Φ60-61-62液压紧配螺栓操作说明书

12000MPVΦ60/Φ61/Φ62液压紧配螺栓装拆操作说明书上海林辉实业有限公司液压紧配螺栓操作说明书一、原理简介液压紧配螺栓是用于法兰联轴节上的新型螺栓，它的最大优点是装拆方便省时。过去法兰式联轴节的联接螺栓采用非液压紧配螺栓（拂配螺栓），采用敲击或冷缩安装。第一种敲击方法费时费力，且易使接触面损伤，安装和拆卸都较困难。第二种冷缩方法，要采用冷却剂，使螺栓收缩后安装进螺孔中。用这种方法因冷却剂易挥发也较麻烦，特别是在拆卸时也要敲击或液压拉出，也易产生接触面损伤等问题。两种方法难于使螺栓重复使用。液压紧配螺栓安装时，就不需要进行冷却，只需要一个液压泵和一个液压拉伸器及简易的定位衬套，就能方便地将液压紧配螺栓安装或拆卸，并能保证所需要的过盈，螺栓可以反复使用。液压紧配螺栓由外表带有一定锥度的螺栓杆、内孔带有相应锥度的衬套及两只紧定螺母组成。螺栓两端有螺纹，衬套的外表是圆柱形的，且与螺栓孔有一定的间隙。对螺栓孔来说只要镗到或铰至公称尺寸的公差范围即可。二、安装和拆卸方法1、安装a）塞进液压螺栓并使衬套膨胀，使衬套和螺栓孔有一个适当过盈：清洗好螺栓孔和各零部件及安装工具。螺栓杆上要均匀的涂上防咬剂。将螺栓杆和衬套放入螺栓孔，装上安装定位座套，使衬套处于二法兰中间，然后装上液压拉伸器，使螺栓杆和衬套相对移动，衬套膨胀并与螺栓孔产生一定的过盈。（见表1）。记录此时的油压，拆下液压拉伸器。（图1）b）对液压紧配螺栓施加预紧力：拆下液压拉伸器，两端装上螺母，并紧，再在同一端装上液压拉伸器座套，然后再装上液压拉伸器，接上高压油泵，注油进液压拉伸器，使螺栓伸长。这时预紧油压分别采取72.76MPa（详见表1），用拨杆旋紧圆形紧定螺母，然后松掉液压拉伸器油压。2、拆卸a)卸下液压紧配螺栓轴向预紧力装上液压拉伸器座套及液压拉伸器，接上高压油泵向液压拉伸器注入高压油，用拨杆旋松紧定螺母，然后松掉液压拉伸器油压。b)松脱螺栓杆和衬套1）第一种松脱螺栓杆和衬套的方法：拆下液压拉伸器，紧定螺母留在螺栓杆上，小端螺母离法兰面6-8mm2）第二种松脱螺栓杆和衬套的方法：拆下螺栓杆紧定螺母，装上拆卸定位套及液压拉伸器，泵动液压位伸器，直至将螺栓杆从衬套中松脱出来，记录此时的松脱油压，即可取出螺栓杆和衬套。（图3）三、安装拆卸工具1、手动高压油泵1台2、液压拉抻器M48×5活塞面积：5360.35mm23、安装定位座套（用于定位中间锥套）1件4、拆卸定位座套（用于定位中间锥套）2件5、液压拉伸器座套1件6、高压软管1根7、压力表（高压泵上带即可不备）1只0-200MPa四、注意事项螺栓的外表面及衬套内表面必须清洁，安装时涂以清洁滑油或防咬剂。液压油牌号为普通46或32液压油，用量约3升。高压油泵用的液压油必须清洁，特别是在用第一种方法拆卸螺栓时。安装时参照液压紧配螺栓安装数据（见表1）。根据螺孔内径与中间锥套外径间隙值选取参数。膨胀中间锥套以相对移动量为主要安装依据，压力为辅。以拉伸器在螺栓螺纹上手动旋紧为移动量的起始点，使用磁性表座及百分表测量。当位移达到要求，安装压力小于表中安装压力的90%时，加压到安装压力的90%。表1液压紧配螺栓安装数据Φ60螺栓（主机与中间轴)Item符号单位计算数值衬套与螺栓孔间隙Δmm0.030.040.050.060.07衬套与螺栓孔安装过盈δ2mm-0.02-0.02-0.02-0.02-0.02安装时相对移动量Smm2.2642.6813.0983.5153.932安装时干拉力FN×103194.93209.72224.50239.29254.07液压拉伸器油缸面积Amm25360.355360.355360.355360.355360.35膨胀中间锥套的安装压力PN/mm236.3739.1241.8844.6447.40螺母预紧压力P1N/mm272.7672.7672.7672.7672.76Φ61螺栓（主机与中间轴)Item符号单位计算数值衬套与螺栓孔间隙Δmm0.030.040.050.060.07衬套与螺栓孔安装过盈δ2mm-0.02-0.02-0.02-0.02-0.02安装时相对移动量Smm2.2652.6823.0993.5163.932安装时干拉力FN×103191.59206.12220.64235.17249.70液压拉伸器油缸面积Amm25360.355360.355360.355360.355360.35膨胀中间锥套的安装压力PN/mm235.7438.4541.1643.8746.58螺母预紧压力P1N/mm272.7672.7672.7672.7672.76Φ62螺栓（主机与中间轴)Item符号单位计算数值衬套与螺栓孔间隙Δmm0.030.040.050.060.07衬套与螺栓孔安装过盈δ2mm-0.02-0.02-0.02-0.02-0.02安装时相对移动量Smm2.2692.6853.1023.5183.935安装时干拉力FN×103188.84203.23217.62232.01246.40液压拉伸器油缸面积Amm25360.355360.355360.355360.355360.35膨胀中间锥套的安装压力PN/mm235.2337.9140.6043.2845.97螺母预紧压力P1N/mm272.7672.7672.7672.7672.76Φ60螺栓(中间轴与螺旋桨轴)Item符号单位计算数值衬套与螺栓孔间隙Δmm0.030.040.050.060.07衬套与螺栓孔安装过盈δ2mm-0