An assembly process of a large marine diesel engine air cooler shell

Abstract

The application discloses a large marine diesel engine air cooler shell assembling process, and solves the problem of unreasonable process in the prior art, has the beneficial effects of ensuring reasonable installation of components, reducing the probability of problems such as rework, and the specific scheme is as follows: a large marine diesel engine air cooler shell assembling process, which comprises the following steps: assembling an air cooler frame, reserving an assembly allowance during the assembling process, the air cooler frame is L-shaped, and the longer side of the air cooler frame is at the bottom; assembling air cooler side plates, taking the air cooler frame as a reference, fixing the air cooler side plates on the two sides of the air cooler frame; taking the air cooler side plate as a reference, fixing a bending component, the bending component is located on the inner side of the air cooler side plate and at the inner corner of the air cooler frame; installing and fixing a steam-water separator frame between the air cooler side plates on the two sides, reserving an allowance when the steam-water separator frame is installed; installing a shell on the side of the steam-water separator frame, and fixing the shell and the air cooler side plate.

Description

Technical Field

[0001] This invention relates to the field of marine diesel engines, and in particular to an assembly process for the housing of a large marine diesel engine air cooler. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] The air cooler housing of a marine diesel engine is an important component of the engine. It houses the air cooler and a steam-water separator, forming a crucial part of the ventilation system. The air compressor forces compressed air into the air cooler housing. When the high-pressure, high-temperature air encounters the air cooler, its temperature drops, and the humid air condenses into water droplets. These water droplets are prohibited from entering the scavenging box. Instead, the air passes through the steam-water separator, where the moisture is separated and flows into the drain pipe below, exiting the diesel engine.

[0004] The air cooler and steam-water separator are important components of the diesel engine's ventilation system. The air cooler housing is a crucial structure that supports both the air cooler and the steam-water separator. If there are deviations in the welding process of the air cooler housing, it can lead to problems such as the air cooler and steam-water separator not being able to be installed or poor sealing, which can seriously affect the ventilation quality of the diesel engine.

[0005] The inventors discovered that due to unreasonable process methods in the early stages of production, the air cooler housing of diesel engines could not be installed smoothly, resulting in problems such as rework, repair welding, and paint damage during the final assembly process. This seriously affected the quality and appearance of the diesel engine, and also restricted the production efficiency and cost of marine diesel engines. Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the purpose of this invention is to provide an assembly process for the air cooler shell of a large marine diesel engine, which ensures the post-weld dimensions and welding quality, and effectively reduces the probability of rework and repair welding problems in the assembly production process of the final assembly plant.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0008] An assembly process for the housing of a large marine diesel engine air cooler includes the following:

[0009] Assemble the air cooler frame, leaving room for assembly during the process. The air cooler frame is L-shaped with the longer side at the bottom.

[0010] Assemble the air cooler side panels, using the air cooler frame as a reference, and fix the air cooler side panels on both sides of the air cooler frame respectively.

[0011] Using the side panel of the air cooler as a reference, fix the bending component. The bending component is located inside the side panel of the air cooler and at the inner corner of the air cooler frame.

[0012] Install and fix the steam-water separator frame between the side plates of the two air coolers, leaving a margin when installing the steam-water separator frame;

[0013] Install the outer casing on the side of the steam-water separator frame and fix the outer casing to the side plate of the air cooler.

[0014] In the above assembly process, the air cooler frame is assembled first, and then the air cooler side plate is fixed. Using the air cooler side plate as a reference, the bending component, the steam-water separator frame and the outer shell are fixed in sequence. This can effectively ensure the smooth and efficient installation of the air cooler filter element and the steam-water separator filter element, avoiding problems such as the air cooler filter element not being able to be installed and the need for grinding and rework in the existing technology.

[0015] As described above, the assembly process for a large marine diesel engine air cooler housing includes the following steps: fixing a first flange and a second flange to the air cooler side plate.

