Segmented manufacturing process for round stack portal steel structures

Abstract

The present application relates to a round stack portal steel structure segmented manufacturing process, comprising the following steps: dividing the portal into segment one, segment two, segment three and segment four according to the inflection point position, and processing and manufacturing; drawing a simple sample line, hoisting segment two and segment three of the first portal, and spot welding the outer side and inner side of segment two and segment three respectively; drawing an integral sample line; hoisting segment one and segment four of the first portal, and spot welding; full welding of each segment of the first portal; hoisting segment two and segment three of the second portal to the first portal, and spot welding the outer side and inner side of segment two and segment three; hoisting segment one and segment four of the second portal, and spot welding; full welding of each segment of the second portal; disassembling the two portals: spot welding the connecting plate at the specified position of the portal, then drilling the connecting plate, and then removing the connecting plate, and disassembling and cutting the portal according to the specified position. The present application re-segments the portal for manufacturing, which can improve the dimensional accuracy of the entire portal.

Description

Technical Field

[0001] This invention relates to the field of circular stacker-reclaimer technology, and more particularly to the segmented manufacturing process of circular stacker gantry steel structures. Background Technology

[0002] A circular stacker-reclaimer is a continuous stacking and reclaiming machine used within an enclosed spherical shed, enabling efficient, environmentally friendly, and automated material handling and stacking. The gantry steel structure of the circular stacker-reclaimer is a crucial component for realizing its reclaiming function, supporting the scraper reclaimer and serving as its fulcrum for pitching and tilting.

[0003] The performance of the gantry steel structure directly affects the stable operation of the scraper conveyor and even the entire machine. The gantry steel structure adopts a box-shaped double-beam structure, that is, the gantry is composed of two single beams with identical structures, arranged side by side in parallel, and connected together by a certain structure. The structure of each single beam of the gantry is as follows: Figure 1 As shown.

[0004] When fabricating the portal frame steel structure, box girders are used for the single beams. The cross-section of the box girder is as follows: Figure 2 As shown, it includes a rectangular base plate, cover plate, and web plate, as well as multiple partitions spaced apart within the rectangular space. The gantry is assembled from gantry one, gantry two, gantry three, gantry four, and gantry five, as shown. Figure 3 As shown, gantry one is the track end, which is connected to the circular track on the wall of the circular material yard through the walking device, and gantry five is the central column end, which is connected to the central column of the circular stacker-reclaimer through the slewing bearing.

[0005] Therefore, the beam must be cut and manufactured in sections according to the aforementioned segmentation nodes. The entire box girder needs to be cut into portal frames one, two, three, four, and five, then transported to the site for assembly. Connecting plates are used for assembly. Figure 4 As shown, adjacent gantry sections are connected and fixed together by connecting plates using flange connections. At each assembly node, there are multiple connecting plates of this type, arranged in a rectangular pattern. The flange connection refers to drilling holes on both sides of the connecting plate, and also drilling holes at the end of the gantry at each assembly node. Corresponding holes are connected by bolts, thus connecting the connecting plate to the adjacent gantry sections.

[0006] This shows that because the gantry is divided into four straight sections, the length of each section is a critical dimension, denoted by X1, X2, X3, and X4, which requires strict inspection. Each section has a connecting plate, which corresponds to the break point of each section, necessitating cutting and breaking each section. As a result, what could have been a single, integral box girder now requires breaking the box girder, fabricating each section separately, bending the box girder, drilling flange holes, and finally assembling them.

[0007] Because each individually manufactured gantry segment inevitably has precision errors, and these errors accumulate during assembly, leading to significant variations in critical dimensions, the gantry segments at the connecting plates must be adjusted, repaired, and cut to ensure the flange hole positions meet the drawing requirements before being connected together with the connecting plates. This manufacturing process results in relatively low assembly precision. Summary of the Invention

