Installation method for integral uncoupling tube on ship and ocean engineering

Abstract

The invention relates to the technical field of ship and ocean engineering, and discloses a method for installing an integral uncoupling tube on ship and ocean engineering, which comprises the following steps of: modular design and factory preassembly, dividing the integral uncoupling tube into a main shaft tube module, a sealing module, a guide module and an interface module, performing standardized flange design on each module interface, and assembling the main shaft tube module, the sealing module, the guide module and the interface module. The interface machining precision is controlled within 0.02 mm, sealing assembly preassembling, guiding device debugging and module calibration are completed in a factory, air pressure testing and hydraulic testing are conducted on all modules, and interface position data are recorded; module hoisting and hydraulic guide positioning are conducted, specifically, all the modules are hoisted to the installation positions, the modules are controlled to move through a hydraulic guide device, and coarse positioning of the modules is achieved. Through the modularized preassembling and intelligent mounting technology, the mounting efficiency is remarkably improved, and on-site construction steps are simplified; the laser centering and hydraulic correction technology is adopted, high-precision installation is achieved, and stable and reliable operation is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of ships and marine engineering, and in particular to an installation method of an integral decoupling tube in ships and marine engineering. Background Art

[0002] As an important part of the propulsion system in ships and marine engineering, the installation quality of the integral decoupling tube directly affects the ship's propulsion efficiency and the stability of equipment operation. At present, the installation of the integral decoupling tube usually adopts the traditional on-site overall lifting and manual calibration method, with a level and simple mechanical equipment to complete the installation. Although this method is technically mature, it has limitations in construction efficiency, precision control, and adaptability to complex environments. It is difficult to meet the modern ship and marine engineering requirements for efficient, accurate, and durable installation.

[0003] In the prior art, the integral decoupling tube is manufactured in whole sections, and its installation mainly relies on manual centering and primary measuring equipment to complete positioning. The installation accuracy depends on the operator's experience, and the coaxiality and line position deviations are relatively high, which leads to vibration and wear during the operation of the propulsion system. In addition, the existing installation process is complicated, the construction period is long, and the installation efficiency is low. At the same time, traditional anti-corrosion and sealing technologies are difficult to play an effective role in extreme environments such as deep sea, high pressure, and extreme cold. The equipment durability and operational reliability are insufficient, which increases the subsequent maintenance costs and risks. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a method for installing an integral decoupling tube on ships and marine engineering, which solves the problems in the prior art of low installation efficiency, insufficient precision and poor environmental adaptability of the integral decoupling tube under extreme working conditions.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A method for installing an integral decoupling tube on ships and marine engineering, comprising the following steps: Modular design and factory pre-installation, the overall decoupling tube is divided into the main shaft tube module, sealing module, guide module and interface module, and standardized flange design is carried out for the interface of each module. The interface processing accuracy is controlled within 0.02 mm. The sealing component is pre-installed, the guide device is debugged and the module is calibrated in the factory. The air pressure test and hydraulic pressure test are carried out on each module, and the interface position data is recorded; Module hoisting and hydraulic guidance positioning: hoist each module to the installation position, control the movement of the module through the hydraulic guidance device, and realize the rough positioning of the module. The hydraulic guidance device has the ability of three-dimensional movement adjustment; Module splicing and precision calibration: use standardized flange interfaces to connect modules, use laser alignment to detect alignment errors after splicing, and use hydraulic control devices to adjust module positions until the alignment error is less than 0.05 mm; Sealing performance verification: perform high-pressure sealing test on the assembled de-axle tube to ensure that the sealing performance meets the requirement of 1.5 times the working pressure; After installation, functional verification is performed and dynamic operation tests are carried out in combination with the propulsion shaft to ensure that the coaxiality, vibration and operation stability of the decoupling tube meet the design requirements.

[0006] Preferably, the spindle tube module is made of high-strength duplex stainless steel or titanium alloy, and the sealing assembly of the sealing module includes a main sealing ring, a backup sealing ring and a waterproof barrier.

[0007] Preferably, the hydraulic guiding device includes a fixed rail, a hydraulic driving device and a roller slider, and the hydraulic driving device can control the movement and adjustment of the module in the horizontal, vertical and inclination directions, and the positioning accuracy is controlled within 0.05 mm.

[0008] Preferably, the laser centering instrument is used to detect the coaxiality and inclination deviation between modules, and the detection results are transmitted to the hydraulic correction device in real time, and the hydraulic correction device automatically adjusts the module position according to the detection results.

[0009] Preferably, the sealing performance verification includes a static test and a dynamic test, the dynamic test simulates the vibration conditions under normal working pressure, and the static test detects the sealing performance at 1.5 times the working pressure.

