Small steel pile trolley construction process

Abstract

The invention relates to a small steel pile trolley construction process. The small steel pile trolley construction process comprises the following steps that 1, a trolley track and a trolley body structure are manufactured; 2, trolley walking roller and horizontal roller assemblies are manufactured; 3, trolley track scribing and machining are carried out; 4, trolley body lineation and roller assembly installation; step 5, trolley general assembly test; according to the small steel pile trolley construction technology, the trolley walking assembly and the trolley body structure can be synchronously manufactured and integrally installed, only the trolley track needs to be machined on site, cross operation of multiple types of work on site is reduced, construction efficiency is improved, the total construction period is shortened by 15 days, and in the whole construction process, the construction cost is reduced. By finely controlling the manufacturing precision, the horizontal deviation can be controlled within the range of 4 mm after the trolley is integrally installed, and the use requirement of a trolley walking mechanism is met.

Description

Technical Field

[0001] The invention relates to the technical field of shipbuilding, and in particular to a construction process of a small steel pile trolley. Background Art

[0002] The steel pile trolley system is mainly used on cutter suction dredgers for fixing and moving the dredger during operation. During dredging operation, the hydraulic system is used to drive the trolley travel cylinder and the steel pile lifting cylinder to move. The steel pile and the trolley form an integral rigid connection. The steel pile extends into the seabed or riverbed and is fixed at the predetermined operating position. The travel cylinder pushes the trolley, and the trolley transmits the driving force to the hull to realize the hull displacement and rotation.

[0003] The core component of the steel pile trolley system is the trolley travel system, which mainly includes the trolley body, trolley track, trolley travel rollers, trolley guide rollers and other components. The rollers of the trolley travel system and the matching roller shafts, bearings and other moving parts have a small clearance and are all machined parts. In order to ensure the mechanical properties of the components, the conventional process route is: 1. Structural production; 2. Stress release of structural parts; 3. Welding of machined parts such as roller shafts with margins; 4. On-site machining of roller shafts; 5. Installation of bearings, rollers and other components.

[0004] The conventional process is to weld the roller shaft with machining allowance on the structural parts, and then machine it on site after the structure is made to ensure the final assembly size and positioning data. The precision of on-site machining is not easy to ensure, mainly because the on-site machining cycle is long. During the machining period, in order to ensure the machining precision, other types of work need to be staggered, which leads to the extension of the project construction cycle and affects the project progress.

[0005] Therefore, the present invention proposes a small steel pile trolley construction process to solve the above problems. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a small steel pile trolley construction process, in which structural parts and machined parts are manufactured separately, constructed synchronously, and the construction period is shortened.

[0007] In order to solve the above technical problems, the technical solution of the present invention is: a small steel pile trolley construction process, the innovation of which is: comprising the following steps: Step 1: The trolley track and trolley body structure are manufactured. During the manufacturing process, the construction accuracy is controlled within the range of ±4mm. The three-dimensional coordinates of the detection part are generated by a total station, and matched and analyzed with the model data to ensure the accuracy of the structure construction; Step 2: The trolley travel roller and horizontal roller assembly are manufactured in the machining workshop, processed by machine tools, and installed into roller assemblies. Testing equipment is used to ensure that the processing and installation accuracy is controlled within the range of 0-0.3mm; Step 3: Marking and machining of the trolley track. The trolley track is machined on site using machining equipment, and the flatness of the trolley track is controlled within 0.5mm; Step 4: Marking of the trolley body and installation of the roller assembly. After the trolley body and the roller assembly are assembled, the tooling code plate and symmetrical welding process are used to ensure that the overall accuracy after installation is controlled within 2mm; Step 5: Trolley assembly test.

