Rapid replacement method for main roller of ring rolling machine

Abstract

According to the rapid reloading method for the main roller of the ring rolling machine, the reloading process is solidified into 11 processes, the standardized reloading process is obtained, and the reloading time is shortened. The reloading process is solidified into 11 processes of preparation before reloading, equipment setting, core roller dismounting and core shaft mounting, main roller upper support dismounting, main roller cover and petal mold dismounting, upper end cover, main roller and lower end cover dismounting, mold mounting, petal mold and cover mounting, upper support mounting, core roller mold and cushion block mounting and trial operation, and the standardized and normalized reloading process is obtained. Reciprocation of a reloading streamline in the reloading process is eliminated, and the reloading time is shortened. The method has the advantages that unnecessary operation and operation errors in the reloading process are eliminated, the cushion block turnover frequency is reduced, and the one-time installation success probability of the cushion block is improved. The reloading efficiency of the main roller of the ring rolling machine is improved, the safety of the reloading process is improved, and the labor intensity of the reloading process is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of rapid disassembly and replacement of tooling for a ring rolling machine, and in particular to a method for rapid replacement of a main roller of a ring rolling machine. Background Art

[0002] Ring rolling machines are widely used in the forming of ring forgings. The surface quality, dimensional consistency, and uniformity of the ring forgings produced have been significantly improved. With the maturity of rolling technology, the process is gradually developing towards complex cross-section forgings. However, the alternating production of rectangular forgings and complex cross-section forgings requires the replacement of the main roller tooling. During the current replacement process of ring rolling machine equipment, due to the heavy weight of some components and the lack of dedicated lifting equipment, the replacement process is not standardized, resulting in a slow replacement process, high labor intensity for workers, and low safety. This is not conducive to the rapid alternating production of ring forgings with different cross-sections and is not conducive to the development of cross-section forging rolling technology. Yin Guangjun et al. (application publication number CN 218873593U) disclosed a quick-change main roller mechanism for a horizontal ring rolling machine. The main roller mechanism is assembled using mature matching parts, with high reliability, good maintainability, and low cost. A transition sleeve is added between the main roller mold and the main roller shaft to reduce the weight of the main roller mold, shorten the main roller replacement time, reduce labor intensity, and improve work efficiency. Li Guofeng et al. (Application Publication No. CN213002410 U) disclosed a quick-change device for the main roller mold of a ring rolling machine. Through the coordination of a locking mechanism and a mold ejection mechanism, the main roller mold can be easily and safely removed, improving work efficiency, reducing labor intensity, and preventing related safety accidents. However, neither method addresses the difficulty of removing and installing the upper support bearing seat, which is the most difficult component to install during the replacement process. The upper support bearing seat is a heavy and irregular component that must be aligned and level with the main shaft center for installation. It also does not address the long replacement time caused by frequent component removal and installation during the main roller mold installation process. While adding a sleeve can reduce weight, the actual installation method of the sleeve and main roller requires two installations, increasing installation difficulty and operation time. In contrast, the present method mainly improves replacement efficiency by improving the replacement method, tooling, and tools. Through the design of a dedicated lifting device, it solves the problem of component imbalance and jamming during the replacement process. By optimizing the modular structure, the probability of a successful replacement is increased, and the replacement process is streamlined, ultimately achieving rapid replacement. Summary of the Invention

[0003] For the replacement process of the main roller of the ring rolling machine, during the current replacement process, the upper support bearing seat, main roller and other heavy components need to be lifted with a sling and then installed with the core shaft. The installation can be achieved when they are level and aligned. In actual operation, repeated lifting and alignment are required for many times. The installation is successful. The workers have high labor intensity, low safety, and long replacement time, which seriously affects the production cycle of the product. In order to solve the problem of replacement difficulties, a standardized replacement method is proposed, and special lifting tools and molds are designed to improve the replacement efficiency of the ring rolling machine, providing conditions for the research of complex surface ring rolled products.

