Intelligent disassembling and re-manufacturing method and disassembling and re-manufacturing line of hydraulic support

Abstract

The present application relates to a kind of hydraulic support intelligent disassembly reproduction method and disassembly reproduction operation line, its method includes: S1: to the hydraulic support is disassembled and handled, obtains primary component;S2: to primary component is coarsely cleaned and handled, obtains secondary component;S3: to secondary component is damaged detection and quality assessment;S4: to tertiary component is rusted and handled and is treated against rust, obtains quaternary component;S5: quaternary component is assembled, obtains reproduction hydraulic support;When disassembling pin shaft, ultrasonic vibration is applied to pin shaft along the axial direction of pin shaft, elastic wave is excited at the stress concentration between pin shaft and pin hole, and the position of pin shaft is dynamically adjusted according to the intensity of elastic wave, changes the stress action condition between pin shaft and pin hole.Solved the secondary damage of too big in the prior art when disassembling the part connected by pin shaft and pin shaft, which involves the core support and rotary motion function of hydraulic support, and the utilization rate of the technical problem of low.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, and in particular to an intelligent disassembly and remanufacturing method and disassembly and remanufacturing line for hydraulic supports. Background Technology

[0002] Hydraulic supports, as core equipment in existing coal mine fully mechanized mining engineering technology, are generally deployed under extreme conditions such as high loads and humid, dusty environments, and require long-term operation. They are prone to mechanical wear, corrosion, rust, and metal structure fatigue, leading to their scrapping due to malfunctions. However, the cost of a single large hydraulic support can often reach hundreds of thousands or even millions of yuan. Directly scrapping and replacing them with new ones not only incurs high procurement costs for enterprises but may also lead to resource waste and environmental pollution. Current technologies, to reduce the cost of using and purchasing hydraulic supports, typically involve cleaning, disassembly, remanufacturing, and reassembly of used hydraulic supports. The disassembled components are then used to produce new hydraulic supports, achieving the recycling of hydraulic support parts and reducing production costs.

[0003] Existing processes for disassembling and remanufacturing hydraulic supports are not mature, resulting in unsatisfactory utilization rates of the obtained parts, especially those crucial for the core support and rotational functions of the hydraulic support, which are structurally connected via pins. The pins and the pin holes in the connected components are mostly interference fits, making the connection quite tight and requiring considerable force to remove the pins. Furthermore, after prolonged use, the structure of the pins and pin holes often undergoes uncertain and irregular changes due to stress variations, wear, and corrosion. This leads to a mismatch between the pin shape and the pin hole shape, making it easy for the pin and pin hole to come into contact during removal, resulting in severe friction, collision, compression, and scraping, causing secondary damage. In severe cases, this can even lead to pin jamming or breakage. Existing technologies typically employ hydraulic traction combined with vibration impact when disassembling pins. While this method can quickly remove the pin, it can easily cause irreparable secondary damage to the pin or pin hole during the removal process, or amplify existing damage. For example, vibration impact can cause repeated scraping between the pin and pin hole, exacerbating metal fatigue and leading to cracks that further expand existing cracks. During the traction process, the deformed part of the pin can scratch the pin hole, forming long cracks. The pin may also become stuck during disassembly and break under excessive external force, making it difficult to achieve a high utilization rate. Summary of the Invention

[0004] (a) Technical problems to be solved

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

[0006] (II) Technical Solution

[0007] 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 remanufacturing of hydraulic supports, comprising the following steps:

[0009] S1: Disassemble the hydraulic support to obtain the primary component;

[0010] S2: Perform coarse cleaning on the primary components to obtain the secondary components;

[0011] S3: Perform damage detection and quality assessment on the secondary components; if the quality assessment is satisfactory, the tertiary components are obtained.

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

[0013] S5: Select four-level components for assembly to obtain a remanufactured hydraulic support;

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

[0015] Optionally, in S1, the disassembly and processing of the hydraulic support pin includes:

[0016] Ultrasonic vibration is applied to the first end of the pin along its axial direction. After the ultrasonic vibration lasts for a set time, the pin is subjected to a first push and a second push in sequence. In the first push, the pin is directly pushed until the second end of the pin protrudes from the pin hole. In the second push, the elastic waves generated by the ultrasonic vibration of the pin and 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 pushed again.

[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 forward. When the elastic wave intensity exceeds the set range, the above process is repeated until the elastic wave intensity is within the set range.

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

[0019] Optionally, in S2, a rough cleaning process is performed on the primary components, including: alternating high-pressure water jet cleaning and brushing treatment on the primary components; when performing high-pressure water jet cleaning, the pressure of the high-pressure water jet is not less than 80MPa; the traveling speed of the primary components does not exceed 0.5m / s; the nozzle diameter of the high-pressure water jet is between 0.4mm and 1mm; and the distance between the nozzle and the primary components is between 10cm and 30cm.

[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 rating 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 is qualified after repair, a level 3 component is obtained. If the quality evaluation is unqualified after repair, it is scrapped.

[0023] When the quality evaluation score is ≤0.3, it is judged as qualified and a level 3 component is obtained.

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

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

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

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

[0028] Disassembly system: Used for disassembling hydraulic supports;

[0029] Pre-cleaning system: Used for pre-cleaning primary components;

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

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

[0032] Rust prevention system: Used to prevent rust on tertiary components that have undergone rust removal treatment;

[0033] Assembly system: used for assembling four-level components;

[0034] The disassembly system also includes a primary disassembly station.

