A modular integral processing method for a yard crane

Abstract

The present invention relates to a method for integral modular processing of a quay crane, comprising the following steps: Step 1, establishing a three-dimensional model of the quay crane; Step 2, processing the main beam module; Step 3, processing the leg module; Step 4, processing the cross beam; Step 5, performing the general assembly of the main beam module, the leg module and the cross beam. The present invention uses three-dimensional software to generate a three-dimensional model, simulating the assembly states of the legs, the cross beam and the main beam, reducing the adjustment work caused by the cumulative deviation in the production of components in the later stage, effectively shortening the on-site assembly cycle. The main structure main beam and the legs are fabricated modularly. By scribing and processing the component flanges, the pre-assembly process of the legs is cancelled, reducing the use of pre-assembly equipment and improving the utilization rate of the general assembly site. After the components are adjusted horizontally, a single clamping can complete multiple processing procedures, reducing the processing auxiliary time. At the same time, the general assembly large joint welding process is cancelled, fundamentally eliminating the damage to the fire painting of the large joints and reducing the high-altitude paint repair.

Description

Technical Field

[0001] The present invention relates to the technical field of yard crane processing, and in particular to a modular integral processing method for yard cranes. Background Art

[0002] Yard cranes are a type of port machinery. Quayside cranes refer to bridge-type equipment used on the shore for loading and unloading containers from ships to the wharf, and yard cranes refer to bridge-type handling equipment used in the stacking area for in-yard handling. When the production tasks of yard cranes are extremely busy, due to the limitations of the processing capabilities of existing equipment, after the main structural components are individually manufactured, they cannot meet the requirements of the overall machining flange surface. Currently, the manufacturing process of yard cranes includes the following steps: First, each main structural component workshop manufactures separately; Second, pre-assembly of the door frame and main beam components is carried out in the outdoor yard; Third, overall sandblasting and painting; Fourth, general assembly and commissioning, including welding the large joints of the legs and main beams at high altitude; Fifth, painting repair at the welding points where hot work is carried out. Due to various reasons such as welding and flame straightening in the existing technology of yard crane manufacturing, the sizes of each component cannot be accurately controlled, the structures are of different lengths, and both the main beam and the door frame components need to be pre-assembled in advance before entering the general assembly process, resulting in complex processes, time-consuming and laborious; at the same time, the hot work welding of large joints at high altitude during the general assembly of yard cranes will extensively damage the painted paint, increasing a large amount of painting repair work and seriously affecting the quality of the topcoat.

[0003] Therefore, the present invention proposes a modular integral processing method for yard cranes to solve the above problems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a modular integral processing method for yard cranes, which simplifies the general assembly process in the outdoor yard, shortens the general assembly cycle, and improves the utilization rate of the general assembly site and the paint quality.

[0005] To solve the above technical problem, the technical solution of the present invention is: A modular integral processing method for yard cranes, the innovation of which lies in: including the following steps:

[0006] Step 1, establish a three-dimensional model of the yard crane, input the key dimension data of the yard crane into three-dimensional software to generate a three-dimensional model, and simulate the splicing states of the legs, crossbeams, and main beams of the yard crane, so as to screen out the best-matched reserve modules;

[0007] Step 2, main beam module processing;

[0008] Step 2-1, select the main beam processing equipment. Two numerically controlled overhead milling machines are selected for integral processing. One is a fixed equipment, and the other is a rail-mounted mobile equipment. Both numerically controlled overhead milling machines have the function of processing slightly inclined surfaces;

[0009] Step 2-2: After the main beam steel structure is completed, the horizontal and vertical cross center lines of the main beam and the support leg positioning center line are marked in the steel structure workshop with the track center as the reference. Sample punch marks are made at the ends of the main beam and the zero point respectively to form the main beam module;

[0010] Step 2-3: hoist the main beam module as a whole onto the machining auxiliary support frame, and adjust the overall level of the main beam module based on the sample punch mark;

[0011] Step 2-4: After re-measuring the horizontal dimensions of the main beam module and confirming they are correct, tighten the box beam structure of the main beam module and clamp the corresponding stabilizing device at the end;

[0012] Step 2-5: Before machining the flange of the main beam module, re-measure the milling surface and drilling reference line. After confirming that they are correct, mill the surface and drill the flange surface of the main beam module;

[0013] Step 3: Processing the leg module;

[0014] Step 3-1: Select the equipment for leg processing. Two CNC face milling machines are used for overall processing. One is a fixed face milling machine, and the other is a mobile face milling machine with a slide rail underneath.

