A hydraulic bander and method of use

Abstract

The application discloses a hydraulic wrapping machine and a use method thereof, and aims at solving the problems of being difficult to clamp, needing manual hammering adjustment and being inconvenient to wrap an ultra-long cylinder body due to self-weight when wrapping a multilayer high-pressure container cylinder body. The wrapping machine comprises a base, a moving mechanism, a hydraulic jacking mechanism, a clamping mechanism, a hydraulic workstation and an electrical control system. The movable design of the wrapping machine enables the equipment to be actively moved to a position below the cylinder body. The hydraulic jacking mechanism drives a plurality of sets of clamping pincers to ascend and descend and to be aligned, and a self-weight assisted hydraulic clamping force is used to realize efficient and close adhesion of the cylinder body and the layer plate by using a tightening mode from top to bottom, and manual hammering is not needed. The wrapping operation is mechanized and automated, the wrapping efficiency and quality are remarkably improved, and the wrapping machine is particularly suitable for manufacturing of an ultra-long high-pressure container cylinder body.

Description

Technical Field

[0001] This invention relates to the field of wrapping technology for multi-layer high-pressure vessel shells, specifically to a hydraulic wrapping machine and its usage method. Background Technology

[0002] Multi-layer wrapped high-pressure vessels are widely used in chemical and energy fields (such as hydrogen storage) due to their high safety and relatively low manufacturing requirements. One of the core steps in manufacturing this type of vessel is to tightly wrap multiple layers of steel plates (layers) onto the outer wall of the inner cylinder. Currently, the wrapping machines commonly used in this process typically consist of a fixed support frame, a hydraulic clamping mechanism, and a wire rope (belt) tightening mechanism. The working principle involves tightening the wire rope from bottom to top to hold the layers together, and then relying on the hydraulic clamping mechanism above to tighten the layer interfaces.

[0003] However, existing technologies and equipment have significant drawbacks: First, because the wrapping direction is from bottom to top, the weight of the layers themselves becomes an obstacle, making it difficult to achieve a completely tight fit between the layers, especially large-diameter, thick layers, and the inner cylinder using only hydraulic clamping force, resulting in the problem of "difficulty in clamping." Second, to overcome this problem, workers must repeatedly strike the layers with a heavy hammer from below, using vibration to force them to shift and fit together. This process is time-consuming and labor-intensive, requiring multiple workers to work together, resulting in high labor intensity, low efficiency, and safety risks. Finally, existing equipment is mostly a fixed structure, limiting its wrapping range. When manufacturing extra-long cylinders, the wrapping position can only be adjusted by frequently hoisting and moving the heavy cylinder, which is extremely inconvenient and seriously affects production efficiency and operational safety. Therefore, a new type of wrapping equipment and method is urgently needed to overcome these shortcomings. Summary of the Invention

[0004] The present invention aims to overcome the shortcomings of the prior art and provide a hydraulic bandaging machine and its usage method.

[0005] The technical solution adopted in this invention is as follows:

[0006] A hydraulic bandaging machine, characterized in that it comprises:

[0007] Base;

[0008] A moving mechanism, located below the base, is used to drive the bandaging machine to move;

[0009] A hydraulic lifting mechanism is mounted on the base;

[0010] The clamping mechanism is connected to the output end of the hydraulic lifting mechanism and is driven by the hydraulic lifting mechanism to lift and lower to a predetermined height; the clamping mechanism includes multiple sets of clamping clamps for gripping and tightening the shelf;

[0011] A hydraulic workstation is used to provide power to the hydraulic lifting and clamping mechanisms.

[0012] And an electrical control system for controlling the movement of the moving mechanism, the hydraulic lifting mechanism and the clamping mechanism.

[0013] Furthermore, the moving mechanism, including the track, motor reducer, and wheels, is controlled by an electrical control system, enabling the wrapping machine to move along the track to different positions below the workpiece.