[0008] To address the issue of low assembly accuracy in gantry frames manufactured using conventional processes, this invention provides a segmented manufacturing process for circular stacked gantry steel structures. This process utilizes a single box girder to fabricate each gantry segment. After fabrication, multiple gantry segments are first assembled, with holes drilled according to the connecting plate positions. Then, the gantry is divided according to the node positions, transported to the site, and assembled, ensuring high dimensional accuracy.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: The segmented manufacturing process of the circular stacker gantry steel structure includes the following steps: Step 1: Based on the structural and stress characteristics of the gantry steel structure, the gantry is divided into four straight sections according to the inflection point: Section 1, Section 2, Section 3, and Section 4. This helps to improve processing accuracy. Sections 1 to 4 are manufactured according to the design drawings. After completion and inspection, they are assembled. Step 2: Draw a simple layout line on the assembly site, place the pads according to the layout line, and hoist the second and third segments of the first gantry onto the pads. After verifying that the assembly dimensions of the second and third segments are qualified, spot weld the outer and inner sides of the second and third segments respectively. Step 3: Draw the overall ground line based on the simple ground line, and trim the manufacturing allowance of section 1 and section 3; after placing the pads again according to the ground line, hoist section 1 and section 4 of the first gantry. Refer to step 2 to spot weld section 1, section 2, section 3 and section 4 to facilitate the initial spot welding and fixation of the four sections of the first gantry. Step 4: Ensure the gaps at the splicing nodes of each segment according to the design drawings, and place the Z-direction load-bearing plate into the gaps. Fully weld the splicing node positions of each segment of the first gantry, and complete the full welding and fixing of the four segments in the first gantry. Step 5: Using a top-to-bottom stacking method, hoist sections two and three of the second gantry onto the first gantry. Refer to Steps 2 and 3 to spot weld the outer and inner sides of sections two and three of the second gantry, and adjust the manufacturing allowance. Then hoist sections one and four of the second gantry onto the first gantry, and spot weld sections one and two, sections three and four of the second gantry. Finally, refer to Step 4 to perform full welding on each section of the second gantry. Step 6: Lift the second gantry away from the first gantry. According to the design drawings, spot weld the connecting plate to the designated position on the first gantry. Then drill holes in the connecting plate, ensuring the holes penetrate the gantry. Remove the connecting plate and then disassemble and cut the first gantry at the designated position to form the existing gantry segment structure. Refer to the disassembly operation of the first gantry to disassemble and cut the second gantry.

[0010] Furthermore, in step 1, the inflection point of the gantry is the bending point. There are three inflection points of the gantry, namely inflection point a, inflection point b and inflection point c. The three inflection points divide the gantry into group one, group two, group three and group four in sequence. Group one to group four are all straight box beam structures.

[0011] Further, in step 2, the simple ground pattern lines are the ground pattern lines of group two and group three; after copying the horizontal lines, spot weld the outer sides of group two and group three, and then according to the center line of group three, check the dimensions of group two, and after passing the inspection, spot weld the inner sides of group two and group three.

[0012] Furthermore, the horizontal alignment is used to check the elevation and straightness of segments two and three; if there is an error in the dimensions of segment two, the position of segment two is finely adjusted until the dimensions are qualified.

[0013] Furthermore, in step 3, the overall ground pattern line includes the ground pattern lines of group one to group four; group one and group three are manufactured with a manufacturing allowance, which is the repair allowance, and the repaired group one and group three meet the key dimension requirements of two straight sections of the gantry.

[0014] Further, in step 3, after copying the horizontal line, spot weld the outer side of segment 2 and segment 1. Then, according to the centerline of segment 2, check the dimensions of segment 1. If there is an error, fine-tune the position of segment 1. After the dimensions are qualified, spot weld the inner side of segment 2 and segment 1. Repeat the operation to spot weld the outer and inner sides of segment 3 and segment 4.

[0015] Furthermore, in step 4, there are three splicing nodes between group one to group four, and there are three z-direction force plates. The two adjacent groups in the first gantry are fully welded to the z-direction force plates, and the splicing node positions of group one and group two, group two and group three, and group three and group four are fully welded.

[0016] Furthermore, in step 5, after the second and third segments of the second gantry are hoisted, they correspond vertically to the second and third segments of the first gantry; after the first and fourth segments of the second gantry are hoisted, they correspond vertically to the first and fourth segments of the first gantry.

