Split modular assembly process of a molten iron car frame

Abstract

The present application relates to a kind of split modular assembly process of molten iron car frame, comprising the following steps: S1, the support crossbeam of molten iron ladle placement space front area, connecting longitudinal beam and oil cylinder seat beam are assembled, and preliminary welding is integrated, and it is recorded as front module frame;Also the rear area of molten iron ladle placement space is assembled and preliminary welded as a whole, and it is recorded as rear module frame;S2, the flatness and contour dimension of front module frame and rear module frame are checked, and after passing, welding is carried out according to requirements;S3, the flatness of flange mounting surface for welding support flange is checked, and after meeting the requirements, support flange is welded;S4, the flatness of support flange is checked, and after passing, front module frame and rear module frame are sent to processing;S5, the support crossbeam of front module frame and rear module frame is assembled and welded with two main longitudinal beams, and through three times of turning welding, the welding between the support crossbeam of front module frame and rear module frame and main longitudinal beam is welded.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of molten iron car manufacturing, in particular to a split modular assembly process of a molten iron car frame. BACKGROUND

[0002] 380 tons, 260 tons of molten iron ladle transport car (also known as molten iron car) is used for liquid high temperature molten iron transfer between blast furnace and converter, which is a new optimized development of trackless molten iron ladle transport equipment to meet the smelting process of "one ladle to the end". The molten iron car frame is a whole frame structure, as shown in the accompanying drawings, the molten iron car frame is mainly composed of two side main longitudinal beams 1 and a frame structure composed of a plurality of support cross beams 2 connecting the two longitudinal beams in the middle, wherein the middle position of the molten iron car frame is the molten iron ladle placing space 7 for placing the molten iron ladle, the support cross beams 2 are distributed in the front and rear areas of the molten iron car frame, and the connecting longitudinal beams 3 or oil cylinder seat beams 5 are welded between the support cross beams 2 for clamping. In addition, guardrails 6 are welded on the front and rear sides of the molten iron ladle placing space 7, and support flanges 4 are welded on the support cross beams 2 and the connecting longitudinal beams 3, and bread seats (not shown in the figure) are welded under the main longitudinal beams 1. Figure 1 The molten iron car frame is generally 17.2 meters long, 4.3 meters wide, nearly 2 meters high, and weighs about 27-40 tons. Using the traditional whole assembly process, the process flow is as follows: 1, first position the two main longitudinal beams 1, position the two main longitudinal beams 1 with a distance greater than the drawing size of 50mm to facilitate the installation of the support cross beams 2 between them; 2, place each intermediate cross beam and connecting longitudinal beam 3 between the two main longitudinal beams 1, suspend it using support from below, close to one side of the main longitudinal beam 1, then move the other side of the main longitudinal beam 1 to the drawing size, and then adjust the position of each intermediate cross beam, connecting longitudinal beam 3 and oil cylinder seat beam 5. 3, check the flatness of the installation position of all support flanges 4, and then start welding (four times of turning welding); 4, after welding, check the flatness of the installation position of the support flanges 4 again, and correct and adjust the unqualified position; 5, after passing the test, install the support flanges 4, guardrails 6 and bread seats, and then check the flatness of the support flanges 4 again, and then perform turning welding again. 6, after welding, check the flatness of the support flanges 4 again, and correct and adjust the unqualified position.

[0003]

[0004] ​In the traditional integral assembly process, in order to obtain good welding effect, it is necessary to adopt integral turning adjustment welding position, due to the welding position and direction are more, a frame from the complete assembly to the end of welding, a total of 4 times turning, after each turning, it is necessary to keep in this state for a long time, the danger is greater, at the same time, due to the integral size is large, the machining equipment capacity of the integral machining factory has high requirement, the machining cost is high, the machining period is long. During the period, there are secondary assembly and multiple inspection, the whole frame manufacturing period is too long. SUMMARY

[0005] In view of the above-mentioned defects of the prior art, the technical problem to be solved by the present application is to provide a split modular assembly process for a molten iron car frame, which can simplify the assembly of the molten iron car frame, improve the assembly efficiency, and reduce the manufacturing cost and safety risk.

