Manufacturing process of rigid leg of gantry crane

Abstract

The invention relates to the field of gantry crane construction, and discloses a manufacturing process of a rigid leg of a gantry crane, which comprises the following steps: step 1, manufacturing a fishtail section in a segmented manner, A1, manufacturing a fishtail bottom plane in a segmented manner, A2, assembling and welding a partition plate and a T row, A3, hoisting a bottom plate and a side plate plane in a segmented manner, A4, hoisting a top middle plane in a segmented manner, A5, assembling and welding a lug plate assembly, step 2, manufacturing a rigid leg vertical segment, b1, manufacturing a plane jig frame; the method comprises the following steps of S1, rigid leg assembling, B2, rigid leg bottom plane segmented positioning, B3, side plane segmented hoisting, B4, other side plane segmented hoisting, B5, top plane segmented hoisting and III, rigid leg assembling, and C1, the assembling sequence is as follows: firstly, rigid leg vertical segments G2 and G3 are assembled into G23, and rigid leg vertical segments G4 and G5 are assembled into G45; then, the three large segments G1, G23 and G45 of the fishtail segment are folded, and the segments are positioned through flat cars. The welding precision is improved, and the overall construction cost is reduced.

Description

Technical Field

[0001] The invention relates to the field of gantry crane construction, and in particular to a manufacturing process of a rigid leg of a gantry crane. Background Art

[0002] A gantry crane is a mechanical device that uses two outriggers to support a portal-shaped structure, enabling the suspension and movement of heavy loads. As key components, the outriggers provide balance and stability for the crane. Gantry crane outriggers are categorized as rigid or flexible, depending on their structure and function. Rigid outriggers utilize a box-shaped structure, which can easily cause shrinkage and deformation during welding of the four long weld seams, resulting in poor welding accuracy.

[0003] Related reference CN110104546A discloses a method for constructing a gantry crane's rigid leg. The method divides the rigid leg into a column structure and a fishtail beam structure. The column and fishtail beam structures are first fabricated into separate intermediate components. During fabrication, the trimming amount required at the top of the column structure is determined based on the deflection angles of the main beam and the rigid leg assembly. The two intermediate components are then spliced ​​together, and finally, a saddle is attached to the lower end of the fishtail beam structure to form the rigid leg. However, splicing the column box beam intermediate component and the fishtail beam intermediate component requires frequent lifting and positioning operations using large lifting equipment, resulting in a high overall project cost. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a manufacturing process for the rigid legs of a gantry crane, which can improve welding accuracy and reduce the overall construction cost.

[0005] In order to solve the above technical problems, the present invention provides a manufacturing process for a gantry crane rigid leg, comprising the following steps: Step 1: Make the fishtail segment A1. Segmented production of the fishtail bottom plane Carry out the following steps: preparation of the tire frame, assembly of the plates, submerged arc welding on one side, turning over and submerged arc welding on the other side, and installation and welding of the longitudinal reinforcement; A2. Partition and T-row welding Carry out the partition and T-row advance group in sequence, hoist the partition and T-row, weld them, and make patching sections at the joints of the sections; A3. Bottom plate and side plate flat section lifting A4. Sectional hoisting of the top middle plane Carry out the plane segmentation of the middle part of the hoisting top, the internal and external welding of the three-dimensional segmentation, and the marking of the horizontal center line in sequence; A5. Assembly and welding of ear plate components Step 2: Make the rigid leg sections The manufacturing steps of rigid leg stand segment G2, rigid leg stand segment G3, rigid leg stand segment G4 and rigid leg stand segment G5 are the same: B1. Use angle steel or round stool to make a flat tire frame B2, rigid leg bottom plane segment positioning Use double hooks to lift the rigid leg bottom plane segments onto the tire frame; check the fit between the flat tire frame and the rigid leg bottom plane segments; weld and fix the peripheral tire frame and the rigid leg bottom plane segments; B3. Side plane segmented lifting Carry out the side plane section turning 90 degrees for hoisting in sequence; install the process diagonal brace; assemble and position the corner joints; and build the scaffolding; B4, hoisting in sections on the other side B5. Top plane segmented hoisting Step 3: Close the rigid legs C1. The closing order is as follows: First, combine the rigid leg segments G2 and G3 into G23, and combine the rigid leg segments G4 and G5 into G45; Then the three large sections of the fishtail segment G1, G23 and G45 are put together, and the sections are positioned using a flatbed truck.

