Special calibration method for car carrier decks

Abstract

The invention discloses a special correction method for a car carrier deck, which relates to the technical field of deck segment correction, and comprises the following steps: S00, using a universal horizontal frame deck BASE to weld the deck segment, fixing the deck specifically horizontally under a normal state, and then performing segment standard process / procedure correction: S10, measuring the deformation of the deck unit cell, quantifying the overall deformation of the deck: dividing the deck into a plurality of units, and measuring the upper and lower deformation of the unit cell deck by a straight sample ruler and a ruler; S20, performing linear back-burning according to the thickness of the main board, and preliminarily releasing the internal stress of the deck; S30, deck deformation correction-unit cell correction: virtualizing a symmetrically arranged "R" shape and a plurality of concentric "circles" on the unit cell deck, the heating point is located at the intersection of the "R" shape and each concentric "circle", and the lifting force is removed after point heating. The effect of reducing the skill requirements of the deck correction on the personnel, ensuring the deck correction accuracy and improving the production efficiency is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of deck segment correction, in particular to a special correction method for a car transport ship deck. Background Art

[0002] With the development of economic globalization, the number of automobile transportations has increased dramatically. Automobile carriers have become ships specially designed for transporting various types of unpackaged automobiles. They can transport up to 8,500 vehicles, have a 14-story deck design, and a high ship depth. In order to lower the center of gravity, the cargo hold deck is mostly designed with thin plates.

[0003] like Figure 1 The typical cross-section of a 6200PCC cargo hold is shown in the figure. After the ship is divided into sections, the number of deck sections accounts for about 65% of the total number of sections of the whole ship - a high proportion; the deck sections are thin and sheet-like, with beam frames, simple main structures and small deadweight; after section welding, the deck deformation is large and the deck beams are prone to adverse deflection.

[0004] The segmented correction technology of the car carrier deck is a recognized technical difficulty in the industry. Figure 2 As shown in the figure, during conventional production, the deck BASE is used and the beam is welded in the pre-deformed state; after the segment welding, the deck, keel and beam are corrected. The correction requires a high level of employee skills and is more dependent on the experience of the operators; poor control of the correction process will cause interference between the deck correction and the keel and beam correction, resulting in repeated corrections, causing large deviations in the main dimensions of the segment, and in severe cases, the segment will be scrapped; due to the uncertainty of the correction work, the shrinkage of the segment caused by the correction is unstable, and the segment margin needs to be set.

[0005] Conventionally, the deck section manufacturing cradles are not very universal, the correction requires a high level of employee skills, the rework workload is large, the overall correction efficiency is low, and the section accuracy is difficult to ensure; the number of sections accounts for a high proportion, which has a great impact on the man-hour cost of hull construction. Summary of the invention

[0006] The purpose of the present invention is to provide a special correction method for the car carrier deck, optimize the correction process, reduce the use of auxiliary materials, reduce the skill requirements of deck correction for personnel, ensure the accuracy of deck correction and improve production efficiency.

[0007] The above technical objectives of the present invention are achieved through the following technical solutions:

[0008] A special calibration method for a car carrier deck comprises the following steps:

[0009] S00, use the universal horizontal frame deck BASE to weld the deck sections, fix the deck horizontally under normal conditions, and then perform section standard process / procedure correction:

[0010] S10, the deck unit deformation f is measured to quantify the overall deformation of the deck:

[0011] The deck is divided into several cells, and the deformation f of the deck above and below the cell is measured by a straight ruler and a ruler to quantify the deformation of each cell on the deck;

[0012] S20, linear back-burning is performed according to the thickness t of the mainboard to initially release the internal stress of the deck;

[0013] S30, deck deformation correction - cell correction: first apply jacking prestress to the deck cells, and then heat the cells at multiple points;

[0014] The unit deck is virtually designed to form a symmetrical "M" shape and several concentric "circles". The heating points are located at the intersections of the "M" shape and each concentric "circle". After point heating, the lifting force is removed.

[0015] Furthermore, in S20, the linear back burning uses an automatic guided trolley to clamp the drying gun head for linear flame heating. The flame heating temperature, height from the deck surface and moving speed are selected according to the thickness of the deck plate.

[0016] Furthermore, in S20, the linear back-burning is performed using an EFD heating device, and the heating temperature and heating interval are selected according to the thickness of the plate.

[0017] Furthermore, the deck deformation correction in step S30 is performed cell by cell, and the order is specified to be performed radiating from the center of the segment to the surrounding areas.

