Quick replacement device and replacement method for end pulley of cantilever crane of grab ship unloader

Abstract

The invention provides a quick replacement device and method for a pulley at the end of a cantilever crane of a grab ship unloader. The device comprises a main mechanism rope system hardware unit, an arm support end pulley rapid replacement unit and a PLC control unit. The main mechanism rope system hardware unit comprises a main trolley, a lifting winding drum, an opening and closing winding drum and a cantilever crane end pulley, and the main mechanism rope system hardware unit is used for achieving loading and unloading operation of the grab bucket and driving the main trolley to move horizontally and the winding drum to wind and unwind a rope when the pulley is not functionally damaged or is singly damaged; the PLC control unit is electrically connected with the main mechanism rope system hardware unit; the PLC control unit is used for controlling the lifting motor, the opening and closing motor and the trolley motor when the pulleys are damaged or partially damaged, and limited movement of the main trolley and single-action operation of the winding drum are achieved. According to the invention, the hoisting, transporting and replacing device for the end pulley of the cantilever crane is additionally arranged on the grab ship unloader body, so that the end pulley of the cantilever crane of the grab ship unloader can be safely and quickly replaced under the condition of not adding an additional carrier.

Description

Technical Field

[0001] This invention relates to the field of grab unloader technology, and more particularly to a quick replacement device and method for the end pulley of the grab unloader boom. Background Technology

[0002] As an important unloading equipment in bulk cargo terminals, the wire rope system of the grab unloader's main mechanisms, such as hoisting, opening and closing, and trolley, operates under high-speed and high-load conditions for a long time. Once the accessories in the wire rope system are damaged, they must be replaced immediately to ensure the safe and stable operation of the equipment.

[0003] The steel wire rope system of the main mechanism of the grab unloader is an accessory, especially the pulley at the end of the boom, which is the most difficult to replace. This pulley is installed at a height of about 30-40 meters, with an outward extension of more than 50 meters. The pulley itself weighs more than 4 tons. It is difficult to lift it to this position by conventional vehicles such as truck cranes on the dock. Moreover, the bottom of the boom end is the sea surface. If it is transported by ship to the bottom and then lifted by maintenance crane, the cost will be high and there will be certain safety hazards.

[0004] Therefore, there is an urgent need to develop a quick replacement device and method for the end pulleys of the grab unloader boom, so as to safely and quickly replace the end pulleys of the grab unloader boom without adding an extra vehicle. Summary of the Invention

[0005] This invention provides a quick replacement device and method for the end pulleys of the grab unloader boom. By adding a device for lifting, transporting, and replacing the end pulleys of the grab unloader boom to the grab unloader body, the quick replacement of the end pulleys of the grab unloader boom can be carried out safely and quickly without adding an extra vehicle.

[0006] The technical means employed in this invention are as follows: A quick-change device for the end pulley of the boom of a grab unloader includes a main mechanism rope system hardware unit, a quick-change unit for the end pulley of the boom, and a PLC control unit. The main mechanism rope system hardware unit includes a main trolley, a hoisting drum, an opening and closing drum, and a pulley at the end of the boom. The main mechanism rope system hardware unit is used to realize the loading and unloading of the grab bucket and to drive the main trolley to move and the drum to wind up and unwind the rope when the pulley is damaged in a non-functional way or a single pulley is damaged. The quick-change unit for the boom end pulley is integrated into the grab unloader body and includes: The main beam hoisting bracket and main beam electric hoist, installed in the main beam area, are used to hoist pulleys between the ground and the main trolley; The boom end hoisting bracket and boom electric hoist, located in the boom end area, are used to hoist the pulley between the boom end pulley seat, the main trolley and the boom end pulley temporary placement support. A pulley transport fixing device installed on the main trolley is used to fix the pulleys during horizontal transport. Temporary support for the boom end pulley, installed on the boom end maintenance platform; The main trolley seaside traction winch, the main trolley landside traction winch, and the corresponding main trolley seaside towing hook and main trolley landside towing hook are used to pull the main trolley to move horizontally when both the lifting pulley and the opening and closing pulley are damaged. The PLC control unit is electrically connected to the main mechanism rope system hardware unit; the PLC control unit is used to control the hoisting motor, the opening and closing motor and the trolley motor when the pulley is damaged or partially damaged, so as to realize the restricted movement of the main trolley and the single-action operation of the drum.

[0007] Furthermore, the main mechanism rope system hardware unit also includes a seaside rope-supporting trolley, a landside rope-supporting trolley, a hoisting planetary reducer, an opening and closing planetary reducer, a hoisting motor, an opening and closing motor, a trolley motor, a hoisting wire rope, an opening and closing wire rope, and a grab bucket.

[0008] Furthermore, the quick-change unit for the boom end pulley also includes a land-side trolley rope winch, used to release the wire rope wound on the hoisting drum or opening and closing drum during the pulley replacement process.

[0009] Furthermore, the boom end hoisting bracket is a rotatable structure, and the working range of the boom end hoisting bracket simultaneously covers the boom end pulley, the pulley transport fixing device on the main trolley, and the temporary placement support for the boom end pulley.

[0010] Furthermore, the formula for calculating the maximum strength of the material used in the main beam hoisting support is as follows: ; M max = = ,[σ]=σ s / n Where P is the load on the support, m is the sum of the masses of the pulley and the electric hoist, and W x σ is the bending modulus of the support structure, n is the safety factor, L is the length of the support, and σ is the bending modulus of the support structure. max For the maximum bending normal stress, M max This represents the maximum bending moment.

