Pre-assembly device and pre-assembly method for a rotor car dumper

Abstract

The present application relates to the technical field of rotor dumper, and discloses a pre-assembly device and a pre-assembly method of a rotor dumper, which comprises a first auxiliary component, the first auxiliary component comprises a first limiting assembly and a supporting assembly, the first limiting assembly comprises a first supporting column, the first supporting column is provided with a first limiting groove, the first limiting groove is used for limiting the bottom of an end ring at the first limiting groove, so that the end ring is fixed in position in the axial direction of the end ring, and the supporting assembly comprises a supporting frame and a backrest, the backrest is connected to the supporting frame, so that the side surface of the backrest is tightly attached to the front surface or the back surface of the end ring, the front surface of the end ring is the surface where the middle flange on the end ring is located, so that the end ring is inclined at a fixed angle, and the present application provides a pre-assembly device and a pre-assembly method of a rotor dumper, which can make the end ring of the in-out car meet the design requirements of the assembly drawing to the greatest extent when pre-assembled after being manufactured on the production site, and eliminate errors.

Description

Technical Field

[0001] This invention relates to the field of rotor tipper technology, and particularly to a pre-assembly device and pre-assembly method for a rotor tipper. Background Technology

[0002] A rotary tipper is a large mechanical device used to unload bulk materials from open railway wagons. It is a loading and unloading machine that can tilt or tilt rail vehicles to unload materials. It is suitable for ports with large transport volumes and industrial sectors such as metallurgy, coal, and thermal power. The principle of a rotary tipper is that after the wagons are positioned to meet the unloading conditions, they are tilted to 165 degrees. The coal on each wagon is unloaded into the coal hopper, and then fed onto the conveyor belt by the coal feeder. The unloaded coal is then transported to the coal yard or raw coal bunker by the ground conveyor belt. The inlet and outlet end rings, trailer beams, side beams, and pressure beams are important load-bearing components of the rotary tipper.

[0003] The rotor tipper includes symmetrical inlet and outlet end rings, hereinafter referred to as end rings. The end rings primarily employ an open C-shaped box beam structure. After welding, the outer ring of the end ring has a regular shape, being an open circle with a diameter typically around 7000mm. The inner ring has an irregular shape, a combination of a semi-circular arc and a semi-straight line, also an open structure. Additionally, a complete ring of track pads is welded to the outer plate of the end ring. The annular track is tightly fitted to the track pads and secured with track clamps and bolts. Flanges with drilled holes of different sizes are welded to the lower, middle, and upper parts of the end ring, and these flanges are symmetrical about the center line. Figure 1 As shown.

[0004] The rotor tipper's pressure beam, support beam, and trailer beam are all heavy-duty long, box-shaped beam structures. The pressure beam primarily serves to hold the car body in place during tipping, preventing the end rings from opening outwards. The trailer beam provides gravity support for the car bodies entering the end rings, and the support beams hold and support the car bodies during tipping. The pressure beam's upper cover plate has specially shaped flanges welded to both sides, such as... Figure 2 and Figure 3 As shown, the irregular flange has the same number of corresponding round holes as the irregular flange on the upper part of the end ring. Rectangular flanges are welded to both ends of the vehicle beam and the trailer beam. The rectangular flanges have the same external dimensions as the flanges in the middle and lower parts of the end ring, and the drilling positions correspond one-to-one.

[0005] The rotor tipper's inlet / outlet end rings, pressure beams, support beams, and trailer beams are connected by corresponding flange bolts, forming an overall structure as follows: Figure 4 and Figure 5As shown, each component must undergo pre-assembly inspection before leaving the factory. This is mainly because the end rings are symmetrical structures and are manufactured separately. During pre-assembly after manufacturing, it is crucial to ensure that the irregular flanges on the upper part of both end rings are on the same plane and that there is no misalignment in height or front and back. It is also important to ensure that the horizontal and vertical center lines of the inner rings of the middle and lower flanges are coplanar and not misaligned. If these conditions are not met, it will directly affect the on-site installation of the pressure beam, the support beam, and the trailer beam. This could potentially cause a beam to become a slanted beam instead of a straight beam after installation, resulting in uneven stress on the connecting bolts at the flanges. When the end rings are tilted over a fully loaded car, the slanted beams will experience different stresses in different parts, continuously bearing the low-speed heavy load of the car. Furthermore, as the car continuously decelerates and accelerates during the tilting process, the connecting bolts at the flanges will experience compression deformation due to internal stress during operation, and may even move around. Increased movement can lead to bolt breakage, damage to the overall structure, and safety accidents. Therefore, in order to ensure on-site installation accuracy and reduce the waste of manpower and resources in on-site rework, the end rings, pressure beams, support beams, and trailer beams are pre-assembled at the manufacturing site to check the manufacturing accuracy of the components. This ensures that after pre-assembly, the end rings and the three main beams are vertical as a whole, and the upper irregular flanges are on the same plane without misalignment. The horizontal and vertical center lines of the inner rings of the middle and lower flanges are coplanar and do not misalign, thus ensuring that the verticality of the end rings and the overall height and horizontality and front-to-back misalignment of the two ends of the three main beams meet the design requirements.

[0006] In the actual assembly of the rotor tipper, the idler roller assembly is placed in a large concave groove below ground. This groove has a certain depth, and the end ring is placed on the roller assembly of the idler roller assembly, with a portion of it submerged in the groove. According to current technology, during pre-assembly of the end ring with the trailer beam, the support beam, and the pressure beam, the idler roller assembly also supports the end ring. The end ring sits on an assembly platform with a height of 7000mm, and the idler roller assembly is 960mm high, both above the horizontal plane. This reduces structural stability, further increases the difficulty of subsequent operation, lowers accuracy, and increases the risk of safety accidents. When the rotor tipper is in operation, the inbound and outbound end rings are pulled inward by the gravity of the pressure beam, the support beam, and the trailer beam. According to equipment usage requirements, the inbound and outbound end rings must not tilt inward and must maintain their verticality. According to existing technology, no measures were taken during the pre-assembly of the vehicle entry / exit end rings with the trailer beam, the side beam, and the pressure beam. This resulted in the vehicle entry / exit end rings exhibiting a certain degree of inward tilting during pre-assembly at the production site, especially at the top of the end rings. However, at the usage site, in order to eliminate the inward tilting and ensure the end rings are vertical, the top of each end ring needs to be tilted outward by 10mm according to the stress analysis results. This means that after the pressure beams are manufactured according to the original drawings, they may not be able to be bolted to the irregular flange on the upper part of the vehicle entry / exit end rings at the usage site. Summary of the Invention

[0007] To address the aforementioned technical problems, this disclosure provides a pre-assembly device and method for a rotor tipper, which enables the inlet and outlet end rings to conform to the overall assembly drawing design requirements to the greatest extent possible during pre-assembly after manufacturing on-site, thereby eliminating errors.

[0008] This disclosure provides a pre-assembly device for a rotor tipper, including a first auxiliary component. The first auxiliary component includes a first limiting assembly and a support assembly. The first limiting assembly includes a first support column with a first limiting groove for limiting the bottom of an end ring at the first limiting groove, thereby fixing the end ring in its axial direction. The support assembly includes a support frame and a backing plate, with the backing plate connected to the support frame so that the side of the backing plate is in close contact with the front or back of the end ring. The front of the end ring is the surface where the central flange on the end ring is located, thereby tilting the end ring at a fixed angle.

[0009] Optionally, the sides of the backrest are inclined.

[0010] Optionally, a cross brace is fixed to the hollow part of the end ring, with the center of the cross brace coinciding with the center of the end ring. The sides of two backing plates are in close contact with the back of the end ring. There are two backing plates, one of which has its side in close contact with the area of ​​the end ring opposite to the middle flange position, and the other has its side in close contact with the center of the cross brace.

[0011] Optionally, the first limiting component also includes a first base, and the first support column and the first base slide together radially along the end ring, and the first support column and the first base can be locked relative to each other.

[0012] Optionally, the support assembly also includes a second base, the support frame and the second base being slidably engaged along the axial direction of the end ring, and the support frame and the second base being able to be locked relative to each other.

[0013] Optionally, the pre-assembly device also includes a second auxiliary component, which includes a lifting assembly and a tray connected to the lifting assembly. The lifting assembly drives the tray to reciprocate along the height direction of the end ring. The extension direction of the tray is consistent with the extension direction of the first limiting groove. A slider is slidably fitted on the tray. The slider slides along the extension direction of the tray. An emitting element for emitting rays is fixed on the slider.

[0014] This disclosure also discloses a pre-assembly method for a rotor tipper, the pre-assembly method utilizing the aforementioned pre-assembly device, the pre-assembly method comprising:

[0015] A cross brace is fixed in the hollow part of the end ring, with the center point of the cross brace located at the center of the end ring;

[0016] Install the first auxiliary component on the ground assembly platform;

[0017] Move the end ring at the vehicle entry end to the upper end of the first auxiliary component so that the end ring is limited on the first limiting groove;

[0018] Secure the support frame to the ground assembly platform;

[0019] The center of the backplate and the cross brace are aligned and fixed, so that the end ring is tilted at a fixed angle. The pre-assembly method of the end ring at the exit end is the same as that at the inlet end.