[0010] A hydraulic guidance and calibration system for realizing installation of an integrally decoupled axle tube, comprising: Fixed rails, the rail surface is coated with anti-corrosion coating and has high-precision smooth sliding performance; A hydraulic drive device for controlling the three-dimensional movement of the module along the track, including horizontal, vertical and inclination adjustment functions; A roller slider is connected to a hydraulic drive device and is used to smoothly transmit the displacement of the module; The laser centering instrument, linked with the hydraulic control device, is used to detect the centering error and angular deviation between modules in real time, and feed back the detection results to the hydraulic drive device for calibration.

[0011] Preferably, the positioning accuracy of the hydraulic drive device is 0.05 mm, and the sliding friction force of the roller slider is not greater than 1 kN.

[0012] Preferably, the laser centering instrument can detect a coaxiality deviation of 0.01 mm, and the detection data is transmitted to the hydraulic control device in real time via wireless signals.

[0013] Preferably, the interface module adopts a flexible joint design, and the flexible joint allows the angle deviation between modules to be no more than ±1° and the line position deviation to be no more than 20 mm.

[0014] Preferably, after the installation of the decoupling tube, the surface is treated with a multi-layer anti-corrosion coating, and an intelligent anode protection device is installed outside the decoupling tube to adjust the anode current in real time according to the environmental electrochemical conditions to prevent corrosion.

[0015] The present invention provides a method for installing an integrally decoupled axle tube on ships and marine engineering, which has the following beneficial effects: 1. The present invention adopts modular pre-installation design, which disperses the complex installation process into two stages: factory and site. The pre-installation of sealing components and guide devices greatly reduces the assembly and testing steps on site. At the same time, the introduction of hydraulic guide system and rapid splicing technology simplifies the hoisting and positioning process. Compared with the traditional method, the installation period of the present invention is shortened, making the overall decoupling of the axle tube installation more efficient, which is particularly suitable for urgent projects that require rapid construction.

[0016] 2. The present invention controls the coaxiality error during module installation within a smaller range through the synergistic effect of the laser centering instrument and the hydraulic correction system, significantly reduces the coaxiality and line deviation, reduces the vibration and friction problems caused by deviation after installation, and extends the service life of the propulsion system. This high-precision installation is particularly suitable for shaft tube structures under high-pressure or high-speed operating conditions to ensure long-term stable operation.

[0017] 3. The present invention adopts an intelligent anode protection system, a multi-channel sealing structure and a high-performance anti-corrosion coating technology, so that the integral axle tube can maintain excellent performance under extreme working conditions such as deep sea, high pressure and extreme cold. The intelligent anode protection system automatically adjusts the anti-corrosion current according to environmental changes to reduce the corrosion rate. The multi-channel sealing design provides reliable waterproof protection. These technologies extend the service life of the axle tube, reduce maintenance frequency and long-term operating costs, and improve the durability and reliability of the overall system. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a flow chart of the steps of the present invention. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the specification of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Please refer to the attached Figure 1The embodiment of the present invention provides an installation method for an integrally decoupled axle tube in ships and marine engineering. Aiming at the deficiencies of the prior art in installation efficiency, precision and environmental adaptability, a highly efficient, precise and adaptable installation method for complex working conditions is proposed through modular pre-installation design, hydraulic guidance and intelligent calibration technology, standardized process and environmental adaptability optimization. The specific implementation method and core technical content will be described in detail below.

[0021] 1. Modular pre-installed design 1.1 Module Function Division The overall shaft tube is decomposed into the following standardized functional modules: Spindle tube module: The spindle tube module is the core bearing structure of the spindle tube. It is made of duplex stainless steel or titanium alloy and has high strength and corrosion resistance.

[0022] A reinforcing rib structure is set inside to enhance the deformation resistance and reduce the weight.

[0023] Sealing module: The sealing module integrates the main sealing ring, backup sealing ring and waterproof barrier structure, and adopts composite sealing materials (such as fluororubber and metal insert combination) to meet the high-pressure sealing performance requirements.

[0024] A lubrication channel is set up to reduce the running friction of the shaft tube through centralized lubrication technology.

[0025] Guide module: The guide module is designed as an annular rolling device and can be slidably mounted on a hydraulic guide rail to assist the rough positioning of the spindle tube module.

[0026] The rolling device is made of high-strength steel and the outer surface is coated with polytetrafluoroethylene to reduce the friction coefficient.

[0027] Interface module: The interface module adopts a standardized flange design, and the flange surface roughness is controlled within 0.02 μm. The interface allows line adjustment of ±20 mm and angle deviation of ±1° to accommodate slight errors during installation.

