Manufacturing method of stacked and spliced steel plate type ship lift counterweight block

Abstract

The invention discloses a manufacturing method of a stacked and spliced steel plate type ship lift balancing weight. The machining process of a large complex balancing weight is simplified. The method comprises the following steps: firstly, cutting a continuous casting steel billet into a single laminated steel plate with a groove, and measuring and scribing the single laminated steel plate; and then, the two groups of overlapped and spliced steel plates are assembled together by machining and preassembling gap cushion blocks. After primary assembly is completed, secondary scribing is conducted on the balancing weight, then locking bolt holes, pin shaft holes and lifting lug holes are drilled and machined, and counter bore treatment is conducted on the locking bolt holes, the pin shaft holes and the lifting lug holes. And the next step is blanking and mounting edge sealing plates at the top and the bottom of the groove. And carrying out trial hoisting and preassembling a hoisting shaft hole reinforcing plate to ensure the structural stability. And the locking seat plate is machined and mounted, so that a guarantee is provided for final stability. And finally, the overall performance of the balancing weight is verified through secondary trial hoisting, and the remaining edge sealing plates are pre-installed. According to the method, efficient machining of the large stacked steel plate type balancing weight can be achieved by adopting conventional general equipment.

Description

Technical Field

[0001] The invention belongs to the field of water conservancy engineering equipment manufacturing, and in particular relates to a method for manufacturing a balancing weight block of a stacked steel plate type ship lift. Background Art

[0002] The counterweight vertical ship lift uses a counterweight to balance the weight of the ship compartment, and the lifting power is only used to overcome the resistance and inertia of the unbalanced weight and the motion system. The counterweight of a small ship lift is generally made of concrete structure, while that of a large ship lift is generally made of cast steel billets or stacked steel plate counterweights. The stacked steel plate counterweight is made of two layers of steel plates. Compared with cast steel billets, a single stacked steel plate is lighter, the density of the rolled steel plate is more uniform, the thickness dimensional accuracy is higher, and the application range is becoming wider and wider.

[0003] The stacked steel plate ship lift counterweight is made of two layers of stacked steel plates, with a lifting lug on the top. The lifting lug suspends the counterweight through a hanging shaft, and the hanging shaft passes through the stacked steel plates of the counterweight. The stacked steel plates of the counterweight are provided with pin holes and bolt holes that match the pins and connecting bolts, and corresponding countersunk holes. The counterweight is a rectangular block with a groove, and a gap pad is provided at the bolt hole position on the inner side of the stacked steel plate. Peripheral sealing plates are also welded around the counterweight, and a stop plate is provided outside the stacked steel plates of the counterweight.

[0004] The counterweight of a ship lift is usually large in size and heavy in weight. For example, the counterweight of a large ship lift in my country has the following dimensions: 9m×2m×0.368m (height×width×thickness), and the weight of a single piece is 45t, of which each stacked steel plate is 169mm thick and weighs 22.5t. There are 6 bolt holes with a diameter of φ70mm, 4 pin holes with a diameter of φ120mm, and 1 hanging shaft hole with a diameter of φ160mm. There are countersunk holes with a diameter of φ160mm at both ends of the bolt holes and pin holes. The counterweight needs to be assembled with the safety beam, so the requirements for the dimensions are relatively high. The dimensions of the groove of the counterweight and the flatness of the stop plate seat are ±1mm. In addition, the mass error of the counterweight shall not be greater than 200kg, and after the counterweight is installed on site, the deflection in the direction of the water flow shall not exceed 10mm in the entire height range under the state of wire rope suspension, and the deflection in the direction perpendicular to the water flow shall not exceed 5mm.

[0005] Because the stacked steel plate ship lift counterweight is heavy, the processing hole diameter is large, and the external dimensions processing precision is high, the traditional method for the stacked steel plate ship lift counterweight is to use large boring and milling machines, gantry milling machines and other special machine tools for processing. These methods require special large-scale mechanical processing equipment and lifting capacity, the equipment use cost is high, the processing cycle is long, and the work efficiency is low. Therefore, it is necessary to improve the traditional manufacturing and processing methods to improve the manufacturing and processing efficiency and save processing costs. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a method for producing a stacked steel plate ship lift counterweight block, which can solve the problem of processing and producing large stacked steel plate counterweight blocks. Conventional general processing equipment is used for processing, the method is simple and easy, processing efficiency is improved, and production costs are greatly reduced.

[0007] In order to solve the above technical problems, the technical solution adopted by the present invention is: A method for manufacturing a balancing weight block for a stacked steel plate ship lift, comprising the following steps: Step 1: Cut the continuous casting billet into a single stacked steel plate with grooves.

[0008] The cutting process uses a CNC flame cutting machine, which can control the dimensions of the stacked steel plates within the specified tolerance range.

[0009] Step 2: Measure and mark the single stacked steel plate.

[0010] 1) Check the steel plate's dimensional deviation, thickness deviation, surface unevenness, cross-section out-of-squareness, perimeter straightness, diagonal deviation, and groove size to ensure they meet the technical requirements for steel plate ordering.

[0011] 2) According to the measurement records of each overlapped steel plate and the principle of similar deviations of the overlapped steel plates, the overlapped steel plates are grouped in pairs.

[0012] 3) Lift the single balanced overlapping steel plate onto the processing platform, and take a total of 18 measuring points equally on both sides of the upper and lower halves of one side (side A) of the 1# overlapping steel plate. Use a level to measure the elevation of each point. Based on the average measured value, adjust the overlapping steel plate to a horizontal state using the hydraulic jacks under the four corners of the platform, and secure it with wedges on the supporting platform piers.

[0013] 4) Use the two sides of the overlapped steel plate and the two sides of the groove as reference lines to draw the vertical center line of the overlapped steel plate. Similarly, use the bottom end of the overlapped steel plate as a reference line to draw the horizontal center line of the overlapped steel plate (the vertical center line must be perpendicular to the horizontal center line).

[0014] 5) Using the vertical center line and horizontal center line of the overlapped steel plate as reference, mark the center line of the locking bolt hole.

