Manufacturing process for main trolley structure of single-beam quay crane

Abstract

The invention relates to the technical field of trolley manufacturing, and discloses a single-beam quay crane main trolley structure manufacturing process which comprises the following steps: production design of parts: the deformation amount of a main trolley frame during suspension is considered in the production design of the parts in advance, and the deformation amount needs to be applied and cut in a part state; machining allowance needs to be added to wheel holes in the two ends of the walking beam in the part production design stage; manufacturing a main trolley frame structure; a main trolley walking beam structure is manufactured; manufacturing a cab hanger of the lower structure of the main trolley; and manufacturing a middle group structure. As the whole frame structure of the trolley frame is too large and too soft, the trolley frame is manufactured by sub-components and groups, then the sub-components are manufactured in sequence, a dummy shaft tool is adopted for assembling and positioning, and finally the upper and lower components are integrally folded and machined, so that the levelness, straightness and perpendicularity of a walking beam and a steel wire rope structure are effectively controlled; unnecessary transportation, turning and reworking costs are reduced, the manufacturing cost is reduced, and the requirement for the machining capacity of machining equipment is lowered.

Description

Technical Field

[0001] The invention relates to the field of trolley manufacturing, and in particular to a manufacturing process of a main trolley structure of a single-beam quay crane. Background Art

[0002] In recent years, with the rapid development of single-beam quay cranes in ports, the trolleys of single-beam quay cranes are widely used in ports, docks and logistics industries. They are one of the important tools for realizing rapid transshipment of container cargo and efficient logistics operations. At container terminals, trolleys can quickly and accurately transport cargo to cargo yards or finished product warehouses, which improves the work efficiency of container terminals, shortens the berthing time of ships, and reduces operating costs. In logistics transportation, trolleys can also quickly and efficiently complete the task of cargo transportation, improve transportation efficiency and cargo safety. The trolley is the component of the crane responsible for handling cargo. It includes components such as the trolley frame, drive system, traveling mechanism, driving mechanism, driver's cab bracket, suspension traction system, transmission system, brake system, and electrical control system. The operation of the trolley is mainly completed by the drive system and traveling mechanism. The trolley is equipped with an electric motor and a reducer to control the travel speed of the trolley. The trolley travels on the track through the driving mechanism, and the suspension traction system is responsible for grabbing the container, and then the transmission system is used to lift the container and transport it to the required location. The overall structure of the trolley is a frame structure, mainly an I-beam structure. Since there is a frame of the inverted driver's cab at the lower end, the overall structure is irregular, the center of gravity is not centered, and the overall height is relatively high. The wheel span of the trolley will be opened due to the load. The span will be opened due to the weight of the trolley plus the lifting load. Therefore, each leg should be tilted, causing the trolley walking beam to tilt. The four wheels of the trolley must eventually be correctly aligned, requiring wheel positioning that all four wheels should be accurately in the horizontal plane. At the same time, the horizontal and vertical precision requirements of the wire rope wheel sleeve at the lower end are relatively high, which brings certain difficulties to manufacturing, machining and transportation.

[0003] The patent application with publication number CN 110539131B discloses a method for building a gantry crane trolley, which relates to the field of lifting machinery technology. The trolley structure is divided into a platform structure, a leg structure, and an equipment mechanism. The platform structure includes a platform main beam and a platform connecting beam. The construction method is as follows: the platform structure and the leg structure are disassembled into multiple independent box units, which are first prefabricated and formed separately, and then the assembly benchmarks are marked to assemble and weld the box units of the platform structure, and the upper equipment mechanism is installed by overall leveling, and finally the box units of the leg structure are positioned and installed; the platform main beam of the platform structure is added with welding anti-deformation according to the beam arch value designed for the trolley frame; the equipment mechanism is connected to the processed base in advance and then installed on the frame platform structure to shorten the mechanism installation cycle.