[0020] Optionally, the pre-assembly method utilizing the aforementioned pre-assembly apparatus further includes:

[0021] The pre-assembled height of the pressure beam is relatively high from the ground. The upper irregular flange fixed on the end ring has the same size and shape as the irregular flanges at both ends of the pressure beam. They are both irregular parts. In order to ensure that the connection holes of the irregular flange and the upper irregular flange correspond one by one, the upper irregular flanges on the end rings at the inlet and outlet ends are fixed first.

[0022] Then, a non-standard flange is first connected to the upper non-standard flange at the exit end, and the level of the upper non-standard flange at the exit end is checked by the second auxiliary component.

[0023] The upper irregular flange is fixed to the opening of the end ring at the exit end, and the upper irregular flange at the end ring at the inlet end is fixed in the same way.

[0024] Optionally, the level detection specifically includes:

[0025] After leveling the second auxiliary component, fix the emitter on the slider and adjust the height of the support plate by lifting the assembly until the ray emitted by the emitter falls on point B1 of the upper irregular flange at the vehicle exit. Point B1 is a point on the irregular edge of the upper irregular flange. Move the slider and observe whether the ray can coincide with the line connecting the projection B1D1 or the error is within 2mm as the ray moves to point D1. If it is greater than 2mm, the upper irregular flange at the vehicle exit needs to be leveled again. Point D1 is another point on the irregular edge of the upper irregular flange.

[0026] Adjust the lifting assembly to lower the pallet until a ray appears on the lower surface of the upper irregular flange at the vehicle exit end. Take two points, A1 and C1, on the side directly opposite the irregular edge of the upper irregular flange. Check whether the ray and points B1, A1, D1, and C1 are on the same line. If they are all on the same line, it means that the bottom surface of the upper irregular flange is horizontal.

[0027] Optionally, the pre-assembly method also includes:

[0028] Fix the irregular flanges at both ends of the pressure beam to the upper cover plate of the pressure beam. After fixing, ensure that the two irregular flanges are on the same plane and that the front and rear edges of the two irregular flanges are on the same straight line.

[0029] Then, the pressure beam is lifted so that the irregular flanges at both ends of the pressure beam are tightly fitted with the two upper irregular flanges of the end ring. The lifting assembly is adjusted to adjust the height of the pallet until the ray emitted by the emitter falls on point E1 on the front or rear edge of one of the irregular flanges of the pressure beam. If the ray can reach point E2 on the front or rear edge of the pressure beam, point F1 on the front or rear edge of another irregular flange, and point F2 on the front or rear edge of another irregular flange along point E1, it indicates that the straightness of the pre-assembled pressure beam meets the requirements.

[0030] Secure the upper irregular flanges of the two end rings, and then hoist the trailer beam, the side beam, and the pressure beam to the corresponding flanges at the lower, middle, and upper parts of the end rings in sequence for fixation.

[0031] The technical solution provided in this disclosure has the following advantages compared with the prior art:

[0032] The pre-assembly device and method for a rotor tipper provided in this disclosure support the entry and exit end rings of the rotor tipper via a first limiting post in a first limiting component, and limit the bottom of the end ring via a first limiting groove, thus fixing it in its axial position. Unlike existing structures, it does not require the use of roller devices for support, thereby avoiding the overall height of the support structure and ensuring the stability of the overall structure of the end ring. This ensures the overall structural stability during the subsequent pre-assembly of the end ring with the trailer beam, the approach beam, and the pressure beam. The support frame of the support component supports the entry and exit end rings from the side, and the side of the approach plate tilts the top of each entry and exit end ring outward by 10mm, allowing the end rings to be accurately pre-assembled with the pressure beam, ensuring the accuracy of subsequent assembly. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the end ring structure of a rotor tipper in the prior art;

[0034] Figure 2 This is a front view of a pressure beam in the prior art;

[0035] Figure 3 This is a top view of a pressure beam in the prior art;

[0036] Figure 4 This is a schematic diagram of the assembly structure of the rotor tipper in the existing technology, including the inlet / outlet end ring, the pressure beam, the trailer beam, and the approach beam.

[0037] Figure 5 for Figure 4 Sectional view along line AA;

[0038] Figure 6Schematic diagram of the channel steel support structure on the outer side of the end ring;

[0039] Figure 7 for Figure 6 Sectional view along the BB direction;

[0040] Figure 8 A front view of the connection state between the first base and the first support column provided in an embodiment of this disclosure;

[0041] Figure 9 A left view of the connection state between the first base and the first support column provided in an embodiment of this disclosure;

[0042] Figure 10 A structural schematic diagram showing the connection state of the second base, the second column, and the support frame provided in an embodiment of this disclosure;

[0043] Figure 11 This is a schematic diagram of the structure of the second auxiliary component provided in an embodiment of this disclosure;

[0044] Figure 12 for Figure 11 C-axis sectional view;

[0045] Figure 13 This is a schematic diagram of the internal structure of the pre-assembled vehicle entry ring provided in an embodiment of this disclosure;

[0046] Figure 14 This is a schematic diagram showing the installation positions of the first auxiliary component, the vehicle entry ring, and the bracket platform provided in an embodiment of this disclosure.

[0047] Figure 15 A schematic diagram showing the installation positions of the first auxiliary component, the vehicle entry ring, the vehicle exit ring, and the bracket platform provided in this embodiment of the disclosure;

[0048] Figure 16 A schematic diagram showing the installation positions of the first auxiliary component, the second auxiliary component, the vehicle entry end ring, the vehicle exit end ring, and the bracket platform provided in an embodiment of this disclosure;

[0049] Figure 17 A schematic diagram showing the leveling points of the irregular flange at the top of the end ring of the vehicle exit end, provided in an embodiment of this disclosure.

[0050] Figure 18 This is a schematic diagram showing the location of the sampling points for straightness detection of the irregular flanges at both ends of the pressure beam provided in this embodiment of the disclosure;

[0051] Figure 19 A flowchart illustrating the pre-assembly method of the rotor tipper provided in this embodiment of the disclosure.

[0052] Explanation of reference numerals in the attached figures:

[0053] 1-First auxiliary component, 101-First base, 102-First groove, 103-First hole, 111-First support column, 112-First positioning hole, 113-First limiting groove, 121-Bolt fastener, 131-Second base, 132-Second groove, 133-Second hole, 141-Second column, 142-Second positioning hole, 151-First support member, 152-Second support member, 153-Third support member, 154-Connecting flange, 155-Diagonal brace, 1 56-Backing plate, 2-Second auxiliary component, 201-Support, 202-Threaded column, 203-Nut seat, 204-Panel, 205-Slider, 3-End ring, 4-Ladder platform, 5-Trailer beam, 6-Pressing beam, 7-Backing beam, 8-Upper irregular flange, 9-Middle flange, 10-Lower flange, 11-Cross brace, 12-Connecting plate, 13-Trailer beam outer port position line, 14-Upper cover plate, 15-Bracket platform, 16-Irregular flange, 17-Idler roller table, 18-Roller assembly. Detailed Implementation

[0054] The following detailed description of a specific embodiment of the present invention is provided in conjunction with the accompanying drawings. However, it should be understood that the scope of protection of the present invention is not limited to the specific embodiment.

[0055] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the technical solution of this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0056] The rotor tipper's inlet and outlet end rings disclosed herein are structurally identical to those in the drawings, symmetrical about the centerline, and are open C-shaped box beam structures. The two end rings are 15000mm apart, with a diameter of 7000mm. A perforated flange of different sizes is welded to the upper, middle, and lower parts of each inlet and outlet end ring, with the upper, middle, and lower flanges symmetrical about the centerline. The pressure beam, supporting beam, and trailer beam are all heavy-duty long strip box beam structures. The pressure beam is 16020mm long, the supporting beam is 13800mm long, and the trailer beam is 13800mm long. The upper cover plate of the pressure beam has specially shaped thickened steel plates (special-shaped flanges) welded to both sides, and these plates have corresponding round holes of the same shape and number as the special-shaped flanges on the upper part of the inlet and outlet end rings. Rectangular flanges are welded to both ends of the supporting beam and trailer beam, and these flanges have the same external dimensions as the flanges in the middle and lower parts of the inlet and outlet end rings, with the drilling positions corresponding one-to-one.

[0057] Since the entry and exit end rings, pressure beams, support beams, and trailer beams are all welded structures, welding deformation is inevitable. Therefore, the shape and size of each part after the product is manufactured cannot meet the design requirements of the drawings 100%. So, the shape and size of key parts must be strictly controlled.

[0058] The current pre-assembly process for the end rings and main beams of the rotor tipper is as follows:

[0059] 1. Assembly and fixing of the idler roller assembly

[0060] refer to Figure 4 and Figure 5 First, place the roller assembly (including roller platform 17 and roller assembly 18 supported on roller platform 17) on the ground assembly platform. The assembly platform is convenient for equipment hoisting and has ample space. During pre-assembly, fill each rotating point of the roller assembly with lithium-based grease to ensure flexible roller rotation. During pre-assembly, ensure that the ground steel plate is connected to the ground using pre-embedded M20 expansion bolts and level the assembly. The ground steel plates must be on the same horizontal plane (this must be ensured). Then, mark the position lines of the roller assembly on the assembly platform according to the design requirements of the drawings. Use a crane to lift the two roller assemblies onto the assembly platform, aligning the roller assemblies with the marked position lines. The flat roller is located at the inlet end, and the flange roller is located at the outlet end. Weld the roller platform to the assembly platform securely.

