Replacement method for pivotal bearing of circular stacker-reclaimer

Abstract

The invention discloses a method for replacing a pivotal bearing of a circular stacker-reclaimer in the technical field of stacker-reclaimer maintenance. The method comprises the steps that a trestle and a cantilever are vertically supported; the upper rotary platform is jacked upwards for multiple times through an upper jacking oil cylinder arranged between the support and the upper rotary platform, and an upper rotary bearing is moved out and reassembled; a middle jacking oil cylinder arranged between the jacking tool and the follow-up channel steel is used for jacking the lower rotary platform upwards for multiple times, and a middle rotary bearing is moved out and reassembled; the door-shaped frame is jacked upwards for multiple times through a lower jacking oil cylinder installed between the door-shaped frame and the base, the integral bottom pivotal bearing is broken and dismantled, and the split bottom pivotal bearing is installed. By means of the synchronous jacking method, personnel investment can be reduced, operation time can be shortened, maintenance efficiency can be improved, and maintenance quality and operation safety can be guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of stacker-reclaimer maintenance, and in particular to a method for replacing a slewing bearing of a circular stacker-reclaimer. Background Art

[0002] The circular stacker-reclaimer consists of a stacker, a reclaimer, a central column, a trestles and other parts. It has two distinct levels of stacking rotation mechanism and reclaiming rotation mechanism during the reclaiming and stacking operations, so that the stacker and the reclaimer form two sets of relatively independent operating systems that do not interfere with each other, thus realizing the stacking and reclaiming operations at the same time.

[0003] Since the circular stacker reclaimer has been operating in a dusty and harsh environment for a long time, the three sets of slewing bearings at the top, middle and bottom will all wear out to varying degrees, especially the bottom slewing bearings and the middle slewing bearings have abnormal noises and need to be replaced regularly. However, the reinstalled bearings are sleeved on the outside of the center column. When replacing the reinstalled bearings, the center column and accessories on the top of the slewing bearing need to be completely removed, and then the slewing bearings need to be removed and replaced. Not only is the construction period long and difficult, but there is also a risk of overturning due to changes in the center of gravity during the removal and reinstallation process.

[0004] Therefore, how to improve the disassembly and assembly efficiency and safety of the slewing bearing has become a technical problem that needs to be solved urgently by those skilled in the art. Summary of the invention

[0005] In view of this, an object of the present invention is to provide a method for replacing a slewing bearing of a circular stacker-reclaimer, so as to solve the technical problem of a long construction period in the existing slewing bearing replacement method.

[0006] The technical solution adopted by the present invention is: a method for replacing a slewing bearing of a circular stacker-reclaimer, comprising the following steps:

[0007] S11: Use supporting tools to vertically support the trestle and cantilever respectively;

[0008] S12: Use guy ropes to tighten and fix the trestle, cantilever and portal frame respectively;

[0009] S21: Install multiple upper lifting cylinders between the support and the upper rotary platform;

[0010] S22: Lifting the upper rotary platform upwards for multiple times by means of the upper lifting cylinder, and after the upper rotary platform is lifted into place, welding a temporary support channel steel between the support and the upper rotary platform;

[0011] S23: a horizontal slide is arranged on one side of the upper slewing platform, and the upper slewing bearing is removed by a truck crane;

[0012] S24: Reinstall the upper slewing bearing;

[0013] S31: arranging a jacking tool on the outer side of the central column below the lower rotary platform, and fixing and connecting a follower channel steel below the lower rotary platform;

[0014] S32: Install multiple middle lifting cylinders between the lifting fixture and the follower channel steel;

[0015] S33: Lifting the lower rotary platform upwards multiple times by the middle lifting cylinder until the lower rotary platform is lifted into place;

[0016] S34: a horizontal slide is arranged on one side of the lower slewing platform, and the middle slewing bearing is moved out by a truck crane;

[0017] S26: Reinstall the middle slewing bearing;

[0018] S41: Install the lower lifting cylinder between the portal frame and the base below;

[0019] S42: Lifting the portal frame upwards multiple times by the lower lifting cylinder until the portal frame is lifted into place;

[0020] S43: Dismantle the integral bottom slewing bearing;

[0021] S44: Install a split bottom slewing bearing.

[0022] Preferably, the supporting tooling includes a trestle tooling and a cantilever tooling, and an auxiliary lifting cylinder is installed between the trestle tooling and the trestle, and an auxiliary lifting cylinder is installed between the cantilever tooling and the cantilever.

[0023] Preferably, a portal frame tooling is arranged below the portal frame, and an auxiliary lifting cylinder is arranged between the portal frame tooling and the portal frame.

