A preparation method of a running trolley for a semi-circular large beam shore crane

Abstract

The application discloses a preparation method of a running trolley for a semi-circular-arc girder shore-to-ship crane, which comprises the following steps: dividing the running trolley into a plurality of module assemblies; assembling and manufacturing the module assemblies by adopting a forward jacking mode; processing the wheel holes in the module assemblies by adopting a one-time scribing processing mode; and controlling the vertical line precision of the inner opening of the wheel main plate and the lifting sheave main plate after the module assemblies are assembled with the large-angle inclined suspension beam by adopting a detachable adjustable support mode. The application reduces the additional workload caused by the size deviation in high altitude, and reduces the construction difficulty and safety risk.

Description

Technical Field

[0001] This invention relates to the manufacturing technology of trolleys for port machinery, and more specifically, to a method for preparing a trolley for a semi-circular arc girder quay crane. Background Technology

[0002] The semi-circular arc beam quay crane is a new type of quay container crane designed to address the load-bearing capacity issues of inland river terminals. It utilizes the low drag coefficient and lightweight structure of its circular arc cross-section to reduce wheel pressure at the terminal. For example... Figure 1 As shown, since the main beam structure 4 on the semi-circular arc beam quay bridge has a semi-circular arc cross section, its running trolley structure is more compact than that of the conventional double box girder running trolley, and it is a large-angle inclined suspension beam 3. The self-driven motor 1 drives the wheels and the running track 2 to run upside down on the bottom surface of the arc beam of the main beam structure 4.

[0003] Container hoisting is achieved through a trolley. During operation, the trolley must withstand frequent, rapid, and high-load conditions, placing higher demands on the manufacturing precision of its structure. Because the trolley's suspension beam is a large-angle inclined structure, and the four sets of wheels connected to it are arranged horizontally in space, controlling the manufacturing and assembly of this narrow beam, as well as the coaxiality and parallelism of the wheel holes, within acceptable limits during manufacturing, assembly, and transportation is crucial. Therefore, a reasonable construction control method needs to be designed to meet the final operational functions of the arc-beam trolley. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a method for preparing a running trolley for a semi-circular arc girder quay bridge, thereby reducing the extra workload caused by dimensional deviations at high altitudes and lowering construction difficulty and safety risks.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for preparing a running trolley for a semi-circular arc girder quay crane;

[0007] The vehicle is divided into multiple modular components;

[0008] The modular components are assembled and manufactured using a forward lifting method;

[0009] Wheel holes are made on the corresponding module components using a one-time scribing process.

[0010] The vertical accuracy of the wheel main board and the lifting pulley main board is controlled by a detachable and adjustable support to control the verticality of the large-angle inclined suspension beam and the corresponding modular components.

[0011] Preferably, the operating vehicle is divided into multiple modular components, specifically including:

[0012] The operating trolley is divided into an upper structure, a middle structure, and a lower structure;

[0013] The upper structure and the lower structure are further divided into a trolley drive support, a lifting pulley beam assembly, and a land-sea side connecting beam assembly.

[0014] Preferably, the detachable adjustable support includes a horizontal support tube, an insert plate, and a positioning base plate;

[0015] The positioning base plate has two pieces, which are respectively welded to the lower opening of the web of the pulley beams on both sides of the upper structure;

[0016] The insert plate has two pieces, which are respectively inserted into the two ends of the horizontal support tube;

[0017] Each insert plate is connected to a waist-shaped pad, and the waist-shaped pad is connected to the corresponding positioning base plate through an adjustment pad.

[0018] Preferably, fan-shaped sealing plates are provided at both ends of the horizontal support tube;

[0019] The horizontal support tube is equipped with lifting lugs;

[0020] The insert plate is provided with a longitudinal reinforcing plate.

[0021] Preferably, after the main structure of the running trolley is formed, the positioning base plate is welded to the lower opening of the web of the pulley beams on both sides of the upper structure, and 4*M20 threaded through holes are drilled on the positioning base plate.

