Hydraulic twisting device for disassembling reamer head used by heavy cutter suction dredger

Abstract

A hydraulic torsion device for disassembling a reamer head used by a heavy cutter suction dredger comprises a torsion arm frame, an upper check block support, a first oil cylinder base, a first hydraulic oil cylinder, a second oil cylinder base, a second hydraulic oil cylinder, a first check block support, a second check block support, a plug pin assembly and a torsion disc. The two ends of the torsion arm frame are connected with the first hydraulic oil cylinder and the second hydraulic oil cylinder respectively, the first check block support and the second check block support are fixed below the torsion arm frame, the upper check block support is connected with the top end of the torsion arm frame and the second oil cylinder seat, the first oil cylinder seat is connected with the first hydraulic oil cylinder, and the second oil cylinder seat is connected with the second hydraulic oil cylinder. The torsion disc is arranged in the torsion arm frame and connected with the reamer head through the middle shaft, and the bolt assembly is connected with the torsion disc and the torsion arm frame when used. Compared with the prior art, torque is accurately applied through the hydraulic torsion device, the loss of a thrust ring is reduced, the material cost is reduced, and the safety is improved.

Description

Technical Field

[0001] This invention relates to the field of dredging vessels, and more specifically to a hydraulic torsion device for dismantling the cutter head used in heavy-duty cutter suction dredgers. Background Technology

[0002] In the construction process of heavy-duty cutter suction dredgers, the cutter head is one of the key components, responsible for cutting and dredging seabed soil. The cutter head is threaded onto the cutter shaft, with a detachable thrust ring between the cutter head and the shaft. This thrust ring is designed for one-time cutting, allowing the cutter head to be disassembled by cutting it. However, this technical solution mainly leads to the following problems: First, it results in long cutting times, affecting the ship's construction efficiency. Second, the cutter shaft is frequently subjected to high temperatures during cutting, which adversely affects the strength of the shaft and the service life of the connected electric drive equipment. Third, the cutting location is relatively special, causing construction personnel to operate in dangerous areas for extended periods.

[0003] Specifically, firstly, the traditional method is time-consuming. Because the cutterhead is threaded onto the cutter shaft, disassembly requires cutting the thrust ring to release the fastener. This process typically takes 24 hours, significantly delaying construction progress. For projects requiring frequent cutterhead replacements, this inefficient disassembly method significantly reduces the vessel's operational efficiency, increasing project timelines and costs.

[0004] Secondly, the physical damage to the equipment caused by high-temperature cutting of the thrust ring cannot be ignored. High-temperature cutting can not only damage the thrust ring itself, but also adversely affect the auger shaft. The auger shaft is prone to material degradation at high temperatures, leading to decreased strength and consequently affecting the reliability and lifespan of the entire auger system. This damage may result in more frequent maintenance and higher repair costs.

[0005] Furthermore, traditional dismantling methods pose a threat to worker safety. Due to the special location and complex operating environment of the cutting operation, workers perform high-temperature cutting in confined and unstable spaces, resulting in significant safety risks. Prolonged exposure to this environment can lead to worker fatigue and increase the likelihood of accidents. Any operational error could trigger a serious accident, causing incalculable losses.

[0006] The root cause of these problems lies in the technological limitations of traditional methods. Manual cutting requires a large amount of manpower and time, and cannot avoid damage to materials from high temperatures. At the same time, the complexity and danger of the operating environment have not been effectively addressed technologically.

[0007] To address the aforementioned issues, we have made a series of improvements. Summary of the Invention

[0008] The purpose of this invention is to provide a hydraulic torsion device for disassembling the cutter head used in heavy-duty cutter suction dredgers, so as to overcome the above-mentioned disadvantages and deficiencies of the prior art.

[0009] A hydraulic torsion device for dismantling a cutter head used in a heavy-duty cutter suction dredger includes: a torsion boom, an upper stop block bracket, a first cylinder seat, a first hydraulic cylinder, a second cylinder seat, a second hydraulic cylinder, a first stop block bracket, a second stop block bracket, a pin assembly, and a torsion disc. The two ends of the torsion boom are respectively connected to the first and second hydraulic cylinders. The first and second stop block brackets are fixed below the torsion boom. The upper stop block bracket connects the top of the torsion boom to the second cylinder seat. The first cylinder seat is connected to the first hydraulic cylinder, and the second cylinder seat is connected to the second hydraulic cylinder. The torsion disc is disposed inside the torsion boom and is connected to the cutter head via an intermediate shaft. The pin assembly connects the torsion disc to the torsion boom during use.

