Method for disassembling and assembling a rack and pinion vertical ship lift giant pulley unit

Abstract

A method for disassembling and assembling a giant pulley unit in a rack and pinion vertical ship lift is disclosed. This method addresses the inability to change the initial elevation and posture during balancing and reassembly, the disconnection and restoration of the wire rope to the ship-bearing chamber via a tensioning device, and the support and limiting of the wire rope via a supporting device. By using this method, the challenges of rapid support and zero-settlement displacement locking during balancing and reassembly are solved, as is the challenge of rapid bidirectional tensioning of the wire rope. This significantly reduces construction technical difficulty, saves manpower, and allows for the reuse of designed tooling and equipment, greatly saving resource investment and reducing operational safety risks. Furthermore, the simple operation method significantly improves the efficiency of maintenance and replacement of the giant pulley unit in the ship lift, ensuring the safe and stable operation of the ship lift.

Description

Technical Field

[0001] This invention relates to the field of vertical ship lift maintenance technology, and in particular to a method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift. Background Technology

[0002] A full-lift ship crane is a navigation structure that uses a lifting and lowering mechanism to allow ships to overcome differences in water level in a waterway; it belongs to the category of lifting machinery. See also... Figure 1 The ship-carrying compartment 5 is the container component that carries the ship, while the counterweight system, a load-balancing system in lifting machinery, is specifically designed to balance the load on the ship-carrying compartment, reduce motor power, and stabilize the lifting and lowering operation of the compartment. It is one of the core components of the overall structure of the ship lift. A certain ship lift has more than ten counterweight systems installed, symmetrically arranged on both sides of the ship-carrying compartment. The counterweight system consists of pulley units 1, counterweight groups 2, wire ropes 3, counterweight chains 4, and wire rope adjustment devices. Each counterweight group consists of multiple wire ropes that pass through multiple pulley units 1 and connect to the ship-carrying compartment 5. The pulley unit 1 serves as the upper load-bearing support for the ship-carrying compartment 5 and the counterweight group 2 to balance each other during operation, bearing the ballast load from the weight of the ship-carrying compartment 5 and the counterweight group 2 during the operation of the ship lift.

[0003] Pulley unit 1 adopts a single-bearing, double-rope groove structure, with a diameter exceeding 5000mm, a thickness of 500mm, and a single weight of 12t. The central bearing is a self-lubricating bearing. During the long-term operation of the ship lift, the pulley bearing is prone to wear due to ballast load, affecting the working condition of the pulley group and thus the safe operation of the ship lift. Therefore, pulley unit 1 needs to be periodically disassembled and replaced. As the upper load-bearing support point connecting the counterweight system to the ship chamber, the replacement of pulley unit 1 is not simply a matter of replacing a single pulley. It involves the entire counterweight system components, including the counterweight assembly, wire ropes, and ship chamber. This replacement is characterized by high technical requirements, complex construction, long construction period, high cost, and high safety risks. It is the first of its kind in the industry, and there is no mature experience to draw upon. 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 giant pulley unit of a rack and pinion vertical ship lift. This method can overcome various technical difficulties encountered during construction, and efficiently and effectively complete the disassembly, assembly, and replacement of the giant pulley unit of the rack and pinion vertical ship lift, providing a mature and referable experience case for the industry.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift, comprising the following steps:

[0006] S1. The locking device used for limit balance reconfiguration is pre-set on the operating platform;

[0007] S2. The ship carrier and balance reassembly are placed in the required construction position, and the initial values ​​of relevant parameters are measured and recorded.

[0008] S3. The locking device will be positioned in place through the operating platform, so that the locking device is located on the lower side of the balancing reassembly to provide limiting support for the balancing reassembly.

[0009] S4. Place the support device on both sides of the pulley unit that needs to be replaced in the computer room;

[0010] S5. Install the tensioning device onto the wire rope connecting plate on one side of the ship-bearing box and connect and fix it to the wire rope; use the tensioning device to detach the wire rope on one side of the ship-bearing box from the ship-bearing box.

