Large marine tank pump opening and supporting assembly mounting process

Abstract

The invention relates to the technical field of ship outfitting, in particular to a large marine tank pump opening and supporting assembly installation technology which comprises the steps that firstly, equipment preparation is conducted, specifically, welding equipment, optical alignment equipment, a pump opening assembly and a supporting assembly are prepared; 2, preliminary cleaning: cleaning the surfaces of the pump port assembly and the supporting assembly to ensure no dirt and damage; and thirdly, a supporting assembly is arranged, wherein the supporting assembly is arranged at the pump opening mounting position. And 4, a pump opening assembly is arranged, specifically, the pump opening assembly is arranged above the supporting assembly. And 5, optical alignment equipment is arranged, wherein the optical alignment equipment is arranged on the pump port assembly. And sixthly, accurate alignment is conducted, wherein optical alignment equipment is used for accurate alignment, and it is ensured that the centers of the pump opening assembly and the supporting assembly are consistent. And seventhly, welding operation is conducted, specifically, welding equipment is started, and the adjusted pump opening assembly is welded and fixed. And 8, inspection is completed, wherein after welding is completed, the strength and integrity of the connector are inspected. According to the invention, the installation precision is improved, the failure rate is reduced, and the operation stability of equipment is enhanced.

Description

Technical Field

[0001] The present invention belongs to the technical field of ship outfitting, and particularly relates to an installation process for a large marine tank pump nozzle and support assembly. Background Art

[0002] The installation of the pump nozzle and support assembly is crucial in mechanical engineering and manufacturing, ensuring the normal operation and stability of the equipment. With the advancement of industrial automation and intelligence, the installation accuracy requirements for pump nozzle components are gradually increasing. Existing technologies still have certain limitations in practical applications, such as inaccurate alignment, easy damage to equipment, and low installation efficiency, which affect the overall installation effect and production efficiency. Specifically, although the existing alignment flange technology can provide a certain alignment effect, its accuracy is greatly affected by environmental factors, easily resulting in errors. The use of optical instruments and lasers requires high operating skills and high equipment costs, limiting their widespread application. In addition, the guiding structures used for the installation of tank pump nozzles also have deficiencies in terms of accuracy and stability, making it difficult to meet the industrial applications with high-precision requirements. Therefore, the industry urgently needs a more efficient and accurate installation technology to adapt to the continuously improving market demands and technical standards. Summary of the Invention

[0003] The purpose of the present invention is to provide an installation process for a large marine tank pump nozzle and support assembly, which is used to solve the technical problems that the installation accuracy in the prior art is greatly affected by environmental factors, and the operator needs to have high operating skills, resulting in insufficient actual installation accuracy and stability.

[0004] The described installation process for a large marine tank pump nozzle and support assembly includes the following steps.

[0005] I. Equipment Preparation: Prepare welding equipment, optical alignment equipment, pump nozzle components, and support components.

[0006] II. Preliminary Cleaning: Clean the surfaces of the pump nozzle components and support components to ensure no dirt or damage.

[0007] III. Setting the Support Assembly: Set up the support assembly at the pump nozzle installation position.

[0008] IV. Setting the Pump Nozzle Components: Set up the pump nozzle components above the support assembly.

[0009] V. Setting the Optical Alignment Equipment: Set up the optical alignment equipment on the pump nozzle components.

[0010] VI. Precise Alignment: Use the optical alignment equipment for precise alignment to ensure that the centers of the pump nozzle components and the support assembly are consistent.

[0011] VII. Welding Operation: Start the welding equipment and weld and fix the adjusted pump nozzle components.

[0012] VIII. Completion of inspection: After welding is completed, inspect the joint strength and integrity.

[0013] Preferably, the pump port assembly includes a pump body, a pump port flange, a connecting pipe, and an alignment flange for setting an optical alignment device. The alignment flange is concentric with and fixedly connected to the pump port flange, and the center of the alignment flange has a mounting bracket for mounting the optical alignment device.

[0014] Preferably, the support assembly includes a support frame, a fixing clamp, a wooden guide ring, and a calibration table. The support frame is used to support the support assembly and provide overall stability, and the fixing clamp is used for locking and fixing; the wooden guide ring is fixed on the top of the support frame by the fixing clamp, the calibration table is pasted on the top surface of the wooden guide ring, and the calibration center of the calibration table is located at the center of the support assembly and also at the center of the wooden guide ring.

[0015] Preferably, in step three, the support frame is fixed to the pump port installation position by the fixing clamp. In step four, the pump port assembly and the support assembly are initially docked through mechanical alignment, and a spirit level is used to initially align the pump port flange and the alignment flange in the pump port assembly.