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

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

[0037] (III) Beneficial Effects

[0038] The beneficial effects of this invention are as follows: In the intelligent disassembly and remanufacturing method for hydraulic supports of this invention, ultrasonic vibration is applied along the axial direction of the pin during the disassembly process. Compared with the prior art, ultrasonic vibration can not only loosen and peel off the rust and impurities on the surface of the pin, but its better conduction effect can also be conducted along the metal to the part where the pin is connected to the hydraulic support. This reduces the obstruction to the disassembly of the pin caused by rust, dirt and fastening impurities at the connection, and avoids the problem of the pin being difficult to disassemble or the damage to the hydraulic support components caused by forced disassembly due to excessive rust or impurities blocking the pin. Meanwhile, due to the relatively simple waveform of axial ultrasonic vibration, its vibration energy has strong conductivity and low loss, and can be transmitted to the entire pin. Compared with existing technologies, it can not only stably reduce the tightness of the interface between the pin and the pin hole through micro-friction, reducing the friction between the entire pin and the pin hole and avoiding secondary damage that may be caused by forcibly disassembling the pin; it can also stably excite elastic waves at the stress concentration points of the pin and the pin hole through periodic vibration. The excitation of elastic waves clearly reflects the stress relationship between the pin and the pin hole, and based on this, the position of the pin can be dynamically adjusted to improve the stress relationship between the pin and the pin hole, reduce the occurrence of secondary damage, avoid serious secondary damage, and improve the utilization rate of parts and pins that are structurally connected by pins and are involved in the core support and rotational movement functions of hydraulic supports. Attached Figure Description

[0039] Figure 1 This is a schematic flowchart of Embodiment 1 of the intelligent disassembly and remanufacturing method for hydraulic supports of the present invention;

[0040] Figure 2 This is a schematic diagram of the pin disassembly frame of an embodiment 2 of the intelligent disassembly and reprocessing production line for hydraulic supports of the present invention.

[0041] [Explanation of Labels in the Attached Image]

[0042] 1: Frame body; 2: Vibrator push sleeve; 3: First acoustic emission sensor array; 4: Second acoustic emission sensor array; 5: First hydraulic pusher; 6: Second hydraulic pusher; 7: Rotary clamp; 8: Ultrasonic vibrator; 9: Pin to be disassembled. Detailed Implementation

[0043] To better explain and facilitate understanding of the present invention, a detailed description of the invention is provided below with reference to the accompanying drawings and specific embodiments. In this document, directional terms such as "up," "down," "left," and "right" are used interchangeably. Figure 2 The orientation is used as a reference.

[0044] Example 1:

[0045] This embodiment provides a method for intelligent disassembly and remanufacturing of hydraulic supports, such as... Figure 1 As shown, it includes the following steps:

[0046] S1: Disassemble the hydraulic support to obtain the primary component.

[0047] S2: Perform a rough cleaning process on the primary component to obtain a secondary component with no obvious adhering substances on the surface.

[0048] S3: Perform damage detection and quality assessment on the secondary components; if the quality assessment is satisfactory, the tertiary components are obtained.

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

[0050] S5: Select four-level components for assembly to obtain a remanufactured hydraulic support.

[0051] Before disassembling the hydraulic support, it is transported to the disassembly system by a mobile transport vehicle.

[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 order from top to bottom and from small to large. Through the first-level disassembly process, each individual 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 components, and the entire column. However, it does not include further disassembly of the component, such as the disassembly of the column body, hydraulic cylinder, and other components in the column.

[0054] During the first-level disassembly process, a track-mounted hoisting system with identification capabilities identifies the corresponding hydraulic support components based on preset labels and / or visual recognition. According to the disassembly progress of the disassembly system, the corresponding track-mounted hoisting device is activated to perform preliminary hoisting and auxiliary fixation of the components being disassembled. The track-mounted hoisting system helps to fix the hydraulic support components, preventing them from becoming unbalanced during disassembly and facilitating disassembly.

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

[0056] Preferably, in the first-stage disassembly process, when disassembling the pin, ultrasonic vibration is first applied to the first end of the pin along the axial direction of the pin. After the ultrasonic vibration continues for a set time, the pin is subjected to a first pushing process and a second pushing process in sequence. In the first pushing process, the pin is directly pushed until the second end of the pin protrudes from the pin hole. In the second pushing process, ultrasonic vibration continues to be maintained and the pin is pushed. The elastic waves generated by the ultrasonic vibration of 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 pushed again.

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

[0058] S11: An ultrasonic vibration device is installed at the first end of the pin to apply ultrasonic vibration to the pin along the axial direction for a set time.

[0059] S12: Continue to maintain ultrasonic vibration. At the first end where ultrasonic vibration is applied, apply a thrust to the pin in the axial direction of the pin to perform the first pushing process on the pin, pushing the pin out a portion from the second end.