[0061] 2. Installation and fixing of entry and exit end rings

[0062] Since the entry / exit end ring has no internal solid structure, to prevent it from being stretched and deformed during hoisting, the existing technology first welds a cross brace 11 inside the entry / exit end ring. The cross brace 11 is made of H-beams. Figure 7 As shown. First, use a crane to smoothly lift the exit end ring onto the flange roller position of the idler roller device. Use a plumb line to check the verticality of the outer side of the exit end ring and the horizontality of the plane containing points E and F (the upper edges of both sides of the lower flange 10). If it is not vertical or horizontal, use the crane to fine-tune it until the verticality and horizontality meet the requirements. Note that it is best to use lifting slings when lifting the exit end ring to avoid damaging the end ring structure. Then, use channel steel (not lower than 20# channel steel) to weld and fix it to the outer side of the exit end ring. One end of the channel steel should be welded to the upper middle side of the exit end ring, and the other end should be welded to the steel plate of the ground assembly platform. After the exit end ring is fixed, the inlet end ring is then secured using lifting slings and hoisted onto the flat rollers of the idler roller device. A laser theodolite placed outside the end ring and the spacing between the two sets of rollers (18) on the flat rollers are adjusted to ensure that the planes containing points EF on the inlet end ring and GH on the exit end ring are coplanar and without misalignment. Simultaneously, the verticality of the inlet end ring must be guaranteed. Finally, channel steel (no less than 20# channel steel) is welded and fixed to the outside of the inlet end ring. One end of the channel steel should be welded to the upper middle side of the inlet end ring, and the other end should be welded to the steel plate of the ground assembly platform. Figure 6, Figure 7 As shown.

[0063] 3. Pre-assembly of trailer beams and side beams

[0064] First, the rectangular flanges at both ends of the trailer beam 5 are not welded to the main body of the trailer beam 5. Instead, they are spot-welded to the lower rectangular flange (lower flange 10) of the inlet / outlet end ring edge by edge, with round holes drilled around the perimeter. Then, the bracket platform 15 is installed on the ground assembly platform. The bracket platform 15 is welded from a cover plate and a support plate. After welding, the cover plate is shaped and the surface is flat. The width of each side of the cover plate is about 250mm wider than the width of each side of the trailer beam. The height of the bracket platform 15 is designed to be flush with the lower edge of the lower flange 10 of the inlet / outlet end ring. Finally, the trailer beam 5 is lifted onto the bracket platform 15. After aligning the two ends of the trailer beam 5 with the lower flange of the inlet / outlet end ring, three sides are continuously welded. The fourth side, being in an overhead welding position, is only spot-welded for fixation. After the trailer beam 5 is disassembled, it is continuously welded. After continuous welding, it is lifted back to the lower flange 10 of the inlet / outlet end ring and connected to the trailer beam 5 using high-strength bolts and nuts.

[0065] The rectangular flanges at both ends of the vehicle support beam 7 are not welded to the main body of the vehicle support beam 7 yet. Instead, they are first tack-welded to the edge-to-edge flange 9 of the inlet / outlet end ring, with round holes drilled around the perimeter. Then, the vehicle support beam 7 is lifted to the position of the flange 9 of the inlet / outlet end ring. After aligning the two ends of the vehicle support beam 7 with the flange 9 of the inlet / outlet end ring, three edges are continuously welded. The fourth edge, being in an overhead welding position, is only tack-welded for fixation. This welding will continue after the vehicle support beam 7 is disassembled. After continuous welding, it is lifted back to the flange 9 of the inlet / outlet end ring. High-strength bolts and nuts are used to connect the inlet / outlet end ring and the vehicle support beam 7. (Refer to...) Figure 4 .

[0066] 4. Pre-assembly of the vehicle beam

[0067] The shape of the truck beam 6 differs slightly from that of the trailer beam 5 and the approach beam 7. It is also symmetrical about the centerline, and according to design requirements, its end flanges are irregularly shaped and not perpendicularly connected to the beams. (Refer to...) Figure 2 and Figure 3 The irregular flange 16 and the upper cover plate 14 of the beam are welded together by flat butt welding of thick and thin plates. The upper irregular flange 8 of the inlet and outlet end ring and the irregular flange 16 at both ends of the pressure beam 6 are the same size and shape, and are both irregular parts. During the pre-assembly of the pressure beam 6, the irregular flanges 16 at both ends are first welded to the remaining components of the pressure beam 6 and shaped. The upper irregular flange 8 of the inlet and outlet end ring is then spot-welded to the irregular flanges 16 at both ends of the pressure beam edge to edge, and the surrounding round holes are drilled. Then, the pressure beam is lifted to the top of the inlet and outlet end ring by a crane. After visual alignment, the upper irregular flange 8 is spot-welded to the top port of the inlet and outlet end ring. Finally, the top port of the inlet and outlet end ring is continuously welded and the inlet and outlet end ring and the pressure beam 6 are connected by high-strength bolts and nuts.

[0068] The actual pre-assembly site for the aforementioned rotor tipper involves placing the roller assembly in a large concave groove beneath the ground. This groove has a certain depth, and the end ring must be placed on the roller assembly of the roller assembly, with a portion submerged within the groove. According to existing technology, during pre-assembly of the end ring with the trailer beam, the support beam, and the pressure beam, the roller assembly also supports the end ring. However, the end ring sits on an assembly platform with a height of 7000mm, and the roller assembly is 960mm high, both above the horizontal plane. This reduces structural stability, further increases the difficulty of subsequent operations, lowers accuracy, and increases the risk of safety accidents. When the rotor tipper is in operation, the inbound and outbound end rings are pulled inward by the gravity of the pressure beam, the support beam, and the trailer beam. According to equipment usage requirements, the inbound and outbound end rings must not tilt inward and must maintain their verticality. According to existing technology, no measures were taken during the pre-assembly of the vehicle entry / exit end rings with the trailer beam, the side beam, and the pressure beam. This resulted in the vehicle entry / exit end rings exhibiting a certain degree of inward tilting during pre-assembly at the production site, especially the end rings. However, at the usage site, in order to eliminate the inward tilting and ensure the end rings are vertical, the top of each vehicle entry / exit end ring needs to be tilted outward by 10mm according to the stress analysis results. This means that after the pressure beams are manufactured according to the original drawings, they may not be able to be bolted to the irregular flange on the upper part of the vehicle entry / exit end rings at the usage site.

[0069] Therefore, this disclosure provides a pre-assembly device and method for a rotor tipper. The pre-assembly device for the rotor tipper includes a first auxiliary component, comprising a first limiting assembly and a support assembly. The first limiting assembly includes a first support column with a first limiting groove for limiting the bottom of an end ring at the groove, thereby fixing the end ring in its axial direction. The support assembly includes a support frame and a backing plate, the backing plate being connected to the support frame so that the side of the backing plate is in close contact with the front or back of the end ring. The front of the end ring is the surface where the central flange on the end ring is located, thereby tilting the end ring at a fixed angle, allowing it to pass through... The first limiting post in the first limiting assembly supports the inlet and outlet end rings of the rotor tipper and limits the bottom of the end ring through the first limiting groove, so that it can be fixed in its axial position. Unlike the existing structure, it does not need to use a roller device for support, thus avoiding the overall height of the support structure and ensuring the overall structural stability of the end ring. This ensures the overall structural stability when the end ring is pre-assembled with the trailer beam, the approach beam, and the pressure beam. The support frame of the support assembly supports the inlet and outlet end rings from the side, and the side of the approach plate causes the top of the inlet and outlet end rings to tilt outward by 10mm, so that the end ring can be accurately pre-assembled with the pressure beam, ensuring the accuracy of the subsequent assembly.

[0070] The embodiments of this application will be described in detail below with reference to the accompanying drawings and specific implementation details.

[0071] Please see Figures 8 to 10 , Figure 8 This is a front view of the connection state between the first base and the first support column provided in an embodiment of this disclosure. Figure 9 A left view showing the connection state of the first base and the first support column provided in an embodiment of this disclosure. Figure 10 This is a structural diagram illustrating the connection state of the second base, second column, and support frame provided in an embodiment of this disclosure. Figures 8 to 10 As shown, this embodiment provides a pre-assembly device for a rotor tipper, including a first auxiliary component 1. The first auxiliary component 1 includes a first limiting component and a support component. The first limiting component includes a first support column 111, which has a first limiting groove 113. The first limiting groove 113 is used to limit the bottom of the end ring 3 at the first limiting groove 113, so that the end ring 3 is fixed in its axial direction. The support component includes a support frame and a backing plate 156. The backing plate 156 is connected to the support frame so that the side of the backing plate 156 is in close contact with the front or back of the end ring 3. The front of the end ring 3 is the surface where the central flange 9 on the end ring 3 is located, so that the end ring 3 is tilted at a fixed angle.

[0072] In this disclosure, the first auxiliary component 1 comprises two parts. Figure 8 This is a front view of the connection state between the first base and the first support column provided in an embodiment of this disclosure. Figure 9 A left view showing the connection state of the first base and the first support column provided in an embodiment of this disclosure. Figure 10 This is a structural diagram illustrating the connection state of the second base, second column, and support frame provided in an embodiment of this disclosure, as shown below. Figures 8 to 10 As shown, where Figure 8 and Figure 9 The first limiting component shown consists of two parts. Its purpose is to replace the idler roller device. Since the idler roller device is about 960mm high, if the end ring is placed on the idler roller device in the production site, the overall height will increase further, the stability will decrease, the subsequent operation will be more difficult, and safety accidents will be more likely to occur. Therefore, an auxiliary device with a height of about 200mm is used to simulate and replace the idler roller device.

