A production process of a bridge of an electric double-beam crane

Abstract

The application provides a bridge production process of an electric double-beam crane, and relates to the field of cranes.The bridge production process of the electric double-beam crane comprises a bridge assembly, the bridge assembly comprises a bridge frame, a hollow cavity is formed in the inside of the bridge frame, triangular steels are fixedly connected to four corners in the inside of the hollow cavity, and a rhombic steel is arranged in the inside of the hollow cavity, and the four outer walls of the rhombic steel are fixedly connected with threaded steels.In the application, the I-shaped steel is replaced by the rhombic steel, the weight of the rhombic steel after optimization of the material is generally lighter and the strength is unchanged, and the weight of the I-shaped steel depends on the cross-sectional size and thickness, so that the overall weight of the bridge can be significantly reduced by the rhombic steel, and then the threaded steels are fixed to each outer wall of the rhombic steel, so that each inner wall of the hollow cavity forms a triangle with the rhombic steel, thereby reducing the overall weight and improving the supporting strength.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of cranes, in particular to a bridge production process of an electric double-beam crane. BACKGROUND

[0002] The electric double-beam bridge crane is a large lifting equipment, commonly used in industrial and warehouse fields, which is composed of two main beams to form a bridge structure and can move transversely on the track. The electric double-beam crane has relatively high requirements for the process during production. Not only does it need accurate engineering design and calculation to ensure that the crane can withstand the design load, but also it needs high-strength and wear-resistant materials to ensure the long-term stable operation of the crane. In addition, it needs fine manufacturing and assembly process to ensure the quality and accuracy of each part, and finally it needs regular maintenance and repair to maintain the long-term safety and efficiency of the crane.

[0003] Most of the internal parts of the traditional crane bridge use I-beams to increase the overall bearing effect. However, I-beams have relatively high weight, which may increase the overall weight of the crane if used in the bridge. If other steel materials are used, it may reduce the overall bearing capacity. In addition, some cranes may work at construction sites or ports, which may cause the outer surface to be eroded by dust or sea wind for a long time, thereby reducing the service life of the crane to some extent. Therefore, a bridge production process of an electric double-beam crane is proposed. SUMMARY

[0004] (I) Technical problems to be solved

[0005] In view of the deficiencies of the prior art, the present application provides a bridge production process of an electric double-beam crane, which solves the problem that the use of I-beams increases the overall weight of the crane beam to some extent, and the crane may be eroded by dust and salt contained in sea wind during long-term work at construction sites or ports, thereby reducing the service life.

[0006] (II) Technical solutions

[0007] To achieve the above purpose, the present application is realized by the following technical solutions:

[0008] A bridge production process of an electric double-beam crane, comprising a bridge assembly, the bridge assembly comprising a bridge frame, the bridge frame having a hollow cavity inside, four corners inside the hollow cavity being fixedly connected with triangular steel, the hollow cavity being provided with diamond steel inside, four outer walls of the diamond steel being fixedly connected with threaded steel, one end of the threaded steel away from the diamond steel being fixedly connected with the inner wall of the hollow cavity.

[0009] The bridge production process of the electric double-beam crane comprises the following steps:

[0010] S1. Design stage: design drawings according to customer's requirements, and mark detailed dimensions, materials and specifications on the drawings;

[0011] S2. Material selection: select appropriate raw materials according to the designed drawings, then measure and inspect, and mark lines according to the dimensions and specifications of the design drawings. If the raw material plate is not flat enough, it needs to be corrected by a flattening machine. Finally, it is put into storage for standby;

[0012] S3. Rust removal of materials: first, use a sandblasting machine to preliminarily treat the rust on the surface of the raw material plate. The sandblasting process can quickly remove large areas of rust and old paint. Then, use ultrasonic rust removal process to treat small parts and complex shapes;

[0013] S4. Cutting pretreatment: select water jet cutting machine or laser cutting machine according to the thickness of the plate according to the design drawing. After cutting, remove the residue at the welding site, and grind the welding groove. According to the drawing, drill holes at the corresponding position;

[0014] S5. Spray paint layer: before spraying, the dust on the surface of the raw material needs to be blown off, and the environmental temperature and humidity need to be controlled. Then use a high-pressure airless spray gun to spray one layer of epoxy zinc-rich primer with a thickness of 30μm. Then, after the epoxy zinc-rich primer is dried, two layers of epoxy cloud iron thick paste intermediate paint are sprayed, with a single layer thickness of 80μm. Then, two layers of polyurethane topcoat are sprayed, with a single layer thickness of 27μm. When spraying the paint layer, use a paint spraying robot for automatic spraying, with a spraying error of ±5μm;