[0060] S13: Continue to apply ultrasonic vibration to push the pin a second time. At the same time, the waveform (intensity) of the sound wave transmitted through the pin is continuously monitored by a monitoring device set on the outer periphery of the pin hole at the second end of the pin (the applied ultrasonic wave and the elastic wave it excites are transmitted through the pin to the pin hole and then monitored by the detection device). The stress change between the pin 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 jacking process, or if the detected stress anomaly is within the set range, the pin is directly jacked out completely, completing the pin disassembly. If a stress anomaly exceeding the set range is detected, the pin's position is dynamically adjusted: stop the jacking at the first end, maintain ultrasonic vibration, apply thrust at the second end to push the pin back a certain distance until the stress anomaly disappears or decreases to the set range. Then, rotate the pin's position to adjust it. After adjusting to a certain angle, stop the rotation and the second end jacking, resume the first end jacking, and continue jacking the pin to return it to its original position. If there is no stress anomaly after adjustment, or if it decreases to the set range, continue jacking the pin. If a stress anomaly persists after adjustment, repeat the above operation. If a large stress anomaly is detected during rotation, it is deemed unsuitable to continue rotation in that direction. Immediately stop rotation in that direction and continue rotating the pin in the opposite direction for adjustment. If repeated retraction and rotation adjustments are made within the adjustable range (including situations where rotation is impossible), but the abnormal stress cannot be eliminated or reduced to a tolerable level, it is considered that the pin and / or pin hole are severely blocked or deformed. In this case, disassembly of the pin can be stopped, and the hydraulic support can be moved to the manual disassembly area for manual assessment of the subsequent disassembly process. Alternatively, adjustments can be continued to move the pin to a position with lower abnormal stress, i.e., a lower elastic wave intensity and less stress between the pin and pin hole. In this case, the thrust can be increased to push the pin out further. Although some secondary damage may occur, the damage is relatively minor.

[0062] In this embodiment, the primary disassembly process applies a strong axial thrust to the pin during assembly, quickly overcoming the high-strength connection force generated by the interference fit. Furthermore, for hydraulic supports where the pin hole and pin shaft have become tightly connected due to long-term use and wear, corrosion, etc., the axial thrust can also induce relative displacement between the pin shaft and pin hole with minimal damage, facilitating pin disassembly.

[0063] This embodiment also applies high-frequency ultrasonic vibration to the pin, causing the rust and impurities on the pin surface to loosen and peel off. This vibration not only acts on the pin surface but also travels along the metal to the connection between the pin and the hydraulic support, reducing the obstruction to pin disassembly caused by rust, dirt, and fastening impurities (such as tightly attached coal slag) at the connection point. This avoids the problem of the pin being difficult to disassemble due to excessive rust or blockage by impurities, or damage to hydraulic support components caused by forced disassembly.

[0064] Simultaneously, axial ultrasonic vibration can effectively reduce the tightness and connection effect of the interface between the pin and the pin hole through fretting friction. The axial ultrasonic vibration and axial thrust work together to stably and quickly disassemble the pin without prior pretreatment (such as soaking, cleaning, or vibration table loosening), achieving good pin disassembly results and avoiding potential secondary damage caused by forced disassembly (such as damage to the pin and pin hole caused by vibration table loosening or direct high-frequency vibration impact). Furthermore, axial vibration can continuously generate elastic waves (acoustic emission signals) at the stress concentration points between the pin and the pin hole, accurately and clearly reflecting the stress relationship between them.

[0065] Specifically, during the pushing process of the pin, if the pin and pin hole experience obstruction or compression due to deformation or other issues, potentially leading to secondary damage, stress concentration will occur at the main contact point between them—the point where secondary damage may occur. If the deformation at this point is too large, exceeding its tolerance, secondary damage will result. Axial ultrasonic vibration can cause continuous, reciprocating compression or collision at the stress concentration point between the pin and pin hole, periodically changing the normal stress at the interface. By controlling the frequency and amplitude of the ultrasonic waves, this change, while not causing damage to the pin and pin hole, will create periodic stress changes at the stress concentration point, continuously exciting elastic waves (acoustic emission response). The generation of elastic waves indicates an abnormal stress. However, since the pin and pin hole are mostly interference fits or have some contact at their deformation points, a basic elastic wave with low intensity will naturally be generated during the pushing 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 remains at a high level, it indicates that the stress anomaly has exceeded the set range. Continuing to advance may cause serious secondary damage or has already begun to cause secondary damage, requiring immediate cessation of the jacking process. The superposition of ultrasonic waves and the continuous, stable elastic waves they induce allows the monitoring device to accurately identify the phenomenon of stress anomalies between the pin and the pin hole. Furthermore, since the high-frequency ultrasonic vibration in this embodiment is generated along the pin axis, the waveform of the ultrasonic vibration is relatively simple, its vibration energy has strong conductivity and low loss, and it can be transmitted throughout the entire pin. This can reduce the friction between the entire pin and the pin hole, and can also detect stress concentration points in the entire pin and pin hole. The elastic waves generated at stress concentration points are also more continuous and stable, further ensuring stable identification of the elastic waves.

[0066] If ultrasonic vibration is applied to the pin in a radial or inclined direction, its energy is relatively dispersed, the stress excitation efficiency is low, and it is difficult to generate a stable superimposed acoustic emission response, resulting in poor detection and inaccurate identification. At the same time, its poor conduction effect may also prevent it from being effectively and with low loss transmitted to the entire pin, failing to effectively reduce the friction between the pin and the pin hole, thus making it impossible to adjust the pin by rotation.

[0067] By applying a thrust to the second end to retract the pin and cooperating with the rotation adjustment pin, the position of the pin can be adjusted. This allows for the finding of a larger gap by rotating and adjusting the relative position of the pin and pin hole without further damage. This ensures that the bent or deformed part of the pin avoids the severely deformed area of ​​the pin hole, reducing jamming and allowing for smooth disassembly. This improves the integrity of the disassembled pin and hydraulic support, preventing secondary damage during disassembly. If the pin cannot be smoothly removed by repeated rotation and retraction under ultrasonic treatment, it is considered that the pin and / or pin hole have suffered severe corrosion, deformation, or other issues. Continuing to remove it mechanically may cause serious damage, requiring manual intervention. More flexible methods such as lubricant penetration or low / high temperature treatment should be used to remove the pin, avoiding damage to the hydraulic support components caused by mechanical forceful disassembly.

