Dry quenching elevator steel wire rope replacing process

Abstract

The invention discloses a dry quenching elevator steel wire rope replacement process, and belongs to the technical field of steel wire rope replacement. A winch is installed on a lifting tool platform, old steel wire rope fixing pins are dismantled, old steel wire ropes are put down, and the new steel wire ropes and the old steel wire ropes are welded through gas welding in the same twisting direction; loosening the U-shaped fixing clip, putting down the old steel wire rope by using a winding drum, and synchronously winding a new steel wire rope; new and old steel wire ropes are replaced along the rope grooves; adjusting to the required length and keeping the four pieces consistent; and the tail end is compacted and fixed. A traditional single-point operation mode is upgraded into a four-point operation mode, and the stability and reliability of vertical movement of the rope are effectively guaranteed; and meanwhile, joints of the four new and old ropes are respectively processed by adopting a same-direction welding process, so that the action consistency and the operation uniformity of synchronous up-and-down movement of the ropes are realized. The technical effects that the operation process is safe, efficient, rapid, accurate and high in stability are achieved, and the overall operation efficiency is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of wire rope replacement technology, and more specifically, to a wire rope replacement process for a dry quenching coke hoist. Background Technology

[0002] The wire rope system of traditional dry quenching coke elevators typically has a service life of only one and a half years after wear, requiring periodic shutdowns for replacement. This not only takes a long time to operate but also reduces the operating efficiency of the dry quenching system. Furthermore, the cost of each replacement is high, and the replaced wire ropes require repeated adjustments, resulting in a high failure rate and severely restricting the safe and stable operation of the dry quenching system. Summary of the Invention

[0003] 1. The technical problem that the invention aims to solve

[0004] To address the shortcomings and deficiencies of existing technologies, this invention provides a wire rope replacement process for dry quenching coke elevators. Through the rational use of combined devices and precise control of the operational process, this invention optimizes the traditional single-rope replacement operation of the elevator wire ropes into a simultaneous replacement of four ropes. During the operation, welding, unloading, fixing, and adjustment processes are implemented simultaneously and effectively integrated. This not only significantly reduces the impact of wire rope replacement operations on production but also reduces spare parts costs. It achieves a safe, efficient, fast, precise, and highly stable operational process, significantly improving overall operational efficiency.

[0005] 2. Technical Solution

[0006] To achieve the above objectives, the technical solution provided by the present invention is as follows:

[0007] The present invention provides a wire rope replacement process for a dry quenching coke elevator, comprising the following steps:

[0008] S1: Pre-fabricate the necessary tooling and cable fixing brackets for replacement;

[0009] S2: After determining the length of the new and old wire ropes, place the new wire rope on the rope fixing bracket, with the new wire rope and the old wire rope having the same lay direction;

[0010] S3: Hoist fixedly installed on the elevated platform;

[0011] S4: Install U-shaped fixing clips on the old wire rope near the rope outlet on the hoisting drum to secure the four old wire ropes.

[0012] S5: Remove the old wire rope fixing end and fix it with a hoist;

[0013] S6: Start the winch to lower the old rope to the lower platform at a uniform speed;

[0014] S7: After the four ends of the old wire rope are lowered, cut the old wire rope 3-5 meters from the lowered end to the moving pulley of the lifting device.

[0015] S8: Connect the new wire rope to the old wire rope and weld them together using gas welding.

[0016] S9: After the new and old wire ropes are welded together, loosen the U-shaped fixing clips; start the hoist winding action, winding up the new wire rope while simultaneously winding down the old wire rope, which falls to the ground under its own weight;

[0017] S10: When the connection point of the new and old wire ropes passes through the drum, the drum is now full of new wire rope. Stop the drum motor and use U-shaped fixing clips to lock the wire rope inlet and outlet ends.