[0028] 1.2 Factory pre-installation and testing Complete pre-installation and performance testing of each module in the factory: Interface calibration: Use laser interferometer to calibrate the interface position, reference hole position and sealing structure to ensure the splicing accuracy between modules.

[0029] Sealing test: Apply air pressure (5 MPa) and hydraulic pressure (10 MPa) inside the sealing module to verify the sealing performance.

[0030] Guide device debugging: Test the guide rail sliding resistance to ensure that the sliding friction does not exceed 1 kN.

[0031] Module protection and packaging: The module surface is coated with an anti-corrosion coating, and the transport frame uses a bubble shock-absorbing device to fix the module position to ensure no deformation during transportation.

[0032] 2. Hydraulic guidance and intelligent calibration 2.1 Hydraulic guidance system System composition: The hydraulic guidance system consists of a fixed rail, a hydraulic drive and a roller slider.

[0033] The rails are made of high-strength steel and coated with polyurethane anti-corrosion coating to ensure smooth sliding.

[0034] Functionality: The hydraulic drive unit provides three-dimensional movement capabilities (horizontal, vertical and tilt adjustment) and is used to move the module to the installation location.

[0035] The roller slider is connected to the hydraulic drive device and is used for smoothly transmitting the displacement of the module.

[0036] 2.2 Laser alignment and feedback calibration principle: The laser centering instrument is installed at both ends of the decoupling tube to measure the coaxiality and inclination deviation of the module in real time.

[0037] The deviation data is transmitted to the hydraulic control system via wireless signals, and the control system drives the hydraulic device to adjust the module position until the design accuracy is met.

[0038] Calibration process: After the initial positioning, the laser centering instrument detects the current centering error, and the hydraulic drive device adjusts the inclination and position through feedback.

[0039] The calibration accuracy is controlled within 0.05 mm.

[0040] 2.3 Quick locking and flexible interface Quick lock device: After the module position is adjusted, the hydraulic chuck automatically clamps the flange interface to achieve temporary fixation.

[0041] Flexible interface design: The use of spherical joints and elastic gaskets allows small angles and alignment adjustments between modules, avoiding stress concentrations caused by installation errors.

[0042] 3. Module splicing and installation test 3.1 Module splicing Stitching steps: Lift and splice the flange interfaces in module order, and use standardized bolts to gradually fix the flanges.

[0043] Apply uniform torque to the flange bolts in diagonal order to prevent local force deviation.

[0044] Precision calibration: Use a laser alignment instrument to check the coaxiality and angle of the modules after splicing to ensure that the cumulative error is less than 0.05 mm.

[0045] 3.2 Sealing test High voltage test: Apply 1.5 times the design working pressure to the installed decoupling tube to check whether there is any leakage in the sealing structure.

[0046] Running tests dynamically: Simulate the propulsion shaft operating conditions and test the stability and sealing performance of the shaft tube under dynamic vibration.

[0047] 4. Environmental adaptability and protective measures 4.1 Application of high performance materials Axle tube material: The spindle tube module is made of titanium alloy, which has lightweight and high strength performance.

[0048] Seal Material: The sealing ring is made of composite elastomer material (such as fluororubber + metal insert) and has strong corrosion resistance.

[0049] 4.2 Intelligent anode protection Anode system design: An intelligent anode protection device is installed outside the shaft tube, which detects environmental corrosion conditions through electrochemical sensors and automatically adjusts the anode current.

[0050] Real-time monitoring: The system records the coating corrosion status in real time and provides data support for subsequent maintenance.

[0051] 4.3 Adaptation to extreme working conditions Deep sea adaptability: In deep-sea environments, the sealing module adds multiple sealing structures to provide redundant protection.

[0052] Extreme cold adaptability: An antifreeze coating is added to the surface of the guide rail and a local heating device is installed to ensure sliding performance in low temperature environments.

[0053] Example 1: Overall decoupling of the shaft tube installation in deep sea environment Specific steps and process parameters Modular pre-installed: The spindle tube module is made of titanium alloy, the flange interface roughness is 0.02 μm, and the sealing module uses fluororubber main sealing ring + metal insert.

[0054] The sealing test was completed in the factory, and a pressure of 15 MPa was applied to detect leakage. The sliding friction force of the guide module was controlled at 0.8 kN.

[0055] On-site installation: A hydraulic guide device is used to position the module, and the three-dimensional motion accuracy is controlled within ±0.05 mm.

[0056] The laser centering instrument monitors the inclination and coaxiality in real time, and the cumulative installation error is controlled within 0.04 mm.

