Method for manufacturing a large turntable structure with high precision control

Abstract

The present application provides a large-scale rotary disc structure manufacturing high-precision control method in the field of rotary disc structure. The method realizes the high-precision control of the large-scale rotary disc structure manufacturing through the margin adding principle, blanking precision control, part manufacturing precision control, assembly scheme design and welding sequence optimization technology, and comprises the following steps: step 1, according to the type and thickness specification of the large-scale rotary disc structure, the margin adding principle of each plate part is formulated; step 2, mathematical lofting and numerical control cutting machine marking, after marking, the blanking is carried out after being confirmed by the quality inspection personnel, the plate materials that cannot be cut by numerical control are cut by a semi-automatic cutting machine, and the precision control target value of each stage in the blanking stage is clear; step 3, the radiating rib plate and the center shaft seat part are manufactured, and the precision control target value is clear; step 4, the overall assembly scheme of the large-scale rotary disc structure is designed, the structure welding sequence is optimized, and the precision control target value is finally realized. It is suitable to be applied as a high-precision control method for rotary disc structure manufacturing.

Description

Technical Field

[0001] This invention relates to precision control in the field of turntable structures, and in particular to a method for high-precision control in the manufacturing of large turntable structures. Background Technology

[0002] A turntable is a tooling fixture used to adjust the direction of large vehicles and equipment within a depot. It has a large diameter and bears heavy loads, and its corresponding supporting facilities require extremely high precision. Given the complex stress conditions, the turntable structure needs to possess sufficient strength and stability, and its precision must be effectively controlled during manufacturing and assembly.

[0003] The turntable structure has numerous longitudinal and transverse frames and is quite large. It also houses a central rotating shaft, single-support rollers, and double-support roller devices. The outer ring of the turntable is a large pinion gear for rotary drive. Due to repeated heat input during welding and installation, the turntable may undergo significant deformation, which in severe cases can affect the strength and stability of the entire turntable structure, posing a safety hazard to large vehicles and equipment.

[0004] By studying the high-precision control of the turntable structure, theoretically researching the material cutting precision control of the turntable structure, the assembly process of the longitudinal and transverse structures and support plate components, and optimizing the assembly and welding sequence, the high-precision control requirements for the manufacture of the turntable structure can be met. Summary of the Invention

[0005] To address the shortcomings of existing technologies and the strength and stability issues of turntable structures, this invention provides a method for high-precision control in the manufacturing of large turntable structures. This method improves the precision and quality of turntable manufacturing and solves the technical problems of turntable structure strength and stability by establishing principles for adding allowances, controlling material cutting precision, controlling component manufacturing precision, designing assembly schemes, and optimizing welding sequences.

[0006] The solution adopted by this invention to solve the technical problem is:

[0007] A method for high-precision control in the manufacturing of large turntable structures, which achieves high-precision control in the manufacturing of large turntable structures by establishing principles for adding allowances, controlling material cutting accuracy, controlling component manufacturing accuracy, designing assembly schemes, and optimizing welding sequences, includes the following steps:

[0008] Step 1: Based on the structural type and plate thickness specifications of the large turntable, formulate the principle for adding allowances for each plate component.

[0009] Step 2: Mathematical layout and CNC cutting machine marking. After marking, the material is cut after confirmation by the quality inspector. For the board material that cannot be cut by CNC, a semi-automatic cutting machine is used for cutting. The precision control target values ​​of each stage of the cutting are clearly defined.

[0010] Step 3: Fabricate the radial stiffeners and central shaft bearing components, and define the precision control target values;

[0011] Step 4: Design the overall assembly scheme for the large turntable structure, optimize the welding sequence, and ultimately achieve the target value for precision control.

[0012] The positive effects are significant. By controlling the precision of material cutting, the precision of component manufacturing, and optimizing the assembly scheme design and welding sequence, this invention achieves high-precision control in the manufacturing of large turntable structures. This solves the problem of high precision control during turntable construction, ensuring the precision and quality of the turntable during manufacturing and installation, shortening construction time, improving construction efficiency, and safeguarding the quality of equipment production and operation. It is suitable as a method for high-precision control in the manufacturing of large turntable structures. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. The description of the present invention is given for the purpose of illustration and description, and is not intended to be exhaustive or to limit the present invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical applications of the present invention, and to enable those skilled in the art to understand the present invention and design various embodiments with various modifications suitable for a particular purpose.