[0018] S11: Secure the old wire rope with a 15-ton shackle and use a hoist to hold it in place to prevent it from falling. Cut the wire rope 150-200mm from the weld point between the new and old wire ropes towards the new wire rope. Use a winch wire rope to hook the shackle position of the old wire rope, release the U-shaped fixing clips on the hoist and the end of the old wire rope, start the winch, and lower the old wire rope to the ground.

[0019] S12: Jog the drum to adjust the number of turns of wire rope on the drum; start the winch to move the cut end of the new wire rope to the fixed position of the rope pressing plate on the drum, and adjust the wire rope so that the wire rope enters the corresponding rope groove on the drum surface in an orderly manner.

[0020] S13: Reverse rotation of the drum. Utilizing the action of the U-shaped fixing clip, the wire rope can only rotate slowly in the opposite direction with the drum, causing the wire rope in the drum's rope groove to become loose. After the wire rope becomes loose, stop the drum rotation. Arrange personnel on both sides of the drum to pull the wire rope towards the rope end to the rope pressing plate. Other personnel drag the wire rope towards the rope pressing plate while simultaneously straightening the wire rope so that it enters the corresponding rope groove on the drum surface in an orderly manner. Adjust the rope end of the new wire rope to the bolt fixing point of the rope pressing plate, leave an adjustment length, and then tighten the bolt.

[0021] S14: One end of the new wire rope is fused to the old wire rope, and the other end is used as the fixed end. Make the ends of the four wire ropes of the new wire rope, leaving a distance of one meter from the fixed end of the wire rope. After the four fixed ends are made, use the winch wire rope to pull the four fixed ends to the balancer for installation, and fix them with fixing pins.

[0022] Furthermore, after the new wire rope is fixed, a horizontal adjustment is performed, that is, the wire ropes on the two drums are adjusted, and the horizontal height difference Δh of the coke can cover is measured:

[0023] The measurement method is as follows: lower the coke can lid to the maintenance position, mark the position of the first or second guide wheel fixed point on the east and west sides with a right angle ruler, raise the coke can lid by 0.5m, mark the position of the guide wheel fixed point marked before, and measure the height h1 and h2 between the two marks. The difference between h1 and h2 is the horizontal height difference of the coke can lid.

[0024] Furthermore, before operation, the diameter of each new wire rope is randomly checked at 20 points using vernier calipers; the diameter error is no more than 0.05. The lay direction of the wire rope is also confirmed to ensure that it is consistent with the lay direction of the old wire rope.

[0025] Furthermore, in S11, after a portion of the wire rope is cut off, the end of the wire rope must be re-wrapped with wire.

[0026] Furthermore, when the new wire rope is released to its lowest position, there should be no fewer than 6 turns of new wire rope wound on the drum.

[0027] Furthermore, after the new wire rope is replaced, a test lift is performed on the new wire rope. The test lift is conducted in three stages: the first test lift is performed at no less than 10% of the rated weight, the second test lift is performed at no less than 50% of the rated weight, and the third test lift is performed with the load loaded in the coke can.

[0028] Furthermore, technicians use a measuring tape to check the levelness of the coke can lid, ensuring that the height difference of the coke can lid is ≤10mm; technicians use a right-angle ruler to check the distance difference between the balancer and the left and right limits, ensuring that it is ≤5mm.

[0029] 3. Beneficial effects

[0030] Compared with the prior art, the technical solution provided by this invention has the following advantages:

[0031] This invention optimizes the traditional single-rod replacement operation of hoist wire ropes into a four-rod simultaneous replacement by rationally utilizing the combined device and precisely controlling the operation process. During the operation, the welding, winding, fixing, and adjustment processes are implemented simultaneously and effectively connected and integrated. This not only significantly reduces the impact of dry quenching coke hoist wire rope replacement operations on production, but also reduces spare parts costs. It achieves the technical effects of safe, efficient, fast, accurate, and highly stable operation, significantly improving overall operation efficiency. Attached Figure Description

[0032] Figure 1 This is a structural diagram of the cable fixing bracket of the present invention;

[0033] Figure 2 This is a diagram illustrating the placement effect of the new steel wire rope of the present invention.