[0011] S6. Lift the wire rope using the lifting equipment in the machine room, so that the wire rope is detached from the pulley unit, and place the wire rope on the support device;

[0012] S7. Remove the pulley unit using lifting equipment and then install a new pulley unit;

[0013] S8. Re-hoist and arrange the wire rope on the pulley unit;

[0014] S9. Restore the connection between the ship-bearing box and the wire rope using the tensioning device;

[0015] S10. Remove the locking device and support device;

[0016] S11. Complete the retesting and recording of relevant parameters.

[0017] In S1, when the balancing reassembly is below the operating platform, the locking device is hoisted onto the operating platform.

[0018] In S2, the construction requirement status of the ship carrier and the balance reassembly is that the ship carrier is in the low-level maintenance position, the balance reassembly is in the high-level maintenance position, and the high-level maintenance position is above the operating platform.

[0019] In this state, the following initial measurements of relevant parameters are recorded:

[0020] Elevation of the center axis of the pulley unit to be removed;

[0021] The actual lengths of the two steel wire ropes corresponding to the pulley unit to be removed;

[0022] The bottom elevation of the balance reassembly of the two steel wire ropes corresponding to the pulley unit to be removed;

[0023] The two steel wire ropes corresponding to the pulley unit to be removed correspond to the elevation of the side deck of the ship's compartment.

[0024] In S3, when not in maintenance mode, the locking device is parked on the operating platform on one side of the counterweight well;

[0025] During maintenance, the locking device is stopped in the cross-balance weight well state. Then, steel wedge pads are used to seal the space between the balance weight and the locking device to prevent the balance weight from descending and changing its initial elevation and attitude.

[0026] In S4, two support devices are hoisted to both sides of the pulley unit to be dismantled; the top of the support device is at the same elevation as the central axis of the pulley unit, and the bottom is firmly pressed into contact with the ground; by adjusting the distance between the locking device and the concrete support, the support device is made to be in close contact with the concrete support on the other side.

[0027] In S5, the locking connecting beam of the tensioning device is hoisted onto the turnbuckle connecting bolt at the head of the wire rope and then tightened and fixed by tightening the bolt;

[0028] The hydraulic cylinder is hoisted onto the ship compartment wire rope connecting plate, and the lower part of the hydraulic cylinder is connected to the lug on the ship compartment wire rope connecting plate using the connecting shaft.

[0029] The connecting rod is hoisted and connected to the locking connecting beam via a through-axis;

[0030] The hydraulic pump station was hoisted onto the deck of the ship's cargo box, and the hydraulic pump station was connected to the hydraulic cylinder via a high-pressure hose;

[0031] Start the hydraulic pump station, control the piston rod of the hydraulic cylinder to extend upward, and connect the piston rod end of the hydraulic cylinder to the connecting rod through the shaft;

[0032] The piston rod of the hydraulic cylinder is controlled to retract downwards, so that the hydraulic cylinders on both sides are loaded synchronously.

[0033] Control the two hydraulic cylinders to simultaneously pull the load downward to the set value, remove the connecting shaft between the flower basket connecting bolt and the ship chamber steel wire rope connecting plate, and disconnect the steel wire rope from the ship chamber;

[0034] The piston rod of the hydraulic cylinder is controlled to extend upward synchronously to an unloaded state, at which point the wire rope returns to its free state; and the coupling between the hydraulic cylinder and the corresponding connecting rod is released.

[0035] In S6, the lifting equipment is moved above the pulley unit to be removed;

[0036] The two hooks of the lifting equipment are respectively hooked onto the lifting ropes, and the lifting ropes and wire ropes are secured together using rope clamps;

[0037] The lifting equipment synchronously lifts the wire rope upwards so that the wire rope is disengaged from the pulley unit;

[0038] The lifting equipment moves, causing the wire rope to move above the support device;

[0039] The two hoisting ropes are lowered simultaneously so that the wire ropes fall into the notch on the support device;

[0040] The locking beam is manually placed close to the wire rope at the counterweight wellhead;

[0041] Disconnect the lifting rope from the lifting equipment and connect the lifting rope to the locking lug of the locking beam using a shackle.

[0042] In S7, the verticality and installation position of the pulley unit to be removed are measured and recorded;

[0043] A new lifting rope is hooked onto the hook of the lifting equipment. The hook is lowered and the lifting rope is connected to the hole directly above the pulley unit. The pulley unit is lifted off the concrete support to a high position and moved downstream to the lifting hole. The pulley unit is then lowered to the maintenance platform, and the connection between the lifting rope and the pulley unit is disconnected.

