A method for manufacturing a counterweight of a steel sheet pile ship lift

Abstract

A method for manufacturing a large-scale balance weight of a steel sheet pile ship lift, which simplifies the processing flow of the large-scale balance weight. The method first cuts a continuous casting steel blank into single pieces of steel sheet pile with grooves, and measures and marks the steel sheet pile. Then, two groups of steel sheet pile are assembled together by processing and pre-installing gap pads. After the preliminary assembly is completed, the balance weight is marked again, and then the locking bolt holes, pin shaft holes and lifting lug holes are drilled and processed, and the holes are counterbored. The next step is to cut and install the edge plates at the top and bottom of the grooves. The trial lifting is performed and the lifting shaft hole reinforcing plates are pre-installed to ensure the stability of the structure. The stop seat plates are further processed and installed to provide protection for the final stability. Finally, the overall performance of the balance weight is verified by the second trial lifting, and the remaining edge plates are pre-installed. The present application can realize efficient processing of large-scale steel sheet pile balance weight by using conventional general equipment.

Description

Technical Field

[0001] This invention belongs to the field of water conservancy engineering equipment manufacturing, and specifically relates to a method for manufacturing counterweights for a stacked steel plate ship lift. Background Technology

[0002] A counterbalanced vertical ship lift uses counterweights to balance the weight of the ship's cargo box. The lifting power is only used to overcome the imbalance and the resistance and inertial forces of the motion system. Small ship lifts typically use concrete counterweights, while large ship lifts generally use cast steel billets or stacked steel plates. Stacked steel plate counterweights are composed of two layers of steel plates. Compared to cast steel billets, individual stacked steel plates are lighter, have more uniform density, and higher dimensional accuracy, leading to their increasingly wider application.

[0003] The counterweight of the stacked steel plate ship lift is composed of two layers of steel plates stacked together. A lifting lug is installed at the top, suspending the counterweight via a lifting shaft that passes through the stacked steel plates. The stacked steel plates of the counterweight have pin holes and bolt holes that match the pins and connecting bolts, allowing for corresponding countersunk holes. The counterweight is a cuboid with grooves, and gap shims are provided at the bolt hole positions on the inner side of the stacked steel plates. Peripheral sealing plates are welded around the counterweight, and a stop plate is installed on the outer side of the stacked steel plates.

[0004] The counterweights of ship lifts are typically large and heavy. For example, the counterweights of a large ship lift in my country have the following dimensions: 9m × 2m × 0.368m (height × width × thickness), with a single unit weighing 45t. Each stacked steel plate is 169mm thick and weighs 22.5t. It has six φ70mm diameter bolt holes, four φ120mm diameter pin holes, and one φ160mm diameter lifting shaft hole. The bolt holes and pin holes have φ160mm diameter countersunk holes at both ends. Because the counterweights need to be assembled with the safety beam, the dimensional requirements are high. The dimensions of the counterweight groove and the flatness of the stop plate seat are within ±1mm. Furthermore, the mass tolerance of the counterweights must not exceed 200kg, and after on-site installation and suspension by wire ropes, the deviation along the water flow direction must not exceed 10mm, and the deviation perpendicular to the water flow direction must not exceed 5mm throughout the entire height range.

[0005] Because the counterweights of stacked steel plate ship lifts are heavy, have large machining holes, and require high dimensional accuracy, the traditional method for processing these counterweights involves using specialized machine tools such as large boring and milling machines and gantry milling machines. These methods require specialized large-scale machining equipment and lifting capabilities, resulting in high equipment operating costs, long processing cycles, and low efficiency. Therefore, it is necessary to improve the traditional manufacturing and processing methods to increase efficiency and reduce processing costs. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a method for manufacturing counterweights for stacked steel plate ship lifts. This method can solve the problem of processing and manufacturing large stacked steel plate counterweights. It adopts conventional and general-purpose processing equipment, is simple and easy to implement, improves processing efficiency, and greatly reduces manufacturing costs.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0008] A method for manufacturing counterweights for a stacked steel plate ship lift, comprising the following steps:

[0009] Step 1: Cut the continuously cast steel billet into single stacked steel plates with grooves.

[0010] The material cutting is done using a CNC flame cutting machine, which can control the dimensions of the stacked steel plates within the specified tolerance range.

[0011] Step 2: Measure and mark the lines on the single stacked steel plates.

[0012] 1) Check the steel plate's dimensional deviation, thickness deviation, surface unevenness, cross-sectional squareness, straightness of the four perimeters, diagonal deviation, and groove dimensions to ensure they meet the technical requirements for steel plate ordering.

[0013] 2) Based on the measurement records of each stacked steel plate, and according to the principle that the deviations of the stacked steel plates are similar, pair the stacked steel plates together.

[0014] 3) Hoist the single stacked steel plate onto the processing platform. On one side (A side) of the No. 1 stacked steel plate, take a total of 18 measuring points on both sides of the upper and lower half. Use a level to measure the elevation of each point. Based on the average measurement value, adjust the stacked steel plate to a horizontal state using the hydraulic jacks under the four corners of the platform, and secure it firmly with wedges on the support platform piers.

[0015] 4) Using the two sides of the stacked steel plate and the two sides of the groove as reference lines, draw the vertical center line of the stacked steel plate. Similarly, using the bottom surface of the stacked steel plate as a reference line, draw the horizontal center line of the stacked steel plate (the vertical center line must be perpendicular to the horizontal center line).

[0016] 5) Using the vertical and horizontal center lines of the stacked steel plates as references, mark the center lines of the locking bolt holes.

[0017] 6) Measure the elevation of each point using a level instrument, and use the average value as the reference elevation of surface A. Weld a round steel bar to each of the four corners of surface A of the stacked steel plate, and grind it to the same height using an angle grinder to make it the reference measurement point of surface A.

[0018] Step 3: Processing and pre-installation of gap spacers for stacked steel plates.