[0004] In the prior art, the weight of the trolley plus the lifting load are heavy, and the span of the trolley wheels is easily opened, causing the legs to tilt and the trolley walking beam to tilt. Therefore, the horizontal and vertical precisions required by the trolley are difficult to manufacture, machine and transport.

[0005] Therefore, a new technical solution is needed to solve the above technical problems. Summary of the invention

[0006] The purpose of the present invention is to provide a manufacturing process for the main trolley structure of a single-beam quay crane. In view of the fact that the overall frame structure of the trolley frame is relatively large and the structure is relatively soft, it is manufactured by sub-components and groups, and then assembled in sequence, and assembled and positioned by a dummy shaft tooling. Finally, the upper and lower components are closed as a whole and machined, which effectively controls the horizontality, straightness and verticality of the walking beam and the wire rope structure, reduces unnecessary transportation, turning over and rework costs, reduces manufacturing costs, and reduces the processing capacity requirements for machining equipment.

[0007] The technical solution adopted by the present invention is: A single-beam quay crane main trolley structure manufacturing process comprises the following steps: Step 1: Part production design: The deformation of the main trolley frame when it is suspended should be taken into account in advance in the production design of the parts. The deformation should be placed and cut in the part state. The wheel holes at both ends of the walking beam should be added with machining allowances during the part production design stage. Step 2: Make the main trolley frame structure; Step 3: Make the main trolley walking beam structure; Step 4: Make the driver's cab bracket of the lower structure of the main trolley; Step 5: Make the middle group structure.

[0008] Preferably, step 2 comprises the following steps: Step 2-1: On a horizontal frame, the web plates of the U-shaped frame structure in the frame are assembled; Step 2-2: Assemble and weld the panels of the frame, using a welding trolley to form a U-shaped frame structure; Step 2-3: On the horizontal tire frame, make the bottom frame piece of the I-beam support group; Step 2-4: On the horizontal tire frame, the bottom middle I-beam is assembled first to form the bottom frame sheet 4, U-shaped components are assembled on both sides of the bottom frame sheet 4, and pipe diagonal braces are assembled. The pipe diagonal braces include components a, b, c, and d to form a three-dimensional frame structure.

[0009] Preferably, step 3 comprises the following steps: Step 3-1: Make the walking beam in reverse, and assemble the top plate and side plates of the walking beam on the horizontal tire frame. First assemble the top plate, then assemble the partition plate, and the bottom plate is the last closing plate; Step 3-2: Use the structural centerline as the reference line, assemble the partitions, draw lines on the top plate partitions, and use the machine to spray powder and draw lines when unloading parts. Position directly on site according to the powder spray lines; Step 3-3: Position according to the powder spraying marking lines, assemble the side panels, weld the partitions, and when welding the partitions to the top panels, start from the middle partition and have two people weld from the middle to both sides. The welding directions of the fillet welds on both sides of the same partition must be opposite; Step 3-4: The bottom plate is used as the final cover plate, and the two sides are welded to the web plate on one side to form a walking beam.

[0010] Preferably, step 4 comprises the following steps: Step 4-1: The I-beam of the pipe diagonal brace a is first made into a group, and a slow welding area is left at both ends of the I-beam group. The pipe and the end head plate and the connecting plate are first made into a group. The connecting plate parts are punched in the state. After the group, the connecting plate on the pipe and the connecting plate on the structure are tightened with process bolts, and welded to the structure when closed.

[0011] Step 4-2: With the bottom surface as the reference plane and the center line of the structure as the reference line, build on the tire frame, assemble the vertical I-beam on one side first, assemble the middle bend reinforcement, assemble the vertical I-beam on the other side, assemble the I-beam and the middle bend reinforcement that connect the end to the upper structure, assemble small parts, and then weld and correct, punch and mark the reference line and closing line to form the lower structure driver's cab frame component.

