Automatic valve disassembling system and method

Abstract

The invention relates to the technical field of valve disassembling, and discloses an automatic valve disassembling system and method.The automatic valve disassembling system comprises a ground rail robot; a truss robot; the position changing machine comprises a rotary working table used for clamping the valve to be disassembled, and the rotary working table drives the valve to be disassembled to rotate to a corresponding working area; a radial drilling machine; a quick-change clamp head I mounted on a six-degree-of-freedom mechanical arm of the industrial robot can be used for clamping any one of an electric wrench with an offset head, a pneumatic clamping toe and an electromagnetic induction heating head; and any one of an impact hammer, a nut splitter, a cutting machine, a large-torque electric wrench and an electric impact wrench can be clamped by a quick-change clamp head II on the power-assisted manipulator. Semi-automatic and full-automatic valve disassembly can be achieved, control of an overall disassembly system is integrated, the disassembly efficiency is improved, and the problems of low-efficiency, high-risk and low-automation-level disassembly of coal chemical industry valves are solved.

Description

Technical Field

[0001] The present invention relates to the technical field of valve disassembly, and more particularly to a valve automatic disassembly system and method. Background Art

[0002] The environment in which valves in coal chemical and petrochemical industries are located is generally harsh. During long-term use, these valves need to be disassembled and maintained. The current valve disassembly process mainly includes: the nut on the valve has a high strength with the screw after rust / corrosion, and it is currently mainly disassembled by manual labor with special tools (tighten and cut after baking); after the screw thread is damaged after rust / corrosion, it is still disassembled by manual labor with special tools (exposed valve body screw part is cut off, embedded valve body screw part is drilled out); the disassembly and transportation of each component must be completed manually or with a crane. At present, the repair cycle of large-size valves can reach 15 days. Since there is no automatic valve disassembly line at this stage, the disassembly process is time-consuming and labor-intensive, and the labor cost is high. Summary of the invention

[0003] In view of this, in order to solve the problems existing in the prior art, the present invention proposes a valve automatic disassembly system and method, and its specific technical solution is as follows:

[0004] A valve automatic disassembly system, comprising:

[0005] A ground rail robot, which is installed on the ground rail for transporting valves and can move horizontally along the axis of the ground rail for transporting valves, and is used to transport valves and their components;

[0006] The truss robot comprises a support frame, two X-axis motion mechanisms spaced apart on the support frame, a Y-axis motion mechanism slidably connected between the two X-axis motion mechanisms, and a Z-axis motion mechanism that can slide along the Y-axis, wherein a clamping portion is provided on the Z-axis motion mechanism and drives the clamping portion to reciprocate along the Z-axis direction, and the clamping portion can clamp a tool for disassembling a valve stem or a tool for disassembling an upper valve body;

[0007] The positioner is installed on the ground rail for the positioner and can move horizontally along the axis of the ground rail for the positioner; the positioner includes a rotary table for clamping the valve to be disassembled, and the rotary table drives the valve to be disassembled to rotate to the corresponding working area; the clamping part on the truss robot can use the upper valve body disassembly tooling to place the valve and its parts on the ground rail robot on the positioner;

[0008] The radial drilling machine is located outside the positioner. The drill bit on the radial drilling machine is used to machine a bottom hole for a wire extractor on the screw and to directly drill out the screw that has not been removed;

[0009] The industrial robot comprises a first industrial robot and a second industrial robot respectively arranged on both sides of the positioner, the first industrial robot and the second industrial robot are both equipped with a six-degree-of-freedom mechanical arm, the quick-change fixture head installed on the six-degree-of-freedom mechanical arm can be equipped with any one of an electric wrench with an offset head, a pneumatic clamp toe, and an electromagnetic induction heating head; the valve core removal clamp can be clamped on the quick-change fixture head or on the clamping part of the truss robot;

[0010] There are five power-assisted manipulators, which are arranged on both sides of the positioner. Among them, the first power-assisted manipulator, the second power-assisted manipulator and the second industrial robot are located on the same side, and the third power-assisted manipulator, the fourth power-assisted manipulator and the fifth power-assisted manipulator and the first industrial robot are located on the same side; the quick-change clamp head 2 installed on the power-assisted manipulator can clamp any one of the impact hammer, nut cutter, cutting machine, high-torque electric wrench and electric impact wrench.

[0011] Preferably, a telescopic tray for placing valves and components thereof is provided on the ground rail robot; and / or a hydraulic chuck for clamping the valve to be disassembled is provided on the rotary workbench of the positioner.

[0012] Preferably, the first power-assist manipulator, the second industrial robot, and the second power-assist manipulator are arranged sequentially along the extension direction of the positioner ground rail, and the first power-assist manipulator is closest to the radial drilling machine; the fifth power-assist manipulator, the fourth power-assist manipulator, and the third power-assist manipulator are also arranged sequentially along the extension direction of the positioner ground rail, and the fifth power-assist manipulator is closest to the radial drilling machine, and the fifth power-assist manipulator is installed close to the first industrial robot on the side facing the positioner ground rail.

[0013] The present invention also proposes an automated valve disassembly method, which uses the automated valve disassembly system described above, including a semi-automated valve disassembly method and a fully automated valve disassembly method, wherein the fully automated valve disassembly method is suitable for valves with a very light degree of rust.

[0014] In the first semi-automatic valve disassembly method, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the fifth power manipulator is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦;

[0015] Clamp the upper valve body disassembly tooling on the truss robot, use the truss robot and the upper valve body disassembly tooling to transfer the valve to be disassembled from the ground rail robot to the positioner, and clamp the valve to be disassembled on the rotary workbench of the positioner, and transfer the valve to be disassembled to each workstation by the rotary workbench;

[0016] The semi-automatic valve disassembly method has the following steps for disassembling a single valve:

[0017] (ii) For valves with no or slight corrosion, where most nuts and screws are easy to remove

[0018] S1. Use the fifth power-assisted manipulator to clamp the electric impact wrench at workstation ⑥ to quickly disassemble the nut;

[0019] S2. After the nut is disassembled, the position is changed to the workstation ① through the positioner. The upper and lower valve bodies are disassembled by using the first power-assisted manipulator to clamp the impact hammer, and the upper valve body is removed by the truss robot quick-change clamping tooling for the upper valve body disassembly;

[0020] S3, change the position to the workstation ⑥ through the positioner, and use the electric impact wrench on the fifth power manipulator to add nuts to the screw;

[0021] S4. The screw with the nut on it is transferred to the workstation through the positioner ⑤ and the electric impact wrench is clamped by the fourth power manipulator for quick disassembly;

[0022] (III) For the situation where the valve is severely corroded and most of the nuts and screws are difficult to remove

[0023] Nut disassembly:

[0024] S1. At workstation ⑤, use the fourth power-assisted manipulator to clamp a high-torque electric wrench to loosen the nut. The loosened nut is transferred to workstation ⑥ by a positioner and clamped with an electric impact wrench for quick disassembly by the fifth power-assisted manipulator;

[0025] S2. The remaining unloosened nuts are heated at station ② by using the six-degree-of-freedom manipulator on the second industrial robot to clamp the electromagnetic induction heating head; the heated nuts are transferred to station ⑤ by the positioner to clamp the high-torque electric wrench by the fourth power-assisted manipulator to loosen them; the loosened nuts are transferred to station ⑥ by the positioner to clamp the electric impact wrench by the fifth power-assisted manipulator for quick disassembly;

[0026] S3. The remaining unscrewed nuts are directly transferred to the workstation ① through the positioner, and the nut cutter is clamped and cut by the first power manipulator;

[0027] Disassembly of upper valve body:

[0028] After the nut is disassembled, the upper and lower valve bodies are disassembled at workstation ① using the first power-assisted manipulator quick-change clamping impact hammer, and the upper valve body is removed by the truss robot quick-change clamping upper valve body disassembly tooling;