[0017] Furthermore, in step 6, after the two gantry frames are disassembled, five segments of the existing gantry frame structure are formed. After being transported to the project construction site, the overall structure of the gantry frame is assembled according to the precise position of the connecting plate. Then, the connecting plate and the gantry frame steel structure are fixed by the connecting plate and high-strength bolts, nuts and washers.

[0018] The beneficial effects of the present invention through the above technical solution are: This invention optimizes the existing gantry manufacturing process. In existing gantry manufacturing, five gantry sections are manufactured separately, some sections require bending, and holes need to be drilled at the joints of each section to facilitate subsequent connection using connecting plates and flanges. Because each gantry section is manufactured separately, precision errors are inevitable after manufacturing. During assembly, the sum of the errors of each gantry section increases, making it difficult to guarantee the accuracy of critical dimensions of each straight section of the gantry and making it difficult to align the connecting plates.

[0019] Based on this, the present invention divides the gantry into four straight sections according to its structure and stress characteristics, namely Section 1 to Section 4. All four sections are straight structures, and each section, during manufacturing, can meet the critical dimensional accuracy requirements of each straight section of the gantry. After processing and manufacturing, Section 1 includes the original gantry 1 and gantry 2; after processing and manufacturing, Section 3 includes the original gantry 3 and gantry 4, thus reducing one accuracy error. After each section of the gantry is fully welded and fixed, connecting plates are spot-welded without cutting. Then, holes are drilled, with holes drilled together on the connecting plates and the gantry. After drilling, the connecting plates are removed before cutting the gantry, ensuring that the holes are not misaligned, guaranteeing the accuracy of the holes, and facilitating the installation of the connecting plates. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of each single beam structure of the gantry.

[0021] Figure 2 These are cross-sectional views of each single beam of the gantry.

[0022] Figure 3 This is a schematic diagram of the gantry segment manufacturing process.

[0023] Figure 4This is a schematic diagram showing the disassembled state of the gantry frame, where each section is connected by a connecting plate flange.

[0024] Figure 5 This is a schematic diagram of the distribution of inflection points in step 1 of the segmented manufacturing process of the circular stack gantry steel structure of the present invention.

[0025] Figure 6 This is a schematic diagram of the segmented arrangement of the gantry in step 1 of the segmented manufacturing process of the circular stack gantry steel structure of the present invention.

[0026] Figure 7 This is a schematic diagram of the assembly state of segment two and segment three in step 2 of the segmented manufacturing process of the circular stack gantry steel structure of the present invention.

[0027] Figure 8 This is a schematic diagram of the spot welding and fixing state of the first gantry in step 3 of the segmented manufacturing process of the circular stack gantry steel structure of the present invention.

[0028] Figure 9 This is a schematic diagram of the first gantry in the fully welded and fixed state in step 4 of the segmented manufacturing process of the circular stack gantry steel structure of the present invention.

[0029] Figure 10 This is a schematic diagram comparing the assembly dimensions of the gantry before and after the process optimization of the segmented manufacturing process of the circular stack gantry steel structure of this invention.

[0030] Figure 11 This is a schematic diagram comparing the external dimensions of the gantry before and after the process optimization of the segmented manufacturing process of the circular stack gantry steel structure of this invention.

[0031] The attached diagram is labeled as follows: 1. Base plate, 2. Cover plate, 3. Web plate, 4. Partition plate, 51. Portal Frame 1, 52. Portal Frame 2, 53. Portal Frame 3, 54. Portal Frame 4, 55. Portal Frame 5, 6. Connecting plate, 71. Section 1, 72. Section 2, 73. Section 3, 74. Section 4, 8. Z-direction load-bearing plate. Detailed Implementation

[0032] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings: like Figures 5-9 As shown, the segmented manufacturing process of the circular gantry steel structure includes the following steps: Step 1: Based on the structural and stress characteristics of the gantry steel structure, divide the gantry into segments according to the inflection points. The inflection points of the gantry are the bending points. There are three inflection points in the gantry: inflection point a, inflection point b, and inflection point c. Figure 5 As shown; this inflection point is also the tensile stress point of the gantry.