[0015] Step 3-2: When CNC lofting and making the outrigger box, the trimming allowance of the outrigger is placed at the saddle beam end of the outrigger, and no allowance is left at the beam end of the outrigger. After the outrigger box is completed, the installation position of the accessories is marked based on the beam end of the outrigger and the center line of the box, and positioning welding is carried out;

[0016] Step 3-3: After the outrigger steel structure is completed, mark the structural horizontal reference line on both sides of the box body, and use this as a reference to mark the flange milling surface and drilling reference line, punch the sample inspection mark, form the outrigger module, and arrange the tire frame according to the outrigger length size parameters;

[0017] Step 3-4: hoist the outrigger module onto the shelf as a whole, and adjust the overall level of the outrigger module based on the sample punch mark. After the outrigger module is adjusted to the right level, tighten it;

[0018] Step 3-5: Before flange processing, re-measure the milling surface and drilling reference line. After confirming that they are correct, proceed with milling and drilling the flange surface where the legs are connected.

[0019] Step 4: Beam processing;

[0020] Step 5: Assemble the main beam module, support leg module and cross beam.

[0021] Further, the machining auxiliary shelving jig in step 2-3 includes a box girder stabilizing jig and two main girder locking jigs. The box girder stabilizing jig is arranged in the middle of the box girder structure of the main girder module, and the two main girder locking jigs are respectively arranged at the two ends of the box girder structure of the main girder module. Both the box girder stabilizing jig and the main girder locking jig are fixedly connected to the embedded iron on the ground by pressing plates.

[0022] Further, the main girder locking jig includes a leg module, a T-slot adjusting and locking platform, and a box girder auxiliary clamping device;

[0023] The T-slot adjusting and locking platform adopts a box girder structure and is installed on the top of the leg module. The box girder auxiliary clamping device includes a horizontal clamping device and a vertical locking device. The upper surface of the T-slot adjusting and locking platform is provided with T-slots. Both the horizontal clamping device and the vertical locking device are installed in the T-slots. The horizontal clamping device uses a jack in cooperation with an adjusting support to fix the main girder module in the horizontal direction, and the vertical locking device uses a pressure bar in cooperation with a turnbuckle to fix the main girder module in the vertical direction.

[0024] Further, the stabilizing device in step 2-4 includes an adjusting strut and a movable cast iron platform. One end of the adjusting strut is hinged to the movable cast iron platform, and the other end is hinged to the end face of the main girder module.

[0025] Further, in step 3-5, when the fixed end face milling machine processes the connecting flange surface of the leg, the milling cutter head of the fixed end face milling machine processes along a top-down walking track.

[0026] The advantages of the present invention are as follows:

[0027] (1) The yard crane of the present invention generates a 3D model using 3D software to simulate the assembly states of the legs, cross beams and main girders, reducing the adjustment work caused by the cumulative deviation in component manufacturing in the later stage, effectively shortening the on-site assembly cycle. The main structure main girder and legs are fabricated modularly. Through component flange scribing and machining, the pre-assembly process of the legs is cancelled, reducing the use of pre-assembly equipment and improving the utilization rate of the general assembly site. In addition, after the components are adjusted horizontally and clamped once, multiple machining processes such as milling and drilling can be completed, reducing the machining auxiliary time. At the same time, the general assembly large joint welding process is cancelled, fundamentally eliminating the damage of the large joint to the fire and paint, and reducing the high-altitude paint repair.