[0068] Preferably, in steps S11-S14, the frequency of the ultrasonic vibration is in the range of 20-60kHz, more preferably in the range of 35-45kHz, and the amplitude is between 15-35μm, more preferably between 20-30μm. It is important to note that the elastic waves generated by stress concentration between the pin and the pin hole are generally high-frequency waves, typically between 100-400kHz. To ensure accurate identification and effective excitation of the elastic waves, it is best to control the ultrasonic vibration frequency within the range of 35-45kHz. This avoids problems such as poor excitation effect due to excessively low ultrasonic frequency, unclear elastic waves, or partial coverage of the elastic waves due to excessively high ultrasonic frequency, leading to decreased identifiability. Simultaneously, the amplitude of the ultrasonic vibration also needs to be controlled to avoid situations where the elastic waves are unidentifiable due to excessively small amplitude or damage to the pin or pin hole due to excessively large amplitude.

[0069] Furthermore, if the amplitude of the ultrasonic vibration is less than 5μm, the friction-reducing effect of the ultrasonic wave may decrease, resulting in excessive friction between the interference-fit pin and the pin hole, making rotation impossible. In this case, attempting rotation may cause the pin to break. Whether rotation is possible 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] Meanwhile, controlling the frequency of ultrasonic vibration within the range of 35-45kHz can further prevent resonance in the pin or other parts of the hydraulic support, and avoid damage such as metal fatigue to the pin, pin hole or other components caused by uncontrollable resonance or excessive ultrasonic vibration.

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

[0072] Preferably, in S12, during the first jacking process, the waveform of the sound wave transmitted through the pin is continuously monitored to determine the stress condition of the pin and the pin hole.

[0073] More preferably, in S12, if the second end of the pin is provided with a pre-set point for connection to the rotating mechanism, so that the pin can be rotated without first pushing it out a portion, then during the first push, the position of the pin is dynamically adjusted according to the stress in the pin and the pin hole, further avoiding damage to the pin and its connecting parts.

[0074] Preferably, in step S12, the magnitude of the thrust needs to be adjustable according to the actual disassembly situation and progress of the pin. In the initial stage of pin disassembly, a small pressure is applied and gradually increased, combined with ultrasonic vibration. Once the pin begins to move, this thrust is maintained, slowly pushing the pin out. This ensures that the pin or pin hole is not damaged due to unstable increases in axial thrust during the initial disassembly. In subsequent processes, as the pin is pushed out to a greater length, the pressure is increased appropriately. This ensures both disassembly efficiency and quality without damaging the pin and related components due to excessive instantaneous force.

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

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

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

[0078] Preferably, in step S1, when the hydraulic support is disassembled down to the base, the base is directly transported to the pre-cleaning treatment line via a mobile transport vehicle, and then hoisted onto the line. This avoids problems caused by an excessively heavy base during hoisting or excessive wear on the base due to prolonged hoisting by the track hoisting device.

[0079] Preferably, in step S1, when disassembling the primary components, they are categorized into three sizes based on their dimensions: large components (such as top beams, bases, and large cylinders), medium components (such as connecting rods, large pins, and valve assemblies), and small components (such as bolts, sealing rings, and small pins). Components of different sizes are then transferred to the corresponding pre-cleaning process to ensure its effectiveness. These three sizes also apply to subsequent processing steps. Separating different components into three different processing steps based on their size facilitates the use of appropriate processing equipment and specialized treatments in later stages, which will not be elaborated further.

[0080] Preferably, in step S2, the rough cleaning process includes high-pressure water jet cleaning and brushing. After the primary component enters the rough cleaning process, high-pressure water jet is first used to thoroughly rinse the surface of the primary component to remove obvious dirt and rust products in severely corroded areas. After rinsing, a roller brush or other type of cleaning brush is used to brush the primary component to remove dirt and rust products that were loosened or detached after the high-pressure water jet cleaning but did not leave the surface of the primary component with the water flow, thus obtaining the secondary component.

[0081] High-pressure water jet cleaning differs from conventional high-pressure water jet cleaning technologies. Through specially designed nozzles, it generates high-speed, high-energy-density water jets. Utilizing the impact, shearing force, and cavitation effect of the water jet, it rapidly removes deposits, especially hard and stubborn dirt (such as metal oxide / rust layers and petrochemical scale), from the surface of primary components, achieving highly efficient cleaning. Furthermore, compared to existing technologies, the diameter of the high-pressure water jet produced by the specific nozzle is relatively small. By adjusting the nozzle angle, it can reach into crevices and holes in areas such as columns and jacks, achieving more comprehensive cleaning. In addition, while providing excellent cleaning results, high-pressure water jet cleaning requires less water.

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

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

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

[0085] The impact force of the high-pressure water jet is controlled by adjusting the pressure, nozzle diameter, and distance between the nozzle and the primary component. This prevents the impact force from being too high, which could damage or cause excessive wear to the primary component, or too low, which could prevent the effective removal of deposits from the surface of the primary component.

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

[0087] More preferably, in S2, after the brushing treatment, a high-pressure water jet treatment is performed again to ensure that the surface of the obtained secondary component is free of obvious deposits.

