A kind of based on track type roller press roller system jacking transfer overhauling device

Abstract

A maintenance device based on the lifting and transfer of the roller system of a track-type roller press includes: tracks laid on the ground on both sides of the roller system, extending along the transfer direction of the roller system; at least two mobile trolleys, each adapted to and installed on the two tracks and moving along the length of the tracks; a frame mounted on the mobile trolleys; and a hydraulic lifting mechanism integrated into the frame. The tracks are two in number and symmetrically arranged about the central axis of the roller system. Their starting point extends to below the roller press frame, and their ending point extends to the outside of the factory building. This eliminates the need for openings in the floor, thus avoiding damage to the factory's civil engineering structure. Furthermore, the track length can be flexibly adjusted according to the actual maintenance needs of the factory, meeting the requirements for long-distance transfer of the roller system from the frame to the outside of the factory building. The mobile trolleys correspond one-to-one with the tracks, consisting of two independent trolleys, left and right, with identical structures and specifications and mirror-image arrangement. This adapts to the structural characteristics of the roller system, where the span between the two bearings is large and a flatcar cannot be used, and can stably support the roller system.

Description

Technical Field

[0001] This invention relates to the field of roller press maintenance technology, specifically to a maintenance device based on the lifting and transporting of the roller system of a track-type roller press. Background Technology

[0002] Roller presses are core equipment in grinding systems in industries such as cement, mining, and metallurgy. The roller system, as a component directly involved in the grinding process, is susceptible to material wear and impact, requiring regular inspection, maintenance, and replacement. The roller system itself is heavy; a typical roller press roller system can weigh over 110 tons, and it is installed inside the roller press frame. Its inspection, maintenance, and relocation have always been technical challenges in the industry.

[0003] Currently, the industry mainly adopts two solutions for the maintenance and transfer of roller press roller systems. The first solution is the roller press shaft system maintenance platform solution. This solution requires adding an elevated steel structure to the outside of the roller press to extend the lower crossbeam. At the same time, multiple traction machines are installed on the steel structure. The roller system assembly is dragged from the frame to the outside of the workshop by manually controlling the dragging speed and position through winches. However, this solution has obvious drawbacks. The elevated steel structure suspended in the air not only occupies a lot of working space, but also causes great inconvenience to maintenance operations and personnel movement. In addition, the process of manually controlling multiple winches to drag the roller system is prone to speed and angle deviations, making the operation difficult. Furthermore, this solution can only realize the removal of the roller system from the frame, but cannot drag the repaired roller system back to the frame from outside the factory for reinstallation. It requires the cooperation of other equipment to complete the subsequent operations, resulting in extremely low maintenance efficiency.

[0004] The second option is a mobile trolley solution involving floor openings and rail laying. This solution requires openings in the factory floor and laying steel rails, then mounting the mobile trolley on the rails. An electric hoist suspended from the trolley is used to lift and transport the roller system. However, this floor opening operation directly damages the overall civil engineering structure of the factory, reducing the floor's structural strength. Furthermore, the vibrations generated during the operation of the roller press can easily resonate with the floor opening, severely affecting the stability of the factory structure. Simultaneously, the steel rails laid on the floor are limited by the civil engineering framework, restricting the transport distance and making it impossible to transport the roller system outside the factory. Additionally, the mobile trolley is typically installed on floors above 9 meters, with the roller system located at ground level. The excessive vertical distance between the lifting power source and the load poses a significant safety hazard to equipment and personnel when hoisting large-tonnage roller systems exceeding 110 tons at heights, easily leading to hoisting accidents.

[0005] Neither of the above two maintenance solutions can simultaneously solve the core problems of floor structure damage, safety hazards of high-altitude hoisting, difficulty in transporting the roller system outside the factory, and inability to achieve reciprocating assembly and disassembly of the roller system. This results in high safety risks, high operational difficulty, and low maintenance efficiency for the roller system maintenance of the roller press, and causes irreversible damage to the factory structure. Therefore, there is an urgent need for a brand-new roller press roller system lifting, transporting and maintenance device to fundamentally solve many of the shortcomings of the existing technology. Summary of the Invention

[0006] The purpose of this invention is to solve the problems of damage to the floor structure, safety hazards of high-altitude hoisting, limited transfer distance and inability to reciprocate the assembly and disassembly in the maintenance and transfer of the roller system of existing roller presses, and to propose a maintenance device based on the lifting and transfer of the roller system of a track-type roller press.

