Assembly line and assembly process of a reach stacker

Abstract

The application discloses a kind of assembly line and assembly process of front-end crane, and the assembly line includes: guide rail, be arranged throughout the whole assembly line, eight workstations are sequentially arranged on guide rail;Workstation I is used to complete the assembly of product front axle tire assembly piece, rear axle tire assembly piece and frame on line;Workstation II-workstation VI, for hoisting work of component divided by each workstation process of product;Workstation VII, for the hoisting of product boom assembly and the whole machine off line;Workstation VIII, for the debugging and reporting of product;On-line rail shuttle vehicle can be back and forth between workstation I and workstation II in the direction of guide rail, for the on-line product conveying of workstation I assembly;Passing rail shuttle vehicle moves in the direction of guide rail, for the product conveying between workstation II-workstation VII.The disclosure of the present application can realize the linear assembly of front-end crane, and the assembly efficiency doubles compared with the disc rack type mode.

Description

Technical Field

[0001] This invention relates to the field of vehicle assembly technology, and more specifically to an assembly line and assembly process for a front-end lifting crane. Background Technology

[0002] Reaching cranes are commonly used logistics equipment in ports, docks, railway and highway transfer stations, and various container yards for loading, unloading, stacking, and handling containers. They are characterized by high operating efficiency and are less constrained by port terrain, logistics channels, and throughput. In recent years, with the vigorous development of inland port economies, reaching cranes have become one of the most important container handling machines in inland port construction.

[0003] Currently, the assembly process of reach stacker cranes commonly employs a panel-type assembly method. This method is relatively crude, resulting in low overall production efficiency, long production cycles, large assembly area requirements, and a low level of overall lean production management. With increasingly fierce market competition, higher demands are being placed on reach stacker cranes in terms of both output and quality, rendering the panel-type assembly method obsolete. In the existing technology, Chinese patent (CN 114013536A) proposes an assembly line and vehicle assembly process suitable for passenger cars. This patent includes a conveying device, a racking device, and a loading robot, which can effectively improve assembly efficiency. However, this assembly line and method are not suitable for transporting, gripping, and installing large, heavy-load components using reach stacker cranes.

[0004] Chinese patent (CN 111791972A) disclosed a vehicle assembly line and assembly method in 2020. The vehicle assembly line includes guide rails and interior assembly stations, chassis assembly stations and frame assembly stations arranged sequentially along the guide rails. The chassis assembly station includes a body hoist, a lifting drive mechanism for lifting the body hoist, and a horizontal drive mechanism for moving the lifting drive mechanism along the guide rails. This method of lifting the hoist and then moving the vehicle horizontally is prone to causing vehicle swaying and is not suitable for large-sized, heavy-load vehicles, such as those transported by front-end cranes.

[0005] Therefore, a new front-end lifting crane assembly line and assembly process are needed to meet market demands. Summary of the Invention

[0006] The purpose of this invention is to disclose an assembly line and assembly process for a front-mounted crane, design a front-mounted crane assembly line, plan the assembly process layout of the front-mounted crane, and formulate a process technology solution for front-mounted crane frame loading, transit conveying, and unloading of the whole machine. The aim is to solve the problems of large assembly area, low production efficiency, and low level of lean production management in the panel-type assembly mode.

[0007] To achieve the above objectives, the present invention provides an assembly line for a front-end lifting crane, comprising:

[0008] The guide rail runs through the entire assembly line, and eight workstations, from workstation I to workstation VIII, are arranged sequentially on the guide rail.

[0009] Workstation 1 is used to complete the assembly of the front axle tire assembly, rear axle tire assembly, and vehicle frame.

[0010] Workstations II to VI are used for hoisting the components of each workstation process of the product.

[0011] Workstation VII is used for hoisting the product's outrigger assembly and for the entire machine to be rolled off the production line.

[0012] Workstation VIII is used for product debugging and inspection.

[0013] The online track shuttle can travel back and forth between workstation I and workstation II along the guide rail direction for transporting online products assembled at workstation I.

[0014] The overpass shuttle car moves along the guide rail and is used for product transport between workstations II and VII.