[0088] More preferably, in S2, during the coarse cleaning process, the primary components are treated alternately in a sequence of 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 processes during the coarse cleaning process improve the removal effect on more noticeable deposits. After the final brushing process, a final high-pressure water jet cleaning process is performed to finish, preventing any remaining deposits on the cleaning brush from transferring to the primary components and ensuring the cleanliness of the resulting secondary components.

[0089] More preferably, in S2, when multiple sets of high-pressure water jet cleaning processes are set, the nozzles of adjacent high-pressure water jet cleaning processes are positioned at different angles when arranged in a ring. By varying the spray angle of the high-pressure water jets, the high-pressure water jets in different processes can directly contact different positions of the primary component, thereby improving the cleaning effect.

[0090] By combining high-pressure water jet cleaning with brushing, compared to existing high-pressure water jet rinsing techniques, this method can more thoroughly remove obvious rust, rust spots, and oil stains from the surface of primary components, especially from holes and crevices. This results in a cleaner secondary component, creating a better foundation for subsequent damage detection. It avoids incorrectly testing secondary components for their contents, leading to erroneous data on deformation and wear. This significantly improves the accuracy of damage detection, reduces misjudgments, and increases the utilization rate of hydraulic support components.

[0091] Preferably, in S3, the damage detection includes deformation detection, corrosion detection, and wear detection. 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, three-dimensional point cloud data is obtained through laser three-dimensional scanning to acquire the three-dimensional point cloud data of the secondary components and compare it with preset standard data to calculate the wear rate and deformation degree. Corrosion depth is detected using an eddy current flaw detector, and its measurement data is analyzed simultaneously with the three-dimensional point cloud data. Specifically, the wear rate = wear amount / maximum wear threshold. Wherein, the wear amount is the volume loss rate, wear amount = 100% - current volume / original volume × 100%. The maximum wear threshold is a preset, acceptable, and highest wear amount; in this embodiment, it is preferably 5%. The corrosion degree = average corrosion depth of all corrosion points / maximum set corrosion threshold × 100%, where the corrosion depth is the maximum corrosion depth at a certain corrosion point, and the maximum corrosion depth threshold is a preset, acceptable, and maximum corrosion depth. The maximum corrosion depth threshold needs to be determined based on the specific components of the hydraulic support. For example, in this embodiment, the base is 2.5mm and the top beam is 2mm; the maximum corrosion depth threshold is determined based on the material thickness and importance of the component. Deformation degree = Average value of deformation error at all deformation points / Maximum set deformation threshold × 100%, where deformation error is the absolute value of the deformation at that point compared to its original position. The maximum set deformation threshold is a preset, acceptable, and maximum deformation error. The maximum set deformation threshold also needs to be determined based on 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 based on the thickness and importance of the component's material. 0.6, 0.3, and 0.1 are empirical parameters, representing the magnitude of their impact on the lifespan of the hydraulic support components during subsequent use.

[0093] Preferred, such as Figure 1 As shown in S3, when the quality evaluation score is >0.8, it is judged as unqualified and has low repair value, and is scrapped.

[0094] When 0.3 < quality evaluation ≤ 0.8, it is judged as unqualified, but has some repair value. It can be taken off the production line and repaired using the corresponding repair process. After repair, it is reintegrated into the damage detection section's production line. If the quality evaluation is qualified after repair, it becomes a level 3 component. If the quality evaluation is still unqualified after repair, it is scrapped.

[0095] When the quality evaluation score is ≤0.3, it is judged as qualified and a level 3 component is obtained.

[0096] Preferably, damage detection and quality assessment are carried out on key parts of certain components, such as pin holes, connecting rod inner walls, and hydraulic cylinder walls, which play a key role in the normal assembly and operation of hydraulic supports. The point cloud density of this area is increased and an appropriate threshold is set for separate evaluation. If this part is determined to be unqualified, the entire component is considered unqualified and needs to be scrapped or repaired.

[0097] Preferably, in step S4, the rust removal treatment is ultrasonic electrolysis. The obtained tertiary component is immersed in an ultrasonic electrolysis cell, and electrolysis and ultrasonic treatment are used to synergistically remove rust from the tertiary component.

[0098] Electrolytic cleaning involves applying an electric current to an electrolyte solution, causing a chemical reaction on the workpiece surface to decompose stubborn oxides and dirt. Ultrasonic cleaning utilizes the cavitation effect generated when ultrasound waves propagate in a liquid. As ultrasound waves propagate in a liquid, they form tiny bubbles. These bubbles rapidly expand and burst under sound pressure, generating significant impact force that further removes tiny particles and oil stains adhering to the workpiece surface. Electrolytic cleaning first uses chemical methods to quickly decompose stubborn stains (such as grease, rust, and rust deposits), followed by ultrasonic cleaning, which uses physical methods to further remove tiny particles. The synergistic effect of these two methods significantly improves the cleaning efficiency and shortens the cleaning time for tertiary components while achieving a surface cleanliness level of Sa2.5 or higher for tertiary components. Furthermore, the combined use of these two methods greatly improves the cleaning effect on complex areas such as pin holes, mounting holes, and narrow crevices, avoiding blind spots that may exist when using a single method. Furthermore, when ultrasonic treatment is used in combination with electrolytic treatment, by adjusting the electrolytic current and ultrasonic frequency, cavitation corrosion of precision surfaces by high-power ultrasonic waves or excessive oxidation of metals by strong electrolysis can be avoided. Good cleaning results can be achieved without large power. Compared with traditional high-power ultrasonic cleaning or alkaline immersion + ultrasonic cleaning technologies, it not only has a fast cleaning speed and good cleaning effect, but also avoids damage that may be caused during the cleaning process and improves the treatment effect of subsequent rust prevention treatment.