[0015] 6) Use a level to measure the elevation of each point, and use the average value as the reference elevation of surface A. Weld a round steel bar at each of the four corners of surface A of the stacked steel plate, and grind them to the same height with an angle grinder to serve as the reference surface measurement point of surface A.

[0016] Step 3: Processing and pre-installation of gap pads between stacked steel plates.

[0017] 1) Place the measuring plate with adjustment screws at the marked position of the locking bolt hole. Place a frame level ruler on top of it, and use a level to measure the four quadrant points on the measuring plate and the four round steel reference points by adjusting the four adjustment screws on the measuring plate, and make sure that the elevations are equal, and the frame level ruler is horizontal in both the vertical and horizontal directions.

[0018] 2) According to the thickness values ​​at the 4 adjustment screws of the measuring plate, select a steel plate of appropriate thickness and cut a circular ring plate with a CNC cutting machine. Place the measuring plate (with adjustment screws) and the gap pad to be processed in the lathe chuck in sequence and put them close together. Use the lathe to process the circular ring plate with the eccentric processing method to process the gap pad with the required eccentric thickness.

[0019] 3) Place the gap pad on the corresponding locking bolt hole position, check the fit between the pad and the surface of the stacked steel plate, and install and spot weld the pad after passing the test. Install other locking bolt hole gap pads in sequence.

[0020] 4) Use a level to measure the elevation of each quadrant point of the circular ring plate again to see if they are on the same horizontal plane. After confirming that they are correct, weld the circular ring pad. The welding of the plug welding hole should be polished, and the weld excess height should not protrude from the upper plane of the circular ring pad.

[0021] Step 4: Assemble two sets of overlapping steel plates.

[0022] 1) After the processing of the two stacked steel plates in the same group is completed, after checking that the center line of the stacked steel plates and the position of the locking bolt holes are correct, and the height of the locking bolt hole pads are in the same plane, prepare for the assembly of the stacked steel plates.

[0023] 2) Re-measure whether the A-surface reference plane of the 1# stacked steel plate is horizontal. If qualified, turn over the 2# stacked steel plate with a special tool so that its A-surface faces downward.

[0024] 3) Lift the 2# stacked steel plate above the 1# stacked steel plate, align the vertical and horizontal center lines of the two stacked steel plates, and then drop the 2# stacked steel plate onto the 1# stacked steel plate. Check the offset of each center line and each side line, as well as the contact of the locking bolt pad. After confirming that they are correct, use the pad to weld the two stacked steel plates firmly to form a counterweight.

[0025] Step 5: Mark the balance block a second time.

[0026] 1) On the marking platform, use the two sides of the two stacked steel plates and the two sides of the groove as reference lines to re-mark the vertical center line of the counterweight; use the bottom sides of the two stacked steel plates and the two sides of the groove as reference lines to re-mark the horizontal center line (the vertical center line must be perpendicular to the horizontal center line).

[0027] 2) Using the vertical center line and horizontal center line of the counterweight as reference, re-mark the center lines of the lifting ear holes, bolt holes, shear pin holes, hole processing lines, and inspection circle lines.

[0028] 3) Measure the distance between the upper surface of the four round steels at the four corners of the 2# balancing weight stacked steel plate (B surface) and the lower surface of the corresponding round steel of the 1# stacked steel plate (B surface), and take their average height as the center plane of the thickness direction of the balancing block. Take this plane elevation as the reference elevation of the thickness plane of the balancing block.

[0029] Step 6: Process the locking bolt hole, pin hole, and ear hole.

[0030] 1) Lift the stacked steel plate to the bottom of the radial drilling machine. Adjust the drilling machine base to a horizontal state and fix the drilling machine on the foundation.

[0031] 2) Adjust the position of the drilling machine spindle box, align the drill bit with the center of the locking bolt hole, and use a large-diameter adjustable U drill to drill the locking bolt hole.

[0032] 3) Use the same method to drill other shear pin holes with a large-diameter adjustable U drill; use the large-diameter adjustable U drill to drill the lifting ear holes.

[0033] Note: The drilling diameter of the locking bolt hole and the shear pin shaft hole should match the diameter of the reamer positioning bearing.

[0034] Step 7: Process the countersink holes for locking bolt holes in the stacked steel plates.

[0035] 1) Place the torque balance weight under the radial drilling machine and adjust the balance weight to a horizontal state.

[0036] 2) Adjust the position of the drilling machine spindle box, align the U-shaped reaming drill with the locating bearing with the center of the locking bolt hole, and use the reaming drill to drill and countersink the locking bolt hole.

[0037] 3) Adjust the position of the drilling machine spindle box, align the U-shaped reaming drill bit with the center of the shear pin shaft hole, and use the reaming drill to countersink the shear pin shaft hole.

[0038] 4) Turn the counterweight block over with a special tool (1# stacked steel plate B side facing up) and adjust the counterweight block to a horizontal state. Adjust the position of the drilling machine spindle box, use the same method to align the U-shaped reaming drill bit with the center of the locking bolt hole, and use the reaming drill to drill and countersink the locking bolt hole. Use the reaming drill to drill and countersink the shear pin shaft hole.

[0039] 5) Insert the bolt into the locking bolt hole and tighten it.

[0040] Step 8: Cut and install the counterweight groove and the top and bottom plate edge banding panels.

[0041] 1) Take the vertical center line of the balance weight as the reference, draw the side lines of the balance weight and the side lines of the groove on both sides of the upper surface of the balance weight, use the vertical line method to check the distance between the vertical surface of the side line and the side of the balance weight and record it, cut the flat steel as the adjustment patch plate for the groove seal and the top and bottom plate edge plates, and weld them.

[0042] 2) After the welding of the groove and the top and bottom plate edge plates is completed, use a wire to check the distance between the vertical surface of the edge and the side of the counterweight block, as well as the verticality of the side plate of the counterweight block. After confirming that everything is correct, cut the groove edge plates and the top and bottom plate edge plates.