[0057] Sealing performance verification: The dynamic running test simulates the deep sea environment vibration frequency (1 Hz to 5 Hz, amplitude ±2 mm) without leakage.

[0058] Environmental adaptability treatment: Apply multi-layer self-repairing coating and install intelligent anode protection system to automatically adjust the anti-corrosion current range from 0.1-0.5A.

[0059] Comparative Example 1: Traditional installation method in deep sea environment Modular pre-installed: The whole shaft tube is directly transported to the site without segmented modularization, and the interface processing roughness is 0.1 μm.

[0060] On-site installation: Manual positioning is used and a level is used for calibration, and the coaxiality deviation is controlled within ±0.2 mm.

[0061] Sealing performance verification: In the static pressure test, a slight leakage occurred when 15 MPa was applied.

[0062] Environmental adaptability treatment: Ordinary coating is used for corrosion protection and no intelligent anode protection device is installed.

[0063] Example 2: Overall decoupling of the axle tube installation in extremely cold environments Specific steps and process parameters Modular pre-installed: The spindle tube module is made of duplex stainless steel, the sealing module adopts double-pass sealing (main sealing ring + backup sealing ring), and the lubrication channel is pre-coated with antifreeze lubricant.

[0064] Static pressure testing (20 MPa) is completed in the factory to ensure the sealing integrity.

[0065] On-site installation: Add antifreeze coating on the surface of the guide rail and keep the guide rail heated to 5℃ before installation.

[0066] The hydraulic guidance system drives the spindle tube module to move to the installation position and monitors the line position error in real time (≤0.05 mm).

[0067] Sealing performance verification: After cooling to -30℃, a dynamic running test was carried out with an amplitude of ±1 mm and a running time of 2 hours, with no leakage.

[0068] Environmental adaptability treatment: The outer surface of the spindle tube is sprayed with a polyurethane composite protective coating, and the guide module is added with a heat-insulating coating.

[0069] Comparative Example 2: Traditional installation method in extremely cold environment Modular pre-installed: The integral decoupling tube does not adopt a segmented modular design, and the sealing assembly is not lubricated or preheated in advance.

[0070] On-site installation: The guide rails were not treated with antifreeze measures, the hydraulic drive device operated unstably at low temperatures, and the module got stuck when sliding.

[0071] Sealing performance verification: Under low temperature conditions, a small amount of leakage occurred after 2 hours of dynamic operation test.

[0072] Environmental adaptability treatment: A single layer of ordinary coating is used without thermal insulation measures.

[0073] Example 3: Integral decoupling of the shaft tube installation under high pressure environment Specific steps and process parameters Modular pre-installed: The shaft tube is made of titanium alloy, and the sealing module uses a high-pressure metal sealing ring + composite elastomer.

[0074] The test of 1.5 times the design pressure (30 MPa) was completed in the factory and no leakage was found.

[0075] On-site installation: The laser centering instrument and hydraulic correction system cooperate to adjust, and the coaxiality deviation is ≤0.03 mm after installation.

[0076] Sealing performance verification: A simulated 30 MPa high-pressure dynamic test was conducted with a vibration frequency of 1 Hz and a test time of 4 hours, with no leakage.

[0077] Environmental adaptability treatment: The intelligent anode protection system adjusts the anti-corrosion current (0.2-0.6 A), and the spindle tube surface is coated with 3 layers of anti-corrosion coating.

[0078] Comparative Example 3: Traditional installation method under high pressure environment Modular pre-installed: The integral de-axle tube is not modularized, the interface processing accuracy is low, and the flange roughness is 0.1 μm.

[0079] On-site installation: Using traditional lifting and manual positioning, the installation error is large (coaxiality deviation is 0.15 mm).

[0080] Sealing performance verification: A simulated 30 MPa high-pressure dynamic test was conducted with a vibration frequency of 1 Hz. Leakage occurred after 4 hours of testing.

[0081] Environmental adaptability treatment: Ordinary coatings and fixed anode protection devices failed to effectively prevent corrosion, and corrosion occurred on the surface.

[0082] Comparative Experimental Design Experimental purpose: To verify the superiority of the installation method of the present invention in terms of efficiency, accuracy, sealing and environmental adaptability.

[0083] Experimental design Experimental environment: simulate deep sea, high pressure, extreme cold and other working conditions.

[0084] Experimental content: Duration test: Compare the overall installation time.

[0085] Precision test: detect coaxiality and line deviation.

[0086] Leakage test: dynamic operating pressure and time.

[0087] Corrosion resistance test: Corrosion damage rate.