[0029] Screw disassembly:

[0030] S1. At workstation ⑥, use the fifth power-assisting manipulator to clamp an electric impact wrench to put a nut on the screw; the screw with the nut is transferred to workstation ⑤ by a positioner and then clamped with a high-torque electric wrench by the fourth power-assisting manipulator for loosening; the loosened screw is transferred to workstation ⑥ by a positioner and then clamped with an electric impact wrench by the fifth power-assisting manipulator for quick disassembly;

[0031] S2. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted robot is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ⑥ by the positioner and the fifth power-assisted robot is used to clamp the electric impact wrench for quick disassembly;

[0032] S3. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the remaining screws are cut by the fifth power-assisted manipulator quick-change cutting machine; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamping toe on the six-degree-of-freedom manipulator on the second industrial robot; the position is changed to station ⑤ by the positioner, and the high-torque electric wrench is clamped by the fourth power-assisted manipulator to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ⑥ by the positioner, and the electric impact wrench is clamped by the fifth power-assisted manipulator for quick disassembly;

[0033] S4. The screws that have not been disassembled are finally transferred to the workstation ⑦ by the positioner and drilled out in sequence by the radial drilling machine;

[0034] (III) For the situation where the nut and screw in the valve cannot be disassembled and need to be cut directly

[0035] S1, at workstation ①, use the first power manipulator to clamp the nut cutter and cut the nuts in sequence;

[0036] S2. After the nuts are disassembled, use the first power-assisted manipulator quick-change clamping impact hammer to disassemble the upper and lower valve bodies at workstation ①, and remove the upper valve body through the truss robot quick-change clamping tooling for upper valve body disassembly;

[0037] S3, the position is changed by the positioner to the workstation ⑥, and the fifth power-assisting manipulator is used to clamp the electric impact wrench to put the nut on the screw; the screw with the nut is changed by the positioner to the workstation ⑤, and the fourth power-assisting manipulator is used to clamp the high-torque electric wrench to loosen it; the loosened screw is changed by the positioner to the workstation ⑥, and the fifth power-assisting manipulator is used to clamp the electric impact wrench for quick disassembly;

[0038] S4. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted robot is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ⑥ by the positioner and the fifth power-assisted robot is used to clamp the electric impact wrench for quick disassembly;

[0039] S5. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the remaining screws are cut by the fifth power-assisted manipulator quick-change cutting machine; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamp toe on the six-degree-of-freedom manipulator on the second industrial robot; the position is changed to station ⑤ by the positioner, and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ⑥ by the positioner, and the fifth power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly;

[0040] S6. The screws that have not been disassembled are finally transferred to the workstation ⑦ by the positioner and drilled out one by one by the radial drilling machine.

[0041] In the second semi-automatic valve disassembly method, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the fifth power manipulator is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦; the middle of station ①, station ②, station ⑤, and station ⑥ corresponds to the left working area, and the middle of station ②, station ③, station ④, and station ⑤ corresponds to the right working area;

[0042] Clamp the upper valve body disassembly tooling on the truss robot, use the truss robot and the upper valve body disassembly tooling to transfer the valve to be disassembled from the ground rail robot to the positioner, and clamp the valve to be disassembled on the rotary workbench of the positioner, and transfer the valve to be disassembled to each workstation by the rotary workbench;

[0043] The semi-automatic valve disassembly method has the following steps for disassembling a single valve:

[0044] (ii) For valves with no or slight corrosion, where most nuts and screws are easy to remove

[0045] S1. Use the fifth power-assisted manipulator to clamp the electric impact wrench at workstation ⑥ to quickly disassemble the nut;

[0046] S2. After the nut is disassembled, the position is changed to the workstation ① through the positioner. The upper and lower valve bodies are disassembled by using the first power-assisted manipulator to clamp the impact hammer, and the upper valve body is removed by the truss robot quick-change clamping tooling for the upper valve body disassembly;

[0047] S3. After disassembling the upper valve body, transfer the positioner to station ③ through the positioner ground rail; at station ③, use the second power manipulator to clamp the electric impact wrench to back the nut on the screw;

[0048] S4. The screw with the nut on it is transferred to the workstation ④ by the positioner, and the electric impact wrench is clamped by the third power manipulator for quick disassembly;

[0049] (ii) For the situation where the valve is severely corroded and most of the nuts and screws are difficult to remove

[0050] Nut disassembly:

[0051] S1, at station ⑤, use the fourth power-assisted manipulator to clamp a high-torque electric wrench to loosen the nut, and the loosened nut is transferred to station ③ by a positioner to use the second power-assisted manipulator to clamp an electric impact wrench for quick disassembly;

[0052] S2. The remaining unloosened nuts are heated by the electromagnetic induction heating head clamped by the six-degree-of-freedom manipulator on the second industrial robot at station ②; the heated nuts are transferred to station ⑤ by the fourth power-assisted manipulator to loosen them by clamping a high-torque electric wrench; the loosened nuts are transferred to station ③ by the positioner to clamp an electric impact wrench by the second power-assisted manipulator for quick disassembly;

[0053] S3. The remaining unscrewed nuts are directly transferred to the workstation ④ through the positioner, and the nut cutter is clamped and cut by the third power manipulator;

[0054] Disassembly of upper valve body:

[0055] After the nut is disassembled, the positioner is transferred to the workstation ① through the positioner ground rail; at workstation ①, the upper and lower valve bodies are disassembled by clamping the impact hammer with the first power-assisted manipulator, and the upper valve body is removed by the truss robot quick-change clamping tooling for disassembly of the upper valve body;

[0056] Screw disassembly:

[0057] S1. After the upper valve body is disassembled, the positioner is transferred to station ③ through the positioner ground rail; at station ③, the second power-assisting manipulator is used to clamp the electric impact wrench to put the nut on the screw; the screw with the nut is transferred to station ⑤ by the positioner and the fourth power-assisting manipulator is used to clamp the high-torque electric wrench to loosen it; the loosened screw is transferred to station ③ by the positioner and the second power-assisting manipulator is used to clamp the electric impact wrench for quick disassembly;

[0058] S2. For the screw that still cannot be disassembled, the six-degree-of-freedom mechanical arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ③ by the positioner and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly;

[0059] S3. For the screws that still cannot be disassembled, the positioner is transferred to station ⑥ through the positioner ground rail, and the remaining screws are cut by the fifth power-assisted manipulator quick-change cutting machine; the cut screw is transferred to station ⑦ through the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is transferred to between stations ① and ② through the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamp toe on the six-degree-of-freedom manipulator on the second industrial robot; the positioner is moved to the right working area through the positioner ground rail, and the position is transferred to station ⑤ through the positioner, and the fourth power-assisted manipulator is used to clamp a large-torque electric wrench to loosen the screw equipped with the wire extractor; the loosened screw is transferred to station ③ through the positioner, and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly;

[0060] S4, the positioner is moved to the workstation ⑦ through the positioner ground rail, and the screws that have not been disassembled are drilled out one by one using a radial drilling machine;

[0061] (III) For the situation where the nut and screw in the valve cannot be disassembled and need to be cut directly

[0062] S1, at station ④, use the third power manipulator to clamp the nut cutter and cut the nuts in sequence;

[0063] S2. After the nuts are disassembled, the positioner is transferred to the workstation ① through the positioner ground rail. At workstation ①, the upper and lower valve bodies are disassembled by using the first power-assisted manipulator quick-change clamping impact hammer, and the upper valve body is removed by using the truss robot quick-change clamping tooling for upper valve body disassembly;