[0006] By adopting the above technical solution, G2 and G3 are closed, G4 and G5 are closed, and then the three large sections of the fishtail section G1, G23 and G45 are closed in a step-by-step closing manner. During each small closing process, errors are discovered and corrected in a timely manner to improve welding accuracy. The use of flatbed trucks for segmentation positioning avoids the use of large lifting equipment for frequent lifting and positioning operations. Especially when there is no lifting equipment at the large closing site, the flatbed truck positioning method directly saves the cost of renting or calling crawler cranes and other lifting equipment, reducing the overall cost of the project. The entire manufacturing process is divided into three major steps: fishtail segment production, rigid leg segment production, and rigid leg closing. Each major step is further subdivided into multiple specific small steps with clear levels, which makes it easier for staff to operate in an orderly manner according to the process, so that the manufacturing process is carried out in an orderly manner, effectively improving production efficiency.

[0007] Preferably, the fishtail section is manufactured in sections, and in step 2, the partition and T-bar assembly and welding, the length of the patching section is 400 mm.

[0008] By adopting the above technical solution, the 400mm patching section accurately fills the joint gaps between the segments to ensure structural integrity.

[0009] Preferably, the fishtail section is manufactured in sections. In step three, the bottom plate and side plate plane sections are hoisted in sections, and the top inclined plane sections are hoisted, the bottom plate is hoisted, the internal diagonal braces are hoisted, the side plate plane sections are hoisted, the internal auxiliary steel is welded, and the elevator shaft frame and electrical brackets are welded.

[0010] By adopting the above technical solution, the piece-by-piece lifting allows each component to be independently corrected, such as verticality and horizontality, to ensure that the installation accuracy meets the specifications.

[0011] Preferably, the fishtail section is manufactured in sections, and in the step five ear plate assembly welding, the ear plate assembly advance group, shear block installation, ear plate assembly welding, horizontal center line marking, and section completion inspection are carried out in sequence.

[0012] By adopting the above technical solution, the ear plates are directly welded without traditional machining, which effectively saves production and manufacturing costs. The installation of shear blocks effectively transmits shear force, prevents welding displacement, and improves structural stability.

[0013] Preferably, the rigid legs are manufactured in sections, and in step 4, the other side plane sections are hoisted, and the other side plane sections are turned over 90 degrees for hoisting, the process diagonal braces are installed, the corner joints are assembled and positioned, the internal auxiliary steel is installed, and the scaffolding is built.

[0014] By adopting the above technical solution, the process diagonal bracing reduces the relative displacement between sections, ensuring the overall rigidity of the structure during the lifting process. The five small steps are implemented in a coordinated manner to achieve the goals of improving structural stability, efficient construction, and controllable quality.

[0015] Preferably, the rigid legs are manufactured in sections, and in step five, the top plane sections are hoisted, and the top plane sections are turned over 180 degrees and then hoisted with double hooks; the corner joints are assembled and positioned; and the edge operations are protected by railings.

[0016] By adopting the above technical solution, the top segment is turned over 180 degrees on the ground to avoid the complicated operation of high-altitude flipping, reduce the risk of high-altitude operations, install edge working railings to prevent the top plane segment from falling, and ensure the personal safety of construction workers. The three small steps are implemented one by one, using precise assembly positioning and edge working railing protection to ensure structural stability during the lifting process.