[0007] The objective of this invention can be achieved through the following technical solutions:

[0008] A maintenance device based on the lifting and transfer of the roller system of a track-type roller press includes: The track is laid on the ground on both sides of the roller system and extends along the direction of roller system transport; At least two mobile trolleys are respectively fitted and installed on the two said tracks and move along the length of the tracks; The frame is mounted on the mobile vehicle; A hydraulic lifting mechanism is integrated on the frame, and the output end of the hydraulic lifting mechanism is connected to the roller system for lifting the roller system.

[0009] The track consists of two tracks arranged symmetrically about the central axis of the roller system. The starting point of the track extends to the bottom of the roller press frame and the ending point extends to the outside of the factory building. There is no need to open holes in the floor for laying the track, thus avoiding damage to the civil structure of the factory building from the source. At the same time, the length of the track can be flexibly adjusted according to the actual maintenance needs of the factory building, meeting the long-distance transfer requirements of the roller system from the frame to the outside of the factory building. The moving trolleys correspond one-to-one with the tracks, consisting of two independent moving trolleys on the left and right. The two trolleys have the same structure and specifications and are arranged in a mirror image. This is suitable for the structural characteristics of the roller system where the span between the two bearings is large and a flat car cannot be used. It can stably support the roller system.

[0010] As a further embodiment of the present invention: the hydraulic lifting mechanism includes a hydraulic station, at least two hydraulic cylinders and a hydraulic control valve group. The hydraulic control valve group is installed on the hydraulic station. The hydraulic station is connected to each hydraulic cylinder through pipelines. The hydraulic control valve group independently controls the hydraulic pressure of each hydraulic cylinder. The output end of the hydraulic cylinder is connected to a transition tool. The transition tool is used to fix and connect to the bearing seat of the roller system.

[0011] The number of hydraulic cylinders is matched with the number of bearing seats in the roller system, with at least two cylinders, each corresponding to a bearing seat in the roller system. The hydraulic station is an electric hydraulic station that can output high-pressure oil to provide lifting power for the hydraulic cylinders. The hydraulic control valve group can independently and differentially control the hydraulic pressure and lifting speed of each hydraulic cylinder, and can compensate for the pressure loss of high-pressure oil in pipelines and valves. The adapter and the output end of the hydraulic cylinder, as well as the adapter and the bearing housing of the roller system, are all bolted together, which provides high connection strength and convenient assembly and disassembly. This allows for quick assembly and disassembly of the hydraulic lifting mechanism and the roller system, and can also be adapted to roller bearing housings of different specifications.

[0012] As a further aspect of the present invention: the mobile trolley includes two sets of wheels, the wheels of the wheel sets are engaged on the track, and the frame is fixedly connected to the front and rear sets of wheels to form a stable placement plane.

[0013] The wheel set consists of two independent forged wheels installed back to back. The forged wheels have high structural strength and can withstand the load of large-tonnage roller systems. The engagement and cooperation between the wheels and the rail can prevent the trolley from deviating or derailing when it moves on the rail. The frame is made of steel and is fixedly connected to the front and rear wheel sets. The resulting placement plane has high flatness and strong stability, and can stably bear the entire load of the hydraulic jacking mechanism and roller system, providing a solid foundation for the integrated installation of the hydraulic jacking mechanism.

[0014] As a further aspect of the present invention: multiple sets of drive motors are provided on the frame, and each set of wheels is configured with a set of drive motors, and the drive motors are connected to the wheel sets in a transmission connection.