[0015] S6. Welding assembly: in the assembly workshop or production line, weld the threaded steel with the four outer walls of the diamond-shaped steel, then weld the threaded steel on the two faces of the diamond-shaped steel with one of the plates, then position and pre-assemble the cut and processed materials according to the design drawing. Use clamps and positioning devices to ensure accurate alignment of each part, and weld other structural parts to connect each part. The welding process includes electric arc welding, gas shielded welding, etc. During the welding process, heat input needs to be controlled to avoid deformation and stress concentration. Finally, use a self-propelled welding robot to weld the threaded steel on the remaining two faces of the diamond-shaped steel inside the bridge frame welded by four plates;

[0016] S7. Quality detection: after welding, perform weld inspection, including visual inspection and non-destructive testing, to ensure that the welding quality meets the standards;

[0017] By the technical scheme, the design of the rhombic steel and the threaded steel inside the hollow cavity helps to effectively disperse the load and enhance the overall structural strength and stability of the bridge, which can improve the performance of the bridge under high load conditions and ensure its safety and reliability, and the spraying of each paint surface in step S5 should be performed after the drying of the upper paint surface, which can be detected by touch or drying instruments to avoid the problem of paint surface peeling caused by the spraying of the lower paint surface before the complete drying of the upper paint surface, and the non-destructive testing can use ultrasonic detection and X-ray detection.

[0018] Further, the rhombic steel is Q460 or S690 high-strength steel, and the composition of the rhombic steel contains carbon fiber reinforced plastic.

[0019] By the technical scheme, the rhombic steel is Q460 or S690 high-strength steel, so that the same or higher strength can be maintained while reducing the weight, and the composition of the rhombic steel contains carbon fiber reinforced plastic, so that the strength and rigidity can be improved without significantly increasing the weight.

[0020] Further, the sand blasting machine in step S3 should use angular grit, quartz sand or siliceous river sand, and the water content should not be more than 1%, and sea sand should be strictly prohibited.

[0021] By the technical scheme, the sand blasting machine in step S3 should use angular grit, quartz sand or siliceous river sand, and the water content should not be more than 1%, which avoids excessive wear of the raw material plate caused by the problem of sand.

[0022] Further, the environmental temperature in step S5 is 10-38℃, and the maximum relative humidity is 85%.

[0023] By the technical scheme, the environmental temperature in step S5 is 10-38℃, and the maximum relative humidity is 85%, which avoids the problem of paint quality caused by environmental problems.

[0024] Further, the pressure of the high-pressure airless spray gun in step S5 is between 7-15 MPa, and the distance between the high-pressure airless spray gun and the workpiece surface is between 15-30 cm.

[0025] By the technical scheme, the pressure of the high-pressure airless spray gun in step S5 is between 7-15 MPa, which provides a more uniform coating, and the distance between the high-pressure airless spray gun and the workpiece surface is between 15-30 cm, which avoids the problem of uneven coating thickness caused by too close distance, and the problem of serious coating mist caused by too far distance, which affects the quality of the coating.

[0026] (Three) beneficial effects

[0027] The application provides a bridge production process of an electric double-beam crane.

[0028] 1、The application provides a bridge production process of an electric double-beam crane, which replaces the channel steel with the rhombic steel, so that the weight of the rhombic steel is generally light and the strength is unchanged, the weight of the channel steel depends on the cross-sectional size and thickness, the overall weight of the bridge can be significantly reduced through the rhombic steel, then the multiple threaded steels are fixed to each outer wall of the rhombic steel, so that each inner wall of the hollow cavity forms a triangle with the rhombic steel, thereby improving the supporting strength while reducing the overall weight.

[0029] 2、The application provides a bridge production process of an electric double-beam crane, which is simple and reasonable, greatly improves the rigidity of the crane bridge, through electric arc welding and gas shielded welding, the welding deformation is small, the weld strength is high, the residual stress is small, the carrying capacity of the crane is improved, the service life is prolonged, the manufacturing cost is reduced, and the economic benefit of the enterprise is improved.

[0030] 3、The application provides a bridge production process of an electric double-beam crane, through the multi-layer spraying process, the corrosion resistance of the bridge assembly is significantly improved, which can effectively prolong the service life of the crane and reduce the maintenance cost in the later use, and through this production process, the overall quality and performance of the electric double-beam crane bridge assembly can be effectively improved, and the failure rate can be reduced. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 It is a partial axial sectional view of the application;

[0032] Figure 2 It is an elevation view of the application.

