Manufacturing method of large box girder structure and assembling method of tyre crane

Abstract

The present invention provides a manufacturing method for a large box girder structure and an assembly method for a rubber tyred gantry crane. Among them, the manufacturing method includes assembling a top plate, a bottom plate and two web plates into a pre-box girder structure; pre-positioning the positions between the top plate, the bottom plate and the two web plates by spot welding; measuring the verticality and twist of the pre-box girder structure; when the measurement results of the pre-box girder structure are within a preset range, fixing the positions between the top plate, the bottom plate and the two web plates by continuous welding to form a box girder structure, and the box girder structure at least includes a saddle beam and a leg. The manufacturing method according to the embodiment of the present invention avoids large deviations in the center line during splicing by pre-fixing the four-sided steel plates by spot welding, ensures the verticality and twist of each panel of the box girder structure, and improves the manufacturing accuracy of the large box girder structure.

Description

Technical Field

[0001] The present invention relates to the field of manufacturing of rubber tyred gantry cranes, and particularly to a manufacturing method for a large box girder structure and an assembly method for a rubber tyred gantry crane. Background Art

[0002] Rubber tyred gantry cranes usually adopt a self-propelled load-carrying trolley form and a counterweight container spreader, and are used for stacking operations in container yards. Rubber tyred gantry cranes generally use a diesel engine to drive a generator set as power, and can also be intelligently connected to a slip line groove to take power from the commercial power for driving operations. They are mainly used for free movement in a container yard at a port, and are not affected by towed cables and external power supplies.

[0003] Since the span of a rubber tyred gantry crane is dozens of meters long, components such as the saddle beam and the legs that form the rubber tyred gantry crane are also relatively large in volume. Components such as the saddle beam and the legs are all box girder structures, and long steel plates are prone to twist and deform during the process of forming the box girder structure, affecting the assembly effect of the box girder structure. Summary of the Invention

[0004] In view of this, an object of the present invention is to provide a manufacturing method for a large box girder structure and an assembly method for a rubber tyred gantry crane.

[0005] To solve the above technical problems, the present invention adopts the following technical solutions:

[0006] In a first aspect, a manufacturing method for a large box girder structure according to an embodiment of the present invention, the large box girder structure includes a saddle beam or a leg, and the method includes:

[0007] Assembling a top plate, a bottom plate and two web plates into a pre-box girder structure;

[0008] Pre-positioning the positions between the top plate, the bottom plate and the two web plates by spot welding;

[0009] Measuring the verticality and the twist of the pre-box girder structure;

[0010] When the measurement result of the pre-box girder structure is within a preset range, fixing the positions between the top plate, the bottom plate and the two web plates by continuous welding to form a box girder structure.

[0011] Further, assembling the top plate, the bottom plate and the two web plates into a pre-box girder structure includes:

[0012] Placing the top plate, the bottom plate and the two web plates on a jig;

[0013] Adding stiffeners to both ends of the jig;

[0014] Fixing the bottom plate to the jig by using a code plate.

[0015] Further, assembling the top plate, bottom plate and two web plates into a pre-box girder structure further includes:

[0016] Increasing the length allowance of the top plate, bottom plate and two web plates.

[0017] In a second aspect, an embodiment of the present invention further provides an assembling method for a rubber-tyred gantry crane, the method including:

[0018] Arranging a jig;

[0019] Arranging two saddle girders onto the jig;

[0020] Lifting and hoisting the gantry frame door to the saddle girders for assembly, the gantry frame door including legs and a girder;

[0021] Lifting and hoisting the trolley track, electrical house and power house;

[0022] Lifting and hoisting the gantry frame and arranging the traveling of the crane;

[0023] Lifting and hoisting the trolley frame assembly and installing accessories.

[0024] Further, arranging the jig includes:

[0025] Using a laser theodolite to draw a ground cross center line and taking this as a reference;

[0026] Drawing the center line of the saddle girder opening, the center line of the saddle girder and the large vehicle hole, and the jig layout line.

[0027] Further, arranging the two saddle girders onto the jig includes:

[0028] Arranging the saddle girders onto the jig based on the jig layout line;

[0029] Adjusting the horizontal center lines of the two saddle girders and making them on the same horizontal plane.