.02-0.02-0.02-0.02-0.02安装时相对移动量Smm2.2402.6573.0743.4913.908安装时干拉力FN×103205.31220.09234.87249.66264.44液压拉伸器油缸面积Amm25360.355360.355360.355360.355360.35膨胀中间锥套的安装压力PN/mm238.3041.0643.8246.5749.33螺母预紧压力P1N/mm272.7672.7672.7672.7672.76Φ61螺栓(中间轴与螺旋桨轴)Item符号单位计算数值衬套与螺栓孔间隙Δmm0.030.040.050.060.07衬套与螺栓孔安装过盈δ2mm-0.02-0.02-0.02-0.02-0.02安装时相对移动量Smm2.2412.6583.0753.4913.908安装时干拉力FN×103202.33216.86231.39245.91260.44液压拉伸器油缸面积Amm25360.355360.355360.355360.355360.35膨胀中间锥套的安装压力PN/mm237.7540.4643.1745.8848.59螺母预紧压力P1N/mm272.7672.7672.7672.7672.76Φ62螺栓(中间轴与螺旋桨轴)Item符号单位计算数值衬套与螺栓孔间隙Δmm0.030.040.050.060.07衬套与螺栓孔安装过盈δ2mm-0.02-0.02-0.02-0.02-0.02安装时相对移动量Smm2.2442.6603.0773.4933.910安装时干拉力FN×103199.95214.34228.73243.12257.51液压拉伸器油缸面积Amm25360.355360.355360.355360.355360.35膨胀中间锥套的安装压力PN/mm237.3039.9942.6745.3648.04螺母预紧压力P1N/mm272.7672.7672.7672.7672.76图1液压紧配螺栓安装示意图图2液压紧配螺栓拆卸示意图（方法一）图3液压紧配螺栓拆卸示意图（方法二）InstructionforassemblinganddisassemblingAbstractofprinciplesHydraulicsupergripboltisanew-typeboltusedonflangeshaftjoints.Easytoassembleanddisassembleisitskeymerit.Traditionalconnectingboltusedonflange-formshaftjointsarenon-hydraulicsupergripbolt,usinghammeringorshrinktechniquetoassembling.Hammeringwastestimeaswellaseffortsandmakesiteasytoimpairthesurfaceandhardtoassembleanddisassemble.Shrinkingneedsrefrigerant,puttheboltintoholeafteritshrinks.Thistechniqueisnotsoconvenientbecauseofvolatilizationoftherefrigerant.Whenremoving,hammeringandhydraulicpulloutmayeasilycausesurfaceimpairment.Bothtechniquemaketheboltshardtoberepeatedlyused.Whenfixinghydraulicsupergripbolt,shrinkisnotneeded.Weonlyneedahydraulicpump,ahydraulicstretcherandsimplepositioningbushtoassembleanddisassembleandmakesureofdesiredinterference.Boltscanbeusedrepeatedly.Hydraulicsupergripboltcomprisesofaboltshankwithcone-shapedexteriorsurface,abushwiththerelevantdegreeofcone-shapedinnerholeandtwoholdingnuts.Thereisscrewatbothendsofthebolt,andtheexteriorsurfaceofthebushiscylindricalwithsomeclearancefromthebolthole.Theboltonlyneedtobeboredorreamedtothetolerancerangeofthenominaldimension.Techniquesforassemblinganddisassembling1.Assemblinga)Corkinthehydraulicbolttomakethebushexpand,sothatthereisaproperinterferencebetweenthebushandthebolthole:Washtheboltholeandotherpartsandinstallationkits.Boltshankshouldbesmearedwithanti-bitesubstancehomogeneously.Puttheboltshankandbushintothebolthole,assembleinstallationpositioningsleeve,makesurethebushisatthemiddleofthetwoflanges,andthenfitoverhydraulicstretcher,makesurethereisrelativeshiftbetweenboltshankandbush.Expansionthebushuntilthereissomeshrinkrangebetweenbushandbolthole.writedownthecurrentoilpressure,thenremovethehydraulicstretcher.