[0015] An assembly auxiliary flatbed cart is located between the upper track shuttle and the transit track shuttle, and moves along the guide rail direction for transporting components installed at the bottom of the product.

[0016] The front end of the online track shuttle car is equipped with a first lifting support mechanism for supporting and lifting the front axle, and the rear end is equipped with a second lifting support mechanism for supporting and lifting the rear of the car frame.

[0017] The front and rear ends of the over-position track shuttle are arranged in a matrix with four sets of third lifting support mechanisms, which are used to support and lift the front and rear axles of the product respectively.

[0018] The power supply system provides power to the upper track shuttle and the overpass track shuttle;

[0019] The central control system is used to coordinate the transport of products from the online track shuttle and the transit track shuttle to the designated workstation.

[0020] The auxiliary support platform is arranged on workstations II to VI, and each workstation has 4 sets of support for the four tires of the product.

[0021] The off-line auxiliary support platform has two sets, symmetrically arranged on both sides of the track at workstation VII, with a slope at the front end to assist the whole product in being unloaded from the production line;

[0022] Single-girder bridge crane equipment is used for hoisting various components of products between workstations II and VI;

[0023] Double-girder bridge crane equipment is used for hoisting the outrigger assembly of products at workstation VII.

[0024] As a further improvement of the present invention, the first lifting support mechanism is arranged in two sets, symmetrically arranged on both sides of the guide rail, each set including:

[0025] The first lifting platform has several first circular holes evenly distributed on its upper surface perpendicular to the vehicle body direction.

[0026] The first support block has multiple first cylinders spaced apart on its lower end face along the vehicle body direction, and two first limiting blocks arranged parallel to each other on its upper end face along the vehicle body direction. The two first limiting blocks are located at the front and rear ends of the upper end face respectively.

[0027] The first lifting platform and the first support block are detachably connected by the first cylinder and the first circular hole, which is used to adjust the adjacent spacing of the first support blocks of the two sets of first lifting support mechanisms to meet different front axle lengths.

[0028] As a further improvement of the present invention, the second lifting support mechanism includes:

[0029] The second lifting platform is arranged perpendicular to the vehicle body, and several second circular holes are symmetrically and evenly arranged on both sides of the upper end face.

[0030] Two sets of second support blocks are symmetrically arranged at both ends of the second lifting platform. The lower end face of each block is provided with a second cylinder that mates with the second circular hole, and the upper end face is provided with a second limiting block. The two limiting blocks are used to limit the width of the vehicle body.

[0031] The second lifting platform and the second support block are detachably connected by the second cylinder and the second circular hole, which is used to adjust the distance between the two sets of second support blocks and the distance between the second support block and the first support block to meet the different frame lengths.

[0032] As a further improvement of the present invention, the online track shuttle and the overtaking track shuttle are both heavy-duty track-type guided transport vehicles, and both are equipped with automatic photoelectric scanning obstacle removal function.

[0033] This invention also discloses an assembly process for a front-end lifting crane, comprising the following steps:

[0034] S1. At workstation I, the front axle tire assembly, rear axle tire assembly, and chassis of the product are assembled and put on the line. First, the front axle tire assembly is placed on the first lifting support mechanism of the online track shuttle. The product chassis is lifted using a double beam bridge crane. The front end of the chassis is connected to the front axle tire assembly. The rear end of the chassis is placed on the second lifting support mechanism. The height of the second lifting support mechanism is adjusted so that the bottom surface of the chassis is at the same level. Finally, the rear axle tire assembly is lifted using a double beam bridge crane and installed to the rear end of the chassis. Assembly is complete.

[0035] S2, the first and second lifting support mechanisms of the online track shuttle lift the product to a height of more than 380mm. After the online track shuttle travels along the guide rail to work station II, it drops the product onto the work station auxiliary support platform. The online track shuttle then returns to work station I to start the next round of work.

[0036] S3: The products are transported sequentially to workstations II-VII via a track shuttle. Single-beam bridge cranes are used to hoist the components of the products in each process between workstations II-VI. Oil is added to the products. Double-beam bridge cranes are used to hoist the outrigger assembly of the products at workstation VII. At the same time, between workstations II-VII, auxiliary flatbed trucks are used to transport and assemble the bottom components of the products.

