A valve core replacement tool for a pipeline ball valve

Abstract

The utility model discloses a valve core replacement tool of pipeline ball valve, including connecting handle, and the both ends of connecting handle are connected with valve cap dismounting subassembly and valve core dismounting subassembly respectively, the valve cap dismounting subassembly is the C-shaped block of cooperation to be dismounted valve cap, and the outer wall of one end of C-shaped block is connected with the end of connecting handle, the utility model discloses the combination of valve cap dismounting subassembly and valve core dismounting subassembly with connecting handle has realized the quick, safe dismounting and installation of valve cap and valve core under the condition of taking pressure, and this tool simple structure, convenient operation has reduced maintenance time and production interruption significantly, and the spare part cost and the repair expense have been reduced greatly, and production operation efficiency and maintenance safety have been improved effectively.

Description

Technical Field

[0001] This utility model relates to the field of ball valve technology for electrolytic cell pipelines, and specifically to a valve core replacement tool for a pipeline ball valve. Background Technology

[0002] In the cathode copper production process, precise control of the electrolyte circulation volume plays a crucial role in the quality of the cathode copper. To achieve this control, each electrolytic cell on the production site is equipped with a DN50 ball valve for controlling the electrolyte flow. Its core structure includes components such as valve body, valve core, valve cap, and handle. Operators adjust the opening of the ball valve by turning the handle to control the electrolyte circulation volume, thereby maintaining the dynamic balance of composition, temperature, and additives in the electrolytic cell and ensuring that the production parameters always meet the technical standards for cathode copper. However, a prominent problem exists in the electrolytic production process: impurities such as As, Sb, and Bi in the electrolyte easily form salts and scale at the valve core. When the circulation rate is adjusted through the valve, the scaled salts firmly adhere to the valve core surface. This not only damages the connection mechanism between the ball valve core and the valve body but also directly prevents the valve from opening and closing properly. Once this happens, the liquid must be stopped and the entire valve replaced. This problem results in a high number of valve replacements each year, seriously affecting production efficiency and cathode copper output, while significantly increasing maintenance costs and spare parts costs. Therefore, to address the problems of scale buildup and difficulty in replacing existing ball valve cores, it is urgent to design a special tool to achieve efficient and low-cost valve core replacement, reduce production downtime, and improve the safety of maintenance operations. Summary of the Invention

[0003] To address the shortcomings of DN50 ball valves that require complete replacement due to scale buildup and blockage in the valve core, resulting in low operational efficiency and high maintenance costs, this utility model provides a valve core replacement tool for partial replacement of pipeline ball valve components. This tool is simple and convenient to operate and can reduce maintenance costs.

[0004] To achieve the above objectives, the technical solution of this utility model is as follows: A valve core replacement tool for a pipeline ball valve includes a connecting handle, with a valve cap removal assembly and a valve core removal assembly respectively connected to both ends of the connecting handle; the valve cap removal assembly is a C-shaped block that mates with the valve cap to be removed, and the outer wall of one end of the C-shaped block is connected to the end of the connecting handle.

[0005] Furthermore, the inner side of the C-shaped block is uniformly provided with several anti-slip teeth. During operation, the opening of the C-shaped block is inserted into the valve cap, and the several anti-slip teeth on the inner side can effectively engage with the outer circumference of the valve cap, preventing slippage during force application. This structure significantly enhances the adhesion between the tool and the valve cap, enabling efficient transmission of rotational torque, thereby ensuring smooth disassembly of the valve cap and avoiding potential damage to the tool or valve due to slippage, thus improving the reliability and safety of operation.

[0006] Furthermore, the C-shaped block is connected to the operating handle by welding. The welding structure makes the C-shaped block and the handle form a high-strength whole, ensuring the rigidity and reliability of torque transmission during valve cap disassembly, avoiding the risk of failure due to loose connection or displacement, while simplifying the tool structure and reducing manufacturing costs.

