of the hydraulic cylinder 100 and the adjustable bracket 201 on the ceiling 200 to separate the hydraulic cylinder 100 from the ceiling 200.

[0036] In S3, see Figure 10 , 11 It also includes the steps for ceiling renovation: The oil cylinder and its accessories are protected with asbestos cloth inside the 200mm canopy. Draw a circular cutting line 202 on the side wall of the ceiling at position 200; See Figure 2 The lifting equipment 400 is stopped at the designated position and unfolded. Preferably, the lifting equipment 400 is a truck crane. The top of the roof 200 is suspended by the lifting equipment 400, and the roof is cut along the cutting line 202 to form a lower roof section 203 and an upper roof section 204. The lower roof section 203 is lifted open, and the cut positions of the lower roof section 203 and the upper roof section 204 are polished smooth. The first flange 205 and the second flange 206 are connected and fixed into a whole using bolts; Hoist the flange to the top of the lower section 203 of the roof and position it there. Then hoist the upper section 204 of the roof to the top of the flange and position it there. Weld the first flange 205 to the lower section 203 of the roof and weld the second flange 206 to the upper section 204 of the roof. After welding, remove the connecting bolts of the first flange 205 and the second flange 206, and lift the section 204 on the roof apart.

[0037] Through the above steps, the roof 200 is divided into a lower roof section 203 and an upper roof section 204 that are easy to disassemble and assemble, thereby facilitating the lifting out by the hydraulic cylinder 100.

[0038] In S4, see Figure 3 A rigid support 601 and a jack 602 are arranged below the tube bearing of the displacement adaptation mechanism 600. The 50T jack 602 is placed on the rigid support 601 to support the displacement adaptation mechanism. The displacement adaptation mechanism 600 is connected and fixed to the ground by a support 603, and the lower flange 103 of the hydro-pneumatic spring is fixed and supported by a tooling support 604.

[0039] By following the above steps, the displacement adaptation mechanism 600 is supported and fixed to prevent it from shaking.

[0040] In S6, see Figure 4 , 5 The steps for lifting out the hydraulic cylinder 100 are as follows: Secure the sling to the hydraulic cylinder 100, and hang the other end of the sling on the main hook of the bridge crane. Remove the connecting bolts between the support seat 300 and the support plates 301 on both sides of the cylinder; After the main hook of the bridge crane is lifted and the support plates 301 on both sides of the hydraulic cylinder 100 are separated from the support seat 300, the support plates 301 on both sides are fixed to the hydraulic cylinder 100 with wire. Then lift the main hook to hoist the hydraulic cylinder 100 out of the machine room; Use the lifting equipment 400 in conjunction with the bridge crane to adjust the hydraulic cylinder 100 to a horizontal position and place it on the cylinder support fixture.

[0041] Through the above steps, the hydraulic cylinder 100 is smoothly lifted out. The lifted-out state of the hydraulic cylinder 100 is as follows: Figure 5 As shown.

[0042] In S7, see Figure 6 , 7 8. The steps for removing the measuring shaft 302 are as follows: Hang a hoist on the main hook of the lifting equipment 400. The hoist is connected to the lower flange 103. Tighten the hoist to make it strong. Remove the support supporting the lower flange 103. The measuring shaft 302 is protected with sheet metal inside the support 300. A hole is made in the web 303 of the support 300 with a cutting tool, and the inner wall of the hole is polished smooth. Remove the end baffle of the fixed measuring shaft 302, use a jack to push the measuring shaft 302 out of the shaft hole from the side, and then lift out the lower flange 103.

[0043] Install the reinforcing ring 304 at the opening position, weld the weld between the reinforcing ring 304 and the web plate 303, grind the weld smooth after welding, and repair the paint. Replace the slider 305 inside the support seat and lift the lower flange 103 back to its original position; Reinstall the new measuring shaft 302; Fix and support the lower flange 103, then unload using the hoist.

[0044] The above steps enable the disassembly and assembly of the measuring shaft 302 and the replacement of the slider 305 inside the support. Furthermore, drilling holes in the web 303 facilitates subsequent disassembly and assembly of the measuring shaft 302. After removing the measuring shaft 302, the bearing at the hinge point between the measuring shaft 302 and the lower flange 103 can be replaced.

