Vertical manufacturing method of large winch drum

Abstract

The invention provides a vertical manufacturing method of a large winch drum, which comprises the following steps of: processing a drum body shaft assembly, manufacturing and assembling a drum shaft, a drum body, a flange plate and an inner ring rib plate of the drum body shaft assembly according to an industrial drawing, and ensuring the concentricity of two sections of drum shaft bearing retainers of the drum body shaft assembly; machining a rope-crossing assembly, dividing a fan-shaped box sealing plate of the rope-crossing assembly into a first fan-shaped box sealing plate and a second fan-shaped box sealing plate, and pre-machining a plane of the rope-crossing assembly; a brake assembly, a barrel shaft assembly, a rope crossing assembly, a rope blocking assembly and a driving end assembly are sequentially and vertically assembled on the horizontal plane, and the brake assembly, the barrel shaft assembly, the rope crossing assembly, the rope blocking assembly and the driving end assembly are connected through welding during assembly; the installed and welded winding drum is integrally hoisted, the winding drum is rotated up and down by 180 degrees, the winding drum is further welded, the requirement for concentricity of shafts at the two ends of the winding drum can be met during vertical welding, and the welding efficiency can be improved and the welding difficulty can be reduced in a plane welding mode.

Description

Technical Field

[0001] The invention relates to the technical field of ship winch manufacturing, and more specifically to a vertical manufacturing method of a large winch drum. Background Art

[0002] When a ship is operating in the ocean, it needs to perform tasks such as mooring, moving, and positioning in a complex marine environment. When the ship completes these actions, the winch is one of the most important equipment. With the rapid development of the world's shipping industry, the carrying capacity of ships continues to increase, resulting in the weight of ships becoming larger and larger, and the load borne by the winch also increases accordingly. The drum is a key component in the entire winch set, and its stable quality can directly affect the efficiency and safety of the entire winch.

[0003] The large winch drum is divided into five parts during production: the drum shaft assembly, brake assembly, drive end assembly, rope stop assembly, and cross-rope assembly, which are manufactured and processed separately. The cross-rope assembly plays the role of crossing and storing the rope when the drum is winding the rope. It adopts a box structure with a wide cross-rope gap. The sealing plate is a fan-shaped embedded structure and is single-sided groove welded. The welding amount is extremely large, and the flatness of the assembly after welding will be difficult to control. The overall size and weight of the drum are large, and the structure is small at both ends and large in the middle. It needs to be processed on a large horizontal lathe, and the process needs to be turned around, which increases the equipment operation cycle and cost. Therefore, a set of process plans must be formulated to ensure that the overall accuracy requirements of the drum can be met, and welding deformation can be effectively controlled and the processing cycle can be reduced. Summary of the invention

[0004] The present invention provides a vertical manufacturing method for a large winch drum, aiming to eliminate deformation caused by welding heat, reduce the difficulty of assembly and welding in the manufacturing process, reduce the machining cycle and the number of hoisting times, and improve the manufacturing efficiency of the winch drum.

[0005] To achieve the above object, the present invention provides a vertical manufacturing method for a large winch drum, comprising:

[0006] Process the barrel shaft assembly, manufacture and assemble the reel shaft, barrel, flange plate, and inner ring rib plate of the barrel shaft assembly according to the work drawing, and ensure the concentricity of the bearing gears of the two sections of the barrel shaft assembly during the assembly process;

[0007] Processing the cross-rope assembly, dividing the fan-shaped sealing plate of the cross-rope assembly into a first fan-shaped sealing plate and a second fan-shaped sealing plate, and pre-processing the plane of the cross-rope assembly;

[0008] The brake assembly, the cylinder shaft assembly, the cross-rope assembly, the rope stop assembly, and the drive end assembly are assembled vertically in sequence on a horizontal plane, and the brake assembly, the cylinder shaft assembly, the cross-rope assembly, the rope stop assembly, and the drive end assembly are connected by welding during assembly;

[0009] The assembled and welded reel is hoisted as a whole, the reel is rotated 180° up and down, and the reel is further welded;

[0010] During the assembly and welding process of the reel, the reel is always perpendicular to the horizontal plane.

[0011] In one embodiment, when processing the barrel shaft assembly, the barrel shaft, barrel, flange plate, and inner ring rib plate of the barrel shaft assembly are firstly made into a group according to the work drawing, and then the whole is processed after the stress is removed by vibration;

[0012] A roller frame is used to weld the drum shaft, drum, flange plate and inner ring rib plate of the drum shaft assembly.