[0012] Preferably, step 5 comprises the following steps: Step 5-1: Lift the main trolley frame structure onto the horizontal tire frame, take the center of the structure as the reference line, measure the margin line at the connection between the frame and the walking beam, and trim the margin; Step 5-2: After trimming the excess, assemble the walking beam of the main trolley, weld the closing mouth of the walking beam, and form the upper structure of the main trolley after welding; in order to prevent the structure from deforming during transportation, it is necessary to add support after welding the upper structure, use channel steel to punch holes, and tighten the bolts with the original structure holes to increase the structural strength; Step 5-3: Remake the tire frame, lift the upper components of the main trolley, assemble the lower cab bracket components, connect the pipe diagonal brace b of the cab bracket components of the upper frame structure of the main trolley, first make a group with the end head plate and the connecting plate, and punch holes in the connecting plate parts. After the group, tighten the connecting plate on the pipe and the connecting plate on the structure with the process bolts and weld them to the structure to ensure the angle; Step 5-4: Install the wire rope wheel sleeve. The sleeve has been machined in the part state and is positioned with a dummy shaft to ensure coaxiality. After positioning, weld it. After welding, use the manufactured dummy wheel tooling to check the verticality of the sleeve. Step 5-5: Using the center line of the wheel of walking beam 1 as the reference, use boring to machine the main trolley walking beam as a whole.

[0013] By adopting the above process, the overall frame structure of the trolley frame is relatively large and the structure is relatively soft. It is produced by sub-components and groups, then assembled in sequence, and assembled and positioned using dummy shaft tooling. Finally, the upper and lower components are closed as a whole and machined, which effectively controls the horizontality, straightness and verticality of the walking beam and wire rope structure, reduces unnecessary transportation, turning over and rework costs, reduces manufacturing costs, and reduces the processing capacity requirements for machining equipment.

[0014] Preferably, in step 2-1, when the web panels are made, the deformation of the main trolley frame when it is suspended is reflected by first making panels according to the panel marking diagram.

[0015] By adopting the above process, the welding deformation can be reduced.

[0016] Preferably, in step 2-3, a 200 mm slow-welding zone is reserved between the panel and the web of the I-beam support group for adjusting the panel docking during assembly.

[0017] By adopting the above process, panel misalignment is reduced.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. When manufacturing the present invention, the deadweight and lifting load of the trolley are considered in advance, each leg of the trolley frame is tilted, the span of the overall trolley wheel is opened, and the wheel hole is tilted according to the inclination of the leg during the later machining, thereby ensuring the accuracy of the deadweight and the lifting load when the trolley is finally running on the beam.

[0019] 2. The device of the present invention adopts a dummy shaft to install the HALF sleeve of the wire rope wheel, and the sleeve is given a margin. The sleeve is machined in place according to the drawing in the component state. During installation, the sleeve is installed at both ends of the dummy shaft for positioning. When the dummy wheel is positioned, the verticality of the sleeve is detected, thereby improving the assembly accuracy and avoiding rework at a later stage.

[0020] 3. In view of the fact that the overall frame structure of the trolley frame is relatively large and the structure is relatively soft, the present invention adopts sub-components and small groups to manufacture, and then manufactures them in sequence, adopts dummy shaft tooling to assemble and position, and finally the upper and lower components are closed as a whole and machined, which effectively controls the horizontality, straightness and verticality of the walking beam and the wire rope structure, reduces unnecessary transportation, turning over and rework costs, reduces manufacturing costs, and reduces the processing capacity requirements for machining equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 This is a front view of the overall trolley structure of the present invention; Figure 3 The present invention is a side view of the overall trolley structure; Figure 4 A schematic diagram of an I-beam U-shaped assembly (walking legs) of the group structure of the present invention; Figure 5 A schematic diagram of a three-dimensional frame structure of the group structure of the present invention; Figure 6 This is a schematic diagram of the walking beam structure of the group structure of the present invention; Figure 7 A schematic diagram of a driver's cab bracket component of the group structure of the present invention; Figure 8 The components of the group structure in the present invention are mounted on the frame to form a schematic diagram of the upper components of the main trolley; Fig. 9 It is a schematic diagram of the pipe diagonal brace of the main trolley upper frame structure connected to the driver's cab hanger in the group structure of the present invention; Fig.10 It is a schematic diagram of the assembly structure of the present invention using a false shaft to position and install the shaft sleeve.