[0015] The drive motor is a variable frequency speed control motor, and its output end is connected to the wheel set through a coupling to achieve transmission, which has high transmission efficiency and stable operation. Each set of wheels corresponds to an independent drive motor, meaning each mobile trolley is equipped with two sets of drive motors, forming a dual-drive structure. By adjusting the output parameters of the drive motors, the transmission loss between parts and the friction loss between the wheels and the track can be overcome, ensuring the synchronous rotation of the wheel sets and thus achieving smooth movement of the mobile trolley on the track. The drive motors of the left and right mobile carts are independent of each other and can be controlled separately to meet the requirements of subsequent synchronous motion control.

[0016] As a further aspect of the present invention: the maintenance device also includes a PLC control system, which is electrically connected to the hydraulic station and the hydraulic control valve group respectively, and is equipped with sensors. The sensors are used to collect the relative position of the independent mobile trolley and the hydraulic cylinder pressure parameters in real time.

[0017] The sensor is a pressure sensor, which is installed on the hydraulic cylinder and / or pipeline.

[0018] The PLC control system is the core of the entire maintenance unit. It can send start / stop and pressure regulation commands to the hydraulic station and valve action commands to the hydraulic control valve group, thereby achieving precise electrical control of the hydraulic lifting mechanism. The hydraulic cylinder pressure parameters collected by the sensors can be fed back to the PLC control system in real time, providing data support for the differentiated control of the hydraulic pressure of each hydraulic cylinder by the hydraulic control valve group. The relative position parameters of the moving trolley collected by the sensors can help determine the horizontal status of the roller system during the lifting process, and avoid the roller system from tilting due to uneven lifting force.

[0019] The pressure sensor is a hydraulic-specific pressure sensor with high detection accuracy and strong anti-interference ability. It is installed in the rodless chamber of the hydraulic cylinder and / or the high-pressure pipeline. It can detect the hydraulic oil pressure in the hydraulic cylinder and the hydraulic oil pressure in the pipeline in real time, and accurately feed back the actual lifting pressure of each hydraulic cylinder. When the pressure of a certain hydraulic cylinder deviates, the PLC control system can adjust the oil inlet pressure of that hydraulic cylinder in time through the hydraulic control valve group to ensure the matching of the lifting force of each hydraulic cylinder.

[0020] As a further aspect of the present invention: the maintenance device also includes a PLC control system, which is electrically connected to the drive motor and equipped with sensors. The sensors are used to collect the drive motor speed, wheel set speed, and relative position of the independent mobile trolleys in real time. The PLC control system uses a differential speed algorithm based on the sensor feedback parameters to adjust the output parameters of the drive motor, thereby realizing the synchronous movement of multiple independent mobile trolleys. At the same time, it links and controls the hydraulic lifting mechanism to complete the horizontal lifting and lowering of the roller system.

[0021] The sensors include a position sensor and a speed sensor. The position sensor is disposed on the track and / or frame, and the speed sensor is disposed at the drive motor and / or wheel assembly.

[0022] The PLC control system has a pre-programmed differential speed control algorithm that can calculate the optimal output speed and torque of each drive motor based on real-time parameters fed back by sensors. It then sends speed adjustment commands to the corresponding drive motors, adjusting the output parameters of the drive motors of the left and right moving trolleys in real time. This compensates for the speed and position differences between the two trolleys during movement, enabling unmanned synchronous movement of the two trolleys on the track. The PLC control system's control of the drive motors is linked to its control of the hydraulic lifting mechanism. After the roller system completes horizontal lifting, the drive motors are automatically started to achieve transfer. After the roller system reaches the designated position, the hydraulic lifting mechanism is automatically controlled to complete the smooth descent of the roller system, achieving integrated linkage control of lifting, transfer, and descent without the need for manual on-site operation.

[0023] The position sensor uses a laser displacement sensor or a proximity sensor, which is set on the side of the track and / or the frame of the moving trolley. It can detect the absolute position of the left and right moving trolleys on the track and the relative position between them in real time, providing accurate position data for synchronous motion control. The speed sensor adopts a Hall speed sensor, which is directly connected to the output shaft of the drive motor and / or the wheel axle of the wheel set. It can collect the actual speed of the drive motor and the actual rotation speed of the wheel set in real time, and provide feedback on the transmission efficiency between the drive motor and the wheel set. When a speed deviation occurs, the PLC control system can adjust the output parameters of the drive motor in time to ensure the rotation synchronization of the wheel set. The position sensor, speed sensor and the aforementioned pressure sensor work together, and all detection data are transmitted to the PLC control system in real time to form a multi-parameter closed-loop control, ensuring that the various actions of the maintenance device are accurate and stable.