[0043] 3) Install the cut edge plate to the groove of the counterweight block and the top and bottom sealing plates of the counterweight. The vertical position of the edge plate is based on the center line of the counterweight elevation. After spot welding the edge plate, check again to confirm the three sides of the groove of the counterweight block, the verticality of the top and bottom sealing plates of the counterweight, and the distance to the center line. After confirming that they are correct, weld the edge plate.

[0044] 4) After welding the edge banding, check its verticality and external dimensions to ensure they meet the design requirements.

[0045] Step 9: Try to lift the counterweight block and pre-install the lifting shaft hole reinforcement plate.

[0046] 1) Place the counterweight on the tire frame and adjust it to a horizontal state. Using the reference elevation of the average thickness plane of the counterweight as the reference, measure the distance from the upper plane of the lifting lug to the base plane, and process the lifting lug reinforcement plate of the 2# stacked steel plate. Similarly, measure and process the lifting lug reinforcement plate of the 1# stacked steel plate.

[0047] 2) Temporarily spot weld the lifting lug reinforcement plate to both sides of the lifting lug hole, install the tooling lifting lug, and install the measuring plumb line under the lifting shaft hole.

[0048] 3) Use a crane (with an electronic crane scale installed under the main hook) to slowly lift the counterweight until it is in an upright suspension state, and measure the weight of the torque and the offset of the plumb line. If the offset of the counterweight port along the water flow direction is too large, first drop the hook and lay the counterweight horizontally, adjust the thickness of the reinforcement plates on both sides of the lifting ears, and lift it again until it meets the design requirements.

[0049] Step 10: Processing and installation of stop seat plate.

[0050] 1) Use a crane to first drop the counterweight block onto the marking platform, and adjust the counterweight block to a horizontal state according to the average thickness reference plane of the counterweight.

[0051] 2) Using the upper surface of the lifting ear reinforcement plate as the reference, place the measuring plate with the adjustment screws at the marked position of the stop plate seat plate. Place the frame level ruler on top of it, and use the level to measure the four corner points of the measuring plate and the four round steel reference points by adjusting the four adjustment screws on the measuring plate, and the frame level ruler is horizontal in both the vertical and horizontal directions.

[0052] 3) According to the thickness values ​​at the 4 adjustment screws of the measuring plate, select a steel plate of appropriate thickness and cut a rectangular plate with a CNC cutting machine. Place the measuring plate (with adjustment screws) and the gap pad to be processed in the lathe chuck in sequence and put them close together. Use the lathe to process the rectangular plate into a gap pad with the required eccentric thickness using the eccentric processing method. The method is the same as the locking bolt gap pad processing method.

[0053] 4) Place the rectangular plate on the corresponding stopper seat plate position, check the fit between the pad and the surface of the stacked steel plate, and install the seat plate for spot welding after passing the test. Install other stopper seat plates in sequence.

[0054] 5) Use a level to measure the elevations of the corner points of each stop block seat plate again to see if they are on the same horizontal plane. After confirming that they are correct, weld the stop block seat plates.

[0055] 6) Use the same method to process and weld the stop block seat plate of the stacked steel plate of the 1# counterweight block.

[0056] Step 11: Perform a second trial lift of the counterweight and pre-install the remaining edge panels.

[0057] 1) Install the counterweight on the tooling lifting lug and install a measuring plumb line below the lifting shaft hole.

[0058] 2) Use a crane to slowly lift the counterweight again until it is in an upright suspended state, and measure the weight of the torque balance and the offset of the plumb line. Check the offset of the counterweight in the direction perpendicular to the water flow. Calculate the thickness of the edge plates on both sides of the counterweight based on the weight difference of the counterweight and the offset of the counterweight in the direction perpendicular to the water flow.

[0059] 3) First, lay the counterweight block horizontally and slowly place it on the marking platform. Cut and process it according to the pre-calculated plate thickness, and position and weld it on both sides of the counterweight.

[0060] 4) Use the crane to slowly lift the counterweight again until it is in an upright suspended state, and check the offset value of the counterweight in the vertical direction of the water flow and the offset value along the water flow. After confirming that there is no error, place the counterweight horizontally with the hook, and weld the edge plates on both sides of the counterweight.

[0061] Note: The alignment and installation methods of the edge banding are the same as those of the groove edge banding. The leveling of the edge banding can be carried out while the groove edge banding is being leveled.

[0062] The present invention can achieve the following beneficial effects: 1. Use continuous casting steel billet as the mother material of the stacked steel plate of the balance weight, and then use the CNC flame cutting machine to cut the stacked steel plate with grooves, which not only ensures the overall dimensional accuracy of the balance weight, but also effectively controls the weight deviation. Compared with cast steel balance weights, it saves casting molds, reduces casting difficulty, improves material quality, and reduces processing costs.

[0063] 2. Use a level, gap pad measuring plate, and stop block pad measuring plate to measure the thickness of the pad to be processed, use a lathe to turn the pad, and then use welding to ensure that the flatness of the pad is controlled within ±1mm. This method avoids the need for large-scale boring and milling machines and other mechanical processing equipment, improves construction efficiency, and reduces processing costs.

[0064] 3. Use overlapping steel plates to weld edge plates around, and determine the thickness of the edge plates by weighing, which effectively guarantees the size of the counterweight block and accurately controls the weight of the counterweight block. This method is easy to operate and does not require large-scale machine tool boring and milling processing, which improves processing efficiency and saves machine tool processing costs.

[0065] 4. The counterweight lug holes and pin holes are both large-diameter holes. A radial drilling machine and an adjustable large-diameter U drill are used. The positioning of the adjustable large-diameter U drill center drill solves the problem of processing large-diameter holes with ordinary drilling machines. For large-diameter countersinks, a radial drilling machine and an adjustable large-diameter countersink U drill with a positioning bearing are used. The positioning function of the bearing solves the problem of processing large-diameter countersinks with an adjustable large-diameter countersink U drill. Direct processing is more convenient and faster.