[0019] 1) Place the gap shim measuring plate with adjusting screws at the marked position of the locking bolt hole. Place a frame level on top of it. By adjusting the four adjusting screws on the gap shim measuring plate, use a level to measure that the elevations of the four quadrant points on the gap shim measuring plate are equal to the elevations of the four round steel reference points, and that the frame level is horizontal in both the longitudinal and transverse directions.

[0020] 2) Based on the thickness values ​​at the four adjusting screws on the gap shim measuring plate, select a steel plate of appropriate thickness and cut a circular ring plate using a CNC cutting machine. Place the gap shim measuring plate (with adjusting screws) and the gap shim to be processed in the lathe chuck in sequence and make them fit tightly. Use the lathe to process the circular ring plate to produce a gap shim with the required eccentric thickness using an eccentric machining method.

[0021] 3) Place the gap shims on the corresponding locking bolt holes and check the fit between the shims and the surface of the stacked steel plates. If the fit is satisfactory, spot weld the shims. Install the gap shims for the other locking bolt holes in sequence.

[0022] 4) Use a level instrument again to measure whether the elevations of the quadrant points of each annular plate are on the same horizontal plane. After confirming that there are no errors, weld the annular pads. The plug weld holes should be ground, and the weld excess should not protrude beyond the upper surface of the annular pad.

[0023] Step 4: Assemble the two sets of stacked steel plates.

[0024] 1) After the two stacked steel plates in the same group are processed, and after checking that the center line of the stacked steel plates and the position of the locking bolt holes are correct, and that the height of the locking bolt hole pads is on the same plane, the stacked steel plates are ready to be assembled.

[0025] 2) Re-test whether the reference surface A of the No. 1 stacked steel plate is horizontal. If it is qualified, flip the No. 2 stacked steel plate with special tooling so that its A surface is facing down.

[0026] 3) Hoist 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 lower the #2 stacked steel plate onto the #1 stacked steel plate. Check the offset of each center line and edge line, as well as the contact of the locking bolt pads. After confirming that everything is correct, weld the two stacked steel plates firmly with pads to form a counterweight.

[0027] Step 5: Draw lines on the balance blocks a second time.

[0028] 1) On the marking platform, using the two sides of the two stacked steel plates and the two sides of the groove as reference lines, redraw the vertical center line of the counterweight; using the bottom side of the two stacked steel plates and the two sides of the groove as reference lines, redraw the horizontal center line (the vertical center line must be perpendicular to the horizontal center line).

[0029] 2) Using the vertical and horizontal center lines of the counterweight as references, redraw the center lines, hole machining lines, and inspection circles for the lifting lug holes, bolt holes, and shear pin holes.

[0030] 3) Measure the distance from the upper surface of the four round steel bars at the four corners of the No. 2 counterweight stacked steel plate (side B) to the lower surface of the corresponding round steel bar of the No. 1 stacked steel plate (side B). Use the average height of these distances as the center plane of the counterweight block in the thickness direction. Use this plane elevation as the reference elevation of the counterweight block thickness plane.

[0031] Step 6: Machining of locking bolt holes, pin holes, and lifting lug holes.

[0032] 1) Hoist the stacked steel plates to the bottom of the radial drilling machine. Adjust the drilling machine base to a horizontal position and fix the drilling machine on the foundation.

[0033] 2) Adjust the position of the drill press 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.

[0034] 3) Drill other shear pin holes in sequence using a large-diameter adjustable U-drill; drill lifting lug holes using a large-diameter adjustable U-drill.

[0035] Note: The diameter of the locking bolt hole and the anti-shear pin hole should match the diameter of the positioning bearing of the reamer.

[0036] Step 7: Countersunk hole processing for locking bolt holes and other parts of the stacked steel plates.

[0037] 1) Place the torque counterweight under the radial drilling machine and adjust the counterweight to a horizontal position.

[0038] 2) Adjust the position of the drill press spindle box, align the U-shaped reaming drill bit with the positioning bearing with the center of the locking bolt hole, and use the reaming drill to drill and mill the countersunk hole of the locking bolt hole.

[0039] 3) Adjust the position of the drill press spindle box, align the U-shaped reaming drill bit with the center of the anti-shear pin hole, and use the reaming drill to drill the countersunk hole of the anti-shear pin hole.

[0040] 4) Using a special tooling, flip the counterweight over (B side of the #1 stacked steel plate facing upwards) and adjust the counterweight to a horizontal position. Position the spindle box of the adjusting drill press, and using the same method, align the U-shaped reamer with the center of the locking bolt hole, and use the reamer to drill and mill the countersunk hole of the locking bolt hole. Use the reamer to drill the countersunk hole of the shear pin.

[0041] 5) Insert the bolt into the locking bolt hole and tighten it.

[0042] Step 8: Cut and install the counterweight groove and the top and bottom edge sealing plates.

[0043] 1) Using the vertical center line of the counterweight as a reference, draw the edge lines of the counterweight on both sides of the upper surface of the counterweight and the distance from the edge line of the groove on both sides. Use the plumb line method to check and record the distance from the vertical plane of the edge line to the side of the counterweight. Cut flat steel into adjustment and patching plates for the groove seal and the top and bottom plate sealing plates, and weld them.

[0044] 2) After the adjustment and patching plates for the groove and top and bottom edge sealing plates are welded, use a string line to check again the distance between the vertical plane of the edge line and the side of the counterweight block, as well as the verticality of the patching plate on the side of the counterweight block. After confirming that everything is correct, cut the groove edge sealing plates and the top and bottom edge sealing plates.

[0045] 3) Install the cut edge banding plate onto the three sides of the groove of the counterweight block, as well as onto the top and bottom edge banding plates of the counterweight. The vertical positioning of the edge banding plate is based on the center line of the counterweight elevation. After spot welding the edge banding plate, check again to confirm the verticality of the three sides of the groove of the counterweight block, as well as the top and bottom edge banding plates of the counterweight, and the distance to the center line. If everything is correct, weld the edge banding plate.