[0006] To achieve the above-mentioned purpose, the present application provides a split modular assembly process for a molten iron car frame, the molten iron car frame comprising two left and right main longitudinal beams, support cross beams welded between the two main longitudinal beams, and a molten iron ladle placement space in the middle of the molten iron car frame for placing a molten iron ladle, a plurality of support cross beams are arranged in the front area of the molten iron ladle placement space and the front area, and connecting longitudinal beams or oil cylinder seat beams are welded between the support cross beams, support flanges are also welded on the support cross beams and the connecting longitudinal beams, the split modular assembly process comprising the following steps:

[0007] S1, the support cross beams, connecting longitudinal beams and oil cylinder seat beams in the front area of the molten iron ladle placement space are assembled and preliminarily welded into one, which is recorded as a front module frame; the support cross beams, connecting longitudinal beams and oil cylinder seat beams in the rear area of the molten iron ladle placement space are assembled and preliminarily welded into one, which is recorded as a rear module frame;

[0008] S2, the flatness and outer dimensions of the front module frame and the rear module frame are checked, and after being qualified, welding is carried out according to the requirements;

[0009] S3, after the welding of the front module frame and the rear module frame is completed, the flatness of the flange mounting surface for welding the support flanges is checked, and after meeting the requirements, the support flanges are welded;

[0010] S4, after the welding of the support flanges is completed, the flatness of the support flanges is checked, and after being qualified, the front module frame and the rear module frame are sent to machining;

[0011] S5, after the machining is completed, the two main longitudinal beams are positioned to be parallel, the front module frame and the rear module frame are placed between the two main longitudinal beams and positioned, the support cross beams of the front module frame and the rear module frame are assembled and welded with the two main longitudinal beams, and through three times of turning welding, the welding between the support cross beams in the front module frame and the rear module frame and the main longitudinal beams is completed.

[0012] Further, in the step S1, the assembling process of the front and rear module frames both further comprises: setting a reverse deformation support between the two adjacent support beams, the two ends of the reverse deformation support respectively abutting against the two support beams; then the reverse deformation support is preliminarily welded with the support beams to be integrated; and after the welding of the front and rear module frames is completed and before the module frames are sent to the machining, the reverse deformation supports are cut off.

[0013] Further, in the step S1, the assembling process of the front and rear module frames both comprises: S11, according to the structure of the module frame, a welding assembly platform is built, the welding assembly platform comprising a platform plate and a limiting block fixed on the platform plate; S12, the module frame is placed and assembled on the platform plate, the limiting block abutting against the outer side of the module frame to limit the position of the module frame, and the assembly is completed; S13, the support beams, the connecting longitudinal beams and the cylinder seat beams of the module frame are preliminarily welded to be integrated.

[0014] Further, in the step S2, the welding process of the front and rear module frames comprises: S21, the horizontal weld seams between the support beams and the connecting longitudinal beams in the module frame are welded first; S22, on the welding platform, L-shaped fixing clamps are arranged around the module frame, the L-shaped fixing clamps are fixed on the platform plate and are pressed on the upper surface of the module frame to fix the module frame; S23, the front surface weld seams on the upper surface of the module frame and the back surface weld seams on the lower surface of the module frame are welded, then the module frame is turned over once, the module frame is fixed again in the same way as the step S22, and the front surface weld seams on the lower surface of the module frame and the back surface weld seams on the upper surface of the module frame are welded.

[0015] Further, the step S3 comprises: checking the entire flange mounting surface by using an infrared level gauge, the number of checking points of each flange mounting surface is not less than 4, and the height difference is not more than 3mm.

[0016] Further, in the step S4, the process of checking the flatness of the support flange comprises: measuring the flatness of the top surface of the support flange by using an infrared level gauge, the number of checking points of each support flange is not less than 4, and the height difference is not more than 3mm.

[0017] Further, the step S4 further comprises: after the welding of the support flange is completed, a baking gun is used to bake the welding area of the support flange to release stress, and the rigid fixing of the module frame is removed after the module frame is completely cooled.

[0018] Further, in the step S4, the temperature for baking the welding area of the support flange by using the baking gun is 80-100℃.

[0019] Further, the step S5 further comprises: welding the guardrails and the bread seats.

[0020] As described above, the split modular assembly process involved in the present application has the following beneficial effects:

[0021] By adopting the modular manufacturing mode, the front and rear module frames are welded first, and then welded with the two main longitudinal beams 1. Compared with the existing process, the number of turning over is reduced, the high-altitude stay time after turning over is reduced, and the safety risk is reduced. The adjustment frequency during overall assembly process is reduced, the assembly efficiency is improved, the equipment capacity requirement of the machining manufacturer is reduced, the outsourcing machining cost is reduced, and the machining cycle is shortened. After adopting the process, the overall assembly of the frame is simplified, the operation is simple and easy to implement, the precision requirement is met, the machining cost is greatly reduced, and the manufacturing efficiency is improved. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 FIG. 1 is a structural schematic diagram of a molten iron car frame in the present application.

[0023] Figure 2 FIG. 2 is a structural schematic diagram of a front module frame in the present application.

