CN111559095A - Raw material replacing device and method for vertical insulating tower production line - Google Patents

Abstract

The invention provides a raw material replacing device and a raw material replacing method for a vertical insulating tower production line, wherein the replacing device comprises a plurality of raw material frames, a lifter is arranged beside each raw material frame, and a hanging basket is arranged on each lifter; the raw material frame is distributed around the die in a surrounding way through a latticed track structure. The invention is convenient for replacing the raw materials in the production line of the large vertical insulating tower without stopping the machine, thereby ensuring the production efficiency.

Description

Raw material replacing device and method for vertical insulating tower production line

Technical Field

The invention relates to the field of insulating towers, in particular to a raw material replacing device and method for a vertical insulating tower production line.

Background

In the power industry, the FRP composite material also plays an important role, wherein the FRP composite material has the widest application range and the largest effect and is used on a power transmission line tower. Compared with the traditional material pole tower, the glass fiber composite material pole tower has the technical advantages of light weight, high strength, high insulation and corrosion resistance, and is recognized by various countries in the world, so that the glass fiber composite material pole tower becomes a target product which is actively researched, developed, popularized and applied in the global power grid construction. The manufacture and application of foreign composite electric poles are mainly concentrated in North america and european regions, wherein the most mature research, development and application are in the united states, and product manufacturers such as Ebert Composites, powerthrust Composites, Shakespear, North Pacific and CTC in the united states all develop their own composite pole products, apply for patents and have been widely applied. The manufacturing and application work of the composite material pole tower is actively carried out in developing countries such as Egypt, Brazil, Chile, Iran and the like, China also carries out research on the composite material pole tower technology in the near term, such as Beijing 703 research institute, Anshan Yuanda, Qinchuan, North glass institute and other units, and in addition, national grid companies also carry out research on the preparation and application technology of the composite material pole tower and actively promote pilot engineering experiments. Research related to the composite material pole tower becomes a development direction of the global power transmission line. Composite material towers have become an ideal substitute for conventional towers.

Traditional transmission tower, such as wooden pole, steel pipe pole and concrete pole, ubiquitous quality is big, perishable, defects such as corrosion or fracture, and the durability is poor, and life is shorter and construction transportation and operation maintenance are difficult, appear various potential safety hazards easily. The corresponding composite material has excellent mechanical property and electrical property, has obvious advantages of aging resistance and corrosion resistance compared with metal and cement materials, and is an ideal material for replacing the traditional material to prepare the transmission tower. Compared with an iron tower, the excellent insulating property and the hydrophobicity of the composite material tower can greatly increase the insulating gap, so that the lightning protection, pollution prevention, ice disaster prevention and wind bias prevention capabilities of the power transmission line can be effectively improved, and the width of a line corridor can be reduced. For example, when the 110kV composite material pole tower grounding wire is suspended and led down along the line direction, the lightning impulse discharge voltage of the tower head phase is improved by about 76% compared with the conventional 110kV iron tower, the air gap of the pole tower phase ground can reach 1.7m and is far larger than 1.0m of the conventional iron tower, and the lightning trip-out rate of the line in a medium-voltage area is reduced to below 0.28 times/100 km years from 0.70 times/100 km years. In addition, the creepage distance of the 110kV polyurethane composite material tower is increased by 47% compared with that of the insulator string of the traditional iron tower line due to the excellent insulating property, the antifouling level is improved, the number of the insulator pieces is reduced, and the length of the insulator string is reduced, so that the probability of windage yaw discharge accidents is prevented from being reduced to a greater extent. Meanwhile, the power transmission line corridor of the same-tower double-circuit composite material tower can be reduced by 33% compared with the traditional steel tube tower, and can be reduced by about 46% compared with an angle steel tower. The GFRP composite material tower has the advantages of outstanding comprehensive cost, light weight, corrosion resistance and the like, can reduce the transportation, installation and maintenance cost of line construction, and prolongs the service life of the tower. Taking a 110kV tangent tower as an example, the calculation result shows that the total weight of the composite material tower is only about 58% of that of the steel tube tower even under the conservative design condition. On the basis of considering cost factors such as raw materials, transportation and installation, land use, product service life and the like, the annual average comprehensive cost of the composite material tower line can be reduced by more than 15% compared with that of a steel pipe tower and an angle steel tower, and the cost of the line in the aspect of operation and maintenance can be reduced due to the advantages of application technology, so that the economic benefit is further highlighted.

