An assembly tool and method

Abstract

The application discloses an assembling tool and an assembling method, which ensure that the loading and unloading device is successfully assembled once, improve work efficiency, and realize flexible extension and non-interference. The assembling tool comprises a lower side beam assembling component, an upper frame assembling component and a general assembling component, wherein the lower side beam assembling component comprises a first supporting pad assembly for supporting the lower side beam along the length direction of the lower side beam, a clamp assembly for clamping two opposite webs of the lower side beam and a pressurizing assembly for pressurizing from top to bottom; the upper frame assembling component comprises a second supporting pad assembly for supporting the upper frame, and the second supporting pad assembly is provided with a first positioning assembly for positioning the upper side beam and a transverse extension assembly of the upper frame; and the general assembling component comprises two supporting seats and a perpendicularity adjusting assembly for adjusting the perpendicularity of a vertical extension assembly, and the perpendicularity adjusting assembly comprises a transverse adjusting mechanism and a longitudinal adjusting mechanism, so that the assembling efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of loading and unloading device manufacturing technology, specifically to an assembly tooling and assembly method. Background Technology

[0002] In order to realize the handling and transfer of objects or materials, there are already many loading and unloading devices in related technologies. There is a type of loading and unloading device that can walk and is adjustable in height in the longitudinal direction and width in the lateral direction. It is large in size, difficult to manufacture and has high technical requirements. The assembly requirements of the lateral and longitudinal telescopic structures are also high. Existing technologies have technical problems such as difficult manufacturing and low assembly efficiency. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides an assembly fixture and assembly method, which ensures that the loading and unloading device is successfully assembled in one go, improves work efficiency, achieves flexible extension and retraction without mutual interference, and realizes the function of lifting goods.

[0004] The solution to achieve the technical objective of this invention is an assembly fixture, comprising a lower side beam assembly assembly, an upper frame assembly assembly, and a final assembly assembly, wherein:

[0005] The lower side beam assembly includes a first support pad assembly for supporting the lower side beam at intervals along its length, a clamping assembly for clamping the two opposing webs of the lower side beam, and a pressurizing assembly for applying pressure from top to bottom.

[0006] The upper frame assembly includes a second support pad assembly for supporting the upper frame, and the second support pad assembly is provided with a first positioning assembly for positioning the upper side beam and the lateral telescopic assembly of the upper frame.

[0007] The assembly includes two support seats and a verticality adjustment assembly for adjusting the verticality of the vertical telescopic component. The verticality adjustment assembly includes a lateral adjustment mechanism and a longitudinal adjustment mechanism.

[0008] In some embodiments, both the lateral adjustment mechanism and the longitudinal adjustment mechanism include a bidirectional screw and two connecting rods threaded to both ends of the bidirectional screw.

[0009] In some embodiments, the clamp assembly includes a U-shaped bracket and an adjustable lead screw threaded to at least one side plate of the U-shaped bracket.

[0010] In some embodiments, the first support pad assembly is provided with a second positioning assembly for positioning the two end faces of the lower cover plate of the lower side beam in the width direction.

[0011] Based on the same inventive concept, the present invention also provides an assembly method based on the above-described assembly tooling, comprising:

[0012] The lower side beam is obtained by assembling the lower cover plate, two web plates and the upper cover plate of the lower side beam;

[0013] The upper frame is obtained by assembling the upper frame into two upper side beams and two transverse telescopic components that connect the two upper beams.

[0014] The frame assembly is obtained by assembling the upper frame, two lower side beams, and four vertical telescopic components connecting the two upper side beams and the two lower side beams in the final assembly.

[0015] In some embodiments, the assembly of the lower side beam, comprising the lower cover plate, two web plates, and the upper cover plate, specifically includes:

[0016] The lower cover plate of the lower side beam is placed on at least two first support pads, and the two web plates are clamped and positioned by the clamping assembly. The two web plates are pressed onto the lower cover plate or the first support pad by the pressure assembly, and the lower cover plate and the two web plates are spot welded to fix them.

[0017] Place the top cover plate on the top surface of the two web plates and adjust its position. Press the top cover plate onto the two web plates using the pressure assembly, and spot weld the top cover plate and the two web plates to fix them.

[0018] Welding operations are performed at each connection point.

[0019] In some embodiments, the lower side beam further includes a partition;

[0020] After placing the lower cover plate of the lower side beam on the at least two first support pads, and before spot welding the lower cover plate and the two web plates, the assembly method specifically includes: drawing the center line of the lower cover plate and the partition assembly dimension line on the lower cover plate; spot welding multiple partition plates to the lower cover plate according to the position of the partition assembly dimension line; placing the two web plates on the lower cover plate, and clamping and positioning the two web plates at both ends of the partition plate along the width direction of the lower side beam by a clamping assembly; and pressing the two web plates onto the lower cover plate by a pressure assembly.

[0021] Before placing the upper cover plate on the top surface of the two web plates and positioning it, the assembly method specifically includes: welding the connection seam between the partition plate and the lower cover plate and the two web plates.

[0022] In some embodiments, the lateral telescopic assembly includes a sleeved first crossbeam and a second crossbeam, the first crossbeam having a guide cavity;

[0023] The two upper side beams assembled by the upper frame and the two lateral telescopic components connecting the two upper beams specifically include:

[0024] The first upper beam is placed on at least two second support pads on the first side and positioned by the first positioning component;

[0025] The two first crossbeams are positioned by the first positioning components on at least two second support pads on the first side, and the first upper beam and the two first crossbeams are spot welded to fix them.

