CN114161135A - Novel large-diameter valve assembly line and assembly method - Google Patents
Novel large-diameter valve assembly line and assembly method Download PDFInfo
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- CN114161135A CN114161135A CN202111299176.8A CN202111299176A CN114161135A CN 114161135 A CN114161135 A CN 114161135A CN 202111299176 A CN202111299176 A CN 202111299176A CN 114161135 A CN114161135 A CN 114161135A
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- B23P21/00—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
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Abstract
The invention discloses a novel large-diameter valve assembly line and an assembly method. The transport line is used for transporting valve parts. The assembly platform is used for placing valve parts during assembly and providing an assembly site. The assembly station is used for assembling the valve, and the assembly station is provided with a lifting platform which is used for an operator to stand and driving the operator to a required height. And the valve pre-tightening station is provided with a valve pre-tightening machine for pre-tightening the valve and locking the large nut. And a pressure-resistant test device is arranged at the valve test station and used for detecting whether the assembled valve is qualified or not. The trolley is connected with the assembly platform and used for driving the assembly platform to an assembly station, a valve pre-tightening station, an assembly station and a valve test station in sequence according to an assembly process.
Description
Technical Field
The invention belongs to the field of production and manufacturing of large-diameter valves, and particularly relates to a novel assembly line and an assembly method of a large-diameter valve.
Background
The common scale of domestic valve enterprises is not large, most of the domestic valve enterprises are private enterprises developed in recent years, and with the rapid expansion of the industrial scale of China, the valve order quantity is rapidly increased, so that the changes of valve variety diversification, complicated production mode, complicated production site, diversified production equipment, lean product quality and the like are caused, and the traditional island type production mode can not meet the requirements of modern valve enterprises at all. Some valve manufacturing enterprises have begun to grope and use intelligent assembly lines for conventional batch valve products, but still adopt the traditional manual operation mode for the assembly of multi-variety and small-batch large-caliber valves, and the assembly line has the disadvantages of high labor intensity, difficult turnover, large occupied space and no mature large-caliber valve intelligent assembly line case.
Disclosure of Invention
The invention aims to provide a novel assembly line and an assembly method for a large-diameter valve, and aims to solve the problem that the production efficiency is low when the large-diameter valve is produced by traditional island-type manual operation in the prior art.
The technical scheme of the invention is as follows:
a novel large-diameter valve assembly line comprises:
a transport line for transporting the valve parts;
the assembly platform is used for placing the valve parts during assembly and providing an assembly field;
the assembling station is used for assembling the valve, a lifting platform is arranged on the assembling station, and the lifting platform is used for an operator to stand and drive the operator to a required height;
the valve pre-tightening station is provided with a valve pre-tightening machine and is used for pre-tightening the valve and locking the large nut;
the valve test station is provided with pressure test equipment and is used for detecting whether the assembled valve is qualified or not;
and the trolley is connected with the assembly platform and is used for driving the assembly platform to the assembly station, the valve pre-tightening station, the assembly station and the valve test station in sequence according to an assembly process.
In one embodiment, the assembly stations include a first assembly station and a second assembly station, the first assembly station is used for installing a valve body assembly in the valve, and the second assembly station is used for connecting the valve body assembly and an actuator assembly in the valve body and connecting the actuator assembly and an accessory part assembly;
and the trolley drives the assembly platform to the first assembly station, the valve pre-tightening station, the second assembly station and the valve test station in sequence according to the assembly process.
In the novel large-diameter valve assembly line provided in one embodiment, a running track is provided according to a running track of the trolley in the assembly process, and the trolley runs on the running track.
In the novel large-caliber valve assembly line provided by one embodiment, the trolley is an automatic trolley and automatically runs along the track on the running track.
In the novel large-diameter valve assembly line provided in one embodiment, the running rail is a closed rail, and the closed rail is sequentially connected in series with the first assembly station, the valve pre-tightening station, the second assembly station and the valve test station to form a closed loop;
the valve pre-tightening station and the valve testing station are arranged in the closed track, and the conveying line and the assembling station are arranged outside the closed track.
In one embodiment, the novel large-caliber valve assembly line is provided, and the transportation line is arranged close to the first assembly station.
The novel large-caliber valve assembly line provided by one embodiment further comprises a packaging area and a defective product area, wherein the packaging area is used for packaging the qualified valves, and the defective product area is used for placing the unqualified valves; the closed track passes through the packaging area and the unqualified product area, and the packaging area and the unqualified product area are arranged between the valve test station and the first assembly station.
