A tooling assembly method for machining a split-type cable saddle

Abstract

This invention discloses an assembly fixture and method for integral processing of a split-type cable saddle. The assembly fixture includes an assembly platform. The top surface of the assembly platform corresponds to the two saddle segments to be assembled and is longitudinally divided into a first support area and a second support area. In the first support area, multiple sets of roller assemblies are distributed around the bottom surface of the first saddle segment, with the rollers of each assembly rotating in the transverse direction of the assembly platform. In the second support area, multiple sets of jacks and multiple sets of leveling blocks are distributed around the bottom surface of the second saddle segment, with the jacks positioned adjacent to the first support area and the leveling blocks having a protrusion height corresponding to the protrusion height of the roller assemblies. This invention reduces the technical difficulty of assembling segmented cable saddles, improves the efficiency of segmented saddle assembly, and is time-saving, labor-saving, and economical.

Description

Technical Field

[0001] This invention relates to a tooling for processing cable saddles for suspension bridges, specifically a tooling for assembling segmented composite cable saddles during overall processing, and a method for assembling based on this tooling. Background Technology

[0002] In suspension bridge structures, the cable saddle is a critical load-bearing component, and its manufacturing precision directly affects the stress conditions and thus the overall quality and safety of the bridge. To ensure the quality of suspension bridge projects, the design requirements for cable saddles include:

[0003] 1. The bottom surface of the saddle body is a single plane with an overall flatness of ≤0.08mm / 1000mm and ≤0.5mm / the entire plane;

[0004] 2. The side walls of the saddle groove are on the same plane and the overall flatness is ≤0.08mm / 1000mm and ≤0.5mm / the entire plane;

[0005] 3. The surface profile of each arc rope groove at the bottom of the saddle groove is ≤1mm / 1000mm.

[0006] Currently, cable saddles can be classified into integral cable saddles and split cable saddles. Integral cable saddles are manufactured as a single piece, making it easy to ensure molding quality, but their structural volume and stress are relatively small, which cannot meet the technical requirements of large suspension bridges. In order to meet the technical requirements of large suspension bridges and adapt to current processing equipment, split cable saddles with larger structural volume and stress have emerged.

[0007] Split-type cable saddles typically divide the entire saddle body into two or three relatively small saddle sections along its length (i.e., the direction of the main cable extension), such as a mid-span saddle and a side-span saddle. In engineering applications, these relatively small saddle sections are assembled into a whole by connecting bolts.

[0008] Limited by processing equipment and technology, traditional split-type cable saddles are made by machining each saddle segment separately (including roughing and finishing), and then assembling the segments into a whole using bolts. Machining errors are then corrected by manual grinding. Cable saddles produced using this method rarely meet the design requirements mentioned above because: since each saddle segment is machined separately, dimensional and cumulative errors inevitably exist between them. This directly leads to the following quality problems in the assembled saddle:

[0009] 1. Misalignment occurs at the bottom joint of adjacent saddle sections, forming a step, which causes the overall flatness of the bottom surface of the saddle to fail to meet the design requirements of ≤0.08mm / 1000mm and ≤0.5mm / full flatness.

[0010] 2. The radius dimensions of the circular arc rope grooves and the width dimensions of the steps on the rope groove surfaces of adjacent saddle sections are not consistent. The center position dimensions of the rope grooves between adjacent saddle sections are also not completely consistent. This leads to step misalignment at the joint of each circular arc rope groove surface. As a result, the flatness of the groove walls on both sides of the saddle groove cannot meet the design requirements of ≤0.08mm / 1000mm and ≤0.5mm / full plane, respectively. At the same time, the surface profile of each circular arc rope groove surface cannot meet the design requirement of ≤1mm / 1000mm.

[0011] In view of this, the applicant previously disclosed a technique for integral finishing of a split-type cable saddle, as detailed in the Chinese patent document entitled "A Method for Integral Finishing of a Split-Type Main Cable Saddle for Suspension Bridges" (Publication No. CN 106271437A, Publication Date January 4, 2017). In this technique, each saddle segment is first rough-machined, then the mid-section joint surfaces of each saddle segment are finished, then adjacent saddle segments are assembled together using locating pins and connecting bolts at the mid-section joint surfaces, and finally the bottom surface and saddle groove surface of the assembled saddle are finished, thereby obtaining a high-quality split-type cable saddle that meets design requirements.

[0012] In the aforementioned two types of split-type cable saddle manufacturing technologies, the final control of machining errors, and the key factor determining the final product quality, is clearly achieved after the overall assembly of the split sections. Therefore, the overall assembly precision of the segmented cable saddle directly affects the overall finishing quality. To ensure the overall assembly precision of the segmented cable saddle, it is necessary to precisely position and connect the segments using locating pins with a dimensional tolerance of 0 / +0.025mm through locating pin holes. For a cable saddle weighing tens of tons, such high-precision "threading" obviously increases the technical difficulty of assembling the saddle sections.

[0013] Currently, the technical measures to solve the problem of saddle segment assembly are:

[0014] First, hoist the two saddle sections that need to be assembled onto the assembly platform and achieve basic alignment and tight fit.