[0037] S4, start the vehicle, drive off the auxiliary support platform, arrive at workstation VIII, complete the initial debugging of the power, electrical, hydraulic and other systems, and submit the whole machine for inspection.

[0038] As a further improvement of the present invention, the second lifting support mechanism in the assembly line includes:

[0039] The second lifting platform is arranged perpendicular to the vehicle body, and several second circular holes are symmetrically and evenly arranged on both sides of the upper end face.

[0040] Two sets of second support blocks are symmetrically arranged at both ends of the second lifting platform. The lower end face of each block is provided with a second cylinder that mates with the second circular hole, and the upper end face is provided with a second limiting block for limiting the width of the vehicle body.

[0041] The second lifting platform and the second support block are detachably connected through the second cylinder and the second circular hole, which is used to adjust the distance between the two sets of second support blocks and the distance between the second support block and the first support block to meet the different frame lengths;

[0042] In step S1, after adjusting the height of the second lifting support mechanism, the spacing between the two sets of second support blocks is adjusted to ensure that the second support blocks are in surface contact with the rear end plane of the vehicle frame.

[0043] Compared with the prior art, the beneficial effects of the present invention are:

[0044] (1) Compared with the panel assembly process technology: By arranging eight workstations along the track in sequence, the assembly process of each workstation is divided in detail to ensure the balance of the working time of each workstation. The product car is transported by the upper track shuttle car and the overpass track shuttle car, realizing the linear assembly of the front hoisting crane. The assembly efficiency can be doubled compared with the panel mode. The flexible assembly of the support block and the lifting platform improves the versatility of the two track shuttle cars, and can realize the assembly production of multiple models on a single assembly line, effectively reducing construction and maintenance costs. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the assembly line and assembly process of a front-mounted hoisting crane according to the present invention.

[0046] Figure 2 This is a schematic diagram of the structure of the upper track shuttle car in the assembly line and assembly process of the front lifting crane of the present invention;

[0047] Figure 3 This is an enlarged view of the first lifting support mechanism in the assembly line and assembly process of a front-mounted hoisting crane according to the present invention.

[0048] Figure 4 This is an enlarged view of the second lifting support mechanism in the assembly line and assembly process of a front-mounted hoisting crane according to the present invention.

[0049] Figure 5 This is a schematic diagram of the assembly line and assembly process of a front-mounted hoisting crane according to the present invention, showing the product loading process.

[0050] Figure 6 This is a schematic diagram of the structure of the shuttle car on the overpass track in the assembly line and assembly process of the front lifting crane of the present invention.

[0051] Figure 7 This is a schematic diagram of the assembly line and product transit process of a front-mounted hoisting crane according to the present invention, which shows the auxiliary support platform at the workstation.

[0052] In the diagram: 10, guide rail; 20, central control system; 30, assembly auxiliary flatbed cart; 40, single-girder bridge crane; 50, double-girder bridge crane; 100, upper track shuttle; 101, first lifting support mechanism; 102, second lifting support mechanism; 200, transit track shuttle; 201, third lifting support mechanism; 300, workstation auxiliary support platform; 101a, first lifting platform; 101b, first support block; 102a, second lifting platform; 102b, second support block; 1010, first circular hole; 1011, first cylinder; 1012, first limiting block; 1020, second circular hole; 1021, second cylinder; 1022, second limiting block; 1a, front axle tire assembly; 1b, rear axle tire assembly; 1c, chassis. Detailed Implementation

[0053] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings. However, it should be noted that these embodiments are not intended to limit the present invention. Equivalent changes or substitutions in function, method, or structure made by those skilled in the art based on these embodiments are all within the scope of protection of the present invention.

[0054] Please refer to Figures 1 to 7 The illustration shows a specific embodiment of the assembly line and assembly process for a front-end lifting crane according to the present invention. It should be understood that the product referred to herein is the front-end lifting crane trolley.

[0055] An assembly line for a front-end lifting crane includes: a guide rail 10, an upper rail shuttle 100, a transit rail shuttle 200, an assembly auxiliary flatbed 30, a power supply system, a central control system 20, a workstation auxiliary support platform 300, a lower rail auxiliary support platform, a single-girder bridge crane 40, a double-girder bridge crane 50, and eight workstations arranged sequentially along the guide rail 10: workstation I to workstation VIII.