[0024] Preferably, the trestle is arranged in parallel with the portal frame, and the cantilever is arranged perpendicular to the trestle.

[0025] Preferably, before lifting the upper slewing platform, the movable hinge support between the upper slewing platform and the trestle needs to be removed, and the lifting distance of the upper slewing bearing is 50 mm to 100 mm.

[0026] Preferably, a guide sleeve is installed between the support and the lower rotary platform.

[0027] Preferably, the follower channel steel is located directly below the connecting column above the lower slewing platform, and the lifting distance of the middle slewing bearing is 50mm to 100mm.

[0028] Preferably, the lifting distance of the bottom slewing bearing is 30 mm to 50 mm.

[0029] Beneficial effects of the present invention:

[0030] The present invention utilizes a synchronous jacking method. After the upper slewing platform is jacked into place by the upper jacking cylinder, the upper slewing bearing can be directly moved out by a car crane, and then a jacking tool fixedly arranged under the lower slewing platform is used to provide jacking support for the middle jacking cylinder, and the jacking force of the middle jacking cylinder is transmitted to the connecting column between the upper slewing platform and the lower slewing platform by using the follower channel steel fixedly welded on the lower slewing platform, which not only realizes the jacking and disassembly of the middle slewing bearing, but also ensures the safety of the entire jacking operation. After the portal frame is jacked into place by the lower jacking cylinder, the integral bottom slewing bearing is removed from the center column by a destructive dismantling method, and then the split bottom slewing bearing is installed on the center column, which not only reduces the personnel input, shortens the operation time, and improves the maintenance efficiency, but also ensures the maintenance quality and operation safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 A three-dimensional schematic diagram of the replacement of the slewing bearing of the circular stacker-reclaimer of the present invention;

[0032] Figure 2 The figure is a front view of the replacement of the slewing bearing of the circular stacker and reclaimer of the present invention.

[0033] Description of reference numerals in the figures:

[0034] 1. Trestle; 2. Cantilever; 3. Door frame; 4. Upper lifting cylinder; 5. Support; 6. Upper slewing platform; 7. Upper slewing bearing; 8. Lower slewing platform; 9. Center column; 10. Lifting tooling; 11. Follow-up channel steel; 12. Middle lifting cylinder; 13. Middle slewing bearing; 14. Lower lifting cylinder; 15. Base; 16. Bottom slewing bearing; 17. Trestle tooling; 18. Cantilever tooling; 19. Door frame tooling; 20. Connecting column. DETAILED DESCRIPTION

[0035] The specific embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings. These embodiments are only used to illustrate the present invention, but not to limit the present invention.

[0036] In the description of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying 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 operate in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0037] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0038] Furthermore, in the description of the present invention, unless otherwise specified, “plurality” means two or more.

[0039] Examples, such as Figure 1 and Figure 2 As shown, a method for replacing a slewing bearing of a circular stacker and reclaimer comprises the following steps:

[0040] S11: Use supporting tools to vertically support the trestle 1 and the cantilever 2 respectively.

[0041] S12: Use guy ropes to tighten and fix the trestle 1, the cantilever 2 and the portal frame 3 respectively.

[0042] S21: Install multiple upper lifting cylinders 4 between the support 5 and the upper rotating platform 6.

[0043] S22: The upper jacking cylinder 4 is used to jack up the upper rotating platform 6 for multiple times, and after the upper rotating platform 6 is jacked up into place, a temporary support channel steel is welded between the support and the upper rotating platform 6 .

[0044] S23: A horizontal slide is arranged on one side of the upper slewing platform 6, and the upper slewing bearing 7 is moved out by a truck crane.

[0045] S24: Reinstall the upper slewing bearing 7.

[0046] S31: a lifting tool 10 is arranged outside the central column 9 below the lower rotary platform 8, and a follower channel steel 11 is fixedly connected below the lower rotary platform 8.

[0047] S32: Install multiple middle lifting cylinders 12 between the lifting tooling 10 and the follower channel steel 11;

[0048] S33: The lower rotary platform 8 is lifted upward for multiple times by the middle lifting cylinder 12 until the lower rotary platform 8 is lifted into place.

[0049] S34: A horizontal slideway is arranged on one side of the lower slewing platform 8, and the middle slewing bearing 13 is moved out by a truck crane.

[0050] S26: Reinstall the middle slewing bearing 13.

[0051] S41: Install the lower lifting cylinder 14 between the portal frame 3 and the base 15 below.

[0052] S42: The portal frame 3 is lifted upwards for multiple times by the lower lifting cylinder 14 until the portal frame 3 is lifted into place.

