A novel electric shovel bucket rope replacement device that eliminates the need for a crane

Abstract

This utility model discloses a novel crane-free bucket rope replacement device for electric shovels, relating to the field of electric shovel technology. The electric shovel includes a machine house and a lifting mechanism. The lifting mechanism includes a drum, four bucket ropes, a sheave, and four rope grooves. The drum is rotatably mounted inside the machine house. The bucket rope replacement device includes a base plate, a pair of support frames, and four winding mechanisms. The base plate is fixedly mounted inside the machine house and located behind the drum. The pair of support frames are fixedly mounted on the base plate, with their front sides corresponding to the left and right sides of the drum, respectively. This utility model places the four winding mechanisms inside the electric shovel's machine house. The old bucket rope is released from the lifting mechanism by the wire rope on the winding mechanism, and the new bucket rope is pulled back to the lifting mechanism by the wire rope reeling in, completing the bucket rope replacement. Four bucket ropes can be replaced at once. The replacement method is simple and convenient, improving work efficiency, reducing labor intensity, eliminating the need for cranes or other auxiliary equipment, and saving maintenance costs.

Description

Technical Field

[0001] This utility model relates to the field of electric shovel technology, specifically a novel electric shovel bucket rope replacement device that eliminates the need for a crane. Background Technology

[0002] The WK-35 electric shovel is a core piece of production equipment in open-pit coal mines. During maintenance, the efficiency of spare parts replacement greatly affects the equipment's production efficiency. Over long-term use, the shovel's bucket rope will experience wear, aging, and may even become damaged, necessitating its replacement.

[0003] The current method mainly relies on auxiliary equipment such as cranes and manual labor to replace bucket ropes for maintenance. Personnel disassemble the end of the bucket rope connected to the drum, and then use a crane to pull the bucket rope away from the outside. Then, the new bucket rope is installed on the four rope grooves of the sheave with the help of a crane and manual labor, and then connected to the drum. Moreover, the four bucket ropes can only be replaced one by one and cannot be done simultaneously. The whole process consumes a lot of manpower, occupies auxiliary equipment such as cranes, has high maintenance costs, takes a long time to replace bucket ropes, and has low replacement efficiency. Utility Model Content

[0004] To address the aforementioned shortcomings of existing technologies, this utility model provides a novel crane-free bucket rope replacement device for electric shovels. Four winding mechanisms are installed inside the shovel's shed. The old bucket rope is released from the lifting mechanism via wire rope on the winding mechanism, and the new bucket rope is pulled back to the lifting mechanism via wire rope winding, thus completing the bucket rope replacement. Four bucket ropes can be replaced at a time. The replacement method is simple and convenient, improving work efficiency, reducing labor intensity, eliminating the need for cranes or other auxiliary equipment, and saving maintenance costs.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a novel electric shovel bucket rope replacement device without crane. The electric shovel includes a machine shed and a lifting mechanism. The lifting mechanism includes a drum, four bucket ropes, a sheave, and four rope grooves. The drum is rotatably mounted inside the machine shed. The bucket rope replacement device includes a base plate, a pair of support frames, and four winding mechanisms. The base plate is fixedly mounted inside the machine shed and located behind the drum. The pair of support frames is fixedly mounted on the base plate, with the front of each pair of support frames corresponding to the left and right sides of the drum. Each support plate has a pair of support plates fixedly mounted on it, and the pair of support plates are designed to correspond vertically. The four winding mechanisms are respectively mounted on the two pairs of support plates. Each winding mechanism includes a motor, a reducer, a drum, and a fixed plate. The reducer and the fixed plate are respectively mounted on both sides of the upper surface of the support plate. The drum is rotatably mounted between the reducer and the fixed plate. The output shaft end of the reducer is fixedly connected to the shaft end of the drum. The motor is fixedly mounted on the reducer, and the output end of the motor is fixedly connected to the input shaft end of the reducer. A steel wire rope is wound on the drum.

[0006] Preferably, a rope guide frame is provided between the reducer and the fixed plate and on the outside of the drum.

[0007] Preferably, the reducer is equipped with a brake.

[0008] Preferably, the four motors can be controlled and operated independently.

[0009] This utility model provides a novel device for replacing the bucket rope of an electric shovel without the need for a crane, which has the following advantages:

[0010] 1. This utility model sets four winding mechanisms inside the shed of the electric shovel. The old bucket rope is released by the wire rope on the winding mechanism and the new bucket rope is pulled back to the lifting mechanism by the wire rope winding, thus completing the replacement of the bucket rope. Four bucket ropes can be replaced at one time. The replacement method is simple and convenient, which improves work efficiency, reduces the labor intensity of personnel, eliminates the need for auxiliary equipment such as cranes, and saves maintenance costs.

[0011] 2. In this utility model, the four winding mechanisms can also work independently, and a single bucket rope can be replaced individually, improving practicality; a rope guide frame is set between the fixed plate and the reducer, the main function of which is to ensure that the wire rope is wound normally from the drum and to avoid misalignment or tangling. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the entire utility model;

[0013] Figure 2 This is a schematic diagram of the present invention in operation.