[0030] Further, lifting and hoisting the gantry frame door to the saddle girders for assembly includes:

[0031] Fixing the legs using guy ropes;

[0032] Calibrating the verticality of the gantry frame door using a laser and a chain block;

[0033] Making the gantry frame door match the saddle girders using a guide plate;

[0034] Adjusting each dimension parameter of the gantry frame door using the guy ropes and the chain block so that the intersection points of the leg center lines are in the same plane;

[0035] Welding the lower openings of the legs and the saddle girders.

[0036] Further, hoisting the gantry frame to the saddle beam for assembly further includes:

[0037] Connecting and fixing the strut between the two legs by hoisting, the strut being parallel to the saddle beam.

[0038] Further, before hoisting the gantry frame to the saddle beam for assembly, it includes:

[0039] Assembling the trolley ear plate on the saddle beam;

[0040] Assembling the trolley ear plate on the saddle beam includes:

[0041] Using a process strut to increase the open dimension of the trolley ear plate.

[0042] Further, hoisting the gantry and arranging the trolley to move includes:

[0043] Drawing the base distance and wheel distance of the tyre crane with the ground cross center line as the reference;

[0044] Using a forklift to arrange the trolley to move based on the base distance and wheel distance of the tyre crane, and making the open dimension of the trolley balance beam shaft hole match the open dimension of the saddle beam end.

[0045] At least one of the above technical solutions of the present invention has the following beneficial effects:

[0046] The manufacturing method of the large box girder structure disclosed by the present invention avoids large deviations in the center line during splicing by pre-fixing the four-sided steel plates through spot welding, ensures the perpendicularity and twist of each panel of the box girder structure, and improves the manufacturing accuracy of the large box girder structure. Description of the Drawings

[0047] Figure 1 It is a schematic diagram of the overall process of the manufacturing method of the large box girder structure provided by the embodiment of the present invention;

[0048] Figure 2 It is a schematic diagram of the saddle beam manufacturing in the manufacturing method of the large box girder structure provided by the embodiment of the present invention;

[0049] Figure 3 It is a schematic diagram of the structure with additional allowance for the legs in the manufacturing method of the large box girder structure provided by the embodiment of the present invention;

[0050] Figure 4 It is a schematic diagram of the overall process of the assembly method of the tyre crane provided by the embodiment of the present invention;

[0051] Figure 5Another overall process schematic diagram of the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0052] Figure 6 Schematic diagram of arranging the tyre rack in the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0053] Figure 7 Schematic diagram of installing the gantry frame door in the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0054] Figure 8 Schematic diagram of installing the power house and the electrical house in the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0055] Figure 9 Schematic diagram of assembling the trolley traveling of the rubber tyred gantry crane in the assembling method provided by the embodiment of the present invention;

[0056] Figure 10 Schematic diagram of hoisting the trolley frame assembly in the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0057] Figure 11 Right view of the rubber tyred gantry crane assembled by using the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0058] Figure 12 Front view of the rubber tyred gantry crane assembled by using the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention;

[0059] Figure 13 Left view of the rubber tyred gantry crane assembled by using the assembling method of the rubber tyred gantry crane provided by the embodiment of the present invention.

[0060] Reference numerals:

[0061] a, center line of the trolley hole; b, ground cross center line;

[0062] 10, saddle beam; 20, rib plate; 30, leg; 30a, allowance at the end of the saddle beam; 30b, allowance at the end of the girder; 40, guy wire; 50, power house; 60, electrical house; 70, trolley traveling; 80, trolley frame; 90, girder. Detailed implementation manners

[0063] In order to make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are some but not all of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the described embodiments of the present invention fall within the scope of protection of the present invention.

[0064] The large box girder structure is hollow inside and is shaped like a box, such as the legs and saddle beams of a large box girder structure. In the prior art, the assembly of a large box girder structure generally involves welding three sides first and then welding the last side. Such an installation process cannot ensure the perpendicularity and twist of each panel of the box girder structure.

[0065] In view of the above technical problems, an embodiment of the present invention provides a manufacturing method for a large box girder structure. In this method, the four panels of the box girder structure are initially positioned by spot welding. After measuring various parameters of the box girder structure, continuous welding is performed on the box girder structure to ensure the perpendicularity, twist, flatness, etc. of each panel of the box girder structure, and further improve the manufacturing accuracy of the box girder structure.