[0024] The beneficial effects of this invention are as follows: This invention adopts a ground track laying design, with the track laid directly on the ground on both sides of the roller system and extending to the outside of the factory building. There is no need to make openings in the factory building floor, which avoids damage to the factory building's civil structure from the root and eliminates the risk of floor resonance. At the same time, it abandons the operation methods of high-altitude steel structure and high-altitude hoisting, completely solves the safety hazards of high-altitude hoisting of large-tonnage roller systems, and greatly improves the safety of roller system maintenance operations.

[0025] This invention features an independent mobile trolley that adapts to ground tracks, taking into account the structural characteristics of the roller system where the span between the two bearings is too large to be accommodated by a flatcar. It can stably support large-tonnage roller systems of over 110t, and the track extends to the outside of the factory building, enabling long-distance transport of the roller system from the roller press frame to the outside of the factory building. At the same time, it can complete the reinstallation operation of the roller system from the outside of the factory building to the frame after maintenance, realizing the round-trip assembly and disassembly of the roller system without the need for other transport equipment, which greatly improves the efficiency of maintenance operations.

[0026] The hydraulic lifting mechanism of this invention is integrated with the mobile trolley. The hydraulic cylinders are bolted to the roller bearing seats via adapters, making disassembly and assembly convenient and adaptable to roller systems of different specifications. At the same time, the hydraulic control valve group can differentially control the hydraulic pressure of each hydraulic cylinder, compensating for the pressure loss of hydraulic oil in pipelines and valves, achieving horizontal and stable lifting of the roller system, avoiding interference between the roller system tilting and the frame limiting mechanism during the lifting process, and ensuring the equipment safety during the roller system lifting process. Attached Figure Description

[0027] The invention will now be further described with reference to the accompanying drawings.

[0028] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram showing the positions of the frame, wheel assembly, and drive motor; Figure 3 This is a structural diagram of the hydraulic lifting mechanism.

[0029] In the diagram: 1. Track; 2. Moving trolley; 3. Hydraulic station; 4. Hydraulic cylinder; 5. Drive motor; 6. Roller system; 7. Frame; 8. Wheel set; 10. Hydraulic control valve group. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] This embodiment provides a maintenance device based on the lifting and transporting of the roller system of a track-type roller press, suitable for the maintenance of the roller system of a 110t roller press. Its specific structure is shown in the attached figure. Figure 1-3 As shown, it includes track 1, mobile trolley 2, hydraulic station 3, hydraulic cylinder 4, drive motor 5, roller system 6, frame 7, wheel set 8, and hydraulic control valve group 10; track 1 consists of two steel rails, symmetrically laid on the ground about the central axis of roller system 6. One end of track 1 extends to the bottom of the roller press frame, and the other end extends to the outside of the factory building, with a laying length of 20m to meet the needs of long-distance transportation; mobile trolley 2 consists of two independent trolleys, left and right, corresponding one-to-one with track 1. The two have completely identical structures and specifications and are arranged in a mirror image.

[0032] Each mobile trolley 2 includes a frame 7 and two sets of wheels 8. The frame 7 is made of Q345 steel structure welded to ensure structural strength and load-bearing capacity. The wheel set 8 consists of two forged wheels installed back to back. The wheels are engaged on the track 1 to effectively prevent the trolley from deviating or derailing. The frame 7 and the front and rear sets of wheels 8 are fixedly connected by bolts to form a flat and stable placement plane. Two sets of variable frequency speed control drive motors 5 are installed on the frame 7. Each set of wheels 8 corresponds to one set of drive motors 5. The drive motors 5 and the wheel sets 8 are connected by a coupling to form a dual-drive structure. The drive motors 5 of the left and right mobile trolleys 2 are controlled independently.

