Manufacturing technology of large pile gripper gantry travel

Abstract

The present invention relates to the technical field of large-scale marine equipment manufacturing, and discloses a manufacturing process for a large-scale pile gripper gantry walk, comprising the following steps: machining, making independent segments, staged closure, and large frame closure. The making of independent segments includes making shoulder beams, columns, connecting beams, and drive seat frames. The present invention simultaneously adopts the method of individual segmentation and sheet segmentation during manufacturing, which is more reasonable for occupying existing sites, has a simpler process, is more convenient for welding operations, and has high production operation efficiency. The welding process is reasonably controlled to avoid the influence of welding heat on welding deformation, reduce the difficulty of controlling the straightness, horizontality, and verticality of the structure, and effectively improve the precision of equipment manufacturing. During manufacturing, some steps that require machining are moved forward, avoiding exceeding the limit range of the machining equipment due to the size and weight of the structure, and saving a large amount of machining costs accumulated in the final construction period.

Description

Technical Field

[0001] The invention relates to the field of large-scale marine equipment manufacturing, and in particular to a manufacturing process for a large-scale pile gripper with gantry travel. Background Art

[0002] In recent years, rapid socioeconomic development has led to a rapid increase in global energy demand, driving the utilization of renewable energy. The development of offshore wind energy is a crucial component. Wind turbine pile equipment is a crucial and fundamental component of this development. As generator power increases, wind turbines are becoming increasingly large, with a trend toward further expansion. Single piles can now exceed 100 meters in length and 15 meters in diameter. With such enormous equipment size, and the uncertainties of ocean currents, waves, and tides, the demand for equipment for wind turbine installation is urgent. However, this massive increase in equipment also significantly increases its weight and size, significantly impacting the travel mechanism. The large size and thick plates create manufacturing challenges that exceed existing manufacturing capabilities. The significant welding heat generated by the thick plates increases welding deformation, making it more difficult to control structural straightness, horizontal alignment, and verticality. Structural precision and manufacturing methods have become particularly important. Currently, there is no mature manufacturing process in China for large-scale pile gripper gantry travel mechanisms.

[0003] The patent application with publication number CN109454405A discloses a process for processing and manufacturing ultra-long and ultra-wide lattice columns. The specific steps are as follows: making shoulder beams, column bases and H-shaped steel components; establishing a steel assembly frame and performing positioning and layout; lifting the standard H-shaped steel components onto the assembly frame and fixing them; assembling the various tie bar components and tie bar connecting plates; assembling the shoulder beam ends; assembling the column base ends; assembling the top cover plate, the horizontal cover plate and the sealing plate; and assembling the bottom cover plate and external small components.

[0004] The manufacturing process of the existing technology is used for the production of huge equipment. The huge welding heat increases the welding deformation, and it is difficult to control the structural straightness, horizontality and verticality. It is also not convenient to save construction time and cost during operation.

[0005] Therefore, a new technical solution is needed to solve the above technical problems. Summary of the Invention

[0006] The purpose of the present invention is to provide a manufacturing process for a large-scale pile gripper with a gantry-type walking structure. During the independent segmentation and closing manufacturing process, corresponding construction methods are adopted for different manufacturing stages and different structures, thereby reducing welding deformation. By using a relatively simple method, the stringent requirements for manufacturing conditions are reduced, thereby ensuring the manufacturing accuracy of the large-scale pile gripper with a gantry-type walking structure.

[0007] The technical solution adopted in the present invention is:

[0008] The manufacturing process of the large pile gripper gantry walking includes the following steps: machining, production of independent segments, stage closure production, and large frame closure. The production of independent segments includes the production of shoulder beams, columns, connecting beams, and drive seat frames.

[0009] By adopting the above-mentioned technology, in the process of independent segmentation and assembly, corresponding construction methods are adopted for different production stages and different structures to reduce welding deformation, and the stringent requirements for production conditions are reduced through relatively simple methods.