[0066] 5. The counterweight is heavy and needs to be turned over frequently during processing. The conventional method is to weld lifting ears on both sides of the counterweight to assist in turning over, which not only wastes materials but also requires cutting and grinding in the later stage, which is time-consuming and laborious. Using a frame-type special fixture with lifting ears to assist in turning over reduces the workload of welding and grinding, and improves processing efficiency and construction safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] The present invention will be further described below in conjunction with the accompanying drawings and embodiments: Figure 1 It is a schematic front view of the balancing weight structure of the present invention; Figure 2 A schematic side view of the balancing weight structure of the present invention; Figure 3 The structure of the counterweight block of the present invention is a schematic diagram of the lifting ear hole and a partial view of the lifting ear; Figure 4 The structure of the counterweight block of the present invention is schematically shown with bolt holes and a partial view of bolts; Figure 5 The structure of the counterweight block of the present invention is a schematic diagram of the pin hole and a partial view of the pin; Figure 6 It is a schematic diagram of measuring and marking the stacked steel plate of the present invention; Figure 7 This is a schematic diagram of the measurement and marking points of the stacked steel plate of the present invention; Figure 8 This is a schematic diagram of measuring the gap spacer of the stacked steel plates of the present invention; Fig. 9 It is a schematic diagram of the gap pad measuring plate of the present invention; Fig.10 This is a schematic diagram of the processing of the gap pad of the present invention; Fig.11 This is a schematic diagram of assembling the stacked steel plates of the present invention; Fig.12 It is a schematic diagram of drilling holes for locking bolts of the counterweight block of the present invention; Fig.13 This is a schematic diagram of the installation of the edge sealing plate of the counterweight block of the present invention; Fig.14 This is a schematic diagram of a test hoisting of a counterweight block of the present invention; Fig.15 A partial view of the lifting lug for trial lifting of the counterweight block of the present invention; Fig.16 It is a schematic diagram of a measuring plate of a balancing weight stop seat plate of the present invention; Fig.17 The present invention is a flow chart of the turning and hoisting of the counterweight block.

[0068] In the figure: balancing weight 1, stacked steel plate 2, lifting ear 3, lifting shaft 4, stop block seat plate 5, bolt 6, pin shaft 7, edge sealing plate 8, gap pad 9, level 10, ruler 11, pier 12, frame level 13, gap pad measuring plate 14, measuring plate adjusting screw 15, lathe four-jaw chuck 16, radial drilling machine 17, adjustable large aperture adjustable U drill 18, adjustable large aperture countersink U drill 19, adjustment patch plate 20, electronic crane scale 21, plumb bob 22, line pile 23, lifting ear hole reinforcement plate 24, hook 25, stop plate seat plate measuring plate 26, turning fixture 27. DETAILED DESCRIPTION

[0069] Embodiment 1: Take a large ship lift in my country as an example: like Figure 1-5As shown, a large ship lift counterweight 1 in my country is made of two layers of steel plates 2, with a lifting lug 3 on the top. The lifting lug 3 suspends the counterweight 1 through a hanging shaft 4, and the hanging shaft 4 passes through the stacked steel plates 2 of the counterweight. The stacked steel plates 2 of the counterweight are provided with pin holes and bolt holes that match the pins 7 and the connecting bolts 6, and corresponding countersunk holes. The counterweight 1 is a rectangular parallelepiped with a groove, and a gap pad 9 is provided at the bolt hole position on the inner side of the stacked steel plates 2. Peripheral sealing plates 8 are also welded around the counterweight, and a stop plate 5 is provided outside the stacked steel plates 2 of the counterweight.

[0070] The overall dimensions of the counterweight block are: 9m×2m×0.368m (height×width×thickness), and the weight of a single piece is 45t, of which each stacked steel plate is 169mm thick and weighs 22.5t. There are 6 bolt holes with a diameter of φ70mm, 4 pin holes with a diameter of φ120mm, and 1 hanging shaft hole with a diameter of φ160mm. There are countersunk holes with a diameter of φ160mm at both ends of the bolt holes and pin holes.

[0071] A method for manufacturing a balancing weight block for a stacked steel plate ship lift, the method comprising the following steps: Step 1: Cut the continuous casting steel billet to produce a single stacked steel plate 2 with a groove.

[0072] The cutting is done by CNC flame cutting machine. After cutting, the deviation of the length and width of the stacked steel plate 2 is -2 to -5mm; the deviation of the length and width of the groove is +2 to +5mm.

[0073] Step 2: Measure and mark the single stacked steel plate.

[0074] 1) Check the steel plate's dimensional deviation, thickness deviation, surface unevenness, cross-section out-of-squareness, perimeter straightness, diagonal deviation, and groove size to ensure they meet the technical requirements for steel plate ordering.

[0075] 2) According to the measurement records of each stacked steel plate 2, the stacked steel plates 2 are paired up according to the principle of similar deviations.

[0076] 3) If Figure 6-7 As shown, a single balanced overlapping steel plate 2 is hoisted onto the processing platform, and a total of 18 measuring points (A10-A18, A20-A28) are equally divided on both sides of the upper half and lower half of the A surface of the 1# overlapping steel plate 2. The elevation of each point is measured with a level meter 10. According to the average measured value, the overlapping steel plate 2 is adjusted to a horizontal state by the hydraulic jacks under the four corners of the platform, and is securely padded with wedges on the supporting platform piers 12.

[0077] Note: After the stacked steel plate 2 is adjusted to a level, the elevation of each point should meet H A10 + H A11 +…+H A18= H A20 + H A21 +…+H A28 H A10 + H A11 +…+H A13 + H A20 + H A21 +…+H A23 = H A15 + H A16 +…+H A18 + H A25 + H A26 +…+H A28 4) Use the two sides of the overlapped steel plate 2 and the two sides of the groove as reference lines to draw the vertical center line. Similarly, use the bottom end surface of the overlapped steel plate 2 as a reference line to draw the horizontal center line (the vertical center line must be perpendicular to the horizontal center line).

[0078] 5) Using the vertical center line and horizontal center line of the overlapped steel plate 2 as reference, mark the center line of the locking bolt 6 holes.

