A trolley frame manufacturing and assembling process

Abstract

The present application relates to a kind of trolley frame manufacturing and assembling process, comprising the following steps: step 1, trolley frame manufacturing;Step 2, trolley frame splicing;Step 3, track installation and processing;Step 4, trolley wheel plate manufacturing, install wheel;The present application is divided into six components when trolley frame is manufactured, and the manufacturing process is simplified, the manufacturing difficulty is reduced, and the manufacturing efficiency is improved, when the assembly splicing, first splicing crossbeam and intermediate connecting beam, then install component circular arc i-beam and contact beam, then end beam splicing is carried out, finally track installation and wheel installation are carried out, splicing process is simple, splicing efficiency is high, and in the splicing process, with splicing center line as reference line, by accurately controlling each processing allowance, and each size retest correction, effectively improve the trolley frame machining precision.

Description

Technical Field

[0001] This invention relates to the field of rail-mounted crane manufacturing technology, and in particular to a process for manufacturing and assembling a trolley frame. Background Technology

[0002] Rail-mounted gantry cranes, also known as rail-mounted cranes, are primarily used for loading and unloading containers in container yards. For example... Figure 1 , Figure 2 As shown, the trolley has a split upper and lower structure. The upper structure, called the rotary trolley 1, operates in a rotary mode, while the lower structure, called the main trolley, operates in a linear reciprocating motion. The track 3 of the rotary trolley is welded and installed on the trolley frame 2 of the main trolley. The rotary trolley 1 rotates by contacting the rotary track with its four wheels. Under the combined action of the rotary trolley's own weight and the weight of the suspended object, the contact surface between the wheels and the track is not horizontal, but at a certain angle. Therefore, the track needs to be mechanically machined with a certain slope according to the track's inclination angle. To ensure the accuracy of the track slope machining, higher requirements are placed on the accuracy of the trolley frame. Currently, the trolley frame machining process often results in excessive cumulative errors from the manufacturing and assembly of the trolley frame, leading to substandard accuracy, resulting in more correction work and lower production efficiency.

[0003] Therefore, this invention proposes a small frame manufacturing and assembly process to solve the above problems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a small car frame manufacturing and assembly process to improve the manufacturing and assembly accuracy of the small car frame and improve the production efficiency of the small car frame.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a small vehicle frame manufacturing and assembly process, the innovation of which is: including the following steps: Step 1: Fabrication of the trolley frame; Divide the trolley frame into six components and fabricate them separately. The six components are I, II, III, IV, V, and VI. I and II correspond to the two crossbeams of the trolley frame, III and IV correspond to the two end beams of the trolley frame, and V and VI correspond to the two intermediate connecting beams of the trolley frame. When fabricating each of the six components, allowance must be reserved for camber and allowance for welding shrinkage. Step 2: Assemble the small car frame; Step 2.1: Before splicing, measure the straightness, camber, and lateral curvature of each component to see if they are within the tolerance requirements. If they exceed the tolerance, they need to be corrected. Step 2.2: Before assembly, build a horizontal jig. First, place the V and VI boxes on the horizontal jig and mark the lines to ensure that the V and VI boxes are aligned. Then, place the I and II boxes in place according to the opening size. Use a laser to mark the assembly center line and longitudinal center line of I and II to ensure that the stiffeners of I and II are aligned. After measuring the opening and diagonal dimensions of I and II, mark the trimming allowance of the V and VI boxes and spot weld them in place. Step 2.3: Position and weld the arc-shaped I-beam and connecting beam. The arc-shaped I-beams are spliced ​​to form the rail support beam. Ensure the roundness of the inner circle and the position and dimensions of the web of the rail support beam. Weld the components symmetrically according to the blueprint requirements. After the components are made, they are corrected and the dimensions are re-measured to meet the requirements before proceeding to the next assembly process. Step 2.4: Using the assembly center line as a reference, place components III and IV in place, ensuring the symmetry, spacing, and diagonal dimensions of III and IV relative to the assembly center line. Mark and trim the excess at the joint, and ensure that the ribs are aligned and then welded. Then mark and spot weld the H-beam connecting beams, and perform symmetrical welding according to the drawing requirements. Finally, install and weld the other components of the trolley frame and the prefabricated components. Step 3: Track installation and fabrication; Step 4: Make the wheel plates for the car and install the wheels.

[0006] Furthermore, the jig used in the manufacturing process of the trolley frame in step 1 needs to be pre-cambered.

[0007] Furthermore, in step 1, a 28mm camber allowance is reserved when manufacturing components I and II, and an 8mm camber allowance is reserved when manufacturing components III, IV, V, and VI. The 200mm range at the end of the box of components I, II, V, and VI will not be welded temporarily, but will be welded when the trolley frame structure is assembled.

