Vertical manufacturing method of large winch drums

Abstract

The application provides a vertical manufacturing method of a large winch drum, comprising the following steps: processing a drum shaft assembly, manufacturing and assembling a drum shaft, a drum, a flange plate and an inner ring rib plate of the drum shaft assembly according to a drawing, and ensuring the concentricity of two drum shaft bearing steps of the drum shaft assembly; processing a rope crossing assembly, dividing a sector sealing box plate of the rope crossing assembly into a first sector sealing box plate and a second sector sealing box plate, and pre-processing a plane of the rope crossing assembly; vertically assembling a brake assembly, the drum shaft assembly, the rope crossing assembly, a rope blocking assembly and a driving end assembly on a horizontal plane in sequence, connecting the brake assembly, the drum shaft assembly, the rope crossing assembly, the rope blocking assembly and the driving end assembly by welding during the assembly; hoisting the drum which is installed and welded as a whole, rotating the drum by 180 degrees up and down, further welding the drum, and ensuring the concentricity requirement of the two drum shafts during the vertical welding, and the welding efficiency can be improved and the welding difficulty can be reduced by using the plane welding mode.

Description

Technical Field

[0001] This invention relates to the technical field of marine winch manufacturing, and more specifically, to a vertical manufacturing method for a large winch drum. Background Technology

[0002] When ships operate at sea, they need to perform tasks such as mooring, shifting, and positioning in complex marine environments. Winches are one of the most crucial pieces of equipment when ships complete these operations. With the rapid development of the global shipping industry, the carrying capacity of ships is constantly increasing, leading to greater ship weights. Consequently, the load on winches is also increasing. As a key component of the entire winch system, the quality and stability of the drum directly affect the overall efficiency and safety of the winch.

[0003] The manufacturing of large winch drums is divided into five parts: drum shaft assembly, brake assembly, drive end assembly, rope guard assembly, and rope crossing assembly, each manufactured and processed separately. The rope crossing assembly serves to cross and store the rope during drum winding. It adopts a box structure with a wide rope crossing notch. The sealing plate has a fan-shaped embedded structure and is entirely single-sided bevel welded, resulting in a large amount of welding. Controlling the flatness of the assembly after welding is difficult. The drum's overall size and weight are large, and its structure is narrow at both ends and wide in the middle, requiring machining on a large horizontal lathe. This process necessitates turning the machine around, increasing equipment operating time and costs. Therefore, a process plan needs to be developed to ensure both the overall precision requirements of the drum and effective control of welding deformation while reducing processing time. Summary of the Invention

[0004] This invention provides a vertical manufacturing method for large winch drums, which aims to eliminate deformation caused by welding heat, reduce assembly and welding difficulties during the manufacturing process, reduce machining cycle and hoisting times, and improve the manufacturing efficiency of winch drums.

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

[0006] Machining the cylinder shaft assembly involves fabricating and assembling the drum shaft, cylinder, flange plate, and inner ring stiffener plate of the cylinder shaft assembly according to the engineering drawings. During the assembly process, ensure the concentricity of the bearing stops of the two sections of the drum shaft assembly.

[0007] Process the rope crossing assembly, divide the fan-shaped sealing plate of the rope crossing assembly into a first fan-shaped sealing plate and a second fan-shaped sealing plate, and pre-process the plane of the rope crossing assembly;

[0008] The brake assembly, cylinder shaft assembly, rope crossing assembly, rope blocking assembly, and drive end assembly are sequentially and vertically assembled on a horizontal surface. During assembly, the brake assembly, cylinder shaft assembly, rope crossing assembly, rope blocking assembly, and drive end assembly are connected by welding.

[0009] The assembled and welded drum is hoisted as a whole, rotated 180° up and down, and then further welded.

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

[0011] In one embodiment, when processing the cylinder shaft assembly, the cylinder shaft, cylinder, flange plate, and inner ring stiffener plate of the cylinder shaft assembly are first assembled according to the engineering drawing, and then the stress is removed by vibration before overall processing is carried out.

