Intelligent disassembly and reproduction method for hydraulic support and disassembly and reproduction operation line

Abstract

The invention relates to an intelligent disassembly and reproduction method for a hydraulic support and a disassembly and reproduction operation line, and the method comprises the following steps: S1, carrying out disassembly treatment on the hydraulic support to obtain a primary assembly; s2, performing rough cleaning treatment on the first-stage assembly to obtain a second-stage assembly; s3, carrying out damage detection and quality evaluation on the secondary assembly; s4, the third-stage assembly is subjected to rust removal treatment and rust prevention treatment, and a fourth-stage assembly is obtained; s5, assembling the fourth-stage assembly to obtain a reproduced hydraulic support; when the pin shaft is disassembled, ultrasonic vibration is applied to the pin shaft in the axial direction of the pin shaft, elastic waves are excited at the stress concentration position between the pin shaft and the pin hole, the position of the pin shaft is dynamically adjusted according to the strength of the elastic waves, and the stress action condition between the pin shaft and the pin hole is changed. The technical problems that in the prior art, secondary damage is too large and the utilization rate is low when parts which relate to hydraulic support core supporting and rotating motion functions and are structurally connected through pin shafts and the pin shafts are disassembled are solved.

Description

Technical Field

[0001] The present invention relates to the field of intelligent manufacturing technology, and in particular to an intelligent disassembly and reproduction method for a hydraulic support and a disassembly and reproduction operation line. Background Art

[0002] As the core equipment in the existing coal mine comprehensive mining engineering technology, hydraulic supports are generally deployed under extreme working conditions such as high load, humidity and dust, and need to operate for a long time. They are prone to mechanical wear, corrosion and rust, metal structure fatigue and other losses, which lead to them being scrapped due to reasons such as failure to operate normally. However, the cost of a large hydraulic support can often reach hundreds of thousands or even millions of yuan. If it is directly scrapped and replaced with a new one, it will not only cause the company to incur high hydraulic support procurement costs, but may also cause waste of resources and environmental pollution. In the existing technology, in order to reduce the cost of using and purchasing hydraulic supports, waste hydraulic supports are usually processed through processes such as cleaning, disassembly, remanufacturing and assembly, and new hydraulic supports are reproduced using the disassembled parts to achieve the recycling of hydraulic support parts and reduce the production cost of hydraulic supports.

[0003] The existing processes for disassembling and reproducing hydraulic supports are not mature, and the utilization rate of the parts obtained is often unsatisfactory, especially the parts related to the core support and rotational motion functions of the hydraulic support, which are structurally connected by pins. The pins and the pin holes in the components they are connected to are mostly interference fit, and the connection is relatively tight, requiring a large force to remove the pins. On this basis, and after long-term use, the structure of the pins and pin holes often undergo uncertain and irregular changes due to factors such as stress changes, wear and corrosion, which in turn causes the shape of the pins to be unable to adapt to the pin holes. When removing the pin holes, the pins and pin holes are prone to conflict with each other, resulting in severe friction, collisions, extrusion, and scratches, causing secondary damage. In severe cases, the pins may even become stuck or break. The existing technology generally adopts the method of hydraulic traction + vibration impact when disassembling the pin shaft. Although the pin shaft can be removed quickly, it is easy to cause difficult-to-repair secondary damage to the pin shaft or the pin hole or cause the existing damage to be amplified during the process of removing the pin shaft. For example, when using vibration impact, the pin shaft and the pin hole are repeatedly scratched and the metal fatigue of the two is aggravated, cracks are generated and the existing cracks are further expanded. In the process of pulling out the pin shaft, the deformed part of the pin shaft scratches the pin hole, forming long cracks. The pin shaft gets stuck during the disassembly process and breaks under the action of excessive external force. It is difficult to achieve a high utilization rate. Summary of the Invention

[0004] (1) Technical issues to be resolved

[0005] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides an intelligent disassembly and reproduction method and a disassembly and reproduction operation line for a hydraulic support, which solves the technical problems in the prior art of excessive secondary damage and low utilization rate when disassembling parts and pins that are structurally connected by pins and involve the core support and rotational motion functions of the hydraulic support.

[0006] (2) Technical solution

[0007] In order to achieve the above objectives, the main technical solutions adopted by the present invention include:

[0008] In a first aspect, the present invention provides a method for intelligent disassembly and reproduction of a hydraulic support, comprising the following steps:

[0009] S1: dismantle the hydraulic support to obtain the first-level components;

[0010] S2: performing rough cleaning on the first-level components to obtain second-level components;

[0011] S3: Damage detection and quality assessment of the second-level components; if the quality assessment is qualified, the third-level components are obtained;

[0012] S4: performing rust removal and rust prevention treatment on the third-level components to obtain fourth-level components;

[0013] S5: Select the fourth-level components for assembly to obtain a reproduced hydraulic support;

[0014] In S1, the disassembly process of the pin shaft of the hydraulic support includes: continuously applying ultrasonic vibration to the pin shaft along the axial direction of the pin shaft; pushing the pin shaft during the ultrasonic vibration process; in the process of pushing the pin shaft, real-time detection of the elastic waves excited by the ultrasonic vibration on the pin shaft and the pin hole; when the elastic wave intensity exceeds the set range, dynamically adjusting the position of the pin shaft until the detected elastic wave intensity is within the set range; then continuing to push the pin shaft; the frequency of the ultrasonic vibration is in the range of 20-60kHz, and the amplitude is between 15-35μm.

[0015] Optional disassembly of the pins of the hydraulic support in S1, including:

[0016] Ultrasonic vibration is applied to the pin at the first end of the pin along the axial direction of the pin. After the ultrasonic wave lasts for a set time, the pin is sequentially subjected to a first pushing treatment and a second pushing treatment. In the first pushing treatment, the pin is directly pushed until the pin hole is extended out of the second end of the pin. In the second pushing treatment, the elastic waves excited by the ultrasonic vibration on the pin and the pin hole are detected in real time. When the intensity of the elastic wave exceeds the set range, the position of the pin is dynamically adjusted until the detected elastic wave intensity is within the set range; then the pin is continued to be pushed.

[0017] Optionally, in S1, dynamically adjusting the position of the pin includes: first retracting the pin a certain distance, then rotating the pin a certain angle, and then continuing to push the pin out. When the elastic wave intensity exceeds the set range, repeat the above process until the elastic wave intensity is within the set range.

[0018] Optionally, the frequency of the ultrasonic vibration is in the range of 35-45 kHz, and the amplitude is between 20-30 μm.

[0019] Optionally, in S2, the first-level components are subjected to rough cleaning, including: alternating high-pressure water jet cleaning and brushing treatments on the first-level components; when performing high-pressure water jet cleaning, the pressure of the high-pressure water jet is not less than 80 MPa; the travel speed of the first-level components does not exceed 0.5 m / s; the nozzle diameter of the high-pressure water jet is between 0.4 mm and 1 mm; the distance between the nozzle and the first-level components is between 10 cm and 30 cm.

[0020] Optionally, in S3, damage detection includes deformation detection, corrosion detection, and wear detection; quality assessment is performed according to the following weights: quality assessment = 0.6 × wear rate + 0.3 × corrosion degree + 0.1 × deformation degree;

[0021] When the quality evaluation is >0.8, it is judged as unqualified and scrapped;

[0022] When 0.3 < quality evaluation ≤ 0.8, it is judged as unqualified and repaired. If the quality evaluation after repair is qualified, it will be a third-level component. If the quality evaluation after repair is unqualified, it will be scrapped.

