A method for installing anti-roller rollers on a roller crane

Abstract

This invention relates to a method for installing a reverse roller on a roller crane. The roller crane includes a reverse roller structure and, arranged on one side of the reverse roller structure and distributed from top to bottom, a forward roller, a forward roller track, a slewing lower support, a pressure plate, an upper reverse roller track, a reverse roller, a lower reverse roller track, and a support beam. The side of the slewing lower support near the upper reverse roller track is the upper support surface, and the side of the support beam near the lower reverse roller track is the lower support surface. The installation of the reverse roller includes the following steps: machining the upper and lower support surfaces; machining the lower support surfaces; installing the upper and lower reverse roller tracks; installing the reverse roller; and installing the reverse roller components. The advantage of this invention is that, through marking and positioning during the manufacturing stage, the installation accuracy of each individual step is improved, thereby improving the overall installation accuracy of the reverse roller and ensuring the high precision requirements of the installed reverse roller.

Description

Technical Field

[0001] This invention relates to the field of cranes, and in particular to a method for installing anti-roller rollers on a roller crane. Background Technology

[0002] As the lifting capacity of floating cranes increases, the size of domestically produced bearings can no longer meet their requirements. A reverse roller device was designed and developed to replace the bearings. The reverse rollers bear all the load of the crane and perform the rotational motion. The reverse roller assembly mainly consists of: the reverse roller, the reverse roller structure, the lower track of the reverse roller, and the rope-pressing plate.

[0003] Currently, the installation of the anti-roller is extremely difficult because it hangs upside down on the reverse side of the structure, making flatness control particularly critical. This is mainly reflected in the following points: First, the track is installed on the reverse bottom of the structure, requiring high precision in machining the flatness of the reverse bottom structure; second, the anti-roller assembly must meet roundness requirements; and third, the contact surface between the anti-roller structure and the track during installation requires high precision. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for installing the anti-roller of a roller crane with high installation accuracy.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: a method for installing a reverse roller on a roller crane, the roller crane including a reverse roller structure and a forward roller, a forward roller track, a slewing lower support, a pressure plate, an upper reverse roller track, a reverse roller, a lower reverse roller track, and a support beam arranged sequentially from top to bottom on one side of the reverse roller structure. The side of the slewing lower support near the upper reverse roller track is the upper support surface, and the side of the support beam near the lower reverse roller track is the lower support surface. The innovation lies in that the reverse roller installation method includes the following steps:

[0006] S1: Upper bearing rail surface scribing and machining: First, after the overall structure of the slewing lower support is completed, scribing is performed on the upper rail surface of the reverse roller using the positive roller rail surface as a reference, and elevation data is obtained according to the overall structural dimensions. The machining allowance of the upper bearing rail surface of the slewing lower support is calculated based on the measurement data and theoretical data, and then machining is performed, with the machining allowance added in advance.

[0007] S2: Marking and machining of the lower bearing rail surface: First, the anti-roller structure is made in sections. After the anti-roller structure is made as a whole, it is pre-assembled in the workshop. Then, the center line of the anti-roller lower rail and the machining allowance of the lower bearing rail surface are measured, marked, and machined, and the machining allowance is added in advance.

[0008] S3: Installation of the upper track of the anti-roller: Make special tooling and platform required for the installation of the upper track of the anti-roller, install the upper track of the anti-roller onto the upper bearing rail surface, and ensure that the contact area between the upper track of the anti-roller and the lower support of the slewing is not less than 85%.

[0009] S4: Installation of the lower track of the anti-roller: Install the lower track of the anti-roller onto the lower bearing rail surface, and ensure that the contact area between the lower track of the anti-roller and the bearing rail beam is not less than 85%.

[0010] S5: Anti-roller installation: Make special tooling and platform required for anti-roller installation, and install the anti-roller between the upper and lower tracks of the anti-roller;

[0011] S6: Installation of anti-roller components: Fabricate special tooling and platform required for the installation of the anti-roller structure, install the anti-roller structure in place, and complete the overall installation of the anti-roller.

[0012] Furthermore, in step S1, after the upper bearing rail surface is scribing and processed, the height difference between the upper rail plane of the reverse roller and the upper rail plane shall not exceed 1 / 1000 of the circumference of the reverse roller, i.e., 1mm / 1m. The maximum height difference of the upper rail of the reverse roller shall not exceed 3mm, and the distance between the upper rail of the positive roller and the upper rail of the reverse roller shall be controlled to be D3±0.5mm.

