Emergency device and method for metallurgical crane walking wheel damage

Abstract

The invention discloses an emergency device and method for metallurgical crane traveling wheel damage. The device is made of Q235 steel, is trapezoidal, has the lower side length of 200mm, the upper side length of 100mm, the height of 100mm and the thickness of 40mm, is provided with 10mm grooves on two surfaces of the longest side, is welded on two sides of a cart traveling wheel fixing seat of a traveling crane, and is 5mm away from a supporting column. When the travelling wheels are seriously damaged, the damaged travelling wheels are detached, and the device bears original travelling wheel supporting force to maintain travelling balance and stability. The method comprises the steps of manufacturing the device, confirming the mounting position, welding, dismounting the travelling wheels, bearing force and recovering production. The method is suitable for damage such as hub breakage and rim abrasion, production halt is not needed, four hours are saved each time, safety risks such as object falling and molten metal scattering are eliminated, and the indirect economic benefit is about 14.40 thousand yuan per time.

Description

Technical Field

[0001] The present invention relates to the technical field of metallurgical cranes, and particularly relates to an emergency device and method for damage of a traveling wheel of a metallurgical overhead crane, which are used to solve the problem of non-stop production treatment when the traveling wheels of the overhead crane are severely damaged, and ensure the continuous production and operation safety of metallurgical enterprises. Background Art

[0002] An overhead crane, also known as a gantry crane, is a lifting device widely used in industries such as metallurgy, manufacturing, and logistics. It usually realizes the traveling function through two parallel I-beam rails arranged at the bottom. The traveling of the overhead crane depends on the traveling wheels, and the traveling wheels play multiple key roles during the operation of the overhead crane:

[0003] 1. Supporting the crane: The traveling wheels support the weight of the entire crane, including the crane body and the heavy objects it hoists, ensuring the stable operation of the equipment.

[0004] 2. Guiding function: The traveling wheels move along the rails, guiding the crane to maintain the correct direction and avoid deviation or derailment.

[0005] 3. Driving function: Some traveling wheels are equipped with motors or hydraulic drive systems to drive the crane to move to the designated working position.

[0006] 4. Bearing load: The traveling wheels bear the vertical and horizontal loads during operation and need to have high strength and durability.

[0007] 5. Reducing friction: The design of the traveling wheels needs to reduce the friction with the rails, improve the smoothness of movement and extend the service life.

[0008] 6. Safety protection: The traveling wheels need to have functions such as anti-slip and anti-derailment to ensure safe operation.

[0009] In metallurgical enterprises, the overhead crane is the core equipment for material transfer, and is widely used for equipment hoisting, transportation of high-temperature materials such as molten iron, molten steel, and steel slag, and transfer of products such as steel plates. Since the metallurgical industry belongs to heavy industry, the overhead crane has a high usage frequency and a harsh working environment, involving factors such as high temperature, humidity, and dust. These conditions significantly exacerbate the wear and damage of the traveling wheels. During long-term operation, due to heavy loads, frequent movement, and environmental impacts, the traveling wheels of the overhead crane often show damage forms such as hub fracture, flange wear, tread wear, bearing damage, fatigue cracks, seal aging, and rail gnawing. These damages not only affect the performance of the overhead crane, but may also cause serious consequences. For example, damaged traveling wheels may cause components to fall from a height, damage the traveling rails, or cause the overhead crane to lose balance due to missing components, threatening the safety of personnel. Especially in the scenario of lifting molten metal in metallurgical enterprises, the damage of the traveling wheels may cause the material to spill, triggering group death and injury accidents, resulting in major safety and economic losses.

[0010] At present, the main methods for metallurgical enterprises to deal with the damage of the traveling wheels of the overhead crane include the following three:

[0011] 1. Shutdown and replacement:

[0012] Advantages: It can thoroughly inspect and repair the running wheels and related components to ensure the repair quality.

[0013] Disadvantages: The shutdown time is long. It takes about 4 hours to replace one running wheel of a large overhead crane and about 2 hours for a small overhead crane, seriously affecting production efficiency.

[0014] Applicable scenarios: The running wheels are severely worn and cannot continue to operate, or the production plan allows for a long shutdown.

[0015] 2. Replacement without shutdown:

[0016] Advantages: It has less impact on production and can be gradually replaced during production breaks.