[0026] The two second crossbeams are positioned by the first positioning components of at least two second support pads on the second side, so that the second crossbeams extend into the guide cavity of the first crossbeam one by one, and assembly templates are set in the circumference of the first and second crossbeams.

[0027] The second upper beam is placed on at least two support pads on the second side and positioned by the first positioning component. After the spacing between the two upper beams is qualified, the second upper beam and the two second cross beams are spot welded to fix them.

[0028] Welding is performed on each connecting part of the upper frame assembly.

[0029] In some embodiments, before welding is performed on the various connecting parts of the upper frame assembly, the assembly method further includes removing the assembly template and moving at least one upper side beam on the second support pad along the telescopic direction of the transverse telescopic mechanism to ensure free telescopic movement.

[0030] In some embodiments, the vertical telescopic assembly includes a column and a guide sleeve; the assembly of the two lower side beams of the upper frame and the four vertical telescopic assemblies connecting the two upper side beams and the two lower side beams in the final assembly specifically includes:

[0031] Using the bottom surface of the flange on the bottom surface of the lower cover plate of the lower side beam as the reference surface, place the two lower side beams at intervals on the support base of the assembly. After adjusting the position of the two lower side beams to meet the size requirements, fix the two lower side beams to the support base.

[0032] Two columns are vertically installed on the upper cover plates of the two lower side beams respectively, and assembly templates are evenly arranged around the columns. Four guide sleeves are hoisted in sequence and fitted to the four columns respectively. The verticality of the guide sleeves is adjusted by the verticality adjustment component. After the hole spacing of the four guide sleeves is qualified, the guide sleeves and columns are spot welded to fix them one by one.

[0033] Hoist the upper frame onto the guide sleeve, align the guide sleeve and the upper side beam at the mating position, and connect and fix the guide sleeve and the upper side beam.

[0034] In some embodiments, before hoisting the upper frame onto the guide sleeve, the assembly method further includes uniformly placing an assembly template circumferentially between the first crossbeam and the second crossbeam to ensure uniform gaps between the surfaces.

[0035] In some embodiments, adjusting the perpendicularity of the guide sleeve using the perpendicularity adjustment component specifically includes,

[0036] One end of the lateral adjustment mechanism and the longitudinal adjustment mechanism are fixedly connected to the guide sleeve, and the other end is fixedly connected to the lower side beam or the ground; the lateral adjustment mechanism and the longitudinal adjustment mechanism are respectively set at an angle to the guide sleeve, and the lateral adjustment mechanism and the longitudinal adjustment mechanism are set at an angle.

[0037] As can be seen from the above technical solution, the assembly fixture provided by the present invention includes a lower side beam assembly, an upper frame assembly, and a final assembly, wherein: the lower side beam assembly includes a first support pad assembly for supporting the lower side beam at intervals along the length direction of the lower side beam, a clamping assembly for clamping the two opposing webs of the lower side beam, and a pressurizing assembly for applying pressure from top to bottom; the upper frame assembly includes a second support pad assembly for supporting the upper frame, and the second support pad assembly is provided with a first positioning assembly for positioning the upper side beam and the lateral telescopic assembly of the upper frame; the final assembly includes two support seats and a verticality adjustment assembly for adjusting the verticality of the vertical telescopic assembly, the verticality adjustment assembly including a lateral adjustment mechanism and a longitudinal adjustment mechanism.

[0038] An assembly mode of first assembling components and then connecting them as a whole is adopted. Each component corresponds to a separate prefabricated fixture, ensuring the assembly of the lower side beam, upper frame, and overall steel structure. This guarantees the dimensions and functions of each component of the loading and unloading device, meeting technical requirements. Based on this assembly fixture, a reliable assembly method is provided. This method ensures successful assembly of the loading and unloading device in one go, improves efficiency, and ensures flexible extension and retraction, convenient lifting, and no interference between components, thus realizing the function of lifting goods. This assembly fixture and method are simple to operate and easily meet technical requirements, providing an effective assembly fixture and method for controlling assembly quality and meeting technical requirements. Attached Figure Description

[0039] Figure 1 A schematic diagram of the frame structure of an application object of the assembly tooling provided in Embodiment 1 of the present invention;

[0040] Figure 2 This is a front view schematic diagram of the lower side beam assembly of the assembly fixture provided in Embodiment 1 of the present invention in its usage state;

[0041] Figure 3 for Figure 2 A side view of the lower side beam assembly in its operational state;

[0042] Figure 4 This is a front view schematic diagram of the upper frame assembly of the assembly tooling provided in Embodiment 1 of the present invention in its usage state.

[0043] Figure 5 for Figure 4 A top view of the upper frame assembly in its usage configuration;

[0044] Figure 6 for Figure 4 A schematic diagram showing the connection between the first and second crossbeams, which are composed of the upper frame.

[0045] Figure 7 This is a front view schematic diagram of the assembly assembly of the tooling provided in Embodiment 1 of the present invention in its usage state.

[0046] Explanation of reference numerals in the attached drawings: 100 - lower side beam assembly, 110 - first support pad, 111 - gantry bracket, 120 - pressurization component, 121 - mounting rod, 122 - jack;

[0047] 200 - Upper frame assembly, 210 - Second support pad, 220 - First positioning component, 221 - Positioning block, 222 - Screw clamp, 230 - Third support pad;

[0048] 300 - General assembly, 310 - Support base, 320 - Verticality adjustment assembly, 321 - Lateral adjustment mechanism, 322 - Longitudinal adjustment mechanism, 323 - Bidirectional screw, 324 - Connecting rod.