[0011] Furthermore, the PLC control unit includes a PLC module, a DI module, a local control box in the machine room, a switch, a hoisting inverter, a switching inverter, and a trolley inverter. The PLC module, DI module, and switch are located in the control cabinet inside the PLC room. The DI module receives rope winding and unwinding commands from the local control station in the machine room via hard-wiring, and then sends them to the PLC module. Upon receiving the rope winding and unwinding commands, the PLC module sends them via the switch to the hoisting inverter, switching inverter, and trolley inverter respectively, using the Profinet protocol. The switch is used for communication between the PLC module and the hoisting inverter, switching inverter, and trolley inverter. Data transmission between the trolley frequency converters; the lifting frequency converter is located in the lifting frequency converter cabinet in the electrical room. After receiving the PLC control command, the lifting frequency converter drives the lifting motor in the main mechanism rope system hardware unit to perform the corresponding forward and reverse actions in a hard-wired manner; the opening and closing frequency converter is located in the opening and closing frequency converter cabinet in the electrical room. After receiving the PLC control command, the opening and closing frequency converter drives the opening and closing motor in the main mechanism rope system hardware unit to perform the corresponding forward and reverse actions in a hard-wired manner; the trolley frequency converter is located in the trolley frequency converter cabinet in the electrical room. After receiving the PLC control command, the trolley frequency converter drives the trolley motor in the main mechanism rope system hardware unit to perform the corresponding forward and reverse actions in a hard-wired manner.

[0012] The present invention also provides a method for quick replacement of the end pulley of the grab unloader boom, which is based on any of the above-mentioned quick replacement devices for the end pulley of the grab unloader boom, and includes the following steps: Determine the damage status of the lifting pulley and the opening and closing pulley; the damage status includes non-functional damage to the lifting pulley and the opening and closing pulley at the boom end, damage to a single lifting pulley and the opening and closing pulley at the boom end, and damage to both the lifting pulley and the opening and closing pulley at the boom end; When the lifting pulley and opening / closing pulley at the boom end suffer non-functional damage, the first procedure is adopted, using the main mechanism rope system hardware unit to drive the main trolley to complete the transport of the pulley; the non-functional damage is defined as the pulley's wheel body, bearing, and wheel groove functional components having only shallow surface wear, local coating peeling, or scratches in non-stressed areas. When a single lifting pulley at the boom end is damaged, the second process is adopted, using the wire rope system on the undamaged side to suspend the counterweight, and cooperating with the restricted operation of the PLC control unit to drive the main trolley. When both the lifting pulley and the opening pulley at the boom end are damaged, the third process is adopted, which uses the sea-side traction winch and the land-side traction winch of the main trolley in the boom end pulley replacement unit to drag the main trolley to achieve translation.

[0013] Furthermore, the first process includes the following steps: The new pulley is hoisted onto the main trolley and secured using the main beam electric hoist. Drive the main trolley to the stop position at the end of the boom; The new pulley is temporarily stored in a temporary support using an electric hoist on a boom; Remove the old pulleys and transfer them to the main trolley; Install the new pulley from the temporary support to the pulley seat; The main trolley is driven back to lift the old pulley to the ground.

[0014] Furthermore, the second process includes the following steps: Disconnect the hoisting wire rope and the opening / closing wire rope from the grab bucket; Operate at the local operating station in the machine room, and coordinate with the landside trolley to wind up the rope and release the wire rope on the damaged drum; A temporary counterweight is suspended below the wire rope on the undamaged side, and the temporary counterweight is raised to a safe height via a PLC control unit; The new pulley is hoisted from the ground and fixed on the main trolley using an electric hoist on the main beam; Drive the main trolley to the stop position on the sea side of the boom end; The new pulley is lifted from the pulley transport fixing device of the trolley to the temporary placement support of the pulley at the end of the boom using the boom electric hoist; Remove the old pulleys that need to be disassembled from the pulley seats, and use the boom electric hoist to lift the old pulleys to the pulley transport fixing device of the trolley and fix them. The new pulley, which was placed on the temporary support, was hoisted to the pulley seat at the end of the boom and installed. Drive the main trolley to the land side of the main beam hoisting support, and use the main beam electric hoist to lift the old pulley to the ground; The temporary counterweight was placed on the ground below the main beam and then removed. The hoisting wire rope and the opening and closing wire rope were then reconnected to the grab bucket.

[0015] Furthermore, the third process includes the following steps: Disconnect the hoisting wire rope and the opening / closing wire rope from the grab bucket; Operate at the local control station in the machine room, and coordinate with the landside trolley to wind up the rope and release the wire rope on the hoisting drum and the opening and closing drum. The main trolley seaside traction winch and the main trolley seaside towing hook are connected by temporary traction steel wire ropes, as well as the main trolley landside traction winch and the main trolley landside towing hook. By operating the traction winches on the sea and land sides of the main trolley, the main trolley is moved to the land side of the main beam hoisting support. The new pulley is hoisted from the ground and fixed on the main trolley using an electric hoist on the main beam; By operating the traction winch, the main trolley is moved to the main trolley stop position on the sea side of the boom end; The new pulley is lifted from the pulley transport fixing device of the trolley to the temporary placement support of the pulley at the end of the boom using the boom electric hoist; Remove the old pulleys that need to be disassembled from the pulley seats, and use the boom electric hoist to lift the old pulleys to the pulley transport fixing device of the trolley and fix them. The new pulley, which was placed on the temporary support, was hoisted to the pulley seat at the end of the boom and installed. By operating the traction winch, the main trolley is moved to the land side of the main beam hoisting support, and the old pulley is lifted to the ground using the main beam electric hoist. Repeat the above steps to replace the other pulley; Reconnect the hoisting and opening / closing wire ropes to the grab bucket and remove all temporary traction wire ropes.