[0033] The three inflection points of the gantry divide it into four straight sections: Section 1 (71), Section 2 (72), Section 3 (73), and Section 4 (74). In other words, the three inflection points sequentially divide the gantry into Section 1 (71), Section 2 (72), Section 3 (73), and Section 4 (74). All sections from 71 to 74 are straight box-beam structures. Figure 6 As shown. The lengths of group 3 (73), group 1 (71), group 4 (74), and group 2 (72) decrease sequentially, and all four groups are straight, which helps to ensure the dimensional accuracy of each straight segment of the gantry.

[0034] Segments 71 to 74 are manufactured according to the design drawings. Because segments 71 and 73 are relatively long, manufacturing allowances are provided during their production to facilitate subsequent cutting and fitting. After completion and inspection, they are assembled, with inflection points a, b, and c serving as assembly nodes.

[0035] Note: Since the gantry is composed of two single beams with the same structure, it is necessary to manufacture the first gantry and the second gantry. The two gantry can be regarded as two single beams. Both gantry include group 1 71 to group 4 74.

[0036] Step 2: Draw a simple layout line on the assembly site. The simple layout line is the layout line for section 2 (72) and section 3 (73). Place the pad blocks according to the layout line, and then hoist section 2 (72) and section 3 (73) of the first gantry frame onto the pad blocks one after another for assembly. After assembly, check whether the assembly dimensions of section 2 (72) and section 3 (73) are qualified. After passing the inspection, spot weld the outer and inner sides of section 2 (72) and section 3 (73) respectively. Figure 7 As shown.

[0037] Specifically, after leveling the sections, that is, after verifying that the elevation and straightness of section 2 (72) and section 3 (73) are qualified, spot weld the outer sides of section 2 (72) and section 3 (73). Then, based on the centerline of section 3 (73), check the assembly dimensions of section 2 (72). If there is an error in the checked assembly dimensions of section 2 (72), fine adjust the position of section 2 (72) until the dimensions are qualified. After passing the inspection, spot weld the inner sides of section 2 (72) and section 3 (73).

[0038] Step 3: Draw the overall ground layout line based on the simple layout line. The overall ground layout line includes the layout lines of group 1 71 to group 4 74. Trim the manufacturing allowance of group 1 71 and group 3 73. The manufacturing allowance is the fitting allowance. After trimming, group 1 71 and group 3 73 meet the critical dimension requirements of two straight sections of the gantry.

[0039] Following the guidance of the site survey line, after placing the pads again, hoist up the first gantry segment 1 (71) and segment 4 (74). According to the design drawings, bevels are made at the assembly nodes of segments 1 (71), 2 (72), 3 (73), and 4 (74) to facilitate subsequent welding operations. Refer to step 2 for tack welding of segments 1 (71), 2 (72), 3 (73), and 4 (74). After tack welding and fixing segments 2 (72) and 3 (73), hoist up segments 1 (71) and 4 (74), then tack weld and fix segments 1 (71) to segments 2 (72) and to segments 3 (73) and 4 (74).

[0040] Specifically, after leveling the section, spot weld the outer sides of section 2 (72) and section 1 (71). Then, based on the centerline of section 2 (72), check the dimensions of section 1 (71). If there are any errors, fine-tune the position of section 1 (71). After the dimensions are qualified, spot weld the inner sides of section 2 (72) and section 1 (71). Repeat the above operation to spot weld the outer and inner sides of section 3 (73) and section 4 (74), thus completing the spot welding and fixing of the four sections in the first gantry. Figure 8 As shown.

[0041] Step 4: Ensure the gaps at the splicing nodes of each segment according to the design drawings. That is, during the hoisting and spot welding of the four segments, pay attention to leaving gaps between adjacent segments and arrange the Z-direction load-bearing plates 8 within the gaps. Since there are three splicing nodes between segment 1 71 and segment 4 74, the number of Z-direction load-bearing plates 8 is three.

[0042] The splicing node positions of each segment of the first gantry are fully welded, specifically the splicing node positions of segments 1-71 and 2-72, 2-72 and 3-73, and 3-73 and 4-74. Adjacent segments in the first gantry are fully welded to the z-axis load-bearing plate 8, as shown below. Figure 9 As shown, the full welding and fixing of the four sections in the first gantry has been completed.