[0015] During the dynamic observation process, wedge blocks were used to fine-tune the relative height position of saddle segment one and saddle segment two;

[0016] Once the height is adjusted to the correct position and the positioning pin holes are aligned in the height direction, the relative positions of saddle section one and saddle section two in the width direction can be finely adjusted by jacking or hoisting.

[0017] This process is repeated until the axial centers of the locating pin holes at the mating surfaces of saddle section one and saddle section two are aligned, then the locating pins are inserted to connect them and the connection is secured with bolts.

[0018] During the assembly process described above, repeated fine-tuning in both the height and width directions is required to ensure high-precision alignment of the axial centers of the locating pin holes. Alignment in the height direction may affect alignment in the width direction, and vice versa. The entire assembly process is time-consuming and labor-intensive; inserting the locating pins into the locating pin holes is technically challenging and directly increases manufacturing costs. Summary of the Invention

[0019] The technical objective of this invention is to provide an assembly tooling that reduces the technical difficulty of assembling split cable saddles and improves assembly efficiency, and an assembly method based on the above-mentioned assembly tooling, in view of the special characteristics of the above-mentioned integral processing of split cable saddle assembly, especially the precision processing, and the shortcomings of the prior art.

[0020] The technical objective of this invention is achieved through the following technical solution: a tooling assembly for machining a split-type cable saddle, including an assembly platform;

[0021] The top surface of the assembly platform corresponds to the saddle section one and saddle section two to be assembled, and is divided into a first support area and a second support area in the longitudinal direction; during the assembly operation, the longitudinal direction of the assembly platform corresponds to the length direction of the saddle section one and the saddle section two, and the transverse direction of the assembly platform corresponds to the width direction of the saddle section one and the saddle section two.

[0022] The first support area of ​​the assembly platform, corresponding to the bottom surface of the saddle section one to be supported, has multiple sets of roller assemblies distributed around it, and the rotation direction of the rollers in each set of roller assemblies is along the lateral direction of the assembly platform.

[0023] The second support area of ​​the assembly platform corresponds to the bottom surface of the second saddle section to be supported. Multiple sets of jacks and multiple sets of equal-height pads are distributed around the perimeter of the second support area. The jacks are arranged close to the first support area. The height of the equal-height pads on the top surface of the assembly platform corresponds to the height of the roller assembly on the top surface of the assembly platform.

[0024] The aforementioned technical measures address the unique characteristics of the integral processing of the split-type cable saddle assembly, particularly the precision processing of the split-type cable saddle assembly disclosed in patent document CN106271437 A. The saddle sections are supported on the first and second support areas of the assembly platform by corresponding roller assemblies, jacks, and leveling blocks. The lifting and lowering motion of the jacks in the height direction, and the horizontal movement of the corresponding saddle sections along the width direction on the roller assemblies, allow for easy and convenient alignment of the positioning pin holes between the assembled saddle sections. This facilitates reliable and smooth installation of the positioning pins, thereby reducing the technical difficulty of the segmented cable saddle assembly operation, improving the efficiency of the segmented saddle assembly operation, saving time and effort, and offering good economic benefits.

[0025] As one preferred embodiment, the height of the roller assembly protruding from the top surface of the assembly platform is lower than the height of the equal-height pad protruding from the top surface of the assembly platform in the initial state.

[0026] The height of the roller assembly protruding from the top surface of the assembly platform can be dynamically adjusted.

[0027] The aforementioned roller assembly, in addition to enabling the saddle body to move horizontally, also allows for lifting and lowering in the vertical direction. This enables fine-tuning of the height of the saddle body segment and the relative saddle body segment using equal-height pads as a reference, in conjunction with jacks. This makes it easier, more convenient, and more efficient to align the positioning pin holes of the assembled saddle body segments, further reducing the technical difficulty of segmented cable saddle assembly operations.

[0028] Furthermore, the height of the roller assembly protruding from the top surface of the assembly platform is adjusted by a wedge between the bottom of the roller assembly and the top surface of the assembly platform;

[0029] The bottom of the roller assembly has at least one wedge groove formed laterally along the assembly platform, with the larger end of the wedge groove facing outwards.

[0030] The wedge is embedded at the larger end of the corresponding wedge slot.

[0031] The aforementioned height-adjustable roller assembly is designed based on the reference of the equal-height pad and the technical requirements for fine-tuning. It has a simple structure, stable force distribution, and is easy to apply force to.

[0032] As one of the preferred solutions, the top surface of the assembly platform is provided with multiple recessed grooves arranged along the lateral spacing, and each groove is formed along the longitudinal direction of the assembly platform.

[0033] The bottom of the roller assembly is inserted into a corresponding groove on the assembly platform with a raised structure, and is positioned at the upper limit of the horizontal direction of the assembly platform.

[0034] The above-mentioned technical measures can not only satisfy the lateral limiting and fixing of the roller assembly, but also flexibly adjust the relative arrangement position in the longitudinal and lateral directions to adapt to the assembly operation of saddle sections with different design specifications, and have good versatility.

