Mdel 1000 tire handler and method of manufacture

Abstract

The present application belongs to the technical field of mechanical manufacturing, and particularly relates to a MDEL1000 tire carrier and a manufacturing method. The method comprises the following steps: assembling a cover plate and a plate to form a first component, assembling a web plate and the plate to form a second component, drilling holes by using a numerical control machining center device, and dividing the two components into upper and lower layers; manufacturing a lower main beam and adhering the lower main beam to the lower layer component to assemble a three-type beam structure, wherein the lower layer component serves as the bottom surface and side surface of the three-type beam. Then, a connecting plate is adhered to the lower layer component of the three-type beam structure, and an upper layer component and longitudinal reinforcement are assembled to obtain an unwelded main beam segment after positioning. Next, internal and external welding and correction are completed, and the arch of the lower main beam segment is detected. After passing the test, the upper and lower main beam segment connecting plates are hoisted and fastened, a plurality of main beam segments are assembled as a whole, and the main beam segments are fixed by electric welding and drilled. The method effectively solves the problems of arch control and welding deformation, and improves the manufacturing efficiency and quality reliability.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of mechanical manufacturing, and particularly relates to an MDEL1000 tire-type carrier and a manufacturing method. BACKGROUND

[0002] With the continuous development of modern engineering construction, the manufacturing and installation demand of large structural parts is increasing. Especially in the field of bridge construction, heavy carrying equipment such as beam lifting machine and tire-type carrier has become an indispensable important tool. The beam lifting machine and the carrier not only need to have sufficient carrying capacity, but also need to meet the strict size, camber and welding quality requirements to ensure the safety and reliability of the structure.

[0003] The traditional beam lifting machine, such as the 550-ton beam lifting machine of China Railway, adopts a single-layer structure, with an outer dimension of 46.19m x 6.15m x 3.7m, and the heaviest segment is 21.56 tons, each segment containing 366 holes. The web and cover plate structure is a part level, with a 60mm camber, and there is no special requirement for the middle part of the main beam web. Although this structure form meets certain use requirements, there are certain technical challenges in the manufacturing and installation process.

[0004] In contrast, the MDEL1000 tire-type carrier adopts a double-layer structure, with an outer dimension of 43.28m x 6.8m x 4.09m, and the heaviest segment reaches 39.46 tons, with 1080 holes per segment. The web and cover plate structure is a component level, with a camber of 80mm, and the connecting plates between the middle parts of the main beam web need to be closely fitted, with a fitting degree requirement of 0mm to 1mm. These characteristics put higher requirements on the manufacturing process, including how to ensure the overall camber value of the main beam, interchangeability and 100% hole rate, and how to control the welding deformation, which are the key points of technical research. SUMMARY

[0005] (I) Technical problems to be solved

[0006] The present application mainly aims at the above problems, and proposes an MDEL1000 tire-type carrier and a manufacturing method, which aims to solve how to ensure the accurate realization of the camber value of the main beam, the interchangeability of the main beam segment and the 100% hole rate, and control the welding deformation of the main beam in the production and manufacturing process.

[0007] (II) Technical solutions

[0008] To achieve the above purpose, the first aspect of the present application provides a manufacturing method of an MDEL1000 tire-type carrier, comprising the following steps:

[0009] The cover plate and the plate group are welded to form a first component, the web plate and the plate group are welded to form a second component, and then the numerical control machining center equipment is used for drilling, the first component is divided into an upper first component and a lower first component, and the second component is divided into an upper second component and a lower second component;

[0010] The shrinkage allowance of the whole main beam is released, and the lower main beam is formed by integrating the lower tool jig frame and the lower partition plate set, after the lower main beam is completed, the lower first component and the lower second component are respectively matched with the jig frame of the lower main beam, and the three-type beam structure is assembled, wherein the lower first component is used as the bottom surface of the three-type beam structure, and the lower second component is used as the side surface of the three-type beam structure;

[0011] After the three-type beam is formed, the connecting plate is matched with the lower second component of the three-type beam structure, the upper partition plate set, the upper tool jig frame, the upper second component and the longitudinal reinforcement are assembled with the connecting plate, after the assembly is completed, the upper first component is matched with the upper second component and is positioned, and the un-welded main beam segment combined by the upper main beam segment and the lower main beam segment is obtained;