[0014] Furthermore, the hydraulic lifting mechanism includes at least one hydraulic cylinder and a guiding mechanism, which ensures that the clamping mechanism remains stable during the lifting process.

[0015] Furthermore, the clamping mechanism includes at least two sets of clamping jaws, each set of clamping jaws arranged along the width direction of the shelf and capable of independent small-range lateral position adjustment.

[0016] Furthermore, the clamping pliers include jaws driven by a hydraulic cylinder, with pins on the jaws for inserting into the process holes of the shelf plate; the pressure of the hydraulic cylinder is continuously adjustable and has a pressure display function.

[0017] Furthermore, the hydraulic workstation includes an oil tank, an oil pump motor, a relief valve, and a control system, capable of providing continuously adjustable hydraulic pressure within the range of 0-25MPa.

[0018] Furthermore, the jaws are machined from high-strength alloy steel, and the diameter of the pin is of a predetermined specification to accommodate the process holes of different layers.

[0019] Furthermore, a method of using a hydraulic bandaging machine includes the following steps:

[0020] S1: Move the bandaging machine to the predetermined position directly below the tube to be bandaged using the moving mechanism;

[0021] S2: Control the hydraulic lifting mechanism to lift the clamping mechanism to a position that matches the height of the shelf;

[0022] S3: Control the clamping action of the clamping mechanism so that the pin on its jaws inserts into the process hole of the shelf and grips the shelf.

[0023] S4: Control the clamping clamp to tighten under hydraulic drive, using the self-weight of the shelf and hydraulic pulling force to pull the shelf from top to bottom and stick it to the outer wall of the cylinder.

[0024] S5: After the layers meet the predetermined bonding requirements, weld them in place.

[0025] Furthermore, in step S4, the clamping process can achieve a tight fit between the shelf and the cylinder without the need for manual hammering of the shelf.

[0026] Furthermore, after completing the wrapping of one section of the cylinder, the hydraulic lifting mechanism is lowered and the clamping clamps are released. The wrapping machine is then moved to the next station of the cylinder via the moving mechanism. Steps S2 to S5 are repeated to achieve continuous wrapping of ultra-long cylinders.

[0027] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0028] Effectively overcoming the influence of shelf weight, resulting in superior clamping and bonding: This invention innovatively adopts a "top-down" wrapping and tightening direction. After the hydraulic clamping mechanism grabs the shelf from above, it applies downward pulling force. At this point, the shelf's own weight is no longer an obstacle to the bonding process, but rather becomes a beneficial factor that assists bonding. Together with the hydraulic pulling force, they form a combined force that promotes the shelf to wrap more quickly and tightly around the outer wall of the cylinder, fundamentally solving the pain point of "difficulty in clamping" in traditional methods.

[0029] Automated clamping operations are achieved, saving time and labor while improving safety: Thanks to the efficient and controllable hydraulic clamping system and the use of self-weight assistance, the tightening and bonding process of the shelves is entirely completed by mechanical equipment, completely eliminating the manual hammering step required in traditional processes. This not only significantly reduces the labor intensity of operators, saves manpower, avoids the uncertainties of manual operations, and improves bandaging efficiency, but also eliminates the safety hazards caused by hammering, achieving inherent safety in the operation process.

[0030] The equipment is highly mobile, greatly facilitating the manufacturing of ultra-long cylindrical containers: This invention integrates the wrapping machine onto a movable trolley base, allowing it to move freely along a pre-set track. When wrapping ultra-long cylindrical containers, there is no need to hoist and move heavy containers; simply drive the lightweight wrapping machine to the next workstation for continuous operation. This simplifies the operation process, reduces reliance on large lifting equipment and the risks of frequent hoisting, and significantly improves the convenience, continuity, and overall efficiency of ultra-long container manufacturing.