[0010] Furthermore, the first and second hydraulic cylinders are provided with a cylinder shaft, a cylinder shaft bushing, and a cylinder shaft end cap. The cylinder shaft connects the two ends of the torsion boom to the first and second hydraulic cylinders respectively. The connection between the torsion boom and the first and second hydraulic cylinders is provided with a cylinder shaft bushing and a cylinder shaft end cap.

[0011] Furthermore, the first cylinder seat and the second cylinder seat are provided with: a hinge point sealing plate, a hinge point bushing and a hinge point end cap. The hinge point bushing is respectively provided at the connection between the first hydraulic cylinder and the second hydraulic cylinder and the first cylinder seat and the second cylinder seat. The hinge point end cap connects the hinge point bushing and the hinge point sealing plate.

[0012] Furthermore, the upper stop block bracket is provided with: an upper stop block end cover, an upper stop block wear-resistant block, and an upper stop block bushing. The upper stop block end cover is connected to the upper stop block bracket, the upper stop block wear-resistant block is disposed between the upper stop block end cover and the torsion boom, and the upper stop block bushing is connected to the torsion boom.

[0013] Furthermore, the first stop block bracket and the second stop block bracket are provided with: a lower stop block end cover, a lower stop block wear-resistant block and a lower stop block bushing. The lower stop block end cover is connected to the first stop block bracket and the second stop block bracket respectively. The lower stop block wear-resistant block is located between the lower stop block end cover and the torsion boom. The lower stop block bushing is connected to the torsion boom.

[0014] The beneficial effects of this invention are:

[0015] Compared with traditional technologies, this invention achieves a rapid and efficient auger head disassembly process through the innovative design of a hydraulic torsion device. This device utilizes a hydraulically driven torsion disc to apply precise torque, quickly loosening the threaded connections on the auger shaft, significantly shortening disassembly time from the traditional 24 hours to just 2 hours. This not only improves construction efficiency but also reduces wear on the thrust ring, allowing for its reuse and lowering material costs. Furthermore, this device reduces manual intervention, lowering the risk to operators working in high-temperature and hazardous environments, and improving construction safety. In summary, this invention has significant advantages in improving construction efficiency, reducing material and labor costs, and enhancing safety. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention.

[0017] Figure 2 This is a diagram showing the usage state of the present invention.

[0018] Figure 3 This is a diagram of the internal structure of a hydraulic cylinder.

[0019] Figure 4 This is a diagram of the internal structure of the hydraulic cylinder housing.

[0020] Figure 5 This is a schematic diagram of the upper stop block support.

[0021] Figure 6 This is a schematic diagram of the structure of the first stop block bracket and the second stop block bracket.

[0022] Figure label:

[0023] The components include a torsion boom 100, an upper stop block bracket 200, an upper stop block end cap 210, an upper stop block wear-resistant block 220, and an upper stop block bushing 230.

[0024] First cylinder seat 300, first hydraulic cylinder 400, second cylinder seat 500, and second hydraulic cylinder 600.

[0025] The components include a first stop block bracket 700, a lower stop block end cap 710, a lower stop block wear-resistant block 720, and a lower stop block bushing 730.

[0026] The second stop bracket 800, the pin assembly 900, and the torsion plate 1000.

[0027] The cylinder shaft 1100, the cylinder shaft bushing 1200, and the cylinder shaft end cap 1300.

[0028] Hinge point sealing plate 1400, hinge point bushing 1500, and hinge point end cap 1600.

[0029] Intermediate shaft 2000. Detailed Implementation

[0030] The present invention will be further described below with reference to specific embodiments. It should be understood that the following embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0031] Example 1

[0032] Figure 1 This is a schematic diagram of the structure of the present invention. Figure 2 This is a diagram showing the usage state of the present invention. Figure 3 This is a diagram of the internal structure of a hydraulic cylinder. Figure 4 This is a diagram of the internal structure of the hydraulic cylinder housing. Figure 5 This is a schematic diagram of the upper stop block support. Figure 6 This is a schematic diagram of the structure of the first stop block bracket and the second stop block bracket.