[0049] 400-Lower side beam, 410-Lower cover plate, 420-Web plate, 430-Upper cover plate; 500-Upper frame, 510-Upper side beam, 520-Transverse telescopic assembly, 521-First crossbeam, 522-Second crossbeam, 600-Vertical telescopic assembly, 610-Column, 620-Guide sleeve; 700-Wearing plate. Detailed Implementation

[0050] To enable those skilled in the art to better understand this application, the technical solution of this application will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0051] To address the technical problems of difficult assembly and low assembly efficiency in existing loading and unloading devices, this invention provides an assembly fixture and method that ensures successful assembly of the loading and unloading device in one go, improves work efficiency, achieves flexible extension and retraction without interference, and realizes the function of lifting goods. The invention is further described in detail below through two specific embodiments:

[0052] Example 1

[0053] To achieve the assembly of loading and unloading devices, such as Figures 1-7This embodiment provides an assembly fixture, including a lower side beam assembly 100, an upper frame assembly 200, and a final assembly 300. The loading and unloading device is manufactured using a component assembly method, where each component is first welded to its corresponding assembly, and then assembled in the final assembly 300. This type of loading and unloading device mainly consists of a lower side beam 400, a vertical telescopic component 600, and an upper frame 500. The lower side beam 400 is a fish-belly shaped beam and is an important structure for housing the vertical telescopic component 600 and wheel supports. Wherein:

[0054] The lower side beam 400 is a box girder assembled and welded from at least a lower cover plate 410, an upper cover plate 430, and a web plate 420. The difficulty in assembling and welding the lower side beam 400 is that the lateral bending is no more than 1 mm per meter and the total length is ≤3 mm, and the perpendicularity between the web plate 420 and the lower cover plate 410 is no more than 1 mm. The lower side beam assembly 100 includes a first support pad assembly for supporting the lower side beam 400 at intervals along its length, a clamping assembly for clamping the two opposing web plates 420 of the lower side beam 400, and a pressure assembly 120 for applying pressure from top to bottom.

[0055] In this embodiment, the number of first support pads 110 in the first support pad assembly is not specifically limited. At least two first support pads 110 are required to stably support both ends of the lower side beam 400. The number of first support pads 110 supporting the middle part of the lower side beam 400 can be increased according to the length of the lower side beam 400 and the requirements.

[0056] This embodiment does not specifically limit the clamping assembly. The clamping assembly can be adjusted and fixed on the first support pad 110. When the inner side of the web plate 420 abuts against the outer side of the lower cover plate 410, the clamping assembly clamps the web plate 420 and the lower cover plate 410. When the web plate 420 is located on the upper cover plate 430 and there is no supporting positioning structure on the inner side, the clamping assembly can have four position-adjustable action plates. The web plate 420 is located between two action plates, and the verticality and position are ensured by the positioning of the two action plates.

[0057] In this embodiment, a partition is provided on the lower cover plate 410. The partition is located in the inner cavity of the lower side beam 400. The partition abuts against the inner side surfaces of the two web plates 420 to achieve positioning. After the partition is fixed on the lower cover plate 410, only a clamping force needs to be applied to the outer side of the web plate 420. The clamping assembly includes a U-shaped bracket and an adjustable screw threaded to at least one side plate of the U-shaped bracket. In use, the U-shaped bracket is directly covered on the lower web plate 420. The two side plates are located on the outer side of the two web plates 420 respectively, and the adjustable screw acts on the web plates 420 to clamp the two web plates 420.

[0058] This embodiment does not specifically limit the pressurizing component 120. The pressurizing component 120 may not have a connection with the first support pad 110, and can simply achieve pressure from top to bottom. As one implementation, a gantry bracket 111 is provided on the first support pad 110. The gantry bracket 111 has a mounting position for installing the pressurizing component 120. The pressurizing component 120 includes a mounting rod 121 and a jack 122 provided on the mounting rod 121. When pressure is required, the mounting rod 121 is fixed in the mounting position, the jack 122 is located above the lower cover plate 410, and other components are pressed against the lower cover plate 410. When it is necessary to hoist the web plate 420 or the upper cover plate 430 from above, the pressurizing component 120 can be disassembled.

[0059] Since the upper cover plate 430 is necessarily supported by the top surfaces of the two web plates 420, after the web plates 420 and the lower cover plate 430 are spot-welded together, when installing the upper cover plate 430, after adjusting the position of the upper cover plate 430, the upper cover plate 430 is pressed against the top of the two web plates 420 by the pressure assembly 120, thus spot-welding the upper cover plate 430 and the web plates 420 together. Since the web plates 420 can be connected to the two sides of the lower cover plate 410 or to the top surface of the lower cover plate 410, when the web plates 420 are connected to the two sides of the lower cover plate 410, the pressure assembly 120 presses the web plates 420 against the first support pad 110 during the spot-welding positioning of the lower cover plate 410 and the web plates 420. When the web plates 420 are connected to the upper surface of the lower cover plate 410, the pressure assembly 120 presses the web plates 420 against the lower cover plate 410.

[0060] Due to the large overall size of the upper frame 500, tooling is necessary to ensure that the assembly meets the technical requirements. The upper frame assembly 200 includes a second support pad assembly for supporting the upper frame 500, and the second support pad assembly is provided with a first positioning assembly 220 for positioning the upper side beam 510 and the lateral telescopic assembly 520 of the upper frame 500.

[0061] The present invention does not limit the specific shape of the upper frame, as long as it can ensure that the second support pad 210 of the second support pad assembly can support both the upper side beam and the lateral telescopic assembly of the upper frame. For example, in this embodiment, the upper frame is square with four corners, and the second support pad assembly includes at least four second support pads 210 supporting the four corners.