[0017] Preferably, the rigid legs are closed, further comprising the following steps: C2, Inclined ladders and elevator shafts are pre-installed in the rigid leg sections and welded at the joints; C3, internal and external partner scaffolding at the annular joint; C4. Elevator tracks, cable trays, and cables are laid inside the rigid legs; C5. Install the cab platform and lighting platform; C6. Process the main hinge point after the overall welding is completed and inspected.

[0018] By adopting this technical solution, inclined ladders and elevator shafts were pre-installed within the rigid leg segments, providing construction workers with convenient access and reducing the workload and risks of constructing temporary access routes at height. The installation of elevator tracks, cable trays, and cables within the rigid legs was carried out simultaneously during the closure process, ensuring that these internal facilities were accurately positioned and securely fixed, avoiding quality issues that could arise from later separate installations due to space constraints or construction difficulties.

[0019] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention allows simultaneous closing of G2 and G3 while simultaneously closing G4 and G5, shortening the overall construction period and improving construction efficiency. By closing G2 and G3, then G4 and G5, and then closing the three large sections of the fishtail (G1, G23, and G45), this step-by-step closing method allows for timely detection and correction of errors during each small closing process, improving welding accuracy.

[0020] 2. This invention uses a flatbed truck for segmented positioning, avoiding the frequent lifting and positioning operations with large cranes. Especially when there is no crane available at a large assembly site, the flatbed truck positioning method directly saves the cost of renting or deploying crawler cranes and other lifting equipment, reducing the overall project cost.

[0021] 3. The present invention divides the entire manufacturing process into three major steps: segmented production of the fishtail segment, segmented production of the rigid legs, and folding of the rigid legs. Each major step is further subdivided into multiple specific small steps with clear levels, which makes it convenient for staff to operate in an orderly manner according to the process, so that the manufacturing process can proceed in an orderly manner and effectively improve production efficiency.

[0022] 4. In the segmented production of the bottom plane of the fishtail section, the present invention adopts a method of single-sided submerged arc welding after splicing the panels, turning them over and then performing submerged arc welding on the other side, so that the welds are uniform and firm, the occurrence of welding defects is reduced, the welding quality is improved, and the strength and stability of the structure are increased. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a structural diagram of the present invention; Figure 2 This is a schematic diagram of step A1 of the fishtail segment production process of the present invention; Figure 3 This is a schematic diagram of step A2 of the fishtail segment production process of the present invention; Figure 4 This is a schematic diagram of step A3 of the fishtail segment production process of the present invention; Figure 5 This is a schematic diagram of step A4 of the fishtail segment production process of the present invention; Figure 6 This is a schematic diagram of step A5 of the fishtail segment production process of the present invention; Figure 7 This is a schematic diagram of step B1 of manufacturing the rigid leg stand segments of the present invention; Figure 8 This is a schematic diagram of step B2 of manufacturing the rigid leg stand segments of the present invention; Figure 9 This is a schematic diagram of step B3 of manufacturing the rigid leg stand segments of the present invention; Figure 10 This is a schematic diagram of step B4 of manufacturing the rigid leg stand segments of the present invention; Figure 11 This is a schematic diagram of step B5 of manufacturing the rigid leg segments of the present invention.

[0024] Figure number: 1. Fishtail bottom plane segment, 2. Partition, 3. T row, 4. Bottom plate, 5. Diagonal brace, 6. Side plate plane segment, 7. Top middle plane segment, 8. Shear block, 9. Rigid leg bottom plane segment, 10. Side plane segment, 11. Top plane segment, 12. Ear plate assembly. DETAILED DESCRIPTION

[0025] A manufacturing process for a gantry crane rigid leg comprises the following steps:

[0026] Step 1: Make the fishtail segment A1、 Figure 2 , fishtail bottom plane segment 1 production

[0027] 1. Tire frame preparation; 2. Panel → single-sided submerged arc welding; 3. Turn over and perform submerged arc welding on the other side; 3. Install and weld longitudinal reinforcement.