[0016] Preferably, the alignment flange of the pump port assembly is fixedly connected with an adjusting structure. The adjusting structure is threadedly installed with adjusting screws at the outer edge, and the bottom end of the adjusting screw abuts against the installation base surface. A number of adjusting screws are arranged on the periphery of the alignment flange; in step six, the position and flatness of the pump port assembly can be dynamically adjusted by adjusting the adjusting screws.

[0017] Preferably, in step six, first use the optical alignment device for initial alignment to ensure that the centers of the pump port flange and the wooden guide ring are consistent; then perform dynamic adjustment, and gradually adjust the position of the pump port assembly according to the measurement data until the flatness and alignment requirements of the pump port assembly are met; the adjustment of the pump port assembly is mainly based on the feedback obtained from the calibration table by the optical alignment device.

[0018] Preferably, in step seven, after ensuring the alignment accuracy, start the welding equipment for welding; a monitoring system can be used to collect data during the installation process in real time, monitor the welding temperature and welding strength in real time, and control the welding temperature within an appropriate range to prevent deformation of relevant materials and ensure the reliability of the joint.

[0019] Preferably, the welding equipment is a high-precision argon arc welding equipment, and the optical alignment device uses a high-precision optical instrument or a laser.

[0020] Preferably, the flatness requirement of the support assembly is ≤5 mm, the flatness requirement of the pump port assembly is ≤0.4 mm, and the measurement accuracy of the optical alignment device should reach 0.1 mm.

[0021] Preferably, the material of the pump port flange is stainless steel 304, and the welding temperature is controlled between 140 and 200 degrees Celsius during the welding process.

[0022] The present invention has the following advantages:

[0023] First, the installation accuracy is improved: The present invention uses an optical alignment device for precise alignment, and can strictly control the flatness of the pump port component flange to be less than or equal to 0.4 mm, and the flatness of the support component to be less than or equal to 3 mm. Therefore, this technical solution significantly improves the installation accuracy of the pump port and the support component. Compared with the prior art, the installation accuracy is improved by about 30%. This improvement in accuracy ensures the central alignment of the pump port component and the guide ring, thereby reducing the risk of fluid leakage and equipment failure caused by improper alignment.

[0024] Second, the failure rate is reduced: During the implementation process, the present invention monitors the welding process in real time to ensure that the welding strength and temperature are controlled within a reasonable range, reducing the failure rate during subsequent use. Experimental data shows that after applying this technical solution, the failure rate is reduced by 40%. Compared with traditional methods, the maintenance and replacement frequency are reduced, and the long-term operation and maintenance costs are reduced, which is reflected as higher equipment reliability in practical applications.

[0025] Third, the operation stability is enhanced: The present invention controls the key parameters during the installation process to ensure the normal operation of the pump. Data shows that in actual operation, the operation stability of the equipment is improved by 35%. This effect directly comes from the combination of optical alignment technology and real-time data feedback, enabling the components to always maintain a stable state during the welding process, reducing performance fluctuations caused by deformation. The innovation of this technical feature ensures the efficient operation of the entire system and further improves the work efficiency. Description of the Drawings

[0026] Figure 1 It is a schematic structural diagram of the pump port component in the installation process of a large marine tank pump port and support component of the present invention.

[0027] Figure 2 It is Figure 1 A schematic structural diagram of the alignment flange in the shown structure.

[0028] Figure 3 It is a schematic structural diagram of the support component in the present invention.

[0029] Figure 4 It is Figure 3 A schematic structural diagram of the wooden guide ring in the shown structure.

[0030] In the figure: 1, connecting pipe; 2, pump port flange; 3, alignment flange; 4, optical alignment device; 5, adjustment structure; 6, adjustment screw; 7, mounting bracket; 8, wooden guide ring; 9, calibration table; 10, support frame. Specific Embodiments

[0031] The following describes the specific embodiments of the present invention in further detail with reference to the accompanying drawings and through the description of the embodiments, so as to help those skilled in the art have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention.

[0032] As Figures 1-4 shown, the present invention provides an installation process for a large marine tank pump port and support assembly, including the following steps.

[0033] I. Equipment Preparation: Prepare welding equipment, optical alignment equipment 4, pump port assembly and support assembly.

[0034] The welding equipment should be a high-precision argon arc welding equipment.

[0035] The optical alignment equipment 4 uses high-precision optical instruments or lasers, which can measure the flatness and alignment of the flange in real time during the installation process.

[0036] The pump port assembly consists of a pump body, a pump port flange 2 and a connecting pipe 1. The connecting pipe 1 is composed of barrel sections, and the pump port flange 2 is fixed on the top of the connecting pipe 1.

[0037] The pump port assembly further includes an alignment flange 3 for setting the optical alignment equipment 4. The alignment flange 3 is concentric with the pump port flange 2 and fixedly connected together. The center of the alignment flange 3 has a mounting bracket 7, and the optical alignment equipment 4 is fixed on the mounting bracket 7 and can be aligned downward.

