Ball valve on-line cutting apparatus

Abstract

The utility model discloses a ball valve on -line cutting equipment, it includes frame, first drive mechanism, second drive mechanism, electric spark cutting spare and water circulation device, one end of frame is used for installing and locating the valve body, electric spark cutting spare is connected in the second drive mechanism, the second drive mechanism is connected on the first drive mechanism, the first drive mechanism is connected on the frame, and water circulation device includes water tank, water pump, outlet pipeline, backwater tank and backwater pipeline, and the import of water pump is connected in water tank, and one end of outlet pipeline is connected in the export of water pump, and the other end of outlet pipeline is inserted to the valve body and is towards the valve body cutting surface, and backwater tank is connected in the frame, and both ends of backwater pipeline are connected in backwater tank and water tank respectively. Thus realize the high accuracy positioning of electric spark cutting spare and cutting precision height, make the high integration and adopt modularization design, and the overall weight is light, and the structure is compact. Meanwhile, effectively avoid pollution, and further improve cutting machining precision.

Description

Technical Field

[0001] This utility model relates to an online cutting device for ball valves. Background Technology

[0002] Ball valves are widely used in fields with extremely high safety requirements, such as nuclear power plants, petrochemical plants, and long-distance pipelines. However, during long-term use, the inner bore of ball valves is prone to wear and corrosion, affecting sealing performance and service life. Traditional repair methods require disassembling and cutting the valve for repair, which is not only complex, time-consuming, and costly, but also disrupts the normal operation of the system. Furthermore, the cutting process requires water cooling and chip removal, which can cause on-site pollution, and the overall structure occupies a large space, making it unsuitable for in-sleeving repair work of ball valves in critical industrial settings such as nuclear power plants. Utility Model Content

[0003] The purpose of this invention is to overcome the above-mentioned shortcomings of existing devices and to provide an online ball valve cutting device.

[0004] This utility model is achieved through the following technical solution:

[0005] An online ball valve cutting device includes a frame, a first drive mechanism, a second drive mechanism, an electrical discharge machining (EDM) cutter, and a water circulation device. One end of the frame is used to mount and position the valve body. The EDM cutter is connected to the second drive mechanism, and the second drive mechanism is connected to and moves on the first drive mechanism to drive the EDM cutter to move in a direction close to or away from the valve body's cutting surface. The first drive mechanism is connected to and moves on the frame to drive the EDM cutter to extend into the valve body. The water circulation device includes a water tank, a water pump, an outlet pipe, a return water tank, and a return water pipe. The inlet of the water pump is connected to the water tank. One end of the outlet pipe is connected to the outlet of the water pump, and the other end of the outlet pipe extends into the valve body and faces the cut surface of the valve body. The return water tank is connected to the frame and is used to collect water flowing out of the valve body. The two ends of the return water pipe are respectively connected to the return water tank and the water tank, so that a water circulation channel is formed between the water tank, the water pump, the outlet pipe, the return water tank, and the return water pipe.

[0006] Furthermore, the water circulation device also includes a filter screen located on the water tank, and the outlet of the return water pipe is located on the filter screen, so that the water flowing out of the return water pipe is filtered through the filter screen and then flows back into the water tank.

[0007] Furthermore, the filter screen is connected to the top of the water tank, and the filter screen is located directly below the return water tank and the valve body.

[0008] Furthermore, the ball valve online cutting equipment also includes a control device, which is electrically connected to the first drive mechanism, the second drive mechanism, the EDM cutting component, and the water pump, and is used to control the opening and closing of the first drive mechanism, the second drive mechanism, the EDM cutting component, and the water pump, respectively.

[0009] Furthermore, the frame includes a mounting plate and a positioning plate. The first drive mechanism is connected to the mounting plate, and the positioning plate is connected to one end of the mounting plate. The positioning plate and the mounting plate are L-shaped. The positioning plate is provided with a plurality of positioning holes, and the plurality of positioning holes are respectively connected to the valve body through positioning elements.

[0010] Furthermore, the frame also includes multiple reinforcing ribs, all of which are connected to the mounting plate and the positioning plate.