[0073] The pre-assembly device for a rotor tipper provided in the above-described embodiments supports the inlet and outlet end rings of the rotor tipper through the first limiting post in the first limiting component, and limits the bottom of the end ring through the first limiting groove, so that it can be fixed in its axial position. Unlike existing structures, it does not need to use a roller device for support, thereby avoiding the overall height of the support structure, ensuring the stability of the overall structure of the end ring, and ensuring the overall structural stability when the end ring is pre-assembled with the trailer beam, the approach beam, and the pressure beam. The support frame of the support component supports the inlet and outlet end rings from the side, and the side of the approach plate causes the top of the inlet and outlet end rings to tilt outward by 10mm, so that the end rings can be accurately pre-assembled with the pressure beam, ensuring the assembly accuracy in the later stage.

[0074] To simplify the equipment and improve the overall accuracy of the device, the side of the back plate 156 is machined into an inclined surface. The inclined surface is then set to match the inclination angle of the end ring. By machining the side into an inclined surface, it is only necessary to control the machining accuracy of the inclined surface to match the outward tilt angle of the end ring.

[0075] Specifically, a cross brace 11 is fixed to the hollow position of the end ring 3. The center of the cross brace 11 coincides with the center of the end ring 3. The sides of two backing plates 156 are in close contact with the back of the end ring 3. There are two backing plates 156. The area of ​​one side of the end ring 3 that is in close contact with the middle flange 9 is opposite to the position of the other side. The side of the other side is in close contact with the center of the cross brace 11. Thus, when assembling the end ring at the vehicle entry end and the end ring at the vehicle exit end, the center of each end ring and the position on the same horizontal line as the center are supported from the opposite side of the two end rings. This will not affect the subsequent assembly and adjustment of the trailer beam, the pressure beam and the backing beam, while ensuring stable support for the end ring.

[0076] To facilitate the installation and adjustment of the first support column, in this disclosure, the first limiting assembly also includes a first base 101. The first support column 111 and the first base 101 slide together radially along the end ring 3, and the first support column 111 and the first base 101 can be locked relative to each other. Specifically, during manufacturing, the first base 101 is a short concave slide, consisting of two pieces, which can be made of solid square steel. A square groove (first groove 102) is milled according to the dimensions shown in the drawing. Several first holes 103 are drilled on both sides of the first groove 102 according to the actual situation. The first support column 111 is... The rectangular column slide rail can be machined from solid square steel. Drill first positioning holes 112 on both sides of the slide rail according to the figure. The position of the first positioning holes 112 corresponds to the center of the first hole 103. Then, mill a concave square groove (first limiting groove 113) in the middle of the first support column 111 according to the track size to ensure that the end ring 3 track can be stably embedded therein. Make your own bolt fasteners 121 (i.e., high-strength bolts) M40×500 and nuts M40. Fix the first base 101 and the first support column 111 with the bolt fasteners 121.

[0077] During assembly, the first base 101 is first welded and fixed to the ground assembly platform. The first support column 111 is installed into the first groove 102 of the first base 101 and can slide freely. When it needs to be stationary, bolt fasteners 121 can be inserted into the corresponding first positioning hole 112 and first strip hole 103 for fixation. The first limiting groove 113 is mainly to allow the track of the end ring 3 at the vehicle end to be stably embedded therein.

[0078] Refer again Figure 10 The support assembly also includes a second base 131, the support frame and the second base 131 are slidably engaged along the axial direction of the end ring 3, and the support frame and the second base 131 can be locked relative to each other.

[0079] There are four support components in total. Their main purpose is to support the end rings 3 at the vehicle entry and exit ends. Each end ring 3 is equipped with two support components on its outer side. Each set of support components is connected to a backing plate 156. The contact point between the backing plate 156 and the end ring 3 is the support point. Figure 13 This is a schematic diagram of the internal structure of the pre-assembled vehicle entry end ring provided in an embodiment of this disclosure, specifically a schematic diagram of the back of the end ring. (Refer to...) Figure 13Each end ring has two support points on the back, A and B. In this disclosure, the second base 131 is a long concave slide rail. For ease of manufacturing, it can be made by welding three long strip steel plates, with the bottom plate being 30mm thick and the two side uprights being 20mm thick. After welding, the shape is adjusted so that the second base 131 has a second groove 132 inside, ensuring the perpendicularity of the uprights and the bottom plate. Several second holes 133 are drilled on both sides of the second groove 132 according to the actual situation. The second column 141 is a rectangular column slide rail, which can be made of solid material. The square steel is machined to its shape. Second positioning holes 142 are drilled on both sides according to the drawing. The center of the second positioning hole 142 corresponds to the center of the second hole 133. The support frame includes a first support member 151, a second support member 152, a third support member 153, a connecting flange 154, and a diagonal brace 155. The first support member 151, the second support member 152, and the third support member 153 are non-standard straight H-beams, which can be made from long steel plates cut and welded. The thickness of the middle web is 20mm, and the two side flanges... The plate thickness is 30mm. The diagonal brace 155 is a non-standard zigzag H-beam, with the same plate thickness as the non-standard straight H-beam. Long steel plates are cut and welded according to the drawing. The plate 156 is welded perpendicularly to the diagonal brace 155 and fixed. The overall dimensions are 40×1350×1350mm. A certain angle needs to be machined in the thickness direction (the angle is determined based on the outward inclination value of the end ring). The connecting flange 154 is a perforated square plate, 25mm thick, with 4 pieces in total. Each square plate has symmetrically drilled Ф45 round holes on the top, bottom, left, and right sides. The connecting flange 154... The connection is achieved by self-made high-strength M44×120 bolts and M44 nuts. The first support 151, the second support 152, the second column 141, and the connecting flange 154 are continuously welded by CO2 gas shielded welding to ensure the perpendicularity of the first support 151 and the second support 152 after welding. In addition, the diagonal brace 155 and the connecting flange 154, and the diagonal brace 155 and the backing plate 156 are also continuously welded by CO2 gas shielded welding to ensure the perpendicularity of the diagonal brace 155 and the connecting flange 154 after welding.

[0080] During assembly, the second base 131 of the first auxiliary device is welded and fixed to the ground assembly platform. The second column 141 is installed in the second groove 132 of the second base 131 and can slide freely. The second column 141, the first support member 151 and the second support member 152, the third support member 153, the diagonal brace 155 and the backing plate 156 are continuously welded and fixed. The first support member 151 and the diagonal brace 155, and the second support member 152 and the third support member 153 are connected and fixed by the connecting flange 154 and the self-made high-strength bolts and nuts. After the support frame is fixed to the second column 141, the second column 141 can move freely in the second groove 132. When it needs to be stationary, the self-made high-strength bolts and nuts can be inserted into the corresponding second positioning holes 142 and second slot holes 133 for fixing.

[0081] According to assembly requirements, a laser theodolite needs to be used to calibrate the planes containing points EF and GH on the outer side of the end ring of the vehicle entry and exit rings to ensure they are coplanar and without misalignment. Based on this... Figure 11 This is a schematic diagram of the structure of the second auxiliary component provided in an embodiment of this disclosure. Figure 12 for Figure 11 The sectional view along the CC direction is shown in the disclosure. For ease of adjusting the height of the pallet 204, please refer to the following reference: Figure 11 and Figure 12 The pre-assembly device also includes a second auxiliary component 2, which includes a lifting assembly and a support plate 204 connected to the lifting assembly. The lifting assembly drives the support plate 204 to reciprocate along the height direction of the end ring 3. The extension direction of the support plate 204 is consistent with the extension direction of the first limiting groove 113. A slider 205 is slidably fitted on the support plate 204. The slider 205 slides along the extension direction of the support plate 204. An emitting element for emitting rays is fixed on the slider 205.

[0082] The lifting assembly includes a support 201, a threaded column 202, and a nut seat 203. The support 201 is made of 20mm thick steel plate. The nut seat 203 is a self-made square nut M30. The threaded column 202 can be made from round steel, with threads machined. The length L is measured and cut according to the site conditions. It is then spot-welded to the support 201 using shielded metal arc welding to ensure perpendicularity. The support plate 204 is made from 12mm thick steel plate and milled in both the thickness and width directions using a milling machine. The thickness direction is milled to 10mm to make the machined surface level. Holes are drilled at appropriate positions on both sides. The slider 205 is a slider with holes. It can be made from 50mm thick steel plate, with a concave square groove milled in the middle using a milling machine. The central round hole is not machined initially but will be drilled on-site according to the diameter of the laser pointer used later.

[0083] Figure 16 This is a schematic diagram showing the installation positions of the first auxiliary component, the second auxiliary component, the vehicle entry end ring, the vehicle exit end ring, and the bracket platform provided in this embodiment. During assembly, refer to... Figure 16 Support 201 is placed on ladder platform 4. There are two symmetrical threaded columns 202, which are spot welded to support 201 to ensure verticality. Nut seat 203 is screwed onto threaded column 202. The round hole on the support plate 204 passes through the threaded column 202 and is supported by nut seat 203. By screwing the nut seat 203, the support plate 204 can move smoothly up and down on the threaded column 202. The concave square groove in the slider 205 is embedded in the support plate 204. The two are fitted with a clearance. The slider 205 can slide horizontally left and right on the support plate 204 and can also move up and down by relying on the support plate 204 and threaded column 202.