[0033] A hydraulic lifting mechanism is integrated on frame 7. The hydraulic lifting mechanism includes an electric hydraulic station 3, two hydraulic cylinders 4, and a hydraulic control valve group 10. The hydraulic control valve group 10 is installed on the hydraulic station 3. The hydraulic station 3 is connected to the two hydraulic cylinders 4 through a high-pressure seamless pipeline. The hydraulic control valve group 10 is an electromagnetic directional valve group, which can independently control the hydraulic pressure and lifting speed of each hydraulic cylinder 4. The output end of the hydraulic cylinder 4 is connected to a steel adapter. The adapter and the output end of the hydraulic cylinder 4, as well as the adapter and the bearing seat of the roller system 6, are all connected by high-strength bolts, which have high connection strength and are easy to disassemble and assemble. The two hydraulic cylinders 4 are respectively set to the two bearing seats of the roller system 6 to ensure uniform lifting force.

[0034] This device is equipped with a PLC control system, using a Siemens S7-300 PLC as the control core. It is electrically connected to the hydraulic station 3, the hydraulic control valve group 10, and all drive motors 5. It is also equipped with multiple types of sensors: hydraulic pressure sensors are installed on the rodless chamber of the hydraulic cylinder 4 and the high-pressure pipeline to collect the pressure parameters of the hydraulic cylinder 4 in real time; laser displacement sensors are installed on the side of the track 1 and the frame 7 of the moving trolley 2 to collect the absolute and relative position parameters of the left and right moving trolleys 2 in real time; Hall speed sensors are installed on the output shaft of the drive motor 5 and the wheel axle of the wheel set 8 to collect the speed parameters of the drive motor 5 and the wheel set 8 in real time.

[0035] The PLC control system has a pre-programmed differential speed control algorithm that can adjust the output speed and torque of each drive motor 5 in real time based on the position and speed parameters fed back by the sensors. This enables unmanned synchronous movement of the left and right moving trolleys 2, with the synchronous position error controlled within ±5mm. At the same time, the PLC control system links and controls the hydraulic lifting mechanism and drive motor 5. The hydraulic cylinder pressure parameters fed back by the pressure sensor provide data support for the differentiated pressure control of the hydraulic control valve group 10, ensuring that the lifting force of the two hydraulic cylinders 4 is matched, realizing the horizontal lifting of the roller system 6 with a lifting levelness error ≤0.5°. After the roller system 6 completes the lifting, the drive motor 5 is automatically started to realize the transfer. After the roller system 6 reaches the designated position, the hydraulic cylinder 4 is automatically controlled to fall back, realizing integrated automated operation.