[0014] Figure 1 This is a schematic diagram of the turntable structure in this embodiment.

[0015] In the diagram, 1. Radial stiffener, 2. Circular stiffener, 3. Single-wheel stiffener, 4. Double-wheel stiffener, 5. Single-wheel mounting plate, 6. Double-wheel mounting plate, 7. Tie seat. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0017] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0018] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0019] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0020] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0021] In the description of the embodiments in this application, the term "multiple" refers to two or more (including two). Similarly,

[0022] "Multiple sets" refers to two or more sets (including two sets), and "multiple tablets" refers to two or more tablets (including two tablets).

[0023] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "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 embodiments of this application and simplifying the description, and are not intended to 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 the embodiments of this application.

[0024] In the description of the embodiments in this application, unless otherwise expressly specified and limited, the technical term "installation" will be used.

[0025] Terms such as “connected,” “linked,” and “fixed” should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0026] As shown in the figure, a method for high-precision control in the manufacturing of large turntable structures achieves high-precision control through establishing principles for adding allowances, controlling material cutting accuracy, controlling component manufacturing accuracy, designing assembly schemes, and optimizing welding sequences. The method includes the following steps:

[0027] Step 1: In the design phase, based on the structural type and plate thickness specifications of the large turntable, formulate the principle for adding allowances to each plate component.

[0028] In some optional embodiments, step 1 further includes:

[0029] When the plate thickness d510mm, each butt joint has a 12mm allowance;

[0030] Add a 10mm machining allowance to the outer diameter of the top plate;

[0031] The outer panel is formed by rolling and pressing four pieces of material. One splicing panel has a 100mm assembly allowance on one side of the circumference, and the remaining parts are assembled without excess material.

[0032] The pin tooth mounting plate is cut into eight pieces. Among them, four splicing plates have an additional 30mm assembly allowance at the joint and an additional 5mm machining allowance in the radial direction.

[0033] The inner and outer circular tracks are assembled and welded on site in eight pieces. A 30mm assembly allowance is added at the joint of four of the splicing plates, and there is no radial allowance.

[0034] After welding, the center cover mounting plate is machined, and the plate thickness is increased by 2 mm to make the machining allowance 12 mm.

[0035] The center shaft mounting plate is machined after welding.

[0036] The single wheel mounting plate 5 is machined after welding, and its thickness is increased by 5 mm to make the machining allowance 25 mm.

[0037] Add 10mm of machining allowance radially to the center shaft mounting plate.

[0038] Step 2: Use mathematical layout and CNC cutting machine to mark the lines. After marking, the quality inspector will confirm the lines before cutting. For boards that cannot be cut by CNC, use a semi-automatic cutting machine to cut the boards. Clarify the precision control target values ​​for each stage of the cutting process.

[0039] In some optional embodiments, step 2 further includes:

[0040] 1) Pre-treatment of sheet metal and profiles:

[0041] All steel plates and profiles undergo shot blasting on the steel plate production line, achieving a surface cleanliness of Sa2.5 grade in GB8923 and a surface roughness of Ra40~75μm. All steel plates and profiles with a thickness of 6mm or less are derusted by sandblasting or power tools, with power tool derusting meeting St2~3 grade in GB8923. Plates with a thickness of ≤12mm are leveled before being cut.

[0042] 2) Equipment precision control:

[0043] The scribing accuracy of the CNC cutting machine is ±0.5mm;

[0044] The deviation between the scribing template and the layout template is ±0.5mm;

[0045] Check the deviation between the template and the layout within ±1.0mm.

[0046] 3) Steel straightening:

[0047] Plate thickness d≤14mm, local deflection of steel plate f≤1.5mm;

[0048] For plates with a thickness d > 14 mm, the local deflection height f of the steel plate is ≤ 1 mm.