[0013] Furthermore, in step S2, after the lower bearing rail surface is scribing, the height difference of the lower rail plane of the anti-roller shall not exceed 1 / 1000 of the circumference of the anti-roller, i.e., 1mm / 1m, and the maximum height difference of the entire circumference of the lower rail of the anti-roller shall not exceed 3mm.

[0014] Furthermore, in step S3, the special tooling and platform required for installing the upper track of the anti-roller include a first platform for placing the upper track of the anti-roller, jacks for driving the upper track of the anti-roller up and down, and a gantry for hoisting the upper track of the anti-roller. During the installation of the upper track of the anti-roller, the upper track of the anti-roller is first hoisted onto the first platform. The jacks are then used to push the upper track of the anti-roller into place below the upper track mounting surface. After checking that the arc dimension of the upper track of the anti-roller is qualified, the gantry and jacks are used to press the upper track of the anti-roller onto the upper track mounting surface for installation. When installing the pressure plate, the contact surfaces of the pressure plate and the upper rail of the anti-roller must be matched and machined on-site according to the site conditions to ensure that there are no gaps when the pressure plate is installed. After the arrangement, the gap between two adjacent upper rails of the anti-roller should not be greater than 0.5mm, and the height difference between two adjacent upper rails of the anti-roller should not be greater than 0.5mm. The gap of the pressure plate should be rust-proofed. When arranging the upper rails of the anti-roller, it is necessary to ensure that they are flat and tight, the end faces at the joints are aligned, the diameter tolerance should be within ±3mm, the radius tolerance should be within ±2mm, and the center of all upper rails of the anti-roller should be concentric with the center bearing.

[0015] Furthermore, in step S4, after the upper surface of the bearing beam is machined, an installation inspection line for the anti-roller lower track with a radius from the center crosshair is marked on the upper surface. After the dimensions of the marked line are verified by precision control, the mark is made with a punch. The inspection line with the radius marked on the upper surface of the bearing beam is the installation center line of the anti-roller lower track. After installation, the gap between two adjacent anti-roller lower tracks is no more than 0.5mm, and the height difference between two adjacent anti-roller lower tracks is no more than 0.5mm. When installing the tracks, it is necessary to ensure that they are flat and tight, the end faces at the joints are aligned, the diameter tolerance is within ±3mm, the radius tolerance is within ±2mm, and the center of all anti-roller lower tracks should be concentric with the center bearing.

[0016] Furthermore, in step S5, the special tooling and platform required for installing the anti-roller includes 2-3 sets of mobile jigs, with slide rails arranged on the mobile jigs. The anti-roller is placed on the mobile jigs, and lifting lugs are arranged inside the structure of the crane. A hand-operated hoist is used to pull the anti-roller between the upper and lower tracks of the anti-roller.

[0017] Furthermore, in step S6, the special tooling and platform required for installing the anti-roller structure include a process support and a manual hoist. The process support is used to position the anti-roller structure, and then lifting lugs are set on the anti-roller structure and the slewing lower support. The manual hoist is used to pull the lifting lugs to achieve fine-tuning and positioning of the anti-roller structure.

[0018] The advantages of this invention are as follows: The anti-roller installation method of this invention is realized by the following steps: upper bearing rail surface marking machine processing, lower bearing rail surface marking machine processing, anti-roller upper rail installation, anti-roller lower rail installation, anti-roller installation, and anti-roller component installation. In each step, the installation accuracy of the individual step is improved by marking and positioning during the manufacturing stage, which in turn improves the overall installation accuracy of the anti-roller and ensures the high accuracy requirements of the installed anti-roller. Attached Figure Description

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0020] Figure 1 This is a schematic diagram of the roller crane in this invention.

[0021] Figure 2 This is a schematic diagram of the machining and scribing of the upper bearing rail surface in this invention.

[0022] Figure 3 This is a schematic diagram of the machining and scribing of the lower bearing rail surface in this invention.

[0023] Figure 4 This is a schematic diagram of the installation of the anti-roller on the track in this invention.

[0024] Figure 5 This is a schematic diagram of the installation of the anti-roller in this invention.

[0025] Figure 6 This is a schematic diagram of the installation of the anti-roller structure in this invention. Detailed Implementation

[0026] 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.

[0027] like Figure 1 The roller crane shown includes a reverse roller structure 7 and a forward roller 1, a forward roller track 2, a slewing lower support 3, a pressure plate 5, a reverse roller upper track 6, a reverse roller 8, a reverse roller lower track 9, and a rail support beam 10 arranged on one side of the reverse roller structure 7 and distributed from top to bottom. The side of the slewing lower support 3 near the reverse roller upper track 6 is the upper rail support surface 4, and the side of the rail support beam 10 near the reverse roller lower track 9 is the lower rail support surface.