[0062] In some embodiments, the second support pad 210 can be made larger in size, so as to simultaneously support and position the upper side beam 510 and the first crossbeam 521 or the second crossbeam 522 connected to the upper side beam 510. In some embodiments, a third support pad 230 can also be provided separately to support the first crossbeam 521 and the second crossbeam 522. In some embodiments, an auxiliary support pad can also be added to support the middle part of the upper side beam 510 in the length direction; however, no specific limitation is made in this embodiment.

[0063] In one implementation, the first positioning component 220 may include positioning blocks 221 and lead screw clamps 222. Using a self-made tooling, four level platforms are set on the platform mold. Positioning blocks 221 are set in the length and width directions of the upper frame 500 to position the upper side beam 510, the first crossbeam 521, and the second crossbeam 522 respectively, ensuring that the diagonal of the upper frame assembly 200 is controlled within 2mm. Preferably, the flatness of the four level platforms is 0.5mm.

[0064] Since it is necessary to ensure that the lateral telescopic component 520 can extend and retract smoothly after the initial positioning, it is necessary to ensure that at least one side of the first positioning component 220 is adjustable so that at least one upper side beam 510 can move relative to the other in the telescopic direction. In this embodiment, the first positioning components 220 corresponding to the two upper side beams 510 are set in the same way on the second support pad 210. Specifically, along the width direction of the upper side beam 510, the positioning block 221 and the screw clamp 222 are distributed on both sides of the upper side beam 510, and the positioning blocks are all located on the same side of the positioned upper side beam 510.

[0065] The uniformity of the hole spacing and perpendicularity of the guide sleeve 620, as well as the gaps between the various surfaces of the assembly, are challenging aspects of the assembly. In this embodiment, the final assembly 300 includes two support seats 310 and a verticality adjustment assembly 320 for adjusting the verticality of the vertical telescopic assembly 600 connecting the upper and lower side beams. The verticality adjustment assembly 320 includes a lateral adjustment mechanism 321 and a longitudinal adjustment mechanism 322. Preferably, the number of verticality adjustment assemblies 320 is the same as the number of vertical telescopic assemblies 600, allowing for individual adjustment.

[0066] In some embodiments, the lateral adjustment mechanism 321 and the longitudinal adjustment mechanism 322 can be electric telescopic cylinders, etc. As one embodiment, both the lateral adjustment mechanism 321 and the longitudinal adjustment mechanism 322 include a bidirectional screw 323 and two connecting rods 324 threaded to both ends of the bidirectional screw 323.

[0067] In some embodiments, the first crossbeam 521 and the second crossbeam 522 are required to move relative to each other in the coaxial direction without interference. The four assembly gaps between the first crossbeam 521 and the second crossbeam 522 are all required to be 5mm, making assembly difficult. Similarly, the guide sleeve 620 and the column 610 are required to move relative to each other in the coaxial direction without interference. The guide sleeve 620 wear plate 700 and the column 610 must simultaneously maintain a 5mm spacing on four surfaces, allowing for flexible extension and retraction to achieve the function of lifting goods. To ensure the required gaps on each surface, in this embodiment, the assembly fixture also includes an assembly template. The thickness of the assembly template is set to match the required assembly gaps. The assembly template ensures that both the horizontal telescopic component 520 and the vertical telescopic component 600 of the finished product have the required assembly gaps.

[0068] It should be noted that since the lower side beam 400 is assembled as a single structure, unlike the two upper side beams 510 in the upper frame 500, in some embodiments, when there is no partition in the inner cavity of the lower side beam 400, the web plate 420 can be directly positioned by the two sides of the lower cover plate 410 and the clamping assembly. In this case, whether the lower cover plate 410 is tilted in the horizontal plane does not affect the subsequent assembly and welding, and the first support pad 110 does not need to be specially provided with structural components for positioning the lower cover plate 410. When a partition is provided in the inner cavity of the lower side beam 400, the web plate 420 is set on the lower cover plate 410 and positioned by the two sides of the partition. In this case, the positioning of the lower cover plate 410 has a significant impact on the positioning of the partition, which in turn affects the verticality and lateral bending of the web plate 420. Preferably, the first support pad assembly is provided with a second positioning component for positioning the two end faces of the lower cover plate 410 in the width direction of the lower side beam 400.

[0069] In one embodiment, the second positioning component includes a limiting block and an adjustable abutment, such as a lead screw structure. After the lower cover plate 410 is disposed on the first support pad 110, one side contacts the limiting block, and the other side is pressed against the limiting block by the abutment.

[0070] It should be noted that, in order to avoid wear on the first crossbeam 521 and the guide sleeve 620, wear plates 700 are provided on the four cavity walls of the inner cavity of the first crossbeam 521 and the guide sleeve 620. The above-mentioned assembly gap is the gap between the second crossbeam 522 / column 610 and the wear plate 700.

[0071] In one implementation, when the assembly template is installed, there is no gap between the second crossbeam and the first crossbeam. After the assembly template is removed, the first and second crossbeams have a fitting gap on all four circumferences equal to the thickness of the assembly template. This facilitates the installation of the lateral telescopic components of the upper frame, ensures the fitting gap, and provides sufficient space for the installation of the drive components that drive the telescopic movement, ensuring that there will be no drive jamming or sticking.