[0046] 4) After welding, the edge banding should be inspected for verticality and external dimensions to ensure they meet design requirements.

[0047] Step 9: Test lift the pre-installed lifting shaft hole reinforcing plate with the counterweight.

[0048] 1) Place the counterweight on the jig and adjust it to a horizontal position. Using the average elevation of the counterweight thickness plane as a reference, measure the distance from the upper plane of the lifting lug to the base plane, and process the lifting lug reinforcing plate for #2 stacked steel plate. Similarly, measure and process the lifting lug reinforcing plate for #1 stacked steel plate.

[0049] 2) Temporarily spot weld the lifting lug reinforcing plate to both sides of the lifting lug hole, install the tooling lifting lug, and at the same time install a measuring plumb line below the lifting shaft hole.

[0050] 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 suspended state. Measure the weight of the torque counterweight and the offset of the plumb line. If the offset of the counterweight along the water flow direction is too large, first lower the counterweight to a horizontal position, adjust the thickness of the reinforcing plates on both sides of the lifting lugs, and lift it again until the design requirements are met.

[0051] Step 10: Machining and installation of the stop plate.

[0052] 1) Use a crane to first lower 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 block.

[0053] 2) Using the upper surface of the lifting lug reinforcement plate as a reference, place the stop plate base measuring plate with adjusting screws at the marked position on the stop plate base plate. Place a frame level above it, and by adjusting the four adjusting screws on the stop plate base measuring plate, use a level to measure that the elevations of the four corner points on the stop plate base measuring plate are equal to the elevations of the four round steel reference points, and that the frame level is horizontal in both the longitudinal and transverse directions.

[0054] 3) Based on the thickness values ​​at the four adjusting screws on the stop plate base plate measuring plate, select a steel plate of appropriate thickness and cut a rectangular plate using a CNC cutting machine. Place the stop plate base plate measuring plate (with adjusting screws) and the clearance shim to be processed sequentially in the lathe chuck and ensure they are tightly fitted. Use an eccentric machining method on the lathe to process the rectangular plate to create a clearance shim block with the required eccentric thickness. The method is the same as the method for processing clearance shims for locking bolts.

[0055] 4) Place the rectangular plate on the corresponding stop block seat plate position, check the fit between the pad and the surface of the stacked steel plate, and after passing the inspection, spot weld the seat plate. Install the other stop block seat plates in sequence.

[0056] 5) Use a level instrument again to measure whether the elevation of the corner points of each stop block base plate is on the same horizontal plane. If there is no error, weld the stop block base plate.

[0057] 6) Use the same method to process and weld the stop block seat plate of the No. 1 counterweight stacked steel plate.

[0058] Step 11: Second trial lifting of the counterweight and pre-installation of the remaining edge banding plates.

[0059] 1) Install the counterweight block onto the tooling lifting lug, and at the same time install a measuring plumb line below the lifting shaft hole.

[0060] 2) Use the crane to slowly lift the counterweight again until it is in an upright suspended state. Measure the weight of the torque counterweight and the offset of the plumb line. Check the offset of the counterweight in the vertical direction of the water flow. Based on the weight difference of the counterweight and the offset of the counterweight in the vertical direction of the water flow, calculate the thickness of the sealing plates on both sides of the counterweight.

[0061] 3) First, place the counterweight on the hook and slowly place it on the marking platform. Then, cut the plate according to the pre-calculated plate thickness and weld it to both sides of the counterweight.

[0062] 4) Use the crane to slowly lift the counterweight again until it is in an upright suspended state. Check the offset value of the counterweight in the vertical direction of the water flow and the offset value along the water flow direction. After confirming that there are no errors, lower the counterweight to a horizontal position and weld the sealing plates on both sides of the counterweight.

[0063] Note: The method for aligning and installing the edge banding is the same as that for the grooved edge banding. Leveling the edge banding can be done while leveling the grooved edge banding.

[0064] The present invention can achieve the following beneficial effects:

[0065] 1. Continuously cast steel billets are used as the base material for the stacked steel plates of the counterweight. A CNC flame cutting machine is then used to cut the stacked steel plates with grooves, ensuring the overall dimensional accuracy of the counterweight and effectively controlling weight deviation. Compared to cast steel counterweights, this method eliminates the need for casting molds, reduces casting difficulty, improves material quality, and lowers processing costs.

[0066] 2. The thickness of the pad to be processed is measured using a level and a gap pad measuring plate and a stop block pad measuring plate. The pad is then machined on a lathe and welded to ensure that the flatness of the pad is controlled within ±1mm. This method avoids the need for large boring and milling machines and other machining equipment, improves construction efficiency, and reduces processing costs.

[0067] 3. By welding edge banding plates around the perimeter of stacked steel plates and determining the thickness of the edge banding plates by weighing, the external dimensions of the counterweight are effectively guaranteed, and the weight of the counterweight can be precisely controlled. This method is simple to operate, does not require large machine tools for boring and milling, improves processing efficiency, and saves machine tool processing costs.

[0068] 4. The counterweight lifting 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 as a center drill solves the problem of machining large-diameter holes with ordinary drilling machines. For large-diameter countersunk holes, a radial drilling machine and an adjustable large-diameter countersunk U-drill with a positioning bearing are used. The positioning effect of the bearing is utilized to solve the problem of machining large-diameter countersunk holes with the adjustable large-diameter U-drill. Direct machining is more convenient and faster.