[0028] The roller crane anti-roller installation method of the present invention is achieved through the following steps:

[0029] S1: Upper bearing rail surface scribing machine processing: such as Figure 2 As shown, firstly, after the overall structure of the lower rotating support 3 is manufactured, the track surface of the upper track 6 of the reverse roller is marked with the track surface of the positive roller track 2 as a reference, and the elevation data is obtained according to the overall structural dimensions. The machining allowance of the upper bearing track surface 4 of the lower rotating support 3 is calculated based on the measurement data and theoretical data, and then machined, with the machining allowance added in advance.

[0030] After the upper bearing rail surface 4 is scribing and machining, the height difference between the plane of the upper track 6 of the reverse roller shall not exceed 1 / 1000 of the circumference of the reverse roller, i.e., 1mm / 1m. The maximum height difference of the upper track of the reverse roller shall not exceed 3mm. The distance between the upper track of the forward roller 2 and the upper track of the reverse roller 6 shall be controlled to be D3±0.5mm. D3 represents the theoretical distance between the upper track of the forward roller 2 and the upper track of the reverse roller 6, while ±0.5mm represents the allowable error value based on the theoretical distance.

[0031] S2: Marking and machining of the lower bearing rail surface: First, the anti-roller structure 7 is manufactured in sections. After the anti-roller structure 7 is fully manufactured, it is pre-assembled in the workshop. Then, based on the center line of the anti-roller lower rail 9 and the machining allowance of the lower bearing rail surface of the bearing beam 10, the marking is performed and machined, with machining allowance added in advance, such as... Figure 3 As shown.

[0032] After the lower bearing rail surface is scribing and machining, the height difference of the plane of the lower track 9 of the anti-roller shall not exceed 1 / 1000 of the circumference of the anti-roller 8, that is, 1mm / 1m, and the maximum height difference of the entire circle of the lower track 9 of the anti-roller shall not exceed 3mm.

[0033] S3: Installation of the upper track of the anti-roller: Make special tooling and platform required for the installation of the upper track of the anti-roller 6, install the upper track of the anti-roller 6 onto the upper bearing rail surface, and ensure that the contact area between the upper track of the anti-roller 6 and the lower slewing support 3 is not less than 85%.

[0034] The special tooling and platform required for the installation of the upper track 6 of the anti-roller includes a first platform 61 for placing the upper track 6 of the anti-roller, a jack 62 for driving the upper track 6 of the anti-roller up and down, and a gantry for hoisting the upper track 6 of the anti-roller. The jack 62 is installed on the first platform 61. When installing the upper track 6 of the anti-roller, the upper track 6 of the anti-roller is first hoisted onto the first platform, and then the upper track 6 of the anti-roller is pushed to the jack 62. The jack 62 is used to push the upper track 6 of the anti-roller into the lower track mounting surface. After checking that the arc dimension of the upper track of the anti-roller is qualified, the upper track 6 of the anti-roller is pressed tightly onto the upper track mounting surface of the anti-roller with the help of the gantry and the jack 62 for assembly.

[0035] When installing the upper track 6 of the anti-roller, the pressure plate 5 should be installed simultaneously. When installing the pressure plate 5, the mating surfaces of the pressure plate 5, the upper track 6 of the anti-roller, and the track surface of the anti-roller need to be matched and machined on-site according to the site conditions to ensure that there are no gaps when the pressure plate 5 is installed. After the arrangement, the gap between two adjacent upper tracks 6 of the anti-roller should not be greater than 0.5mm, and the height difference between two adjacent upper tracks 6 of the anti-roller should not be greater than 0.5mm. The gap of the pressure plate 5 needs to be rust-proofed. When arranging the upper tracks 6 of the anti-roller, it is necessary to ensure that they are flat and tight. The end faces of the joints of the upper tracks 6 of the anti-roller should be aligned, the diameter tolerance should be within ±3mm, and the radius tolerance should be within ±2mm. The center of all upper tracks 6 of the anti-roller should be concentric with the center bearing, which is the center bearing of the anti-roller 8.

[0036] S4: Installation of the lower anti-roller rail: Install the lower anti-roller rail 9 onto the lower bearing surface of the bearing beam 10, and ensure that the contact area between the lower anti-roller rail 9 and the bearing beam 10 is not less than 85%.

