Disclosure of Invention
Aiming at the problems in the prior art, the invention provides an automatic butt joint device which can realize alignment, butt joint and sealing force application of a low-temperature hose, improve the working efficiency of connection and disconnection of a low-temperature system and reduce the working intensity of personnel.
In order to solve the technical problems, the invention provides the following technical scheme:
the invention provides an automatic butt joint device, comprising: the device comprises a universal platform vehicle, a first positioning system, a second positioning system, a sealing and pressing system, an insurance system and an air distribution electric control cabinet;
the gas distribution electric control cabinet is respectively connected with the first positioning system, the second positioning system, the sealing and pressing system and the safety system cylinder;
a first positioning system is arranged on one side of the universal platform truck; the top of the universal platform truck is provided with an air distribution electric control cabinet and a guide rail; the second positioning system is arranged on the guide rail and moves on the guide rail; the sealing and pressing system and the safety system are both arranged on the second positioning system.
Wherein, universal platform truck includes: the device comprises a storage battery, a motor and a control handle; the control handle is respectively electrically connected with the storage battery and the motor.
Wherein the first positioning system comprises: the device comprises a left clamping knife, a right clamping knife, a supporting cylinder and a pre-clamping cylinder; the left clamping knife and the right clamping knife are connected with a piston rod of the pre-clamping cylinder;
a supporting cylinder frame is fixed on a piston rod of the supporting cylinder; the pre-clamping cylinder is fixedly arranged in the middle of the supporting and lifting cylinder frame.
Wherein, automatically controlled cabinet of distribution includes: the air distribution part is connected with an air source and a valve;
the electric control part comprises: the device comprises an air switch, a fuse, a PLC control module, a relay, an isolation module, a wiring terminal and a surge protector;
the gas distribution part comprises: an intake valve (K1), a high pressure exhaust valve (K2), a low pressure exhaust valve (K3, K4), a pressure reducer (J1, J2) and a safety valve (A1, A2).
Wherein the second positioning system comprises: the positioning device comprises a movable positioning support, a positioning flange upper part, a positioning flange lower part, a main positioning cylinder and an auxiliary positioning cylinder;
the main positioning cylinder is located below the movable positioning support, the auxiliary positioning cylinder is located above the movable positioning support, and the positioning flange upper part and the positioning flange lower part are embedded in the movable positioning support.
Wherein the seal-compressing system comprises: push-pull sealing cylinder; the fixed end flange is fixed on the universal platform vehicle, push-pull sealing cylinders are arranged on two sides of the fixed end flange, and piston rods of the push-pull sealing cylinders are connected with the movable positioning support on the second positioning system; and a force sensor is arranged between a piston rod of the push-pull sealing cylinder and a contact surface of the movable positioning support.
Wherein the insurance system comprises: an anti-leakage injection device and a locking device;
the anti-leakage injection device is arranged on the fixed end flange, and the locking device is arranged at the rear end of the piston rod of the push-pull sealing cylinder; the locking device includes: thread bush, lock joint and lock nut.
According to the technical scheme, the automatic butt joint device can realize alignment, butt joint and sealing force application of the low-temperature hose. Automatic butt joint and sealing are achieved through the first positioning system, the second positioning system and the sealing pressing and safety system. After being sealed, the sealing device can realize the effects of improving the working efficiency of connection and disconnection of the low-temperature system and reducing the working intensity of personnel by using a limit safety.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention provides an automatic docking device, which specifically comprises the following contents as shown in figure 1: the device comprises a universal platform truck 1, a first positioning system 2, a second positioning system 3, a sealing and pressing system 4, a safety system 6 and a gas distribution electric control cabinet 5;
the gas distribution electric control cabinet 5 is respectively connected with the first positioning system 2, the second positioning system 3, the sealing and pressing system 4 and the safety system 6 through cylinders;
a first positioning system 2 is arranged on one side of the universal platform truck 1; the top of the universal platform truck 1 is provided with an air distribution electric control cabinet 5 and a guide rail; the second positioning system 3 is arranged on the guide rail and moves on the guide rail; the seal pressing system 4 and the safety system 6 are arranged on the second positioning system 3.