[0044] Connect the new pulley unit to the hoisting rope, hoist the new pulley unit, and hoist the new pulley unit onto the support of the concrete pier.

[0045] Re-measure the verticality and installation position of the newly installed pulley unit to ensure that it is restored to its state before removal;

[0046] Disconnect the hoisting rope from the pulley unit.

[0047] In S8, the two hooks of the lifting equipment are lowered to above the locking beam;

[0048] Release the shackle connection between the lifting rope and the locking lug of the locking beam, and connect the lifting rope to the two hooks respectively;

[0049] Move the locking beam away from the counterweight wellhead;

[0050] The two hooks are lifted upwards simultaneously, causing the wire rope to detach from the support device and raising the height of the wire rope above the highest point of the pulley unit;

[0051] Once the hook is moved above the pulley unit, the wire rope is simultaneously lowered onto the pulley unit, and then the rope clamp is released.

[0052] In S9, the hydraulic pump station is started, and the two hydraulic cylinders are controlled to extend upward synchronously to complete the through-shaft connection with the corresponding connecting rod;

[0053] The hydraulic cylinders are controlled to retract synchronously downwards to load and stretch the steel wire rope.

[0054] After the ear holes between the turnbuckle connecting bolts and the ship's steel wire rope connecting plate are aligned, restore the through-shaft connection between the turnbuckle connecting bolts and the ship's steel wire rope connecting plate.

[0055] Control the hydraulic cylinders to extend upwards synchronously to an unloaded state, at which point the wire rope is in the working state under load.

[0056] Disconnect the hydraulic cylinders from their corresponding connecting rods;

[0057] Disconnect the high-pressure hose between the hydraulic pump station and the hydraulic cylinder;

[0058] Remove the locking connecting beam, connecting rod, and hydraulic cylinder in sequence from top to bottom.

[0059] The present invention has the following beneficial effects:

[0060] By using the method of this invention, the problems of rapid support for balanced reorganization and zero settlement displacement locking are solved, as well as the problem of rapid bidirectional tensioning of steel wire ropes. This can greatly reduce the technical difficulty of construction, save manpower, and the designed tooling and equipment can be reused, greatly saving resource input, reducing operational safety risks, and the operation method is simple. It significantly improves the efficiency of maintenance and replacement of the giant pulley of the ship lift, ensuring the safe and stable operation of the ship lift. Attached Figure Description

[0061] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0062] Figure 1 This is a schematic diagram of the interior of the counterweight well of the ship lift.

[0063] Figure 2 This is a front view schematic diagram of the locking device of the present invention placed below the balance recombination.

[0064] Figure 3 This is a side view of the locking device of the present invention placed below the balance recombination.

[0065] Figure 4 This is a front view schematic diagram of the support device installed on both sides of the pulley unit of the present invention.

[0066] Figure 5 This is a side view of the structure of the pulley unit of the present invention, showing the installation of support devices on both sides.

[0067] Figure 6 This is a schematic diagram of the tensioning device of the present invention.

[0068] Figure 7 This is a diagram showing the state of the wire rope before it detaches from the pulley unit.

[0069] Figure 8 This is a diagram showing the state of the wire rope after it detaches from the pulley unit.

[0070] Figure 9 This is a diagram showing the state of preparation for lifting out the pulley unit.

[0071] Figure 10 This is a diagram showing the state when the pulley unit is lifted out.

[0072] In the picture:

[0073] 1. Pulley unit; 2. Balance reassembly; 3. Wire rope; 4. Balance chain; 5. Ship support box; 6. Operating platform; 7. Concrete support pier; 8. Ship support box wire rope connecting plate; 9. Turnbuckle connecting bolt.

[0074] Locking device 10, steel wedge plate 11;

[0075] Support device 20, adjusting and locking device 21, notch 22;

[0076] Tensioning device 30, locking connecting beam 31, fastening bolt 32, connecting rod 33, hydraulic cylinder 34, connecting shaft 35, hydraulic pump station 36, high-pressure hose 37;

[0077] 40 lifting equipment;

[0078] 50 lifting rope, 51 rope clamps;

[0079] Locking beam 60, locking lug 61. Detailed Implementation

[0080] See Figure 1-10 As shown, a method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift includes the following steps:

[0081] S1. The locking device 10 used for limit balance recombination 2 is pre-positioned on the operating platform 6;

[0082] S2, ship-bearing box 5 and balance reassembly 2 are parked in the required construction position, and the initial values ​​of relevant parameters are measured and recorded.