[0017] Disadvantages: It is only applicable to slightly worn running wheels or partial replacements, and cannot be used for serious damage such as hub fractures and flange wear.

[0018] Applicable scenarios: The running wheels are slightly damaged, or the production tasks are urgent and shutdown is not allowed.

[0019] 3. Online replacement:

[0020] Advantages: It hardly affects production, has a fast replacement speed, is suitable for emergency situations, and reduces economic losses.

[0021] Disadvantages: It has high technical requirements, requires professional equipment and personnel, there are safety hazards during the replacement process, and the running wheels need additional debugging after replacement.

[0022] Applicable scenarios: The running wheels are slightly worn and the enterprise has the corresponding technical conditions.

[0023] The deficiencies of the above methods are significant: Shutdown replacement takes a long time, affecting the continuous production rhythm of metallurgical enterprises. Especially in key processes such as steelmaking and rolling, the shutdown of one overhead crane will disrupt the production plans of converters, continuous casters, rolling mills, etc.; Replacement without shutdown and online replacement are only applicable to minor damages, and cannot handle situations such as hub fractures and severe flange wear. Moreover, online replacement has high technical and equipment requirements and there are safety risks. These problems make it difficult for enterprises to quickly resume operation while ensuring safety and production efficiency when facing serious damage to the running wheels. Summary of the Invention

[0024] In view of this, the purpose of the present invention is to provide an emergency device and method for damaged running wheels of metallurgical overhead cranes, to solve the problem of shutdown replacement required when the running wheels of the overhead crane of the large car are severely damaged, and to ensure the continuous production and operation safety of metallurgical enterprises.

[0025] To achieve the above purpose, the present invention provides the following technical solutions:

[0026] An emergency device for a metallurgical crane travel wheel damage, the emergency device is made of Q235 steel, in a trapezoidal structure, the length of the lower side of the trapezoid is 200mm, the length of the upper side is 100mm, the height is 100mm, and the thickness is 40mm;

[0027] On the two large surfaces of the longest side of the emergency device, there are 10mm bevels respectively; the emergency device is welded on both sides of the fixed seat of the crane trolley travel wheel, with a 5mm interval from the support column of the crane trolley travel wheel; when the crane trolley travel wheel is damaged, remove the damaged travel wheel, and the emergency device interacts with the support column of the crane trolley to bear the support force of the original travel wheel to maintain the balance and running stability of the crane.

[0028] Furthermore, the welding position of the emergency device ensures that the long side of the bottom of the device is completely welded on the fixed seat of the crane trolley travel wheel, and the welding quality meets the requirement of bearing the support force of the original travel wheel.

[0029] Furthermore, the emergency device is welded and installed on both sides of each fixed seat of the crane trolley travel wheel during the crane shutdown and maintenance period.

[0030] An emergency method for a metallurgical crane travel wheel damage using the above emergency device, including the following steps:

[0031] (1) Manufacture the emergency device according to the design requirements;

[0032] (2) Confirm the installation position of the device on the fixed seat of the crane trolley travel wheel, ensure that the interval between the device and the support column of the crane trolley travel wheel is ≤5mm, and the long side of the bottom of the device is completely welded on the fixed seat;

[0033] (3) During the crane shutdown and maintenance period, weld the device on both sides of each fixed seat of the crane trolley travel wheel;

[0034] (4) When the crane trolley travel wheel is severely damaged, use the production gap of the crane operation to remove the damaged travel wheel;

[0035] (5) Make the emergency device installed on the fixed seat interact with the support column of the crane trolley to bear the support force of the original travel wheel to maintain the balance and running stability of the crane;

[0036] (6) Resume the production of the crane.

[0037] Furthermore, this method is applicable when the hub of the crane trolley travel wheel breaks, the wheel rim wears, the tread wears, the bearing is damaged, or there are fatigue cracks.

[0038] Furthermore, this method does not require production suspension to replace the travel wheel, and saves at least 4 hours of replacement time for each treatment.

[0039] Furthermore, through the load-bearing effect of the emergency device, this method eliminates the safety risks of object strikes, unstable operation of the crane, spillage of molten metal during hoisting, or dropping of items caused by damaged running wheels.

[0040] The beneficial effects of the present invention are as follows:

[0041] The present invention provides an emergency device and method for damaged running wheels of a metallurgical crane, which have significant technical advantages and economic benefits.

