Method for off-site assembly of wide-body nacelle sections

Abstract

This invention relates to the field of shipbuilding technology and discloses a method for off-site assembly of a full-width engine room section. The off-site assembly mechanism includes a large portal frame and an engine room section. The engine room section includes a second segment hoisted and resting on the portal frame, and a first segment assembled with the second segment. Supports are provided on the portal frame at the suspended portion of the engine room section. Supports are provided at the ribs of the engine room section and the resting points of the portal frame. A first I-beam and a second I-beam are respectively installed at both ends of the portal frame. This method for off-site assembly of a full-width engine room section solves the problem that the engine room section is the most complex part of the hull structure, is a super-large component requiring off-site transportation, and its irregular shape poses a significant risk of deformation during assembly and transportation, making it generally unsuitable for off-site assembly and increasing the difficulty of shipbuilding.

Description

Technical Field

[0001] The invention relates to the field of shipbuilding technology, specifically a method for off-site assembly of a full-width engine room section. Background Technology

[0002] Under the current shipbuilding model, whether it is the renovation of an old shipyard or the planning of a new shipyard, the emphasis is on expanding the assembly area around the dock (or slipway) and using large lifting equipment to weld several sections into a whole section, which is then hoisted and assembled in one go. The number of sections hoisted and the degree of integrity of a ship's assembly reflect the shipyard's technological level and production capacity.

[0003] However, assembly space is limited. With the diversification of ship types and the acceleration of production pace, the lack of assembly space restricts the improvement of dock turnover rate. In order to shorten the dock cycle, the method of assembling the sections in other areas covered by medium-sized cranes in other locations, and then transporting them as a whole to the assembly site for hoisting into the dock can effectively solve the problem of insufficient assembly space, thereby achieving the goal of making full use of the dock's assembly capacity.

[0004] However, the engine room section is the most complex part of the hull structure. Taking the three-deck full-beam section of a 180,000-ton dual-fuel bulk carrier as an example, its main dimensions (length × width × height) are 28.9 × 40.3 × 4.6 (m) and its weight is 622 tons. It is an ultra-large item that needs to be transported to a different location. Its full-beam engine room section has an irregular shape, and there is a great risk of deformation during assembly and transportation. It is usually not suitable for assembly in a different location, which increases the difficulty of ship construction. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a method for off-site assembly of full-width cabin sections, which solves the problems mentioned in the background above.

[0006] The invention provides the following technical solution: a method for off-site assembly of a full-width engine compartment section, wherein the off-site assembly mechanism includes: a large gate frame and an engine compartment section;

[0007] The nacelle assembly includes a second section hoisted and placed on the main gate, and a first section that is assembled and mounted together with the second section.

[0008] The main gate is equipped with a support, which is located at the suspended part of the engine compartment section. The engine compartment section ribs and the support points of the main gate are equipped with piers. The two ends of the main gate are respectively equipped with a first I-beam and a second I-beam. A flatbed cart travels on the bottom of the main gate. The bottom of the engine compartment section is welded with channel steel.

[0009] The steps for remote group formation include:

[0010] S1 uses steel to be welded and assembled in a different location to form a large gate frame as the main assembly tooling structure;

[0011] S2, the gate frame is arranged in a different location according to the dimensions of the engine compartment sections, and supports are installed on the gate frame according to the lifting position of the engine compartment sections to support the lower end face of the sections, thus completing the section lifting;

[0012] S3, by setting channel steel to weld the lower end face of the engine room section to the large gate frame, and at the same time, a support is set at the bottom of the suspended part of the engine room section deck;

[0013] S4. The first and second sections fixed on the gantry are mounted and assembled into the main engine compartment section using a flatbed truck. Then, the first and second I-beams are installed on the gantry to fix the position of the gantry after the arrangement.

[0014] S5 uses a flatbed truck to lift the assembled engine compartment section and transport it from a remote site to the final assembly site for final assembly.

[0015] Preferably, eight gantry frames are installed in the main assembly area, and the eight gantry frames are arranged symmetrically about the centerline of the engine room deck and divided into four groups, which are respectively placed at the bottom of the first section and the second section.

[0016] Preferably, the first I-beams installed on the two gate frames with their symmetrical ends attached are connected as one unit, and the first I-beam and the second I-beam rigidly fix the gate frames that are in contact along the longitudinal path.

[0017] Preferably, the gate frame includes a frame body and legs. The frame body is a frame-shaped platform structure welded from steel, and the legs are integrally set at both ends of the frame body.