[0008] Furthermore, the manufacturing of the trolley track and trolley body structure in step 1 has three stages, namely: The first stage, trolley pontoon production: Step 1.1.1: When manufacturing the trolley pontoon structure, reserve a 10mm machining allowance at the trolley track position, and machine the trolley track after the trolley pontoon structure is welded; Step 1.1.2, the horizontal and vertical rails of the trolley pontoon are processed after welding. The flatness of the horizontal rail is not more than 1.5mm in the longitudinal direction and not more than 0.2mm in the transverse direction. The verticality of the horizontal and vertical rails is less than 0.4mm. The second stage, trolley track welding: Step 1.2.1, before welding the trolley rails on the trolley pontoon, add process support between the trolley rails; Step 1.2.2: The trolley track is welded symmetrically to prevent structural deformation; The third stage: the production of the trolley body: Step 1.3.1, draw the center line of the trolley on the tire frame for making the trolley body, and make the trolley body according to the center line of the trolley; Step 1.3.2, after the trolley body is welded, use the wire to adjust the steel pile clamp to find the center of the steel pile on the trolley body, draw the center line of the trolley body and make a sample punch mark, and bore the pin shaft hole of the steel pile clamp; Step 1.3.3, leave a 20mm margin at the front and rear travel roller shaft holes of the trolley body, mark the center line of the steel pile, and then mark the processing lines and inspection lines of the front travel roller shaft hole, rear travel roller shaft hole, and horizontal roller shaft hole according to the center line of the steel pile; Step 1.3.4: After the boring of the front travel roller shaft hole, the rear travel roller shaft hole and the horizontal roller shaft hole is completed, the front travel roller shaft, the rear travel roller shaft and the horizontal roller shaft are positioned and welded according to the inspection circle; Step 1.3.5: Mark the positions of the travel cylinder support, lifting cylinder support, and lifting wire rope suspension point support according to the center line of the trolley body and the position of the steel piles, and install and weld each support.

[0009] Furthermore, in the step 1.3.3, when marking the processing lines and inspection lines of the front travel roller shaft holes and the rear travel roller shaft holes, the center of the front balance beam of the trolley is offset by 20 mm from the center of the rear travel roller.

[0010] Furthermore, the detailed process of manufacturing the trolley walking roller and horizontal roller assembly in step 2 includes: Step 2.1, process each component according to the manufacturing drawing of the trolley walking roller and horizontal roller; Step 2.2, assemble the front balance beam cylinder, the front balance beam and the front walking roller of the trolley as a whole; Step 2.2: Assemble the rear walking beam of the trolley by welding the ear plate, rear walking beam and rear walking roller as a whole.

[0011] Furthermore, the detailed process of the trolley track marking and machining in step 3 includes: Step 3.1, perform pyrotechnic correction on the out-of-tolerance position of the trolley track manufacturing data; Step 3.2, draw lines on the trolley pontoon according to the trolley track data to determine the center line of the trolley travel mechanism and the trolley track processing allowance; Step 3.3: machining of trolley rails.

[0012] Furthermore, the detailed process of marking the trolley body and installing the roller assembly in step 4 includes: Step 4.1. According to the structural dimensions of the trolley body, draw the center line of the trolley body, determine the installation positions of the front running roller, rear running roller and horizontal roller, and draw the positioning line and inspection line; Step 4.2: Weld the roller assembly and horizontal roller onto the trolley body according to the positioning line. Use symmetrical welding to reduce structural deformation. Step 4.3: Check the deviation between the roller assembly and the horizontal roller and the inspection line after welding. The allowable deviation is ±2mm.

[0013] Furthermore, the detailed process of the trolley assembly test in step 5 includes: Step 5.1, hoist the trolley body with the roller assembly and horizontal roller installed into the trolley track as a whole; Step 5.2: Position the trolley travel cylinder according to the trolley track and the center line of the trolley body; Step 5.3: Start the trolley hydraulic system, test whether the entire hydraulic system works smoothly, and check whether the hydraulic system pressure is within the design value range.

[0014] The advantages of the present invention are: In the construction process of the small steel pile trolley of the present invention, the trolley walking assembly and the trolley main structure can be manufactured simultaneously and installed as a whole, and only the trolley track needs to be machined on site, which reduces the cross-operation of multiple types of work on site, improves construction efficiency, and shortens the total construction period by 15 days. In addition, during the entire construction process, by finely controlling the manufacturing accuracy, it can be ensured that the horizontal deviation is controlled within the range of 4mm after the overall installation of the trolley, meeting the use requirements of the trolley walking mechanism. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0016] Figure 1 It is the front view of the small steel pile trolley of the present invention.

[0017] Figure 2 It is a side view of the small steel pile trolley of the present invention.

[0018] Figure 3 The figure is a flow chart of the construction process of the small steel pile trolley of the present invention. DETAILED DESCRIPTION

[0019] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the specific implementation mode, structure, characteristics and effects of the present invention are described in detail below in combination with the accompanying drawings and preferred embodiments.

[0020] Example The small steel pile trolley of the present embodiment is applied to a cutter suction dredger, and comprises a trolley pontoon 1, a trolley body 5, steel piles 10, a trolley track 11 and a trolley travel mechanism.