[0099] More preferably, the current density during electrolytic cleaning is between 3-8 A / dm². The components of the hydraulic support are generally made of low-carbon steel or alloy steel (accounting for more than 95% of the weight), and the electrolysis voltage needs to be controlled according to the material of the hydraulic support to avoid excessive current leading to over-oxidation or hydrogen embrittlement. If the surface of the tertiary component to be treated has a plating (such as chromium plating), a current density of 3-5 A / dm² is preferred to reduce the current density and avoid damage to the plating.

[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. Using DC pulses reduces polarization, ensuring cleaning efficiency while preventing damage to the tertiary components.

[0101] The electrolyte (cleaning solution) has a pH between 9.5 and 11.5. A low-alkalinity electrolyte is used to decompose and saponify grease and other contaminants while preventing corrosion of the steel structure of the three-stage components.

[0102] The electrolyte temperature should be between 50-65℃. Excessive temperature during electrolysis will cause the electrolytic reaction rate to be too fast and a large amount of electrolyte to evaporate.

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

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

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

[0106] More preferably, during ultrasonic cleaning, the power density of the ultrasonic waves is between 0.5 and 1.2 W / cm². 2 Excessive ultrasonic power can easily cause cavitation corrosion in steel, while insufficient power may prevent the removal of microporous particles. The ultrasonic frequency should be between 20-40kHz. For large components, a frequency of 20-30kHz is recommended to ensure the generated bubbles have sufficient impact force. For small and medium-sized components, a frequency of 30-40kHz is recommended to ensure effective cleaning of complex structures while avoiding damage to the tertiary components. The ultrasonic cleaning time should be between 8-15 minutes. Combined with prior electrolytic cleaning, the ultrasonic treatment time can be significantly shortened, resulting in better cleaning outcomes.

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

[0108] Preferably, in step S4, after rust removal, the third-level components are dried to ensure their surface is dry.

[0109] Preferably, in step S4, depending on production needs, the rust prevention treatment includes vapor phase rust prevention and product rust prevention, or only product rust prevention. Specifically, if the rust-removed tertiary components do not need to be directly assembled, they are first subjected to vapor phase rust prevention treatment. Then, the vapor phase rust-prevented tertiary components are temporarily removed from the production line and stored in a temporary warehouse, awaiting later use. Vapor phase rust prevention treatment prevents the rust-removed tertiary components from rusting during storage or transportation, thus avoiding impact on their subsequent use.

[0110] When used and retrieved later, it is hoisted into the corresponding production line for product rust prevention treatment and anti-corrosion coating to obtain the fourth-level component.

[0111] If the obtained rust-removed level 3 components need to be directly assembled, then only rust prevention treatment is performed on the products. The anti-corrosion coating is then applied directly to the rust-removed level 3 components to obtain level 4 components.

[0112] Preferably, in S4, the vapor phase rust prevention treatment is performed using either a spraying or immersion method. For large and medium-sized components, the rust-preventive spray is applied to the rust-removed tertiary components using a spraying method, followed by drying. For small components, the components are immersed in the rust-preventive coating solution using an immersion method, then removed and dried.

[0113] Preferably, in S5, components of the same hydraulic support are identified and selected first for assembly based on the 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 step S5, the assembly of the hydraulic support includes a primary assembly process and a secondary assembly process. First, the corresponding primary assembly process assembles the more fragmented components of the hydraulic support into a unified structure. For example, the column is pre-assembled into a single structure in the primary assembly process, and this column then proceeds as a unified structure to the subsequent secondary assembly process. The primary assembly process also includes the installation of some piping structures within the hydraulic support components.

[0115] In the secondary assembly process, the hydraulic support pins are assembled using the reverse process of the primary disassembly process.

[0116] Preferably, in step S5, after the hydraulic support is assembled, a hydraulic support operation test is also required to ensure the overall quality of the assembled system.

[0117] Example 2:

[0118] This embodiment provides an intelligent disassembly and reprocessing line for hydraulic supports, including a disassembly system arranged in sequence for disassembling hydraulic supports;

[0119] Pre-cleaning system: Used for pre-cleaning primary components;

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

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

[0122] Rust prevention system: Used to prevent rust on tertiary components that have undergone rust removal treatment;

[0123] Assembly system: Used for assembling four-level components.

[0124] The intelligent disassembly and remanufacturing line for hydraulic supports also includes an integrated transfer system for transporting hydraulic support components. This integrated transfer system comprises a rail-mounted hoisting system and a ground-based transfer system.

[0125] Preferably, the rail hoisting system includes an overhead track, a railcar, and a rail hoisting device mounted on the railcar that can move with the railcar.

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

[0127] The disassembly system includes a primary disassembly station for primary disassembly processing. During primary disassembly, the rail hoisting system identifies the components of the hydraulic support through RFID tags and / or image recognition pre-installed in the hydraulic support components. Simultaneously, it coordinates the disassembly process of the disassembly system, mobilizing the corresponding rail hoisting device to perform preliminary hoisting and auxiliary fixation of the components being disassembled, preventing them from becoming unbalanced during disassembly and facilitating disassembly.

