An overhead transverse wire saw cutting device for large propeller risers

Abstract

The application discloses an overhead transverse rope saw cutting device for large propeller risers, which comprises a base frame, a horizontal sliding mechanism, a vertical stand, a cutting driving mechanism, a guide wheel set and a ring-shaped cutting rope saw; the base frame is arranged on the upper end of a propeller blade and is provided with a space for the riser to pass through; the horizontal sliding mechanism is arranged on the base frame and can move along the length direction of the base frame; the vertical stand is installed on the horizontal sliding mechanism; the cutting driving mechanism is arranged on the top of the vertical stand and can move along the vertical stand; the guide wheel set comprises first, second and third guide wheels and forms a closed-loop guide path; the ring-shaped cutting rope saw is arranged around the driving pulley and the guide wheels and forms a transversely extending cutting section in the middle of the base frame; the application can realize the horizontal mechanized cutting of the stern shaft end riser without lifting and overturning the propeller, directly arranging the device above the propeller blade, greatly simplifying the technological process and improving the operation safety and cutting efficiency.

Description

Technical Field

[0001] This invention belongs to the field of casting engineering technology, specifically relating to a special equipment for cutting off risers of large metal castings, and more particularly to an overhead wire saw cutting device for mechanized transverse sawing of cast risers at the stern shaft end of a marine integral propeller. Background Technology

[0002] Large propellers are usually formed by integral casting. During the casting process, in order to ensure that the thick sections such as the blades and hub receive sufficient molten metal for feeding during solidification and shrinkage, an additional casting riser is usually set at the end of the propeller stern shaft. This riser serves as a temporary feeding and liquid storage channel and becomes ineffective after the casting is solidified. It must be removed to obtain a finished propeller that meets the design requirements.

[0003] However, for the removal of risers at the stern shaft end of large propellers, the traditional process currently used in the industry mainly relies on hoisting and turning and manual semi-mechanical cutting: that is, the propeller, which weighs hundreds of tons, is hoisted as a whole to the turning station, and the lifting equipment is used to adjust it to a specific angle. Then, workers use hand-held cutting torches to perform gas cutting or use large floor-mounted saws to cut it in sections.

[0004] However, with the increasing trend towards larger ships, the size and weight of propellers are constantly rising, and the aforementioned traditional processes are gradually revealing significant technical bottlenecks, making it difficult to meet the demands of efficient and safe production.

[0005] First, the traditional process requires a cyclical process of hoisting and positioning, turning over, cutting, turning over again, and cutting again. Due to the enormous size of the large propeller, each turning over requires high-precision hoisting and positioning, and the turning over action itself takes a very long time, resulting in a lengthy overall processing cycle, which seriously restricts the production pace of casting post-processing.

[0006] Secondly, large propellers have complex centers of gravity, making them prone to swaying or even overturning during frequent hoisting and turning operations, posing a significant threat to on-site equipment and personnel. In addition, if manual gas cutting is used, operators need to work at close range in a high-temperature, high-dust environment, which is not only labor-intensive but also highly likely to cause safety accidents.

[0007] Third, the quality of manual cutting is highly dependent on the operator's experience, and unevenness and slag are often found on the cut surface, which often requires secondary grinding and repair, increasing the cost of subsequent processes. At the same time, due to the spatial interference of the propeller blades, traditional floor-standing saws cannot directly make horizontal cuts at the riser position, which greatly limits the application scenarios of mechanized equipment.

[0008] Fourth, traditional processes have rigid requirements for large lifting equipment and spacious turning areas, which further exacerbates the difficulty of production scheduling given the tight space in the foundry workshop.

[0009] In summary, existing large propeller riser cutting technologies suffer from drawbacks such as low automation, long processing cycles, significant safety hazards, and poor quality consistency. Therefore, developing a specialized equipment and process that can achieve efficient, safe, and precise riser removal without lifting or flipping the propeller has become a critical technical problem that urgently needs to be solved in this field. Summary of the Invention

[0010] To address the technical problems of existing large propeller riser cutting processes, such as cumbersome procedures, significant safety hazards, and unstable quality, this invention provides an overhead horizontal wire saw cutting device for large propeller risers. This device eliminates the need to lift and rotate the propeller, achieving horizontal mechanized cutting of the stern shaft riser by directly mounting it above the propeller blades. It aims to simplify the process, improve operational safety, and enhance cutting quality.

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] An overhead transverse wire saw cutting device for large propeller risers includes a support structure, a horizontal moving mechanism, a vertical support, a cutting drive mechanism, a drive wheel, a guide wheel, and an annular cutting cable.