[0053] S43: Dismantle the integral bottom slewing bearing 16.

[0054] S44: Install the split bottom slewing bearing 16.

[0055] The present application utilizes a synchronous lifting method. After the upper slewing platform 6 is lifted into place by the upper lifting cylinder 4, the upper slewing bearing 7 can be directly removed by a car crane, and then a lifting tool 10 fixedly arranged under the lower slewing platform 8 provides jacking support for the middle jacking cylinder 12, and a follower channel steel 11 fixedly welded on the lower slewing platform 8 is used to transmit the jacking force of the middle jacking cylinder 12 to the connecting column 20 between the upper slewing platform 6 and the lower slewing platform 8, which not only realizes the synchronous jacking and disassembly of the middle slewing bearing 13, but also ensures the safety of the entire jacking operation; after the portal frame 3 is lifted into place by the lower lifting cylinder 14, the integral bottom slewing bearing 16 is removed from the center column 9 by a destructive dismantling method, and then the split bottom slewing bearing 16 is installed on the center column 9, which can not only reduce personnel input, shorten operation time, and improve maintenance efficiency, but also ensure maintenance quality and operation safety.

[0056] Specific embodiment 1, as Figure 1 and Figure 2 As shown, a method for replacing a slewing bearing of a circular stacker and reclaimer comprises the following steps:

[0057] S10: Support fixed.

[0058] Specifically include: the construction site should be flat, compacted and hard, a power outage sign should be posted, materials in the construction area at the shutdown point need to be cleaned up, warning tape should be pulled, and the lower walking mechanism of the stacker and reclaimer should be locked and fixed with a track clamp.

[0059] S11: Use channel steel to weld the trestle fixture 17, cantilever fixture 18, lifting fixture 10 and portal fixture 19, then fix the trestle fixture 17 to the bottom of one end of the trestle 1 close to the center column 9, and install two auxiliary lifting cylinders between the trestle fixture 17 and the trestle 1, so as to lift the end of the trestle 1 upward within a distance of 5mm through the auxiliary lifting cylinders; rotate the cantilever 2 to a vertical position with the trestle 1, fix the cantilever fixture 18 to the bottom of the cantilever 2, and Two auxiliary lifting cylinders are installed between the tooling 18 and the cantilever 2 to lift the cantilever 2 upward by 50mm to 100mm through the auxiliary lifting cylinders; the lifting tooling 10 is arranged around the central column 9 for a circle; the portal frame 3 is rotated to a position parallel to the trestle 1, the portal frame tooling 19 is fixed to the bottom of the portal frame 3, and two auxiliary lifting cylinders are installed between the portal frame 3 and the portal frame tooling 19 to lift the portal frame 3 upward by 30mm to 50mm through the auxiliary lifting cylinders.

[0060] S12: Use cables (not shown in the figure) to tighten and fix the trestle 1, cantilever 2 and portal frame 3 respectively; the cables are fixed on the column base of the factory structure, and the six cables are pre-tightened by hand winches to ensure the stability of the equipment, but the cables cannot be pulled too tight, otherwise the lifting weight will increase.

[0061] The guy rope is tied to the top of the trestle tooling, the top of the cantilever belt tooling and the highest part of the portal frame; the model of the guy rope is φ20mm.

[0062] S20: Replace the upper slewing bearing 7.

[0063] Specifically: remove the lubricating oil pipe on the inner side of the upper slewing bearing 7, wrap the pipe head with cloth, classify and mark it; remove the two movable rolling bearings to free up 300mm of lifting space for the upper slewing platform 6; remove the upper inner and outer center body accessories.

[0064] S21: Install four upper lifting cylinders 4 evenly distributed around the circumference between the support 5 and the upper rotating platform 6, and weld four sets of guide sleeves (not shown in the figure) between the support 5 and the upper rotating platform 6.

[0065] S22: Loosen the fixing bolts of the upper slewing bearing 7, and jack up the upper slewing platform 6 several times through the upper jacking cylinder 4. During the jacking process, a dedicated person will give unified command to make the jacking heights of the four upper jacking cylinders 4 (also called hydraulic jacks) consistent, jacking 10 mm each time, and stop when the jacking distance reaches 300 mm, and add safety pads while jacking.

[0066] Before lifting, the upper lifting cylinder 4 should be marked, and during the lifting process, the lifting height should be measured at any time to ensure that the lifting height of each synchronous jack is consistent; during the lifting, the guiding condition of the guide sleeve should be checked at any time to adjust the lifting progress of the synchronous jack; at the same time, a 300mm steel ruler should be used for rechecking.