[0021] The trolley pontoon 1 is connected to the hull of the cutter suction dredger. The trolley pontoon 1 is provided with horizontal and vertical tracks for transporting heavy objects. A passage for the trolley body 5 to travel is provided in the middle of the trolley pontoon 1. The trolley body 5 is movably arranged in the passage through the cooperation between the trolley travel mechanism and the trolley track 11, and is driven to move by the travel cylinder 14. Track grooves for installing the trolley track are provided on the side walls on both sides of the passage of the trolley pontoon 1. The trolley track 11 is installed in the track groove. The travel cylinder 14 is installed on the trolley pontoon 1. The telescopic end of the travel cylinder 14 is connected to the trolley body 5 through the travel cylinder support.

[0022] The trolley travel mechanism includes two roller assemblies and a horizontal roller for guiding. The two roller assemblies include a front travel roller assembly 4 and a rear travel roller assembly 3. The front travel roller assembly 4 includes mutually connected front travel rollers, a trolley front balance beam cylinder and a front balance beam 2. The rear travel roller assembly 3 includes mutually connected rear travel rollers, a rear travel beam and a trolley rear travel beam welding ear plate. The side wall of the trolley body 5 is provided with a front travel roller shaft, a rear travel roller shaft and a horizontal roller shaft for installing the front travel roller, the rear travel roller and the horizontal roller respectively. The front travel roller is rotatably mounted on the front travel roller shaft, the front travel roller assembly 4 is mounted on the trolley body 5, the rear travel roller is rotatably mounted on the rear travel roller shaft, the rear travel roller assembly 3 is mounted on the trolley body 5, and the horizontal roller is rotatably mounted on the horizontal roller shaft. When the trolley body 5 is installed in the channel of the trolley pontoon 1, the front travel roller, the rear travel roller and the horizontal roller are rollingly mounted on the corresponding trolley track 11.

[0023] The trolley body 5 is provided with a steel pile lifting hole for lifting and lowering the steel pile 10. The steel pile 10 is movably arranged in the steel pile lifting hole and is moved by the lifting cylinder 13. The lifting cylinder 13 is installed on the top surface of the trolley body 5 through the lifting cylinder support, and is connected to the steel pile 10 through the lifting wire rope 9 for power transmission. One end of the lifting wire rope 9 is connected to the trolley body 5 through the lifting wire rope hanging point support 12, and the other end is connected to the steel pile 10 after passing through the wire rope steering wheel 8 on the top of the lifting cylinder 13. A steel pile clamp for steel pile braking is installed at the steel pile lifting hole.

[0024] The small steel pile trolley also includes a hydraulic system for controlling the travel cylinder 14 and the lifting cylinder 13. This embodiment provides a construction process of the above-mentioned small steel pile trolley, including the following steps: Step 1: The trolley track and trolley body structure are manufactured. During the manufacturing process, the construction accuracy is controlled within the range of ±4mm. The three-dimensional coordinates of the detection part are generated by the total station, and the model data is matched and analyzed to ensure the accuracy of the structure construction. This step has three stages, namely: Phase 1: Production of trolley pontoon 1: Step 1.1.1, when manufacturing the trolley pontoon 1 structure, reserve a 10mm machining allowance at the trolley track position, and machine the trolley track 11 after the trolley pontoon 1 structure is welded; Step 1.1.2, the horizontal track and the vertical track of the trolley pontoon 1 are processed after welding, the flatness of the horizontal track does not exceed 1.5mm in the longitudinal direction, does not exceed 0.2mm in the transverse direction, and the verticality of the horizontal track and the vertical track is less than 0.4mm; The second stage, trolley track 11 welding: Step 1.2.1, before welding the trolley rails 11 on the trolley pontoon 1, adding process supports between the trolley rails 11; Step 1.2.2, the trolley track 11 is symmetrically welded to prevent structural deformation; The third stage: the production of the trolley body 5: Step 1.3.1, draw a sample line of the center line of the trolley on the tire frame for making the trolley body, and make the trolley body 5 according to the sample line of the center line of the trolley; Step 1.3.2, after the trolley body 5 is welded, use the wire to adjust the steel pile clamp to find the center of the steel pile on the trolley body, draw the center line of the trolley body in the horizontal direction of the trolley body and make a sample punch mark, and bore the pin shaft hole of the steel pile clamp; Step 1.3.3, leave a 20mm margin at the front walking roller shaft hole and the rear walking roller shaft hole of the trolley body 5, mark the center line of the steel pile, and then mark the processing lines and inspection lines of the front walking roller shaft hole, the rear walking roller shaft hole, and the horizontal roller shaft hole according to the center line of the steel pile. When marking the processing lines and inspection lines of the front walking roller shaft hole and the rear walking roller shaft hole, the center of the front balance beam of the trolley is offset by 20mm from the center of the rear walking roller; Step 1.3.4: After the boring of the front travel roller shaft hole, the rear travel roller shaft hole and the horizontal roller shaft hole is completed, the front travel roller shaft, the rear travel roller shaft and the horizontal roller shaft are positioned and welded according to the inspection circle; Step 1.3.5, mark the positions of the travel cylinder support, lifting cylinder support, and lifting wire rope suspension point support 12 according to the center line of the trolley body and the position of the steel piles in the horizontal direction of the trolley body, install and weld each support. Each support has been processed in place before welding, and protection must be done before welding and painting.