[0045] In S8, see Figure 9 The steps for reinstalling the new hydraulic cylinder 100 are as follows: Use the lifting equipment 400 in conjunction with the bridge crane to lift the new hydraulic cylinder 100 horizontally from the bracket, and then adjust the hydraulic cylinder 100 to a vertical position. The lifting equipment 400 is fitted with support plates 301 on both sides, and the support plates 301 are fixed to the hydraulic cylinder 100 with wire; The hydraulic cylinder 100 is hoisted into the machine room by a bridge crane. When the hydraulic cylinder 100 is hoisted to 800mm above the support seat 300, it is stopped. The distance between the two support plates 301 is adjusted to ensure that the distance between the two support plates 301 matches the distance between the clamping plates at the upper end of the support seat 300. Slowly lower the main hook of the bridge crane so that the guide slider 102 at the lower end of the hydraulic cylinder 100 enters the groove of the lower flange 103. Then slowly lower the main hook and adjust its position so that the support plate 301 enters the clamping plate of the support seat 300. After the support plate 301 is aligned with the bolt holes of the support seat 300, the support plate 301 and the support seat 300 are connected and tightened with bolts.

[0046] The above steps are used to reinstall the hydraulic cylinder 100.

[0047] In S10, the hydraulic system commissioning steps are as follows: After energizing the two proportional pump motors, first start the control pump, then start one of the proportional pumps, and adjust the system overflow valve in the pressure regulating valve block to be energized. After the system pressure is adjusted to 20MPa, the system overflow valve is repeatedly energized and de-energized three times to verify the system pressure. When the system overflow valve is energized, the system pressure is always displayed as 20MPa, and when the system overflow valve is de-energized, the system pressure is always displayed as zero. Close all manual pressure relief valves and oil inlet valves in the safety shut-off valve block of each accumulator, close the plate-type high-pressure ball valve in the valve block next to hydraulic cylinder 100, and tighten the overflow valve adjusting screw to the correct position and then turn it back one and a half to two turns. Start the control pump. After starting one proportional pump, open the high-pressure ball valve in the main pressure oil pipe. The system overflow valve and the ball-type solenoid directional valve will be energized. After observing that the pressure gauge shows 20MPa, start opening the accumulator inlet valve one by one to fill the oil. Adjust the overflow valve in the accumulator safety shut-off valve block to the actual value measured. Then close the accumulator inlet valve and start the next accumulator. Repeat the above steps to adjust the overflow valve in the safety shut-off valve block of all four accumulators. Open the oil supply ball valve of the high-position oil tank of the rod chamber of hydraulic cylinder 100 to inject hydraulic oil into the rod chamber of hydraulic cylinder 100; After all the inlet valves in the accumulator safety shut-off valve block are closed, start adjusting the overflow valve in the cylinder-side valve block of hydraulic cylinder 100 to the actual measured value before opening the plate-type high-pressure ball valve in the cylinder-side valve block to start pressurizing the rodless chamber of hydraulic cylinder 100. When the pressure gauge reading is the same as the overflow valve adjustment value, the ball-type solenoid directional valve is de-energized and the cylinder pressure relief solenoid valve is energized to start depressurizing the rodless chamber of hydraulic cylinder 100. After observing that the pressure gauge pointer is zero, the ball-type solenoid directional valve is energized and the cylinder pressure relief solenoid valve is de-energized. Repeat this process multiple times to exhaust air from the cylinder. After the hydraulic cylinder 100 is vented, the relief valve is adjusted. First, tighten the relief valve adjusting screw to the correct position and then turn it back one and a half to two turns. Then, pressurize the hydraulic cylinder 100. After the ball solenoid directional valve is energized, observe the pressure gauge reading. When the pressure reaches 20MPa, energize the cylinder pressure relief solenoid valve to begin depressurizing the rodless chamber of the hydraulic cylinder 100. Observe the pressure gauge reading. If it is higher than 2MPa, adjust the relief valve in the cylinder side block of the hydraulic cylinder 100 to 2MPa. Then, connect the pressure gauge to the pressure measurement point between the hydraulic cylinder 100 and the cylinder side block, and slowly loosen the relief valve again to adjust the pressure to the actual test value. Repeat this process multiple times, energizing the ball solenoid directional valve and de-energizing the cylinder pressure relief solenoid valve, to verify whether the relief valve pressure is consistent with the actual test value. After all the oil inlet valves in the accumulator safety shut-off valve block are in the open state, the local station linkage test is carried out. The first five local station linkage tests need to be further checked and verified to see if the overflow valve pressure is consistent with the actual value measured. The local station's hydraulic cylinder 100 operates normally, maintains normal pressure, the accumulator pressure replenishment is normal, there is no jamming, and there is no oil leakage.

