RU2465167C2 - Method for assembling flat sections of ship hull - Google Patents

Abstract

FIELD: transport.

SUBSTANCE: invention relates to ship-building, in particular to production tooling and equipment to equip process of manufacturing hull structures. Method for assembling flat sections of ship hull consists in manufacturing flat sections on single working place-position without moving up to complete production. Assembling-welding operations with assembled sections are made by self-propelled floor-standing machines which are wheeled and tracked, manoeuvrable, small-sized, multifunctional, equipped with load-handling, electrosticking, assembling and arc-welding devices.

EFFECT: higher productivity of labour due to section manufacturing on single place.

9 dwg

Description

The invention relates to shipbuilding, and in particular to means of mechanization for the manufacture of flat sections, which are panels on which longitudinal and transverse beams are installed, from these sections the ship's hull is assembled.

Known sources for section assembly methods:

1. ESAB NEVE - Sweden, in cooperation with TTS-Norway, developed and introduced in many foreign shipyards flow-position lines for the production of flat sections of the ship's hull.

On these production lines, all movement operations: moving the panel to the installation position of the longitudinal beams, moving to the welding position of the longitudinal set with the panels and then to the next installation positions of the transverse beams and their welding are carried out on the stand rollers by pulling endless chain conveyors.

Assembly, electric pick-up, electric welding, etc. are made by gantry units moving on rails and having working bodies for performing the above operations.

2. There is another analogue of the production and positional line for assembling flat panels with beams - Yantar-2, developed in the USSR and introduced at a number of shipyards.

In this line, the well-known principles of the assembly of flat sections are laid, namely, the flow-positional method of manufacturing sections. Moving from position to position is carried out by transport trolleys on the rollers of assembly stands. Beam feeding, assembly, electric pick-up, welding operations are carried out using portal stops. The level of mechanization degree of this analogue is slightly higher than that of ESAB NEVE.

The disadvantages of these production lines are as follows.

1. In the manufacturing process of sections involved in large dimensions and large mass gantry devices that move along rails. Cloths, cloths with stopped longitudinal beams, cloths with transverse beams from position to position are transmitted by endless chain conveyors or carts. The costs of manufacturing gantry installations, vehicles, stand frontal roller devices for rolling sections, their installation and operation are huge.

2. The working bodies for stripping, assembling, electric gripping, welding, etc., installed on the portals are incomparably small in relation to the mass of the entire portal structure, which means that in order to perform a certain operation, these bodies have to spend additional energy on moving the mass of the metal structures of the gantry installations, and if they are still assigned the functions of transferring sheets and beams or compressing the beams along the entire length of the panel, then during design the corresponding additional safety margins are laid in the calculations and that greatly increase their mass.

3. The unequal laboriousness of performing operations on positions - this will result in malfunctioning of the assembly rhythm and downtime on production lines. In addition, at positions, for example, when assembling panels or when assembling beams with panels, only one portal can work - the other does not have a work front, there is no room for placement because of their dimensions.

4. There is no concern and attention to the conditions working on portal installations. To manage portals, power, tack and other devices of portal installations for assembling hull structures when assembling panels and when assembling a set of beams with panels, the worker has to accompany them for a whole shift, walk along the assembled joints of sheets of panels, along the assembled beams incline, on all fours, and when the installation of transverse beams still step over the longitudinal beams, and at the same time he has to breathe welding gases.

The aim of the present invention is to provide a method for assembling flat metal structures and mechanization means, excluding the use of portal assembly machines in the manufacture of flat sections, excluding from the production process the transfer of section elements from position to position by endless chain conveyors or transport trolleys, eliminating roller assemblies for assembling rolling assemblies from assembly stands sections. Increasing labor productivity and improving working conditions.

The goal is achieved by a method of manufacturing flat sections, in which the sections are made until complete production without movement, on one assembly site / position /, without portal assembly rail machines, without endless chain conveyors or transport trolleys and without roller bench stands for rolling sections.

The sequence of technological operations in the manufacture of sections at one assembly place is carried out by special self-propelled, maneuverable, multifunctional, small-sized, small-mass machines. All technological operations of the manufacturing process of flat sections are carried out by three types of machines:

1. Machine No. 1, see FIGS. 1 and 2, for removing sheets from the stack, feeding and laying them out on an assembly stand and bringing the sheets closer to each other at the theoretical installation site. This machine has the additional function of installing the beams on the panels, namely: grabbing the beams from the cassette and transferring to the theoretical line of installation on the panel and electro-grabbing the ends of the beams, see Fig.7.