[0042] First of all, the present invention does not require production stoppage to replace the running wheels. The damaged running wheels are removed during the production gap, and the emergency device is used to bear the supporting force. Each treatment can save at least 4 hours of production stoppage time, significantly improving production efficiency. For metallurgical enterprises, continuous production is the core competitiveness. The traditional production stoppage and replacement method may disrupt the production rhythm of processes such as steelmaking and rolling. However, the present invention ensures the rapid restoration of the crane's operation and maintains the stability of the production plan.

[0043] Secondly, through the load-bearing effect of the emergency device, the present invention eliminates various safety risks caused by damaged running wheels, including high-altitude falling of objects, unstable operation of the crane, spillage of molten metal during hoisting, and dropping of items, etc., preventing mass casualty accidents caused by damaged running wheels and ensuring the safety of personnel and equipment.

[0044] In addition, the present invention creates significant economic benefits for enterprises. Calculated based on saving 4 hours per treatment, a smelting cycle of 35 minutes per furnace, a production of 210 tons per furnace, and a profit of 100 yuan per ton, each treatment can generate indirect economic benefits of approximately 144,000 yuan (4×60 / 35×210×100 = 144,000 yuan). For metallurgical cranes with high-frequency use, multiple applications of the present invention can accumulate considerable economic returns.

[0045] At the same time, the present invention has a wide range of applicability and can cope with various serious damage scenarios such as hub fracture, flange wear, tread wear, bearing damage, and fatigue cracks, making up for the limitations of non-production stoppage replacement and on-line replacement which are only applicable to minor damage.

[0046] Furthermore, the present invention is made of Q235 steel, with low cost, simple processing, and easy to promote and apply. The emergency device can be reused during planned maintenance, reducing the maintenance cost and extending the overall service life of the crane.

[0047] In summary, the present invention has significant advantages in ensuring safety, improving efficiency, creating benefits, and promoting application, providing an efficient and economic emergency solution for damaged running wheels for metallurgical enterprises.

[0048] Other advantages, objects and features of the present invention will be set forth in part in the following description, and in part will be obvious to those skilled in the art upon examination of the following, or may be learned by practice of the present invention. The objects and other advantages of the present invention may be realized and obtained by the following description of the specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be described in detail preferably with reference to the accompanying drawings, where:

[0050] Figure 1 It is the front view of the emergency device for the damage of the metallurgical crane wheel in the present invention.

[0051] Figure 2 is Figure 1 the left view of. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0052] The following specific examples illustrate the embodiments of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the drawings provided in the following embodiments only illustrate the basic concept of the present invention in a schematic manner. Without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0053] Among them, the drawings are only for illustrative purposes, showing only schematic diagrams, not physical diagrams, and should not be construed as a limitation to the present invention; in order to better illustrate the embodiments of the present invention, some components in the drawings will be omitted, enlarged or reduced, which do not represent the dimensions of the actual product; for those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted.

[0054] In the drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", "front", "rear", etc. indicating the orientation or positional relationship, they are based on the orientation or positional relationship shown in the drawings. It is 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. Therefore, the terms describing the positional relationship in the drawings are only for illustrative purposes and should not be construed as a limitation to the present invention. For those of ordinary skill in the art, the specific meanings of the above terms can be understood according to specific circumstances.

[0055] Example 1: Emergency Device and Method in the Scenario of Wheel Hub Fracture

[0056] In this example, aiming at the serious damage situation of the wheel hub fracture of the traveling wheels of the metallurgical crane trolley, an emergency device and method for the damage of the traveling wheels of the metallurgical crane are applied to quickly resume the operation of the crane and ensure the continuity and safety of production.

[0057] Structure and Fabrication of the Emergency Device

[0058] As Figures 1-2 shown, the emergency device is made of Q235 steel, with a trapezoidal structure. The length of the lower side of the trapezoid is 200 mm, the length of the upper side is 100 mm, the height is 100 mm, and the thickness is 40 mm. Grooves with a depth of 10 mm are machined on the two large surfaces of the longest side of the device to ensure firm welding. During the fabrication process, the steel is processed using numerical control cutting equipment strictly according to the requirements of the design drawings to ensure dimensional accuracy. The groove machining uses special equipment to ensure that the groove angle and depth are consistent.