[0066] First, a manufacturing method for a large box girder structure according to an embodiment of the present invention will be specifically described below with reference to the accompanying drawings.

[0067] Specifically, as Figure 1 shown, a manufacturing method for a large box girder structure provided by an embodiment of the present invention, the box girder structure includes a saddle beam 10 or a leg 30. The legs 30 and saddle beams 10 in a tire crane are both box girder structures, and the manufacturing of the legs 30 and saddle beams 10 is applicable to the above steps. Of course, the above manufacturing method can also be applicable to other components in a tire crane, such as: a main beam 90, a cross bar, etc. The method includes the following steps:

[0068] S10. Assemble the top plate, bottom plate and two web plates into a pre-box girder structure.

[0069] That is to say, place the top plate, bottom plate and two web plates in place to present a pre-box girder structure.

[0070] In one embodiment, as Figure 2 shown, step S10 further includes:

[0071] Place the top plate, bottom plate and two web plates on a jig.

[0072] Add stiffeners 20 to both ends of the jig.

[0073] Fix the bottom plate to the jig using a spacer plate.

[0074] In an embodiment of the present invention, by adding stiffeners 20 and spacer plates to both ends of the jig, the stability and firmness of the box girder structure during the manufacturing process are improved, and the manufacturing accuracy of the box girder structure is further improved.

[0075] In one embodiment, step S10 further includes:

[0076] Increase the allowance for the lengths of the top plate, bottom plate and two web plates.

[0077] After the splicing and welding of the large vehicle ear plates on the saddle beam 10 are completed, the inward shrinkage and deformation of the web affect the overall opening dimension. Based on this, a margin is placed at the upper opening of the web during blanking. After the web splicing is completed, the upper opening margin is trimmed. The length of the center of the large vehicle ear plates in the length direction is increased by the margin, and the total length is lengthened. Margins are added to both ends of the lower opening in the length direction to ensure the overall opening dimension of the web, and further ensure that the flatness can be guaranteed within the range of the upper panels at both ends when the support leg 30 and the saddle beam 10 are spliced.

[0078] As Figure 3 shown, when blanking the panel web of the support leg 30, a trimming margin, i.e., the margin 30b at the end of the girder 90, needs to be placed at the upper opening, and a trimming margin, i.e., the margin 30a at the end of the saddle beam, is placed at the lower opening. It will be trimmed during the on-site door frame assembly to prevent the problem of excessive clearance at the upper opening of the support leg 30.

[0079] S20. Pre-position the positions between the top plate, the bottom plate and the two webs by spot welding.

[0080] The positions between the top plate, the bottom plate and the two webs are initially positioned by spot welding. That is to say, the relative positions between the top plate, the bottom plate and the two webs can still be changed.

[0081] S30. Measure the verticality and twist of the prefabricated box girder structure.

[0082] When the measured parameters such as the verticality, twist and flatness of the prefabricated box girder structure are unqualified, return to step S20 to re-adjust the relative positions between the top plate, the bottom plate and the two webs, and re-initial position by spot welding again.

[0083] S40. When the measurement result of the prefabricated box girder structure is within the preset range, fix the positions between the top plate, the bottom plate and the two webs by continuous welding to form a box girder structure.

[0084] When the measurement result in step S30 is within the preset range, i.e., qualified, fix the positions between the top plate, the bottom plate and the two webs by continuous welding. After continuous welding, the positions between the bottom plate, the top plate and the two webs will not change.

[0085] In one embodiment, the method further includes the fabrication of the trolley frame 80. After the mechanism of the trolley frame 80 is arranged, the I-beam of the girder 90 has a downward deflection. A pre-arch needs to be placed when fabricating the I-beam of the girder 90, and a pre-arch is placed for the I-beam of the mechanism girder 90. After the auxiliary mechanism base prefabrication components are made, the small flange surface is machined integrally and then installed with the trolley frame 80 to ensure the angle and flatness of the auxiliary mechanism base.

