CN105773138B

CN105773138B - O-shaped four-tipping car dumper mounting process

Info

Publication number: CN105773138B
Application number: CN201610229161.7A
Authority: CN
Inventors: 张琦; 周合亭; 靳立开; 韩伯涛; 白赫; 杜国瑞
Original assignee: CCCC First Harbor Installation Engineering Co Ltd
Current assignee: CCCC First Harbor Installation Engineering Co Ltd
Priority date: 2016-04-12
Filing date: 2016-04-12
Publication date: 2020-04-28
Anticipated expiration: 2036-04-12
Also published as: CN105773138A

Abstract

The invention relates to an O-shaped four-tippler mounting process, which comprises the following steps: early preparation, basic retest, measurement unwrapping wire, equipment fixing. The installation process of the O-shaped four-tippler provided by the invention is convenient to operate, high in efficiency and high in precision, and can be installed in place.

Description

O-shaped four-tipping car dumper mounting process

Technical Field

The invention relates to the field of tippler installation, in particular to an O-shaped four-tippler installation process.

Background

With the increase of social demands on coal and ore port construction, various tipplers are continuously present therein. The mechanical equipment for harbor construction belongs to a loading and unloading mechanical part, and the tippler is in an important position in the loading and unloading machine and is a tap operated in the whole harbor, so the tippler is an indispensable important unit in harbor construction. Because of this, the process of installing the tippler is particularly important for harbour machinery.

Disclosure of Invention

The invention provides an O-shaped four-tippler installation process for realizing the aim, which comprises the following steps: preparing in an early stage, retesting and surveying again, paying off and installing equipment;

(1) early preparation:

when steel members are stacked, the same parts are stacked together, and the principle that the steel members are firstly mounted on the upper portion and then mounted on the lower portion is met;

preparing a cushion for adjustment, H-shaped steel for fixing a truss and corresponding safety facilities;

checking elevation before installation, and positioning the axis, the base axis and the position of the embedded plate;

before hoisting the member, checking whether the dimension of the member is consistent with the design requirement and whether the shape of the member is deformed;

determining and checking mechanical equipment for construction which can meet the requirements of site construction;

before installation, the integrity of mechanical equipment, a steel wire rope and a lifting appliance is checked, and trial lifting is ensured;

loading, unloading, transporting and stacking steel members, and taking measures for preventing damage and deformation;

(2) basic retesting and measurement setting:

the key points for carrying out comprehensive review and acceptance on the civil engineering foundation are as follows:

the deviation between the central line of the installation base of the tippler and the central line of the equipment body and the deviation between the central line of the positioning car cannot be more than 2 mm;

the span error of the tipper installation foundation cannot be larger than 2mm, the diagonal length error is within 2mm, the elevation deviation must be a negative value, secondary grouting is reserved, and the elevation deviation cannot exceed 10 mm;

the elevations of all the positions meet the installation design requirements of drawings;

deviation between the central lines of a reserved hole of a foundation bolt of the positioning lathe rack device and a reserved buried pipe is not more than 3 mm;

the positions of all civil embedded parts, the distribution and the trend of all ground cable ditches, and the cable bridges in the ditches are ensured to be reasonable, correct and complete and meet the requirements of equipment drawings;

carrying out basic scribing and determining an installation reference;

establishing and determining a central line of a tippler mounting base as a first datum line of all equipment mounting datum lines;

in the installation process, a measurer is arranged to measure basic elevation control points and elevations of each layer of the tipper pit regularly, and changes are found to be required to be reported in time so as to ensure the installation accuracy of the tipper;

rechecking the axes of the tipper pit, the belt conveyor system and the tipper system according to a design drawing, and if the deviation of the axes of the tipper pit is not large, determining the axis of the tipper system by taking the axis of the belt conveyor system as a basis;

(3) equipment installation:

the tippler integral frame comprises a feeding system, a main body structure, a driving device and a vehicle traction device, wherein the four parts are installed one by one;