[0022] Among them: 1. Walking beam; 2. Pipe diagonal brace; 2-1. Component a; 2-2. Component b; 2-3. Component c; 2-4. Component d; 3. U-shaped frame structure; 4. Bottom frame sheet; 5. Pipe diagonal brace b; 6. Pipe diagonal brace a; 7. Driver's cab bracket; 9. Vertical I-beam. DETAILED DESCRIPTION

[0023] like Figure 1-10 As shown, a manufacturing process of a single-beam quay crane main trolley structure includes the following steps: Step 1: Part production design: The deformation of the main trolley frame when it is suspended should be taken into account in advance in the production design of the parts. The deformation should be placed and cut in the part state. The wheel holes at both ends of the walking beam should be added with machining allowances during the part production design stage. Step 2: Make the main car frame structure: Step 2-1: On the horizontal tire frame, the web of the U-shaped frame structure 3 in the frame is assembled and made into a plank drawing. The deformation of the main trolley frame when it is suspended is reflected by first assembling the planks, and the web is tilted according to the plank drawing; Step 2-2: Assemble and weld the panels of the frame, use a welding trolley to weld, reduce welding deformation, and form a U-shaped frame structure 3, i.e., the walking beam legs, such as Figure 4 As shown; Step 2-3: On the horizontal tire frame, the bottom frame piece 4 of the I-beam support group is manufactured. A 200mm slow welding area is reserved between the panel and the web of the I-beam support group to adjust the panel docking during assembly and reduce panel misalignment; Step 2-4: On the horizontal tire frame, the bottom middle I-beam is assembled first to form the bottom frame sheet 4, and U-shaped components are assembled on both sides of the bottom frame sheet 4, and the pipe diagonal brace 2 is assembled. The pipe diagonal brace 2 includes components a2-1, b2-2, c2-3, and d2-4 to form a three-dimensional frame structure, such as Figure 5 As shown; Step 3: Make the main trolley walking beam structure: Step 3-1: The walking beam 1 is reversed, and the top plate and side plates of the walking beam 1 are assembled on the horizontal tire frame. The top plate is assembled first, and then the partition plate is assembled. The bottom plate is the last plate to be closed, which reduces turning over, reduces the production cycle, and improves production efficiency; Step 3-2: Use the structural centerline as the reference line to assemble the partitions and mark the top partitions. When unloading parts, the machine sprays powder and marks the lines. The on-site positioning is directly based on the powder spraying lines to reduce the error rate and improve efficiency. Step 3-3: Position according to the powder spraying marking lines, assemble the side panels, weld the partitions, and when welding the partitions to the top panels, start from the middle partition and have two people weld from the middle to both sides. The welding directions of the fillet welds on both sides of the same partition must be opposite; Step 3-4: The bottom plate is used as the final cover plate, and the two sides are welded to the web plate on one side to form a walking beam 1, such as Figure 6 As shown, the broken axle protection device, the width direction of the part is increased to 100mm, the part is machined, and the assembly and welding are performed after the cross center line of the walking beam wheel is determined. When installing, pay attention to the distance from the upper end of the part to the track surface, and the distance from the outer end to the center of the track; Step 4: Make the main trolley lower structure cab bracket: Step 4-1: The I-beam of the pipe diagonal brace a6 is first made into a group, and the slow welding area is left at both ends of the I-beam group. The pipe and the end head plate and the connecting plate are first made into a group. The connecting plate parts are punched in the state. After the group, the connecting plate on the pipe and the connecting plate on the structure are tightened with process bolts. When closed, they are welded with the structure to ensure that the holes on the connecting plate can be adapted to avoid the holes not matching due to welding deformation when welding separately, such as Fig. 9 shown.