[0064] S3. After the upper valve body is disassembled, the positioner is transferred to station ③ through the positioner ground rail; at station ③, the second power-assisting manipulator is used to clamp the electric impact wrench to put the nut on the screw; the screw with the nut is transferred to station ⑤ through the positioner to loosen it with a high-torque electric wrench; the loosened screw is transferred to station ③ through the positioner to be clamped with the electric impact wrench by the second power-assisting manipulator for quick disassembly;

[0065] S4. For the screw that still cannot be disassembled, the six-degree-of-freedom mechanical arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ③ by the positioner and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly;

[0066] S5. For the screws that still cannot be disassembled, the position is changed by the positioner to the workstation ⑥, and the fifth power-assisted manipulator is used to clamp the cutting machine to cut the remaining screws; the cut screw is changed by the positioner to the workstation ⑦, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is changed by the positioner to between the workstation ① and the workstation ②, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamp toe on the six-degree-of-freedom manipulator on the second industrial robot; after all the undisassembled screws are installed with the wire extractor, the positioner is moved to the right working area by the positioner ground rail, and the position is changed by the positioner to the workstation ⑤, and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench to loosen the screw equipped with the wire extractor; the loosened screw is changed by the positioner to the workstation ③, and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly;

[0067] S6. The positioner is moved to the workstation ⑦ via the positioner ground rail, and the screws that have not been disassembled are drilled out one by one using a radial drilling machine.

[0068] Preferably, in the above two semi-automatic valve disassembly methods, after all the screws are disassembled, the valve stem in the valve is disassembled by clamping the valve stem disassembly tooling with the clamping part of the truss robot, and then the valve core in the valve is disassembled by quickly changing the clamping valve core disassembly jaws on the clamping part of the truss robot.

[0069] Preferably, in the above two semi-automatic valve disassembly methods, the method of using an electric impact wrench to fasten a nut to the screw includes using a long sleeve to fasten the nut, cutting a flat end to the screw, or welding a nut to the screw.

[0070] Preferably, in the above two semi-automatic valve disassembly methods, the method of loosening the screw with a nut on the back using a high-torque electric wrench includes using a high-torque electric wrench with an offset head, a hydraulic wrench plus a ring, or designing a split sleeve.

[0071] In the fully automated valve disassembly method, the working area of ​​the first power manipulator in the valve automated disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the first industrial robot is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦;

[0072] Clamp the upper valve body disassembly tooling on the truss robot, use the truss robot and the upper valve body disassembly tooling to transfer the valve to be disassembled from the ground rail robot to the positioner, and clamp the valve to be disassembled on the rotary workbench of the positioner, and transfer the valve to be disassembled to each workstation by the rotary workbench;

[0073] The fully automated valve disassembly method comprises the following steps:

[0074] S1. At workstation ⑥, use the six-degree-of-freedom mechanical arm on the first industrial robot to install an electric wrench with an offset head to quickly disassemble the nut and screw;

[0075] S2. Clamp the upper valve body with the disassembly tooling by the truss robot to disassemble and remove the upper valve body;

[0076] S3. Remove the valve stem by using the truss robot quick-change clamp and valve stem disassembly tooling;

[0077] S4. Use the positioner to change the position to workstation ②, and use the six-degree-of-freedom mechanical arm on the second industrial robot to clamp the valve core and remove the valve core from the lower valve body.

[0078] Compared with the prior art, the present invention proposes a valve disassembly production line based on a power manipulator, an industrial robot, a positioner, a radial drilling machine, a truss robot, a ground rail robot, and ground rail equipment, which can realize both semi-automatic and fully automated. The valve to be disassembled is clamped on a positioner that can move on the ground rail of the positioner. With the positioner as the center, two industrial robots and a truss robot are used to clamp special disassembly tooling (tooling for upper valve body disassembly and tooling for valve stem disassembly) to realize the automatic disassembly of valves with a relatively light degree of rust / corrosion; the truss robot, the radial drilling machine, the power manipulator, and the industrial robot are used to clamp the corresponding special disassembly tooling to realize the automatic disassembly of valves with a severe degree of rust / corrosion. The method of the present invention is an automated, efficient, safe and reliable disassembly method for coal chemical valve parts (nuts, screws, valve cores, valve stems, valve bodies).

[0079] The manual working area of ​​the present invention is separated from the working area of ​​the radial drilling machine and the industrial robot, which reduces the danger of human-machine collaboration; the disassembly tools are clamped on the power manipulator and the industrial robot, which reduces the labor intensity and danger of manual disassembly. The present invention also integrates the overall disassembly system control, improves the disassembly efficiency, solves the problem of low efficiency, high risk and low automation level disassembly of coal chemical valves, and provides key technology and equipment support for valve remanufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0080] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying creative work.

[0081] Figure 1 The figure is a schematic diagram of the overall structure of an automatic valve disassembly system of the present invention.

[0082] Figure 2 It is a schematic diagram of the cooperation between the floor rail robot and the floor rail for transporting valves in the present invention.

[0083] Figure 3 It is a schematic diagram of the truss robot of the present invention and the corresponding special disassembly tooling that can cooperate with it.

[0084] Figure 4 It is a schematic diagram of the coordination between the positioner and the ground rail for the positioner in the present invention.

[0085] Figure 5 It is a schematic diagram of the industrial robot of the present invention and the corresponding special disassembly tooling that can cooperate with it.

[0086] Figure 6 It is a schematic diagram of the power-assisting manipulator in the present invention and the corresponding special disassembly tooling that can cooperate with it.

[0087] Figure 7 Schematic diagram of the workstations in the semi-automatic valve disassembly method.

[0088] Figure 8 This is a schematic diagram of the workstations in the fully automated valve disassembly method.

[0089] In the figure: 1-ground rail robot, 2-truss robot, 3-positioner, 4-radial drilling machine, 5-first industrial robot, 6-second industrial robot, 7-first power-assisted manipulator, 8-second power-assisted manipulator, 9-third power-assisted manipulator, 10-fourth power-assisted manipulator, 11-fifth power-assisted manipulator, 12-ground rail for carrying valves, 13-ground rail for positioner, 14-hydraulic chuck, 15-telescopic pallet, 16-tool for valve stem disassembly, 17-tool for upper valve body disassembly, 18-electric wrench with offset head, 19-pneumatic clamp toe, 20-electromagnetic induction heating head, 21-valve core disassembly jaws, 22-impact hammer, 23-nut splitter, 24-cutting machine, 25-high torque electric wrench, 26-electric impact wrench, 27-support frame, 28-X-axis motion mechanism, 29-Y-axis motion mechanism, 30-Z-axis motion mechanism, 31-clamping part. DETAILED DESCRIPTION

[0090] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0091] In the description of the present invention, it is necessary to understand that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0092] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0093] Example:

[0094] See also Figure 1-Figure 6 The present invention provides a valve automatic disassembly system, comprising:

[0095] The ground rail robot 1 is installed on the ground rail 12 for transporting valves and can move horizontally along the axis of the ground rail 12 for transporting valves, so as to transport valves and their components;

[0096] The truss robot 2 includes a support frame 27, two X-axis motion mechanisms 28 spaced apart on the support frame 27, a Y-axis motion mechanism 29 slidably connected between the two X-axis motion mechanisms 28, and a Z-axis motion mechanism 30 that can slide along the Y-axis. The Z-axis motion mechanism 30 is provided with a clamping portion 31 and drives the clamping portion 31 to reciprocate along the Z-axis direction. The clamping portion 31 can clamp a valve stem disassembly tool 16 or an upper valve body disassembly tool 17. Workers will replace the valve stem disassembly tool 16, the upper valve body disassembly tool 17, and the valve core disassembly jaw 21 on the clamping portion 31 as needed; wherein, the upper valve body disassembly tool 17 specifically adopts an internal support type clamp;

[0097] The positioner 3 is installed on the positioner ground rail 13 and can move horizontally along the axis of the positioner ground rail 13; the positioner 3 includes a rotating workbench for clamping the valve to be disassembled, and the rotating workbench drives the valve to be disassembled to rotate to the corresponding working area; the clamping part 31 on the truss robot 2 can use the upper valve body disassembly tool 17 to place the valve and its parts on the ground rail robot 1 on the positioner 3;

[0098] The radial drilling machine 4 is arranged outside the positioner. The drill bit on the radial drilling machine 4 is used to process a bottom hole for a wire extractor on the screw rod and to directly drill out the screw rod that has not been removed.