[0067] After the upper rotating platform 6 is lifted into place, a temporary support channel steel is welded between the support 5 and the upper rotating platform 6 to temporarily support and fix the upper rotating platform 6 .

[0068] S23: A horizontal slideway is provided on one side of the upper slewing platform 6, and the horizontal slideway uses a φ50 galvanized steel pipe to horizontally move the old upper slewing bearing 7 out, and the old upper slewing bearing 7 is lifted away by a 25t truck crane.

[0069] S24: Before installing the new upper slewing bearing 7, confirm the size of the spare part again, lift the upper slewing bearing 7 to the horizontal slideway by a 25t truck crane, and align and install it according to the assembly drawing of the equipment.

[0070] First, evenly install six long bolts M24*280 for positioning, then remove the temporary supporting channel steel, lower the upper lifting cylinder 4 by 10 mm each time, check the guiding condition of the guide sleeve at any time, and start tightening the bolts until the upper slewing bearing 7 falls back to its original position.

[0071] Restore the upper center body accessories and complete the replacement of the upper slewing bearing 7.

[0072] S30: Replace the middle slewing bearing 13.

[0073] Specifically: remove the internal and external accessories of the center body.

[0074] S31: a lifting tool 10 is arranged outside the central column 9 below the lower rotary platform 8, and a follower channel steel 11 is fixedly connected below the lower rotary platform 8.

[0075] The follower channel steel 11 is located directly below the connecting column 20 above the lower rotary platform 8, and the length of the follower channel steel 11 is greater than the center distance between the two connecting columns 20;

[0076] The reason for such arrangement is that the center size of the four connecting columns 20 above the middle slewing bearing 13 is 2000mm×2000mm, which is slightly smaller than the outer size of the middle slewing bearing 13 (diameter 2060mm), and it is impossible to directly lift the lower slewing platform 8. In this embodiment, in order to increase the support strength, the connecting columns 20 are first reinforced with δ=10mm steel plates inside the rotating platform, and then a 600mm×300mm steel section is used to overlap the lower part of the lower slewing platform 8 to form a well-shaped lifting tool 10, and the center distance of the four middle lifting cylinders 12 is expanded, so that the support point is moved outward.

[0077] Loosen the inner circle bolts and remove the outer circle bolts. When dismantling, loosen the nuts of one circle of bolts first, and check whether the cantilever belt beam has any unbalanced weight. If so, adjust the cantilever belt beam.

[0078] S32: Install multiple middle lifting cylinders 12 between the lifting fixture 10 and the follower channel steel 11, and have a dedicated person operate them. Perform a test on the lifting height of each point every 2mm to ensure that the lifting height of each point is always consistent and the lifting height is not greater than 300mm. Add a safety pad every 10mm during the lifting process. When the middle lifting cylinder 12 is used to lift the lower rotary platform 8 upward, the auxiliary lifting cylinder needs to be used to synchronously lift the cantilever 2 upward.

[0079] S33: Use φ48 steel pipe to make a horizontal slide. The horizontal slide should keep the installation position horizontal to ensure that the middle slewing bearing 13 is placed stably and securely. Remove the inner ring bolts, and slowly drop the middle slewing bearing 13 onto the rollers. Move the old middle slewing bearing 13 out horizontally, and then use a crane to lift the middle slewing bearing 13 away.

[0080] Before installing the new middle slewing bearing 13, compare the new and old bearings to confirm the bearing size, use a crane to lift the middle slewing bearing 13 onto the roller, and move the middle slewing bearing 13 horizontally to the installation position.

[0081] Correct the installation and tighten the inner ring bolts in place, pull out the roller bar, and lower it slowly and synchronously, check the height every 2mm, pull out a piece of washer every 10mm, until it falls to the upper edge of the stop, and install all the bolts.

[0082] S40: Replace the bottom slewing bearing 16.

[0083] Specifically, the lubricating oil pipe inside the bottom slewing bearing 16 is removed, the pipe head is wrapped with cloth, and the pipe is classified and marked.

[0084] S41: Install the lower lifting cylinder 14 between the portal frame 3 and the base 15 below.

[0085] S42: Lift the portal frame 3 upwards for many times through the lower lifting cylinder 14; the lifting is operated by a dedicated person and checked every 2mm. Use a 300mm steel ruler next to the lower lifting cylinder 14 to measure the lifting height. The lifting height of the split slewing bearing is 250mm. Add shims every 10mm during the entire lifting process; and when the lower lifting cylinder 14 is used to lift the portal frame 3 upwards, the auxiliary lifting cylinder needs to be used to synchronously lift the portal frame 3 upwards.