Wherein, universal platform truck 1 is used for removing the flange to near the stiff end flange, and in this embodiment, universal platform truck 1 includes: the device comprises a storage battery, a motor and a control handle; the control handle is respectively electrically connected with the storage battery and the motor. The universal platform car 1 has the size of 2000x1200x500mm, is driven by a storage battery, has the duration of 5-6 hours, the total weight of 1T and the bearing capacity of 2T, adopts a stepless speed change motor to further realize the adjustable moving speed, and adopts a remote control handle for operation.
In this embodiment, the gas distribution electric control cabinet 5 includes: the air distribution part is connected with an air source and a valve;
wherein, the automatically controlled part includes: air switch, fuse, PLC control module, relay, isolation module, binding post, surge protector.
In order to realize automatic control, the air inlet valve is an electric ball valve, and the exhaust valve is an electromagnetic valve. The PLC control module outputs a signal to the relay, the relay finishes level conversion and output isolation, the signal is transmitted to the electromagnetic valve, the electromagnetic valve acts to control air supply on-off, and automatic air supply and distribution control of the action of the second positioning system 3 and the action of the air cylinder, namely the sealed air cylinder, on the first positioning system 2 is achieved.
The electric control part also comprises a direct current power supply, and the direct current power supply is obtained by rectifying an external 220V power supply.
Referring to fig. 2, the air distribution part supplies air to the air cylinder assembly, is integrated in the air distribution electric control cabinet 5, and comprises an air inlet valve K1, a high-pressure air outlet valve K2, low-pressure air outlet valves K3 and K4, pressure reducers J1 and J2 and safety valves A1 and A2. A gas supply and distribution input path, wherein the inlet gas pressure is 5-23MPa, and the inlet diameter is 6 mm; outputting two paths, wherein the diameter of an outlet of the first path is 10mm, the outlet pressure is 0.8MPa, and supplying gas to the saddle cylinder, the pre-tightening cylinder, the main positioning cylinder and the auxiliary positioning cylinder; the diameter of the second path of outlet is 6mm, the outlet pressure is 1-5MPa adjustable, and the air supply is supplied to the main push-pull sealing cylinder to provide sealing pressure. The air source of the air distribution electric control cabinet 5 is an external air source.
In this embodiment, the air distribution electric control cabinet 5 has a size of 1200x800x400mm and is made of stainless steel 316L skin.
In this embodiment, the action of the cylinder is controlled by an electromagnetic valve, which is divided into a handle control mode and a panel control mode, and the panel control mode is located on the gas distribution electric control cabinet 5. All cylinder actuating control valves and electric elements are integrated in the gas distribution electric control cabinet 5, and the position travel switch and the sensor are installed in the actuating mechanism. The handle and the control panel are both provided with a force sensor display screen and a control button, and can be manually and automatically switched. The automatic mode can realize one-key automatic butt joint. The manual mode may control each action individually through a button. The control panel is shown in fig. 3.
(1) Manual butt joint mode:
the automatic butt joint platform is controlled to a butt joint pipeline, each control flow can be independently controlled, and the butt joint platform comprises a butt joint end flange hose supporting platform, a pre-clamping cylinder, a main and auxiliary positioning cylinder, a main push-pull sealing cylinder and a main push-pull sealing cylinder, wherein the butt joint end flange hose supporting platform is arranged at a coarse positioning position, the butt joint end flange is positioned coarsely, the main and auxiliary positioning.
(2) Automatic butt joint mode:
when automatic butt joint is carried out, the butt joint process is automatically completed. And determining whether each process meets an automatic docking program or not through measurement measures such as a displacement sensor, automatically interpreting a docking state after each process is automatically completed, continuously executing the next operation when the conditions are met, prompting warning information when the conditions are not met, and terminating the automatic docking process.
The first positioning system 2 includes: the device comprises a left clamping knife, a right clamping knife, a supporting cylinder and a pre-clamping cylinder; the left clamping knife and the right clamping knife are connected with a piston rod of the pre-clamping cylinder;
a supporting cylinder frame is fixed on a piston rod of the supporting cylinder; the pre-clamping cylinder is arranged on the supporting and lifting cylinder frame.
