A small steel pile platform car construction process

Abstract

The present application relates to a kind of small steel pile trolley construction process, comprising the following steps: step 1, trolley track and trolley body structure production;Step 2, trolley walking roller and horizontal roller assembly production;Step 3, trolley track scribing and machining;Step 4, trolley body scribing and roller assembly installation;Step 5, trolley assembly test;Small steel pile trolley construction process in the present application, trolley walking assembly and trolley body structure can be made synchronously, and overall installation is carried out, and only trolley track needs on-site machining, reduces the cross operation of multiple trades on site, improves construction efficiency, makes the total cycle shorten 15 days, and in the whole construction process, through the fine control of production accuracy, it can be guaranteed that the horizontal deviation is controlled within 4mm after trolley overall installation, meets the use requirements of trolley walking mechanism.

Description

Technical Field

[0001] This invention relates to the field of shipbuilding technology, and in particular to a construction process for a small steel pile trolley. Background Technology

[0002] The steel pile trolley system is mainly used on cutter suction dredgers for fixing and moving the dredger during operation. During dredging, the hydraulic system drives the trolley's traveling 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 in the predetermined working position. The traveling cylinder pushes the trolley, and the trolley transmits the thrust to the hull to realize the hull's 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, and trolley guide rollers. The rollers of the trolley travel system, along with their matching roller shafts, bearings, and other moving parts, have small clearances and are all machined parts. To ensure the mechanical performance of the components, the conventional process route is: 1. Structural fabrication; 2. Stress relief of structural components; 3. Welding of machined parts such as roller shafts with allowance; 4. On-site machining of roller shafts; 5. Installation of bearings, rollers, and other components.

[0004] The conventional process involves welding roller shafts with machining allowances onto structural components. After the structure is fabricated, it is then machined on-site to ensure the final assembly dimensions and positioning data. However, on-site machining accuracy is difficult to guarantee, primarily due to the long machining cycle. During machining, other trades need to stagger their operations to ensure accuracy, leading to extended project construction periods and impacting project progress.

[0005] Therefore, this 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 construction process for a small steel pile trolley, which separates the manufacturing of structural components and machining components, allows for simultaneous construction, and shortens the construction cycle.

[0007] To solve the above-mentioned technical problems, the technical solution of the present invention is: a construction process for a small steel pile trolley, the innovation of which is: including the following steps: Step 1: Fabrication of the trolley track and trolley body structure. During the fabrication process, the construction accuracy is controlled within ±4mm. A total station is used to generate the three-dimensional coordinates of the inspection parts and match and analyze them with the model data to ensure the construction accuracy of the structure. Step 2: Fabrication of trolley traveling rollers and horizontal rollers. The trolley traveling rollers and horizontal rollers are fabricated in the machining workshop, machined using machine tools, and assembled into roller assemblies. Testing equipment is used to ensure that the machining 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 the trolley body and installing the roller assembly. After assembling the trolley body and roller assembly, use tooling plates and symmetrical welding to ensure that the overall accuracy is controlled within 2mm after installation. Step 5: Final assembly and testing of the trolley.

[0008] Furthermore, the fabrication of the trolley track and trolley body structure in step 1 has three stages, namely: Phase 1: Construction of the trolley pontoon: Step 1.1.1: When fabricating the trolley pontoon structure, leave a 10mm machining allowance at the trolley track position. After the trolley pontoon structure is welded, machine the trolley track. Step 1.1.2: After welding, the horizontal and vertical rails of the trolley float box are processed. The flatness of the horizontal rails should not exceed 1.5mm in the longitudinal direction and 0.2mm in the transverse direction. The perpendicularity of the horizontal and vertical rails should be less than 0.4mm. Phase Two: Welding of the Trolley Tracks Step 1.2.1: Before welding the trolley tracks onto the trolley float, add process supports between the trolley tracks; Step 1.2.2: The trolley track is symmetrically welded to prevent structural deformation; Phase Three: Construction of the Cart Body Step 1.3.1: Draw the center line of the trolley on the trolley body fabrication jig, and fabricate the trolley body according to the center line of the trolley body; Step 1.3.2: After the trolley body is welded, use a string line to adjust the steel pile clamps to find the center of the steel pile on the trolley body, mark the center line of the trolley body and make a punch mark, and bore the pin hole of the steel pile clamp. Step 1.3.3: Leave a 20mm allowance in the structure at the front travel roller shaft hole and the rear travel roller shaft hole of the trolley body. After marking the center line of the steel pile, mark the machining line and inspection line of the front travel roller shaft hole, the rear travel roller shaft hole, and the horizontal roller shaft hole according to the center line of the steel pile. After boring the front travel roller shaft hole, rear travel roller shaft hole and horizontal roller shaft hole in steps 1.3.4, locate and weld the front travel roller shaft, rear travel roller shaft and horizontal roller shaft 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 pile, and install and weld each support.

