A method of installing a hydraulic pump station with a modular tool

Abstract

A method for installing a hydraulic pump station using a combination of tools: S1. The hydraulic pump station is lifted using claw jacks. Three pallet jacks are placed at the bottom of the hydraulic pump station, one of which is a main pallet jack with electric power and remote steering function, and the other two are follow-up auxiliary pallet jacks. The hydraulic pump station is lowered to support it on the three pallet jacks. S2. The hydraulic pump station is moved horizontally by the electric power of the main pallet jack. The direction of the rollers of the main pallet jack is controlled by a remote control to achieve steering. The two auxiliary pallet jacks follow the movement, moving the hydraulic pump station to the vicinity of the installation foundation. S3. The hydraulic pump station is lifted again using claw jacks, all pallet jacks are removed, and the hydraulic pump station is lowered onto the installation base. S4. The level of the hydraulic pump station is adjusted, the anchor bolts are tightened, and the connection between the hydraulic pump station and the external hydraulic pipeline is completed. This method solves the technical problems of existing installation methods, which make it difficult to lift, steer, and accurately position equipment in narrow spaces.

Description

Technical Field

[0001] This invention belongs to the field of equipment installation and construction technology, and specifically relates to a method for installing a hydraulic pump station using a combination of tools. Background Technology

[0002] There are numerous hydraulic gate hoist installation projects in the water conservancy industry. If the hydraulic equipment is installed first, temporary supports are required, and the equipment is susceptible to contamination or damage. This also increases the difficulty of subsequent civil engineering construction of the gate hoist room. Therefore, the gate hoist room frame is usually built first, followed by the installation of the hydraulic gate hoist equipment. However, the space in the gate hoist room is often very limited, requiring heavy equipment such as pump stations to be moved, turned, and precisely positioned on the foundation within a short distance indoors.

[0003] Traditional installation and handling methods have the following shortcomings: Overhead crane or forklift handling: Requires overhead lifting points or sufficiently wide passageways above the equipment, and the equipment weight must be limited by its rated load. Most existing hoist rooms lack overhead crane coverage, and forklifts cannot enter due to their large turning radius.

[0004] Electric forklift handling: Although electric forklifts (also known as electric pallet trucks) can reduce manpower, their bodies are relatively high, making it difficult to insert them into the low space at the bottom of the hydraulic pump station, and their turning radius is still relatively large, making them unsuitable for extremely narrow hoisting machine rooms.

[0005] Roller or roller handling: Steel pipes or rollers are placed under the equipment and driven by manpower or pry bars. Although this method is simple, it is difficult to turn, can easily injure people, requires a high degree of ground flatness, and the equipment is prone to shifting or tipping over.

[0006] Using a pallet jack alone: ​​A pallet jack (transportation tank) is a low-profile transport vehicle capable of carrying heavy equipment. However, the foundation of the hydraulic pump station is often low, and the bottom of the equipment has little clearance from the ground. Putting in and taking out the pallet jack requires raising the equipment to a certain height. In addition, ordinary pallet jacks still require manual assistance to turn, making them inconvenient to operate in narrow spaces.

[0007] Currently, there is no established method for combining a claw jack, a remote-controlled electric steering pallet jack (one main and two auxiliary), and a crowbar in a specific procedure to achieve "lifting-cart placement-remote movement-precise steering-positioning and lowering" in a hydraulic pump station within a confined space. Therefore, it is necessary to provide an installation method that is easy to operate, has low requirements for space and ground conditions, is safe and reliable, and is suitable for use in small gatehouses. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to provide a method for installing a hydraulic pump station using a combination of tools, thereby solving the technical problem that existing installation methods are difficult to use in narrow spaces to lift the equipment smoothly, steer it flexibly, and position it accurately.