[0013] In one embodiment, when assembling the cross-rope assembly on the cylinder shaft assembly, the first sector-shaped sealing plate is first assembled and welded to the cylinder shaft assembly, and then the second sector-shaped sealing plate is assembled and welded to the first sector-shaped sealing plate and the cylinder shaft assembly.

[0014] In one embodiment, during the welding process of the second sector-shaped sealing plate and the cylinder shaft assembly, the weld is divided into a plurality of small sections, each section is subjected to multi-layer welding, and each layer includes a plurality of weld passes.

[0015] In one embodiment, the first sector-shaped sealing plate, the second sector-shaped sealing plate and the barrel shaft assembly are assembled and welded by gasket welding.

[0016] In one embodiment, the cross-rope assembly plane is pre-machined using a vertical lathe;

[0017] During pre-processing, a cutting breakpoint is reserved for the main board of the cross-rope assembly.

[0018] In one embodiment, when the assembled and welded reel is hoisted as a whole, the lifting ears are installed on both side end surfaces of the cylinder body, avoiding the hole diameter reserved on the cylinder shaft assembly.

[0019] In one embodiment, when welding the drum, a plane arc submerged arc automatic welding method is selected for welding.

[0020] In one embodiment, the butt joint of the cylinder body is formed by a U-shaped narrow gap welding groove, and the corner joints of the brake assembly, the rope crossing assembly, the rope retaining assembly and the drive end assembly with the cylinder body are formed by a J-shaped welding groove.

[0021] In one embodiment, the assembly and welding of the roll specifically includes:

[0022] The brake assembly is placed on a horizontal steel plate, and a pad is arranged under the brake assembly;

[0023] A positioning block is welded on the cylinder shaft assembly and installed in the brake assembly;

[0024] Assemble and weld the cross-rope assembly, the rope retaining assembly, and the driving end assembly in sequence from bottom to top;

[0025] Among them, during assembly, cylinder welding positioning blocks or process support methods are used for positioning and assembly.

[0026] The present invention has the following beneficial effects:

[0027] 1. High efficiency: This method completes the processing of the cylinder shaft assembly before assembling multiple components. There is no need to assemble the cylinder shaft assembly later, which reduces the machining cycle and the number of hoisting times. All processing content can be completed in one clamping, thereby improving the manufacturing efficiency of the winch drum.

[0028] 2. High quality: This method adopts a vertical manufacturing process, which eliminates the deformation caused by heat in horizontal welding, converts vertical welding into flat welding, reduces the difficulty of assembly and welding in the production process, and ensures the concentricity requirements of the reel shaft. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic flow chart of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention;

[0030] Figure 2 It is a schematic diagram of the process structure of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention;

[0031] Figure 3 It is a structural schematic diagram of a drum shaft assembly of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention;

[0032] Figure 4 It is a structural schematic diagram of a fan-shaped sealing plate of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention;

[0033] Figure 5 It is a schematic diagram of the installation of the lifting lugs of the vertical manufacturing method of the large winch drum according to one embodiment of the present invention;

[0034] Figure 6 It is a structural schematic diagram of a reserved cutting breakpoint of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention;

[0035] Figure 7 A schematic diagram of a vertical installation structure of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention;

[0036] Figure 8 This is a schematic diagram of the connection between a first sector-shaped sealing plate and a second sector-shaped sealing plate in a vertical manufacturing method for a large winch drum according to an embodiment of the present invention.

[0037] Among them, 100 is the cylinder shaft assembly; 200 is the brake assembly; 300 is the cross rope assembly; 310 is the first fan-shaped sealing plate; 320 is the second fan-shaped sealing plate; 400 is the rope stop assembly; 500 is the drive end assembly DETAILED DESCRIPTION

[0038] In order to make the purpose, technical scheme and advantages of the implementation of this application clearer, the technical scheme in the embodiment of this application will be described in more detail below in conjunction with the drawings in the embodiment of this application. In the drawings, the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions. The described embodiments are part of the embodiments of this application, not all of them. The embodiments described below with reference to the drawings are exemplary and are intended to be used to explain this application, and should not be construed as limitations on this application. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0039] Figure 1 The figure is a schematic flow chart of a vertical manufacturing method of a large winch drum according to an embodiment of the present invention. The vertical manufacturing method of a large winch drum comprises:

[0040] Processing barrel shaft assembly 100, such as Figure 3 As shown, the reel shaft, cylinder, flange plate, and inner ring rib plate of the cylinder shaft assembly 100 are manufactured and assembled according to the work drawing, and the concentricity of the two reel shaft bearings of the cylinder shaft assembly 100 is ensured during the assembly process;