[0007] Furthermore, the valve core disassembly assembly includes a mounting sleeve, a connecting ring sleeve, and a rotating block. The outer side of the mounting sleeve is connected to the connecting handle. The connecting ring sleeve is rotatably fitted inside the mounting sleeve, with one end having a notch adapted to the outer circumference of the valve core, and the other end protruding from the mounting sleeve, with a notch near the end position. The rotating block has a locking block on its inner side that matches the notch, and the connection is completed by the locking block engaging with the notch. The connecting ring sleeve is detachable, allowing for quick selection of a connecting ring sleeve with a notch size that matches the valve core's actual dimensions during operation. This ensures the notch precisely engages with the outer circumference of the valve core and fits tightly. Then, by holding and rotating the rotating block at the end of the connecting ring sleeve, a rotational torque can be directly applied to the valve core. This torque acts directly and smoothly on the valve core through the connecting ring sleeve, allowing it to be easily loosened and separated from the valve stem. The rotating block facilitates valve core disassembly, making the tool adaptable to valve core disassembly in confined spaces.

[0008] Furthermore, a threaded ring is fixedly provided at the upper end of the connecting handle; the outer circumference of the mounting sleeve is provided with an external thread corresponding to the threaded ring, and the mounting sleeve is connected to the threaded ring through the thread. During operation, the external thread on the outer circumference of the mounting sleeve can be engaged or disengaged from the threaded ring at the end of the connecting handle by rotating the mounting sleeve, realizing the quick installation or replacement of the valve core disassembly assembly. The threaded connection structure is simple, easy to install and disassemble, and convenient for subsequent inspection and maintenance operations.

[0009] Furthermore, at least one pulley is fitted on the outer side of the connecting ring sleeve, and the outer ring of the pulley is interference-fitted with the mounting sleeve. The connecting ring sleeve forms an interference fit with the inner wall of the mounting sleeve through the pulley on its outer side, so that the connecting ring sleeve is firmly confined inside the mounting sleeve, preventing it from axially dislodging, while allowing it to rotate freely around its own axis with low resistance. After the notch of the connecting ring sleeve is fixedly fitted with the outer circumference of the valve core, the operator rotates the rotating block at the end, and the connecting ring sleeve drives the mounting sleeve to rotate, completing the disassembly or installation of the valve core. The structure is simple and the performance is good.

[0010] Furthermore, the mounting sleeve is symmetrically provided with a pair of limiting holes on its side, and a threaded sleeve is fixedly installed on the limiting holes; the threaded sleeve is internally connected to a limiting bolt, and the end of the limiting bolt passes through the limiting hole and abuts against the outer circumference of the connecting ring sleeve to limit the connection ring sleeve. In situations where there is ample space and the handle can rotate freely, the connecting ring sleeve and the mounting sleeve are fixed together by tightening the limiting bolt. At this time, rotating the connecting handle will drive the connecting ring sleeve to rotate synchronously, efficiently transmitting torque to the valve core and completing disassembly. This mode is labor-saving and provides stable torque output. In confined environments where space is limited and the connecting handle cannot rotate a full circle, it is not necessary to tighten the limiting bolt. The connecting ring sleeve can be kept in a state of free rotation. The operator can directly rotate the rotating block at the end of the connecting ring sleeve to make local fine adjustments or small-angle screwing to disassemble the valve core in confined spaces. This dual-mode design greatly expands the applicable scenarios of the tool, ensuring operational efficiency under normal conditions and solving the disassembly problem in extremely confined spaces, significantly improving the flexibility and reliability of maintenance operations.

[0011] How to use this utility model: When an abnormality is found in the ball valve during maintenance, first confirm that the ball valve is in the closed position during operation. Observe the valve indicator or the feedback signal from the actuator to ensure that the valve core has completely cut off the medium flow channel, providing safe operating conditions for subsequent operations. This process does not require closing the upstream or downstream main valve, achieving preparation for pressurized operation. Then, the operator holds the valve cap disassembly assembly, aligning the opening of its C-block with the outer circumference of the ball valve cap. Adjust it to ensure a tight fit between the C-block and the valve cap, forming a stable connection between the tool and the valve cap. Then, hold the connecting handle with both hands and apply a uniform rotational force according to the direction of the valve cap thread. Use the torque generated by the tool lever arm to gradually loosen the valve cap thread connection. Continue the operation until the valve cap is completely detached from the upper edge of the valve body. During this process, maintain the coaxiality of the tool and the valve body to avoid thread damage. After the valve cap is disassembled, the valve core assembly inside the valve body is exposed. At this time, align the valve core disassembly assembly with the connection between the valve core and the valve stem, and adjust it to ensure a tight fit between the assembly and the connection structure. Then operate the connecting handle and press... Apply rotational force in the disassembly direction to loosen the connecting threads or snap-fit ​​structure between the valve core and the valve stem. After the connection is completely disengaged, use a special hook or your hand to remove the scaled valve core from the valve body cavity. Carefully observe the scale condition on the valve core sealing surface to provide a reference for subsequent maintenance. The direction of rotation (clockwise or counterclockwise) depends on the specific structure. After removing the old valve core, immediately align the new valve core of the same model and specifications with the valve stem connection interface. Slowly screw or snap it into the connection structure in the assembly direction. After confirming that the valve core is installed in place, use the valve core disassembly assembly to tighten the connection structure in the opposite direction to ensure that the connection strength between the valve core and the valve stem meets the operating requirements. After the valve core is installed, align the valve cap with the threaded interface on the upper edge of the valve body. First, pre-tighten it by hand for a few turns to allow the threads to engage initially. After ensuring that there is no mis-threading, use the valve cap disassembly assembly to operate in the opposite direction and apply rotational force through the connecting handle to gradually tighten the valve cap until the specified sealing pre-tightening force is reached. Usually, a noticeable increase in resistance is the standard. Avoid over-tightening, which may damage the threads or deform the seal.