[0014] In the diagram: 1. Base plate; 2. Support frame; 3. Support plate; 4. Winding mechanism; 5. Wire rope; 6. Machine shed; 7. Lifting mechanism; 41. Reducer; 42. Motor; 43. Drum; 44. Fixing plate; 45. Rope guide frame; 71. Roller; 72. Hoisting rope; 73. Sheave; 74. Rope groove; 8. Brake. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0016] like Figure 1-2As shown, a novel crane-free bucket rope replacement device for an electric shovel is disclosed. The electric shovel includes a machine shed 6 and a lifting mechanism 7. The lifting mechanism 7 includes a drum 71, four bucket ropes 72, a sheave 73, and four rope grooves 74. The drum 71 is rotatably mounted inside the machine shed 6. The bucket rope replacement device includes a base plate 1, a pair of support frames 2, and four winding mechanisms 4. The base plate 1 is fixedly mounted inside the machine shed 6 and located behind the drum 71. The pair of support frames 2 are fixedly mounted on the base plate 1, with their front sides corresponding to the left and right sides of the drum 71, respectively. Each support plate 3 has a pair of support plates 3 fixedly mounted on it, with the pair of support plates 3 arranged vertically in a corresponding manner. The four winding mechanisms 4 are respectively mounted on the two pairs of support plates 3. The winding mechanism 4 includes a motor 42, a reducer 41, a drum 43, and a fixing plate 44. The reducer 41 and the fixing plate 44 are respectively disposed on both sides of the upper surface of the support plate 3. The drum 43 is rotatably disposed between the reducer 41 and the fixing plate 44. The output shaft end of the reducer 41 is fixedly connected to the shaft end of the drum 43. The motor 42 is fixedly disposed on the reducer 41, and the output end of the motor 42 is fixedly connected to the input shaft end of the reducer 41. A steel wire rope 5 is wound on the drum 43. A rope guide frame 45 is disposed between the reducer 41 and the fixing plate 44 and corresponding to the outside of the drum 43. A brake 8 is disposed on the reducer 41. The four motors 42 can be controlled to work independently.

[0017] Its detailed connection methods are well-known technologies in this field. The following mainly introduces the working principle and process, as follows:

[0018] According to the instruction manual Figure 1-2 As can be seen, when this utility model is in operation, the operator releases the old bucket rope 72 from the drum 71, and then disconnects the old bucket rope 72 from the drum 71 and connects it to the wire rope 5 in the winding mechanism 4. The wire rope 5 is then released, and the old bucket rope 72 is detached from the drum 71 and the sheave 73 and placed on the external ground. At this time, the wire rope 5 is on the sheave 73. Here, the length of the wire rope 5 is sufficient to loosen the ends of the four bucket ropes 72 to 20 meters outside the bucket. The operator then disconnects the old bucket rope 72 and connects the new bucket rope 72 to the wire rope 5. The winding mechanism 4 then winds the rope. Specifically, the motor 42 drives the drum 43 to wind the wire rope 5 through the reducer 41. The new bucket rope 72 passes through the four rope grooves 74 on the sheave 73 to the drum 71. The operator then connects the new bucket rope 72 to the drum 71, and the replacement is complete. This utility model allows for the direct replacement of four bucket ropes 72 at a time, and the replacement method is simple and convenient, improving work efficiency, reducing the labor intensity of personnel, eliminating the need for auxiliary equipment such as cranes, and saving maintenance costs.

[0019] Among them, a rope guide frame 45 is provided between the reducer 41 and the fixed plate 44 and on the outside of the drum 43 to ensure that the wire rope 5 is wound normally on the drum 43 and to avoid misalignment or entanglement.

[0020] The reducer 41 is equipped with a brake 8, which, together with the self-locking function of the motor 42, ensures that the equipment can stop quickly in an emergency, preventing damage caused by the equipment continuing to run due to inertia.

[0021] Among them, the four motors 42 can be controlled independently, and a single bucket rope 72 can be replaced individually, improving practicality.

[0022] The electrical control system that may be used in the implementation of this utility model includes:

[0023] The electrical control system adopts a distributed control architecture, with a Siemens S7-1500 series PLC as the core, and achieves high-speed communication (transmission rate 100Mbps, scan cycle ≤1ms) through the Profinet industrial Ethernet protocol. The system is divided into the following modules:

[0024] Power drive module: 380V three-phase AC power input, distributed to four servo motor drivers via Schneider GV3 series circuit breakers to ensure the stability and safety of power output;

[0025] Logic control module: The PLC integrates a safe torque shutdown (STO) function, complies with ISO13849-1PLe safety level, and supports multi-axis synchronous control and real-time fault diagnosis;

[0026] Human-machine interaction module: 12-inch Kunlun Tongtai industrial-grade touch screen (1280×800 resolution), supporting HMI dynamic graphical interface, real-time display of key parameters such as rope speed, tension, motor temperature, etc.

[0027] Optional features that may be used during the implementation of this utility model:

[0028] (1) Core hardware configuration:

[0029] Servo drive unit: It adopts Siemens multi-axis drive and is equipped with 1FT7 high dynamic servo motor (rated torque 12Nm, overload capacity 300%), supports closed-loop vector control, and achieves speed accuracy of ±0.01%.

