A valve plate corrector

Abstract

The utility model discloses a valve plate corrector relates to valve maintenance technical field. The corrector includes base, gantry, hydraulic ware, pressure bar and two independent support frames. The pressure bar bottom is equipped with inverted V-shaped pressure head, is used for accurate contact valve plate convex position. Two support frames top are equipped with V-shaped positioning structure, are used for stabilizing the support both ends of valve plate, and the interval between both constitutes the avoidance space for the middle part of valve plate downward deformation. The utility model discloses through the cooperation of inverted V-shaped pressure head and double support frame, has realized to the efficient, accurate three -point bending correction of valve plate bending position, has effectively solved the problem of difficult deformation valve plate repair, inconvenient calibration.

Description

Technical Field

[0001] This utility model relates to the field of valve repair technology, specifically to a special straightener for correcting butterfly valve plates that have failed due to deformation. Background Technology

[0002] Butterfly valves, as a common fluid control component, are prone to plastic bending deformation of their valve plates during long-term use due to factors such as media pressure fluctuations, misoperation, or accidental impacts. This can lead to malfunctions such as incomplete valve closure and leakage. In particular, bending of the raised ridge in the middle of the valve plate can severely affect its sealing performance.

[0003] Currently, repair methods for this type of deformed valve plate are very limited. Common on-site repair methods include: Manual hammering correction: Operators use tools such as sledgehammers and copper rods to strike the bent parts. This method relies entirely on the operator's experience, and it is difficult to precisely control the magnitude and direction of the force applied, which can easily cause secondary damage to the valve plate, such as surface pits, cracks, or new deformations. The correction accuracy and success rate are extremely low.

[0004] General-purpose press straightening: The valve plate is placed under a general-purpose hydraulic press or jack for pressing. However, general-purpose presses lack specialized tooling for the valve plate's unique structure. The valve plate has protrusions at both the top and bottom; if placed directly on a flat workbench, there is no room for the central protrusion, making effective support and stable three-point bending straightening impossible. Supporting only the edges of the valve plate makes it prone to slippage and overturning during pressure application, posing a safety hazard, and the straightening force cannot be precisely applied to the bending ridge, resulting in poor effectiveness.

[0005] Due to a lack of specialized and efficient straightening tools, most companies tend to replace valve plates with new ones when they encounter bending problems. This not only increases the material costs of equipment maintenance but also prolongs downtime due to waiting for new parts to arrive, resulting in significant economic losses.

[0006] Therefore, there is an urgent need in this field for a special straightening tool designed for the structural characteristics of butterfly valve plates. This tool can provide stable and reliable support for the valve plate and apply the straightening force precisely and in a concentrated manner to the bending ridge of the valve plate, thereby achieving fast, safe, and non-damaging repair of the workpiece and solving the aforementioned long-standing technical problems. Utility Model Content

[0007] To solve at least one of the above-mentioned technical problems, this utility model provides a valve plate straightener, including a base, a gantry frame fixed on the base, a hydraulic device installed on the gantry frame, a pressure rod connected to the lower end of the piston rod of the hydraulic device, and two independent support frames; The bottom of the pressure rod is provided with an inverted V-shaped pressure head, which is composed of two intersecting inclined surfaces; The two support frames are fixedly installed on the base side by side and at a certain distance, and are located directly below the pressure rod; each support frame is provided with a V-shaped positioning structure at the top for positioning the end of the valve plate, which is composed of two inclined surfaces; the distance between the two support frames forms a clearance space for the valve plate to deform downward in the middle. The inverted V-shaped pressure head at the bottom of the pressure rod and the area between the two support frames are vertically aligned with each other.

[0008] In some implementations, the inverted V-shaped pressure head of the pressure rod has an included angle of 120° between its two inclined surfaces; the V-shaped positioning structure of the support frame has an included angle of 90° between its two inclined surfaces.

[0009] In some implementations, the V-shaped positioning structure of each support frame is configured to form a stable line contact with the edge of the valve plate end to limit horizontal movement of the valve plate.

[0010] In some implementations, the inverted V-shaped pressure head at the bottom of the pressure rod has two bevels configured to simultaneously contact both sides of the transition protrusion on the valve plate located between the end and the middle.

[0011] In some implementations, the support frame is a one-piece molded component; horizontal mounting planes extend from both sides of the V-shaped positioning structure at its top, and the mounting planes are provided with first threaded holes.

[0012] In some implementations, the gantry frame is welded from channel-shaped I-beams, and its bottom is fixedly connected to a base made of steel plates by full welding.

