CN109596376B - Ship lift host machine electromechanical joint debugging test method - Google Patents
Ship lift host machine electromechanical joint debugging test method Download PDFInfo
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- CN109596376B CN109596376B CN201811646341.0A CN201811646341A CN109596376B CN 109596376 B CN109596376 B CN 109596376B CN 201811646341 A CN201811646341 A CN 201811646341A CN 109596376 B CN109596376 B CN 109596376B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/005—Testing of complete machines, e.g. washing-machines or mobile phones
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02C—SHIP-LIFTING DEVICES OR MECHANISMS
- E02C5/00—Mechanisms for lifting ships vertically
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Abstract
The invention relates to an electromechanical joint debugging test method for a ship lift host, and belongs to the field of water conservancy and hydropower engineering navigation buildings. The invention relates to a method for testing the electromechanical joint debugging of a ship lift main engine, which comprises the following steps: preparing before debugging test; secondly, mounting a rack; thirdly, mounting a speed reducer; (IV) installing a winding drum; fifthly, mounting a high-speed driving device; (VI) installing a brake system; (VII) single machine debugging test; (eighth) installing a synchronous shaft; and (ninthly) debugging and testing the whole system of the main elevator. The main engine and electricity joint debugging test of the ship lift is one of key tests before the ship lift is installed and debugged, and mainly aims to test the assembly size of each component of a main lifting system and the integrity of the components, test the integral control performance of an electrical control system on a mechanical system and a brake system and test the safety performance of the main lifting system under an accident condition. By the method, the accuracy and the reliability of the test result can be ensured.
Description
Technical Field
The invention relates to an electromechanical joint debugging test method for a ship lift host, and belongs to the field of water conservancy and hydropower engineering navigation buildings.
Background
A ship lift is a navigation building which utilizes a mechanical device to lift a ship so as to overcome the concentrated water level drop on a channel. The ship lift equipment system is complex, and relates to the professions of machinery, golden knot, electricity, hydraulic pressure and the like, how to ensure that complex equipment can meet the use requirement after being concentrated becomes one of key processes in the ship lift construction process, and the main purpose is to inspect the assembly size of the main lifting equipment of the ship lift and the integrity of parts and components and to inspect the overall operation performance of the main lifting system.
In view of the above, patent document No. 201610473555.7 discloses a full-chamber water condition testing method for a fully balanced primary vertical ship lift, comprising the steps of: 1) preparing before testing; 2) connecting the counterweight system to the ship compartment through a steel wire rope; 3) the ship chamber and the balance weight system are primarily balanced; 4) accurately balancing the ship chamber and the balance weight system; 5) adjusting the position of the ship chamber; 6) installing test protection facilities; 7) adjusting the safety mechanism; 8) and (4) filling water into the ship chamber through the ship chamber water replenishing and draining system, and then carrying out the inspection of the ship chamber test project. The comparison file has the defects of inaccurate experimental result, large detection error and the like.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a reasonable-design method for testing the electromechanical joint debugging of the main engine of the ship lift.
The technical scheme adopted by the invention for solving the problems is as follows: the ship lift host machine electromechanical joint debugging test method is characterized in that: the method for the test of the electromechanical joint debugging of the main engine of the ship lift comprises the following steps:
preparing before debugging test;
secondly, mounting a rack;
thirdly, mounting a speed reducer;
(IV) installing a winding drum;
fifthly, mounting a high-speed driving device;
(VI) installing a brake system;
(VII) single machine debugging test;
(eighth) installing a synchronous shaft;
and (ninthly) debugging and testing the whole system of the main elevator.
Further, the step (one) specifically includes the steps of:
1) preparing an installation site: the length direction size is arranged according to the actual size of the main lifting system, the width direction can be subjected to reduced scale arrangement, and the positions of the transverse center line and the longitudinal center line of the main lifting system are determined; determining the central position of the speed reducer according to the positions of the transverse center line and the longitudinal center line, determining the axis position of an output shaft of the speed reducer, and determining the axis of a winding drum shaft, the axis of a motor shaft, the axis of a synchronizing shaft and the axis position of a brake disc of a working brake by taking the axis position as a reference;
2) preparing an equipment bracket: manufacturing and arranging a support of the equipment, wherein the support is of a temporary steel support or a concrete structure, and the height requirement of the support is consistent with that of a construction drawing;
3) preparation before installation of the device: all main lifting equipment participating in debugging are finished products, and the reduced scale part except the synchronous shaft can be replaced by a temporary process shaft;
4) preparing a debugging technology, specifically: the command, management, construction, supervision and detection personnel are in place, the work division duty is clear, and the construction personnel shall cover the technical personnel related to the process, the quality, the machinery, the electricity and the hydraulic pressure.