[0025] Step 2: The trolley travel roller and horizontal roller assembly are manufactured in the machining workshop, processed by machine tools, and installed into roller assemblies. Testing equipment is used to ensure that the processing and installation accuracy is controlled within the range of 0-0.3mm. The detailed process includes: Step 2.1, process each component according to the manufacturing drawing of the trolley walking roller and horizontal roller; Step 2.2, integrally assemble the front balance beam cylinder, the front balance beam 2 and the front travel roller of the trolley to form a front travel roller assembly 4; Step 2.2, assemble the rear walking beam welding ear plate, the rear walking beam and the rear walking roller of the trolley as a whole to form a rear walking roller assembly 3.

[0026] Step 3: Marking and machining of the trolley track. The trolley track is machined on site using processing equipment. The flatness of the trolley track is controlled within 0.5mm. The detailed process includes: Step 3.1, perform pyrotechnic correction on the out-of-tolerance position of the trolley track manufacturing data; Step 3.2, draw lines on the trolley pontoon according to the trolley track data to determine the center line of the trolley travel mechanism and the trolley track processing allowance; Step 3.3: machining of trolley rails.

[0027] Step 4: Marking of the trolley body and installation of the roller assembly. After the trolley body and the roller assembly are assembled, the tooling code plate and symmetrical welding process are used to ensure that the overall accuracy after installation is controlled within 2mm. The detailed process includes: Step 4.1. According to the structural dimensions of the trolley body, draw the center line of the trolley body in the vertical direction of the trolley body, determine the installation positions of the front running rollers, rear running rollers and horizontal rollers, and draw positioning lines and inspection lines; Step 4.2: Weld the roller assembly and horizontal roller onto the trolley body according to the positioning line. Use symmetrical welding to reduce structural deformation. Step 4.3: Check the deviation between the roller assembly and the horizontal roller and the inspection line after welding. The allowable deviation is ±2mm.

[0028] Step 5: Trolley assembly test, the detailed process includes: Step 5.1, hoist the trolley body with the roller assembly and the horizontal roller installed into the channel as a whole, and assemble the roller assembly and the horizontal roller into the trolley track 11; Step 5.2, positioning the trolley travel cylinder according to the trolley track 11 and the center line of the trolley body; Step 5.3: Start the hydraulic system of the trolley, test whether the entire hydraulic system works smoothly, and check whether the hydraulic system pressure is within the design value range.

[0029] The application of small steel pile trolley construction technology can ensure that the horizontal deviation of the trolley system is controlled within 4mm after installation, meeting the use requirements of the trolley travel system. Using this construction technology, the trolley travel mechanism and the trolley body structure are manufactured simultaneously and installed as a whole. The total construction period is shortened by 15 days. Only the trolley track needs to be processed on site, which reduces the cross-operation of multiple types of work on site, improves construction efficiency and shortens the construction period.

[0030] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technical personnel in this field can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A small steel pile trolley construction process, characterized in that: The following steps are involved: Step 1: The trolley track and trolley body structure are manufactured. During the manufacturing process, the construction accuracy is controlled within the range of ±4mm. The three-dimensional coordinates of the detection part are generated by a total station, and matched and analyzed with the model data to ensure the accuracy of the structure construction; Step 2: The trolley travel roller and horizontal roller assembly are manufactured in the machining workshop, processed by machine tools, and installed into roller assemblies. Testing equipment is used to ensure that the processing and installation accuracy is controlled within the range of 0-0.3mm; Step 3: Marking and machining of the trolley track. The trolley track is machined on site using machining equipment, and the flatness of the trolley track is controlled within 0.5mm; Step 4: Marking of the trolley body and installation of the roller assembly. After the trolley body and the roller assembly are assembled, the tooling code plate and symmetrical welding process are used to ensure that the overall accuracy after installation is controlled within 2mm; Step 5: Trolley assembly test.