[0011] Furthermore, the first driving mechanism includes a first slide, a first drive motor, and a first lead screw. The first drive motor is connected to the top surface of the first slide, and the bottom surface of the first slide is threaded to the first lead screw. The first drive motor is connected to the frame and is also connected to the first lead screw to drive the rotation of the first lead screw, thereby moving the first slide on the first lead screw.

[0012] Furthermore, the first drive mechanism also includes a first bearing housing, which is connected to the frame, and the first lead screw passes through the first bearing housing. A first bearing is provided between the first bearing housing and the first lead screw.

[0013] And / or, the first drive mechanism further includes a first guide rail and a first slider, the first guide rail being connected to the frame, the first slider being connected to the bottom surface of the first slide table, and the first slider being connected to the first guide rail and moving on the first guide rail.

[0014] Furthermore, the second driving mechanism includes a second slide, a second drive motor, and a second lead screw. The electrical discharge cutting component is connected to the top surface of the second slide, and the bottom surface of the second slide is threaded to the second lead screw. The second drive motor is connected to the first driving mechanism and is also connected to the second lead screw to drive the rotation of the second lead screw, thereby causing the second slide to move on the second lead screw.

[0015] Furthermore, the second drive mechanism also includes a second bearing housing, which is connected to the first drive mechanism. The second lead screw passes through the second bearing housing, and a second bearing is provided between the second bearing housing and the second lead screw.

[0016] And / or, the second drive mechanism further includes a second guide rail and a second slider, the second guide rail being connected to the first drive mechanism, the second slider being connected to the bottom surface of the second slide table, and the second slider being connected to the second guide rail and moving on the second guide rail.

[0017] The beneficial effects of this utility model are as follows:

[0018] This utility model discloses an online ball valve cutting device. A first drive mechanism and a second drive mechanism respectively drive the EDM cutting component to extend into the valve body and move along the direction close to or away from the valve body's cutting surface, thereby achieving high-precision positioning and cutting accuracy of the EDM cutting component. Furthermore, the frame, first drive mechanism, second drive mechanism, and EDM cutting component are interconnected, resulting in a highly integrated and modular design. The overall device is lightweight and compact, facilitating deployment and operation in confined spaces, making it particularly suitable for online maintenance operations in narrow spaces such as nuclear power plants. Simultaneously, a water circulation device enables real-time, efficient cooling and chip recovery, effectively preventing contamination and further improving cutting accuracy. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the ball valve online cutting device in use according to an embodiment of the present invention.

[0020] Figure 2 This is a partial structural schematic diagram of the ball valve online cutting device according to an embodiment of the present invention.

[0021] Figure 3 This is a schematic diagram of the positioning plate in an embodiment of the present utility model.

[0022] Explanation of reference numerals in the attached figures:

[0023] Rack 1

[0024] Mounting plate 11

[0025] Positioning plate 12

[0026] Positioning hole 121

[0027] Through hole 122

[0028] First drive mechanism 2

[0029] First slide 21

[0030] First drive motor 22

[0031] First lead screw 23

[0032] First bearing housing 24

[0033] First guide rail 25

[0034] First slider 26

[0035] Second drive mechanism 3

[0036] Second slide 31

[0037] Second drive motor 32

[0038] Second lead screw 33

[0039] Second bearing housing 34

[0040] Second guide rail 35

[0041] Second slider 36

[0042] Electrical Discharge Cutting Part 4

[0043] Water circulation device 5

[0044] Water tank 51

[0045] Water pump 52

[0046] Water outlet pipe 53

[0047] Return water tank 54

[0048] Return water pipe 55

[0049] Filter 56

[0050] Valve body 10

[0051] Valve body cut surface 101 Detailed Implementation

[0052] The following description of the embodiments is with reference to the accompanying drawings, which illustrate specific embodiments in which the present invention can be implemented.