[0031] The clamping force is precisely adjustable, highly adaptable, and provides high-quality wrapping: A hydraulic system provides continuously adjustable pressure from 0-25MPa, equipped with a pressure display device, allowing for the application of the most suitable clamping force to plywood of different thicknesses and materials. This ensures sufficient preload while preventing damage to the plywood due to overload, guaranteeing the stability and consistency of wrapping quality and broadening the equipment's application range.

[0032] In summary, this invention, through structural and methodological innovation, systematically solves many shortcomings of existing technologies and achieves significant progress in improving bandaging quality, efficiency, and automation. Attached Figure Description

[0033] Figure 1 This is a front view structural diagram of the present invention;

[0034] Figure 2 This is a side view (clamping state) structural schematic diagram of the present invention;

[0035] Figure 3 This is a side view (clamping clamp in open state) of the present invention.

[0036] Figure 4 This is a schematic diagram of the overall structure of the present invention.

[0037] Marked in the image:

[0038] 1-Base; 2-Moving mechanism; 3-Hydraulic lifting mechanism; 4-Clamping mechanism; 5-Clamping clamp; 6-Hydraulic workstation; 7-Railway; 8-Walking wheels. Detailed Implementation

[0039] The present invention will now be described in detail with reference to the accompanying drawings.

[0040] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0041] Example 1

[0042] In this embodiment, as Figure 1-4 As shown, a hydraulic bandaging machine is characterized by comprising:

[0043] Base;

[0044] A moving mechanism, located below the base, is used to drive the bandaging machine to move;

[0045] A hydraulic lifting mechanism is mounted on the base;

[0046] The clamping mechanism is connected to the output end of the hydraulic lifting mechanism and is driven by the hydraulic lifting mechanism to lift and lower to a predetermined height; the clamping mechanism includes multiple sets of clamping clamps for gripping and tightening the shelf;

[0047] A hydraulic workstation is used to provide power to the hydraulic lifting and clamping mechanisms.

[0048] And an electrical control system for controlling the movement of the moving mechanism, the hydraulic lifting mechanism and the clamping mechanism.

[0049] The base is a rigid platform welded from structural steel and steel plates, serving as the foundation of the entire equipment. A moving mechanism (such as wheels with drive motors) is mounted at the bottom of the base, responsible for supporting the entire machine and moving it. A hydraulic lifting mechanism (such as a multi-stage hydraulic cylinder or a combination of a hydraulic cylinder and a scissor lift) is fixedly mounted at the center of the upper surface of the base platform. The clamping mechanism (a frame containing multiple clamping jaws) is directly connected to the top of the piston rod of the hydraulic lifting mechanism via bolts or flanges, rising and falling together with it. The hydraulic workstation and electrical control system are typically independent units, connected to the lifting mechanism, moving mechanism motor, and clamping mechanism hydraulic valve block on the base via high-pressure hoses and cable harnesses, respectively, providing them with power and control signals.

[0050] During operation, the moving mechanism first transports the entire machine to the bottom of the cylinder; then the hydraulic lifting mechanism is activated to lift the clamping mechanism to the working height; next, the clamping mechanism performs the action of gripping and tightening the shelves; all actions are centrally controlled by the electrical control system.

[0051] It has achieved the integration, mobility, and automation of equipment.

[0052] By integrating the three major functional modules of lifting, clamping, and moving onto a movable base, the working mode of traditional fixed wrapping machines has been fundamentally changed. This allows the equipment to actively approach the workpiece, solving the problem of "inconvenient position adjustment when wrapping ultra-long cylinders" in the background technology, eliminating the need for frequent lifting of heavy cylinders. Centralized electrical control reduces the number of coordination steps required by multiple people, improving operational efficiency and safety.

[0053] Furthermore, the moving mechanism, including the track, motor reducer, and wheels, is controlled by an electrical control system, enabling the wrapping machine to move along the track to different positions below the workpiece.