Further, the step (ii) specifically includes the steps of: a speed reducer rack, a winding drum support, a brake rack, a high-speed driving device rack and a synchronous shaft support are arranged on a support, and the levelness and the relative height of the rack or the support are adjusted according to the pattern requirement.
Further, the step (three) specifically includes the steps of:
1) installing the speed reducer and the rack on a corresponding support, and adjusting the position according to the axis mark on the speed reducer, the reference shown by the horizontal reference block and the site installation reference line according to the requirement of the factory state of the speed reducer;
2) detaching the independent small box cover, detaching the connecting bolt on the crowned tooth coupler in the V-axis assembly, and taking out the half coupler connected with the reel shaft and the reel bearing;
3) installing a speed reducer lubricating system, communicating an oil inlet of a pump station with an oil outlet of the speed reducer, and supplying oil;
4) after the winding drum is installed, installing the independent small box cover of the speed reducer, and spraying a proper amount of sealant on all the combined surfaces of the small box cover and the lower box body.
Further, the step (iv) specifically includes the steps of:
1) all the winding drums are grouped according to the actually measured diameter of the bottoms of the rope grooves of the winding drums before installation; dividing the left and right winding drums with the minimum relative error into a group to be arranged on two sides of the same speed reducer, and arranging the left and right winding drums on two sides of the speed reducer at the diagonal angle from small to large according to the error between the groups;
2) installing a bearing seat support on the side of a winding drum brake disc, wherein the misalignment between the center line of a bearing seat and the center line of an output shaft of a speed reducer on one side is required to be not more than 1mm, and the misalignment between all the axes is not more than 2 mm;
3) a bearing, a half coupling and corresponding parts are arranged on a shaft of the winding drum close to the reducer, and a bearing and related parts on the brake disc side are arranged;
4) installing a brake disc on the winding drum, and measuring the end face runout amount (in a braking radius area) of the brake disc and recording after screwing the connecting bolt of the brake disc and the winding drum;
5) the combined reel device, the bearings and the half couplers carried by the two shaft ends are arranged in a reduction gearbox and are arranged on a bearing support, the upper cover of each bearing seat is arranged, the connecting bolts of the upper cover and the lower cover of the bearing seat are screwed down, the connecting piece on the crowned tooth coupler is screwed down, so that the coupler is integrated, and one pressing plate bolt in the middle of the pressing plate on each rope groove on the reel is required to be positioned at the highest position;
6) the temporary driving device is used for driving the speed reducer, and the winding drum device and the speed reducer can flexibly run without clamping stagnation.
Further, the step (five) specifically includes the following steps:
1) the working brake disc is installed together with the relevant connecting piece;
2) cleaning each part before installing the coupler, and adding 60% of oil bath lubricating liquid mixed by No. 100 gear oil and 40% of lithium-based grease during installation, wherein the adding amount is 60% of the space of a cavity in the coupler;
3) installing all equipment and parts on a rack, requiring that the different axial degrees between a motor shaft and an input shaft of a speed reducer are not more than 0.2mm, after installing a coupler with a brake and related connecting pieces, measuring the assembly precision on the brake disc, and requiring that the end face runout is not more than 0.2mm (measured at a position 50mm away from the outer edge);
4) after the motor, the coupler with the brake disc, the floating shaft and the flange coupler are installed in place, finally screwing a connecting bolt of the rack and the motor, and firmly welding and positioning the rack and a motor positioning block;
5) installing a working brake, switching in a power supply, enabling the working brake to enter a brake release state by using a manual switch or a manual pump, carefully adjusting the gap between the brake and the two sides of a brake pad, screwing a connecting bolt of the working brake and a rack, and welding a positioning plate on the rack to position the brake;
6) the installed high-speed driving device should manually brake the disc by a hand in a state of releasing the working brake, and the speed reducer and the motor should flexibly rotate without any clamping stagnation.