[0022] The horizontal support tube has slots at both ends to install the insert plate, and then it is welded to the waist-shaped pad to form an assembly.

[0023] The two ends of the horizontal support tube have a fan-shaped cross-section and are sealed by the fan-shaped gasket;

[0024] The horizontal support pipe is hoisted into the interior of the running trolley using the lifting lugs, and the waist-shaped pad is connected and fixed to the positioning base plate using M20 bolts;

[0025] The opening dimensions at both ends of the horizontal support tube are adjusted according to the opening of the upper structure, using adjusting shims of different thicknesses for positioning.

[0026] Preferably, a mobile boring machine is used to machine four sets of wheel holes on the corresponding module component in one operation.

[0027] The present invention provides a method for preparing a running trolley for a semi-circular arc girder quay crane, which has the following advantages:

[0028] Beneficial effects:

[0029] 1) A modular, small-component manufacturing method was adopted, dividing the entire trolley into three parts: upper structure, middle structure (tilted suspension beam), and lower structure. The upper structure is further divided into trolley drive support, lifting pulley beam assembly, and land-sea side connecting beam assembly according to product functional characteristics and convenience. Each component is manufactured separately and its dimensions are tested and controlled in advance to reduce the extra workload caused by dimensional deviations at high altitudes, thereby reducing construction difficulty and safety risks.

[0030] 2) The large-module forward lifting and assembly process is adopted to reduce the difficulty of assembling and assembling the large-angle inclined suspension beam and effectively control the accuracy error of the superstructure.

[0031] 3) An integral one-time scribing and boring process was designed, which uses a high-precision mobile boring machine to process four sets of wheel holes at one time, thereby ensuring that the coaxiality, parallelism, perpendicularity and other accuracy of the wheel holes meet the design requirements;

[0032] 4) Design corresponding detachable and adjustable support fixtures to control the vertical accuracy of the wheel main plate opening and the lifting pulley main plate after the large-angle suspension beam and the upper component are assembled. The fixtures can be reused to effectively solve problems such as component deformation and uncontrolled dimensional accuracy during manufacturing and transportation. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of a trolley running on a semi-circular arc beam quay bridge;

[0034] Figure 2 This is a schematic diagram illustrating the modular components of the trolley in the trolley preparation method of the present invention;

[0035] Figure 3 yes Figure 2 A schematic diagram of direction A in the middle;

[0036] Figure 4 This is a schematic diagram of the detachable and adjustable support in the method for preparing the trolley of the present invention;

[0037] Figure 5 This is a schematic diagram of the wheel mainboard and clamp in an embodiment of the method for preparing the trolley of the present invention. (a) is a front view of the upper structure, and (b) is a schematic diagram of the E1-E1 direction in (a).

[0038] Figure 6 These are schematic diagrams of wheel bearing seats in an embodiment of the method for preparing a trolley according to the present invention. (a) is a schematic diagram of the trolley wheel assembly bearing seat, (b) is a schematic diagram of the lower bearing seat, and (c) is a schematic diagram of the upper bearing seat.

[0039] Figure 7This is a schematic diagram of the lifting pulley beam in an embodiment of the method for preparing the trolley of the present invention. (a) is the main view, (b) is a schematic diagram of the AA direction in (a), and (c) is a schematic diagram of the b direction in (b).

[0040] Figure 8 This is a schematic diagram of the lower structure in an embodiment of the method for preparing the trolley of the present invention. (a) is the front view, (b) is an enlarged schematic diagram of part V in (a), (c) is the top view of (b), (d) is a schematic diagram of the weight in (b), and (e) is the top view of (d).