[0083] S3. The locking device 10 will be positioned in place by operating platform 6, so that the locking device 10 is located on the lower side of the balance recombination 2, so as to provide limiting support for the balance recombination 2.

[0084] S4. Arrange the support device 20 on both sides of the pulley unit 1 that needs to be replaced in the computer room;

[0085] S5. Install the tensioning device 30 onto the wire rope connecting plate 8 on one side of the ship-bearing chamber 5 and connect and fix it to the wire rope 3; use the tensioning device 30 to detach the wire rope 3 on one side of the ship-bearing chamber 5 from the ship-bearing chamber 5.

[0086] S6. Lift the wire rope 3 using the lifting equipment in the machine room, so that the wire rope 3 is detached from the pulley unit 1, and place the wire rope 3 on the support device 20;

[0087] S7. Remove pulley unit 1 using lifting equipment, and then install a new pulley unit 1;

[0088] S8. Re-hoist and arrange the wire rope on pulley unit 1;

[0089] S9. Restore the connection between the ship-bearing box 5 and the wire rope 3 by using the tensioning device 30;

[0090] S10, Remove the locking device 10 and the supporting device 20;

[0091] S11. Complete the retesting and recording of relevant parameters.

[0092] By using the method of this invention, the problems of rapid support for balanced reorganization and zero settlement displacement locking are solved, as well as the problem of rapid bidirectional tensioning of steel wire ropes. This can greatly reduce the technical difficulty of construction, save manpower, and the designed tooling and equipment can be reused, greatly saving resource input, reducing operational safety risks, and the operation method is simple. It significantly improves the efficiency of maintenance and replacement of the giant pulley unit of the ship lift, ensuring the safe and stable operation of the ship lift.

[0093] like Figure 1 As shown, in S1, when the balancing and reassembly 2 is below the operating platform 6, the locking device 10 is hoisted onto the operating platform 6.

[0094] Since the ship lift tower is a fully enclosed structure, when the ship lift is shut down for maintenance, the ship-carrying chamber 5 is at an elevation of 62m for maintenance, the balancing and reassembly 2 is at an elevation of 176m for maintenance, and the locking device 10 is located on the 175m operating platform 6 during maintenance. It needs to be hoisted and transferred from the operating route of the balancing and reassembly 2 to the operating platform 6. Therefore, it needs to be hoisted and transferred to the operating platform 6 for storage when the balancing and reassembly 2 is at an elevation below the operating platform 6.

[0095] like Figure 1 As shown in S2, the construction requirement status of the ship-bearing box 5 and the balancing reassembly 2 is that the ship-bearing box 5 is in the low-level maintenance position and the balancing reassembly 2 is in the high-level maintenance position. The high-level maintenance position is above the operating platform 6, which facilitates the installation of the locking device 10.

[0096] In this state, the following initial measurements of relevant parameters are recorded:

[0097] Elevation of the center axis of pulley unit 1 to be removed;

[0098] The actual lengths of the two steel wire ropes 3 corresponding to the pulley unit 1 to be dismantled;

[0099] The bottom elevation of the balance reassembly 2, which is attached to the two steel wire ropes 3 corresponding to the pulley unit 1 to be dismantled;

[0100] The two steel wire ropes 3 corresponding to the pulley unit 1 to be dismantled correspond to the elevation of the side deck of the ship compartment 5.

[0101] This facilitates verification of the installation data after replacing pulley unit 1.

[0102] See Figure 2 , 3 In S3, when not in maintenance mode, the locking device 10 is parked on the operating platform 6 on one side of the counterweight well;

[0103] During maintenance, the locking device 10 is stopped in the cross-balance weight well state. Then, the steel wedge plate 11 is used to seal the space between the balance weight 2 and the locking device 10 so that the balance weight 2 cannot descend and change its initial elevation attitude.