[0033] Among them, 1, bridge assembly; 101, bridge frame; 102, hollow cavity; 103, rhombic steel; 104, triangular plate; 105, threaded steel. DETAILED DESCRIPTION

[0034] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, not all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the application.

[0035] Embodiment:

[0036] A bridge production process for an electric double-girder crane includes a bridge assembly 1, wherein the bridge assembly 1 includes a bridge frame 101. A hollow cavity 102 is defined within the bridge frame 101. Triangular steels 104 are fixedly connected to the four corners of the hollow cavity 102. Diamond steels 103 are disposed within the hollow cavity 102. Threaded steels 105 are fixedly connected to the four outer walls of the diamond steels 103. Ends of the threaded steels 105 away from the diamond steels 103 are fixedly connected to the inner wall of the hollow cavity 102.

[0037] The design of using diamond steel 103 and threaded steel 105 inside the hollow cavity 102 helps to effectively distribute the load and enhance the overall structural strength and stability of the bridge. This design can improve the performance of the bridge under high load conditions and ensure its safety and reliability.

[0038] The bridge production process of the electric double-girder crane includes the following steps:

[0039] S1. Design stage: Design drawings according to customer needs and mark detailed dimensions, materials and specifications on the drawings;

[0040] S2. Material selection: Select appropriate raw materials based on the design drawings. Then, after measurement and inspection, mark them according to the dimensions and specifications of the design drawings. If the raw material sheets are not flat enough, they need to be leveled and finally stored for future use.

[0041] S3. Rust removal: First, use a sandblaster to remove any rust from the surface of the raw material sheet. Sandblasting can quickly remove large areas of rust and old coatings. Then, ultrasonic rust removal is used to treat small parts and complex shapes.

[0042] S4. Cutting pretreatment: Select water jet cutting machine or laser cutting machine to cut according to the thickness of the plate in the design drawing. After cutting, remove the residue in the welding part, grind the welding groove, and drill holes in the corresponding positions according to the drawing;

[0043] S5. Paint spraying: Before spraying, dust on the raw material surface must be blown away, and the ambient temperature and humidity must be controlled. Then, use a high-pressure airless spray gun to spray a layer of epoxy zinc-rich primer with a thickness of 30μm. After the epoxy zinc-rich primer is air-dried, two layers of epoxy micaceous iron thick paste intermediate paint are sprayed, with a single layer thickness of 80μm. Then, two layers of polyurethane topcoat are sprayed, with a single layer thickness of 27μm. The paint layer is sprayed automatically by a paint spraying robot, with a spraying error of ±5μm.

[0044] S6. Welding assembly: In the assembly workshop or production line, the threaded steel 105 is welded with the four outer walls of the diamond steel 103 respectively, and then the threaded steel 105 on both sides of the diamond steel 103 is welded with one of the plates. Then the cut and processed materials are positioned and pre-assembled according to the design drawings, the clamps and positioning devices are used to ensure the accurate alignment of each part, and other structural parts are welded, connected and welded, and the welding process includes arc welding, gas shielded welding, etc. During the welding process, the heat input needs to be controlled to avoid deformation and stress concentration. Finally, the self-propelled welding robot enters the bridge frame 101 welded by four plates to weld the threaded steel 105 on the remaining two sides of the diamond steel 103.

[0045] S7. Quality inspection: After welding, the weld inspection is carried out, including visual inspection and non-destructive testing, to ensure that the welding quality meets the standard.

[0046] Each paint surface in step S5 should be sprayed after the upper paint surface is dry. Touching method or drying instrument can be used for detection to avoid the problem of paint peeling caused by spraying the lower paint surface before the upper paint surface is completely dry. Non-destructive testing can use ultrasonic detection and X-ray detection.

[0047] The diamond steel 103 is Q460 or S690 high-strength steel, and the composition of the diamond steel 103 contains carbon fiber reinforced plastic. By using Q460 or S690 high-strength steel for the diamond steel 103, the same or higher strength can be maintained while reducing weight. By adding carbon fiber reinforced plastic to the composition of the diamond steel 103, the strength and stiffness can be improved without significantly increasing the weight.

[0048] In step S3, the sandblasting machine should use angular grit, quartz sand or siliceous river sand, and the water content should not be more than 1%, and sea sand should be strictly prohibited. By using angular grit, quartz sand or siliceous river sand with water content not more than 1% in step S3, the problem of excessive wear of raw material plates caused by sand is avoided.

[0049] In step S5, the environmental temperature is 10℃ to 38℃, and the maximum relative humidity is 85%. By controlling the environmental temperature to be 10℃ to 38℃ and the maximum relative humidity to be 85% in step S5, the problem of paint quality caused by environmental problems is avoided.