[0041] Figure 9 This is a schematic diagram of the assembly size control of the trolley in the embodiment of the trolley preparation method of the present invention. (a) is the front view and (b) is a schematic diagram of the CC direction in (a). Detailed Implementation

[0042] To better understand the above-mentioned technical solutions of the present invention, the technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0043] This invention provides a method for preparing a running trolley for a semi-circular arc girder quay crane:

[0044] The trolley is divided into three parts: upper structure 100, middle structure 200 (tilted suspension beam), and lower structure 300. Figure 2 As shown. Among them, the upper structure 100 and the lower structure 300 are further divided into the trolley drive support 400, the lifting pulley beam assembly 500, and the sea-land side connecting beam assembly 600 according to the product's functional characteristics and convenience. They are manufactured separately and through pre-expansion shrinkage, machining allowance, setting multiple welding sequences, opening process holes in narrow boxes, and pre-positioning and installing auxiliary pre-welded parts and checking and controlling the accuracy of dimensions, the trolley is finally assembled into shape using the same benchmark and an integrated forward assembly method. This can effectively reduce the extra workload caused by dimensional deviations at high altitudes, and reduce construction difficulty and safety risks.

[0045] Combination Figure 3 As shown, the detachable adjustable support includes a horizontal support tube 10, an insert plate 20, and a positioning base plate 30.

[0046] After the main structure of the trolley is formed, the positioning base plate 30 is welded to the lower opening of the web of the pulley beams on both sides of the upper structure 100, and 4*M20 threaded through holes are pre-drilled on the positioning base plate 30.

[0047] The intermediate structure 200 is connected by pipes, which is lighter and has higher bending resistance than I-beam structures. The horizontal support pipe 10 has slots at both ends to install the insert plate 20, and then welds it to the waist-shaped pad 40 to form a component.

[0048] The two ends of the horizontal support tube 10 adopt a fan-shaped cross section, which is aesthetically pleasing and reduces stress concentration. It is sealed by the fan-shaped gasket 50, which not only solves the problem that the inside of the horizontal support tube 10 cannot be painted and is prone to corrosion, but also makes the sealed cross section more reliable in terms of stability than the open cross section and less prone to instability and deformation.

[0049] The horizontal support pipe 10 is hoisted into the interior of the running trolley using the lifting lug 60, and the waist-shaped pad 40 is connected and fixed to the positioning base plate 30 using M20 bolts 70. The waist-shaped pad 40 is provided with elongated waist-shaped bolt holes to adjust for dimensional deviations in the height direction, facilitating quick positioning and installation onto the positioning base plate 30.

[0050] The opening dimensions at both ends of the horizontal support tube 10 are adjusted according to the opening of the upper structure using adjusting shims 80 of different thicknesses. The entire support can effectively control the opening dimensions of the upper structure and avoid deformation problems of the trolley during transportation and hoisting.

[0051] Example

[0052] This embodiment provides a method for preparing a running trolley for a semi-circular arc girder quay crane, specifically including:

[0053] I. Requirements for the creation of each module component:

[0054] 1. Requirements for the fabrication and processing of the trolley wheel drive support:

[0055] (1) When cutting the wheel main plate 24 in the upper structure of the trolley, the inner hole needs to be (φB5+14)mm, the wheel clamp 25 should have a 25mm allowance in the thickness direction, the outer diameter should be (φB5+20)mm, and the inner diameter should be (φB3-30)mm. The allowance will not be processed for the time being. Figure 5 As shown;

[0056] (2) When cutting the upper and lower bearing housings, allowances are left for machining the external dimensions to meet the blueprint requirements. Allowances are left for the internal holes and machining is not performed initially. The upper and lower bearing housings are fitted together, and the φD1 through hole in the upper bearing housing and the 2-M(D2) threaded hole in the lower bearing housing are drilled. Then, they are connected with process bolts. The bearing housing connecting assembly is fixed to the adjusting shim and sent to the machine shop for machining of the 4-A*B oblong holes (see...). Figure 6 (As shown), after completion, install it onto the upper structure of the trolley according to the drawing requirements;

[0057] (3) Machining the inner diameter allowance of the wheel main plate 24, machining the inner diameter to (φB5+24)mm, to facilitate the subsequent installation of the wheel clamp 25, and then machining the slope and bevel according to the drawing requirements.