[0072] Because the installation accuracy requirements for the lateral and vertical telescopic components are relatively high, if they are installed at an angle, the subsequent installation of the hydraulic cylinder drive may cause the operation to jam or stop. Taking a lateral telescopic component as an example, the first crossbeam can be accurately positioned by the limiting block and the second support pad. The fixed end of the second crossbeam and the upper side beam can also be determined by the limiting block and the second support pad. However, the movable end near the first crossbeam needs to be sleeved with the first crossbeam and inserted into the guide cavity of the first crossbeam by about 200mm axially during installation. It is also necessary to ensure that the gaps in all four directions are uniform and consistent. Only by using an assembly template can the requirements be met. The uniformity of the gaps on each surface is related to the lateral telescopic movement stroke and there can be no deviation. The assembly template is used to ensure that when the first and second crossbeams are assembled, the second crossbeam and the first crossbeam have the same assembly gap on all four sides, which meets the theoretical operating trajectory position of the telescopic movement.

[0073] Example 2

[0074] Based on the same inventive concept, this embodiment provides an assembly method for the assembly fixture based on Embodiment 1. The manufacturing process of the loading and unloading device adopts a component assembly method. That is, each component is first welded to its respective mold, and then the final assembly is performed. This assembly method includes the following steps:

[0075] The lower side beam is obtained by assembling the lower cover plate, two web plates and the upper cover plate of the lower side beam;

[0076] The upper frame is obtained by assembling the upper frame into two upper side beams and two transverse telescopic components that connect the two upper beams.

[0077] The frame is assembled by assembling the upper frame, two lower side beams, and four vertical telescopic components connecting the two upper side beams and the two lower side beams.

[0078] The lower side beam comprises at least a lower cover plate, an upper cover plate, and two opposing web plates connecting the upper and lower cover plates, which are welded together to form a box-beam frame structure. After the frame structure of the lower side beam is formed, a flange for connecting the wheels is installed on the bottom surface of the lower cover plate. The difficulty in assembling and welding the lower side beam lies in requiring that the lateral bend not exceed 1 mm per meter, the total lateral bend not exceed 3 mm, and the perpendicularity between the web plate and the lower cover plate not exceed 1 mm.

[0079] To ensure that the lateral bending and verticality requirements are met, in this embodiment, the lower side beam assembly comprises a lower cover plate, two web plates, and an upper cover plate, specifically including:

[0080] The lower cover plate of the lower side beam is placed on at least two first support pads. The two web plates are clamped and positioned by the clamping assembly. The two web plates are pressed onto the lower cover plate or the first support pads by the pressure assembly. The lower cover plate and the two web plates are spot welded to fix them. The clamping assembly ensures the parallelism of the two web plates.

[0081] Place the top cover plate on the top surface of the two web plates and adjust its position. Press the top cover plate onto the two web plates using the pressure assembly. Spot weld the top cover plate and the two web plates to fix them. In each step, the pressure assembly ensures that the two connecting parts fit tightly and cooperates with the fixture assembly to ensure that the dimensions meet the requirements.

[0082] Welding operations are performed at each connection point.

[0083] In some embodiments, to enhance the overall structural strength of the lower side beam and further ensure the accuracy of lateral bending and verticality, the lower side beam also includes a diaphragm. To position the two webs via the diaphragm, after placing the lower cover plate of the lower side beam on at least two first support pads, and before spot welding the lower cover plate and the two webs together, the assembly method specifically includes:

[0084] Draw the center line of the lower cover plate and the assembly dimension lines of the partition plates on the lower cover plate. According to the positions of the partition plate assembly dimension lines, spot weld multiple partition plates to the lower cover plate to determine the position of the inner side of the web plate. Place two web plates on the lower cover plate and clamp them using clamping components, positioning them at both ends of the partition plate along the width direction of the lower side beam. Ensure that the lateral bending and perpendicularity meet the requirements using the center line of the lower cover plate and the assembly dimension lines of the partition plates. Then, press both web plates firmly onto the lower cover plate using a pressure assembly, ensuring that the lower cover plate is flush with the bottom surface of the web plate before spot welding to secure the inner cavity dimensions.

[0085] Since the partition is located in the inner cavity of the lower side beam, the assembly method, before placing the upper cover plate on the top surface of the two web plates and positioning it, specifically includes: welding the connection seam between the partition and the lower cover plate and the two web plates.

[0086] As one implementation method, when assembling and spot-welding various partitions, the spot weld length should be 20mm to 30mm. After spot welding, the assembly should proceed from the middle outwards to ensure the internal cavity dimensions are maintained.

[0087] To ensure the internal cavity dimensions and reduce welding deformation, when spot welding the web plate and lower cover plate, spot welding should begin from the middle of the lower side beam and proceed towards both ends.

[0088] When welding the joints of the inner cavity partitions, two people weld symmetrically from the middle to both ends.

[0089] When spot welding the top cover plate, ensure that the dimensions on both sides are aligned before pressing and spot welding.

[0090] When performing overall welding on all connection points of the lower side beam, four people are used for welding, two people on each side, and they work from the middle to both ends to perform symmetrical welding to reduce welding deformation.

[0091] The lateral telescopic assembly includes a first crossbeam and a second crossbeam that are sleeved together. The first crossbeam has a guide cavity. The first positioning assembly is located in both the length and width directions of the upper frame. The difficulty in assembling the upper frame lies in ensuring that the mating gap between the first crossbeam and the second crossbeam of the lateral telescopic assembly meets the requirement that the gap on each surface is uniform, so as to ensure smooth operation within the telescopic stroke range.

[0092] In this embodiment, the upper frame assembly comprises two upper side beams and two transverse telescopic components connecting the two upper beams, specifically including:

[0093] The first upper beam is placed on at least two second support pads on the first side and positioned by the first positioning component;

[0094] The two first crossbeams are positioned by the first positioning components on at least two second support pads on the first side, and the first upper beam and the two first crossbeams are spot welded to fix them.