[0010] Preferably, the machining comprises the following steps: machining the column track beam, the sprocket limiter, the drive seat flange, and machining the sprocket limiter.

[0011] By adopting the above process, some steps that require machining are moved forward during production, avoiding exceeding the limitations of machining equipment due to structural size and weight, and saving a lot of machining costs accumulated in the final construction period.

[0012] Preferably, the shoulder beam production includes the following steps:

[0013] Step 1: Production of group welded parts: Separately make two shoulder beam bottom flanges with a length of 3150mm and a width of 1650mm, and weld them to the columns after machining and waiting for closure. Make four shoulder beam top flanges with a length of 800mm and a width of 800mm, and assemble and weld them after the box beam is formed.

[0014] Step 2: Fabrication of the shoulder beam box girder: Fabricate a 15800mm long and 2900mm wide bottom plate, position the bottom plate, assemble the partition, weld the weld between the partition and the bottom plate, back burn to release stress, then assemble the side plates and top plate in sequence, weld the partition and the side plates, and then weld the weld between the partition and the top plate. After the internal welds are qualified, assemble and weld the end plates of the box and the middle box manhole to control the welding deformation of the box girder;

[0015] Step 3: Assemble the flange seat: After leveling and correcting the box beam, install the top flange of the shoulder beam, and machine the flange plane and connecting bolt holes after welding.

[0016] Preferably, the production of the pillars includes the following steps:

[0017] Step 1: Preparation for column track beam production: Splice 90mm thick plates on the tire frame, check the position of the anchor pin holes, and align with the reference line;

[0018] Step 2: Production of column track beams: After assembly, a long trihedron frame with a small box is formed. First, weld the track beam side plates to the track beam bottom plate, then weld the track beam partitions to the track beam bottom plate, and finally weld the track beam partitions to the track beam side plates. Multiple batches of welding are used to reduce welding deformation.

[0019] Step 3: Production of column box beam: positioning track beam, welding of track beam bottom plate, pyrotechnic correction, assembly of track beam partition and welding of track beam bottom plate, assembly of track beam side plate and welding of track beam partition and track beam bottom plate, assembly of track beam top plate to complete welding.

[0020] Step 4: Installation of the walking sprocket limiter: According to the size of the reference line, locate the sprocket limiter and weld it.

[0021] Preferably, the production of the connecting beam includes: producing a tetrahedral box beam: positioning the connecting beam bottom plate, assembling the connecting beam partition plate, the connecting beam side plate and the connecting beam top plate, and then symmetrically welding and then correcting them with pyrotechnics.

[0022] Preferably, the production of the drive seat frame includes the following steps:

[0023] Step 1: Production of the drive seat box beam frame: Position the bottom plate, assemble the drive seat partition plate, drive seat side plate, drive seat cover top plate, drive seat sealing plate, and perform pyrotechnic correction after symmetrical welding;

[0024] Step 2: Production of the drive seat bracket support: Level the drive seat flange, assemble the partition and side panels, check the horizontal surface of the drive seat flange after welding, and weld the top plate and sealing plate.

[0025] Preferably, the production of the track clamp includes the following steps: side production, assembling the track clamp partition after positioning the bottom plate, using the other side track clamp side plate as the top plate, turning over and welding in all positions, and welding the track clamp cover plate.

[0026] Preferably, the stage closing production includes the following steps:

[0027] Step 1: Closing the walking frame piece: The piece is made by side-by-side method, with the column lying on the tire frame; positioning the column, and then positioning the driving seat frame and connecting beam according to the square size, welding the butt welds between the driving seat frame and the column, welding the butt welds between the column and the connecting beam, trimming the allowance, adjusting the weld gap between the connecting beam and the driving seat frame, and completing the welding;

[0028] Step 2: Pairing and production of track clamps: For track clamps with high precision requirements, pair and fix them, adjust the size of the machined sprocket limit according to the pairing sprocket limit spacing, and weld them after assembly.