[0013] The support structure is mounted on the upper end of the propeller blades, and its middle part has a clearance space for the riser to pass through.

[0014] The horizontal moving mechanism is mounted on the support structure and moves back and forth along the length of the support structure.

[0015] The vertical support is mounted on the horizontal moving mechanism and is driven by the horizontal moving mechanism to move in the horizontal direction.

[0016] The cutting drive mechanism is located at the top of the vertical support and reciprocates horizontally along the top of the vertical support.

[0017] The drive wheel is mounted on the cutting drive mechanism and is driven to rotate by the cutting drive mechanism.

[0018] The guide wheels are provided in several parts, which are respectively installed on the horizontal moving mechanism, the vertical bracket and the supporting structure to form a closed-loop guide path.

[0019] The annular cutting cable is wound around the drive wheel and the plurality of guide wheels, and circulates under the drive of the drive wheel.

[0020] The annular cutting cable forms a laterally extending cutting segment in the middle of the support structure, and the cutting segment horizontally cuts the riser.

[0021] Preferably, the support structure is a base frame, which is a six-sided hollow frame structure with linear guide rails on both long sides.

[0022] Preferably, the horizontal moving mechanism includes two slide blocks and a crossbeam, wherein the two slide blocks are slidably mounted on the linear guide rail; and the crossbeam is fixedly connected between the two slide blocks.

[0023] Preferably, the vertical support is a frame, which is arch-shaped and has its two ends fixed to the two slides respectively. A horizontal guide rail is provided on the top crossbeam of the frame.

[0024] Preferably, the cutting drive mechanism includes a drive base and a cutting motor. The drive base is slidably mounted on the horizontal guide rail. The cutting motor is fixed on the drive base. The drive wheel is a drive rope wheel, which is mounted on the side of the drive base and driven by the cutting motor.

[0025] Preferably, the plurality of guide wheels constitute a guide wheel group, including a first guide wheel, a second guide wheel and a third guide wheel. The first guide wheel is disposed on the side of the upright to change the movement direction of the annular cutting cable. The second guide wheel is disposed on the side of the slide to turn the annular cutting cable from the vertical direction to the horizontal direction. The third guide wheel is disposed on the crossbeam, and the interval between two third guide wheels forms the cutting segment.

[0026] Preferably, the annular cutting cable is an annular cutting wire saw, and its winding path is as follows: the active rope wheel is connected to the third guide wheel on the same side via the first guide wheel and the second guide wheel, and then returns to the active rope wheel via the third guide wheel, the second guide wheel, and the first guide wheel on the other side.

[0027] As a further preferred embodiment, the drive sheave is mounted on the drive base in a tilting manner. By adjusting the tilting angle of the drive sheave, the tension of the annular cutting wire saw is adjusted. Specifically, the tilting direction of the drive sheave is as follows: when its top tilts away from the support frame, the annular cutting wire saw is relaxed; when its top tilts towards the support frame, the annular cutting wire saw is tensioned.

[0028] As a further preferred embodiment, the horizontal moving mechanism is controlled by wireless remote control to achieve synchronous movement of the two slides.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] 1. The overhead design eliminates the need to lift and turn over propellers weighing tens or even hundreds of tons as a whole. The device can be directly cut by simply hoisting it above the blades, eliminating the cumbersome process of multiple hoisting and turning in traditional processes. This significantly shortens the processing cycle and improves the production pace of post-casting processing.

[0031] 2. It avoids the risks of swaying and overturning of large propellers during frequent hoisting and turning, and realizes mechanized cutting to replace manual gas cutting. Operators do not need to work at close range in high temperature and dusty environment, which fundamentally ensures the safety of personnel and equipment.

[0032] 3. The horizontal sliding mechanism and the cutting drive mechanism work together to achieve precise adjustment of the cutting position; the closed-loop path design of the guide wheel group ensures the smooth operation of the annular wire saw in the cutting section, resulting in a flat and smooth cutting surface and reducing the amount of subsequent secondary grinding work.

[0033] 4. The adjustable structure of the active rope wheel allows for easy adjustment of the wire saw tension, ensuring cutting efficiency while preventing the wire saw from breaking due to excessive tension or slipping due to excessive looseness, effectively extending the service life of the cutting wire saw.

[0034] 5. The horizontal moving mechanism adopts wireless remote control synchronous control, and the operator can flexibly adjust the cutting position according to the site conditions; at the same time, the hollow structure design of the base frame allows it to adapt to large propellers of different specifications.