[0095] The two second crossbeams are positioned by the first positioning components of at least two second support pads on the second side, so that the second crossbeams extend into the guide cavity of the first crossbeam one by one, and assembly templates are set in the circumference of the first and second crossbeams; for example, the cross sections of the first and second crossbeams are both square, and assembly templates with the same thickness and matching the required fitting clearance are set on all four sides.

[0096] The second upper beam is placed on at least two support pads on the second side and positioned by the first positioning component. After the spacing between the two upper beams is qualified, the second upper beam and the two second cross beams are spot welded to fix them, thus completing the initial positioning.

[0097] Welding is performed on each connecting part of the upper frame assembly.

[0098] As one implementation method, in order to simplify the process and avoid the assembly and disassembly process, the assembly template is not connected to the first and second crossbeams or fixed by spot welding. An assembly template is placed on the lower cavity wall, left cavity wall and right cavity wall of the guide cavity of the first crossbeam. When the second crossbeam is hoisted, an assembly template is placed on the top surface of the second crossbeam. Then, an assembly template is set on each of the four circumferences to ensure uniform spacing.

[0099] To ensure smooth operation throughout the telescopic range, before welding is performed on the various connecting parts of the upper frame assembly, the assembly method also includes removing the assembly template and moving at least one upper side beam on the second support pad along the telescopic direction of the transverse telescopic mechanism to ensure free telescopic movement.

[0100] Similar to the lateral telescopic assembly, the vertical telescopic assembly includes columns and guide sleeves. Two lower side beams are spaced apart along the telescopic direction of the lateral telescopic assembly. Uniform gaps must be maintained around the guide sleeves and columns, and the verticality of the vertical telescopic assembly on the lower side beams must be ensured to guarantee smooth installation and engagement of the subsequent telescopic drive components. The final assembly involves assembling the two lower side beams of the upper frame and the four vertical telescopic components connecting the two upper and two lower side beams. Specifically, this includes:

[0101] Using the bottom surface of the flange on the bottom surface of the lower cover plate of the lower side beam as the reference surface, place the two lower side beams at intervals on the support base of the assembly. After adjusting the position of the two lower side beams to meet the size requirements, fix the two lower side beams to the support base.

[0102] Two columns are vertically installed on the upper cover plates of the two lower side beams respectively. Assembly templates are evenly installed around the columns (see the explanation in the transverse telescopic assembly). The assembly templates with a thickness matching the set mating clearance ensure that the mating clearance on each surface meets the requirements. Four guide sleeves are hoisted in one by one and fitted to the four columns respectively. The verticality of the guide sleeves is adjusted by the verticality adjustment component. After the hole spacing of the four guide sleeves is qualified, the guide sleeves and columns are spot welded to fix them one by one.

[0103] Hoist the upper frame onto the guide sleeve, align the guide sleeve and the upper side beam at the mating position, and connect and fix the guide sleeve and the upper side beam.

[0104] This embodiment does not specify the verticality adjustment of the columns. Since the columns are directly installed on the top cover plate and the guide sleeves are connected and fixed to the upper frame, but the installation sequence of the guide sleeves is before that of the upper frame, the verticality of the guide sleeves is a challenge. The columns can be measured and adjusted using any feasible method, such as using a plumb line to detect verticality, and the installation positions of the four columns are determined and fixed in sequence.

[0105] To control the installation accuracy and perpendicularity of the guide sleeve, in this embodiment, the perpendicularity of the guide sleeve is adjusted by a perpendicularity adjustment component, specifically including:

[0106] One end of the lateral adjustment mechanism and the longitudinal adjustment mechanism are fixedly connected to the guide sleeve, and the other end is fixedly connected to the lower side beam or the ground. The lateral adjustment mechanism and the longitudinal adjustment mechanism are set at an angle to the guide sleeve. By adjusting the length of the lateral adjustment mechanism and the longitudinal adjustment mechanism, the position and angle of the guide sleeve in two directions can be adjusted.

[0107] Since the circumferential clearance of the transverse telescopic component may change during lifting after the assembly template is disassembled, which may lead to a change in the mating position, in order to ensure that the transverse telescopic component still meets the clearance requirements after final assembly, in this embodiment, before hoisting the upper frame onto the guide sleeve, the assembly method further includes evenly placing the assembly template circumferentially between the first and second crossbeams to ensure that the clearance of each surface is uniform.

[0108] To ensure the positioning of the first upper beam and thus the accuracy of subsequent installation, in this embodiment, the first upper beam is brought close to the top surface of the second support pad and the first positioning component on the second support pad, and the first upper beam and the second support pad are spot welded together.

[0109] Application Examples

[0110] The loading and unloading device is manufactured using a component assembly method, where each component is first welded to its respective mold before final assembly. The upper frame of the loading and unloading device requires that the first and second crossbeams be coaxial and able to move relative to each other without interference. The wear plate inside the first crossbeam must be 5mm away from all four outer surfaces of the second crossbeam, making assembly challenging. The guide sleeve of the vertical telescopic assembly must be coaxial and able to move relative to the column without interference. The wear plate inside the guide sleeve and the column must simultaneously maintain a 5mm gap on all four surfaces, ensuring flexible telescopic movement and enabling the lifting of goods. This is achieved through the following processes:

[0111] ① Lower side beam

[0112] 1. First, hoist the lower cover plate of the lower side beam into the assembly mold. The bottom surface of the lower cover plate should be tightly attached to the working surface of the mold. Draw the center line of the lower cover plate and the assembly dimension line of the partition plate on the lower cover plate.

