Method for manufacturing portal crane cross beam and portal crane cross beam

Abstract

The invention provides a manufacturing method of a portal crane cross beam and the portal crane cross beam. The manufacturing method of the portal crane cross beam comprises the following steps: arranging a jig frame at a workshop doorway; the bottom plate is laid on the jig frame to serve as the manufacturing reference of the portal crane cross beam; mounting the cylinder on a bottom plate, and mounting a web plate and a wing plate; a welding operation platform is built, and the web and the cylinder are welded; and installing and welding the panel. The manufacturing method can improve the operation safety.

Description

Technical Field

[0001] The invention relates to a method for manufacturing large-scale port equipment, and in particular to a method for manufacturing a gantry crane crossbeam and the gantry crane crossbeam. Background Art

[0002] Gantry crane is the abbreviation of portal crane, which is a large lifting equipment widely used in ports, docks and other places. Gantry crane crossbeam is the key part of the gantry crane. It is usually a large component installed horizontally, connecting the two side legs or other main structural parts of the gantry crane. The crossbeam plays the role of bearing and transmitting force in the entire gantry crane structure.

[0003] The weight of a 1000T gantry crane crossbeam is about 400T. Under the existing conditions, the crossbeam needs to be made in a high-span workshop. Since the crossbeam of a gantry crane is not only heavy and large in size, but also very special in form, with the cylinder exposed 2.5m above the deck, it needs to be lifted by two 500T gantry cranes in the field, or transferred to the dock and turned over by a floating crane.

[0004] However, the lifting capacity of a single crane in the high-span workshop is only 80+80=160T, and it is impossible to lift and transport the 400T component out of the workshop, making it difficult to transport the gantry crane beam from the high-span workshop; the 500T gantry crane is lifted or transported to the dock by floating crane turning over, which results in the occupation of large equipment resources; at the same time, the cylinder is exposed 2.5m above the deck surface, and the transfer height after turning over is too high, which poses a great risk of transportation. If the subsequent construction work is continued in the turning over area without transportation, the resources around the gantry crane or the dock site will be occupied. Summary of the invention

[0005] The purpose of the present invention is to provide a method for manufacturing a gantry crane cross beam and a gantry crane cross beam, which can improve operation safety.

[0006] One aspect of the present invention provides a method for manufacturing a gantry crane cross beam, comprising: arranging a tire frame at the workshop door; laying a bottom plate on the tire frame as a manufacturing basis for the gantry crane cross beam; installing a cylinder on the bottom plate, and installing a web and a wing plate; building a welding work platform, and welding the web and the cylinder; and installing and welding a panel.

[0007] In one embodiment, the manufacturing method further comprises: building a tire frame, and setting the height of the tire frame to be greater than the height of the legs on both sides of the web.

[0008] In one embodiment, the height of the tire frame is 1.6m.

[0009] In one embodiment, the construction of a welding work platform and the welding of the web and the cylinder include: making a partition and installing the partition on the bottom plate; building a welding work platform between the partition and the web; and welding the vertical welds between the web and the cylinder and the vertical welds between the web and the partition.

[0010] In one embodiment, the manufacturing of the partition and installing the partition on the base plate includes: opening a plurality of holes at intervals on a plate to form a partition; installing the partition on the base plate, and welding the partition and the base plate.

[0011] In one embodiment, building a welding work platform between the partition and the web includes: inserting one end of a wooden board into the hole of the partition, and overlapping the other end of the wooden board with the web to form the welding work platform.

[0012] In one embodiment, the number of the holes is five, and the interval between adjacent holes is 1.5 m or 1.35 m.

[0013] In one embodiment, the manufacturing method further comprises: manufacturing a bottom plate, and setting a downward reverse deformation amount on the bottom plate.

[0014] In one embodiment, the reverse deformation amount is -15 mm to -25 mm.

[0015] Another aspect of the present invention provides a gantry crane cross beam, which is manufactured by the manufacturing method of the gantry crane cross beam as described in any one of the above embodiments.