In the novel large-diameter valve assembly line provided in one embodiment, the pressure-resistant test equipment performs a valve sealing performance test and a torque test on the valve after assembly, and the valve sealing performance test includes at least one of a shell water pressure test, an a/B surface water pressure test and an a/B surface air pressure test.
In the novel large-diameter valve assembly line provided by one embodiment, a marking machine is arranged on the valve test station and used for marking the qualified valve and the unqualified valve differently.
In the novel large-diameter valve assembly line provided in one embodiment, the valve pre-tightening station and the valve testing station are both provided with valve carrying equipment, the valve carrying equipment on the valve pre-tightening station is used for carrying the valve between the valve pre-tightening station and the assembly platform during assembly, and the valve carrying equipment on the valve testing station is used for carrying the valve between the valve testing station and the assembly platform after assembly is completed.
In the novel large-diameter valve assembly line provided by one embodiment, the assembly platform is provided with circumferential tooth punching holes or V-shaped blocks with guide rails, and the circumferential tooth punching holes or the V-shaped blocks are used for compressing and fixing the valve in assembly.
In the novel large-diameter valve assembly line provided by one embodiment, a slope type material frame and a tool hanging chain are arranged on the assembly platform, the slope type material frame is used for taking and placing the valve parts, and the tool hanging chain is used for hanging tools needed to be used in the assembly process.
In the novel large-diameter valve assembly line provided in one embodiment, the valve pre-tightening machine is provided with a hydraulic station, a translation mechanism and a rotation mechanism, and is used for tightening the large nuts in the circumferential direction of the valve only by using an adjustable torque wrench without moving an operator in a pre-pressing state.
In the novel large-caliber valve assembly line provided by one embodiment, the trolley, the lifting platform, the valve pre-tightening machine and the pressure resistance test equipment are all provided with an overload protection device, an emergency braking device and a self-locking device.
In the novel large-caliber valve assembly line provided by one embodiment, the valve pre-tightening machine and the pressure resistance test equipment are respectively provided with a data acquisition module, and the data acquisition module is used for acquiring data and outputting the data for monitoring and recording the data in the valve assembly process;
the data collected by the data collection equipment on the valve pre-tightening machine comprises valve pre-tightening force, and the data collected by the data collection equipment on the pressure measurement test equipment comprises at least one of torque, test pressure, test time and leakage amount.
A method of assembling a large diameter valve comprising:
s1: transporting valve parts by a transport line;
s2: moving the valve parts from the shipping line to an assembly platform;
s3: the trolley drives the assembling platform to move to a first assembling station;
s4: completing the primary assembly of a valve body assembly in the valve on the assembly platform;
s5: the trolley drives the assembly platform to move to a valve pre-tightening station, and pre-tightening of the upper valve cover and the valve body of the valve body assembly and locking of the large nut are completed;
s6: the trolley drives the assembly platform to move to a second assembly station, connection of the valve body assembly and the actuating mechanism assembly, and connection of the actuating mechanism assembly and the accessory part assembly after the large nut is locked are completed, and assembly of the valve is completed;
s7: the trolley drives the assembly platform to move to a valve test station, the sealing performance of the assembled valve is tested, and qualified products and unqualified products are distinguished;
s8: the trolley transports the qualified products to a packaging area, and transports the unqualified products to an unqualified product area;
wherein the sequence of the step S2 and the step S3 can be switched.
In an embodiment, in the method for assembling a large-diameter valve, the step S4 includes: fixing a valve body on the assembly platform by a tool, installing a valve internal part according to an operation sequence, screwing a screw into a threaded hole of the valve body, and placing an upper cover on the valve body to finish the primary assembly of a valve body assembly in the valve;
the step S5 includes: the trolley drives the assembly platform to move to a valve pre-tightening station, the valve body assembly preliminarily assembled on the assembly platform is moved to a pre-tightening machine of the valve pre-tightening station, the pre-tightening machine presses a valve cover, a large nut is locked by a torque wrench, and then the valve body assembly locked by the large nut is moved to the assembly platform;
the step S6 includes: the trolley drives the assembly platform to move to a second assembly station, an actuating mechanism assembly in the valve is connected with the valve body assembly after the nut is locked, and then an accessory part in the valve is connected with the actuating mechanism assembly to complete assembly of the valve;
the step S7 includes: the trolley drives the assembly platform to move to a valve test station, the valve which is assembled is moved to the valve test station, the valve which is assembled is tested for sealing performance and is divided into a qualified product and an unqualified product, and the qualified product and the unqualified product are marked differently;
the step S8 includes: and moving the marked valve to the assembly platform, transporting the qualified product to a packaging area by the trolley, and transporting the unqualified product to an unqualified product area by the trolley.