[0009] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A method for installing a hydraulic pump station using a combination tool, comprising the following steps: S1. Use claw jacks to lift the hydraulic pump station, place three pallet jacks at the bottom of the hydraulic pump station, one of which is a main pallet jack with electric power and remote steering function, and the other two are follow-up auxiliary pallet jacks. Lower the hydraulic pump station so that it is supported on the three pallet jacks. S2. The hydraulic pump station is moved horizontally by the electric power of the main ground jack tank. The direction of the rollers of the main ground jack tank is controlled by the remote control to achieve steering. The two auxiliary ground jack tanks follow suit and move the hydraulic pump station to the vicinity of the installation foundation. S3. Use claw jacks again to lift the hydraulic pump station, remove all the pallet jacks, and lower the hydraulic pump station onto the mounting base; S4. Adjust the level of the hydraulic pump station, tighten the anchor bolts, and complete the connection between the hydraulic pump station and the external hydraulic pipeline.

[0010] Preferably, in step S1, at least two claw jacks are used in conjunction; the lower claw of the claw jack is inserted into the gap at the bottom of the hydraulic pump station. If the gap size is insufficient, a pry bar is used to pry the hydraulic pump station to create a gap before inserting the lower claw.

[0011] Preferably, in step S1, the lifting height of the hydraulic pump station is 50mm to 100mm.

[0012] Preferably, in step S1, the three ground jacks are arranged in a three-point support configuration at the load-bearing positions at the bottom of the hydraulic pump station; the main ground jack is positioned at the front or rear end of the hydraulic pump station in the direction of travel.

[0013] Preferably, in step S2, when the main ground-mounted tank is positioned at the front end of the direction of travel, the remote-controlled steering direction is consistent with the steering direction required by the hydraulic pump station; when the main ground-mounted tank is positioned at the rear end of the direction of travel, the remote-controlled steering direction is opposite to the steering direction required by the hydraulic pump station.

[0014] Preferably, in step S2, after the hydraulic pump station is moved to the vicinity of the installation foundation, its position is adjusted by the remote micro-motion function of the main ground jack tank so that the mounting hole of the hydraulic pump station is precisely aligned with the anchor bolts of the installation foundation.

[0015] Preferably, in step S3, the claw jack is inserted into the bottom of the hydraulic pump station, avoiding the position of the pallet jack, and the hydraulic pump station is raised to a height where the pallet jack can be freely pulled out. Then, all the pallet jacks are removed one by one.

[0016] Preferably, in step S4, adjusting shims are placed between the hydraulic pump station base and the mounting base, and a leveling tool is used to check the longitudinal and lateral levelness of the hydraulic pump station. The levelness is adjusted to meet the equipment installation specifications by adjusting the height of the shims.

[0017] Preferably, in step S4, a torque wrench is used to tighten the anchor bolts and nuts in a symmetrical and phased manner according to a predetermined torque, and the levelness of the hydraulic pump station is re-measured after tightening is completed.

[0018] Preferably, in step S4, the inlet and outlet ports of the hydraulic pump station are aligned with the hydraulic system pipeline, the seals are installed, the connecting bolts are tightened according to the torque requirements, and the sealing is checked.

[0019] The present invention can achieve the following beneficial effects: 1. Claw jacks solve the problem of not being able to fit a transport trolley under low-profile equipment; remote-controlled electric active pallet jacks enable horizontal movement and flexible steering without human intervention; crowbars, as auxiliary tools, solve the problem of gaps at the end when the jacks are withdrawn. The overall effect of the combination of these three is far greater than the simple sum of their individual uses.

[0020] 2. The entire tool set is low in height and occupies very little space, eliminating the need for large passageways required by overhead cranes, forklifts, or electric forklifts. It is especially suitable for locations without lifting capabilities, such as hoisting machine rooms and areas with dense equipment.

[0021] 3. It can be turned at any angle via remote control, completely eliminating the limitations of manual pushing or pulling or crowbar-assisted steering, and solving the problem of difficult steering of traditional rollers and ordinary ground jacks.