[0016] The manufacturing method of the gantry crane cross beam of the present invention is to select to manufacture it at the workshop door, and after completion, it can be transported out of the workshop by a flatbed truck, and the component is selected for regular manufacturing in the process, and the components are adopted in the workshop with the bottom plate as the reference as the overall manufacturing plan, which can reduce the turning over and hoisting of the component manufacturing, reduce the requirements for the lifting capacity of the workshop, provide more options for the production of gantry crane cross beams, ensure the overall production progress of 1000T gantry cranes, and improve the operating safety of gantry crane cross beams. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and other features, properties and advantages of the present invention will become more apparent through the following description in conjunction with the accompanying drawings and embodiments, in which:

[0018] Figure 1 This is a structural diagram of the finished gantry crane crossbeam;

[0019] Figure 2 1. It is a schematic flow chart of an embodiment of a method for manufacturing a gantry crane crossbeam according to the present invention;

[0020] Figure 3 It is a schematic diagram for controlling the reverse deformation of the bottom plate of the gantry crane cross beam;

[0021] Figure 4 yes Figure 3 A top view of

[0022] Figure 5 It is a schematic diagram of the marking process requirements in the method for manufacturing the gantry crane crossbeam of the present invention;

[0023] Figure 6 It is a schematic diagram of a welding work platform in the method for manufacturing a gantry crane cross beam of the present invention;

[0024] Figure 7 yes Figure 6 Schematic diagram of the structure of the partition shown. DETAILED DESCRIPTION

[0025] The weight of the 1000T gantry crane crossbeam is about 400T. Under the existing conditions, it is preferred to arrange the production of this component in the heavy-duty workshop, which has the largest lifting capacity. A single crane can lift 200+200=400T, and two cranes can be used to lift and move it out of the workshop. Since the workshop is used for other purposes, after many consultations and technical support, the crossbeam is arranged to be produced in the high-span workshop.

[0026] The gantry crane crossbeam component is not only heavy and large in size, but also very special in shape. The cylinder is 2.5m above the deck surface and needs to be lifted by two 500T gantry cranes outside, or transferred to the dock and turned over by a floating crane.

[0027] However, the lifting capacity of a single crane in the high-span workshop is only 80+80=160T, and it is impossible to lift and transport the 400T component out of the workshop, making it difficult to transport the gantry crane beam from the high-span workshop; the 500T gantry crane is lifted or transported to the dock by floating crane turning over, which results in the occupation of large equipment resources; at the same time, the cylinder is exposed 2.5m above the deck surface, and the transfer height after turning over is too high, which poses a great risk of transportation. If the subsequent construction work is continued in the turning over area without transportation, the resources around the gantry crane or the dock site will be occupied.

[0028] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided to explain the present invention, not to limit the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature illustrated or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, the present invention is intended to cover these modifications and variations within the scope of the appended claims and their equivalents.

[0029] It should be noted that these and other subsequent drawings are only examples and are not drawn to scale, and should not be used to limit the actual scope of protection required by the present invention.

[0030] like Figure 1 The structure of the gantry crane beam shown in the figure, the gantry crane beam of the present invention comprises a bottom plate 10 ( Figure 1 Not shown, please refer to Figure 3 ), cylinder 20, web 30, wing 40 and panel, each component is connected by welding to form a crossbeam. Among them, the web 30 and the wing 40 are welded to the four sides of the bottom plate 10 to enclose a box structure. There are four webs 30, each of which is welded to the cylinder 20. The lower end of the web 30 is provided with a protruding leg 31 with a height of 1.5m. There are two wing 40, which are welded between the two webs 30. The panel includes a middle panel 51 and two side panels 52. The middle panel 51 is installed on the top of the cylinder 20, and the two side panels 52 are installed on the top of the box structure formed by the web 30 and the wing 40. The two side panels 52 form a deck surface. The cylinder 20 is exposed 2.5m above the deck surface.

[0031] Figure 2 An embodiment of the method for manufacturing a gantry crane cross beam of the present invention is shown. Figure 2 As shown, the manufacturing method of the portal crane cross beam of the present invention includes steps S100 to S500:

[0032] In step S100, a tire stand (not shown) is arranged at the entrance of a workshop.

[0033] In step S200, the base plate 10 is laid on the tire frame as a basis for manufacturing the gantry crane cross beam.

[0034] In step S300 , the cylinder 20 is mounted on the base plate 10 , and the web plate 30 and the wing plate 40 are installed.

[0035] In step S400 , a welding work platform is built to weld the web 30 and the cylinder 20 .