[0054] Two parallel tracks are fixed to the ground, running through the entire bandaging work area. The traveling wheels of the moving mechanism are mounted under the base via wheel seats and bearings, matching the tracks. A motor reducer is connected to the main shaft of the traveling wheels via a sprocket or gear, providing driving force. The power supply and control signals for the motor reducer are provided by the electrical control system through an automatic cable reel or safety conductor rail.

[0055] The operator issues commands via a handheld control box, which activates the electrical control system to drive the motor reducer, causing the wheels to roll precisely on the track. This allows the entire wrapping machine to move smoothly and linearly to the designated workstation. It achieves precise positioning and stable movement, adapting to continuous operation of ultra-long workpieces.

[0056] The equipment is guided by a pre-set ground track, ensuring the accuracy of the movement path and the repeatability of the positioning, thus avoiding the deviation problem that may occur with trackless equipment. The motor reducer drive is less strenuous, more controllable, and provides more accurate movement distance than manual pushing, allowing for convenient and quick movement to the appropriate position under the cylinder.

[0057] Furthermore, the hydraulic lifting mechanism includes at least one hydraulic cylinder and a guiding mechanism, which ensures that the clamping mechanism remains stable during the lifting process.

[0058] The hydraulic cylinder is vertically mounted on the base. The guiding mechanism consists of multiple smooth guide posts fixed to the base and guide sleeves fixed to the clamping mechanism frame, with the guide posts and guide sleeves forming a sliding fit. Alternatively, it can be guide rails and sliders mounted on both sides of the hydraulic cylinder.

[0059] The hydraulic workstation supplies oil to the rodless chamber of the hydraulic cylinder, causing the piston rod to extend and push the clamping mechanism upward. A guiding mechanism ensures that the clamping mechanism only undergoes vertical displacement throughout the entire lifting process, without twisting or swaying. This ensures the smoothness and positional accuracy of the clamping mechanism's lifting process.

[0060] The guiding mechanism withstands the lateral forces and torques generated during the lifting process, avoiding the piston rod bending, cylinder damage, and mispositioning that could occur if these forces were borne solely by the hydraulic cylinder. This allows the clamping mechanism to accurately align with the process holes on the shelf, laying the foundation for reliable gripping and efficient tightening operations.

[0061] Furthermore, the clamping mechanism includes at least two sets of clamping jaws, each set of clamping jaws arranged along the width direction of the shelf and capable of independent small-range lateral position adjustment.

[0062] Multiple clamping clamps are mounted on one or more transversely arranged guide rails by bolts or similar means. Each clamping clamp can be manually slid along the guide rail by loosening the locking mechanism to adjust its position in the width direction of the shelf, and then locked in place.

[0063] Before wrapping, workers pre-adjust the lateral spacing of each set of clamping clamps according to the width of the shelf and the distribution of its process holes, ensuring that the pins are accurately aligned with the process holes. This enhances the versatility and adaptability of the equipment, allowing it to wrap shelves of different widths.

[0064] The width of the shelves and the spacing of the process holes may vary depending on the container size. The adjustable spacing design allows the clamping mechanism to flexibly match shelves of different sizes, enabling a single machine to cover more product types, thus improving equipment utilization and economic value.

[0065] Furthermore, the clamping pliers include jaws driven by a hydraulic cylinder, with pins on the jaws for inserting into the process holes of the shelf plate; the pressure of the hydraulic cylinder is continuously adjustable and has a pressure display function.

[0066] Each clamping jaw houses a small hydraulic cylinder. The cylinder's piston rod is connected to two jaws with pins via a linkage mechanism, converting the cylinder's linear motion into the jaws' opening and closing motion. The hydraulic circuit is equipped with a precision relief valve and pressure sensor, with the pressure signal displayed on the control panel. When the cylinder extends, the jaws close, and the pins insert into the shelf's process holes, firmly gripping the shelf edge. The system presets a tightening pressure based on the shelf thickness and material; the cylinder continuously applies tension, and a pressure gauge displays the current pressure in real time, ensuring sufficient clamping force without damaging the shelf.