[0033] like Figure 1 and Figure 2 As shown, a hydraulic torsion device for dismantling the cutter head used in a heavy-duty cutter suction dredger includes: a torsion boom 100, an upper stop support 200, a first cylinder seat 300, a first hydraulic cylinder 400, a second cylinder seat 500, a second hydraulic cylinder 600, a first stop support 700, a second stop support 800, a pin assembly 900, and a torsion disc 1000. The two ends of the torsion boom 100 are respectively connected to the first hydraulic cylinder 400 and the second hydraulic cylinder 600. The first stop support 700... The upper stop bracket 800 and the second stop block bracket 800 are fixed below the torsion boom 100. The upper stop block bracket 200 connects the top of the torsion boom 100 to the second cylinder seat 500. The first cylinder seat 300 is connected to the first hydraulic cylinder 400, and the second cylinder seat 500 is connected to the second hydraulic cylinder 600. The torsion disc 1000 is located inside the torsion boom 100 and is connected to the reamer head via the intermediate shaft 2000. The pin assembly 900 connects the torsion disc 1000 to the torsion boom 100 during use. The intermediate shaft 2000 is part of the reamer head.

[0034] like Figure 3 As shown, the first hydraulic cylinder 400 and the second hydraulic cylinder 600 are provided with: a cylinder shaft 1100, a cylinder shaft bushing 1200 and a cylinder shaft end cover 1300. The cylinder shaft 1100 connects the two ends of the torsion boom 100 to the first hydraulic cylinder 400 and the second hydraulic cylinder 600 respectively. The cylinder shaft bushing 1200 and the cylinder shaft end cover 1300 are provided at the connection between the torsion boom 100 and the first hydraulic cylinder 400 and the second hydraulic cylinder 600.

[0035] like Figure 4As shown, the first cylinder seat 300 and the second cylinder seat 500 are provided with: a hinge point sealing plate 1400, a hinge point bushing 1500 and a hinge point end cap 1600. The hinge point bushing 1500 is respectively provided at the connection between the first hydraulic cylinder 400 and the second hydraulic cylinder 600 and the first cylinder seat 300 and the second cylinder seat 500. The hinge point end cap 1600 connects the hinge point bushing 1500 and the hinge point sealing plate 1400.

[0036] like Figure 5 As shown, the upper stop block bracket 200 is provided with: an upper stop block end cover 210, an upper stop block wear-resistant block 220 and an upper stop block bushing 230. The upper stop block end cover 210 is connected to the upper stop block bracket 200, the upper stop block wear-resistant block 220 is located between the upper stop block end cover 210 and the torsion boom 100, and the upper stop block bushing 230 is connected to the torsion boom 100.

[0037] like Figure 6 As shown, the first stop block bracket 700 and the second stop block bracket 800 are provided with: a lower stop block end cover 710, a lower stop block wear-resistant block 720 and a lower stop block bushing 730. The lower stop block end cover 710 is connected to the first stop block bracket 700 and the second stop block bracket 800 respectively. The lower stop block wear-resistant block 720 is located between the lower stop block end cover 710 and the torsion boom 100. The lower stop block bushing 730 is connected to the torsion boom 100.

[0038] The beneficial effects of this invention are reflected in the following aspects: First, the high efficiency of rapid disassembly: The hydraulic torsion device, through the powerful torque generated by the hydraulic cylinder, can loosen and disassemble the auger head in a short time. Compared with the traditional manual cutting method, this device reduces the disassembly time from 24 hours to less than 2 hours. Second, safety: 1. Reduced risk of high-temperature operation: Traditional methods rely on high-temperature cutting of the thrust ring, posing a risk of high-temperature burns and equipment damage. The hydraulic torsion device achieves disassembly through mechanical force, avoiding high-temperature operation. 2. Safety monitoring: The device is equipped with sensors to monitor the status of the pins in real time, ensuring that the equipment operates in a safe state and preventing misoperation. Third, environmental friendliness and protection of the thrust ring: The hydraulic torsion device avoids destructive disassembly of the thrust ring and can be reused multiple times, reducing material consumption and replacement costs. Finally, automated control: The on-site operation control box provides an intuitive operating interface, allowing operators to perform local operation through a handheld control panel, reducing reliance on manual experience.