[0022] 4. Use shims and a level to accurately level the system, and combine this with tightening anchor bolts and connecting pipelines to ensure the operational stability of the hydraulic pump station.

[0023] 5. The equipment remains under control throughout the entire process, preventing personal injury caused by equipment tipping over or rollers popping out; remote control operation allows personnel to maintain a safe distance.

[0024] 6. The polyurethane wheels of the Di Niu Tank cause virtually no damage to epoxy flooring and ceramic tile floors, which is superior to steel rollers.

[0025] 7. All tools are commercially available standard finished products, requiring no customization, and the equipment investment cost is far lower than that of specialized handling machinery. Attached Figure Description

[0026] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is the general layout diagram of the hydraulic pump station in the gatehouse; Figure 2 This is a three-dimensional schematic diagram of the earth bull tank of the present invention; Figure 3 This is a three-dimensional schematic diagram of the claw jack of the present invention; Figure 4 This is a three-dimensional schematic diagram of the crowbar of the present invention; Figure 5 This is a construction diagram illustrating the lifting of the hydraulic pump station by the claw jack and the placement of the ground jack tank in step one of the present invention. Figure 6 This is a schematic diagram illustrating the operation of controlling the main earth bull tank using a remote control in step two of the present invention; Figure 7 This is a schematic diagram of the jack lifting state before the equipment is lowered in step three of this invention. Figure 8 This is a schematic diagram of the leveling adjustment and anchor bolts in step four of the present invention.

[0027] In the diagram: 1-Hydraulic pump station, 2-Claw jack, 3-Pulley tank, 31-Main pulley tank, 32-Auxiliary pulley tank, 33-Main pulley tank remote control, 4-Crowbar, 5-Ground, 6-Gateway room, 7-Adjusting shims, 8-Anchor bolts. Detailed Implementation

[0028] Preferred solutions include Figures 1 to 8 As shown, a method for installing a hydraulic pump station using a combination tool includes the following steps: Step 1: Lifting and inserting the pallet jack tank: Use at least two hydraulic claw jacks and insert their lower claws into the reserved gaps at both ends or three places at the bottom of the hydraulic pump station (if the gaps are insufficient, they can be pried out in advance with a pry bar). Start the claw jacks synchronously or in stages to lift the hydraulic pump station as a whole by 50mm to 100mm; Place one pallet jack at each of the three load-bearing points at the bottom of the hydraulic pump station: one is the main pallet jack, equipped with electric power and remote steering; the other two are auxiliary pallet jacks, unpowered and driven by the system. Adjust the upper surfaces of the three pallet jacks to keep them basically level. Slowly release the claw jacks so that the hydraulic pump station can be smoothly placed on the pallet jack, and then remove the jacks.

[0029] Step Two: Use the main ground bull tank for remote control to move and turn: The operator is located on one side of the hydraulic pump station and controls the main earth bull tank with a remote control, using its electric power to drive the equipment to move horizontally. When a turn is required: 1) If the main ground bull tank is located at the front of the equipment's direction of travel, then remotely control its turning direction to be consistent with the equipment's required turning direction; 2) If the main ground bull tank is located at the rear of the equipment's direction of travel, then remotely control its turning direction to be opposite to the equipment's required turning direction.

[0030] The auxiliary earth-bull tank moves with the vehicle, requiring no additional operation.

[0031] Step 3: Precise Fine-tuning and Positioning: Using the remote control micro-motion function of the main ground bull tank, the position of the hydraulic pump station is repeatedly adjusted to ensure that it is precisely aligned with the anchor bolts or positioning lines of the installation foundation.

[0032] Step 4: Equipment Landing Use the claw jack again to insert it into the bottom of the hydraulic pump station (avoiding the position of the pallet jack) and lift the equipment to the height where the pallet jack can be pulled out. The three ground-bull tanks were withdrawn one by one. Slowly release the claw jacks to lower the hydraulic pump station onto the mounting base. When finally removing the jacks, if the gap between the lower claws is too small, use a pry bar to gently pry up the edge of the equipment, leaving a gap for removing the jacks.