[0079] 6) Use the level 10 to measure the elevations of points A10~A18 and A20~A28, and use their average value as the reference elevation of surface A. Weld a round steel with a diameter of φ20 and a height of about 20mm at the four corners of surface A of the stacked steel plate 2 (points A1~A4, about 50mm away from the corner points), grind them to the same height with an angle grinder to use them as the reference surface measurement points of surface A, and make the distance from the reference surface of the round steel to the average plane of the thickness of the stacked steel plate 2 be H=84.5+15=99.5mm.

[0080] Step 3: Processing and pre-installation of gap pads.

[0081] 1) If Figure 8 As shown, a measuring plate 14 (outer diameter φ295, plate thickness about 10mm) with adjusting screws 15 is placed at the marked position of the locking bolt hole. A frame level ruler 13 is placed on it. By adjusting the four adjusting screws 15 on the measuring plate 14, the level 10 is used to measure the four quadrant points (C1~C4) on the measuring plate 14 and the four round steel reference points (A1~A4) to be equal in elevation, and the frame level ruler 13 is horizontal in both the vertical and horizontal directions.

[0082] 2) If Figure 8-9 As shown, according to the measuring plate 14, there are 4 adjusting screws at H C1 ~H C4The thickness value is selected, and a steel plate of appropriate thickness is cut into a circular ring plate with a diameter of φ300×φ70 by a CNC cutting machine. The measuring plate 14 and the gap pad 9 to be processed are placed in the lathe chuck 16 in sequence and closely attached, and the circular ring plate is processed into a gap pad 9 of a satisfactory eccentric thickness by an eccentric processing method on the lathe.

[0083] 3) Place the gap pad 9 at the position of the corresponding locking bolt hole, check the fit between the pad and the surface of the stacked steel plate 2, and install and spot weld the pad after passing the test. Install the gap pads 9 of other locking bolt holes in sequence.

[0084] 4) Use the level 10 to measure the elevation of each block quadrant to see if they are on the same horizontal plane. The elevation difference should not exceed 1mm of the benchmark. After confirming that they are correct, weld the block.

[0085] Step 4: Assemble the stacked steel plates.

[0086] 1) After the processing of the two stacked steel plates 2 in the same group is completed, after checking that the center line and the position of the locking bolt 6 holes are correct, and the height of the locking bolt hole pad 9 is in the same plane, prepare to assemble the stacked steel plates 2.

[0087] 2) Re-measure whether the A-surface reference plane of the 1# stacked steel plate 2 is horizontal. If qualified, turn over the 2# stacked steel plate 2 with a special tool so that its A-surface faces downward.

[0088] 3) If Fig.11 As shown, the 2# stacked steel plate 2 is hoisted above the 1# stacked steel plate 2, and after aligning the vertical and horizontal center lines of the two stacked steel plates, the 2# stacked steel plate 2 is dropped onto the 1# stacked steel plate 2. Check the offset of each center line and each side line, as well as the contact of the locking bolt pad 9. After confirming that they are correct, use 8 -20×100×200 pads to weld the two stacked steel plates firmly to form a counterweight block 1.

[0089] Step 5: Mark the balance block a second time.

[0090] 1) On the marking platform, use the two sides of the two stacked steel plates 2 and the two sides of the groove as reference lines to re-correct and mark the vertical center line of the balance weight 1; use the bottom sides of the two stacked steel plates and the two sides of the groove as reference lines to re-correct and mark the horizontal center line (the vertical center line must be perpendicular to the horizontal center line).

[0091] 2) Taking the vertical center line and horizontal center line of the counterweight 1 as reference, re-mark the center lines of the lifting ear holes, bolt holes, shear pin shaft holes, hole processing lines, and inspection circle lines.

[0092] 3) Measure the distance between the upper surface of the four φ20 round steels located at the four corners of the B surface of the 2# balancing weight stacked steel plate 2 and the lower surface of the corresponding round steels of the B surface of the 1# stacked steel plate 2, and use their average height as the center plane of the thickness direction of the balancing block. Use this plane elevation as the reference elevation of the thickness plane of the balancing block.

[0093] Step 6: Process the locking bolt hole, pin hole, and ear hole.

[0094] 1) Hang the counterweight 1 below the radial drilling machine 17. Adjust the base of the drilling machine 17 to a horizontal state and fix the drilling machine 17 on the foundation.

[0095] 2) If Fig.12 As shown, adjust the position of the drilling machine spindle box, align the drill bit with the center of the locking bolt hole, and use the large-diameter adjustable U drill 18 to drill the locking bolt hole φ70.

[0096] 3) Use the same method to drill other shear pin holes to φ100 with a large-diameter adjustable U drill 18; use a large-diameter adjustable U drill 18 to drill the ear holes to φ160. When the radial drilling arm does not rotate enough, move the torque balance weight and readjust the level.

[0097] Note: The hole diameters of the locking bolt hole and the shear pin hole should match the locating bearing diameter of the adjustable large-diameter countersink U drill 19.

[0098] Step 7: Process the countersink holes for locking bolt holes in the stacked steel plates.

[0099] 1) Place the torque balance weight 1 under the radial drilling machine and adjust the balance weight to a horizontal state.

[0100] 2) If Fig.12 As shown, adjust the position of the drilling machine spindle box, align the adjustable large-diameter countersink U drill 19 with the center of the locking bolt hole, and use the adjustable large-diameter countersink U drill 19 to drill and countersink the locking bolt hole until the countersink diameter is φ160mm and the countersink depth is about 65mm.

[0101] 3) Adjust the position of the drilling machine spindle box, align the adjustable large-diameter countersink U drill 19 with the center of the shear pin shaft hole, and use the adjustable large-diameter countersink U drill 19 to drill the shear pin shaft hole until the countersink diameter is φ160mm and the countersink depth is about 25mm.

[0102] 4) Turn the counterweight 1 over with a special tool (the B surface of the 1# stacked steel plate 2 faces upwards) and adjust the counterweight to a horizontal state. Adjust the position of the drilling machine spindle box, use the same method to align the adjustable large-diameter countersink U drill 19 with the center of the locking bolt hole, and use the adjustable large-diameter countersink U drill 19 to drill and mill the locking bolt hole countersink until the countersink diameter is φ160mm and the countersink depth is about 95mm. Use the adjustable large-diameter countersink U drill 19 to drill the shear pin shaft hole countersink until the countersink diameter is φ160mm and the countersink depth is about 25mm.