[0029] Preferably, closing the large frame includes the following steps:

[0030] Step 1: The overall frame is built, and the overall reference line and the section layout reference line are drawn on the fetal position; the two walking frame sections and the connecting beam are positioned;

[0031] Step 2: Position the shoulder beam bottom flange and the shoulder beam, weld the T-shaped butt joint between the connecting beam and the sheet, and weld the T-shaped butt joint between the shoulder beam bottom flange and the shoulder beam;

[0032] Step 3: Position the paired rail clamps and weld the T-shaped butt joint between the rail clamps and the main frame structure;

[0033] Step 4: Final assembly, assemble with other parts after debugging.

[0034] By adopting the above process, the welding process is reasonably controlled by operating the parts in separate sections and sheets, avoiding the influence of welding heat on welding deformation, reducing the difficulty of controlling the straightness, horizontality and verticality of the structure, and effectively improving the accuracy of equipment manufacturing.

[0035] Preferably, the large pile gripper gantry walking includes a shoulder beam, a column, a connecting beam, a drive seat frame, and a rail clamp. The shoulder beam is arranged across the top of the columns on both sides, and the bottom ends are connected by a connecting beam. The front side of the bottom of the column is connected to the rear end of the drive seat frame, and the front end of the drive seat frame is connected to the column body through a connecting beam 3, and the front ends of the drive seat frames on both sides are connected by a connecting beam. Track clamps are provided under the drive seat frames on both sides, and a sprocket limiter is provided at the bottom of the column, which corresponds to the machined sprocket limiter on the rail clamp. A connecting beam is provided between the column bodies on both sides, and a diagonal brace is provided between the connecting beam at the bottom of the column.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] 1. The present invention adopts both individual segmentation and sheet segmentation methods during production, which makes more reasonable use of existing sites, simpler processes, more convenient welding operations, and higher production operation efficiency.

[0038] 2. When the present invention is manufactured, some steps that require machining are moved forward, avoiding exceeding the limitation range of machining equipment due to structural size and weight, and saving a lot of machining costs accumulated in the final construction period.

[0039] 3. The present invention adopts the method of individual segmentation and sheet segmentation, and the welding process is reasonably controlled, avoiding the influence of welding heat on welding deformation, reducing the difficulty of controlling the straightness, horizontality and verticality of the structure, and effectively improving the accuracy of equipment manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0041] Figure 1 It is a schematic diagram of the structure of the present invention;

[0042] Figure 2 is a side view of the present invention;

[0043] Figure 3 is a schematic diagram of a connecting beam of the present invention;

[0044] Figure 4 This is a front view of the shoulder beam of the present invention;

[0045] Figure 5 This is a front view of the column of the present invention;

[0046] Figure 6 A top view of the column of the present invention;

[0047] Figure 7 is a schematic diagram of the connecting beam;

[0048] Figure 8 Schematic diagram of the drive seat frame;

[0049] Figure 9 It is a top view of the drive seat frame;

[0050] Figure 10 Schematic diagram of the track clamp.

[0051] Among them: 1. Shoulder beam; 2. Column; 3. Connecting beam; 4. Drive seat frame; 5. Track clamp; 6. Shoulder beam box beam; 7. Shoulder beam bottom flange; 8. Shoulder beam top flange; 9. Column track beam; 10. Track beam bottom plate; 11. Track beam partition; 12. Track beam side plate; 13. Track beam top plate; 14. Connecting beam bottom plate; 15. Connecting beam partition; 16. Connecting beam side plate; 17. Connecting beam top plate; 18. Drive seat box beam frame; 19. Drive seat flange corbel support; 20. Track clamp side plate; 21. Track clamp partition; 22. Track clamp cover plate; 23. Sprocket limiter; 24. Drive seat flange; 25. Drive seat side plate; 26. Drive seat partition; 27. Drive seat cover top plate; 28. Drive seat sealing plate; 29. ​​Machined sprocket limiter; 30. Diagonal brace. Implementation Method

[0052] like Figure 1-10 As shown, the manufacturing process of the large pile gripper gantry walking includes the following steps: machining, production of independent segments, stage closure production, and large frame closure. The production of independent segments includes the production of shoulder beams 1, columns 2, connecting beams 3, and drive seat frames 4.