The first positioning system 2 comprises two supporting and lifting cylinders (a cylinder 1 and a cylinder 2), supporting and lifting cylinder guide rails, supporting and lifting cylinder frames, supporting and lifting cylinder bases, two pre-clamping cylinders (a cylinder 3 and a cylinder 4), pre-clamping cylinder guide rails, left and right clamping knives and clamping knife pin shafts in the height direction. Wherein, the cylinder frame is arranged on the cylinder base. The support lifting cylinder guide rail is arranged on the support lifting cylinder frame, and the support lifting cylinder moves along the support lifting cylinder guide rail. The pre-clamping cylinders move along the pre-clamping cylinder guide rails, and the left clamping knife and the right clamping knife are controlled to be closed by the two pre-clamping cylinders through the clamping knife pin shafts to clamp the movable end flange. The first positioning system 2 is positioned at the tail end of the universal platform truck 1, and the supporting and lifting cylinder moves up and down and is used for lifting the movable end flange to realize coarse positioning in the height direction; the pre-clamping cylinder moves left and right, and the movable end flange is embraced by the clamping knife for realizing left and right coarse positioning.
The butt flange is divided into a movable end flange and a fixed end flange. The flange adopts the vacuum flange structure, flange latus rectum 150, and the rear end sets up DN100 and changes DN150 adapter, connects 5m long DN100 hoses respectively. The movable end flange and the hose are placed on a bracket fixed on the ground and can freely move along the axial direction. The fixed end flange is placed on the universal platform truck 1 and is positioned at the rear end. The vacuum flange can insulate heat, and prevent the normal work of the positioning system equipment from being influenced by the heat transfer of the low-temperature fluid through the wall surface. It should be noted that low temperature in this application means below-180 degrees celsius.
The second positioning system 3 includes: the device comprises a movable positioning support, a positioning flange upper part, a positioning flange lower part, a main positioning cylinder, an auxiliary positioning cylinder, a fixed positioning flange plate and a translation guide rail.
In this embodiment, the main positioning cylinder is the cylinder 5, and the auxiliary positioning cylinder is the cylinder 6.
The main positioning cylinder is located below the movable positioning support, the auxiliary positioning cylinder is located above the movable positioning support, and the positioning flange upper part and the positioning flange lower part are embedded in the movable positioning support.
After the first positioning system 2 finishes positioning, the movable positioning support is moved to the movable end flange along the translation guide rail, the main positioning cylinder and the auxiliary positioning cylinder move the upper positioning flange and the lower positioning flange to hold the front end of the movable end flange and reach the clamping groove position of the movable positioning support, and the movable end flange is accurately positioned, so that the aim of centering the movable end flange and the fixed end flange is fulfilled.
The seal pressing system 4 includes: two push-pull sealing cylinders; the fixed end flange is fixed on the universal platform truck 1, and the two sides of the fixed end flange are provided with push-pull sealing cylinders, wherein the single push-pull sealing cylinder provides the maximum sealing pressure 250000N. A piston rod of the push-pull sealing cylinder is connected with a movable positioning bracket on the second positioning system 3; a force sensor is arranged between the contact surface of the piston rod of the push-pull sealing cylinder and the movable positioning support.
In the present embodiment, the two push-pull sealed cylinders are the cylinder 7 and the cylinder 8, respectively. Force sensor range 250000N.
The insurance system 6 includes: an anti-leakage injection device and a locking device; the anti-leakage injection device is arranged on the flange at the fixed end, and even if the flange is in butt joint, the low-temperature fluid is drained to the outer side of the platform car through the anti-leakage injection device even if the accidental leakage condition occurs, so that the butt joint equipment is prevented from being damaged.
The locking device is arranged at the rear end of the piston rod of the push-pull sealing cylinder; the locking device includes: thread bush, lock joint and lock nut. The locking device is manually installed after the butt joint is completed.
In the embodiment, the center of the movable end hose adapter is adjusted to a preset position and fixed by the supporting cylinder and the pre-clamping cylinder group of the first positioning system 2;
and the movable end flange and the fixed end flange are centered by adopting the second positioning system 3, and the butt flange is compressed and locked by the sealing and compressing system 4 and the safety system 6. The center concentricity of the movable end cylinder and the fixed end cylinder is ensured by respective support and rail mounting process. Namely, when the system is installed and debugged, the concentricity of the butting flange is measured and adjusted by adjusting the height and the position of the movable positioning bracket in place, the height and the position of the fixed bracket, the position of the track and the like, and the system can be in a curing state after being adjusted. The mating flanges are folded and separated by a main push-pull sealing cylinder group and a piston rod. The piston rod is connected to the companion flange, and the companion flange is folded by inflating the process cavity of the air cylinder and deflating the return cavity, otherwise, the companion flange is separated by deflating the process cavity of the air cylinder and inflating the return cavity.