[0016] Compared with the prior art, the present invention has the following advantages: This invention adds a lifting, transporting, and replacing device to the boom end pulley of the grab unloader, enabling safe and rapid replacement of the boom end pulley without adding additional carriers. The application of this rapid replacement device and method can address various maintenance and replacement needs, including non-functional damage to the lifting pulley opening and closing pulleys, damage to a single lifting pulley opening or closing pulley, and damage to both lifting pulleys opening and closing pulleys. This reduces maintenance costs associated with pulley replacement, improves safety during the replacement process, saves maintenance time, and significantly reduces terminal operation and maintenance costs. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a structural diagram of the quick-change device for the end pulley of the grab bucket unloader boom of the present invention.

[0019] Figure 2 This is a diagram showing the arrangement of hardware components for the main mechanism rope system of this invention.

[0020] Figure 3 for Figure 2 A-direction view.

[0021] Figure 4 for Figure 2 Enlarged view of the marine survey.

[0022] Figure 5 This is a diagram showing the arrangement of components in the quick-change unit for the boom end pulley of the present invention.

[0023] Figure 6 for Figure 4 Top view.

[0024] Figure 7 for Figure 4 Enlarged view of the marine survey.

[0025] Figure 8 for Figure 4 Enlarged view of the land survey.

[0026] Figure 9 This is a component layout diagram of the PLC control unit of the present invention.

[0027] Figure 10 This is a component layout diagram of the PLC control unit of the present invention.

[0028] Figure 11 This is a flowchart of the method for quickly replacing the boom end pulley under non-functional damage conditions of the lifting pulley opening and closing pulley, according to the present invention.

[0029] Figure 12 This is a flowchart of the method for quickly replacing the boom end pulley when a single lifting pulley opening / closing pulley is damaged, according to the present invention.

[0030] Figure 13 This is a flowchart of the method for quickly replacing the boom end pulley when both the opening and closing pulleys of the lifting pulley are damaged, according to the present invention.

[0031] In the diagram: 1. Boom end pulley; 2. Seaside rope trolley; 3. Main trolley; 4. Grab bucket; 5. Landside rope trolley; 6. Hoisting and closing wire rope; 7. Closing motor; 8. Closing planetary reducer; 9. Closing drum; 10. Hoisting drum; 11. Hoisting planetary reducer; 12. Trolley motor; 13. Hoisting motor; 14. Boom end hoisting bracket; 15. Boom electric hoist; 16. Main trolley seaside traction winch; 17. Main trolley seaside towing hook; 18. Main trolley landside towing hook; 19. Main beam hoisting bracket; 20. Main beam electric hoist; 21. Main trolley landside traction winch; 22. Local control box in machine room; 23. Trolley frequency converter; 24. Closing frequency converter; 25. Hoisting frequency converter; 26. Switch; 27. DI module; 28. PLC module. Detailed Implementation

[0032] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0035] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0036] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0037] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0038] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0039] This invention aims to provide a quick replacement device and method for the end pulleys of a grab unloader boom. By adding a lifting, transporting, and replacing device for the end pulleys of the grab unloader boom to the main body of the grab unloader, it achieves safe and rapid replacement of the end pulleys of the grab unloader boom without adding additional carriers. The application of the quick replacement device and method for the end pulleys of the grab unloader boom can address various maintenance and replacement needs, such as non-functional damage to the lifting pulley opening and closing pulleys, damage to a single lifting pulley opening and closing pulley, and damage to both lifting pulley opening and closing pulleys. It reduces the maintenance costs required for pulley replacement, improves the safety of the pulley replacement process, saves the maintenance time required for pulley replacement, and greatly reduces the operating and maintenance costs of the terminal.

[0040] like Figure 1 As shown, the present invention provides a quick-change device for the end pulley of the boom of a grab unloader, including a main mechanism rope system hardware unit, a quick-change unit for the end pulley of the boom, and a PLC control unit.