[0104] Specifically, in this embodiment, the locking device 10 is a steel support beam structure.

[0105] See Figure 4 , 5 In S4, the arrangement steps of the wire rope support device 20 are as follows:

[0106] Two support devices 20 are hoisted to both sides of the pulley unit 1 to be dismantled. The top of the support device 20 is at the same elevation as the central axis of the pulley unit 1, and the bottom is firmly in contact with the ground. By adjusting the distance between the locking device 21 and the concrete support 7, the support device 20 is made to be in close contact with the concrete support 7 on the other side. The support device 20 is installed and fixed in this way. In this embodiment, the locking device 21 is in the form of a screw and a nut sleeve. The screw extends out of the nut sleeve and abuts against the concrete support 7 to fix the support device 20.

[0107] See Figure 6 In S5, the arrangement steps of the wire rope tensioning device 30 are as follows:

[0108] Using the lifting equipment 40, the locking connecting beam 31 of the tensioning device 30 is hoisted onto the turnbuckle connecting bolt 9 at the head of the wire rope 3, and then tightened and fixed by the fastening bolt 32;

[0109] The hydraulic cylinder 34 is hoisted onto the ship compartment wire rope connecting plate 8 using the lifting equipment 40, and the lower part of the hydraulic cylinder 34 is connected to the lug on the ship compartment wire rope connecting plate 8 using the connecting shaft 35.

[0110] The connecting rod 33 is hoisted and connected to the locking connecting beam 31 through the shaft using the lifting equipment 40;

[0111] The hydraulic pump station 36 is hoisted onto the deck of the ship carrier 5 using the lifting equipment 40. The hydraulic pump station 36 is connected to the hydraulic cylinder 34 through the high-pressure hose 37.

[0112] Start the hydraulic pump station 36 to control the piston rod of the hydraulic cylinder 34 to extend upward, and connect the piston rod end of the hydraulic cylinder 34 to the connecting rod 33 through the shaft;

[0113] The piston rod of the hydraulic cylinder 34 is controlled to retract downward, so that the hydraulic cylinders 34 on both sides can be loaded with 10KN simultaneously.

[0114] After controlling the two hydraulic cylinders 34 to simultaneously pull the load downward to the set value of 80t, stop loading, remove the connecting shaft 35 between the basket connecting bolt 9 and the ship box wire rope connecting plate 8, and disconnect the connection between the wire rope 3 and the ship box 5.

[0115] The piston rod of the hydraulic cylinder 34 is controlled to extend upward synchronously to the unloaded state, at which point the wire rope 3 returns to its free state;

[0116] The lifting equipment 40 is used to disconnect the coupling between the hydraulic cylinder 34 and the corresponding connecting rod 33.

[0117] By using the above method, the connection between the wire rope 3 and the ship-bearing box 5 is released, so that the wire rope 3 is in a free state.

[0118] See Figure 5 , 7 8. In S6, the steps for detaching the wire rope 3 from the pulley unit 1 are as follows:

[0119] The bridge crane in the machine room is moved above the pulley unit 1 to be removed;

[0120] The two hooks of the bridge crane are respectively hooked with the lifting rope 50, and the lifting rope 50 is installed and clamped to the wire rope 3 using the rope clamp 51;

[0121] The lifting equipment synchronously lifts the wire rope 3 upwards so that the wire rope 3 is disengaged from the pulley unit 1;

[0122] The lifting equipment moves, causing the wire rope 3 to move above the support device 20;

[0123] The two hoisting ropes 50 are lowered simultaneously, so that the wire rope 3 falls into the notch 22 on the support device 20;

[0124] The locking beam 60 is manually placed close to the steel wire rope 3 at the counterweight wellhead;

[0125] Disconnect the lifting rope 50 from the lifting equipment and connect the lifting rope 50 to the locking lug 61 of the locking beam 60 using a shackle.

[0126] Using the above method, the steel wire rope 3 on the pulley unit 1 is transferred to the support device 20.

[0127] See Figure 9 , 10In S7, the steps for removing the pulley unit and installing a new pulley unit are as follows:

[0128] Measure and record the verticality and installation position of the pulley unit 1 to be removed;

[0129] A new lifting rope 50 is hooked onto the hook of the lifting equipment. The hook is lowered and the lifting rope 50 is connected to the hole directly above the pulley unit 1. The pulley unit 1 is lifted off the concrete support 7 to a high position and moved downstream to the lifting hole. The pulley unit 1 is lowered to the maintenance platform and the connection between the lifting rope 50 and the pulley unit 1 is released.