[0009] Furthermore, in step 1.3.3, when marking the machining lines and inspection lines for 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 from the center of the rear travel roller by 20mm.

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

[0011] Furthermore, the detailed process of trolley track marking and machining in step 3 includes: Step 3.1: Perform heat treatment to correct any out-of-tolerance locations in the trolley track manufacturing data; Step 3.2: Mark lines on the trolley float according to the trolley track data to determine the center line of the trolley traveling mechanism and the machining allowance of the trolley track; Step 3.3: Machining the trolley track.

[0012] Furthermore, the detailed process of marking the trolley body and installing the roller assembly in step 4 includes: Step 4.1: Based on the structural dimensions of the trolley body, draw the center line of the trolley body, determine the installation positions of the front traveling roller, the rear traveling roller and the horizontal roller, and draw positioning lines and inspection lines. Step 4.2: Weld the roller assembly and horizontal rollers onto the trolley body according to the positioning lines. Symmetrical welding should be used to reduce structural deformation. Step 4.3: Check the deviation of the roller assembly and horizontal roller from 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 entire trolley body, equipped with roller assemblies and horizontal rollers, into the trolley track; 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 range.

[0014] The advantages of this invention are: In the construction process of the small steel pile trolley of the present invention, the trolley traveling components and the trolley body structure can be manufactured simultaneously and installed as a whole. Moreover, only the trolley track needs to be machined on site, which reduces the cross-operation of multiple trades on site, improves construction efficiency, shortens the total construction cycle by 15 days, and ensures that the horizontal deviation is controlled within 4mm after the trolley is installed as a whole by fine control of the manufacturing precision throughout the construction process, thus meeting the usage requirements of the trolley traveling mechanism. Attached Figure Description

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

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

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

[0018] Figure 3 This is a flowchart of the construction process of the small steel pile trolley of the present invention. Detailed Implementation

[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0020] Example The small steel pile trolley of this embodiment is used on a cutter suction dredger and includes a trolley float 1, a trolley body 5, steel piles 10, a trolley track 11, and a trolley traveling mechanism.

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

[0022] The trolley traveling mechanism includes two roller assemblies and a horizontal roller for guidance. The two roller assemblies include a front traveling roller assembly 4 and a rear traveling roller assembly 3. The front traveling roller assembly 4 includes interconnected front traveling rollers, a front balance beam cylinder, and a front balance beam 2. The rear traveling roller assembly 3 includes interconnected rear traveling rollers, a rear traveling beam, and welded lugs to the rear traveling beam. The trolley body 5 has front traveling roller shafts, rear traveling roller shafts, and horizontal roller shafts respectively installed on its side walls for mounting the front traveling rollers, rear traveling rollers, and horizontal rollers. The front traveling rollers are rotatably mounted on the front traveling roller shafts. The front traveling roller assembly 4 is mounted on the trolley body 5. The rear traveling rollers are rotatably mounted on the rear traveling roller shafts. The rear traveling roller assembly 3 is mounted on the trolley body 5. The horizontal rollers are rotatably mounted on the horizontal roller shafts. When the trolley body 5 is installed within the channel of the trolley float 1, the front traveling rollers, rear traveling rollers, and horizontal rollers roll on their corresponding trolley tracks 11.

[0023] The trolley body 5 has a steel pile lifting hole for raising and lowering the steel pile 10. The steel pile 10 is movably installed 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 lifting 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 braking the steel pile is installed at the steel pile lifting hole.