Further, the step (six) specifically includes the following steps:
1) installing a brake bracket, and adjusting the position of a brake frame according to the position of a brake disc;
2) installing a safety brake, and screwing the installation bolt according to the screwing torque required by the equipment supply unit;
3) installing a brake pad, and adjusting the gap between a drum brake disc and a brake pad of a brake by using a special tool;
4) installing a brake hydraulic system, installing a pipe according to the equipment arrangement condition of a debugging site, and carrying out acid washing and phosphating treatment on the pipe;
5) performing pressure resistance test on the pipeline, wherein the test pressure is 22.5MPa, and the pressure maintaining time is 10 min; (after the pipeline is connected, a pressure test is carried out, the test pressure is 1.5 times of the working pressure when the working pressure is less than 16MPa, the test pressure is 1.25 times of the working pressure when the working pressure is more than or equal to 16MPa, and the pressure maintaining time is 10 min)
6) After the pressure test is carried out, the test oil in the pipeline is connected with the hydraulic station after being qualified.
Further, the step (seven) specifically includes the steps of:
1) main motor control performance test
a) Switching on a power supply, conducting an overspeed control contact of a speed measuring motor of the main motor (namely, a control signal displays the overspeed of the main motor), and starting the main motor in a brake releasing state;
b) the power supply is switched on, the speed measuring motor of the main motor is connected in a normal working state, so that the control circuit displays a switching-on state (the brake is actually in a brake release working condition) on the working brake, and the main motor cannot be started;
c) the motor can be started after the lubricating station supplies oil to the speed reducer for 5 minutes;
2) no-load running test of main motor
The main motor runs according to an S-shaped speed curve, the running mode is carried out according to the running requirement of an electric part, and the following parameters are detected:
a) the rotating speed of a main motor, the current of the main motor, the rotating speed of a winding drum and the working noise of a system;
b) detecting electrical control performance, including emergency parking control performance of the operation terminal;
c) detecting the display performance of the electrical control system;
c) when the system works, whether the whole system runs stably or not is checked, and whether operation jamming, impact phenomena and abnormal noise occur or not is checked;
3) detection of a retarder
a) Checking the sealing performance of the joint surface of the box body and all shaft ends, and judging whether an oil leakage phenomenon exists or not;
b) checking whether the temperature rise of the bearing is normal or not and whether abnormal noise occurs or not;
4) detection of spool arrangement
Checking the sealing performance of a bearing seat at the end of a brake disc during the operation of a winding drum, whether the oil leakage phenomenon occurs, whether the temperature rise of the bearing is normal, and whether abnormal noise occurs;
5) installation detection and test of safety brake and brake hydraulic station
And checking whether the brake releasing time and the brake applying time of all the safety brakes are consistent, wherein the action time difference is required to be not more than 0.5 second.
Further, the step (eight) specifically includes the steps of:
1) installing a synchronous shaft system according to the axial position of the synchronous shaft;
2) and the positions of the winding drums are adjusted, so that the steel wire rope pressing plates on the winding drums are connected with the synchronous shaft system and the speed reducer after being at the same position.
Further, the step (nine) specifically includes the steps of:
1) determining that all the couplers are installed correctly and adding lubricating oil; confirming that the relative position of the winding drum is correct and screwing an expansion sleeve bolt with an expansion sleeve coupler on the synchronous shaft as required; confirming that the torsion sensor on the synchronous shaft is correctly installed and the electrical signal wiring is correct; confirming that all electrical wiring is complete and accurate;
2) in the non-running state of the motor, the overspeed control contact of an optional group of main hoists is conducted (displaying the overspeed of the motor), and the system cannot be started in the brake releasing state of the brake; the brake of an optional group of main hoists displays the switching-on working condition, and the system cannot be started; after the normal oil supply of the lubrication station is confirmed for 5 minutes, the main motor can be started;
3) start and stop test of motor
Starting: the main motor is pre-applied with torque according to the running direction, when the armature current reaches a rated value of 20%, the working brake is switched off, after the delay time is 5-10 seconds, the safety brake is switched off, and the system starts to run;
stopping the machine: when the main motor is powered off, the working brake is switched on, and the safety brake is switched on after the time delay of 5-10 seconds;
4) no-load test of the whole machine
The motor operates the whole machine according to an S-shaped speed curve, and operates in the forward direction and the reverse direction for three times; detecting the rotating speed of a motor, the rotating speed of a winding drum, the current of the motor, the torsion of a synchronous shaft, the operating parameters of a hydraulic station, the operating parameters of a lubricating station, the noise of each part, the temperature rise of a bearing, all sealing performances and the vibration and the stability of a system;
5) test for simulating various accident conditions
a) Simulating an accident condition that one synchronous shaft is damaged or a motor is damaged to respectively perform tests;
b) simulating the influence of the fault of the thin oil pump station on the main dragging operation;
c) simulating the influence of the fault of the working brake on the main dragging operation;
d) simulating the influence of the main lifting power supply fault on the main dragging operation;
e) simulating the influence of the main hoisting network communication fault on the main dragging operation;
f) and checking whether the brake is normal or not when the machine is stopped and braked.