[0053] Machining includes the following steps: machining the column track beam 9, the sprocket limiter 23, the drive seat flange 24, and machining the sprocket limiter 29.

[0054] Shoulder beam 1 Figure 4 As shown, the production includes the following steps:

[0055] Step 1: Production of group welded parts: Separately make two shoulder beam bottom flanges 7 with a length of 3150mm and a width of 1650mm, and weld them to the column 2 after machining and waiting to be closed. Make four shoulder beam top flanges 8 with a length of 800mm and a width of 800mm, and assemble and weld them after the box beam is formed;

[0056] Step 2: Production of the shoulder beam box girder 6: Make a bottom plate with a length of 15800mm and a width of 2900mm, position the bottom plate to assemble the partition, weld the weld between the partition and the bottom plate, back burn to release stress, then assemble the side plates and top plate in sequence, weld the partition and the side plates, and then weld the weld between the partition and the top plate. After the internal welds are qualified, assemble and weld the end plates of the box body at both ends and the middle box body manhole to control the welding deformation of the box girder;

[0057] Step 3: Assemble the flange seat: After leveling and correcting the box beam, install the top flange 8 of the shoulder beam, and machine the flange plane and connecting bolt holes after welding.

[0058] Column 2 Figure 5-6 As shown, the production includes the following steps:

[0059] Step 1: Preparation for the production of column track beam 9: Splice 90mm thick plates on the tire frame, check the position of the anchor pin holes, and align the reference line;

[0060] Step 2: Production of column track beam 9: After assembly, a long trihedron frame with a small box is formed. First, weld the track beam side plate 12 and the track beam bottom plate 10, then weld the track beam partition 11 and the track beam bottom plate 10, and finally weld the track beam partition 11 and the track beam side plate 12. Multiple batches of welding are used to reduce welding deformation;

[0061] Step 3: Production of column box beam: Positioning track beam 9, welding track beam bottom plate 10, pyrotechnic correction, assembling track beam partition 11 and welding it to track beam bottom plate 10, assembling track beam side plate 12 and welding it to track beam partition 11 and track beam bottom plate 10, and assembling track beam top plate 13 to complete welding.

[0062] Step 4: Installation of the walking sprocket limiter 23: Position the sprocket limiter 23 according to the size of the reference line and weld it.

[0063] Connecting beam 3 Figure 7 As shown, the production includes: producing a tetrahedral box girder: positioning the connecting beam bottom plate 14, assembling the connecting beam partition plate 15, the connecting beam side plate 16 and the connecting beam top plate 17, and then symmetrically welding and then correcting with pyrotechnics.

[0064] Drive seat frame 4 Figure 8-9 As shown, the production includes the following steps:

[0065] Step 1: Production of the driving seat box beam frame 18: Positioning the bottom plate, assembling the driving seat partition plate 26, the driving seat side plate 25, the driving seat cover top plate 27, and the driving seat sealing plate 28, symmetrically welding and then pyrotechnic correction;

[0066] Step 2: Production of the drive seat bracket support 19: Level the drive seat flange 24, assemble the partition and side panels, check the horizontal surface of the drive seat flange 24 after welding, and weld the top plate and sealing plate.

[0067] Track clamp 5 Figure 10 As shown, the production includes the following steps: side construction, assembling the track clamp partition plate 21 after positioning the bottom plate, using the other side track clamp side plate 20 as the top plate, turning over and welding in all positions, and welding the track clamp cover plate 22.