[0039] The entire hydraulic torsion device is also equipped with a control system, which, by connecting the ship's hydraulic lines and the hydraulic structure of the torsion device, can precisely adjust the pressure and flow of the hydraulic system to achieve precise control of the torsion process.

[0040] The disassembly process of this invention is as follows: I. Preparation: 1. Confirm that the lubricating oil at each node is sufficient. 2. Confirm that the wiring from the sensor to the control box and from the control box to the control system is intact. 3. Confirm that the clutches of cutters #1 and #2 are disengaged, and confirm that the gearbox and gearbox mechanism in the cutter's sealed chamber are disengaged. 4. Confirm that the hydraulic pump F is turned on. 5. Confirm that the switch in the cutter control box inside the upper deck gantry is in the ON position, and the power indicator light is green. II. Disassembling the cutter: 1. Insert the pin assembly 900 into the pin hole of the torsion boom 100, so that the pin assembly 900 internally connects the torsion disc 1000 and the torsion boom. 2. Extend the cutter stop block remotely on-site. 3. Turn on the remote control. From left to right, turn the first knob to working pressure, the second knob to 0, the third knob to forward rotation, and the fourth knob to adjust the speed. After the protruding part on the large ring of the cutter head is fully engaged with the stop block, return the speed knob to 0. 4. Adjust the position of crane No. 3 so that the hook connects to the cutter head assembly. At this point, the crane cable is not under tension. Secure the stabilizing ropes to the symmetrical arms of the cutter head. 5. Continue rotating the speed knob, paying attention to the pressure changes on the remote control (note that the hydraulic system pressure must not exceed 250 bar). Personnel should check near the cutter stop block to see if the cutter head is loose. After the cutter head retracts a few notches, return the speed knob to 0. 6. Turn the third knob to reverse rotation. Slowly adjust the speed knob and remove the four limit pins, placing them back into the limit pin holes on the left gantry. 7. Prepare the cutter head on the operator's platform. Use the remote control to jog the forward rotation of the cutter head until the protruding part on the large ring of the cutter head separates from the cutter stop block. 8. Use the remote control to retract the cutter stop block. 9. Tighten the No. 3 crane appropriately, and remotely reverse the cutter head on site. During this process, the No. 3 crane should adjust the force in time until the cutter thread is completely disengaged and the weight is completely on the No. 3 crane.

[0041] The above effects are achieved based on the innovations of this invention, which include: Firstly, the hydraulic drive system: 1. High torque output: The hydraulic cylinders are powered by a hydraulic pump, generating a torque of up to 10,000 kN·m, sufficient to loosen the threaded connection of a large auger head. 2. Stepping torsion: Two cylinders alternately operate, ensuring smooth stepping operation under high torque conditions, avoiding the impact of sudden torque changes on the equipment. Compared to traditional manual cutting, it is more risky: Manual cutting of the thrust ring requires high-temperature operation, posing a risk of burns and fire. It is less efficient: The cutting process is time-consuming, typically requiring 8 hours to complete the cutting of the thrust ring, with a replacement cycle of up to 24 hours. It is more costly: The thrust ring is disposable and requires frequent replacement, increasing material and labor costs. Compared to mechanical disassembly, it is less stable: Traditional mechanical force is difficult to provide stable torque output, easily leading to equipment damage or operational failure. It poses safety hazards: Operators must work in a high-risk environment for extended periods, posing significant safety risks. In summary, the hydraulic drive system of this invention represents a significant advancement. The principle is as follows: 1. Compared to human or mechanical force, hydraulic power offers greater torque and better controllability. Pressurized oil enters the cylinder, pushing the piston and generating linear mechanical force. In this device, this force is used to generate torque up to 10,000 kN·m. By adjusting the pressure valve in the hydraulic system, the force and speed output by the cylinder can be precisely controlled to adapt to different operational needs. 2. Stepping operation principle: Alternating action: The system uses two cylinders that alternately operate. When one cylinder applies force, the other is in a standby state. By controlling the alternating force application of the cylinders, smooth stepping torsion is achieved. Torque balance: Alternating action avoids sudden torque changes, ensuring stable torque output and reducing impact on the connecting threads. 3. Monitoring and safety interlock: Sensor feedback: Sensors are installed at key locations to monitor the status and position of the cylinders in real time. Sensor signals are fed back to the control system to ensure the device operates in a safe state. Safety Interlock Mechanism: The system is designed with a safety interlock mechanism, ensuring that the equipment is only allowed to start when all conditions are met (e.g., the pin is in place, the cylinder is in normal condition), thus ensuring operational safety. 4. Economy and Environmental Friendliness of the Hydraulic System: Energy-Saving Design: The hydraulic system reduces energy loss and improves system efficiency through optimized pipeline design and pressure regulation. Material Protection: Hydraulic operation avoids high-temperature cutting, protecting critical components such as the thrust ring, extending their service life, and reducing replacement frequency and material consumption.