[0016] The air cooler side plate is welded to the air cooler frame using circumferential welding. After welding, the flatness of the air cooler side plate after welding is measured. If the flatness is >3mm, the high point needs to be adjusted by flame shaping.

[0017] As described above, the assembly process for a large marine diesel engine air cooler housing, to ensure the strength of the air cooler frame, includes the following:

[0018] A first frame and a second frame are provided. The length of the first frame is greater than that of the second frame and there is a set distance between them. The first frame and the second frame are connected by end longitudinal beams.

[0019] Both the first and second frames are equipped with intermediate vertical beams.

[0020] As described above, the assembly process for a large marine diesel engine air cooler housing includes the following: installing a cylinder on the inner side of the air cooler side plate, installing an annular ring at the end of the cylinder, installing a second cylinder between the two annular rings, and installing a portal frame on the outer side of the second cylinder.

[0021] The components of the bending component are fixed by positioning welding, which effectively ensures the curvature of the bending component.

[0022] The assembly process for a large marine diesel engine air cooler housing, as described above, includes the following steps: Installing and fixing the steam-water separator frame between the two side plates of the air cooler.

[0023] Two steam-water separator base plates are installed between the side plates of the two air coolers. The base plates are fixed at an angle on both sides of the bottom side of one steam-water separator base plate. A long strip is fixed inside the base plate. The steam-water separator top plate is installed on the steam-water separator base plate. During the assembly process, the top plate has a margin in both the height and horizontal directions.

[0024] The components of the steam-water separator frame are fixed by positioning welding.

[0025] As described above, a large marine diesel engine air cooler housing assembly process is described, wherein the housing covers the opposite sides of the bent component and the steam-water separator frame;

[0026] Before the housing is installed, a lifting lug is fixed to the side of the housing away from the bending component.

[0027] The assembly process for a large marine diesel engine air cooler housing, as described above, further includes the following steps after the housing is installed: fixing the top seat and fixing the vent flange.

[0028] As described above, in the assembly process of a large marine diesel engine air cooler housing, multiple top seats are provided, and the multiple top seats are respectively fixed to the end of the side plate of the air cooler; the multiple top seats are fixed on the same horizontal plane.

[0029] As described above, in the assembly process of a large marine diesel engine air cooler housing, multiple vent flanges are provided, and the vent flanges are fixed to the housing, which is arc-shaped.

[0030] The flatness of multiple vent flanges is within the set range.

[0031] As described above, in the assembly process of a large marine diesel engine air cooler housing, after the steam-water separator frame is installed, the entire unit is flipped over, and the outer shell is welded to the air cooler frame. After flipping, any unwelded parts are welded to ensure assembly quality.

[0032] The beneficial effects of the present invention are as follows:

[0033] 1) The present invention provides an overall process in which the air cooler frame is assembled first, and then the air cooler side plate is fixed. Using the air cooler side plate as a reference, the bending component, the steam-water separator frame and the outer shell are fixed in sequence. The overall assembly and fixing sequence is reasonable, which can effectively ensure the smooth and effective installation of the air cooler filter element and the steam-water separator filter element, avoiding the installation difficulties of the prior art.

[0034] 2) In the process of this invention, the air cooler frame is assembled first and an assembly allowance is reserved. Based on this, the air cooler side plate, etc. are assembled, which effectively ensures the post-weld dimensions and welding quality. This effectively avoids problems such as rework, repair welding and paint damage in the assembly production process of the final assembly plant, solves the problem from the root and improves production efficiency.

[0035] 3) The present invention provides a margin for the installation of the steam-water separator frame, especially the top plate, which provides margin in both the height and horizontal directions, so as to facilitate the smooth installation of the steam-water separator after welding.

[0036] 4) The present invention fixes the lifting lugs, top plate and vent flange after the outer shell is installed. The assembly sequence is reasonable and facilitates the smooth installation of subsequent components. Attached Figure Description

[0037] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0038] Figure 1 This is a schematic diagram of the air cooler frame in an assembly process of a large marine diesel engine air cooler housing according to one or more embodiments of the present invention.