[0068] Staged closure production includes the following steps:

[0069] Step 1: Closing the walking frame piece: The piece is made by side-building method, with the column 2 lying on its side on the tire frame; positioning the column 2, and then positioning the driving seat frame 4 and the connecting beam 3 according to the square size, welding the butt welds between the driving seat frame 4 and the column 2, and weld the butt welds between the column 2 and the connecting beam 3, trimming the allowance, adjusting the weld gap between the connecting beam 3 and the driving seat frame 4, and completing the welding;

[0070] Step 2: Pairing and production of track clamps 5: For track clamps 5 with very high precision requirements, pair and fix them, adjust the size of the machined sprocket limiter 29 according to the spacing of the paired sprocket limiter 23, and weld them after assembly.

[0071] The folding of the large frame includes the following steps:

[0072] Step 1: The overall frame is built, and the overall reference line and the section layout reference line are drawn on the fetal position; the two walking frame sections and the connecting beam are positioned;

[0073] Step 2: Position the shoulder beam bottom flange 7 and the shoulder beam 1, weld the T-shaped butt joint between the connecting beam 3 and the sheet body, and weld the T-shaped butt joint between the shoulder beam bottom flange 7 and the shoulder beam 1;

[0074] Step 3: Position the paired rail clamps 5 and weld the T-shaped butt joint between the rail clamps 5 and the main frame structure;

[0075] Step 4: Final assembly, assemble with other parts after debugging.

[0076] The present invention adopts both individual segmentation and sheet segmentation methods during production, which makes more reasonable use of existing sites, has a simpler process, more convenient welding operations, and high production operation efficiency. The welding process is also reasonably controlled, thus avoiding the influence of welding heat on welding deformation, reducing the difficulty of controlling the straightness, horizontality, and verticality of the structure, and effectively improving the precision of equipment manufacturing. During production, some steps that require machining are moved forward, thus avoiding exceeding the limit range of the machining equipment due to structural size and weight, and saving a large amount of machining costs accumulated in the final construction period.

[0077] like Figure 1-10 As shown, the large pile gripper gantry walking includes a shoulder beam 1, a column 2, a connecting beam 3, a drive seat frame 4, and a track clamp 5. The shoulder beam 1 is arranged across the top of the columns 2 on both sides, and the bottom ends are connected by a connecting beam 3. The front side of the bottom of the column 2 is connected to the rear end of the drive seat frame 4, and the front end of the drive seat frame 4 is connected to the column body of the column 2 through the connecting beam 3, and the front ends of the drive seat frames 4 on both sides are connected through the connecting beam 3. Track clamps 5 are provided under the drive seat frames 4 on both sides, and a sprocket limiter 23 is provided at the bottom of the column 2, which corresponds to the machined sprocket limiter 29 on the track clamp 5. A connecting beam 3 is provided between the column bodies of the columns 2 on both sides, and a diagonal brace 30 is provided between the connecting beam 3 at the bottom of the column 2.

[0078] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by those skilled in the art should be included in the scope of protection determined by the claims of the present invention.