Compared with the prior art, the invention has the following advantages:
the main engine and electricity joint debugging test of the ship lift is one of key tests before the ship lift is installed and debugged, and mainly aims to test the assembly size of each component of a main lifting system and the integrity of the components, test the integral control performance of an electrical control system on a mechanical system and a brake system and test the safety performance of the main lifting system under an accident condition. By the method, the accuracy and the reliability of the test result can be ensured.
Detailed Description
The following examples are illustrative of the present invention and the present invention is not limited to the following examples.
Examples are given.
In the present specification, the terms "upper", "lower", "left", "right", "middle" and "one" are used for clarity of description only, and are not used to limit the scope of the present invention, and changes or modifications in the relative relationship may be made without substantial changes in the technical contents.
The ship lift host machine electromechanical joint debugging test method in the embodiment comprises the following steps:
preparing before debugging test, specifically comprising the following steps:
1) preparing an installation site: the length direction size is arranged according to the actual size of the main lifting system, the width direction can be subjected to reduced scale arrangement, and the positions of the transverse center line and the longitudinal center line of the main lifting system are determined; determining the central position of the speed reducer according to the positions of the transverse center line and the longitudinal center line, determining the axis position of an output shaft of the speed reducer, and determining the axis of a winding drum shaft, the axis of a motor shaft, the axis of a synchronizing shaft and the axis position of a brake disc of a working brake by taking the axis position as a reference;
2) preparing an equipment bracket: manufacturing and arranging a support of the equipment, wherein the support is of a temporary steel support or a concrete structure, and the height requirement of the support is consistent with that of a construction drawing;
3) preparation before installation of the device: all main lifting equipment participating in debugging are finished products, and the reduced scale part except the synchronous shaft can be replaced by a temporary process shaft;
4) preparing a debugging technology, specifically: the command, management, construction, supervision and detection personnel are in place, the work division duty is clear, and the construction personnel shall cover the technical personnel related to the process, the quality, the machinery, the electricity and the hydraulic pressure.
The rack mounting specifically comprises the following steps:
a speed reducer rack, a winding drum support, a brake rack, a high-speed driving device rack and a synchronous shaft support are arranged on a support, and the levelness and the relative height of the rack or the support are adjusted according to the pattern requirement.
And (III) the installation of the speed reducer specifically comprises the following steps:
1) installing the speed reducer and the rack on a corresponding support, and adjusting the position according to the axis mark on the speed reducer, the reference shown by the horizontal reference block and the site installation reference line according to the requirement of the factory state of the speed reducer;
2) detaching the independent small box cover, detaching the connecting bolt on the crowned tooth coupler in the V-axis assembly, and taking out the half coupler connected with the reel shaft and the reel bearing;
3) installing a speed reducer lubricating system, communicating an oil inlet of a pump station with an oil outlet of the speed reducer, and supplying oil;
4) after the winding drum is installed, installing the independent small box cover of the speed reducer, and spraying a proper amount of sealant on all the combined surfaces of the small box cover and the lower box body.
And (IV) reel installation, which specifically comprises the following steps:
1) all the winding drums are grouped according to the actually measured diameter of the bottoms of the rope grooves of the winding drums before installation; dividing the left and right winding drums with the minimum relative error into a group to be arranged on two sides of the same speed reducer, and arranging the left and right winding drums on two sides of the speed reducer at the diagonal angle from small to large according to the error between the groups;
2) installing a bearing seat support on the side of a winding drum brake disc, wherein the misalignment between the center line of a bearing seat and the center line of an output shaft of a speed reducer on one side is required to be not more than 1mm, and the misalignment between all the axes is not more than 2 mm;
3) a bearing, a half coupling and corresponding parts are arranged on a shaft of the winding drum close to the reducer, and a bearing and related parts on the brake disc side are arranged;
4) installing a brake disc on the winding drum, and measuring the end face runout amount (in a braking radius area) of the brake disc and recording after screwing the connecting bolt of the brake disc and the winding drum;
5) the combined reel device, the bearings and the half couplers carried by the two shaft ends are arranged in a reduction gearbox and are arranged on a bearing support, the upper cover of each bearing seat is arranged, the connecting bolts of the upper cover and the lower cover of the bearing seat are screwed down, the connecting piece on the crowned tooth coupler is screwed down, so that the coupler is integrated, and one pressing plate bolt in the middle of the pressing plate on each rope groove on the reel is required to be positioned at the highest position;
6) the temporary driving device is used for driving the speed reducer, and the winding drum device and the speed reducer can flexibly run without clamping stagnation.