[0056] Specifically, guide rail 10 runs through the entire assembly line and has a maximum load capacity of ≥80t; workstations I to VIII are responsible for assembling different parts respectively; workstation I directly uses the online track shuttle car 100 as a carrier to complete the assembly of the front axle tire assembly 1a, the rear axle tire assembly 1b and the frame 1c.

[0057] The online track shuttle 100 can travel back and forth between workstation I and workstation II along guide rail 10 for transporting products assembled at workstation I, with a maximum load capacity of ≥25t; the transit track shuttle 200 moves along guide rail 10 for transporting products between workstation II and workstation VII; both the online track shuttle 100 and the transit track shuttle 200 are heavy-duty track-guided transport vehicles, equipped with automatic photoelectric scanning obstacle removal functions, which can effectively ensure the safety of the vehicles themselves and personnel; assembly auxiliary flatbed 30 Located between the upper track shuttle 100 and the transit track shuttle 200, it moves along the guide rail 10 and is used to transport the components installed at the bottom of the product. The upper track shuttle 100 has a first lifting support mechanism 101 at its front end for supporting and lifting the front axle, and a second lifting support mechanism 102 at its rear end for supporting and lifting the tail of the frame 1c. The transit track shuttle 200 has four sets of third lifting support mechanisms 201 arranged in a matrix at its front and rear ends for supporting and lifting the front and rear axles of the product, respectively.

[0058] Workstations II to VI are used for hoisting the components divided into processes at each workstation of the product. The product is transported to the workstation auxiliary support platform 300 and hoisted into each workstation and process in sequence according to the assembly sequence of each process of the whole machine assembly process. Single beam bridge crane 40 is used to complete the hoisting of the components divided into each process at each workstation of the whole machine. Each workstation is symmetrically equipped with an independent workstation auxiliary support platform 300 and a single-beam bridge-type lifting device 40 spanning the workstation along the track. Each workstation has four sets of workstation auxiliary support platforms 300 to support the four tires of the product. This not only allows the shuttle car 200 to travel without obstacles, but also increases the overall height of the machine, increases the operating space at the bottom of the machine, reduces the difficulty of the assembly work at the bottom of the vehicle, and reduces the labor intensity. Workstation VII is used for hoisting the product's outrigger assembly and unloading the entire machine. There are two sets of unloading auxiliary support platforms, symmetrically arranged on both sides of the track at workstation VII, with a slope at the front end to assist in unloading the entire product. The vehicle can drive directly to the ground to enter workstation VIII. Workstation VIII is used for product debugging and inspection.

[0059] The power supply system provides power to the online rail shuttle 100 and the transit rail shuttle 200; it can ensure the power supply of heavy-duty rail-guided transport vehicles and has the characteristics of convenience, speed and stable operation.

[0060] The central control system 20 coordinates the transport of products from the online track shuttle 100 and the transit track shuttle 200 to designated workstations. The central control system 20 mainly consists of a transfer line main control unit, a heavy-duty rail-guided transport vehicle system, a distributed I / O control station, a field engineer station, an industrial bus network, and cable trays. Through the scheduling of the main control unit, it automatically and reliably coordinates the online track shuttle 100 and the transit track shuttle 200 to transport products to designated workstations safely and reliably.

[0061] The single-girder bridge crane 40 is arranged across workstations II-VI and is used for hoisting various components of the products between workstations II and VI; the double-girder bridge crane 50 is used for hoisting the boom assembly of the products at workstation VII. It can run along the entire track and is responsible for the assembly of the counterweight, engine assembly, operator's cab, boom assembly, and lifting gear assembly, which constitute the entire front-end lifting crane.