(seefig1)b)Applypre-tighteningforcetothehydraulicsupergripbolt:Removethehydraulicstretcher,fixnutsatbothends,andscrewthemtight,thenfixthesocketsleeveofhydraulicstretcheratthesameend,thenfixthehydraulicstretcher,switchonthehigh-pressureoilpumptopumpoilintothehydraulicstretcherinordertomaketheboltelongate.Letthecurrentpre-tighteningoilpressureequal72.76MPa,screwtighttheholdingnutswithdeflectorrod,andthenreleasetheoilpressureofthehydraulicstretcher.2.Disassemblinga)Releasetheaxialpre-tighteningforceofthehydraulicsupergripbolt.Fixhydraulicstretchersocketsleeveandhydraulicstretcher;switchonthehigh-pressureoilpumptopumpinhigh-pressureoilunscrewtheholdingnutswithdeflectorrodandthenreleasetheoilpressureofthehydraulicstretcher.b)Unscrewtheboltshankandbush.1)TechniqueNO.1:removethehydraulicstretcher,leavetheholdingnutsontheboltshank,withthesmallendnut6-8mmawayfromthesurfaceoftheflange,connectthehigh-pressureoiltothecorenutoftheboltshank,pumpinoil,untilthebushandtheboltshankgetloosethemselves,whitedownthecurrentoilpressure,andthentheboltshankandbushcanbetakenout.(Seefig2)2)TechniqueNO.2:removeboltshankholdingnuts,fixinstallationpositioningsleeveandhydraulicstretcher,andpumpthehydraulicstretcheruntiltheboltshankgetloosefromthebush.Writedownthecurrentloosingoilpressure,andtheboltshadandbushcanbetakenout.(Seefig3)Installationofremovingtools1.Manualhigh-pressureoilpumpl2.Hydraulicstretcher1M48X5(Areaofhydraulicstretcheris5360.35mm2.)3.Installationpositioningsocketsleeve14.Assemblingpositioningsocketsleeve25.Socketsleeveofhydraulicstretcher16.High-pressuretube17.Manometer10-200MPa(unnecessaryifmanometerhasone)Mattersneedattention1.Theexteriorsurfaceoftheboltandtheinternalsurfaceofthebushmustbeclean,andshouldbesmearedwithlubricatingoilandanti-bitesubstance.2.Thehigh-pressureoilusedinthehigh-pressureoilpumpmustbeclean,especiallywhenusingtechniqueNO.1toremovethebolt.3.Selecttheparametersaccordingtotheclearanceoftheintersleeveandtheholeoftheflange.Whenexpandingtheintersleeve,therelativemovementisthemaininstallationbasis,andthepressureissecondary.Manuallytightenthestretcherontheboltthreadasthestartingpointofthemovement.Whenthedisplacementreachestherequirementsandtheinstallationpressureislessthan90%oftheinstallationpressureinthetable,90%oftheinstallationpressureispressurized.List1TheDataofInstallationΦ60Bolts（forcouplingshaftbetweenintermediateshaftandmainengine）ItemSymbolUnitDataClearanceofTheInterSleeveandTheHoleofTheFlangeΔmm0.030.040.050.060.07ClearanceofTheInterSleeveandTheHoleofTheFlangeAfterInstallationδ2mm-0.02-0.02-0.02-0.02-0.02RemoveAfterInstallationSmm2.2642.6813.0983.5153.932PullofInstallationFN×103194.93209.72224.50239.29254.07AreaofhydraulicstretcherAmm25360.355360.355360.355360.355360.35PressureofinstalltheboltPN/mm236.3739.1241.8844.6447.40PressureofinstallthenutPN/mm272.7672.7672.7672.7672.76Φ61Bolts（forcouplingshaftbetweenintermediateshaftandmainengine）ItemSymbolUnitDataClearanceofTheInterSleeveandTheHoleofTheFlangeΔmm0.030.040.050.060.07ClearanceofTheInterSleeveandTheHoleofTheFlangeAfterInstallationδ2mm-0.02-0.02-0.02-0.02-0.02RemoveAfterInstallationSmm2.2652.6823.0993.5163.932PullofInstallationFN×103191.59206.12220.64235.17249.70AreaofhydraulicstretcherAmm25360.355360.355360.355360.355360.35PressureofinstalltheboltPN/mm235.7438.4541.1643.8746.58PressureofinstallthenutPN/mm272.7672.7672.7672.7672.76Φ62Bolts（forcouplingshaftbetweenintermediateshaftandmainengine）ItemSymbolUnitDataClearanceofTheInterSleeveandTheHoleofTheFlangeΔmm0.030.040.050.060.07ClearanceofTheInterSleeveandTheHoleofTheFlangeAfterInstallationδ2mm-0.02-0.02-0.02-0.02-0.02RemoveAfterInstallationSmm2.2692.6853.1023.5183.935PullofInstallationFN×103188.84203.23217.62232.01246.40AreaofhydraulicstretcherAmm25360.355360.355360.355360.355360.35PressureofinstalltheboltPN/mm235.2337.9140.6043.2845.97PressureofinstallthenutPN/mm272.7672.7672.7672.7672.76Φ60Bolts（forandpropellershaft）ItemSymbolUnitDataClearanceofTheInterSleeveandTheHoleofTheFlangeΔmm0.030.040.050.060.07ClearanceofTheInterSleeveandTheHoleofTheFlangeAfterInstallationδ2mm-0.02-0.02-0.02-0.02-0.02RemoveAfterInstallationSmm2.2402.6573.0743.4913.908PullofInstallationFN×103205.31220.09234.87249.66264.44AreaofhydraulicstretcherAmm25360.355360.355360.355360.355360.35PressureofinstalltheboltPN/mm238.3041.0643.8246.5749.33PressureofinstallthenutPN/mm272.7672.