阅读说明：本技术 一种适用于旋塞阀检维修作业的成套装置及作业方法 (Complete device and operation method suitable for plug valve maintenance operation ) 是由 林耀军 张前 敖潘 王艳 卢晨 李娜 于 2021-09-02 设计创作，主要内容包括：一种适用于旋塞阀检维修作业的成套装置,上下料模块用于抓取待检旋塞阀；输送装置设置在两个模块之间,用于传输旋塞阀。拆卸模块拆卸阀芯和阀盖,清洗模块对旋塞阀进行清洗；检测模块对旋塞阀进行磁粉检测；维修装配模块将维修好的旋塞阀重新装配液压控制系统7用于控制所有模块中的液压缸和液压马达；各功能模块可单独使用,也可以组合使用。本发明从输送、拆卸、到清洗、检测都环节都无需人工搬运,规范检维修流程,大幅降低劳动强度,提升工作效率。(A complete set of device suitable for plug valve maintenance work is provided, wherein a feeding and discharging module is used for grabbing a plug valve to be detected; the conveying device is arranged between the two modules and used for conveying the plug valves. The disassembly module is used for disassembling the valve core and the valve cover, and the cleaning module is used for cleaning the plug valve; the detection module performs magnetic particle detection on the plug valve; the maintenance assembly module reassembles the maintained plug valve with the hydraulic control system 7 to control hydraulic cylinders and hydraulic motors in all modules; each functional module can be used independently or in combination. The invention does not need manual transportation from the links of conveying, disassembling, cleaning and detecting, standardizes the inspection and maintenance process, greatly reduces the labor intensity and improves the working efficiency.)

1. The utility model provides a complete sets suitable for maintenance operation is examined to plug valve which characterized in that includes: the device comprises a feeding and discharging module, a conveying device, a disassembling module, a cleaning module, a detection module, a maintenance assembly module and a hydraulic control system;

the feeding and discharging module is used for grabbing the plug valve to be detected;

the conveying device consists of a feeding conveying device, an intermediate conveying device and a discharging conveying device; the conveying device module is arranged between the two modules and is used for conveying the plug valve;

the disassembly module comprises a plug valve clamping device, a valve cover knocking device, a valve cover disassembling device, a valve core disassembling device and a cantilever crane; the plug valve clamping device is used for clamping the plug valve, the valve cover knocking device releases the thread stress of the valve cover, the valve cover dismounting device demounts the valve cover, the valve core dismounting device demounts the valve core, and the cantilever crane is used for hoisting and displacing the plug valve component;

the cleaning module cleans the plug valve;

the detection module performs magnetic particle detection on the plug valve;

the maintenance assembly module reassembles the repaired plug valve

The hydraulic control system 7 is used for controlling hydraulic cylinders and hydraulic motors in all the modules;

each functional module can be used independently or in combination.

2. A use method of a complete device suitable for plug valve maintenance operation comprises the following specific steps:

(1) starting a power supply of the equipment, starting a hydraulic control system and preparing;

(2) automatically identifying and grabbing the plug valve to be detected on the ground through the feeding and discharging module, and placing the plug valve to be detected on the feeding and discharging device;

(3) the conveying device moves the plug valve to the disassembling module to disassemble the plug valve; when the valve cover is disassembled, the thread stress of the valve cover is released firstly, and then the valve cover and the valve core are disassembled in sequence;

(4) conveying the disassembled plug valve to a cleaning module through a conveying device; the cleaning module consists of a soaking tank and an air purging device, wherein the air purging device is used for purging the plug valve part to remove surface impurities after the plug valve part is soaked in kerosene in the soaking tank;

(4) the conveying device conveys the cleaned plug valve component to the detection module, and the detection module performs wall thickness measurement, hardness measurement and magnetic powder detection on the plug valve component; removing the defective product;

(5) the maintenance assembly module reassembles the qualified products detected in the step 4;

(6) the assembled stopcock is delivered to a blanking conveyor to move it from the ground.

Technical Field

The invention relates to the technical field of plug valve maintenance, in particular to a complete device and an operation method suitable for plug valve maintenance operation.