[0043] Step 5: After the first gantry is assembled and fixed, begin assembling the second gantry, using the segments of the first gantry as a reference. Using a top-to-bottom stacking method, hoist segments 2 (72) and 3 (73) of the second gantry onto the first gantry, ensuring they align vertically with those of the first gantry. Referring to Steps 2 and 3, spot weld the outer and inner sides of segments 2 (72) and 3 (73) of the second gantry, and adjust manufacturing allowances.

[0044] Then, sections 71 and 74 of the second gantry are hoisted onto the first gantry, aligning them vertically with those of the first gantry. Sections 71 and 74 of the second gantry are then spot-welded. Finally, referring to step 4, all sections of the second gantry are fully welded, completing the full welding and fixing of all four sections of the second gantry. At this point, the first and second gantry are stacked vertically, with consistent assembly dimensions and angles. Consequently, the first and second gantry have identical structures and dimensions, fulfilling the requirement of two identical single beams.

[0045] Step 6: Lift the second gantry away from the first gantry and disassemble both gantry. The disassembly of the first gantry is as follows: According to the design drawings, spot weld the connecting plate 6 to the designated position on the first gantry. Place one connecting plate 6 on each of section 1 (71) and section 2 (72), and two connecting plates 6 on section 3 (73). Then drill holes in the connecting plates 6, ensuring the holes penetrate the gantry. Remove the connecting plates 6, and then disassemble and cut the first gantry according to the designated positions. These designated positions are as follows: Figure 3 The disconnection points shown form the existing segmented structure of the gantry, which in turn constitutes the existing gantry one through gantry five. The second gantry is disassembled and cut in accordance with the disassembly operation of the first gantry.

[0046] After the two gantry frames are disassembled, they are divided into five segments. After being transported to the project construction site, the gantry frame structure is assembled according to the precise position of the connecting plate 6. The connecting plate 6 and the gantry frame steel structure are then fixed by the connecting plate 6 and high-strength bolts, nuts and washers.

[0047] To demonstrate the effectiveness of the process of this invention, the following comparative experiment was conducted: The assembly dimensions of the gantry manufactured using conventional processes were measured, and the assembly dimensions of the gantry manufactured using the optimized segmented manufacturing process were also measured. Two sets of assembly dimension measurement data were obtained before and after the manufacturing process optimization, as follows: Figure 10 As shown in the figure, a comparison of the data before and after reveals that the dimensional accuracy of the gantry structure manufactured using the segmented manufacturing process is significantly higher than that of conventionally manufactured gantry structures, with an accuracy improvement of approximately 50%.

[0048] Simultaneously, the external dimensions of the gantry were measured before and after manufacturing process optimization, resulting in two sets of external dimensional measurement data, such as... Figure 11 As shown in the figure, the comparison of data before and after demonstrates that the segmented manufacturing process significantly reduces the stress concentration problem caused by the large amount of welding work during the welding process, resulting in better control of welding deformation and a significant improvement in the dimensional accuracy of the gantry structure components.

[0049] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention should be included within the scope of the present invention.

