Method for synchronously replacing gantry hook and steel wire rope of bridge crane

Abstract

The invention relates to the field of crane gantry hook and steel wire rope replacement, in particular to a method for synchronously replacing a gantry hook and a steel wire rope of a bridge crane, which comprises the following steps: S1, manufacturing a detachable folding steel wire rope traction device according to gantry hook machine pulley blocks of different specifications of the bridge crane; s2, a new steel wire rope penetrates into a new gantry hook pulley block and a new traction device according to regulations; s3, placing the new gantry hook and the old gantry hook in parallel; s4, after the old steel wire ropes are completely loosened, steel wire rope heads are removed, and the steel wire ropes are conveyed to the ground; s5, the parts influencing operation are processed; s6, the old steel wire rope is treated through a traction device, so that the old steel wire rope is separated from the old gantry hook and the bridge crane; and S7, the new gantry hook and the steel wire rope are installed on the bridge crane through the traction device to complete replacement. The method has the advantages that the method for replacing the gantry hook and the steel wire rope of the bridge crane is simplified, and operation time is shortened.

Description

Technical Field

[0001] This application relates to the field of replacing crane gantry hooks and wire ropes, and in particular to a method for simultaneously replacing bridge crane gantry hooks and wire ropes. Background Technology

[0002] Currently, when replacing gantry hooks and wire ropes on large bridge cranes, the commonly used method is the welding-traction sequential winding method. The specific operation is as follows: First, the ends of the old and new wire ropes are welded together. Then, the old wire rope is rotated using the bridge crane's drum, pulling the new wire rope sequentially through the old gantry hook pulley block, the bridge crane's fixed pulley block, and the new gantry hook pulley block. This process requires repeating the winding operation four times: 1. Old rope through the old hook; 2. Old rope through the fixed pulley; 3. New rope through the new hook; 4. New rope through the fixed pulley. Each winding requires manual guidance from personnel working at height. While this method allows for simultaneous replacement, it inherently suffers from a lengthy process chain and frequent human-machine interaction.

[0003] When using existing technology for replacement, the average time for a single replacement is ≥6 hours, including 1.5 hours for welding preparation and inspection, 3.5 hours for four winding operations, and 1 hour for reset and debugging. Especially in multi-rope systems, the time for manual correction increases exponentially with the number of ropes; at the same time, the high-temperature slag during welding can easily reduce the tensile strength of the wire rope, and the weld point is prone to jamming when passing through the pulley groove, causing local bending of the wire rope.

[0004] Due to insufficient space, the fixed pulley block is fixed in place, resulting in insufficient width of the working passage. A multi-stage rope threading scheme is required, and welding traction is used. It is difficult to transfer multiple ropes synchronously. At the same time, there is cross-process interference between the removal of old ropes and the installation of new ropes. Summary of the Invention

[0005] To simplify the replacement of gantry hooks and wire ropes for bridge cranes and reduce operation time, this application provides a method for simultaneously replacing gantry hooks and wire ropes for bridge cranes.

[0006] The method for synchronously replacing the gantry hook and wire rope of a bridge crane provided in this application adopts the following technical solution:

[0007] The method for simultaneously replacing the gantry hook and wire rope of a bridge crane includes the following steps:

[0008] S1. To manufacture detachable and foldable wire rope traction devices according to the different specifications of gantry crane pulley blocks of bridge cranes;

[0009] S2. Thread the new steel wire rope into the new gantry hook pulley block and the new traction device as specified;

[0010] S3. Place the new gantry hook parallel to the old gantry hook;

[0011] S4. After loosening the old wire rope completely, remove the wire rope ends and transport it to the ground;

[0012] S5. Address any components that affect the operation;

[0013] S6. Use a traction device to process the old wire rope, separating it from the old gantry hook and the bridge crane;

[0014] S7. The new gantry hook and wire rope are installed onto the bridge crane using a traction device to complete the replacement.

