Device and method for replacing a wire rope of a casting suspension
Patent Information
- Application Number
- CN202611186866.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-08-06
- Publication Date
- 2026-10-27
AI Technical Summary
[0013]与现有技术相比，本发明的优点在于：利用合理的制作装置解决了钢丝绳更换过程中繁琐的维修工作，利用机械传动替代人工操作，并且利用合理的方式方法，解决了更换钢丝绳步骤，节省更换时间，由原来的12小时更换，节省为7小时更换，为车间高产稳产量打下良好基础，提高了作业效率。其主要技术特征：1、利用卷筒上的旧钢丝绳以旧带新钢丝绳，割断楔套上的旧钢丝绳楔套头放置地面与新钢丝绳头子焊接碰头，卷筒收卷旧的钢丝绳把四根新钢丝绳带上卷筒。2、利用制作的旋转托盘使新钢丝绳不用先展开，直接放置在旋转托盘上，随着卷筒的动作被动旋转释放钢丝绳，过程中只要一个工人扶持就解决了新钢丝绳的释放；3、吊装楔套头利用卷扬机和转向滑轮组解决了人工拉楔套头的繁重体力问题；4、精细的定尺四根钢丝绳余量、及制作楔套头尺寸，精确到毫米级定尺，节省了龙门架调整水平的工序。本申请更换钢丝绳的装置及方法能有效的减少了劳动强度，减少了繁琐的操作维修步骤，节省了铸造吊的停机时间，提高了分厂的炼钢产量，并且极具在炼钢分厂具有推广价值，带动整个铸造吊检修作业的高效率、高标准。
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Figure CN122977258A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of casting crane technology, specifically to a method for replacing the wire rope of a casting crane. Background Technology
[0002] The casting cranes in steel plants are mainly used for lifting steel ladles. A typical structure of a single casting crane includes two gantry cranes, two balance beams, and two drums. The two gantry cranes are arranged horizontally opposite each other. Above each gantry crane is a balance beam and a drum, and hooks are suspended below each gantry crane. Each gantry crane is connected to the two ends of the balance beams by a wire rope and pulley system. Wedge heads are installed at both ends of the balance beams. One end of the wire rope is fixed to the wedge head, and the other end is wound upwards around the drum and fixed by the drum pressure plate. The drum is driven to rotate, causing the wire rope to be wound and released on the drum, thereby controlling the lifting and lowering of the gantry crane and realizing the lifting and transport of the steel ladle.
[0003] A single casting crane involves four independent wire ropes. Routine maintenance of these wire ropes is time-consuming and labor-intensive. Because there are four independent wire ropes, a single replacement must involve replacing all four simultaneously to ensure the gantry crane itself and the two gantry cranes are at the same horizontal level. Each wire rope replacement takes 10-12 hours, making the work tedious and the operation difficult for personnel. During replacement, all four wire ropes are released manually. The wire rope reel is held in place by the casting crane's auxiliary hook, and the reel is manually rotated on the ground. Simultaneous and synchronized release of all four wire ropes requires a high degree of coordination among the operators. Especially when wedge-heading one end of the wire rope, the sizing accuracy of the four wire ropes is extremely critical. Precise sizing of the wire rope allowance is required; otherwise, the balance beam, the gantry crane itself, and the two gantry cranes will become unbalanced. Several adjustments are needed on-site to achieve the required level, delaying maintenance and impacting production schedules. Summary of the Invention
[0004] In view of the above-mentioned technical status, the purpose of this application is to provide a device and method for replacing wire ropes of a casting crane, so as to realize the replacement of multiple wire ropes of a single casting crane.
[0005] The technical solution adopted by this invention to solve the above problems is as follows: a device for replacing steel wire ropes in a casting crane, involving two sets of horizontally opposite lifting mechanisms. Each set of lifting mechanisms includes a gantry frame, a balance beam, a drum, and two steel wire ropes arranged from bottom to top. Pulley blocks are installed at both ends of the gantry frame, both ends of the balance beam, and both ends of the drum. The two steel wire ropes are symmetrically wound up and down through the pulley blocks at both ends of the gantry frame and the balance beam, and then upwards through the pulley blocks at both ends of the drum before being wound around the drum ends. One end of the steel wire rope is fixed with a wedge head on the balance beam, and the other end is pressed against the drum for fixation. The drum's rotating shaft is horizontally supported by a bearing seat and driven to rotate to synchronously release or wind up the wire ropes at both ends, thereby raising and lowering the gantry. Its features include: a rotating tray for passively releasing new wire ropes and a hoisting mechanism for hoisting wedge heads. Four rotating trays are arranged in pairs below the two lifting mechanisms for releasing new wire ropes. The hoisting mechanism includes a steering pulley block and a winch. When reinstalling the wedge head to the balance beam, the pull rope released from the winch sequentially passes around the steering pulley block and its end is temporarily connected to the wedge head to lift it.