[0103] 5) Insert six M64×290 bolts 6 into the locking bolt holes and tighten them.

[0104] Step 8: Cut and install the counterweight groove and the top and bottom plate edge banding panels.

[0105] 1) Taking the vertical center line of the counterweight 1 as the reference, draw the side lines (1000mm from the center) and the side lines (700mm from the center) of the groove on both sides of the upper surface of the counterweight 1, and use the vertical line method to check the distance between the vertical surface of the line and the side edge of the counterweight (the upper and lower lines are measured at intervals of 200mm) and record them. Cut the flat steel with a thickness of t=H2-20mm and a width of 30mm as the adjustment patch plate 20 for the groove seal and the top and bottom plate edge seal plates 8, and weld them.

[0106] like Fig.13 The installation method of the adjustment patch plate 20 is shown, where if the gap between the edge banding plate 8 and the stacked steel plate 2 is less than 2 mm, the C1 node method is adopted; if the gap between the edge banding plate 8 and the stacked steel plate 2 is greater than 2 mm, the C2 node method is adopted.

[0107] 2) After the welding of the groove and the top and bottom plate edge plates 8, the adjustment patch plate 20 is completed, use a wire to check the distance between the vertical surface of the edge and the side of the balance weight, as well as the verticality of the side patch plate of the balance weight. After confirming that there is no error, cut the groove edge plates and the top and bottom plate edge plates.

[0108] 3) Install the cut edge plate 8 to the three sides of the groove of the counterweight block, as well as the top and bottom sealing plates of the counterweight. The vertical position of the edge plate is based on the center line of the counterweight elevation. After spot welding the edge plate, check again to confirm the three sides of the groove of the counterweight block, as well as the verticality of the top and bottom sealing plates of the counterweight, and the distance to the center line. After confirming that they are correct, weld the edge plate.

[0109] 4) Check the verticality of the edge banding after welding. The parallelism of the grooves on both sides shall not exceed 0.8mm, and the verticality of the top and bottom edges shall not exceed 1.2mm; the parallel spacing of the grooves on both sides is 1400±2mm, and the parallel spacing of the grooves above and below is 2300±2mm.

[0110] Step 9: Try to lift the counterweight block and pre-install the lifting shaft hole reinforcement plate.

[0111] Place the balancing weight 1 on the tire frame and adjust it to a horizontal state. Take the reference elevation of the average plane of the balancing weight thickness as the reference, measure the distance H3 from the upper plane of the lifting lug 3 to the base plane, and process the lifting lug reinforcement plate 24 of the 2# stacked steel plate with t3=199-H3 as the plate thickness. Similarly, measure and process the lifting lug reinforcement plate 24 of the 1# stacked steel plate.

[0112] 1) Temporarily spot weld the lifting lug reinforcement plate 24 to both sides of the lifting lug hole, install the tooling lifting lug 3, and install the wire pile 23 and the measuring plumb bob 22 350mm below the lifting shaft hole.

[0113] 2) If Figure 14-15 As shown, use a crane (with an electronic crane scale 21 installed under the main hook) to slowly lift the counterweight 1 until it is in an upright suspension state, and measure the weight of the horizontal moment weight and the offset value of the plumb bob 22. If the offset value of the counterweight along the water flow direction is greater than 10mm, first place the counterweight down the hook and lay it horizontally, adjust the thickness of the lifting ear reinforcement plates 24 on both sides, and lift it again until the offset value of the counterweight along the water flow direction is greater than 10mm.

[0114] Step 10: Processing and installation of stop seat plate.

[0115] 1) Use a crane to first drop the counterweight block 1 onto the marking platform, and adjust the counterweight block to a horizontal state according to the average thickness reference plane of the counterweight.

[0116] 2) If Fig.16 As shown, with the upper surface of the lifting ear reinforcement plate 24 as the reference, a measuring plate 26 (length × width = 345mm × 195mm, plate thickness of about 10mm) with adjustment screws is placed at the marked position of the stop plate base plate 5. A frame level ruler 13 is placed above it, and by adjusting the four adjustment screws 15 on the measuring plate 26, the level 10 is used to measure that the elevations of the four corner points (C1 to C4) on the measuring plate 26 and the four round steel reference points (B1 to B4) are equal, and the frame level ruler 13 is horizontal in both the vertical and horizontal directions.

[0117] 3) Adjust the H according to the 4 adjustment screws of the measuring plate 26. C1 ~H C4 The thickness value is selected, and a steel plate of appropriate thickness is used to cut a rectangular plate of 350×200 by a CNC cutting machine. The measuring plate 26 and the stop plate seat plate 5 to be processed are placed in the lathe chuck 16 in sequence and closely attached, and the rectangular plate is processed into a stop plate seat plate 5 of a satisfying eccentric thickness by the lathe using an eccentric processing method. The method is the same as the processing method of the locking bolt gap spacer 9.

[0118] 4) Place the rectangular plate on the corresponding stopper seat plate 5, check the fit between the pad and the surface of the stacked steel plate 2, and install the seat plate by spot welding after passing the test. Install other stopper seat plates in sequence.

[0119] 5) Use the level 10 to measure the elevation of each corner of the stop block seat plate 5 again to see if they are on the same horizontal plane. The elevation difference should not exceed 1mm. After it is correct, weld the stop block seat plate 5.

[0120] 6) Use the same method to process and weld the stop block seat plate of the stacked steel plate of the 1# counterweight block.

[0121] Step 11: Perform a second trial lift of the counterweight and pre-install the remaining edge panels.

[0122] 1) If Fig.16 As shown, the balancing weight 1 is installed with the tooling lifting lug 3, and at the same time, a wire pile 23 and a measuring wire bob 22 are installed 350 mm below the hanging shaft hole.

