Method for pouring epoxy resin gasket between main beam flange and shoulder beam of travelling crane

Abstract

The invention relates to the field of crane girder installation, and discloses a crane girder flange and shoulder beam epoxy resin gasket pouring method which comprises the following steps: pouring preparation: coating engine oil in an epoxy resin contact area as a separating agent; the main beam jig frame positions and supports the main beam, and the shoulder beam jig frame positions and supports the shoulder beam; reamed bolt mounting holes of the flange are reamed; the peripheries of a main beam flange and a shoulder beam top plate are surrounded by thin flat iron coated with a separating agent in advance; except for the exhaust hole of the flat iron fence, the other free edges are sealed by sealant; a rubber tube coated with a separating agent needs to be inserted into a flange reamed bolt mounting hole; stirring the epoxy resin uniformly and then adding a proper amount of curing agent; the epoxy resin is poured into the pouring holes until the pouring material in the peripheral exhaust holes emerges and is higher than the bottom surface of the flange, and air in the original space is exhausted from the exhaust holes. The shape and the thickness of the gasket are accurately controlled, so that loads are uniformly transmitted, local stress concentration is reduced, the reliability and the durability of a connecting part are improved, and the service life of a travelling crane is prolonged.

Description

Technical Field

[0001] The invention relates to the field of crane main beam installation, in particular to a method for casting a crane main beam flange and a shoulder beam epoxy resin gasket. Background Art

[0002] The connection between the main beam flange and the shoulder beam is a crucial structural element in crane equipment. Traditional machined flange surfaces or the use of ordinary metal gaskets make it difficult to precisely adjust the gap and levelness between the main beam and shoulder beam. Furthermore, vibration, impact, and other factors can easily cause the connection to loosen during long-term operation, impacting the stability and safety of the crane.

[0003] The contact area of ​​machined surfaces or metal gaskets can only reach about 70%, and they need to be disassembled and then put together, which will inevitably lead to dimensional problems. They also need to be ground, which will reduce efficiency and fail to improve accuracy.

[0004] Document CN 115613478 A discloses a cantilever casting method for a continuous beam, comprising the following steps: S1. Installing a cantilever casting machine, the cantilever casting machine comprising a support frame system, a travel system provided below the support frame system, a suspension mechanism provided at the front end, and a bottom load-bearing mechanism connected at the lower end of the suspension mechanism; S2. The cantilever casting machine travels to the construction front end, hoisting a prefabricated steel cage above the bottom formwork and between the outer formworks, assembling the inner formwork, and pouring concrete; S3. After the concrete solidifies and reaches a certain strength, the bottom formwork, the outer formwork, and the inner formwork are separated from the poured continuous beam segment, and the outer formwork and the bottom formwork follow the cantilever casting machine to the construction front end of the next pouring segment, adjusting the outer formwork and the bottom formwork, and then hoisting the prefabricated steel cage above the bottom formwork and between the outer formworks, moving the inner formwork to the matching channel position in the middle of the steel cage, and pouring concrete after the formwork device is installed; and repeating step S3 until the continuous beam casting is completed. This method requires the template to be disassembled and then put back together, which cannot be achieved by one-time molding and has low precision.

[0005] Therefore, a new technical solution is needed to solve the above technical problems. Summary of the Invention

[0006] In order to solve the above problems, the present invention discloses a method for casting epoxy resin gaskets between the main beam flange and the shoulder beam of a crane, which accurately controls the shape and thickness of the gasket so that the contact surface between the main beam flange and the shoulder beam top plate can fit better, thereby evenly transferring the load, reducing local stress concentration, improving the reliability and durability of the connection parts, and extending the service life of the crane.

[0007] The technical solution of the present invention is: a method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam, comprising the following steps: Step 1: Prepare for pouring. Clean the bottom of the main beam flange and the shoulder beam top plate where epoxy resin will be poured to ensure that there are no impurities on the surface. Apply engine oil as a separating agent to the contact area between the bottom of the main beam flange and the shoulder beam top plate and the epoxy resin. Step 2: Position the main beam frame to support the main beam, adjust the straightness and camber of the main beam, and adjust the straightness and levelness of the trolley track; Step 3: Position and support the shoulder beam with the shoulder beam frame, adjust the straightness and levelness of the traveling wheels, adjust the wheelbase, and adjust the gap between the main beam flange and the shoulder beam; Step 4: Ream the flange bolt mounting holes; Step 5: Use thin flat iron enclosures coated with a separator in advance around the main beam flange and the shoulder beam top plate. Leave a 1-3mm gap between the top of the flat iron enclosure and the main beam flange as a vent during pouring; Step 6: Except for the vent holes on the flat iron enclosure, seal all other free edges with sealant; Step 7: Insert the rubber tube coated with a release agent into the flange hinge bolt mounting hole; Step 8: Stir the epoxy resin until it is uniform, then add an appropriate amount of curing agent and continue stirring; Step 9: Immediately pour the evenly mixed epoxy resin into the casting hole until the casting material in the surrounding vent holes comes out above the bottom surface of the flange and the air in the original space is discharged from the vent holes.