[0018] Preferably, the channel steel is connected to the engine room section and the main gate frame by a sealing welding process.

[0019] Preferably, in S3, the segment positioning strictly follows the rib reference line in the segment to determine the allowance value. For each segment large joint, the rib spacing is increased by 5 to 8m for welding compensation, and the rib spacing of the large joint is controlled within ±15m.

[0020] Preferably, in S3, the joint between the first segment and the second segment is located in a straight section with a small curvature of the cabin segment, and the joint between the first segment and the second segment is set within the same rib spacing.

[0021] Preferably, in S4, the engine room section is divided into sections based on the hull, increasing the total number of sections, with the main deck, anchorage, and bulwark all completed in the section stage.

[0022] Preferably, in S4, the butt joint of the outer plates of the first and second sections of the cabin should first be welded with a transverse weld along the width of the cabin, and then with a longitudinal weld.

[0023] Preferably, in S5, the gantry is welded to the bottom of the engine compartment by a frame formed by the combination of supports, piers and channel steel, and then lifted by a flatbed truck from the bottom of the gantry for land transportation.

[0024] Compared with existing technologies, the invention has the following beneficial effects:

[0025] 1. This method of off-site assembly of the full-width engine room section utilizes supports, piers, and a large frame to form a jig, adaptably setting the large frame to support the engine room sections and smoothly assembling them into the main section. Subsequently, first and second I-beams are used to combine the jig formed by the large frame with the engine room section into a rigid whole, enabling stable transportation of the engine room section and preventing deformation of irregular parts during assembly and transportation. This allows for high-quality and efficient construction and assembly of the main section, thereby reducing the difficulty of shipbuilding.

[0026] 2. This method for off-site assembly of the full-width engine compartment section involves fabricating eight separate large gantry frames using simple materials at an off-site location based on the engine compartment section data. These eight gantry frames are then adjusted according to the hoisting positions of the engine compartment sections, assisting in fine-tuning the assembly of the engine compartment sections. Finally, the gantry frames, which are integrated into a single engine compartment section jig, can be transported together using a flatbed truck. This method completes the off-site assembly of the engine compartment section without the need for other complex auxiliary mechanisms, effectively reducing material input and site occupation, and enabling multi-purpose application of tooling. Attached Figure Description

[0027] Figure 1 A schematic diagram of the overall structure of the engine room assembly;

[0028] Figure 2 A schematic diagram of the typical rib structure of the invention from the front view;

[0029] Figure 3 A schematic diagram illustrating the placement and arrangement of the main gate frame;

[0030] Figure 4 A schematic diagram of a rigid fixing structure for a large gate frame;

[0031] Figure 5 A schematic diagram of the gate frame structure for the invention.

[0032] In the diagram: 100, main gate frame; 101, frame body; 102, support leg; 200, engine compartment section; 201, first section; 202, second section; 300, support; 400, pier; 500, channel steel; 600, first I-beam; 700, second I-beam; 800, flatbed truck. Detailed Implementation

[0033] The technical solutions of the embodiments of the invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the invention, and not all embodiments. Based on the embodiments of the invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the invention.

[0034] Please see Figure 1-5 A method for off-site assembly of a full-width engine compartment assembly section, wherein the off-site assembly mechanism includes: a large gate frame 100 and an engine compartment assembly section 200;

[0035] The nacelle assembly 200 includes a second section 202 that is hoisted and placed on the gantry frame 100, and a first section 201 that is assembled and mounted together with the second section 202.

[0036] A support 300 is installed on the main gate 100. The support 300 is located at the suspended part of the engine compartment section 200. A support 400 is installed at the rib of the engine compartment section 200 and the resting place of the main gate 100. A first I-beam 600 and a second I-beam 700 are installed at both ends of the main gate 100 respectively. A flatbed 800 travels on the bottom of the main gate 100. A channel steel 500 is welded to the bottom of the engine compartment section 200.

[0037] The steps for remote group formation include:

[0038] S1, using steel to weld and assemble a large gate frame 100 at an off-site location as the overall assembly tooling structure;

[0039] S2, Arrange the gantry frame 100 in the off-site area according to the dimensions of the engine compartment sections, and install supports 400 on the gantry frame 100 according to the lifting position of the engine compartment sections to support the lower end face of the sections, thus completing the section lifting.

[0040] S3, by setting channel steel 500, the lower end face of the engine room section is welded to the large gate frame 100, and at the same time, a support 300 is set at the bottom of the suspended part of the engine room section deck.