[0069] 5. The counterweight is heavy and frequently needs to be turned over during processing. The conventional method is to weld lifting lugs to both sides of the counterweight to assist in turning, which not only wastes materials but also requires subsequent cutting and grinding, which is time-consuming and labor-intensive. Using a special frame-type fixture with lifting lugs to assist in turning reduces the amount of welding and grinding work, improves processing efficiency and construction safety. Attached Figure Description

[0070] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0071] Figure 1 This is a schematic front view of the counterweight structure of the present invention;

[0072] Figure 2 This is a schematic side view of the counterweight structure of the present invention;

[0073] Figure 3 This is a schematic diagram of the lifting lug hole and a partial view of the lifting lug of the counterweight structure of the present invention;

[0074] Figure 4 This is a schematic view of the bolt holes and a partial view of the bolts in the counterweight structure of the present invention;

[0075] Figure 5 This is a schematic diagram of the counterweight structure of the present invention, including the pin hole and a partial view of the pin.

[0076] Figure 6 This is a schematic diagram of the measurement and scribing of the stacked steel plates of the present invention;

[0077] Figure 7 This is a schematic diagram of the measurement and marking points for the stacked steel plates of the present invention;

[0078] Figure 8 This is a schematic diagram of the measurement of the gap pads between stacked steel plates according to the present invention;

[0079] Figure 9 This is a schematic diagram of the gap pad measuring plate of the present invention;

[0080] Figure 10 This is a schematic diagram of the gap pad manufacturing process according to the present invention;

[0081] Figure 11 This is a schematic diagram of the assembly of the stacked steel plates of the present invention;

[0082] Figure 12 This is a schematic diagram of the drilling of the locking bolt holes for the counterweight in this invention;

[0083] Figure 13 This is a schematic diagram of the installation of the counterweight edge sealing plate of the present invention;

[0084] Figure 14 This is a schematic diagram of the test lifting of the counterweight of the present invention;

[0085] Figure 15 This is a partial view of the lifting lugs in a schematic diagram of the test lifting of the counterweight of the present invention;

[0086] Figure 16 This is a schematic diagram of the stop plate base plate measuring plate of the present invention;

[0087] Figure 17 This is a flowchart of the counterweight turning and hoisting process of the present invention.

[0088] In the diagram: 1. Counterweight 2. Stacked steel plate 3. Lifting lug 4. Lifting shaft 5. Stop block seat plate 6. Bolt 7. Pin 8. Sealing plate 9. Gap pad 10. Level 11. Scale 12. Support 13. Frame level 14. Gap pad measuring plate 15. Measuring screw for measuring plate 16. Lathe four-jaw chuck 17. Radial drilling machine 18. Adjustable large-diameter U-drill 19. Adjustable large-diameter countersinking U-drill 20. Adjustment patch plate 21. Electronic crane scale 22. Plumb bob 23. Line stake 24. Lifting lug hole reinforcing plate 25. Lifting hook 26. Stop plate seat plate measuring plate 27. Turning fixture 28. Detailed Implementation

[0089] Example 1:

[0090] Let's take a large ship lift in my country as an example:

[0091] like Figure 1-5 As shown, the counterweight 1 of a large ship lift in my country is composed of two layers of steel plates 2 stacked together. A lifting lug 3 is installed at the top, and the lug 3 suspends the counterweight 1 via a lifting shaft 4, which passes through the stacked steel plates 2. The stacked steel plates 2 of the counterweight have pin holes and bolt holes that match the pin shaft 7 and connecting bolts 6, allowing for corresponding countersunk holes. The counterweight 1 is a cuboid with grooves, and gap shims 9 are provided at the bolt hole positions on the inner side of the stacked steel plates 2. Peripheral sealing plates 8 are welded around the counterweight, and stop plates 5 are installed on the outer side of the stacked steel plates 2.

[0092] The counterweight's dimensions are: 9m × 2m × 0.368m (height × width × thickness), with a single unit weight of 45t. Each stacked steel plate is 169mm thick and weighs 22.5t. It has 6 bolt holes (φ70mm diameter), 4 pin holes (φ120mm diameter), and 1 lifting shaft hole (φ160mm diameter). Countersunk holes (φ160mm diameter) are provided at both ends of the bolt holes and pin holes.

[0093] A method for manufacturing the counterweight of a stacked steel plate ship lift, comprising the following steps:

[0094] Step 1: Cut the continuously cast steel billet into single stacked steel plates with grooves 2.

[0095] The blanking is done using a CNC flame cutting machine. After blanking, the length and width of the stacked steel plates have a deviation of -2 to -5 mm; the length and width of the grooves have a deviation of +2 to +5 mm.

[0096] Step 2: Measure and mark the lines on the single stacked steel plates.

[0097] 1) Check the steel plate's dimensional deviation, thickness deviation, surface unevenness, cross-sectional squareness, straightness of the four perimeters, diagonal deviation, and groove dimensions to ensure they meet the technical requirements for steel plate ordering.

[0098] 2) Based on the measurement records of each stacked steel plate 2, and according to the principle of similar deviation, the stacked steel plates 2 are paired up in pairs.

[0099] 3) such as Figure 6-7As shown, the single stacked steel plate 2 is hoisted onto the processing platform. A total of 18 measuring points (A10~A18, A20~A28) are equally divided on both sides of the upper and lower half of surface A of the #1 stacked steel plate 2. The elevation of each point is measured with a level 10. Based on the average measurement value, the stacked steel plate 2 is adjusted to a horizontal state by hydraulic jacks under the four corners of the platform, and wedges are used to secure it on the support piers 12 of the support platform.

[0100] Note: After adjusting the level of the stacked steel plates 2, the elevation of each point should meet the requirements.

[0101] H A10 + H A11 +…+H A18 = H A20 + H A21 +…+H A28

[0102] H A10 + H A11 +…+H A13 + H A20 + H A21 +…+H A23 = H A15 + H A16 +…+H A18 + H A25 + H A26 +…+H A28

[0103] 4) Using the two sides of the stacked steel plate 2 and the two sides of the groove as reference lines, draw the vertical center line. Similarly, using the bottom surface of the stacked steel plate 2 as a reference line, draw the horizontal center line (the vertical center line must be perpendicular to the horizontal center line).