[0086] As Figures 11 to 13 shown, the rubber tyred gantry crane includes components such as a saddle beam 10, a support leg 30, a girder 90, a large vehicle traveling crane 70, a power house 50, an electrical house 60, etc.

[0087] An embodiment of the present invention also provides an assembly method for a rubber-tyred gantry crane, as Figure 4 and Figure 5 shown. The method includes the following steps:

[0088] S1. Arrange the jig.

[0089] The gantry steel structure is manufactured by a split manufacturing technique, that is, each structural member is manufactured in the workshop and then the manufactured components are assembled, thus reducing the construction period, improving the workshop utilization rate and reducing the production and manufacturing cost at the same time.

[0090] When assembling the gantry steel structure, first arrange the jig, as Figure 6 shown. Specifically, it includes the following steps:

[0091] Use a laser theodolite to draw the ground cross center line b and use this as a reference.

[0092] Draw the center line of the saddle beam 10 opening, the center line a of the saddle beam 10 and the large vehicle hole, and the jig layout line.

[0093] S2. Arrange two saddle beams 10 on the jig.

[0094] Align the center line of the saddle beam 10 opening with the ground cross center line b, arrange the two saddle beams 10 on the jig respectively, and adjust so that the horizontal center lines of the two saddle beams 10 are on the same horizontal plane, ensure the overall level of the saddle beam 10, and detect the gauge opening size and diagonal size tolerance.

[0095] S3. Lift and assemble the gantry frame to the saddle beam 10. The gantry frame includes legs 30 and a girder 90.

[0096] Before lifting the gantry frame, assemble the legs 30 and the girder 90 to form the gantry frame. Specifically, it includes the following steps:

[0097] Fix the legs 30 with guy ropes.

[0098] Use a laser in cooperation with a chain block to calibrate the perpendicularity of the gantry frame.

[0099] Use a guide plate to make the gantry frame match the saddle beam 10.

[0100] Use the guy ropes and chain blocks to adjust the various dimensional parameters of the gantry frame so that the intersection points of the center lines of the legs 30 are in the same plane.

[0101] Weld the lower ends of the legs 30 and the saddle beam 10.

[0102] That is to say, as Figure 7As shown, use the gantry crane to hoist the door frame on the drag chain side to the saddle beam 10, align the guide plate, pull the Langfeng wire rope, use the laser to cooperate with the hand chain hoist to calibrate the verticality of the door frame, and tighten the Langfeng rope 40. Then move the door frame on the non-drag chain side to the saddle beam 10 position and align the guide plate. Check the opening size of the two door frames, the opening size and horizontal size of the main beam track, the diagonal size, etc., and use the Langfeng rope 40 to cooperate with the hand chain hoist to make adjustments.

[0103] Measure and adjust the dimensions of the gantry to ensure that the zero points of the four main beams, i.e., the intersection of the center lines of the legs 30, are in the same plane, and the lower end of the legs 30 is aligned with the inner reinforcement of the saddle beam 10. Complete the weld between the lower end of the legs 30 and the saddle beam 10, and weld sequentially from the inside to the outside.

[0104] Further, the support rod is connected to the support leg 30 by using a car crane, the pin shaft is inserted, and the bolts are tightened, and finally the trolley rail is hoisted by the car crane and installed in place side by side.

[0105] In one embodiment, the following steps are also included before step S3:

[0106] The cart lug is assembled on the saddle beam 10 .

[0107] When assembling the trolley lug plate on the saddle beam 10, the steps include:

[0108] The opening assembly size of the large vehicle ear plate is enlarged by utilizing a process support.

[0109] That is to say, when assembling the car ear plate, the process support is used to increase the opening assembly size. After welding, the opening size on the drawing is guaranteed to improve the assembly accuracy.

[0110] S4, hoisting trolley track, electrical room 60 and power room 50.

[0111] like Figure 8 As shown, re-measure the shear block openings and angles of the brackets of the electrical room 60 and the power room 50, and check the corresponding connection openings and angles of the bottom frames of the electrical room 60 and the power room 50. Use a car crane to hoist the electrical room 60 and the power room 50 into place. Finally, install the ladder platform inclined ladder and platform. When installing the upper platform of the electrical room 60, use the pin shaft end as the reference, and locate the installation of the waist-shaped hole at the other end according to the actual length of the platform; install the anti-collision frame of the electrical room 60 and the power room 50, and after the accessories are installed in place, measure the relevant dimensions.