[0099] The industrial robot comprises a first industrial robot 5 and a second industrial robot 6 respectively arranged on both sides of the positioner. The first industrial robot 5 and the second industrial robot 6 are both equipped with a six-degree-of-freedom mechanical arm. The quick-change fixture head installed on the six-degree-of-freedom mechanical arm can be equipped with any one of an electric wrench 18 with an offset head, a pneumatic clamp toe 19, and an electromagnetic induction heating head 20. The valve core disassembly jaw 21 can be clamped on the quick-change fixture head or the clamping part 31 of the truss robot 2. The worker will replace the electric wrench 18 with an offset head, the pneumatic clamp toe 19, the electromagnetic induction heating head 20, and the valve core disassembly jaw 21 on the quick-change fixture head according to the needs.

[0100] There are five power-assisting manipulators, which are arranged on both sides of the positioner. Among them, the first power-assisting manipulator 7, the second power-assisting manipulator 8 and the second industrial robot 6 are located on the same side, and the third power-assisting manipulator 9, the fourth power-assisting manipulator 10, and the fifth power-assisting manipulator 11 are located on the same side as the first industrial robot 5; the quick-change clamp head 2 installed on the power-assisting manipulator can clamp any one of the impact hammer 22, nut cutter 23, cutter 24, high-torque electric wrench 25, and electric impact wrench 26. Workers will replace the impact hammer 22, nut cutter 23, cutter 24, high-torque electric wrench 25, and electric impact wrench 26 on the quick-change clamp head 2 according to their needs.

[0101] A telescopic tray 15 for placing valves and their components is provided on the ground rail robot 1. A hydraulic chuck 14 for clamping the valve to be disassembled is provided on the rotary workbench of the positioner 3.

[0102] The specific positions of the mechanisms in this embodiment are arranged as follows: the first power-assist manipulator 7, the second industrial robot 6, and the second power-assist manipulator 8 are arranged in sequence along the extension direction of the positioner ground rail, and the first power-assist manipulator 7 is closest to the radial drilling machine 4; the fifth power-assist manipulator 11, the fourth power-assist manipulator 10, and the third power-assist manipulator 9 are also arranged in sequence along the extension direction of the positioner ground rail, and the fifth power-assist manipulator 11 is closest to the radial drilling machine 4, and the fifth power-assist manipulator 11 is installed adjacent to the first industrial robot 5 on the side facing the positioner ground rail 13.

[0103] In a further specific embodiment, two positioners 3 may be arranged on the positioner ground rail 13 along its axial direction, wherein the first positioner 3 close to the radial drilling machine 4 is used to dismantle valves with a relatively light degree of corrosion, and the second positioner 3 is used to dismantle valves with a relatively heavy degree of corrosion. Alternatively, the two positioners 3 may work together at the same time, and after the first positioner 3 dismantles the part of the valve that is easy to dismantle, the truss robot 2 is used to transfer the remaining part of the valve to the second positioner 3 for further dismantling, so as to improve the dismantling efficiency of the valve.

[0104] In a further specific embodiment, the high-torque electric wrench 25 and the electric impact wrench 26 clamped on the power-assist manipulator can be replaced with a high-torque electric wrench with an offset head and an electric impact wrench with an offset head, respectively, according to actual needs.

[0105] The electromagnetic induction heating head 20 installed on the industrial robot is used to heat the nuts and screws that are difficult to remove due to rust, and destroy the rust layer structure based on the principle of thermal expansion and contraction to facilitate disassembly.

[0106] For screws that are difficult to disassemble, a wire extractor is required for disassembly. Since the wire extractor is a reverse wire structure, when using it, it is necessary to first use a radial drilling machine 4 to drill a bottom hole for the wire extractor on the screw, and use a pneumatic clamp 19 in conjunction with an impact hammer 22 to drive the wire extractor into the bottom hole for the wire extractor. This process requires cutting off the screw protruding from the valve body first, so a cutting machine 24 is required.

[0107] The present invention also applies the above-mentioned valve automatic disassembly system to provide a valve automatic disassembly method, which specifically includes a semi-automatic valve disassembly method and a fully-automatic valve disassembly method, wherein the fully-automatic valve disassembly method is suitable for valves with very light corrosion.

[0108] In one of the semi-automatic valve removal methods, such as Figure 7As shown, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the fifth power manipulator is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦;

[0109] The valve body disassembly tool 17 is clamped on the truss robot 2, and the valve to be disassembled is transferred from the ground rail robot 1 to the positioner 3 by the truss robot 2 and the valve body disassembly tool 17, and the valve to be disassembled is clamped on the rotary table of the positioner 3, and the valve to be disassembled is transferred to each station by the rotary table;

[0110] The semi-automatic valve disassembly method has the following steps for disassembling a single valve:

[0111] (III) For valves with no or slight corrosion, most of the nuts and screws are easy to remove and can be directly and quickly disassembled

[0112] S1, at workstation ⑥, use the fifth power-assisted manipulator 11 to clamp the electric impact wrench 26 to quickly disassemble the nut;

[0113] S2. After the nut is disassembled, the position is changed to the workstation ① by the positioner, and the upper and lower valve bodies are disassembled by clamping the impact hammer 22 with the first power-assisting manipulator 7, and the upper valve body is removed by the truss robot 2 with the quick-change clamping tool 17 for disassembling the upper valve body;

[0114] S3, changing the position to the workstation ⑥ by means of the positioner, and using the electric impact wrench 26 on the fifth power manipulator 11 to add a nut to the screw;

[0115] S4, the screw with the nut on it is transferred to the workstation ⑤ by the positioner, and the electric impact wrench 26 is clamped by the fourth power manipulator 10 for quick disassembly;

[0116] (IV) Nut disassembly for severe corrosion of valves, where most nuts and screws are difficult to disassemble:

[0117] S1, at workstation ⑤, use the fourth power-assisted manipulator 10 to clamp the high-torque electric wrench 25 to loosen the nut, and the loosened nut is transferred to workstation ⑥ by the positioner to use the fifth power-assisted manipulator 11 to clamp the electric impact wrench 26 for quick disassembly;

[0118] S2, the remaining unloosened nuts are heated by clamping the electromagnetic induction heating head 20 with the six-degree-of-freedom manipulator on the second industrial robot 6 at station ②; the heated nuts are transferred to station ⑤ by the fourth power-assisted manipulator 10 to loosen them by clamping the large-torque electric wrench 25; the loosened nuts are transferred to station ⑥ by the fifth power-assisted manipulator 11 to clamp the electric impact wrench 26 for quick disassembly;

[0119] S3, the remaining unscrewed nuts are directly transferred to the workstation ① through the positioner 3, and the nut cutter 23 is clamped and cut by the first power manipulator 7;

[0120] Disassembly of the upper valve body: After the nuts are disassembled, the upper and lower valve bodies are disassembled by using the first power-assisted manipulator 7 quick-change clamping impact hammer 22 at station ①, and the upper valve body is removed by using the truss robot 2 quick-change clamping upper valve body disassembly tool 17;

[0121] Screw disassembly:

[0122] S1. At workstation ⑥, use the fifth power-assisting manipulator 11 to clamp the electric impact wrench 26 to put the nut on the screw; the screw with the nut is transferred to workstation ⑤ by the positioner, and the fourth power-assisting manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen it; the loosened screw is transferred to workstation ⑥ by the positioner, and the fifth power-assisting manipulator 11 is used to clamp the electric impact wrench 26 for quick disassembly;

[0123] S2. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot 6 is used to clamp the electromagnetic induction heating head 20 at station ② to heat the screw; the heated screw is transferred to station ⑤ by the positioner and the fourth power-assisted robot 10 is used to clamp the high-torque electric wrench 25 for loosening; the loosened screw is transferred to station ⑥ by the positioner and the fifth power-assisted robot 11 is used to clamp the electric impact wrench 26 for quick disassembly;

[0124] S3. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the remaining screws are cut by the fifth power-assisted manipulator 11 with a quick-change cutting machine 24; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine 4; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer 22 on the first power-assisted manipulator 7 and the six-degree-of-freedom mechanical arm clamping pneumatic clamping toe 19 on the second industrial robot 6; the position is changed to station ⑤ by the positioner, and the fourth power-assisted manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ⑥ by the positioner, and the fifth power-assisted manipulator 11 is used to quickly clamp the electric impact wrench 26 for quick disassembly;

[0125] S4, the screws that have not been disassembled are finally transferred to the workstation ⑦ by the positioner and drilled out in sequence by the radial drilling machine 4;

[0126] (III) For the situation where the nut and screw in the valve cannot be disassembled and need to be cut directly

[0127] S1, at workstation ①, use the first power-assisting manipulator 7 to clamp the nut cutter 23 and cut the nuts in sequence;

[0128] S2. After the nut is disassembled, the upper and lower valve bodies are disassembled by using the first power-assisted manipulator 7 quick-change clamping impact hammer 22 at workstation ①, and the upper valve body is removed by using the truss robot 2 quick-change clamping upper valve body disassembly tool 17;

[0129] S3, the position of the screw rod is changed to the work position ⑥ by the positioner, and the fifth power-assisting manipulator 11 is used to clamp the electric impact wrench 26 to put the nut on the screw rod; the screw rod with the nut is changed to the work position ⑤ by the positioner, and the fourth power-assisting manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen it; the loosened screw rod is changed to the work position ⑥ by the positioner, and the fifth power-assisting manipulator 11 is used to clamp the electric impact wrench 26 for quick disassembly;

[0130] S4. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot 6 is used to clamp the electromagnetic induction heating head 20 at station ② to heat the screw; the heated screw is transferred to station ⑤ by the positioner and the fourth power-assisted robot 10 is used to clamp the high-torque electric wrench 25 for loosening; the loosened screw is transferred to station ⑥ by the positioner and the fifth power-assisted robot 11 is used to clamp the electric impact wrench 26 for quick disassembly;

[0131] S5. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the fifth power-assisted manipulator 11 is used to quickly change the cutting machine 24 to cut the remaining screws; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine 4; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer 22 on the first power-assisted manipulator 7 and the six-degree-of-freedom manipulator arm clamping pneumatic clamping toe 19 on the second industrial robot 6; the position is changed to station ⑤ by the positioner, and the fourth power-assisted manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ⑥ by the positioner, and the fifth power-assisted manipulator 11 is used to clamp the electric impact wrench 26 for quick disassembly;

[0132] S6. The screws that have not been disassembled are finally transferred to the workstation ⑦ by the positioner and drilled out in sequence by the radial drilling machine 4.

[0133] In another semi-automatic valve removal method, such as Figure 7As shown, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the fifth power manipulator is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦; the middle of station ①, station ②, station ⑤, and station ⑥ corresponds to the left working area, and the middle of station ②, station ③, station ④, and station ⑤ corresponds to the right working area;

[0134] The valve body disassembly tool 17 is clamped on the truss robot 2, and the valve to be disassembled is transferred from the ground rail robot 1 to the positioner 3 by the truss robot 2 and the valve body disassembly tool 17, and the valve to be disassembled is clamped on the rotary table of the positioner 3, and the valve to be disassembled is transferred to each station by the rotary table;

[0135] The semi-automatic valve disassembly method has the following steps for disassembling a single valve:

[0136] (III) For valves with no or slight corrosion, most of the nuts and screws are easy to remove and can be directly and quickly disassembled

[0137] S1, at workstation ⑥, use the fifth power-assisted manipulator 11 to clamp the electric impact wrench 26 to quickly disassemble the nut;

[0138] S2. After the nut is disassembled, the position is changed to the workstation ① by the positioner, and the upper and lower valve bodies are disassembled by clamping the impact hammer 22 with the first power-assisting manipulator 7, and the upper valve body is removed by the truss robot 2 with the quick-change clamping tool 17 for disassembling the upper valve body;

[0139] S3. After the upper valve body is disassembled, the positioner 3 is transferred to the workstation ③ through the positioner ground rail 13; at the workstation ③, the second power manipulator 8 is used to clamp the electric impact wrench 26 to back the nut of the screw;

[0140] S4, the screw with the nut on it is transferred to the workstation ④ by the positioner, and the electric impact wrench 26 is clamped by the third power manipulator 9 for rapid disassembly;

[0141] (ii) For the situation where the valve is severely corroded and most of the nuts and screws are difficult to remove

[0142] Nut disassembly:

[0143] S1, at workstation ⑤, use the fourth power-assisted manipulator 10 to clamp the high-torque electric wrench 25 to loosen the nut, and the loosened nut is transferred to workstation ③ by the positioner to use the second power-assisted manipulator 8 to clamp the electric impact wrench 26 for quick disassembly;

[0144] S2, the remaining unloosened nuts are heated by clamping the electromagnetic induction heating head 20 with the six-degree-of-freedom manipulator on the second industrial robot 6 at station ②; the heated nuts are transferred to station ⑤ by the fourth power-assisted manipulator 10 to loosen them by clamping the high-torque electric wrench 25; the loosened nuts are transferred to station ③ by the second power-assisted manipulator 8 to clamp the electric impact wrench 26 for quick disassembly;

[0145] S3, the remaining unscrewed nuts are directly transferred to the workstation ④ by the positioner 3, and the nut cutter 23 is clamped and cut by the third power manipulator 9;

[0146] Disassembly of the upper valve body: After the nut is disassembled, the positioner 3 is transferred to the workstation ① through the positioner ground rail 13; at the workstation ①, the first power manipulator 7 is used to clamp the impact hammer 22 to disassemble the upper and lower valve bodies, and the upper valve body is removed by the truss robot 2 with a quick-change clamping tool 17 for disassembly of the upper valve body;

[0147] Screw disassembly:

[0148] S1. After the upper valve body is disassembled, the positioner 3 is transferred to the workstation ③ through the positioner ground rail 13; at workstation ③, the second power-assisting manipulator 8 is used to clamp the electric impact wrench 26 to put the nut on the screw; the screw with the nut is transferred to the workstation ⑤ by the positioner and the fourth power-assisting manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen it; the loosened screw is transferred to the workstation ③ by the positioner and the second power-assisting manipulator 8 is used to clamp the electric impact wrench 26 for quick disassembly;

[0149] S2. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot 6 is used to clamp the electromagnetic induction heating head 20 at the workstation ② to heat the screw; the heated screw is transferred to the workstation ⑤ by the positioner and the fourth power-assisted robot 10 is used to clamp the high-torque electric wrench 25 for loosening; the loosened screw is transferred to the workstation ③ by the positioner and the second power-assisted robot 8 is used to clamp the electric impact wrench 26 for quick disassembly;