[0104] 5) Using the vertical and horizontal center lines of the stacked steel plate 2 as references, mark the center lines of the locking bolt holes 6.

[0105] 6) Use 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 bar with a diameter of φ20 and a height of about 20mm to each of the four corners of surface A of the stacked steel plate 2 (points A1~A4, about 50mm from the corner point). Grind the round steel bars to the same height using an angle grinder to make them the reference measurement points of surface A. Make the distance from the reference surface of the round steel bar to the average horizontal surface of the thickness of the stacked steel plate 2 H=84.5+15=99.5mm.

[0106] Step 3: Gap spacer processing and pre-installation.

[0107] 1) such as Figure 8As shown, a gap shim measuring plate 14 (outer diameter φ295, plate thickness approximately 10mm) with adjusting screws 15 is placed at the marked position of the locking bolt hole. A frame level 13 is placed above it. By adjusting the four adjusting screws 15 on the gap shim measuring plate 14, the elevation of the four quadrant points (C1~C4) on the gap shim measuring plate 14 is measured with a level 10 to be equal to the elevation of the four round steel reference points (A1~A4), and the frame level 13 is horizontal in both the longitudinal and transverse directions.

[0108] 2) such as Figure 8-9 As shown, according to the gap shim measuring plate 14, there are 4 adjusting screws at H. C1 ~H C4 To determine the thickness value, select a steel plate of appropriate thickness and cut a circular ring plate with a diameter of φ300×φ70 using a CNC cutting machine. Place the gap shim measuring plate 14 and the gap shim 9 to be processed in the lathe chuck 16 and keep them close together. Use the lathe to process the circular ring plate to produce the gap shim 9 with the required eccentric thickness using an eccentric machining method.

[0109] 3) Place the gap shim 9 at the corresponding locking bolt hole position, check the fit between the shim and the surface of the stacked steel plate 2, and spot weld the shim after it is qualified. Install the gap shims 9 for the other locking bolt holes in sequence.

[0110] 4) Use a level 10 instrument again to measure whether the elevation of each quadrant point of the pad blocks is on the same horizontal plane. The elevation difference should not exceed 1mm from the reference. After confirming that there are no errors, weld the pad blocks.

[0111] Step 4: Assemble the stacked steel plates.

[0112] 1) After the two stacked steel plates 2 in the same group are processed, and after checking that the center line and the position of the locking bolt 6 holes are correct, and that the height of the locking bolt hole pads 9 are on the same plane, the assembly of the stacked steel plates 2 is prepared.

[0113] 2) Re-test whether the reference surface A of the #1 stacked steel plate 2 is horizontal. If it is qualified, flip the #2 stacked steel plate 2 with special tooling so that its A surface is facing down.

[0114] 3) such as Figure 11 As shown, hoist steel plate #2 above steel plate #1. Align the vertical and horizontal center lines of the two steel plates, then lower steel plate #2 onto steel plate #1. Check the offset of each center line and edge line, as well as the contact of the locking bolt pads 9. Once everything is correct, weld the two steel plates firmly together using eight 20×100×200 pads to form the counterweight 1.

[0115] Step 5: Draw lines on the balance blocks a second time.

[0116] 1) On the marking platform, using the two sides of the two stacked steel plates 2 and the two sides of the groove as reference lines, redraw the vertical center line of the counterweight 1; using the bottom side of the two stacked steel plates and the two sides of the groove as reference lines, redraw the horizontal center line (the vertical center line must be perpendicular to the horizontal center line).

[0117] 2) Using the vertical and horizontal center lines of counterweight 1 as references, redraw the center lines, hole machining lines, and inspection circles for the lifting lug holes, bolt holes, and shear pin holes.

[0118] 3) Measure the distance from the upper surface of the four φ20 diameter round steel bars located at the four corners of the B side of the #2 counterweight stacked steel plate 2 to the lower surface of the corresponding round steel bar on the B side of the #1 stacked steel plate 2. Use the average height of this distance as the center plane of the counterweight block in the thickness direction. Use this plane elevation as the reference elevation of the counterweight block thickness plane.

[0119] Step 6: Machining of locking bolt holes, pin holes, and lifting lug holes.

[0120] 1) Hoist the counterweight 1 below the radial drilling machine 17. Adjust the base of the drilling machine 17 to a horizontal position and fix the drilling machine 17 on the foundation.

[0121] 2) such as Figure 12 As shown, adjust the position of the drill press 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 φ70 locking bolt hole.

[0122] 3) Using the same method, drill the other shear pin holes to φ100 using a large-diameter adjustable U-drill 18; drill the lifting lug holes to φ160 using a large-diameter adjustable U-drill 18. When the radial drilling machine arm's rotation position is insufficient, the torque counterweight needs to be moved and the level readjusted.

[0123] Note: The diameter of the locking bolt hole and the anti-shear pin hole should match the diameter of the positioning bearing of the adjustable large-diameter countersunk U-drill 19.

[0124] Step 7: Countersunk hole processing for locking bolt holes and other parts of the stacked steel plates.

[0125] 1) Place the torque counterweight 1 under the radial drilling machine and adjust the counterweight to a horizontal position.

[0126] 2) such as Figure 12 As shown, adjust the position of the drill press spindle box, align the adjustable large-diameter countersinking U-drill 19 with the center of the locking bolt hole, and use the adjustable large-diameter countersinking U-drill 19 to drill and mill the locking bolt hole until the countersink diameter is φ160mm and the countersink depth is about 65mm.

[0127] 3) Adjust the position of the drill press spindle box, align the adjustable large-diameter countersinking U-drill 19 with the center of the anti-shear pin hole, and use the adjustable large-diameter countersinking U-drill 19 to drill the anti-shear pin hole until the countersink diameter is φ160mm and the countersink depth is about 25mm.