Research, development and application of FRP composite materials have become active areas in developed countries in europe and america and japan. In a future period, FRP (fiber reinforced Plastic) is used as a high-performance material, has the performance characteristics of light weight, high strength, corrosion resistance, good durability, convenient construction and the like, is bound to become a necessary supplementary material for maintenance, detection and repair of various roads, bridges and civil building structures, is widely applied, and brings considerable comprehensive benefits to the building economic field of China. Therefore, the application of the FRP composite material can greatly reduce the steel consumption of a power grid system and can build a low-carbon environment-friendly green power transmission line. The smelting process of the steel is high in energy consumption and heavy in pollution, and a large amount of coal and water resources are consumed. Statistics show that in 2018 years, the yield of crude steel in China exceeds 10 hundred million tons, while the production of 1 ton of crude steel consumes 0.6 ton of coal, 5 tons of water, and simultaneously emits 290 g of dust and 1450 g of SO₂Gas and 85 g CO₂Gas (chinese iron and steel industry association statistics). The use of a large number of steel products has put a great pressure on the environmental protection of China, especially China has established the important status of low carbon and environmental protection in the high and new technology industry, and after the national strategy of national economic sustainable development is realized, the industrial development of common steel products is severely restricted. Although the production process of chemical products such as resin and the like also causes emission problems, the emission is much lower than that of steel, and statistical data show that the emission of greenhouse gases in chemical industry can be reduced by 2.1-2.6 tons for other industries every 1 ton of greenhouse gases, and the net emission reduction is 1.1-1.6 tons (statistical data of China chemical industry Association). Therefore, the application of the FRP composite material has great significance for building green environment-friendly new materials and national new material strategies.

Although the advantages of FRP composites are quite outstanding, there are also significant disadvantages:

1) the technological stability of the material is poor, the main forming process of the FRP composite material comprises hand lay-up forming, lamination forming, RTM method, pultrusion method, compression molding and winding forming, wherein the material stability is better than pultrusion forming, RTM method and compression molding, the dispersion of the material performance is smaller, but the production procedures of the two latter methods are more complicated, the production efficiency is low, and the main composite material products in the market at present tend to the pultrusion forming process;

2) the dispersion of the material performance is large, because the performance of the FRP composite material is closely related to the layer structure of the fiber, and the fiber layer in the FRP material slowly ensures the uniformity of each part, the mechanical property of the material after the sampling at different positions of the material has deviation, the dispersion of the FRP material produced by some processes is large, so that designers try to get the lower limit of the test value of the material when designing the structure of the FRP composite material, and the structure causes the problems of excessive and rich performance during the material design, excessive material use, serious material waste, high product cost and the like;

3) the long-term environmental aging resistance is poor, the FRP composite material is an organic resin composite material, the weather resistance of organic resin, especially the ultraviolet aging resistance in sunlight, is a fatal weakness of outdoor application of the FRP composite material, in order to improve the weather resistance of the FRP material, a plurality of corresponding material weather resistance researches are carried out, and a surface weather-resistant coating method and a surface weather-resistant material composite method are common;

4) the modulus of the material is low, the strength of the FRP composite material is even higher than that of a steel material, the tensile strength of the FRP composite material can reach 1200-2000GPa, but the modulus of the material is generally low, and by using a GFRP composite material, the modulus of the GFRP composite material is 30-60GPa, the modulus of the AFRP composite material is 50-90GPa, the modulus of the CFRP composite material is 60-200GPa, the higher the modulus of the carbon fiber composite material is, the higher the material cost is, the anisotropy of the material is, the strength modulus of the rock fiber in the direction is high, and the modulus of the material in the direction perpendicular to the fiber is low; the modulus of common steel reaches 120GPa at least, the modulus of common cast steel can approach 200GPa, and the material is isotropic. The modulus is low, the product has overlarge deformation under the same load, and the application of the FRP product is limited to a certain extent;