[0048] During the reinstallation of hydraulic cylinder 100, mark the direction of the arrow on the oil window cover of the high-level oil tank of hydraulic cylinder 100. After removing the oil window cover and cleaning out the remaining oil, use kneaded dough to stick the inner wall of the high-level oil tank. After the inner wall of the high-level oil tank is clean and free of impurities, reinstall the oil window cover and air filter, and close the drain ball valve at the bottom of the high-level oil tank and the oil supply ball valve of the rod chamber of hydraulic cylinder 100. After the hydraulic cylinder 100 is reinstalled, tighten the connection to the cylinder interface according to the markings when the oil pipe was removed; when reinstalling, make sure the combination gasket and sealing ring are intact, and apply grease evenly to the sealing ring. After filtering the new hydraulic oil to NAS8 cleanliness level, use a refueling cart to fill the hydraulic oil into the high-level oil tank. During the filling process, pay close attention to whether there is any oil leakage at the oil window cover seal.

[0049] By following the steps above, the hydraulic system was debugged, ensuring its normal operation.

Claims

1. A method for disassembling and assembling the hydropneumatic spring of a fully balanced gear and rack climbing vertical ship lift, characterized in that... Includes the following steps: S1. Remove the oil pipe of the hydraulic cylinder (100) of the hydropneumatic spring, mark the oil pipe, and remove the sensor and its wiring; before removing the oil pipe, confirm that the hydraulic cylinder (100) is in a depressurized state. S2. Remove the connecting bolts between the top of the hydraulic cylinder (100) and the adjustable bracket (201) on the ceiling (200); S3. The top of the ceiling (200) is suspended by the lifting equipment (400), and the ceiling is cut along the cutting line (202) to form the lower section (203) and the upper section (204) of the ceiling. The upper section (204) of the ceiling is lifted open by the lifting equipment (400). S4. Support and fix the displacement adaptation mechanism (600) and the lower flange (103) of the hydro-pneumatic spring; S5. Remove the connecting rod (101) of the hydraulic spring. S6. Lift out the hydraulic cylinder (100); S7. Remove and replace the measuring shaft (302), and reinstall the lower flange (103); when removing the measuring shaft (302), make a hole in the web plate (303) of the support seat (300), remove the shaft end baffle that fixes the measuring shaft (302), and use a jack to push the measuring shaft (302) out of the shaft hole from the side. S8. Reinstall the new hydraulic cylinder (100). S9, connecting rod (101) for reinstalling the hydraulic spring; S10. Connect the top of the hydraulic cylinder (100) to the adjustable bracket (201), reinstall the sensor, reinstall the oil pipe, and debug the hydraulic system. S11, Reinstall the upper section of the roof (204).

2. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, In S1, the method for depressurizing the hydraulic cylinder (100) is as follows: In the maintenance mode, the hydraulic cylinder (100) is pressurized, so that the piston rods at both ends of the hydraulic cylinder (100) extend and discharge the oil in the rod chamber to the high-level oil tank. Open the drain ball valve at the bottom of the high-level oil tank, use a clean container to collect the oil, drain all the hydraulic oil from the high-level oil tank, and then remove the air filter at the top of the high-level oil tank. Adjust the system relief valve in the hydraulic system pressure regulating valve block to the fully relaxed state, then disconnect the power to the two proportional pump motors and close the oil supply high-pressure ball valve in the main pressure oil pipe. The accumulator and hydraulic cylinder (100) are depressurized; the cylinder depressurization solenoid valve is energized to start depressurizing the rodless chamber of the hydraulic cylinder (100), and after observing that the pressure gauge pointer is zero, all the overflow valve adjusting screws in the safety shut-off valve block of each accumulator are loosened, and the manual pressure relief valve is opened. After observing that the pressure gauge pointer is zero, all the adjusting screws of the two overflow valves in the cylinder-side valve block of the hydraulic cylinder (100) are loosened. Then, the pressure is measured using the pressure measuring point between the hydraulic cylinder (100) and the cylinder-side valve block. Only after the pressure gauge shows zero can the oil pipe connected to the hydraulic cylinder (100) and the cylinder-side valve block be disconnected.

3. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, S3 also includes the steps for ceiling renovation: The cylinder and its accessories are protected with asbestos cloth inside the canopy (200); Draw a circular cutting line (202) on the side wall of the ceiling (200); Using a lifting device (400), the top of the ceiling (200) is suspended, and the ceiling is cut along the cutting line (202) to form a lower section (203) and an upper section (204) of the ceiling. The upper section (204) of the ceiling is lifted open, and the cut positions of the lower section (203) and the upper section (204) of the ceiling are polished smooth. The first flange (205) and the second flange (206) are connected and fixed into a whole using bolts; The flange is hoisted to the top of the lower section (203) of the roof and positioned thereon. The upper section (204) of the roof is then hoisted to the top of the flange and positioned thereon. The first flange (205) and the lower section (203) of the roof are welded together. The second flange (206) and the upper section (204) of the roof are welded together. After welding, remove the connecting bolts of the first flange (205) and the second flange (206), and lift the section (204) on the roof apart.

4. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, In S4, a rigid support (601) and a jack (602) are arranged below the tube bearing of the displacement adaptation mechanism (600). The jack (602) is placed on the rigid support (601), and the displacement adaptation mechanism (600) is connected and fixed to the ground by a support (603). The lower flange (103) of the hydro-pneumatic spring is fixed and supported by a tooling support (604).

5. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, In S6, the steps for lifting out the hydraulic cylinder (100) are as follows: Secure the sling to the hydraulic cylinder (100), and hang the other end of the sling on the main hook of the bridge crane; Remove the connecting bolts between the support base (300) and the support plates (301) on both sides of the cylinder; When the main hook of the bridge crane is lifted, after the support plates (301) on both sides of the hydraulic cylinder (100) are separated from the support seat (300), the support plates (301) on both sides are fixed together with the hydraulic cylinder (100) with wire. Then lift the main hook to hoist the hydraulic cylinder (100) out of the machine room; Use a lifting device (400) in conjunction with a bridge crane to adjust the hydraulic cylinder (100) to a horizontal position and place it on the cylinder support fixture.

6. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, In S7, the steps for removing the measuring shaft (302) are as follows: Hang a hoist on the main hook of the lifting equipment (400), connect the hoist to the lower flange (103), tighten the hoist to make it strong, and remove the support supporting the lower flange (103). The measuring shaft (302) is protected with sheet metal inside the support (300). A hole is made in the web plate (303) of the support (300) with a cutting tool, and the inner wall of the hole is polished smooth. Remove the end baffle of the fixed measuring shaft (302), use a jack to push the measuring shaft (302) out of the shaft hole from the side, and then lift out the lower flange (103).

7. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 6, characterized in that, Install a reinforcing ring (304) at the opening position, weld the weld between the reinforcing ring (304) and the web plate (303), grind the weld smooth after welding, and repair the paint. Replace the slider (305) inside the support seat and lift the lower flange (103) back to its original position; Reinstall the new measuring shaft (302); Fix and support the lower flange (103), and unload the hoist.

8. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, In S8, the steps for reinstalling the new hydraulic cylinder (100) are as follows: Use a lifting device (400) in conjunction with a bridge crane to lift the new hydraulic cylinder (100) horizontally from the bracket, and then adjust the hydraulic cylinder (100) to a vertical position; The lifting equipment (400) is fitted with support plates (301) on both sides, and the support plates (301) are fixed to the hydraulic cylinder (100) with wire; The hydraulic cylinder (100) is hoisted into the machine room by the bridge crane. When the hydraulic cylinder (100) is hoisted to a certain distance above the support seat (300), it stops and the distance between the two support plates (301) is adjusted to ensure that the distance between the two support plates (301) matches the distance between the clamping plates at the upper end of the support seat (300). Slowly lower the main hook of the bridge crane so that the guide slider (102) at the lower end of the hydraulic cylinder (100) enters the groove of the lower flange (103). Then slowly lower the main hook and adjust its position so that the support plate (301) enters the clamping plate of the support seat (300). After the support plate (301) and the bolt holes of the support seat (300) are aligned, the support plate (301) and the support seat (300) are connected and tightened with bolts.