[0038] The support assembly includes a support frame 10 and a fixing clamp. The support frame 10 is used to support the support assembly and provide overall stability, and the fixing clamp is used for locking and fixing. The support assembly further includes a wooden guide ring 8 and a calibration table 9 pasted on the top surface of the wooden guide ring 8. The wooden guide ring 8 is fixed on the top of the support frame 10 by the fixing clamp, and the calibration center of the calibration table 9 is located at the center of the support assembly, that is, the center of the wooden guide ring 8 after installation.

[0039] The calibration table 9 is marked with adjustment parameters at different distances from the calibration center and corresponding marking lines. When the calibration light spot emitted by the optical instrument falls on different marking lines, the operator can adjust the pump port assembly according to the adjustment parameters corresponding to the marking line.

[0040] If a monitoring system is set up, it also needs to be prepared. The monitoring system can collect data during the installation process in real time, ensure that all parameters meet the design requirements, and make timely adjustments. In a preferred embodiment, the response time of the monitoring system ≤ 1 second.

[0041] II. Preliminary Cleaning: Clean the surfaces of the pump port assembly and the support assembly to ensure no dirt or damage.

[0042] III. Set up the support component: Set up the support component at the pump port installation position.

[0043] The material of the support frame 10 is low-carbon steel, and it is fixed to the pump port installation position through another set of fixing jigs. This set of fixing jigs should be able to withstand a tensile force of at least 200 kg. The flatness requirement of the support component is ≤5 mm. In a preferred embodiment, the flatness requirement of the support component is ≤3 mm.

[0044] IV. Set up the pump port component: Set up the pump port component above the support component.

[0045] The pump port component and the support component are initially docked through mechanical alignment, and a simple level is used to initially align each flange in the pump port component. In the embodiment, the diameter of the pump port component flange is 80 mm and the thickness is 10 mm. The size of the pump port flange 2 is DN80, the material is stainless steel 304, and the flatness requirement is ≤0.4 mm.

[0046] The pump port component is connected to the fixing jig of the support component through a flange, and the alignment flange 3 of the pump port component is fixedly connected with an adjustment structure 5. The adjustment structure 5 is threadedly installed with an adjustment screw 6 at the outer edge. The bottom end of the adjustment screw 6 abuts against the installation base surface. A number of adjustment screws 6 are arranged on the periphery of the alignment flange 3. In step VI later, the position, flatness and other parameters of the pump port component can be dynamically adjusted by adjusting the adjustment screw 6.

[0047] V. Set up the optical alignment device 4: Set up the optical alignment device 4 on the pump port component to prepare for precise alignment.

[0048] The optical alignment device 4 is installed at the center of the pump port component, and the alignment direction is directly downward. The measurement accuracy of the optical alignment device 4 should reach 0.1 mm. The pump port component includes an installation frame 7 at the center of the alignment flange 3. The installation frame 7 is cross-shaped and has a central hole at the center. The optical alignment device 4 is fixed on the installation frame 7 and the alignment structure such as the laser emission head is located at the center of the central hole.

[0049] VI. Precise alignment: Use the optical alignment device 4 for precise alignment to ensure that the centers of the pump port component and the support component are consistent.

[0050] During alignment, first use the optical alignment device 4 for preliminary alignment to ensure that the centers of the pump port flange 2 and the wooden guide ring 8 are consistent. Then perform dynamic adjustment, and gradually adjust the position of the pump port component according to the measurement data until the flatness and alignment requirements of the pump port component are met. The adjustment of the pump port component is mainly based on the feedback obtained by the optical alignment device 4 from the calibration table 9.

[0051] VII. Welding operation: Start the welding equipment and weld and fix the adjusted pump port component.

[0052] After ensuring the alignment accuracy, start the welding equipment for welding, and monitor the welding temperature and welding strength in real time through the monitoring system. This step controls the welding temperature within an appropriate range to prevent deformation of relevant materials and ensure the reliability of the joint. During the whole process, the welding equipment and the monitoring system cooperate to ensure that the welding temperature is controlled between 140 and 200 degrees Celsius during the welding process, ensuring the welding quality. In a preferred embodiment, the welding temperature is controlled between 140 and 180 degrees Celsius.

[0053] VIII. Completion inspection: After welding is completed, inspect the joint strength and integrity.

[0054] This step can also record the welding process through the installed monitoring system to assist in the inspection of the welding effect. The monitoring system should have the functions of real-time data recording and feedback.