And (V) mounting the high-speed driving device, and specifically comprising the following steps:
1) installing a brake disc of a working brake and a related connecting piece;
2) cleaning each part before installing the coupler, and adding 60% of oil bath lubricating liquid mixed by No. 100 gear oil and 40% of lithium-based grease during installation, wherein the adding amount is 60% of the space of a cavity in the coupler;
3) installing all equipment and parts on a rack, requiring that the different axial degrees between a motor shaft and an input shaft of a speed reducer are not more than 0.2mm, after installing a coupler with a brake and related connecting pieces, measuring the assembly precision on the brake disc, and requiring that the end face runout is not more than 0.2mm (measured at a position 50mm away from the outer edge);
4) after the motor, the coupler with the brake disc, the floating shaft and the flange coupler are installed in place, finally screwing a connecting bolt of the rack and the motor, and firmly welding and positioning the rack and a motor positioning block;
5) installing a working brake, switching in a power supply, enabling the working brake to enter a brake release state by using a manual switch or a manual pump, carefully adjusting the gap between the brake and the two sides of a brake pad, screwing a connecting bolt of the working brake and a rack, and welding a positioning plate on the rack to position the brake;
6) the installed high-speed driving device should manually brake the disc by a hand in a state of releasing the working brake, and the speed reducer and the motor should flexibly rotate without any clamping stagnation.
(VI) installing a brake system, and specifically comprising the following steps:
1) installing a brake bracket, and adjusting the position of a brake frame according to the position of a brake disc;
2) installing a safety brake, and screwing the installation bolt according to the screwing torque required by the equipment supply unit;
3) installing a brake pad, and adjusting the gap between a drum brake disc and a brake pad of a brake by using a special tool;
4) installing a brake hydraulic system, installing a pipe according to the equipment arrangement condition of a debugging site, and carrying out acid washing and phosphating treatment on the pipe;
5) performing pressure resistance test on the pipeline, wherein the test pressure is 22.5MPa, and the pressure maintaining time is 10 min; (after the pipeline is connected, a pressure test is carried out, the test pressure is 1.5 times of the working pressure when the working pressure is less than 16MPa, the test pressure is 1.25 times of the working pressure when the working pressure is more than or equal to 16MPa, and the pressure maintaining time is 10 min)
6) After the pressure test is carried out, the test oil in the pipeline is connected with the hydraulic station after being qualified.
(VII) single machine debugging test, which comprises the following steps:
1) main motor control performance test
a) Switching on a power supply, conducting an overspeed control contact of a speed measuring motor of the main motor (namely, a control signal displays the overspeed of the main motor), and starting the main motor in a brake releasing state;
b) the power supply is switched on, the speed measuring motor of the main motor is connected in a normal working state, so that the control circuit displays a switching-on state (the brake is actually in a brake release working condition) on the working brake, and the main motor cannot be started;
c) the motor can be started after the lubricating station supplies oil to the speed reducer for 5 minutes;
2) no-load running test of main motor
The main motor runs according to an S-shaped speed curve, the running mode is carried out according to the running requirement of an electric part, and the following parameters are detected:
a) the rotating speed of a main motor, the current of the main motor, the rotating speed of a winding drum and the working noise of a system;
b) detecting electrical control performance, including emergency parking control performance of the operation terminal;
c) detecting the display performance of the electrical control system;
c) when the system works, whether the whole system runs stably or not is checked, and whether operation jamming, impact phenomena and abnormal noise occur or not is checked;
3) detection of a retarder
a) Checking the sealing performance of the joint surface of the box body and all shaft ends, and judging whether an oil leakage phenomenon exists or not;
b) checking whether the temperature rise of the bearing is normal or not and whether abnormal noise occurs or not;
4) detection of spool arrangement
Checking the sealing performance of a bearing seat at the end of a brake disc during the operation of a winding drum, whether the oil leakage phenomenon occurs, whether the temperature rise of the bearing is normal, and whether abnormal noise occurs;
5) installation detection and test of safety brake and brake hydraulic station
And checking whether the brake releasing time and the brake applying time of all the safety brakes are consistent, wherein the action time difference is required to be not more than 0.5 second.