[0008] Preferably, the bottom surface of the main beam flange and the top plate of the shoulder beam in step 1 are coated with 48-72um epoxy primer to protect the contact area between the bottom surface of the main beam flange and the top plate of the shoulder beam and the epoxy resin.

[0009] By adopting the above technical solution, the bottom of the main beam flange and the contact area between the shoulder beam top plate and the epoxy resin are protected from rust while waiting for pouring.

[0010] Preferably, in steps 2 and 3, the main beam and shoulder beam are supported separately, and the epoxy resin is always under no pressure during the entire pouring process.

[0011] Preferably, all data checks in step 3 are qualified, the gap between the main beam flange and the shoulder beam top plate is controlled at 10-20 mm, the main beam and the shoulder beam no longer undergo any displacement during the entire casting process, and the traveling wheels of the crane are located at the bottom of the shoulder beam.

[0012] By adopting the above technical solution, the camber is calculated according to the working load of the crane. The camber of cranes of different specifications is different. The remaining levelness and straightness are checked according to the ISO 12488-1 crane wheel and trolley and car track tolerance standard.

[0013] Preferably, the flange hinge bolt mounting hole in step 4 is located at the mounting hole of the hinge bolt on the shoulder beam top plate, which is used to connect the main beam flange and the epoxy resin gasket.

[0014] Preferably, in step 5, the flat iron enclosure is connected to the structural plate by electric welding, and the enclosure flat iron needs to be 15-25 mm higher than the bottom surface of the main beam flange.

[0015] By adopting the above technical solution, the enclosure flat iron needs to be higher than the bottom surface of the main beam flange, which can effectively prevent the epoxy resin from flowing away during the pouring process.

[0016] Preferably, the exhaust hole in step 6 is the gap at the top of the flat iron enclosure.

[0017] By adopting the above technical solution, the resin is prevented from flowing out during the pouring process.

[0018] Preferably, in step 7, the rubber tube must pass through the flange hinged bolt mounting holes of the upper and lower epoxy resin main beam flanges and the shoulder beam top plate.

[0019] By adopting the above technical solution, it is possible to effectively prevent epoxy resin from blocking the bolt hole. Preferably, in step 8, a low-speed electric drill is connected to a stirring rod as power. Stirring begins after the head of the stirring rod is completely immersed in the epoxy resin. The epoxy resin must be stirred completely and evenly before adding the curing agent. The stirring time after adding the curing agent cannot be more than 5 minutes to avoid premature solidification of the epoxy resin during the pouring process due to excessive stirring time.

[0020] Preferably, the pouring hole in step 9 is located in the middle of the main beam flange, and the epoxy resin should be kept above 25° C. for more than 10 hours after pouring.

[0021] By adopting the above technical solution, epoxy resin is poured in from the pouring hole, and the air in the original space is discharged from the exhaust hole.

[0022] The benefits of the present invention are as follows: 1. The present invention can cast the epoxy resin gasket on site after the main beam and shoulder beam are accurately positioned, and form it in one step, saving the time of marking the reference line and avoiding the time of disassembling and then closing the machine. While saving time, it can also meet the accuracy requirements of driving and greatly improve the accuracy.

[0023] 2. The present invention adopts epoxy resin gasket casting, which can accurately control the shape and thickness of the gasket, so that the gasket fits better on the contact surface between the main beam flange and the shoulder beam top plate, thereby evenly transferring the load, reducing local stress concentration, improving the reliability and durability of the connection part, and extending the service life of the vehicle.