[0084] The purpose of this disclosure is to ensure that, under the premise that the distance between the inlet and outlet end rings of the rotor tipper is 15000mm, the inlet and outlet end rings, the pressure beam, the support beam, and the trailer beam are pre-assembled. During the assembly process, it is ensured that the end rings are vertical as a whole, and the upper irregular flanges are on the same plane without any misalignment in height or front and back. The horizontal and vertical center lines of the inner rings of the middle and lower flanges are coplanar and not misaligned. This ensures that the verticality of the inlet and outlet end rings and the overall height and horizontality and front and back misalignment of the two ends of the three major beams meet the design requirements. Only in this way can the smooth installation of the rotor tipper at the use site be effectively guaranteed.

[0085] According to existing technology, although laser theodolites can be used to calibrate the planes containing points EF and GH on the outer side of the end rings of the vehicle entry and exit rings to ensure they are coplanar and without misalignment, the structure is mainly manufactured by welding. Considering welding deformation, the two end rings cannot be perfectly identical. This could potentially cause the horizontal and vertical center lines of the lower flange and the inner ring of the middle flange on the inner side of the vehicle entry and exit rings to be non-coplanar, resulting in height and front-to-back misalignment. This directly affects the on-site installation of the vehicle beam and trailer beam. It could result in a beam being installed as a slanted beam instead of a straight beam, and uneven stress on the connecting bolts at the flanges. When the end rings are tilted and the fully loaded wagons are overloaded, the slanted beams will experience different stresses, continuously bearing the low-speed heavy load of the wagons. Furthermore, as the wagons continuously decelerate and accelerate during the tilting process, the connecting bolts at the flanges will be squeezed and deformed due to internal stress during operation, and may even shift. Increased shifting could lead to bolt breakage, damage to the overall structure, and safety accidents.

[0086] After the trailer beam and the approach beam are installed on the inlet / outlet end ring, the end ring has tilted inward to a certain extent. At this time, the crane lifts the pressure beam with the superimposed irregular flange with drilled round holes to the top port of the inlet / outlet end ring for welding. However, the existing technology uses visual inspection, which makes it difficult to guarantee the height and front-back misalignment of the pressure beam. In addition, after the irregular flange is welded to the top port of the inlet / outlet end ring, it needs to be bolted to the pressure beam. After pre-assembly, the pressure beam is separated from the end ring. At the site of use, in order to eliminate the inward tilt and ensure the verticality of the end ring, the top of the inlet / outlet end ring must be tilted outward by 10mm. This makes it very likely that the pressure beam will not be aligned with the hole of the irregular flange on the top of the inlet / outlet end ring when it arrives at the site, making it impossible to insert the bolts.

[0087] Based on this, this embodiment also provides a pre-assembly method for the pre-assembly device of the rotor tipper as described above. The specific structure of the pre-assembly device of the rotor tipper has been described in detail in the above embodiments and will not be repeated here.

[0088] refer to Figure 19 A pre-assembly method for a rotor tipper, the pre-assembly method utilizing the aforementioned pre-assembly device, the pre-assembly method comprising:

[0089] A cross brace 11 is fixed in the hollow position of the end ring 3, with the center point of the cross brace 11 located at the center of the end ring 3;

[0090] Install the first auxiliary component 1 on the ground assembly platform;

[0091] Move the end ring 3 at the vehicle entry end to the upper end of the first auxiliary component 1 so that the end ring 3 is limited on the first limiting groove 113;

[0092] Secure the support frame to the ground assembly platform;

[0093] The center of the backing plate 156 is attached to the cross brace 11 and the two are fixed, so that the end ring 3 is tilted at a fixed angle. The pre-assembly method of the end ring 3 at the exit end is the same as that at the inlet end.

[0094] Specifically, the pre-assembly method utilizing the aforementioned pre-assembly device further includes:

[0095] The pre-assembled height of the pressure beam 6 is relatively high from the ground. The upper irregular flange 8 fixed on the end ring 3 has the same size and shape as the irregular flange 16 at both ends of the pressure beam 6. Both are irregular parts. In order to ensure that the connection holes of the irregular flange 16 and the upper irregular flange 8 correspond one-to-one, the upper irregular flange 8 on the end ring 3 at the inlet end and the outlet end are fixed first.

[0096] Then, a non-circular flange 16 is first connected to the upper non-circular flange 8 at the exit end, and the upper non-circular flange 8 at the exit end is horizontally checked by the second auxiliary component 2.

[0097] The upper irregular flange 8 is fixed to the opening of the end ring 3 at the exit end, and the upper irregular flange 8 of the end ring 3 at the inlet end is fixed in the same way.

[0098] Specifically, the level test includes:

[0099] After leveling the second auxiliary component 2, fix the emitter on the slider 205. Adjust the height of the support plate 204 through the lifting assembly until the ray emitted by the emitter falls on point B1 of the upper irregular flange 8 at the vehicle exit. Point B1 is a point on the irregular edge of the upper irregular flange 8. Move the slider 205. During the process of the ray moving to point D1, observe whether the ray can coincide with the line connecting the projection B1D1 or the error is within 2mm. If it is greater than 2mm, the upper irregular flange 8 at the vehicle exit needs to be leveled again. Point D1 is another point on the irregular edge of the upper irregular flange 8.

[0100] Adjust the lifting assembly to lower the pallet 204 until a ray appears on the lower surface of the upper irregular flange 8 at the vehicle exit end. Take two points, A1 and C1, on the side directly opposite the irregular edge of the upper irregular flange 8. Check whether the ray and points B1, A1, D1, and C1 are on the same line. If they are all on the same line, it means that the bottom surface of the upper irregular flange 8 is horizontal.

[0101] (1) Pre-assembly of the vehicle entry end ring

[0102] Figure 13 This is a schematic diagram of the internal structure of the pre-assembled vehicle entry ring provided in an embodiment of this disclosure. Figure 14 This is a schematic diagram showing the installation positions of the first auxiliary component, the vehicle entry ring, and the bracket platform provided in an embodiment of this disclosure. (Refer to...) Figure 13 and Figure 14 Since the end ring 3 at the vehicle entry end has no internal solid structure, in order to prevent it from being pulled and deformed during hoisting, a cross brace 11 can be welded inside the end ring 3 at the vehicle entry end. The cross brace 11 is made of H-beam steel. In addition, a connecting plate 12 is welded to the center of the end ring 3 at the vehicle entry end. The connecting plate 12 is a rectangular steel plate with dimensions of 40×1350×1250mm. The surface of this steel plate is drilled with 6-Ф50 holes. The 6 round holes are symmetrical about the horizontal and vertical center lines. The center of the left and right round holes is 450mm apart from each other, and the center of the top and bottom round holes is 450mm apart from each other.