2. Machine No. 2, see FIGS. 3, 4, 5 and 7, for assembly and welding.

The machine performs the following operations:

- alignment of the edges of the joints of the panels and their electric pickup;

- cleaning of installation sites for longitudinal and transverse dialing;

- crimping panels with beams, fixing them with electric grippers;

- welding of panels and welding of beams to panels.

In addition, this machine also has the function of installing beams on the panels, see Fig.6 and 7.

3. Machine No. 3, see Figs. 8 and 9, is intended for assembly of transverse beams with panels, fixing them with electric grippers.

At the same time, in a specific operation on the sections, several machines can operate on the same assembly site, thereby accelerating the manufacturing process of the sections. Machines after completion of work can be moved to other assembly sites to perform this or other operations.

The number of assembly places / positions / and the required number of vehicles are determined depending on the timing of the construction of the ships.

With this method, working conditions are improved, because a ship-builder is already an operator controlling the machine and working bodies from the workplace on the machine using a stationary control panel.

Depending on the operating conditions, the machines may have internal combustion engines when working in open assembly areas, for closed ones they must have non-toxic engines. Power supply of working bodies is carried out from batteries and industrial power supply.

List of drawings

Figure 1. A side view of the machine No. 1, the stacker, is shown in the process of capturing the sheet with columns with electromagnets, scale 1:40.

Figure 2. A front view of machine No. 1 is depicted - a scale of 1:40.

Figure 3. Shows a side view of the machine No. 2, installed above the longitudinal beam in the process of assembling the panel with the beam, and their electric pick-up, scale 1:40.

Figure 4. A front view of machine No. 2 is shown when assembling the longitudinal beam to the panel, scale 1:40.

Figure 5. An organ for assembling the joints of panels and their electric gripper is depicted.

6. A side view of machine No. 2 is shown at the time of installing the longitudinal beam on the panel and the electric pick-up of the tip of the beam to the panel, scale 1:40.

7. A top view of the panel is shown during installation of longitudinal beams by machine No. 2, scale 1: 100.

Fig. 8. A side view of the machine No. 3 is shown on the caterpillar track in the position before setting on the transverse beam, scale 1:40.

Fig.9. A front view of the machine No. 3 is shown on the caterpillar during the assembly of the transverse beam, scale 1:40.

Machine design description

Machine number 1.

The machine is designed for laying sheets on an assembly stand and for drawing sheets closer together by machine pushers when forming the panel on the stand, as well as for feeding the beams from the cassette to the theoretical installation site on the panel and for electrically grabbing the ends of the beams to the panel.

Machine No. 1, see figures 1 and 2, contains:

1. Housing with engine and battery compartments, with a transmission, chassis, control mechanisms, a power supply system for wires from an industrial network and a protective gas supply system for welding, etc.

2. The device for changing the direction of movement of the machine consists of manual steering.

3. Movers - wheels.

4. Drive mover - chain.

5. Telescopic column for installing the working body 11 to remove the beams from the cassette, see Fig. 7, cassette 20 and their assembly and electric pick-up with sheets.

6, 7, 8, 9 - Details of a device for moving a telescopic column in a horizontal plane, 6 - a plate for fixing a plate 7 with a telescopic column 5, a lead screw - 8, a guide 9. The drive is not shown, with these parts axial correction of the telescopic columns when installing the beam on the panel.

10. Capture for fixing the working bodies on a telescopic column.

11. The organ for capturing, transferring, compressing and electrically grabbing the beams to the panels contains the details: 12 - a U-shaped bracket, 13 - electromagnets, 14 - a power drive - a jack, 15 - an electric gripper device, 22 - automatic grip of the beams by the working body to transfer them from cartridges and installations on a cloth.

16. Stationary control panel.

17. Workplace of the operator.

18. Sheets of the cloth.

19. Assembly stand.

20. Organizational and technological equipment (office equipment) or a method of stapling the accumulation of parts to ensure an uninterrupted assembly process. In this case, the process is carried out by a stack of sheets, each of which is mounted on washers.