[0028] (2) Both the box girder stabilizing jig and the main girder locking jig in the present invention are fixedly connected to the embedded iron on the ground by pressing plates, improving the overall stability of the machining auxiliary shelving jig, reducing the vibration transmission generated during the machining of the main girder ends, and reducing the resonance influence generated between the two ends of the main girder during synchronous machining.

[0029] (3) In the present invention, the adjustment support is used in cooperation with the moving cast iron platform to stabilize the end of the main beam, further reducing the resonance effect generated during the machining of the main beam.

[0030] (4) In the present invention, the milling cutter head of the fixed-end face milling machine adopts a downward walking trajectory for machining, effectively reducing the generation of cutting force in the horizontal direction, reducing the lateral torque of the support member, and reducing the vibration of the leg member. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention will be further described in detail below with reference to the drawings and specific embodiments.

[0032] Figure 1 It is a schematic diagram of the machining of the main beam module in the present invention.

[0033] Figure 2 It is a schematic diagram of the machining of the leg module in the present invention. SPECIFIC EMBODIMENTS

[0034] The following embodiments can enable those skilled in the art to understand the present invention more comprehensively, but do not limit the present invention to the scope of the described embodiments.

[0035] A method for integral machining of a quay crane module provided by the present invention includes the following steps:

[0036] Step 1: Establish a three-dimensional model of the quay crane, input the key dimension data of the quay crane into three-dimensional software to generate a three-dimensional model, and simulate the splicing states of the legs, crossbeams, and main beams of the quay crane, so as to screen out the best-matched reserve modules, reduce the adjustment work caused by the cumulative deviation of component manufacturing in the later stage, and shorten the production cycle;

[0037] Step 2: Machine the main beam module;

[0038] Step 2-1: Select the machining equipment for the main beam. Two numerically controlled overhead milling machines 1 are selected for integral machining. One is a fixed equipment, and the other is a rail-mounted mobile equipment. Both numerically controlled overhead milling machines 1 have the function of machining slightly inclined surfaces to meet the requirement that the flange surface of the main beam has an inclination angle relative to the horizontal plane;

[0039] Step 2-2: After the steel structure of the main beam is fabricated, with the rail center as the reference in the steel structure workshop, the horizontal and vertical cross centerlines of the main beam and the leg positioning centerline are marked out integrally, and sample punch marks are knocked at the end of the main beam and the zero point respectively to form the main beam module;

[0040] Step 2-3: Hoist the main beam module integrally onto the machining auxiliary resting jig, and adjust the overall level of the main beam module with the sample punch mark as the reference;

[0041] Among them, the machining auxiliary shelving cradle includes a box beam stabilizing cradle 3 and two main beam locking cradles. The box beam stabilizing cradle 3 is arranged in the middle of the box beam structure of the main beam module, and the two main beam locking cradles are respectively arranged at the two ends of the box beam structure of the main beam module. The box beam stabilizing cradle 3 and the main beam locking cradle are fixedly connected to the pre-buried iron on the ground with a pressure plate, which improves the overall stability of the machining auxiliary shelving cradle, reduces the vibration transmission generated during the machining of the main beam end, and reduces the resonance effect generated by the synchronous machining of the two ends of the main beam; the main beam locking cradle includes a leg module Group 2, T-slot adjustment locking platform and box beam auxiliary clamping device 4, the T-slot adjustment locking platform adopts a box beam structure and is installed on the top of the leg module 2, the box beam auxiliary clamping device 4 includes a horizontal clamping device and a vertical locking device, the upper surface of the T-slot adjustment locking platform is provided with a T-slot, the horizontal clamping device and the vertical locking device are both installed in the T-slot, the horizontal clamping device uses a jack with an adjustment support to fix the main beam module in the horizontal direction, and the vertical locking device uses a pressure rod with a turnbuckle screw to fix the main beam module in the vertical direction;

[0042] Step 2-4: After re-measurement of the horizontal dimensions of the main beam module, tighten the box beam structure of the main beam module and clamp the corresponding stabilization device at the end. The stabilization device includes an adjustment support rod and a movable cast iron platform. One end of the adjustment support rod is hinged to the movable cast iron platform, and the other end is hinged to the end face of the main beam module. The adjustment support is used in conjunction with the movable cast iron platform to stabilize the end of the main beam to reduce the resonance effect generated during the main beam processing.

