A process for setting a roll-on dolly for a rolling crane

Abstract

The application relates to a setting process of a roller type crane rolling mounting jig frame, and is characterized in that: specific size control is as follows: S1: jig frame arrangement; S2: operation before the turning chassis turns over; S3: total assembly of the jig frame on the reverse roller assembly; S4: total assembly of the jig frame on the turning chassis structure; S5: welding of the reverse roller and the turning chassis; S6: total assembly of the counterweight box and grouting; S7: installation of the winch base and mechanism arrangement; S8: installation of the turning mechanism; in the application, the installation size precision of each component is controlled from the jig frame arrangement of the roller type crane, the precision needs to be controlled in a reasonable range in each step, and the size precision control of the turning structure is realized when the crane turning structure is finally installed; compared with the final detection installation mode, the installation step of gradually detecting and controlling the precision reduces the assembly efficiency, guarantees the precision requirement, and reduces the probability of rework and trimming.

Description

Technical Field

[0001] This invention relates to the field of roller crane assembly jig setup technology, and more particularly to a roller crane roll-on / roll-off jig setup process. Background Technology

[0002] The slewing chassis includes the anti-roller structure, the main structure of the slewing chassis, the counterweight box, the slewing mechanism, the truss frame, and the cast-in-place counterweight; the total weight of the slewing chassis assembly is approximately 1950T. The installation sequence and the arrangement of the jigs involve the overall dimensional installation accuracy. Therefore, in order to ensure the installation accuracy of the slewing structure of this roller crane, it is necessary to gradually control the installation gears at each position to achieve overall dimensional accuracy control of the slewing structure. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a process for setting up a roll-on / roll-off jig for a roller crane, which can solve the problem of large dimensional errors in the slewing structure of a typical roller crane after installation.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: a process for setting up a roll-on / roll-off (Ro-Ro) jig for a roller crane, wherein after the slewing chassis and truss frame are assembled, counterweights are poured as required, and the jig is loaded onto a ship using a modular roll-on / roll-off method and transported to a shipyard for final assembly; its innovation lies in the following specific dimensional control:

[0005] S1: Jig Frame Arrangement: To ensure that the assembled jig frame meets the load-bearing requirements, three additional jig frames are required and arranged in the set positions. Other requirements shall be implemented in accordance with the jig frame arrangement requirements of the slewing chassis assembly.

[0006] S2: Operations before turning the slewing chassis: Measure the distance from the outer arc surface of the slewing chassis arc plate to the center. Correct any out-of-tolerance dimensions before assembling the slewing chassis and the anti-roller. Measure the distance from the upper plane of the slewing chassis rail beam to the outer arc surface, as well as the height difference at the upper plane of the cover plate. Based on the measurement results, trim the upper margin of the web plate and partition at the anti-roller structure joint. Due to the need to trim the anti-roller structure margin by marking lines, after the slewing chassis rail beam track surface is machined, use the machined surface of the rail beam as a reference to measure the distance from the assembly position of the slewing chassis and the anti-roller assembly to the machined surface of the rail beam. The margin at the front anti-tilt structure interface will not be trimmed temporarily. It will be trimmed according to the actual site conditions when the anti-roller structure bracket that it is connected to is installed after the slewing chassis is assembled onto the hull.

[0007] S3: Assembly jig for the anti-roller assembly: After the anti-roller is hoisted into place, adjust the rail bearing surface to be level, requiring a horizontality of <3mm and a verticality of ≤0.5mm; transfer the cross center of the anti-roller assembly to the upper plane of the machining fixture and mark it with a punch mark; check the contact between the anti-roller assembly and the jig, and padded the jig and the anti-roller structure within 200mm on both sides with steel plates, and arrange the jacking jacks; arrange the four jigs on the inner side of the anti-roller in place;

[0008] S4: Slewing chassis structure assembly frame: Hoist the slewing chassis onto the frame, check that the center of the slewing chassis and the anti-roller structure are aligned, with a deviation of less than 2mm. After passing the inspection, place the slewing chassis onto the lifting frame; adjust the track surface of the slewing chassis bearing beam to a horizontal state using hydraulic jacks, requiring a levelness of ≤1mm.

[0009] S5: Welding of the anti-roller and the slewing chassis: The thickness of the anti-roller structural component bearing rail surface includes a 15mm machining allowance. According to the size, the dimensional allowance for joining and trimming is measured and trimmed. The anti-roller structure is lifted to the joining height using a hydraulic jack. During the lifting process, shims are used between the jig and the structure to ensure proper shimming. Welding is carried out after inspection and approval before welding. Post-weld dimensional requirements: The horizontality of the anti-roller bearing rail surface ≤ 5mm; the distance between the bearing rail surface and the stiffening plate and the center of rotation ± 3mm.