[0023] When the quality evaluation is ≤0.3, it is judged to be qualified and a third-level component is obtained.

[0024] Optionally, in S4, the rust removal treatment includes electrolytic treatment and ultrasonic treatment;

[0025] During electrolysis, the current density is between 3-8A / dm2, DC pulses are used, the pulse frequency is between 80-200Hz, and the duty cycle is between 1-1.5:3;

[0026] During ultrasonic treatment, the power density of the ultrasonic wave is between 0.5-1.2W / cm2 and the frequency is between 20-40kHz.

[0027] In a second aspect, the present invention further provides a disassembly and reproduction line for implementing the intelligent disassembly and reproduction method of the hydraulic support according to any one of the first aspects, comprising:

[0028] Disassembly system: used to disassemble the hydraulic support;

[0029] Rough cleaning system: used for rough cleaning of primary components;

[0030] Damage Detection System: used for damage detection and quality assessment of secondary components;

[0031] Fine cleaning system: used for rust removal of tertiary components;

[0032] Anti-rust treatment system: used for rust-proofing the tertiary components that have undergone rust removal treatment;

[0033] Assembly system: used to assemble four-level components;

[0034] The disassembly system also includes a first-level disassembly station.

[0035] Optionally, a pin disassembly frame is provided in the first-level disassembly station; the pin disassembly frame includes a frame body and a vibrator propulsion sleeve, a first acoustic emission sensor array, a first hydraulic pusher, a second hydraulic pusher and a rotary clamp arranged on the frame body, and an ultrasonic vibrator is provided at the top of the vibrator propulsion sleeve.

[0036] Optionally, the rough cleaning system includes a chain conveyor belt and a high-pressure water jet cleaning device and an electric roller brush cleaning device alternately arranged along the chain conveying direction.

[0037] (3) Beneficial effects

[0038] The beneficial effects of the present invention are as follows: the intelligent disassembly and reproduction method of a hydraulic support of the present invention applies ultrasonic vibration along the axial direction of the pin shaft during the disassembly of the pin shaft. Compared with the prior art, the ultrasonic vibration can not only loosen and peel off the rust layer and impurities on the surface of the pin shaft, but its better conduction effect can also be conducted along the metal to the part where the pin shaft and the hydraulic support are connected, thereby weakening the obstruction of the pin shaft to disassembly caused by rust, dirt and fastening impurities at the connection point, and avoiding the problem that the pin shaft is difficult to disassemble due to excessive rust or impurity blockage or forced disassembly causes damage to the parts of the hydraulic support. At the same time, since the waveform of the axial ultrasonic vibration is relatively simple, its vibration energy is highly conductive and has low loss, and can be transmitted to the entire pin shaft. Compared with the existing technology, it can not only stably reduce the tightness of the interface between the pin shaft and the pin hole through micro-friction, reduce the friction between the entire pin shaft and the pin hole, and avoid the secondary damage that may be caused by forced dismantling of the pin shaft; it can also stably excite elastic waves at the stress concentration point of the pin shaft and the pin hole through periodic vibration, and clearly reflect the stress relationship between the pin shaft and the pin hole through the excitation of the elastic wave, and dynamically adjust the position of the pin shaft based on this, improve the stress situation between the pin shaft and the pin hole, reduce the occurrence of secondary damage, avoid more serious secondary damage, and improve the utilization rate of parts and pin shafts that are structurally connected by pin shafts and the core support and rotational motion functions of the hydraulic support. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 This is a flow chart of Example 1 of a method for intelligent disassembly and reproduction of a hydraulic support according to the present invention;

[0040] Figure 2 This is a schematic diagram of a pin disassembly frame of Example 2 of an intelligent disassembly and reproduction line for a hydraulic support according to the present invention.

[0041] [Description of Reference Numerals]

[0042] 1: Frame body; 2: Vibrator propulsion sleeve; 3: First acoustic emission sensor array; 4: Second acoustic emission sensor array; 5: First hydraulic thruster; 6: Second hydraulic thruster; 7: Rotary clamp; 8: Ultrasonic vibrator; 9: Pin shaft to be disassembled. DETAILED DESCRIPTION

[0043] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below with reference to the accompanying drawings and through specific embodiments. Figure 2 The orientation is referenced.

[0044] Example 1:

[0045] This embodiment provides a method for intelligent disassembly and reproduction of a hydraulic support, such as Figure 1 As shown, the following steps are included:

[0046] S1: Disassemble the hydraulic support to obtain the first-level components.

[0047] S2: Perform a rough cleaning process on the first-level component to obtain a second-level component with no obvious attachments on the surface.

[0048] S3: Perform damage detection and quality assessment on the second-level components; if the quality assessment is qualified, the third-level components are obtained.

[0049] S4: performing rust removal and rust prevention treatment on the third-level components to obtain fourth-level components.

[0050] S5: Select the fourth-level components for assembly to obtain a reproduced hydraulic support.

[0051] Before dismantling the hydraulic support, the hydraulic support is transported to the dismantling system by a movable carrier for dismantling.

[0052] Preferably, in S1, the disassembly process of the hydraulic support includes a primary disassembly process and a secondary disassembly process.

[0053] During the first-level disassembly process, the main structure of the hydraulic support is disassembled in the order from top to bottom and from small to large. Through the first-level disassembly process, each single component with a relatively simple disassembly process is disassembled and separated from the hydraulic support one by one, such as the disassembly and separation of the pin shaft, hydraulic support structural parts, column as a whole and other structures, but does not include further disassembly of the component, such as the disassembly of the column body, hydraulic cylinder and other constituent structures in the column.

[0054] During the first-level disassembly process, the rail hoisting system with identification function is used to identify the corresponding hydraulic support components according to preset labels and / or visual recognition, and according to the disassembly progress of the disassembly system, the corresponding rail hoisting device is mobilized to perform preliminary hoisting and auxiliary fixation on the components being disassembled. The rail hoisting system is used to assist in fixing the components of the hydraulic support to avoid imbalance during the disassembly process and facilitate disassembly.

[0055] After disassembly, components such as pins and hydraulic support structures are immediately hoisted to a coarse cleaning system of corresponding specifications via a rail hoisting system. Components requiring further processing, such as columns, are transferred to a secondary disassembly station via the rail hoisting system for secondary disassembly. Once secondary disassembly is complete, they are hoisted to a coarse cleaning system of corresponding specifications via the rail hoisting system for further processing.

[0056] Preferably, in the first-level disassembly process, when disassembling the pin, ultrasonic vibration is first applied to the pin at the first end of the pin along the axial direction of the pin, and after the ultrasonic wave continues for a set time, the pin is sequentially subjected to a first pushing process and a second pushing process. In the first pushing process, the pin is directly pushed to the pin hole extending out of the second end of the pin; in the second pushing process, the ultrasonic vibration is continued to be maintained and the pin is pushed out, and the elastic waves excited by the ultrasonic vibration on the pin and the pin hole are detected in real time. When the elastic wave intensity exceeds the set range, the position of the pin is dynamically adjusted until the detected elastic wave intensity is within the set range; then the pin is continued to be pushed.

[0057] Specifically, when disassembling the pin, use the following method:

[0058] S11: An ultrasonic vibration device is provided at the first end of the pin shaft, and ultrasonic vibration is applied to the pin shaft along the axial direction of the pin shaft for a set time.

[0059] S12: Continuing to maintain the ultrasonic vibration, at the first end where the ultrasonic vibration is applied, applying a thrust to the pin in the axial direction of the pin, performing a first pushing process on the pin, and pushing the pin out partially from the second end.