[0013] In some implementations, the hydraulic device is a manual hydraulic jack with external threads on the outer surface of its cylinder body, which engage with a second threaded hole on the gantry beam via these external threads.

[0014] In some implementations, a reinforcing rib is welded to the bottom of the base.

[0015] In some implementations, each support frame is connected to the base by a bolt passing through a first threaded hole in its mounting plane; the base is provided with adjustment holes for the bolts to pass through, so that the position of each support frame can be adjusted independently to change the distance between them, thereby accommodating valve plates of different sizes.

[0016] In some implementations, a laser marking device is also included; the laser marking device is detachably mounted on the base via a magnetic attachment assembly.

[0017] All materials used in this utility model are existing materials and do not involve new materials.

[0018] Compared with the prior art, the valve plate straightener provided by this utility model has the following significant advantages: 1. Precise and efficient correction with reliable results: By simultaneously contacting the inverted V-shaped pressure head at the bottom of the pressure rod with both sides of the specific transition protrusion on the valve plate, the enormous pressure generated by the hydraulic unit can be concentrated, precisely transmitted, and applied to the root cause of bending deformation, achieving efficient three-point bending correction. Combined with the V-shaped positioning structure at the top of the support frame for stable line contact positioning at both ends of the valve plate, the accuracy and stability of the force application process are ensured, allowing the corrected valve plate to return to the required flat state.

[0019] 2. Rational structural design: Two independent support frames are used, and their spacing is adjusted to accommodate different valve plates. The area between the two frames constitutes a crucial clearance space. This design creatively provides the necessary clearance area for the downward plastic deformation of the valve plate under pressure, fundamentally solving the technical bottleneck that double-sided protruding valve plates cannot be effectively compressed and corrected on a traditional flat surface.

[0020] 3. Safe and stable operation, strong versatility: The V-shaped positioning of the support frame and its adjustable connection with the base (via the mounting plane, the second threaded hole, and the adjustment hole) allow the tool to stably adapt to valve plates of various sizes. The rigid welded structure of the gantry frame and the base, as well as the design of the reinforcing ribs, ensure the overall stability and operational safety of the equipment when subjected to huge corrective reaction forces.

[0021] 4. Integrated Inspection Functions Enhance Repair Quality and Efficiency: By adding a magnetically mountable laser line marker, the equipment can immediately perform optical inspection after mechanical correction. Operators can easily attach the laser line marker to a suitable position and use the reference laser line emitted parallel to the upper surface of the base to quickly and intuitively inspect the straightness or flatness of the valve plate's key contours. This achieves integrated "correction-inspection," effectively ensuring the reliability of repair results and improving overall work efficiency.

[0022] 5. Easy maintenance and high practicality: The laser marking instrument is detachable and installable using a magnetic attachment method, which not only facilitates quick disassembly and assembly and position adjustment to adapt to different inspection angles, but also makes daily maintenance and storage of the equipment convenient, greatly enhancing the practicality of the tool and the user experience.

[0023] In summary, this utility model integrates the advantages of precise correction, reliable structure, safe operation, and online inspection function, successfully solving the industry problem of difficult repair and verification of repair quality after butterfly valve plate bending, and has significant practical and economic value. Attached Figure Description

[0024] Figure 1 This is a front view of the structure of the valve plate straightener provided in Embodiment 1 of this utility model.

[0025] Figure 2 This is a schematic diagram of the pressure rod structure in the valve plate straightener of Embodiment 1 of this utility model.

[0026] Figure 3 This is a schematic diagram of the support frame structure in the valve plate straightener of Embodiment 1 of this utility model.

[0027] Figure 4 This is a top view of the valve plate straightener provided in Embodiment 2 of this utility model.

[0028] Reference numerals: 1-Gantry frame, 2-Hydraulic unit, 3-Pressure rod, 4-Base, 4a-Adjustment hole, 5-Support frame, 5a-V-shaped positioning structure, 5b-Mounting plane, 5c-First threaded hole, 6-Laser line marker. Detailed Implementation

[0029] In order to make the technical means, inventive features, objectives and effects of the utility model easy to understand, the utility model is further described in conjunction with specific illustrations, but the utility model is not limited to the following embodiments.

[0030] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which this utility model can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.

[0031] Terms such as “comprising” and “including” indicate that, in addition to the components that are directly and explicitly stated in the specification and claims, the technical solution of this utility model does not exclude the presence of other components that are not directly or explicitly stated.