[0012] After the main beam segment is assembled, the inner welding of the upper main beam segment and the lower main beam segment is completed, the upper main beam segment is moved from the upper end of the lower main beam segment to a low position, and the outer side welding of the upper main beam segment and the lower main beam segment is respectively performed, and after the welding is qualified, the upper main beam segment and the lower main beam segment are corrected;

[0013] The theodolite is used for detecting the arch degree of the lower main beam segment, after the arch degree is qualified, the upper main beam segment is hoisted on the upper end of the lower main beam segment, and the connecting plate of the upper main beam segment is fastened with the lower main beam segment by using bolts;

[0014] After the main beam segment is assembled, a plurality of main beam segments are made, the plurality of main beam segments are fixed by electric welding of the web plate connecting plate, the cover plate connecting plate and the corresponding web plate and cover plate, and corresponding drilling is performed.

[0015] Further, the blanking process of the web plate further includes releasing the process arch shrinkage allowance and beveling.

[0016] Further, the manufacturing process of the connecting plate further includes blanking, spot welding, overall machining and assembling to form a frame.

[0017] Further, before the drilling is performed by using the numerical control machining center equipment, the first component and the second component after welding are further corrected.

[0018] Further, the correction method includes using the combination of fire attack and cold correction to correct the first component and the second component.

[0019] Further, 20mm shrinkage camber allowance is added to the whole main beam, and a lower main beam is made by integrating the lower tooling jig frame and the lower spacer kit.

[0020] Further, the plurality of main beam segments are fixed by electric welding using the web plate connecting plate, the cover plate connecting plate, and the corresponding web plate and cover plate, and corresponding drilling is performed, in which the web plate and the cover plate are aligned and corresponding drilling is performed using a magnetic drill and a radial drill device.

[0021] To achieve the above-mentioned purpose, the second aspect of the present application provides a MDEL1000 tire carrier made by the manufacturing method described above.

[0022] (III) Beneficial Effects

[0023] Compared with the prior art, the MDEL1000 tire carrier and the manufacturing method provided by the present application aim to solve the technical challenges faced by the traditional beam lifting machine in the manufacturing and installation process. By adopting a double-layer structure design, accurately controlling the camber, and achieving high interchangeability and hole rate, the present application proposes a systematic assembly and welding process, including separately assembling and welding the cover plate and the attached plate, the web plate and the attached plate into components, and then performing numerical control drilling processing; then assembling the lower layer and the upper layer main beam segments in a predetermined order, and performing inside and outside welding and correction, and finally detecting and tightening the bolts through the theodolite detection and screw tightening steps, to ensure the accuracy and stability of the main beam segment as a whole. This method effectively solves the key problems of camber control, welding deformation, and structural fit, and improves the manufacturing efficiency and quality reliability. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 A structure diagram of a MDEL1000 tire carrier disclosed by the present application.

[0025] Figure 2 A structure diagram of a main beam segment disclosed by the present application.

[0026] Figure 3 A structure diagram of a connecting plate disclosed by the present application.

[0027] Figure 4 A structure diagram of a first component disclosed by the present application.

[0028] Figure 5 A structure diagram of a second component disclosed by the present application.

[0029] Figure 6 A structure diagram of a lower main beam disclosed by the present application.

[0030] Figure 7 A structure diagram of a lower main beam provided with a connecting plate disclosed by the present application.

[0031] Figure 8 A pre-assembly structural diagram of a girder segment according to the present application.

[0032] Reference numerals shown in the figure: 1, cover plate; 2, cladding plate; 3, web plate; 4, first component; 5, second component; 6, lower layer jig frame; 7, lower layer partition kit; 8, lower layer girder; 9, connecting plate; 10, girder segment; 11, upper girder segment; 12, lower girder segment; 13, web plate connecting plate; 14, cover plate connecting plate. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present application will be described in detail below with reference to the drawings, and it is obvious that the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0034] It should be noted that when a component is referred to as being "fixed" to another component, it can be directly on the other component or there can be an intervening component. When a component is referred to as being "connected" to another component, it can be directly connected to the other component or there can be an intervening component. When a component is referred to as being "disposed" on another component, it can be directly on the other component or there can be an intervening component. The terms "vertical", "horizontal", "left", "right", and similar terms as used herein are for purposes of description only.