[0015] By adopting the above technical solution and manufacturing a special foldable traction device, a lightweight carrier is provided for the synchronous transfer of multi-rope systems. The new steel wire rope is pre-threaded to achieve physical isolation between the old and new systems. The old and new gantry hooks are placed in parallel to form a safe operation buffer zone, eliminating the risk of hoisting interference. The old steel wire rope is completely relaxed and lowered to relieve system tension and avoid impact accidents caused by dismantling under load. After disassembling the fixed pulley block base and guard, it is horizontally moved 50-80cm to create a dedicated working channel. The old system is moved out as a whole by the traction device, eliminating the strength loss of steel wire rope caused by welding traction. The pre-installed traction device carries the new steel wire rope and accurately falls into the fixed pulley groove. With the fixed pulley block reset and end fixing, the old system is removed and the new system is installed at the same time.

[0016] Preferably, the new wire rope is threaded into the new gantry hook pulley block and the new traction device as specified, and the number of traction rings of the traction device is the same as the number of fixed pulleys of the bridge crane.

[0017] By adopting the above technical solution, the number of traction rings and fixed pulleys is consistent, and multiple old steel wire ropes can be locked and removed as a whole during the old system dismantling stage. This avoids problems such as manual counting errors, single rope overload risks, and rope path interference, thus achieving safe and efficient operation.

[0018] Preferably, the length of the pulley assembly of the new gantry hook is adapted to the length of the traction ring.

[0019] By adopting the above technical solution, the length of the pulley block arrangement is matched with the length of the traction ring. When the length of the traction ring is less than the length of the pulley block arrangement, the outer wire rope is forced to contract radially. The precise matching ensures that each rope maintains a parallel spacing in the free state, avoiding deformation of the wire rope structure due to uneven force. The matching length makes the projection plane of the center of gravity of the traction device coincide with the center of symmetry of the suspension point, avoiding collision between the wire rope and the fixed pulley block.

[0020] Preferably, the error between the length of the pulley block of the new gantry hook and the length of the traction ring does not exceed 5%.

[0021] By adopting the above technical solution, when the error is greater than 5%, the outer wire rope is prone to distortion, thus avoiding surface scratches caused by the collision between the wire rope and the fixed pulley block.

[0022] Preferably, the step of completely loosening the old wire rope and then removing the wire rope end specifically includes the following steps:

[0023] Loosen all the old wire rope on the drum of the bridge crane;

[0024] Remove the wire rope ends fixed to the drum;

[0025] Remove the ends of the steel wire ropes from the balance beam.

[0026] By adopting the above technical solution, the design of first loosening the drum, then removing the drum rope end, and finally removing the balance beam rope end avoids the elastic rebound of the wire rope. The final removal of the balance beam rope end maintains the balance during the unloading process and reduces the risk of the gantry hook overturning.

[0027] Preferably, the end of the old steel wire rope is hoisted to the ground using a traction device.

[0028] By adopting the above technical solution, the rope head is locked by the guide groove of the traction device and then lowered as a whole, so that personnel can be completely evacuated from the high-risk area, avoiding secondary damage to the rope and avoiding interference with the crane structure, thus reducing collisions.

[0029] Preferably, the process of handling components that affect the operation specifically includes the following steps:

[0030] Remove all components that affect or hinder the disassembly of the wire rope, such as the base of the fixed pulley block and the pulley cover.

[0031] Move the fixed pulley block away from the mounting holes on the platform.

[0032] By adopting the above technical solution, the width formed by the displacement eliminates the forced bending caused by the original operation. After removing the outer protective cover, it is moved in conjunction with the fixed pulley group, which increases the operating space for maintenance personnel.

[0033] Preferably, the step of handling the old wire rope with a traction device to separate it from the old gantry hook and the bridge crane includes the following steps:

[0034] Lift the traction device and attach the old steel wire rope of the fixed pulley block to the traction ring of the traction device one by one;

[0035] Continue lifting to remove the old steel wire rope from the fixed pulley block;

[0036] Move the old wire rope to the position of the upper and lower wire ropes, and then put the old wire rope on the ground;

[0037] Complete the separation of the old wire rope, old gantry hook, and bridge crane.