[0062] Two sets of first lifting support mechanisms 101 are arranged symmetrically on both sides of the guide rail 10. Each set includes: a first lifting platform 101a, with a plurality of first circular holes 1010 evenly distributed on its upper end face perpendicular to the vehicle body direction; a first support block 101b, with a plurality of first cylinders 1011 spaced apart along the vehicle body direction on its lower end face; and two first limiting blocks 1012 arranged parallel along the vehicle body direction on its upper end face, with the two first limiting blocks 1012 located at the front and rear ends of the upper end face respectively. The first lifting platform 101a and the first support block 101b are detachably connected through the first cylinders 1011 and the first circular holes 1010, which is used to adjust the adjacent spacing of the first support blocks 101b of the two sets of first lifting support mechanisms 101 to meet different front axle lengths. The second lifting support mechanism 102 includes: a second lifting platform 102a, arranged perpendicular to the vehicle body, with a plurality of second circular holes 1020 symmetrically and evenly arranged on both sides of the upper end face; two sets of second support blocks 102b, symmetrically arranged at both ends of the second lifting platform 102a, each with a second cylinder 1021 that mates with the second circular holes 1020 on its lower end face, and a second limiting block 1022 on its upper end face, the two limiting blocks being used to limit the width of the vehicle body; the second lifting platform 102a and the second support blocks 102b are detachably connected through the second cylinder 1021 and the second circular holes 1020, for adjusting the distance between the two sets of second support blocks 102b and the distance between the second support block 102b and the first support block 101b, to meet the lengths of different vehicle frames 1c.

[0063] This invention also discloses an assembly process for a front-end lifting crane, comprising the following steps:

[0064] S1. At workstation I, the front axle tire assembly 1a, rear axle tire assembly 1b, and chassis 1c are assembled and installed. First, the front axle tire assembly 1a is placed on the first lifting support mechanism 101 of the online track shuttle 100. The chassis 1c is lifted using a double-beam bridge crane 50, and the front end of the chassis 1c is connected to the front axle tire assembly 1a. The rear end of the chassis 1c is placed on the second lifting support mechanism 102. The height of the second lifting support mechanism 102 is adjusted so that the bottom surface of the chassis 1c is at the same level. Finally, the rear axle tire assembly 1b is lifted using the double-beam bridge crane 50 and installed to the rear end of the chassis 1c. Assembly is complete. S2. The first lifting support mechanism 101 and the second lifting support mechanism 102 of the online track shuttle 100 lift the product to 380mm. At the above height, the online track shuttle 100 travels along guide rail 10 to workstation II and then lowers the product onto the workstation auxiliary support platform 300. The online track shuttle 100 then returns to workstation I for the next round of work. S3, the transit track shuttle 200 transports the product sequentially to workstations II-VII. The single-girder bridge crane 40 sequentially completes the hoisting of the components of the product in each process between workstations II-VI. The product is then lubricated. The double-girder bridge crane 50 completes the hoisting of the outrigger assembly of the product at workstation VII. At the same time, between workstations II and VII, the assembly auxiliary flatbed 30 assists in the transportation and assembly of the bottom components of the product. S4, the vehicle is started, the offline auxiliary support platform is opened, and the product arrives at workstation VIII. The initial debugging of the power, electrical, and hydraulic systems is completed, and the entire machine is inspected. In step S1, after adjusting the height of the second lifting support mechanism 102, the spacing between the two sets of second support blocks 102b is adjusted to ensure that the second support block 102b and the rear end plane of the frame 1c are in surface contact.

[0065] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An assembly line for a front-end lifting crane, characterized in that, include: The guide rail runs through the entire assembly line, and eight workstations, from workstation I to workstation VIII, are arranged sequentially on the guide rail. Workstation 1 is used to complete the assembly of the front axle tire assembly, rear axle tire assembly, and vehicle frame. Workstations II to VI are used for hoisting the components of each workstation process of the product. Workstation VII is used for hoisting the product's outrigger assembly and for the entire machine to be rolled off the production line. Workstation VIII is used for product debugging and inspection. The online track shuttle can travel back and forth between workstation I and workstation II along the guide rail direction for transporting online products assembled at workstation I. The overpass shuttle car moves along the guide rail and is used for product transport between workstations II and VII. An assembly auxiliary flatbed cart is located between the upper track shuttle and the transit track shuttle, and moves along the guide rail direction for transporting components installed at the bottom of the product. The front end of the online track shuttle car is equipped with a first lifting support mechanism for supporting and lifting the front axle, and the rear end is equipped with a second lifting support mechanism for supporting and lifting the rear of the car frame. The front and rear ends of the over-position track shuttle are arranged in a matrix with four sets of third lifting support mechanisms, which are used to support and lift the front and rear axles of the product respectively. The power supply system provides power to the upper track shuttle and the overpass track shuttle; The central control system is used to coordinate the transport of products from the online track shuttle and the transit track shuttle to the designated workstation. The auxiliary support platform is arranged on workstations II to VI, and each workstation has 4 sets of support for the four tires of the product. The off-line auxiliary support platform has two sets, symmetrically arranged on both sides of the track at workstation VII, with a slope at the front end to assist the whole product in being unloaded from the production line; Single-girder bridge crane equipment is used for hoisting various components of products between workstations II and VI; Double-girder bridge crane equipment is used for hoisting the outrigger assembly of products at workstation VII.