[0032] Example 1 like Figure 1-3 The valve plate straightener described in this example has a main structure consisting of a rigid load-bearing frame made up of a base 4 and a gantry frame 1. The base 4 is cut from a steel plate. To resist the huge bending moment generated during straightening and to prevent deformation of the base, reinforcing ribs are welded to its lower surface.

[0033] The gantry frame 1 is formed by cutting and welding I-beams. The bottom of its two columns is firmly welded to the upper surface of the base 4 by full welding, which ensures the continuity of force transmission. The entire frame has extremely high rigidity and strength.

[0034] Hydraulic unit 2 uses a manual hydraulic jack as its power source. Its cylinder body has external threads machined on its outer surface, and correspondingly, a matching second threaded hole is provided at the center of the crossbeam of the gantry frame 1. During installation, the cylinder body of the hydraulic jack is screwed into this second threaded hole and tightened, achieving a reliable and easy-to-disassemble connection.

[0035] The upper end of pressure rod 3 is connected to the lower end of piston rod of hydraulic actuator 2. Pressure rod 3 is forged from alloy steel, and its core feature is an inverted V-shaped pressure head machined at the bottom. This pressure head consists of two precision-ground inclined surfaces with an included angle of 120°. The mechanical principle of this design is that this specific angle design allows the two inclined surfaces of the pressure head to simultaneously contact the two sides of the transition protrusion on the valve plate between the end and the middle (usually a stress concentration and easily deformable reinforcing rib), forming two contact lines. When hydraulic actuator 2 drives pressure rod 3 downward, the vertically downward force is decomposed and transmitted to the protrusion on the valve plate through these two contact lines, producing a concentrated and efficient combined mechanical effect of "pressing down" and "spreading out," thereby accurately correcting the bending deformation at that point.

[0036] Two independent support frames 5 are another core component of this invention. Each support frame 5 is a one-piece molded component, forged from steel and then milled. Its top is provided with a V-shaped positioning structure 5a, the included angle between the two inclined surfaces of which is 90°. On both sides of the V-shaped positioning structure 5a, horizontal mounting planes 5b extend, and first threaded holes 5c are formed on the mounting planes 5b. The support frame 5 is connected to the adjustment hole 4a on the base 4 by high-strength bolts that pass through the first threaded holes 5c.

[0037] The function and working principle of support frame 5 are as follows: First, positioning and stabilization: Two support frames 5 are installed side by side, with a 90° V-shaped positioning structure 5a at the top supporting both ends of the valve plate. The cylindrical edge of the valve plate end is embedded in the V-shaped groove (i.e., the groove formed by the V-shaped positioning structure 5a), forming a stable line contact. This design can automatically center and effectively limit the horizontal movement of the valve plate, providing two stable and reliable lower support points for the correction process.

[0038] Secondly, providing clearance space: the spacing between the two support frames 5 is a key design feature. Its function is to create a physical clearance space. When the pressure rod 3 presses down on the center of the valve plate, the valve plate will inevitably undergo downward elastic and plastic bending deformation. This spacing area is precisely the space reserved to accommodate the downward deformation of the valve plate, ensuring that the correction action can be completed smoothly. Without this space, the valve plate cannot be effectively pressed down.

[0039] Third, adjustability and versatility: By loosening the bolts, the support frame 5 can slide on the adjustment hole 4a of the base 4, thereby adjusting the distance between the two support frames 5. This allows the corrector to adapt to butterfly valve plates of different lengths, greatly improving the equipment's versatility. After adjustment, tightening the bolts will secure it.

[0040] The working process of this utility model is as follows: First, adjust the position of the two support frames 5 on the base 4 according to the length of the valve plate to be corrected, so that after the valve plate is placed, the protrusion that needs to be corrected is approximately above the center of the distance between the two support frames 5, and then lock the support frames 5.

[0041] Next, securely place both ends of the bent butterfly valve plate into the V-shaped positioning structure 5a of the two support brackets 5. Manually adjust the valve plate so that the protruding part to be corrected is precisely aligned with the inverted V-shaped pressure head of the upper pressure rod 3.

[0042] Finally, the operator presses the force-applying handle of the hydraulic actuator 2, driving the pressure rod 3 to move slowly downwards. The 120° inverted V-shaped pressure head at the bottom of the pressure rod 3 contacts and presses against the protruding part of the valve plate, continuously applying pressure. Under the action of the "three-point bending" principle (two support points below and one force application point above), the central protruding part of the valve plate deforms downwards, and the deformed part enters the clearance space between the two support frames 5. Depending on the degree of deformation, pressure needs to be applied in stages until the valve plate returns to a straight position.