[0035] Furthermore, the roller assembly mainly consists of a wheel seat, a wheel axle, and a roller. The upper part of the wheel seat forms a U-shaped roller mounting groove. The roller is mounted in the middle of the wheel axle. Both ends of the wheel axle are rotatably mounted on the wheel seat via bearings. The roller is located in the roller mounting groove in the upper part of the wheel seat.

[0036] The bottom of the wheel seat is inserted into a corresponding groove on the assembly platform with a raised structure.

[0037] The roller assembly structure of the above-mentioned technical measures is simple and reliable in bearing load. It can be stably limited in the lateral direction within the groove of the assembly platform, effectively meeting the support force requirements of the saddle section.

[0038] Furthermore, the wheel seat has fixed feet that are folded outward from both ends in the direction corresponding to the slide groove, and each fixed foot has a pin hole.

[0039] The wheel seat is inserted into the corresponding groove on the assembly platform through the pin hole of the fixed foot and the limiting pin.

[0040] The above-mentioned technical measures not only meet the requirements of reliable positioning, but also facilitate assembly and disassembly operations on the assembly platform. The operation process is easy and convenient, and it also facilitates the easy molding of the wheel seat, especially the easy molding of the structure with wedge groove at the bottom.

[0041] Furthermore, at the bottom of the wheel seat, corresponding to the two support arms on both sides of the roller mounting groove, two wedge-shaped grooves are formed with an inwardly concave inclined surface structure. This technical measure effectively satisfies the load-bearing capacity of the saddle section by fine-tuning it in a wedge-like manner.

[0042] A method for assembling the assembly tooling for the integral finishing of the above-mentioned segmented cable saddle, the assembly method comprising the following process steps:

[0043] Step 1. Based on the bottom dimensions of the saddle section one and saddle section two to be supported, arrange multiple sets of roller assemblies in the first support area of ​​the assembly platform, and arrange multiple sets of jacks and equal-height pads in the second support area of ​​the assembly platform.

[0044] Step 2. According to the set assembly direction and position, hoist the second saddle section into the second support area and place it on multiple sets of jacks and multiple sets of equal height pads;

[0045] Based on the relative position of saddle section 2, saddle section 1 is hoisted into the first support area in a center-aligned and adjacent manner and placed on multiple sets of roller assemblies (2);

[0046] Step 3. Insert process bolts into the corresponding bolt holes at the mating surfaces of saddle section one and saddle section two, and tighten the process bolts to make the mating surfaces of saddle section one and saddle section two fit tightly together.

[0047] Step 4. Remove the process bolts;

[0048] Observe the alignment of the pin holes at the joint surfaces of saddle section one and saddle section two in the height direction;

[0049] Step 5. Based on the alignment of the pin holes at the mating surface in the height direction observed in Step 4, fine-tune the relative support height of the jack and roller assembly to align the pin holes at the mating surface in the height direction.

[0050] Step 6. From one side of saddle section two, insert the positioning pin into the height-aligned pin hole and tap it in.

[0051] The positioning pin passes through the pin hole 2 of saddle section 2 and enters the pin hole 1 of saddle section 1. The fitting of the self-adaptive positioning pin on the roller assembly of saddle section 1 is finely adjusted in the width direction.

[0052] Step 7. Insert bolts into the corresponding bolt holes at the mating surfaces of saddle body section one and saddle body section two and tighten them to achieve assembly.

[0053] The above assembly method is based on the above assembly tooling, which makes fine adjustments to the height and width of the segmented saddle body segments to be assembled, so that the positioning pin holes between the assembled saddle body segments can be aligned more easily and smoothly. This is conducive to the reliable and smooth installation of the positioning pins, reduces the technical difficulty of segmented cable saddle assembly operations, improves the efficiency of segmented saddle body assembly operations, and is more time-saving, labor-saving, and economical.

[0054] Furthermore, the axial length of the positioning pin is greater than the total depth of the pin holes of saddle section one and saddle section two at the mating surface.

[0055] The front end of the positioning pin has a rounded corner structure.

[0056] The above-mentioned technical measures are beneficial to the pulling and disassembly of the positioning pin after the overall processing is completed; on the other hand, they are beneficial to the positioning pin going from the reference side to the fine adjustment side. After the positioning pin hole meets the height alignment, the saddle section under force can adapt to the displacement on the roller assembly by inserting the positioning pin with the rounded corner at the front end.

[0057] The beneficial technical effects of the present invention are as follows: The above-mentioned technical measures address the special characteristics of the integral processing of the split cable saddle assembly, especially the special characteristics of the integral precision processing of the split cable saddle assembly disclosed in patent document CN 106271437 A. It can make fine adjustments in the height and width directions of the segmented saddle body segments to be assembled, so that the positioning pin holes between the assembled saddle body segments can be aligned more easily and smoothly. This is conducive to the reliable and smooth installation of the positioning pins, reduces the technical difficulty of the segmented cable saddle assembly operation, improves the efficiency of the segmented saddle body assembly operation, and is more time-saving, labor-saving, and economical. Attached Figure Description

[0058] Figure 1 This is a schematic diagram of one structure of the present invention.

