CN110871328A - Manufacturing process of ultra-large rail crane girder structure - Google Patents
Manufacturing process of ultra-large rail crane girder structure Download PDFInfo
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- CN110871328A CN110871328A CN201911053627.2A CN201911053627A CN110871328A CN 110871328 A CN110871328 A CN 110871328A CN 201911053627 A CN201911053627 A CN 201911053627A CN 110871328 A CN110871328 A CN 110871328A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/28—Beams
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Abstract
The invention relates to a manufacturing process of a girder structure of an ultra-large type rail crane, which is characterized by comprising the following steps: the specific manufacturing process is as follows: including S1: manufacturing a main beam assembly; s2: manufacturing a rigid leg assembly; s3: manufacturing a flexible leg assembly; s4: integrally assembling; the box body adopts a process method of manufacturing and detecting at the same time, and the detection of key data is carried out in each step to ensure the manufacturing precision of the box body; in addition, the welding precision of the box body is ensured and the prestress generated in the welding process is reduced according to the principle that the box body is welded from inside to outside and from the middle to two sides; the box body in the invention forms pre-camber in the processing process, and finally releases stress under the action of self-weight, thereby reducing the subsequent stress elimination treatment.
Description
Technical Field
The invention relates to the field of manufacturing of rail crane girders, in particular to a manufacturing process of an ultra-large rail crane girder structure.
Background
With the development of inland China, the transportation industry develops rapidly, the transportation along rivers and railways is prosperous, a large number of containers are transported to the inland, and the requirements of each container yard on the rail type container crane are more and more increased.
The weight and the size of a girder of a traditional rail type container crane (called a rail crane for short) are large, the manufacturing and welding processes of a flexible leg assembly and a rigid leg assembly on a girder box body and the box body are time-consuming, the effect of construction steps is often not detected in time in the process sequence, the integral structural error is large, and the prestress needs to spend a large amount of time for correction. How to ensure the product quality of the rail crane girder after the manufacturing, welding and installation is an important subject of rail crane manufacturing and installation enterprises.
Disclosure of Invention
The invention aims to provide a manufacturing process of an ultra-large rail crane girder structure, which can solve the problems that the whole structure error is large and the prestress needs to spend a large amount of time for correcting because the general rail crane girder manufacturing and welding process is time-consuming and the effect of construction steps is often not detected in time in the process sequence.
In order to solve the technical problems, the technical scheme of the invention is as follows: a manufacturing process of a girder structure of an ultra-large type rail crane has the innovation points that: the specific manufacturing process is as follows: including S1: manufacturing a main beam assembly; s2: manufacturing a rigid leg assembly; s3: manufacturing a flexible leg assembly; s4: integrally assembling;
s1: manufacturing a main beam assembly:
s1.1: assembling a box body: assembling and forming the box body by adopting a reverse manufacturing method, after the panel is hoisted to the box body assembly jig frame, arranging partition plates to be welded in the panel in sequence at equal intervals, and enabling the panel to surround the partition plates; placing a reverse deformation block at the inner section of the central line of the supporting leg, bending the reverse deformation block by 20-25mm, placing the reverse deformation block from the central line of the supporting leg to the end beam section, bending the reverse deformation block by 15-20mm outwards to ensure that the central lines correspond, and then performing spot welding and fixing; before welding the box body, the center of the rail bearing beam is used as a reference, the equal distance from the centers of the upper panel and the lower panel to the center of the rail bearing beam is detected, and the box body is not required to be adjusted in place;
s1.2: welding a box body: welding external fillet welds by using an automatic fillet welding trolley, wherein the welding sequence of the box body is divided into the steps of before turning over and after turning over, and the turning-over angle is 180 degrees; before turning over, welding according to the sequence of the welding seam in the length direction of the partition board, the welding seam in the width direction of the bottom end of the partition board, the fillet welding seam at the inner end of the bottom end of the box body and the fillet welding seam at the outer end of the bottom end of the box body; after the box body is turned over for 180 degrees, welding seams in the width direction of the bottom end of the partition plate, fillet welding seams at the inner end of the bottom end of the box body, fillet welding seams at the outer end of the bottom end of the box body and welding seams between the outer surface of the top end of the box body and the rail supporting beam are welded in sequence;