[0018] Furthermore, in step S30, when the measured deformation amount f of the cell is convex and ≥0mm, the end of the sleeve is lifted up by 4 to 6mm after it is pressed against the deck; when the measured deformation amount f of the cell is concave, the end of the sleeve is lifted up by 12 to 18mm after it is pressed against the deck.

[0019] Furthermore, the diameter of the heating point is d=8t / 10+10, the radius difference between adjacent concentric circles is a=d-4f / 10+150mm, and when the distance between two adjacent heating points on the same circle is a'≥2a, a heating point is added in the middle.

[0020] Furthermore, it also includes step S40, dragon tendon correction: use a drying gun to heat the dragon tendon surface web in a triangular shape at the lower part of the segment, follow up with water cooling, the dragon tendon web is heated on the lower side of the web, and the dragon tendon panel is heated on the panel facing side.

[0021] Furthermore, when the curvature of the face and belly plate is 3 to 6 mm, two corrections are made within one rib distance; when the curvature of the face and belly plate is ≥ 6 mm, 3 to 5 corrections are made.

[0022] Furthermore, the heating triangle has a height h'=20-25 mm and a width b≤20 mm.

[0023] Furthermore, the method further comprises step S50, beam calibration: basically the same as step S40, except that:

[0024] It increases the deflection of the beam by +3 to 5mm upward through variable height support; the face and web are corrected at the same time and in the same position; the face plate is changed to a dot-shaped correction, and the heating diameter d' is 1 / 2 of the face plate width; the web is heated in a triangular shape, and the heating width b' is the same as the face plate heating point diameter d', and the height h' is less than 1 / 2 of the web height.

[0025] In summary, the present invention has the following beneficial effects:

[0026] 1) The present invention eliminates the pre-deformation construction of the cross beam during the BASE welding of the car carrier deck, adopts a universal horizontal tire frame to make the sections, simplifies the section production process, reduces the amount of consumables used in the section production, and is conducive to the section plate layout in the workshop;

[0027] 2) After the correction process is optimized, the process parameters are quantified, the process is standardized, the skill level requirements for the correction personnel are reduced, rework during the operation is avoided, and production efficiency is greatly improved;

[0028] 3) The present invention ensures the deck correction accuracy, the correction shrinkage is stable, and the production without margin is achieved in sections. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a typical cross-sectional view of 6200PCC in the prior art;

[0030] Figure 2 It is a schematic diagram of welding of the BASE beam of the segmented deck in the deflection pre-deformation state in the prior art;

[0031] Figure 3 It is a schematic diagram of the welding of the horizontal frame of the universal I-beam of the segmented deck BASE in the present invention;

[0032] Figure 4 It is a schematic diagram of the segmented level special fixing in the present invention;

[0033] Figure 5 It is a schematic diagram of deck correction standardization process 1-deck cell deformation measurement in the present invention;

[0034] Figure 6 This is a schematic diagram of the deck correction standardization process 2—linear back burning in the present invention;

[0035] Figure 7 This is a schematic diagram of deck deformation correction in the deck correction standardization process 3 of the present invention;

[0036] Figure 8 This is a schematic diagram of deck keel correction in the deck correction standardization process 4 of the present invention;

[0037] Fig. 9 This is a schematic diagram of deck beam correction in the deck correction standardization process 5 of the present invention. DETAILED DESCRIPTION

[0038] The specific implementation manner of the present invention is further described below in conjunction with the accompanying drawings, and this embodiment does not constitute a limitation of the present invention.

[0039] A special calibration method for a car carrier deck comprises the following steps:

[0040] S00, such as Figure 3 and Figure 4 As shown, the present invention cancels the pre-deformation construction of the cross beam when the BASE of the car carrier deck is assembled and welded, adopts a universal horizontal frame to make the segments, uses the universal horizontal frame deck BASE to weld the deck segments, fixes the deck specifically horizontally under the normal state, and then performs segment standard process / procedure correction:

[0041] S10, such as Figure 5 As shown, the deck unit cell deformation f is measured to quantify the overall deformation of the deck:

[0042] The deck is divided into a number of cells. In this embodiment, the deck is composed of transverse beams, longitudinal ribs, and anti-deformation strips between the ribs and perpendicular to the ribs. The rectangle formed by the beams (or anti-deformation strips), adjacent ribs, and anti-deformation strips is defined as a deck cell, and the deck is divided into N cells;

[0043] The upper and lower deformation f of the unit deck is measured by an aluminum alloy straight ruler and a 150mm steel ruler, and marked on the segments. By measuring all the units, the deformation of each unit on the deck is quantified;