① installation of feeding system

Before the funnel is installed, feeding system equipment below the funnel, including an activation feeder and a funnel lower walking platform, needs to be completely placed in a pit of a tipper;

the funnel is generally formed by welding steel plates, a wear-resistant lining plate is additionally arranged inside the funnel, the funnel is processed into 2 sections in a factory and is connected by bolts on site, and an assembling platform is required to be erected for ensuring the assembling precision during on-site assembly;

the funnel hoisting is carried out, according to the hoisting mechanical capacity, an integral hoisting mode is adopted, firstly, after the upper part and the lower part of the funnel are assembled, a main crane hoisting point is arranged at a small opening position at the top of the funnel, an auxiliary machine is arranged at the bottom of the funnel, then, the funnel is integrally laid on the ground, then, the funnel is integrally hoisted to the inside of a tipper pit, a first large-tonnage crane is needed, the hoisting radius and the hoisting angle of the crane are determined according to the actual weight of the funnel, and the funnel is placed in the tipper pit;

after the funnel is in place, adjusting the center line and the elevation of the funnel to meet the requirements of a drawing, fixing the funnel, installing and adjusting a steel grating, and pouring a bolt for the second time to coat the concrete at the joint;

before installing the bottom layer of the feeding system, firstly, hoisting all required equipment into the bottom layer;

before installation, firstly determining the central line of an activation feeder, wherein the central line of the activation feeder is consistent with the central lines of a belt conveyor and a support of the belt conveyor, the activation feeder and a vibration feeder are similar and are fed by the vibration of the equipment, a vibration system of the activation feeder consists of a vibration motor and a vibration spring, a main groove body is driven by the excitation force of the vibration motor to obtain required amplitude, the connection mode of the main groove body is the same as that of the vibration feeder and is supported by the support of the vibration feeder, and the support of the activation feeder is firstly installed and then the activation feeder is directly erected on the support;

after the central line of the belt conveyor is determined, the activating feeder support is installed according to a drawing, the support legs are installed at corresponding positions according to a construction drawing, the levelness and the verticality are adjusted and fixed, the activating feeder support and the foundation embedded part are connected in a welding mode, welding is carried out after the support adjustment is finished, and the requirement of the drawing is met;

when the walking platform is installed, the top surface of the walking platform is ensured to be consistent in level, the support foundation is retested before being installed, and is installed after being adjusted;

the mounting of the walking board on the tippler is coordinated with the mounting of other equipment, the mounting of the walking board at the opening side can be only carried out in a subsection mode, and after the support of the walking board is mounted in place, the platform cover plate can be fixed temporarily only, and the cover plate can be removed when needed, but the fixing form of the cover plate needs to adopt bolt connection so as to ensure the reliability of the mounting of the cover plate;

② mounting of main structure

The supporting device of the riding wheel is a supporting piece of the tipper rotating body, and the structure of the supporting device must bear the weight of the tipper main body;

the riding wheels are divided into two parts with wheel rims and two parts without wheel rims, and are installed according to the designed positions during installation, because the O-shaped four-tipping type tippler is installed at this time, the number of the riding wheel beams is four, each riding wheel needs to be installed in a number-matching manner during installation, under general conditions, the riding wheel beam at the vehicle inlet end is a fixed end, the riding wheel beam at the vehicle outlet end is a free end, and the riding wheel beams need to be installed in a number-matching manner during installation;

cleaning the surface of a connecting plate connected with a bottom beam and an end ring, wherein dirty soil, iron rust and burrs are not allowed, polishing once by using an angle grinder, keeping the lifting of the bottom beam horizontal, fastening two 10-ton chain blocks for adjustment, stably lifting the bottom beam, connecting one end of the bottom beam with the end ring by using bolts and a punching pin, supporting and adjusting the platform by using a tool support and a jack at the other end of the bottom beam, mounting the connecting plate and a high-strength bolt, detecting the perpendicularity of the end ring and the elevation of the bottom beam again after the connection is finished, fixing the platform until the platform is qualified, and adjusting the unqualified platform again;