[0006] Preferably, each gantry crane has two plate hooks pinned to its bottom, and the two plate hooks of a single gantry crane are at the same horizontal height, thereby ensuring the stability of the steel ladle hoisting operation.
[0007] Preferably, multiple drum pressure plates are provided at both ends of the drum to fix the other end of the wire rope to the drum. Each wire rope wound on the drum generally requires 3-5 drum pressure plates to fix its end.
[0008] Preferably, the drum pressure plate has two grooves, which respectively press down on two adjacent turns of the wire rope wound on the drum, and the drum pressure plate is pressed onto the surface of the drum by fasteners.
[0009] Preferably, the wedge head is pinned to the balance beam, such as by fixing it with a wedge shaft.
[0010] Preferably, the rotating tray includes a base, a rotating shaft, a bearing, and a turntable. The rotating shaft passes through the bearing and stands upright on the base. The bearing is mounted on the base. The turntable is then mounted on the bearing and the turntable is fixedly assembled with the bearing. The turntable can rotate freely horizontally around the rotating shaft. A new steel wire rope is wound on the turntable.
[0011] The method for replacing the wire rope in the above-mentioned casting hoisting structure includes the following steps: Step 1: Place 4 rolls of new steel wire rope on the rotating tray. The operator rotates the tray to check for any obstruction. Step 2: Start the drum and release the old wire rope until the gantry crane is lowered to the ground, so that the old wire rope of the casting crane is in a slack state. Remove the wedge head from the balance beam, cut off the end of the old wire rope of the wedge head, and let the old wire rope hang down to the ground. There are a total of 4 old wire ropes in the two lifting mechanisms. Weld the ends of the 4 hanging old wire ropes to the ends of the new wire ropes on the rotating tray. Step 3: Restart the drum. The drum rewinds the wire rope. The four old wire ropes on the drum, carrying the new wire rope, travel along the path of the old wire ropes. The rotating tray passively releases the new wire rope until the front end of the new wire rope is wound onto the drum. At the same time, four operators manually rotate the rotating tray to slowly release the wire rope. After the new wire rope has wound two to three times on the drum, it is cut at the weld between the old and new wire ropes. The operators remove the new wire rope from the drum, clamp the ends of the four new wire ropes with wire rope clamps, and suspend them on the support points around the drum so as not to affect the rotation of the drum. Step 5: Restart the drum to release the old wire rope on the drum. Remove the drum pressure plate used to fix the end of the old wire rope on the drum. Completely remove the old wire rope from the drum. Then, the operator manually rewinds the new wire rope onto the drum and uses the drum pressure plate to fix the end of the new wire rope onto the drum. Start the drum and let the new wire rope wind 8-10 times on the drum. Step 6: After all the new steel wire ropes on the ground have passed through the pulley system of the gantry frame, the remaining steel wire ropes are cut to length. Step 7: Measure the same length at the ends of the four new steel wire ropes and make wedge heads. Use the cast lifting hook to tighten the wedge heads. Step 8: Use the hoisting mechanism to lift the four wedge heads onto the balance beam, then connect the wedge heads to the corresponding wedge shafts on the balance beam. Start the drum to wind up the wire rope and slowly raise the gantry until the gantry and the hooks are off the ground. After the hooks are off the ground, measure the horizontal height of the two hooks. The difference in horizontal height between the two hooks should be controlled within 1 cm. If it is not within the range, direct the operator to lower the gantry hooks back to the ground to adjust the level. After adjusting the level, start the lifting and lowering limit switches of the casting crane and clean up the site after the work is completed and materials are used up.
[0012] Preferably, in step six, when determining the length of the remaining wire rope, the remaining wire rope length of the gantry pulley block is manually compared with the wire rope of the pre-prepared design length, so that the remaining wire rope from the gantry pulley block is determined to the design length.