[0053] like Figure 1 , Figure 2 and Figure 3As shown, this embodiment discloses an online ball valve cutting device, which includes a frame 1, a first drive mechanism 2, a second drive mechanism 3, an electric spark cutter 4, and a water circulation device 5. One end of the frame 1 is used to install and position the ball valve body 10. The electric spark cutter 4 is connected to the second drive mechanism 3. The second drive mechanism 3 is connected to the first drive mechanism 2 and moves on the first drive mechanism 2 to drive the electric spark cutter 4 to move in a direction close to or away from the valve body cutting surface 101. The first drive mechanism 2 is connected to the frame 1 and moves on the frame 1 to drive the electric spark cutter 4 to extend into the valve body 10. The first drive mechanism 2 provides driving force to insert the EDM cutting component 4 into the valve body 10. Then, the second drive mechanism 3 provides driving force to move the EDM cutting component 4 along a direction close to or away from the valve body cutting surface 101. After setting the feed rate, the cutting program is started. The EDM cutting component 4 etches away the ball valve bushing layer by layer along a preset trajectory. After cutting, the ball valve bushing is completely removed without damaging the valve body 10. The first and second drive mechanisms 2 and 3 drive the EDM cutting component 4, achieving high-precision positioning and cutting accuracy. Simultaneously, the frame 1, the first drive mechanism 2, the second drive mechanism 3, and the EDM cutting component 4 are interconnected, resulting in high integration and modular design. This enables precise online cutting and repair of the ball valve bushing using the online ball valve cutting equipment. Furthermore, the overall design is lightweight and compact, facilitating deployment and operation in confined spaces. It is particularly suitable for online maintenance operations in confined spaces such as nuclear power plants, fully meeting the technical requirements for online ball valve repair in important industrial settings like nuclear power plants, and possessing significant engineering application value.

[0054] The water circulation device 5 includes a water tank 51, a water pump 52, an outlet pipe 53, a return water tank 54, and a return water pipe 55. The inlet of the water pump 52 is connected to the water tank 51. One end of the outlet pipe 53 is connected to the outlet of the water pump 52, and the other end of the outlet pipe 53 extends into the valve body 10 and faces the valve body cutting surface 101. The return water tank 54 is connected to the frame 1 and is used to collect water flowing out of the valve body 10. The two ends of the return water pipe 55 are connected to the return water tank 54 and the water tank 51, respectively, so that a water circulation channel is formed between the water tank 51, the water pump 52, the outlet pipe 53, the return water tank 54, and the return water pipe 55. The water tank 51 contains water, and the water pump 52 provides driving force to flow the water in the water tank 51 through the outlet pipe 53 to the valve body 10, thereby enabling real-time and efficient cooling and chip recovery, effectively avoiding pollution, and further improving the cutting accuracy. After use, the water in the valve body 10 will flow into the return water tank 54 and then flow to the water tank 51 through the return water pipe 55, thereby realizing the water circulation through the water circulation channel.

[0055] The water circulation device 5 also includes a filter screen 56, which is located on the water tank 51. The outlet of the return water pipe 55 is located on the filter screen 56, so that the water flowing out of the return water pipe 55 is filtered by the filter screen 56 and then flows back into the water tank 51. The cutting residue is fed into the return water tank 54 by the electric spark cutter 4. A small amount of residue in the return water tank 54 will flow into the water tank 51 through the return water pipe 55. The filter screen 56, located at the outlet of the return water pipe 55, filters the residue in the water flowing through the return water pipe 55 and prevents it from entering the water tank 51, effectively preventing damage to the water pump 52 and ensuring high stability.

[0056] In this embodiment, the filter screen 56 is connected to the top of the water tank 51, and the filter screen 56 is located directly below the return water tank 54 and the valve body 10. The water tank 51 is located directly below the return water tank 54 and the valve body 10 and is filtered by the filter screen 56. Even if there is a leak, the water will flow into the water tank 51 through the filter screen 56, effectively avoiding on-site pollution.

[0057] The frame 1 includes a mounting plate 11 and a positioning plate 12. A first drive mechanism 2 is connected to the mounting plate 11, and the positioning plate 12 is connected to one end of the mounting plate 11, forming an L-shape with the mounting plate 11. The positioning plate 12 has multiple positioning holes 121, through which positioning elements pass and connect to the valve body 10. The valve body 10 has multiple connection holes, through which positioning elements pass and are inserted into the connection holes of the valve body 10. This allows the positioning plate 12 to be connected to the valve body 10 via the multiple positioning holes 121, enabling the ball valve online cutting equipment to connect and precisely position itself with the valve body 10, resulting in higher stability during use. Furthermore, the L-shape between the positioning plate 12 and the mounting plate 11, along with the first drive mechanism 2 mounted on the mounting plate 11, facilitates easy installation and connection.