[0043] Example 2 This embodiment provides another valve plate straightener, which differs from Embodiment 1 in that a laser marking instrument 6 is provided as a verification component for the straightening result.

[0044] See Figure 4 In this embodiment, the valve plate straightener includes all the components described in Embodiment 1 (i.e., base 4, gantry 1, hydraulic device 2, pressure rod 3 and two support frames 5) and their connection relationships, angular characteristics and working principles, and adds a laser line marker 6.

[0045] The laser marking device 6 is detachably mounted to the side of the base 4 via a magnetic attachment assembly. Specifically, the bottom of the laser marking device 6 integrates a strong magnet, and the base 4 is a steel plate, allowing the laser marking device 6 to be firmly attached to the base 4 and its attachment position to be manually changed.

[0046] Its function and working process are as follows: After the mechanical correction of the valve plate is completed, the operator can attach the laser line marker 6 to a suitable position on the base 4. Once activated, the laser line marker 6 emits a visible laser line parallel to the upper surface of the base 4. Projecting this laser line onto the corrected valve plate surface, and observing the deviation between the laser line and the valve plate contour, the operator can quickly and intuitively inspect and determine whether the straightness or flatness of the valve plate has returned to the acceptable range. The magnetic installation method facilitates quick assembly, disassembly, and position adjustment, making the inspection operation extremely flexible and convenient.

[0047] The remaining structures, technical features, functions, and correction procedures of this embodiment are the same as those of Embodiment 1, and therefore will not be repeated here.

[0048] The preferred embodiments of this utility model have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of this utility model without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of this utility model through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A valve plate straightener, characterized in that, Includes a base (4), a gantry (1) fixed on the base (4), a hydraulic device (2) installed on the gantry (1), a pressure rod (3) connected to the lower end of the piston rod of the hydraulic device (2), and two independent support frames (5); The bottom of the pressure rod (3) is provided with an inverted V-shaped pressure head, which is composed of two intersecting inclined surfaces; The two support frames (5) are fixedly installed on the base (4) side by side and at a certain distance apart, and are located directly below the pressure rod (3); the top of each support frame (5) is provided with a V-shaped positioning structure (5a) for positioning the end of the valve plate, which is composed of two inclined surfaces; the distance between the two support frames (5) forms a clearance space for the valve plate to deform downward in the middle. The inverted V-shaped pressure head at the bottom of the pressure rod (3) and the area between the two support frames (5) are directly opposite each other in vertical space.

2. The valve plate straightener according to claim 1, characterized in that, The inverted V-shaped pressure head of the pressure rod (3) has an included angle of 120° formed by its two inclined surfaces; the V-shaped positioning structure (5a) of the support frame (5) has an included angle of 90° formed by its two inclined surfaces.

3. The valve plate straightener according to claim 1, characterized in that, The V-shaped positioning structure (5a) of each of the support frames (5) is configured to form a stable line contact with the edge of the valve plate end to limit horizontal movement of the valve plate.

4. The valve plate straightener according to claim 1 or 2, characterized in that, The inverted V-shaped pressure head at the bottom of the pressure rod (3) has two inclined surfaces configured to simultaneously contact both sides of the transition protrusion located between the end and the middle of the valve plate.

5. The valve plate straightener according to claim 1, characterized in that, The support frame (5) is an integrally formed component; the V-shaped positioning structure (5a) at its top has horizontal mounting planes (5b) extending on both sides, and the mounting planes (5b) are provided with first threaded holes (5c).

6. The valve plate straightener according to claim 1, characterized in that, The gantry frame (1) is welded from channel-shaped I-beams, and its bottom is fixedly connected to the base (4) made of steel plate by full welding.

7. The valve plate straightener according to claim 1, characterized in that, The hydraulic device (2) is a manual hydraulic jack. Its cylinder body has an external thread on its outer surface, and it is connected to the second threaded hole on the crossbeam of the gantry frame (1) through the external thread.

8. The valve plate straightener according to claim 1, characterized in that, The bottom of the base (4) is welded with a reinforcing rib plate.

9. The valve plate straightener according to claim 5, characterized in that, Each of the support frames (5) is connected to the base (4) by a bolt passing through a first threaded hole (5c) in its mounting plane (5b); the base (4) is provided with an adjustment hole (4a) for the bolt to pass through, so that the position of each support frame (5) can be adjusted independently to change the distance between them, thereby adapting to valve plates of different sizes.

10. The valve plate straightener according to claim 1, characterized in that, It also includes a laser line marker (6); the laser line marker (6) is detachably mounted on the base (4) by means of a magnetic attachment assembly.

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