[0013] Compared with existing technologies, the advantages of this invention are: it solves the tedious maintenance work in the process of replacing wire ropes by using a reasonable manufacturing device, replaces manual operation with mechanical transmission, and uses reasonable methods to solve the replacement steps, saving replacement time from the original 12 hours to 7 hours, laying a good foundation for high and stable output in the workshop and improving work efficiency. Its main technical features are: 1. Using the old wire rope on the drum to carry the new wire rope, the old wire rope wedge head on the wedge sleeve is cut off and placed on the ground to weld the head of the new wire rope together, and the drum winds up the old wire rope to bring the four new wire ropes onto the drum. 2. By utilizing a specially designed rotating pallet, new wire ropes can be placed directly on the pallet without being unrolled first. The ropes are passively released as the drum rotates, requiring only one worker for support during the release process. 3. The hoisting of the wedge head utilizes a winch and a guide pulley system, eliminating the heavy physical labor required for manually pulling the wedge head. 4. Precise length control of the four wire rope allowances and the wedge head dimensions, accurate to the millimeter, saves the step of adjusting the gantry crane's level. This proposed device and method for replacing wire ropes effectively reduces labor intensity, streamlines operation and maintenance procedures, saves downtime for the foundry crane, increases steelmaking output in the branch plant, and has significant potential for widespread adoption in the steelmaking branch plant, driving high efficiency and high standards in the entire foundry crane maintenance operation. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the wire rope replacement operation of the casting hoisting device in an embodiment of the present invention; Figure 2 This is a schematic diagram of the operation of lifting the hoisting wedge head to the balance beam in the later stage of the wire rope replacement operation in an embodiment of the present invention. Figure 3 This is a schematic diagram of the structure of the wire rope rotating tray in an embodiment of the present invention; Figure 4 This is an axial sectional view of the drum in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the roll pressure plate in an embodiment of the present invention; Figure 6 This is an axial sectional view of the pulley blocks installed at both ends of the drum in an embodiment of the present invention; Figure 7 This is a schematic diagram of the installation structure of the gantry frame below the balance beam (not shown in the figure) in an embodiment of the present invention; Figure 8 for Figure 7 Side view; In the diagram, 1 is the gantry frame, 2 is the balance beam, 3 is the drum, 4 is the plate hook, 5 is the wire rope, 6 is the wedge head, 7 is the rotating tray, 8 is the drum pressure plate, 701 is the base, 702 is the shaft, 703 is the bearing, and 704 is the turntable. Detailed Implementation
[0015] The present invention will be further described in detail below with reference to the accompanying drawings. The embodiments described are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention. The textual descriptions in this embodiment correspond to the accompanying drawings, and the descriptions involving orientation are also based on the descriptions in the accompanying drawings, and should not be construed as limiting the scope of protection of the present invention.
[0016] like Figure 1-8 As shown, the casting crane wire rope replacement device of this embodiment involves two horizontally opposite sets of lifting mechanisms, a rotating pallet 7, and a hoisting mechanism. Each set of lifting mechanisms includes a gantry frame 1, a balance beam 2, and a drum 3 arranged from bottom to top, as well as two wire ropes 5. Two plate hooks 4 are pinned to the bottom of each gantry frame 1 and can be disassembled and installed individually. The four plate hooks of each set of lifting mechanisms are at the same horizontal height.
[0017] Pulley blocks are installed at both ends of the gantry frame 1, both ends of the balance beam 2, and both ends of the drum 3. Two steel wire ropes 5 are symmetrically wound up and down through the pulley blocks at both ends of the gantry frame 1 and the balance beam 2, respectively. Then, they are wound upwards through the pulley blocks at both ends of the drum 3 before being wound around the drum ends. One end of the steel wire rope 5 is made into a wedge head 6 and fixed to the wedge shaft on the balance beam 2. The other end is fixed to the surface of the drum 3 by multiple drum pressure plates 8. The drum pressure plates 8 have two grooves, which respectively press down on two adjacent turns of the steel wire rope wound on the drum. The drum pressure plates 8 are bolted to the surface of the drum 3. The rotating shaft of the drum 3 is horizontally supported by bearing seats and driven to rotate to synchronously release or rewind the steel wire ropes 5 at both ends, realizing the lifting and lowering of the gantry frame.
[0018] The rotating tray 7 is used for the passive release of the new wire rope 5. There are four rotating trays 7, arranged in pairs below the two lifting mechanisms for the synchronous release of the new wire rope. The rotating tray includes a base 701, a rotating shaft 702, a bearing 703, and a turntable 704. The rotating shaft 702 passes through the bearing 703 and stands upright on the base 701. The bearing 703 is mounted on the base 701. The turntable 704 is then mounted on the bearing 703 and is fixedly assembled with the bearing 703. The bearing allows the turntable 704 to rotate freely around the rotating shaft 702. The new wire rope is wound on the turntable 704. When the old wire rope pulls the new wire rope towards the drum, the new wire rope is released freely from the rotating tray 7.