[0036] In step S500 , the panels are mounted and welded.

[0037] The manufacturing method of the portal crane cross beam of the present invention is to manufacture it at the workshop door, and after completion and inspection, it can be transported out of the workshop by a hydraulic flatbed truck. Compared with the manufacturing scheme of the portal crane cross beam in the workshop, the manufacturing method of the portal crane cross beam of the present invention can reduce the turning over and hoisting of the component manufacturing, reduce the requirements for the lifting capacity of the workshop, provide more options for the production of portal crane cross beams, ensure the overall production progress of the 1000T portal crane, and improve the safety of the operation.

[0038] From the perspective of cycle cost and safety, the manufacturing method of the gantry crane cross beam of the present invention selects the component manufacturing, and the component is not turned over and welded for overall manufacturing, that is, the component is manufactured in the workshop with the bottom plate 10 as the reference as the overall manufacturing plan, and is transported out of the workshop after completion. Compared with the manufacturing plan of using two 500T gantry cranes to lift in the field, or transporting to the dock and turning over by floating crane, it avoids the occupation of large equipment resources and the risk of transportation.

[0039] In the manufacturing method of the present invention, the tire frame serves as a structure for supporting the base plate 10, which can ensure that the gantry crane cross beam maintains a correct shape and position during the manufacturing process, and is convenient for personnel to perform installation and welding operations.

[0040] According to the structural characteristics of the portal crane crossbeam of the present invention, the height of the legs 31 on both sides of the web 30 is 1.5m. In order to affect the installation and welding of the web 30, a special height tire frame is built. In one embodiment, the manufacturing method further includes step S101:

[0041] In step S101 , a tire frame is constructed, and the height of the tire frame is set to be greater than the height of the legs 31 on both sides of the web 30 .

[0042] In this way, it is convenient for the production of components and also for the subsequent removal of the middle groove position for placing a transfer vehicle for transporting out of the workshop.

[0043] Preferably, the height of the tire frame is 1.6m, which is convenient for the hydraulic flatbed truck to transport the gantry crane beam out of the workshop from the workshop door.

[0044] Considering that the size of the middle groove between the two side legs 31 is about 10m, in order to ensure the strength of the tire frame after the middle cylinder 20 is installed, multiple cylindrical structures are placed on the bottom plane of the tire frame as strong support points, which is also convenient for subsequent rapid removal. The cylindrical structure is located directly below the cylinder 20 and can provide better support.

[0045] The number of the cylindrical structures is preferably four, which are arranged near the four corners of the tire frame respectively.

[0046] According to factors such as the structural form and welding shrinkage, the camber that needs to be controlled when manufacturing the bottom plate 10 is determined. In one embodiment, the manufacturing method of the present invention further includes step S102:

[0047] In step S102, a bottom plate 10 is manufactured, and a downward reverse deformation amount is set on the bottom plate 10. The reverse deformation amount is as follows: Figure 3 and Figure 4 shown.

[0048] The amount of reverse deformation can be determined by combining on-site welding experience and theoretical dimensional data analysis.

[0049] Optionally, the value range of the reverse deformation is -15mm to -25mm, preferably -20mm. Subsequent on-site data re-measurement verifies the accuracy of this deformation. The control of the reverse deformation ensures the opening size of the two door legs of the component, which is one of the most critical dimensions for the production of the crossbeam.

[0050] Since the manufacturing difficulty of the portal crane cross beam of the present invention is relatively large and the plate thickness is relatively thick, the dimensions of each step need to be strictly controlled during the manufacturing process.

[0051] Therefore, strict requirements need to be met during the production process of each component and the overall production process of the gantry crane crossbeam. In this way, not only the design and use functions of the component itself are ensured, but also the matching dimensions with other gantry crane components are ensured. The gantry crane crossbeam plays a connecting role, so the control of the crossbeam size is crucial.

[0052] Figure 5 The positions of the markings on the beam are shown, including the upper trimming contour inspection line 101, the cylinder center line 102, the gauge center line 103, the margin trimming line 104, the center line of the two side sealing plates 105, the four surface margin trimming inspection lines 106, and the panel and cylinder center cross line 107. Among them, the cylinder center line 102 is marked on the upper process support for the subsequent inspection of the upper diameter size of the cylinder 20.