[0038] By adopting the above technical solution, the rope can be locked and lifted off as a whole by ground-operated traction device, avoiding manual operation at height, ensuring the integrity of the wire rope, and reducing swaying by utilizing the rigidity of the traction device to avoid collision with the crane structure.

[0039] Preferably, the replacement process, which involves installing the new gantry hook and wire rope onto the bridge crane using a traction device, includes the following steps:

[0040] Hoist the new gantry hook wire rope traction device;

[0041] Hoist the new steel wire rope into the fixed pulley block;

[0042] The wire rope should be placed in the corresponding fixed pulley as required;

[0043] Reassemble the disassembled parts of the fixed pulley block one by one;

[0044] Secure the mounting holes on the fixed pulley block mounting platform;

[0045] The new wire rope ends were hoisted one by one to their respective positions.

[0046] Complete the installation of the new wire rope and the new gantry hook.

[0047] By adopting the above technical solution, the new gantry hook and wire rope are hoisted using a traction device, avoiding the safety risks of manual labor. The new wire rope is directly hoisted to the fixed pulley block and placed in a standardized manner, which simplifies the process of repeatedly adjusting the position of the wire rope. Furthermore, the standardized operation avoids abnormal wear caused by misalignment of the wire rope in the pulley block. By disassembling and restoring the fixed pulley block components one by one, the integrity of the pulley block structure and the stability of operation are ensured, preventing equipment failures caused by missing or incorrectly installed components.

[0048] Preferably, hoisting is used for all lifting operations.

[0049] By adopting the above technical solutions, stability is ensured during the replacement of the gantry hook and wire rope of the bridge crane.

[0050] In summary, this application includes at least one of the following beneficial technical effects:

[0051] 1. By manufacturing a special foldable traction device, a lightweight carrier is provided for the synchronous transfer of multi-rope systems. The new steel wire rope is pre-threaded to achieve physical isolation between the old and new systems. The old and new gantry hooks are placed in parallel to form a safe operation buffer zone, eliminating the risk of hoisting interference. The old steel wire rope is completely relaxed and lowered to relieve system tension and avoid impact accidents caused by disassembly under load. After disassembling the fixed pulley block base and guard, it is horizontally moved 50-80cm to create a dedicated working channel. The old system is moved out as a whole by the traction device, eliminating the strength loss of steel wire rope caused by welding traction. The pre-installed traction device carries the new steel wire rope and accurately falls into the fixed pulley groove. With the fixed pulley block reset and end fixing, the old system is removed and the new system is installed at the same time.

[0052] 2. The length of the pulley block arrangement is matched with the length of the traction ring. When the length of the traction ring is less than the length of the pulley block arrangement, the outer wire rope is forced to contract radially. Precise matching ensures that each rope maintains a parallel spacing in the free state, avoiding deformation of the wire rope structure due to uneven force. The matching length makes the projection plane of the center of gravity of the traction device coincide with the center of symmetry of the suspension point, avoiding collision between the wire rope and the fixed pulley block.

[0053] 3. The use of a traction device to hoist the new gantry hook and wire rope avoids the safety risks of manual labor. The new wire rope is directly hoisted to the fixed pulley block and placed in a standardized manner, which simplifies the process of repeatedly adjusting the position of the wire rope and avoids abnormal wear caused by misalignment of the wire rope in the pulley block through standardized operation. The integrity of the pulley block structure and the stability of operation are ensured by disassembling and restoring the fixed pulley block components one by one, and equipment failure caused by missing or incorrect installation of components is prevented. Attached Figure Description

[0054] Figure 1 This is a flowchart of the method for synchronously replacing the gantry hook and wire rope of a bridge crane in an embodiment of this application;

[0055] Figure 2 It is a structural diagram illustrating each component;

[0056] Figure 3 This is a schematic diagram illustrating the structure of the traction device;

[0057] Figures 4-8 This is a schematic diagram illustrating the steps of simultaneously replacing the gantry hook and wire rope of a bridge crane.