[0035] In summary, this invention provides a large propeller riser cutting device that is compact, safe to operate, and highly efficient in cutting, solving many drawbacks of existing technologies that rely on hoisting and turning and manual cutting. It is of great significance for improving the post-processing technology of large castings. Attached Figure Description

[0036] Figure 1 This is a three-dimensional structural schematic diagram of the invention from the first perspective (mainly showing the overall structure and main components).

[0037] Figure 2 This is a three-dimensional structural diagram of the second perspective of the present invention (mainly showing the sub-components and internal structure).

[0038] Figure 3 This is the front view of the present invention;

[0039] Figure 4 This is a top view of the present invention;

[0040] Figure 5 This is a schematic diagram of the wire saw's routing principle in this invention;

[0041] Figure 6 This is a schematic diagram of the active rope pulley yaw adjustment.

[0042] The markings in the diagram are as follows: 1. Base frame; 2. Horizontal sliding mechanism; 201. Slide; 202. Crossbeam; 3. Upright frame; 301. Upright frame body; 302. Linear guide rail; 4. Cutting drive mechanism; 401. Drive base; 402. Cutting motor; 403. Drive rope pulley; 5. Guide wheel assembly; 501. First guide wheel; 502. Second guide wheel; 503. Third guide wheel; 6. Circular cutting wire saw. Detailed Implementation

[0043] To enhance understanding of the present invention, the invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only for explaining the invention and do not constitute a limitation on the scope of protection of the invention.

[0044] like Figures 1 to 6 As shown, the present invention provides an overhead transverse wire saw cutting device for large propeller risers. Its main innovation is that it does not require lifting and turning the large propeller, but is directly mounted above the blades, and achieves horizontal mechanized cutting of the stern shaft riser through a gear train layout.

[0045] like Figure 1 , Figure 2 As shown, this device includes a base frame 1, a horizontal sliding mechanism 2, a vertical frame 3, a cutting drive mechanism 4, a guide wheel group 5, and a ring-shaped cutting wire saw 6.

[0046] The base frame 1 serves as the supporting foundation for this device. It adopts a six-sided hollow frame structure design, which not only ensures structural strength but also effectively reduces the overall weight. In use, the base frame 1 is directly mounted on the upper end of the propeller blades, and the clearance space in the middle is just enough to accommodate the riser at the end of the propeller stern shaft, so that the entire device is mounted on the propeller in a straddle position.

[0047] Linear guide rails are provided on both long sides of the base frame 1 as the moving track of the horizontal sliding mechanism 2.

[0048] The horizontal sliding mechanism 2 includes two slide blocks 201 and a crossbeam 202. The two slide blocks 201 are slidably mounted on linear guide rails on both sides of the base frame 1. The crossbeam 202 is fixedly connected between the two slide blocks 201 to form a stable moving frame. In this embodiment, the two slide blocks 201 are controlled synchronously by wireless remote control to ensure the coordination and consistency of movement on both sides.

[0049] The frame 3 has an arch-shaped structure, with its two ends fixed to two slide blocks 201. It moves back and forth along the length of the machine base frame 1 together with the horizontal sliding mechanism 2. The top crossbeam of the frame 3 is equipped with a linear guide rail 302 for mounting the cutting drive mechanism 4.

[0050] The cutting drive mechanism 4 includes a drive base 401 and a cutting motor 402. The drive base 401 is slidably mounted on the linear guide rail 302. The cutting motor 402 is fixed on the drive base 401. The drive pulley 403 is mounted on the side of the drive base 401 and is driven to rotate by the cutting motor 402.

[0051] like Figures 2 to 5 As shown, the guide wheel assembly 5 is one of the core components of the present invention, used to guide the annular cutting wire saw 6 to form a closed-loop motion path. Specifically, the guide wheel assembly 5 includes a first guide wheel 501, a second guide wheel 502 and a third guide wheel 503.

[0052] The first guide wheel 501 is located on the side of the upright frame 3 and is used to change the vertical movement direction of the annular cutting wire saw 6; the second guide wheel 502 is located on the side of the slide block 201 and is used to turn the annular cutting wire saw 6 from the vertical direction to the horizontal direction; the third guide wheel 503 is located on the crossbeam 202, with one on each side, and the interval between the two third guide wheels 503 forms the working section for cutting the riser.

[0053] The winding path of the annular cutting wire saw 6 is as follows: the drive rope wheel 403 is connected to the third guide wheel 503 on the same side via the first guide wheel 501 and the second guide wheel 502, and then returns to the drive rope wheel 403 via the third guide wheel 503, the second guide wheel 502, and the first guide wheel 501 on the other side, forming a complete closed loop. After the cutting motor 402 is started, the drive rope wheel 403 drives the annular cutting wire saw 6 to circulate at high speed along the above path. The cutting section located between the two third guide wheels 503 can perform horizontal cutting on the riser.