[0024] Step 4-2: With the bottom surface as the reference surface and the structure center line as the reference line, build on the tire frame, assemble the vertical I-beam 9 on one side first, assemble the middle bend reinforcement, assemble the vertical I-beam 9 on the other side, assemble the I-beam and the middle bend reinforcement connecting the end of the upper structure, assemble small parts, and then weld and correct, punch the reference line and the closing line sample mark to form the lower structure cab bracket 7 component, such as Figure 7 As shown; Step 5: Make the middle group structure: Step 5-1: Lift the main trolley frame structure onto the horizontal tire frame, take the center of the structure as the reference line, measure the margin line at the connection between the frame and the walking beam, and trim the margin; Step 5-2: After trimming the excess, assemble the walking beam 1 of the main trolley, weld the closing mouth of the walking beam 1, and form the upper component of the main trolley after welding, such as Figure 8 As shown; in order to prevent the structure from deforming during transportation, it is necessary to add support after the upper structure is welded, use channel steel to punch holes, and tighten the bolts with the original structure holes to increase the structural strength; Step 5-3: Remake the tire frame, lift the upper components of the main trolley, assemble the lower cab bracket component 7, connect the upper frame structure of the main trolley to the pipe diagonal brace b5 of the cab bracket component 7, and first make a group with the end head plate and the connecting plate (the connecting plate parts are equipped with punching), and then tighten the connecting plate on the pipe and the connecting plate on the structure with the process bolts and weld them to the structure to ensure the angle; Step 5-4: Install the wire rope wheel sleeve, use a dummy shaft for installation, the sleeve has been machined in the part state, use a dummy shaft for positioning, add a margin to the sleeve to ensure coaxiality, install the sleeve at both ends of the dummy shaft for positioning, check the verticality of the sleeve when positioning the dummy wheel, improve the assembly accuracy, avoid rework later, weld after positioning, and use the manufactured dummy wheel tooling to check the verticality of the sleeve, such as Fig.10 As shown; Step 5-5: Using the center line of the wheel of walking beam 1 as the reference, use boring to machine the main trolley walking beam as a whole.

[0025] The process of the present invention aims at the problem that the overall frame structure of the trolley frame is relatively large and the structure is relatively soft. It is manufactured by dividing the components and groups, then assembling them in sequence, and using a dummy shaft tooling to assemble and position them. Finally, the upper and lower components are closed as a whole and machined, which effectively controls the horizontality, straightness and verticality of the walking beam and the wire rope structure, reduces unnecessary transportation, turning over and rework costs, reduces manufacturing costs, and reduces the processing capacity requirements for machining equipment.

[0026] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by those skilled in the art should be included in the protection scope determined by the claims of the present invention.

Claims

1. A manufacturing process for the main trolley structure of a single-beam quay crane. Features: The following steps are involved: Step 1: Part production design: The deformation of the main trolley frame when it is suspended should be taken into account in advance in the production design of the parts. The deformation should be placed and cut in the part state. The wheel holes at both ends of the walking beam should be added with machining allowances during the part production design stage. Step 2: Make the main trolley frame structure; Step 3: Make the main trolley walking beam structure; Step 4: Make the driver's cab bracket of the lower structure of the main trolley; Step 5: Make the middle group structure.

2. According to the manufacturing process of the single-beam quay crane main trolley structure of claim 1, Features: The step 2 comprises the following steps: Step 2-1: On a horizontal frame, the web plates of the U-shaped frame structure in the frame are assembled; Step 2-2: Assemble and weld the panels of the frame, using a welding trolley to form a U-shaped frame structure; Step 2-3: On the horizontal tire frame, make the bottom frame piece of the I-beam support group; Step 2-4: On the horizontal tire frame, the bottom middle I-beam is assembled first to form the bottom frame sheet 4, U-shaped components are assembled on both sides of the bottom frame sheet 4, and pipe diagonal braces are assembled. The pipe diagonal braces include components a, b, c, and d to form a three-dimensional frame structure.