[0044] The measured value f of deck deformation provides a basis for the selection of subsequent linear backburning and cell correction process parameters. Figure 6 As shown, linear backburning is performed according to the thickness t of the mainboard to initially release the internal stress of the deck;

[0045] Linear back burning generally uses an automatic guided trolley to clamp the drying gun head for linear heating. According to the thickness of the deck plate, the flame heating temperature, the height from the deck surface and the moving speed are selected, as shown in the following table; Linear back burning reduces the upper and lower deformation f of the deck near the aggregate, making the deformation of the unit cell deck tend to the average value, and initially releasing the internal stress of the deck;

[0046] Deck thickness (mm) Heating temperature(℃) Height of burner from steel plate h(mm) Heating speed (mm / min) Flame reference color t≤12 600 30 700～500 brown 12≤t≤20 700 25 500～600 Dark red

[0047] Linear back burning can also be operated using EFD heating device. According to the thickness of the plate, the heating temperature and heating distance are selected, as shown in the following table:

[0048] Deck thickness (mm) Heating temperature(℃) Heating distance L(mm) t≤12 600 300～500 12≤t≤20 700 100～300

[0049] Linear backburning will increase the downward deflection of the aggregate in the up-down direction, and will cause a certain amount of deck shrinkage perpendicular to the backburning direction {shrinkage = (-0.023*t+0.67)*n}, where n is the number of backburned longitudinal ribs. Combined with the measurement of deck deformation f, all transverse beams are backburned, and the number of backburned longitudinal ribs n is set to be the same as the total number of the same beams, so that the deck shrinkage is stable. The deck deformation f of the cells on both sides of the backburned ribs generally exceeds the average deformation value.

[0050] S30, such as Figure 7 As shown, deck deformation correction - cell correction: deck deformation correction is performed cell by cell, and the order is specified to radiate from the center of the segment to the surrounding areas.

[0051] The cell correction is point heating. Before heating, the cell deck is first prestressed with lifting stress. Under the segment, an oil pump and a sleeve are used to lift the central point of the deck cell. When the measured deformation f of the cell is convex and ≥0mm, the end of the sleeve is lifted by 4 to 6mm after it is pressed against the deck (5mm in this embodiment). When the measured deformation of the cell is concave, the end of the sleeve is lifted by 12 to 18mm after it is pressed against the deck (15mm in this embodiment). The implementation of lifting prestress mainly makes the surface tension of the cell deck evenly distributed from the center to the surrounding area, and makes the flatness of the cell deck have a certain margin after point correction.

[0052] Then use a drying gun to heat the cells at multiple points and calibrate using the "meter / circle" method. First, virtualize a symmetrical "meter" shape and several concentric "circles" on the cell deck. The center of gravity of the "meter" and the "circle" coincides. The cell heating point is located at the intersection of the "meter" shape and each concentric "circle". Heat is performed in the order of the path shown in the figure.

[0053] The diameter of the heating point d = 8t / 10 + 10 (t is the mainboard thickness, unit: mm), the radius difference between adjacent concentric circles, i.e., the spacing a = d-4f / 10 + 150 (f is the mainboard unit cell deformation, unit: mm), when the spacing a' ≥ 2a between two adjacent heating points on the same circle, a heating point is added between them; the height of the gun tip from the surface and the heating temperature are the same as those for linear heating; in order to meet the needs of single-person operation, it is stipulated that when the deck is heated to the flame temperature in a point-like manner, water cooling is performed on the front side; the lifting force is removed after point heating.

[0054] Step S40, as Figure 8 As shown, the dragon tendon correction:

[0055] This type of deck longitudinal keel uses unequal angle steel. After segmented welding, the angle steel web will produce downward deflection and lateral bending of the panel within a rib distance. The deformation of the keel will increase when the deck is straightened, and some may exceed the requirements.

[0056] Therefore, the "triangle" method is used for correction: a drying gun is used to heat the rib surface web in a triangular shape at the lower part of the segment, and water cooling is performed. The rib web is heated on the lower side of the web, and the rib panel is heated on the panel facing side. The required deviation of the heating position of the surface web is 130-170 mm (150 mm in this embodiment);

[0057] When the bending amount of the web is 3-6mm, two correction points are made within one rib distance (the distance L' is about 1.6m), i.e. two correction points; when the bending amount of the web is ≥6mm, 3-5 correction points are made (the distance L' is 0.5-1m); the height of the heating triangle h'=20-25mm, the width b≤20mm, the height of the gun tip from the surface and the heating temperature are the same as those for linear heating;

[0058] The inspection adopts cotton thread or laser line comparison. Through the quantification of the above correction process parameters, the linearity of the ribs after correction is ensured, so that the longitudinal shrinkage caused by the rib correction is within the set range, and the secondary deformation of the deck caused by the shrinkage is extremely small.