9. The method for disassembling and assembling the hydropneumatic spring of the fully balanced gear and rack climbing vertical ship lift according to claim 1, characterized in that, In S10, the hydraulic system commissioning steps are as follows: After energizing the two proportional pump motors, first start the control pump, then start one of the proportional pumps, and adjust the system overflow valve in the pressure regulating valve block to be energized. After the system pressure is adjusted to 20MPa, the system overflow valve is repeatedly energized and de-energized three times to verify the system pressure. When the system overflow valve is energized, the system pressure is always displayed as 20MPa, and when the system overflow valve is de-energized, the system pressure is always displayed as zero. Close all manual pressure relief valves and oil inlet valves in the safety shut-off valve block of each accumulator, and close the plate-type high-pressure ball valve in the cylinder-side valve block of the hydraulic cylinder (100) and tighten the overflow valve adjusting screw to the correct position and then turn it back one and a half to two turns. Start the control pump. After starting one proportional pump, open the high-pressure ball valve in the main pressure oil pipe. The system overflow valve and the ball-type solenoid directional valve will be energized. After observing that the pressure gauge shows 20MPa, start opening the accumulator inlet valve one by one to fill the oil. Adjust the overflow valve in the accumulator safety shut-off valve block to the actual value measured. Then close the accumulator inlet valve and start the next accumulator. Repeat the above steps to adjust the overflow valve in the safety shut-off valve block of all four accumulators. Open the high-position oil tank supply ball valve of the rod chamber of the hydraulic cylinder (100) to inject hydraulic oil into the rod chamber of the hydraulic cylinder (100); After all the inlet valves in the accumulator safety shut-off valve block are closed, start adjusting the overflow valve in the cylinder-side valve block of the hydraulic cylinder (100) to the actual value measured before opening the plate-type high-pressure ball valve in the cylinder-side valve block to start pressurizing the rodless chamber of the hydraulic cylinder (100). When the pressure gauge reading is the same as the overflow valve adjustment value, the ball-type solenoid directional valve is de-energized and the cylinder pressure relief solenoid valve is energized to start depressurizing the rodless chamber of the hydraulic cylinder (100). After observing that the pressure gauge pointer is zero, the ball-type solenoid directional valve is energized and the cylinder pressure relief solenoid valve is de-energized. Repeat the operation multiple times to exhaust the cylinder body. After the hydraulic cylinder (100) is vented, the relief valve is adjusted. First, tighten the relief valve adjusting screw to the correct position and then turn it back one and a half to two turns. Then, pressurize the hydraulic cylinder (100). After the ball solenoid directional valve is energized, observe the pressure gauge reading. When the pressure is 20MPa, the cylinder pressure relief solenoid valve is energized to start depressurizing the rodless chamber of the hydraulic cylinder (100). Observe the pressure gauge pointer. If it is higher than 2MPa, adjust the relief valve in the cylinder-side valve block of the hydraulic cylinder (100) to 2MPa. Then, connect the pressure gauge to the pressure measurement point between the hydraulic cylinder (100) and the cylinder-side valve block. Slowly loosen the relief valve again to adjust the pressure to the actual value measured. Repeat the process of energizing the ball solenoid directional valve and de-energizing the cylinder pressure relief solenoid valve multiple times to verify whether the relief valve pressure is consistent with the actual value measured. After all the oil inlet valves in the accumulator safety shut-off valve block are in the open state, the local station linkage test is carried out. The first five local station linkage tests need to be further checked and verified to see if the overflow valve pressure is consistent with the actual value measured. The local station linkage hydraulic cylinder (100) operates normally, the pressure remains normal, the accumulator pressure replenishment is normal, there is no jamming, and there is no oil leakage.

10. The method for disassembling and assembling the hydropneumatic spring of a fully balanced gear and rack climbing vertical ship lift according to claim 9, characterized in that, During the reinstallation process of the hydraulic cylinder (100), mark the direction of the arrow on the oil window cover of the high-level oil tank of the hydraulic cylinder (100), remove the oil window cover and clean the remaining oil inside, then use the kneaded dough to stick the inner wall of the high-level oil tank once. After the inner wall of the high-level oil tank is clean and free of impurities, reinstall the oil window cover and the air filter, and close the drain ball valve at the bottom of the high-level oil tank and the oil supply ball valve of the rod chamber of the hydraulic cylinder (100). After the hydraulic cylinder (100) is reinstalled, tighten the connection to the cylinder interface according to the markings when the oil pipe was removed; when reinstalling, make sure the combination gasket and the sealing ring are intact and apply grease evenly to the sealing ring. After filtering the new hydraulic oil, use the refueling trolley to add the hydraulic oil to the high-level oil tank. During the refueling process, pay close attention to whether there is any oil leakage at the oil window cover seal.

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