[0033] 1) Step 5: Equipment Installation and Fixing: Levelness adjustment: Place adjusting shims (wedge shims or flat shims) between the hydraulic pump station base and the mounting base. Use a level or frame level to check the longitudinal and lateral levelness of the pump station. Adjust the height of the shims (knock in or out the wedge shims, add or remove thin shims) to make the levelness meet the requirements of the equipment technical documents, usually not greater than 0.1mm / m.

[0034] 2) Fixing: Install anchor bolts, and use a torque wrench to tighten the nuts symmetrically and in stages to the predetermined torque to prevent tilting. After tightening, re-measure the levelness. If there is any change, readjust. For projects without anchor bolts, directly weld and fix them to the pre-embedded foundation plate.

[0035] 3) Final inspection: Check the levelness and bolt tightness, and record the installation data.

[0036] Example 1: A hydraulic pump station weighing approximately 8 tons needed to be installed in the gatehouse of a water conservancy project. The relocation distance was 10 meters, passing through a 90° right-angle bend, with a passage width of only 0.6 meters. There were no overhead cranes, forklifts, or electric forklifts in the machine room. The method of this invention was used for installation and placement.

[0037] Tools needed: Main Earth Bull Tank: Rated load 5 tons, equipped with 24V electric drive wheels and wireless remote control, can steer independently; Auxiliary pallet jack tank: Two polyurethane wheeled pallet jacks with a rated load of 3 tons. Claw jacks: each unit has a rated lifting capacity of 5 tons, 2 units in total; Adjusting shims: 4 sets of wedge shims, 8 flat shims; Crowbar: One hexagonal steel crowbar, 1.2 meters long and 30 mm in diameter.

[0038] Implementation process: Lifting and Inserting the Tanks: Use a pry bar to create a gap of approximately 10mm at the bottom of the hydraulic pump station. Insert the lower jaws of two claw jacks into the sides of the equipment's bottom. Two operators simultaneously start the jacks, lifting the entire equipment to a height of approximately 50mm. Place padding blocks under the equipment. Depressurize the jacks to temporarily support the equipment with the padding blocks, then push the lower jaws of the jacks fully into the bottom of the equipment. Simultaneously lift again to a height of 100mm. Place one main pallet jack (positioned at the front in the direction of travel) and two auxiliary pallet jacks at the three support points at the bottom of the equipment, adjusting the top surfaces of each jack to ensure they are level. Slowly release the claw jacks, allowing the equipment to rest smoothly on the three jacks, then remove the jacks.

[0039] Remote Movement and Steering: The operator stands to the side and rear of the equipment and starts the main ground jack tank to move forward using the remote control. When moving in a straight line to a turn, since the main tank is in front, the operator uses the remote control to turn the main tank to the left (in the same direction as the equipment's required left turn). The entire equipment turns to the left, and the auxiliary tank follows suit. After turning, the equipment resumes straight-line movement until it reaches the vicinity of the installation foundation.

[0040] Precise positioning: Using the fine-tuning function of the remote control, the hydraulic pump station is moved slightly forward, backward, left, and right to ensure that the bottom hole of the equipment is precisely aligned with the foundation anchor bolts.

[0041] Lowering and removing the equipment: Insert the claw jacks back into the bottom of the equipment (avoiding the tank position), and raise the equipment to a height where the pallet jacks can be freely pulled out (approximately 80mm). Remove the main and auxiliary pallet jacks one by one. Slowly release the jacks to lower the equipment onto the mounting pads. When finally releasing the jacks, gently pry up one corner of the equipment with a crowbar to remove the jack claws.