(eight) the installation of the synchronous shaft specifically comprises the following steps:
1) installing a synchronous shaft system according to the axial position of the synchronous shaft;
2) and the positions of the winding drums are adjusted, so that the steel wire rope pressing plates on the winding drums are connected with the synchronous shaft system and the speed reducer after being at the same position.
(nine) debugging test of the whole main elevator system specifically comprises the following steps:
1) determining that all the couplers are installed correctly and adding lubricating oil; confirming that the relative position of the winding drum is correct and screwing an expansion sleeve bolt with an expansion sleeve coupler on the synchronous shaft as required; confirming that the torsion sensor on the synchronous shaft is correctly installed and the electrical signal wiring is correct; confirming that all electrical wiring is complete and accurate;
2) in the non-running state of the motor, the overspeed control contact of an optional group of main hoists is conducted (displaying the overspeed of the motor), and the system cannot be started in the brake releasing state of the brake; the brake of an optional group of main hoists displays the switching-on working condition, and the system cannot be started; after the normal oil supply of the lubrication station is confirmed for 5 minutes, the main motor can be started;
3) start and stop test of motor
Starting: the main motor is pre-applied with torque according to the running direction, when the armature current reaches a rated value of 20%, the working brake is switched off, after the delay time is 5-10 seconds, the safety brake is switched off, and the system starts to run;
stopping the machine: when the main motor is powered off, the working brake is switched on, and the safety brake is switched on after the time delay of 5-10 seconds;
4) no-load test of the whole machine
The motor operates the whole machine according to an S-shaped speed curve, and operates in the forward direction and the reverse direction for three times; detecting the rotating speed of a motor, the rotating speed of a winding drum, the current of the motor, the torsion of a synchronous shaft, the operating parameters of a hydraulic station, the operating parameters of a lubricating station, the noise of each part, the temperature rise of a bearing, all sealing performances and the vibration and the stability of a system;
5) test for simulating various accident conditions
a) Simulating an accident condition that one synchronous shaft is damaged or a motor is damaged to respectively perform tests;
b) simulating the influence of the fault of the thin oil pump station on the main dragging operation;
c) simulating the influence of the fault of the working brake on the main dragging operation;
d) simulating the influence of the main lifting power supply fault on the main dragging operation;
e) simulating the influence of the main hoisting network communication fault on the main dragging operation;
f) and checking whether the brake is normal or not when the machine is stopped and braked.
In addition, it should be noted that the specific embodiments described in the present specification may be different in the components, the shapes of the components, the names of the components, and the like, and the above description is only an illustration of the structure of the present invention. Equivalent or simple changes in the structure, characteristics and principles of the invention are included in the protection scope of the patent. Various modifications, additions and substitutions for the specific embodiments described may be made by those skilled in the art without departing from the scope of the invention as defined in the accompanying claims.
Claims (1)
1. A ship lift host machine electromechanical joint debugging test method is characterized in that: the method for the test of the electromechanical joint debugging of the main engine of the ship lift comprises the following steps:
preparing before debugging test;
the preparation before debugging test specifically comprises the following steps:
1) preparing an installation site: the length direction size is arranged according to the actual size of the main lifting system, the width direction is subjected to reduced scale arrangement, and the positions of the transverse center line and the longitudinal center line of the main lifting system are determined; determining the central position of the speed reducer according to the positions of the transverse center line and the longitudinal center line, determining the axis position of an output shaft of the speed reducer, and determining the axis of a winding drum shaft, the axis of a motor shaft, the axis of a synchronizing shaft and the axis position of a brake disc of a working brake by taking the axis position as a reference;
2) preparing an equipment bracket: manufacturing and arranging a support of the equipment, wherein the support is a temporary steel support or a concrete structure, and the height requirement of the support is consistent with that of a construction drawing;
3) preparation before installation of the device: all main lifting equipment participating in debugging are finished products, and except the reduced scale part of the synchronous shaft, a temporary process shaft is used for replacing the reduced scale part;
4) preparing a debugging technology, specifically: commanding, managing, constructing, supervising and detecting personnel are in place, work division duties are clear, and constructors cover technical personnel, quality personnel, machinery personnel, electricity personnel and hydraulic technical personnel;