[0024] The small steel pile trolley also includes a hydraulic system for controlling the traveling cylinder 14 and the lifting cylinder 13. This embodiment provides the construction process of the aforementioned small steel pile trolley, including the following steps: Step 1: Fabrication of the trolley track and trolley body structure. During fabrication, the construction accuracy is controlled within ±4mm. A total station is used to generate the 3D coordinates of the inspection area, which are then matched and analyzed with the model data to ensure the structural construction accuracy. This step has three stages: Phase 1: Construction of the trolley pontoon 1 Step 1.1.1 When manufacturing the trolley float 1 structure, a 10mm machining allowance is reserved at the position of the trolley track. After the trolley float 1 structure is welded, the trolley track 11 is machined. Step 1.1.2: After welding, the horizontal and vertical rails of the trolley float box 1 are processed. The flatness of the horizontal rails shall not exceed 1.5mm in the longitudinal direction and 0.2mm in the transverse direction. The perpendicularity of the horizontal and vertical rails shall be less than 0.4mm. Second stage, welding of trolley track 11: Step 1.2.1: Before welding the trolley track 11 onto the trolley float 1, add process supports between the trolley tracks 11; Step 1.2.2: The trolley track 11 is symmetrically welded to prevent structural deformation; Phase 3: Construction of the trolley body (5 stages): Step 1.3.1: Draw the center line of the trolley on the trolley body fabrication jig, and fabricate the trolley body 5 according to the center line of the trolley body; Step 1.3.2: After the trolley body 5 is welded, use a string line 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 and make a punch mark, and bore the pin hole of the steel pile clamp. Step 1.3.3: Leave a 20mm allowance in the structure at the front travel roller shaft hole and the rear travel roller shaft hole of the trolley body 5. After marking the center line of the steel pile, mark the machining lines and inspection lines of the front travel roller shaft hole, the rear travel roller shaft hole, and the horizontal roller shaft hole according to the center line of the steel pile. When marking the machining lines and inspection lines of the front travel roller shaft hole and the rear travel roller shaft hole, the center of the front balance beam of the trolley is offset from the center of the rear travel roller by 20mm. After boring the front travel roller shaft hole, rear travel roller shaft hole and horizontal roller shaft hole in steps 1.3.4, locate and weld the front travel roller shaft, rear travel roller shaft and horizontal roller shaft 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 in the horizontal direction and the position of the steel pile. Install and weld each support. Each support has been processed in place before welding. Protective measures should be taken before welding and painting.

[0025] Step 2: Fabrication of the trolley traveling rollers and horizontal rollers. The trolley traveling rollers and horizontal rollers are fabricated in the machining workshop using machine tools and then assembled into roller assemblies. Testing equipment is used to ensure that the machining and installation accuracy is controlled within the range of 0-0.3mm. The detailed process includes: Step 2.1: Machining each component according to the manufacturing drawings of the trolley traveling rollers and horizontal rollers; Step 2.2: Assemble the front balance beam cylinder, the front balance beam 2 and the front traveling roller as a whole to form the front traveling roller assembly 4; Step 2.2: Assemble the rear traveling beam of the trolley, the rear traveling beam, and the rear traveling rollers as a whole to form the rear traveling roller assembly 3.

[0026] Step 3: Marking and machining of the trolley track. The trolley track is machined on-site using specialized equipment. The flatness of the trolley track is controlled within 0.5mm. Detailed process includes: Step 3.1: Perform heat treatment to correct any out-of-tolerance locations in the trolley track manufacturing data; Step 3.2: Mark lines on the trolley float according to the trolley track data to determine the center line of the trolley traveling mechanism and the machining allowance of the trolley track; Step 3.3: Machining the trolley track.

[0027] Step 4: Marking the trolley body and installing the roller assembly. After assembling the trolley body and roller assembly, use tooling plates and symmetrical welding to ensure that the overall accuracy is controlled within 2mm after installation. The detailed process includes: Step 4.1: Based on the structural dimensions of the trolley body, draw the center line of the trolley body in the vertical direction, determine the installation positions of the front traveling roller, the rear traveling roller and the horizontal roller, and draw positioning lines and inspection lines. Step 4.2: Weld the roller assembly and horizontal rollers onto the trolley body according to the positioning lines. Symmetrical welding should be used to reduce structural deformation. Step 4.3: Check the deviation of the roller assembly and horizontal roller from the inspection line after welding. The allowable deviation is ±2mm.