Claims

1. The manufacturing process of large pile gripper gantry type walking is characterized by: The following steps are involved: Machining: machining column track beam, sprocket stop, drive seat flange, machining sprocket stop; Production of independent segments: Production of shoulder beams: Step 1: Production of group welded parts: Separately produce two shoulder beam bottom flanges with a length of 3150mm and a width of 1650mm, and weld them to the columns after machining and waiting to be closed. Make four shoulder beam top flanges with a length of 800mm and a width of 800mm, and assemble and weld them after the box beam is formed; Step 2: Production of the shoulder beam box beam: Make a bottom plate with a length of 15800mm and a width of 2900mm, position the bottom plate and assemble the partition, weld the weld between the partition and the bottom plate, back burn to release stress, and then assemble the side plate and top plate in sequence, weld the partition and the side plate, and then weld the weld between the partition and the top plate. After the internal welds are qualified, assemble and weld the end plates of the box at both ends and the middle box manhole to control the welding deformation of the box beam; Step 3: Assemble the flange seat: After leveling and correcting the box beam, install the top flange of the shoulder beam, and machine the flange plane and connecting bolt holes after welding; Production of columns: Step 1: Preparation for the production of column track beams: Splice 90mm thick plates on the tire frame, check the position of the anchor pin holes, and align the reference line; Step 2: Production of column track beams: After assembly, a long trihedron frame with a small box is formed. First, weld the track beam side plates and the track beam bottom plate, then weld the track beam partitions and the track beam bottom plate, and finally weld the track beam partitions and the track beam side plates. Multiple batches of welding can reduce welding deformation; Step 3: Production of column box beams: Position the track beam, weld the track beam bottom plate, correct it with pyrotechnics, assemble the track beam partitions and the track beam bottom plate, assemble the track beam side plates and the track beam partitions and the track beam bottom plate, and assemble the track beam top plate to complete the welding; Step 4: Installation of the walking sprocket limiter: According to the size of the reference line, position the sprocket limiter and weld it; Fabrication of the connecting beam: Fabrication of the tetrahedral box beam: Positioning the connecting beam bottom plate, assembling the connecting beam diaphragm, connecting beam side plate and connecting beam top plate, then symmetrically welding and then pyrotechnic correction; Production of the drive seat frame: Step 1: Production of the drive seat box beam frame: Position the bottom plate, assemble the drive seat partition plate, drive seat side plate, drive seat cover top plate, drive seat sealing plate, and perform pyrotechnic correction after symmetrical welding; Step 2: Production of the drive seat bracket support: Level the drive seat flange, assemble the partition plate and side plate, check the horizontal surface of the drive seat flange after welding, and weld the cover top plate and sealing plate; Staged assembly and production: Step 1: Assemble the walking frame in a single piece: The piece is manufactured using the side-by-side method, with the columns lying on their side on the tire frame; position the columns, then position the drive frame and connecting beam according to the square size, weld the butt welds between the drive frame and the columns, weld the butt welds between the columns and the connecting beam, trim the allowance, adjust the weld gap between the connecting beam and the driving frame, and complete the welding; Step 2: Pairing and production of track clamps: For track clamps with very high precision requirements, pair and fix them, adjust the size of the machined sprocket limit according to the matching sprocket limit spacing, and weld after assembly; The main frame is closed: Step 1: The overall frame is built, and the overall reference line and the reference line of the sheet are drawn on the tire position; the two walking frame sheets and the connecting beam are positioned; Step 2: The bottom flange of the shoulder beam and the shoulder beam are positioned, and the T-shaped butt joint seam between the connecting beam and the sheet body is welded, and the T-shaped butt joint seam between the bottom flange of the shoulder beam and the shoulder beam is welded; Step 3: The paired rail clamps are positioned, and the T-shaped butt joint seam between the rail clamp and the main frame structure is welded; Step 4: Final assembly, and assembly with other components after debugging.

2. The manufacturing process of the large-scale pile gripper gantry travel according to claim 1 is characterized in that: The production of the rail clamp includes the following steps: side production, assembling the rail clamp partition after positioning the bottom plate, using the other side rail clamp side plate as the top plate, turning over and welding in all positions, and welding the rail clamp cover plate.

3. The manufacturing process of the large-scale pile gripper gantry travel according to claim 1 is characterized in that: The large pile gripper gantry walking includes a shoulder beam, a column, a connecting beam, a drive seat frame, and a track clamp. A shoulder beam is arranged across the top of the columns on both sides, and the bottom ends are connected by a connecting beam. The front side of the bottom of the column is connected to the rear end of the drive seat frame, and the front end of the drive seat frame is connected to the column body through a connecting beam, and the front ends of the drive seat frames on both sides are connected by a connecting beam. Track clamps are provided under the drive seat frames on both sides, and a sprocket limiter is provided at the bottom of the column, which corresponds to the machined sprocket limiter on the track clamp. A connecting beam is provided between the column bodies on both sides, and a diagonal brace is provided between the connecting beam at the bottom of the column.

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