[0035] 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 belongs. The terminology used in the description of the application herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0036] Please refer to Figure 1 The first aspect of the present application provides a manufacturing method of a MDEL 1000 rubber-tired carrier, and the specific steps are as follows:

[0037] First, the cover plate 1 and the cladding plate 2 are welded to form a first component 4 (see Figure 4 ), and the web plate 3 and the cladding plate 2 are welded to form a second component 5 (see Figure 5 ). Then, a numerical control machining center device is used for drilling operation, and then the first component 4 and the second component 5 are respectively divided into two parts of upper layer and lower layer, i.e. upper layer first component and lower layer first component, upper layer second component and lower layer second component.

[0038] Next, in order to ensure the accurate camber of the main girder, the preset camber adjustment is performed on the entire main girder, and the overall lower main girder 8 composed of the lower tool jig frame 6 and the lower partition sleeve kit 7 is made. After the lower main girder 8 is completed, the lower first part and the lower second part are tightly attached to the jig camber surface of the lower main girder 8, and assembled into a three-type girder structure, wherein the lower first part serves as the bottom surface and the lower second part serves as the side surface (see Figure 6 ).

[0039] Then, after the three-type girder structure is formed, the connecting plate 9 is attached to the lower second part (see Figure 3 and Figure 7 ), and the upper partition sleeve kit, the upper tool jig, the upper second part and the longitudinal reinforcement are assembled with the connecting plate 9 (see Figure 8 ). After the assembly is completed, the upper first part and the upper second part are attached and positioned according to the predetermined camber, thereby obtaining a complete unwelded main girder segment.

[0040] After the main girder segment is assembled, the internal welding of the upper main girder segment 11 and the lower main girder segment 12 is performed respectively. After the internal welding is completed, the upper main girder segment 11 is moved to a lower position, and then the external welding of the upper main girder segment 11 and the lower main girder segment 12 is performed respectively. After the welding is completed and the inspection is qualified, the upper main girder segment 11 and the lower main girder segment 12 are corrected.

[0041] The theodolite is used to detect the camber of the lower main girder segment 12, and after the confirmation of the qualification, the upper main girder segment 11 is hoisted onto the lower main girder segment 12, and the connecting plates of the upper and lower main girder segments are firmly connected by the bolt fastening method (see Figure 2 ).

[0042] Finally, a plurality of main girder segments 10 are integrally assembled, the web plates and the cover plates of each segment are welded and fixed by using the web connecting plate 13 and the cover connecting plate 14, and the corresponding drilling operation is performed, thereby finally forming a complete main girder structure (see Figure 1 ).

[0043] Through this systematic manufacturing method, the present application not only effectively solves the technical problems of controlling the camber, welding deformation and structural fit, but also greatly improves the manufacturing efficiency and the reliability of product quality.

[0044] In the blanking process of the web plate, the process camber shrinkage allowance is reserved and the beveling is performed, so as to ensure the accuracy and welding quality of the final structure.

[0045] In addition, the manufacturing process of the connecting plate 9 is also very critical, including the steps of material blanking, spot welding fixing, overall machining and assembly into a frame, so as to ensure the stability and reliability of the connecting part.

[0046] Before drilling with the numerical control machining center equipment, the first part 4 and the second part 5 after welding also need to be corrected. The correction method adopts the combination of fire attack and cold correction to ensure that the flatness and fit of the parts meet the requirements.

[0047] In order to control the camber of the main beam, 20mm shrinkage camber allowance is reserved for the whole main beam, and the integrated lower main beam structure composed of the lower tool cradle 6 and the lower partition sleeve set 7 is made to ensure the dimensional accuracy in the manufacturing process.

[0048] Finally, the plurality of main beam segments 10 are welded and fixed through the web connecting plate 13 and the cover connecting plate 14, and the corresponding drilling operation is carried out. In this process, the magnetic drill and the radial drill are used to align the web and the cover to ensure the accuracy and consistency of the drilling position.

[0049] Through the process research project of MDEL1000 tire type carrier, remarkable results and economic and benefits have been achieved. In terms of economic benefits, the optimization of the connecting plate machining process shortens the production cycle by 15 days, saves 627 kg of materials, avoids the use of 10 tons of drilling mold materials, and saves 75,000 yuan of drilling mold manufacturing cost. In addition, the main beam crane cost is also saved by 70,000 yuan. In terms of benefits, through the process research of this time, the company provides a reference for similar projects, and gropes out the production experience of shrinkage allowance parameters and assembly welding sequence of large closed box structure, which lays a foundation for subsequent process preparation. The successful promotion of the project not only improves the production efficiency, but also reserves a complete and effective technical file for similar products in the future, and lays a solid foundation for extensive cooperation. Finally, the smooth completion of this process research further solidifies the process at the summary meeting, providing valuable reference for the process preparation of subsequent products.