[0067] It achieves precise, controllable, and stepless adjustment of clamping force, ensuring the quality of bandaging. The hydraulic drive provides a large and stable clamping force. Adjustable pressure and pressure display transform operation from a blind, experience-based process into a quantifiable and repeatable precision operation. This directly solves the problems of "difficulty in clamping" and "requirement of repeated hammering" in existing technologies, replacing crude manual hammering with precise hydraulic tension, achieving highly efficient operation of the hydraulic clamping mechanism.

[0068] Furthermore, the hydraulic workstation includes an oil tank, an oil pump motor, a relief valve, and a control system, capable of providing continuously adjustable hydraulic pressure within the range of 0-25MPa.

[0069] The core of a hydraulic workstation is a variable displacement pump or a combination of a fixed displacement pump and a proportional relief valve. By adjusting the swashplate angle of the variable displacement pump or the current signal of the proportional relief valve through the electrical control system, the maximum system pressure can be set steplessly and continuously within the range of 0-25 MPa. This provides the necessary, precise, and controllable hydraulic power for lifting and clamping operations.

[0070] Continuously adjustable high pressure is the prerequisite and power guarantee for precise adjustment of clamping force. It ensures that the equipment can handle plywood of various thicknesses and strengths, and is the foundation for achieving efficient and high-quality automated wrapping.

[0071] Furthermore, the jaws are machined from high-strength alloy steel, and the diameter of the pin is of a predetermined specification to accommodate the process holes of different layers.

[0072] The jaws and pins are manufactured using high-strength alloy steel such as 40CrNiMoA through forging, machining, and heat treatment processes to achieve extremely high strength, hardness, and toughness. During clamping, they withstand enormous shear and bending stresses. This ensures the durability, reliability, and safety of the clamping jaws, preventing accidents caused by component deformation or breakage.

[0073] The clamping process involves extremely high forces. The use of high-strength alloy steel and heat treatment ensures that the jaws and pins do not undergo permanent deformation or fatigue fracture under long-term high-load operation, guaranteeing the equipment's lifespan and operational safety, and reducing maintenance costs.

[0074] Example 2

[0075] A method of using a hydraulic bandaging machine includes the following steps:

[0076] S1: Move the bandaging machine to the predetermined position directly below the tube to be bandaged using the moving mechanism;

[0077] S2: Control the hydraulic lifting mechanism to lift the clamping mechanism to a position that matches the height of the shelf;

[0078] S3: Control the clamping action of the clamping mechanism so that the pin on its jaws inserts into the process hole of the shelf and grips the shelf.

[0079] S4: Control the clamping clamp to tighten under hydraulic drive, using the self-weight of the shelf and hydraulic pulling force to pull the shelf from top to bottom and stick it to the outer wall of the cylinder.

[0080] S5: After the layers meet the predetermined bonding requirements, weld them in place.

[0081] This method details the logical sequence of operating the equipment: movement - lifting - gripping - tightening (from top to bottom - welding). Its core is to utilize the movable and lifting characteristics of the equipment to actively adapt to the workpiece, and to cleverly utilize the weight of the shelf itself during tightening.

[0082] A standardized bandaging process that is efficient, labor-saving, and of high quality has been defined.

[0083] The tightening direction from top to bottom transforms the self-weight of the sheath from an obstacle to an aid in traditional methods, greatly promoting the fit between the sheath and the inner cylinder. This solves the problem of the self-weight of the sheath while using its weight to assist in the clamping process.

[0084] Furthermore, in step S4, the clamping process can achieve a tight fit between the shelf and the cylinder without the need for manual hammering of the shelf.