[0060] S13: Continue to apply ultrasonic vibration to perform a second pushing treatment on the pin shaft. At the same time, the waveform (intensity) of the sound wave transmitted through the pin shaft is continuously monitored by a monitoring device set at the periphery of the pin hole at the second end of the pin shaft (the applied ultrasonic wave and the elastic wave it excites are transmitted to the pin hole through the pin shaft and then monitored by the detection device), and the stress change between the pin shaft and the pin hole is detected by the waveform of the sound wave.

[0061] S14: If no stress anomaly is detected between the pin and the hydraulic support during the second push-out process, or if the detected stress anomaly is within the set range, the pin is completely ejected, completing the disassembly of the pin. If a stress anomaly is detected that exceeds the set range, the pin's position is dynamically adjusted: pushing at the first end is stopped, ultrasonic vibration is maintained, and a thrust is applied at the second end to push the pin back a certain distance until the stress anomaly disappears or falls within the set range. The pin's position is then rotated and adjusted. After adjusting the angle, rotation and pushing at the second end are stopped, pushing at the first end is resumed, and pushing the pin forward is continued to re-enter the pin. If the stress anomaly is eliminated after the adjustment or falls within the set range, the pin is pushed back again. If the stress anomaly persists after the adjustment, the above steps are repeated. If a significant stress anomaly is detected during rotation, further rotation in that direction is deemed unacceptable. Rotation in that direction is immediately stopped, and the pin is rotated in the opposite direction for further adjustment. If the retraction and rotation adjustments are repeatedly performed within the range of rotational adjustment (including the case where rotation is impossible at all), but the stress anomaly cannot be eliminated or reduced to a tolerable range, it is considered that the pin and / or pin hole are seriously blocked or deformed. The disassembly of the pin can be stopped and the hydraulic support can be moved to the manual disassembly area, and the subsequent disassembly method can be manually determined; or the adjustment can be continued to adjust the pin to a position with smaller stress anomaly, that is, a position with lower intensity of elastic wave and smaller stress between the pin and the pin hole, and the thrust is increased to continue to push the pin out. Although some secondary damage may occur at this time, the damage is relatively small.

[0062] The primary disassembly process of this embodiment applies a strong axial thrust to the pin during pin removal, quickly overcoming the high-strength connection force generated by the interference fit during pin assembly. Furthermore, for hydraulic mounts with pin holes and pin shafts that have been tightly coupled due to long-term use and potential wear and corrosion, the axial thrust can also cause relative displacement between the pin shaft and the pin hole with minimal damage, facilitating pin disassembly.

[0063] This embodiment also applies high-frequency ultrasonic vibrations to the pin, loosening and peeling off rust and impurities on the pin's surface. This vibration not only acts on the pin's surface but also transmits along the metal to the connection between the pin and the hydraulic support. This reduces the resistance to pin disassembly caused by rust, dirt, and fastening impurities (such as tightly attached coal slag) at the connection. This prevents problems such as difficulty in disassembling the pin due to excessive rust or impurity blockage, or damage to hydraulic support components caused by forced disassembly.

[0064] At the same time, axial ultrasonic vibration can also effectively reduce the tightness and connection effect of the interface between the pin and the pin hole through micro-friction. The axial ultrasonic vibration works together with the axial thrust to stably and quickly complete the disassembly of the pin, and no pretreatment is required in advance (such as soaking and cleaning, vibration table vibration loosening, etc.). It can also achieve a good pin disassembly effect and avoid the secondary damage that may be caused by forced disassembly of the pin (such as damage to the pin and pin hole caused by vibration table loosening or direct high-frequency vibration impact forced disassembly). On this basis, axial vibration can also continuously excite elastic waves (acoustic emission signals) at the stress concentration point between the pin and the pin hole, accurately and clearly reflecting the stress relationship between the pin and the pin hole.

[0065] Specifically, during the pin's ejection process, if the pin and the pin hole abut against each other due to deformation, causing obstruction, extrusion, and other problems that may lead to secondary damage, stress concentration will occur at the main contact point between the two, that is, the point where secondary damage may occur. If the stress deformation at this point is too large, exceeding its tolerance range, secondary damage will occur. Axial ultrasonic vibration can cause the stress concentration point between the pin and the pin hole to produce continuous, reciprocating extrusion or collision due to the ultrasonic wave, periodically changing the normal stress at the interface between the pin and the pin hole. By controlling the frequency and amplitude of the ultrasonic wave, although this change does not cause damage to the pin and the pin hole, it will cause periodic stress changes at the stress concentration point, continuously stimulating elastic waves (acoustic emission response). The generation of elastic waves represents the generation of stress abnormalities. However, since the pin and the pin hole are mostly interference fits or have certain contact at their deformed locations, basic elastic waves with low strength will be generated during the pin's ejection process. In this case, even if damage occurs, it is relatively easy to repair and falls within the set normal range. If the elastic wave intensity suddenly increases, exceeds the basic range, or continues to maintain at a higher range, it means that the stress anomaly exceeds the set range. Continuing to push forward may cause more serious secondary damage or has begun to cause secondary damage, and it is necessary to immediately stop pushing. The superposition of ultrasonic waves and the continuous and stable elastic waves induced by them can enable the monitoring device to accurately identify the phenomenon of stress anomaly between the pin shaft and the pin hole. In addition, since the high-frequency ultrasonic vibration of this embodiment is carried out along the axial direction of the pin shaft, the axial generation of the ultrasonic vibration has a relatively simple waveform, and its vibration energy is highly conductive and has low loss. It can be transmitted to the entire pin shaft, which can not only reduce the friction between the entire pin shaft and the pin hole, but also detect the stress concentration points in the entire pin shaft and the pin hole. The elastic waves generated at the stress concentration points are also relatively continuous and stable, which can further ensure the stable identification of the elastic waves.

[0066] If ultrasonic vibration is applied to the pin in a radial or oblique direction, its energy is dispersed, resulting in low stress excitation efficiency and difficulty in generating a stable and superimposed acoustic emission response. This results in poor detection and may result in inaccurate identification. Furthermore, poor transmission may prevent the energy from being effectively and efficiently transmitted throughout the pin, effectively reducing friction between the pin and the pin hole, making it impossible to adjust the pin by rotation.

[0067] By applying a thrust at the second end to retract the pin and coordinate with the rotation adjustment pin to adjust the position of the pin, the relative position of the pin and the pin hole can be adjusted to find the direction with the largest gap without further damage, so that the bent or deformed part of the pin avoids the area of ​​the pin hole that is severely deformed, thereby reducing the obstruction and enabling the pin to be disassembled smoothly, thereby improving the integrity of the disassembled pin and the hydraulic support of this embodiment and avoiding secondary damage during the disassembly process. If the pin cannot be successfully removed through repeated rotation and retraction under the action of ultrasound, it is considered that the pin and / or the pin hole have been severely corroded, deformed, or in other conditions. If mechanical removal is continued, it may cause serious damage, requiring manual intervention. More flexible methods such as lubricant penetration and low / high temperature treatment are used to remove the pin to avoid damage to the components of the hydraulic support caused by mechanical removal.