5) the transverse strength and the interlaminar shear strength are poor, which is the typical characteristic of the FRP composite material, the strength of the material in the fiber distribution direction is extremely high, the mechanical strength in the fiber vertical direction with less fiber distribution is extremely poor, the glass fiber composite material plate produced by a GFRP composite material manufacturer in China is shown in the figure, the bending strength and the modulus of the longitudinal composite material are obviously higher than those of the corresponding transverse direction, and the transverse bending strength and the modulus of the material are gradually increased after the surface fiber mat is added; the interlaminar shear strength data of the corresponding composite material is 18MPa, the average value is relatively low, and the cross-sectional view of the interlaminar shear strength data shows a honeycomb surface structure cut by fibers.

Based on the defects of the FRP composite material, the application of the FRP composite material in China is limited, the technical advantages of the composite material in light weight and high strength are not really exerted, the disadvantages in large-infrastructure construction and large-size sample processing are particularly obvious, the use of the FRP composite material in engineering structural materials is limited, the application amount of the FRP composite material in large-infrastructure construction is far lower than that of steel, and the reason that the application of the composite material in structural engineering materials is limited is analyzed from several aspects.

The research of the composite material pole tower in China is started from the beginning of the twenty-first century, and through the research of nearly 20 years, the structural design and the mechanical property of the 110kV composite material pole tower are completed in China, through the third-party test, the product is applied to nearly half province test points in China, all application requirements are met, and the problems of lightning stroke or wind prevention of the original line and the like are effectively solved, but the composite material pole tower is not applied in a large scale all the time, and the popularization and application reasons are limited to two aspects:

1) most of towers designed by composite materials are single-pole type, the transmission voltage level of the towers is limited below 110KV, the composite material towers with the voltage level of 110KV and above are directly overlarge and can only be prepared by manually laying or large winding machines, the production cost of the towers is overhigh, the production efficiency is extremely low, the composite material pole is excessively thick in production, and the material cost is also overhigh.

The preparation links of the hand lay-up construction and small-angle winding process of the large-size composite material tower are as follows: hoisting the mould, waxing and oiling the mould, then manually pasting or winding to finish the tower prefabricated product, solidifying the prefabricated product again, cooling, cutting, demoulding, placing the finished product and the like. The hand pasting process needs at least 8 workers, and the fiber cloth is laid manually, so that the production link is complicated, and the production environment of workers is also relatively severe; the winding forming improves manual cloth laying of workers, small-angle winding of fibers is changed, the minimum cross angle of longitudinal winding can be close to 30 degrees, and the smaller the theoretical longitudinal fiber winding cross is, the larger the contribution to the strength of the pole tower is. Although the large size solves the problem of slow hand lay-up process, the curing and demolding links of the winding process still exist, and the two links are the bottleneck of production efficiency, the average curing time of a group of composite material electric poles is 2-3 hours, the cooling time is 0.5 hour, and the hoisting and demolding time is about 0.5 hour, so that the winding production efficiency of a GFRP single pole tower is extremely low, and one electric pole is about 6-8 hours; meanwhile, the winding tower cannot completely and longitudinally lay the fibers, the fibers cannot be laid in the longitudinal direction to the maximum, and part of strength can be dispersed in the circumferential direction. In the production links, the material cost, the labor cost and the production management cost are very high, and the production capacity of corresponding products is extremely low, so that the cost of the FRP composite material pole tower is 3-4 times that of the traditional steel pipe tower, and the popularization and the application of the FRP composite material pole are restricted.

2) Although the composite material tower has larger bearing capacity than the traditional tower, the elastic modulus of the material is lower, the modulus of the fiber reinforced resin matrix composite material is 50-70GPa, which is about half of that of steel materials, the upper end of the tower generates larger deflection under the load of the extreme working condition, for example, the bending moment strength of a 10kV composite material pole is 2-3 times that of a cement pole, but the damage bending deformation of the pole can reach 3 times, the application of the composite material tower is limited by the larger deformation, and the industrialization of the composite material pole is not facilitated.