[0085] It emphasizes that in the S4 tightening step, the fit is achieved entirely through the controllable and powerful clamping force provided by the hydraulic system and the assistance of its own weight, without the need for additional manual intervention. This completely eliminates the need for hammering, saving manpower and improving efficiency and safety.

[0086] Furthermore, after completing the wrapping of one section of the cylinder, the hydraulic lifting mechanism is lowered and the clamping clamps are released. The wrapping machine is then moved to the next station of the cylinder via the moving mechanism. Steps S2 to S5 are repeated to achieve continuous wrapping of ultra-long cylinders.

[0087] The method describes a sequence of steps: after completing the wrapping at one station, the equipment descends, releases, moves to the next station, and then repeats the wrapping process. This enables efficient and continuous operation of ultra-long cylinders.

[0088] The above description is merely a preferred embodiment of the invention and is not intended to limit the invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A hydraulic bandaging machine, characterized in that, include: Base; A moving mechanism, located below the base, is used to drive the bandaging machine to move; A hydraulic lifting mechanism is mounted on the base; A clamping mechanism is connected to the output end of the hydraulic lifting mechanism and is driven by the hydraulic lifting mechanism to lift and lower to a predetermined height; the clamping mechanism includes multiple sets of clamping clamps for gripping and tightening the shelf; A hydraulic workstation is used to provide power to the hydraulic lifting mechanism and the clamping mechanism; And an electrical control system for controlling the movement mechanism, the hydraulic lifting mechanism and the clamping mechanism; The moving mechanism includes a motor reducer and traveling wheels. Controlled by the electrical control system, the wrapping machine can move on the track to different positions below the workpiece. The hydraulic lifting mechanism includes at least one hydraulic cylinder and a guide mechanism, which ensures that the clamping mechanism remains stable during the lifting process.

2. The hydraulic bandaging machine according to claim 1, characterized in that: The clamping mechanism includes at least two sets of clamping clamps, each set of clamping clamps is arranged along the width direction of the shelf and can be independently adjusted in a small range of lateral positions.

3. A hydraulic bandaging machine according to claim 2, characterized in that: The clamping pliers include jaws driven by a hydraulic cylinder, and the jaws are provided with pins for inserting into the process holes of the layer plate; the pressure of the hydraulic cylinder is continuously adjustable and has a pressure display function.

4. A hydraulic bandaging machine according to claim 1, characterized in that: The hydraulic workstation includes an oil tank, an oil pump motor, an overflow valve, and a control system, and can provide continuously adjustable hydraulic pressure within the range of 0-25MPa.

5. A hydraulic bandaging machine according to claim 3, characterized in that: The jaws are made of high-strength alloy steel, and the diameter of the pin is a predetermined specification to accommodate the process holes of different layers.

6. A method of using a hydraulic bandaging machine, applied to the hydraulic bandaging machine according to any one of claims 1-5, characterized in that, Includes the following steps: S1: The bandaging machine is moved to a predetermined position directly below the tube to be bandaged by the moving mechanism; S2: Control the hydraulic lifting mechanism to lift the clamping mechanism to a position that matches the height of the shelf; S3: Control the clamping action of the clamping mechanism so that the pin on its jaws inserts into the process hole of the layer plate and grips the layer plate; S4: Control the clamping clamp to tighten under hydraulic drive, and use the weight of the shelf and hydraulic pulling force to pull the shelf from top to bottom and stick it to the outer wall of the cylinder. S5: After the layers meet the predetermined bonding requirements, weld them in place.

7. The method according to claim 6, characterized in that: In step S4, the clamping process can achieve a tight fit between the shelf and the cylinder without manual hammering of the shelf.

8. The method according to claim 6 or 7, characterized in that: After completing the wrapping of a section of the cylinder, the hydraulic lifting mechanism is controlled to descend and the clamping clamps are released. The wrapping machine is then moved to the next station of the cylinder by the moving mechanism. Steps S2 to S5 are repeated to achieve continuous wrapping of ultra-long cylinders.

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