[0034] Figure 3This is a diagram illustrating the effect of using the U-shaped fixing clip of the present invention.

[0035] Figure 4 This is a diagram illustrating the welding effect of the old and new steel wire ropes according to the present invention.

[0036] Figure 5 This is a diagram of the wire rope end crimping of the present invention;

[0037] Figure 6 This is a flowchart of the process nodes of the present invention.

[0038] In the picture: 1. Rope and cable fixing bracket; 2. U-shaped fixing clip. Detailed Implementation

[0039] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0040] Example 1

[0041] from Figure 1-6 As can be seen, the steps of the wire rope replacement process for a dry quenching coke elevator in this embodiment are as follows:

[0042] S1: Pre-fabricate the necessary tooling for replacement, including cable fixing bracket 1;

[0043] S2: After determining the length of the new and old wire ropes, place the new wire rope on the rope fixing bracket 1, with the new wire rope and the old wire rope having the same lay direction;

[0044] S3: Hoist fixedly installed on the elevated platform;

[0045] S4: Install U-shaped fixing clips 2 near the outlet of the old wire rope on the hoisting drum to hold 4 old wire ropes in place. U-shaped fixing clips 2 are used to fix the wire ropes and prevent them from falling.

[0046] S5: Remove the old wire rope fixing end and fix it with a hoist;

[0047] S6: Start the winch to lower the old rope to the lower platform at a uniform speed;

[0048] S7: After the four ends of the old wire rope are lowered, cut the old wire rope 3-5 meters from the lowered end to the moving pulley of the lifting device.

[0049] S8: Connect the new wire rope to the old wire rope and weld them together using gas welding.

[0050] S9: After the new and old wire ropes are welded together, loosen the U-shaped fixing clip 2; start the hoist winding action, winding up the new wire rope while simultaneously winding down the old wire rope, and the old wire rope falls to the ground under its own weight;

[0051] S10: When the connection point of the new and old wire ropes passes through the drum, the drum is now full of new wire rope. Stop the drum motor and use U-shaped fixing clips 2 to lock the wire rope inlet and outlet ends.

[0052] S11: Secure the old wire rope with a 15-ton shackle and use a hoist to pull and fix it to prevent the wire rope from falling; cut the wire rope 150-200mm from the weld point of the new and old wire ropes towards the new wire rope; use the winch wire rope to hook the shackle position of the old wire rope; release the hoist and the U-shaped fixing clip 2 at the end of the old wire rope; start the winch and lower the old wire rope to the ground;

[0053] S12: Jog the drum to adjust the number of turns of wire rope on the drum; start the winch to move the cut end of the new wire rope to the fixed position of the rope pressing plate on the drum, and adjust the wire rope so that the wire rope enters the corresponding rope groove on the drum surface in an orderly manner.

[0054] S13: Reverse rotation of the drum. Utilizing the action of the U-shaped fixing clip 2, the wire rope can only rotate slowly in the opposite direction with the drum, causing the wire rope in the drum's rope groove to become loose. After the wire rope becomes loose, stop the drum rotation. Arrange personnel on both sides of the drum to pull the wire rope towards the rope end to the rope pressing plate. Other personnel drag the wire rope towards the rope pressing plate while simultaneously straightening the wire rope so that it enters the corresponding rope groove on the drum surface in an orderly manner. Adjust the rope end of the new wire rope to the bolt fixing point of the rope pressing plate, leave an adjustment length, and then tighten the bolt.

[0055] S14: One end of the new wire rope is fused to the old wire rope, and the other end is used as the fixed end. Make the ends of the four wire ropes of the new wire rope, leaving a distance of one meter from the fixed end of the wire rope. After the four fixed ends are made, use the winch wire rope to pull the four fixed ends to the balancer for installation, and fix them with fixing pins.