[0059] Figure 2 for Figure 1 A magnified view of a portion of the image.

[0060] Figure 3 for Figure 2 A schematic diagram of the roller assembly.

[0061] Figure 4 for Figure 3 Side view.

[0062] Figure 5 for Figure 4 The CC view.

[0063] Figure 6 for Figure 3 AA view.

[0064] Figure 7 for Figure 3 A partial view of BB.

[0065] Figure 8 This is a reference diagram showing one usage state of the present invention.

[0066] The symbols in the diagram mean: 1—Assembly platform; 11—Slide groove; 2—Roller assembly; 21—Wheel seat; 22—Wheel axle; 23—Roller; 24—Bearing; 25—Bearing cover; 26—End cover; 27—Limit pin; 28—Wedge groove; 29—Wedge; 210—Fixing foot; 3—Jack; 4—Equal height pad; 5—Saddle section one; 51—Pin hole one; 6—Saddle section two; 62—Pin hole two. Detailed Implementation

[0067] This invention relates to a tooling for machining suspension bridge cable saddles, specifically an assembly tooling for precision machining of segmented composite cable saddles, and an assembly method based on this tooling. The main technical solution of this invention will be described in detail below with reference to several embodiments. Embodiment 1 is illustrated in conjunction with the accompanying drawings—that is… Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 The technical solution of the present invention is clearly and in detail explained; although other embodiments are not shown in separate drawings, their main structure can still be referred to the drawings of Embodiment 1.

[0068] It should be noted that the accompanying drawings of this invention are schematic, and unnecessary details have been simplified in order to clarify the technical objectives of this invention, so as to avoid obscuring the technical solutions contributed by this invention to the prior art.

[0069] Example 1

[0070] See Figure 1 and Figure 2 As shown, the present invention includes an assembly platform 1, four sets of roller assemblies 2, two sets of jacks 3, and two sets of equal-height pads 4.

[0071] Specifically, the top profile of assembly platform 1 is a rectangular structure with a length greater than its width. The top surface of assembly platform 1 corresponds to the saddle segment 5 and saddle segment 6 to be assembled, and is longitudinally divided into a first support area and a second support area. The first support area is used for placing saddle segment 5, and the second support area is used for placing saddle segment 6. During assembly, the longitudinal direction of assembly platform 1 corresponds to the length direction of saddle segment 5 and saddle segment 6, and the transverse direction of assembly platform 1 corresponds to the width direction of saddle segment 5 and saddle segment 6.

[0072] On the top surface of the assembly platform 1, multiple grooves 11 are evenly arranged at equal intervals along the transverse direction. Each groove 11 is formed with a concave structure in the thickness direction of the assembly platform 1, and the length of each groove 11 is formed along the longitudinal direction of the assembly platform 1.

[0073] Four sets of roller assemblies 2 are distributed within the first support area of ​​the assembly platform 1. They are laterally limited by corresponding grooves 11 on the assembly platform 1, and are not constrained longitudinally. They are self-limiting under gravity and can slide under tension. The distributed positions of the four sets of roller assemblies 2 within the first support area correspond to the inner sides of the four corners of the bottom surface of the saddle section 5 to be supported; that is, the area enclosed by the four sets of roller assemblies 2 is smaller than the bottom surface area of ​​the saddle section 5 to be supported. The rollers 23 of each set of roller assemblies 2 rotate in the lateral direction of the assembly platform 1.

[0074] See Figure 3 , Figure 4 , Figure 5 , Figure 6 and Figure 7As shown, the roller assembly 2 mainly consists of a wheel seat 21, a wheel axle 22, and a roller 23. More specifically, the upper part of the wheel seat 21 has a U-shaped roller mounting groove with an inward concave structure, and roller support arms are formed on both sides of the roller mounting groove. The roller 23 is axially mounted in the middle of the wheel axle 22. The two ends of the wheel axle 22 are rotatably mounted on the wheel seat 21 through corresponding bearings 24. The bearings 24 are sealed on the support arms by bearing caps 25, end caps 26, etc. The roller 23 is located in the roller mounting groove in the upper part of the wheel seat 21 and is rotatable.

[0075] As described above, the roller assembly 2 is the basic structure. To enable insertion into the groove 11 of the assembly platform 1, the wheel seat 21 has fixing feet 210 formed by L-shaped outward folding from both ends along the length direction corresponding to the groove 11. Each fixing foot 210 has a pin hole in its central area. The wheel seat 21, through the limiting pins 27 inserted into the pin holes of the fixing feet 210 at both ends, can be inserted into the corresponding groove 11 on the assembly platform 1 in a concave-convex structure. That is, the width of the wheel seat 21 in the width direction is greater than the width of the groove 11. In the initial state, when the wheel seat 21 is inserted into the groove 11 through the limiting pins 27, the bottom surface of the wheel seat 21 rests on the top surface of the assembly platform 1 in a surface-to-surface contact manner.