[0008] Furthermore, during the welding process in step 2.4, it is necessary to ensure that the surface flatness of the rail beam is ≤5mm.

[0009] Furthermore, the detailed steps for track installation and processing in step 3 are as follows: Step 3.1: Cut the slewing support track component and leave machining allowance in the circumferential inner diameter direction; Step 3.2: Leave machining allowance in the height direction for the rotary trolley track components and cut them into sections; Step 3.3: Mark the overall lines and locate the track position to ensure that the center line of the slewing trolley track component is aligned with the web reinforcement of the rail beam, as well as the circumferential dimensions of the slewing trolley track component; Step 3.4: Weld the slewing trolley track components to ensure the perpendicularity of the slewing trolley track components to the upper surface of the support beam; Step 3.5: Machining the allowance in the height direction of the rotary trolley track component, and machining the rounded corners; Step 3.6: Quench the rotary trolley track components as required; Step 3.7: Machining allowance in the inner diameter direction of the slewing support track component to ensure the roundness of the slewing support track component, and machining fillet transition.

[0010] Furthermore, in step 3.1, the rotary support track component has a machining allowance of 10mm in the circumferential inner diameter direction, and in step 3.7, the fillet transition dimension is ≤R5mm.

[0011] Furthermore, in step 3.2, the rotary trolley track component has a 10mm machining allowance in the height direction and is cut into four sections. In step 3.5, the fillet transition dimension is R5mm.

[0012] Furthermore, the detailed steps of step 4 are as follows: Step 4.1: CNC layout of the trolley wheel plate, with allowances for both inner diameter and thickness. After milling the edges of the trolley wheel plates symmetrically in pairs, weld them to the trolley frame structure and then weld the process plate to the trolley wheel plate. Step 4.2: After the overall marking of the trolley wheel plate is completed, bore the holes and scrape the outer surface. After the machining is completed, cut off the process plate and grind the excess material on the cut surface of the trolley wheel plate to make the surface smooth. Step 4.3: When installing the wheels, drill threaded holes on the trolley wheel plate according to the corresponding position of the eccentric sleeve.

[0013] Furthermore, in step 4.1, the inner diameter of the car wheel plate is left with a margin of 30mm, and the thickness of the car wheel plate is left with a margin of 9mm, of which a margin of 2mm is left on the inner side and a margin of 7mm is left on the outer side.

[0014] The advantages of this invention are: This invention divides the trolley frame into six components for separate manufacturing, simplifying the process, reducing manufacturing difficulty, and improving efficiency. During component assembly, the crossbeams and intermediate connecting beams are assembled first, followed by the installation of the arc-shaped I-beams and connecting beams. Then, the end beams are assembled, and finally, the tracks and wheels are installed. This simple assembly process is highly efficient. Furthermore, by using the assembly centerline as a baseline and precisely controlling the machining allowances and re-measuring and correcting each dimension, the machining accuracy of the trolley frame is effectively improved. 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 the front view of the vehicle in this invention.

[0017] Figure 2 This is a top view of the vehicle of the present invention.

[0018] Figure 3 This is a schematic diagram of the six components of the frame of the present invention.

[0019] Figure 4 This is a structural diagram of the assembly of components I, II, V, and VI of the present invention.

[0020] Figure 5 This is a structural schematic diagram of the arc-shaped I-beam and the connecting beam of the welded components of this invention.

[0021] Figure 6 This is a cross-sectional view of the circular arc I-beam in the OO direction of the present invention.

[0022] Figure 7 This is a schematic diagram of the assembly components III and IV of the present invention.

[0023] Figure 8 This is a schematic diagram of the track installation structure of the present invention.

[0024] Figure 9 This is a cross-sectional view of the track in the AA direction of the present invention.

[0025] Figure 10 This is an enlarged view of point B in the present invention.

[0026] Figure 11 This is a schematic diagram of the structure of the wheel plate of the car according to the present invention.

[0027] Figure 12 This is a schematic diagram of the trolley wheel plate and process plate of the present invention mounted on the trolley frame. Detailed Implementation

[0028] The following embodiments are intended to enable those skilled in the art to more fully understand the present invention, but do not limit the invention to the scope of the embodiments described.

[0029] The present invention provides a small vehicle frame manufacturing and assembly process, comprising the following steps: Step 1: Making the frame; Divide the frame into six components and make them separately, such as... Figure 3As shown, the six components are I, II, III, IV, V, and VI. I and II correspond to the two crossbeams of the trolley frame, III and IV correspond to the two end beams of the trolley frame, and V and VI correspond to the two intermediate connecting beams of the trolley frame. All six components must be manufactured with a camber allowance and a welding shrinkage allowance. Specifically, components I and II are manufactured with a 28mm camber allowance, and components III, IV, V, and VI are manufactured with an 8mm camber allowance. The 200mm range at the end of the box of components I, II, V, and VI will not be welded until the trolley frame structure is assembled. In addition, the jig used during the manufacture of the trolley frame must be pre-cambered to improve the load-bearing capacity of the trolley frame and reduce the downward deformation of the trolley frame under load.