[0012] The drum shaft, drum body, flange plate, and inner ring stiffener plate of the cylinder shaft assembly are welded using a roller frame.

[0013] In one embodiment, when assembling the rope-crossing assembly onto 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 cylindrical shaft assembly, the weld is divided into multiple segments, each segment is welded in multiple layers, and each layer includes multiple weld passes.

[0015] In one embodiment, the first sector-shaped sealing plate, the second sector-shaped sealing plate, and the cylindrical shaft assembly are assembled and welded by a backing weld.

[0016] In one embodiment, a vertical lathe is used to pre-machine the plane of the rope crossing assembly;

[0017] During pre-processing, a cutting break point is reserved on the main board of the rope crossing assembly.

[0018] In one embodiment, when hoisting the assembled and welded drum as a whole, the lifting lugs are installed on both ends of the drum body, avoiding the pre-drilled holes on the drum body shaft assembly.

[0019] In one embodiment, when welding the roll, a planar circular arc submerged arc automatic welding method is selected for welding.

[0020] In one embodiment, the butt joint of the cylinder is made with a U-shaped narrow gap welding bevel, and the corner joints of the brake assembly, the rope crossing assembly, the rope blocking assembly, and the drive end assembly with the cylinder are all made with a J-shaped welding bevel.

[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 onto the cylinder shaft assembly and installed in the brake assembly;

[0024] The rope crossing assembly, rope blocking assembly, and drive end assembly are assembled and welded sequentially from bottom to top;

[0025] During assembly, the cylindrical body is positioned using welding positioning blocks or process supports.

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

[0027] 1. High efficiency: This method completes the machining of the cylinder shaft assembly before the assembly of multiple components, eliminating the need for subsequent assembly of the cylinder shaft assembly. This reduces the machining cycle and the number of hoisting operations, enabling all machining to be completed in one clamping operation, 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 heating in horizontal welding, turns vertical welding into flat welding, reduces the assembly and welding difficulty in the manufacturing process, and ensures the concentricity requirements of the drum shaft. Attached Figure Description

[0029] Figure 1 This is a schematic flowchart of a vertical manufacturing method for a large winch drum according to an embodiment of the present invention.

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

[0031] Figure 3 This is a schematic diagram of the structure of the cylinder shaft assembly in a vertical manufacturing method for a large winch drum according to an embodiment of the present invention.

[0032] Figure 4 This is a schematic diagram of the structure of the fan-shaped sealing plate in a vertical manufacturing method for a large winch drum according to an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram of the lifting lug installation in a vertical manufacturing method for a large winch drum according to an embodiment of the present invention;

[0034] Figure 6 This is a schematic diagram of the structure of the reserved cutting point in the vertical manufacturing method of a large winch drum according to an embodiment of the present invention.

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

[0036] Figure 8 This is a schematic diagram showing the connection between the first sector-shaped sealing plate and the 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 rope crossing assembly; 310 is the first sector-shaped sealing plate; 320 is the second sector-shaped sealing plate; 400 is the rope blocking assembly; and 500 is the drive end assembly. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions. The described embodiments are some embodiments of this application, but not all embodiments. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0039] Figure 1 This is a schematic flowchart of a vertical manufacturing method for a large winch drum according to an embodiment of the present invention. The vertical manufacturing method for the large winch drum includes:

[0040] Machining cylinder shaft assembly 100, such as Figure 3 As shown, the drum shaft, drum body, flange plate, and inner ring stiffener of the drum shaft assembly 100 are manufactured and assembled according to the engineering drawings. During the assembly process, the concentricity of the bearing stops of the two sections of the drum shaft assembly 100 is ensured.