[0039] Figure 2 This is a schematic diagram of a single-sided air cooler side plate in the assembly process of a large marine diesel engine air cooler housing according to one or more embodiments of the present invention.

[0040] Figure 3 This is a schematic diagram of the installation of bent components in the assembly process of a large marine diesel engine air cooler housing according to one or more embodiments of the present invention.

[0041] Figure 4 This is a schematic diagram of the steam-water separator frame assembly in a large marine diesel engine air cooler shell assembly process according to one or more embodiments of the present invention.

[0042] Figure 5 This is a schematic diagram of the component arrangement at the outer shell in a large marine diesel engine air cooler shell assembly process according to one or more embodiments of the present invention.

[0043] The diagram exaggerates the spacing or dimensions between parts to show their positions; the diagram is for illustrative purposes only.

[0044] The components are: 1. First frame, 2. First vertical beam, 3. Second vertical beam, 4. Second frame, 5. Horizontal beam, 6. End longitudinal beam, 7. First air cooler side plate, 8. First flange, 9. Second flange, 10. Second air cooler side plate, 11. Steam-water separator side plate, 12. Portal component, 13. Second cylinder, 14. Annular ring, 15. First cylinder, 16. Second cylinder, 17. First top plate, 18. Second top plate, 19. Long strip, 20. First bottom plate, 21. Second bottom plate, 22. Steam-water separator bottom plate, 23. Internal support pipe, 24. Lifting lug, 25. Outer shell, 26. Top seat, 27. First vent flange, 28. Second vent flange, 29. Third vent flange. Detailed Implementation

[0045] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0046] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0047] For ease of description, the words "up," "down," "left," and "right" appearing in this invention only indicate that they are consistent with the up, down, left, and right directions of the accompanying drawings themselves, and do not limit the structure. They are merely for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0048] Terminology Explanation: The terms "installation," "connection," "linking," and "fixing" in this invention should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction relationship between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] As described in the background section, there is a problem with the air cooler housing requiring rework in the prior art. In order to solve the above-mentioned technical problem, the present invention proposes an assembly process for the air cooler housing of a large marine diesel engine.

[0050] In a typical embodiment of the present invention, an assembly process for a large marine diesel engine air cooler housing includes the following:

[0051] Assemble the air cooler frame, leaving room for assembly during the process. The air cooler frame is L-shaped with the longer side at the bottom.

[0052] Assemble the air cooler side panels, using the air cooler frame as a reference, and fix the air cooler side panels on both sides of the air cooler frame respectively.

[0053] Using the side panel of the air cooler as a reference, fix the bending component. The bending component is located inside the side panel of the air cooler and at the inner corner of the air cooler frame.

[0054] Install and fix the steam-water separator frame between the side plates of the two air coolers, leaving a margin when installing the steam-water separator frame;

[0055] Install the outer casing on the side of the steam-water separator frame and fix the outer casing to the side plate of the air cooler.

[0056] To ensure the strength of the air cooler frame, refer to Figure 1 As shown, assembling the air cooler frame includes the following components:

[0057] A first frame 1 and a second frame 4 are provided. The length of the first frame 1 is greater than that of the second frame 4 and there is a set distance between them. The first frame 1 and the second frame 4 are connected by an end longitudinal beam 6. It can be understood that the end longitudinal beam 6 is located at the four corners of the second frame. In this embodiment, one end of the first frame 1 is flush with one end of the second frame 4, and a crossbeam 5 is provided at the other end of the first frame flush with the second frame.

[0058] In this embodiment, both the first frame and the second frame are assembled from horizontal beams and vertical beams.

[0059] Both the first frame 1 and the second frame 4 are provided with intermediate vertical beams. One side of the intermediate vertical beam on both sides of the crossbeam in the first frame is the first vertical beam 2, and the other side is the second vertical beam 3. There are multiple intermediate vertical beams, first vertical beams and second vertical beams.