Claims

1. A segmented manufacturing process for the steel structure of a circular stacker gantry, characterized in that, Includes the following steps: Step 1: Based on the structure and stress characteristics of the gantry steel structure, the gantry is divided into four straight sections according to the inflection point position: Section 1 (71), Section 2 (72), Section 3 (73), and Section 4 (74). Sections 1 (71) to 4 (74) are manufactured according to the design drawings. After the production is completed and the inspection is qualified, they are assembled. Step 2: Draw a simple line at the assembly site, place the pads according to the line, and hoist the second (72) and third (73) segments of the first gantry onto the pads. After verifying that the assembly dimensions of the second (72) and third (73) segments are qualified, spot weld the outer and inner sides of the second (72) and third (73) segments respectively. Step 3: Draw the overall ground line based on the simple ground line, trim the manufacturing allowance of section 1 (71) and section 3 (73); after placing the pads again according to the ground line, hoist section 1 (71) and section 4 (74) of the first gantry, and spot weld section 1 (71) and section 2 (72), section 3 (73) and section 4 (74) according to step 2. Step 4: Ensure the gap at the splicing nodes of each group section according to the design drawings, and arrange the Z-direction load-bearing plate (8) in the gap, and fully weld the splicing node positions of each group section of the first gantry. Step 5: Using a top-to-bottom stacking method, hoist the second segment (72) and the third segment (73) of the second gantry onto the first gantry. Refer to Step 2 and Step 3 to spot weld the outer and inner sides of the second segment (72) and the third segment (73) of the second gantry, and adjust the manufacturing allowance. Then hoist the first segment (71) and the fourth segment (74) of the second gantry onto the first gantry, and spot weld the first segment (71), the second segment (72), the third segment (73), and the fourth segment (74) of the second gantry. Finally, refer to Step 4 to perform full welding of each segment of the second gantry. Step 6: Lift the second gantry away from the first gantry, spot weld the connecting plate (6) to the designated position of the first gantry according to the design drawings, then drill holes in the connecting plate (6) to ensure that the holes penetrate the gantry, then remove the connecting plate (6), and then disassemble and cut the first gantry according to the designated position to form the existing gantry segment structure; refer to the disassembly operation of the first gantry to disassemble and cut the second gantry.

2. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 1, characterized in that, In step 1, the inflection point of the gantry is the bending point. There are three inflection points of the gantry, namely inflection point a, inflection point b and inflection point c. The three inflection points divide the gantry into group one (71), group two (72), group three (73) and group four (74) in sequence. Group one (71) to group four (74) are all straight box beam structures.

3. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 1, characterized in that, In step 2, the simple ground pattern lines are the ground pattern lines of group two (72) and group three (73); after copying the horizontal line, spot weld the outer side of group two (72) and group three (73), and then according to the center line of group three (73), check the assembly dimensions of group two (72), and after passing the inspection, spot weld the inner side of group two (72) and group three (73).

4. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 3, characterized in that, The horizontal alignment is used to check the elevation and straightness of section two (72) and section three (73); if there is an error in the dimensions of section two (72), the position of section two (72) is finely adjusted until the dimensions are qualified.

5. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 1, characterized in that, In step 3, the overall ground pattern line includes the ground pattern lines of group one (71) to group four (74); group one (71) and group three (73) are manufactured with a manufacturing allowance, which is the repair allowance. After repair, group one (71) and group three (73) meet the key dimension requirements of two straight sections of the gantry.

6. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 4, characterized in that, In step 3, after copying the horizontal line, spot weld the outer side of group segment 2 (72) and group segment 1 (71). Then, according to the center line of group segment 2 (72), check the dimensions of group segment 1 (71). If there is an error, finely adjust the position of group segment 1 (71). After the dimensions are qualified, spot weld the inner side of group segment 2 (72) and group segment 1 (71). Repeat the operation to spot weld the outer and inner sides of group segment 3 (73) and group segment 4 (74).

7. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 1, characterized in that, In step 4, there are three splicing nodes between group 1 (71) and group 4 (74), and there are three z-direction force plates (8). The two adjacent groups in the first gantry are fully welded to the z-direction force plates (8). The splicing node positions of group 1 (71) and group 2 (72), group 2 (72) and group 3 (73), and group 3 (73) and group 4 (74) are fully welded.

8. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 1, characterized in that, In step 5, after the second gantry segment 2 (72) and segment 3 (73) are hoisted, they correspond vertically to the first gantry segment 2 (72) and segment 3 (73); after the second gantry segment 1 (71) and segment 4 (74) are hoisted, they correspond vertically to the first gantry segment 1 (71) and segment 4 (74).

9. The segmented manufacturing process of the circular stacker gantry steel structure according to claim 1, characterized in that, In step 6, after the two gantry disassembly operations, the existing gantry is formed into five segmented structures. After being transported to the project construction site, the overall structure of the gantry is assembled according to the precise position of the connecting plate (6). Then, the connecting plate (6) and the gantry steel structure are fixed by the connecting plate (6) and high-strength bolts, nuts and washers.

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