[0050] Therefore, the embodiments should be considered in all respects as illustrative and not restrictive, the scope of the application being defined by the appended claims rather than the description given above, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference signs in the claims should not be construed as limiting the claims. Moreover, the word 'comprising' does not exclude not having anything else contained in the composition, mixture, article, or method that claims the word 'comprising'. The singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. The use of the word "about" in relation to a numerical value preferably means ± 10 % of the value.

[0051] The above examples are only used to illustrate the technical solutions of the present application but not limit the present application, and although the present application has been described in detail with reference to the preferable embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or equivalent replaced without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A method of manufacturing a MDEL 1000 tire handler, characterized by, The method comprises the following steps: The cover plate and the panel are assembled to form a first component, the web plate and the panel are assembled to form a second component, then drilling is performed by using a numerical control machining center device, the first component is divided into an upper first component and a lower first component, and the second component is divided into an upper second component and a lower second component; The whole main beam is placed with a shrinkage camber allowance, and a lower main beam is made by integrating a lower tooling jig frame and a lower partition plate set, after the lower main beam is completed, the lower first component and the lower second component are respectively attached to the jig frame camber surface of the lower main beam to form a three-type beam structure, wherein the lower first component serves as the bottom surface of the three-type beam structure, and the lower second component serves as the side surface of the three-type beam structure; After the three-type beam structure is formed, a connecting plate is attached to the lower second component of the three-type beam structure, an upper partition plate set, an upper tooling jig frame, the upper second component and longitudinal reinforcement are assembled with the connecting plate, after the assembly is completed, the upper first component is attached to the upper second component and is positioned to obtain an unwelded main beam segment which is combined by an upper main beam segment and a lower main beam segment; After the main beam segment is assembled, inner welding of the upper main beam segment and the lower main beam segment is respectively completed, the upper main beam segment is moved from the upper end of the lower main beam segment to a lower position, and outer side welding of the upper main beam segment and the lower main beam segment is respectively performed, after the welding is qualified, the upper main beam segment and the lower main beam segment are corrected; The camber of the lower main beam segment is detected by using a theodolite, after the camber is qualified, the upper main beam segment is hoisted on the upper end of the lower main beam segment, and the connecting plate of the upper main beam segment is fastened to the lower main beam segment by using bolts. After the main beam segment is completely assembled, a plurality of main beam segments are made, the plurality of main beam segments are fixed by electric welding by using web plate connecting plates, cover plate connecting plates and corresponding webs and cover plates, and corresponding drilling is performed.

2. A method of manufacturing a MDEL 1000 tire handler as defined in claim 1, wherein, The web plate further comprises the following steps of placing a process camber shrinkage allowance and beveling.

3. The method of claim 1, wherein the MDEL 1000 tire handler is manufactured by the steps of: The manufacturing process of the connecting plate further comprises the following steps of blanking, spot welding, overall machining and assembling to form a frame.

4. The method of manufacturing a MDEL 1000 tire handler as defined in claim 1, wherein, Before drilling is performed by using the numerical control machining center device, the first component and the second component after welding are further corrected.

5. A method of manufacturing a MDEL 1000 tire handler as defined in claim 4, wherein, The correction method comprises the following steps of combining fire attack and cold correction to correct the first component and the second component.

6. The method of manufacturing a MDEL 1000 tire handler as defined in claim 1, wherein, The whole main beam is placed with a 20mm shrinkage camber allowance, and a lower main beam is made by integrating a lower tooling jig frame and a lower partition plate set.

7. The method of claim 1, wherein the MDEL 1000 tire handler is manufactured by the steps of: The plurality of main beam segments are fixed by electric welding by using web plate connecting plates, cover plate connecting plates and corresponding webs and cover plates, and corresponding drilling is performed, wherein the webs and the cover plates are aligned by using a magnetic drill and a radial drill device to perform corresponding drilling.

8. An MDEL 1000 tire handler characterized by, The manufacturing method is made by the method according to any one of the preceding claims 1-7.

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