[0076] To enable height adjustment of the roller assembly 2 on the assembly platform 1, two wedge slots 28 are formed at the bottom of the wheel seat 21, directly below the two support arms corresponding to the roller mounting slots. Each wedge slot 28 is formed with a concave, inclined structure, and the larger end of each slot faces outwards on the assembly platform 1. When the roller assembly 2 is seated on the top surface of the assembly platform 1 via the insertion of the limiting pin 27, the wedge slots 28 are positioned on the top surface of the assembly platform 1, allowing wedges 29 to be inserted. The wedges 29 are inserted into the larger ends of the corresponding wedge slots 28. As the depth of insertion of the wedges 29 increases, the protrusion height of the roller assembly 2 on the top surface of the assembly platform 1 is raised, achieving dynamic height adjustment. The wedges 29 are wedge-shaped structures with an inclined top surface and a flat bottom surface. It should also be noted that when the wedge 29 is fully embedded in the wedge groove 28 and the roller assembly 2 is raised to its highest point on the top surface of the assembly platform 1, the limit pin 27 should still be inserted in the slide groove 11 of the assembly platform 1 to ensure the stability of the roller assembly 2 in the lateral arrangement on the top surface of the assembly platform 1.

[0077] See Figure 1As shown, the two sets of jacks 3 are hydraulic jacks. The two sets of jacks 3 and the two sets of equal-height pads 4 are distributed in the second support area of ​​the assembly platform 1, corresponding to the inner sides of the four corners of the bottom surface of the second saddle section 6 to be supported. Compared with the two sets of equal-height pads 4, the arrangement of the two sets of jacks 3 is closer to the first support area, that is, the plane area enclosed by the two sets of jacks 3 and the two sets of equal-height pads 4 is smaller than the bottom surface area of ​​the second saddle section 6 to be supported.

[0078] Furthermore, the initial protrusion height of the jack 3 on the top surface of the assembly platform 1 is equal to or slightly less than the protrusion height of the leveling block 4 on the top surface of the assembly platform 1. The protrusion height of the leveling block 4 on the top surface of the assembly platform 1 is equal to or slightly greater than the initial protrusion height of the roller assembly 2 on the top surface of the assembly platform 1.

[0079] The structural states of saddle body section 5 and saddle body section 6 to which the above assembly tooling is applicable are as follows:

[0080] Saddle body section 1 (5) and saddle body section 2 (6) were respectively rough-machined;

[0081] Semi-finishing treatment is carried out on saddle body section 5 and saddle body section 6 respectively, leaving a 3mm allowance on the bottom surface;

[0082] The mid-section joint surfaces of saddle body segment 5 and saddle body segment 6 are respectively precision machined to ensure that the flatness of their mid-section joint surfaces is ≤0.08mm / 1000mm and the entire flatness is ≤0.2mm.

[0083] Drill and ream corresponding connecting holes on the mid-parting surfaces of saddle body section 5 and saddle body section 6. The connecting holes include two locating pin holes and multiple bolt holes. The dimensional tolerance of the locating pin holes is required to be 0 / +0.025mm, and the dimensional tolerance of the bolt holes is required to match the connecting bolts.

[0084] Based on the above assembly tooling, the assembly method for saddle body section 5 and saddle body section 6 in the above structural state includes the following process steps:

[0085] Step 1. Based on the bottom dimensions of the saddle section 1 5 and saddle section 2 6 to be supported, four sets of roller assemblies 2 are distributed in the first support area of ​​the assembly platform 1, and two sets of jacks 3 and two sets of equal height pads 4 are distributed in the second support area of ​​the assembly platform 1.

[0086] The height of the leveling block 4 is slightly higher than that of the roller assembly 2 and the jack 3 in the initial state;

[0087] Step 2. According to the set assembly direction and position, hoist the second saddle section 6 into the second support area and place it on the two sets of jacks 3 and the two sets of equal height pads 4;

[0088] Based on the relative position of saddle body section 2 6, saddle body section 1 5 is hoisted into the first support area and placed on the four sets of roller assemblies 2 in a basically center-aligned and adjacent manner;

[0089] Step 3. Insert process bolts into the corresponding bolt holes at the mating surfaces of saddle section 1 5 and saddle section 2 6. With the tightening force of the process bolts, saddle section 2 6 remains basically stationary. Under the action of friction and the sliding fit of the roller assembly 2 in the slide groove 11, saddle section 1 5 moves closer to saddle section 2 6, so that the mating surfaces of saddle section 1 5 and saddle section 2 6 are tightly attached.

[0090] Step 4. Remove the process bolts;

[0091] Observe the alignment of the pin holes at the joint surfaces of saddle body section 5 and saddle body section 6 in the height direction;

[0092] Step 5. Based on the alignment of the pin holes at the mating surfaces observed in Step 4 in the height direction, adjust the relative support height of the hydraulic fine-tuning jack 3 and the relative support height of the roller assembly 2 by adjusting the wedge block 29, so that the pin holes at the mating surfaces of saddle section 1 5 and saddle section 2 6 are aligned and engaged in the height direction.