[0059] Implementation Steps of the Emergency Method

[0060] Device Fabrication: According to the design requirements, select Q235 steel and process it into a trapezoidal structure with dimensions of 200 mm for the lower side, 100 mm for the upper side, 100 mm for the height, and 40 mm for the thickness. Grooves with a depth of 10 mm are machined on the two large surfaces of the longest side.

[0061] Installation Position Confirmation: Measure and mark the installation position on the fixed seat of the traveling wheel of the crane trolley to ensure that the interval between the device and the support column of the traveling wheel of the crane trolley is ≤ 5 mm, and the long side at the bottom of the device can be completely welded to the surface of the fixed seat.

[0062] Device Welding: Utilize the planned shutdown and maintenance time of the crane (such as monthly maintenance), and weld the emergency device to both sides of the fixed seat of each traveling wheel of the crane trolley using manual arc welding. When welding, use E5015 electrodes to ensure that the welds are full and free of pores, and the welding quality meets the requirements of bearing the original wheel support force (about 50 tons of vertical load).

[0063] Wheel Removal: In a continuous casting workshop of a metallurgical enterprise, the wheel hub of a traveling wheel of a crane trolley fractured, resulting in the crane being unable to operate normally. During the production gap (about 30 minutes), use a hydraulic jack to lift the crane and remove the damaged wheel.

[0064] Device Bearing Force: After the wheel is removed, the emergency device welded to the fixed seat interacts with the support column of the traveling wheel of the crane trolley to bear the original wheel support force. The trapezoidal structure of the device and the high strength of Q235 steel ensure that the crane remains balanced and stable under heavy load (about 100 tons).

[0065] Production Resumption: Check the operation status of the crane. After confirming that there is no abnormality, the crane resumes normal production and is used for transporting continuous casting billets.

[0066] In this embodiment, the emergency device and method successfully cope with the serious damage caused by the fracture of the wheel hub, eliminating the need to stop production for replacing the running wheel. The treatment process only takes 30 minutes, saving more than 3.5 hours compared with the traditional method of stopping production for replacement (about 4 hours), and avoiding the interruption of the production rhythm of the continuous casting machine. The load-bearing function of the device eliminates the risks of object falling and crane instability caused by the fracture of the running wheel, ensuring the safety of the molten steel hoisting. By maintaining continuous production, this embodiment creates an indirect economic benefit of approximately 144,000 yuan for the enterprise (calculated based on a smelting cycle of 35 minutes per furnace, 210 tons per furnace, and 100 yuan per ton).

[0067] Embodiment 2: Emergency Device and Method in the Scenario of Rim Wear

[0068] In this embodiment, aiming at the situation of severe wear on the rim of the driving wheels of the metallurgical crane, the emergency device and method are applied in the high-temperature environment of the steelmaking workshop to quickly resume the operation of the crane, demonstrating economic benefits and applicability.

[0069] Structure and Fabrication of the Emergency Device

[0070] The emergency device is made of Q235 steel, with a trapezoidal structure. The length of the lower side of the trapezoid is 200 mm, the length of the upper side is 100 mm, the height is 100 mm, and the thickness is 40 mm. There are 10-mm grooves on the two large surfaces of the longest side of the device to ensure firm welding. During fabrication, Q235 steel plates meeting the GB / T 700 standard are selected, cut into trapezoids by a numerical control cutting machine, and the grooves are processed by a plasma cutting device to ensure smooth groove surfaces and excellent welding performance.

[0071] Implementation Steps of the Emergency Method

[0072] Device Fabrication: Process Q235 steel into a trapezoidal structure according to the requirements of the design drawings, with dimensions of 200 mm for the lower side, 100 mm for the upper side, 100 mm for the height, and 40 mm for the thickness, and process 10-mm grooves on the two large surfaces of the longest side.

[0073] Installation Position Confirmation: Use a laser rangefinder on the fixed seat of the driving wheels of the crane to confirm the installation position, ensuring that the distance between the device and the support column is ≤5 mm, the long side at the bottom is completely fitted to the surface of the fixed seat, and there is no oil stain or rust in the welding area.

[0074] Device Welding: During the annual maintenance of the crane (with an 8-hour shutdown), weld the emergency device to both sides of each driving wheel fixed seat using gas shielded welding (CO2 welding). The welding process parameters are a current of 180 A and a voltage of 22 V to ensure that the weld strength meets the requirement of a support force of more than 50 tons.