[0041] The main mechanism's rope system hardware unit consists of a main trolley 3, a sea-side rope-supporting trolley 2, a land-side rope-supporting trolley 5, a hoisting planetary reducer 11, an opening and closing planetary reducer 8, a hoisting drum 10, an opening and closing drum 9, a hoisting motor 13, an opening and closing motor 7, a trolley motor 12, a boom end pulley 1, a hoisting and opening / closing wire rope 6, and a grab bucket 4. The specific layout is as follows: Figure 2 , Figure 3 and Figure 4As shown, the main trolley is located above the main beam and boom structure, and includes four wire rope pulleys: a lifting sea-side wire rope pulley, a lifting land-side wire rope pulley, an opening / closing sea-side wire rope pulley, and an opening / closing land-side wire rope pulley. The lifting and opening / closing wire ropes pass through the machine room drum and external rope system, then through these four wire rope pulleys to the grab bucket, driving the grab bucket to perform sea-side and land-side translation, lifting and lowering, and opening / closing actions. The sea-side rope support trolley is located between the main trolley and the boom end pulley, used to support the lifting and opening / closing sea-side wire ropes to prevent them from sagging excessively. The land-side rope support trolley is located between the main trolley and the machine room, used to support the lifting and opening / closing land-side wire ropes to prevent them from sagging excessively. The wire rope is excessively sagging. The hoisting planetary reducer, hoisting motor, and hoisting drum are all located in the machine room. The hoisting drum is divided into a sea-side hoisting drum and a land-side hoisting drum. The sea-side hoisting drum is used to wind up and unwind the sea-side wire rope, and the land-side hoisting drum is used to wind up and unwind the land-side wire rope. The hoisting motor drives the hoisting planetary reducer, which in turn drives both the sea-side and land-side hoisting drums to simultaneously wind up and unwind the rope. The opening and closing planetary reducer, opening and closing motor, and opening and closing drum are all located in the machine room. The opening and closing drum is divided into an opening and closing sea-side drum and an opening and closing land-side drum. The sea-side drum is used to wind up and unwind the sea-side wire rope, and the land-side drum is used to wind up and unwind the land-side wire rope. The opening and closing motor drives the opening and closing planetary reducer. The reducer then drives the opening and closing sea-side drum and the opening and closing land-side drum to simultaneously perform rope winding and unwinding actions; the trolley motor is located in the machine room between the lifting planetary reducer and the opening and closing planetary reducer, and is used to drive the lifting planetary reducer and the opening and closing planetary reducer, which in turn drive the lifting sea-side drum and the opening and closing sea-side drum to simultaneously wind up the rope, and the lifting land-side drum and the opening and closing land-side drum to simultaneously wind up the rope. This is transmitted through the rope system, thereby enabling the main trolley and the grab bucket suspended below to move horizontally in the sea-side direction, or to drive the lifting sea-side drum and the opening and closing sea-side drum to simultaneously wind up the rope, and the lifting land-side drum and the opening and closing land-side drum to simultaneously wind up the rope. This is transmitted through the rope system, thereby enabling the main trolley and the grab bucket suspended below to move horizontally in the land-side direction; boom The end pulley is located at the seaside end of the boom and includes a pulley seat, a lifting pulley, and an opening / closing pulley. The pulley seat is used to install the lifting pulley and the opening / closing pulley. The lifting pulley is used to redirect the lifting seaside wire rope at the boom end, and the opening / closing pulley is used to redirect the opening / closing of the seaside wire rope at the boom end. The lifting wire rope is divided into a lifting seaside wire rope and a lifting landside wire rope. The lifting seaside wire rope passes through the lifting seaside drum in the machine room to the lifting pulley at the boom end, then turns back to the main trolley, and then turns downward to the lifting seaside wire rope pulley inside the main trolley to the top of the grab bucket. The lifting landside wire rope passes through the lifting landside drum in the machine room to the main trolley, and then turns downward to the top of the grab bucket via the lifting landside wire rope pulley inside the main trolley.The opening and closing wire ropes are divided into opening and closing sea-side wire ropes and opening and closing land-side wire ropes. The sea-side wire rope travels from the opening and closing sea-side drum in the machine room to the opening and closing pulley at the end of the boom, then folds back to the main trolley, and finally, through its internal opening and closing sea-side wire rope pulley, it is redirected downwards to the grab bucket. The land-side wire rope travels from the opening and closing land-side drum in the machine room to the main trolley, and through its internal opening and closing land-side wire rope pulley, it is redirected downwards to the grab bucket. The grab bucket is pulled by the hoisting wire rope and the opening and closing wire rope, enabling translation, lifting and lowering, and opening and closing actions in both sea and land directions.

[0042] The boom end pulley quick-change unit consists of a main beam hoisting bracket 19, a main beam electric hoist 20, a boom end hoisting bracket 14, a boom electric hoist 15, a pulley transport fixing device, a temporary support for the boom end pulley, a main trolley seaside traction winch 16, a main trolley landside traction winch 21, a main trolley seaside towing hook 17, a main trolley landside towing hook 18, and a landside trolley rope winding winch. The specific layout is as follows: Figures 5-8As shown, the main beam hoisting support is a portal-shaped support located in the middle of the main beam of the grab unloader, used to suspend the main beam electric hoist. The main beam electric hoist is suspended on the main beam hoisting support, with a rated lifting capacity of 5t. It can be dragged left and right along the main beam hoisting support. The hook can be raised and lowered via its built-in remote control. It is used to lift new pulleys to be replaced from the ground to the main trolley, and to lift old pulleys to be repaired from the main trolley to the ground. The boom end hoisting support is located near the boom end. When the main trolley is stopped at the seaside stop position, the boom end hoisting support can simultaneously cover the boom end pulley and the pulleys on the main trolley for transportation. A fixed device and a temporary support for the boom end pulley are used to suspend the electric boom hoist. The electric boom hoist is suspended on the boom end lifting bracket, with a rated lifting capacity of 5t. It can be dragged along the boom end lifting bracket. The hook raising and lowering operation can be achieved through its built-in remote control. It is used to lift and move the boom end pulley between the boom end pulley seat, the temporary support for the boom end pulley, and the pulley transport fixing device on the main trolley after the boom end pulley is removed. The pulley transport fixing device is located on the sea side of the main trolley and is used to fix the new pulley and the removed old pulley to the main trolley, thereby realizing horizontal transportation between the boom end and the middle position of the main beam. The temporary support for the boom end pulley is located on the boom end maintenance platform and is used for temporary placement after the boom end pulley is disassembled. The main trolley seaside traction winch is located on the boom end maintenance platform. When in use, a temporary traction wire rope can be connected to the main trolley seaside towing hook on the seaside side of the main trolley. This allows the main trolley to be towed towards the seaside via its built-in remote control when both the boom end lifting pulleys (opening and closing pulleys) are damaged, i.e., the main trolley cannot move actively. The main trolley landside traction winch is located on the main beam landside maintenance platform. When in use, a temporary traction wire rope can be connected to the main trolley landside towing hook on the landside side of the main trolley. This allows the main trolley to be towed towards the seaside via its built-in remote control when both the boom end lifting pulleys (opening and closing pulleys) are damaged. When all closed pulleys are damaged, meaning the main trolley cannot move actively, the main trolley is towed to the land side using the winch's built-in remote control. The main trolley's sea-side towing hook is located on the sea side of the main trolley and is used to connect a temporary traction wire rope. The main trolley's land-side towing hook is located on the land side of the main trolley and is used to connect a temporary traction wire rope. The land-side trolley's rope-retrieving winch is located on the land-side trolley on the ground. In the process of replacing pulleys in the two cases of damage to a single lifting pulley at the boom end and damage to both the opening and closing pulleys at the boom end, the winch, in conjunction with the operation of the local operating station in the machine room of the PLC control unit, releases the wire rope wound on the corresponding lifting drum and opening / closing drum.