the set of the tipper is provided with 2 groups of diagonal lines, when the diagonal lines are adjusted, two ends of the fixed two ends need to be pulled up by a spring scale, the adjustment precision is ensured, the fixed two ends are fixed after the adjustment is finished according to the requirements of drawings, and then the second-stage pouring and surface plastering are carried out;

each set of tippler has four end rings which are respectively set as 1#, 2#, 3#, 4#, 1# and 2# are a group, and 3# and 4# are a group;

when the end ring is hoisted, firstly, the end ring is overturned and hoisted by a main crane and an auxiliary crane, and when the end ring reaches the position of being hoisted into a pit of the tipper, the end ring is placed into the pit of the tipper by the main crane;

when the No. 1 end ring is in place, the center line of the end ring rail needs to be aligned with the center of a supporting wheel and the center line of a tipper, the elevation of a platform in the end ring needs to be adjusted, the spacing precision of the end ring needs to be controlled within +/-5 mm, and after the verticality is checked to be qualified by a theodolite, the platform is fixed by a steel wire rope and a chain block;

after the end ring is hoisted, the relative position and levelness of the end ring are adjusted by using a chain block, so that a platform is horizontally installed, a driving pinion and an end ring gear ring are meshed at the same elevation, a tooth type stopper which temporarily prevents rotation is timely installed for preventing the end ring from rotating due to unbalance weight, and the tooth type stopper is required to be removed after the whole tipper is installed and before trial run and operation;

before hoisting a No. 2 end ring, a main beam needs to be hoisted and adjusted;

the platform is a welded rigid frame type steel structure, the center distance of two main beams is the same as the track gauge of a train track, the two main beams are connected into a whole by a transverse secondary beam, and a pattern steel plate is welded on the transverse secondary beam and a steel rail is installed on the transverse secondary beam;

the total weight of the platform of the O-shaped four-tipping car dumper is about 40 tons and is as long as 20 meters, and the platform can be integrally hoisted; when the platform is hoisted, the platform is firstly translated along the ground and then hoisted to a mounting position, one end of each platform beam is placed on an end ring, two ends of each platform beam are respectively supported by steel structure supports, and two positions are jacked up by a jack at the contact position to adjust the levelness of the platform beam;

then hoisting a No. 2 end ring, after fixing the No. 1 end ring and the platform beam, hoisting the No. 2 end ring into a pit of the tipper, hoisting and adjusting the No. 1 end ring, after finishing the adjustment of all the end rings, driving positioning pins on each surface to fix the tipper body, then retesting the tipper body, after each group of end rings are installed in place, measuring the homotopic teeth, ensuring that the dislocation degree is normal within 2mm, and connecting high-strength bolts after retesting;

the No. 1 end ring, the No. 2 end ring, the platform and the front and rear beams are independent units, so when the No. 3 end ring, the No. 4 end ring, the platform and the front and rear beams are installed, the steps of the method are the same as the steps of the method;

the front beam and the rear beam are delivered integrally, the front beam and the rear beam are hoisted after the end ring and the platform are installed, and the hoisting and adjusting method is similar to that of the platform;

the car backing plate is large in size, is hoisted in place, is well connected with the pillar and the oil cylinder by the pin shaft, is positioned on a quasi plane vertical to the track surface of the bottom beam on the position where the car backing plate surface is parallel to the pillar, has deviation with the quasi plane not more than +/-5 mm, adjusts the baffle plates at two sides of the car backing plate to ensure that the clearance between the baffle plates and two sides of the back beam is 2.5mm, then fixes the car backing plate and the back beam by a chain block, removes all fixed facilities after the installation work is finished, can be provided with a hoisting nose before hoisting, and is provided with an adjustable point in the hoisting process to meet the requirement of micro adjustment in the process of installing each pin shaft;