[0024] Figure 3 FIG. 3 is a working schematic diagram of the front module frame fixed on a welding platform in the present application.

[0025] Figure 4 FIG. 4 is a schematic diagram of the front module frame, the rear module frame and the main cross beam during assembly and welding in the present application.

[0026] Figure 5 FIG. 5 is a structural schematic diagram of the molten iron car frame after welding in the present application.

[0027] ELEMENT NUMBER EXPLANATION

[0028] 1 main longitudinal beam

[0029] 2 support cross beam

[0030] 3 connecting longitudinal beam

[0031] 4 support flange

[0032] 5 oil cylinder seat beam

[0033] 6 guardrail

[0034] 7 ladle placing space

[0035] 8 limiting block

[0036] 9 L-shaped fixed clamp

[0037] 10 platform plate

[0038] 11 reverse deformation support DETAILED DESCRIPTION

[0039] The present application will be described in greater detail by specific embodiments, and other advantages and effects of the present application can be easily understood by those skilled in the art from the contents disclosed in the specification.

[0040] It should be understood that the structure, proportion, size, etc. shown in the drawings of the specification are only used to cooperate with the contents disclosed in the specification for understanding and reading by those skilled in the art, and are not used to limit the defined conditions for implementing the present application, so they do not have technical substantive significance. Any modification of the structure, change of the proportional relationship, or adjustment of the size, without affecting the effects and purposes that can be achieved by the present application, should still fall within the scope of the technical content disclosed by the present application. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and the like used in the specification are only for easy understanding and description, and are not used to limit the scope of the present application. The change or adjustment of the relative relationship, without substantially changing the technical content, is also considered as the scope of the present application.

[0041] Referring to Figures 1 to 5 The present application provides a split modular assembly process of a molten iron car frame, wherein the molten iron car frame comprises two left and right main longitudinal beams 1, support cross beams 2 welded between the two main longitudinal beams 1, the main longitudinal beams 1 are arranged in the front-back direction, the support cross beams 2 are arranged in the left-right direction, the middle position of the molten iron car frame is a ladle placing space 7 for placing a ladle, a plurality of support cross beams 2 are arranged in the front area of the ladle placing space 7 and the front area, and connecting longitudinal beams 3 or cylinder seat beams 5 are welded between the support cross beams 2, and support flanges 4 are welded on the support cross beams 2 and the connecting longitudinal beams 3.

[0042] The split modular assembly process of the present application comprises the following steps S1-S5:

[0043] S1, the support cross beams 2, the connecting longitudinal beams 3, and the cylinder seat beams 5 in the front area of the ladle placing space 7 are assembled and preliminarily welded into one body, and are recorded as a front module frame, referring to Figure 2 Similarly, the support cross beams 2, the connecting longitudinal beams 3, and the cylinder seat beams 5 in the rear area of the ladle placing space 7 are assembled and preliminarily welded into one body, and are recorded as a rear module frame. In this embodiment, the front module frame and the rear module frame are mirror images of each other, and have the same structure. Of course, in other cases, the two can also be different.

[0044] As a preferred design, referring to Figure 1In the embodiment, both the front module frame and the rear module frame further comprise a reverse deformation support 11 arranged between two adjacent support cross beams 2 during assembly, the two ends of the reverse deformation support 11 abutting against the two support cross beams 2 respectively; and the reverse deformation support 11 is preliminarily welded with the support cross beams 2 to be integrated, the reverse deformation support 11 being used to increase the overall rigidity of the module frame to reduce deformation. The reverse deformation support 11 is arranged at a suitable position as required, and specifically, see Figure 2 and Figure 3 For some adjacent support cross beams 2, only a connecting longitudinal beam 3 or a cylinder seat beam 5 is arranged between the two support cross beams 2 at the middle position, and the left and right sides are vacant, thus deformation is prone to occur, and therefore a reverse deformation support 11 is arranged at each of the left and right sides. The reverse deformation supports 11 are cut off after the front module frame and the rear module frame are welded and before being sent for machining, so as not to affect subsequent machining and welding.