[0004] The present invention proposes a method for quickly replacing the main roller of a ring rolling machine. By solidifying the replacement process into 11 processes, a standardized replacement process is obtained, which shortens the replacement time. In the case where the upper support components are difficult to disassemble during the replacement process, a special sling is designed to automatically align the horizontal position to achieve rapid replacement of the upper support. The special sling is a rigid structure, which improves the safety of the replacement process. In the process of replacement, the main roller pads rotate multiple times and are prone to jamming during the installation process. By designing an integral pad and optimizing the coordination with the main shaft, the pads can be successfully installed in one rotation. Multiple measures are implemented in parallel to achieve rapid replacement of the main rollers of the ring rolling machine, providing conditions for rapid alternating production of different products.

[0005] The rapid replacement process of the main roller of the ring rolling machine is characterized by:

[0006] A quick replacement process for the main roller of a ring rolling machine solidifies the replacement process into 11 processes, including preparation before replacement, setting up equipment, removing the core roller and installing the core shaft, disassembling the upper support of the main roller, removing the main roller cover and flap mold, removing the upper end cover, main roller and lower end cover, installing the mold, installing the flap mold and cover, installing the upper support, installing the core roller mold and gasket, and trial operation. This obtains a standardized and normalized replacement process, eliminates the reciprocating replacement flow line in the replacement process, and shortens the replacement time.

[0007] Special lifting device design: During the disassembly of the upper support components during the replacement process, the lifting belt becomes unbalanced after lifting and cannot be aligned with the axis, resulting in difficulties in disassembly and installation. By designing a special lifting device, the horizontal position can be automatically aligned to achieve rapid replacement of the upper support. The special lifting device has a rigid structure, which improves the safety of the replacement process.

[0008] Design an integrated pad that is separate from the effective forming surface of the main roller: In order to reduce the weight of the main roller, the effective forming surface and the ineffective forming surface of the main roller are designed separately. The ineffective forming surface is designed as a pad. The standardized pad can be used to match the main rollers of multiple products with different cross-sections, reducing the mold cost in the development and production of complex-profile ring forgings. The pad is designed as an integrated structure to reduce the number of hoisting times and avoid the installation cycle of multiple hoisting turnovers of multiple pads. The fitting clearance between the pad and the main shaft is increased by 1mm on one side to avoid the phenomenon of jamming during installation and achieve successful installation of the pad in one turnover.

[0009] Advantages of the present invention:

[0010] The present invention proposes a method for quickly replacing the main rollers of a ring rolling machine. The standardization and normalization of the replacement process reduces the back and forth flow of the replacement process and eliminates unnecessary operations and operational errors during the replacement process. The design and use of a special lifting device for the upper support bearing seat improve the efficiency and safety of the disassembly and installation of the upper support bearing seat. The optimization and use of the quick-change structure of the main roller pads reduce the turnover frequency of the pads and increase the probability of successful installation of the pads in one time. Compared with the original replacement process, the operation time is shortened to 1 / 3 of the original, which greatly improves the replacement efficiency of the main rollers of the ring rolling machine, improves the safety of the replacement process, and reduces the labor intensity of the replacement process.

[0011] Figures in the specification

[0012] Figure 1 This is the rolling die diagram;

[0013] Figure 2 Schematic diagram of main roller pad;

[0014] Figure 3 This is the distribution diagram of the lifting holes for the spreader;

[0015] Figure 4 It is a diagram of the spreader;

[0016] Figure 5 It is the connection diagram;

[0017] Figure 6 Diagram for drilling holes for the upper support bearing seat.