[0028] Step 5: Final assembly and testing of the trolley. The detailed process includes: Step 5.1: The trolley body equipped with roller assemblies and horizontal rollers is hoisted into the channel as a whole, and the roller assemblies and horizontal rollers are assembled in the trolley track 11; Step 5.2: Position 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 range.

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

[0030] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A construction process for a small steel pile trolley, characterized in that: Includes the following steps: Step 1: Fabrication of the trolley track and trolley body structure. During the fabrication process, the construction accuracy is controlled within ±4mm. A total station is used to generate the three-dimensional coordinates of the inspection parts and match and analyze them with the model data to ensure the construction accuracy of the structure. Step 2: Fabrication of trolley traveling rollers and horizontal rollers. The trolley traveling rollers and horizontal rollers are fabricated in the machining workshop, machined using machine tools, and assembled into roller assemblies. Testing equipment is used to ensure that the machining 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 the trolley body and installing the roller assembly. After assembling the trolley body and roller assembly, use tooling plates and symmetrical welding to ensure that the overall accuracy is controlled within 2mm after installation. Step 5: Final assembly and testing of the trolley; The fabrication of the trolley track and trolley body structure in step 1 has three stages: Phase 1: Construction of the trolley pontoon: Step 1.1.1: When fabricating the trolley pontoon structure, leave a 10mm machining allowance at the trolley track position. After the trolley pontoon structure is welded, machine the trolley track. Step 1.1.2: After welding, the horizontal and vertical rails of the trolley float box are processed. The flatness of the horizontal rails should not exceed 1.5mm in the longitudinal direction and 0.2mm in the transverse direction. The perpendicularity of the horizontal and vertical rails should be less than 0.4mm. Phase Two: Welding of the Trolley Tracks Step 1.2.1: Before welding the trolley tracks onto the trolley float, add process supports between the trolley tracks; Step 1.2.2: The trolley track is symmetrically welded to prevent structural deformation; Phase Three: Construction of the Cart Body Step 1.3.1: Draw the center line of the trolley on the trolley body fabrication jig, and fabricate the trolley body according to the center line of the trolley body; Step 1.3.2: After the trolley body is welded, use a string line to adjust the steel pile clamps to find the center of the steel pile on the trolley body, mark the center line of the trolley body and make a punch mark, and bore the pin hole of the steel pile clamp. Step 1.3.3: Leave a 20mm allowance in the structure at the front travel roller shaft hole and the rear travel roller shaft hole of the trolley body. After marking the center line of the steel pile, mark the machining line and inspection line of the front travel roller shaft hole, the rear travel roller shaft hole, and the horizontal roller shaft hole according to the center line of the steel pile. After boring the front travel roller shaft hole, rear travel roller shaft hole and horizontal roller shaft hole in steps 1.3.4, locate and weld the front travel roller shaft, rear travel roller shaft and horizontal roller shaft 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 pile, and install and weld each support.

2. The construction process of the small steel pile trolley according to claim 1, characterized in that: In step 1.3.3, when marking the machining lines and inspection lines for 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 from the center of the rear travel roller by 20mm.

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

4. The construction process of the small steel pile trolley according to claim 1, characterized in that: The detailed process of trolley track marking and machining in step 3 includes: Step 3.1: Perform heat treatment to correct any out-of-tolerance locations in the trolley track manufacturing data; Step 3.2: Mark lines on the trolley float according to the trolley track data to determine the center line of the trolley traveling mechanism and the machining allowance of the trolley track; Step 3.3: Machining the trolley track.

5. The construction process of the small steel pile trolley according to claim 1, characterized in that: The detailed process of marking the trolley body and installing the roller assembly in step 4 includes: Step 4.1: Based on the structural dimensions of the trolley body, draw the center line of the trolley body, determine the installation positions of the front traveling roller, the rear traveling roller and the horizontal roller, and draw positioning lines and inspection lines. Step 4.2: Weld the roller assembly and horizontal rollers onto the trolley body according to the positioning lines. Symmetrical welding should be used to reduce structural deformation. Step 4.3: Check the deviation of the roller assembly and horizontal roller from the inspection line after welding. The allowable deviation is ±2mm.

6. The construction process of the small steel pile trolley according to claim 1, characterized in that: The detailed process of the trolley assembly test in step 5 includes: Step 5.1: Hoist the entire trolley body, equipped with roller assemblies and horizontal rollers, into the trolley track; 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 range.

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