[0058] The frame 1 also includes multiple reinforcing ribs, which are connected to the mounting plate 11 and the positioning plate 12. The reinforcing ribs 13 have a strengthening function, and the connection strength between the mounting plate 11 and the positioning plate 12 can be effectively strengthened through multiple reinforcing ribs 13, so as to achieve high structural stability of the frame 1 and further enhance high-precision positioning and operation.

[0059] The positioning plate 12 has a through hole 122 through which the EDM cutting component 4 extends into the valve body 10. Multiple positioning holes 121 are spaced around the through hole 122. A return water tank 54 is connected to the side of the positioning plate 12 facing away from the valve body 10, allowing water in the valve body 10 to flow into the return water tank 54 through the through hole 122.

[0060] In this embodiment, the first driving mechanism 2 includes a first slide 21, a first driving motor 22, and a first lead screw 23. The first driving motor 22 is connected to the top surface of the first slide 21, and the bottom surface of the first slide 21 is threadedly connected to the first lead screw 23. The first driving motor 22 is connected to the frame 1 and is also connected to the first lead screw 23 to drive its rotation, thereby moving the first slide 21 along the lead screw 23. The first driving motor 22 is mounted on the mounting plate 11. It provides driving force and drives the first lead screw 23 to rotate. The rotation of the lead screw 23 causes the first slide 21 to move linearly along it, i.e., the first slide 21 moves in the direction of extending into or retracting out of the valve body 10. Simultaneously, a high-precision first lead screw 23, in conjunction with a servo drive, achieves a feed accuracy of ±0.002mm, enabling precise motion control.

[0061] The first drive mechanism 2 also includes a first bearing housing 24, which is connected to the frame 1. A first lead screw 23 passes through the first bearing housing 24, and a first bearing is provided between the first bearing housing 24 and the first lead screw 23. The first bearing housing 24 provides support, making the first lead screw 23 more stable during rotation. Simultaneously, the first bearing reduces frictional losses on the first lead screw 23, further enabling precise motion control.

[0062] The first drive motor 22 is a miniaturized motor. Smooth feeding is achieved through this miniaturized motor and the first bearing seat 24. The moving parts are lightweight and have low inertia, effectively avoiding precision deviations caused by vibration. After cutting, the ball valve bushing is completely removed without damaging the valve body 10. There are two first bearing seats 24, with both ends of the first lead screw 23 connected to the two bearing seats 24 respectively. The first slide 21 is positioned between the two bearing seats 24. This ensures that both ends of the first lead screw 23 are supported on the two bearing seats 24, further enhancing the stability of the rotation of the first lead screw 23 and the movement of the first slide 21.

[0063] The first drive mechanism 2 also includes a first guide rail 25 and a first slider 26. The first guide rail 25 is connected to the frame 1, and the first slider 26 is connected to the bottom surface of the first slide table 21. The first slider 26 is connected to the first guide rail 25 and moves on the first guide rail 25. The first guide rail 25 provides guidance, resulting in higher stability for the movement of the first slider 26 and the first slide table 21 on the first guide rail 25, further enabling precise motion control. Simultaneously, the use of a compact first lead screw 23 and first guide rail 25 results in high driving efficiency and low inertia, which is beneficial for rapid response and precise positioning. There are two first guide rails 25, spaced apart on the mounting plate 11, with the first lead screw 23 located in the middle of the two first guide rails 25.

[0064] The second drive mechanism 3 includes a second slide 31, a second drive motor 32, and a second lead screw 33. An EDM cutting element 4 is connected to the top surface of the second slide 31, and the bottom surface of the second slide 31 is threadedly connected to the second lead screw 33. The second drive motor 32 is connected to the first drive mechanism 2 and is also connected to the second lead screw 33 to drive its rotation, thereby moving the second slide 31 along the lead screw 33. The second drive motor 32 is mounted on the first slide 21, providing driving force and driving the second lead screw 33 to rotate. This rotation of the lead screw 33 causes the second slide 31 to move linearly along it, i.e., the second slide 31 moves towards or away from the valve body cutting surface 101. Simultaneously, a high-precision second lead screw 33, combined with a servo drive, achieves a feed accuracy of ±0.002mm, enabling precise motion control.