[0056] After the new wire rope is fixed, perform a horizontal adjustment, that is, adjust the wire rope on the two drums and measure the horizontal height difference △h of the coke can lid:

[0057] The measurement method is as follows: lower the coke can lid to the maintenance position, mark the position of the first or second guide wheel fixed point on the east and west sides with a right angle ruler, raise the coke can lid by 0.5m, mark the position of the guide wheel fixed point marked before, and measure the height h1 and h2 between the two marks. The difference between h1 and h2 is the horizontal height difference of the coke can lid.

[0058] Technicians use a measuring tape to check the levelness of the coke can lid, ensuring that the height difference of the coke can lid is ≤10mm; technicians use a right-angle ruler to check the distance difference between the balancer and the left and right limits, ensuring that it is ≤5mm.

[0059] Before operation, the diameter of each new wire rope is randomly checked at 20 points using vernier calipers; the diameter error should not exceed 0.05. The lay direction of the wire rope is confirmed to ensure that it is consistent with that of the old wire rope.

[0060] In S11, after a portion of the wire rope is cut off, the end of the wire rope must be re-wrapped with wire.

[0061] When the new wire rope is released to its lowest position, the new wire rope should be wound around the drum at least 6 times.

[0062] After the new wire rope is replaced, a test lift is carried out on the new wire rope. The test lift is carried out in three parts: the first test lift is carried out at no less than 10% of the rated weight, the second test lift is carried out at no less than 50% of the rated weight, and the third test lift is carried out with the load loaded in the coke can.

[0063] This invention uses a rope fixing bracket 1 as a tooling. During the rope changing operation, the U-shaped fixing clip 2 precisely limits the rope. By combining and applying this set of devices, the traditional single-point operation mode is upgraded to a four-point operation mode, which effectively ensures the stability and reliability of the rope's up and down movement. At the same time, the joints of the four new and old ropes are treated with a unidirectional welding process, which realizes the consistency of the rope's synchronous up and down movement and the uniformity of its operation.

[0064] This invention optimizes the traditional single-rod replacement operation of hoist wire ropes into a four-rod simultaneous replacement by rationally utilizing the combined device and precisely controlling the operation process. During the operation, the welding, winding, fixing, and adjustment processes are implemented simultaneously and effectively connected and integrated. This not only significantly reduces the impact of dry quenching coke hoist wire rope replacement operations on production, but also reduces spare parts costs. It achieves the technical effects of safe, efficient, fast, accurate, and highly stable operation, significantly improving overall operation efficiency.

[0065] This invention offers the following significant advantages and benefits: The steel wire rope replacement process for the dry quenching coke elevator reliably secures the old steel wire rope to be removed, eliminating the safety hazard of falling from heights at the source, while also making the disassembly of the old rope more time-saving and labor-saving. After welding the old and new steel wire ropes together in the same twist direction, the new rope can be precisely and without damage inserted into the groove through a parallel track replacement method, making subsequent precise adjustments and fixation of the steel wire rope more convenient. Compared to conventional replacement methods, this device can significantly reduce operation time, increase operation efficiency by 4 times, effectively save manpower and material costs, reduce system downtime due to failures, and thus significantly improve the production and supply capacity of the dry quenching coke system, ensuring continuous and stable production operation.