[0041] Processing the spanning rope assembly 300, dividing the fan-shaped sealing plate of the spanning rope assembly 300 into a first fan-shaped sealing plate 310 and a second fan-shaped sealing plate 320, and pre-processing the plane of the spanning rope assembly 300;

[0042] like Figure 7 As shown, the brake assembly 200, the cylinder shaft assembly 100, the cross-rope assembly 300, the rope blocking assembly, and the driving end assembly are sequentially assembled vertically on a horizontal plane, and the brake assembly 200, the cylinder shaft assembly 100, the cross-rope assembly 300, the rope blocking assembly, and the driving end assembly are connected by welding during assembly;

[0043] The assembled and welded reel is hoisted as a whole, the reel is rotated 180° up and down, and the reel is further welded;

[0044] During the assembly and welding process of the reel, the reel is always perpendicular to the horizontal plane.

[0045] Specifically, the fan-shaped sealing plate of the cross-rope assembly 300 has the structural characteristics. If it is made as a whole, the cross-rope assembly 300 and the cylinder shaft assembly 100 need to be assembled before welding. In this way, the reel is prone to deformation after welding and the cycle is long. Therefore, it is made in sections, and the fan-shaped sealing plate is divided into a first fan-shaped sealing plate 310 and a second fan-shaped sealing plate 320.

[0046] Furthermore, the plane pre-processing process of the cross-rope assembly 300 mainly involves the preparation, processing and assembly of the cross-rope assembly 300.

[0047] For example, the cylinder can be divided into multiple parts to facilitate subsequent processing and welding connection, and each part is provided with a butt weld.

[0048] In one embodiment, when processing the barrel shaft assembly 100, the barrel shaft, barrel, flange plate, and inner ring rib plate of the barrel shaft assembly 100 are firstly made into a group according to the work drawing, and then the whole is processed after the stress is removed by vibration;

[0049] The roller frame is used to weld the reel shaft, cylinder, flange plate and inner ring rib plate of the cylinder shaft assembly 100.

[0050] Specifically, the drum shaft assembly 100 is welded with a roller frame. During processing, the outer diameter needs to be processed according to the drawing to ensure the size. The straightness error should be less than 0.5mm, and the concentricity of the drum shafts at both ends is ≤0.1mm.

[0051] In one embodiment, when assembling the cross-rope assembly 300 on the cylinder shaft assembly 100, the first fan-shaped sealing plate 310 is first assembled and welded to the cylinder shaft assembly 100, and then the second fan-shaped sealing plate 320 is assembled and welded to the first fan-shaped sealing plate 310 and the cylinder shaft assembly 100.

[0052] In one embodiment, during the welding process of the second sector-shaped sealing plate 320 and the barrel shaft assembly 100, the weld is divided into a plurality of small sections, each section is welded in multiple layers, and each layer includes a plurality of weld passes.

[0053] In one embodiment, the first sector-shaped sealing plate 310 , the second sector-shaped sealing plate 320 and the barrel shaft assembly 100 are assembled and welded by gasket welding.

[0054] In one embodiment, a vertical lathe is used to pre-process the plane of the cross-rope assembly 300;

[0055] During pre-processing, a cutting breakpoint is reserved for the main board of the cross-rope assembly 300.

[0056] Specifically, the prefabrication is carried out separately in sections, and the welding is carried out by dispersed multi-pass welding to reduce heat input and control welding deformation;

[0057] The dispersed multi-pass welding method specifically divides the weld into multiple small sections, performs multi-layer welding on each section, and each layer includes multiple weld passes.

[0058] like Figure 4 , Figure 8 As shown, the plane of the cross-rope assembly 300 is pre-processed by using a vertical lathe, and after being assembled with the cylinder shaft assembly 100 and all welds are completed, the interface of the second fan-shaped sealing plate 320 is welded into place using a gasket to ensure that the requirements are met after welding.

[0059] Furthermore, if Figure 6 As shown, the main board of the cross-rope assembly 300 needs to be cut at breakpoints to avoid large deformation caused by the overall cutting. The gap of the cross-rope assembly 300 is cut after the cross-rope assembly 300 and the cylinder shaft assembly 100 are welded, and the main board of the cross-rope assembly 300 is reserved for cutting breakpoints.

[0060] In one embodiment, when the assembled and welded reel is hoisted as a whole, the lifting ears are installed on both side end surfaces of the cylinder body, avoiding the reserved apertures on the cylinder shaft assembly 100 .

[0061] Specifically, Figure 5 As shown in the figure, when installing the lifting lugs, the components need to be hoisted as a whole and turned up and down 180 degrees after assembly and welding, so the lifting lugs are installed on the end face of the drum and need to be installed on both sides. Due to the limitations of the drum structure and assembly requirements, the installation position needs to avoid the matching aperture of the components.