[0043] To ensure safety during pulley hoisting and conveying, the strength and rigidity calculation methods for the main beam hoisting bracket and the boom end hoisting bracket selected in the quick-change unit for the boom end pulley are as follows: Maximum strength of main beam hoisting support material: ; M max = = ,[σ]=σ s / n Where P is the load on the support, m is the mass of the pulley and electric hoist, Wx is the bending modulus of the support structure, σs=235Mpa, and n (safety factor)=1.2.

[0044] Taking a 3000tph grab unloader as an example, with L=8385mm and m=5000kg, the lifting support is made of 32a I-beams made of Q235B steel. x =692cm 3 , [σ]=195Mpa.

[0045] After substituting, σmax = 151 MPa < [σ], which satisfies the condition.

[0046] Maximum strength of main beam hoisting support material: ; M max = = ,[σ]=σ s / n Where P is the load on the support, m is the mass of the pulley and electric hoist, Wx is the bending modulus of the support structure, σs=235Mpa, and n (safety factor)=1.2.

[0047] Taking a 3000tph grab unloader as an example, with L=7175mm and m=5000kg, the lifting support is made of 28a I-beams of Q235B material. x =508cm 3 , [σ]=195Mpa.

[0048] After substituting, σmax = 176 MPa < [σ], which satisfies the condition.

[0049] The PLC control unit consists of PLC module 28, DI module 27, local operation box 22, switch 26, hoisting inverter 25, switching inverter 24, and trolley inverter 23. The specific layout is as follows: Figure 9As shown, the PLC module, DI module, and switch are located in the control cabinet inside the PLC room. The DI module receives the rope winding and unwinding commands for the main trolley horizontal movement, hoisting drum, and opening and closing drum from the local operator station in the machine room via hardwiring, and then sends them to the PLC module. After receiving the commands, the PLC module sends the control commands via the switch to the hoisting inverter, opening and closing inverter, and trolley inverter respectively, using the Profinet protocol. The switch supports the Profinet communication protocol and is used for data transmission between the PLC module and the hoisting inverter, opening and closing inverter, and trolley inverter. The frequency converter is located in the hoisting frequency converter cabinet in the electrical room. After receiving control commands from the PLC, it drives the hoisting motor in the main mechanism rope system hardware unit to perform corresponding forward and reverse actions via hard wiring. The switching frequency converter is located in the switching frequency converter cabinet in the electrical room. After receiving control commands from the PLC, it drives the switching motor in the main mechanism rope system hardware unit to perform corresponding forward and reverse actions via hard wiring. The trolley frequency converter is located in the trolley frequency converter cabinet in the electrical room. After receiving control commands from the PLC, it drives the trolley motor in the main mechanism rope system hardware unit to perform corresponding forward and reverse actions via hard wiring. The specific wiring is as follows: Figure 10 As shown.

[0050] During prolonged operation, the pulleys at the end of the boom of a grab unloader may experience varying degrees of damage. Based on the severity of this damage, they can be categorized into three maintenance-required states, as follows: 1. Non-functional damage to the lifting pulleys and opening / closing pulleys at the boom end: In this case, the grab unloader can perform low-speed operations such as the main trolley's sea-land side translation and the grab's lifting and lowering while the grab is suspended and unloaded. Non-functional damage means that the functional components of the pulley, such as the wheel body, bearing, and wheel groove, only have shallow surface wear (wear amount ≤ 20% of the design allowable wear limit), local coating peeling, or scratches in non-stressed areas (depth ≤ 0.3mm). After testing, its load-bearing capacity, rotational friction coefficient, and other core performance parameters still meet the original design standards of the component, and there is no functional abnormality such as jamming or load attenuation.

[0051] 2. If a single lifting pulley or opening / closing pulley at the boom end is damaged, the grab unloader cannot suspend the grab bucket. However, it can rely on the undamaged lifting or opening / closing mechanism wire rope to suspend the counterweight and achieve the main trolley's low-speed sea-land side translation and the counterweight's low-speed rising and falling. 3. If both the lifting pulley and the opening pulley at the boom end are damaged, the grab unloader cannot rely on the main mechanism rope system to perform actions such as the trolley's sea-land side translation. It can only rely on the boom end pulley to quickly replace the main trolley sea-side traction winch, main trolley land-side traction winch, main trolley sea-side towing hook, and main trolley land-side towing hook components in the unit to achieve the main trolley's low-speed sea-land side translation operation by towing.

