Rapid replacement method suitable for crane cart wheels

Abstract

The invention provides a quick replacement method suitable for crane cart wheels, and belongs to the technical field of hoisting machinery. The method comprises the following steps: mounting a guide pulley below an end beam of the crown block, and mounting a lifting lug on the outer side of the end beam; after old wheel bolts are dismantled and a trolley frame is jacked up, one end of a steel wire rope buckle is fixed to the lifting lug, the other end of the steel wire rope buckle penetrates through a wheel to be connected with lifting equipment, and a rope body is embedded into two pulley grooves; the steel wire rope buckle is tightened to move the old wheel out and put down to the maintenance platform; a new wheel is connected and embedded into the pulley groove, the steel wire rope buckle and the end beam form an isosceles triangle through the guiding effect of the two pulleys after lifting, and automatic centering of the new wheel and the track is achieved; and finally, lowering and pushing into the bogie frame for fastening. By additionally arranging the guide device, inclined pulling of lifting equipment and abrasion of a steel wire rope can be eliminated, automatic centering of the wheels is achieved, and the safety, efficiency and convenience of replacement operation are greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of crane machinery technology and relates to a method for quick replacement of overhead crane wheels. Background Technology

[0002] Overhead cranes (hereinafter referred to as overhead cranes) are common lifting equipment in industrial production. During long-term operation, due to reasons such as wheel misalignment, the wheel flange often rubs against the side of the rail, which is called rail wear. Rail wear will aggravate the wear of the wheel flange and is the main reason for the replacement of overhead crane wheels. In addition, bearing damage, bearing housing cracking, wheel cracking, shaft misalignment, and keyway failure also require wheel replacement.

[0003] Currently, the following method is typically used when replacing overhead crane wheels: First, remove the wheel's fixing bolts and use a hydraulic jack to lift the overhead crane's trolley frame to a certain height. Then, use a pry bar to detach the wheel's angular bearing housing fixing keyway from the trolley frame fixing key plate. Next, use a maintenance electric hoist to thread a wire rope through the round hole in the wheel spoke and hook it onto the hoist's hook. Due to the limited space under the overhead crane's end beam, the operator must sit on the track and pull the wheel out of the trolley frame. At the same time, other personnel must hold the wheel flange from the side and use a chain hoist to prevent the wheel from slipping out of control. After the old wheel is hoisted to the ground, the new wheel is hoisted to the installation position in a similar manner. During this process, a pry bar must be used manually to adjust the wheel's posture to make it parallel to the track. Finally, the wheel is pushed into the trolley frame.

[0004] The above replacement method has several shortcomings: First, the operation process is cumbersome, requiring a large number of operators, usually 5-6 people, with complex tools and equipment, resulting in low work efficiency; replacing a single drive wheel typically takes 4-5 hours. Second, safety is poor; the electric hoist is often in an oblique pulling state under the constraint of the end beam, posing a risk of disengagement and wire rope wear and breakage. When adjusting the wheel's posture, personnel need to use a crowbar at close range to operate the hoisted heavy object, posing a risk of being struck or crushed. At the same time, the direct friction between the wire rope and the edge of the end beam leads to damage and scrapping of the wire rope, increasing costs and safety risks.

[0005] Therefore, it is necessary to improve the existing method for replacing overhead crane wheels. Summary of the Invention

[0006] The present invention aims to solve the above-mentioned problems existing in the prior art and provide a method for replacing the wheels of overhead cranes that is simple to operate, safe, and efficient.