[0068] Preferably, in S11-S14, the frequency of the ultrasonic vibration is in the range of 20-60kHz, preferably in the range of 35-45kHz, and the amplitude is between 15-35μm, preferably between 20-30μm. It should be noted that the elastic wave generated when the stress is concentrated between the pin and the pin hole is generally a high-frequency wave, and its frequency is generally between 100-400kHz. In order to ensure the accurate recognition of the elastic wave and the excitation effect of the elastic wave, it is best to control the frequency of the ultrasonic vibration within the range of 35-45kHz to avoid problems such as the elastic wave excitation effect being poor due to the ultrasonic frequency being too low, the elastic wave being unclear, or the elastic wave being partially covered by the ultrasonic frequency being too high, resulting in a decrease in the recognizability of the elastic wave. At the same time, the amplitude of the ultrasonic vibration also needs to be controlled to avoid situations such as the elastic wave being unable to be recognized due to the amplitude being too small or the pin or pin hole being damaged due to the amplitude being too large.

[0069] Furthermore, if the ultrasonic vibration amplitude is less than 5μm, the ultrasonic wave's effectiveness in reducing friction may be reduced. This can lead to excessive friction between the interference-fit pin and the pin hole, making rotational adjustment impossible. Attempting rotation in this situation could result in the pin breaking. The ability to rotate can be determined by monitoring the ultrasonic and elastic waves during rotation. If necessary, the amplitude can be increased to allow the pin to rotate.

[0070] At the same time, controlling the frequency of ultrasonic vibration within the range of 35-45kHz can further avoid resonance of the pin or other parts of the hydraulic support, and avoid uncontrollable resonance or excessive ultrasonic vibration causing metal fatigue and other damage to the pin, pin hole or other components.

[0071] Preferably, in S11, the duration of the ultrasonic vibration is not less than 30 seconds, preferably not less than 60 seconds.

[0072] Preferably, in S12, when performing the first jacking process, the waveform of the sound wave transmitted through the pin shaft is also continuously monitored to determine the stress conditions in the pin shaft and the pin hole.

[0073] More preferably, in S12, if the second end of the pin is pre-set with a point for connection to the rotating mechanism, the pin can be rotated without having to use the first push to push the pin out a part. Then, when the first push is performed, the position of the pin is dynamically adjusted according to the stress conditions in the pin and the pin hole, so as to further avoid damage to the pin and its connecting parts.

[0074] Preferably, in S12, the magnitude of the thrust needs to be able to be regulated according to the actual disassembly situation and disassembly progress of the pin. In the initial stage of disassembly of the pin, a small pressure is applied and gradually increased. Combined with ultrasonic vibration, the thrust is maintained after the pin starts to move, and the pin is slowly pushed out to ensure that the pin or pin hole will not be damaged due to the unstable increase in axial thrust in the early stage of disassembly of the pin. In the subsequent process, as the length of the pin is pushed out increases, the pressure is increased in a timely manner, which can ensure the disassembly efficiency and quality, and will not cause damage to the pin and related components due to excessive force at the moment.

[0075] Preferably, in S13 and / or S12, a monitoring device is also provided on the periphery of the pin hole at the first end of the pin shaft to monitor the acoustic wave signal, which is compared and analyzed with the acoustic wave signal obtained by monitoring the periphery at the second end, so as to avoid the influence of noise that may be generated by the vibration of the hydraulic support caused by pushing the pin shaft and other environmental factors, thereby improving the sensitivity and accuracy of monitoring abnormal stress conditions.

[0076] More preferably, in S13, the monitoring device includes an acoustic emission sensor array.

[0077] Preferably, in S14, during rotation adjustment, the angle of each adjustment is between 5-15 degrees, and the torque is slowly increased during rotation until the pin starts to rotate and stops. The torque during rotation does not exceed 50% of the shear force limit of the pin when it is designed, so as to avoid damage to the pin or other components during rotation.

[0078] Preferably, in S1, when the hydraulic support is disassembled to only the base, the base is directly transported to the front of the rough cleaning processing line by a mobile carrier, and then hoisted onto the line. This prevents the overly heavy base from causing problems during the hoisting process or causing excessive wear of the base by the track hoisting device during long-term hoisting.

[0079] Preferably, in S1, when the first-level components are disassembled, they are divided into three specifications according to their external volume: large components (such as top beams, bases, and large cylinders), medium-sized components (such as connecting rods, large pins, and valve groups), and small components (such as bolts, sealing rings, and small pins). Components of different types and specifications are transported separately to the rough cleaning process of corresponding specifications and sizes to ensure the treatment effect of the rough cleaning process. These three specifications and sizes are also applicable to other subsequent processing flows. Different components are separated into three different specifications and processing flows according to the size of their external volumes, which facilitates the setting of processing equipment of corresponding specifications and sizes and specialized processing in the subsequent processing flows, which will not be elaborated later.

[0080] Preferably, in S2, the rough cleaning process includes high-pressure water jet cleaning and brushing. After the primary component enters the rough cleaning process, a high-pressure water jet is first used to comprehensively rinse the dirt on the primary component surface, removing obvious dirt, rust products in severely corroded areas, and other attachments on the primary component surface. After the rinse is completed, a roller brush or other type of cleaning brush is used to brush the primary component to remove dirt and rust products that have loosened or fallen off the primary component surface after the high-pressure water jet cleaning but have not been completely rinsed off, thereby obtaining a secondary component.

[0081] Among them, high-pressure water jets are different from ordinary high-pressure water flow cleaning commonly used in the prior art. They can form high-speed, high-energy-density water jets through specially designed nozzles, and use the impact force, shear force and cavitation effect generated by the water jets to quickly remove attachments on the surface of the first-level components, especially hard and stubborn dirt (such as metal oxidation / rust layers, petrochemical scale layers, etc.), and flush them away from the surface of the first-level components, thereby achieving efficient cleaning of the first-level components. At the same time, compared with the existing technology, the diameter of the high-pressure water jet sprayed by a specific nozzle is also relatively small. By adjusting the angle of the nozzle, it can penetrate into some gaps and holes in parts such as columns and jacks, achieving more comprehensive cleaning. In addition, while having a good cleaning effect, the amount of water required for cleaning using a high-pressure water jet is also relatively small.

[0082] Preferably, in S2, the pressure of the high-pressure water jet is not less than 80 MPa, preferably not less than 100 MPa. The traveling speed of the first-stage component does not exceed 0.5 m / s, preferably does not exceed 0.3 m / s.

[0083] More preferably, in S2, the pressure of the high-pressure water jet is between 80 MPa and 150 MPa.

[0084] Preferably, the diameter of the nozzle of the high-pressure water jet is between 0.4 mm and 1 mm, preferably between 0.6 mm and 1 mm. The distance between the nozzle of the high-pressure water jet and the first-stage component is between 10 cm and 30 cm, preferably between 10 cm and 20 cm.

[0085] The impact force of the high-pressure water jet is controlled by controlling the pressure of the high-pressure water jet, the diameter of the nozzle and the distance between the nozzle and the first-level component, so as to avoid the impact force of the high-pressure water jet being too high, causing damage or excessive wear of the first-level component, or the impact force being too low, resulting in ineffective removal of attachments on the surface of the first-level component.

[0086] Preferably, the nozzles of the high-pressure water jet are arranged in a ring shape at certain intervals or angles.

[0087] More preferably, in S2, a high-pressure water jet treatment is performed after the brushing treatment to ensure that there is no obvious attachment on the surface of the obtained secondary component.

[0088] More preferably, during the rough cleaning process in S2, the primary components are treated alternately in the following order: high-pressure water jet cleaning - brushing - high-pressure water jet cleaning - brushing - high-pressure water jet cleaning. Multiple alternating high-pressure water jet cleaning and brushing cycles are provided during the rough cleaning process to improve the removal of significant deposits. After the final brushing cycle, a final high-pressure water jet cleaning cycle is performed to prevent any deposits remaining on the brush from transferring to the primary components, thereby ensuring the cleanliness of the secondary components.