[0052] To reduce maintenance costs associated with pulley replacement, improve safety during the replacement process, and save maintenance time, corresponding quick-replacement solutions are provided for the three types of boom end pulley maintenance-ready states, as follows: like Figure 11 As shown, the procedure for quickly replacing the boom end pulley under non-functional damage conditions of the lifting pulley opening and closing pulley is as follows: Step 1: The procedure for quickly replacing the boom end pulley under non-functional damage conditions of the lifting pulley opening and closing pulleys begins; Step 2: Operate at the local operating station in the computer room to move the main trolley to the land side of the main beam hoisting support; Step 3: At the main beam hoisting support, use the main beam electric hoist to lift the new pulley from the ground to the height of the main beam. At the same time, cooperate with the local operation station in the machine room to place and fix the new pulley on the pulley transport fixing device on the main trolley. Step 4: Operate at the local control station in the computer room to move the main trolley to the stop position on the sea side of the main trolley at the end of the boom; Step 5: Rotate the boom end hoisting bracket to the top of the pulley transport fixing device on the trolley. Using the boom electric hoist and in conjunction with the rotation operation of the boom end hoisting bracket, lift the new pulley from the position of the pulley transport fixing device on the trolley to the temporary placement support of the boom end pulley. Step Six: Remove the old pulley to be disassembled from the pulley seat, and use the boom electric hoist in conjunction with the rotation operation of the boom end lifting bracket to lift the old pulley from the pulley seat position at the boom end to the pulley transport fixing device position on the trolley and fix it. Step 7: Using the boom electric hoist and in conjunction with the rotation operation of the boom end hoisting bracket, the new pulley placed on the temporary support of the boom end pulley is hoisted to the position of the boom end pulley seat and the installation is completed. Step 8: Operate at the local operating station in the computer room to move the main trolley to the land side of the main beam hoisting support, and use the main beam electric hoist to remove the old pulley from the pulley transport fixing device on the main trolley and hoist it to the ground; Step 9: The pulley replacement process is complete.

[0053] like Figure 12 As shown, taking the damage of a hoisting pulley as an example, this document describes a quick replacement procedure for the boom end pulley when a single hoisting pulley (opening or closing pulley) is damaged. The replacement procedure for damaged opening or closing pulleys can be referenced here: Step 1: The procedure for quickly replacing the boom end pulley when a single lifting pulley or opening / closing pulley is damaged begins. Step 2: Disconnect the hoisting wire rope and the opening / closing wire rope from the grab bucket; Step 3: Operate at the local control station in the machine room and coordinate with the landside trolley to wind up the hoisting wire rope on the hoisting drum and release it. Step 4: Suspend a temporary counterweight below the opening and closing wire rope, and operate the local control station in the computer room to raise the temporary counterweight to a safe height; Step 5: At the main beam hoisting support, use the main beam electric hoist to lift the new pulley from the ground to the height of the main beam, and use the main beam electric hoist to place and fix the new pulley on the pulley transport fixing device on the main trolley; Step Six: Operate at the local control station in the computer room to move the main trolley to the stop position on the sea side of the main trolley at the end of the boom; Step 7: Rotate the boom end hoisting bracket to the top of the pulley transport fixing device on the trolley. Using the boom electric hoist and in conjunction with the rotation operation of the boom end hoisting bracket, lift the new pulley from the position of the pulley transport fixing device on the trolley to the temporary placement support of the boom end pulley. Step 8: Remove the old pulley to be disassembled from the pulley seat, and use the boom electric hoist in conjunction with the rotation operation of the boom end lifting bracket to lift the old pulley from the pulley seat position at the boom end to the pulley transport fixing device position on the trolley and fix it. Step 9: Using the boom electric hoist and in conjunction with the rotation operation of the boom end hoisting bracket, the new pulley placed on the temporary support of the boom end pulley is hoisted to the position of the boom end pulley seat and the installation is completed. Step 10: Operate at the local operating station in the computer room to move the main trolley to the land side of the main beam hoisting support, and use the main beam electric hoist to remove the old pulley from the pulley transport fixing device on the main trolley and hoist it to the ground; Step 11: Operate at the local control station in the machine room, place the temporary counterweight on the ground below the main beam and remove it, and reconnect the hoisting wire rope to the hoisting drum, restoring the connection between the hoisting wire rope and the opening and closing wire rope and the grab bucket. Step 12: The pulley replacement process is complete.