3. According to the manufacturing process of the single-beam quay crane main trolley structure of claim 1, Features: The step 3 comprises the following steps: Step 3-1: Make the walking beam in reverse, and assemble the top plate and side plates of the walking beam on the horizontal tire frame. First assemble the top plate, then assemble the partition plate, and the bottom plate is the last closing plate; Step 3-2: Use the structural centerline as the reference line, assemble the partitions, mark the top partitions, and use the machine to spray powder and draw lines when unloading parts. Position directly on site according to the powder spray lines; Step 3-3: Position according to the powder spraying marking lines, assemble the side panels, weld the partitions, and when welding the partitions to the top panels, start from the middle partition and have two people weld from the middle to both sides. The welding directions of the fillet welds on both sides of the same partition must be opposite; Step 3-4: The bottom plate is used as the final cover plate, and the two sides are welded to the web plate on one side to form a walking beam.

4. According to the manufacturing process of the main trolley structure of a single-beam quay crane according to claim 1, Features: The step 4 comprises the following steps: Step 4-1: The I-beam of the pipe diagonal brace a is first made into a group, and the slow welding area is left at both ends of the I-beam group. The pipe and the end head plate and the connecting plate are first made into a group. The connecting plate parts are punched in the state. After the group, the connecting plate on the pipe and the connecting plate on the structure are tightened with process bolts, and welded to the structure when closed; Step 4-2: With the bottom surface as the reference plane and the center line of the structure as the reference line, build on the tire frame, assemble the vertical I-beam on one side first, assemble the middle bend reinforcement, assemble the vertical I-beam on the other side, assemble the I-beam and the middle bend reinforcement that connect the end to the upper structure, assemble small parts, and then weld and correct, punch and mark the reference line and closing line to form the lower structure driver's cab frame component.

5. According to the manufacturing process of the single-beam quay crane main trolley structure of claim 1, Features: The step 5 comprises the following steps: Step 5-1: Lift the main trolley frame structure onto the horizontal tire frame, take the center of the structure as the reference line, measure the margin line at the connection between the frame and the walking beam, and trim the margin; Step 5-2: After trimming the excess, assemble the walking beam of the main trolley, weld the closing mouth of the walking beam, and form the upper structure of the main trolley after welding; in order to prevent the structure from deforming during transportation, it is necessary to add support after welding the upper structure, use channel steel to punch holes, and tighten the bolts with the original structure holes to increase the structural strength; Step 5-3: Remake the tire frame, lift the upper components of the main trolley, assemble the lower cab bracket components, connect the pipe diagonal brace b of the cab bracket components of the upper frame structure of the main trolley, first make a group with the end head plate and the connecting plate, and punch holes in the connecting plate parts. After the group, tighten the connecting plate on the pipe and the connecting plate on the structure with the process bolts and weld them to the structure to ensure the angle; Step 5-4: Install the wire rope wheel sleeve. The sleeve has been machined in the part state and is positioned with a dummy shaft to ensure coaxiality. After positioning, weld it. After welding, use the manufactured dummy wheel tooling to check the verticality of the sleeve. Step 5-5: Using the center line of the wheel of walking beam 1 as the reference, use boring to machine the main trolley walking beam as a whole.

6. A manufacturing process for a single-beam quay crane main trolley structure according to claim 2, Features: In step 2-1, when the web panels are made, the deformation of the main trolley frame when it is suspended is reflected by first assembling the panels according to the panel marking diagram.

7. According to claim 2, a manufacturing process for a main trolley structure of a single-beam quay crane, Features: In the steps 2-3, a 200 mm slow-welding zone is reserved between the panel and the web of the I-beam support group for adjusting the panel butt joint during assembly.

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