A vertical speed reducer assembly tool

Abstract

This utility model discloses a vertical speed reducer assembly tool, including a trolley frame and a speed reducer body. Multiple jacks are fixedly mounted on the top of the trolley frame, and the output shafts of the multiple jacks are fixedly connected to the same support plate. The support plate is used to place the speed reducer body. Limiting components for limiting the height of the support plate are provided on both sides of the support plate. The jacks are used to synchronously adjust the height of the support plate to achieve concentricity adjustment between the speed reducer output shaft and the drive shaft. This utility model not only achieves precise adjustment through a four-point synchronous lifting mechanism—four jacks arranged in a rectangular array on the top of the trolley frame, whose piston rods jointly fix the support plate, and the flatness of the support plate is adjusted by synchronously operating the jack lifting handles, allowing the speed reducer output shaft and drive shaft to be quickly aligned—but also features a mechanical locking structure to ensure adjustment accuracy: limiting components are provided on both sides of the support plate.

Description

Technical Field

[0001] This utility model relates to the field of vertical speed reducer technology, and in particular to a vertical speed reducer assembly tool. Background Technology

[0002] The installation and dismantling of the vertical reducer on the QJ-T type crane is limited by space (operating height ≤ 2 meters, lateral space < 1.5 meters). It is necessary to alternately use a hand-operated hoist to suspend the reducer and a jack to lift the set shaft to adjust concentricity, which has three defects: 1. Low adjustment efficiency - the tools cannot be raised and lowered synchronously, resulting in an average time of 2.5 hours for concentricity adjustment, and requiring more than 3 people to work together; 2. Installation accuracy out of control – The jack lacks a locking structure after lifting, and the reducer misaligns, causing misalignment of the spline gear sleeve, resulting in a first-time installation pass rate of less than 60%. 3. Safety hazards during movement – ​​The reducer weighs over 1 ton, and the hand chain hoist needs to be moved midway, which may cause the reducer to slip, resulting in minor indentations between the output shaft spline and the reducer bushing, affecting further assembly.

[0003] The aforementioned problems increase labor costs by more than 30% and are accompanied by the risk of falls from heights, becoming a key bottleneck restricting the safe and efficient maintenance of cranes. Utility Model Content

[0004] The purpose of this utility model is to address the shortcomings of existing technologies by proposing a vertical reducer assembly tool.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A vertical speed reducer assembly tool includes a trolley frame and a speed reducer body. Multiple jacks are fixedly installed on the top of the trolley frame, and the output shafts of the multiple jacks are fixedly connected to the same support plate, which is used to place the reducer body. Both sides of the support plate are provided with limiting components for limiting the height of the support plate; The jack is used to synchronously adjust the height of the support plate in order to adjust the concentricity of the reducer output shaft and the transmission shaft.

[0006] As a further embodiment of this utility model, the limiting component includes a vertical plate fixedly connected to both sides of the support plate, a horizontal plate fixedly connected to the vertical plate, a fixing nut fixedly embedded in the horizontal plate, an adjusting bolt threadedly connected to the fixing nut, and an adjusting block fixedly connected to the top of the adjusting bolt. The rotating adjusting bolt presses its bottom end against the top surface of the trolley frame, forming a mechanical locking structure.

[0007] As a further embodiment of this utility model, the bottom of the trolley frame is rotatably connected to multiple movable wheels, and the outer wall of the movable wheels is fixedly fitted with an anti-slip pad. The anti-slip mat ensures friction when the trolley moves.

[0008] As a further improvement of this utility model, the surface of the support plate is provided with a groove for limiting the base of the reducer body.

[0009] As a further improvement of this utility model, the surface of the ball head adjusting block is processed with knurled anti-slip texture.

[0010] As a further improvement of this invention, the anti-slip mat is made of nitrile rubber.

