Half-round girder track crane trolley frame manufacturing process

Abstract

The application relates to a semi-circular girder track crane frame manufacturing process, and the track crane frame comprises an upper structure assembly, a supporting leg assembly and a lower structure assembly; the specific manufacturing process is as follows: S1: manufacturing of the upper structure assembly; S2: integral machining of the upper structure assembly; S3: manufacturing of the lower structure assembly; S4: integral machining of the lower structure assembly; S5: machining of the supporting leg assembly; S6: assembling of the crane frame; S7: removal of the tooling; the upper structure assembly tooling is adopted to realize installation of the main beam structure, so that the deformation amount of the main beam of the track crane frame in the manufacturing process is guaranteed; in addition, the assembly of a horizontal wheel side lifting base, a non-horizontal wheel side lifting base, a rear bearing seat base and a traction frame base is carried out on the upper structure assembly tooling, the assembly efficiency is high, and the integral lifting can be directly carried out after the assembly is completed; after the integral assembling of the crane frame, each component structure needs to be rechecked to meet the welding requirements, so that the assembly precision is guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of semi-circular girder rail hoist, in particular to a semi-circular girder rail hoist trolley frame manufacturing process. BACKGROUND

[0002] In the project of rail hoist, the girder structure is composed of a girder box body and an end beam box body, one end of the girder is inserted into the end beam box body; the girder box body adopts a single semi-circular box body design; the semi-circular girder rail hoist needs to be supported by a trolley frame, and the product precision is poor during the manufacturing of the general trolley frame, the main reason is that the main beam structure is prone to deformation in subsequent processing, resulting in poor overall assembly precision, and even the situation of unable to assemble. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a semi-circular girder rail hoist trolley frame manufacturing process, which can solve the problem that the semi-circular girder rail hoist trolley frame is prone to main beam deformation during manufacturing and assembly, resulting in poor overall assembly precision, and even the situation of unable to assemble.

[0004] To solve the above technical problems, the technical scheme of the present application is as follows: a semi-circular girder rail hoist trolley frame manufacturing process, the rail hoist trolley frame includes an upper structure assembly, a leg assembly and a lower structure assembly; the innovation point is that the specific manufacturing process is as follows:

[0005] S1: manufacturing of the upper structure assembly: first process the upper structure assembly tooling for placing the upper structure assembly; the upper structure assembly includes a main beam, a horizontal wheel side lifting base, a non-horizontal wheel side lifting base, a rear bearing seat base and a traction frame base; a pair of mutually parallel main beams are bolted on the upper structure assembly tooling and installation lines are drawn on the main beams, a pair of horizontal wheel side lifting bases are installed on the outer sides of the main beams, and a pair of non-horizontal wheel side lifting bases are positioned and installed on the inner sides of the main beams through process shafts; the rear bearing seat base is welded at the two end sides of the main beam; the traction frame base is installed on the main beam with the trolley frame wheel center line as the reference;

[0006] S2: overall processing of the upper structure assembly: the upper structure assembly is hoisted and placed on a transfer car using a steel wire rope, the lower part of the upper structure assembly is placed on a sleeper and firmly tied, and is transferred to a boring position; the level is adjusted using a laser and a jack to ensure that the positions of the four wheels are horizontal and the height difference is within 1mm; boring is performed on the upper structure assembly using a boring machine; then the upper structure assembly is hoisted to the overall processing position, and the trolley frame machining plane and hole are reviewed to see whether they meet the overall processing requirements;

[0007] S3: Fabrication of lower structural components: Construct a horizontal jig, first place the component I-beams and H-beams on the jig to ensure level and spacing requirements; using the cross center line of the trolley frame as a reference, mark the lines to assemble the middle part of the H-beams, and complete the welding after re-measurement; correct the structural level, use the center of the trolley frame as a reference to mark the lines to install the push rod supports, ensuring spacing and height difference requirements; adjust the four corner planes of the driver's cab support to ensure flatness ±1mm, mark the lines to ensure that the push rod support surface has machining allowance, and install the pre-welded parts;

[0008] S4: Overall machining of lower structural components: Transfer and hoist the lower structural components to the overall machining station. Follow the marking and punching pattern to make the cutter. Using the four corner reference points as references, check whether the machining plane and holes of the push rod support meet the overall machining requirements. Mill the push rod support flange plane to ensure flatness and height difference.