[0062] In one embodiment, when welding the drum, a plane arc submerged arc automatic welding method is selected for welding.

[0063] In one embodiment, the butt joint of the cylinder body is formed by a U-shaped narrow gap welding groove, and the corner joints of the brake assembly 200, the rope crossing assembly 300, the rope retaining assembly and the driving end assembly with the cylinder body are formed by a J-shaped welding groove.

[0064] Specifically, the overall welding filling volume of the drum is large, so the butt annular seam of the drum adopts a U-shaped narrow gap welding groove, and the corner joints of the remaining components and the drum adopt a J-shaped welding groove. At the same time, the welding method adopts plane arc submerged arc automatic welding. This solution can reduce the welding filling volume and easily meet the welding quality requirements.

[0065] In one embodiment, Figure 2 As shown, the assembly and welding of the reel specifically includes:

[0066] The brake assembly 200 is placed on a horizontal steel plate, and a pad is arranged under the brake assembly 200;

[0067] A positioning block is welded on the cylinder shaft assembly 100 and installed in the brake assembly 200;

[0068] Assemble and weld the rope-crossing assembly 300, the rope-blocking assembly, and the driving end assembly in sequence from bottom to top;

[0069] Among them, during assembly, cylinder welding positioning blocks or process support methods are used for positioning and assembly.

[0070] Specifically, this method adopts a vertical manufacturing method, and welds and assembles the drum perpendicular to the blowing plane. On the one hand, it can facilitate the hoisting of the drum and the assembly of various components. On the other hand, it can change the welding position from 3G vertical welding to 1G flat welding. During the welding process, plane arc submerged arc automatic welding is used. This welding method can improve welding efficiency and quality. In this method, since the drum shaft has been processed before assembly, the drum shafts at both ends have met the concentricity requirements when processing the drum shafts. Using this manufacturing method can ensure that no deformation occurs after welding. If a horizontal manufacturing method is used, the heat generated during welding will cause micro-deformation under the weight of the drum, and the concentricity of the drum shaft cannot be guaranteed.

[0071] like Figure 2 As shown, the brake assembly 200 is placed on a horizontal steel plate and the pad is arranged in place. The positioning block is welded on the cylinder shaft assembly 100 and installed in the brake assembly 200. During the installation process, it is necessary to ensure that the end face of the cylinder is completely fitted with the pad. The remaining components are also positioned and assembled by using the cylinder welding positioning block or process support. They are assembled and welded from bottom to top in sequence as shown in the figure. This manufacturing method will change the welding position from vertical welding to flat welding, improve welding quality, increase welding efficiency, and ensure the concentricity of the reel shaft.

[0072] The notch production of the cross rope assembly 300 includes: cutting off the excess part according to the reserved cutting breakpoint and installing the semicircular pipe, and finally attaching the steel liner to install the second fan-shaped sealing plate 320 and welding it. Figure 8 The fan-shaped sealing plate is segmented to facilitate the control of welding deformation, avoid the pot cover deformation caused by concentrated welding and reduce the production cycle.

[0073] For example, when processing a winding shaft, if the cylinder plate thickness is 110, the inner diameter is φ1300, and the length is 6900mm, it needs to be rolled by heating, the heating temperature should not exceed 1000℃, and the final rolling temperature should not exceed 800℃. After rolling and welding, the inner diameter of the cylinder is Φmm, and the ovality should be ≤3mm.

[0074] The present invention has the following beneficial effects:

[0075] 1. High efficiency: This method completes the processing of the cylinder shaft assembly before assembling multiple components. There is no need to assemble the cylinder shaft assembly later, which reduces the machining cycle and the number of hoisting times. All processing content can be completed in one clamping, thereby improving the manufacturing efficiency of the winch drum.

[0076] 2. High quality: This method adopts a vertical manufacturing process, which eliminates the deformation caused by heat in horizontal welding, converts vertical welding into flat welding, reduces the difficulty of assembly and welding in the production process, and ensures the concentricity requirements of the reel shaft.

[0077] In the description of the present application, it should be noted that the terms used herein are only for describing specific embodiments, and are not intended to limit the exemplary embodiments according to the present application. For ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The technology, methods and equipment known to ordinary technicians in the relevant field may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be regarded as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary, rather than as a limitation. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further discussed in subsequent drawings.

[0078] It should be noted that, in the present application, the terms "comprises", "includes" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. It should also be pointed out that the scope of the methods and devices in the embodiments of the present application is not limited to performing functions in the order shown or discussed, and may also include performing functions in a substantially simultaneous manner or in reverse order according to the functions involved. For example, the described method may be performed in an order different from that described, and various steps may be added, omitted, or combined. In addition, the features described with reference to certain examples may be combined in other examples.