[0150] S3. For the screws that still cannot be disassembled, the positioner 3 is transferred to the workstation ⑥ through the positioner ground rail 13, and the fifth power-assisted manipulator 11 is used to quickly change the cutting machine 24 to cut the remaining screws; the cut screw is transferred to the workstation ⑦ through the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine 4; the screw with the drilled bottom hole is transferred to between the workstation ① and the workstation ② through the positioner, and the wire extractor is driven into the bottom hole for the wire extractor through the impact hammer 22 on the first power-assisted manipulator 7 and the pneumatic clamping toe 19 on the second industrial robot 6; the positioner 3 is moved to the right working area through the positioner ground rail 13, and the position is transferred to the workstation ⑤ through the positioner, and the fourth power-assisted manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen the screw equipped with the wire extractor; the loosened screw is transferred to the workstation ③ through the positioner, and the electric impact wrench 26 is clamped by the second power-assisted manipulator 8 for quick disassembly;

[0151] S4, the positioner 3 is moved to the workstation ⑦ via the positioner ground rail 13, and the screws that have not been disassembled are drilled out one by one by the radial drilling machine 4;

[0152] (III) For the situation where the nut and screw in the valve cannot be disassembled and need to be cut directly

[0153] S1, at station ④, use the third power-assisted manipulator 9 to clamp the nut cutter 23 to cut the nuts in sequence;

[0154] S2. After the nut is disassembled, the positioner 3 is transferred to the workstation ① through the positioner ground rail 13. At the workstation ①, the first power manipulator 7 is used to quickly change and clamp the impact hammer 22 to disassemble the upper and lower valve bodies, and the truss robot 2 is used to quickly change and clamp the upper valve body disassembly tool 17 to remove the upper valve body;

[0155] S3. After the upper valve body is disassembled, the positioner 3 is transferred to the workstation ③ through the positioner ground rail 13; at the workstation ③, the second power-assisting manipulator 8 is used to clamp the electric impact wrench 26 to put the nut on the screw; the screw with the nut is transferred to the workstation ⑤ through the positioner to loosen it with a large torque electric wrench 25; the loosened screw is transferred to the workstation ③ through the positioner to clamp the electric impact wrench 26 with the second power-assisting manipulator 8 for quick disassembly;

[0156] S4. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot 6 is used to clamp the electromagnetic induction heating head 20 at station ② to heat the screw; the heated screw is transferred to station ⑤ by the positioner and the fourth power-assisted manipulator 10 is used to clamp the large-torque electric wrench 25 for loosening; the loosened screw is transferred to station ③ by the positioner and the second power-assisted manipulator 8 is used to clamp the electric impact wrench 26 for quick disassembly;

[0157] S5. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the fifth power-assisted manipulator 11 is used to clamp the cutting machine 24 to cut the remaining screws; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine 4; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer 22 on the first power-assisted manipulator 7 and the pneumatic clamp 19 on the six-degree-of-freedom manipulator 6; after all the undisassembled screws are installed with the wire extractor, the positioner 3 is moved to the right working area by the positioner ground rail 13, and the position is changed to station ⑤ by the positioner, and the fourth power-assisted manipulator 10 is used to clamp the high-torque electric wrench 25 to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ③ by the positioner, and the electric impact wrench 26 is clamped by the second power-assisted manipulator 8 for quick disassembly;

[0158] S6, the positioner 3 is moved to the workstation ⑦ via the positioner ground rail 13, and the screws that have not been disassembled are drilled out one by one by the radial drilling machine 4.

[0159] In the above two semi-automatic valve disassembly methods, after all the screws are disassembled, the clamping part 31 of the truss robot 2 clamps the valve stem disassembly tool 16 to disassemble the valve stem in the valve, and then the valve core disassembly clamping jaws 21 are quickly replaced on the clamping part 31 of the truss robot 2 to disassemble the valve core in the valve.

[0160] In the above two semi-automatic valve disassembly methods, the method of using the electric impact wrench 26 to back the nut on the screw includes using a long sleeve back nut, cutting a flat end on the screw or welding a nut on the screw, among which the method of using a long sleeve back nut is preferred.

[0161] In the above two semi-automatic valve disassembly methods, the method of using a high-torque electric wrench 25 to loosen the screw with a nut on the back includes using a high-torque electric wrench with an offset head, a hydraulic wrench plus a ring, or designing a split sleeve. Among them, it is preferred to use a high-torque electric wrench with an offset head.

[0162] In the fully automated valve disassembly method, Figure 8 As shown, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the first industrial robot is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦;

[0163] The valve body disassembly tool 17 is clamped on the truss robot 2, and the valve to be disassembled is transferred from the ground rail robot 1 to the positioner 3 by the truss robot 2 and the valve body disassembly tool 17, and the valve to be disassembled is clamped on the rotary table of the positioner 3, and the valve to be disassembled is transferred to each station by the rotary table;

[0164] The fully automated valve disassembly method comprises the following steps:

[0165] S1, at workstation ⑥, use the six-degree-of-freedom mechanical arm on the first industrial robot 5 to install an electric wrench 18 with an offset head to quickly disassemble the nut and the screw;

[0166] S2, using the truss robot 2 to clamp the upper valve body disassembly tool 17 to disassemble and remove the upper valve body;

[0167] S3, remove the valve stem by using the truss robot 2 to quickly change the valve stem disassembly tool 16;

[0168] S4, the position is changed to the workstation ② by the positioner, and the valve core is taken out from the lower valve body by using the six-degree-of-freedom mechanical arm of the second industrial robot 6 to clamp the valve core disassembly jaws 21.

[0169] The present invention provides an automatic valve disassembly system and method to solve the problem that the prior art cannot disassemble coal chemical valves automatically, save time and effort, and the system and method can be applied to valves of different specifications.

[0170] In this specification, each embodiment is described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the embodiments can be referred to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the method part.

[0171] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A valve automatic disassembly system, characterized in that: include: A ground rail robot, which is installed on the ground rail for transporting valves and can move horizontally along the axis of the ground rail for transporting valves, and is used to transport valves and their components; The truss robot comprises a support frame, two X-axis motion mechanisms spaced apart on the support frame, a Y-axis motion mechanism slidably connected between the two X-axis motion mechanisms, and a Z-axis motion mechanism that can slide along the Y-axis, wherein a clamping portion is provided on the Z-axis motion mechanism and drives the clamping portion to reciprocate along the Z-axis direction, and the clamping portion can clamp a tool for disassembling a valve stem or a tool for disassembling an upper valve body; The positioner is installed on the ground rail for the positioner and can move horizontally along the axis of the ground rail for the positioner; the positioner includes a rotary table for clamping the valve to be disassembled, and the rotary table drives the valve to be disassembled to rotate to the corresponding working area; the clamping part on the truss robot can use the upper valve body disassembly tooling to place the valve and its parts on the ground rail robot on the positioner; The radial drilling machine is located outside the positioner. The drill bit on the radial drilling machine is used to machine a bottom hole for a wire extractor on the screw and to directly drill out the screw that has not been removed; The industrial robot comprises a first industrial robot and a second industrial robot respectively arranged on both sides of the positioner, the first industrial robot and the second industrial robot are both equipped with a six-degree-of-freedom mechanical arm, the quick-change fixture head installed on the six-degree-of-freedom mechanical arm can be equipped with any one of an electric wrench with an offset head, a pneumatic clamp toe, and an electromagnetic induction heating head; the valve core removal clamp can be clamped on the quick-change fixture head or on the clamping part of the truss robot; There are five power-assisted manipulators, which are arranged on both sides of the positioner. Among them, the first power-assisted manipulator, the second power-assisted manipulator and the second industrial robot are located on the same side, and the third power-assisted manipulator, the fourth power-assisted manipulator and the fifth power-assisted manipulator and the first industrial robot are located on the same side; the quick-change clamp head 2 installed on the power-assisted manipulator can clamp any one of the impact hammer, nut cutter, cutting machine, high-torque electric wrench and electric impact wrench.