[0009] S5: Outrigger assembly processing: The outrigger assemblies are made symmetrically in pairs. Welding is not done within the top 500mm area to facilitate adjustment. Welding is done on-site after assembly.

[0010] S6: Assembly of the trolley frame: Arrange the jig, assemble each component in place, ensure the upper and lower structural components are level, recheck the level of the wheel hole center of the upper structural component, and recheck that the four corner planes of the driver's cab support of the lower structural component meet the drawing requirements; ensure that the centers of the upper and lower structural components of the trolley frame are consistent, adjust the outrigger components in place, adjust the gaps evenly, complete the welding according to the drawings and process requirements, and assemble and weld the remaining structural parts and pre-welded parts in place;

[0011] S7: Dismantle the fixture: Connect the process support to the trolley frame to ensure the opening, remove the connecting bolts between the upper structural component fixture and the main beam; raise the trolley frame, and detach the upper connecting structural component fixture from the upper connecting structural component.

[0012] Furthermore, the upper structural component tooling in S1 includes a roller beam and a lifting beam; the roller beams are a pair and parallel to each other, and the lifting beams are a pair and parallel to each other. The lifting beams are horizontally arranged on the upper surface of the roller beams and perpendicular to the extension direction of the roller beams. The roller beams and the lifting beams form a grid structure. Bolt hole groups for connecting with the upper structural component are respectively provided on both sides of the lifting beams on the roller beams.

[0013] Furthermore, when the upper structural component tooling in S7 is detached, the main weld seam needs to be removed by carbon planing and grinding, and the lifting beam needs to be lowered. Then, the roller beam is lifted and placed on the ground, and the lap joint on the roller beam is cut off or ground off. Finally, the roller beam and the lifting beam are repainted and returned to the warehouse.

[0014] The advantages of this invention are:

[0015] 1) In the present application, the main beam structure is installed by using the upper structure assembly tooling, which ensures the deformation amount of the main beam of the track crane trolley frame during the manufacturing process. In addition, the assembly of the horizontal wheel side lifting base, the non-horizontal wheel side lifting base, the rear bearing seat base and the traction frame base is carried out on the upper structure assembly tooling, which has high assembly efficiency and can be directly lifted as a whole after assembly. After the overall assembly of the trolley frame, each component structure needs to be re-measured to meet the welding requirements, which ensures the assembly accuracy. BRIEF DESCRIPTION OF DRAWINGS

[0016] The present application will be further described in detail below in combination with the drawings and specific embodiments.

[0017] Fig. 1 A semi-circular girder track crane trolley frame manufacturing process chart.

[0018] Figs. 2 to 6 A semi-circular girder track crane trolley frame manufacturing process chart. DETAILED DESCRIPTION

[0019] To make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all the embodiments. The components of the embodiments of the present application described and shown in the drawings can be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed application, but only represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor are within the scope of protection of the present application.

[0021] As Figs. 1 to 6 shown in a semi-circular girder track crane trolley frame manufacturing process, the track crane trolley frame includes an upper structure assembly, a leg assembly and a lower structure assembly; the specific manufacturing process is as follows:

[0022] S1: Fabrication of the upper structure assembly: first process the upper structure assembly tooling for placing the upper structure assembly; the upper structure assembly includes the main beam, the horizontal wheel side lifting base, the non-horizontal wheel side lifting base, the rear bearing seat base and the traction frame base; a pair of mutually parallel main beams are bolted on the upper structure assembly tooling and installation lines are drawn on the main beams, a pair of horizontal wheel side lifting bases are installed on the outer sides of the main beams, and a pair of non-horizontal wheel side lifting bases are positioned and installed on the inner sides of the main beams through process shafts; the rear bearing seat base is welded at the two end sides of the main beam; the traction frame base is installed on the main beam with the center line of the trolley frame wheel as the reference;