[0065] The second drive mechanism 3 also includes a second bearing housing 34, which is connected to the first drive mechanism 2. The second lead screw 33 passes through the second bearing housing 34, and a second bearing is provided between the second bearing housing 34 and the second lead screw 33. The second bearing housing 34 provides support, making the second lead screw 33 more stable during rotation. At the same time, the second bearing reduces friction loss on the second lead screw 33, further enabling precise motion control.

[0066] The second drive motor 32 is a miniaturized motor. Smooth feeding is achieved with the help of this miniaturized motor and the second bearing seat 34. The moving parts are lightweight and have low inertia, effectively avoiding precision deviations caused by vibration. After cutting, the ball valve bushing is completely removed without damaging the valve body 10. There are two second bearing seats 34, with both ends of the second lead screw 33 connected to the two bearing seats 34 respectively. The second slide 31 is positioned between the two bearing seats 34. This ensures that both ends of the second lead screw 33 are supported on the two bearing seats 34, further enhancing the stability of the rotation of the second lead screw 33 and the movement of the first slide 21.

[0067] The second drive mechanism 3 also includes a second guide rail 35 and a second slider 36. The second guide rail 35 is connected to the first drive mechanism 2, and the second slider 36 is connected to the bottom surface of the second slide table 31. The second slider 36 is connected to the second guide rail 35 and moves on the second guide rail 35. The second guide rail 35 provides guidance, resulting in higher stability for the movement of the second slider 36 and the second slide table 31 on the second guide rail 35, further enabling precise motion control. Simultaneously, the use of a compact second lead screw 33 and second guide rail 35 results in high drive efficiency and low inertia, which is beneficial for rapid response and precise positioning. There are two second guide rails 35, spaced apart on the mounting plate 11, with the second lead screw 33 located in the middle of the two second guide rails 35.

[0068] The frame 1, the first slide 21, and the second slide 31 can all be made of lightweight alloy materials, such as 6061 aluminum alloy, significantly reducing the weight of moving parts while ensuring rigidity. The overall dimensions of the ball valve online cutting equipment are 375mm wide × 492mm high, achieving significant weight reduction while ensuring functionality and corrosion resistance. The compact layout and modular design reduce the equipment weight by more than 40%, making it easy to carry and install on-site, especially suitable for online maintenance scenarios with limited space.

[0069] The ball valve online cutting equipment also includes a control device, which is electrically connected to the first drive mechanism 2, the second drive mechanism 3, the EDM cutting component 4, and the water pump 52, and is used to control the opening and closing of the first drive mechanism 2, the second drive mechanism 3, the EDM cutting component 4, and the water pump 52, respectively. The control device controls the opening and closing of the first drive motor 22, the second drive motor 32, the EDM cutting component 4, and the water pump 52. Based on the actual dimensions of the valve design drawings, the geometric relationship between the valve body center and the reference plane is calculated, and the actual dimensions of the valve body center are calibrated using an automatic sleeve placement device. The data is then entered into the control system for archiving. The zero point for EDM machining is calculated using the valve body center as a reference, and an initial test run is performed after setting the zero point. The optimal feed parameters are determined through the cutting accuracy-feed rate relationship curve to ensure that the cutting trajectory matches the bushing structure. After setting the feed rate, the cutting program is started, and the EDM cutting component 4 etches away the bushing layer by layer along the preset trajectory. This significantly improves repair efficiency and quality stability, achieves intelligent operation control, and is very convenient to use.

[0070] The above-disclosed embodiments are merely preferred embodiments of the present utility model and should not be construed as limiting the scope of the present utility model. Therefore, any equivalent variations made in accordance with the claims of the present utility model shall still fall within the scope of the present utility model.