Due to the adoption of the technical scheme, compared with the prior art, the invention has the following advantages and positive effects:
the novel assembly line and the assembly method for the large-diameter valve provided by the invention have the advantages that after the valve body assembly in the valve is preliminarily assembled at the assembly station, the large nut is locked at the valve pre-tightening station, the valve pre-tightening station is returned to the assembly station to be connected with the actuating mechanism assembly and the accessory part assembly, the integral assembly of the valve is completed, and then the assembled valve is subjected to the test of whether the assembled valve is qualified at the valve test station. According to the novel large-diameter valve assembly line and the novel large-diameter valve assembly method, the assembly process of the whole valve is reasonably planned, and the assembly and acceptance are reasonably divided into fields, so that the labor intensity of personnel can be greatly reduced, the logistics turnover frequency is reduced, the operation field area is saved, and the problem of low production efficiency of the traditional island type manual operation in the prior art when the large-diameter valve is produced is solved.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.
FIG. 1 is a schematic view of a novel large diameter valve assembly line of the present invention;
fig. 2 is a schematic structural diagram of a large-diameter valve.
Description of reference numerals:
1: a transport line; 2: a lifting platform; 3: assembling a platform; 4: a trolley; 5: a valve pre-tightening machine; 6: a rocker arm crane; 7: a multifunctional valve test bed; 8: running the track; 9: a valve body assembly; 10: an actuator assembly; 11: an accessory portion assembly.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following description will be made with reference to the accompanying drawings. It is obvious that the drawings in the following description are only some examples of the invention, and that for a person skilled in the art, other drawings and embodiments can be derived from them without inventive effort.
For the sake of simplicity, the drawings only schematically show the parts relevant to the present invention, and they do not represent the actual structure as a product. In addition, in order to make the drawings concise and understandable, components having the same structure or function in some of the drawings are only schematically illustrated or only labeled. In this document, "one" means not only "only one" but also a case of "more than one".
The large-diameter valve refers to a series of large-sized valve products which have the nominal diameter of more than DN150, occupy large space and are heavy, and the equipment such as a traveling crane, a rocker arm crane 6, prepressing, tightening, lifting and the like is needed during production and assembly. Usually, such a valve will be equipped with a large actuator, the height of the complete machine after assembly being generally not less than 2 meters.
Referring to fig. 1 and 2, the embodiment provides a novel large-diameter valve assembly line, which includes a transportation line 1, an assembly platform 3, an assembly station, a valve pre-tightening station, a valve testing station and a trolley 1. The transport line 1 is used for transporting valve parts. The assembly platform 3 is used for placing valve parts during assembly and providing an assembly site. The assembly station is used for assembling the valve, the lifting platform 2 is arranged on the assembly station, and the lifting platform 2 is used for an operator to stand and drive the operator to the required height. And a valve pre-tightening machine 5 is arranged at the valve pre-tightening station and used for locking a large nut on the valve. And the valve test station is provided with pressure-resistant test equipment for detecting whether the assembled valve is qualified or not. The trolley 1 is connected with the assembly platform 3 and is used for driving the assembly platform 3 to an assembly station, a valve pre-tightening station, an assembly station and a valve test station in sequence according to an assembly process.
The structure of the present embodiment will now be explained.
The valve complete machine mainly comprises three parts, which are respectively: a valve body assembly 9, an actuator assembly 10 and an attachment portion assembly 11. The valve body assembly 9 comprises parts such as a valve body, a valve cover, a valve core, a valve seat, a valve rod and the like, and realizes the basic functions of controlling and conveying media after being assembled; the actuator assembly 10 is essentially a pneumatic or electric drive for opening and closing the valve; the accessory part assembly 11 mainly comprises accessories such as a positioner, a pressure reducing valve, a quick-release valve, a limit switch and the like, and is mainly used for remotely controlling or accurately controlling the valve.