[0030] Step 2: Assemble the small car frame; Step 2.1: Before splicing, measure the straightness, camber, and lateral curvature of each component to see if they are within the tolerance requirements. If they exceed the tolerance, they need to be corrected. Step 2.2: Before assembly, construct a horizontal jig. First, place components V and VI on the horizontal jig, marking lines to ensure alignment. Then, place components I and II according to the opening dimensions. Use a laser to mark the assembly center line and longitudinal center line of I and II, ensuring the stiffeners of I and II are aligned. After measuring the opening and diagonal dimensions of I and II, mark the trimming allowance for components V and VI, and spot weld them in place. Figure 4 As shown; Step 2.3: Position and weld the arc-shaped I-beam 49 and the connecting beam. The arc-shaped I-beam 49 are spliced ​​together to form the rail support beam, as shown below. Figure 5 As shown, to ensure the roundness of the inner circle of the rail beam and the position and dimensions of the web, the components should be welded symmetrically according to the blueprint requirements. After the components are made, they should be corrected and the dimensions should be re-measured to meet the requirements before proceeding to the next assembly process. Step 2.4: Using the assembly centerline as a reference, place components III and IV in place, ensuring the symmetry, spacing, and diagonal dimensions of III and IV relative to the assembly centerline. Mark and trim the excess material at the joints, ensuring proper alignment and welding after rigging. Then, mark and spot weld the H-beam connecting beams, performing symmetrical welding according to the drawings. Figure 7 As shown, ensure the flatness of the rail beam surface is ≤5mm; finally, weld the other components of the trolley frame and prefabricated components.

[0031] Step 3: Track installation and fabrication; Step 3.1: Cut the rotary support track component 35 into blanks and leave a 10mm machining allowance in the inner diameter direction of the circumference; Step 3.2: Leave a 10mm machining allowance in the height direction for the rotary trolley track component 19, cut it into four sections, and place the joints at 0°, 90°, 180° and 270° of the circumference. Step 3.3: Mark the overall lines and locate the track position to ensure that the center line of the rotary trolley track component 19 is aligned with the web reinforcement of the rail beam, as well as the circumferential dimensions of the rotary trolley track component 19. Step 3.4: Weld the rotary trolley track component 19 to ensure the perpendicularity of the rotary trolley track component 19 to the upper surface of the support beam; Step 3.5: Machining the allowance in the height direction of the rotary trolley track component 19, and machining a 5mm radius fillet transition; Step 3.6: Perform quenching treatment on the rotary trolley track component 19 as required; Step 3.7: Machining allowance in the inner diameter direction of the slewing support track component to ensure the roundness of the slewing support track component, machining fillet transition, the fillet transition dimension ≤R5mm.

[0032] Step 4: Make the wheel plates for the car and install the wheels; Step 4.1, as follows Figure 11 As shown, the trolley wheel plate 6 is CNC-layouted, with allowances for both the inner diameter and thickness. The inner diameter of the trolley wheel plate 6 has a 30mm allowance, and the thickness has a 9mm allowance, with 2mm on the inner side and 7mm on the outer side. After symmetrical milling of both sides, the trolley wheel plates are welded to the trolley frame structure, and the process plate 8 is electrically welded and fixed to the trolley wheel plate 6. Figure 12 As shown; Step 4.2: After the overall marking of the trolley wheel plate 6 is completed, the hole is bored and the outer surface is scraped. The process plate can effectively reduce the deformation of the trolley wheel plate during boring and improve the machining accuracy. After the machining is completed, the process plate 8 is cut off and the excess on the cut surface of the trolley wheel plate 6 is ground to a smooth surface. Step 4.3: When installing the wheels, drill the threaded holes 9 on the trolley wheel plate according to the corresponding position of the eccentric sleeve.

[0033] This invention divides the trolley frame into six components for separate manufacturing, simplifying the process, reducing manufacturing difficulty, and improving efficiency. During component assembly, the crossbeams and intermediate connecting beams are assembled first, followed by the installation of the arc-shaped I-beams and connecting beams. Then, the end beams are assembled, and finally, the tracks and wheels are installed. This simple assembly process is highly efficient. Furthermore, by using the assembly centerline as a baseline and precisely controlling the machining allowances and re-measuring and correcting each dimension, the machining accuracy of the trolley frame is effectively improved.