[0018] Main roller 1, main roller pad 2, core roller pad 3, core roller 4, lower cover 5, letter ring 6, bow-shaped shackle (with nut cotter pin) 7, 0U turnbuckle 8, single-strand steel wire rope 9, seamless steel pipe 10, nameplate 11, circular belt 12, universal lifting ring 13, universal lifting ring 2 14, bearing cover 15, bearing seat 16, connecting piece 17. DETAILED DESCRIPTION

[0019] The present invention will be further explained below in conjunction with specific implementation plans, but the present invention is not limited thereto. The structures, proportions, sizes, etc. illustrated in the drawings of the specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the conditions under which the present invention can be implemented. Therefore, they have no technical significance. Any structural modification, change in proportional relationship or adjustment of size should still fall within the scope of the technical content disclosed in the present invention without affecting the efficacy and purpose that can be achieved by the present invention.

[0020] Example 1:

[0021] A special lifting device is designed for the upper supporting components to automatically align the horizontal position after lifting. The special lifting device adopts a rigid structural link. The specific design method is as follows:

[0022] 1) Find the center of gravity

[0023] Use UG software and the three-dimensional model of the upper support bearing seat to calculate the center of gravity position and mass of the upper support bearing seat. After the lifting device is lifted, the lifting point should be on the same vertical line as the center of gravity of the upper support bearing seat, and the load-bearing capacity of the lifting device should be greater than the mass of the upper support bearing seat.

[0024] 2) Design the location of the lifting holes

[0025] Design the position of the lifting holes according to the shape and center of gravity of the upper support bearing seat. Figure 3 , the four points bear the same force and are designed to bear a load of up to 2500kg, which is twice the mass of the upper support bearing seat to ensure a safety factor.

[0026] 3) Design the sling structure

[0027] The structure of the four slings of the sling is designed with universal parts and quick-change structure. The upper end of the sling is connected with a large lifting ring, which can be directly connected to the overhead crane. The lower end of the sling is connected with a detachable buckle, which can be connected to the upper support bearing seat. The middle is designed to achieve fine-tuning of the sling length by rotation. The entire sling is a rigid structure, which ensures safety while eliminating the influence of the deformation of the original sling.

[0028] 4) Upper support bearing seat link design

[0029] Since the punching position is at the edge of the upper support cover, if the hole is punched directly, the edge may crack. In order to ensure the safety of the lifting process, a small link is designed to be welded to the upper bearing cover. After welding, it is polished and then punched.

[0030] 5) Design of lifting hole position

[0031] Four M24 lifting holes are processed on the upper support. The specific positions refer to the center of gravity position, which are used to install the lifting rings and the sling connection.

[0032] 6) Spreader manufacturing and debugging

[0033] Place a spirit level on the upper surface of the upper support bearing seat and perform horizontal correction in a cross-shaped manner; fine-tune the length of the sling strap to perform horizontal alignment; use the sling to lift the upper support bearing seat to achieve a self-balancing state after lifting; use a crane to lift it repeatedly 15 times and maintain the load for 3 minutes. Plastic deformation of the sling is not allowed.

[0034] Example 2:

[0035] In order to solve the problems of heavy main roller, long transportation turnaround time during installation, tight fit with the main shaft, and easy jamming during installation, an integrated pad is designed that is separated from the effective forming surface of the main roller. The specific design method is as follows:

[0036] 1) Under the premise of ensuring that the total closed height of the equipment is 680mm, the overall pad is designed with a height of 450mm to reduce the turnover number of the pad and thus shorten the installation time.

[0037] 2) The gap between the pad and the main shaft is increased, the size of the key and the circumference is designed to be 582, the width of the key is designed to be 106, and the inner diameter is designed to be φ566, which increases the fitting clearance, reduces the installation difficulty, increases the probability of successful installation in one time, and thus shortens the replacement time.

[0038] 3) Lifting holes are designed on the upper and lower sides of the pad. There is no need to consider the fixed placement method during the installation and disassembly process. Both sides can be lifted and installed, avoiding the lifting work required to match the lifting holes, thereby reducing unnecessary operating steps and shortening the replacement time.