The assembly stations comprise a first assembly station for mounting the valve body assembly 9 in the valve and a second assembly station for connecting the valve body assembly 9 and the actuator assembly 10 in the valve body and connecting the actuator assembly and the accessory part assembly 11. The trolley 1 drives the assembly platform 3 to a first assembly station, a valve pre-tightening station, a second assembly station and a valve test station in sequence according to an assembly process.
The novel heavy-calibre valve assembly line that this embodiment provided can also include packing district and defective work district, and the packing district is used for the packing of qualified valve, and the defective work district is used for placing unqualified valve.
Corresponding to a novel large-caliber valve assembly line, the embodiment also provides a large-caliber valve assembly method, which comprises the following steps:
s1: the transportation line 1 transports valve parts;
s2: moving the valve parts from the transport line 1 to the assembly platform 3;
s3: the trolley 1 drives the assembly platform 3 to move to a first assembly station;
s4: completing the primary assembly of the valve body assembly 9 in the valve on the assembly platform 3;
s5: the trolley 1 drives the assembly platform 3 to move to a valve pre-tightening station to lock the large nut at the upper valve cover of the valve body assembly 9;
s6: the trolley 1 drives the assembly platform 3 to move to a second assembly station, connection of the valve body assembly 9 and the execution mechanism assembly 10 after the large nut is locked, connection of the execution mechanism assembly 10 and the accessory part assembly 11 are completed, and assembly of the valve is completed;
s7: the trolley 1 drives the assembly platform 3 to move to a valve test station, and the assembled valve is subjected to sealing performance test and is divided into qualified products and unqualified products;
s8: the trolley 1 transports qualified products to a packaging area, and the trolley 1 transports unqualified products to an unqualified product area;
the sequence of step S2 and step S3 can be switched.
In the novel large-diameter valve assembly line provided by this embodiment, the operation track 8 is set according to the operation track of the trolley 1 in the assembly process, and the trolley 1 runs on the operation track 8. The operation rail 8 is a closed rail, and the closed rail is sequentially connected in series with a first assembly station, a valve pre-tightening station, a second assembly station and a valve test station to form a closed loop. The valve pre-tightening station and the valve testing station are arranged in the closed track, and the conveying line 1 and the assembling station are arranged outside the closed track. And the closed track passes through the packaging area and the unqualified product area, and the packaging area and the unqualified product area are arranged between the valve test station and the first assembly station. The trolley 1 can be an automatic trolley 1 and automatically runs along a track on a running track 8, and the specific trolley 1 can be an AGV trolley 1.
The warehouse prepares materials according to the sequence of an assembly delivery plan, the trolley 1 transports the materials to be in butt joint with the transport line 1, and the transport line 1 conveys the valve parts to the designated position according to requirements, namely the position of the assembly platform 3 for receiving the valve parts. Specifically, the conveying line 1 is arranged close to the first assembly station, and the trolley 1 can drive the assembly platform 3 to be parked on the first assembly station to receive the valve parts on the conveying line 1. The valve components are transferred from the transport line 1 to the assembly platform 3 either manually or mechanically or by a combination of both, without limitation. In the present embodiment, the transport line 1 is a roller line, but the specific structure of the transport line 1 is not limited in other embodiments.
On the place of novel heavy-calibre valve assembly line, can set up a plurality of first assembly stations in first assembly station region, can set up a plurality of second assembly stations in second assembly station region, all be equipped with lift platform 2 on every first assembly station and the second assembly station, every lift platform 2 is independent individual, is equipped with solitary lift footboard, can go up and down the height alone, satisfies the high needs of assembly operation. All lift platform 2 place side by side in first assembly station area or the second assembly station area, and when lift platform 2 was in same height, operating personnel can shift between adjacent lift platform 2, and the both sides of all lift platforms 2 are equipped with stair in first assembly station area or the second assembly station area, make things convenient for operating personnel to come in and go out.
When the valve assembling device is used at the first assembling station or the second assembling station, an operator can assemble the valve through the assembling platform 3 on the lifting platform 2. Can set up ramp type material frame and instrument chaining on assembly platform 3, ramp type material frame is placed around operating personnel, conveniently gets and puts the valve part, and the instrument chaining conveniently hangs the instrument that needs use in the assembling process, makes manual work lighter, convenient.
The assembly platform 3 is designed in a universal type, and a platform plate of the assembly platform is provided with universal structures such as circumferential tooth punching holes or V-shaped blocks with guide rails, so that the valve in assembly is conveniently compressed and fixed.