[0037] After the upper surface of the support beam 10 is machined, the installation inspection line of the anti-roll lower track 9 with a radius from the center cross line is marked on the upper surface of the support beam 10. After the dimensions of the marked line are verified by precision control, the mark is made with a punch. The inspection line with the radius marked on the upper surface of the support beam 10 is the installation center line of the anti-roll lower track 9. After installation, the gap between two adjacent anti-roll lower tracks 9 is not greater than 0.5mm, and the height difference between two adjacent anti-roll lower tracks 9 is not greater than 0.5mm. When installing the tracks, it is necessary to ensure that the anti-roll lower tracks 9 are flat and tight, the end faces at the joints are aligned, the diameter tolerance is within ±3mm, and the radius tolerance is within ±2mm. The center of all anti-roll lower tracks 9 should be concentric with the center bearing, which is the center bearing of the anti-roller 8.

[0038] S5: Reverse Roller Installation: Make special tooling and platform required for the installation of reverse roller 8, and install reverse roller 8 between the upper track 6 and the lower track 8 of reverse roller.

[0039] like Figure 5 As shown, the special tooling and platform required for installing the anti-roller include 2-3 sets of mobile jigs 81 and manual hoists 82. Slide rails are arranged on the mobile jigs 81. The anti-roller 8 is placed on the mobile jigs 81. Lifting lugs 83 are arranged inside the structure of the crane. One side of the manual hoist 82 is connected to the lifting lug 83, and the other side of the manual hoist 82 is connected to the anti-roller 8. The manual hoist 82 is used to pull the anti-roller 8 between the upper anti-roller rail 6 and the lower anti-roller rail 9.

[0040] S6: Installation of anti-roller components: Fabricate special tooling and platform required for the installation of anti-roller structure 7, install anti-roller structure 7 in place, and complete the overall installation of the anti-roller.

[0041] The special tooling and platform required for the installation of the anti-roller structure 7 include a process support 71 and a manual hoist 72. The process support 71 is used to position the anti-roller structure 7 and the slewing lower support 3. Then, lifting lugs 73 are installed on the anti-roller structure 7 and the slewing lower support 3. One side of the manual hoist 72 is adjacent to the lifting lug 73, and the other side of the manual hoist 72 is connected to the anti-roller structure 7. The lifting lug 73 is pulled by the hand hoist 81 to achieve fine-tuning and positioning of the anti-roller structure 7. After the anti-roller structure 7 is assembled in place, sleepers 74 are added to the bottom surface of the anti-roller structure 7 for stabilization.

[0042] The anti-roller installation method of the present invention is realized by the following steps: upper bearing rail surface marking machine processing, lower bearing rail surface marking machine processing, anti-roller upper rail installation, anti-roller lower rail installation, anti-roller installation, and anti-roller component installation. In each step, the installation accuracy of the individual step is improved by marking and positioning during the manufacturing stage, which in turn improves the overall installation accuracy of the anti-roller and ensures the high accuracy requirements of the installed anti-roller.

[0043] 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 method for installing a reverse roller on a roller crane, the roller crane comprising a reverse roller structure and, arranged on one side of the reverse roller structure and sequentially distributed from top to bottom, a forward roller, a forward roller track, a slewing lower support, a pressure plate, an upper reverse roller track, a reverse roller, a lower reverse roller track, and a support beam, wherein the side of the slewing lower support near the upper reverse roller track is the upper support surface, and the side of the support beam near the lower reverse roller track is the lower support surface, characterized in that: The method for installing the anti-roller includes the following steps. S1: Upper bearing rail surface scribing and machining: First, after the overall structure of the slewing lower support is completed, scribing is performed on the upper rail surface of the reverse roller using the positive roller rail surface as a reference, and elevation data is obtained according to the overall structural dimensions. The machining allowance of the upper bearing rail surface of the slewing lower support is calculated based on the measurement data and theoretical data, and then machining is performed, with the machining allowance added in advance. S2: Marking and machining of the lower bearing rail surface: First, the anti-roller structure is made in sections. After the anti-roller structure is made as a whole, it is pre-assembled in the workshop. Then, the center line of the anti-roller lower rail and the machining allowance of the lower bearing rail surface are measured, marked, and machined, and the machining allowance is added in advance. S3: Installation of the upper track of the anti-roller: Make special tooling and platform required for the installation of the upper track of the anti-roller, install the upper track of the anti-roller onto the upper bearing rail surface, and ensure that the contact area between the upper track of the anti-roller and the lower support of the slewing is not less than 85%. S4: Installation of the lower track of the anti-roller: Install the lower track of the anti-roller onto the lower bearing rail surface, and ensure that the contact area between the lower track of the anti-roller and the bearing rail beam is not less than 85%. S5: Anti-roller installation: Make special tooling and platform required for anti-roller installation, and install the anti-roller between the upper and lower tracks of the anti-roller; S6: Installation of anti-roller components: Fabricate special tooling and platform required for the installation of the anti-roller structure, install the anti-roller structure in place, and complete the overall installation of the anti-roller.