[0055] During the whole installation process, the optical alignment device 4 cooperates with the pump port assembly and the support assembly. Through real-time data feedback, it ensures the stability and docking accuracy of the flange during the welding process. The monitoring system records and analyzes the whole process, providing data support for subsequent improvements. Through the implementation of the basic embodiment, a pressure test is carried out after installation. The results show that there is no leakage phenomenon after installation and the equipment operates stably.

[0056] This technical solution significantly improves the installation accuracy of the pump port and the support assembly. Compared with the prior art, the installation accuracy is improved by about 30%. This improvement in accuracy ensures the central alignment of the pump port assembly and the guide ring, thereby reducing the risk of fluid leakage and equipment failure caused by improper alignment.

[0057] The present invention has been described exemplarily above in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited by the above methods. As long as various non-substantial improvements are made by adopting the inventive concept and technical solution of the present invention, or the inventive concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention.

Claims

1. An installation process for a large marine tank pump port and support assembly, characterized in that: It includes the following steps: I. Equipment preparation: Prepare welding equipment, optical alignment equipment, pump port assembly and support assembly; II. Preliminary cleaning: Clean the surfaces of the pump port assembly and the support assembly to ensure no dirt or damage; III. Set up the support assembly: Set up the support assembly at the pump port installation position; IV. Set up the pump port assembly: Set up the pump port assembly above the support assembly; V. Set up the optical alignment equipment: Set up the optical alignment equipment on the pump port assembly; VI. Precise alignment: Use the optical alignment equipment for precise alignment to ensure that the centers of the pump port assembly and the support assembly are consistent; VII. Welding operation: Start the welding equipment to weld and fix the adjusted pump port assembly; VIII. Completion inspection: After welding, check the joint strength and integrity.

2. The installation process of a large marine tank pump port and support assembly according to claim 1, characterized in that: The pump port assembly includes a pump body, a pump port flange, a connecting pipe, and an alignment flange for setting the optical alignment equipment. The alignment flange is concentric with the pump port flange and fixedly connected together. The center of the alignment flange has a mounting bracket for installing the optical alignment equipment.

3. A mounting process for a large marine tank pump port and support assembly according to claim 2, characterized in that: The support assembly includes a support frame, a fixing clamp, a wooden guide ring, and a calibration table. The support frame is used to support the support assembly and provide overall stability. The fixing clamp is used for locking and fixing. The wooden guide ring is fixed on the top of the support frame by the fixing clamp. The calibration table is pasted on the top surface of the wooden guide ring. The calibration center of the calibration table is located at the center of the support assembly and also at the center of the wooden guide ring.

4. A mounting process for a large marine tank pump port and support assembly according to claim 3, characterized in that: In step III, the support frame is fixed to the pump port installation position by the fixing clamp. In step IV, the pump port assembly and the support assembly are initially docked through mechanical alignment, and a spirit level is used to initially align the pump port flange and the alignment flange in the pump port assembly.

5. A mounting process for a large marine tank pump port and support assembly according to claim 4, characterized in that: The alignment flange of the pump port assembly is fixedly connected with an adjustment structure. The adjustment structure is threadedly installed with adjustment screws at the outer edge. The bottom end of the adjustment screw abuts against the installation base surface. Several adjustment screws are arranged on the periphery of the alignment flange. In step VI, the position and flatness of the pump port assembly can be dynamically adjusted by adjusting the adjustment screws.

6. A mounting process for a large marine tank pump port and support assembly according to claim 5, characterized in that: In step VI, first use the optical alignment equipment for preliminary alignment to ensure that the centers of the pump port flange and the wooden guide ring are consistent; then perform dynamic adjustment, and gradually adjust the position of the pump port assembly according to the measurement data until the flatness and alignment requirements of the pump port assembly are met; the adjustment of the pump port assembly is mainly based on the feedback obtained from the calibration table by the optical alignment equipment.

7. A mounting process for a large marine tank pump port and support assembly according to claim 6, characterized in that: In step VII, after ensuring the alignment accuracy, start the welding equipment for welding; a monitoring system can be used to collect data during the installation process in real time, monitor the welding temperature and welding strength in real time, and control the welding temperature within an appropriate range to prevent deformation of relevant materials and ensure the reliability of the joint.

8. A mounting process for a large marine tank pump port and support assembly according to claim 1, characterized in that: The welding equipment is a high-precision argon arc welding equipment, and the optical alignment equipment uses a high-precision optical instrument or laser.

9. A mounting process for a large marine tank pump port and support assembly according to claim 1, characterized in that: The flatness requirement of the support assembly is ≤5 mm, the flatness requirement of the pump port assembly is ≤0.4 mm, and the measurement accuracy of the optical alignment equipment should reach 0.1 mm.

10. A mounting process for a large marine tank pump port and support assembly according to claim 2, characterized in that: The material of the pump port flange is stainless steel 304, and the welding temperature is controlled between 140 and 200 degrees Celsius during the welding process.

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