21. A device for passing over a stack of sheets is made in the form of a portal.

22. Captures. On machine No. 1, two types of grips are provided:

- magnetic for removing sheets from the foot, holding them when moving to the assembly site, see pos.24;

- mechanical-automatic, necessary to perform the second function of the machine, namely to remove the beams from the cassette and transfer them to the installation site on the panel.

23. Special folding jacks of shock and pulse action.

24. Special columns with magnets for gripping sheets.

Machine number 2.

The machine is intended for assembly of panels, electric grippers and their welding, for supplying beams to panels, for assembly, electric grips, welding of longitudinal beams to panels, as well as for cleaning the places of installation of beams.

Machine No. 2 (see Fig. 3, 4, 5, 6 and 7) has the following contents:

1-19. The description and content of these devices is the same as for machine No. 1, see figures 1 and 2.

20. Organizational and technological equipment for beam stapling - cassette.

21. The device for passing over the beams is a tunnel made in the bottom of the machine, which lowers the operator’s workplace, thereby improving the conditions for visual control of the assembly and welding process.

22. Automatic capture of beams from the cartridge and for transferring them to the panel.

23, 24. These devices are not necessary, because they are not in the design of the machine.

25. Longitudinal beams.

Machine number 3.

The machine, see Fig. 8 and 9, is intended for the assembly and electro-grabbing of the transverse beams and has the following contents:

1, 5-19. The description and content of these devices is the same as on machines No. 1 and No. 2.

2. Device for changing the direction of movement of the machine, type of device - lever.

3. Movers, mover type - tracks.

4. Propulsion drive, conventional transmission for tractors with pinion gears, the transmission is not shown in FIGS. 8 and 9.

20. Office equipment for beam stapling. This equipment is not required for this machine, as the installation of beams is performed by machines No. 1 and No. 2.

21. The device for passing over the beams is a tunnel made in the bottom of the machine.

22. Automatic capture - this device is not necessary, because the operation for the capture and transfer of beams is not intended to be performed on machine No. 3 and is performed by machines No. 1 and No. 2.

23. Special folding jacks for installing the machine on the longitudinal beams.

24. Special columns are columns with wheels and lifting the machine to the level of the longitudinal beams.

25. Longitudinal beams.

26. Cross beams.

Description of the technological process of assembly sections.

but. Assembly of the panel.

1. Ha assembly stand, a crane feeds a stack of sheets with prepared edges for welding. Machine No. 1 is started at the foot, the top sheet is removed by columns 24 with electromagnets and laid on a stand at the theoretical installation site. Correction of the installation site is carried out by the machine shock-impact jacks pushers 23.

2. Then the next sheet is separated from the foot and laid next to the first, the gaps between the sheets and the installation location are corrected again with jacks.

3. Without waiting for the installation of the third sheet, a machine No. 2 with a working body is started at the joint of sheets 1 and 2, see figure 5, which equalizes the waviness, the edges of the joint, and then the electric pickup.

4. Next, install the third sheet, align the undulation of the junction of sheets 2 and 3, and so on, until then, until it is secured by electric grips 1/2 of the panel.

5. On the machine No. 2, an organ is installed to perform welding of the joints of the sheets, or another machine is brought in with a pre-installed welding organ, which is used to weld half of the panel.

6. The assembly, tacking and welding of the second half of the panel is carried out in the same way.

7. After appropriate preparation of the joint of the halves of the panel, they are brought together and assembled in the manner described above, electric grabbing, and then welding.

8. After welding, the panel is turned over and welding is done from the second side.

9. After marking the installation sites of the longitudinal and transverse beams, machines No. 2 with the stripping organ are again started, which are used to clean the installation sites of the kit. Cleaning devices can be used in various designs: needle-milling, portable, shot-blasting, abrasive, etc.

10. The technologies for assembling the panels may be different, for example: not from two halves, but assembled as a whole panel or assembled by belts along the entire length of the section.

b. Assembly of panels with longitudinal beams.

1. Each beam on the installation line on the panel is fed by two machines No. 1 or No. 2. On machine No. 2, the column with the assembly and electric gripping body adjusts to the side that is involved in capturing the end of the beams, while the working body is rotated 90 degrees. Machine # 1 does not need this setting. The machines capture the ends of the beam in opposite directions, then at the same time one machine moves forward, the other back with the general direction of movement to the installation line.