[0128] 4) Using a special tooling, flip the counterweight 1 over (with the B-side of the #1 stacked steel plate 2 facing upwards) and adjust the counterweight to a horizontal position. Position the spindle box of the adjusting drill press, and using the same method, align the adjustable large-diameter countersinking U-drill 19 with the center of the locking bolt hole. Use the adjustable large-diameter countersinking U-drill 19 to drill and mill the locking bolt hole until the countersink diameter is φ160mm and the countersink depth is approximately 95mm. Use the adjustable large-diameter countersinking U-drill 19 to drill the anti-shear pin hole until the countersink diameter is φ160mm and the countersink depth is approximately 25mm.

[0129] 5) Insert the 6 M64×290 bolts into the locking bolt holes and tighten them.

[0130] Step 8: Cut and install the counterweight groove and the top and bottom edge sealing plates.

[0131] 1) Using the vertical center line of counterweight 1 as a reference, draw two side lines (1000mm from the center) on both sides of the upper surface of counterweight 1 and two side lines of the groove (700mm from the center). Use the plumb line method to check the distance between the vertical plane of the side line and the side of the counterweight (take measurement points at 200mm intervals on the upper and lower side lines) and record them. Cut flat steel with a thickness of t=H2-20mm and a width of 30mm as adjustment patch plates 20 for the groove seal and the top and bottom plate sealing edge plates 8, and weld them.

[0132] like Figure 13 The installation method of the adjustment patch plate 20 is shown. If the gap between the edge sealing plate 8 and the overlapping steel plate 2 is less than 2mm, the C1 node method is adopted; if the gap between the edge sealing plate 8 and the overlapping steel plate 2 is greater than 2mm, the C2 node method is adopted.

[0133] 2) After the adjustment patch plates 20 for the groove and the top and bottom edge sealing plates 8 are welded, check again with a string line the distance between the vertical plane of the edge line and the side of the counterweight block, as well as the verticality of the patch plate on the side of the counterweight block. After confirming that everything is correct, cut the groove edge sealing plates and the top and bottom edge sealing plates.

[0134] 3) Install the cut edge banding plate 8 onto the three sides of the groove of the counterweight block, as well as onto the top and bottom edge banding plates of the counterweight. The vertical positioning of the edge banding plate is based on the center line of the counterweight elevation. After spot welding the edge banding plate, check again to confirm the verticality of the three sides of the groove of the counterweight block, as well as the top and bottom edge banding plates of the counterweight, and the distance to the center line. If everything is correct, weld the edge banding plate.

[0135] 4) After welding the edge sealing plate, check its verticality. The parallelism of the grooves on both sides should not exceed 0.8mm, and the verticality of the top and bottom edges should not exceed 1.2mm. The parallel spacing between the grooves on both sides should be 1400±2mm, and the parallel spacing between the top and bottom grooves should be 2300±2mm.

[0136] Step 9: Test lift the pre-installed lifting shaft hole reinforcing plate with the counterweight.

[0137] Place the counterweight 1 on the jig and adjust it to a horizontal position. Using the reference elevation of the average thickness plane of the counterweight as a reference, measure the distance H3 from the upper plane of the lifting lug 3 to the base plane. Process the lifting lug reinforcing plate 24 of the #2 stacked steel plate with a plate thickness of t3=199-H3. Similarly, measure and process the lifting lug reinforcing plate 24 of the #1 stacked steel plate.

[0138] 1) Temporarily spot weld the lifting lug reinforcing plate 24 to both sides of the lifting lug hole, install the tooling lifting lug 3, and at the same time install the line stake 23 and the measuring plumb bob 22 350mm below the lifting shaft hole.

[0139] 2) such as Figure 14-15 As shown, a crane (with an electronic crane scale 21 installed under the main hook) is used to slowly lift the counterweight 1 until it is in an upright suspended state. The weight of the counterweight and the offset value of the plumb bob 22 are measured. If the offset value of the counterweight along the water flow direction is greater than 10mm, the counterweight is first lowered and laid flat, the thickness of the reinforcing plates 24 on both sides of the lifting lugs is adjusted, and then it is lifted again until the offset value of the counterweight along the water flow direction is greater than 10mm.

[0140] Step 10: Machining and installation of the stop plate.

[0141] 1) Use a crane to first place the counterweight 1 horizontally on the marking platform, and adjust the counterweight to a horizontal state according to the average thickness reference plane of the counterweight.

[0142] 2) such as Figure 16 As shown, using the upper surface of the lifting lug reinforcing plate 24 as a reference, the stop plate base plate measuring plate 26 (length × width = 345mm × 195mm, plate thickness approximately 10mm) with adjusting screws is placed at the marked position on the stop plate base plate 5. A frame level 13 is placed above it. By adjusting the four adjusting screws 15 on the stop plate base plate measuring plate 26, the elevation of the four corner points (C1~C4) on the stop plate base plate measuring plate 26 is measured using a level 10 to ensure that the elevations are equal to the four round steel reference points (B1~B4), and that the frame level 13 is horizontal in both the longitudinal and transverse directions.

[0143] 3) According to the four adjusting screws H on the stop plate seat plate measuring plate 26 C1 ~H C4To determine the thickness value, select a steel plate of appropriate thickness and cut a 350×200 rectangular plate using a CNC cutting machine. Place the stop plate base measuring plate 26 and the stop plate base 5 to be processed in sequence in the lathe chuck 16 and keep them tightly against each other. Use the lathe to process the rectangular plate to obtain the stop plate base 5 with the required eccentric thickness using an eccentric machining method. The method is the same as the processing method of the locking bolt gap shim 9.

[0144] 4) Place the rectangular plate on the corresponding stop block seat plate 5, check the fit between the pad and the surface of the stacked steel plate 2. If it is qualified, spot weld the seat plate. Install the other stop block seat plates in sequence.