[0089] More preferably, in S2, when multiple high-pressure water jet cleaning processes are provided, the nozzles used in adjacent different high-pressure water jet cleaning processes are arranged at different angles along the annular arrangement. By varying the spray angles of the high-pressure water jets, the high-pressure water jets in different treatments directly contact different locations of the primary component, thereby improving the cleaning effect.

[0090] By combining high-pressure water jet cleaning with brushing, compared with the high-pressure water flushing technology used in the existing technology, it can more comprehensively remove the more obvious rust blocks, rust spots, oil stains and other attachments on the surface of the first-level components, especially in the holes and gaps, to obtain a second-level component with a higher degree of cleanliness, creating a good foundation for subsequent damage detection, avoiding the subsequent damage detection, mistakenly testing the attachments on the second-level components as part of the second-level components, and obtaining erroneous data on deformation, wear, etc., greatly improving the accuracy of damage detection, reducing misjudgments, and improving the utilization rate of parts obtained by hydraulic supports.

[0091] Preferably, in S3, the damage detection includes deformation detection, corrosion detection, and wear detection. The quality assessment is performed according to the following weights: quality evaluation = 0.6×wear rate + 0.3×corrosion degree + 0.1×deformation degree.

[0092] During damage detection, laser 3D scanning is used to perform 3D point cloud data detection. 3D point cloud data of the secondary component is obtained and compared with pre-set standard data to calculate the wear rate and deformation degree. Corrosion depth is measured using an eddy current flaw detector, and the measured data is analyzed simultaneously with the 3D point cloud data. Specifically, wear rate = wear volume / maximum wear threshold. Wear volume is the volume loss rate: wear volume = 100% - current volume / original volume × 100%. The maximum wear threshold is the preset, acceptable, maximum wear volume. In this embodiment, 5% is preferred. Corrosion degree = the average corrosion depth of all corrosion points / maximum set corrosion threshold × 100%, where corrosion depth is the maximum corrosion depth at a particular corrosion point, and the maximum corrosion depth threshold is the preset, acceptable, maximum corrosion depth. The maximum corrosion depth threshold is determined based on the specific hydraulic support components. For example, in this embodiment, the base is 2.5 mm and the top beam is 2 mm. The maximum corrosion depth threshold is determined based on the thickness and importance of the component material. Deformation degree = average value of deformation error of all deformation points / maximum set deformation threshold × 100%, where the deformation error is the absolute value of the deformation amount of the deformation point compared to the original position after deformation. The maximum set deformation threshold is a preset, acceptable, maximum deformation error. The maximum set deformation threshold also needs to be determined according to the specific components of the hydraulic support. For example, in this embodiment, the base is 1.5mm and the top beam is 1mm. The maximum set deformation threshold is determined according to the thickness and importance of the material of the component. 0.6, 0.3 and 0.1 are empirical parameters, representing the influence of their corresponding parameters on the life of the parts of the hydraulic support during subsequent use.

[0093] Preferably, Figure 1 As shown, in S3, when the quality evaluation is greater than 0.8, it is judged as unqualified and has a low repair value, so it is scrapped.

[0094] If 0.3 < Quality Assessment ≤ 0.8, the component is deemed unqualified but has some repair value. It can be removed from production and repaired using the appropriate repair process. After repair, it can be reintegrated into the damage detection process. If the quality assessment after repair is qualified, it will be a Class 3 component. If the quality assessment after repair is still unqualified, it will be scrapped.

[0095] When the quality evaluation is ≤0.3, it is judged to be qualified and a third-level component is obtained.

[0096] Preferably, damage detection and quality assessment are focused on key parts of certain components, such as pin holes, inner walls of connecting rods, hydraulic cylinder walls, and other key parts that play a key role in the normal assembly and operation of hydraulic supports. The point cloud density of this area is increased and corresponding thresholds are set for separate assessment. If this part is judged to be unqualified, the entire component is directly considered to be unqualified and needs to be scrapped or repaired.

[0097] Preferably, in S4, the rust removal treatment is ultrasonic electrolysis treatment. The obtained three-stage assembly is immersed in an ultrasonic electrolysis tank, and the three-stage assembly is rust-removed by electrolysis treatment and ultrasonic treatment.

[0098] Among them, electrolytic cleaning is to apply electric current to the electrolyte to cause a chemical reaction on the surface of the workpiece, decomposing stubborn oxides and dirt. Ultrasonic cleaning uses the cavitation effect produced when ultrasonic waves propagate in a liquid. When ultrasonic waves propagate in a liquid, tiny bubbles are formed. These bubbles rapidly expand and burst under the action of sound pressure, generating a large impact force, further removing tiny particles and oil stains attached to the surface of the workpiece. Electrolytic cleaning is first used to quickly decompose stubborn stains (such as grease, rust, and rust blocks) using chemical methods, and then ultrasonic cleaning is performed to further remove tiny particles using physical methods. The synergistic effect of these two methods can greatly improve the cleaning efficiency of the third-level components while making the surface cleanliness of the fourth-level components reach Sa2.5 level and above, and shorten the cleaning time. At the same time, the combined use of the two can also greatly improve the cleaning effect of complex-shaped areas such as pin holes, mounting holes, and slits, avoiding the dead corners that may exist when using a single cleaning method. In addition, when ultrasonic treatment is used in combination with electrolytic treatment, the electrolytic current and ultrasonic frequency can be adjusted to avoid cavitation corrosion of precision surfaces caused by high-power ultrasonic waves or excessive oxidation of metals caused by strong electrolysis. Better cleaning effects can be achieved without requiring high power. Compared with traditional high-power ultrasonic cleaning or alkaline solution immersion + ultrasonic cleaning technologies, it not only has a fast cleaning speed and good cleaning effect, but can also avoid damage that may be caused during the cleaning process and improve the treatment effect of subsequent anti-rust treatment.

[0099] More preferably, the current density during electrolytic cleaning is between 3-8A / dm2. Hydraulic supports are typically constructed of low-carbon steel or alloy steel (over 95% by weight), and the electrolytic voltage should be controlled based on the material of the hydraulic support to avoid problems such as excessive current leading to excessive oxidation or hydrogen embrittlement. If the surface of the tertiary component to be treated is coated (such as chrome), a current density of 3-5A / dm2 is preferred to reduce the current density and avoid damage to the coating.

[0100] During electrolytic cleaning, the voltage is between 6-12V. DC pulses are used, with a pulse frequency between 80-200Hz and a duty cycle between 1-1.5:3. DC pulses reduce polarization, ensuring cleaning efficiency while preventing damage to tertiary components.

[0101] The pH of the electrolyte (cleaning fluid) is between 9.5 and 11.5. A low-alkalinity electrolyte is used to decompose and saponify impurities such as grease while preventing the steel structure of the tertiary component from being corroded.

[0102] The temperature of the electrolyte is between 50-65°C. During electrolysis, if the temperature is too high, the electrolysis reaction rate will be too fast and a large amount of electrolyte will evaporate.

[0103] The electrolytic cleaning time is between 4-8 minutes.

[0104] More preferably, for small and medium-sized modules, the pulse frequency is controlled between 120-200 Hz and the current density is between 3-5 A / dm2. For large modules, the pulse frequency may be controlled between 80-120 Hz and the current density is between 6-8 A / dm2.

[0105] Most small and medium-sized components often have complex structures, such as numerous threaded holes and gaps, which easily accumulate fine particles such as coal dust. High frequency and low current density are used to ensure effective cleaning and prevent damage. Large components may contain more corrosion and dirt residues. Due to the generally higher strength of their metal structures, low frequency and high current density can be used to improve decontamination effectiveness.