[0058] Explanation of reference numerals in the attached drawings: 1. Hoist; 2. Fixed pulley block; 3. Trolley; 4. Old wire rope; 5. Old gantry hook; 6. New gantry hook; 7. New wire rope; 8. Traction device; 801. Traction attachment point; 802. Detachable folding buckle; 803. Guide groove. Detailed Implementation

[0059] The following is in conjunction with the appendix Figure 1-8 This application will be described in further detail.

[0060] This application discloses a method for simultaneously replacing the gantry hook and wire rope of a bridge crane. The method for replacing the gantry hook and wire rope of a bridge crane includes the following steps:

[0061] S1. To manufacture detachable and foldable wire rope traction devices based on the pulley blocks of gantry cranes of different specifications of bridge cranes.

[0062] In an optional embodiment, the weight of the device shall not be less than 20 kg and its strength shall be sufficient to support the weight of the wire rope. It shall be easy for a single person to operate and install. The device is mainly used to hang new wire rope 7 and old wire rope 4. When needed, the traction device 8 shall be opened and the wire ropes shall be hung into the guide grooves in sequence and then locked to prevent the wire ropes from shifting from the guide grooves. The above steps shall be repeated until all the wire ropes are in the guide grooves and then the traction device 8 shall be folded to reduce the width of the device and facilitate the loading and unloading of the wire ropes.

[0063] S2. Thread the new steel wire rope 7 into the pulley block of the new gantry hook 6 and the new traction device 8 as required.

[0064] Specifically, the new wire rope 7 is threaded into the pulley block of the new gantry hook 6 and the new traction device 8 as specified. The number of traction rings in the traction device 8 is consistent with the number of fixed pulleys of the bridge crane. The arrangement length of the pulley block of the new gantry hook 6 is adapted to the length of the traction ring. The error between the arrangement length of the pulley block of the new gantry hook 6 and the length of the traction ring does not exceed 5%.

[0065] The number of traction rings and fixed pulleys is consistent, enabling the synchronous locking and overall removal of multiple old wire ropes 4 during the old system dismantling phase. This avoids problems such as manual counting errors, single rope overload risks, and rope path interference, achieving safe and efficient operation. The pulley block arrangement length is matched with the traction ring length. When the traction ring length is less than the pulley block arrangement length, the outer wire rope is forced to contract radially. Precise matching ensures that each rope maintains parallel spacing in the free state, avoiding wire rope structural deformation caused by uneven force. The matched length ensures that the center of gravity projection plane of the traction device 8 coincides with the center of symmetry of the lifting point, preventing collisions between the wire rope and the fixed pulley block 2. When the error between the pulley block arrangement length of the new gantry hook 6 and the traction ring length is greater than 5%, the outer wire rope is prone to distortion. This prevents surface scratches caused by collisions between the wire rope and the fixed pulley block 2.

[0066] In a preferred embodiment, the number of traction rings in the traction device 8 and the number of fixed pulleys in the bridge crane are the same, and the length of the gantry hook pulley group that is threaded through the new wire rope 7 is the same as that of the traction ring.

[0067] S3. Place the new gantry hook 6 parallel to the old gantry hook 5.

[0068] In an alternative embodiment, the spacing between the old and new gantry hooks must ensure that construction workers have adequate operating space.

[0069] S4. After loosening the old wire rope 4 completely, remove the wire rope ends and transport it to the ground.

[0070] The specific steps include:

[0071] S4.1 Loosen all the old wire rope 4 on the bridge crane drum;

[0072] S4.2 Remove the wire rope end fixed to the drum;

[0073] S4.3 Remove the wire rope ends from the balance beam.

[0074] The design of first loosening the drum, then removing the drum rope end, and finally removing the balance beam rope end prevents the wire rope from rebounding elastically. The final removal of the balance beam rope end maintains balance during the unloading process and reduces the risk of the gantry hook overturning.