[0023] S2: Overall processing of the upper structure assembly: the upper structure assembly is hoisted and placed on the transfer trolley with wooden blocks placed under the upper structure assembly for firmness, and is transferred to the boring position; the level is adjusted using laser and jack to ensure that the positions of the four wheels are horizontal and the height difference is within 1mm; boring is performed on the upper structure assembly using a boring machine; then the upper structure assembly is hoisted to the overall processing position to check whether the machining plane and hole of the trolley frame meet the overall processing requirements;

[0024] S3: Fabrication of the lower structure assembly: the horizontal jig is assembled, the assembly I-beam and H-shaped steel are placed on the jig to ensure the level and opening requirements; the H-shaped steel in the middle part is assembled by marking with the cross center line of the trolley frame as the reference, and the welding is completed after rechecking; the structure level is corrected, the push rod support is installed by marking as a whole with the trolley frame center as the reference to ensure the opening and height difference requirements; the four end corner planes of the driver's cabin support are adjusted to ensure the flatness of ±1mm, the push rod support surface is marked to ensure the machining allowance, and the pre-welded parts are installed;

[0025] S4: Overall processing of the lower structure assembly: the lower structure assembly is transferred and hoisted to the overall processing position, the cutter is guided according to the marking, and the four corner reference points are used as the reference to check whether the machining plane and hole of the push rod support meet the overall processing requirements; the flange plane of the push rod support is milled to ensure the flatness and height difference;

[0026] S5: Processing of the leg assembly: the leg assembly is fabricated in pairs, and the upper 500mm range is not welded first to facilitate adjustment, and is welded on site after assembly in place;

[0027] S6: Assembly of the trolley frame: the jig is arranged, and each component is assembled in place; the upper and lower structure assemblies are leveled, the wheel hole center of the upper structure assembly is rechecked, and the four end corner planes of the driver's cabin support of the lower structure assembly are rechecked to meet the requirements of the drawings; the centers of the upper and lower structure assemblies of the trolley frame are consistent, the leg assembly is adjusted in place, the gap is uniformly adjusted, and the welding of the remaining structural parts and pre-welded parts is completed according to the drawings and process requirements;

[0028] S7: dismounting tool: connecting the process support with the trolley frame to ensure the opening of the gap, dismounting the connecting bolts between the upper structure assembly tool and the main beam; lifting the trolley frame, and separating the upper connecting structure assembly tool from the upper connecting structure assembly.

[0029] The upper structure assembly tool in S1 comprises a roller way beam and a jacking beam; the roller way beam has a pair of parallel ones, and the jacking beam has a pair of parallel ones; the jacking beam is horizontally arranged on the upper surface of the roller way beam, and is perpendicular to the extension direction of the roller way beam; the roller way beam and the jacking beam form a well-shaped structure; a group of bolt holes for connecting with the upper structure assembly are arranged on the roller way beam at both sides of the jacking beam.

[0030] In S7, when the upper structure assembly tool is separated, the main weld carbon planer, polisher and jacking beam are removed, then the roller way beam is lifted and placed on the ground, the lap joint on the roller way beam is cut or polished, and finally the roller way beam and the jacking beam are repainted and stored in the warehouse.