[0049] 4) Deviation between the cutting line and the marking line:

[0050] Manual cutting accuracy ±2.0mm;

[0051] Automatic and semi-automatic cutting accuracy ±1.5mm;

[0052] CNC cutting accuracy ±0.5mm.

[0053] 5) Edge processing requirements:

[0054] The bevel angle deviation is ±2.5°;

[0055] The straightness of the gas-cut surface at the edge of the steel plate is ≤1.0mm;

[0056] The straightness of the planed edge surface of the steel plate is ≤0.5mm;

[0057] The perpendicularity between the gas-cut edge of the steel plate and the plate surface is ≤1.0mm;

[0058] The length deviation of the steel plate edge is ±1.5mm.

[0059] Step 3: Fabricate the radial stiffeners and central shaft bearing components, and define the precision control target values;

[0060] In some optional embodiments, step 3 further includes:

[0061] The web and face of the T-section are welded by submerged arc welding or semi-automatic welding. The perpendicularity between the face and the web is ≤1 mm; the length of the T-section is ±2 mm; and the flatness of the face is ≤2 mm.

[0062] The total height of the central shaft seat is ±1 mm, the flatness of the central shaft mounting plate is ≤0.1 mm, the flatness of the central cover mounting plate is ≤0.1 mm, the flatness of the central base plate is ≤1 mm, and the center distance between any two adjacent holes is ±0.3 mm.

[0063] Step 4: Design the overall assembly scheme for the large turntable structure, optimize the welding sequence, and ultimately achieve the target value for precision control.

[0064] In some optional embodiments, step 4 further includes:

[0065] Overall assembly sequence:

[0066] 1) Top plate assembly, welding, fixing, and marking on the jig: The top plate is positioned and welded on the jig according to the assembly sequence required by the manufacturing process. The top plate is then welded into a fixed jig. A ceramic backing is attached to the non-structural surface of the top plate. Gas shielded welding is used for the assembly of the top plate. The welding sequence is performed by two welders simultaneously, symmetrically from the inside out. After leveling, the center position line is marked on the inside of the top plate, and the position lines of each assembly component and opening are marked to facilitate subsequent assembly and welding work. After assembly and welding, the top plate misalignment is ≤1mm, the outer circle roundness is ≤10mm, the outer circle radius is ≤5mm, the concentricity is φ1.2mm, the outer circle circumference is ±18mm, the weld height difference is ≤1mm, the panel flatness is ≤3mm, the distance from the center line of the single / double wheel mounting hole to the center of the top plate is ±1mm, and the center distance between the single / double wheel mounting holes on the same circumference is ±1mm.

[0067] 2) Sealing Plate Assembly and Welding: After removing the assembly allowance from the pressed sealing plate, it is positioned and welded to the top plate. The verticality tolerance after welding is ≤1mm, the height tolerance is ±1mm, the flatness of the top edge is ≤2mm, the misalignment is ≤1mm, the diameter is ±8mm, and the circumference is ±15mm.

[0068] 3) Central shaft seat assembly and welding: Position, install and weld the central shaft seat as a whole to the top plate.