s1.3: and (3) detection of the box body: the box body is provided with 10-15mm of inward bend at the inner sides of the central lines of the two supporting legs, and 0-10mm of outward bend is arranged from the central line of the supporting leg to the end part of the box body without sudden change; after welding, checking that the outline dimensions of four sides and the deviation within the range of 1m of the central lines of the upper and lower panels need to be less than 3mm, and the flatness error of the rail bearing beam is +/-0.5 mm; the camber of the box body is 1.25-1.4F, and the box body needs to be adjusted in place if the camber is not met;
s1.4: and (3) mounting a box body assembly: jacks are respectively adopted to support two zero-position points on the box body, the central line of the rail bearing beam, the installation line of the pressure plate bottom plate and the installation line of the buffer bracket component are drawn out, the pressure plate bottom plate and the buffer bracket are installed in place according to the drawing, and the welding is firm; after welding, re-testing the inward bending, the flatness and the finished product camber of the box body again according to the detection requirement of S1.3;
s1.5: the box body is provided with a sample punching hole: releasing stress of the box body in a free state, and knocking out a sample punching hole at the center of a pressing plate bottom plate deleted at a rigid leg zero point, a box body transverse center position and a flexible leg zero point of the box body respectively to make a mark after the center line of a re-measured pressing plate is superposed with the center line of a rail supporting beam; marking a sample punching hole after the central line of the box body is retested to be qualified, wherein the sample punching hole is used as a reference for assembling the box body out of the workshop;
s2: manufacturing the rigid leg assembly: the rigid leg assembly comprises a pair of side plates and a pair of main plates; a pair of side plates of the rigid leg assembly is connected with a pair of side plates end to form a column structure; the side plates of the rigid leg assemblies are connected with the main plate in a welding mode, the welding seams between the side plates and the bottom plate of the rigid leg assemblies are fixed by spot welding within 400mm from the top ends, and the rest welding seams are completely welded; completely welding the box body when the box body is assembled;
s3: manufacturing the leg-softening component: the flexible leg assembly also includes a pair of side plates and a pair of main plates; a pair of side plates of the flexible leg assembly is connected with a pair of side plates end to form a column structure; the side plates of the flexible leg assembly are connected with the main plate in a welding mode, the welding seams between the side plates and the bottom plate of the flexible leg assembly are fixed by spot welding at positions 400mm away from the top end and 400mm away from the bottom end, and the rest welding seams are completely welded; completely welding the box body when the box body is assembled;
s4: and (3) integral assembly: ear plates are respectively welded on the upper surface of the box body at positions close to the two ends, and the ear plates are symmetrical about the central line of the box body; respectively installing welding seats on the upper surfaces of a rigid side zero point and a flexible side zero point of the box body; and a rigid leg assembly and a flexible leg assembly are respectively arranged on the lower surfaces of the rigid side zero point of the box body and the flexible side zero point of the box body.
Further, each of the pair of main boards in the S2 includes a first main board unit and a second main board unit; the side surfaces of the first main board unit and the second main board unit are spliced and positioned in the same plane; the first main board unit is provided with a vent hole with the diameter of 200mm, and a round cake is left to serve as a subsequent sealing plate when the hole is formed.
The invention has the advantages that:
1) the box body adopts a process method of manufacturing and detecting at the same time, and the detection of key data is carried out in each step to ensure the manufacturing precision of the box body; in addition, the welding precision of the box body is ensured and the prestress generated in the welding process is reduced according to the principle that the box body is welded from inside to outside and from the middle to two sides; the box body in the invention forms pre-camber in the processing process, and finally releases stress under the action of self-weight, thereby reducing the subsequent stress elimination treatment.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
Fig. 1 is a front view of a girder structure of an ultra-large type rail crane according to the present invention.
Fig. 2 is a side view of a rigid leg assembly of a girder structure of an ultra-large type rail crane according to the present invention.
Fig. 3 is a side view of a flexible leg assembly of a girder structure of an ultra-large type rail crane according to the present invention.
Fig. 4 is a schematic diagram of the pre-camber of a girder structure of an ultra-large track crane according to the present invention.
Detailed Description
The following examples are presented to enable one of ordinary skill in the art to more fully understand the present invention and are not intended to limit the scope of the embodiments described herein.