[0060] The second frame has a 5mm allowance in the length direction, the end longitudinal beams have a 5mm allowance in the length direction (height direction of the air cooler shell), the weld quality meets MAN technical specification EN601M, Q2 level, and flame shaping is performed where the flatness of the air cooler frame exceeds 2mm.

[0061] Specifically, assembling the air cooler side panel includes the following: (See reference) Figure 2 As shown, the first flange 8 and the second flange 9 are fixed to the side plate of the air cooler for the subsequent installation of other components; the first flange is circular and the second flange is frame-shaped.

[0062] refer to Figure 3 As shown, when installing the air cooler side panels, the first frame is below and the second frame is above. The air cooler side panels include the first air cooler side panel 7 and the second air cooler side panel 10. After the air cooler side panels are installed, the verticality of the side panels is measured using a plumb line to ensure ±2mm. The air cooler side panels on both sides are welded to the air cooler frame using circumferential welding. After welding, the flatness of the air cooler side panels after welding is measured. If the flatness is >3mm, the high point needs to be adjusted and flame-shaped.

[0063] Additionally, refer to Figure 4 As shown, assembling the bending component includes the following: a cylinder is installed inside the side plate of the air cooler, one side of the cylinder is the first cylinder 15, and the other side is the second cylinder 16. An annular ring 14 is installed at the end of the cylinder, the annular ring is located at the end of the cylinder away from the side plate of the air cooler. The second cylinder 13 is installed between the two annular rings. A gate-shaped component 12 is installed on the outside of the second cylinder.

[0064] The components of the bending part are fixed by positioning welding, which effectively ensures the curvature and minimum straight distance of the bending part.

[0065] The installation and fixing of the steam-water separator frame between the side plates of the two air coolers includes the following:

[0066] Two steam-water separator base plates 22 are installed between the side plates of the two air coolers. The steam-water separator base plates 22 are welded to the steam-water separator side plates 11. The steam-water separator side plates 11 are located inside the second flange 9. The two steam-water separator base plates 22 are set parallel to each other. The base plates are fixed at an angle on both sides of the bottom side of one steam-water separator base plate. One base plate is the first base plate 20, and the other base plate is the second base plate 21. The long strip 19 is fixed inside the base plate. The steam-water separator base plate is installed with the steam-water separator top plate (the first top plate 17 and the second top plate 18, respectively). During the assembly process, the top plate has a margin in both the height and horizontal directions.

[0067] The components of the steam-water separator frame are fixed by positioning welding.

[0068] In addition, the air cooler side plate has an opening on the second flange 9 side, and an internal support tube 23 is installed at the opening. After the second top plate and the first top plate are installed, the internal support tube 23 is installed.

[0069] It should be explained that one end of the outer casing 25 is welded to the bending component, and the outer casing covers the opposite side of the bending component and the steam-water separator frame;

[0070] Before the housing 25 is installed, a lifting lug 24 is fixed on the side of the housing 25 away from the bending component. There are two lifting lugs, and the openings of the two lifting lugs are located on the same horizontal plane.

[0071] In addition, after the housing is installed, the following are also included: fixing the top seat 26 and fixing the vent flange.

[0072] It needs to be explained that, reference Figure 5 As shown, multiple top seats are provided. The top seats are flat plates and are fixed to the ends of the side plates of the air cooler. Thus, two top seats 26 are fixed to the ends of the side plates of the air cooler on each side. The top seats 26 on each side are spaced apart by a set distance. The multiple top seats are fixed on the same horizontal plane. The top seats 26 are welded to the side plates of the air cooler and then machined and milled after welding.

[0073] Multiple vent flanges are provided. The vent flanges are fixed to the outer shell near the side plate of the air cooler. Three vent flanges are fixed at a time, namely the first vent flange 27, the second vent flange 28, and the third vent flange 29. The distance between adjacent vent flanges is set. The vent flanges are fixed to the outer shell 25 and are located near the second vent flange. The outer shell is arc-shaped. The flatness of the multiple vent flanges is within the set range. During assembly, the flatness of the vent flanges must be measured with a level to ensure ±2mm. The vent flanges are machined and milled after welding. The vent piping system is installed during diesel engine assembly to ensure assembly accuracy.