[0103] When installing the end ring 3 at the vehicle entry end, firstly, install the first limiting component on the ground assembly platform, and spot weld the first base 101 to the ground assembly platform. Then, use self-made high-strength M40×500 bolts and M40 nuts (bolt fasteners 121) to fix the first base 101 and the first support column 111. Next, use a crane to lift the end ring 3 at the vehicle entry end above the first support column 111, allowing the annular track of the end ring 3 at the vehicle entry end to smoothly fall into the first groove 102. Since the end rings 3 at both the vehicle entry and exit ends are pulled inward by the gravity of the pressure beam, the support beam, and the trailer beam during pre-assembly, to ensure that the end rings remain vertical after pre-assembly, according to the force analysis results, the top of the end ring 3 at the vehicle entry end should tilt outward by 10mm after smoothly falling into the first groove 102. This can be calculated using drawing software to tilt areas A and B outward by 5mm. Figure 13As shown, region A is the connecting plate 12 located at the center of the end ring, which is welded and fixed to the cross brace 11. Region B is a rectangular area drawn on the C-shaped web of the end ring to the right of region A. This region is at the same height as region A and has dimensions of 1350×1250mm, and is symmetrical about the transverse center line of the end ring. Adjust the end ring 3 at the vehicle entry end, first making it vertical. Determine points E and F at the lower part of the vehicle entry end ring (points E and F can be determined on the lower plane of the end ring according to the positions of the two ends of the flange length direction of the end ring), and keep the plane containing points E and F horizontal. Next, two support components are installed on the left side of the end ring 3 at the vehicle entry end. Based on the outward inclination values ​​of areas A and B of the end ring, the front of the backing plate 156 is machined to an inclined surface using a milling machine, with an inclination value of 5mm. A 6-Ф50 hole is drilled, with the drilling position consistent with the hole position of the rectangular steel plate inside the end ring 3 at the vehicle entry end. After machining, the backing plate 156 is vertically welded to the diagonal brace 155. The two support components are then attached to areas A and B of the end ring 3 at the vehicle entry end, respectively. A crane is used to slowly tilt the end ring 3 outward. Continue until areas A and B are aligned and tightly fitted with the backing plate 156, ensuring that the outward tilt of the top of the end ring 3 at the vehicle entry end is 10mm. Then, continuously weld and fix the second base 131 to the assembly platform. Use high-strength bolts and nuts to fix the second base 131 and the second column 142. At the same time, use positioning pins to insert into the corresponding round holes of the connecting plate 12 inside the backing plate 156 and the end ring 3 at the vehicle entry end. At this time, the end ring 3 at the vehicle entry end is fixed in position under the action of the crane, support components and positioning pins. Then, align the rectangular flange at one end of the trailer beam 5 with the corresponding edge of the lower flange 10 of the end ring 3 at the vehicle entry end, spot weld them together and fix them in place, drill four round holes around the flange, spot weld two long strip steel plates on the inner ring of the lower flange 10, and mark the center position lines of the two stacked flanges on the long strip steel plates (first, take two midpoints on the two corresponding wide sides and two midpoints on the two corresponding long sides of the inner ring of the two stacked flanges, and mark them, then spot weld two long strip steel plates at approximately the middle position of the inner ring of the stacked flanges, connect the midpoints of the corresponding sides, and the line will fall on the long strip steel plate, which is the center line of the stacked flanges). Using this position line as a reference, drill a center hole and several round holes symmetrically drilled on the two rectangular steel plates, all with a diameter of Ф20. The actual length and width dimensions of the outer port of one end of the trailer beam 5 are measured. Using the center line as a reference, the position line 13 of the outer port of one end of the trailer beam 5 is marked on the two overlapping flanges below the end ring 3 at the vehicle entry end, according to the actual measured dimensions. Finally, the bracket platform 15 is installed on the ground assembly platform. The bracket platform 15 is welded from a cover plate and a support plate. After welding, the cover plate is shaped and the surface is flat. The width of each side of the cover plate is approximately 250mm wider than the width of each side of the trailer beam 5. The designed height of the bracket platform 15 should be flush with the lower edge of the flange 10 at the lower part of the end ring 3 at the vehicle entry end. Figure 15 This is a schematic diagram showing the installation positions of the first auxiliary component, the vehicle entry ring, the vehicle exit ring, and the bracket platform provided in an embodiment of this disclosure. Figure 16This is a schematic diagram showing the installation positions of the first auxiliary component, the second auxiliary component, the vehicle entry ring, the vehicle exit ring, and the bracket platform provided in the embodiments of this disclosure. As can be seen from the above... Figure 15 and Figure 16 As shown.

[0104] (2) Pre-assembly of the vehicle exit ring

[0105] Since the end ring 3 at the vehicle exit end also lacks a solid internal structure, to prevent it from being stretched and deformed during hoisting, a cross brace 11 can be welded inside the end ring 3 at the vehicle exit end. The cross brace 11 is made of H-beam steel. Additionally, a connecting plate 12 is welded to the center of the inside of the end ring 3 at the vehicle exit end. The connecting plate 12 is a rectangular steel plate with dimensions of 40×1350×1250mm. Six Ф50 holes are drilled on the surface of this steel plate, symmetrical about the horizontal and vertical center lines. The center of each pair of the left and right holes is 450mm apart, and the center of each pair of the top and bottom holes is also 450mm apart. Figure 7 As shown.

[0106] When assembling the end ring 3 at the exit end, firstly, install another first limiting component on the ground assembly platform. Align the two first limiting components with consistent height. Spot weld the first base 101 to the ground assembly platform. Use self-made high-strength M40×500 bolts and M40 nuts (bolt fasteners 121) to fix the first base 101 and the first support column 111. Then, use a crane to raise the end ring 3 at the exit end above the first support column 111, ensuring the annular track of the end ring 3 at the exit end smoothly falls into the first groove 102, making it vertical and aligned with the positions of points E and F on the entry end ring. Determine points G and H at corresponding positions on the lower part of the end ring 3 at the exit end. Figure 7 As shown, by adjusting the two first support columns 111, the shape formed by connecting points E, F, G, and H is ensured to be a rectangle, not other irregular shapes. That is, the planes containing points G and H should not be misaligned with the planes containing points E and F. Next, the two first bases 101 are continuously and securely welded to the ground assembly platform. Then, a support assembly is installed on the right side of the end ring 3 at the exit end, causing the end ring 3 at the exit end to tilt outwards by 10mm. The installation method is the same as for the end ring 3 at the inlet end. After installation, a positioning pin is inserted into the corresponding round hole of the connecting plate 12 inside the end ring 3 at the exit end using the backing plate 156. At this point, the positions of the end rings 3 at the inlet and exit ends are finally fixed under the action of the crane, support assembly, and positioning pin. According to the design drawings, the gap between the inlet and outlet end rings is ensured to be 15000mm. Figure 15As shown, after the two first limiting components are installed on the assembly platform, a vertical center line is drawn on the cross-section of the first limiting groove 113 of each first limiting component. The distance between the center lines should be 15000. If there is a deviation in size, the position of one of the first support columns 111 can be adjusted until the distance meets the requirements. Finally, align the rectangular flange at one end of the trailer beam 5 with the corresponding edge of the lower flange 10 of the end ring 3 at the exit end, spot weld them together, and drill four circular holes. Spot weld two long strip steel plates on the inner ring of the rectangular flange. To determine the position line of the outer end of the trailer beam on the rectangular flange, a laser pointer can be vertically inserted into the middle of the circular hole a in the inner ring of the long strip steel plate of the lower flange 10 of the end ring 3 at the entry end. Mark a1 immediately after the laser point falls on a certain position of the long strip steel plate of the inner ring of the rectangular flange at the exit end ring. Similarly, vertically insert the laser pointer into holes b, c, d, and e (draw the width center line on the horizontal long strip steel plate of the inner ring of the overlapping flange at the entry end ring, and draw the width center line on the vertical steel plate. The intersection of the two center lines is point a, and point a is used as the base). Determine four points (b, c, d, e) at a position 200mm above, below, left, and right on the center line. Mark the laser point on a certain position (b1, c1, d1, e1) of the long strip steel plate of the inner ring of the lower flange 10 of the end ring 3 at the exit end. Connect a1c1e1 and a1b1d1. At this time, the two vertical lines correspond to the horizontal and vertical center lines of the lower flange 10 of the end ring 3 at the entry end. Measure the length and width of the outer port of the other end of the trailer beam 5. Using the line connecting a1c1e1 and a1b1d1 as a reference, draw the position line 13 of the outer port of the trailer beam 5 at the other end of the lower flange 10. At this time, the position lines of the outer ports of both ends of the trailer beam 5 at the lower flange 10 of the entry and exit end rings are determined, and the horizontal and vertical center lines of the inner ring of the lower flange of the entry and exit end rings are coplanar and not misaligned.

[0107] Since the entry / exit end rings, pressure beams, support beams, and trailer beams are all welded structures, welding deformation is inevitable. Therefore, the shape and dimensions of each part after product manufacturing cannot perfectly match the design drawings. Thus, strict control must be exercised over the shape and dimensions of critical parts. The pre-assembly method for the entry / exit end rings has been explained above. The following will detail the pre-assembly methods for the trailer beams, pressure beams, and support beams. The pre-assembly methods also include:

[0108] The irregular flanges 16 at both ends of the pressure beam 6 are fixed to the upper cover plate 14 of the pressure beam 6. After the fixing is completed, the two irregular flanges 16 are on the same plane, and the front and rear edges of the two irregular flanges 16 are respectively on a straight line.

[0109] Then, the pressure beam 6 is lifted so that the irregular flanges 16 at both ends of the pressure beam 6 are tightly fitted with the two upper irregular flanges 8 of the end ring 3. The lifting assembly is adjusted to adjust the height of the support plate 204 until the ray emitted by the emitter falls on a point E1 on the front or rear edge of one irregular flange 16 of the pressure beam 6. If the ray can reach another point E2 on the front or rear edge of the pressure beam 6, a point F1 on the front or rear edge of another irregular flange 16, and another point F2 on the front or rear edge of another irregular flange 16 along point E1, it indicates that the straightness of the pre-assembled pressure beam meets the requirements.

[0110] Fix the upper irregular flanges 8 of the two end rings 3, and hoist the trailer beam 5, the vehicle support beam 7, and the vehicle pressure beam 6 to the corresponding flanges at the lower, middle, and upper parts of the end rings 3 in sequence for fixing.

[0111] (3) Pre-assembly of trailer beam and side beam

[0112] First, lift the trailer beam 5 and place it on the bracket platform 15. Elevate the bottom of the trailer beam 5 by adding a certain number or thickness of thin iron plates to the ends of the trailer beam 5 and at the bottom of the beam every few meters until the outer ends of the trailer beam 5 are aligned with the position line 13 of the outer ends of the trailer beam marked by the two overlapping flanges at the bottom of the vehicle entry and exit end rings. Fix the two with spot welding. Note that the marked position line and the outer ends must correspond and cannot be reversed. Grind off the weld points between the two overlapping flanges. Lift the trailer beam 5 to the assembly platform and continuously weld the trailer beam 5 and the rectangular flanges at both ends.