2. The valve automatic disassembly system according to claim 1, characterized in that: The ground rail robot is provided with a telescopic tray for placing valves and their components; and / or, the rotary workbench of the positioner is provided with a hydraulic chuck for clamping the valve to be disassembled.

3. The valve automatic disassembly system according to claim 1, characterized in that: The first power-assist manipulator, the second industrial robot and the second power-assist manipulator are arranged sequentially along the extension direction of the positioner ground rail, and the first power-assist manipulator is closest to the radial drilling machine; the fifth power-assist manipulator, the fourth power-assist manipulator and the third power-assist manipulator are also arranged sequentially along the extension direction of the positioner ground rail, and the fifth power-assist manipulator is closest to the radial drilling machine, and the fifth power-assist manipulator is installed close to the first industrial robot on the side facing the positioner ground rail.

4. A valve automated disassembly method, characterized in that: The valve automated disassembly system according to any one of claims 1 to 3 includes a semi-automated valve disassembly method and a fully automated valve disassembly method, wherein the fully automated valve disassembly method is suitable for valves with a very light degree of rust.

5. The method for automatic valve disassembly according to claim 4, characterized in that: In the first semi-automatic valve disassembly method, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the fifth power manipulator is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦; Clamp the upper valve body disassembly tooling on the truss robot, use the truss robot and the upper valve body disassembly tooling to transfer the valve to be disassembled from the ground rail robot to the positioner, and clamp the valve to be disassembled on the rotary workbench of the positioner, and transfer the valve to be disassembled to each workstation by the rotary workbench; The semi-automatic valve disassembly method has the following steps for disassembling a single valve: (I) For valves with no or slight corrosion, where most nuts and screws are easy to remove S1. Use the fifth power-assisted manipulator to clamp the electric impact wrench at workstation ⑥ to quickly disassemble the nut; S2. After the nut is disassembled, the position is changed to the workstation ① through the positioner. The upper and lower valve bodies are disassembled by using the first power-assisted manipulator to clamp the impact hammer, and the upper valve body is removed by the truss robot quick-change clamping tooling for the upper valve body disassembly; S3, change the position to the workstation ⑥ through the positioner, and use the electric impact wrench on the fifth power manipulator to add nuts to the screw; S4. The screw with the nut on it is transferred to the workstation through the positioner ⑤ and the electric impact wrench is clamped by the fourth power manipulator for quick disassembly; (ii) For the situation where the valve is severely corroded and most of the nuts and screws are difficult to remove Nut disassembly: S1. At workstation ⑤, use the fourth power-assisted manipulator to clamp a high-torque electric wrench to loosen the nut. The loosened nut is transferred to workstation ⑥ by a positioner and clamped with an electric impact wrench for quick disassembly by the fifth power-assisted manipulator; S2. The remaining unloosened nuts are heated at station ② by using the six-degree-of-freedom manipulator on the second industrial robot to clamp the electromagnetic induction heating head; the heated nuts are transferred to station ⑤ by the positioner to clamp the high-torque electric wrench by the fourth power-assisted manipulator to loosen them; the loosened nuts are transferred to station ⑥ by the positioner to clamp the electric impact wrench by the fifth power-assisted manipulator for quick disassembly; S3. The remaining unscrewed nuts are directly transferred to the workstation ① through the positioner, and the nut cutter is clamped and cut by the first power manipulator; Disassembly of upper valve body: After the nut is disassembled, the upper and lower valve bodies are disassembled at workstation ① using the first power-assisted manipulator quick-change clamping impact hammer, and the upper valve body is removed by the truss robot quick-change clamping upper valve body disassembly tooling; Screw disassembly: S1. At workstation ⑥, use the fifth power-assisting manipulator to clamp an electric impact wrench to put a nut on the screw; the screw with the nut is transferred to workstation ⑤ by a positioner and then clamped with a high-torque electric wrench by the fourth power-assisting manipulator for loosening; the loosened screw is transferred to workstation ⑥ by a positioner and then clamped with an electric impact wrench by the fifth power-assisting manipulator for quick disassembly; S2. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted robot is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ⑥ by the positioner and the fifth power-assisted robot is used to clamp the electric impact wrench for quick disassembly; S3. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the remaining screws are cut by the fifth power-assisted manipulator quick-change cutting machine; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamping toe on the six-degree-of-freedom manipulator on the second industrial robot; the position is changed to station ⑤ by the positioner, and the high-torque electric wrench is clamped by the fourth power-assisted manipulator to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ⑥ by the positioner, and the electric impact wrench is clamped by the fifth power-assisted manipulator for quick disassembly; S4. The screws that have not been disassembled are finally transferred to the workstation ⑦ by the positioner and drilled out in sequence by the radial drilling machine; (III) For the situation where the nut and screw in the valve cannot be disassembled and need to be cut directly S1, at workstation ①, use the first power-assisted manipulator to clamp the nut cutter and cut the nuts in sequence; S2. After the nuts are disassembled, use the first power-assisted manipulator quick-change clamping impact hammer to disassemble the upper and lower valve bodies at workstation ①, and remove the upper valve body through the truss robot quick-change clamping tooling for upper valve body disassembly; S3, the position is changed by the positioner to the workstation ⑥, and the fifth power-assisting manipulator is used to clamp the electric impact wrench to put the nut on the screw; the screw with the nut is changed by the positioner to the workstation ⑤, and the fourth power-assisting manipulator is used to clamp the high-torque electric wrench to loosen it; the loosened screw is changed by the positioner to the workstation ⑥, and the fifth power-assisting manipulator is used to clamp the electric impact wrench for quick disassembly; S4. For the screw that still cannot be disassembled, the six-degree-of-freedom robot arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted robot is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ⑥ by the positioner and the fifth power-assisted robot is used to clamp the electric impact wrench for quick disassembly; S5. For the screws that still cannot be disassembled, the position is changed to station ⑥ by the positioner, and the remaining screws are cut by the fifth power-assisted manipulator quick-change cutting machine; the cut screw is changed to station ⑦ by the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is changed to between stations ① and ② by the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamp toe on the six-degree-of-freedom manipulator on the second industrial robot; the position is changed to station ⑤ by the positioner, and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench to loosen the screw equipped with the wire extractor; the loosened screw is changed to station ⑥ by the positioner, and the fifth power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly; S6. The screws that have not been disassembled are finally transferred to the workstation ⑦ by the positioner and drilled out one by one by the radial drilling machine.