[0050] The pressure of the high-pressure airless spray gun in step S5 is between 7-15 MPa, and the distance between the high-pressure airless spray gun and the workpiece surface is between 15-30 cm. The pressure of the high-pressure airless spray gun in step S5 is between 7-15 MPa, so that a more uniform coating is provided. The distance between the high-pressure airless spray gun and the workpiece surface is between 15-30 cm, so that the coating thickness is not uniform due to the distance being too close, and the coating is not atomized too much due to the distance being too far, which affects the quality of the coating.

[0051] While embodiments of the application have been shown and described, it is to be understood that the embodiments described are merely divergences of the principles and spirit of the application and that numerous modifications, changes, substitutions, and alterations can be made thereto without departing from the spirit and scope of the application as defined by the appended claims and their equivalents.

Claims

1. A bridge production process for an electric double-girder crane, the bridge comprising a bridge assembly (1), characterized in that: The bridge assembly (1) includes a bridge frame (101), a hollow cavity (102) is provided inside the bridge frame (101), four corners inside the hollow cavity (102) are fixedly connected with triangular steels (104), a diamond steel (103) is provided inside the hollow cavity (102), four outer walls of the diamond steel (103) are fixedly connected with threaded steels (105), and one end of the threaded steel (105) away from the diamond steel (103) is fixedly connected to the inner wall of the hollow cavity (102); The bridge production process of the electric double-girder crane includes the following steps: S1. Design stage: Design drawings according to customer needs and mark detailed dimensions, materials and specifications on the drawings; S2. Material selection: Select appropriate raw materials based on the design drawings. Then, after measurement and inspection, mark them according to the dimensions and specifications of the design drawings. If the raw material sheets are not flat enough, they need to be leveled and finally stored for future use. S3. Rust removal: First, use a sandblaster to remove any rust from the surface of the raw material sheet. Sandblasting can quickly remove large areas of rust and old coatings. Then, ultrasonic rust removal is used to treat small parts and complex shapes. S4. Cutting pretreatment: Select water jet cutting machine or laser cutting machine to cut according to the thickness of the plate in the design drawing. After cutting, remove the residue in the welding part, grind the welding groove, and drill holes in the corresponding positions according to the drawing; S5. Paint spraying: Before spraying, dust on the raw material surface must be blown away, and the ambient temperature and humidity must be controlled. Then, use a high-pressure airless spray gun to spray a layer of epoxy zinc-rich primer with a thickness of 30μm. After the epoxy zinc-rich primer is air-dried, two layers of epoxy micaceous iron thick paste intermediate paint are sprayed, with a single layer thickness of 80μm. Then, two layers of polyurethane topcoat are sprayed, with a single layer thickness of 27μm. The paint layer is sprayed automatically by a paint spraying robot, with a spraying error of ±5μm. S6. Welding assembly: In an assembly workshop or production line, the threaded steel (105) is welded to the four outer walls of the diamond steel (103) respectively, and then the threaded steel (105) on two sides of the diamond steel (103) is welded to one of the plates. Then, the cut and processed materials are positioned and pre-assembled according to the design drawings. Fixtures and positioning devices are used to ensure that each part is accurately aligned, and other structural parts are welded to connect the various parts. The welding process includes arc welding and gas shielded welding. The heat input needs to be controlled during the welding process to avoid deformation and stress concentration. Finally, a self-propelled welding robot is used to enter the interior of the bridge frame (101) welded by the four plates to weld the threaded steel (105) on the remaining two sides of the diamond steel (103); S7. Quality inspection: After welding is completed, weld inspection is carried out, including visual inspection and non-destructive testing to ensure that the welding quality meets the standards.

2. The bridge production process of an electric double-girder crane according to claim 1, characterized in that: The diamond steel (103) is Q460 or S690 high-strength steel, and the diamond steel (103) contains carbon fiber reinforced plastic.

3. The bridge production process of an electric double-girder crane according to claim 1, characterized in that: In step S3, the sandblasting machine should use ridged corundum, quartz sand or siliceous river sand, the water content of which should not be greater than 1%, and the use of sea sand is strictly prohibited.

4. The bridge production process of an electric double-girder crane according to claim 1, characterized in that: In step S5, the ambient temperature is 10° C. to 38° C., and the maximum relative humidity is 85%.

5. The bridge production process of an electric double-girder crane according to claim 1, characterized in that: In step S5, the pressure of the high-pressure airless spray gun is between 7-15 MPa, and the distance between the high-pressure airless spray gun and the workpiece surface is between 15-30 cm.

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