Background

The plug valve is a core component for well cementation and fracturing operation construction, is used for controlling sand fluid delivery, and has the working pressure of between 35 and 140MPa and the diameter range of between 2 and 4 inches. According to the standard, after the oil well is used for a period of time, the oil well needs to be detected and maintained. The traditional detection and maintenance steps of the plug valve in service are that the union joint of the plug valve is fixed on an upright post, a special disassembling tool is utilized to open the valve cover of the plug valve, the valve core is pulled out, cleaning and detection are carried out, and finally parts are replaced and assembly is carried out. If the valve cover of the plug valve is seriously corroded in thread, sand grains block the threaded connection part or the valve cover is suppressed and deformed, the valve cover is time-consuming and labor-consuming to disassemble. The whole process needs manual carrying, particularly for the large-drift-diameter plug valve, the weight of the plug valve can reach more than 200 kilograms, the labor intensity of personnel is high, the working efficiency is low, and the quality of inspection and maintenance is influenced.

Disclosure of Invention

The invention provides a complete device and an operation method suitable for plug valve inspection and maintenance operation, which do not need manual transportation in the links from conveying, disassembling, cleaning and detecting, standardize inspection and maintenance processes, greatly reduce labor intensity and improve working efficiency.

In order to solve the technical problems, the invention is realized by the following technical scheme:

the utility model provides a complete sets suitable for maintenance operation is examined to plug valve which characterized in that includes: the device comprises a feeding and discharging module, a conveying device, a disassembling module, a cleaning module, a detection module, a maintenance assembly module and a hydraulic control system;

the feeding and discharging module is used for grabbing the plug valve to be detected;

the conveying device consists of a feeding conveying device, an intermediate conveying device and a discharging conveying device; the conveying device module is arranged between the two modules and used for conveying the plug valves.

The disassembly module comprises a plug valve clamping device, a valve cover knocking device, a valve cover disassembling device, a valve core disassembling device and a cantilever crane; the plug valve clamping device is used for clamping the plug valve, the valve cover knocking device releases the thread stress of the valve cover, the valve cover dismounting device demounts the valve cover, the valve core dismounting device demounts the valve core, and the cantilever crane is used for hoisting and displacing the plug valve component;

the cleaning module cleans the plug valve;

the detection module performs magnetic particle detection on the plug valve;

the maintenance assembly module reassembles the repaired plug valve

The hydraulic control system 7 is used for controlling hydraulic cylinders and hydraulic motors in all the modules;

each functional module can be used independently or in combination.

A use method of a complete device suitable for plug valve maintenance operation comprises the following specific steps:

(1) starting a power supply of the equipment, starting a hydraulic control system and preparing;

(2) automatically identifying and grabbing the plug valve to be detected on the ground through the feeding and discharging module, and placing the plug valve to be detected on the feeding and discharging device;

(3) the conveying device moves the plug valve to the disassembling module to disassemble the plug valve; when the valve cover is disassembled, the thread stress of the valve cover is released firstly, and then the valve cover and the valve core are disassembled in sequence;

(4) conveying the disassembled plug valve to a cleaning module through a conveying device; the cleaning module consists of a soaking tank and an air purging device, wherein the air purging device is used for purging the plug valve part to remove surface impurities after the plug valve part is soaked in kerosene in the soaking tank;

(4) the conveying device conveys the cleaned plug valve component to the detection module, and the detection module performs wall thickness measurement, hardness measurement and magnetic powder detection on the plug valve component; removing the defective product;

(5) the maintenance assembly module reassembles the qualified products detected in the step 4;

(6) the assembled stopcock is delivered to a blanking conveyor to move it from the ground.

After the technical scheme is adopted, the invention has the beneficial effects that:

1) the traditional plug valve inspection and maintenance mode is that the plug valve is placed on the ground and all actions are completed, disassembling, detecting and assembling stations are scattered, carrying actions are repeated and frequent, the flow is disordered, and the inspection and maintenance quality is influenced. The invention adopts a flow line operation mode, has compact detection and maintenance procedures, high working efficiency and standard flow, avoids the omission and omission of detection and improves the detection and maintenance quality.

2) The maintenance needs rely on the manual transport of personnel to traditional plug valve is examined, when dismantling the valve gap, relies on special extracting tool manual dismantlement, especially to the serious plug valve of corrosion, needs the manual work to strike to pound and just can open the valve gap, and staff's whole intensity of labour is big. The plug valve inspection and maintenance device designed by the invention is carried, disassembled and assembled by depending on hydraulic driving force, has high automation degree, and greatly reduces the labor intensity of personnel in a plurality of processes.

Drawings

Fig. 1 is a schematic structural diagram of an embodiment of the present invention.

Detailed Description

The present invention will now be described in further detail with reference to the accompanying drawings and examples, it being understood that the examples described are only some, but not all, of the examples of the invention.