[0053] Combination Figure 1 and Figure 5 , using the four points on the diameter center line of the cylinder 20 of the cross beam as the reference plane, draw the cross center lines of the upper and lower ports of the cylinder 20, all of which are clearly marked with sample punching holes 201, and draw the gauge center line based on the center line.

[0054] like Figure 5 The marking requirements shown not only need to be checked at all times during the production process, but also need to be marked on the corresponding positions of the components after completion, so as to provide the necessary reference basis for the subsequent assembly of components with other related components.

[0055] Due to the special structure of the portal crane crossbeam of the present invention, the working space in some positions is narrow, and the welding requirements are high, a simple welding work platform needs to be built for welding operations. In one embodiment, step S400 further includes steps S410 to S430:

[0056] In step S410, a partition 60 is manufactured and installed on the bottom plate 10. The partition 60 plays a role in supporting the welding work platform, and the number is preferably four.

[0057] In step S420, a welding work platform is built between the partition plate 60 and the web 30. Figure 6The middle panel 51 is installed and welded to the cylinder 20 , and the two side panels 52 are welded to the web 30 and the wing 40 .

[0058] In step S430 , the vertical welds between the web 30 and the cylindrical body 20 and the vertical welds between the web 30 and the partition plate 60 are welded.

[0059] Further, step S410 includes steps S411 to S412:

[0060] In step S411, a plurality of holes 61 are formed on the plate at intervals to form a partition 60. Figure 7 shown.

[0061] In step S412 , the partition plate 60 is installed on the bottom plate 10 , and the partition plate 60 and the bottom plate 10 are welded.

[0062] In the related art, the partition 60 is only provided with a hole 61 at the bottom, and a welding operation platform cannot be built on the upper layer, resulting in the inability to perform welding operations on the upper layer.

[0063] The manufacturing method of the present invention provides a plurality of holes 61 on the partition 60, which changes the design of the partition 60 and facilitates the construction of a multi-layer platform for welding operations, so as to complete welding work in a narrow space.

[0064] like Figure 7 As shown, preferably, the number of holes 61 is five, and the interval between adjacent holes 61 is 1.5m or 1.35m. 1.5m or 1.35m is approximately the height of an adult, which is convenient for personnel to perform welding operations, and also takes into account the stability and functional requirements of the overall structure of the partition 60 to a certain extent.

[0065] In one embodiment, step S420 includes step S421:

[0066] In step S421, one end of the wooden board 70 is inserted into the hole 61 of the partition 60, and the other end of the wooden board 70 is overlapped with the web 30 to form a welding operation platform. Figure 6 shown.

[0067] refer to Figure 6 A relatively closed and narrow triangular space is formed between the cylinder 20, the web 30 and the partition 60, and a scaffolding platform for welding cannot be built inside. The manufacturing method of the present invention adopts welding threaded steel at the angle formed by the cylinder 20 and the outer web 30, one end of the wooden board 70 is placed in the hole 61, and the other end of the wooden board 70 is placed on the threaded steel on the web 30, and tied firmly to form a simple welding operation platform.

[0068] The wooden board 70 is a detachable design, and can be overlapped at different heights according to the situation, so as to facilitate the welding operation. After welding is completed, the wooden board 70 needs to be removed.

[0069] The detailed steps of the method for manufacturing the portal crane cross beam of the present invention are as follows:

[0070] First, make each component, including the bottom plate 10, cylinder 20, web 30, wing plate 40, middle panel 51, two side panels 52 and partition 60. The production steps of each component require marking the plate. That is, mark the center line on each plate, and use the center line of each plate as the reference to mark the partition 60, angle steel, T row, and circular cylinder installation line. When marking, reserve the welding shrinkage allowance for each level in advance. Then weld according to the drawings to obtain each component. It is also necessary to make a tire frame of exclusive height in advance and place the tire frame at the door of the workshop for easy transportation.

[0071] The bottom plate 10 is laid on a 1.6m high tire frame and is made as a reference surface, and a certain welding camber amount is left during the production.

[0072] The cross center line of the entire plate and the circular cylinder installation line need to be marked in advance on the bottom plate 10, and the diameter tolerance of the circular cylinder installation line is controlled within ±2.