2. The assembly line for a front-end lifting crane according to claim 1, characterized in that, The first lifting support mechanism has two sets, symmetrically arranged on both sides of the guide rail, each set including: The first lifting platform has several first circular holes evenly distributed on its upper surface perpendicular to the vehicle body direction. The first support block has multiple first cylinders spaced apart on its lower end face along the vehicle body direction, and two first limiting blocks arranged parallel to each other on its upper end face along the vehicle body direction. The two first limiting blocks are located at the front and rear ends of the upper end face respectively. The first lifting platform and the first support block are detachably connected by the first cylinder and the first circular hole, which is used to adjust the adjacent spacing of the first support blocks of the two sets of first lifting support mechanisms to meet different front axle lengths.

3. The assembly line for a front-end lifting crane according to claim 2, characterized in that, The second lifting support mechanism includes: The second lifting platform is arranged perpendicular to the vehicle body, and several second circular holes are symmetrically and evenly arranged on both sides of the upper end face. Two sets of second support blocks are symmetrically arranged at both ends of the second lifting platform. The lower end face of each block is provided with a second cylinder that mates with the second circular hole, and the upper end face is provided with a second limiting block. The two limiting blocks are used to limit the width of the vehicle body. The second lifting platform and the second support block are detachably connected by the second cylinder and the second circular hole, which is used to adjust the distance between the two sets of second support blocks and the distance between the second support block and the first support block to meet the different frame lengths.

4. The assembly line for a front-end lifting crane according to claim 1, characterized in that, Both the online track shuttle and the transit track shuttle are heavy-duty track-guided transport vehicles, and both are equipped with automatic photoelectric scanning and obstacle removal functions.

5. An assembly process for a front-end lifting crane, based on an assembly line for a front-end lifting crane according to any one of claims 1-4, characterized in that, Includes the following steps: S1. At workstation I, the front axle tire assembly, rear axle tire assembly, and chassis of the product are assembled and put on the line. First, the front axle tire assembly is placed on the first lifting support mechanism of the online track shuttle. The product chassis is lifted using a double beam bridge crane. The front end of the chassis is connected to the front axle tire assembly. The rear end of the chassis is placed on the second lifting support mechanism. The height of the second lifting support mechanism is adjusted so that the bottom surface of the chassis is at the same level. Finally, the rear axle tire assembly is lifted using a double beam bridge crane and installed to the rear end of the chassis. Assembly is complete. S2, the first and second lifting support mechanisms of the online track shuttle lift the product to a height of more than 380mm. After the online track shuttle travels along the guide rail to work station II, it drops the product onto the work station auxiliary support platform. The online track shuttle then returns to work station I to start the next round of work. S3: The products are transported sequentially to workstations II-VII via a track shuttle. Single-beam bridge cranes are used to hoist the components of the products in each process between workstations II-VI. Oil is added to the products. Double-beam bridge cranes are used to hoist the outrigger assembly of the products at workstation VII. At the same time, between workstations II-VII, auxiliary flatbed trucks are used to transport and assemble the bottom components of the products. S4, start the vehicle, open the auxiliary support platform for the off-line, arrive at workstation VIII, complete the initial debugging of the power, electrical and hydraulic systems, and submit the whole machine for inspection.

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