[0012] Compared with the prior art, the present invention has the following advantages and beneficial effects: 1. This utility model achieves rapid and safe disassembly and installation of valve caps and valve cores under pressure by combining valve cap disassembly components and valve core disassembly components with connecting handles. The tool has a simple structure and is easy to operate, which significantly reduces maintenance time and production interruption, greatly reduces spare parts costs and maintenance expenses, and effectively improves production efficiency and maintenance safety.

[0013] 2. This utility model eliminates the need for complete valve replacement, enabling rapid valve core replacement without interrupting the liquid supply in the system. This effectively avoids disruptions to production caused by equipment downtime for maintenance, and does not affect operational efficiency or cathode copper production. By replacing only the vulnerable valve core, the service life of the valve body is significantly extended, and the consumption of spare parts for the entire valve is significantly reduced, thereby lowering maintenance costs at the source.

[0014] 3. This utility model enhances the engagement strength and reliability of valve cap disassembly through anti-slip teeth and welding structure, reducing costs; the valve core disassembly assembly adopts a replaceable connecting ring, rotating block and pulley design, realizing direct operation and low-resistance rotation in narrow spaces; the dual-mode limiting structure takes into account both conventional labor-saving disassembly and fine-tuning operation in confined spaces, significantly improving work adaptability, efficiency and safety. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0016] Figure 2 This is a schematic diagram of the internal structure of the valve core disassembly assembly of this utility model.

[0017] Attached image labels: Connecting handle-1, threaded ring sleeve-11, valve cap removal assembly-2, anti-slip teeth-21, valve core removal assembly-3, mounting sleeve-31, connecting ring sleeve-32, notch-33, rotating block-34, pulley-35, threaded sleeve-36, limit bolt-37. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings.

[0019] Example 1: A valve core replacement tool for a pipeline ball valve includes a connecting handle 1, with a valve cap removal assembly 2 and a valve core removal assembly 3 connected to both ends of the connecting handle 1 respectively; the valve cap removal assembly 2 is a C-shaped block that matches the valve cap to be removed, and the outer wall of one end of the C-shaped block is connected to the end of the connecting handle 1.