[0073] The circular body can be made according to the blueprint, and its diameter and verticality can be corrected, with the control dimensions being within ±2.

[0074] Hoist the cylinder 20 onto the base plate 10, adjust the positioning size, and control the deviation size within 2.

[0075] When installing the cylinder 20 , the center line of the cylinder 20 must be aligned with the center line of the base plate 10 .

[0076] Install the partition 60 and fix it with a process support. Each surface supports a process support and is fixed with a fillet weld. The height of the process support is greater than 1 / 2 of the height of the partition 60 to ensure that the support is above the center of gravity. Weld the partition 60 to the bottom plate 10 according to the blueprint requirements.

[0077] Install the wing plate 40 and fix it with process braces. Each surface supports two process braces and fixes them with fillet welds. Install the web plate 30 and support two process braces on the outer side and fix them with fillet welds. The height of the process brace is greater than 1 / 2 of the height of the partition 60 to ensure that the support is above the center of gravity. Weld the weld between the bottom plate 10 according to the blueprint requirements. Use positioning welding to fix the vertical weld.

[0078] After checking the verticality of the middle circular cylinder and finding that it meets the size requirements, install the middle panel 51 and the two side panels 52 and weld them according to the blueprint requirements.

[0079] Among them, welding can be carried out according to the principle of from the middle to both sides, from top to bottom, first inside and then outside.

[0080] After the four-sided forming and welding is completed, the box is corrected so that its flatness, straightness, etc. meet the relevant acceptance standards.

[0081] Remove all process supports without damaging the parent material.

[0082] Finally, sandblasting and painting are carried out according to the painting process.

[0083] After the gantry crane crossbeam is manufactured through the above steps, it can be transported out of the workshop by a hydraulic flatbed truck.

[0084] The portal crane cross beam of the present invention is manufactured by the manufacturing method of the portal crane cross beam described in any one of the above embodiments.

[0085] At the same time, the present application uses specific words to describe the embodiments of the present application. For example, "one embodiment", "an embodiment", and / or "some embodiments" refer to a certain feature, structure or characteristic related to at least one embodiment of the present application. Therefore, it should be emphasized and noted that "one embodiment" or "an embodiment" or "an alternative embodiment" mentioned twice or more in different positions in this specification does not necessarily refer to the same embodiment. In addition, some features, structures or characteristics in one or more embodiments of the present application can be appropriately combined.

[0086] Although the present invention is disclosed as above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, any modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for manufacturing a gantry crane crossbeam, characterized in that: include: Place the tire stand at the workshop door; Laying the bottom plate on the tire frame as a basis for making the gantry crane crossbeam; Install the cylinder on the bottom plate, and install the web plate and wing plate; Building a welding work platform to weld the web and the cylinder; Install and weld the panels.

2. The method according to claim 1, characterized in that: The production method further comprises: A tire frame is constructed, and the height of the tire frame is set to be greater than the height of the legs on both sides of the web.

3. The method according to claim 2, characterized in that: The height of the tire frame is 1.6m.

4. The method according to any one of claims 1 to 3, characterized in that: The step of constructing a welding work platform and welding the web and the cylinder comprises: Making a partition, and installing the partition on the bottom plate; Building a welding work platform between the partition plate and the web plate; The vertical welds between the web and the cylinder and the vertical welds between the web and the partition are welded.

5. The method according to claim 4, characterized in that: The step of manufacturing the partition and installing the partition on the base plate comprises: A plurality of holes are provided at intervals on the plate to form a partition; The partition is installed on the bottom plate, and the partition and the bottom plate are welded.

6. The method according to claim 5, characterized in that: The welding work platform is constructed between the partition plate and the web plate, comprising: One end of the wooden board is inserted into the hole of the partition plate, and the other end of the wooden board is overlapped with the web to form a welding work platform.

7. The method according to claim 5, characterized in that: The number of the holes is five, and the interval between adjacent holes is 1.5m or 1.35m.

8. The production method according to any one of claims 1 to 3, characterized in that: The production method further comprises: A base plate is produced on which a downward counter-deformation is provided.

9. The method of claim 8, wherein: The reverse deformation amount is -15mm to -25mm.

10. A portal crane beam, characterized in that: The gantry crane cross beam is manufactured by the manufacturing method of the gantry crane cross beam according to any one of claims 1-9.

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