[0093] Step 6. Use a locating pin with a rounded front end;

[0094] From one side of saddle section 26, insert the positioning pin into the height-aligned pin hole and tap it in.

[0095] The positioning pin passes through the pin hole 61 of the second saddle section 6 and initially enters the pin hole 51 of the first saddle section 5. At this time, the first saddle section 5 under force adapts to the insertion of the positioning pin on the roller assembly 2 and makes a slight adjustment and translation in the width direction to achieve adaptive alignment of the positioning pin hole in the width direction.

[0096] Step 7. Insert bolts into the corresponding bolt holes at the mating surfaces of saddle body section 1 5 and saddle body section 2 6 and tighten them to achieve assembly.

[0097] To facilitate the disassembly of the locating pin after the overall machining is completed, the axial length of the locating pin should preferably be greater than the total depth of the pin holes at the mating surfaces of saddle body section 5 and saddle body section 6.

[0098] Example 2

[0099] The present invention includes an assembly platform, four sets of roller assemblies, two sets of jacks, and two sets of equal-height pads.

[0100] Specifically, the top profile of the assembly platform is a rectangular structure with a length greater than its width. The top surface of the assembly platform corresponds to the saddle segment one and saddle segment two to be assembled, and is longitudinally divided into a first support area and a second support area. The first support area is used for placing saddle segment one, and the second support area is used for placing saddle segment two. During the assembly operation, the longitudinal direction of the assembly platform corresponds to the length direction of saddle segment one and saddle segment two, and the transverse direction of the assembly platform corresponds to the width direction of saddle segment one and saddle segment two.

[0101] The top surface of the assembly platform has multiple grooves evenly spaced along the transverse direction. Each groove is formed with a concave structure in the thickness direction of the assembly platform, and the length of each groove is formed along the longitudinal direction of the assembly platform.

[0102] Four sets of roller assemblies are distributed within the first support area of ​​the assembly platform. They are laterally limited by corresponding grooves on the platform, but not longitudinally constrained. They are self-limiting under gravity and can slide under tension. The distribution of the four sets of roller assemblies within the first support area corresponds to the inner sides of the four corners of the bottom surface of the first saddle section to be supported; that is, the area enclosed by the four sets of roller assemblies is smaller than the bottom surface area of ​​the first saddle section to be supported. The rollers in each set of roller assemblies rotate laterally along the assembly platform.

[0103] The roller assembly mainly consists of a wheel seat, a wheel axle, and rollers. More specifically, the upper part of the wheel seat has a U-shaped roller mounting groove with an inward concave structure, and roller support arms are formed on both sides of the roller mounting groove. The roller is axially mounted in the middle of the wheel axle. The two ends of the wheel axle are rotatably mounted on the wheel seat through corresponding bearings. The bearings are sealed on the support arms by bearing caps, end caps, etc. The roller is located in the roller mounting groove in the upper part of the wheel seat and can rotate.

[0104] As described above, the roller assembly forms the basic structure. To enable insertion into the grooves of the assembly platform, a raised slider is provided along the length of the wheel base. The wheel base, via the bottom slider, can be inserted into the corresponding groove on the assembly platform in a concave-convex structure. That is, the width of the wheel base is greater than the width of the groove. In the initial state, when the wheel base is inserted into the groove via the slider, the bottom surface of the wheel base rests on the top surface of the assembly platform in surface contact.

[0105] To enable height adjustment of the roller assembly on the assembly platform, two wedge slots are formed at intervals on the bottom of the wheel seat, directly below the two support arms corresponding to the roller mounting slots. Each wedge slot is formed laterally along the assembly platform, passes through the slider (which is segmented along its length), and has its larger end facing outwards on the assembly platform. When the roller assembly is seated on the top surface of the assembly platform via the slider, the wedge slots are positioned on the top surface of the platform, allowing the wedges to be inserted. The wedges are inserted into the larger end of the corresponding slots. As the wedges are inserted deeper, the protrusion of the roller assembly on the top surface of the assembly platform is increased, achieving dynamic height adjustment. The wedges are wedge-shaped structures with a sloping top surface and a flat bottom surface. It should also be noted that when the wedge is fully embedded in the wedge slot and the roller assembly is raised to its highest point on the top surface of the assembly platform, the slider should still be inserted in the slide groove of the assembly platform to ensure the stability of the roller assembly in the lateral arrangement on the top surface of the assembly platform.

[0106] The two sets of jacks are hydraulic jacks. The two sets of jacks and two sets of leveling blocks are distributed in the second support area of ​​the assembly platform, corresponding to the inner sides of the four corners of the bottom surface of the second saddle section to be supported. Compared with the two sets of leveling blocks, the arrangement of the two sets of jacks is closer to the first support area, that is, the plane area enclosed by the two sets of jacks and the two sets of leveling blocks is smaller than the bottom surface area of ​​the second saddle section to be supported.

[0107] Furthermore, the initial protrusion height of the jack on the top surface of the assembly platform is equal to or slightly less than the protrusion height of the leveling block on the top surface of the assembly platform. The protrusion height of the leveling block on the top surface of the assembly platform is equal to or slightly greater than the initial protrusion height of the roller assembly on the top surface of the assembly platform.