[0007] To achieve the above objectives, the present invention provides a method for quick replacement of overhead crane wheels, comprising the following steps: Step a: Install inner and outer guide pulleys below the end beam of the crane, and install lifting lugs on the outside of the end beam of the crane; Step b: Hoist the new wheels to be installed to the overhead crane corridor maintenance platform and park the overhead crane at the designated maintenance position; Step c: Remove the fixing bolts of the old wheel to be replaced, and use the lifting device to lift the trolley frame so that the old wheel fixing keyway is separated from the trolley frame fixing key plate. Step d: Provide a first wire rope buckle, connect one end of the first wire rope buckle to the lifting lug, and connect the other end through the spoke hole of the old wheel to the hook of the lifting equipment. Embed the first wire rope buckle rope body located between the lifting lug and the old wheel into the wheel grooves of the inner guide pulley and the outer guide pulley. Step e: Operate the lifting equipment to tighten the first wire rope buckle, and use the pry bar to remove the old wheel from the trolley frame. During the removal process, keep the first wire rope buckle taut. Step f: After the old wheel is completely detached from the trolley frame, apply force to the old wheel in the direction away from the end beam of the gantry crane, and at the same time operate the lifting equipment to lower it until the old wheel is smoothly placed on the maintenance platform of the gantry crane corridor. Step g: Remove the first wire rope buckle from the old wheel and pass the first wire rope buckle through the spoke hole of the new wheel to be installed; Step h: Reconnect one end of the first wire rope buckle to the lifting lug and the other end to the hook of the lifting equipment, and re-embed the first wire rope buckle body located between the lifting lug and the new wheel into the grooves of the inner guide pulley and the outer guide pulley; Step i: Operate the lifting equipment to lift the new wheel above the trolley track. At this time, due to the guiding effect of the inner and outer guide pulleys, the first wire rope buckle and the bottom of the trolley end beam form an isosceles triangle, and the center line of the new wheel coincides with the center line of the trolley track. Step j: Operate the lifting equipment to slowly lower the new wheel, and at the same time push the new wheel into the trolley frame so that the new wheel fixing keyway and the trolley frame fixing key plate are properly engaged. Step k: Remove the lifting device, tighten the fixing bolts of the new wheel, and the replacement is complete.

[0008] The inner guide pulley and the outer guide pulley are installed below the end beam of the gantry crane at a predetermined distance from the trolley frame, and the two guide pulleys are located on the inner and outer sides of the end beam of the gantry crane, respectively; specifically, the predetermined distance is 400-600mm; preferably 500mm.

[0009] The bottom of the inner and outer guide pulleys extends 30-50mm beyond the bottom of the overhead crane end beam.

[0010] The lifting lugs are installed on the vertical surface of the crane end beam, which is vertically above the outer guide pulley; the lifting lugs are standardized lifting lugs that meet the lifting load requirements.

[0011] In steps d and h, a protective sleeve is padded inside the wheel spoke hole before the first wire rope buckle is passed through it; specifically, the protective sleeve is a rubber tube or a nylon tube.

[0012] The lifting equipment is an electric hoist or a manual hoist, and the jacking device is a hydraulic jack.

[0013] The beneficial effects of this invention are as follows: 1. By setting guide pulleys, this invention can eliminate the oblique pulling phenomenon of the lifting equipment, avoid the risk of disengagement, and prevent the wire rope from rubbing against the edge of the end beam, thus eliminating the risk of heavy objects falling due to wire rope wear and breakage. In addition, the wheel posture is automatically centered during the entire replacement process, eliminating the need for personnel to use pry bars to adjust the lifted heavy objects, thereby eliminating the risk of objects hitting and squeezing the object. 2. This invention simplifies the operation steps, reduces manual intervention, and significantly shortens the wheel replacement time; the replacement time of the drive wheel can be shortened from 4-5 hours to 1.5-2 hours, and the replacement time of the driven wheel can be shortened from 2-3 hours to 0.5-1 hour. 3. This invention can save manpower and material resources, reduce the labor intensity of personnel, avoid additional wear and tear on wire rope buckles, extend their service life, and reduce tool wear and tear costs. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the first state of the existing overhead crane wheel replacement method. Figure 2 This is a schematic diagram of the second state of the existing overhead crane wheel replacement method; Figure 3 This is a schematic diagram showing the installation positions of the guide pulley and the lifting lug in the crane wheel replacement method provided in this embodiment of the invention; Figure 4 This is a schematic diagram of the state when the old wheel is removed in the overhead crane wheel replacement method provided in the embodiment of the present invention; Figure 5 This is a schematic diagram illustrating the installation of the wheel and the trolley frame in the overhead crane wheel replacement method provided in this embodiment of the invention.

[0015] In the diagram, 1-electric hoist; 2-crane end beam; 3-crane wheel; 4-main trolley track; 5-chain hoist; 6-steel structure; 7-crane corridor maintenance platform; 8-inner lifting lug; 9-outer lifting lug; 10-inner guide pulley; 11-outer guide pulley; 12-wheel lifting wire rope buckle; 13-wheel traction wire rope buckle; 14-carriage frame; 15-wheel angular bearing seat positioning keyway; 16-carriage frame wheel positioning key plate. Detailed Implementation

[0016] The technical solution of the present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0017] In the description of this invention, it should be understood that the terms "inner", "outer", "upper", "lower", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to facilitate the description of this invention and to simplify the description, and 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. Therefore, they should not be construed as limitations on this invention. Example

[0018] This embodiment provides a method for quick replacement of overhead crane trolley wheels, mainly applied to the rapid and safe replacement of overhead crane trolley wheels, including the following steps: Preparation and equipment installation; First, a modified installation is carried out below the end beam 2 of the overhead crane, such as... Figure 3 As shown, at a position 14,500 mm away from the trolley frame below the end beam 2 of the crane, an inner guide pulley 10 and an outer guide pulley 11 are welded and installed on the inner and outer sides of the end beam 2, respectively, with their bottoms extending 30 mm beyond the bottom of the end beam 2, to ensure that the wire rope buckle can slide smoothly in the pulley groove without interfering with the bottom of the end beam.