[0045] See Figure 3 Preferably, in the step, the assembly and preliminary welding of the front module frame and the rear module frame are both completed on a welding platform, and the process comprises: S11, assembling a welding platform according to the structure of the module frame, the welding platform comprising a platform plate 10 and a limiting block 8 fixed on the platform plate 10; S12, placing and assembling the module frame on the platform plate 10, specifically, assembling the support cross beams 2, the connecting longitudinal beams 3 and the cylinder seat beams 5 according to the size requirements, the limiting block 8 abutting against the outer sides of the module frame, specifically, abutting against the outer sides of the support cross beams 2 and the connecting longitudinal beams 3, so as to limit the position of the module frame and complete the assembly to ensure the size accuracy; and S13, preliminarily welding the support cross beams 2, the connecting longitudinal beams 3 and the cylinder seat beams 5 of the module frame to be integrated. In the step, the preliminary welding can be simple welding such as spot welding, and only the support cross beams 2, the connecting longitudinal beams 3 and the cylinder seat beams 5 need to be welded and fixed, without strict welding according to the process requirements.

[0046] S2, checking the flatness and the outer shape size of the front module frame and the rear module frame, and welding according to the requirements after passing the check, specifically, including welding between the support cross beams 2 and the connecting longitudinal beams 3, and welding between the support cross beams 2 and the cylinder seat beams 5.

[0047] Preferably, in this step, the welding process of the front and rear module frames includes: S21, first welding the horizontal weld between the support cross beam 2 and the connecting longitudinal beam 3 in the module frame, which is free state welding because the welding amount is small; S22, on the welding platform, L-shaped fixed clamps 9 are arranged around the module frame, the L-shaped fixed clamps 9 are fixed on the platform plate 10 and are pressed on the upper surface of the module frame, specifically on the outer side of the support cross beam 2 and the connecting longitudinal beam 3, to fix the module frame on the welding platform; S23, after the front surface weld and the back surface weld on the module frame are welded, the module frame is turned over once, is fixed again in the same way as step S22, and the front surface weld and the back surface weld are welded.

[0048] S3, after the front module frame and the rear module frame are welded, the flatness of the flange mounting surface for welding the support flange 4 is checked, and the support flange 4 is welded after meeting the requirements. Preferably, in this embodiment, the infrared level gauge is used to check the entire flange mounting surface, and the number of check points of each flange mounting surface is not less than 4, and the height difference is not more than 3 mm.

[0049] S4, after the support flange 4 is welded, the flatness of the support flange 4 is checked, and the front module frame and the rear module frame are sent to processing after passing the inspection, wherein the content of sending to processing can include surface treatment, pickling and other conventional processing, which can be completed in the factory or sent to an external factory. In this embodiment, preferably, the process of checking the flatness of the support flange 4 includes: using an infrared level gauge to measure the flatness of the top surface of the support flange 4, and the number of check points of each support flange 4 is not less than 4, and the height difference is not more than 3 mm. After the welding of the support flange 4 is completed, a baking gun is used to bake the welding area of the support flange 4, the temperature during baking is 80-100℃, stress release is performed, and the rigid fixation of the module frame is released after completely cooling.

[0050] S5, after the processing is completed, the two main longitudinal beams 1 are positioned to be parallel, the front module frame and the rear module frame are placed between the two main longitudinal beams 1 and are positioned, see Figure 4 The support cross beam 2 of the front module frame and the rear module frame is assembled and welded with the two main longitudinal beams 1, and the welding of the weld between the support cross beam 2 and the main longitudinal beam 1 in the front module frame and the rear module frame is completed through three times of turning over. Since the front module frame and the rear module frame have been stably integrated at this time, the turning over is convenient, and the number of times of turning over can be reduced compared with the existing design. And the welding in this step is only concentrated between the support cross beam 2 and the main longitudinal beam 1, so the welding task is less, and the high-altitude stay time after each turning over can be reduced, thereby reducing the danger in work. In addition, the guardrails 6 and the bread seats can also be welded at this stage, and thus the welding of the entire iron water vehicle frame is completed, see Figure 5 .

[0051] The split modular assembly process of the present application can reduce the number of turning over, reduce the high-altitude time after turning over, and reduce the safety risk by adopting the modular manufacturing mode to weld the front and rear module frames first and then weld them with the two main longitudinal beams 1. The process can reduce the number of adjustments in the overall assembly process, improve the assembly efficiency, reduce the requirement for the equipment capacity of the machining manufacturer, reduce the outsourcing machining cost, and shorten the machining cycle. After adopting the process, the overall assembly of the vehicle frame is simplified, the operation is simple and easy to implement, the machining cost is greatly reduced while the precision requirement is met, and the manufacturing efficiency is improved.

[0052] In summary, the present application effectively overcomes the various shortcomings in the prior art and has a high industrial utilization value.

[0053] The above examples only illustratively explain the principles and effects of the present application, and are not used to limit the present application. Any person skilled in the art can modify or change the above examples without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes completed by those skilled in the art without departing from the spirit and technical thought disclosed by the present application should be covered by the claims of the present application.