[0043] Step 2-5: Before machining the flange of the main beam module, re-measure the milling surface and drilling reference line. After confirming that they are correct, mill the surface and drill the flange surface of the main beam module;

[0044] Step 3: Processing the leg module;

[0045] Step 3-1. Select the equipment for leg processing. Two CNC face milling machines 7 are used for overall processing. One is a fixed face milling machine and the other is a mobile face milling machine. The fixed face milling machine is firmly fixed to the ground foundation. The mobile face milling machine is equipped with a slide rail under it to facilitate equipment movement.

[0046] Step 3-2: When CNC lofting and making the outrigger box, the trimming allowance of the outrigger is placed on the saddle beam end of the outrigger, and no allowance is left on the beam end of the outrigger. After the outrigger box is completed, the beam end of the outrigger and the center line of the box are used as references to mark the installation position of the accessories, and then position and weld them. When the support rod ear plate is CNC cut, the inner hole of the support rod ear plate is not CNC machined for the time being. After the outrigger and main beam are assembled and in a horizontal state, the position of the support rod ear plate hole is marked based on the center line of the main beam and the center line of the track, and the holes are drilled on site using a magnetic drill;

[0047] Step 3-3: After the steel structure of the outrigger is completed, a structural horizontal reference line is drawn on both sides of the box body, and the flange milling surface and drilling reference line are drawn based on this reference line. The sample punching inspection mark is hammered to form the outrigger module. The shelving cradle 6 is arranged according to the outrigger length size parameters. The arrangement of the shelving cradle is the same as the machining auxiliary shelving cradle of the main beam. The two ends of the outrigger are mainly locked cradles, and the middle part is supplemented by a stabilizing cradle. Laterally adjustable diagonal bracing brackets are added to improve the rigidity of the outrigger after tightening.

[0048] Step 3-4: hoist the outrigger module onto the shelf as a whole, and adjust the overall level of the outrigger module based on the sample punch mark. After the outrigger module is adjusted to the right level, tighten it;

[0049] Step 3-5: Before flange processing, re-measure the milling surface and drilling processing reference line. After confirming that they are correct, proceed with milling and drilling the flange surface of the leg connection. When the fixed end milling machine processes the flange surface of the leg connection, the milling cutter head of the fixed end milling machine adopts a top-down walking trajectory for processing, utilizing the tool feed direction to reduce the generation of horizontal cutting force, reduce the lateral torque of the support component, and alleviate the vibration of the leg component;

[0050] Step 4: Beam processing;

[0051] Step 5: Assemble the main beam module, support leg module and cross beam.

[0052] The modular overall processing method of the field bridge of the present invention uses three-dimensional software to generate a three-dimensional model, simulates the assembly state of the legs, crossbeams and main beams, reduces the adjustment work caused by the cumulative deviation of component production in the later stage, and effectively shortens the field assembly cycle. The main structure main beam and legs are manufactured in a modular manner, and the pre-assembly process of the legs is eliminated through the component flange marking process, which reduces the use of pre-assembly equipment and improves the utilization rate of the assembly site. In addition, after the component is adjusted to be level, it can be clamped once to complete multiple processing processes such as milling and drilling, reducing auxiliary processing time and canceling the large seam welding process of the assembly. It fundamentally eliminates the damage to the paint of large joints caused by open flames and reduces high-altitude paint repairs.