At a first assembly station, a valve body is fixed on the assembly platform 3 through tooling, various valve internals are installed according to the operation sequence, the screw rod is screwed into the threaded hole of the valve body, the upper cover is placed on the valve body, and the assembly of the valve body assembly 9 is completed preliminarily.
The valve pre-tightening station and the valve testing station are respectively provided with a valve carrying device, the valve carrying devices on the valve pre-tightening station are used for carrying the valves in the assembling process between the valve pre-tightening station and the assembling platform 3, and the valve carrying devices on the valve testing station are used for carrying the valves after the assembling process between the valve testing station and the assembling platform 3. Specifically, the valve handling equipment can be a rocker arm crane 6, and when the trolley 1 conveys the assembly station to the valve pre-tightening station, the rocker arm crane 6 can be used for hoisting the valve in assembly from the assembly platform 3 to the valve pre-tightening machine 5 and hoisting the valve in assembly from the pre-tightening machine to the assembly platform 3; when the trolley 1 conveys the assembly station to the valve test station, the assembled valve can be hung to the valve test station from the assembly platform 3 and the assembled valve can be hung to the assembly platform 3 from the valve test station through the rocker arm hanger 6.
At a valve pre-tightening station, a valve in assembly is placed on a valve pre-tightening machine 5, the valve pre-tightening machine 5 compresses a valve cover, and a torque wrench locks a large nut. Furthermore, a hydraulic station, a translation mechanism and a rotating mechanism are arranged on the valve pre-tightening machine 5, so that the large nuts in the circumferential direction of the valve can be tightened only by an adjustable torque wrench without moving an operator in a pre-tightening state.
At the second assembly station, the actuator part is connected to the valve body assembly 9 and then the attachment part assembly 11 is connected to the actuator assembly 10, during which the operator can move to a suitable height by means of the lifting platform 2.
The valve test station is used for detecting whether the assembled valve is qualified or not. And carrying out a valve sealing performance test and a torque test on the assembled valve by pressure-resistant test equipment in a valve test station, wherein the valve sealing performance test comprises at least one of a shell water pressure test, an A/B surface water pressure test and an A/B surface air pressure test. In the implementation, a multifunctional valve test bed 7, a torque switch mechanism and a marking machine are arranged on a valve test station. The multifunctional valve test bed 7 is used for testing the shell water pressure of the assembled valve, detecting the water pressure of the A/B surface, detecting the air pressure and the like; the torque switch mechanism switches the valve, detects whether the torque is qualified or not and can output a torque curve; and repeatedly detecting the valve which is detected to be unqualified, and if the detection results of the two times are unqualified, determining that the valve is an unqualified product. The marking machine marks the qualified valve and the unqualified valve differently for distinguishing. After the test is finished, the valve is moved to the assembly platform 3 through the rocker arm crane 6, and the valve is transported to a packaging area or an unqualified area through the trolley 1 according to the identification of the marking machine.
Furthermore, the trolley 4, the lifting platform 2, the valve pre-tightening machine 5 and the pressure resistance testing equipment on the novel large-diameter valve assembly line are all provided with an overload protection device, an emergency braking device and a self-locking device so as to ensure the safe operation of operators. The valve pre-tightening machine 5 and the pressure resistance test equipment are respectively provided with a data acquisition module, the data acquisition module is used for acquiring data and outputting the data, the data acquisition module is used for monitoring and recording the data in the valve assembling process, namely the data acquired by the data acquisition module is uploaded to a data system, the recording of the whole production process, test data and the like is completed, and the traceability is realized. Specifically, the data collected by the data collection device on the valve pre-tightening machine 5 includes the valve pre-tightening force, and the data collected by the data collection device on the pressure measurement test device includes at least one of torque, test pressure, test time and leakage amount.