[0079] In addition, it should be noted that, unless otherwise clearly specified and limited, the words "connect" and "drive" used in the description of this application should be understood in a broad sense, which can be direct, through an intermediate medium, or the relationship between two elements. Those skilled in the art can understand their specific meanings in this application according to specific circumstances. In this article, "first" and "second" and other similar words are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations.

[0080] The above embodiments are provided for persons familiar with the art to implement or use the present application. Personnel familiar with the art can make various modifications or changes to the above embodiments without departing from the application concept of the present application. Therefore, the protection scope of the present application is not limited to the above embodiments, but should be the maximum scope of the innovative features mentioned in the claims.

Claims

1. A vertical manufacturing method for a large winch drum, characterized in that: The vertical manufacturing method of the large winch drum comprises: Process the barrel shaft assembly, manufacture and assemble the reel shaft, barrel, flange plate, and inner ring rib plate of the barrel shaft assembly according to the work drawing, and ensure the concentricity of the bearing gears of the two sections of the barrel shaft assembly during the assembly process; Processing the cross-rope assembly, dividing the fan-shaped sealing plate of the cross-rope assembly into a first fan-shaped sealing plate and a second fan-shaped sealing plate, and pre-processing the plane of the cross-rope assembly; The brake assembly, the cylinder shaft assembly, the cross-rope assembly, the rope stop assembly, and the drive end assembly are assembled vertically in sequence on a horizontal plane, and the brake assembly, the cylinder shaft assembly, the cross-rope assembly, the rope stop assembly, and the drive end assembly are connected by welding during assembly; The assembled and welded reel is hoisted as a whole, the reel is rotated 180° up and down, and the reel is further welded; During the assembly and welding process of the reel, the reel is always perpendicular to the horizontal plane.

2. The vertical manufacturing method of a large winch drum according to claim 1, characterized in that: When processing the barrel shaft assembly, the barrel shaft, barrel, flange plate, and inner ring rib plate of the barrel shaft assembly are first made into groups according to the work drawing, and then processed as a whole after the stress is removed by vibration; A roller frame is used to weld the drum shaft, drum, flange plate and inner ring rib plate of the drum shaft assembly.

3. The vertical manufacturing method of a large winch drum according to claim 1, characterized in that: When assembling the cross-rope assembly on the cylinder shaft assembly, first assemble and weld the first sector-shaped box sealing plate and the cylinder shaft assembly, and then assemble and weld the second sector-shaped box sealing plate, the first sector-shaped box sealing plate and the cylinder shaft assembly.

4. The vertical manufacturing method of a large winch drum according to claim 3, characterized in that: During the welding process of the second sector sealing plate and the cylinder shaft assembly, the weld is divided into a plurality of small sections, each section is welded in multiple layers, and each layer includes a plurality of weld passes.

5. The vertical manufacturing method of a large winch drum according to claim 4, characterized in that: The first sector-shaped box sealing plate, the second sector-shaped box sealing plate and the cylinder shaft assembly are assembled and welded by gasket welding.

6. The vertical manufacturing method of a large winch drum according to claim 1, characterized in that: Use a vertical lathe to pre-process the plane of the cross-rope assembly; During pre-processing, a cutting breakpoint is reserved for the main board of the cross-rope assembly.

7. The vertical manufacturing method of a large winch drum according to claim 1, characterized in that: When hoisting the assembled and welded drum as a whole, install the lifting ears on both side end faces of the drum, avoiding the reserved apertures on the drum shaft assembly.

8. The vertical manufacturing method of a large winch drum according to claim 1, characterized in that: When welding the drum, the plane arc submerged arc automatic welding method is used for welding.

9. The vertical manufacturing method of a large winch drum according to claim 2, characterized in that: The butt joint of the cylinder body is welded with a U-shaped narrow gap groove, and the corner joints of the brake assembly, the cross-rope assembly, the rope stop assembly and the drive end assembly with the cylinder body are welded with a J-shaped groove.

10. The vertical manufacturing method of a large winch drum according to claim 2, characterized in that: The assembly and welding of the reel specifically includes: The brake assembly is placed on a horizontal steel plate, and a pad is arranged under the brake assembly; A positioning block is welded on the cylinder shaft assembly and installed in the brake assembly; Assemble and weld the cross-rope assembly, the rope retaining assembly, and the driving end assembly in sequence from bottom to top; Among them, during assembly, cylinder welding positioning blocks or process support methods are used for positioning and assembly.

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