[0112] S5, hoisting the gantry and arranging the trolley to travel 70.

[0113] Draw the tire crane base distance and wheel track based on the ground cross center line b;

[0114] Use a forklift to arrange the trolley traveling mechanism 70 based on the wheelbase and track gauge of the tire crane, and make the opening dimension of the axle hole of the trolley balance beam match the opening dimension of the end of the saddle beam 10.

[0115] That is to say, as Figure 9 shown, use a forklift to arrange the four sets of trolley traveling mechanisms of the tire crane according to the dimensions, and adjust the trolley to ensure that the flatness of the torn axle hole plane is within the preset range. Measure and adjust the four sets of trolley traveling mechanisms to meet the tolerance requirements of the track gauge and wheelbase, and the diagonal dimension is within the specified range. Also measure the straightness of the trolley. It is required that the overall straightness of a single set of trolleys be controlled within the preset range, and the opening dimension of the axle hole of the trolley balance beam is guaranteed to match the opening of the end of the saddle beam 10.

[0116] S6. Hoist the trolley frame 80 assembly and install the accessories.

[0117] Specifically, as Figure 10 shown, first arrange the ladder platform, each mechanism, etc. properly. Install all electrical cables, parts, hydraulic lubrication pipelines and parts on the trolley frame 80 to minimize high-altitude operations. Use a gantry crane to hoist the trolley assembly onto the trolley track and place it at the middle position of the main beam, that is, the trolley anchoring position. After aligning the trolley wheels with the center line of the track and making them coincide, the trolley can be lowered onto the track. Fix the trolley with steel wires and hoists, etc. Install other accessories, such as: exhaust system, fuel tank pipeline system, boarding straight ladder, tire pressure monitoring, antenna and other accessories.

[0118] For the above assembly method, each component of the tire crane is assembled in sequence to form a tire crane as Figures 11 to 13 shown. This assembly method breaks through the conventional manufacturing and assembly methods, improves the production and manufacturing efficiency, and further improves the assembly accuracy of the tire crane.

[0119] The above is the preferred embodiment of the present invention. It should be noted that for those of ordinary skill in the art of this technology, without departing from the principle described in the present invention, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present invention.

Claims

1. An assembly method for a tire crane, characterized in that, the method includes: Arranging a tire rack; Arranging two saddle beams on the tire rack; Lifting and assembling the gantry frame door to the saddle beam, where the gantry frame door includes legs and a girder; Lifting the trolley track, electrical room and power room; Lifting the gantry and arranging the trolley travel; Lifting the trolley frame assembly and installing accessories; Arranging the tire rack includes: Using a laser theodolite to draw a ground cross center line and taking this as a reference; Drawing the saddle beam opening center line, the center line between the saddle beam and the trolley hole, and the tire rack layout line; Arranging two saddle beams on the tire rack includes: Arranging the saddle beam on the tire rack based on the tire rack layout line; Adjusting the horizontal center lines of the two saddle beams and making them lie on the same horizontal plane; Lifting the gantry frame door to the saddle beam for assembly includes: Fixing the legs with guy ropes; Calibrating the perpendicularity of the gantry frame door using a laser and a chain block; Using a guide plate to make the gantry frame door match the saddle beam; Adjusting each dimensional parameter of the gantry frame door using guy ropes and a chain block so that the intersection point of the leg center lines lies in the same plane; Welding the lower opening of the leg to the saddle beam; Connecting and fixing a strut between the two legs by lifting, with the strut parallel to the saddle beam; Before lifting the gantry frame door to the saddle beam for assembly includes: Assembling the trolley ear plate on the saddle beam; When assembling the trolley ear plate on the saddle beam, includes: Increasing the opening assembly dimension of the trolley ear plate using a process strut; Lifting the gantry and arranging the trolley travel, includes: Drawing the base distance and wheelbase of the tire crane with the ground cross center line as a reference; Using a forklift to arrange the trolley travel based on the base distance and wheelbase of the tire crane and making the opening dimension of the trolley balance beam axle hole match the end opening dimension of the saddle beam.

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