[0066] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A dry quenching hoist rope replacement process, characterized by: The steps are: S1: Pre-made replacement required tooling, rope fixed bracket (1); S2: Determine the length of the new and old wire rope after replacement, the new wire rope is placed on the rope fixed bracket (1), the new wire rope is arranged with the same twist direction as the old wire rope; S3: High platform fixed installation of winch; S4: Old wire rope on the lifting drum near the rope outlet, install U-shaped fixed card (2), clamp 4 old wire rope; S5: Disassemble the old wire rope fixed end with a coil; S6: Start the winch and put the old rope to the low platform at a constant speed; S7: After the four ends of the old wire rope are put down, cut the old wire rope at a position of 3-5 meters between the lowered end and the lifting sling movable pulley; S8: The new wire rope is connected with the old wire rope, and the new and old wire ropes are welded by gas welding; S9: After the new and old wire ropes are welded, loosen the U-shaped fixed card (2); start the lifting machine and roll up the new wire rope while rolling down the old wire rope, and the old wire rope falls to the ground under its own weight; S10: When the joint of the new and old wire ropes passes through the drum, the drum is full of new wire rope at this time, stop the drum motor action, and use the U-shaped fixed card (2) to clamp the steel wire rope inlet and outlet end; S11: Use a 15-ton shackle to hold the old wire rope, use a coil to pull and fix it to prevent the wire rope from falling; cut the wire rope at a position of 150-200mm from the new wire rope direction along the new and old wire rope welding point, use the winch wire rope to hang the old wire rope shackle position, release the U-shaped fixed card (2) at the old wire rope end, and start the winch to put the old wire rope to the ground; S12: Jog the drum to adjust the number of wire rope coils on the drum; start the winch to move the cut end of the new wire rope to the fixed position of the pressing rope plate on the drum, and adjust the wire rope so that the wire rope is orderly put into the corresponding rope groove on the surface of the drum; S13: Reverse rotation of the drum, the wire rope can only rotate slowly in the opposite direction with the drum under the action of the U-shaped fixed card (2), so that the wire rope on the drum rope groove is loose, and the wire rope is stopped after loosening, personnel are arranged on both sides of the drum to pull the wire rope to the pressing rope plate, and the other person drags the wire rope to the pressing rope plate, and clears the wire rope so that the wire rope is orderly put into the corresponding rope groove on the surface of the drum, adjusts the wire rope head to the pressing rope plate bolt fixing position, and fastens the bolt after reserving the adjustment length; S14: One end of the new wire rope is welded with the old wire rope, and the other end is used as a fixed end. The other end of the four new wire ropes is made into a head, and the head is reserved one meter away from the fixed end. After the four fixed ends are made, the winch wire rope is used to pull the four fixed ends to the balancer for installation, and the fixed pin is used for fixation.

2. A dry quenching hoist rope changing process according to claim 1, characterized in that: After the new wire rope is fixed, the horizontal adjustment is made, that is, the wire rope on the two drums is adjusted, and the horizontal height difference △h of the coke tank cover is measured: The measurement method is as follows: the coke pot cover is placed down to the maintenance position, the first or second guide wheel fixed point positions corresponding to the two sides of the object are marked with a right-angle ruler, the coke pot cover is lifted by 0.5 m, the guide wheel fixed point positions marked last time are marked again, the height h1 and h2 between the two markings is measured, and the difference between h1 and h2 is the horizontal height difference of the coke pot cover.

3. A dry quenching hoist rope changing process according to claim 1, characterized in that: Before operation, the diameter of each new steel wire rope is randomly checked at 20 points with a vernier caliper; the diameter error is not more than 0.05, and the twisting direction of the steel wire rope is confirmed to ensure that it is consistent with the twisting direction of the old steel wire rope.

4. A dry quenching hoist rope changing process according to claim 1, characterized in that: In S11, after cutting a part of the steel wire rope, the end of the steel wire rope must be re-wrapped with iron wire.

5. A dry quenching hoist rope changing process according to claim 1, characterized in that: When the new steel wire rope is released to the lowest position, the new steel wire rope wound on the drum is not less than 6 turns.

6. A dry quenching hoist rope changing process according to claim 1, characterized in that: After the replacement of the new steel wire rope is completed, the replaced new steel wire rope is tested, and the test is divided into three times: the first test is not less than 10% of the rated weight, the second test is not less than 50% of the rated weight, and the third test is to load the coke pot.

7. A dry quenching hoist rope changing process according to claim 1, characterized in that: The technician checks the levelness of the coke pot cover with a tape measure to ensure that the horizontal height difference of the coke pot cover is ≤10 mm; the technician checks the distance difference between the balancer and the left and right limit positions with a right-angle ruler to ensure that it is ≤5 mm.

Images