[0054] like Figure 13 As shown, the procedure for quickly replacing the boom end pulley when both the opening and closing pulleys are damaged is as follows: Step 1: The procedure for quickly replacing the boom end pulley when both the lifting pulley and the opening pulley are damaged begins. Step 2: Disconnect the hoisting wire rope and the opening / closing wire rope from the grab bucket; Step 3: Operate at the local control station in the machine room, and coordinate with the landside trolley to wind up the hoisting wire rope on the hoisting drum and the opening and closing wire rope on the opening and closing drum. Step 4: Connect the main trolley seaside traction winch and the main trolley seaside towing hook using temporary traction steel wire ropes, as well as the main trolley landside traction winch and the main trolley landside towing hook. Step 5: Using the combined operation of the main trolley seaside traction winch and the main trolley landside traction winch, move the main trolley to the landside of the main beam hoisting support. Then, with the help of the main beam electric hoist, lift the new pulley from the ground and fix it on the pulley transport fixing device on the main trolley. Step 6: Using the combined operation of the main trolley seaside traction winch and the main trolley landside traction winch, move the main trolley to the main trolley seaside stopping position at the end of the boom; Step 7: Rotate the boom end hoisting bracket to the top of the pulley transport fixing device on the trolley. Using the boom electric hoist and in conjunction with the rotation operation of the boom end hoisting bracket, lift the new pulley from the position of the pulley transport fixing device on the trolley to the temporary placement support of the boom end pulley. Step 8: Remove the old pulley to be disassembled from the pulley seat, and use the boom electric hoist in conjunction with the rotation operation of the boom end lifting bracket to lift the old pulley from the pulley seat position at the boom end to the pulley transport fixing device position on the trolley and fix it. Step 9: Using the boom electric hoist and in conjunction with the rotation operation of the boom end hoisting bracket, the new pulley placed on the temporary support of the boom end pulley is hoisted to the position of the boom end pulley seat and the installation is completed. Step 10: Using the combined operation of the main trolley seaside traction winch and the main trolley landside traction winch, move the main trolley to the landside of the main beam hoisting support. Then, with the help of the main beam electric hoist, remove the old pulley from the pulley transport fixing device on the main trolley and hoist it to the ground. Step 11: Repeat steps 5 through 10 to replace the other pulley; Step 12: Operate at the local control station in the machine room to reconnect the hoisting wire rope on the hoisting drum and the opening and closing wire rope on the opening and closing drum, and restore the connection between the hoisting wire rope and the opening and closing wire rope and the grab bucket. Step Thirteen: Remove the temporary traction wire ropes between the seaside traction winch and the seaside towing hook of the main trolley, and between the landside traction winch and the landside towing hook of the main trolley. Step Fourteen: The pulley replacement process is complete.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A quick-change device for the end pulley of the grab bucket unloader boom, characterized in that: Includes the main mechanism rope system hardware unit, the boom end pulley quick-change unit, and the PLC control unit; The main mechanism rope system hardware unit includes a main trolley, a hoisting drum, an opening and closing drum, and a pulley at the end of the boom. The main mechanism rope system hardware unit is used to realize the loading and unloading of the grab bucket and to drive the main trolley to move and the drum to wind up and unwind the rope when the pulley is damaged in a non-functional way or a single pulley is damaged. The quick-change unit for the boom end pulley is integrated into the grab unloader body and includes: The main beam hoisting bracket and main beam electric hoist, installed in the main beam area, are used to hoist pulleys between the ground and the main trolley; The boom end hoisting bracket and boom electric hoist, located in the boom end area, are used to hoist the pulley between the boom end pulley seat, the main trolley and the boom end pulley temporary placement support. A pulley transport fixing device installed on the main trolley is used to fix the pulleys during horizontal transport. Temporary support for the boom end pulley, installed on the boom end maintenance platform; The main trolley seaside traction winch, the main trolley landside traction winch, and the corresponding main trolley seaside towing hook and main trolley landside towing hook are used to pull the main trolley to move horizontally when both the lifting pulley and the opening and closing pulley are damaged. The PLC control unit is electrically connected to the main mechanism rope system hardware unit; the PLC control unit is used to control the hoisting motor, the opening and closing motor and the trolley motor when the pulley is damaged or partially damaged, so as to realize the restricted movement of the main trolley and the single-action operation of the drum.

2. The quick-change device for the end pulley of the grab bucket unloader boom according to claim 1, characterized in that, The main mechanism rope system hardware unit also includes a seaside rope-supporting trolley, a landside rope-supporting trolley, a hoisting planetary reducer, an opening and closing planetary reducer, a hoisting motor, an opening and closing motor, a trolley motor, a hoisting wire rope, an opening and closing wire rope, and a grab bucket.

3. The quick-change device for the end pulley of the grab bucket unloader boom according to claim 1, characterized in that, The quick-change unit for the boom end pulley also includes a land-side trolley rope winch, used to release the wire rope wound on the hoisting drum or opening and closing drum during the pulley replacement process.

4. The quick-change device for the end pulley of the grab bucket unloader boom according to claim 1, characterized in that, The boom end hoisting bracket is a rotatable structure, and its working range simultaneously covers the boom end pulley, the pulley transport fixing device on the main trolley, and the temporary placement support for the boom end pulley.

5. The quick-change device for the end pulley of the grab bucket unloader boom according to claim 1, characterized in that, The formula for calculating the maximum strength of the material used in the main beam hoisting support is as follows: ； M max = = ,[σ]=σ s / n Where P is the load on the support, m is the sum of the masses of the pulley and the electric hoist, and W x σ is the bending modulus of the support structure, n is the safety factor, L is the length of the support, and σ is the bending modulus of the support structure. max For the maximum bending normal stress, M max This represents the maximum bending moment.