[0042] Secondly, the flange clamping design offers stability and reliability: the torsion disc is clamped between intermediate shafts using flanges and secured with hydraulic connecting bolts, ensuring the stability of the device during operation. Flexible installation: This design allows for flexible installation between different shaft systems, adapting to various construction needs. Traditional fixing methods rely heavily on mechanical fastening: traditional methods depend on mechanical bolts and manual tightening, resulting in limited and uneven tightening force, making them prone to loosening under high stress. Mechanical connections are susceptible to vibration and impact, leading to loosening and wear at the connection points. This innovation lies in the linkage between the flange clamping design and the hydraulic system: the torsion disc is clamped between intermediate shafts using flanges, ensuring the stability of the device under high torque operation. The flange design provides a larger contact surface and a more uniform force distribution. Hydraulic connecting bolts achieve uniform clamping force, effectively resisting vibration and impact, reducing the risk of loosening and fatigue fracture. Durability: the use of hydraulic bolts extends the service life of the device and reduces failures caused by mechanical wear. On the other hand, compared to traditional methods, which are often designed for specific equipment and lack flexibility, making it difficult to adapt to different construction environments, adjusting the mechanical system requires more time and manpower, increasing construction preparation time. The flange clamping design of this invention allows for flexible installation between different shaft systems, adapting to various construction needs and ship type variations. Due to the use of a hydraulic system, the installation and adjustment process is simple and quick, reducing downtime.

[0043] Therefore, the creativity of the flange clamping design is reflected in: Stability: The flange clamping design provides a larger contact surface and a more uniform force distribution, significantly improving the stability of the device. Reliability: The use of hydraulic connection bolts reduces the risk of loosening and fatigue fracture, improving the reliability of the system. Flexibility: The modular and adjustable design allows the device to quickly adapt to different construction needs, enhancing the equipment's versatility. Efficiency: Rapid installation and adjustment capabilities shorten construction preparation time and improve overall construction efficiency.

[0044] Finally, sensor applications: Real-time monitoring: The device is equipped with multiple sensors to monitor the position of the latches, ensuring that the cutter shaft system is only allowed to rotate when all latches are in the safe position. Safety interlocking: The sensors provide switching signals, interlocked with the motor, to prevent equipment damage or safety accidents caused by misoperation. When not in operation, the four latches are mounted on the deck; when in operation, the four latches are mounted on the shaft system. The sensors corresponding to the four latches are all mounted on the deck, providing four switching signals, any one of which is interlocked with the motor. The sensor signals for the latches are output from the control box to the ship's control room, and the implementation of related control interlocks is completed on-board. The specific control strategy requires that the cutter shaft system is only allowed to rotate when the sensors detect that all latches have returned to their deck latch positions; otherwise, the cutter shaft system is not allowed to start. When the cutter shaft system is running, if the sensors do not detect the position status signal of the latches, only an alarm signal is provided, reminding the user to check whether the sensors are damaged.

[0045] In this embodiment, the present invention utilizes the "New Sea Shark" self-propelled all-electric heavy-duty cutter suction dredger with a cutter power of 6000kw, which is suitable for dredging of coastal ports and waterways, ultra-long-distance reclamation projects, and is particularly suitable for excavating dense sandy soil, gravel, strongly weathered rock, and moderately weakly weathered rock with an unconfined compressive strength of 50MPa (rock quality index RQD≤80%).