2. The method for installing the anti-roller of a roller crane according to claim 1, characterized in that: In step S1, after the upper bearing rail surface is scribing, the height difference between the upper rail plane and the upper rail plane of the reverse roller shall not exceed 1 / 1000 of the circumference of the reverse roller, i.e., 1mm / 1m. The maximum height difference of the upper rail of the reverse roller shall not exceed 3mm, and the distance between the upper rail of the positive roller and the upper rail of the reverse roller shall be controlled to be D3±0.5mm.

3. The method for installing the anti-roller of a roller crane according to claim 1, characterized in that: In step S2, after the lower bearing rail surface is scribing, the height difference of the lower rail plane of the anti-roller shall not exceed 1 / 1000 of the circumference of the anti-roller, i.e., 1mm / 1m, and the maximum height difference of the entire circumference of the lower rail of the anti-roller shall not exceed 3mm.

4. The method for installing the anti-roller of a roller crane according to claim 1, characterized in that: In step S3, the special tooling and platform required for installing the upper track of the anti-roller include a first platform for placing the upper track of the anti-roller, jacks for driving the upper track of the anti-roller up and down, and a gantry crane for hoisting the upper track of the anti-roller. During the installation of the upper track of the anti-roller, the upper track of the anti-roller is first hoisted onto the first platform. The jacks are then used to push the upper track of the anti-roller below the upper track mounting surface. After checking that the arc dimension of the upper track of the anti-roller is qualified, the gantry crane and jacks are used to press the upper track of the anti-roller onto the mounting surface of the upper track of the anti-roller for assembly. When installing the pressure plate, the contact surfaces of the pressure plate and the upper rail of the anti-roller must be matched and machined on-site according to the site conditions to ensure that there are no gaps when the pressure plate is installed. After the arrangement, the gap between two adjacent upper rails of the anti-roller should not be greater than 0.5mm, and the height difference between two adjacent upper rails of the anti-roller should not be greater than 0.5mm. The gap of the pressure plate should be treated with rust prevention. When arranging the upper rails of the anti-roller, it is necessary to ensure that they are flat and tight, the end faces at the joints are aligned, the diameter tolerance should be within ±3mm, the radius tolerance should be within ±2mm, and the center of all upper rails of the anti-roller should be concentric with the center bearing.

5. The method for installing the anti-roller of a roller crane according to claim 1, characterized in that: In step S4, after the upper surface of the rail support beam is machined, an installation inspection line for the anti-roller lower rail is marked on the upper surface with a radius from the center crosshair. After the dimensions of the marked line are verified by precision control, the mark is made with a punch. The inspection line with the radius marked on the upper surface of the rail support beam is the installation center line of the anti-roller lower rail. After installation, the gap between two adjacent anti-roller lower rails should not be greater than 0.5mm, and the height difference between two adjacent anti-roller lower rails should not be greater than 0.5mm. When installing the rails, it is necessary to ensure that they are flat and tight, the end faces at the joints are aligned, the diameter tolerance should be within ±3mm, the radius tolerance should be within ±2mm, and the center of all anti-roller lower rails should be concentric with the center bearing.

6. The method for installing the anti-roller of a roller crane according to claim 1, characterized in that: In step S5, the special tooling and platform required for installing the anti-roller include 2-3 sets of mobile jigs. Slide rails are arranged on the mobile jigs. The anti-roller is placed on the mobile jigs. Lifting lugs are arranged inside the structure of the crane. A hand-operated hoist is used to pull the anti-roller between the upper and lower tracks of the anti-roller.

7. The method for installing the anti-roller of a roller crane according to claim 1, characterized in that: In step S6, the special tooling and platform required for the installation of the anti-roller structure include a process support and a manual hoist. The process support is used to position the anti-roller structure, and then lifting lugs are set on the anti-roller structure and the slewing lower support. The manual hoist is used to pull the lifting lugs to achieve fine-tuning and positioning of the anti-roller structure.

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