[0145] 5) Use a level instrument 10 again to measure whether the elevation of each corner point of the stop block base plate 5 is on the same horizontal plane. The elevation difference should not exceed 1mm. After confirming that there are no errors, weld the stop block base plate 5.

[0146] 6) Use the same method to process and weld the stop block seat plate of the No. 1 counterweight stacked steel plate.

[0147] Step 11: Second trial lifting of the counterweight and pre-installation of the remaining edge banding plates.

[0148] 1) such as Figure 16 As shown, the counterweight 1 is installed with the tooling lifting lug 3, and the plumb bob 23 and measuring plumb bob 22 are installed 350mm below the lifting shaft hole.

[0149] 2) Use the crane to slowly lift the counterweight 1 again until it is in an upright suspended state. Measure the weight of the counterweight and the offset of the plumb bob 22. Check if the offset of the counterweight in the vertical direction of the water flow is greater than 5mm. Calculate the thickness of the sealing plates 8 on both sides of the counterweight based on the weight difference of the counterweight and the offset of the counterweight in the vertical direction of the water flow.

[0150] 3) First, place the counterweight 1 horizontally on the marking platform, cut it according to the pre-calculated plate thickness, and then position and weld it to both sides of the counterweight 1.

[0151] 4) Use the crane to slowly lift the counterweight 1 again until it is in an upright suspended state. Check whether the offset of the counterweight in the vertical direction of the water flow is greater than 5mm and the offset along the water flow direction is greater than 10mm. After confirming that there are no errors, lower the counterweight to a horizontal position and weld the sealing plates 8 on both sides of the counterweight.

[0152] In addition, the method for aligning and installing the edge banding plate 8 is the same as that for the grooved edge banding plate. Leveling the edge banding plate can be done while leveling the grooved edge banding plate.

[0153] like Figure 17 As shown, during the measurement and processing of the pad plate, when the counterweight 1 is turned over, the counterweight 1 is first clamped by the turning fixture 27, and then the lifting lug of the turning fixture 27 is lifted by a crane to turn it over.

[0154] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A method for manufacturing counterweights for a stacked steel plate ship lift, characterized in that... Includes the following steps: Step 1: Cut the continuously cast steel billet into single stacked steel plates with grooves (2). Step 2: Measure and mark the lines on the single stacked steel plate (2); Step 3: Fabricate and pre-install gap spacers for the stacked steel plates (9); Step 4: Assemble the two sets of stacked steel plates (2); Step 5: Draw lines on the counterweight (1) a second time; Step 6: Drill and machine the locking bolt holes, pin holes, and lifting lug holes of the counterweight; Step 7: Countersink the locking bolt holes of the counterweight; Step 8: Cut and install the counterweight groove and the top and bottom edge sealing plates; Step 9: Test lift the counterweight and pre-install the reinforcing plate for the lifting shaft hole; Step 10: Process and install the stop plate seat (5); Step 11: Perform a second trial lift of the counterweight and pre-install the remaining edge banding plates (8); Step 3 sub-steps are as follows: Step 3-1: Place the gap shim measuring plate (14) with adjusting screws (15) at the marked position of the locking bolt hole; place the frame level (13) above it, and use a level (10) to measure the elevation of the four quadrant points on the gap shim measuring plate (14) and the four round steel reference points by adjusting the four adjusting screws (15) on the gap shim measuring plate (14). The elevations are equal, and the frame level (13) is horizontal in both the longitudinal and transverse directions. Step 3-2: Based on the thickness values ​​at the four adjusting screws of the gap shim measuring plate (14), select a steel plate of appropriate thickness and cut a ring plate using a CNC cutting machine; place the gap shim measuring plate (14) and the gap shim to be processed (9) in the lathe chuck (16) and place them close together; use the lathe to process the ring plate to produce a gap shim (9) with the required eccentric thickness using an eccentric machining method. Step 3-3: Check the fit between the pad (9) and the surface of the stacked steel plate (2). If it is qualified, install the pad by spot welding.

2. The method for manufacturing counterweights 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 continuously cast steel billet.

3. The method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 2 sub-steps are as follows: Step 2-1: Based on the measurement records of each stacked steel plate (2), pair up the stacked steel plates (2) in pairs according to the principle of similar deviations; Step 2-2: Hoist the single stacked steel plate (2) onto the processing platform, and adjust the stacked steel plate (2) to a horizontal state using the hydraulic jacks under the four corners of the platform; Steps 2-3: Draw the vertical center line and the horizontal center line; Steps 2-4: Draw the center line of the locking bolt (6) hole; Steps 2-5: Use a level (10) to measure the elevation of the point and use its average value as the reference elevation of surface A.

4. The method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 4 is as follows: There are multiple stacked steel plates. The 2# stacked steel plate is hoisted above the 1# stacked steel plate. After aligning the vertical and horizontal center lines of the two stacked steel plates, the 2# stacked steel plate (2) is placed on the 1# stacked steel plate (2). The two stacked steel plates are welded firmly with pads to form a counterweight (1).

5. A method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 5 is a sub-step: Step 5-1: On the marking platform, using the two sides of the two stacked steel plates (2) and the two sides of the groove as reference lines, re-mark the vertical center line of the counterweight (1); using the bottom side of the two stacked steel plates and the two sides of the groove as reference lines, re-mark the horizontal center line. Step 5-2: Using the vertical center line and horizontal center line of the counterweight (1) as the reference, redraw the center lines, hole machining lines, and inspection circles of the lifting lug hole, bolt hole, and anti-shear pin hole respectively; Step 5-3: Measure the distance from the upper surface of the four φ20 round steel bars at the four corners of the B side of the #2 counterweight stacked steel plate (2) to the lower surface of the corresponding round steel bar of the #1 stacked steel plate (2), and use the average height of the average height of the average height of the average height of the average height of the counterweight in the thickness direction as the reference elevation of the thickness plane of the counterweight.