[0113] Next, align the rectangular flange at one end of the vehicle beam 7 with the corresponding edge of the flange 9 in the middle of the end ring 3 at the vehicle entry end, and spot weld them together for fixation. Similarly, spot weld two long strip steel plates on the inner ring of the rectangular flange, and mark the center position lines of the two stacked rectangular flanges on the long strip steel plates. Using these position lines as a reference, drill a center hole and several round holes symmetrically drilled on the top, bottom, left, and right sides of the two rectangular steel plates. The hole diameter is Ф20. Measure the actual length and width of the outer port at one end of the vehicle beam 7. Using the center line as a reference, mark the position line of the outer port at one end of the vehicle beam 7 on the two stacked flanges in the middle of the end ring 3 at the vehicle entry end according to the actual measured dimensions.

[0114] Then, align the rectangular flange at the other end of the vehicle beam 7 with the corresponding edge of the flange 9 in the middle of the end ring 3 at the exit end, and spot weld them together for fixation. Similarly, spot weld two long strip steel plates to the inner ring of the rectangular flange. To determine the position line of the outer end of the vehicle beam 7 on the rectangular flange, a laser pointer can be vertically inserted into the a2 hole in the middle of the long strip steel plate in the middle ring of the flange 9 in the middle ring of the end ring 3 at the exit end. Mark the position immediately after the laser point falls on a certain location on the long strip steel plate in the middle ring of the flange 9 in the middle ring of the end ring at the exit end. Similarly, vertically insert the laser pointer into holes b2, c2, d2, and e2, and mark the position after the laser point falls on the end ring 3 in the middle ring of the exit end. Mark a certain position (a3, b3, c3, d3, e3) on the inner ring of the middle flange 9. Connect a3c3e3 and a3b3d3. At this time, the two vertical lines correspond to the horizontal and vertical center lines of the middle flange 9 of the end ring 3 at the vehicle entry end. Measure the length and width of the outer port of the other end near the vehicle beam 7. Using the line connecting ace and abd as a reference, draw the position line of the outer port of the other end near the vehicle beam 7 on the middle flange. At this time, the position lines of the outer ports of the two ends near the vehicle beam 7 at the vehicle entry end and the vehicle exit end of the end ring middle flange 9 are determined, and the horizontal and vertical center lines of the inner ring of the middle flange 9 of the end ring at the vehicle entry end and the vehicle exit end are coplanar and not misaligned.

[0115] Finally, lift the support beam 7 until the outer ports at both ends of the support beam 7 are aligned with the outer port position lines 13 marked on the middle flanges 9 of the end rings at the inlet and outlet ends. Spot weld them together, ensuring that the marked position lines correspond to the outer ports and are not reversed. Grind away the welds between the two stacked flanges, lift the support beam 7 to the assembly platform, and continuously weld the support beam 7 and the rectangular flanges at both ends.

[0116] (4) Pre-assembly of the car beam

[0117] The pre-assembled height of the pressure beam 6 is 5800mm, which is relatively high from the ground. The shape of the pressure beam 6 differs slightly from that of the trailer beam 5 and the approach beam 7. It is also symmetrical about the centerline. According to design requirements, its end flanges are irregularly shaped and not perpendicular to the beam. The irregularly shaped flange 16 and the upper cover plate 14 of the beam are welded together using a butt joint method with thick and thin plates. Figure 2 As shown, the upper irregular flange 8 of the end ring 3 at the vehicle entry and exit end and the irregular flange 16 at both ends of the pressure beam 6 have the same size and shape, and are both irregular parts. In order to ensure that the connection holes of the irregular flange 16 at both ends of the pressure beam 6 and the upper irregular flange 8 of the end ring 3 at the vehicle entry and exit end correspond one-to-one, the two upper irregular flanges 8 of the end ring 3 at the vehicle entry and exit end are first spot welded and fixed and drilled. After drilling, the two flanges are separated. At this time, the irregular flanges 16 at both ends of the pressure beam 6 are not drilled and the length and width of the irregular flanges 16 are increased by 50mm during manufacturing.

[0118] Then, use an angle grinder to ensure the connection between the top of the end ring 3 at the vehicle entry / exit end and the upper irregular flange 8 is level. First, connect one of the upper irregular flanges 8 to the top of the end ring 3 at the vehicle exit end, and spot weld it in place. Then, use the second auxiliary component 2 to check the level of the upper irregular flange 8 on the end ring 3 at the vehicle exit end. Figure 16 As shown, place the ladder platform 4 on the left side of the end ring 3 at the vehicle entry end, and place the second auxiliary component 2 at the highest point of the ladder platform 4. After leveling, insert a laser pointer into the round hole of the slider 205 in the second auxiliary component 2, and adjust the height of the support plate 204 and slider 205 until the laser point can fall on point B1 of the irregular flange 8 on the upper part of the end ring 3 at the vehicle exit end (e.g., ...). Figure 17 The top irregular flange 16 of the pressure beam 6 has already been drilled with round holes around its perimeter according to the drawings. Based on this, extend the horizontal center line of the upper round holes to the edges of the left and right plates to determine points B1 and A1, and similarly determine points D1 and C1. Move the slider 205, and while the laser point moves to point D1, observe whether the laser point coincides with the line connecting the projected B1 and D1, or if the error is within approximately 2mm. If it is greater than 2mm, the upper irregular flange 8 of the end ring 3 at the exit end needs further leveling. Then, tighten the nut seat 203, and slowly move the support plate 204 and slider 205 down until a laser line appears on the lower surface of the upper irregular flange 8 of the end ring 3 at the exit end. Check whether the laser pointer light source point is on the same line as points B1, A1, D1, and C1. If they are all on the same line, it indicates that the bottom surface of the upper irregular flange 8 is level and the installation is accurate. Spot weld the upper irregular flange 8 to the top of the exit end ring. Figure 17 As shown. Similarly, the upper irregular flange 8 of the end ring 3 at the vehicle entry end is also installed in the same way. The upper irregular flange 8 is spot-welded to the top of the end ring 3 at the vehicle entry end. The nut seat 203 is tightened, and the support plate 204 and slider 205 are slowly moved down. The slider 205 carries the laser pointer and moves horizontally until a laser line appears on the corresponding ends (B1A1 is one end, D1C1 is the other end) of the lower surfaces of the two upper irregular flanges 8 at the top of the end ring at the vehicle entry end. This indicates that the lower surfaces of the two upper irregular flanges 8 are on the same horizontal plane and are installed accurately. If no laser line appears on the lower surface of a certain upper irregular flange 8, it indicates that there is a deviation in the manufacturing or pre-assembly of the vehicle entry end ring. A shim of the same thickness can be added at the corresponding connection holes near and far on the lower surface of this upper irregular flange 8. The thickness of the shim is adjusted until the laser line falls on the lower surface of the shim. All connection holes use shims. The shims are spot-welded to the lower surface of the upper irregular flange 8.

[0119] Next, weld the irregular flanges 16 at both ends of the press beam 6 to the upper cover plate 14 of the beam and other components. After welding, it is crucial to ensure that the two irregular flanges 16 are on the same plane, and that the lines connecting E1 and E2, F1 and F2, and G1 and G2, and H1 and H2 are on a straight line. Figure 18 As shown.

[0120] Then, using a crane, the pressure beam 6 is lifted to below the upper irregular flange 8 of the end ring 3 at the vehicle entry / exit end, ensuring a tight fit between the irregular flanges 16 at both ends of the pressure beam 6 and the upper irregular flange 8 of the end ring. Using the second auxiliary component 2, a laser pointer is inserted into the round hole of the slider 205. The height of the nut seat 203, the adjusting plate 204, and the slider 205 are adjusted until the laser point falls on point E1 of the pressure beam 6. If the laser line can reach points E2, F1, and F2 along point E1, it indicates that the pre-assembled straightness of the pressure beam 6 meets the requirements. Since the length and width dimensions of the irregular flanges 16 at both ends of the pressure beam 6 were increased by 60mm each from the design drawings during manufacturing, once the pre-assembled straightness of the pressure beam 16 meets the standard, lines can be drawn and stamped on the upper surface of the irregular flanges 16 at both ends of the pressure beam 6 according to the edges of the upper irregular flanges 8 at both ends of the end ring to facilitate on-site assembly of the pressure beam 16 according to these marks.

[0121] According to the hole positions of the upper irregular flange 8 of the inlet and outlet end ring, mark the hole position lines on the irregular flanges 16 at both ends of the pressure beam 6. The crane removes the pressure beam 6 and drills holes on the irregular flanges at both ends according to the hole position lines. The hole diameter can be appropriately enlarged as needed to prevent some round holes of the irregular flanges from not corresponding when the pressure beam 6 is pre-assembled with the inlet and outlet end ring, which would cause the bolts to be unable to be inserted and tightened smoothly.

[0122] Finally, the upper irregular flange 8 of the entry and exit end ring is continuously welded. The bracket platform 15 is removed, and the trailer beam 5, the supporting beam 7, and the pressure beam 6 are lifted by a crane to the corresponding flanges at the lower, middle, and upper parts of the entry and exit end ring in sequence for bolt connection. During this process, the crane and support components are required to assist in protecting the entry and exit end ring to prevent it from tilting. Subsequently, the verticality of the entry and exit end ring, the overall height and level of the two ends of the three beams, and the front and rear misalignment all meet the design requirements.