[0041] Process the rope crossing assembly 300, divide the fan-shaped sealing plate of the rope crossing assembly 300 into a first fan-shaped sealing plate 310 and a second fan-shaped sealing plate 320, and pre-process the plane of the rope crossing assembly 300.

[0042] like Figure 7 As shown, the brake assembly 200, cylinder shaft assembly 100, rope crossing assembly 300, rope blocking assembly, and drive end assembly are sequentially and vertically assembled on a horizontal surface. During assembly, the brake assembly 200, cylinder shaft assembly 100, rope crossing assembly 300, rope blocking assembly, and drive end assembly are connected by welding.

[0043] The assembled and welded drum is hoisted as a whole, rotated 180° up and down, and then further welded.

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

[0045] Specifically, if the fan-shaped sealing plate structure of the rope-crossing assembly 300 were manufactured as a single piece, the rope-crossing assembly 300 and the drum shaft assembly 100 would need to be assembled before welding. This would easily cause deformation of the drum after welding and result in a long production cycle. Therefore, a segmented manufacturing method is adopted, dividing the fan-shaped sealing plate into a first fan-shaped sealing plate 310 and a second fan-shaped sealing plate 320.

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

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

[0048] In one embodiment, when processing the cylinder shaft assembly 100, the drum shaft, cylinder, flange plate, and inner ring stiffener of the cylinder shaft assembly 100 are first assembled according to the engineering drawing, and then the stress is removed by vibration before overall processing is carried out.

[0049] The drum shaft, drum body, flange plate, and inner ring stiffener plate of the cylinder shaft assembly 100 are welded using a roller frame.

[0050] Specifically, the cylinder shaft assembly 100 is welded using a roller frame. During processing, the outer diameter must be processed according to the drawing to ensure the dimensions. The straightness error should be less than 0.5mm, and the concentricity of the two end drum shafts should be ≤0.1mm.

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

[0052] In one embodiment, during the welding process between the second sector-shaped sealing plate 320 and the cylindrical shaft assembly 100, the weld is divided into multiple segments, each segment is welded in multiple layers, and each layer includes multiple weld passes.

[0053] In one embodiment, the first sector-shaped sealing plate 310, the second sector-shaped sealing plate 320, and the cylinder shaft assembly 100 are assembled and welded by a backing weld.

[0054] In one embodiment, the cross-rope assembly 300 plane is pre-machined using a vertical lathe;

[0055] During pre-processing, a cutting break point is reserved on the main board of the rope crossing assembly 300.

[0056] Specifically, the components are prefabricated in sections and welded using a distributed multi-pass welding method to reduce heat input and control welding deformation.

[0057] The distributed multi-pass welding method specifically involves dividing the weld into multiple small segments, with each segment undergoing multi-layer welding, and each layer including multiple weld passes.

[0058] like Figure 4 , Figure 8 As shown, the plane of the rope-crossing assembly 300 is pre-machined using a vertical lathe. After it is assembled with the cylinder shaft assembly 100 and all welds are completed, the interface of the second sector-shaped sealing plate 320 is welded in place using a backing weld, which can ensure that the requirements are met after the welding is completed.

[0059] Furthermore, such as Figure 6 As shown, the main board of the rope-crossing assembly 300 needs to be cut at breakpoints to avoid large deformation caused by overall cutting. The notch in the rope-crossing assembly 300 will be trimmed after the rope-crossing assembly 300 and the cylinder shaft assembly 100 are welded together. The main board of the rope-crossing assembly 300 has reserved cutting breakpoints.

[0060] In one embodiment, when hoisting the assembled and welded drum as a whole, the lifting lugs are installed on both ends of the drum body, avoiding the pre-drilled holes on the drum shaft assembly 100.

[0061] Specifically, such as Figure 5 As shown, during the installation of the lifting lugs, after the components are assembled and welded, they need to be hoisted as a whole and rotated 180°. Therefore, the lifting lugs are installed on the end face of the cylinder, and both sides need to be installed. Due to the limitations of the drum structure and assembly requirements, the installation position must avoid the component mating holes.