[0086] S43: Demolishing the integral bottom slewing bearing 16, the bottom slewing bearing 16 sleeved on the central column 9 is an integral structure and cannot be directly removed. In this embodiment, after the bottom slewing bearing 16 is lifted up to the right position, the old bottom slewing bearing 16 is removed by destroying and forcibly dismantling.

[0087] S44: Install the split bottom slewing bearing 16, that is, introduce the new split bottom slewing bearing 16 into the lower bearing seat for assembly and adjustment. Before installation, the connection between the base plane and the bearing plane must be cleaned to ensure that there is no oil, dust or protrusions.

[0088] When the portal frame 3 falls back, check the falling amount every 2 mm. After the slewing bearing is hoisted into place, use a feeler gauge to check the flatness of the fitting surface.

[0089] Restore center body attachments and remove guy ropes.

[0090] Carry out no-load and load tests according to the instruction manual and keep records.

[0091] Compared with the prior art, this application has at least the following beneficial technical effects:

[0092] By using the replacement method in this application to replace the slewing bearing of the circular stacker-reclaimer, the construction operation time is reduced from the planned 45 days to 20 days, and the number of operators is reduced from the original 25 to 18. This not only reduces labor costs and labor load, and improves labor efficiency, but also reduces the risk of toppling of the trestle and center column during the replacement construction process, thereby ensuring the safety of the construction.

[0093] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and substitutions can be made without departing from the technical principles of the present invention. These improvements and substitutions should also be regarded as the scope of protection of the present invention.

Claims

1. A method for replacing a slewing bearing of a circular stacker and reclaimer, characterized in that: The steps include: S11: Use supporting tools to vertically support the trestle (1) and the cantilever (2) respectively; S12: Using wind ropes to tighten and fix the trestle (1), the cantilever (2) and the portal frame (3) respectively; S21: installing a plurality of upper lifting cylinders (4) between the support (5) and the upper rotary platform (6); S22: The upper jacking cylinder (4) is used to jack up the upper rotating platform (6) for multiple times, and after the upper rotating platform (6) is jacked up to the right position, a temporary support channel steel is welded between the support (5) and the upper rotating platform (6); S23: a horizontal slide is arranged on one side of the upper slewing platform (6), and the upper slewing bearing (7) is removed by a truck crane; S24: Reinstall the upper slewing bearing (7); S31: a lifting tool (10) is arranged on the outer side of the central column (9) below the lower rotating platform (8), and a follower channel steel (11) is fixedly connected below the lower rotating platform (8); S32: installing a plurality of middle lifting cylinders (12) between the lifting tooling (10) and the follower channel steel (11); S33: Lifting the lower rotary platform (8) upwards multiple times by means of the middle lifting cylinder (12) until the lower rotary platform (8) is lifted into place; S34: a horizontal slide is arranged on one side of the lower slewing platform (8), and the middle slewing bearing (13) is removed by a truck crane; S26: Reinstall the middle slewing bearing (13); S41: Install the lower lifting cylinder (14) between the portal frame (3) and the base (15) below; S42: Lifting the portal frame (3) upwards multiple times by means of the lower lifting cylinder (14) until the portal frame (3) is lifted into place; S43: Dismantle the integral bottom slewing bearing (16); S44: Install the split bottom slewing bearing (16).

2. A method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 1, characterized in that: The supporting tooling comprises a trestle tooling (17) and a cantilever tooling (18), and an auxiliary lifting cylinder is installed between the trestle tooling (17) and the trestle (1), and an auxiliary lifting cylinder is installed between the cantilever tooling (18) and the cantilever (2).

3. The method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 2, characterized in that: A portal frame tooling (19) is arranged below the portal frame (3), and an auxiliary lifting cylinder is arranged between the portal frame tooling (19) and the portal frame (3).

4. The method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 1, characterized in that: The trestle (1) and the portal frame (3) are arranged in parallel, and the cantilever (2) and the trestle (1) are arranged perpendicularly.

5. The method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 1, characterized in that: Before lifting the upper slewing platform (6), the movable hinge support between the upper slewing platform (6) and the trestle (1) needs to be removed, and the lifting distance of the upper slewing bearing (7) is 50mm to 100mm.

6. A method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 5, characterized in that: A guide sleeve is installed between the support (5) and the lower rotary platform (8).

7. The method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 1, characterized in that: The follower channel steel (11) is located directly below the connecting column (20) above the lower slewing platform (8), and the lifting distance of the middle slewing bearing (13) is 50mm to 100mm.

8. The method for replacing a slewing bearing of a circular stacker and reclaimer according to claim 1, characterized in that: The lifting distance of the bottom slewing bearing (16) is 30 mm to 50 mm.

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