[0041] S4, using a flatbed truck 800 to load and assemble the first section 201 and the second section 202 fixed on the main gate frame 100 into the main engine compartment section 200, and then installing the first I-beam 600 and the second I-beam 700 on the main gate frame 100 to fix the position of the arranged main gate frame 100.

[0042] S5 uses a flatbed truck 800 to lift the assembled engine compartment section 200 and transport it from a remote site to the assembly site for final assembly.

[0043] Among them, eight large gate frames 100 are set in the assembly site, and the eight large gate frames 100 are arranged symmetrically with the centerline of the deck of the engine room section 200 as the axis, divided into four groups and placed at the bottom of the first section 201 and the second section 202 respectively. The large gate frames 100 are set as eight segmented brackets as tooling structures. During the hoisting of the first section 201 and the second section 202, they can be adjusted in time according to the hoisting situation. During the assembly of the first section 201 and the second section 202, the assembly position can be adjusted to achieve the purpose of multi-purpose application.

[0044] Among them, the first I-beams 600 installed on the two large gate frames 100 with their symmetrical ends are connected as one unit, and the first I-beams 600 and the second I-beams 700 rigidly fix the gate frames 100 that are in contact along the longitudinal path. After the first section 201 and the second section 202 are assembled, the eight large gate frames 100 located below the engine compartment section 200 can be connected into an integral frame by the installation of the first I-beams 600 and the second I-beams 700. This frame is used to rigidly fix the irregular parts of the engine compartment section 200, improve the stability of the engine compartment section 200 when assembled in different locations, and reduce the risk of deformation during subsequent transportation.

[0045] The gate frame 100 includes a frame body 101 and supports 102. The frame body 101 is a frame-like platform structure welded from steel. The supports 102 are integrally set at both ends of the frame body 101. The gate frame 100 as a whole is formed by welding steel from an off-site site to form a prototype frame. With its simple processing procedures and size, it can perform a variety of auxiliary functions, effectively reducing material input and site occupation.

[0046] Among them, the channel steel 500 is connected to the engine room section 200 and the main gate frame 100 by a sealing welding process. The sealing welding process can improve the stability of the connection between the engine room section 200 and the main gate frame 100. Compared with bolt installation, it can effectively avoid the loosening of the structure during the construction period and improve the strength and durability of the engine room section 200 structure.

[0047] In S3, the segment positioning strictly follows the rib reference line in the segment to determine the allowance value. For each segment's large joint, the rib spacing is increased by 5-8m for welding compensation. At the same time, the rib spacing of the large joint is controlled within ±15m. In order to ensure that the shape and size of the components, segments and cabins after assembly and welding meet the allowable error requirements, some edges of the parts are not cut according to the theoretical size during material cutting. Instead, an additional amount is added beyond the theoretical value to keep the welding shrinkage during the assembly stage within the control range. Finally, the excess is removed.

[0048] In S3, the joint of the first segment 201 and the second segment 202 is located in the straight part of the cabin segment with small curvature, and the joint of the first segment 201 and the second segment 202 is set within the same rib spacing. Using the straight part as the joint is conducive to maximizing the use of semi-automatic or automatic welding process, making welding more convenient. At the same time, setting the joint within the same rib spacing can control welding deformation to a certain extent, which is beneficial to the joint operation.

[0049] In S4, the engine room section 200 is divided into sections based on the hull, expanding the total number of sections. The main deck, anchorage, and bulwark are all completed in the section stage. Before the engine room section 200 is assembled, some necessary structures can be assembled and processed in advance to achieve the effect of simultaneous construction in multiple different sites, which can save a lot of re-assembly time during the subsequent assembly and shorten the construction cycle.

[0050] In S4, the butt joint of the outer panels of the first section 201 and the second section 202 of the cabin should first be welded with a transverse weld along the width of the cabin, followed by a longitudinal weld. When welding the joint of the first section 201 and the second section 202, a transverse weld along the width of the cabin should be welded first to initially constrain the first section 201 and the second section 202. After the first section 201 and the second section 202 are joined by the transverse weld, the longitudinal welds at the staggered details left by the joint should be welded step by step to facilitate operation and control welding deformation.