[0123] 2) Use a crane to slowly lift the counterweight 1 again until it is in an upright hanging state, and measure the weight of the horizontal moment weight and the offset value of the plumb bob 22. Check whether the offset value of the counterweight in the vertical water flow direction is greater than 5mm. According to the weight difference of the counterweight and the offset value of the counterweight in the vertical water flow direction, calculate the thickness of the edge sealing plates 8 on both sides of the counterweight.

[0124] 3) First, lay the counterweight 1 horizontally with the hook down, and slowly place it on the marking platform. Cut and process it according to the pre-calculated plate thickness, and position and weld it on both sides of the counterweight 1.

[0125] 4) Use the crane to slowly lift the counterweight 1 again until it is in an upright suspended state, and check whether the offset value of the counterweight in the vertical direction of the water flow is greater than 5mm, and whether the offset value along the water flow direction is greater than 10mm. After confirming that it is correct, place the counterweight down on the hook and lay it horizontally, and weld the edge plates 8 on both sides of the counterweight.

[0126] In addition, the edge banding 8 is aligned and installed in the same way as the groove edge banding. The edge banding leveling can be constructed when the groove edge banding is leveled.

[0127] like Fig.17 As shown, during the pad measurement process, the balancing weight 1 is turned over by first installing and clamping the balancing weight 1 with a turning fixture 27, and then using a crane to hang the lifting ears of the turning fixture 27 to turn it over.

[0128] The above embodiments are only preferred technical solutions of the present invention and should not be regarded as limiting the present invention. The protection scope of the present invention shall be the technical solutions recorded in the claims, including equivalent replacement solutions of the technical features in the technical solutions recorded in the claims. That is, equivalent replacement improvements within this scope are also within the protection scope of the present invention.

Claims

1. A method for manufacturing a balancing weight block for a stacked steel plate ship lift, characterized in that The following methods are included: Step 1: Cutting the continuous casting steel billet into a single stacked steel plate (2) with a groove; Step 2: measuring and marking the single stacked steel plate (2); Step 3: Make and pre-install the stacked steel plate gap spacer (9); Step 4: Stack and assemble two sets of stacked steel plates (2); Step 5: Mark the counterweight (1) a second time; Step 6: Drill the locking bolt holes, pin holes, and lifting ear holes of the counterweight block; Step 7: Countersink the locking bolt holes of the counterweight block; Step 8: Cut and install the counterweight groove and the top and bottom plate edge sealing plates; Step 9: Test-hang the counterweight and pre-install the lifting shaft hole reinforcement plate; Step 10: Process and install the counterweight stop plate (5); Step 11: Perform a second trial lift of the counterweight and pre-install the remaining edge panels (8).

2. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that In step 1, a CNC flame cutting machine is used to cut the continuous casting billet.

3. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 2 are: Step 2-1: Based on the measurement records of each stacked steel plate (2), the stacked steel plates (2) are paired in pairs according to the principle of similar deviations; Step 2-2: hoisting a single balanced overlapping steel plate (2) onto a processing platform, and adjusting the overlapping steel plate (2) to a horizontal state by hydraulic jacks under the four corners of the platform; Step 2-3: Draw the vertical center line and the horizontal center line; Step 2-4: Draw the center line of the locking bolt (6) hole; Step 2-5: Use a level (10) to measure the elevations of the points and use the average value as the reference elevation of surface A.

4. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 3 are: Step 3-1: Place the measuring plate (14) with the adjusting screws (15) at the marked position of the locking bolt hole; place the frame level ruler (13) on it, and adjust the four adjusting screws (15) on the measuring plate (14) to measure with a level (10) that the elevations of the four quadrant points on the measuring plate (14) and the four round steel reference points are equal, and the frame level ruler (13) is horizontal in both the vertical and horizontal directions; Step 3-2: According to the thickness values ​​at the four adjusting screws of the measuring plate (14), a steel plate of appropriate thickness is selected and cut into a circular ring plate by a CNC cutting machine; the measuring plate (14) and the gap pad (9) to be processed are sequentially placed in the lathe chuck (16) and closely attached to each other, and the circular ring plate is processed into a gap pad (9) of a satisfactory eccentric thickness by an eccentric processing method on the lathe; Step 3-3: Check the fit between the pad (9) and the surface of the stacked steel plate (2). If the fit is acceptable, install the pad and spot weld it.

5. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 4 are as follows: if there are multiple stacked steel plates, the 2# stacked steel plate is hoisted above the 1# stacked steel plate, and after aligning the vertical and horizontal center lines of the two stacked steel plates, the 2# stacked steel plate (2) is dropped onto the 1# stacked steel plate (2); and the two stacked steel plates are firmly welded with a pad to form a balancing weight (1).

6. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 5 are: Step 5-1: On the marking platform, use the two sides of the two stacked steel plates (2) and the two sides of the groove as reference lines to re-mark the vertical center line of the counterweight (1); use the bottom sides of the two stacked steel plates and the two sides of the groove as reference lines to re-mark the horizontal center line; Step 5-2: Using the vertical center line and horizontal center line of the counterweight (1) as reference, re-mark the center lines of the lifting lug hole, bolt hole, shear pin hole, hole processing line, and inspection circle line respectively; Step 5-3: Measure the distance between the upper surface of the four φ20 round steels located at the four corners of the B surface of the 2# counterweight stacked steel plate (2) and the lower surface of the corresponding round steel of the 1# stacked steel plate (2), and use the average height as the center plane of the thickness direction of the counterweight; use this plane elevation as the reference elevation of the thickness plane of the counterweight.

7. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 6 are: Step 6-1: Hang the counterweight (1) below the radial drilling machine (17); adjust the base of the drilling machine (17) to a horizontal state, and fix the drilling machine (17) on the foundation; Step 6-2: Adjust the position of the drilling machine spindle box, align the drill bit with the center of the locking bolt hole, and use a large-diameter adjustable U drill (18) to drill the locking bolt hole; Step 6-3: Use the large-diameter adjustable U drill (18) to drill other shear pin holes and eye holes in the same way. The diameter of the locking bolt hole and shear pin hole should match the positioning bearing diameter of the adjustable large-diameter countersink U drill (19).