[0020] How to use this utility model: When an abnormality is found in the ball valve during maintenance, first confirm that the ball valve is in the closed position during operation. Observe the valve indicator or the feedback signal from the actuator to ensure that the valve core has completely cut off the medium flow channel, providing safe operating conditions for subsequent operations. This process does not require closing the upstream or downstream main valve, achieving preparation for pressurized operation. Then, the operator holds the valve cap disassembly assembly 2, aligning its C-shaped block opening with the outer circumference of the ball valve cap. Adjust the C-shaped block to ensure a tight fit with the valve cap, forming a stable connection between the tool and the valve cap. Then, hold the connecting handle 1 with both hands and apply a uniform rotational force according to the direction of the valve cap thread. Use the torque generated by the tool lever arm to gradually loosen the valve cap thread connection. Continue the operation until the valve cap is completely detached from the upper edge of the valve body. During the process, maintain the coaxiality of the tool and the valve body to avoid thread damage. After the valve cap is disassembled, the valve core assembly inside the valve body is exposed. At this time, align the valve core disassembly assembly 3 with the connection between the valve core and the valve stem, and adjust to ensure a tight fit between the assembly and the connection structure. Then operate the connecting handle 1. Apply rotational force in the disassembly direction to loosen the connecting threads or snap-fit ​​structure between the valve core and the valve stem. After the connection is completely released, use a special hook or your hand to remove the scaled valve core from the valve body cavity. Observe the scale condition on the valve core sealing surface to provide a reference for subsequent maintenance. The direction of rotation (clockwise or counterclockwise) depends on the specific structure. After removing the old valve core, immediately align the new valve core of the same model and specifications with the valve stem connection interface. Slowly screw or snap it into the connection structure in the assembly direction. After confirming that the valve core is installed in place, use the valve core disassembly assembly 3 to tighten the connection structure in the opposite direction to ensure that the connection strength between the valve core and the valve stem meets the operating requirements. After the valve core is installed, align the valve cap with the threaded interface on the upper edge of the valve body. First, pre-tighten it by hand for a few turns to allow the threads to engage initially. After ensuring that there is no mis-threading, use the valve cap disassembly assembly 2 to operate in the opposite direction. Apply rotational force through the connecting handle 1 to gradually tighten the valve cap until the specified sealing pre-tightening force is reached. Usually, a noticeable increase in resistance is the standard. Avoid over-tightening, which may damage the threads or deform the seal.

[0021] Example 2: The difference from Example 1 is that the C-shaped block has a plurality of anti-slip teeth 21 evenly distributed on its inner side. During operation, the opening of the C-shaped block is inserted into the valve cap, and the plurality of anti-slip teeth 21 on the inner side can effectively engage the outer circumferential surface of the valve cap, preventing slippage during force application. This structure significantly enhances the adhesion between the tool and the valve cap, enabling efficient transmission of rotational torque, thereby ensuring smooth disassembly of the valve cap and avoiding damage to the tool or valve that may be caused by slippage, thus improving the reliability and safety of operation.

[0022] The C-shaped block is connected to the operating handle 1 by welding. The welding structure makes the C-shaped block and the handle form a high-strength whole, ensuring the rigidity and reliability of torque transmission during valve cap disassembly, avoiding the risk of failure due to loose connection or displacement, while simplifying the tool structure and reducing manufacturing costs.

[0023] Example 3: The difference from Example 2 is that the valve core disassembly assembly 3 includes an installation sleeve 31, a connecting ring sleeve 32, and a rotating block 34. The outer side of the installation sleeve 31 is connected to the connecting handle 1. The connecting ring sleeve 32 is rotatably fitted inside the installation sleeve 31. One end of the connecting ring sleeve 32 has a notch 33 that matches the outer circumference of the valve core, and the other end protrudes from the installation sleeve 31 and has a notch near the end position. The rotating block 34 has a locking block that matches the notch on its inner side. The connection is completed by the locking block engaging with the notch. The connecting ring 32 is detachable. During operation, the connecting ring 32 with the size of the notch 33 that matches the valve core can be quickly selected according to the actual size of the valve core, so that the notch 33 can be accurately inserted into the outer circumference of the valve core and fit tightly. Then, by holding and rotating the rotating block 34 at the end of the connecting ring 32, a rotational torque can be directly applied to the valve core. This torque acts directly and smoothly on the valve core through the connecting ring 32, so that it can be easily loosened and separated from the valve stem. The valve core can be disassembled by rotating the block 34, making the tool suitable for valve core disassembly in small spaces.

[0024] A threaded ring sleeve 11 is fixedly provided at the upper end of the connecting handle 1; the outer circumference of the mounting sleeve 31 is provided with an external thread corresponding to the threaded ring sleeve 11, and the mounting sleeve 31 is connected to the threaded ring sleeve 11 through the thread. During operation, the external thread on the outer circumference of the mounting sleeve 31 can be engaged or disengaged from the threaded ring sleeve 11 at the end of the connecting handle 1 by rotating it, so as to realize the quick installation or replacement of the valve core disassembly assembly 3. The threaded connection structure is simple, easy to install and disassemble, and convenient for subsequent inspection and maintenance operations.