[0130] Connect the new pulley unit 1 to the hoisting rope 50, hoist the new pulley unit 1, and hoist the new pulley unit 1 onto the support of the concrete pier 7;

[0131] Re-measure the verticality and installation position of the newly installed pulley unit 1 to ensure that it is restored to its state before removal;

[0132] Disconnect the hoisting rope 50 from the pulley unit 1.

[0133] The old pulley unit 1 can be disassembled and the new pulley unit 1 can be installed in the above manner.

[0134] See Figure 7 , 6 In S8, the steps for re-hoisting and arranging the wire rope 3 on the pulley unit 1 are as follows:

[0135] The two hooks of the lifting equipment were lowered above the locking beam 60;

[0136] Release the shackle connection between the lifting rope 50 and the locking lug 61 of the locking beam 60, and connect the lifting rope 50 to the two hooks respectively;

[0137] Move locking beam 60 away from the counterweight wellhead;

[0138] The two hooks are lifted upwards in sync, causing the wire rope 3 to detach from the support device 20 and making the height of the wire rope 3 exceed the highest point of the pulley unit 1;

[0139] After the hook moves above the pulley unit 1, the wire rope 3 is simultaneously lowered onto the pulley unit 1, and then the rope clamp 51 is released.

[0140] Using the above method, the wire rope 3 is reinstalled onto the new pulley unit 1.

[0141] See Figure 6 In S9, the steps for restoring the connection between the ship-bearing box 5 and the wire rope 3 using the tensioning device 30 are as follows:

[0142] Start the hydraulic pump station 36 and control the hydraulic cylinders 34 to extend upward synchronously in pairs to complete the through-shaft connection with the corresponding connecting rod 33.

[0143] The hydraulic cylinders 34 are controlled to retract synchronously downwards to load and stretch the steel wire rope 3.

[0144] After the ear holes between the turnbuckle connecting bolt 9 and the ship box wire rope connecting plate 8 are aligned, restore the through-shaft connection between the turnbuckle connecting bolt 9 and the ship box wire rope connecting plate 8.

[0145] Control the hydraulic cylinders 34 to extend the cylinders upward synchronously to the unloaded state, at which time the wire rope 3 is in the working state with load;

[0146] Disconnect the hydraulic cylinder 34 (double cylinder) from the corresponding connecting rod 33;

[0147] Disconnect the high-pressure hose 37 between the hydraulic pump station 36 and the hydraulic cylinder 34;

[0148] Remove the locking connecting beam 31, connecting rod 33 and hydraulic cylinder 34 from top to bottom in sequence.

[0149] By using the above method, the connection between the ship-bearing chamber 5 and the steel wire rope 3 is restored, and the tensioning device 30 is removed.

[0150] In S10, such as Figure 3 As shown, the steps for removing the locking device 10 and the support device 20 are as follows:

[0151] Remove the steel wedge pad 11 between the balance reassembly 2 and the locking device 10;

[0152] Move the locking device 10 onto the operating platform 6.

[0153] Tighten the bolts of the adjusting locking device 21 to loosen the support device 20 from the concrete support 7, and then hoist the support device 20 to the storage area.

[0154] In S1, complete the retest of the following key parameters:

[0155] Elevation of the center axis of newly installed pulley unit 1;

[0156] The actual lengths of the two steel wire ropes 3 corresponding to the newly installed pulley unit 1;

[0157] The bottom elevation of the balance reassembly 2 corresponding to the two steel wire ropes 3 of the newly installed pulley unit 1;

[0158] The elevation of the side deck of the ship-bearing box 5 corresponding to the two steel wire ropes 3 corresponding to the newly installed pulley unit 1.

[0159] The parameters were compared and recorded with those before construction, and the parameter deviations were not greater than the design values.

[0160] At this point, the ship-bearing chamber 5 and the counterweight return to normal operating conditions.