Claims

1. An online cutting device for ball valves, characterized in that, It includes a frame, a first drive mechanism, a second drive mechanism, an EDM cutting element, and a water circulation device. One end of the frame is used to mount and position the valve body. The EDM cutting element is connected to the second drive mechanism, and the second drive mechanism is connected to and moves on the first drive mechanism to drive the EDM cutting element to move in a direction close to or away from the valve body's cutting surface. The first drive mechanism is connected to the frame and moves on the frame to drive the EDM cutting element to extend into the valve body. The water circulation device... The circulation device includes a water tank, a water pump, an outlet pipe, a return water tank, and a return water pipe. The inlet of the water pump is connected to the water tank. One end of the outlet pipe is connected to the outlet of the water pump, and the other end of the outlet pipe extends into the valve body and faces the cut surface of the valve body. The return water tank is connected to the frame and is used to collect water flowing out of the valve body. The two ends of the return water pipe are respectively connected to the return water tank and the water tank, so that a water circulation channel is formed between the water tank, the water pump, the outlet pipe, the return water tank, and the return water pipe.

2. The ball valve online cutting equipment as described in claim 1, characterized in that, The water circulation device also includes a filter screen located on the water tank, and the outlet of the return water pipe is located on the filter screen, so that the water flowing out of the return water pipe is filtered through the filter screen and then flows back into the water tank.

3. The ball valve online cutting equipment as described in claim 2, characterized in that, The filter screen is connected to the top of the water tank and is located directly below the return water tank and the valve body.

4. The ball valve online cutting equipment as described in claim 1, characterized in that, The ball valve online cutting equipment also includes a control device, which is electrically connected to the first drive mechanism, the second drive mechanism, the electric spark cutter and the water pump and is used to control the opening and closing of the first drive mechanism, the second drive mechanism, the electric spark cutter and the water pump respectively.

5. The ball valve online cutting equipment as described in claim 1, characterized in that, The frame includes a mounting plate and a positioning plate. The first drive mechanism is connected to the mounting plate, and the positioning plate is connected to one end of the mounting plate. The positioning plate and the mounting plate are L-shaped. The positioning plate is provided with a plurality of positioning holes, and the plurality of positioning holes are respectively connected to the valve body through positioning elements.

6. The ball valve online cutting equipment as described in claim 5, characterized in that, The frame also includes multiple reinforcing ribs, all of which are connected to the mounting plate and the positioning plate.

7. The ball valve online cutting equipment as described in claim 1, characterized in that, The first driving mechanism includes a first slide, a first drive motor, and a first lead screw. The first drive motor is connected to the top surface of the first slide, and the bottom surface of the first slide is threaded to the first lead screw. The first drive motor is connected to the frame and is also connected to the first lead screw to drive the rotation of the first lead screw, thereby moving the first slide on the first lead screw.

8. The ball valve online cutting equipment as described in claim 7, characterized in that, The first drive mechanism further includes a first bearing housing, which is connected to the frame. The first lead screw passes through the first bearing housing, and a first bearing is provided between the first bearing housing and the first lead screw. And / or, the first drive mechanism further includes a first guide rail and a first slider, the first guide rail being connected to the frame, the first slider being connected to the bottom surface of the first slide table, and the first slider being connected to the first guide rail and moving on the first guide rail.

9. The ball valve online cutting equipment as described in claim 1, characterized in that, The second drive mechanism includes a second slide, a second drive motor, and a second lead screw. The electrical discharge cutting component is connected to the top surface of the second slide, and the bottom surface of the second slide is threaded to the second lead screw. The second drive motor is connected to the first drive mechanism and is also connected to the second lead screw to drive the rotation of the second lead screw, thereby moving the second slide on the second lead screw.

10. The ball valve online cutting equipment as described in claim 9, characterized in that, The second drive mechanism further includes a second bearing housing, which is connected to the first drive mechanism. The second lead screw passes through the second bearing housing, and a second bearing is provided between the second bearing housing and the second lead screw. And / or, the second drive mechanism further includes a second guide rail and a second slider, the second guide rail being connected to the first drive mechanism, the second slider being connected to the bottom surface of the second slide table, and the second slider being connected to the second guide rail and moving on the second guide rail.

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