6. The method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 6 is a sub-step: Step 6-1: Hoist the counterweight (1) to the bottom of 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 drill head, align the drill bit with the center of the locking bolt hole, and drill the locking bolt hole with a large-diameter adjustable U-drill (18); Step 6-3: Drill other anti-shear pin holes and lifting lug holes in sequence using the large-diameter adjustable U-drill (18) in the same way; the hole diameter of the locking bolt hole and anti-shear pin hole should match the positioning bearing diameter of the adjustable large-diameter countersunk U-drill (19).

7. The method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 7 is a sub-step: Step 7-1: Place the torque counterweight (1) under the radial drilling machine and adjust the counterweight to a horizontal position; Step 7-2: Adjust the position of the drill press spindle box and drill and mill the locking bolt hole and shear pin hole of the adjustable large diameter U-drill (19); Step 7-3: Use the tooling to turn the counterweight (1) over so that the B side of the #1 stacked steel plate (2) is facing up, and adjust the counterweight to a horizontal state; use the adjustable large-diameter countersinking U drill (19) to drill and mill the countersinking holes of the locking bolts and the countersinking holes of the shear pins. Step 7-4: Insert the bolt (6) into the locking bolt hole and tighten it.

8. A method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 8 is a sub-step: Step 8-1: Using the vertical center line of the counterweight (1) as a reference, pull the side lines on both sides of the upper surface of the counterweight (1) and the distance from the side line on both sides of the groove. Use the vertical line method to check and record the distance from the vertical plane of the side line to the side of the counterweight. Calculate the flat steel cutting and use it as the adjustment patch plate (20) for the groove seal and the top and bottom plate sealing edge plate (8), and weld it. Step 8-2: Adjust the installation method of the patch plate (20). If the gap between the edge sealing plate (8) and the overlapping steel plate (2) is less than 2mm, the C1 node method is adopted; if the gap between the edge sealing plate (8) and the overlapping steel plate (2) is greater than 2mm, the C2 node method is adopted. Step 8-3: After the adjustment patch plate (20) of the groove and the top and bottom plate edge sealing plate (8) is welded, check the distance between the vertical plane of the edge line and the side of the counterweight block, as well as the verticality of the patch plate on the side of the counterweight block, with a string; after confirming that there are no errors, cut the groove edge sealing plate and the top and bottom plate edge sealing plate. Step 8-4: Install the cut edge sealing plate (8) onto the three sides of the groove of the counterweight block, as well as the top and bottom sealing plates of the counterweight block. The vertical position of the edge sealing plate is based on the center line of the counterweight block elevation. After spot welding the edge sealing plate, check again to confirm the verticality of the three sides of the groove of the counterweight block, as well as the top and bottom sealing plates of the counterweight block, and the distance to the center line. If there are no errors, weld the edge sealing plate.

9. A method for manufacturing counterweights for a stacked steel plate ship lift according to claim 1, characterized in that... Step 9 is a sub-step: Step 9-1: Place the counterweight (1) on the jig and adjust it to a horizontal state; take the average elevation of the counterweight thickness plane as the reference and measure the distance from the upper plane of the lifting lug (3) to the base plane to process the lifting lug reinforcing plate (24) of the stacked steel plate. Step 9-2: Temporarily spot weld the lifting lug reinforcing plate (24) to both sides of the lifting lug hole, install the tooling lifting lug (3), and at the same time install the line stake (23) and 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 suspended state, measure the weight of the counterweight and the offset value of the plumb bob (22); If the offset of the counterweight along the water flow direction is greater than 10mm, the thickness of the reinforcing plates (24) on both sides of the lifting lugs shall be adjusted; an electronic crane scale (21) is installed under the main hook of the crane. Step 10 sub-steps are as follows: Step 10-1: Use a crane to first lower 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: Using the upper surface of the lifting lug reinforcing plate (24) as a reference, place the stop plate base plate measuring plate (26) with adjusting screws at the marked position of the stop plate base plate (5); place the frame level (13) above it, and use a level (10) to measure the elevation of the four corner points on the stop plate base plate measuring plate (26) and the four round steel reference points by adjusting the four adjusting screws (15) on the stop plate base plate measuring plate (26), and the frame level (13) is horizontal in both the longitudinal and transverse directions; Step 10-3: Based on the thickness values ​​at the four adjusting screws of the stop plate seat plate measuring plate (26), select a steel plate of appropriate thickness and cut a rectangular plate using a CNC cutting machine; place the stop plate seat plate measuring plate (26) and the stop plate seat plate (5) to be processed in the lathe chuck (16) and place them close together; use the lathe to process the rectangular plate to produce a stop plate seat plate (5) with the required eccentric thickness using an eccentric machining method. Step 10-4: Place the rectangular plate on the corresponding stop plate seat (5) position, check the fit between the pad and the surface of the stacked steel plate (2), and after passing the inspection, spot weld the stop plate seat (5); install the other stop plate seats (5) in sequence. Step 11 sub-step is as follows: Step 11-1: Install the tooling lifting lug (3) on the counterweight (1), and at the same time install the line stake (23) and the measuring plumb 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 suspended state, measure the weight of the horizontal weight and the offset value of the plumb bob (22); check whether the offset value of the counterweight in the vertical direction of the water flow is greater than 5mm; calculate the thickness of the 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 vertical direction of the water flow. Step 11-3: First, place the counterweight (1) on the hook and slowly place it on the marking platform. Then, cut the plate according to the pre-calculated plate thickness and weld it to 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. Check whether the offset value of the counterweight in the vertical direction of the water flow is greater than 5mm and the offset value in the direction of the water flow is greater than 10mm. After confirming that there are no errors, lower the counterweight and lay it down. Weld the sealing plates (8) on both sides of the counterweight. Step 11-5: During the measurement and processing of the pad plate, when turning the counterweight (1), first use the turning fixture (27) to clamp the counterweight (1), and then use a crane to lift the lifting lug of the turning fixture (27) to turn it over.

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