[0069] 4) Alternately install the positioning radial stiffeners 1, annular stiffeners 2, single-wheel stiffeners 3, and double-wheel stiffeners 4: Install the positioning radial stiffeners 1, annular stiffeners 2, single-wheel stiffeners 3, and double-wheel stiffeners 4 alternately, following a clockwise or counterclockwise principle. After all annular stiffeners 2 and radial stiffeners 2 are installed and positioned, weld the vertical fillet welds between radial stiffeners 1 and annular stiffeners 2; four shielded metal arc welders simultaneously and symmetrically perform the welding of the vertical fillet welds between radial stiffeners 1 and annular stiffeners 2 between #12 and #1, #3 and #4, #6 and #7, and #9 and #10. The welding position is vertically upward. Then perform shielded metal arc welding of the vertical fillet welds between radial stiffeners 1 and annular stiffeners 2 between radial stiffeners 1 and #2, #4 and #5, #7 and #8, and #10 and #11. Next, perform shielded metal arc welding (SMAW) on the fillet welds between radial stiffener 1 and annular stiffener 2 between radial stiffeners #2 and #3, #5 and #6, #8 and #9, and #11 and #12. Then, four gas shielded welders simultaneously perform fillet welds between radial stiffener 1, annular stiffener 2, single-wheel stiffener 3, and double-wheel stiffener 4 and the panel between radial stiffeners #12 and #1, #3 and #4, #6 and #7, and #9 and #10. The overall welding direction for the fillet welds between a single radial stiffener 1 and the panel is from the center of the panel outwards. Then, perform gas shielded welding on the fillet welds between radial stiffener 1, annular stiffener 2, single-wheel stiffener 3, and double-wheel stiffener 4 and the panel between radial stiffeners #1 and #2, #4 and #5, #7 and #8, and #10 and #11. Finally, gas-shielded welding was performed on the fillet welds between the radial stiffeners 1, annular stiffeners 2, single-wheel stiffeners 3, and double-wheel stiffeners 4 of the turntable and the turntable panel, connecting them to the radial stiffeners 2 and 3, 5 and 6, 8 and 9, and 11 and 12. After the assembly and welding of the radial stiffeners 1 and annular stiffeners 2 of the turntable body were completed, the levelness of any square meter was measured to be less than 1 mm, and the overall flatness of the turntable body was ≤6 mm.

[0070] 5) Pin Tooth Mounting Plate Welding: After the main structure of the turntable is welded, the pin tooth mounting plates are positioned, assembled, and welded. Each layer of pin tooth mounting plates is divided into 8 arc-shaped plates for splicing and welding. The flatness of the mounting plate is ≤4mm; the parallelism of the mounting plate is ≤2mm; the perpendicularity between the mounting plate and the sealing plate is ≤1mm; the distance between two mounting plates is ±2mm; the roundness of the outer circle of the mounting plate is ≤10mm; the outer radius of the mounting plate is -1mm to +4mm; the outer circumference of the mounting plate is ±15mm; and the misalignment is ≤1mm.

[0071] 6) Opening holes for tie-down block, single wheel and double wheel mounting holes: After the main structure of the turntable is assembled and welded, the holes for the central shaft mounting hole, tie-down block, single wheel and double wheel mounting holes are opened.

[0072] 7) Welding of single wheel mounting plate 5 and double wheel mounting plate 6 and their elbow plates: Install single wheel mounting plate 5 and double wheel mounting plate 6 and related stiffeners and elbow plates. In order to ensure the flatness manufacturing accuracy of single and double wheels, single wheel mounting plate 5 and double wheel mounting plate 6 adopt the form of welding first and then machining. The holes of the mounting plates are drilled using templates.

[0073] 8) Make holes and weld the tether seat 7.

[0074] 9) Pin Mounting Plate Hole Opening: After the turntable is fully welded, determine the marked positions of the pin mounting holes. Use a template for overall drilling and opening. The holes in the mounting plate should be evenly distributed, avoiding the weld seams of the plate joints. The center distance between any two adjacent pin mounting holes should be ±0.3 mm; the center circle radius of the pin mounting hole should be ±0.5 mm; the concentricity of corresponding pin holes on the two mounting plates should be φ1 mm.

[0075] 10) Machining of single-wheel mounting plate 5, double-wheel mounting plate 6, central shaft mounting plate, and central base plate: After the turntable is welded as a whole, the central shaft seat, single-wheel mounting plate 5, and double-wheel mounting plate 6 are machined. The total height of the central shaft seat is ±1 mm; the flatness of the central shaft mounting plate is ≤0.1 mm, and its perpendicularity to the turntable's central axis is ≤0.1 mm; the flatness of the central cover mounting plate is ≤0.1 mm, and its perpendicularity to the turntable's central axis is ≤0.1 mm; the flatness of the central base plate is ≤1 mm, and its perpendicularity to the turntable's central axis is ≤1 mm; the center distance between any adjacent holes is ±0.3 mm. The flatness of the single / double wheel mounting plates is ≤1 mm; the radius tolerance of the center circle of the double-wheel mounting plate 6 is ±1 mm; the radius tolerance of the center circle of the single-wheel mounting plate 5 is ±1 mm; the perpendicularity of the mounting plate to the turntable's central axis is ≤1.5 mm; and the distance tolerance between the upper surface of the mounting plate and the upper surface of the top plate is 0–1 mm.