[0059] Step S50, as Fig. 9 As shown, beam correction:

[0060] The transverse beams are all T-shaped composite materials. The basic correction method is the same as the S40 rib correction. The difference is:

[0061] First, the deflection of the beam is increased by +3 to 5 mm upwards through variable height supports;

[0062] Second, the web plates are corrected at the same time and in the same position, and the correction position should avoid being below the web SLOT hole of the beam;

[0063] Third, the panel "triangle" correction method is changed to dot correction, and the heating diameter d' is 1 / 2 of the panel width, which can avoid the panel from bending due to correction;

[0064] Fourth, when the web is corrected by the "triangle method", the heating width b' is the same as the diameter d' of the panel heating point, and the height h' is less than 1 / 2 of the web height;

[0065] Fifth, the beam is generally calibrated at three points, with a spacing of 3 to 5 m (4 m in this embodiment). When the variable height support end and the beam panel are not subjected to force, the calibration effect can be determined. If the calibration effect is not obvious, it can be achieved by adding more points.

[0066] This correction method of the beam ensures the deflection of the beam and increases the surface tension of the deck, which is beneficial to the control of deck deformation.

[0067] S60, completion inspection:

[0068] During the calibration process of the entire deck, the flatness of the deck cells is first ensured, then the flatness of the deck area, and finally the flatness of the deck as a whole. At the end of the calibration, the above process quantities are tested, and any individual points that do not meet the requirements will be processed.

[0069] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art may make various modifications or equivalent substitutions to the present invention within the essence and protection scope of the present invention, and such modifications or equivalent substitutions should also be deemed to fall within the protection scope of the technical solution of the present invention.

Claims

1. A special calibration method for a car carrier deck, characterized in that: The steps include: S00, use the universal horizontal frame deck BASE to weld the deck sections, fix the deck specifically horizontally under normal conditions, and then perform section standard process / procedure calibration: S10, the deck unit deformation f is measured to quantify the overall deformation of the deck: The deck is divided into several cells, and the deformation f of the deck above and below the cell is measured by a straight ruler and a ruler to quantify the deformation of each cell on the deck; S20, linear back-burning is performed according to the thickness t of the mainboard to initially release the internal stress of the deck; S30, deck deformation correction - cell correction: first apply jacking prestress to the deck cells, and then heat the cells at multiple points; The unit deck is virtualized into a symmetrically set "R" shape and several concentric "circles", and the heating point is located at the intersection of the "R" shape and each concentric "circle". After point heating, the lifting force is removed; Among them, the deck deformation correction is performed cell by cell, and the order is specified to be performed radiating from the center of the segment to the surrounding areas; when the cell deformation f is convex and ≥0mm, the sleeve end is lifted 4~6mm after it is against the deck; when the cell deformation is concave, the sleeve end is lifted 12~18mm after it is against the deck; the diameter of the heating point d=8t / 10+10, the radius difference between adjacent concentric circles a=d-4f / 10+150mm, when the distance between two adjacent heating points on the same circle a'≥2a, add a heating point in the middle; Step S40, tendon correction: use a drying gun to heat the tendon surface web in a triangular shape at the lower part of the segment, and follow the water cooling. The tendon web is heated on the lower side of the web, and the tendon panel is heated on the panel facing side; When the bending amount of the face and web plate is 3~6mm, two fires are corrected within one rib distance; when the bending amount of the face and web plate is ≥6mm, 3~5 fires are corrected; the height of the heating triangle h'=20~25mm, the width b≤20mm; Step S50, beam calibration: basically the same as S40, the differences include: It increases the deflection of the beam by +3~5mm upward through variable height support; the face and web are corrected at the same time and in the same position; the face plate is changed to a dot-shaped correction, and the heating diameter d' is 1 / 2 of the face plate width; the web is heated in a triangular shape, and the heating width b' is the same as the face plate heating point diameter d', and the height h' is less than 1 / 2 of the web height.

2. The special calibration method for the car carrier deck according to claim 1, characterized in that: In S20, linear back burning uses an automatic guided trolley to clamp the drying gun head for linear flame heating. The flame heating temperature, height from the deck surface and moving speed are selected according to the thickness of the deck plate.

3. The special calibration method for the car carrier deck according to claim 1, characterized in that: In S20, the linear back burning is performed using an EFD heating device, and the heating temperature and heating spacing are selected according to the thickness of the plate.

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