6. The method for automatic valve disassembly according to claim 4, characterized in that: In the second semi-automatic valve disassembly method, the working area of ​​the first power manipulator in the valve automatic disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the fifth power manipulator is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦; the middle of station ①, station ②, station ⑤, and station ⑥ corresponds to the left working area, and the middle of station ②, station ③, station ④, and station ⑤ corresponds to the right working area; Clamp the upper valve body disassembly tooling on the truss robot, use the truss robot and the upper valve body disassembly tooling to transfer the valve to be disassembled from the ground rail robot to the positioner, and clamp the valve to be disassembled on the rotary workbench of the positioner, and transfer the valve to be disassembled to each workstation by the rotary workbench; The semi-automatic valve disassembly method has the following steps for disassembling a single valve: (I) For valves with no or slight corrosion, where most nuts and screws are easy to remove S1. Use the fifth power-assisted manipulator to clamp the electric impact wrench at workstation ⑥ to quickly disassemble the nut; S2. After the nut is disassembled, the position is changed to the workstation ① through the positioner. The upper and lower valve bodies are disassembled by using the first power-assisted manipulator to clamp the impact hammer, and the upper valve body is removed by the truss robot quick-change clamping tooling for the upper valve body disassembly; S3. After disassembling the upper valve body, transfer the positioner to station ③ through the positioner ground rail; at station ③, use the second power manipulator to clamp the electric impact wrench to back the nut on the screw; S4. The screw with the nut on it is transferred to the workstation ④ by the positioner, and the electric impact wrench is clamped by the third power manipulator for quick disassembly; (ii) For the situation where the valve is severely corroded and most of the nuts and screws are difficult to remove Nut disassembly: S1, at station ⑤, use the fourth power-assisted manipulator to clamp a high-torque electric wrench to loosen the nut, and the loosened nut is transferred to station ③ by a positioner to use the second power-assisted manipulator to clamp an electric impact wrench for quick disassembly; S2. The remaining unloosened nuts are heated by the electromagnetic induction heating head clamped by the six-degree-of-freedom manipulator on the second industrial robot at station ②; the heated nuts are transferred to station ⑤ by the fourth power-assisted manipulator to loosen them by clamping a high-torque electric wrench; the loosened nuts are transferred to station ③ by the positioner to clamp an electric impact wrench by the second power-assisted manipulator for quick disassembly; S3. The remaining unscrewed nuts are directly transferred to the workstation ④ through the positioner, and the nut cutter is clamped and cut by the third power manipulator; Disassembly of upper valve body: After the nut is disassembled, the positioner is transferred to the workstation ① through the positioner ground rail; at workstation ①, the upper and lower valve bodies are disassembled by clamping the impact hammer with the first power-assisted manipulator, and the upper valve body is removed by the truss robot quick-change clamping tooling for disassembly of the upper valve body; Screw disassembly: S1. After the upper valve body is disassembled, the positioner is transferred to station ③ through the positioner ground rail; at station ③, the second power-assisting manipulator is used to clamp the electric impact wrench to put the nut on the screw; the screw with the nut is transferred to station ⑤ by the positioner and the fourth power-assisting manipulator is used to clamp the high-torque electric wrench to loosen it; the loosened screw is transferred to station ③ by the positioner and the second power-assisting manipulator is used to clamp the electric impact wrench for quick disassembly; S2. For the screw that still cannot be disassembled, the six-degree-of-freedom mechanical arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ③ by the positioner and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly; S3. For the screws that still cannot be disassembled, the positioner is transferred to station ⑥ through the positioner ground rail, and the remaining screws are cut by the fifth power-assisted manipulator quick-change cutting machine; the cut screw is transferred to station ⑦ through the positioner, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is transferred to between stations ① and ② through the positioner, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamp toe on the six-degree-of-freedom manipulator on the second industrial robot; the positioner is moved to the right working area through the positioner ground rail, and the position is transferred to station ⑤ through the positioner, and the fourth power-assisted manipulator is used to clamp a large-torque electric wrench to loosen the screw equipped with the wire extractor; the loosened screw is transferred to station ③ through the positioner, and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly; S4, the positioner is moved to the workstation ⑦ through the positioner ground rail, and the screws that have not been disassembled are drilled out one by one using a radial drilling machine; (III) For the situation where the nut and screw in the valve cannot be disassembled and need to be cut directly S1, at station ④, use the third power manipulator to clamp the nut cutter and cut the nuts in sequence; S2. After the nuts are disassembled, the positioner is transferred to the workstation ① through the positioner ground rail. At workstation ①, the upper and lower valve bodies are disassembled by using the first power-assisted manipulator quick-change clamping impact hammer, and the upper valve body is removed by using the truss robot quick-change clamping tooling for upper valve body disassembly; S3. After the upper valve body is disassembled, the positioner is transferred to station ③ through the positioner ground rail; at station ③, the second power-assisting manipulator is used to clamp the electric impact wrench to put the nut on the screw; the screw with the nut is transferred to station ⑤ through the positioner to loosen it with a high-torque electric wrench; the loosened screw is transferred to station ③ through the positioner to be clamped with the electric impact wrench by the second power-assisting manipulator for quick disassembly; S4. For the screw that still cannot be disassembled, the six-degree-of-freedom mechanical arm on the second industrial robot is used to clamp the electromagnetic induction heating head at workstation ② to heat the screw; the heated screw is transferred to workstation ⑤ by the positioner and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench for loosening; the loosened screw is transferred to workstation ③ by the positioner and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly; S5. For the screws that still cannot be disassembled, the position is changed by the positioner to the workstation ⑥, and the fifth power-assisted manipulator is used to clamp the cutting machine to cut the remaining screws; the cut screw is changed by the positioner to the workstation ⑦, and the bottom hole for the wire extractor is drilled by the radial drilling machine; the screw with the bottom hole drilled is changed by the positioner to between the workstation ① and the workstation ②, and the wire extractor is driven into the bottom hole for the wire extractor by the impact hammer on the first power-assisted manipulator and the pneumatic clamp toe on the six-degree-of-freedom manipulator on the second industrial robot; after all the undisassembled screws are installed with the wire extractor, the positioner is moved to the right working area by the positioner ground rail, and the position is changed by the positioner to the workstation ⑤, and the fourth power-assisted manipulator is used to clamp the high-torque electric wrench to loosen the screw equipped with the wire extractor; the loosened screw is changed by the positioner to the workstation ③, and the second power-assisted manipulator is used to clamp the electric impact wrench for quick disassembly; S6. The positioner is moved to the workstation ⑦ via the positioner ground rail, and the screws that have not been disassembled are drilled out one by one using a radial drilling machine.

7. A valve automated disassembly method according to claim 5 or 6, characterized in that: In the semi-automatic valve disassembly method, after all the screws are disassembled, the clamping part of the truss robot clamps the valve stem disassembly tool to disassemble the valve stem in the valve, and then the valve core in the valve is disassembled by quickly changing the valve core disassembly jaws on the clamping part of the truss robot.

8. A valve automated disassembly method according to claim 5 or 6, characterized in that: In the semi-automatic valve disassembly method, the method of using an electric impact wrench to back the nut on the screw includes using a long sleeve to back the nut, cutting a flat end to the screw, or welding a nut to the screw.

9. The method for automatic valve disassembly according to claim 8, characterized in that: In the semi-automatic valve disassembly method, the method of loosening the screw with the nut backed by a high-torque electric wrench includes using a high-torque electric wrench with an offset head, a hydraulic wrench plus a ring, or designing a split socket.

10. The method for automatic valve disassembly according to claim 4, characterized in that: In the fully automated valve disassembly method, the working area of ​​the first power manipulator in the valve automated disassembly system is defined as station ①, the working area of ​​the second industrial robot is defined as station ②, the working area of ​​the second power manipulator is defined as station ③, the working area of ​​the third power manipulator is defined as station ④, the working area of ​​the fourth power manipulator is defined as station ⑤, the working area of ​​the first industrial robot is defined as station ⑥, and the working area of ​​the radial drilling machine is defined as station ⑦; Clamp the upper valve body disassembly tooling on the truss robot, use the truss robot and the upper valve body disassembly tooling to transfer the valve to be disassembled from the ground rail robot to the positioner, and clamp the valve to be disassembled on the rotary workbench of the positioner, and transfer the valve to be disassembled to each workstation by the rotary workbench; The fully automated valve disassembly method comprises the following steps: S1. At workstation ⑥, use the six-degree-of-freedom mechanical arm on the first industrial robot to install an electric wrench with an offset head to quickly disassemble the nut and screw; S2. Clamp the upper valve body with the disassembly tooling by the truss robot to disassemble and remove the upper valve body; S3. Remove the valve stem by using the truss robot quick-change clamp and valve stem disassembly tooling; S4. Use the positioner to change the position to workstation ②, and use the six-degree-of-freedom mechanical arm on the second industrial robot to clamp the valve core and remove the valve core from the lower valve body.

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