[0053] Those skilled in the art will appreciate that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A modular integral processing method for a gantry crane, characterized in that: The following steps are involved: Step 1: Build a 3D model of the field crane. Enter the key dimension data of the field crane into the 3D software to generate a 3D model. Simulate the splicing status of the field crane's legs, beams, and main beams to select the best matching reserve module. Step 2: Processing the main beam module; Step 2-1: Select the main beam processing equipment. Two CNC milling machines are used for overall processing. One is a fixed device and the other is a track-moving device. Both CNC milling machines have the function of processing micro-inclined surfaces. Step 2-2: After the main beam steel structure is completed, the horizontal and vertical cross center lines of the main beam and the support leg positioning center line are marked in the steel structure workshop with the track center as the reference. Sample punch marks are made at the ends of the main beam and the zero point respectively to form the main beam module; Step 2-3: hoist the main beam module as a whole onto the machining auxiliary support frame, and adjust the overall level of the main beam module based on the sample punch mark; Step 2-4: After re-measuring the horizontal dimensions of the main beam module and confirming they are correct, tighten the box beam structure of the main beam module and clamp the corresponding stabilizing device at the end; Step 2-5: Before machining the flange of the main beam module, re-measure the milling surface and drilling reference line. After confirming that they are correct, mill the surface and drill the flange surface of the main beam module; Step 3: Processing the leg module; Step 3-1: Select the equipment for leg processing. Two CNC face milling machines are used for overall processing. One is a fixed face milling machine, and the other is a mobile face milling machine with a slide rail underneath. Step 3-2: When CNC lofting and making the outrigger box, the trimming allowance of the outrigger is placed at the saddle beam end of the outrigger, and no allowance is left at the beam end of the outrigger. After the outrigger box is completed, the installation position of the accessories is marked based on the beam end of the outrigger and the center line of the box, and positioning welding is carried out; Step 3-3: After the outrigger steel structure is completed, mark the structural horizontal reference line on both sides of the box body, and use this as a reference to mark the flange milling surface and drilling reference line, punch the sample inspection mark, form the outrigger module, and arrange the tire frame according to the outrigger length size parameters; Step 3-4: hoist the outrigger module onto the shelf as a whole, and adjust the overall level of the outrigger module based on the sample punch mark. After the outrigger module is adjusted to the right level, tighten it; Step 3-5: Before flange processing, re-measure the milling surface and drilling reference line. After confirming that they are correct, proceed with milling and drilling the flange surface where the legs are connected. Step 4: Beam processing; Step 5: Assemble the main beam module, support leg module and cross beam.

2. The overall machining method for the quay crane modularization according to claim 1, characterized in that: The machined auxiliary mounting cradle in step 2-3 includes a box beam stabilizing cradle and two main beam locking cradles. The box beam stabilizing cradle is arranged in the middle of the box beam structure of the main beam module, and the two main beam locking cradles are respectively arranged at the two ends of the box beam structure of the main beam module. The box beam stabilizing cradle and the main beam locking cradle are both fixedly connected to the embedded iron on the ground by using pressure plates.

3. The modular integrated processing method of a field bridge according to claim 2, characterized in that: The main beam locking frame includes a leg module, a T-slot adjustment locking platform and a box beam auxiliary clamping device; The T-slot adjusting and locking platform adopts a box girder structure and is installed on the top of the leg module. The box girder auxiliary clamping device includes a horizontal clamping device and a vertical locking device. The upper surface of the T-slot adjusting and locking platform is provided with T-slots. Both the horizontal clamping device and the vertical locking device are installed in the T-slots. The horizontal clamping device uses a jack in cooperation with an adjusting support to fix the main beam module in the horizontal direction, and the vertical locking device uses a pressure bar in cooperation with a turnbuckle to fix the main beam module in the vertical direction.

4. The modular integrated processing method of a field bridge according to claim 1, characterized in that: The stabilizing device in the step 2-4 includes an adjusting strut and a movable cast iron platform. One end of the adjusting strut is hinged to the movable cast iron platform, and the other end is hinged to the end face of the main beam module.

5. The field bridge modular integral machining method according to claim 1, characterized in that: In the step 3-5, when the fixed end face milling machine processes the connecting flange face of the leg, the milling cutter head of the fixed end face milling machine adopts a walking track from top to bottom for processing.

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