[0010] S6: Assembly and grouting of the counterweight box: Assemble and connect the counterweight box with the rotating base plate, adjust the level of the counterweight and then weld it; pour the counterweight into the counterweight box body;

[0011] S7: Winch base installation and mechanism assembly: Based on the pre-marked installation position lines of each mechanism base on the slewing chassis, position and install each mechanism base; check the alignment with the structural bottom reinforcement; after ensuring the bottom reinforcement requirements are met, weld the mechanism bases; after each base is welded, assemble the mechanism.

[0012] S8: Installation of the slewing mechanism: Hoist the slewing mechanism onto the slewing bracket, raise the upper part of the mechanism with sleepers, and fix the bottom with clips. After the final assembly is on the ship, position and install the slewing mechanism in place according to the drawings.

[0013] The advantages of this invention are:

[0014] 1) In this invention, the installation dimensional accuracy of each component is controlled starting from the arrangement of the jig frame of the roller crane. At each step, the accuracy needs to be controlled within a reasonable range. When finally installing the crane's slewing structure, the dimensional accuracy of the slewing structure is controlled. This step-by-step installation process of checking and controlling accuracy, compared with the final inspection and installation method, reduces assembly efficiency but ensures the accuracy requirements, thereby reducing the probability of rework and repair. Attached Figure Description

[0015] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0016] Figure 1 This is a process flow diagram of the roller crane roll-on / roll-off carriage setup according to the present invention.

[0017] Figures 2 to 7 This is a process assembly diagram of a roller crane roll-on / roll-off jig for the present invention.

[0018] Figure 8 This is an overall assembly diagram of the roller crane roll-on / roll-off carriage assembly process according to the present invention. Implementation

[0019] 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. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0021] like Figure 1 The process for setting up a roll-on / roll-off (Ro-Ro) crane jig for a roller crane is shown. After the slewing chassis and truss frame are assembled, counterweights are poured as required. The jig is then loaded onto a ship using a modular roll-on / roll-off method and transported to a shipyard for final assembly. Specific dimensional controls are as follows:

[0022] S1: Bracket arrangement: as shown Figure 2 As shown, in order to ensure that the assembly jig meets the load-bearing requirements, three additional jigs need to be added and arranged in the set positions. Other requirements shall be implemented in accordance with the overall assembly jig arrangement requirements of the slewing chassis.

[0023] S2: Operations before turning the slewing chassis: Measure the distance from the outer arc surface of the slewing chassis arc plate to the center. Correct any out-of-tolerance dimensions before assembling the slewing chassis and the anti-roller. Measure the distance from the upper plane of the slewing chassis rail beam to the outer arc surface, as well as the height difference at the upper plane of the cover plate. Based on the measurement results, trim the upper margin of the web plate and partition at the anti-roller structure joint. Due to the need to trim the anti-roller structure margin by marking lines, after the slewing chassis rail beam track surface is machined, use the machined surface of the rail beam as a reference to measure the distance from the assembly position of the slewing chassis and the anti-roller assembly to the machined surface of the rail beam. The margin at the front anti-tilt structure interface will not be trimmed temporarily. It will be trimmed according to the actual site conditions when the anti-roller structure bracket that it is connected to is installed after the slewing chassis is assembled onto the hull.

[0024] S3: Final assembly bracket for the anti-roller assembly: such as... Figure 3 As shown: After the anti-roller is hoisted into place, adjust the rail bearing surface to be level, requiring a horizontality of <3mm and a verticality of ≤0.5mm; transfer the cross center of the anti-roller assembly to the upper plane of the machining fixture and mark it with a punch mark; check the contact between the anti-roller assembly and the jig, and padded the jig and the anti-roller structure within 200mm on both sides with steel plates, and arrange the jacking jacks; arrange the four jigs on the inner side of the anti-roller in place;

[0025] S4: Slewing chassis structure assembly frame: Hoist the slewing chassis onto the frame, check that the center of the slewing chassis and the anti-roller structure are aligned, with a deviation of less than 2mm. After passing the inspection, place the slewing chassis onto the lifting frame; adjust the track surface of the slewing chassis bearing beam to a horizontal state using hydraulic jacks, requiring a levelness of ≤1mm.

[0026] S5: Welding of the anti-roller and the slewing chassis: The thickness of the anti-roller structural component bearing rail surface includes a 15mm machining allowance. According to the size, the dimensional allowance for joining and trimming is measured and trimmed. The anti-roller structure is lifted to the joining height using a hydraulic jack. During the lifting process, shims are used between the jig and the structure to ensure proper shimming. Welding is carried out after inspection and approval before welding. Post-weld dimensional requirements: The horizontality of the anti-roller bearing rail surface ≤ 5mm; the distance between the bearing rail surface and the stiffening plate and the center of rotation ± 3mm.