[0106] More preferably, during ultrasonic cleaning, the power density of the ultrasonic wave is between 0.5-1.2 W / cm 2 Too high an ultrasonic power can easily cause cavitation corrosion in steel, while too low an ultrasonic power may prevent the removal of microporous particles. The ultrasonic frequency is between 20-40kHz. For large components, the frequency is controlled at 20-30kHz to ensure that the bubbles generated by the ultrasonic waves have a high impact. For small and medium-sized components, the frequency is controlled between 30-40kHz to ensure effective cleaning of complex structures while avoiding damage to tertiary components. The ultrasonic cleaning time is between 8-15 minutes. In conjunction with the previous electrolytic cleaning, the time required for ultrasonic treatment can be significantly shortened, resulting in better cleaning results.

[0107] If necessary, for hydraulic supports with poor working environments, infrequent cleaning during use, or stubborn deposits, ultrasonic cleaning and electrolytic cleaning can be performed simultaneously or alternately in this step to ensure effective cleaning. The overall treatment time should be within 4-8 minutes, with an electrolytic cleaning current density between 2-5A / dm² and an electrolyte temperature between 50-60°C to avoid damage to the tertiary components. All other conditions remain unchanged.

[0108] Preferably, in S4, after the rust removal treatment is performed, the tertiary component is dried to dry its surface.

[0109] Preferably, in S4, the rust prevention treatment includes both vapor phase rust prevention treatment and product rust prevention treatment, or only product rust prevention treatment, depending on production needs. Specifically, if the rust-removed tertiary assembly does not need to be assembled directly, the rust-removed tertiary assembly is first subjected to vapor phase rust prevention treatment, and then the rust-removed tertiary assembly is temporarily removed from production and stored, such as in a temporary storage warehouse, until it is needed for subsequent use. The vapor phase rust prevention treatment prevents the rust-removed tertiary assembly from rusting during storage or transportation, thereby affecting its subsequent use.

[0110] When it is retrieved for subsequent use, it will be hoisted into the corresponding operation line for product anti-rust treatment and coated with anti-corrosion coating to obtain a fourth-level component.

[0111] If the obtained third-level components that have undergone rust removal need to be directly assembled, only anti-rust treatment is performed on the product, and the third-level components that have undergone rust removal are directly coated with an anti-corrosion coating to obtain fourth-level components.

[0112] Preferably, in S4, the vapor phase rust prevention treatment is performed by spraying or immersion. For large and medium-sized components, the anti-rust spray liquid is sprayed onto the rust-removed tertiary components by spraying, and then dried. For small components, the anti-rust coating liquid is immersed in the small components by immersion, and then removed and dried.

[0113] Preferably, in S5, components of the same hydraulic support are preferentially identified and selected for assembly of the hydraulic support according to pre-set labels. If some components of the hydraulic support are scrapped in the previous process, available third-level components are retrieved from the temporary storage or new components are directly used to supplement them.

[0114] Preferably, in S5, the assembly of the hydraulic support includes a primary assembly process and a secondary assembly process. First, through the corresponding primary assembly process, the relatively fragmented parts of the hydraulic support are pre-assembled into an integral structure. For example, in the primary assembly process, the columns are pre-assembled into columns, and the columns enter the subsequent secondary assembly process as an integral structure. The primary assembly process also includes the installation of some piping structures in the hydraulic support components.

[0115] In the secondary assembly process, the pin shaft of the hydraulic support is assembled using the opposite process to the primary disassembly process.

[0116] Preferably, in S5, after the assembly of the hydraulic support is completed, an action test of the hydraulic support is required to ensure the overall quality of the assembly.

[0117] Example 2:

[0118] This embodiment provides an intelligent disassembly and re-production line for a hydraulic support, comprising a disassembly system arranged in sequence: for disassembling the hydraulic support;

[0119] Rough cleaning system: used for rough cleaning of primary components;

[0120] Damage Detection System: used for damage detection and quality assessment of secondary components;

[0121] Fine cleaning system: used for rust removal of tertiary components;

[0122] Anti-rust treatment system: used for rust-proofing the tertiary components that have undergone rust removal treatment;

[0123] Assembly system: used to assemble four-level components.

[0124] The intelligent disassembly and remanufacturing line for hydraulic supports also includes an integrated transfer system for transferring hydraulic support components. The integrated transfer system includes a rail hoisting system and a ground transfer system.

[0125] Preferably, the rail hoisting system includes an overhead rail, a rail car, and a rail hoisting device arranged on the rail car and capable of moving with the rail car.

[0126] More preferably, the track hoisting system is a double-track hoisting system, and the railcar is a double-track railcar.

[0127] The disassembly system includes a primary disassembly station for primary disassembly. During this process, the rail-mounted lifting system identifies the hydraulic support components using radio frequency tags and / or image recognition. Synchronizing with the disassembly system's progress, the corresponding rail-mounted lifting device performs preliminary lifting and auxiliary securing of the components being disassembled, preventing them from becoming unbalanced during the disassembly process and facilitating disassembly.

[0128] After disassembly, components such as pins and hydraulic support structures are immediately hoisted via a rail-mounted lifting system to the corresponding rough cleaning system's operating line for processing. Components requiring further processing, such as columns, are transferred to a secondary disassembly station via the rail-mounted lifting system for secondary disassembly. Once secondary disassembly is complete, they are then hoisted via the rail-mounted lifting system to the corresponding rough cleaning system for processing.

[0129] A pin disassembly frame is provided in the first-level disassembly station, which includes a frame body 1 and a vibrator propulsion sleeve 2, a first acoustic emission sensor array 3, a second acoustic emission sensor array 4, a first hydraulic thruster 5, a second hydraulic thruster 6 and a rotary clamp 7, which are movably arranged on the frame body 1 through different moving components. An ultrasonic vibrator 8 is provided at the top of the vibrator propulsion sleeve 2.

[0130] The vibrator propulsion sleeve 2 is installed on the frame 1, and the ultrasonic vibrator 8 is installed at the linear motion output end of the vibrator propulsion sleeve 2. The vibrator propulsion sleeve 2 can drive the ultrasonic vibrator 8 to continuously abut against the first end of the pin shaft 9 to be disassembled.

[0131] The first hydraulic pusher 5 is installed on the frame 1 , and the pushing end of the first hydraulic pusher 5 passes through the vibrator propulsion sleeve 2 and abuts against the first end of the pin shaft 9 to be disassembled, so as to push the pin shaft 9 to be disassembled.

[0132] The first acoustic emission sensor array 3 is used to be arranged on the edge surface of the pin hole corresponding to the second end of the pin shaft 9 to be disassembled.

[0133] The second hydraulic pusher 6 is installed on the frame 1 and is used to retract the pin shaft 9 to be disassembled.

[0134] The rotary clamp 7 is installed on the frame 1 and is used to rotate the pin shaft 9 to be disassembled.

[0135] Preferably, the vibrator propulsion sleeve 2 is connected to the frame 1 via a first movable assembly, which can drive the vibrator propulsion sleeve 2 to move between the disassembly stations of multiple pin shafts 9 to be disassembled. The first hydraulic pusher 5 is connected to the frame 1 via a second movable assembly, which can drive the first hydraulic pusher 5 to move between the disassembly stations of multiple pin shafts 9 to be disassembled. The first acoustic emission sensor array 3 is connected to the frame 1 via a third movable assembly, which can drive the first acoustic emission sensor array 3 to move between the disassembly stations of multiple pin shafts 9 to be disassembled. The second hydraulic pusher 6 is connected to the frame 1 via a fourth movable assembly, which can drive the second hydraulic pusher 6 to move between the disassembly stations of multiple pin shafts 9 to be disassembled. The rotary clamp 7 is connected to the frame 1 via a fifth movable assembly, which can drive the rotary clamp 7 to move between the disassembly stations of multiple pin shafts 9 to be disassembled.