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

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

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

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

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

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

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

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

[0136] The vibrator propulsion sleeve 2 includes a top plate, a bottom plate, and several telescopic rods disposed between the top and bottom plates. Both the top and bottom plates are annular structures with a circular through-hole in the center. The telescopic rods are fixedly connected to the annular structures of the top and bottom plates at certain intervals (angles). The ultrasonic vibrator 8 is disposed on the side of the top plate away from the telescopic rods. The ultrasonic vibrator 8 includes several ultrasonic transducers and amplitude transformers connected in series along the annular structure of the top plate. When disassembling the pin, the vibrator propulsion sleeve 2 ensures that the ultrasonic vibrator 8 is always in contact with the first end of the pin 9 to be disassembled by adjusting the length of the telescopic rods, continuously applying stable ultrasonic vibration to the pin 9.

[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 and bottom plates to push the pin 9 to be disassembled.

[0138] Preferably, during the first-stage disassembly process of the pin to be disassembled, the first hydraulic pusher 5 and the first ultrasonic vibrator 8 are first abutted against the first end of the pin 9 to be disassembled. The first acoustic emission sensor array 3 is abutted against the hydraulic support next to the second end of the pin 9 to be disassembled, and the second acoustic emission sensor array 4 is abutted against the hydraulic support next to the first end of the pin 9 to be disassembled. Then, ultrasonic vibration is continuously applied along the axial direction of the pin 9 to be disassembled by the ultrasonic vibrator 8 for a certain period of time. Then, while maintaining ultrasonic vibration, the thrust of the first hydraulic pusher 5 is gradually increased to push out the second end of the pin 9 to be disassembled, while the ultrasonic vibrator 8 is pushed forward by the vibrator pusher, so that the ultrasonic vibrator 8 is always in contact with the pin 9 to be disassembled. During the process of pushing 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 to analyze the stress between the pin 9 to be disassembled and the hydraulic support. After the pin 9 to be disassembled is partially pushed out, the portion of the pin 9 pushed out is held in place by the rotary clamp 7. If no abnormal stress is detected between the pin 9 and the hydraulic support during the pushing process, or if the detected abnormal stress is within the set range, the pin 9 is pushed out completely, completing the disassembly of the pin 9. If an abnormal stress exceeding the set range is detected, the pin 9 is adjusted: the pushing of 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 abnormal stress disappears or decreases to the set range. Then, the position of the pin 9 is rotated and adjusted using the rotary clamp 7. After adjusting to a certain angle, the rotation is stopped, the first hydraulic pusher 5 resumes operation, and the pin 9 is pushed back. If the abnormal stress problem persists after adjustment, the above operation is repeated. During the above process, the vibrator pusher sleeve 2 is adjusted synchronously according to the operation of the second hydraulic pusher 6 to ensure that the ultrasonic vibrator 8 is always in contact with the pin 9 to be disassembled. If abnormal stress is detected during rotation, rotation in that direction is immediately stopped, and rotation of the pin 9 to be disassembled is continued in the opposite direction for adjustment. If repeated adjustments are made within the rotatable adjustment range of the rotary clamp 7, but the abnormal stress cannot be eliminated or reduced to a tolerable range, it is considered that the internal deformation of the pin 9 to be disassembled is serious. 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 manual judgment is made on the subsequent disassembly process.

[0139] The process involves using a vibrator pusher sleeve 2 and an ultrasonic vibrator 8 with an ultrasonic transducer. The ultrasonic vibrator 8 is brought into contact with the pin 9 to be disassembled, applying ultrasonic waves to the pin 9 on the hydraulic support. Under the action of the ultrasonic waves, the pin 9 becomes easier to push out. An acoustic emission sensor array collects the ultrasonic waves applied by the ultrasonic vibrator 8 and transmitted through the pin 9. The waveform of the sound waves is used to determine the stress anomalies that occur during the pushing out of the pin 9 and to make adjustments to prevent further deformation and damage to the pin 9 and to avoid irreversible damage to the pin hole of the hydraulic support during the removal of the pin 9. A clamp is used to hold the pushed-out portion of the pin 9. When the acoustic emission sensor array detects an abnormal stress, the clamping device adjusts the position of the pin 9 and temporarily corrects it by adjusting the angle of the pin 9 to facilitate its removal. Meanwhile, since there is even a vibrator push sleeve 2, it can dynamically adjust the position of the ultrasonic vibrator 8 according to the position of the pin 9 to be disassembled, ensuring that the ultrasonic vibrator 8 is always in contact with the first end of the pin 9 to be disassembled, ensuring the stability and effectiveness of the ultrasonic vibration application.

[0140] Based on the different shapes and sizes of the disassembled hydraulic support components, three different sizes of equipment—large, medium, and small—are used for the coarse cleaning system, damage detection system, fine cleaning system, and rust prevention system. By adjusting the specifications of the equipment in each system, the system can better process the hydraulic support components and improve the processing effect. The coarse cleaning system, damage detection system, fine cleaning system, and rust prevention system are connected by chain conveyor belts or integrated transfer systems.

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

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

[0143] The coarse cleaning system also includes a wastewater recovery device and a slag separation device.

[0144] The damage detection system includes a laser 3D scanning device for acquiring 3D point cloud data of secondary components and an eddy current flaw detector for detecting corrosion and cracks in 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 hoisting the three-stage components into and out of the ultrasonic electrolytic cleaning device.

[0146] The rust prevention system includes a vapor phase rust prevention treatment station and a product rust prevention spraying station arranged sequentially.