[0030] (2) Power Management Unit:

[0031] Power supply: Schneider soft starter, which reduces the starting inrush current of the motor 42 (suppression rate ≥80%).

[0032] Control power supply: Omron switching power supply (output DC24V / 10A), which suppresses electromagnetic interference through a dual filtering circuit (common mode + differential mode).

[0033] (3) Security redundancy mechanism:

[0034] Dual-circuit emergency stop design: a hard-wired emergency stop button (response time ≤ 50ms) and a PLC soft emergency stop (via a safety input module) provide dual protection.

[0035] Braking redundancy: The servo motor has a built-in electromagnetic brake 8 (braking torque 120Nm) that is linked with an external mechanical locking device to meet the SIL3 safety level.

[0036] (4) Intelligent control algorithm:

[0037] Multi-axis synchronous control: Based on a composite algorithm of electronic gearbox (EGB) and electronic cam (CAM), the synchronization accuracy of the four winches is ≤ ±0.3mm, and the following modes are supported:

[0038] Master-slave follow mode: The winch traction speed is dynamically adjusted based on the drum speed of 43.

[0039] Independent control mode: Fine-tuning for a single bucket rope 72 (speed resolution 0.001m / s).

[0040] Adaptive tension control: The rope tension is collected in real time by a tension sensor, and the speed of the drum is dynamically adjusted to ensure that the tension is stable within the set range.

[0041] Overload protection: When the tension exceeds the threshold, a speed reduction or shutdown command is triggered to prevent equipment damage.

[0042] (5) Human-computer interaction and remote operation and maintenance:

[0043] User interface design: The touchscreen integrates a 3D dynamic model to simulate the 72-winding path of the bucket rope, supporting an automated "one-click rope change" process. The parameter setting interface allows customization of traction speed, tension threshold, and safety redundancy level.

[0044] Wireless control: Equipped with Siemens RF180C industrial-grade wireless handle (communication distance 100m, anti-interference level IP67), supporting inching, continuous and emergency operation modes.

[0045] Data Interconnection: Built-in 5G communication module, it uploads operating data to the cloud platform via MQTT protocol to realize remote fault diagnosis, automatically parse fault codes (such as E01-motor 42 overload, E02-communication timeout) and push solutions.

[0046] (6) Safety and reliability verification:

[0047] Electromagnetic compatibility testing: The system has been tested by a third-party laboratory (in accordance with the GB / T 17626 series standards). It operates stably under harsh electromagnetic environments (such as interference from electric shovel frequency converters) with a failure rate of ≤0.1%.

[0048] Environmental adaptability test: High and low temperature cycle test (-40℃ to +70℃), electrical components functioned normally.

[0049] Dust and water resistance: control cabinet IP54 protection rating, winch drive IP65 protection rating.

[0050] (7) Adaptive tension control:

[0051] The rope tension is collected in real time by a tension sensor, and the speed of the drum 43 is dynamically adjusted to ensure that the tension is stable within the set range.

[0052] Overload protection: When the tension exceeds the threshold, a speed reduction or shutdown command is triggered to prevent equipment damage.

[0053] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A novel replacement device for bucket ropes of a power shovel without a crane, the power shovel comprising a house (6) and a hoisting mechanism (7), the hoisting mechanism (7) comprising a drum (71), four bucket ropes (72), a crown sheave (73), and four rope grooves (74), the drum (71) being rotatably provided in the house (6), characterized in that, The bucket rope replacement device (72) includes a base plate (1), a pair of support frames (2), and four winding mechanisms (4). The base plate (1) is fixedly installed inside the machine shed (6) and located behind the drum (71). The pair of support frames (2) are fixedly installed on the base plate (1), with the front of the pair of support frames (2) corresponding to the left and right sides of the drum (71). Each support plate (3) is fixedly equipped with a pair of support plates (3), and the pair of support plates (3) are designed to correspond vertically. The four winding mechanisms (4) are respectively installed on the two pairs of support plates (3). Each winding mechanism (4) includes an electric motor. The machine (42), reducer (41), drum (43) and fixed plate (44) are respectively arranged on both sides of the upper surface of the support plate (3). The drum (43) is rotatably arranged between the reducer (41) and the fixed plate (44). The output shaft end of the reducer (41) is fixedly connected to the shaft end of the drum (43). The motor (42) is fixedly arranged on the reducer (41). The output end of the motor (42) is fixedly connected to the input shaft end of the reducer (41). A steel wire rope (5) is wound on the drum (43).

2. A novel rope replacement device for a shovel without a crane according to claim 1, characterized in that, A rope guide frame (45) is provided between the reducer (41) and the fixed plate (44) and on the outside of the drum (43).

3. A novel rope replacement device for a shovel without a crane according to claim 1, characterized in that, The reducer (41) is equipped with a brake (8).

4. A novel rope replacement device for a shovel without a crane according to claim 1, characterized in that, The four motors (42) can be controlled independently.

Images