[0019] The hoisting mechanism is used to hoist the wedge head 6 at the end of the new wire rope to the balance beam 2 during the later stages of wire rope replacement. The hoisting mechanism includes a steering pulley block and a winch. When reinstalling the wedge head to the balance beam, the pull rope released from the winch passes around the steering pulley block in sequence. The end of the pull rope is temporarily connected to the new wedge head manually. The pull rope is used to lift the wedge head to the balance beam, and the steering pulley block is temporarily installed above the balance beam.
[0020] The working method of the wire rope replacement device for a casting crane is characterized by the following steps: (1) Preparation: Place four (new) steel wire ropes on the rotating pallet and rotate the pallet by hand. There is no jamming.
[0021] (2) Rotate the drum to release the (old) wire rope and lower the gantry to the ground. The wire rope on the gantry is not under force and is in a slack state. Cut off the wedge head of the (old) wire rope on the balance beam so that the (old) wire rope hangs down to the ground. Weld the four hanging old wire ropes to the (new) wire rope on the rotating tray to prepare for the replacement of the old with the new.
[0022] (3) Instruct the operator to rotate the drum so that the old wire rope carries the new wire rope along the path of the old wire rope until the four old wire ropes on the drum slowly wind the new wire rope onto the drum. At the same time, four maintenance personnel hold the rotating tray and rotate it slowly, just enough to keep up with the winding process of the new wire rope on the drum, so that the new wire rope is tightly wound on the drum.
[0023] (4) After the new wire rope is wound three times on the drum, it is cut at the weld between the old and new wire ropes. The four new wire ropes are unwound from the drum, clamped with wire rope clamps, and hung on the railings or support points around the drum without affecting the rotation of the drum.
[0024] (5) Next, instruct the operator to rotate the drum, release the old wire rope on the drum, remove the drum pressure plate used to hold the old wire rope, and completely release the old wire rope; then manually rearrange the new wire rope, manually rewind the end of the new wire rope onto the drum, and use the drum pressure plate to hold down 4 coils of the new wire rope. There are 5 pressure plates at one end of the drum, and 10 pressure plates at both ends of the drum to hold down the wire rope end. Instruct the operator to start the drum and lift the new wire rope. When the drum is full of about 8-10 turns, stop lifting the drum.
[0025] (6) All the steel wire ropes on the ground pass through the pulley system on the gantry. About 10 meters are left. Using a 10-meter 6mm steel wire rope that has been prepared in advance, manually and slowly compare the remaining 10 meters along the pulley system of the gantry to ensure the accuracy of the cut. It is not recommended to use a measuring tape here because the steel wire rope is bent and the measurement with a measuring tape is inaccurate. It is more accurate to use a 10-meter thin steel wire rope that has been set in advance to compare by touch. This will ensure that the work process is reduced and the workload is reduced so that the gantry does not need to be adjusted.
[0026] (7) Measure 2.5 meters at the end of the four new steel wire ropes to ensure they are all the same length, make wedge heads, and tighten the wedge heads with the casting hook.
[0027] (8) Next, use a winch to change the direction of the four wedge heads with the help of the steering pulley and install them on the four wedge shafts of the casting crane balance beam. Then, direct the operator to slowly lift the crane until the gantry crane and the plate hook are off the ground. When the plate hook is about 1.7 meters off the ground, it should be about level with the ground. Use a spirit level to measure the level of the plate hook. Generally, the level of the two plate hooks should not exceed 1 / 1000 and should be controlled within 1 cm. (No level adjustment is required if the above operation steps are followed). If it is not within the range, the operator should be directed to readjust the level of the gantry crane plate hook to the ground. After adjusting the level, adjust the lifting and lowering limits of the casting crane. After the work is completed and the materials are used up, clean up the site.
[0028] The technical effects of the above-mentioned device and method are: improved maintenance progress, reduced labor intensity, reduced workflow, and increased output. It is worth promoting in the field of steel wire rope replacement for casting crane maintenance.
[0029] In addition to the above embodiments, the present invention also includes other embodiments. All technical solutions formed by equivalent transformation or equivalent substitution should fall within the protection scope of the claims of the present invention.
Claims
1. A device for replacing wire ropes in a casting crane, comprising two horizontally opposing lifting mechanisms. Each lifting mechanism includes a gantry frame, a balance beam, and a drum arranged from bottom to top, as well as two wire ropes. Pulley blocks are installed at both ends of the gantry frame, the balance beam, and the drum. The two wire ropes are symmetrically wound up and down through the pulley blocks at both ends of the gantry frame and the balance beam, and then upwards through the pulley blocks at both ends of the drum before being wound around the drum ends. One end of each wire rope is fixed with a wedge head on the balance beam, and the other end is pressed against the drum for fixation. The drum's shaft is horizontally supported by a bearing seat and driven to rotate to synchronously release or rewind the wire ropes at both ends, thereby achieving the lifting and lowering of the gantry frame. The device is characterized by: It also includes a rotating pallet for passively releasing new wire ropes and a hoisting mechanism for hoisting wedge heads. There are four rotating pallets, arranged in pairs below the two lifting mechanisms for releasing new wire ropes. The hoisting mechanism includes a steering pulley block and a winch. When reinstalling the wedge head to the balance beam, the pull rope released from the winch passes through the steering pulley block in sequence and is temporarily connected at the end to the wedge head to lift the wedge head.