[0136] The vibrator propulsion sleeve 2 includes a top plate, a bottom plate, and several telescopic rods arranged between the top plate and the bottom plate. The top plate and the bottom plate are both annular structures with a circular through hole in the middle, and the telescopic rods are fixedly connected to the annular structures of the top plate and the bottom plate at a certain interval (angle). The ultrasonic vibrator 8 is arranged on the side of the top plate away from the telescopic rod. The ultrasonic vibrator 8 includes several ultrasonic transducers and amplitude rods arranged in series along the annular structure of the top plate. When disassembling the pin shaft, the vibrator propulsion sleeve 2 ensures that the ultrasonic vibrator 8 is always in contact with the first end of the pin shaft 9 to be disassembled by adjusting the length of the telescopic rod, and continuously applies stable ultrasonic vibration to the pin shaft 9 to be disassembled.

[0137] Preferably, the first hydraulic pusher 5 includes a hydraulic cylinder and a telescopic push rod. The telescopic push rod can pass through the annular structure of the top plate and the bottom plate to push the pin shaft 9 to be disassembled.

[0138] Preferably, during the primary disassembly process of the pin 9 to be disassembled, the first hydraulic pusher 5 and the first ultrasonic vibrator 8 are first placed against the first end of the pin 9 to be disassembled, the first acoustic emission sensor array 3 is placed against the hydraulic support adjacent to the second end of the pin 9 to be disassembled, and the second acoustic emission sensor array 4 is placed against the hydraulic support adjacent to the first end of the pin 9 to be disassembled. Ultrasonic vibrations are then continuously applied by the ultrasonic vibrator 8 along the axial direction of the pin 9 to be disassembled for a predetermined period of time. The ultrasonic vibrations are then maintained, and the thrust of the first hydraulic pusher 5 is gradually increased to eject the second end of the pin 9 to be disassembled. Simultaneously, the ultrasonic vibrator 8 is propelled by the vibrator propeller, ensuring that the ultrasonic vibrator 8 remains in contact with the pin 9 to be disassembled. During the pushing process of the pin 9 to be disassembled, the waveform of the ultrasonic waves transmitted along the pin 9 to be disassembled is monitored in real time by the first acoustic emission sensor array 3 and the second acoustic emission sensor array 4, analyzing the stress between the pin 9 to be disassembled and the hydraulic support. After the pin 9 to be disassembled is partially ejected, the ejected portion of the pin 9 is clamped by a rotary clamp 7. If no stress anomaly is detected between the pin 9 and the hydraulic support during the ejection process, or if the detected stress anomaly is within the set range, the pin 9 is completely ejected, completing the disassembly of the pin 9. If a stress anomaly outside the set range is detected, the pin 9 is adjusted: the first hydraulic pusher 5 is stopped and retracted, while the second hydraulic pusher 6 pushes the pin 9 back a certain distance until the stress anomaly disappears or falls within the set range. The rotary clamp 7 then rotates and adjusts the position of the pin 9. After adjusting the pin 9 to a certain angle, the rotation is stopped, and the first hydraulic pusher 5 resumes operation, continuing to push the pin 9. If the stress anomaly persists after the adjustment, the above steps are repeated. During this process, the vibrator propulsion sleeve 2 is adjusted synchronously with the operation of the second hydraulic thruster 6 to ensure that the ultrasonic vibrator 8 is always in contact with the pin 9 to be disassembled. If any abnormal stress is detected during rotation, rotation in that direction is immediately stopped and the pin 9 to be disassembled is continued in the opposite direction for rotational adjustment. If repeated adjustments within the adjustable range of the rotary clamp 7 fail to eliminate the abnormal stress or reduce it to a tolerable range, it is considered that the internal deformation of the pin 9 to be disassembled is severe. Disassembly of the pin 9 to be disassembled is stopped and the hydraulic support is transferred to the manual disassembly area via the ground transfer system, where the subsequent disassembly and handling method will be manually determined.

[0139] The vibrator propulsion sleeve 2 and the ultrasonic vibrator 8 ultrasonic transducer are used to bring the ultrasonic vibrator 8 into contact with the pin shaft 9 to be disassembled, applying ultrasonic waves to the pin shaft 9 to be disassembled of the hydraulic support. Under the action of the ultrasonic waves, the pin shaft 9 to be disassembled becomes easier to be ejected. An acoustic emission sensor array is used to collect the ultrasonic waves applied by the ultrasonic vibrator 8 and transmitted through the pin shaft 9 to be disassembled. The waveform of the sound wave is used to determine the stress anomaly that occurs during the ejection process of the pin shaft 9 to be disassembled and to make adjustments to prevent further deformation and damage to the pin shaft 9 to be disassembled and to avoid irreversible damage to the pin hole of the hydraulic support during the removal of the pin shaft 9 to be disassembled. A clamp is used to clamp the ejected portion of the pin shaft 9 to be disassembled. When the acoustic emission sensor array detects stress anomaly, the position of the pin shaft 9 to be disassembled is adjusted by the clamping device, and temporary correction is made by adjusting the angle of the pin shaft 9 to be disassembled to facilitate the removal of the pin shaft 9 to be disassembled. At the same time, since there is even a vibrator propulsion sleeve 2, it can dynamically adjust the position of the ultrasonic vibrator 8 according to the position of the pin shaft 9 to be disassembled, ensuring that the ultrasonic vibrator 8 always abuts against the first end of the pin shaft 9 to be disassembled, ensuring the stability and effectiveness of the application of ultrasonic vibration.

[0140] Based on the different sizes of the disassembled hydraulic support components, three different equipment sizes are set up: large, medium and small. The rough cleaning system, damage detection system, fine cleaning system and rust prevention treatment system are set up. By adjusting the equipment specifications of the different systems, they can better treat the hydraulic support components and improve the treatment effect. The rough cleaning system, damage detection system, fine cleaning system and rust prevention treatment system are connected by chain conveyor belts or transfer integrated systems.

[0141] Preferably, the rough cleaning system includes a chain conveyor belt and a high-pressure water jet cleaning device and an electric roller brush cleaning device alternately arranged along the conveying direction of the chain conveyor belt.

[0142] More preferably, the high-pressure water jet cleaning devices and the electric roller brush cleaning devices are alternately arranged, with at least three high-pressure water jet cleaning devices and at least two electric roller brush cleaning devices being arranged.

[0143] The rough cleaning system also includes a sewage recovery device and a slag separation device.

[0144] The damage detection system includes a laser three-dimensional scanning device for acquiring three-dimensional point cloud data of the secondary components and an eddy current flaw detection device for detecting corrosion and cracks of the secondary components.

[0145] The fine cleaning system includes an ultrasonic electrolytic cleaning device for performing ultrasonic cleaning and electrolytic cleaning and a lifting device for lifting the tertiary component into and out of the ultrasonic electrolytic cleaning device.

[0146] The anti-rust treatment system includes a vapor phase anti-rust treatment station and a product anti-rust spraying station which are arranged in sequence.