secondly, mounting a rack;
the rack mounting specifically comprises the following steps:
a speed reducer rack, a winding drum support, a brake rack, a high-speed driving device rack and a synchronous shaft support are arranged on a support, and the levelness and the relative height of the rack or the support are adjusted according to the pattern requirement;
thirdly, mounting a speed reducer;
the speed reducer installation specifically comprises the following steps:
1) installing the speed reducer and the rack on a corresponding support, and adjusting the position according to the axis mark on the speed reducer, the reference shown by the horizontal reference block and the site installation reference line according to the requirement of the factory state of the speed reducer;
2) detaching the independent small box cover, detaching the connecting bolt on the crowned tooth coupler in the V-axis assembly, and taking out the half coupler connected with the reel shaft and the reel bearing;
3) installing a speed reducer lubricating system, communicating an oil inlet of a pump station with an oil outlet of the speed reducer, and supplying oil;
4) after the winding drum is installed, installing a small independent box cover of the speed reducer, and spraying a proper amount of sealant on all the joint surfaces of the small independent box cover and the lower box body;
(IV) installing a winding drum;
the reel installation specifically comprises the following steps:
1) all the winding drums are grouped according to the actually measured bottom diameter of the rope grooves of the winding drums before installation; dividing the left and right winding drums with the minimum relative error into a group to be arranged on two sides of the same speed reducer, and arranging the left and right winding drums on two sides of the speed reducer at the diagonal angle from small to large according to the error between the groups;
2) installing a bearing seat support on the side of a winding drum brake disc, wherein the misalignment between the center line of a bearing seat and the center line of an output shaft of a speed reducer on one side is required to be not more than 1mm, and the misalignment between all the axes is not more than 2 mm;
3) a bearing, a half coupling and corresponding parts are arranged on a shaft of the winding drum close to the reducer, and a bearing and parts on the brake disc side are arranged;
4) installing a brake disc on the winding drum, and measuring and recording the end face runout amount of the brake disc after screwing the connecting bolt of the brake disc and the winding drum;
5) the combined reel device, the bearings and the half couplers carried by the two shaft ends are arranged in a reduction gearbox and are arranged on a bearing support, the upper cover of each bearing seat is arranged, the connecting bolts of the upper cover and the lower cover of the bearing seat are screwed down, the connecting piece on the crowned tooth coupler is screwed down, so that the coupler is integrated, and one pressing plate bolt in the middle of the pressing plate on each rope groove on the reel is required to be positioned at the highest position;
6) the temporary driving device is used for driving the speed reducer, and the winding drum device and the speed reducer are flexible to operate and free of clamping stagnation;
fifthly, mounting a high-speed driving device;
the installation of the high-speed driving device specifically comprises the following steps:
1) installing a brake disc of a working brake and a connecting piece;
2) cleaning each part before installing the coupler, and adding 60% of oil bath lubricating liquid mixed by No. 100 gear oil and 40% of lithium-based grease during installation, wherein the adding amount is 60% of the space of a cavity in the coupler;
3) installing all equipment and parts on a frame, requiring that the different axial degrees between a motor shaft and an input shaft of a speed reducer are not more than 0.2mm, and after installing a coupler with a brake and a connecting piece, measuring the assembly precision on a brake disc, and requiring that the end face runout is not more than 0.2 mm;
4) after the motor, the coupler with the brake disc, the floating shaft and the flange coupler are installed in place, a connecting bolt of the rack and the motor is screwed down, and the rack and a motor positioning block are firmly welded and positioned;
5) installing a working brake, switching in a power supply, enabling the working brake to enter a brake release state by using a manual switch or a manual pump, adjusting the gap between the brake and the two sides of a brake pad, screwing a connecting bolt of the working brake and a rack, and welding a positioning plate on the rack to position the brake;
6) the installed high-speed driving device manually drives a brake disc by a hand under the state of releasing a working brake, and the speed reducer and the motor flexibly rotate without any clamping stagnation;
(VI) installing a brake system;
the brake system installation specifically comprises the steps of:
1) installing a brake bracket, and adjusting the position of a brake frame according to the position of a brake disc;
2) installing a safety brake, and screwing the installation bolt according to the screwing torque required by the equipment supply unit;
3) mounting a brake pad, and adjusting the gap between a drum brake disc and a brake pad of a brake by using a tool;
4) installing a brake hydraulic system, installing a pipe according to the equipment arrangement condition of a debugging site, and carrying out acid washing and phosphating treatment on the pipe;