3) The composite material pole tower produced by the winding process needs to use a corresponding mould, and the mould is only likely to be circular and regular and multiform because the mould needs to rotate continuously in the process of producing the composite material pole tower, and cannot be processed into a 'tian' -shaped or other hollow opposite-shaped structures.

The traditional transverse pultrusion process has the problems that the diameter of a produced pipe is large, the upper and lower eccentricity of a die from a heavy product is serious, the external pultrusion process can be contacted with air, bubbles and holes are easily formed between layers of pultruded composite products, and the pipe is hollow and eccentric; in addition, due to the action of a traction force, the resin infiltrated in the upper layer can automatically flow downwards in the pultrusion process to cause that the upper layer fiber lacks resin, the lower layer fiber layer is rich in resin, the part lacking the resin in the upper layer can be solidified, the cross section of a product is whitish, the strength of the pipe is seriously influenced, and the stability of the product is extremely low.

The transverse pultrusion die is fixed by the supporting point at one end of the die, and the eccentric problem of a pultrusion product is adjusted by the supporting point, and in the pultrusion of a large-size FRP product, the used die is very large, for example, a 110kV composite material pole tower is taken as an example, the maximum diameter of the pole tower can reach 1500mm, the weight of the die can be very large, the large-size FRP product can be rapidly cured and bent in a short time, a curing and heating device is lengthened, the corresponding pultrusion die is lengthened, the dead weight of the die is very striking, the pultrusion die is fixed by only depending on one end of the die through a cantilever beam mode, if the length of the pultrusion die is shortened, the thermosetting time of the product is not enough, and the product cannot be.

The insulating pole tower production line of the vertical heavy vertical tension method can overcome various defects of a transverse process, but the transverse process equipment is not simply erected to be directly used, and all equipment in the process needs to be correspondingly adjusted.

Disclosure of Invention

The invention provides a raw material replacing device and method for a vertical insulating tower production line, aiming at solving the problems in the prior art, so that raw materials in a large vertical insulating tower production line can be replaced conveniently without stopping the machine, and the production efficiency is ensured.

The device comprises a plurality of raw material frames, wherein a lifter is arranged beside each raw material frame, and a hanging basket is arranged on each lifter; the raw material frame is distributed around the die in a surrounding way through a latticed track structure.

In a further improvement, the raw materials comprise cloth felt yarns.

The raw material rack is further improved into an upper layer, a middle layer and a lower layer on the same horizontal plane, and a rack moving gap is reserved between the middle layer raw material rack and the upper layer raw material rack and the lower layer raw material rack.

The invention also provides a raw material replacing method of the vertical insulating tower production line, which comprises the steps of replacing the upper raw material frame and the lower raw material frame, replacing the left raw material frame and the right raw material frame and replacing raw materials in the raw material frames;

1) the upper and lower raw material rack replacing method comprises the following steps of firstly pushing a replacing raw material rack into one side of a first raw material rack to be replaced in a grid-shaped track, then pushing the first raw material rack out along the track, finally pushing the replacing raw material rack into a fixed position along the track, and removing the first raw material rack;

2) the left and right raw material rack replacing method comprises the following steps of firstly pushing a replacing raw material rack into the back of the side of a second raw material rack to be replaced in a grid-shaped track, then pushing the second raw material rack into a rack moving gap to give a place, then pushing the replacing raw material rack into the track, finally pushing the replacing raw material rack into a fixed position, and removing the second raw material rack;

3) staff rise to the raw materials frame that replaces by following the lift through the hanging flower basket, the raw materials in the artifical replacement raw materials frame waits for the change of next raw materials frame.

The invention has the beneficial effects that: the raw materials in the large-scale vertical insulating tower production line can be replaced conveniently without stopping the machine, and the production efficiency is ensured.

Drawings

Fig. 1 is a front view of the refueling mechanism.

Fig. 2 is a side view of the refueling mechanism.

Fig. 3 is a schematic diagram of a raw material rack replacement track.

Fig. 4 is a schematic diagram of the first step of replacing the left and right raw material frames.

Fig. 5 is a schematic diagram of a second step of replacing the left and right stock racks.