[0147] Preferably, a loading / unloading station is provided between the vapor phase anti-rust treatment station and the product anti-rust spraying station, which is used to load / unload the three-stage components that have undergone vapor phase anti-rust treatment.

[0148] Preferably, a temporary storage warehouse is provided outside the loading / unloading station for storing the third-level components that have undergone vapor phase rust prevention treatment.

[0149] There is also an integrated transfer system between the loading / unloading stations and the temporary storage warehouse.

[0150] The vapor phase rust prevention treatment station is equipped with a rust prevention agent supply device, a spray treatment device and a spray chamber for treating large and medium-sized components, an immersion treatment device and a tunnel drying device for treating small components.

[0151] The product anti-rust spraying station is equipped with a paint spraying room, a high-pressure airless spraying device, a paint supply device and a drying device.

[0152] Preferably, the product anti-rust spraying system also includes a high-pressure water jet cleaning device for cleaning the tertiary components that have undergone vapor phase anti-rust treatment to ensure that their surfaces are clean.

[0153] Preferably, a four-level component temporary storage area is provided between the product anti-rust spraying system and the assembly system for temporarily storing four-level components of all sizes waiting to be assembled.

[0154] Preferably, the product anti-rust spraying system and assembly system are connected to the four-level component storage area through a transfer integration system.

[0155] Preferably, the assembly system includes a first-level assembly station. The first-level assembly station includes a fine assembly station for pre-assembling some hydraulic support components into a whole and a pipeline installation station for installing pipelines. The structure of the second-level assembly station can refer to the first-level disassembly station.

[0156] Preferably, the first-level assembly station also includes a flipping station for adjusting some of the fourth-level components to a position that is convenient for lifting and assembly, such as the top beam of the hydraulic support.

[0157] In the description of the present invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0158] In the present invention, unless otherwise expressly specified or limited, the terms "mounted," "connected," "connect," "fixed," etc. should be understood broadly. For example, they may refer to fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; and internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0159] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0160] In the description of this specification, the terms "one embodiment", "some embodiments", "embodiments", "examples", "specific examples" or "some examples" refer to the specific features, structures, materials or characteristics described in conjunction with the embodiment or example and included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples described in this specification and features of different embodiments or examples, unless they are mutually inconsistent.

[0161] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may alter, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. A method for intelligent disassembly and reproduction of a hydraulic support, characterized in that: The following steps are involved: S1: dismantle the hydraulic support to obtain the first-level components; S2: performing rough cleaning on the first-level components to obtain second-level components; S3: Damage detection and quality assessment of the second-level components; if the quality assessment is qualified, the third-level components are obtained; S4: performing rust removal and rust prevention treatment on the third-level components to obtain fourth-level components; S5: Select the fourth-level components for assembly to obtain a reproduced hydraulic support; In S1, the disassembly process of the pin shaft of the hydraulic support includes: continuously applying ultrasonic vibration to the pin shaft along the axial direction of the pin shaft; pushing the pin shaft during the ultrasonic vibration process; in the process of pushing the pin shaft, real-time detection of the elastic waves excited by the ultrasonic vibration on the pin shaft and the pin hole; when the elastic wave intensity exceeds the set range, dynamically adjusting the position of the pin shaft until the detected elastic wave intensity is within the set range; then continuing to push the pin shaft; the frequency of the ultrasonic vibration is in the range of 20-60kHz, and the amplitude is between 15-35μm.

2. The intelligent disassembly and reproduction method of the hydraulic support according to claim 1, characterized in that: In S1, the hydraulic support pin is disassembled and processed, including: Ultrasonic vibration is applied to the pin at the first end of the pin along the axial direction of the pin. After the ultrasonic wave lasts for a set time, the pin is sequentially subjected to a first pushing treatment and a second pushing treatment. In the first pushing treatment, the pin is directly pushed until the pin hole is extended out of the second end of the pin. In the second pushing treatment, the elastic waves excited by the ultrasonic vibration on the pin and the pin hole are detected in real time. When the intensity of the elastic wave exceeds the set range, the position of the pin is dynamically adjusted until the detected elastic wave intensity is within the set range; then the pin is continued to be pushed.

3. The intelligent disassembly and reproduction method of the hydraulic support according to claim 1, characterized in that: In S1, the dynamic adjustment of the position of the pin includes: first retracting the pin a certain distance, then rotating the pin a certain angle, and then continuing to push the pin. When the elastic wave intensity exceeds the set range, the above process is repeated until the elastic wave intensity is within the set range.

4. The intelligent disassembly and reproduction method of the hydraulic support according to claim 1, characterized in that: The frequency of ultrasonic vibration is in the range of 35-45kHz, and the amplitude is between 20-30μm.

5. The intelligent disassembly and reproduction method of the hydraulic support according to claim 1, characterized in that: In S2, the first-level components are subjected to a rough cleaning treatment, including: alternating high-pressure water jet cleaning and brushing treatment on the first-level components; when performing the high-pressure water jet cleaning treatment, the pressure of the high-pressure water jet is not less than 80 MPa; the travel speed of the first-level components does not exceed 0.5 m / s; the nozzle diameter of the high-pressure water jet is between 0.4 mm and 1 mm; the distance between the nozzle and the first-level components is between 10 cm and 30 cm.

6. The intelligent disassembly and reproduction method of the hydraulic support according to claim 1, characterized in that: In S3, damage detection includes deformation detection, corrosion detection, and wear detection. Quality assessment is performed according to the following weights: quality assessment = 0.6 × wear rate + 0.3 × corrosion degree + 0.1 × deformation degree; When the quality evaluation is >0.8, it is judged as unqualified and scrapped; When 0.3 < quality evaluation ≤ 0.8, it is judged as unqualified and repaired. If the quality evaluation after repair is qualified, it will be a third-level component. If the quality evaluation after repair is unqualified, it will be scrapped. When the quality evaluation is ≤0.3, it is judged to be qualified and a third-level component is obtained.

7. The intelligent disassembly and reproduction method of the hydraulic support according to claim 1, characterized in that: In S4, the rust removal treatment includes electrolytic treatment and ultrasonic treatment; During electrolysis, the current density is 3-8A / dm 2 Between, DC pulse is used, the pulse frequency is between 80-200Hz; the duty ratio is between 1-1.5:3; During ultrasonic treatment, the power density of the ultrasonic wave is between 0.5-1.2W / cm2 and the frequency is between 20-40kHz.

8. A disassembly and re-production line for implementing the intelligent disassembly and re-production method for a hydraulic support according to any one of claims 1 to 7, characterized in that: Including the following settings: Disassembly system: used to disassemble the hydraulic support; Rough cleaning system: used for rough cleaning of primary components; Damage Detection System: used for damage detection and quality assessment of secondary components; Fine cleaning system: used for rust removal of tertiary components; Anti-rust treatment system: used for rust-proofing the tertiary components that have undergone rust removal treatment; Assembly system: used to assemble four-level components; The disassembly system further includes a first-level disassembly station.

9. The disassembly and re-production line according to claim 8, characterized in that: A pin disassembly frame is provided in the first-level disassembly station; the pin disassembly frame includes a frame body and a vibrator propulsion sleeve, a first acoustic emission sensor array, a first hydraulic pusher, a second hydraulic pusher and a rotary clamp arranged on the frame body, and an ultrasonic vibrator is provided at the top of the vibrator propulsion sleeve.

10. The intelligent disassembly and re-production line for hydraulic supports according to claim 8, characterized in that: The rough cleaning system includes a chain conveyor belt and a high-pressure water jet cleaning device and an electric roller brush cleaning device alternately arranged along the chain conveying direction.

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