[0161] By using the method of this invention, the problems of rapid support for balanced reorganization and zero settlement displacement locking are solved, as well as the problem of rapid bidirectional tensioning of steel wire ropes. This can greatly reduce the technical difficulty of construction, save manpower, and the designed tooling and equipment can be reused, greatly saving resource input, reducing operational safety risks, and the operation method is simple. It significantly improves the efficiency of maintenance and replacement of the giant pulley of the ship lift, ensuring the safe and stable operation of the ship lift.

Claims

1. A method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift, characterized in that, Includes the following steps: S1. The locking device (10) used for limit balance reorganization (2) is pre-positioned on the operating platform (6); S2, the ship-bearing box (5) and the balance reassembly (2) are parked in the position required for construction, and the initial values ​​of relevant parameters are measured and recorded; S3. The locking device (10) is positioned in place by operating platform (6) so that the locking device (10) is located on the lower side of the balance reorganization (2) to provide limiting support for the balance reorganization (2); S4. Arrange the support device (20) on both sides of the pulley unit (1) that needs to be replaced in the machine room; S5. Install the tensioning device (30) onto the wire rope connecting plate (8) on one side of the ship-bearing box (5) and connect and fix it to the wire rope (3); use the tensioning device (30) to detach the wire rope (3) on one side of the ship-bearing box (5) from the ship-bearing box (5); S6. The wire rope (3) is lifted by the lifting equipment in the machine room, so that the wire rope (3) is separated from the pulley unit (1) and placed on the support device (20); S7. Remove the pulley unit (1) using a lifting device and then install a new pulley unit (1). S8. Re-install the wire rope on the pulley unit (1); S9. Restore the connection between the ship-bearing box (5) and the wire rope (3) by using the tensioning device (30); S10. Remove the locking device (10) and the support device (20). S11. Complete the retesting and recording of relevant parameters; The relevant parameters include: Elevation of the center axis of the pulley unit (1) to be removed; The actual lengths of the two steel wire ropes (3) corresponding to the pulley unit (1) to be dismantled; The bottom elevation of the two steel wire ropes (3) corresponding to the pulley unit (1) to be removed; The two steel wire ropes (3) corresponding to the pulley unit (1) to be dismantled correspond to the elevation of the side deck of the ship-bearing box (5).

2. The method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 1, characterized in that, In S1, when the balance reorganization (2) is below the operating platform (6), the locking device (10) is hoisted onto the operating platform (6).

3. The method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 1, characterized in that, In S2, the construction requirement state of the ship-bearing box (5) and the balance reassembly (2) is that the ship-bearing box (5) is in the low-level maintenance position and the balance reassembly (2) is in the high-level maintenance position, and the high-level maintenance position is above the operating platform (6); under this state, the initial values ​​of relevant parameters are measured and recorded.

4. The method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 1, characterized in that, In S3, when not under maintenance, the locking device (10) is placed on the operating platform (6) on one side of the counterweight well; During maintenance, the locking device (10) is stopped in the state of crossing the counterbalance well. Then, the steel wedge plate (11) is used to seal the counterbalance reassembly (2) and the locking device (10) so that the counterbalance reassembly (2) cannot descend and change its initial elevation attitude.

5. The method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 1, characterized in that, In S4, two support devices (20) are hoisted to both sides of the pulley unit (1) to be dismantled; the top of the support device (20) is at the same elevation as the central axis of the pulley unit (1), and the bottom is in close contact with the ground and compacted; the distance between the support device (20) and the concrete support (7) is adjusted by adjusting the locking device (21) so that the support device (20) is in close contact with the concrete support (7) on the other side.