5) performing pressure resistance test on the pipeline, wherein the test pressure is 22.5MPa, and the pressure maintaining time is 10 min;
6) after a pressure test is carried out, connecting the test oil in the pipeline with a hydraulic station after the test oil is qualified;
(VII) single machine debugging test;
the single machine debugging test specifically comprises the following steps:
1) main motor control performance test
a) Switching on a power supply, conducting an overspeed control contact of a speed measuring motor of the main motor, and not starting the main motor in a brake releasing state of the brake;
b) the power supply is switched on, the speed measuring motor of the main motor is connected in a normal working state, so that the control circuit displays a switching-on state at the working brake, and the main motor is not started;
c) the lubricating station supplies oil to the speed reducer for 5 minutes and then the motor is started;
2) no-load running test of main motor
The main motor runs according to an S-shaped speed curve, the running mode is carried out according to the running requirement of an electric part, and the following parameters are detected:
a) the rotating speed of a main motor, the current of the main motor, the rotating speed of a winding drum and the working noise of a system;
b) detecting electrical control performance, including emergency parking control performance of the operation terminal;
c) detecting the display performance of the electrical control system;
c) when the system works, whether the whole system runs stably or not is checked, and whether operation jamming, impact phenomena and abnormal noise occur or not is checked;
3) detection of a retarder
a) Checking the sealing performance of the joint surface of the box body and all shaft ends, and judging whether an oil leakage phenomenon exists or not;
b) checking whether the temperature rise of the bearing is normal or not and whether abnormal noise occurs or not;
4) detection of spool arrangement
Checking the sealing performance of a bearing seat at the end of a brake disc during the operation of a winding drum, whether the oil leakage phenomenon occurs, whether the temperature rise of the bearing is normal, and whether abnormal noise occurs;
5) installation detection and test of safety brake and brake hydraulic station
Checking whether the brake releasing time and the brake applying time of all the safety brakes are consistent or not, wherein the action time difference requirement is not more than 0.5 second;
(eighth) installing a synchronous shaft;
the synchronous shaft installation specifically comprises the following steps:
1) installing a synchronous shaft system according to the axial position of the synchronous shaft;
2) adjusting the positions of the winding drums to ensure that the steel wire rope pressing plates on each winding drum are in the same position, and then connecting the synchronous shaft system with the speed reducer;
(ninth), debugging and testing the whole system of the main elevator;
the debugging test of the whole main elevator system specifically comprises the following steps:
1) determining that all the couplers are installed correctly and adding lubricating oil; confirming that the relative position of the winding drum is correct and screwing an expansion sleeve bolt with an expansion sleeve coupler on the synchronous shaft as required; confirming that the torsion sensor on the synchronous shaft is correctly installed and the electrical signal wiring is correct; confirming that all electrical wiring is complete and accurate;
2) in the non-running state of the motor, the overspeed control contact of any group of main hoisting machines is conducted, and the system is not started in the brake releasing state of the brake; the brake of an optional group of main hoists displays the switching-on working condition, and the system is not started; after the normal oil supply of the lubrication station is confirmed for 5 minutes, the main motor is started;
3) start and stop test of motor
Starting: the main motor pre-applies torque according to the running direction, when the armature current reaches a rated value of 20%, the working brake is switched off, after the time delay is 5-10 seconds, the safety brake is switched off, and the system starts to run;
stopping the machine: when the main motor is powered off, the working brake is switched on, and the safety brake is switched on after the time delay of 5-10 seconds;
4) no-load test of the whole machine
The motor operates the whole machine according to an S-shaped speed curve, and operates in the forward direction and the reverse direction for three times; detecting the rotating speed of a motor, the rotating speed of a winding drum, the current of the motor, the torsion of a synchronous shaft, the operating parameters of a hydraulic station, the operating parameters of a lubricating station, the noise of each part, the temperature rise of a bearing, all sealing performances and the vibration and the stability of a system;
5) test for simulating various accident conditions
a) Simulating an accident condition that one synchronous shaft is damaged or a motor is damaged to respectively perform tests;
b) simulating the influence of the fault of the thin oil pump station on the main dragging operation;
c) simulating the influence of the fault of the working brake on the main dragging operation;
d) simulating the influence of the main lifting power supply fault on the main dragging operation;
e) simulating the influence of the main hoisting network communication fault on the main dragging operation;
f) and checking whether the brake is normal or not when the machine is stopped and braked.
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