[0075] The old steel wire rope 4 ends are hoisted to the ground by the traction device 8. After the rope ends are locked by the guide groove 803 of the traction device 8, the whole rope is lowered, allowing personnel to be completely evacuated from the high-risk area, avoiding secondary damage to the rope, and avoiding interference with the crane structure to reduce collisions.

[0076] S5. Take action on components that affect the operation.

[0077] The specific steps include:

[0078] S5.1 Remove all components that affect or hinder the disassembly of the wire rope, such as the base of the fixed pulley block 2 and the pulley cover;

[0079] S5.2 Move the fixed pulley block 2 away from the mounting holes on the platform.

[0080] Among them, the platform is the trolley 3 platform. The width formed by the displacement eliminates the forced bending caused by the original operation. After the outer protective cover is removed, it moves in conjunction with the fixed pulley group 2 to increase the operating space for maintenance personnel.

[0081] S6. The old wire rope 4 is handled by the traction device 8 to separate it from the old gantry hook 5 and the bridge crane.

[0082] The specific steps include:

[0083] S6.1 Lift up the traction device 8 and hang the old steel wire rope 4 of the fixed pulley block 2 one by one into the traction ring of the traction device 8;

[0084] S6.2 Continue lifting to remove the old steel wire rope 4 from the fixed pulley block 2;

[0085] S6.3 Move the old wire rope 4 to the position of the upper and lower wire ropes, and then put the old wire rope 4 on the ground;

[0086] S6.4 Complete the separation of the old wire rope 4 and the old gantry hook 5 from the bridge crane.

[0087] After locking the rope body by ground-operated traction device 8, the whole rope is lifted away, avoiding manual operation at height, ensuring the integrity of the wire rope, and using the rigidity of traction device 8 to reduce swaying and avoid collision with the crane structure.

[0088] S7. The new gantry hook 6 and wire rope are installed onto the bridge crane using the traction device 8 to complete the replacement.

[0089] Including the following steps:

[0090] S7.1 Lifting new gantry hook 6 steel wire rope traction device 8;

[0091] S7.2 Hoist the new steel wire rope 7 into the fixed pulley block 2;

[0092] S7.3 Place the wire rope in the corresponding fixed pulley as specified;

[0093] S7.4 Reinstall the components that were removed from the fixed pulley block 2 one by one;

[0094] S7.5 Secure the mounting holes on the mounting platform of the fixed pulley block 2;

[0095] S7.6 Hoist the new steel wire rope 7 ends one by one to the corresponding positions;

[0096] S7.7 Complete the installation of the new wire rope 7 and the new gantry hook 6.

[0097] The use of traction device 8 to hoist the new gantry hook 6 and wire rope avoids the safety risks of manual labor. The new wire rope 7 is directly hoisted to the fixed pulley block 2 and placed in a standardized manner, which simplifies the process of repeatedly adjusting the position of the wire rope and avoids abnormal wear caused by misalignment of the wire rope in the pulley block through standardized operation. The integrity of the pulley block structure and the stability of operation are ensured by disassembling and restoring the fixed pulley block 2 components one by one, and equipment failure caused by missing or incorrect installation of components is prevented.

[0098] The traction device 8 includes a traction hook 801, a detachable folding buckle 802, and a guide groove 803. When the hoist crane 1 lifts the new gantry hook 6 wire rope traction device 8, the hoist crane 1 lifts the new wire rope 7 into the fixed pulley block 2 and places the wire rope into the corresponding fixed pulley according to regulations. The components that were removed from the fixed pulley block 2 are installed one by one. Then the mounting holes of the fixed pulley block 2 mounting trolley 3 platform are fixed. Then the hoist crane 1 is used to lift the ends of the new wire rope 7 one by one to the corresponding positions.

[0099] In an optional embodiment, hoist 1 is used for all lifting actions or hoisting operations.