[0039] Example 3:

[0040] To address the issue of repeated action flow in the dressing process, a standardized dressing process is designed. The specific design method is as follows:

[0041] 1) Preparation before changing clothes

[0042] Tools required: Overhead crane (including remote control), one set of upper bearing seat lifting equipment, one wire rope, lifting rings (four M24, two M12, one M56), two thick lifting chains, one thin lifting strap, two wrenches, two large spanners, two sledgehammers, two copper rods, two levels, several rags, three sleepers, two tubes of rust remover, and one test ring.

[0043] Drawing preparation: special-shaped ring mold drawing. According to the drawing, identify the main roller mold and core roller mold that need to be replaced, as well as the required pads, and mark them with check marks.

[0044] A conspicuous sign is hung at the door of the control room: "Equipment replacement, entry is strictly prohibited."

[0045] 2) Release the travel switch of the core roller support, start the equipment industrial computer and four oil pumps, increase the force of the core roller knob to 0.8A, and lift the core roller support to the position where the core roller can be lifted. Insert the protective blocking cylinder.

[0046] 3) Remove the core roller and install the core shaft

[0047] Insert the test ring onto the core roller, screw the M56 lifting ring into the top of the core roller, and thread the wire rope onto the overhead crane. Use the remote control to adjust the overhead crane hoist head to ensure it is directly above the core roller and tighten the wire rope. Apply slight radial force to the core roller. Driven by the rotation of the main roller, the ring and core roller rotate. With the cooperation of the overhead crane, the core roller is removed. After the core roller is horizontally positioned in the appropriate position, hoist the core shaft, align the hexagonal grooves, and install it into the core roller seat (to provide additional safety protection in the event of a sudden drop of the core roller support).

[0048] 4) Dismantle the upper support of the main roller

[0049] First, use a small wrench and a screwdriver to remove the lubrication pipeline on the upper end face of the support. Install the upper bearing seat sling on the main roller support through the lifting ring (4 M24 specifications), and hang the sling in the overhead crane hook. Use the remote control to lift and loosen it up and down to ensure that the sling is evenly stressed and the center of gravity of the support is as directly below the overhead crane hook as possible. Add pads to the lower part of the support for protection. Remove the four bolts of the back plate: first loosen the two bolts at the opposite corners, and then loosen the two bolts at the other opposite corners. Lift upwards slightly so that the bolts are no longer subject to shear force, and remove the bolts. Pull the upper support upward with the help of the overhead crane and manual cooperation. For stuck parts, lightly tap with a copper rod or hammer. After pulling out the support, manual cooperation is required to ensure smooth movement of the support and avoid touching the equipment. Transfer the support to flat ground and pad sleepers underneath.

[0050] 5) Remove the main roller cover and flap mold

[0051] Unscrew the eight bolts on the cover, install two M12 lifting rings, and remove the cover using a thin lifting strap and overhead crane hook. Remove the flap mold by striking it horizontally with a copper rod. Spray the removed cover and flap mold with rust remover to prepare for subsequent installation.

[0052] 6) Remove the upper end cover, main roller and lower end cover

[0053] Install two M24 lifting rings, connect them to the overhead crane hook via a thick lifting chain, and remove the upper end cover, main roller, and lower end cover in sequence. Ensure the overhead crane hook is directly above the component's center of gravity during lifting, and apply steady force upward to prevent contact with the equipment. Use a hammer to strike any high points where the component is stuck. Place the component on a level surface, using sleepers to cushion it. Promptly spray rust remover on the main roller spindle mounting surface and the contact surface of the main roller component to effectively remove red rust and other impurities that may affect fit, preparing for subsequent installation.