The assembly method of the large-diameter valve corresponding to the novel assembly line of the large-diameter valve provided by the embodiment specifically includes:
s1: the transportation line 1 transports valve parts;
s2: moving the valve parts from the transport line 1 to the assembly platform 3;
s3: the trolley 1 drives the assembly platform 3 to move to a first assembly station;
s4: fixing a valve body on the assembly platform 3 by a tool, installing the valve internal parts according to the operation sequence, screwing the screw rod into the threaded hole of the valve body, and placing the upper cover on the valve body to finish the primary assembly of the valve body assembly 9 in the valve;
s5: the trolley 1 drives the assembly platform 3 to move to a valve pre-tightening station, a valve body assembly 9 which is preliminarily assembled on the assembly platform 3 is moved to a pre-tightening machine of the valve pre-tightening station, the pre-tightening machine compresses the valve cover, the large nut is locked by the torque wrench, and the valve body assembly 9 which is locked by the large nut is moved to the assembly platform 3;
s6: the trolley 1 drives the assembly platform 3 to move to a second assembly station, an actuating mechanism assembly 10 in the valve is connected with a valve body assembly 9 after the nut is locked, and then an accessory part in the valve is connected with the actuating mechanism assembly 10 to complete assembly of the valve;
s7: the trolley 1 drives the assembly platform 3 to move to a valve test station, moves the assembled valve to the valve test station, tests the sealing performance of the assembled valve, distinguishes the assembled valve into a qualified product and an unqualified product, and marks the qualified product and the unqualified product differently;
s8: the marked valve is moved to an assembly platform 3, the trolley 1 transports qualified products to a packaging area, and the trolley 1 transports unqualified products to an unqualified product area
The sequence of step S2 and step S3 can be switched.
The novel large-diameter valve assembly line that this embodiment provided, synthesize industry advanced automatic production experience, through AGV dolly 1, lift platform 2, valve pretension machine 5, general type assembly bench and advanced intelligent control system and auxiliary information acquisition system's use, thereby realized reducing personnel intensity of labour by a wide margin, reduce logistics turnover number of times, save the operation area, the neglected loading of preventing among the assembling process has been satisfied, the mistake proofing, pressure control detects, torque control, requirements such as assembly position size, be domestic leading intellectuality, the novel large-diameter valve assembly line that automation and degree of safety are high, the needle is to many varieties, small batch, it is bulky, the big mouthful valve customized novel assembly line of heavy weight.
In order to achieve the above purpose, the present embodiment has the following technical solutions:
1. the materials are transported in a turnover way by the application of an intelligent control system, an AGV trolley 1, a transport line 1 and the like;
2. the AGV trolley 1 is used for dragging the assembly platform 3 to move, so that the number of key equipment such as the lifting platform 2, the valve pre-tightening machine 5, the multifunctional valve test bed 7 and the like is reduced to the maximum extent, and the field area and the equipment cost are saved;
3. the assembly platform 3 is provided with circumferential threading holes or V-shaped blocks with guide rails and the like, so that the tool clamp is universal.
4. Through the application of the lifting platform 2, the inclined material rack and the tool hanging chain, people can work in a light and convenient environment;
5. through the use of a valve pre-tightening machine 5 provided with a translation mechanism, a rotation mechanism and a pressing mechanism, the operation personnel can not move and tighten the fastening piece in the circumferential direction under the pre-tightening state;
6. the valve test automation is realized through the application of the multifunctional valve test bed 7, the torque switch mechanism and the marking machine;
7. each device is provided with a data acquisition module, data are uploaded to a data system, the whole production process and the record of test data and the like are completed, and traceability is realized.
The invention is a novel large-caliber valve assembly line which takes industrial 4.0, Chinese manufacturing 2025 and intelligent factory construction as cores, integrates devices such as full-stack data processing, Ethernet, AGV intelligent distribution and transportation, transportation line 1 transmission, a lifting mechanism, a pre-pressing mechanism, a sliding mechanism, an automatic airtight detection mechanism and the like, realizes the assembly and detection of large-caliber valves, and has the functions of full life cycle, end-to-end full-flow digital management, intelligent data detection, flexible production and the like.
The assembly line adopts an end-to-end full-flow digitization technology, meets the requirements of intellectualization, mechanization, digitization, informatization, lean, networking, flexibility, visualization and the like, and maximizes the assembly balancing effect.
The novel large-caliber valve complete machine assembly line provided by the invention is used for assembling the large-caliber valve, the logistics turnover frequency can be reduced, the operation field area is saved, the labor intensity of workers is reduced, and the like, so that the assembly operation efficiency is improved.
At present, most of domestic valve enterprises lack unified information system support in operation, most of equipment does not have local area network access capability, manufacturing BOM data and working hour data which are closely related to production cannot accurately reflect effectiveness, and whole-course tracing cannot be realized in the whole production process.