Fig. 6 is a schematic diagram of a third step of replacing the left and right stock racks.

FIG. 7 is a schematic view of the fourth step of replacing the left and right racks.

Fig. 8 is a schematic diagram of a first step of replacing the upper and lower raw material frames.

Fig. 9 is a schematic diagram of a second step of replacing the upper and lower raw material frames.

Fig. 10 is a third schematic view of the upper and lower stock racks in place of the first.

Detailed Description

The invention will be further explained with reference to the drawings.

The device comprises a plurality of raw material frames, wherein a lifter 2 is arranged beside each raw material frame 1, and as shown in figures 1 and 2, a hanging basket 3 is arranged on the lifter; the raw material frame is distributed around the die in a surrounding way through a latticed track structure.

In a further improvement, the raw materials comprise cloth felt yarns.

The raw material rack is further improved into an upper layer, a middle layer and a lower layer on the same horizontal plane, and a rack moving gap is reserved between the middle layer raw material rack and the upper layer raw material rack and the lower layer raw material rack.

The invention also provides a raw material replacing method of the vertical insulating tower production line, which comprises the steps of replacing the upper raw material frame and the lower raw material frame, replacing the left raw material frame and the right raw material frame and replacing raw materials in the raw material frames;

1) the upper and lower material rack replacing method comprises the following steps of firstly pushing a replacing material rack into one side of a first material rack to be replaced in a grid-shaped track (as shown in figure 8), then pushing the first material rack out along the track (as shown in figure 9), finally pushing the replacing material rack into a fixed position along the track, and removing the first material rack (as shown in figure 10);

2) the left and right raw material rack replacing method comprises the following steps of firstly pushing a replacing raw material rack into the side rear part of a second raw material rack to be replaced in a grid-shaped track (as shown in figure 4), then pushing the second raw material rack into a rack moving gap to make a position out (as shown in figure 5), then pushing the replacing raw material rack into the track (as shown in figure 6), finally pushing the replacing raw material rack into a fixed position, and removing the second raw material rack (as shown in figure 7);

3) staff rise to the raw materials frame that replaces by following the lift through the hanging flower basket, the raw materials in the artifical replacement raw materials frame waits for the change of next raw materials frame.

While the invention has been described in terms of its preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.

Claims (4)

1. The utility model provides a raw and other materials change device of vertical insulating shaft tower production line which characterized in that: the device comprises a plurality of raw material frames, wherein a lifter is arranged beside each raw material frame, and a hanging basket is arranged on each lifter; the raw material frame is distributed around the die in a surrounding way through a latticed track structure.

2. The raw material replacing device for the vertical insulation tower production line according to claim 1, wherein: the raw materials comprise cloth felt yarns.

3. The raw material replacing device for the vertical insulation tower production line according to claim 1, wherein: the raw material frame is divided into an upper layer, a middle layer and a lower layer on the same horizontal plane, and a frame moving gap is reserved between the middle layer raw material frame and the upper layer raw material frame and between the middle layer raw material frame and the lower layer raw material frame.

4. A raw material replacement method for a vertical insulation tower production line is characterized by comprising the following steps: comprises the replacement of an upper raw material frame and a lower raw material frame, the replacement of a left raw material frame and a right raw material frame and the replacement of raw materials in the raw material frames;

1) the upper and lower raw material rack replacing method comprises the following steps of firstly pushing a replacing raw material rack into one side of a first raw material rack to be replaced in a grid-shaped track, then pushing the first raw material rack out along the track, finally pushing the replacing raw material rack into a fixed position along the track, and removing the first raw material rack;

2) the left and right raw material rack replacing method comprises the following steps of firstly pushing a replacing raw material rack into the back of the side of a second raw material rack to be replaced in a grid-shaped track, then pushing the second raw material rack into a rack moving gap to give a place, then pushing the replacing raw material rack into the track, finally pushing the replacing raw material rack into a fixed position, and removing the second raw material rack;

3) staff rise to the raw materials frame that replaces by following the lift through the hanging flower basket, the raw materials in the artifical replacement raw materials frame waits for the change of next raw materials frame.

Images