[0054] As a further improvement to the present invention, such as Figure 6 As shown, the drive pulley 403 is mounted on the drive base 401 in a tilting manner. Specifically, an adjustment mechanism is provided between the mounting shaft of the drive pulley 403 and the drive base 401. By adjusting the tilting angle of the drive pulley 403, the tension of the annular cutting wire saw 6 can be easily adjusted. When the wire saw feels too tight, tilting the top of the drive pulley 403 away from the stand 3 will loosen the annular cutting wire saw 6. When the wire saw feels too loose, tilting the top of the drive pulley 403 closer to the stand 3 will tighten the annular cutting wire saw 6. This design not only simplifies the tension adjustment operation, but also effectively prevents the wire saw from breaking due to excessive tightness or slipping due to excessive looseness, thus extending the service life of consumables.

[0055] like Figure 3 , Figure 4As shown, the symmetrical design of this device can be more clearly seen from the front view and top view. The two slides 201, the two second guide wheels 502, and the two third guide wheels 503 are all arranged symmetrically from left to right, so that the annular cutting wire saw 6 is subjected to uniform force on both sides of the cutting section, ensuring the stability of the cutting process. At the same time, the cutting drive mechanism 4 can move along the linear guide rail 302 on the top of the stand 3, further expanding the adjustment range of the cutting position.

[0056] In summary, this invention, through the overhead design of the base frame 1, completely eliminates the reliance on large lifting equipment and turning areas required by traditional processes; through the multi-dimensional movement of the horizontal sliding mechanism 2, the upright frame 3, and the cutting drive mechanism 4, precise adjustment of the cutting position is achieved; through the reasonable layout of the guide wheel group 5, a stable closed-loop cutting path is formed; and through the sway-capable structure of the active rope wheel 403, convenient adjustment of the wire saw tension is achieved. All components work together to achieve efficient, safe, and precise cutting of large propeller risers.

[0057] Implementation Example

[0058] The feasibility and applicability of the present invention will be further illustrated below through a specific implementation example.

[0059] This embodiment describes the cutting of the stern shaft riser for a large ship propeller. The propeller has a diameter of 8.5 meters and a total weight of approximately 65 tons. The stern shaft riser has a diameter of 1.2 meters and is made of nickel-aluminum bronze alloy. If the traditional process is followed, two 100-ton overhead cranes and a tilting platform would be used for multiple lifting and turning operations, followed by 4 workers assisting with the gas cutting operation. This process is expected to take 3 working days and carries significant safety risks.

[0060] The specific implementation steps after using the device of the present invention are as follows:

[0061] First, the overhead transverse wire saw cutting device of this invention is prepared by hoisting it as a whole using a workshop crane and slowly moving it above the propeller that has been placed on the ground. The operator fine-tunes the position of the device using a wireless remote control so that the hollow center of the base frame 1 is aligned with the riser at the stern shaft end. Then, it is slowly lowered until the base frame 1 is stably mounted on the upper end of the propeller blade. At this time, the riser just passes through the clearance space in the middle of the base frame 1 and is in the position to be cut. The entire hoisting and alignment process takes only 30 minutes and does not require any turning operation of the propeller.

[0062] Next, the cutting parameters are set. Based on the riser diameter, the operator uses a wireless remote control to control the two slide blocks 201 of the horizontal sliding mechanism 2 to move synchronously, adjusting the two third guide wheels 503 on the crossbeam 202 to a suitable distance so that the cutting section is accurately aligned with the riser position. Then, the cutting drive mechanism 4 is started, and the cutting motor 402 drives the active rope wheel 403 to rotate, driving the annular cutting wire saw 6 to circulate at high speed along the preset path. At this time, the operator can observe the running status of the wire saw. If the tension is not appropriate, the operator can directly adjust the sway angle of the active rope wheel 403 until the optimal cutting state is achieved. The entire adjustment process takes about 15 minutes.

[0063] Then the cutting operation begins. The feed program is started, and the horizontal sliding mechanism 2 drives the stand 3 and the entire cutting system to move slowly horizontally along the machine base frame 1. The cutting section of the annular wire saw 6 smoothly cuts in from the side of the riser. During the cutting process, the operator monitors the cutting status in real time through a wireless remote control and fine-tunes the position of the cutting drive mechanism 4 on the top of the stand 3 as needed to keep the cutting line at the optimal angle. Because the annular wire saw 6 has the characteristics of fast cutting speed, narrow kerf, and small heat-affected zone, the entire cutting process only lasts about 2 hours.