[0011] The beneficial effects of this utility model are as follows: 1. Precise adjustment is achieved through a four-point synchronous lifting mechanism: Four jacks arranged in a rectangular array are set on the top of the trolley frame. Their piston rods are used to fix the support plate together. By operating the lifting handles of the jacks synchronously, the flatness of the support plate can be adjusted, so that the output shaft of the reducer and the transmission shaft can be quickly aligned. The concentricity adjustment time is shortened from 2.5 hours to 40 minutes, and the first-time adjustment qualification rate is increased to over 95%.

[0012] 2. Mechanical locking structure ensures adjustment accuracy: Limiting components (vertical plate, horizontal plate, fixing nut and adjusting bolt) are set on both sides of the support plate. After the jack is adjusted to the position, the adjusting bolt is rotated so that its bottom end presses against the top surface of the trolley frame to form a rigid support. This avoids the problem of repeatedly changing the position of the hand chain hoist for adjustment in the traditional method, and significantly reduces the labor intensity.

[0013] 3. Anti-slip movement system adapts to confined spaces: The four corners of the bottom of the trolley frame are equipped with moving wheels with nitrile rubber anti-slip pads. The wheels are 150 mm in diameter and covered with 5 mm anti-slip pads to ensure sufficient friction when moving on the crane rail surface and support a ±2° turning angle, adapting to the complex working environment inside the crane. Attached Figure Description

[0014] Fig. 1 This is a front view structural diagram of a vertical reducer assembly tool proposed in this utility model; Fig. 2 This is a side view of the assembly structure of a vertical speed reducer assembly tool proposed in this utility model.

[0015] In the diagram: 1. Adjusting block; 2. Adjusting bolt; 3. Support plate; 4. Jack; 5. Vertical plate; 6. Horizontal plate; 7. Trolley frame; 8. Anti-slip mat; 9. Moving wheel; 10. Fixing nut; 11. Reducer body. Detailed Implementation

[0016] 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. It should be noted that, unless otherwise expressly specified and limited, the terms "installation", "connection", and "setting" should be interpreted broadly. For those skilled in the art, the specific meaning of the above terms in this patent can be understood according to the specific circumstances.

[0017] Reference Figs. 1-2 A vertical reducer assembly tool, primarily suitable for confined spaces, comprises a trolley frame 7, a lifting mechanism, a limiting device, and a moving system. The trolley frame 7 is constructed of Q235 carbon steel welded into a rectangular frame structure. Four sets of moving wheels 9 are mounted at the four corners of the bottom. The wheels have a diameter of 150 mm and are covered with 5 mm thick nitrile rubber anti-slip pads 8 to ensure sufficient friction when moving on the crane rail surface. Four QYL10T type screw-type mechanical jacks 4 are fixed to the top of the frame with M16 bolts. The jacks 4 are arranged in a rectangular array with an adjacent spacing of 400 mm. A 20 mm thick Q345 steel plate support plate 3 is welded to the top of the piston rod of each jack. The surface of the support plate 3 is blackened and has T-slots for fixing the reducer base.

[0018] Two sets of limiting components are symmetrically arranged on both sides of the support plate 3. Each set includes a vertical plate 5 welded vertically to the side of the support plate 3, and a horizontal plate 6 welded to the top of the vertical plate 5. A Φ22 mm through hole is opened in the middle of the horizontal plate 6 and an M20 standard hexagonal fixing nut 10 is inserted. The adjusting bolt 2 is a 4.8 grade fully threaded screw with an effective thread length of 120 mm. A ball head adjusting block 1 with a diameter of 40 mm is welded to the top of the screw. The surface of the adjusting block 1 is machined with knurled anti-slip texture. After the jack 4 adjusts the support plate 3 to the target height, the operator can rotate the adjusting bolt 2 so that its bottom end presses against the top surface of the trolley frame 7 to form a mechanical locking structure.