The manufacturing process of the ultra-large type rail crane girder structure shown in fig. 1 to 4 specifically comprises the following steps: including S1: manufacturing a main beam assembly; s2: manufacturing a rigid leg assembly; s3: manufacturing a flexible leg assembly; s4: integrally assembling;
s1: manufacturing a main beam assembly:
s1.1: assembling the box body 1: assembling and forming the box body by adopting a reverse manufacturing method, after the panel is hoisted to the box body assembly jig frame, arranging partition plates to be welded in the panel in sequence at equal intervals, and enabling the panel to surround the partition plates; placing a reverse deformation block at the inner section of the central line of the supporting leg, bending the reverse deformation block by 20-25mm, placing the reverse deformation block from the central line of the supporting leg to the end beam section, bending the reverse deformation block by 15-20mm outwards to ensure that the central lines correspond, and then performing spot welding and fixing; before welding the box body, the center of the rail bearing beam is used as a reference, the equal distance from the centers of the upper panel and the lower panel to the center of the rail bearing beam is detected, and the box body is not required to be adjusted in place;
s1.2: welding a box body 1: welding external fillet welds by using an automatic fillet welding trolley, wherein the welding sequence of the box body is divided into the steps of before turning over and after turning over, and the turning-over angle is 180 degrees; before turning over, welding according to the sequence of the welding seam in the length direction of the partition board, the welding seam in the width direction of the bottom end of the partition board, the fillet welding seam at the inner end of the bottom end of the box body and the fillet welding seam at the outer end of the bottom end of the box body; after the box body is turned over for 180 degrees, welding seams in the width direction of the bottom end of the partition plate, fillet welding seams at the inner end of the bottom end of the box body, fillet welding seams at the outer end of the bottom end of the box body and welding seams between the outer surface of the top end of the box body and the rail supporting beam are welded in sequence;
s1.3: and (3) detection of the box body 1: the box body is provided with 10-15mm of inward bend at the inner sides of the central lines of the two supporting legs, and 0-10mm of outward bend is arranged from the central line of the supporting leg to the end part of the box body without sudden change; after welding, checking that the outline dimensions of four sides and the deviation within the range of 1m of the central lines of the upper and lower panels need to be less than 3mm, and the flatness error of the rail bearing beam is +/-0.5 mm; the camber of the box body is 1.25-1.4F, and the box body needs to be adjusted in place if the camber is not met;
s1.4: and (3) assembly installation of the box body 1: jacks are respectively adopted to support two zero-position points on the box body, the central line of the rail bearing beam, the installation line of the pressure plate bottom plate and the installation line of the buffer bracket component are drawn out, the pressure plate bottom plate and the buffer bracket are installed in place according to the drawing, and the welding is firm; after welding, re-testing the inward bending, the flatness and the finished product camber of the box body again according to the detection requirement of S1.3;
s1.5: the box 1 is provided with a sample punching hole: releasing stress of the box body in a free state, and knocking out a sample punching hole at the center of a pressing plate bottom plate deleted at a rigid leg zero point, a box body transverse center position and a flexible leg zero point of the box body respectively to make a mark after the center line of a re-measured pressing plate is superposed with the center line of a rail supporting beam; marking a sample punching hole after the central line of the box body is retested to be qualified, wherein the sample punching hole is used as a reference for assembling the box body out of the workshop;
s2: production of rigid leg Assembly 2: the rigid leg assembly comprises a pair of side plates and a pair of main plates; a pair of side plates of the rigid leg assembly is connected with a pair of side plates end to form a column structure; the side plates of the rigid leg assemblies are connected with the main plate in a welding mode, the welding seams between the side plates and the bottom plate of the rigid leg assemblies are fixed by spot welding within 400mm from the top ends, and the rest welding seams are completely welded; completely welding the box body when the box body is assembled;
s3: manufacturing the leg-bending component 3: the flexible leg assembly also includes a pair of side plates and a pair of main plates; a pair of side plates of the flexible leg assembly is connected with a pair of side plates end to form a column structure; the side plates of the flexible leg assembly are connected with the main plate in a welding mode, the welding seams between the side plates and the bottom plate of the flexible leg assembly are fixed by spot welding at positions 400mm away from the top end and 400mm away from the bottom end, and the rest welding seams are completely welded; completely welding the box body when the box body is assembled;
s4: and (3) integral assembly: ear plates are respectively welded on the upper surface of the box body at positions close to the two ends, and the ear plates are symmetrical about the central line of the box body; respectively installing welding seats on the upper surfaces of a rigid side zero point and a flexible side zero point of the box body; and a rigid leg assembly and a flexible leg assembly are respectively arranged on the lower surfaces of the rigid side zero point of the box body and the flexible side zero point of the box body.
Each of the pair of main boards in S2 includes a first main board unit and a second main board unit; the side surfaces of the first main board unit and the second main board unit are spliced and positioned in the same plane; the first main board unit is provided with a vent hole with the diameter of 200mm, and a round cake is left to serve as a subsequent sealing plate when the hole is formed.