[0108] The structural states of saddle section one and saddle section two to which the above assembly tooling is applicable are as follows:

[0109] Saddle section one and saddle section two were respectively rough-machined;

[0110] Semi-finishing treatment was carried out on saddle body section one and saddle body section two respectively, leaving a 3mm allowance on the bottom surface;

[0111] The mid-section joint surfaces of saddle body section one and saddle body section two are respectively precision machined to ensure that the flatness of their mid-section joint surfaces is ≤0.08mm / 1000mm and the entire flatness is ≤0.2mm.

[0112] Corresponding connecting holes are drilled and reamed on the mid-section joint surfaces of saddle body section one and saddle body section two. The connecting holes include two locating pin holes and multiple bolt holes. The dimensional tolerance of the locating pin holes is required to be 0 / +0.025mm, and the dimensional tolerance of the bolt holes is required to match the connecting bolts.

[0113] Based on the above assembly tooling, the assembly method for saddle body section one and saddle body section two with the above structural state includes the following process steps:

[0114] Step 1. Based on the bottom dimensions of the saddle section 1 and saddle section 2 to be supported, arrange four sets of roller assemblies in the first support area of ​​the assembly platform, and arrange two sets of jacks and two sets of equal-height pads in the second support area of ​​the assembly platform.

[0115] The height of the leveling block is slightly higher than that of the roller assembly and jack in the initial state;

[0116] Step 2. According to the set assembly direction and position, hoist the second saddle section into the second support area and place it on two sets of jacks and two sets of equal height pads;

[0117] Based on the relative position of saddle section two, saddle section one is hoisted into the first support area and placed on the four sets of roller assemblies in a basically center-aligned and adjacent manner;

[0118] Step 3. Insert process bolts into the corresponding bolt holes at the mating surfaces of saddle section 1 and saddle section 2. By tightening the process bolts, saddle section 2 remains basically stationary. Under the action of friction and the sliding fit of the roller assembly in the groove, saddle section 1 moves closer to saddle section 2, so that the mating surfaces of saddle section 1 and saddle section 2 are tightly attached.

[0119] Step 4. Remove the process bolts;

[0120] Observe the alignment of the pin holes at the joint surfaces of saddle section one and saddle section two in the height direction;

[0121] Step 5. Based on the alignment of the pin holes at the mating surfaces observed in Step 4 in the height direction, adjust the relative support height of the hydraulic fine-tuning jack and the relative support height of the roller assembly by adjusting the wedge block, so that the pin holes at the mating surfaces of saddle section one and saddle section two are aligned and fitted in the height direction.

[0122] Step 6. Use a locating pin with a rounded front end;

[0123] From one side of saddle section two, insert the positioning pin into the height-aligned pin hole and tap it in.

[0124] The positioning pin passes through the pin hole 2 of the second saddle section and initially enters the pin hole 1 of the first saddle section. At this time, the first saddle section under force adapts to the insertion of the positioning pin on the roller assembly and makes a slight adjustment and translation in the width direction to achieve adaptive alignment of the positioning pin hole in the width direction.

[0125] Step 7. Insert bolts into the corresponding bolt holes at the mating surfaces of saddle body section one and saddle body section two and tighten them to achieve assembly.

[0126] To facilitate the disassembly of the locating pin after the overall machining is completed, the axial length of the locating pin should preferably be greater than the total depth of the pin holes at the mating surfaces of saddle body section one and saddle body section two.

[0127] Example 3

[0128] The other contents of this embodiment are the same as those of embodiment 1 or 2, except that the height of the roller assembly on the top surface of the assembly platform is not adjustable and is a fixed structure.

[0129] This means that the height of the saddle section supported by the roller assembly is not adjustable; height adjustment during assembly relies entirely on the jack, and the roller assembly only functions to adjust the translation of the saddle section. Ideally, the height of the roller assembly should be the same as that of the leveling pads.

[0130] This embodiment is obviously not as convenient as embodiments 1 and 2 above, but it has certain technical advantages compared to the traditional pairing method.

[0131] The above embodiments are only used to illustrate the present invention and are not intended to limit it.

[0132] Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications can still be made to the above embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the present invention.