[0147] Preferably, an upper / lower station is provided between the vapor phase corrosion inhibitor treatment station and the product corrosion prevention spraying station for loading / unloading three-stage components that have undergone vapor phase corrosion inhibitor treatment.

[0148] Preferably, a temporary storage compartment is provided outside the loading / unloading station to store the third-level components that have undergone vapor phase corrosion prevention treatment.

[0149] An integrated transfer system is also provided between the loading / unloading workstations and the temporary storage warehouse.

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

[0151] The product anti-rust spraying station is equipped with a spray booth, 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 three-stage components that have undergone vapor phase rust prevention treatment, ensuring their surface cleanliness.

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

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

[0155] Preferably, the assembly system includes a primary assembly station. The primary assembly station includes a precision assembly station for pre-assembling some hydraulic support components into a whole, and a pipeline installation station for installing pipelines. The structure of the secondary assembly station can be similar to that of the primary disassembly station.

[0156] Preferably, the primary assembly station also includes a flipping station, used to adjust some of the fourth-level components to a position that facilitates hoisting and assembly, such as the top beam of the hydraulic support.

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

[0158] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0159] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," or "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0160] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0161] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for intelligent disassembly and remanufacturing of hydraulic supports, characterized in that, Includes the following steps: S1: Disassemble the hydraulic support to obtain the primary component; S2: Perform coarse cleaning on the primary components to obtain the secondary components; S3: Perform damage detection and quality assessment on the secondary components; if the quality assessment is satisfactory, the tertiary components are obtained. S4: Rust removal and rust prevention treatments are performed on the third-level components to obtain the fourth-level components; the rust removal treatment includes electrolytic treatment and ultrasonic treatment. S5: Select four-level components for assembly to obtain a remanufactured hydraulic support; In S1, the disassembly process of the hydraulic support pin includes: continuously applying ultrasonic vibration to the pin along its axial direction; pushing the pin during the ultrasonic vibration process; detecting the elastic waves generated by the ultrasonic vibration on the pin and pin hole in real time during the pushing process; dynamically adjusting the position of the pin until the detected elastic wave intensity is within the set range when the elastic wave intensity exceeds the set range; and then continuing to push the pin. The frequency of the ultrasonic vibration is in the range of 20-60kHz, and the amplitude is between 15-35μm. In S1, the dynamic adjustment of the pin position 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. In S2, the primary components undergo a rough cleaning process, including alternating high-pressure water jet cleaning and brushing. During high-pressure water jet cleaning, the pressure of the high-pressure water jet is not less than 80 MPa; the traveling speed of the primary 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; and the distance between the nozzle and the primary components is between 10 cm and 30 cm. 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.

2. The intelligent disassembly and remanufacturing method for hydraulic supports as described in claim 1, characterized in that, In S1, the disassembly and processing of the hydraulic support pin includes: Ultrasonic vibration is applied to the first end of the pin along its axial direction. After the ultrasonic vibration lasts for a set time, the pin is subjected to a first push and a second push in sequence. In the first push, the pin is directly pushed until the second end of the pin protrudes from the pin hole. In the second push, the elastic waves generated by the ultrasonic vibration of the pin and 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 pushed again.

3. The intelligent disassembly and remanufacturing method for hydraulic supports as described in claim 1, characterized in that, The frequency of ultrasonic vibration is in the range of 35-45kHz, and the amplitude is between 20-30μm.

4. The intelligent disassembly and remanufacturing method for hydraulic supports as described in claim 1, characterized in that, When the quality rating 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 is qualified after repair, a level 3 component is obtained. If the quality evaluation is unqualified after repair, it is scrapped. When the quality evaluation score is ≤0.3, it is judged as qualified and a level 3 component is obtained.

5. The intelligent disassembly and remanufacturing method for hydraulic supports as described in claim 1, characterized in that, In S4, during electrolytic treatment, the current density is 3-8 A / dm³. 2 Between these frequencies, DC pulses are used, with a pulse frequency between 80-200Hz and a duty cycle between 1-1.5:

3. During ultrasonic treatment, the power density of the ultrasonic waves is between 0.5 and 1.2 W / cm². 2 The frequency is between 20-40kHz.

6. A dismantling and remanufacturing production line for implementing the intelligent dismantling and remanufacturing method for hydraulic supports as described in any one of claims 1-5, characterized in that, Including the following settings in sequence: Disassembly system: Used for disassembling hydraulic supports; Pre-cleaning system: Used for pre-cleaning primary components; Damage detection system: used for damage detection and quality assessment of secondary components; Fine cleaning system: used for rust removal from tertiary components; Rust prevention system: Used to prevent rust on tertiary components that have undergone rust removal treatment; Assembly system: used for assembling four-level components; The disassembly system also includes a primary disassembly station.

7. The dismantling and reprocessing production line as described in claim 6, characterized in that, The first-level disassembly station is equipped with a pin disassembly frame; the pin disassembly frame includes a frame body and a vibrator pusher sleeve, a first acoustic emission sensor array, a first hydraulic pusher, a second hydraulic pusher, and a rotary clamping device set on the frame body, and an ultrasonic vibrator is provided at the top of the vibrator pusher sleeve.

8. The dismantling and reprocessing production line as described in claim 6, characterized in that, The coarse cleaning system includes a chain conveyor belt and high-pressure water jet cleaning devices and electric roller brush cleaning devices that are alternately arranged along the conveying direction of the chain conveyor belt.

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