[0034] 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 manufacturing and assembling a small vehicle frame, characterized in that: Includes the following steps: Step 1: Fabrication of the trolley frame; Divide the trolley frame into six components and fabricate them separately. The six components are I, II, III, IV, V, and VI. I and II correspond to the two crossbeams of the trolley frame, III and IV correspond to the two end beams of the trolley frame, and V and VI correspond to the two intermediate connecting beams of the trolley frame. When fabricating each of the six components, allowance must be reserved for camber and allowance for welding shrinkage. The jig used in the manufacturing process of the small car frame needs to be pre-cambered; When manufacturing components I and II, a 28mm camber allowance is reserved. When manufacturing components III, IV, V, and VI, an 8mm camber allowance is reserved. Welding will not be performed on the 200mm range at the end of the box of components I, II, V, and VI until the trolley frame structure is assembled. Step 2: Assemble the small car frame; Step 2.1: Before splicing, measure the straightness, camber, and lateral curvature of each component to see if they are within the tolerance requirements. If they exceed the tolerance, they need to be corrected. Step 2.2: Before assembly, build a horizontal jig. First, place the V and VI boxes on the horizontal jig and mark the lines to ensure that the V and VI boxes are aligned. Then, place the I and II boxes in place according to the opening size. Use a laser to mark the assembly center line and longitudinal center line of I and II to ensure that the stiffeners of I and II are aligned. After measuring the opening and diagonal dimensions of I and II, mark the trimming allowance of the V and VI boxes and spot weld them in place. Step 2.3: Position and weld the arc-shaped I-beam and H-beam connecting beam. The arc-shaped I-beams are spliced ​​to form the rail support beam. Ensure the roundness of the inner circle and the position and dimensions of the web of the rail support beam. Weld the components symmetrically according to the blueprint requirements. After the components are made, they are corrected and the dimensions are re-measured to meet the requirements before proceeding to the next assembly process. Step 2.4: Using the assembly centerline as a reference, place components III and IV in place, ensuring the symmetry, spacing, and diagonal dimensions of III and IV relative to the assembly centerline. Mark and trim the excess material at the joints, and ensure that the ribs are aligned and then welded in place. Next, mark and spot weld the H-beam connecting beams, and perform symmetrical welding according to the drawings. Finally, install and weld the other components of the trolley frame and the prefabricated components. During the welding process, ensure that the surface flatness of the rail beam is ≤5mm. Step 3: Track installation and fabrication; Step 4: Make the wheel slabs for the toy car and install the wheels; detailed steps are as follows: Step 4.1: CNC layout of the trolley wheel plate. The inner diameter of the trolley wheel plate is left with a 30mm allowance, and the thickness of the trolley wheel plate is left with a 9mm allowance, of which the inner side of the thickness is left with a 2mm allowance and the outer side of the thickness is left with a 7mm allowance. After the trolley wheel plates are milled symmetrically in pairs, they are welded to the trolley frame structure, and the process plate is electric welded to the trolley wheel plate. Step 4.2: After the overall marking of the trolley wheel plate is completed, bore the holes and scrape the outer surface. After the machining is completed, cut off the process plate and grind the excess material on the cut surface of the trolley wheel plate to make the surface smooth. Step 4.3: When installing the wheels, drill threaded holes on the trolley wheel plate according to the corresponding position of the eccentric sleeve.

2. The manufacturing and assembly process of the trolley frame according to claim 1, characterized in that: The detailed steps for track installation and processing in step 3 are as follows: Step 3.1: Cut the slewing support track component and leave machining allowance in the circumferential inner diameter direction; Step 3.2: Leave machining allowance in the height direction for the rotary trolley track components and cut them into sections; Step 3.3: Mark the overall lines and locate the track position to ensure that the center line of the slewing trolley track component is aligned with the web reinforcement of the rail beam, as well as the circumferential dimensions of the slewing trolley track component; Step 3.4: Weld the slewing trolley track components to ensure the perpendicularity of the slewing trolley track components to the upper surface of the support beam; Step 3.5: Machining the allowance in the height direction of the rotary trolley track components, and machining the rounded corners; Step 3.6: Quench the rotary trolley track components as required; Step 3.7: Machining allowance in the inner diameter direction of the slewing support track component to ensure the roundness of the slewing support track component, and machining fillet transition.

3. The manufacturing and assembly process of the trolley frame according to claim 2, characterized in that: In step 3.1, the rotary support track component has a machining allowance of 10mm in the circumferential inner diameter direction, and in step 3.7, the fillet transition dimension is ≤R5mm.

4. The manufacturing and assembly process of the trolley frame according to claim 2, characterized in that: In step 3.2, the rotary trolley track component has a 10mm machining allowance in the height direction and is cut into four sections. In step 3.5, the fillet transition dimension is R5mm.

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