The invention discloses a structural schematic diagram of an embodiment shown in figure 1, and discloses a complete device and a working method suitable for plug valve maintenance operation, which are characterized by comprising the following steps: the device comprises a feeding and discharging module 1, a conveying device module 2, a disassembling module 3, a cleaning module 4, a detection module 5, a maintenance and assembly module 6 and a hydraulic control system 7. And modules are combined according to actual needs, each module can work independently, and partial functional modules can be added or removed.

Go up unloading module 1 comprises intelligent machine hand, relies on machine vision to snatch the wait to examine plug valve on ground automatically, puts it on material conveying device, perhaps unloads the plug valve of having examined from material conveying device.

The conveyor module 2 includes a feeding conveyor 21, an intermediate conveyor 22, and a discharging conveyor 23. The conveyer belt of the conveyer device is a steel wire rope core conveyer belt, and the conveyer belt moves in the horizontal direction and has a distance of 1m with the ground. Between each functional module is arranged a set of intermediate transfer devices 22, which can be operated individually. The movement of the conveyer belt is driven by a motor.

The disassembling module 3 is composed of a plug valve clamping device, a valve cover knocking device, a valve cover disassembling device, a valve core disassembling device and a cantilever crane. The plug valve clamping device consists of a hydraulic fixed platform and a hydraulic moving platform, clamps of the hydraulic fixed platform and the hydraulic moving platform are V-shaped, the thickness of the clamps is 50mm, and the action of the hydraulic moving platform is controlled by an O-shaped reversing valve. The valve cover knocking device is composed of a copper bar and a vertical movement mechanism, the diameter of the copper bar is 40mm, the vertical movement mechanism drives the copper bar to vertically reciprocate, the action of knocking the valve cover is achieved, and the thread stress of the valve cover is released. The valve cover dismounting device consists of a hydraulic motor and a claw disc, wherein one side of the claw disc is provided with a raised pin, the other side of the claw disc is in threaded connection with the hydraulic motor, the dismounting action of the valve cover is realized by the torque force of the hydraulic motor, and the hydraulic motor is provided with a torque force value display device. The valve core dismounting device consists of a pull rod, a bushing and a rotary motion mechanism, wherein a male buckle of the bushing can be in threaded connection with the valve core of the plug valve, a female buckle of the bushing is in threaded connection with the pull rod, and the thread turning directions of the male buckle and the female buckle are consistent. The rotary motion mechanism drives the pull rod to rotate, so that the valve core of the plug valve can spirally move until the valve core is completely pulled out. A cantilever crane is used to hoist and displace the plug valve member. The hydraulic moving platform, the vertical movement mechanism and the rotary movement mechanism are driven by a hydraulic oil cylinder.

The cleaning module 4 consists of a soaking tank, a filter screen, a horizontal pushing mechanism, a lifting mechanism and an air purging device. The horizontal pushing mechanism is used for pushing the component to the upper part of the filter screen. Under the action of the lifting mechanism, the filter screen can sink below the kerosene liquid level of the soaking tank. When the cock valve member is fully soaked in kerosene, the filter screen can rise to float out of the kerosene liquid level to a specified height under the action of the lifting mechanism. The air purging device is used for purging the plug valve component to remove surface impurities. The actions of the horizontal pushing mechanism and the lifting mechanism are driven by a hydraulic oil cylinder.

The detection module 5 consists of a horizontal pushing mechanism, a flaw detection operating platform, a darkroom, a fluorescent magnetic powder flaw detector, a magnetic suspension circulating and stirring system and a cantilever crane. The horizontal pushing mechanism is used for pushing the part to a flaw detection operating platform, the flaw detection operating platform is located in a darkroom, the fluorescent magnetic powder flaw detector is used for carrying out magnetic powder detection on the part, and the magnetic suspension circulating stirring system is used for recovering, filtering and storing used magnetic suspension for repeated use. The action of the horizontal pushing mechanism is driven by a hydraulic oil cylinder.

The maintenance assembly module 6 consists of a plug valve clamping device, a valve cover screwing device, a valve core jacking device and a lubricating grease filling system. The plug valve clamping device consists of a hydraulic fixed platform and a hydraulic movable platform. The valve core jacking device consists of a jacking hydraulic cylinder and a fixed support, the cylinder barrel of the jacking hydraulic cylinder is hinged with the fixed support, and a piston rod of the jacking hydraulic cylinder jacks the valve core and pushes the valve core into a designated position of an inner cavity of a valve body of the plug valve. The valve cover screwing device consists of a hydraulic motor and a claw disc and is used for screwing the valve cover of the plug valve, and the hydraulic motor is provided with a torsion value display device. And the lubricating grease filling system is used for filling lubricating grease into the assembled plug valve. The hydraulic mobile station is driven by a hydraulic oil cylinder.