2. The small steel pile trolley construction process according to claim 1 is characterized in that: The manufacturing of the trolley track and trolley body structure in step 1 has three stages, namely: The first stage, trolley pontoon production: Step 1.1.1: When manufacturing the trolley pontoon structure, reserve a 10mm machining allowance at the trolley track position, and machine the trolley track after the trolley pontoon structure is welded; Step 1.1.2, the horizontal and vertical rails of the trolley pontoon are processed after welding. The flatness of the horizontal rail is not more than 1.5mm in the longitudinal direction and not more than 0.2mm in the transverse direction. The verticality of the horizontal and vertical rails is less than 0.4mm. The second stage, trolley track welding: Step 1.2.1, before welding the trolley rails on the trolley pontoon, add process support between the trolley rails; Step 1.2.2: The trolley track is welded symmetrically to prevent structural deformation; The third stage: the production of the trolley body: Step 1.3.1, draw the center line of the trolley on the tire frame for making the trolley body, and make the trolley body according to the center line of the trolley; Step 1.3.2, after the trolley body is welded, use the wire to adjust the steel pile clamp to find the center of the steel pile on the trolley body, draw the center line of the trolley body and make a sample punch mark, and bore the pin shaft hole of the steel pile clamp; Step 1.3.3, leave a 20mm margin at the front and rear travel roller shaft holes of the trolley body, mark the center line of the steel pile, and then mark the processing lines and inspection lines of the front travel roller shaft hole, rear travel roller shaft hole, and horizontal roller shaft hole according to the center line of the steel pile; Step 1.3.4: After the boring of the front travel roller shaft hole, the rear travel roller shaft hole and the horizontal roller shaft hole is completed, the front travel roller shaft, the rear travel roller shaft and the horizontal roller shaft are positioned and welded according to the inspection circle; Step 1.3.5: Mark the positions of the travel cylinder support, lifting cylinder support, and lifting wire rope suspension point support according to the center line of the trolley body and the position of the steel piles, and install and weld each support.

3. The small steel pile trolley construction process according to claim 2 is characterized in that: In the step 1.3.3, when marking the processing lines and inspection lines of the front travel roller shaft holes and the rear travel roller shaft holes, the center of the front balance beam of the trolley is offset by 20 mm from the center of the rear travel roller.

4. The small steel pile trolley construction process according to claim 1 is characterized in that: The detailed process of manufacturing the trolley walking roller and horizontal roller assembly in step 2 includes: Step 2.1, process each component according to the manufacturing drawing of the trolley walking roller and horizontal roller; Step 2.2, assemble the front balance beam cylinder, the front balance beam and the front walking roller of the trolley as a whole; Step 2.2: Assemble the rear walking beam of the trolley by welding the ear plate, rear walking beam and rear walking roller as a whole.

5. The small steel pile trolley construction process according to claim 1 is characterized in that: The detailed process of the trolley track marking and machining in step 3 includes: Step 3.1, perform pyrotechnic correction on the out-of-tolerance position of the trolley track manufacturing data; Step 3.2, draw lines on the trolley pontoon according to the trolley track data to determine the center line of the trolley travel mechanism and the trolley track processing allowance; Step 3.3: machining of trolley rails.

6. The small steel pile trolley construction process according to claim 1 is characterized in that: The detailed process of marking the trolley body and installing the roller assembly in step 4 includes: Step 4.

1. According to the structural dimensions of the trolley body, draw the center line of the trolley body, determine the installation positions of the front running roller, rear running roller and horizontal roller, and draw the positioning line and inspection line; Step 4.2: Weld the roller assembly and horizontal roller onto the trolley body according to the positioning line. Use symmetrical welding to reduce structural deformation. Step 4.3: Check the deviation between the roller assembly and the horizontal roller and the inspection line after welding. The allowable deviation is ±2mm.

7. The small steel pile trolley construction process according to claim 1 is characterized in that: The detailed process of the trolley assembly test in step 5 includes: Step 5.1, hoist the trolley body with the roller assembly and horizontal roller installed into the trolley track as a whole; Step 5.2: Position the trolley travel cylinder according to the trolley track and the center line of the trolley body; Step 5.3: Start the trolley hydraulic system, test whether the entire hydraulic system works smoothly, and check whether the hydraulic system pressure is within the design value range.

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