[0074] In addition, after the steam-water separator frame is installed, the whole unit will be flipped over and the outer shell will be welded to the air cooler frame. After flipping, the unwelded parts will be welded to ensure assembly quality. Specifically, the existing AWS A5.20E71-Tφ1.2mm flux-cored welding wire will be selected as the welding material, which is suitable for all-position welding, with good weld formation and less spatter.

[0075] It is understood that the bending components and air cooler side plates mentioned in this embodiment are existing technologies.

[0076] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A process for assembling the housing of a large marine diesel engine air cooler, characterized in that, Includes the following: Assemble the air cooler frame, leaving room for assembly during the process. The air cooler frame is L-shaped with the longer side at the bottom. Assemble the air cooler side panels, using the air cooler frame as a reference, and fix the air cooler side panels on both sides of the air cooler frame respectively. Using the side panel of the air cooler as a reference, assemble the bending component, which is located inside the side panel of the air cooler and at the inner corner of the air cooler frame. Install and fix the steam-water separator frame between the side plates of the two air coolers, leaving a margin when installing the steam-water separator frame; Install the outer casing on the side of the steam-water separator frame and fix the outer casing to the side plate of the air cooler; The assembled air cooler frame includes the following components: A first frame and a second frame are provided. The length of the first frame is greater than that of the second frame and there is a set distance between them. The first frame and the second frame are connected by end longitudinal beams. Both the first and second frames are equipped with intermediate vertical beams; The assembly of the air cooler side plate includes the following: fixing the first flange and the second flange to the air cooler side plate; The air cooler side plate is welded to the air cooler frame using circumferential welding. After welding, the flatness of the air cooler side plate after welding is measured. If the flatness is >3mm, the high point needs to be adjusted by flame shaping. The assembly bending component includes the following: a cylinder is installed inside the side plate of the air cooler, the cylinder on one side is the first cylinder, the cylinder on the other side is the second cylinder, an annular ring is installed at the end of the cylinder, a third cylinder is installed between the two annular rings, and a gate-shaped component is installed on the outside of the third cylinder; The components of the bending component are fixed by positioning welding; The process of installing and fixing the steam-water separator frame between the side plates of the two air coolers includes the following: Two steam-water separator base plates are installed between the side plates of the two air coolers. The steam-water separator base plates are welded to the steam-water separator side plates. The steam-water separator side plates are located inside the second flange. The two steam-water separator base plates are set parallel to each other. The base plates are fixed at an angle on both sides of the bottom side of one steam-water separator base plate. A long strip is fixed inside the base plate. The steam-water separator top plate is installed on the steam-water separator base plate. During the assembly process, the top plate has a reserved allowance in both the height and horizontal directions. The components of the steam-water separator frame are fixed by positioning welding.

2. The assembly process for a large marine diesel engine air cooler housing according to claim 1, characterized in that, The outer casing covers the opposite sides of the bent component and the steam-water separator frame; Before the housing is installed, a lifting lug is fixed to the side of the housing away from the bending component.

3. The assembly process for a large marine diesel engine air cooler housing according to claim 1, characterized in that, After the housing is installed, the following are also included: fixing the top seat and fixing the vent flange.

4. The assembly process for a large marine diesel engine air cooler housing according to claim 3, characterized in that, Multiple top seats are provided, and each top seat is fixed to the end of the side plate of the air cooler; the multiple top seats are fixed on the same horizontal plane.

5. The assembly process for a large marine diesel engine air cooler housing according to claim 3, characterized in that, Multiple vent flanges are provided, and the vent flanges are fixed to the outer shell, which is arc-shaped; The flatness of multiple vent flanges is within the set range.

6. The assembly process for a large marine diesel engine air cooler housing according to claim 1, characterized in that, After the steam-water separator frame is installed, the whole unit is flipped over and the outer shell is welded to the air cooler frame.

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