[0076] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for high-precision control in the manufacturing of a large turntable structure, characterized by: High-precision control of large turntable structure manufacturing is achieved by establishing principles for adding allowances, controlling material cutting accuracy, controlling component manufacturing accuracy, designing assembly schemes, and optimizing welding sequences. This includes the following steps: Step 1: Based on the structural type and plate thickness specifications of the large turntable, formulate the principle for adding allowances for each plate part; Step 2: Mathematical layout and CNC cutting machine marking. After marking, the material is cut after confirmation by the quality inspector. For the material that cannot be cut by CNC, a semi-automatic cutting machine is used for cutting. The precision control target values ​​for each stage of the cutting are clearly defined. Step 2 includes: 1) Pre-treatment of sheet metal and profiles: All steel plates and profiles are shot blasted on the steel plate production line, with a surface roughness of Ra40~75μm. All steel plates and profiles with a thickness of 6mm or less are sandblasted or derusted using power tools. Plates with a thickness of ≤12mm are leveled as a whole before being cut into materials. 2) Equipment precision control: The scribing accuracy of the CNC cutting machine is ±0.5mm; The deviation between the scribing template and the layout template is ±0.5mm; Check the deviation between the template and the layout to be ±1.0mm; 3) Steel straightening: Plate thickness d≤14mm, local deflection of steel plate f≤1.5mm; For plates with a thickness d > 14 mm, the local deflection height f of the steel plate is ≤ 1 mm. 4) Deviation between the cutting line and the marking line: Manual cutting accuracy ±2.0mm; Automatic and semi-automatic cutting accuracy ±1.5mm; CNC cutting accuracy ±0.5mm; 5) Edge processing requirements: The bevel angle deviation is ±2.5°; The straightness of the gas-cut surface at the edge of the steel plate is ≤1.0mm; The straightness of the planed edge surface of the steel plate is ≤0.5mm; The perpendicularity between the gas-cut edge of the steel plate and the plate surface is ≤1.0mm; The length deviation of the steel plate edge is ±1.5mm; Step 3: Fabricate the radial stiffeners and central shaft bearing components, and define the precision control target values; Step 4: Design the overall assembly scheme for the large turntable structure, optimize the welding sequence, and ultimately achieve the target value for precision control. Step 4 includes: overall assembly sequence: 1) The top plate is welded, fixed, and marked on the jig; 2) Sealing plate welding; 3) Welding of the central shaft seat; 4) Alternately install positioning radial stiffeners (1), annular stiffeners (2), single-wheel stiffeners (3) and double-wheel stiffeners (4); 5) Welding of the pin tooth mounting plate; 6) Openings for the tie-down seat connecting block, single wheel, and double wheel mounting holes; 7) Welding of the single-wheel mounting plate (5) and the double-wheel mounting plate (6) and their elbow plates; 8) The mooring seat (7) is drilled and welded; 9) Hole opening in the pin mounting plate; 10) The single wheel mounting plate (5), the double wheel mounting plate (6), the central shaft mounting plate and the central base plate are machined.

2. The method for high-precision control in manufacturing a large turntable structure according to claim 1, characterized in that: Step 3 includes: The web and face of the T-section are welded by submerged arc welding or semi-automatic welding. The perpendicularity between the face and the web is ≤1 mm; the length of the T-section is ±2 mm; and the flatness of the face is ≤2 mm. The total height of the central shaft seat is ±1 mm, the flatness of the central shaft mounting plate is ≤0.1 mm, the flatness of the central cover mounting plate is ≤0.1 mm, the flatness of the central base plate is ≤1 mm, and the center distance between any two adjacent holes is ±0.3 mm.

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