[0019] Meanwhile, a standardized external lifting lug 9 that meets the 5-ton lifting load requirement is welded and installed on the vertical surface of the crane end beam 2, which is vertically above the external guide pulley 11; similarly, an internal lifting lug 8 is welded and installed at the corresponding position on the inner side of the crane end beam 2 for backup.

[0020] After the above installation is completed, the new crane wheels 3 to be replaced are hoisted to the crane corridor maintenance platform 7 in advance, and the crane that needs to have its wheels replaced is parked in the designated maintenance position.

[0021] Remove the old wheels; First, release the constraints: remove the fixing bolts of the crane wheel 3 (not shown in the figure), and use a hydraulic jack (as a lifting device) to lift the trolley frame 14 by 20mm, so that the angular bearing seat positioning keyway 15 of the crane wheel 3 is completely separated from the positioning key plate 16 on the trolley frame 14.

[0022] Secondly, connect the lifting slings: Take a wheel lifting wire rope buckle 12. To prevent the wire rope from being damaged by direct friction with the wheel spokes, before inserting the wire rope buckle 12 into the round hole of the old wheel spoke, first lining the hole with a protective sleeve, preferably a thick-walled rubber tube or nylon tube; pass one end of the wire rope buckle 12 with the protective sleeve inserted through the round hole of the spoke, and then use a shackle to reliably fix it to the outer lifting lug 9. Pass the other end of the wire rope buckle 12 out from the inside and hang it on the hook of the electric hoist 1 (as a lifting device); then, insert the rope of the section of wire rope buckle 12 between the outer lifting lug 9 and the old wheel into the grooves of the already installed outer guide pulley 11 and inner guide pulley 10 in sequence.

[0023] Next, remove the wheel: Operate the electric hoist 1 to slowly lift it, gradually tightening the wheel lifting wire rope buckle 12; when the wire rope buckle 12 is fully tensioned, the maintenance personnel use a crowbar to assist from the side to drive the old wheel out of the trolley frame 14; during the above process, the operation of the electric hoist 1 must be closely coordinated with the prying action of the crowbar to ensure that the wire rope buckle 12 is always in a taut state, thereby smoothly controlling the movement of the wheel; in addition, due to the positioning effect of the inner guide pulley 10 and the outer guide pulley 11, the wire rope buckle 12 always moves along the predetermined path, and the hook of the electric hoist 1 is always located near the top of the wheel, thereby eliminating the phenomenon of the electric hoist pulling at an angle in the prior art.

[0024] Finally, the wheel is lowered: After the old wheel is completely removed from the trolley frame 14, a maintenance worker applies a slight outward push to the old wheel with his hand or a tool, while operating the electric hoist 1 to slowly lower it; as the wire rope buckle 12 gradually loosens, the old wheel will fall smoothly onto the overhead crane corridor maintenance platform 7 below under the combined action of gravity and external force.

[0025] Install new wheels; First, replace the slings: remove the wheel lifting wire rope buckle 12 from the old wheel that has been laid on the ground; similarly, line the protective sleeve inside the spoke hole of the new wheel, and pass the wire rope buckle 12 through the spoke hole of the new wheel.

[0026] Secondly, connection and guidance: fix one end of the wire rope buckle 12 to the outer lifting lug 9 with a shackle and hang the other end on the hook of the electric hoist 1. Re-embed the rope body of the wire rope buckle 12 into the groove of the outer guide pulley 11 and the inner guide pulley 10.

[0027] Next, hoisting and alignment: Operate electric hoist 1 to slowly lift and begin hoisting the new wheel; as... Figure 4As shown, when the new wheel is lifted and gradually approaches the height of the main track 4, the inner guide pulley 10 and the outer guide pulley 11 are fixed in position, and they play a precise guiding and limiting role on the path of the wire rope buckle 12. At this time, from the outer lifting lug 9 to the inner guide pulley 10, and then to the suspension point of the new wheel, the wire rope buckle 12 and the bottom of the overhead crane end beam 2 together form a stable isosceles triangle, and the center line of the main track 4 is exactly the perpendicular bisector of this isosceles triangle. Therefore, when the new wheel is lifted above the main track 4, its wheel center line naturally and precisely coincides with the center line of the main track 4, without any manual or pry bar assistance.