[0031] Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, and the above-mentioned embodiments and descriptions in the specification are only to illustrate the principles of the present application, and various changes and improvements can be made without departing from the spirit and scope of the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a semi-circular beam rail-mounted trolley frame, the rail-mounted trolley frame comprising an upper structural component, a leg component, and a lower structural component; characterized in that: The specific manufacturing process is as follows: S1: Fabrication of the superstructure component: First, fabricate the superstructure component fixture for placing the superstructure component; the superstructure component includes a main beam, a horizontal wheel-side lifting base, a non-horizontal wheel-side lifting base, a rear bearing seat base, and a traction frame base; a pair of parallel main beams are bolted onto the superstructure component fixture and installation lines are marked on the main beams; a pair of horizontal wheel-side lifting bases are installed on the outer side of the main beams respectively, and a pair of non-horizontal wheel-side lifting bases are positioned and installed on the inner side of the main beams through process shafts; the rear bearing seat base is welded to the two ends of the main beams; the traction frame base is installed on the main beam with the center line of the trolley frame wheels as the reference; S2: Overall Machining of the Upper Structure Components: The upper structure components are lifted and placed on a transfer vehicle using steel wire ropes, with wooden sleepers placed underneath to support them and securely tied. They are then transferred to the boring station, where laser and jacks are used to adjust the level, ensuring the height difference between the four sets of wheels is within 1mm. The upper structure components are then bored using a boring machine. Finally, the upper structure components are hoisted to the overall machining station, and the machining planes and holes on the trolley frame are checked to ensure they meet the overall machining requirements. S3: Fabrication of lower structural components: Construct a horizontal jig, first place the component I-beams and H-beams on the jig to ensure level and spacing requirements; using the cross center line of the trolley frame as a reference, mark the lines to assemble the middle part of the H-beams, and complete the welding after re-measurement; correct the structural level, use the center of the trolley frame as a reference to mark the lines to install the push rod supports, ensuring spacing and height difference requirements; adjust the four corner planes of the driver's cab support to ensure flatness ±1mm, mark the lines to ensure that the push rod support surface has machining allowance, and install the pre-welded parts; S4: Overall machining of lower structural components: Transfer and hoist the lower structural components to the overall machining station. Follow the marking and punching pattern to make the cutter. Using the four corner reference points as references, check whether the machining plane and holes of the push rod support meet the overall machining requirements. Mill the push rod support flange plane to ensure flatness and height difference. S5: Outrigger assembly processing: The outrigger assemblies are made symmetrically in pairs. Welding is not done within the top 500mm area to facilitate adjustment. Welding is done on-site after assembly. S6: Assembly of the trolley frame: Arrange the jig, assemble each component in place, ensure the upper and lower structural components are level, recheck the level of the wheel hole center of the upper structural component, and recheck that the four corner planes of the driver's cab support of the lower structural component meet the drawing requirements; ensure that the centers of the upper and lower structural components of the trolley frame are consistent, adjust the outrigger components in place, adjust the gaps evenly, complete the welding according to the drawings and process requirements, and assemble and weld the remaining structural parts and pre-welded parts in place; S7: Remove tooling: Connect the process support to the trolley frame to ensure the opening, and remove the connecting bolts between the upper structural component tooling and the main beam; Raise the trolley frame and detach the upper connecting structure component tooling from the upper connecting structure component.

2. The manufacturing process of a semi-circular beam track crane trolley frame according to claim 1, characterized in that: The upper structure component tooling in S1 includes a roller beam and a lifting beam; there is a pair of roller beams that are parallel to each other, and there is a pair of lifting beams that are parallel to each other. The lifting beams are horizontally arranged on the upper surface of the roller beams and perpendicular to the extension direction of the roller beams. The roller beams and the lifting beams form a grid structure; bolt hole groups for connecting with the upper structure component are respectively provided on both sides of the lifting beams on the roller beams.

3. The manufacturing process of a semi-circular beam track crane trolley frame according to claim 1, characterized in that: When the upper structural component tooling of S7 is detached, the main weld seam needs to be removed by carbon planing and grinding, and the lifting beam needs to be lowered. Then, the roller beam needs to be lifted and placed on the ground, and the lap joint on the roller beam needs to be cut off or ground off. Finally, the roller beam and the lifting beam need to be repainted and returned to the warehouse.

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