[0062] In one embodiment, when welding the roll, a planar circular arc submerged arc automatic welding method is selected for welding.

[0063] In one embodiment, the butt joint of the cylinder body adopts a U-shaped narrow gap welding bevel, and the corner joints of the brake assembly 200, the rope crossing assembly 300, the rope blocking assembly, and the drive end assembly with the cylinder body all adopt a J-shaped welding bevel.

[0064] Specifically, the overall welding filler volume of the drum is relatively large, so the butt joint of the drum body adopts a U-shaped narrow gap welding bevel, and the corner joints of the other components with the drum body adopt a J-shaped welding bevel. At the same time, the welding method adopts planar circular arc submerged arc automatic welding. This solution can reduce the welding filler volume and easily meet the welding quality requirements.

[0065] In one embodiment, such as Figure 2 As shown, the assembly and welding of the drum 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 onto the cylinder shaft assembly 100 and installed in the brake assembly 200;

[0068] The rope-crossing assembly 300, the rope-blocking assembly, and the drive-end assembly are assembled and welded sequentially from bottom to top;

[0069] During assembly, the cylindrical body is positioned using welding positioning blocks or process supports.

[0070] Specifically, this method employs a vertical manufacturing approach, welding and assembling the drum perpendicular to the blowing plane. This facilitates drum hoisting and component assembly, and also changes the welding position from 3G vertical welding to 1G flat welding. The welding process utilizes planar circular arc submerged arc automatic welding, improving both welding efficiency and quality. Because the drum shaft is pre-machined before assembly, and the concentricity of both ends is ensured during shaft machining, this method guarantees no deformation after welding. If a horizontal manufacturing method were used, the heat generated during welding would cause slight deformation under the drum's own weight, compromising the concentricity of the drum shaft.

[0071] like Figure 2 As shown, the brake assembly 200 is placed on a horizontal steel plate and the pads are positioned. Positioning blocks are welded onto the cylinder shaft assembly 100 and installed into the brake assembly 200. During installation, it is essential to ensure that the cylinder end face is fully in contact with the pads. The remaining components are also positioned and assembled using cylinder welding positioning blocks or process supports. Assembly and welding are performed sequentially from bottom to top as shown in the diagram. This manufacturing method changes the welding position from vertical welding to horizontal welding, improving welding quality and increasing welding efficiency, while ensuring the concentricity of the drum shaft.

[0072] The fabrication of the notch in the rope-crossing assembly 300 includes: cutting off the excess portion according to the pre-reserved cutting point and installing the semi-circular tube; finally, attaching the steel liner, installing the second sector-shaped sealing plate 320, and welding it. Figure 8 As shown. Segmenting the fan-shaped sealing plate makes it easier to control welding deformation, avoids concentrated welding that could cause lid-shaped deformation, and reduces the production cycle.

[0073] For example, when processing a roller shaft, if the roller plate is 110mm thick, has an inner diameter of φ1300mm, and a length of 6900mm, it needs to be rolled using a heating method. 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 roller should be Φmm, and the ellipticity should be ≤3mm.

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

[0075] 1. High efficiency: This method completes the machining of the cylinder shaft assembly before the assembly of multiple components, eliminating the need for subsequent assembly of the cylinder shaft assembly. This reduces the machining cycle and the number of hoisting operations, enabling all machining to be completed in one clamping operation, 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 heating in horizontal welding, turns vertical welding into flat welding, reduces the assembly and welding difficulty in the manufacturing process, and ensures the concentricity requirements of the drum shaft.

[0077] In the description of this application, it should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. For ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0078] It should be noted that, in this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. It should also be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Furthermore, features described with reference to certain examples may be combined in other examples.