[0019] During actual assembly, the reducer body 11 is fixed to the support plate 3 with T-bolts, and the trolley is pushed to the predetermined position below the main beam of the crane. By simultaneously operating the lifting handles of the four jacks 4, the output shaft of the reducer and the transmission shaft are initially aligned. When fine adjustment is required, a jack 4 on one side can be controlled individually for fine adjustment within a range of ±5 mm. After the concentricity is adjusted to the correct position, the adjusting bolts 2 of each set of limit components are tightened in sequence to make the support plate 3 form a rigid support. At this time, the connecting bolts between the jacks 4 and the support plate 3 can be removed, and the trolley can be moved out of the work area by moving the wheels 9 to complete the reducer installation process.

[0020] This device achieves flatness adjustment through a four-point synchronous lifting mechanism, coupled with a mechanical limit device to ensure adjustment accuracy, solving the technical problem of repeatedly changing the position of the hand-operated hoist for comparison and adjustment in traditional methods. The anti-slip wheels used in the mobile system can achieve a turning angle of ±2° in confined spaces, adapting to the complex working environment inside the crane. Actual testing has reduced the concentricity adjustment time from 2.5 hours using traditional methods to 40 minutes, and increased the first-time adjustment pass rate to over 95%, significantly reducing the labor intensity of operators.

[0021] Working principle: The trolley is placed under the reducer body (11) and the jack (4) under the trolley is lifted to make the trolley lift the reducer body (11) to be replaced. After confirming that it is stable, the pin on the top of the reducer is removed; the locking nut at the shaft end is removed and the jack (4) under the trolley is lifted. After confirming that the shaft end and the reducer gear sleeve are on the same horizontal plane, the fixing bolts on both sides of the trolley are screwed to the lifting position, and the trolley is dragged to remove the reducer; after the old reducer is removed, the new reducer is placed on the assembly trolley, and a small amount of grease is wiped on the wheel axle. After fine-tuning the concentricity of the reducer shaft sleeve and the wheel axle spline, the trolley is slowly pushed to install. If there is any jamming, fine-tuning of the jacks (4) on both sides and the adjusting bolts (2) is performed. The spline and reducer shaft sleeve are observed and the installation is carried out.

[0022] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A vertical speed reducer assembly tool, comprising a trolley frame (7) and a speed reducer body (11), characterized in that, Multiple jacks (4) are fixedly installed on the top of the trolley frame (7), and the output shafts of the multiple jacks (4) are fixedly connected to the same support plate (3). The support plate (3) is used to place the reducer body (11). Both sides of the support plate (3) are provided with limiting components for limiting the height of the support plate (3); The jack (4) is used to synchronously adjust the height of the support plate (3) in order to achieve the concentricity adjustment of the reducer output shaft and the transmission shaft.

2. The vertical reducer assembly tool according to claim 1, characterized in that, The limiting component includes vertical plates (5) fixedly connected to both sides of the support plate (3), horizontal plates (6) fixedly connected to the vertical plates (5), fixed nuts (10) fixedly embedded in the horizontal plates (6), adjusting bolts (2) threadedly connected to the fixing nuts (10), and adjusting blocks (1) fixedly connected to the top of the adjusting bolts (2). Among them, the rotating adjusting bolt (2) presses its bottom end against the top surface of the trolley frame (7) to form a mechanical locking structure.

3. The vertical reducer assembly tool according to claim 1, characterized in that, The bottom of the trolley frame (7) is rotatably connected to multiple movable wheels (9), and the outer wall of the movable wheels (9) is fixedly fitted with anti-slip pads (8). The anti-slip mat (8) ensures friction when the trolley moves.

4. The vertical reducer assembly tool according to any one of claims 1-3, characterized in that, The surface of the support plate (3) is provided with a groove for limiting the base of the reducer body (11).

5. The vertical reducer assembly tool according to claim 2, characterized in that, The surface of the adjustment block (1) is processed with knurled anti-slip texture.

6. The vertical reducer assembly tool according to claim 3, characterized in that, The anti-slip mat (8) is made of nitrile rubber.

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