8. The method for manufacturing a balancing weight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 7 are: Step 7-1: Place the torque balance weight (1) under the radial drilling machine and adjust the balance weight to a horizontal state; Step 7-2: Adjust the position of the drilling machine spindle box, and use the adjustable large-diameter countersink U drill (19) to drill and mill the countersink holes for the locking bolt holes and the shear pin shaft holes; Step 7-3: Use a tool to turn over the counterweight (1) with the B surface of the 1# stacked steel plate (2) facing upward, and adjust the counterweight to a horizontal state; use an adjustable large-diameter countersink U drill (19) to drill and mill the countersink holes for the locking bolt holes and the countersink holes for the shear pin shaft holes; Step 7-4: Insert the bolt (6) into the locking bolt hole and tighten it.

9. The method for manufacturing a balancing weight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 8 are: Step 8-1: Taking the vertical center line of the counterweight (1) as the reference, draw the side lines on both sides of the upper surface of the counterweight (1) and the side lines of the groove respectively, check the distance between the vertical surface of the side lines and the side edge of the counterweight using the vertical line method and record it, calculate the flat steel cutting material, and use it as the adjustment patch plate (20) for the groove seal and the top and bottom plate edge seal plates (8), and weld them; Step 8-2: adjusting the installation method of the patching plate (20), wherein if the gap between the edge sealing plate (8) and the overlapped steel plate (2) is less than 2 mm, the C1 node method is adopted; if the gap between the edge sealing plate (8) and the overlapped steel plate (2) is greater than 2 mm, the C2 node method is adopted; Step 8-3: After the welding of the groove and the top and bottom plate edge sealing plates (8) is completed, use a wire to check the distance between the vertical surface of the edge and the side of the counterweight block, as well as the verticality of the side plate of the counterweight block; after confirming that there is no error, cut the groove edge sealing plates and the top and bottom plate edge sealing plates; Step 8-4: Install the cut edge plate (8) to the groove of the counterweight block and the top and bottom sealing plates of the counterweight. The vertical position of the edge plate is based on the center line of the counterweight elevation. After spot welding the edge plate, check again to confirm the verticality of the groove of the counterweight block and the top and bottom sealing plates of the counterweight, as well as the distance to the center line. After confirming that they are correct, weld the edge plate.

10. The method for manufacturing a counterweight block for a stacked steel plate ship lift according to claim 1, characterized in that The sub-steps of step 9 are: Step 9-1: Place the balancing weight (1) on the tire frame and adjust it to a horizontal state; take the reference elevation of the average thickness plane of the balancing weight as the reference, measure the distance from the upper plane of the lifting lug (3) to the base plane, and process the lifting lug reinforcement plate (24) of the stacked steel plate; Step 9-2: Temporarily spot weld the lifting lug reinforcement plate (24) to both sides of the lifting lug hole, install the tooling lifting lug (3), and install the wire pile (23) and the measuring plumb bob (22) below the lifting shaft hole; Step 9-3: Use a crane to slowly lift the counterweight (1) until it is in an upright hanging state, measure the weight of the horizontal moment weight and the offset value of the plumb bob (22); if the offset value of the counterweight along the water flow direction is greater than 10 mm, adjust the thickness of the lifting ear reinforcement plates (24) on both sides; an electronic crane scale (21) is installed under the main hook of the crane; The sub-steps of step 10 are: Step 10-1: Use a crane to first drop the counterweight (1) onto the marking platform and adjust the counterweight to a horizontal state according to the average thickness reference plane of the counterweight; Step 10-2: With the upper surface of the lifting ear reinforcement plate (24) as a reference, place the measuring plate (26) with adjustment screws at the marked position of the stop plate base plate (5); place the frame level ruler (13) above it, and by adjusting the four adjustment screws (15) on the measuring plate (26), use the level (10) to measure that the elevations of the four corner points on the measuring plate (26) and the four round steel reference points are equal, and the frame level ruler (13) is horizontal in both the vertical and horizontal directions; Step 10-3: According to the thickness values ​​at the four adjusting screws of the measuring plate (26), a steel plate of appropriate thickness is selected to cut a rectangular plate using a CNC cutting machine; the measuring plate (26) and the stop plate seat plate (5) to be processed are sequentially placed in the lathe chuck (16) and closely attached to each other, and the rectangular plate is processed into a stop plate seat plate (5) of a satisfactory eccentric thickness using an eccentric processing method on the lathe; Step 10-4: Place the rectangular plate on the corresponding stop block seat plate (5), check the fit between the pad plate and the surface of the stacked steel plate (2), and if qualified, install the seat plate by spot welding; install other stop block seat plates in sequence; The sub-steps of step 11 are: Step 11-1: Install the counterweight (1) on the tooling lifting lug (3), and install the wire pile (23) and the measuring wire bob (22) below the lifting shaft hole; Step 11-2: Use the crane to slowly lift the counterweight (1) again until it is in an upright hanging state, measure the weight of the horizontal moment weight and the offset value of the plumb bob (22); check whether the offset value of the counterweight in the direction perpendicular to the water flow is greater than 5 mm; calculate the thickness of the edge sealing plates (8) on both sides of the counterweight according to the weight difference of the counterweight and the offset value of the counterweight in the direction perpendicular to the water flow; Step 11-3: First, lay the counterweight (1) horizontally with the hook down, and slowly place it on the marking platform, cut and process it according to the pre-calculated plate thickness, and position and weld it on both sides of the counterweight (1); Step 11-4: Use the crane to slowly lift the counterweight (1) again until it is in an upright suspended state, and check whether the offset value of the counterweight in the vertical direction of the water flow is greater than 5 mm, and whether the offset value along the water flow direction is greater than 10 mm; if it is correct, place the counterweight down on the hook and lay it horizontally, and weld the side sealing plates (8) on both sides of the counterweight; Step 11-5: During the measurement process of the pad, the balancing weight (1) is first installed and clamped with a turning fixture (27) when turning over, and then the lifting lug of the turning fixture (27) is lifted by a crane to turn over.

Images