[0046] Following practical use and subsequent research, during the period from May 1, 2024 to October 1, 2024, the dismantling was performed 26 times. Based on the daily charter rate of US$59,000 for the "New Sea Shark" vessel in the UAE, the application of the efficient dismantling device generated US$1,405,970 in revenue within six months (excluding the cost of thrust rings and potential equipment damage). Assuming a profit margin of 35%, this translates to a profit of US$492,090, a considerable sum. Therefore, improving the dismantling device can significantly enhance ship construction efficiency, not only creating greater economic benefits but also improving project construction efficiency, further promoting social construction and development.

[0047] The specific embodiments of the present invention have been described above, but the present invention is not limited thereto. Various changes can be made to the present invention as long as they do not depart from the spirit of the present invention.

Claims

1. A hydraulic torsion device for dismantling the cutter head used in heavy-duty cutter suction dredgers, characterized in that, include: The system comprises a torsion boom (100), an upper stop support (200), a first cylinder seat (300), a first hydraulic cylinder (400), a second cylinder seat (500), a second hydraulic cylinder (600), a first stop support (700), a second stop support (800), a pin assembly (900), and a torsion disc (1000). Both ends of the torsion boom (100) are connected to the first hydraulic cylinder (400) and the second hydraulic cylinder (600), respectively. The first stop support (700) and the second stop support (800) are fixed to the torsion boom (100). Below the first cylinder seat (300), the upper stop block bracket (200) connects the top of the torsion boom (100) to the second cylinder seat (500). The first cylinder seat (300) is connected to the first hydraulic cylinder (400), and the second cylinder seat (500) is connected to the second hydraulic cylinder (600). The torsion disc (1000) is located inside the torsion boom (100). The torsion disc (1000) is connected to the reamer head through the intermediate shaft (2000). The pin assembly (900) connects the torsion disc (1000) and the torsion boom (100) when in use.

2. The hydraulic torsion device for dismantling the cutter head used in a heavy-duty cutter suction dredger according to claim 1, characterized in that, The first hydraulic cylinder (400) and the second hydraulic cylinder (600) are provided with: a cylinder shaft (1100), a cylinder shaft bushing (1200) and a cylinder shaft end cap (1300). The cylinder shaft (1100) is connected to both ends of the torsion boom (100) and the first hydraulic cylinder (400) and the second hydraulic cylinder (600) respectively. The connection between the torsion boom (100) and the first hydraulic cylinder (400) and the second hydraulic cylinder (600) is provided with a cylinder shaft bushing (1200) and a cylinder shaft end cap (1300).

3. A hydraulic torsion device for dismantling cutter heads used in heavy-duty cutter suction dredgers according to claim 1, characterized in that, The first cylinder seat (300) and the second cylinder seat (500) are provided with: a hinge point sealing plate (1400), a hinge point bushing (1500) and a hinge point end cap (1600). The hinge point bushing (1500) is respectively located at the connection between the first hydraulic cylinder (400) and the second hydraulic cylinder (600) and the first cylinder seat (300) and the second cylinder seat (500). The hinge point end cap (1600) connects the hinge point bushing (1500) and the hinge point sealing plate (1400).

4. A hydraulic torsion device for dismantling cutter heads used in heavy-duty cutter suction dredgers according to claim 1, characterized in that, The upper stop block bracket (200) is provided with: an upper stop block end cap (210), an upper stop block wear-resistant block (220), and an upper stop block bushing (230). The upper stop block end cap (210) is connected to the upper stop block bracket (200). The upper stop block wear-resistant block (220) is located between the upper stop block end cap (210) and the torsion boom (100). The upper stop block bushing (230) is connected to the torsion boom (100).

5. A hydraulic torsion device for dismantling cutter heads used in heavy-duty cutter suction dredgers according to claim 1, characterized in that, The first stop block bracket (700) and the second stop block bracket (800) are provided with: a lower stop block end cap (710), a lower stop block wear-resistant block (720) and a lower stop block bushing (730). The lower stop block end cap (710) is connected to the first stop block bracket (700) and the second stop block bracket (800) respectively. The lower stop block wear-resistant block (720) is located between the lower stop block end cap (710) and the torsion boom (100). The lower stop block bushing (730) is connected to the torsion boom (100).

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