Claims

1. A split modular assembly process of a molten iron car frame, the molten iron car frame comprising two left and right main longitudinal beams (1), support cross beams (2) welded between the two main longitudinal beams (1), and a ladle placing space (7) for placing a ladle in the middle position of the molten iron car frame, a plurality of support cross beams (2) are arranged in the front area of the ladle placing space (7) and the front area, and connecting longitudinal beams (3) or oil cylinder seat beams (5) are welded between the support cross beams (2), and support flanges (4) are further welded on the support cross beams (2) and the connecting longitudinal beams (3), characterized in that: The split modular assembly process comprises the following steps: S1, the support cross beam (2), the connecting longitudinal beam (3) and the oil cylinder seat beam (5) in the front area of the ladle placing space (7) are assembled and preliminarily welded into one, and are recorded as a front module frame; the support cross beam (2), the connecting longitudinal beam (3) and the oil cylinder seat beam (5) in the rear area of the ladle placing space (7) are assembled and preliminarily welded into one, and are recorded as a rear module frame; the front and rear two module frames both further comprise the following during the assembly process: a reverse deformation support (11) is arranged between the two adjacent support cross beams (2), and the two ends of the reverse deformation support (11) are respectively abutted against the two support cross beams (2); then the reverse deformation support (11) is preliminarily welded into one with the support cross beam (2); and after the welding of the front and rear two module frames is completed and before the module frames are sent to the processing, the reverse deformation support (11) is cut off; S2, the flatness and the outer dimension of the front module frame and the rear module frame are checked, and after the qualification, welding is carried out according to the requirements; S3, after the welding of the front module frame and the rear module frame is completed, the flatness of the flange mounting surface for welding the support flange (4) is checked, and after the requirements are met, the support flange (4) is welded; S4, after the welding of the support flange (4) is completed, the flatness of the support flange (4) is checked, and after the qualification, the front module frame and the rear module frame are sent to the processing; S5, after the processing is completed, the two main longitudinal beams (1) are positioned and kept parallel, the front module frame and the rear module frame are placed between the two main longitudinal beams (1) and are positioned, the support cross beam (2) of the front module frame and the rear module frame is assembled and welded with the two main longitudinal beams (1), and through three times of turning and welding, the welding between the support cross beam (2) in the front module frame and the rear module frame and the main longitudinal beam (1) is completed.

2. The split modular assembly process of claim 1, wherein: In the step S1, the assembly process of the front and rear two module frames comprises: S11, according to the structure of the module frame, an assembly and welding platform is built, and the assembly and welding platform comprises a platform plate (10) and a limiting block (8) fixed on the platform plate (10); S12, the module frame is placed and assembled on the platform plate (10), the limiting block (8) is abutted against the outer side of the module frame to limit the position of the module frame, and the assembly is completed; S13, the support cross beam (2), the connecting longitudinal beam (3) and the oil cylinder seat beam (5) of the module frame are preliminarily welded into one.

3. The split modular assembly process of claim 2, wherein: In the step S2, the welding process of the front and rear two module frames comprises: S21, the horizontal weld between the support cross beam (2) and the connecting longitudinal beam (3) in the module frame is welded first; S22, on the welding platform, an L-shaped fixed clamp (9) is arranged around the module frame, the L-shaped fixed clamp (9) is fixed on the platform plate (10) and is pressed on the upper surface of the module frame to fix the module frame; S23, the front surface weld on the upper surface of the module frame and the back surface weld on the lower surface of the module frame are welded, then the module frame is fixed again according to the same way of the step S22, the lower surface front surface weld and the upper surface back surface weld are completed.

4. The split modular assembly process of claim 1 or 3, wherein: The step S3 comprises: checking the whole flange mounting surface by using infrared level gauge, the number of checking points of each flange mounting surface is not less than 4, and the height difference is not more than 3mm.

5. The split modular assembly process of claim 1, wherein: In the step S4, the process of checking the flatness of the supporting flange (4) comprises: measuring the flatness of the top surface of the supporting flange (4) by using infrared level gauge, the number of checking points of each supporting flange (4) is not less than 4, and the height difference is not more than 3mm.

6. The split modular assembly process of claim 3, wherein: The step S4 further comprises: after the supporting flange (4) is welded, the welding area of the supporting flange (4) is baked by using baking gun to release stress, and the rigid fixation of the module frame is removed after completely cooling after welding.

7. The split modular assembly process of claim 6, wherein: In the step S4, the temperature of the baking gun when baking the welding area of the supporting flange (4) is 80-100℃.

8. The split modular assembly process of claim 1, wherein: The step S5 further comprises: welding the guardrail (6) and the bread seat.

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