2. The device for replacing the wire rope of a casting crane according to claim 1, characterized in that: Two plate hooks are pinned to the bottom of each gantry frame, and the two plate hooks of a single gantry frame are horizontally aligned.
3. The device for replacing the wire rope of a casting crane according to claim 1, characterized in that: Multiple drum pressure plates are provided at both ends of the drum, and the other end of the wire rope is fixed to the drum by the drum pressure plates.
4. The device for replacing the wire rope of a casting crane according to claim 3, characterized in that: The drum pressure plate has two grooves, which respectively press down on two adjacent turns of the wire rope wound on the drum. The drum pressure plate is pressed onto the surface of the drum by fasteners.
5. The device for replacing the wire rope of a casting crane according to claim 3, characterized in that: The wedge head is pinned to the balance beam.
6. The device for replacing the wire rope of a casting crane according to claim 1, characterized in that: The rotating tray includes a base, a rotating shaft, a bearing, and a turntable. The rotating shaft passes through the bearing and stands upright on the base. The bearing is mounted on the base. The turntable is then mounted on the bearing and the turntable is fixedly assembled with the bearing. The turntable can rotate freely horizontally around the rotating shaft. A new steel wire rope is wound on the turntable.
7. A method for replacing a casting hoisting wire rope based on the device described in any one of claims 1-6, characterized in that: Includes the following steps: Step 1: Place 4 rolls of new steel wire rope on the rotating tray. The operator rotates the tray to check for any obstruction. Step 2: Start the drum and release the old wire rope until the gantry crane is lowered to the ground, so that the old wire rope of the casting crane is in a slack state. Remove the wedge head from the balance beam, cut off the end of the old wire rope of the wedge head, and let the old wire rope hang down to the ground. There are a total of 4 old wire ropes in the two lifting mechanisms. Weld the ends of the 4 hanging old wire ropes to the ends of the new wire ropes on the rotating tray. Step 3: Restart the drum. The drum rewinds the wire rope. The four old wire ropes on the drum, carrying the new wire rope, travel along the path of the old wire ropes. The rotating tray passively releases the new wire rope until the front end of the new wire rope is wound onto the drum. At the same time, four operators manually rotate the rotating tray to slowly release the wire rope. After the new wire rope has wound two to three times on the drum, it is cut at the weld between the old and new wire ropes. The operators remove the new wire rope from the drum, clamp the ends of the four new wire ropes with wire rope clamps, and suspend them on the support points around the drum so as not to affect the rotation of the drum. Step 5: Restart the drum to release the old wire rope on the drum. Remove the drum pressure plate used to fix the end of the old wire rope on the drum. Completely remove the old wire rope from the drum. Then, the operator manually rewinds the new wire rope onto the drum and uses the drum pressure plate to fix the end of the new wire rope onto the drum. Start the drum and let the new wire rope wind 8-10 times on the drum. Step 6: After all the new steel wire ropes on the ground have passed through the pulley system of the gantry frame, the remaining steel wire ropes are cut to length. Step 7: Measure the same length at the ends of the four new steel wire ropes and make wedge heads. Use the cast lifting hook to tighten the wedge heads. Step 8: Use the hoisting mechanism to lift the four wedge heads onto the balance beam, then connect the wedge heads to the corresponding wedge shafts on the balance beam. Start the drum to wind up the wire rope and slowly raise the gantry until the gantry and the hooks are off the ground. After the hooks are off the ground, measure the horizontal height of the two hooks. The difference in horizontal height between the two hooks should be controlled within 1 cm. If it is not within the range, direct the operator to lower the gantry hooks back to the ground to adjust the level. After adjusting the level, start the lifting and lowering limit switches of the casting crane and clean up the site after the work is completed and materials are used up.
8. The method according to claim 7, characterized in that: Step six: When determining the length of the remaining wire rope, use a pre-prepared wire rope of the designed length to manually compare the length of the remaining wire rope in the gantry pulley block, so that the remaining wire rope from the gantry pulley block is all measured to the designed length.