[0075] Wheel removal: In the steelmaking workshop of a metallurgical enterprise, a crane was running unsteadily due to severe wear of the wheel rim (wear depth reached 15mm). During the converter replacement interval (about 40 minutes), the crane was lifted by lifting equipment and the damaged wheel was removed.

[0076] Device load-bearing capacity: After the running wheels are removed, the emergency device contacts the support column and takes on the support force of the original running wheels. The trapezoidal design of the device optimizes the force distribution, and the yield strength (235MPa) of Q235 steel ensures driving stability under high temperature (50℃) and heavy load (120 tons) environments.

[0077] Resumption of production: After checking the crane track and running balance, the crane is resumed for lifting of molten steel ladles.

[0078] This embodiment successfully copes with the serious damage caused by wheel rim wear. The treatment process does not require production suspension and is completed in only 40 minutes, saving about 3.5 hours of production suspension time and avoiding losses caused by suspension of the steelmaking process. The emergency device eliminates the risks of rail gnawing, vehicle instability and molten steel spilling due to wheel rim wear, and ensures the safety of personnel and equipment in high-temperature environments. This embodiment creates indirect economic benefits of approximately 144,000 yuan for the enterprise (calculated at 35 minutes per furnace, 210 tons / furnace, and 100 yuan / ton). In addition, the device has a low manufacturing cost (about 500 yuan / unit) and can be reused in multiple overhauls, reducing maintenance costs, making it suitable for promotion to other metallurgical enterprises.

[0079] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution, which should be included in the scope of the claims of the present invention.

Claims

1. An emergency device for metallurgical crane wheel damage, characterized by: The emergency device is made of Q235 steel and has a trapezoidal structure. The lower side of the trapezoid is 200 mm long, the upper side is 100 mm long, the height is 100 mm, and the thickness is 40 mm. The two large surfaces of the longest side of the emergency device are respectively provided with a 10mm groove; the emergency device is welded to both sides of the crane trolley wheel fixing seat, and is 5mm apart from the crane trolley wheel support column; when the crane trolley wheel is damaged, the damaged wheel is removed, and the emergency device interacts with the crane trolley support column to take over the supporting force of the original wheel to maintain the balance and operation stability of the crane.

2. The emergency device for metallurgical crane wheel damage according to claim 1, characterized in that: The welding position of the emergency device ensures that the long side of the bottom of the device is completely welded to the traveling trolley running wheel fixing seat, and the welding quality meets the requirements of bearing the original running wheel supporting force.

3. The emergency device for metallurgical crane wheel damage according to claim 1, characterized in that: The emergency device is welded and installed on both sides of each traveling crane trolley running wheel fixing seat during the crane shutdown and maintenance period.

4. An emergency method for metallurgical crane running wheel damage using the emergency device according to any one of claims 1 to 3, characterized in that: The following steps are involved: (1) Produce the emergency device according to the design requirements; (2) Confirm the installation position of the device on the trolley wheel fixing seat, ensure that the distance between the device and the trolley wheel support column is ≤ 5 mm, and the long side of the bottom of the device is completely welded to the fixing seat; (3) During the crane shutdown and maintenance period, the device is welded to both sides of each crane trolley wheel fixing seat; (4) When the running wheels of the crane are seriously damaged, the damaged running wheels can be removed during the production interval of the crane; (5) The emergency device installed on the fixed seat interacts with the support column of the trolley to bear the support force of the original running wheel to maintain the balance and running stability of the trolley; (6) Resume operation of the vehicle.

5. The emergency method for metallurgical crane wheel damage according to claim 4, characterized in that: This method is applicable when the traveling wheels of a crane have hub breakage, rim wear, tread wear, bearing damage or fatigue crack damage.

6. The emergency method for metallurgical crane wheel damage according to claim 4, characterized in that: This method does not require stopping production to replace the wheels, and saves at least 4 hours of replacement time for each treatment.

7. The emergency method for metallurgical crane wheel damage according to claim 4, characterized in that: The method eliminates the safety risks of being hit by objects, driving instability, spilling of hoisted molten metal, or falling of objects due to damage to the running wheels through the load-bearing effect of the emergency device.

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