And the novel heavy-calibre valve complete machine assembly line that this embodiment provided, configuration transport line 1, pre-compaction device, heavy-calibre workstation, AGV traction trolley 1, lift platform 2, the driving, the rocking arm hangs 6, the hydraulic pressure station, work or material rest etc., realize reducing commodity circulation number of times, save operation area, reduce artifical intensity of labour, data link through ethernet, MES high in the clouds is linked, the data acquisition of hardware has been realized, remote monitoring and diagnosis, realize the link of hardware and information-based system, satisfy the management demand (product quality, product cost, delivery cycle, fund availability factor, stock occupies) and user demand (exchange time limit, the production progress is trailed, production process quality control, completion data provide in real time). The principle of assembly back-pull is used, the catering is pulled through the assembly day operation plan, the logistics is pulled through the catering, the logistics is pulled through the logistics, the warehouse is pulled through the logistics, the linkage operation mode of assembly, catering, logistics and storage is achieved, and the assembly operation efficiency is improved due to the advantages of high safety, intelligence and automation degree of a valve assembly line. The requirements of intellectualization, mechanization, digitization, informatization, lean, networking, flexibility, visualization and the like are met, and the assembly balancing effect is maximized.
The embodiments of the present invention have been described in detail with reference to the accompanying drawings, but the present invention is not limited to the above embodiments. Even if various changes are made to the present invention, it is still within the scope of the present invention if they fall within the scope of the claims of the present invention and their equivalents.
Claims (17)
1. The utility model provides a novel heavy-calibre valve assembly line which characterized in that includes:
a transport line for transporting the valve parts;
the assembly platform is used for placing the valve parts during assembly and providing an assembly field;
the assembling station is used for assembling the valve, a lifting platform is arranged on the assembling station, and the lifting platform is used for an operator to stand and drive the operator to a required height;
the valve pre-tightening station is provided with a valve pre-tightening machine and is used for pre-tightening the valve and locking the large nut;
the valve test station is provided with pressure-resistant test equipment and is used for detecting whether the assembled valve is qualified or not;
and the trolley is connected with the assembly platform and is used for driving the assembly platform to the assembly station, the valve pre-tightening station, the assembly station and the valve test station in sequence according to an assembly process.
2. The novel large-caliber valve assembly line as claimed in claim 1, wherein the assembly stations comprise a first assembly station and a second assembly station, the first assembly station is used for installing the valve body assembly in the valve, and the second assembly station is used for connecting the valve body assembly and the actuator assembly in the valve body and connecting the actuator assembly and the accessory part assembly;
and the trolley drives the assembly platform to the first assembly station, the valve pre-tightening station, the second assembly station and the valve test station in sequence according to the assembly process.
3. The novel large-caliber valve assembly line as claimed in claim 2, wherein a running track is arranged according to the running track of the trolley in the assembly process, and the trolley runs on the running track.
4. The novel large bore valve assembly line of claim 3, wherein the cart is an automated cart that automatically travels along a track on the running rails.
5. The novel large-caliber valve assembly line as claimed in claim 3, wherein the running rail is a closed rail, and the closed rail is sequentially connected in series with the first assembly station, the valve pre-tightening station, the second assembly station and the valve test station to form a closed loop;
the valve pre-tightening station and the valve testing station are arranged in the closed track, and the conveying line and the assembling station are arranged outside the closed track.
6. A novel large bore valve assembly line as claimed in claim 3, wherein the transport line is located proximate to the first assembly station.
7. The novel large-caliber valve assembly line as claimed in claim 3, further comprising a packaging area for packaging the qualified valves and a reject area for placing the unqualified valves; the closed track passes through the packaging area and the unqualified product area, and the packaging area and the unqualified product area are arranged between the valve test station and the first assembly station.
8. The novel large-caliber valve assembly line as claimed in claim 1, wherein the pressure-resistant testing equipment performs a valve sealing performance test and a torque test on the assembled valve, and the valve sealing performance test comprises at least one of a shell water pressure test, an A/B surface water pressure test and an A/B surface air pressure test.
9. The assembly line of claim 1, wherein a marking machine is arranged on the valve test station for marking the qualified valve and the unqualified valve differently.
10. The novel large-diameter valve assembly line as claimed in claim 1, wherein the valve pre-tightening station and the valve testing station are provided with valve handling equipment, the valve handling equipment on the valve pre-tightening station is used for handling the valve during assembly between the valve pre-tightening station and the assembly platform, and the valve handling equipment on the valve testing station is used for handling the valve after assembly between the valve testing station and the assembly platform.