[0042] Leveling adjustment: Place a set of wedge shims (each set consists of two wedge shims joined together) at each of the four corners of the hydraulic pump station base. Place a frame level on the machined surface of the pump station and measure the longitudinal and transverse levelness respectively. By tapping the wedge shims in and out, gradually adjust the height of each point until the longitudinal levelness reaches within 0.05mm / m and the transverse levelness reaches within 0.04mm / m. Insert flat shims outside the wedge shims to prevent loosening.

[0043] Anchor bolt tightening: Install four M24 anchor bolts with nuts. Tighten symmetrically in three stages using a torque wrench. After each tightening, re-measure the levelness. If there is any deviation, use wedge shims for fine adjustment. Once the levelness meets the requirements, the installation is complete.

[0044] Results: The entire installation process took about 40 minutes. A single person could complete the steering and fine-tuning using a remote control. There was no damage to the equipment or the ground, and the installation accuracy met the design requirements.

[0045] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A method for installing a hydraulic pump station using a combination of tools, characterized in that, Includes the following steps: S1. Use claw jacks to lift the hydraulic pump station, place three pallet jacks at the bottom of the hydraulic pump station, one of which is a main pallet jack with electric power and remote steering function, and the other two are follow-up auxiliary pallet jacks. Lower the hydraulic pump station so that it is supported on the three pallet jacks. S2. The hydraulic pump station is moved horizontally by the electric power of the main ground jack tank. The direction of the rollers of the main ground jack tank is controlled by the remote control to achieve steering. The two auxiliary ground jack tanks follow suit and move the hydraulic pump station to the vicinity of the installation foundation. S3. Use claw jacks again to lift the hydraulic pump station, remove all the pallet jacks, and lower the hydraulic pump station onto the mounting base; S4. Adjust the level of the hydraulic pump station, tighten the anchor bolts, and complete the connection between the hydraulic pump station and the external hydraulic pipeline.

2. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S1, at least two claw jacks are used in conjunction. The lower claw of the claw jack is inserted into the gap at the bottom of the hydraulic pump station. If the gap is not large enough, a crowbar is used to pry the hydraulic pump station to create a gap before inserting the lower claw.

3. The method for installing a hydraulic pump station using a combination tool according to claim 2, characterized in that, In step S1, the lifting height of the hydraulic pump station is 50mm to 100mm.

4. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S1, three ground jacks are arranged in a three-point support configuration at the load-bearing positions at the bottom of the hydraulic pump station; the main ground jack is positioned at the front or rear end of the hydraulic pump station in the direction of travel.

5. The method for installing a hydraulic pump station using a combination tool according to claim 4, characterized in that, In step S2, when the main ground-mounted tank is positioned at the front of the direction of travel, the remote steering direction is consistent with the steering direction required by the hydraulic pump station; when the main ground-mounted tank is positioned at the rear of the direction of travel, the remote steering direction is opposite to the steering direction required by the hydraulic pump station.

6. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S2, after the hydraulic pump station is moved to the vicinity of the installation foundation, its position is adjusted by the remote micro-motion function of the main ground jack tank so that the mounting hole of the hydraulic pump station is precisely aligned with the anchor bolts of the installation foundation.

7. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S3, the claw jack is inserted into the bottom of the hydraulic pump station, avoiding the position of the pallet jack. After raising the hydraulic pump station to a height where the pallet jack can be freely pulled out, all the pallet jacks are removed one by one.

8. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S4, adjusting shims are placed between the hydraulic pump station base and the mounting base. A leveling tool is used to check the longitudinal and lateral levelness of the hydraulic pump station. The levelness is adjusted to meet the equipment installation specifications by adjusting the height of the shims.

9. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S4, a torque wrench is used to tighten the anchor bolts and nuts in a symmetrical and phased manner according to the predetermined torque. After tightening, the levelness of the hydraulic pump station is re-measured.

10. The method for installing a hydraulic pump station using a combination tool according to claim 1, characterized in that, In step S4, align the inlet and outlet ports of the hydraulic pump station with the hydraulic system pipeline, install the seals, tighten the connecting bolts according to the torque requirements, and complete the sealing check.

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