[0024] 3. The present invention limits the pouring shape of epoxy resin by using a panel coated with a release agent. The panel can also be dismantled and reused. The use of a rubber tube coated with a release agent can ensure that the bolt hole is not blocked by epoxy resin, thereby reducing secondary drilling. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the structure of the main beam and shoulder beam of the present invention being closed; Figure 2 This is a side view of the main beam and shoulder beam of the present invention when they are closed; Figure 3 This is a schematic diagram of the closure node of the main beam flange and the shoulder beam of the present invention; Figure 4 This is a detailed enlarged schematic diagram of the closing node between the main beam flange and the shoulder beam of the present invention.

[0026] Among them: 1. Main beam, 2. Shoulder beam, 3. Main beam frame, 4. Shoulder beam frame, 5. Main beam flange, 6. Shoulder beam top plate, 7. Trolley track, 8. Traveling wheel, 9. Flat iron enclosure, 10. Exhaust hole, 11. Rubber tube, 12. Casting hole, 13. Epoxy resin, 14. Flange hinged bolt mounting hole. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0028] like Figure 1-4 As shown, a method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam includes the following steps: Step 1: Prepare for pouring. Clean the bottom of the main beam flange 5 and the area on the shoulder beam top plate 6 where the epoxy resin 13 will be poured to ensure that there are no impurities on the surface. Apply engine oil as a release agent to the area where the bottom of the main beam flange 5 and the shoulder beam top plate 6 come into contact with the epoxy resin 13. Step 2: The main beam frame 3 positions and supports the main beam 1, adjusts the straightness and camber of the main beam 1, and adjusts the straightness and levelness of the trolley track 7; Step 3: The shoulder beam frame 4 positions and supports the shoulder beam 2, adjusts the straightness and horizontality of the traveling wheels 8, adjusts the wheelbase, and adjusts the gap between the main beam flange 5 and the shoulder beam 2; Step 4: Ream the flange bolt mounting holes 14; Step 5: Use thin flat iron enclosures 9 coated with a separator in advance around the main beam flange 3 and the shoulder beam top plate 6. Leave a 1-3mm gap between the top of the flat iron enclosure 9 and the main beam flange 5 as a vent during pouring; Step 6: Except for the vent hole 10 of the flat iron enclosure 9, all other free edges are sealed with sealant; Step 7: Insert the rubber tube 11 coated with a release agent into the flange hinge bolt mounting hole 14; Step 8: Stir the epoxy resin 13 until it is uniform, then add an appropriate amount of curing agent and continue stirring; Step 9: Immediately pour the evenly stirred epoxy resin 13 into the pouring hole 12 until the pouring material in the surrounding exhaust holes 10 emerges above the bottom surface of the flange and the air in the original space is discharged from the exhaust holes 10.

[0029] In step 1, apply 48-72um epoxy primer on the bottom surface of the main beam flange 5 and the shoulder beam top plate 6 to protect the contact surface of the bottom surface of the main beam flange 5 and the shoulder beam top plate 6 with the epoxy resin 13, and protect the contact area of ​​the bottom surface of the main beam flange 5 and the shoulder beam top plate 6 with the epoxy resin 13 from rusting while waiting for pouring.

[0030] In step 2 and step 3, the main beam and shoulder beam 2 are supported separately. The epoxy resin 13 is never under pressure during the entire pouring process. All data checks in step 3 are qualified. The gap between the main beam flange 5 and the shoulder beam top plate 6 is controlled at 10-20mm. The main beam 1 and shoulder beam 2 no longer move during the entire pouring process. The crane running wheel 8 is located at the bottom of the shoulder beam. The camber is calculated according to the crane working load. The camber of cranes of different specifications is different. The rest of the levelness and straightness are checked according to the ISO 12488-1 crane wheel and trolley and car track tolerance standard.

[0031] In step 4, the flange hinge bolt mounting hole 14 is located at the mounting hole of the hinge bolt of the shoulder beam top plate 6, and is used to connect the main beam flange 5 and the epoxy resin 13 gasket.

[0032] In step 5, the flat iron enclosure 9 is connected to the structural plate by electric welding. The enclosure flat iron 4 needs to be 15-25 mm higher than the bottom surface of the main beam flange 5. The enclosure flat iron 9 needs to be higher than the bottom surface of the main beam flange 5, which can effectively prevent the epoxy resin 13 from flowing away during the pouring process.

[0033] The vent hole 10 in step 6 is the gap at the top of the flat iron enclosure 9 to prevent the resin from flowing out during the pouring process.