11. The novel large-caliber valve assembly line as claimed in claim 1, wherein the assembly platform is provided with a circumferential tooth punching hole or a V-shaped block with a guide rail for pressing and fixing the valve in assembly.
12. The novel large-caliber valve assembly line according to claim 1, wherein a slope-type material frame and a tool hanging chain are arranged on the assembly platform, the slope-type material frame is used for taking and placing the valve parts, and the tool hanging chain is used for hanging tools needed to be used in the assembly process.
13. The novel large-diameter valve assembly line as claimed in claim 1, wherein the valve pre-tightening machine is provided with a hydraulic station, a translation mechanism and a rotation mechanism, and is used for tightening the large nuts in the circumferential direction of the valve only by an adjustable torque wrench without moving an operator in a pre-pressing state.
14. The novel large-caliber valve assembly line as claimed in claim 1, wherein the trolley, the lifting platform, the valve pre-tightening machine and the pressure resistance testing equipment are provided with an overload protection device, an emergency braking device and a self-locking device.
15. The novel large-caliber valve assembly line as claimed in claim 1, wherein the valve pre-tightening machine and the pressure resistance test equipment are respectively provided with a data acquisition module, and the data acquisition module is used for acquiring data and outputting the data for monitoring and recording the data in the valve assembly process;
the data collected by the data collection equipment on the valve pre-tightening machine comprises valve pre-tightening force, and the data collected by the data collection equipment on the pressure measurement test equipment comprises at least one of torque, test pressure, test time and leakage amount.
16. A method of assembling a large diameter valve, comprising:
s1: transporting valve parts by a transport line;
s2: moving the valve parts from the shipping line to an assembly platform;
s3: the trolley drives the assembling platform to move to a first assembling station;
s4: completing the primary assembly of a valve body assembly in the valve on the assembly platform;
s5: the trolley drives the assembly platform to move to a valve pre-tightening station, and pre-tightening of the upper valve cover and the valve body of the valve body assembly and locking of the large nut are completed;
s6: the trolley drives the assembly platform to move to a second assembly station, connection of the valve body assembly and the actuating mechanism assembly, and connection of the actuating mechanism assembly and the accessory part assembly after the large nut is locked are completed, and assembly of the valve is completed;
s7: the trolley drives the assembly platform to move to a valve test station, the sealing performance of the assembled valve is tested, and qualified products and unqualified products are distinguished;
s8: the trolley transports the qualified products to a packaging area, and transports the unqualified products to an unqualified product area;
wherein the sequence of the step S2 and the step S3 can be switched.
17. The method of assembling a large diameter valve according to claim 16,
the step S4 includes: fixing a valve body on the assembly platform by a tool, installing a valve internal part according to an operation sequence, screwing a screw into a threaded hole of the valve body, and placing an upper cover on the valve body to finish the primary assembly of a valve body assembly in the valve;
the step S5 includes: the trolley drives the assembly platform to move to a valve pre-tightening station, the valve body assembly preliminarily assembled on the assembly platform is moved to a pre-tightening machine of the valve pre-tightening station, the pre-tightening machine presses a valve cover, a large nut is locked by a torque wrench, and then the valve body assembly locked by the large nut is moved to the assembly platform;
the step S6 includes: the trolley drives the assembly platform to move to a second assembly station, an actuating mechanism assembly in the valve is connected with the valve body assembly after the nut is locked, and then an accessory part in the valve is connected with the actuating mechanism assembly to complete assembly of the valve;
the step S7 includes: the trolley drives the assembly platform to move to a valve test station, the valve which is assembled is moved to the valve test station, the valve which is assembled is tested for sealing performance and is divided into a qualified product and an unqualified product, and the qualified product and the unqualified product are marked differently;
the step S8 includes: and moving the marked valve to the assembly platform, transporting the qualified product to a packaging area by the trolley, and transporting the unqualified product to an unqualified product area by the trolley.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111299176.8A CN114161135A (en) | 2021-11-04 | 2021-11-04 | Novel large-diameter valve assembly line and assembly method |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202111299176.8A CN114161135A (en) | 2021-11-04 | 2021-11-04 | Novel large-diameter valve assembly line and assembly method |
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| CN114161135A true CN114161135A (en) | 2022-03-11 |
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| CN202111299176.8A Pending CN114161135A (en) | 2021-11-04 | 2021-11-04 | Novel large-diameter valve assembly line and assembly method |
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Application publication date: 20220311 |