③ mounting of drive device

The driving device is generally delivered integrally, before the hoisting is in place, the assembly conditions of the motor, the speed reducer, the brake and the coupling are checked, the transmission shaft and the bearing support thereof are delivered separately, when the transmission shaft and the bearing support thereof are installed, the transmission shaft is installed by taking the axis of the transmission shaft as a reference, the horizontal size and the elevation are detected so as to ensure the meshing position of the driving pinion and the end ring gear ring, the gap amount of the tooth top meets the requirement, then the driving device is aligned and leveled according to the axis, the elevation of the driving pinion and the motor base is ensured to be +/-3 mm, the horizontal position is ensured to be within 3mm, and the concrete and the plastering surface of the foundation bolt hole of the driving device and the transmission;

the two driving devices of each tippler are kept synchronous in an electrical and mechanical mode, and the mechanical synchronization adopts a low-speed shaft synchronization mode;

the driving device is arranged on a ground layer, and the driving motor, the reduction gearbox, the driving pinion and the synchronizing shaft are all isolated from the tipper pit;

before installation, foundation retest is carried out on embedded parts such as foundation bolts of a driving layer, the accurate size of the embedded parts is ensured, and the embedded parts can be installed after the motor base and the driving pinion base are installed and the elevation of the motor base and the driving pinion base is determined; the specific error requirement is determined according to the specific diameter of the transmission shaft; adjusting the precision requirements of the axle center elevation and the horizontal position of the driving pinion to be +/-3 mm and 3mm respectively, and adjusting the axial dislocation of the driving pinion and the large gear ring, wherein the precision is controlled to be 6 mm; after the driving pinion and the synchronizing shaft are installed, the coaxiality of the driving pinion and the synchronizing shaft needs to be adjusted, the adjustment is carried out according to error values corresponding to the diameters of all sections in the specification, the straightness and the levelness of the synchronizing shaft are ensured, the maximum and the minimum gaps at the two ends of the meshing part of the driving pinion and the large gear ring meet the port specification standard, and the tooth backlash gap is 2mm according to the design drawing technical requirement;

④ vehicle traction device mounting

The positioning vehicle consists of a vehicle body, a vehicle arm, a walking guide system, a driving device and a manual operation box, wherein the vehicle body is a heavy component welded by steel plates; the vehicle body is provided with a vehicle arm, a driving device of the vehicle arm is arranged on the vehicle body, a manual operation box is arranged on the vehicle body so as to be convenient for manual operation under the conditions of failure and maintenance, the vehicle arm is a steel plate welding box type component, the contraction of the vehicle arm and a coupler pin are both driven by hydraulic pressure, the driving device adopts a vector flow control variable frequency speed regulating motor, a driving pinion is driven by a speed reducer to form independent driving devices, the driving devices are arranged on the side of a rack, and the driving pinion is meshed with the rack to drive a positioning vehicle to move on a travelling track;

installing and adjusting each part of the walking track in sections, connecting and fixing the parts after adjusting the elevation and the straightness of the track by using a theodolite, installing a hydraulic buffer, fixing the track foundation, performing secondary grouting, installing a positioning vehicle main body on the track after the concrete strength after grouting meets the requirement, starting to install and adjust a driving device, then installing an encoder and a bracket thereof, installing a positioning vehicle arm frame after leveling the track of the cable trolley, and performing overall adjustment of the positioning vehicle system after connecting a side arm.

The invention has the beneficial effects that: the installation process of the O-shaped four-tippler provided by the invention is convenient to operate, high in efficiency and high in precision, and can be installed in place.

Detailed Description

The following will describe in detail embodiments of the present invention.

The installation process of the O-shaped four-tippler comprises the following steps: preparing in an early stage, retesting and surveying again, paying off and installing equipment;