[0034] In step 7, the rubber tube 11 must pass through the epoxy resin 13 and the bolt mounting holes 14 on the flange of the main beam 5 and the shoulder beam top plate, which can effectively prevent the epoxy resin 13 from blocking the bolt holes. In step 8, a low-speed electric drill is connected to a stirring rod as a power source. After the head of the stirring rod is completely immersed in the epoxy resin 13, stirring begins. The epoxy resin 13 must be stirred completely and evenly before adding the curing agent. The stirring time after adding the curing agent should not exceed 5 minutes to avoid premature solidification of the epoxy resin during the pouring process due to excessive stirring time.

[0035] In step 9, the pouring hole 12 is located in the middle of the main beam flange 5. After the epoxy resin 13 is poured, it should be kept above 25°C for more than 10 hours. The epoxy resin 13 is poured from the pouring hole 12, and the original space air is discharged from the exhaust hole 10.

[0036] Those skilled in the art will understand that the embodiments of the present invention described above and shown in the accompanying drawings are intended to be illustrative only and are not intended to limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functional and structural principles of the present invention have been demonstrated and illustrated in the embodiments. Any variations or modifications may be made to the embodiments of the present invention without departing from the principles described.

Claims

1. A method for casting epoxy resin gaskets of crane main beam flange and shoulder beam, characterized in that: The following steps are involved: Step 1: Prepare for pouring. Clean the bottom of the main beam flange and the shoulder beam top plate where epoxy resin will be poured to ensure that there are no impurities on the surface. Apply engine oil as a separating agent to the contact area between the bottom of the main beam flange and the shoulder beam top plate and the epoxy resin. Step 2: Position the main beam frame to support the main beam, adjust the straightness and camber of the main beam, and adjust the straightness and levelness of the trolley track; Step 3: Position and support the shoulder beam with the shoulder beam frame, adjust the straightness and levelness of the traveling wheels, adjust the wheelbase, and adjust the gap between the main beam flange and the shoulder beam; Step 4: Ream the flange bolt mounting holes; Step 5: Use thin flat iron enclosures coated with a separator in advance around the main beam flange and the shoulder beam top plate. Leave a 1-3mm gap between the top of the flat iron enclosure and the main beam flange as a vent during pouring; Step 6: Except for the vent holes on the flat iron enclosure, seal all other free edges with sealant; Step 7: Insert the rubber tube coated with a release agent into the flange hinge bolt mounting hole; Step 8: Stir the epoxy resin until it is uniform, then add an appropriate amount of curing agent and continue stirring; Step 9: Immediately pour the evenly mixed epoxy resin into the casting hole until the casting material in the surrounding vent holes comes out above the bottom surface of the flange and the air in the original space is discharged from the vent holes.

2. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: In step 1, the bottom surface of the main beam flange and the top plate of the shoulder beam are coated with 48-72um epoxy primer to protect the contact area between the bottom surface of the main beam flange and the top plate of the shoulder beam and the epoxy resin.

3. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: In step 2 and step 3, the main beam and shoulder beam are supported separately, and the epoxy resin is always under no pressure during the entire pouring process.

4. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: All data checks in step 3 are qualified, the gap between the main beam flange and the shoulder beam top plate is controlled at 10-20 mm, no displacement occurs between the main beam and the shoulder beam during the entire casting process, and the traveling wheels of the crane are located at the bottom of the shoulder beam.

5. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: In step 4, the flange hinge bolt mounting hole is located at the mounting hole of the hinge bolt on the shoulder beam top plate, and is used to connect the main beam flange and the epoxy resin gasket.

6. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: In step 5, the flat iron enclosure is connected to the structural plate by electric welding, and the enclosure flat iron needs to be 15-25 mm higher than the bottom surface of the main beam flange.

7. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: The exhaust hole in step 6 is the gap at the top of the flat iron enclosure.

8. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: In step 7, the rubber tube must pass through the flange hinged bolt mounting holes of the upper and lower epoxy resin main beam flanges and the shoulder beam top plate.

9. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: The step 8 uses a low-speed electric drill connected to a stirring rod as power. Stirring begins after the head of the stirring rod is completely immersed in the epoxy resin. The epoxy resin must be stirred completely and evenly before adding the curing agent. The stirring time after adding the curing agent cannot be more than 5 minutes to avoid the epoxy resin solidifying prematurely and being unable to form during the pouring process due to too long stirring time.

10. The method for casting epoxy resin gaskets of a crane main beam flange and a shoulder beam according to claim 1, characterized in that: The pouring hole in step 9 is located in the middle of the main beam flange, and the epoxy resin should be kept above 25° C. for more than 10 hours after pouring.

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