[0064] Finally, the cutting was completed, and the annular cutting wire saw 6 smoothly detached from the other side of the riser. The riser was completely separated from the stern shaft end. The operator used a crane to lift the cut riser away from the site and lift the device off the propeller blade.

[0065] Upon inspection, the cut surface was found to be flat and smooth, with no obvious slag or heat-affected zone. It could meet the requirements for subsequent processing without the need for secondary grinding. The entire cutting operation, from hoisting to completion, took only 3.5 hours, which is more than 85% shorter than the 3 working days of the traditional process.

[0066] This embodiment fully demonstrates that the device of the present invention has important practical value for improving the production efficiency and safety of post-processing of large propeller casting.

[0067] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An overhead transverse wire saw cutting device for large propeller risers, characterized in that, include: Support structure, horizontal moving mechanism, vertical support, cutting drive mechanism, drive wheel, guide wheel and annular cutting cable; The support structure is mounted on the upper end of the propeller blades, and its middle part is provided with a clearance space for the riser to pass through; The horizontal moving mechanism is mounted on the support structure and moves back and forth along the length of the support structure. The vertical support is mounted on the horizontal moving mechanism and is driven by the horizontal moving mechanism to move in the horizontal direction; The cutting drive mechanism is located at the top of the vertical support and reciprocates horizontally along the top of the vertical support. The drive wheel is mounted on the cutting drive mechanism and is driven to rotate by the cutting drive mechanism; The guide wheels are provided in a plurality of manner, and are respectively disposed on the horizontal moving mechanism, the vertical bracket and the supporting structure to form a closed-loop guide path; The annular cutting cable is wound around the drive wheel and the plurality of guide wheels, and circulates under the drive of the drive wheel; The annular cutting cable forms a laterally extending cutting segment in the middle of the support structure, and the cutting segment horizontally cuts the riser.

2. The large propeller riser cutting device according to claim 1, characterized in that, The supporting structure is a base frame; The base frame has a six-sided hollow frame structure, and linear guide rails are provided on both long sides.

3. The large propeller riser cutting device according to claim 2, characterized in that, The horizontal moving mechanism includes two slides and a crossbeam; The two slide blocks are slidably mounted on the linear guide rail; The crossbeam is fixedly connected between the two slide blocks.

4. The large propeller riser cutting device according to claim 3, characterized in that, The vertical support is a frame; The upright frame is arch-shaped, with its two ends fixed to the two sliding blocks respectively; The top crossbeam of the support frame is equipped with a horizontal guide rail.

5. The large propeller riser cutting device according to claim 4, characterized in that, The cutting drive mechanism includes a drive base and a cutting motor; The drive base is slidably mounted on the horizontal guide rail; The cutting motor is fixed on the drive base; The drive wheel is a drive rope wheel, which is installed on the side of the drive base and driven by the cutting motor.

6. The large propeller riser cutting device according to claim 5, characterized in that, The plurality of guide wheels constitute a guide wheel group, including: a first guide wheel, a second guide wheel, and a third guide wheel; The first guide wheel is disposed on the side of the upright to change the direction of movement of the annular cutting cable; The second guide wheel is disposed on the side of the slide to turn the annular cutting cable from the vertical direction to the horizontal direction; The third guide wheel is mounted on the crossbeam, and the interval between the two third guide wheels forms the cutting segment.

7. The large propeller riser cutting device according to claim 6, characterized in that, The ring-shaped cutting cable is a ring-shaped cutting wire saw, and its winding path is as follows: the active rope wheel is connected to the third guide wheel on the same side via the first guide wheel and the second guide wheel, and then returns to the active rope wheel via the third guide wheel, the second guide wheel, and the first guide wheel on the other side.

8. The large propeller riser cutting device according to claim 5, characterized in that, The drive pulley is mounted on the drive base with a tilting motion, and the tension of the annular cutting wire saw is adjusted by adjusting the tilting angle of the drive pulley.

9. The large propeller riser cutting device according to claim 8, characterized in that, The sway direction of the active rope pulley is such that when its top sways away from the upright, the annular cutting rope saw relaxes. When its top tilts toward the support frame, the annular cutting wire saw is tensioned.

10. The large propeller riser cutting device according to any one of claims 1 to 9, characterized in that, The horizontal moving mechanism is controlled by wireless remote control to achieve synchronous movement of the two slides.

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