[0088] Experimental data table: According to the data in the table, the installation method of the present invention is significantly superior to the traditional method in terms of efficiency, accuracy, sealing and environmental adaptability. The combination of modular design and intelligent installation equipment significantly reduces the construction period and errors. At the same time, it shows better adaptability in complex environments and has wide engineering application value.

[0089] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for installing an integrally decoupled shaft tube in ships and marine engineering, characterized in that: The following steps are involved: Modular design and factory pre-installation, the overall decoupling tube is divided into the main shaft tube module, sealing module, guide module and interface module, and standardized flange design is carried out for the interface of each module. The interface processing accuracy is controlled within 0.02 mm. The sealing component is pre-installed, the guide device is debugged and the module is calibrated in the factory. The air pressure test and hydraulic pressure test are carried out on each module, and the interface position data is recorded; Module hoisting and hydraulic guidance positioning: hoist each module to the installation position, control the movement of the module through the hydraulic guidance device, and realize the rough positioning of the module. The hydraulic guidance device has the ability of three-dimensional movement adjustment; Module splicing and precision calibration: use standardized flange interfaces to connect modules, use laser alignment to detect alignment errors after splicing, and use hydraulic control devices to adjust module positions until the alignment error is less than 0.05 mm; Sealing performance verification: perform high-pressure sealing test on the assembled de-axle tube to ensure that the sealing performance meets the requirement of 1.5 times the working pressure; After installation, functional verification is performed and dynamic operation tests are carried out in combination with the propulsion shaft to ensure that the coaxiality, vibration and operation stability of the decoupling tube meet the design requirements.

2. The method for installing an integrally decoupled axle tube in ships and marine engineering according to claim 1, characterized in that: The spindle tube module is made of high-strength duplex stainless steel or titanium alloy, and the sealing components of the sealing module include a main sealing ring, a backup sealing ring and a waterproof barrier.

3. The method for installing an integrally decoupled shaft tube in ships and marine engineering according to claim 1, characterized in that: The hydraulic guiding device includes a fixed track, a hydraulic driving device and a roller slider. The hydraulic driving device can control the movement and adjustment of the module in the horizontal, vertical and inclination directions, and the positioning accuracy is controlled within 0.05 mm.

4. The method for installing an integrally decoupled shaft tube in ships and marine engineering according to claim 1, characterized in that: The laser centering instrument is used to detect the coaxiality and inclination deviation between modules. The detection results are transmitted to the hydraulic correction device in real time, and the hydraulic correction device automatically adjusts the module position according to the detection results.

5. The method for installing an integrally decoupled axle tube in ships and marine engineering according to claim 1, characterized in that: The sealing performance verification includes static testing and dynamic testing. The dynamic test simulates the vibration conditions under normal working pressure, and the static test detects the sealing performance at 1.5 times the working pressure.

6. A hydraulic guidance and calibration system for realizing the installation of an integrally decoupled axle tube, according to a method for installing an integrally decoupled axle tube in a ship or marine engineering according to any one of claims 1 to 5, characterized in that: include: Fixed rails, the rail surface is coated with anti-corrosion coating and has high-precision smooth sliding performance; A hydraulic drive device for controlling the three-dimensional movement of the module along the track, including horizontal, vertical and inclination adjustment functions; A roller slider is connected to a hydraulic drive device and is used to smoothly transmit the displacement of the module; The laser centering instrument, linked with the hydraulic control device, is used to detect the centering error and angular deviation between modules in real time, and feed back the detection results to the hydraulic drive device for calibration.

7. The method for installing an integrally decoupled shaft tube in ships and marine engineering according to claim 6, characterized in that: The positioning accuracy of the hydraulic drive device is 0.05 mm, and the sliding friction force of the roller slider is no more than 1 kN.

8. The method for installing an integrally decoupled axle tube in ships and marine engineering according to claim 6, characterized in that: The laser centering instrument can detect a coaxiality deviation of 0.01 mm, and the detection data is transmitted to the hydraulic control device in real time via wireless signals.

9. The method for installing an integrally decoupled shaft tube in ships and marine engineering according to claim 1, characterized in that: The interface module adopts a flexible joint design, and the flexible joint allows the angle deviation between modules to be no more than ±1° and the line position deviation to be no more than 20 mm.

10. The method for installing an integrally decoupled shaft tube in ships and marine engineering according to claim 1, characterized in that: After the installation of the decoupling tube is completed, the surface is treated with a multi-layer anti-corrosion coating, and an intelligent anode protection device is installed outside the decoupling tube to adjust the anode current in real time according to environmental electrochemical conditions to prevent corrosion.

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