[0054] 7) Install the special-shaped ring mold

[0055] According to the requirements of the special-shaped ring mold drawing, install the lower rib, main roller mold, upper rib and spacer in sequence. The installation method is the same as the disassembly method, that is, through the M24 lifting ring and thick lifting chain, assemble with the cooperation of the overhead crane and manual labor. The main roller mold has up and down direction requirements, which are consistent with the drawings. The spacer is to ensure that the entire closed height is 680mm. The closed height is allowed to be within 3mm higher and not less than 680mm. The main roller and the upper and lower ribs have a small gap with the main shaft, and they often need to be knocked to ensure the level. At the same time, the two longitudinal flat keys on the main shaft must match the grooves of the mold. Sometimes it is necessary to rotate the main roller 180° to interchange the two grooves.

[0056] 8) Install the flap mold and cover

[0057] Install the flap mold in the spindle slot and tap it radially with a copper rod to ensure it is secure. Simultaneously, install the cover using the eyelets and straps, ensuring the holes in the cover align with the threaded holes on the spindle to allow for smooth tightening of the eight bolts.

[0058] 9) Install the upper support

[0059] The upper support head should be placed onto the main shaft, with the tail snapping into the groove in the main roller seat. Insert from the top, ensuring both the head and tail are in place simultaneously. As with removal, use the upper bearing seat hoist to hoist the support using the overhead crane hook. Ensure the support end face is level (measured with a spirit level). With the assistance of two operators, insert the upper support into the main shaft. Add protective pads to the lower portion of the support. Tighten the four bolts on the backplate before removing the hoist. Finally, install the lubrication line to the upper end face of the support.

[0060] 10) Install the core roller mold and spacer, and tighten the nut

[0061] According to the drawing requirements, install the arc pad, core roller mold, and spacer on the core shaft in sequence, and finally tighten the double nuts (one nut is not enough to tighten, and there are precedents of failure). At the same time, the nuts must not prevent the core roller upper support from falling to the bottom dead center.

[0062] 11) Trial run

[0063] Pull out the blocking cylinder on the core roller support and lower the support. Simultaneously, install the support's limit travel switch. Start the machine with no load, ensuring smooth rotation of the main roller and forward movement of the core roller. Do not allow the core roller mold to gnaw at the upper and lower ribs of the main roller.

[0064] Matters not covered by the present invention are known technologies.

[0065] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for quickly replacing the main roller of a ring rolling machine, characterized by: The method for quickly replacing the main roller of the ring rolling machine includes solidifying the replacing process into 11 processes, namely, preparation before replacing, setting up equipment, removing the core roller and installing the core shaft, disassembling the upper support of the main roller, removing the main roller cover and the flap mold, removing the upper end cover, the main roller and the lower end cover, installing the mold, installing the flap mold and the cover, installing the upper support, installing the core roller mold and the pad, and trial operation. A standardized and normalized replacing process is obtained, the reciprocating replacing flow line in the replacing process is eliminated, and the replacing time is shortened.

2. The method for quickly replacing the main roller of a ring rolling machine according to claim 1, characterized in that: The method for quickly replacing the main roller of the ring rolling machine adopts a special lifting device. When the upper support component is disassembled during the replacement process, the lifting belt becomes unbalanced after lifting and cannot be aligned with the axis, resulting in difficulties in disassembly and installation. By designing a special lifting device, the horizontal position is automatically aligned, thereby realizing quick replacement of the upper support. The special lifting device has a rigid structure, which improves the safety of the replacement process. Design an integrated pad that is separate from the effective forming surface of the main roller: In order to reduce the weight of the main roller, the effective forming surface and the ineffective forming surface of the main roller are designed separately. The ineffective forming surface is designed as a pad. The standardized pad can be used to match the main rollers of multiple products with different cross-sections, reducing the mold cost in the development and production of complex-profile ring forgings. The pad is designed as an integrated structure to reduce the number of hoisting times and avoid the installation cycle of multiple hoisting turnovers of multiple pads. The fitting clearance between the pad and the main shaft is increased by 1mm on one side to avoid the phenomenon of jamming during installation and achieve successful installation of the pad in one turnover.

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