[0058] (4) When marking the trolley frame, weld the wheel clamp 25 to the trolley frame. During the welding process, pay attention to ensure its verticality requirements. After assembling the wheel, weld the bearing seat assembly I to the trolley frame as required, and then install the bearing seat assembly I to the trolley frame using process bolts.

[0059] (5) After the clamp welding is completed and passes the flaw detection, according to... Figure 5 In (a), trim and grind the excess material as needed, leaving a 10-15mm allowance at the root of the trimmed area. Simultaneously, trim and grind the grooves of the wheel main plate 24 and wheel clamp 25, leaving a 5mm machining allowance on each side of the groove to be machined together with the wheel hole during overall machining (see...). Figure 5 (As shown).

[0060] 2. Requirements for the fabrication and processing of lifting pulley beams:

[0061] (1) When cutting the pulley main plate 31 in the trolley frame, the inner hole and plate thickness have machining allowances and are not machined for the time being. The pulley main plate 31, stiffening plates 32 and 33 are made into lifting pulley support assembly I, the inner pulley support beams 34, 35, 36, and 37 are made into lifting pulley beam assembly II, and the outer pulley support beams 34, 36, 38, and 39 are made into lifting pulley beam assembly III. The lifting pulley beam assemblies I to III and the wheel main plate are assembled into lifting pulley beam according to the dimensions in the drawing (see drawing). Figure 7 (as shown);

[0062] (2) When marking the trolley frame, weld the lifting pulley beam assembly I to the trolley frame according to the drawing requirements. Pay attention to ensuring the alignment requirements and ensure its verticality during the welding process.

[0063] (3) When the trolley frame is scribing for the second time, scribing out the machining line of the φD1 shaft hole, the inspection line and the cross center line of the 4-M(D2) thread hole on the pulley main board 1, and scribing out the plane machining area of ​​the pulley main board 1 according to the blueprint requirements.

[0064] (4) Boring the φD1 shaft hole, drilling the M(D2) threaded hole, machining the D3 notch, paying attention to the smooth transition of the arc at Q, and machining the pulley main plate 1 plane so that its opening size meets the drawing requirements.

[0065] 3. Requirements for the fabrication and processing of the lower structure:

[0066] (1) The lower structural beams are prefabricated into box-shaped structures according to the drawings. The straightness and twist of the beams are checked to be less than 3mm. A 50mm allowance is left at both ends for trimming and straightening during assembly.

[0067] (2) To facilitate the welding of the internal partition and the bottom plate of the beam, process holes need to be opened on the inner web of the sea-land side beam (3 to 4 holes / unit); after the internal partition is welded and inspected and qualified, the holes are sealed with the original cutting sealing plate. The sealing plate weld is a single-sided bevel backing weld. After welding, it is ground flat and smooth, and 100% UT+100% MT test is performed.

[0068] (3) After the cab hanger is made, mark the cross lines of the cab hanger holes and cut the holes on the rectangular tube 46 to the requirements of the drawing. The cut-off areas need to be polished smooth.

[0069] (4) Process φd2 of the weight 47 according to the drawing requirements, and process a sink trough with a depth of A and a diameter of φd1;

[0070] (5) Mark the installation position line of the weight 47 according to the dimensions in the drawing, weld it onto the rectangular tube 46, and mark and drill the bolt hole 4-φd3. Note that the allowable deviation of the misalignment between the weight 47 and the hole on the rectangular tube 46 should be within 3-5mm (see drawing). Figure 8 (As shown).

[0071] II. Requirements for integrated assembly and marking of each module:

[0072] 1. Assemble the running trolley:

[0073] (1) Place the lower structure on the frame and adjust its level to ensure that the level is within 2mm. Draw the installation position lines of the four sets of middle structures (inclined suspension beams) based on the left and right opening dimensions L1 and the sea and land opening dimensions L2.