It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (2)
1. A manufacturing process of a girder structure of an ultra-large type rail crane is characterized in that: the specific manufacturing process is as follows: including S1: manufacturing a main beam assembly; s2: manufacturing a rigid leg assembly; s3: manufacturing a flexible leg assembly; s4: integrally assembling;
s1: manufacturing a main beam assembly:
s1.1: assembling a box body: assembling and forming the box body by adopting a reverse manufacturing method, after the panel is hoisted to the box body assembly jig frame, arranging partition plates to be welded in the panel in sequence at equal intervals, and enabling the panel to surround the partition plates; placing a reverse deformation block at the inner section of the central line of the supporting leg, bending the reverse deformation block by 20-25mm, placing the reverse deformation block from the central line of the supporting leg to the end beam section, bending the reverse deformation block by 15-20mm outwards to ensure that the central lines correspond, and then performing spot welding and fixing; before welding the box body, the center of the rail bearing beam is used as a reference, the equal distance from the centers of the upper panel and the lower panel to the center of the rail bearing beam is detected, and the box body is not required to be adjusted in place;
s1.2: welding a box body: welding external fillet welds by using an automatic fillet welding trolley, wherein the welding sequence of the box body is divided into the steps of before turning over and after turning over, and the turning-over angle is 180 degrees; before turning over, welding according to the sequence of the welding seam in the length direction of the partition board, the welding seam in the width direction of the bottom end of the partition board, the fillet welding seam at the inner end of the bottom end of the box body and the fillet welding seam at the outer end of the bottom end of the box body; after the box body is turned over for 180 degrees, welding seams in the width direction of the bottom end of the partition plate, fillet welding seams at the inner end of the bottom end of the box body, fillet welding seams at the outer end of the bottom end of the box body and welding seams between the outer surface of the top end of the box body and the rail supporting beam are welded in sequence;
s1.3: and (3) detection of the box body: the box body is provided with 10-15mm of inward bend at the inner sides of the central lines of the two supporting legs, and 0-10mm of outward bend is arranged from the central line of the supporting leg to the end part of the box body without sudden change; after welding, checking that the outline dimensions of four sides and the deviation within the range of 1m of the central lines of the upper and lower panels need to be less than 3mm, and the flatness error of the rail bearing beam is +/-0.5 mm; the camber of the box body is 1.25-1.4F, and the box body needs to be adjusted in place if the camber is not met;
s1.4: and (3) mounting a box body assembly: jacks are respectively adopted to support two zero-position points on the box body, the central line of the rail bearing beam, the installation line of the pressure plate bottom plate and the installation line of the buffer bracket component are drawn out, the pressure plate bottom plate and the buffer bracket are installed in place according to the drawing, and the welding is firm; after welding, re-testing the inward bending, the flatness and the finished product camber of the box body again according to the detection requirement of S1.3;
s1.5: the box body is provided with a sample punching hole: releasing stress of the box body in a free state, and knocking out a sample punching hole at the center of a pressing plate bottom plate deleted at a rigid leg zero point, a box body transverse center position and a flexible leg zero point of the box body respectively to make a mark after the center line of a re-measured pressing plate is superposed with the center line of a rail supporting beam; marking a sample punching hole after the central line of the box body is retested to be qualified, wherein the sample punching hole is used as a reference for assembling the box body out of the workshop;
s2: manufacturing the rigid leg assembly: the rigid leg assembly comprises a pair of side plates and a pair of main plates; a pair of side plates of the rigid leg assembly is connected with a pair of side plates end to form a column structure; the side plates of the rigid leg assemblies are connected with the main plate in a welding mode, the welding seams between the side plates and the bottom plate of the rigid leg assemblies are fixed by spot welding within 400mm from the top ends, and the rest welding seams are completely welded; completely welding the box body when the box body is assembled;
s3: manufacturing the leg-softening component: the flexible leg assembly also includes a pair of side plates and a pair of main plates; a pair of side plates of the flexible leg assembly is connected with a pair of side plates end to form a column structure; the side plates of the flexible leg assembly are connected with the main plate in a welding mode, the welding seams between the side plates and the bottom plate of the flexible leg assembly are fixed by spot welding at positions 400mm away from the top end and 400mm away from the bottom end, and the rest welding seams are completely welded; completely welding the box body when the box body is assembled;
s4: and (3) integral assembly: ear plates are respectively welded on the upper surface of the box body at positions close to the two ends, and the ear plates are symmetrical about the central line of the box body; respectively installing welding seats on the upper surfaces of a rigid side zero point and a flexible side zero point of the box body; and a rigid leg assembly and a flexible leg assembly are respectively arranged on the lower surfaces of the rigid side zero point of the box body and the flexible side zero point of the box body.
2. The manufacturing process of the ultra-large type rail crane girder structure according to claim 1, is characterized in that: each of the pair of main boards in the S2 includes a first main board unit and a second main board unit; the side surfaces of the first main board unit and the second main board unit are spliced and positioned in the same plane; the first main board unit is provided with a vent hole with the diameter of 200mm, and a round cake is left to serve as a subsequent sealing plate when the hole is formed.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115476064A (en) * | 2022-09-14 | 2022-12-16 | 南通中远海运重工装备有限公司 | Manufacturing process of main beam of tyre gantry crane |
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