[0025] At least one pulley 35 is fitted on the outer side of the connecting ring sleeve 32, and the outer ring of the pulley 35 is interference-fitted with the mounting sleeve 31. The connecting ring sleeve 32 forms an interference fit with the inner wall of the mounting sleeve 31 through the pulley 35 on its outer side, so that the connecting ring sleeve 32 is firmly confined inside the mounting sleeve 31, preventing it from axially dislodging, while allowing it to rotate freely around its own axis with low resistance. After the notch 33 of the connecting ring sleeve 32 is fixedly fitted with the outer circumference of the valve core, the operator rotates the rotating block 34 at the end, and the connecting ring sleeve 32 drives the mounting sleeve 31 to rotate, completing the disassembly or installation of the valve core. The structure is simple and the performance is good.

[0026] The mounting sleeve 31 has a pair of symmetrical limiting holes on its side, and a threaded sleeve 36 is fixedly installed on the limiting holes. The threaded sleeve 36 is internally connected to a limiting bolt 37. The end of the limiting bolt 37 passes through the limiting hole and abuts against the outer circumference of the connecting ring sleeve 32 to achieve the limiting of the connecting ring sleeve 32. In situations with ample space and a freely rotating handle, tightening the limiting bolt 37 secures the connecting ring 32 and the mounting sleeve 31 together. Rotating the connecting handle 1 then drives the connecting ring 32 to rotate synchronously, efficiently transmitting torque to the valve core and completing disassembly. This mode is labor-saving and provides stable torque output. However, in confined environments where space is limited and the connecting handle 1 cannot rotate a full circle, tightening the limiting bolt 37 is unnecessary. The connecting ring 32 remains freely rotating, and the operator can directly rotate the rotating block 34 at the end of the connecting ring 32 to make localized fine adjustments or small-angle screwing to disassemble the valve core in confined spaces. This dual-mode design greatly expands the tool's applicable scenarios, ensuring operational efficiency under normal conditions while solving the disassembly problem in extremely confined spaces, significantly improving the flexibility and reliability of maintenance operations.

[0027] Numerous specific details are set forth in this specification. However, it will be understood that embodiments of this invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0028] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model, and they should all be covered within the scope of the claims and specification of this utility model.

Claims

1. A valve core replacement tool for a pipeline ball valve, characterized in that: It includes a connecting handle (1), and valve cap removal assembly (2) and valve core removal assembly (3) are respectively connected to both ends of the connecting handle (1); the valve cap removal assembly (2) is a C-shaped block that matches the valve cap to be removed, and the outer wall of one end of the C-shaped block is connected to the end of the connecting handle (1).

2. The valve core replacement tool for a pipeline ball valve as described in claim 1, characterized in that: The inner side of the C-shaped block is uniformly provided with several anti-slip teeth (21).

3. A valve core replacement tool for a pipeline ball valve as described in any one of claims 1 or 2, characterized in that: The C-shaped block is connected to the connecting handle (1) by welding.

4. The valve core replacement tool for a pipeline ball valve as described in claim 1, characterized in that: The valve core disassembly assembly (3) includes an installation sleeve (31), a connecting ring sleeve (32), and a rotating block (34). The outer side of the installation sleeve (31) is connected to the connecting handle (1). The connecting ring sleeve (32) is rotatably fitted inside the installation sleeve (31). One end of the ring sleeve has a notch (33) that is adapted to the outer circumference of the valve core, and the other end protrudes from the installation sleeve (31) and has a notch near the end. The rotating block (34) has a locking block that matches the notch on its inner side. The connection is completed by the locking block and the notch engaging.

5. The valve core replacement tool for a pipeline ball valve as described in claim 4, characterized in that: The upper end of the connecting handle (1) is fixed with a threaded ring sleeve (11); the outer periphery of the mounting sleeve (31) is provided with an external thread corresponding to the threaded ring sleeve (11), and the mounting sleeve (31) is connected to the threaded ring sleeve (11) through the thread.

6. The valve core replacement tool for a pipeline ball valve as described in claim 4, characterized in that: At least one pulley (35) is fitted on the outside of the connecting ring sleeve (32), and the outer ring of the pulley (35) is interference-fitted with the mounting sleeve (31).

7. A valve core replacement tool for a pipeline ball valve as described in any one of claims 4-6, characterized in that: The mounting sleeve (31) has a pair of symmetrical limiting holes on its side, and a threaded sleeve (36) is fixedly provided on the limiting holes; the threaded sleeve (36) is connected to a limiting bolt (37) inside the threaded sleeve (36), and the end of the limiting bolt (37) passes through the limiting hole and abuts against the outer circumference of the connecting ring sleeve (32) to realize the limiting of the connecting ring sleeve (32).

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