[0123] The first and second auxiliary components in this disclosure can be made from scrap materials, resulting in low cost. Each component is connected only by welding and bolts, requiring no precision fitting, thus simplifying manufacturing. Furthermore, the support assembly, the second auxiliary component, and their operating methods can all be applied in the actual field of equipment use. This ensures that the inlet / outlet end rings, trailer beams, approach beams, and pressure beams conform to the overall assembly drawing design requirements to the greatest extent possible during on-site assembly, eliminating errors and guaranteeing smooth on-site equipment assembly. This disclosure uses a first limiting component with a height of approximately 200mm to replace the idler roller device, which greatly reduces the overall height of the pre-assembly device, increasing the stability of subsequent operations and reducing the difficulty of operation. Since the in-vehicle end ring is pulled inward by the gravity of the pressure beam, the support beam, and the trailer beam during pre-assembly, to ensure the in-vehicle end ring remains vertical after pre-assembly, according to the force analysis results, the top of the in-vehicle end ring needs to tilt outward by 10mm after it smoothly falls into the first limiting groove. This disclosure utilizes the special structure of the support component to allow the in-vehicle end ring to tilt outward from a vertical state and then tightly adhere to the support component, ensuring both the stability of the end ring structure and maintaining the 10mm outward tilt of the end ring top. Since the trailer beam and the support beam are both 13800mm long, their ends are connected to the lower part of the in-vehicle end ring... After welding the overlapping rectangular flanges in the middle, there is a high possibility of beam misalignment. The advantage of this disclosure is that a baseline is first drawn on the two overlapping rectangular flanges at the lower and middle parts of the vehicle entry end ring to determine six points. Holes are drilled at these points, and a laser pointer is used to determine the baseline on the overlapping flanges at the lower and middle parts of the vehicle end ring. Then, the position lines of the two ends of the trailer beam and the vehicle support beam on the overlapping flanges are drawn based on the baseline. The purpose of this is to maintain the height and front-to-back alignment of the main beam during the pre-assembly of the trailer beam and the vehicle support beam, so as to ensure the installation accuracy and quality when the trailer beam and the vehicle support beam are actually assembled with the vehicle entry and exit end rings at the use site, and to prevent rework. The pre-assembly height of the pressure beam is 5800mm, which is relatively high from the ground, and its flanges at both ends are irregular parts. They are not connected perpendicularly to the beam, but are welded to the upper cover plate of the beam by butt welding of thick and thin plates. To address this issue, this disclosure employs a second auxiliary component placed on a ladder platform. A laser pointer is inserted into the circular hole of the slider. By adjusting the slider's height and moving it horizontally at a specific height, the horizontality of the lower surface of a single upper irregular flange on the top of the vehicle end ring can be detected. Simultaneously, it can also detect whether the lower surfaces of the two upper irregular flanges on the upper part of the vehicle end ring are on the same horizontal plane, allowing for timely adjustments if problems are found. Furthermore, using the second auxiliary component, inserting the laser pointer into the circular hole of the slider and adjusting the height of the support plate and slider by tightening the nut seat can detect the straightness of the edges along the length direction of the irregular flanges at both ends of the high-altitude pressure beam. If they are not straight, a crane can be used for timely adjustment.Using the second auxiliary component, under the premise of ensuring that the straightness of the edges of the irregular flanges at both ends of the press beam meets the requirements in the length direction at high altitude, hole position lines can be marked on the irregular flanges at both ends of the press beam according to the hole positions of the irregular flanges on the upper part of the inlet and outlet end rings, and holes can be drilled. The hole diameter can be appropriately enlarged. The advantage of doing this is that when the press beam is assembled on site according to the steel stamp marks on the upper surface of the irregular flanges at both ends, it can prevent some round holes of the press beam and the irregular flanges of the inlet and outlet end rings from not corresponding, which would cause the bolts to be unable to be inserted and tightened smoothly.

[0124] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A method of pre-assembly for a rotor dumper, characterized in that, The pre-assembly method for the rotor tipper is implemented using a pre-assembly device for the rotor tipper, the pre-assembly device including a first auxiliary component (1), the first auxiliary component (1) including: The first limiting component includes a first support post (111), the first support post (111) having a first limiting groove (113), the first limiting groove (113) being used to limit the bottom of the end ring (3) at the first limiting groove (113), so that the end ring (3) is fixed in its axial direction position; and The support assembly includes a support frame and a backing plate (156), the backing plate (156) being connected to the support frame so that the side of the backing plate (156) is in close contact with the back of the end ring (3), the front of the end ring (3) being the face where the central flange (9) is located on the end ring (3), thereby causing the end ring (3) to be tilted at a fixed angle. A cross brace (11) is fixed in the hollow position of the end ring (3). The center of the cross brace (11) coincides with the center of the end ring (3). There are two back plates (156). The sides of the two back plates (156) are close to the back of the end ring (3). The area of ​​the side of one of them that is close to the end ring (3) is opposite to the position of the middle flange (9). The side of the other one is close to the center position of the cross brace (11). The pre-assembly device also includes a second auxiliary component (2), which includes a lifting assembly and a tray (204) connected to the lifting assembly. The lifting assembly drives the tray (204) to reciprocate along the height direction of the end ring (3). The extension direction of the tray (204) is consistent with the extension direction of the first limiting groove (113). A slider (205) is slidably fitted on the tray (204). The slider (205) slides along the extension direction of the tray (204). An emitting element for emitting rays is fixed on the slider (205). The pre-assembly method includes: Install the first auxiliary component (1) on the ground assembly platform; Move the end ring (3) at the vehicle entry end to the upper end of the first auxiliary component (1) so that the end ring (3) is limited on the first limiting groove (113); The support frame is fixed to the ground assembly platform; The center of the back plate (156) is attached to the center of the cross brace (11) and the two are fixed so that the end ring (3) is tilted at a fixed angle. The pre-assembly method of the end ring (3) at the vehicle exit end is the same as that at the vehicle entry end. The pre-assembly height of the pressure beam (6) is relatively high from the ground. The upper irregular flange (8) fixed on the end ring (3) has the same size and shape as the irregular flange (16) at both ends of the pressure beam (6). They are both irregular parts. In order to ensure that the connection holes of the irregular flange (16) and the upper irregular flange (8) correspond one-to-one, the upper irregular flange (8) on the end ring (3) at the inlet end and the outlet end are fixed first. Then, one of the irregular flanges (16) is first connected to the upper irregular flange (8) at the vehicle exit end, and the upper irregular flange (8) at the vehicle exit end is horizontally checked by the second auxiliary component (2); The upper irregular flange (8) is fixed at the opening of the end ring (3) at the vehicle exit end, and the upper irregular flange (8) of the end ring (3) at the vehicle entry end is fixed in the same way. The horizontal detection specifically includes: After leveling the second auxiliary component (2), fix the emitter on the slider (205), and adjust the height of the support plate (204) through the lifting assembly until the ray emitted by the emitter falls on point B1 of the upper irregular flange (8) at the vehicle exit end. Point B1 is a point on the irregular edge of the upper irregular flange (8). Move the slider (205), and observe whether the ray can coincide with the line connecting the projection B1D1 or the error is within 2mm during the process of the ray moving to point D1. If it is greater than 2mm, the upper irregular flange (8) at the vehicle exit end needs to be leveled again. Point D1 is another point on the irregular edge of the upper irregular flange (8). Adjust the lifting assembly to lower the pallet (204) until a ray appears on the lower surface of the upper irregular flange (8) at the vehicle exit end. Take two points, A1 and C1, on the side opposite the irregular edge of the upper irregular flange (8). Check whether the ray and points B1, A1, D1, and C1 are on the same line. If they are all on the same line, it means that the bottom surface of the upper irregular flange (8) is horizontal.

2. The pre-assembly method for a rotor tipper as described in claim 1, characterized in that, The side of the backrest (156) is an inclined surface.

3. The pre-assembly method for a rotor tipper as described in claim 1, characterized in that, The first limiting component also includes a first base (101), the first support column (111) and the first base (101) slide together radially along the end ring (3), and the first support column (111) and the first base (101) can be locked relative to each other.

4. The pre-assembly method for a rotor tipper as described in claim 3, characterized in that, The support assembly also includes a second base (131), the support frame and the second base (131) are slidably engaged along the axial direction of the end ring (3), and the support frame and the second base (131) can be locked relative to each other.

5. A pre-assembly method for a rotor tipper as described in claim 1, characterized in that, The pre-assembly method further includes: The irregular flanges (16) at both ends of the pressure beam (6) are fixed to the upper cover plate (14) of the pressure beam (6). After the fixing is completed, the two irregular flanges (16) are on the same plane, and the front and rear edges of the two irregular flanges (16) are respectively on a straight line. Then the pressure beam (6) is lifted so that the irregular flanges (16) at both ends of the pressure beam (6) are tightly fitted with the two upper irregular flanges (8) of the end ring (3). The lifting assembly is adjusted to adjust the height of the pallet (204) until the ray emitted by the emitter falls on a point E1 on the front or rear edge of one of the irregular flanges (16) of the pressure beam (6). If the ray can reach another point E2 on the front or rear edge of the pressure beam (6), a point F1 on the front or rear edge of another irregular flange (16), and a point F2 on the front or rear edge of another irregular flange (16) along point E1, then it indicates that the straightness of the pre-assembled pressure beam meets the requirements. The upper irregular flanges (8) of the two end rings (3) are fixed, and the trailer beam (5), the side beam (7), and the pressure beam (6) are hoisted to the corresponding flanges at the lower, middle, and upper parts of the end rings (3) in sequence and fixed.

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