6. The quick-change device for the end pulley of the grab bucket unloader boom according to claim 1, characterized in that, The PLC control unit includes a PLC module, a DI module, a local control box in the machine room, a switch, a hoisting inverter, a switching inverter, and a trolley inverter. The PLC module, DI module, and switch are located in the control cabinet inside the PLC room. The DI module receives rope winding and unwinding commands from the local control station in the machine room via hardwiring for the main trolley's horizontal movement, hoisting drum, and switching drum, and then sends them to the PLC module. Upon receiving the rope winding and unwinding commands, the PLC module sends them via the switch to the hoisting inverter, switching inverter, and trolley inverter respectively, using the Profinet protocol. The switch is used for communication between the PLC module and the hoisting inverter, switching inverter, and trolley inverter. Data transmission between frequency converters; the lifting frequency converter is located in the lifting frequency converter cabinet in the electrical room. After receiving the PLC control command, the lifting frequency converter drives the lifting motor in the main mechanism rope system hardware unit to perform the corresponding forward and reverse actions in a hard-wired manner; the switching frequency converter is located in the switching frequency converter cabinet in the electrical room. After receiving the PLC control command, the switching frequency converter drives the switching motor in the main mechanism rope system hardware unit to perform the corresponding forward and reverse actions in a hard-wired manner; the trolley frequency converter is located in the trolley frequency converter cabinet in the electrical room. After receiving the PLC control command, the trolley frequency converter drives the trolley motor in the main mechanism rope system hardware unit to perform the corresponding forward and reverse actions in a hard-wired manner.

7. A method for quickly changing the end pulley of a grab unloader boom, implemented based on the quick-changing device for the end pulley of a grab unloader boom as described in any one of claims 1-6, characterized in that, Includes the following steps: Determine the damage status of the lifting pulley and the opening and closing pulley; the damage status includes non-functional damage to the lifting pulley and the opening and closing pulley at the boom end, damage to a single lifting pulley and the opening and closing pulley at the boom end, and damage to both the lifting pulley and the opening and closing pulley at the boom end; When the lifting pulley and opening / closing pulley at the boom end suffer non-functional damage, the first procedure is adopted, using the main mechanism rope system hardware unit to drive the main trolley to complete the transport of the pulley; the non-functional damage is defined as the pulley's wheel body, bearing, and wheel groove functional components having only shallow surface wear, local coating peeling, or scratches in non-stressed areas. When a single lifting pulley at the boom end is damaged, the second process is adopted, using the wire rope system on the undamaged side to suspend the counterweight, and cooperating with the restricted operation of the PLC control unit to drive the main trolley. When both the lifting pulley and the opening pulley at the boom end are damaged, the third process is adopted, which uses the sea-side traction winch and the land-side traction winch of the main trolley in the boom end pulley replacement unit to drag the main trolley to achieve translation.

8. The method for quick replacement of the end pulley of the grab bucket unloader boom according to claim 7, characterized in that, The first process includes the following steps: The new pulley is hoisted onto the main trolley and secured using the main beam electric hoist. Drive the main trolley to the stop position at the end of the boom; The new pulley is temporarily stored in a temporary support using an electric hoist on a boom; Remove the old pulleys and transfer them to the main trolley; Install the new pulley from the temporary support to the pulley seat; Drive the main trolley back and hoist the old pulley to the ground.

9. The method for quick replacement of the end pulley of the grab bucket unloader boom according to claim 7, characterized in that, The second process includes the following steps: Disconnect the hoisting wire rope and the opening / closing wire rope from the grab bucket; Operate at the local operating station in the machine room, and coordinate with the landside trolley to wind up the rope and release the wire rope on the damaged drum; A temporary counterweight is suspended below the wire rope on the undamaged side, and the temporary counterweight is raised to a safe height via a PLC control unit; The new pulley is hoisted from the ground and fixed on the main trolley using an electric hoist on the main beam; Drive the main trolley to the stop position on the sea side of the boom end; The new pulley is lifted from the pulley transport fixing device of the trolley to the temporary placement support of the pulley at the end of the boom using the boom electric hoist; Remove the old pulleys that need to be disassembled from the pulley seats, and use the boom electric hoist to lift the old pulleys to the pulley transport fixing device of the trolley and fix them. The new pulley, which was placed on the temporary support, was hoisted to the pulley seat at the end of the boom and installed. Drive the main trolley to the land side of the main beam hoisting support, and use the main beam electric hoist to lift the old pulley to the ground; The temporary counterweight was placed on the ground below the main beam and then removed. The hoisting wire rope and the opening and closing wire rope were then reconnected to the grab bucket.

10. The method for quick replacement of the end pulley of the grab bucket unloader boom according to claim 7, characterized in that, The third process includes the following steps: Disconnect the hoisting wire rope and the opening / closing wire rope from the grab bucket; Operate at the local control station in the machine room, and coordinate with the landside trolley to wind up the rope and release the wire rope on the hoisting drum and the opening and closing drum. The main trolley seaside traction winch and the main trolley seaside towing hook are connected by temporary traction steel wire ropes, as well as the main trolley landside traction winch and the main trolley landside towing hook. By operating the traction winches on the seaside and landside of the main trolley, the main trolley is moved to the landside of the main beam hoisting support. The new pulley is hoisted from the ground and fixed on the main trolley using an electric hoist on the main beam; By operating the traction winch, the main trolley is moved to the main trolley stop position on the sea side of the boom end; The new pulley is lifted from the pulley transport fixing device of the trolley to the temporary placement support of the pulley at the end of the boom using the boom electric hoist; Remove the old pulleys that need to be disassembled from the pulley seats, and use the boom electric hoist to lift the old pulleys to the pulley transport fixing device of the trolley and fix them. The new pulley, which was placed on the temporary support, was hoisted to the pulley seat at the end of the boom and installed. By operating the traction winch, the main trolley is moved to the land side of the main beam hoisting support, and the old pulley is lifted to the ground using the main beam electric hoist. Repeat the above steps to replace the other pulley; Reconnect the hoisting and opening / closing wire ropes to the grab bucket and remove all temporary traction wire ropes.

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