[0027] S6: The counterweight box is assembled onto a jig and grouted. (e.g., ...) Figure 5 As shown: Assemble and connect the counterweight box and the rotating base plate, adjust the level of the counterweight, and then weld it; pour the counterweight into the counterweight box body;

[0028] S7: Winch base installation and mechanism arrangement: such as Figure 6 As shown: The installation positions of each mechanism base are pre-marked on the slewing chassis, and each mechanism base is positioned and installed; the alignment with the structural bottom reinforcement is checked; after ensuring the bottom reinforcement requirements are met, the mechanism bases are welded; after each base is welded, the mechanisms are assembled.

[0029] S8: Installation of the slewing mechanism: as follows Figure 7 Figure 8 As shown: The slewing mechanism is hoisted onto the slewing bracket, the upper part is raised by sleepers, and the bottom is fixed by clips. After the final assembly is on the ship, the slewing mechanism is positioned and installed in place according to the drawings.

[0030] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A process for setting up a roll-on / roll-off (Ro-Ro) jig for a roller crane, wherein after the slewing chassis and truss frame are assembled, counterweights are cast as required, and the jig is loaded onto a ship using a modular roll-on / roll-off method and transported to a shipyard for final assembly; characterized in that: Specific dimensional controls include the following: S1: Jig Frame Arrangement: To ensure that the assembled jig frame meets the load-bearing requirements, three additional jig frames are required and arranged in the set positions. Other requirements shall be implemented in accordance with the jig frame arrangement requirements of the slewing chassis assembly. S2: Operations before turning the slewing chassis: Measure the distance from the outer arc surface of the slewing chassis arc plate to the center. Correct any out-of-tolerance dimensions before assembling the slewing chassis and the anti-roller. Measure the distance from the upper plane of the slewing chassis rail beam to the outer arc surface, as well as the height difference at the upper plane of the cover plate. Based on the measurement results, trim the upper margin of the web plate and partition at the anti-roller structure joint. Due to the need to trim the anti-roller structure margin by marking lines, after the slewing chassis rail beam track surface is machined, use the machined surface of the rail beam as a reference to measure the distance from the assembly position of the slewing chassis and the anti-roller assembly to the machined surface of the rail beam. The margin at the front anti-tilt structure interface will not be trimmed temporarily. It will be trimmed according to the actual site conditions when the anti-roller structure bracket that it is connected to is installed after the slewing chassis is assembled onto the hull. S3: Assembly jig for the anti-roller assembly: After the anti-roller is hoisted into place, adjust the rail bearing surface to be level, requiring a horizontality of <3mm and a verticality of ≤0.5mm; transfer the cross center of the anti-roller assembly to the upper plane of the machining fixture and mark it with a punch mark; check the contact between the anti-roller assembly and the jig, and padded the jig and the anti-roller structure within 200mm on both sides with steel plates, and arrange the jacking jacks; arrange the four jigs on the inner side of the anti-roller in place; S4: Slewing chassis structure assembly frame: Hoist the slewing chassis onto the frame, check that the center of the slewing chassis and the anti-roller structure are aligned, with a deviation of less than 2mm. After passing the inspection, place the slewing chassis onto the lifting frame; adjust the track surface of the slewing chassis bearing beam to a horizontal state using hydraulic jacks, requiring a levelness of ≤1mm. S5: Welding of the anti-roller and the slewing chassis: The thickness of the anti-roller structural component bearing rail surface includes a 15mm machining allowance. According to the size, the dimensional allowance for joining and trimming is measured and trimmed. The anti-roller structure is lifted to the joining height using a hydraulic jack. During the lifting process, shims are used between the jig and the structure to ensure proper shimming. Welding is carried out after inspection and approval before welding. Post-weld dimensional requirements: The horizontality of the anti-roller bearing rail surface ≤ 5mm; the distance between the bearing rail surface and the stiffening plate and the center of rotation ± 3mm. S6: Assembly and grouting of the counterweight box: Assemble and connect the counterweight box with the rotating base plate, adjust the level of the counterweight and then weld it; pour the counterweight into the counterweight box body; S7: Winch base installation and mechanism assembly: Based on the pre-marked installation position lines of each mechanism base on the slewing chassis, position and install each mechanism base; check the alignment with the structural bottom reinforcement; after ensuring the bottom reinforcement requirements are met, weld the mechanism bases; after each base is welded, assemble the mechanism. S8: Installation of the slewing mechanism: Hoist the slewing mechanism onto the slewing bracket, raise the upper part of the mechanism with sleepers, and fix the bottom with clips. After the final assembly is on the ship, position and install the slewing mechanism in place according to the drawings.

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