[0113] 2. Assemble various partitions and fix them by spot welding. The spot welding length is 20-30mm.

[0114] 3. Hoist in two web plates and clamp them with clamping components such as bow-shaped screws. Install the gantry on the bracket of the first support pad. The gantry is located above the lower side beam. Use the jacks on the gantry to press the gap between the web plates and the lower cover plate tightly, and then spot weld them in place. When assembling, push from the middle to both ends to ensure the inner cavity dimensions.

[0115] 4. Two people perform welding on the connecting seams of the inner cavity partition. Weld symmetrically from the middle outwards.

[0116] 5. Hoist the top cover plate in, press it down with a jack, ensure that the dimensions on both sides are aligned, and spot weld it in place.

[0117] 6. The overall welding requirements for the lower side beam are as follows: 4 people should be used for welding, 2 people on each side, and welding should be carried out from the middle to both ends. The welding should be symmetrical to reduce welding deformation.

[0118] ② Upper frame

[0119] The upper frame is 7700mm long and 5100mm wide, and tooling is required to ensure that the assembly meets the technical requirements.

[0120] Using self-made tooling, four water platforms, i.e. four second support pads, are set on the platform mold. Positioning blocks are set in the length and width directions of the upper frame to ensure that the diagonal of the upper frame mold is controlled within 2mm and the flatness of the four water platforms is 0.5mm.

[0121] 1. Hoist the upper side beam located at the bottom in the drawing into place, ensuring it is flush with the horizontal plane of the second support pad and the positioning block, and then spot weld it in place.

[0122] 2. Hoist the first crossbeam into place so that it is tightly against the positioning block, and then tighten it with a screw clamp.

[0123] 3. A wear plate is provided in the inner cavity of the first crossbeam. An assembly template of 400×280×5mm is placed on the four inner circumferences of the wear plate to ensure the assembly gap. Then, the second crossbeam is hoisted in for assembly to ensure that the first and second crossbeams form a clearance fit.

[0124] 4. Finally, assemble the upper side beam and tighten it with a screw clamp. Check the dimensions of each part to ensure that the diagonal is ±1mm and the center distance is 4400±1mm. After the dimensions meet the requirements, spot weld it in place.

[0125] 5. Remove the assembly template, and use the overhead crane and personnel to push the upper side beam below to push the telescopic crossbeam to ensure smooth extension and retraction.

[0126] 6. Perform welding operations on all connecting parts.

[0127] ③ Overall assembly of the structure

[0128] The loading and unloading device is 8800mm long, 5400mm wide, and 4800mm high, making the overall steel structure assembly difficult.

[0129] The flange of the lower side beam is used as the assembly reference surface for final assembly.

[0130] 1. Hoist in two lower side beams, measure the flange hole spacing as 4400mm, ensure the flange face is tightly against the top surface of the support, measure the diagonal ±1mm, and the hole spacing as 4400±1mm. After the dimensions meet the requirements, fix the two lower side beams.

[0131] 2. Assemble the columns. Connect the columns to the lower side beam with screws, ensuring that the verticality of the columns is 1mm. Use a plumb line to check the verticality. Assemble 4 columns in sequence.

[0132] 3. Spot weld 400×280×5mm assembly templates around the perimeter of the column to ensure assembly clearance. Then, hoist the guide sleeves into place for assembly, ensuring a clearance fit between the templates and the guide sleeve wear plate. (and) Figure 6 The same applies to the diagram of the fit in the middle.

[0133] 4. When assembling the guide sleeve, the verticality should be controlled within 1mm, the gap between the guide sleeve and the column should be uniform, and both sides should be adjusted with a two-way screw. Then assemble the other guide sleeves in sequence.

[0134] 5. Ensure that the hole spacing of the four guide sleeves is 4400±1mm and the diagonal is within 1mm. After meeting the requirements, spot weld them in place.

[0135] 6. Use an overhead crane to hoist the upper frame into place on the guide sleeves, align the hole spacing of the four guide sleeves, and then connect them with screws. The hole spacing error is zero, and the assembly is successful in one go.

[0136] In summary, the present invention has at least the following beneficial effects:

[0137] This invention employs an assembly mode that first assembles components and then connects them as a whole. Each component corresponds to a pre-fabricated fixture, ensuring the assembly of the lower side beam, upper frame, and overall steel structure. This guarantees the dimensions and functions of each component of the loading and unloading device, meeting technical requirements. Based on this assembly fixture, a reliable assembly method is provided. This method ensures successful assembly of the loading and unloading device in one attempt, improves efficiency, and ensures flexible extension and retraction, convenient lifting, and no interference between components, thus realizing the function of lifting goods. This assembly fixture and method are simple to operate and easily meet technical requirements, providing an effective assembly fixture and method for controlling assembly quality and meeting technical requirements.

[0138] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0139] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. An assembly tooling, characterized in that, It includes the lower side beam assembly, the upper frame assembly, and the final assembly, wherein: The lower side beam assembly includes a first support pad assembly for supporting the lower side beam at intervals along its length, a clamping assembly for clamping the two opposing webs of the lower side beam, and a pressurizing assembly for applying pressure from top to bottom. The upper frame assembly includes a second support pad assembly for supporting the upper frame, and the second support pad assembly is provided with a first positioning assembly for positioning the upper side beam and the lateral telescopic assembly of the upper frame. The assembly includes two support seats and a verticality adjustment assembly for adjusting the verticality of the vertical telescopic component. The verticality adjustment assembly includes a lateral adjustment mechanism and a longitudinal adjustment mechanism. The first support pad assembly includes at least two first support pads, and the second support pad assembly includes at least four second support pads.