[0074] (2) Arrange the pre-designed and manufactured modular construction platform at the corresponding work station to facilitate subsequent measurement, adjustment and welding of the middle and upper structures;

[0075] (3) Using the workshop crane, the prefabricated middle structure (inclined suspension beam) is hoisted to the upper plane of the lower structure, its opening and vertical line are adjusted, and a laser measuring instrument is set up to measure the horizontal level of the upper end of the four middle structures. The height of the suspension beam is corrected to ensure that H1 = H2. After the dimensions are qualified, the lower end is welded to the lower structure for fixation.

[0076] (4) Assemble the superstructure and inclined suspension beam according to the drawings. Using the horizontal reference point of the main wheel plate of the superstructure as a reference, adjust the height and opening size of the superstructure and suspension beam. After adjustment, perform tack welding, paying attention to pre-allowing a welding shrinkage allowance of 6-8mm. The difference between H1 and H2 should be ≤3mm, the upper opening of L1 should be 4-8mm smaller than the lower opening, the diagonal should be controlled within ±5mm, and |L5-L6| should be within 5 (see...). Figure 9 (as shown);

[0077] (5) After the pre-assembly dimensions are inspected and approved, install detachable adjustable supports and anti-overturning process supports to fix the openings of the left and right upper structures and prevent the upper structure from overturning. Assemble and weld the entire trolley frame to ensure that the relevant dimensions of the wheel support plate meet the requirements after welding. If they do not meet the requirements, they need to be adjusted according to the actual situation on site to ensure the dimensional requirements.

[0078] 2. Marking and machining of the running trolley:

[0079] (1) The main welding work needs to be completed for the overall trolley structure.

[0080] a. All the Kama fixtures at the contact points between the trolley structure and the tire frame must be removed, leaving the entire structure in a completely free and unattended state;

[0081] b. Adjust the entire trolley to a horizontal position, maintaining rigid contact with the tire frame; do not use sleepers as padding.

[0082] c. Inspect and remove any components around the trolley that may obstruct the marking process;

[0083] d. The time for marking lines should be controlled during periods of small temperature differences to avoid the impact of severe weather such as sunshine, rain, and high humidity.

[0084] (2) Set up the laser theodolite in the middle of the trolley frame, and make sure it is higher than the upper plane of the trolley frame. Adjust the laser level and use the root of the intersection of the four wheel support plates and the center of the main beam as the reference to remeasure the level of the entire trolley frame. Measure and adjust the level to the best state to ensure that the reference points are on the same horizontal plane.

[0085] (3) Draw the center line, diagonal line and wheel height center line of the trolley with the horizontal point as the reference. Divide the thickness of the four sets of wheel support plates into the center. With the center line point of the thickness direction of the trolley wheel support plate as the reference, use a calibrated tape measure and laser theodolite to measure the track gauge, wheel width and diagonal dimensions of the trolley frame wheel and mark the sample punch.

[0086] (4) Using the punch point as a reference, mark the machining and inspection lines for the inner hole, groove, and inner countersunk groove of the wheel clamp 25, as well as the center line and machining allowance line for the lifting pulley shaft hole and the wheel bearing housing assembly hole. The bearing housing assembly needs to be removed separately and sent to the machining workshop to machine the shaft hole and inner ring groove, and then installed in place when the trolley mechanism is assembled.

[0087] (5) The machining inspection line with the scraped surface dimension should be led to a place outside the scraped surface to facilitate re-measurement and verification of whether the machining dimension is qualified after boring;

[0088] (6) Transfer the entire trolley structure to the machining workshop, and process the wheel clamps, lifting pulley holes and scrape the flat surface, groove and slot according to the machining lines marked above; the wheel clamps with a 10-15mm allowance for flaw detection are also processed in place.