[0036] The maintenance device of this embodiment includes the following steps in actual use: Track laying and trolley positioning: Lay two tracks 1 symmetrically on the ground on both sides of the roller system 6. After fixing, install the left and right moving trolleys 2 on the tracks 1 respectively. Move the trolleys 2 to the designated position under the roller press frame through the PLC control system, calibrate the initial position of the trolleys 2, and ensure that the two are synchronized. Roller system connection: The adapter at the output end of the hydraulic cylinder 4 is fixedly connected to the two bearing seats of the roller system 6 one by one using high-strength bolts. Check the tightness of the bolts and complete the assembly of the hydraulic lifting mechanism and the roller system 6. Horizontal lifting: The hydraulic station 3 is started by the PLC control system. The hydraulic station 3 outputs high-pressure oil. The hydraulic control valve group 10 differentially controls the hydraulic pressure of the two hydraulic cylinders 4, and the roller system 6 is lifted smoothly at a speed of 5mm / s. The lifting height is 300mm, avoiding the limit mechanism on the frame. During the lifting process, the pressure sensor provides real-time feedback of pressure parameters, and the PLC control system dynamically adjusts to ensure that the roller system 6 is horizontal. Synchronous transfer: The PLC control system starts all drive motors 5 and adjusts the output parameters of the drive motors 5 of the left and right moving trolleys 2 based on the differential speed algorithm, so that the trolleys 2 move synchronously to the outside of the factory along the track 1 at a speed of 100mm / s. The sensors collect position and speed parameters in real time and dynamically adjust the drive parameters to ensure that the trolleys 2 move synchronously. Roller system maintenance: After the trolley 2 transfers the roller system 6 to the maintenance position outside the factory, the PLC control system controls the hydraulic cylinder 4 to fall back smoothly, placing the roller system 6 on the maintenance platform, disassembling the transfer tooling, and performing maintenance, repair or replacement on the roller system 6. Reassembly and transfer: After the roller system 6 is overhauled, the transfer tooling is fixedly connected to the bearing seat of the roller system 6. The hydraulic cylinder 4 is controlled by the PLC control system to lift the roller system 6 horizontally. Then, the drive motor 5 is controlled to run in reverse so that the left and right moving trolleys 2 return synchronously to the bottom of the roller press frame along the track 1. Roller system retraction and reset: The PLC control system controls the hydraulic cylinder 4 to gradually reduce the pressure, so that the roller system 6 is smoothly retracted to the designated installation position on the frame. After checking the alignment of the roller system 6, the transfer tooling is disassembled to complete the reinstallation of the roller system 6. Finally, the moving trolley 2 is controlled to move to the initial position of the track 1 to reset, and the maintenance operation is completed.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A maintenance device based on the lifting and transfer of the roller system of a track-type roller press, characterized in that, include: Track (1) is laid on the ground on both sides of the roller system (6) and extends along the transport direction of the roller system (6); At least two mobile trolleys (2) are respectively adapted to be installed on the two said tracks (1) and move along the length direction of the tracks (1); The frame (7) is mounted on the mobile trolley (2); A hydraulic lifting mechanism is integrated on the frame (7). The output end of the hydraulic lifting mechanism is connected to the roller system (6) for lifting the roller system (6).

2. The maintenance device according to claim 1, characterized in that, The hydraulic lifting mechanism includes a hydraulic station (3), at least two hydraulic cylinders (4) and a hydraulic control valve group (10). The hydraulic control valve group (10) is installed on the hydraulic station (3). The hydraulic station (3) is connected to each hydraulic cylinder (4) through pipelines. The hydraulic control valve group (10) independently controls the hydraulic pressure of each hydraulic cylinder (4). The output end of the hydraulic cylinder (4) is connected to a transition tool. The transition tool is used to fix the connection with the bearing seat of the roller system (6).

3. The maintenance device according to claim 1, characterized in that, The mobile trolley (2) includes two sets of wheels (8), the wheels of the wheels (8) are engaged on the track (1), and the frame (7) is fixedly connected to the front and rear sets of wheels (8) to form a stable placement plane.

4. The maintenance device according to claim 3, characterized in that, The frame (7) is provided with multiple sets of drive motors (5), and each set of wheel groups (8) is configured with a set of drive motors (5), and the drive motors (5) are connected to the wheel groups (8) in a transmission connection.

5. The maintenance device according to claim 2, characterized in that, The maintenance device also includes a PLC control system, which is electrically connected to the hydraulic station (4) and the hydraulic control valve group (10) respectively, and is equipped with sensors. The sensors are used to collect the relative position of the independent mobile trolley (2) and the pressure parameters of the hydraulic cylinder (4) in real time.

6. The maintenance device according to claim 5, characterized in that, The sensor is a pressure sensor, which is installed on the hydraulic cylinder (4) and / or the pipeline.

7. The maintenance device according to claim 4, characterized in that, The maintenance device also includes a PLC control system. The PLC control system is electrically connected to the drive motor (5) and is equipped with sensors. The sensors are used to collect the speed of the drive motor (5), the speed of the wheel set (8), and the relative position of the independent mobile trolleys (2) in real time. The PLC control system uses a differential speed algorithm based on the sensor feedback parameters to adjust the output parameters of the drive motor (5) and realize the synchronous movement of multiple independent mobile trolleys (2). At the same time, it links and controls the hydraulic lifting mechanism to complete the horizontal lifting and lowering of the roller system (6).

8. The maintenance device according to claim 7, characterized in that, The sensors include a position sensor and a speed sensor. The position sensor is located on the track (1) and / or the frame (7), and the speed sensor is located at the drive motor (5) and / or the wheel assembly (8).

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