The quick butt joint process of the low-temperature hose joint comprises the following steps:
(1) remote control universal platform car reaches expansion end hose flange scope department, space range: x =642mm (including 320mm of the diameter of the adapter), Y =180mm, and Z =200 mm.
(2) A docking or undocking auto-program is initiated.
And (3) docking procedure:
a. the movable end flange supports the cylinder 1 and the cylinder 2 to ascend in the height direction, and the movable end flange contacts and supports the outer wall of the flange and lifts to a fixed height in the ascending process;
b. two opposite pre-clamping cylinders push the movable end flange to the middle point and clamp the movable end flange to achieve coarse positioning, and judge whether the Z direction of the joint meets the distance of 0-200mm through a travel switch, if not, the cylinder is released to adjust the vehicle weight;
c. the main push-pull sealing cylinder leaves the sealing surface position and goes to the direction of the pre-clamped movable end flange, and stops when the travel switch senses a joint fixing point;
d. the main positioning cylinder and the auxiliary positioning cylinder position and clamp the movable end flange, the auxiliary positioning cylinder assists the main positioning cylinder to realize accurate positioning, the pre-clamping cylinder is loosened to the original position, and the saddle cylinder is descended to the original position;
e. installing a sealing ring and a sealing gasket;
f. the main push-pull sealing cylinder pulls back the movable positioning bracket, so that the left flange and the right flange are accurately butted; when the butt joint, the safety cover on the fixed end flange docks with the expansion end flange simultaneously, avoids in case the leakage causes the influence to equipment normal work.
g. The corresponding sealing force (output display of a force sensor) is obtained by adjusting the air pressure of the main push-pull sealing cylinder, and after the sealing air pressure reaches a required value, two safety tightening thread sleeves are used for protection in order to ensure that the gas is failed due to accidental pressure loss. In order to avoid damage to the vacuum flange or damage to the sealing gasket due to overpressure, the tightening force needs to be controlled. The numerical value display of the force sensor can be observed while screwing, or the screwing force of the thread bush can be measured independently after the air cylinder is decompressed.
Separation procedure:
a. and loosening the safety nut, discharging air from the process cavity of the main push-pull sealing cylinder, inflating air from the return cavity, and pushing the movable end flange by the piston rod to realize separation of the mating flanges.
b. Lifting the supporting cylinder to support the butt flange, and re-clamping the pipeline by the pre-clamping cylinder;
c. and (4) loosening the main positioning cylinder and the auxiliary positioning cylinder, pulling the movable positioning bracket back through the main push-pull sealing cylinder, and separating the butting flange from the movable positioning bracket.
And loosening the pre-clamping cylinder, lifting the cylinder to an initial position, automatically stopping the butting flange on the original support, and separating the quick connection prototype from the butting flange.
It should be noted that, in this embodiment, the connection object is a liquid hydrogen hose of DN150 type and a pressure of 1.6MPa, which can realize automatic movement, automatic docking, and automatic clamping of the mating hose and the adapter, ensure balanced clamping force, and can realize real-time monitoring of the sealing force at the designated position. After sealing, the limit insurance can be realized, and the research and development of a prototype can achieve the effects of improving the working efficiency of connection and disconnection of a low-temperature system and reducing the working intensity of personnel. Automatic butt joint and sealing are achieved through the first positioning system, the second positioning system, the sealing and pressing system and the safety system.
The embodiments in the present specification are described in a progressive manner, and the same and similar parts among the embodiments are referred to each other, and each embodiment focuses on the differences from the other embodiments. In particular, for the system embodiment, since it is substantially similar to the method embodiment, the description is simple, and for the relevant points, reference may be made to the partial description of the method embodiment. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention is not limited to any single aspect, nor is it limited to any single embodiment, nor is it limited to any combination and/or permutation of these aspects and/or embodiments. Moreover, each aspect and/or embodiment of the present invention may be utilized alone or in combination with one or more other aspects and/or embodiments thereof.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the present invention, and they should be construed as being included in the following claims and description.