[0089] Those skilled in the art should recognize that the above embodiments are merely illustrative of the present invention and are not intended to limit the present invention. Any variations or modifications to the above embodiments that are within the spirit and essence of the present invention will fall within the scope of the claims of the present invention.

Claims

1. A method for preparing a running trolley for a semi-circular arc girder quay crane, characterized in that: The trolley is divided into multiple modular components, specifically including: the trolley is divided into an upper structure, a middle structure, and a lower structure; the middle structure is an inclined suspension beam; wherein, the upper structure and the lower structure are further divided into trolley drive support, lifting pulley beam assembly, and land-sea side connecting beam assembly, which are manufactured separately and controlled by pre-expansion shrinkage, machining allowance, setting multiple welding sequences, opening process holes in narrow boxes, and pre-positioning and installing auxiliary pre-welded parts and checking and controlling the dimensional accuracy. The modular components are assembled using a forward lifting method. The lower structure is placed on the jig and its level is adjusted to be within 2mm. The installation position lines of the four sets of middle structures are marked with the left and right opening dimensions L1 and the sea and land side opening dimensions L2 as references. The prefabricated middle structures are hoisted onto the upper plane of the lower structure, and their opening and plumb lines are adjusted. A laser measuring instrument is set up to measure the level of the upper end of the four sets of middle structures. The height of the suspension beam is corrected to ensure that H1=H2. The lower opening of the middle structure is welded and fixed to the lower structure. The upper structure is assembled with the inclined suspension beam. The height and opening dimensions of the upper structure and the suspension beam are adjusted with the horizontal reference point of the main wheel main board position of the upper structure as a reference. A welding shrinkage allowance of 6~8mm is pre-added. After adjustment, the positioning welding is performed. Wheel holes are drilled on the corresponding module components using a one-time scribing process. After the trolley completes the main welding work, it is placed in a completely free resting state, and the entire trolley is adjusted to a horizontal position, maintaining rigid contact with the jig. The scribing time is controlled during periods of low temperature difference. The horizontal position of the entire trolley is re-measured using the root of the intersection point of the four wheel support plates and the center of the main beam as a reference, ensuring that the reference points are on the same horizontal plane. Four sets of wheel holes are machined on the corresponding module components in one go using a moving boring machine. The vertical accuracy of the wheel main board and the lifting pulley main board is controlled by the detachable and adjustable support to control the verticality of the large-angle inclined suspension beam and the corresponding modular components. The detachable adjustable support includes a horizontal support tube, insert plates, and positioning base plates; there are two positioning base plates, which are respectively welded to the lower opening of the web of the pulley beams on both sides of the upper structure; there are two insert plates, which are respectively inserted into the two ends of the horizontal support tube; each insert plate is connected to a waist-shaped pad, and the waist-shaped pad is connected to the corresponding positioning base plate through an adjustment pad.

2. The method for preparing a running trolley for a semi-circular arc girder quay crane according to claim 1, characterized in that: The horizontal support tube is provided with fan-shaped sealing plates at both ends; The horizontal support tube is equipped with lifting lugs; The insert plate is provided with a longitudinal reinforcing plate.

3. The method for preparing the running trolley for a semi-circular arc girder quay crane according to claim 2, characterized in that: After the main structure of the running trolley is formed, the positioning base plate is welded to the lower opening of the web of the pulley beams on both sides of the upper structure, and 4*M20 threaded through holes are drilled on the positioning base plate. The horizontal support tube has slots at both ends to install the insert plate, and then it is welded to the waist-shaped pad to form an assembly. The two ends of the horizontal support tube have a fan-shaped cross-section and are sealed by the fan-shaped sealing plate; The horizontal support pipe is hoisted into the interior of the running trolley using the lifting lugs, and the waist-shaped pad is connected and fixed to the positioning base plate using M20 bolts; The opening dimensions at both ends of the horizontal support tube are adjusted according to the opening of the upper structure, using adjusting shims of different thicknesses for positioning.

Images