2. The assembly tooling as described in claim 1, characterized in that, Both the lateral adjustment mechanism and the longitudinal adjustment mechanism include a bidirectional screw and two connecting rods threaded to both ends of the bidirectional screw.

3. The assembly tooling as described in claim 1, characterized in that, The clamp assembly includes a U-shaped bracket and an adjustable lead screw threaded to at least one side plate of the U-shaped bracket.

4. The assembly tooling as described in claim 1, characterized in that, The first support pad assembly is provided with a second positioning assembly for positioning the two end faces of the lower cover plate of the lower side beam in the width direction.

5. An assembly method based on the assembly tooling according to any one of claims 1-4, characterized in that, include: The lower side beam is obtained by assembling the lower cover plate, two web plates and the upper cover plate of the lower side beam; The upper frame is obtained by assembling the upper frame into two upper side beams and two transverse telescopic components that connect the two upper beams. The frame assembly is obtained by assembling the upper frame, two lower side beams, and four vertical telescopic components connecting the two upper side beams and the two lower side beams in the final assembly.

6. The assembly method as described in claim 5, characterized in that, The assembly of the lower side beam, comprising the lower cover plate, two web plates, and the upper cover plate, specifically includes: The lower cover plate of the lower side beam is placed on at least two first support pads, and the two web plates are clamped and positioned by the clamping assembly. The two web plates are pressed onto the lower cover plate or the first support pad by the pressure assembly, and the lower cover plate and the two web plates are spot welded to fix them. Place the top cover plate on the top surface of the two web plates and adjust its position. Press the top cover plate onto the two web plates using the pressure assembly, and spot weld the top cover plate and the two web plates to fix them. Welding operations are performed at each connection point.

7. The assembly method as described in claim 6, characterized in that, The lower side beam also includes a partition plate; After placing the lower cover plate of the lower side beam on the at least two first support pads, and before spot welding the lower cover plate and the two web plates, the assembly method specifically includes: drawing the center line of the lower cover plate and the partition assembly dimension line on the lower cover plate; spot welding multiple partition plates to the lower cover plate according to the position of the partition assembly dimension line; placing the two web plates on the lower cover plate, and clamping and positioning the two web plates at both ends of the partition plate along the width direction of the lower side beam by a clamping assembly; and pressing the two web plates onto the lower cover plate by a pressure assembly. Before placing the upper cover plate on the top surface of the two web plates and positioning it, the assembly method specifically includes: welding the connection seam between the partition plate and the lower cover plate and the two web plates.

8. The assembly method as described in claim 5, characterized in that, The lateral telescopic assembly includes a first crossbeam and a second crossbeam that are sleeved together, and the first crossbeam has a guide cavity; The two upper side beams assembled by the upper frame and the two lateral telescopic components connecting the two upper beams specifically include: The first upper beam is placed on at least two second support pads on the first side and positioned by the first positioning component; The two first crossbeams are positioned by the first positioning components on at least two second support pads on the first side, and the first upper beam and the two first crossbeams are spot welded to fix them. The two second crossbeams are positioned by the first positioning components of at least two second support pads on the second side, so that the second crossbeams extend into the guide cavity of the first crossbeam one by one, and assembly templates are set in the circumference of the first and second crossbeams. The second upper beam is placed on at least two support pads on the second side and positioned by the first positioning component. After the spacing between the two upper beams is qualified, the second upper beam and the two second cross beams are spot welded to fix them. Welding is performed on each connecting part of the upper frame assembly.

9. The assembly method as described in claim 8, characterized in that, Before welding is performed on the various connecting parts of the upper frame assembly, the assembly method further includes removing the assembly template and moving at least one upper side beam on the second support pad along the telescopic direction of the transverse telescopic component to ensure free telescopic movement.

10. The assembly method as described in claim 5, characterized in that, The vertical telescopic assembly includes columns and guide sleeves; the assembly of the two lower side beams of the upper frame and the four vertical telescopic assemblies connecting the two upper side beams and the two lower side beams in the overall assembly specifically includes: Using the bottom surface of the flange on the bottom surface of the lower cover plate of the lower side beam as the reference surface, place the two lower side beams at intervals on the support base of the assembly. After adjusting the position of the two lower side beams to meet the size requirements, fix the two lower side beams to the support base. Two columns are vertically installed on the upper cover plates of the two lower side beams respectively, and assembly templates are evenly arranged around the columns. Four guide sleeves are hoisted in sequence and fitted to the four columns respectively. The verticality of the guide sleeves is adjusted by the verticality adjustment component. After the hole spacing of the four guide sleeves is qualified, the guide sleeves and columns are spot welded to fix them one by one. Hoist the upper frame onto the guide sleeve, align the guide sleeve and the upper side beam at the mating position, and connect and fix the guide sleeve and the upper side beam.

11. The assembly method as described in claim 10, characterized in that, Before hoisting the upper frame onto the guide sleeve, the assembly method further includes placing an assembly template evenly along the circumference between the first and second crossbeams to ensure uniform gaps between the surfaces.

12. The assembly method as described in claim 10, characterized in that, The adjustment of the guide sleeve's perpendicularity using the perpendicularity adjustment component specifically includes: One end of the lateral adjustment mechanism and the longitudinal adjustment mechanism are fixedly connected to the guide sleeve, and the other end is fixedly connected to the lower side beam or the ground; the lateral adjustment mechanism and the longitudinal adjustment mechanism are respectively set at an angle to the guide sleeve, and the lateral adjustment mechanism and the longitudinal adjustment mechanism are set at an angle.

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