[0028] Furthermore, the new wheel is positioned and installed: once the wheel's posture and position are precisely aligned, the electric hoist 1 is operated to slowly lower the new wheel. At the same time, a maintenance worker only needs to gently support and guide the new wheel, pushing it smoothly into the trolley frame 14. During the above process, the lowering speed of the electric hoist 1 should be coordinated with the manual pushing speed until the angular bearing seat positioning keyway 15 of the new wheel is fully engaged with the positioning key plate 16 on the trolley frame 14.

[0029] Finally, tighten the bolts: After confirming that the new wheel is installed in place, release the pressure of the hydraulic jack to lower the trolley frame 14, and tighten the four fixing bolts of the new wheel to the specified torque. At this point, the replacement of the overhead crane wheel is complete.

[0030] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art can make various improvements and modifications without departing from the spirit and principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for quickly changing the wheels of an overhead crane, characterized in that, Includes the following steps: Install an inner guide pulley (10) and an outer guide pulley (11) below the crane end beam (2), and install a lifting lug (9) on the outside of the crane end beam (2); Use the lifting device to lift the trolley frame (14) so ​​that the old wheel fixing keyway is separated from the trolley frame (14) fixing key plate; Provide a first wire rope buckle (12), connect one end of the first wire rope buckle (12) to the lug (9), and connect the other end through the spoke hole of the old wheel to the hook of the lifting device (1), and embed the rope of the first wire rope buckle (12) located between the lug (9) and the old wheel into the groove of the inner guide pulley (10) and the outer guide pulley (11); Operate the lifting equipment (1) to tighten the first wire rope buckle (12), and use the pry bar to remove the old wheel from the trolley frame (14). During the removal process, keep the first wire rope buckle (12) in a taut state. After the old wheel is completely detached from the trolley frame (14), apply force to the old wheel in the direction away from the end beam (2) of the gantry crane, and at the same time operate the lifting equipment (1) to lower it until the old wheel is smoothly placed on the gantry crane corridor maintenance platform (7). Remove the first wire rope buckle (12) from the old wheel and thread it through the spoke hole of the new wheel to be installed; Connect one end of the first wire rope buckle (12) to the lug (9) again and the other end to the hook of the lifting device (1) again, and embed the rope of the first wire rope buckle (12) located between the lug (9) and the new wheel into the groove of the inner guide pulley (10) and the outer guide pulley (11) again; Operate the lifting equipment (1) to lift the new wheel to the top of the trolley track (4). At this time, the first wire rope buckle (12) and the bottom of the trolley end beam (2) form an isosceles triangle, and the center line of the new wheel coincides with the center line of the trolley track (4). Operate the lifting equipment (1) to slowly lower the new wheel, and at the same time push the new wheel into the trolley frame (14) so ​​that the fixing keyway of the new wheel and the fixing key plate of the trolley frame (14) are properly engaged. Remove the lifting device, tighten the fixing bolts of the new wheel, and the replacement is complete.

2. The replacement method according to claim 1, characterized in that, The inner guide pulley (10) and the outer guide pulley (11) are installed at a predetermined distance from the trolley frame (14) below the trolley end beam (2), and the two guide pulleys are located on the inner and outer sides of the trolley end beam (2) respectively.

3. The replacement method according to claim 2, characterized in that, The predetermined distance is 400-600mm.

4. The replacement method according to claim 1, characterized in that, The bottom of the inner guide pulley (10) and the outer guide pulley (11) extends 30-50mm beyond the bottom of the crane end beam (2).

5. The replacement method according to claim 1, characterized in that, The lifting lug (9) is installed on the vertical surface of the crane end beam (2) above the outer guide pulley (11).

6. The replacement method according to claim 1, characterized in that, Before passing the first wire rope buckle (12) through the wheel spoke hole, a protective sleeve is placed inside the spoke hole.

7. The replacement method according to claim 6, characterized in that, The protective sleeve is a rubber tube or a nylon tube.

8. The replacement method according to claim 1, characterized in that, The lifting device (1) is an electric hoist.

9. The replacement method according to claim 1, characterized in that, The lifting device is a hydraulic jack.

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