[0100] The implementation principle of this application embodiment is as follows: This method provides a lightweight carrier for the synchronous transfer of multi-rope systems by manufacturing a special foldable traction device 8. The new steel wire rope 7 is pre-threaded to achieve physical isolation between the old and new systems. The old and new gantry hooks 5 are placed in parallel to form a safe operation buffer zone to eliminate the risk of hoisting interference. The old steel wire rope 4 is completely relaxed and lowered to relieve the tension of the system and avoid impact accidents caused by disassembly under load. After disassembling the base and cover of the fixed pulley group 2, it is horizontally moved by 50-80cm to create a special working channel. The old system is moved out as a whole by the traction device 8 to eliminate the strength loss of the steel wire rope caused by welding traction. The pre-installed traction device 8 carries the new steel wire rope 7 and accurately falls into the fixed pulley groove. With the reset and end fixation of the fixed pulley group 2, the old system is removed and the new system is installed at the same time.

[0101] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for simultaneously replacing the gantry hook and wire rope of a bridge crane, characterized in that, Including the following steps: S1. Based on the different specifications of the gantry crane pulley blocks of the bridge crane, a detachable and foldable wire rope traction device is made (8); S2. Insert the new wire rope (7) into the pulley block of the new gantry hook (6) and the new traction device (8) as required; S3. Place the new gantry hook (6) parallel to the old gantry hook (5); S4. After loosening the old wire rope (4) completely, remove the wire rope ends and transport it to the ground; S5. Address any components that affect the operation; S6. The old wire rope (4) is handled by the traction device (8) to separate it from the old gantry hook (5) and the bridge crane; S7. The new gantry hook (6) and wire rope are installed onto the bridge crane using the traction device (8) to complete the replacement.

2. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 1, characterized in that, The new wire rope (7) is threaded into the pulley block of the new gantry hook (6) and the new traction device (8) as specified. The number of traction rings of the traction device (8) is the same as the number of fixed pulleys of the bridge crane.

3. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 2, characterized in that, The length of the pulley block of the new gantry hook (6) is adapted to the length of the traction ring.

4. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 3, characterized in that, The error between the length of the pulley block of the new gantry hook (6) and the length of the traction ring does not exceed 5%.

5. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 1, characterized in that, The specific steps for removing the wire rope head after completely loosening the old wire rope (4) include: Loosen all the old wire rope (4) on the drum of the bridge crane; Remove the wire rope ends fixed to the drum; Remove the ends of the steel wire ropes from the balance beam.

6. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 5, characterized in that, The end of the old steel wire rope (4) is hoisted to the ground by a traction device (8).

7. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 1, characterized in that, The specific steps for handling components that affect the operation include: Remove all components that affect or hinder the disassembly of the wire rope, such as the base and pulley cover of the fixed pulley block (2); Make the fixed pulley block (2) move away from the mounting hole of the platform.

8. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 1, characterized in that, The process of handling the old wire rope (4) by the traction device (8) to separate it from the old gantry hook (5) and the bridge crane includes the following steps: Lift the traction device (8) and hang the old steel wire rope (4) of the fixed pulley block (2) one by one into the traction ring of the traction device (8); Continue lifting to remove the old steel wire rope (4) from the fixed pulley block (2); Move the old wire rope (4) to the position of the upper and lower wire ropes, and then put the old wire rope (4) on the ground; Complete the separation of the old wire rope (4) and the old gantry hook (5) from the bridge crane.

9. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to claim 7, characterized in that, The process of installing the new gantry hook (6) and wire rope onto the bridge crane via the traction device (8) to complete the replacement includes the following steps: Lift the new gantry hook (6) and wire rope traction device (8); The new steel wire rope (7) is hoisted into the fixed pulley block (2); The wire rope should be placed in the corresponding fixed pulley as required; Install the removed parts of the fixed pulley block (2) one by one; Fix the mounting holes of the fixed pulley block (2) on the mounting platform; The new steel wire rope (7) ends are hoisted one by one to the corresponding positions; Complete the installation of the new wire rope (7) and the new gantry hook (6).

10. The method for synchronously replacing the gantry hook and wire rope of a bridge crane according to any one of claims 1-9, characterized in that, When performing lifting actions or hoisting operations, the operation is carried out by using a hoist (1).

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