[0051] In S5, the gantry 100 is welded to the bottom of the engine compartment section 200 by a jig formed by the combination of the support 300, the pier 400 and the channel steel 500. The jig is then lifted by the flatbed truck 800 from the bottom of the gantry 100 for land transportation. According to the condition of the engine compartment section 200, the jig is formed by the combination of the support 300, the pier 400 and the gantry 100. The gantry 100 is adapted to support the engine compartment sections and allows the engine compartment sections to be smoothly assembled into the section. The jig formed by the gantry 100 and the engine compartment section 200 are combined by the first I-beam 600 and the second I-beam 700 to form a rigid whole, so that the engine compartment section 200 can be transported stably.

[0052] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method of assembling full width nacelle sections offsite, the offsite assembly facility comprising: The door frame (100) and the cabin section (200); The cabin section (200) comprises a second section (202) hoisted and rested on the door frame (100), and a first section (201) integrally combined with the second section (202); The door frame (100) is provided with a support (300) at the overhanging part of the cabin section (200), and a support pier (400) is arranged at the resting part of the door frame (100) and the cabin section (200), two first I-beams (600) and two second I-beams (700) are respectively arranged at the two ends of the door frame (100), and a flat car (800) runs at the bottom of the door frame (100), and a channel steel (500) is welded at the bottom of the cabin section (200). The steps of the remote assembly include: S1, using steel to weld the door frame (100) in the remote site as the assembly tool structure; S2, arranging the door frame (100) according to the size of the cabin section in the remote site, and installing the support pier (400) on the door frame (100) according to the hoisting position of the cabin section to rest the lower end face of the section, and completing the hoisting of the section; S3, welding the lower end face of the cabin section on the door frame (100) by arranging the channel steel (500), and arranging the support (300) at the bottom of the overhanging part of the cabin section deck; S4, using the flat car (800) to load and assemble the first section (201) and the second section (202) fixed on the door frame (100) into the cabin section (200), and then installing the first I-beam (600) and the second I-beam (700) on the door frame (100) to fix the position of the arranged door frame (100); S5, using the flat car (800) to lift the combined cabin section (200) and transport it from the remote site to the assembly site for assembly; The first I-beams (600) installed on the two door frames (100) of the symmetrical end part are connected as a whole, and the first I-beam (600) and the second I-beam (700) rigidly connect the door frame (100) contacted along the longitudinal path, after the assembly of the first section (201) and the second section (202) is completed, the eight door frames (100) below the cabin section (200) can be connected as a whole jig frame by the installation of the first I-beam (600) and the second I-beam (700) to rigidly fix the irregular part of the cabin section (200).

2. The method of assembling a full-width nacelle section offsite according to claim 1, wherein, The eight door frames (100) are arranged symmetrically around the centerline of the deck of the cabin section (200) and are divided into four groups and placed at the bottom of the first section (201) and the second section (202).

3. The method of assembling a full-width nacelle section offsite according to claim 1, wherein, The door frame (100) comprises a frame body (101) and a support leg (102), the frame body (101) is a frame-shaped table structure welded by steel, and the support leg (102) is integrally arranged at the two ends of the frame body (101).

4. The method of assembling a full-width nacelle section offsite according to claim 1, wherein, The channel steel (500) is connected with the cabin section (200) and the large gantry (100) by sealing welding process.

5. The method of assembling a full-width nacelle section offsite, according to claim 1, wherein, In S3, the segment positioning is strictly based on the rib position reference line in the segment, and the rib distance of each segment joint is added by 5-8 m for welding compensation, while the rib distance of the large joint is controlled within ±15 m.

6. The method of assembling a full-width nacelle section offsite, according to claim 1, wherein, In S3, the joint position of the first segment (201) and the second segment (202) is at the flat position where the cabin segment curvature is small, and the joint of the first segment (201) and the second segment (202) is arranged in the same rib spacing.

7. The method of assembling a full-width nacelle section offsite, according to claim 1, wherein, In the S4, the cabin section (200) is divided into segments based on the hull, the number of sections is expanded, and the main deck, anchor hole and bulwark are completed in the section stage.

8. The method of assembling a full-width nacelle section offsite, according to claim 1, wherein, In the S4, the butt joint of the first segment (201) and the second segment (202) of the cabin section plate should first weld the transverse weld along the cabin width, and then weld the longitudinal weld.

9. The method of assembling a full-width nacelle section offsite, according to claim 1, wherein, In the S5, the large gantry (100) is welded and supported on the bottom of the cabin section (200) by the combined support (300), support pier (400) and channel steel (500) form a jig, and then lifted and supported by the flat car (800) through the bottom of the large gantry (100) for land transportation.

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