Claims

1. A tooling assembly for integral machining of a split cable saddle, comprising an assembly platform (1); Its features are: The top surface of the assembly platform (1) corresponds to the saddle section one (5) and saddle section two (6) to be assembled, and is divided into a first support area and a second support area in the longitudinal direction; during the assembly operation, the longitudinal direction of the assembly platform (1) corresponds to the length direction of saddle section one (5) and saddle section two (6), and the transverse direction of the assembly platform (1) corresponds to the width direction of saddle section one (5) and saddle section two (6). The first support area of ​​the assembly platform (1) corresponds to the bottom surface of the saddle section (5) to be supported, and multiple sets of roller assemblies (2) are distributed around it, and the rollers (23) of each set of roller assemblies (2) rotate in the same direction as the horizontal side of the assembly platform (1). The second support area of ​​the assembly platform (1) corresponds to the bottom surface of the second saddle section (6) to be supported. Multiple sets of jacks (3) and multiple sets of equal height pads (4) are distributed around it. The jacks (3) are arranged close to the first support area. The height of the equal height pads (4) on the top surface of the assembly platform (1) corresponds to the height of the roller assembly (2) on the top surface of the assembly platform (1). When performing assembly operations, follow these steps: Step 1. Based on the bottom dimensions of the saddle section 1 (5) and saddle section 2 (6) to be supported, multiple sets of roller assemblies (2) are distributed in the first support area of ​​the assembly platform (1), and multiple sets of jacks (3) and equal height pads (4) are distributed in the second support area of ​​the assembly platform (1). Step 2. According to the set assembly direction and position, hoist the second saddle section (6) into the second support area and place it on multiple sets of jacks (3) and multiple sets of equal height pads (4); Based on the relative position of saddle section two (6), saddle section one (5) is hoisted into the first support area and placed on multiple sets of roller assemblies (2) in a center-aligned and adjacent manner; Step 3. Insert process bolts into the corresponding bolt holes at the mating surfaces of saddle section 1 (5) and saddle section 2 (6), and tighten the process bolts to make the mating surfaces of saddle section 1 (5) and saddle section 2 (6) fit tightly together. Step 4. Remove the process bolts; Observe the alignment of the pin holes at the joint surfaces of saddle section one (5) and saddle section two (6) in the height direction; Step 5. Based on the alignment of the pin holes at the mating surface in the height direction observed in Step 4, finely adjust the relative support height of the jack (3) and the roller assembly (2) to align the pin holes at the mating surface in the height direction. Step 6. From one side of saddle section two (6), insert the positioning pin into the height-aligned pin hole and tap it in; The positioning pin passes through the pin hole 2 (61) of the second saddle section (6) and enters the pin hole 1 (51) of the first saddle section (5). The first saddle section (5) adjusts the width direction of the self-adaptive positioning pin on the roller assembly (2). Step 7. Insert bolts into the corresponding bolt holes at the mating surfaces of saddle body section one (5) and saddle body section two (6) and tighten them to achieve assembly.

2. The assembly tooling for integral machining of the split-type cable saddle according to claim 1, characterized in that: The height of the roller assembly (2) protruding on the top surface of the assembly platform (1) is lower than the height of the equal-height pad (4) protruding on the top surface of the assembly platform (1) in the initial state. The height of the roller assembly (2) protruding on the top surface of the assembly platform (1) can be dynamically adjusted.

3. The assembly tooling for integral machining of the split-type cable saddle according to claim 2, characterized in that: The height of the roller assembly (2) protruding on the top surface of the assembly platform (1) is adjusted by a wedge (29) between the bottom of the roller assembly (2) and the top surface of the assembly platform (1); The bottom of the roller assembly (2) has at least one wedge groove (28) formed laterally along the assembly platform (1), with the larger end of the wedge groove (28) facing outwards; The wedge (29) is embedded at the large end of the corresponding wedge groove (28).

4. The assembly tooling for machining a split-type cable saddle as described in claim 1, 2, or 3, characterized in that: The top surface of the assembly platform (1) has multiple recessed grooves (11) arranged along the transverse spacing, and each groove (11) is formed along the longitudinal direction of the assembly platform (1). The bottom of the roller assembly (2) is inserted into the corresponding groove (11) on the assembly platform (1) with a raised structure, and is positioned at the upper limit of the horizontal direction of the assembly platform (1).

5. The assembly tooling for integral machining of the split-type cable saddle according to claim 4, characterized in that: The roller assembly (2) is mainly composed of a wheel seat (21), a wheel axle (22) and a roller (23). The upper part of the wheel seat (21) forms a U-shaped roller mounting groove. The roller (23) is mounted in the middle of the wheel axle (22). The two ends of the wheel axle (22) are mounted on the wheel seat (21) in a rotatable structure through bearings (24). The roller (23) is located in the roller mounting groove in the upper part of the wheel seat (21). The bottom of the wheel seat (21) is inserted into the corresponding groove (11) on the assembly platform (1) with a raised structure.

6. The assembly tooling for integral machining of the split-type cable saddle according to claim 5, characterized in that: The wheel seat (21) has fixed feet (210) formed by folding outward from both ends in the direction corresponding to the slide groove (11), and each fixed foot (210) has a pin hole. The wheel seat (21) is inserted into the corresponding groove (11) on the assembly platform (1) by a limiting pin (27) that passes through the pin hole of the fixed foot (210).

7. The assembly tooling for integral machining of the split-type cable saddle according to claim 5, characterized in that: The bottom of the wheel seat (21) has two wedge grooves (28) arranged at intervals, corresponding to the two support arms on both sides of the roller assembly groove, respectively, with an inwardly concave inclined surface structure.

8. The assembly tooling for machining the split-type cable saddle as described in claim 1, characterized in that: The axial length of the positioning pin is greater than the total depth of the pin holes of saddle section one (5) and saddle section two (6) at the mating surface; The front end of the positioning pin has a rounded corner structure.

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