[0079] Furthermore, it should be noted that, unless otherwise explicitly stated and limited, the terms "connection," "driving," and similar terms used in the description of this application should be interpreted broadly. They can refer to direct connections, connections through an intermediate medium, or relationships within two elements. Those skilled in the art can understand their specific meaning in this application based on the specific circumstances. In this document, terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any actual relationship or order between these entities or operations.

[0080] The above embodiments are provided for those skilled in the art to implement or use this application. Those skilled in the art can make various modifications or changes to the above embodiments without departing from the spirit of this application. Therefore, the scope of protection of this application is not limited to the above embodiments, but should be the maximum scope that conforms to the innovative features mentioned in the claims.

Claims

1. A method of vertical manufacturing of a large winch drum, characterized in that, The vertical manufacturing method of the large winch drum comprises the following steps: Processing the drum shaft assembly, the drum shaft assembly is made of the drum shaft, the drum, the flange plate and the inner ring rib plate according to the drawing, and the two drum shaft bearing grooves of the drum shaft assembly are ensured to be concentric during the assembly process; Processing the cross rope assembly, the cross rope assembly is divided into the first sector sealing box plate and the second sector sealing box plate, and the cross rope assembly plane is pre-processed; The brake assembly, the drum shaft assembly, the cross rope assembly, the rope blocking assembly and the driving end assembly are sequentially vertically assembled on the horizontal plane, and the brake assembly, the drum shaft assembly, the cross rope assembly, the rope blocking assembly and the driving end assembly are connected by welding during the assembly; The assembled and welded drum is integrally hoisted, the drum is rotated by 180°, and the drum is further welded; During the assembly and welding of the drum, the drum is always perpendicular to the horizontal plane; The assembly and welding of the drum specifically comprises the following steps: The brake assembly is placed on the horizontal steel plate, and the cushion block is arranged under the brake assembly; The positioning block is welded on the drum shaft assembly and installed in the brake assembly, and at this time, the drum end face is completely attached to the cushion block; The cross rope assembly, the rope blocking assembly and the driving end assembly are sequentially assembled and welded from bottom to top; During the assembly, the drum welding positioning block or the process support positioning assembly is selected, the vertical welding is changed to the flat welding, and the welding quality is improved; During the assembly of the cross rope assembly on the drum shaft assembly, the first sector sealing box plate is assembled and welded with the drum shaft assembly, the cross rope assembly plane is pre-processed, and after the assembly and welding of all the welds of the drum shaft assembly are completed, the second sector sealing box plate is welded.

2. The method of vertical manufacturing of a large winch drum according to claim 1, characterized in that, During the processing of the drum shaft assembly, the drum shaft assembly is made of the drum shaft, the drum, the flange plate and the inner ring rib plate according to the drawing, and the whole is processed after stress removal by vibration; The drum shaft, the drum, the flange plate and the inner ring rib plate of the drum shaft assembly are welded by using the roller frame.

3. The method of vertical manufacturing of a large winch drum according to claim 1, characterized by, During the assembly of the cross rope assembly on the drum shaft assembly, the first sector sealing box plate is assembled and welded with the drum shaft assembly, and then the second sector sealing box plate is assembled and welded with the first sector sealing box plate and the drum shaft assembly.

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

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

6. The method of vertical manufacturing of a large winch drum according to claim 1, characterized in that, The cross rope assembly plane is pre-processed by using the vertical lathe; During the pre-processing, the main plate of the cross rope assembly is reserved for cutting breakpoints.

7. The method of vertical manufacturing of a large winch drum according to claim 1, characterized in that, During the integral hoisting of the assembled and welded drum, the lifting lug is installed on the two side end faces of the drum, and the reserved hole diameter of the drum shaft assembly is avoided.

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

9. The method of vertical manufacturing of a large winch drum according to claim 2, characterized in that, The butt joint ring seam of the drum selects the U-shaped narrow gap welding groove, and the corner joints of the brake assembly, the cross rope assembly, the rope blocking assembly and the driving end assembly and the drum select the J-shaped welding groove.

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