The hydraulic control system 7 is composed of a hydraulic pump, a hydraulic oil tank, a hydraulic oil circuit and a control valve table and is used for controlling all hydraulic cylinders and hydraulic motors to act.

The using method comprises the following steps:

1) and starting a power supply of the device, starting the hydraulic control system 7 and the magnetic suspension circulating stirring system, and preparing.

2) Rely on intelligent machine hand's machine vision function automatic identification and snatch subaerial waiting to examine plug valve, put it to material loading conveyor 21 on, put behind a certain quantity of plug valves, make material loading conveyor 21's conveyer belt motion, transport the plug valve to dismantling module 3.

3) The plug valve is placed at a reasonable position between the hydraulic fixed platform and the hydraulic moving platform, the hydraulic fixed platform is kept fixed, the hydraulic moving platform is enabled to move horizontally, the plug valve is clamped between the hydraulic moving platform and the hydraulic fixed platform, the O-shaped hydraulic reversing valve is operated, and the position of the plug valve is locked. And spraying a rust remover to the rusted connecting part of the plug valve, and removing the connecting bolt and the valve cap. For the plug valve with the valve cover provided with the dismounting hole and difficult dismounting, the vertical movement mechanism is operated to enable the copper rod to vertically reciprocate, so that the copper rod repeatedly strikes the valve cover to release the thread stress of the valve cover. The claw disc of the valve cover dismounting device is controlled to move, the pin on the claw disc is ensured to be inserted into the dismounting hole of the valve cover of the plug valve, the hydraulic motor is started, the plug valves with different specifications need to be dismounted by adopting different torque values, and the torque value displayed on the torque value display device is observed in real time during dismounting, so that the valve cover is separated from the valve body. And operating the rotary motion mechanism to enable the male buckle of the bushing to be in threaded connection with the plug valve core and realize the spiral motion of the plug valve core until the plug valve core is completely pulled out. And finally, removing the valve clack and the sealing ring in the plug valve. The plug valve components, which are visually observable and confirmed to be rejected, are lifted and removed by the cantilever crane.

4) The disassembled parts are conveyed to the designated position of the cleaning module 4 through the middle conveying device 22, the parts are pushed onto the filter screen by the horizontal pushing mechanism, and the filter screen is sunk below the kerosene liquid level of the soaking tank by the aid of the lifting mechanism. When the plug valve component is fully soaked by kerosene, the filter screen floats out the kerosene liquid level to a specified height by virtue of the lifting of the lifter, and the air purging device purges the plug valve component to remove surface impurities.

5) The cleaned parts are conveyed to the designated position of the detection module 5 through the intermediate conveying device 22, the parts are pushed to a flaw detection operation table by the horizontal pushing mechanism, and part appearance inspection, wall thickness measurement, hardness measurement and magnetic powder detection are carried out according to the detection standard requirements. During magnetic particle inspection, the qualified illuminance of a darkroom is ensured, and a fluorescent magnetic particle flaw detector is adopted to carry out magnetic particle inspection on the component. And classifying the parts with the defects of cracks and the like, and hoisting and removing the parts by using the cantilever crane.

6) The detected components are conveyed to the designated position of the maintenance assembly module 6 through the intermediate transmission device 22, the hydraulic fixing table is kept fixed, the hydraulic moving table moves horizontally, the plug valve is clamped between the hydraulic moving table and the hydraulic fixing table, the O-shaped hydraulic reversing valve is operated, and the position of the plug valve is locked. And installing the valve clack and a sealing ring. The hydraulic cylinder is controlled to be jacked in an operation mode, the axes of a piston rod of the jacking hydraulic cylinder, the valve core and the plug valve body are overlapped, the valve core is jacked by the piston rod of the jacking hydraulic cylinder and pushed into the designated position of the inner cavity of the plug valve body. The control valve cover screwing device is operated to screw the valve cover of the plug valve, the plug valves with different specifications need to adopt different torque values to assemble the valve cover, and the torque value displayed on the torque value display device is observed in real time during screwing, so that the actual torque value is ensured to be equal to the specified torque value. And (4) filling lubricating grease into the assembled plug valve by adopting a lubricating grease filling system.

7) The assembled plug valves are conveyed to the discharging conveying device 23, the inspected plug valves are automatically identified and grabbed by means of the machine vision function of the intelligent mechanical arm, and the inspected plug valves are placed at the designated positions on the ground.

The invention can avoid manual handling of the plug valve in the whole process, and simultaneously, each functional module can be used independently or in combination to finish various operations of the plug valve. The invention has high automation degree and good maintenance quality.