6. The method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 1, characterized in that, In S5, the locking connecting beam (31) of the tensioning device (30) is hoisted onto the turnbuckle connecting bolt (9) at the head of the wire rope (3) and tightened by the fastening bolt (32); The hydraulic cylinder (34) is hoisted onto the ship compartment wire rope connecting plate (8), and the lower part of the hydraulic cylinder (34) is connected to the ear hole on the ship compartment wire rope connecting plate (8) using the connecting shaft (35). The connecting rod (33) is hoisted and connected to the locking connecting beam (31) through the shaft; The hydraulic pump station (36) is hoisted onto the deck of the ship carrier (5), and the hydraulic pump station (36) is connected to the hydraulic cylinder (34) through the high-pressure hose (37); Start the hydraulic pump station (36) and control the piston rod of the hydraulic cylinder (34) to extend upward, and connect the piston rod end of the hydraulic cylinder (34) to the connecting rod (33) through the shaft; The piston rod of the hydraulic cylinder (34) is controlled to retract downward, so that the hydraulic cylinders (34) on both sides are loaded synchronously; Control the two hydraulic cylinders (34) to tension and load downwards to the set value, remove the connecting shaft (35) between the basket connecting bolt (9) and the ship box wire rope connecting plate (8), and disconnect the connection between the wire rope (3) and the ship box (5); The piston rod of the hydraulic cylinder (34) is controlled to extend upward synchronously to a state without load, at which time the wire rope (3) returns to a free state; and the coupling between the hydraulic cylinder (34) and the corresponding connecting rod (33) is released.

7. A method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 6, characterized in that, In S6, the lifting equipment is moved above the pulley unit (1) to be removed; The two hooks of the lifting equipment are respectively hooked onto the lifting rope (50), and the lifting rope (50) and the wire rope (3) are installed and clamped together using rope clamps (51); The lifting equipment synchronously lifts the wire rope (3) upward so that the wire rope (3) is disengaged from the pulley unit (1); The lifting equipment moves, causing the wire rope (3) to move above the support device (20); The two hoisting ropes (50) are lowered simultaneously, so that the wire rope (3) falls into the notch (22) on the support device (20); The locking beam (60) is placed manually next to the wire rope (3) at the counterweight wellhead; Disconnect the hoisting rope (50) from the lifting equipment and connect the hoisting rope (50) to the locking lug (61) of the locking beam (60) by using a shackle.

8. A method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 7, characterized in that, In S7, the verticality and installation position of the pulley unit (1) to be removed are measured and recorded; A new lifting rope (50) is hooked onto the hook of the lifting equipment. The lifting rope (50) is lowered and connected to the hole directly above the pulley unit (1). The pulley unit (1) is lifted off the concrete support (7) to a high position and moved downstream to the lifting hole. The pulley unit (1) is lowered to the maintenance platform and the connection between the lifting rope (50) and the pulley unit (1) is released. Connect the new pulley unit (1) to the hoisting rope (50), hoist the new pulley unit (1), and hoist the new pulley unit (1) onto the support of the concrete pier (7); Re-measure the verticality and installation position of the newly installed pulley unit (1) to ensure that it is restored to its state before removal; Disconnect the hoisting rope (50) from the pulley unit (1).

9. A method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 8, characterized in that, In S8, the two hooks of the lifting equipment are lowered to above the locking beam (60); Release the shackle connection between the lifting rope (50) and the locking lug (61) of the locking beam (60), and connect the lifting rope (50) to the two hooks respectively; Move the locking beam (60) away from the counterweight wellhead; The two hooks are lifted upwards in sync, causing the wire rope (3) to detach from the support device (20) and the height of the wire rope (3) to exceed the highest point of the pulley unit (1); After the hook moves above the pulley unit (1), the wire rope (3) is lowered onto the pulley unit (1) and the rope clamp (51) is released.

10. A method for disassembling and assembling a giant pulley unit of a rack and pinion vertical ship lift according to claim 6, characterized in that, In S9, the hydraulic pump station (36) is started, and the hydraulic cylinders (34) are controlled to extend upward synchronously to complete the through-shaft connection with the corresponding connecting rod (33); Control the hydraulic cylinders (34) to retract and load simultaneously downwards, stretching the steel wire rope (3); After the ear holes of the turnbuckle connecting bolt (9) and the ship box wire rope connecting plate (8) are aligned, restore the through-shaft connection between the turnbuckle connecting bolt (9) and the ship box wire rope connecting plate (8); Control the hydraulic cylinders (34) to extend the cylinders upward synchronously to the unloaded state. At this time, the wire rope (3) is in the working state of being loaded. Disconnect the connection between the hydraulic cylinder (34) and the corresponding connecting rod (33); Disconnect the high-pressure hose (37) between the hydraulic pump station (36) and the hydraulic cylinder (34); Remove the locking connecting beam (31), connecting rod (33), and hydraulic cylinder (34) from top to bottom in sequence.

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