2. Machines are brought to cassette 20 with beams 25, telescopic columns are lowered synchronously with bodies having automatic grip beams 22. Having grasped the ends of the beam, it is removed from the slots of the cassette and transferred to the panel. For example, from position 1-1 on the cassette to position 1-1 on the panel, see Fig.6 and 7.

3. To fix the beam on the panel in a vertical position at the extremities of the beam, reinforced electric grippers are placed, see Fig.6. The process of electric grabbing is as follows: when the working body is lowered on the panel, the electromagnets 13 are turned on, then the power device 14, which by joint interaction eliminates the gap between the beam and the sheet. Next, an electro gripper 15 is supplied and an electro gripper is produced. After that, special grips 22 of the working body, releasing the beam, are retracted to their original position. At the same time, the power device-jack 14, the electromagnets 13, the electric gripper device 15, which are installed in an inoperative position, are switched off. Then the telescopic columns with working bodies rise to the upper position and the machines are sent to the cassette to take the next beam.

4. From the cassette from position 2-2, the beam is removed and fed into position 2-2 on the panel. The rest of the assembly process is similar to paragraphs 2 and 3 and continues until the installation process of all the beams on the panel is completed.

5. On the panel with beams, several machines No. 2 are started simultaneously with bodies for preloading the panels to the beams and securing them with electric grips, see Figs. 3 and 4, which are without automatic grips of the beams 22.

The process of eliminating the gap between the panel and the beam is carried out by the body 11, comprising: electromagnets 13, a U-shaped bracket 12, a power device 14 and an electric gripper device 15. Their interaction is described in position 3.

After setting the tack along the entire length of the beam, each machine moves to the next beam. After tacking operations are completed, the working bodies of welding are installed on machines No. 2. After welding, the sections begin to assemble the transverse beams.

at. Assembly of cross beams.

1. The process of installing the transverse beams is similar to the process of installing longitudinal beams, namely, the capture of the beams with two machines No. 1 or No. 2, transfer to the panel and the electric grab of the ends of the beams.

2. For assembly of transverse beams, machine No. 3 is used on a caterpillar track, see Figs. 8 and 9.

3. With a self-propelled machine, the central plane is mounted in the vertical plane of the transverse beam and pushed close to it.

4. The machine in columns 24 rises to the height level of the longitudinal beams. The jacks 23 are tilted and grabbed by the grips of the second or third longitudinal beam, 2 'or 3'.

5. With the jacks 23, the machine moves on the wheels of the column 24 to the first longitudinal beam, so that it is possible to lower the telescopic column 5 with the assembly and electric grab 11 in the middle of the first cell.

6. The assembly process - the electric gripper of the transverse beam with the panel is similar to the assembly of longitudinal beams, see the description of the working bodies of machines No. 1 and No. 2 and FIGS. 3 and 4.

7. After setting the first tack, the telescopic column is removed from the cell ①, the machine moves with jacks 23 and is mounted with caterpillars on the first longitudinal beam, so that the center of the telescopic column 5 is installed in the middle of the cell ② for the possibility of assembling an electric pick-up in this cell.

8. The process of extracting the telescopic column is repeated, and the process of moving the machine to the next second beam 2 'for setting the electric pick-up in cell ③ is carried out again using jacks 23, while on the machine the first pair of columns 24 with wheels is removed and the jacks 24 are also restored to their original position .

9. In the future, the machine has the ability to independently move along the longitudinal beams of the section and the freedom to perform work for the production of further assembly.

10. When the machine is firmly on the longitudinal beams, the second pair of columns 24 with wheels retracts to its original position.

11. After the assembly and electric pick-up operations of the first transverse beam, the machine independently leaves the sections. The sequence of the process of entering the columns 24 with wheels, jacks 23 and lowering the machine are repeated in the reverse order.

12. Further assembly of subsequent transverse beams is identical to the first.

13. Having completed the assembly of all the transverse beams, they are welded according to the technology adopted at this enterprise.

Claims (1)

The method of assembly of flat sections of the ship’s hull, which consists in the fact that the manufacture of flat sections is performed at one workplace-position without moving until they are fully manufactured, assembly and welding operations of the assembled sections are performed by self-propelled floor-mounted and wheeled, tracked, manoeuvrable, small-sized, multi-purpose machines, equipped with load gripping, electric gripping, assembly and electric welding devices.

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