[0028] The method of performing submerged arc welding on one side after splicing the panels and then turning them over and performing submerged arc welding on the other side makes the welds uniform and firm, reduces the occurrence of welding defects, improves the welding quality, and increases the strength and stability of the structure.

[0029] A2, such as Figure 3 , partition and T-row welding

[0030] 1. Bulkhead 2. T-row 3. Advance group; 2. Installation of partitions and T-rows; 3. Welding; 4. A 400mm long patching section is used at the joints of the sections (not shown in the figure). The 400mm patching section accurately fills the gaps between the sections to ensure structural integrity.

[0031] A3、 Figure 4 , the bottom plate and side plate are hoisted in sections

[0032] 1. Hoisting top inclined plane segmentation; 2. Hoisting base plate 4; 3. Lifting of internal diagonal brace 5; 4. Hoisting side panel plane segment 6; 5. Internal auxiliary steel welding; 6. Installation and welding of elevator shaft frame and electrical bracket.

[0033] Segmented lifting allows for independent correction of each component, such as verticality and horizontality, to ensure that installation accuracy meets specifications.

[0034] A4、 Figure 5 , the top middle plane is hoisted in sections

[0035] 1. The middle plane section of the hoisting top is divided into 7 sections; 2. Three-dimensional segmented internal welding; 3. External welding; 4. The welding inspection is qualified; 5. Draw the horizontal center line.

[0036] A5、 Figure 6 , ear plate assembly welding

[0037] 1. Ear plate assembly advance team; 2. Installation of the shear block 8; one side of the shear block 8 is welded to the base plate 4 and the other side is welded to the ear plate assembly 12.

[0038] 3. Welding of ear plate components; 4. Mark the horizontal center line; 5. Inspection of completion of each section.

[0039] The ear plates are directly welded without traditional machining, effectively saving production costs. The installation of shear blocks effectively transmits shear force, prevents welding displacement, and improves structural stability.

[0040] Step 2: Make the rigid leg sections The manufacturing steps of rigid leg stand segment G2, rigid leg stand segment G3, rigid leg stand segment G4 and rigid leg stand segment G5 are the same: B1、 Figure 7 , tire frame production

[0041] 1. Use angle steel or round spacers to make a flat tire frame; 2. The tire frame is firmly fixed to the ground; 3. The tire frame levelness inspection is qualified.

[0042] B2, such as Figure 8 , rigid leg bottom plane segmented positioning

[0043] 1. Use double hooks to lift the rigid leg bottom plane segment 9 onto the tire frame; 2. Check the fit between the tire frame and the rigid leg bottom plane segment 9; 3. Weld and fix the peripheral tire frame and the rigid leg bottom plane segment 9.

[0044] B3, such as Figure 9 , side plane segmented lifting

[0045] 1. The side plane is divided into 10 sections and turned 90 degrees for lifting; 2. Installation of process diagonal braces; 3. Assembly and positioning of corner joints; 4. Scaffolding construction.

[0046] B4, such as Figure 10 , the other side is hoisted in sections

[0047] 1. The other side of the plane is divided into 10 sections and turned 90 degrees for hoisting; 2. Installation of process diagonal braces; process diagonal braces reduce the relative displacement between sections and ensure the overall rigidity of the structure during the lifting process.

[0048] 3. Assembly and positioning of corner joints; 4. Internal auxiliary steel installation; including elevator shaft, electrical bracket, inclined ladder, and platform; 5. Scaffolding construction.

[0049] The coordinated implementation of these five steps improved structural stability, enhanced construction efficiency, and ensured quality control. The elevator shaft, electrical supports, inclined ladder, and platform were pre-installed inside the rigid legs, eliminating conflicts during later overhead operations and shortening the overall construction period.

[0050] B5, such as Figure 11 , top plane segmented lifting

[0051] 1. Turn the top plane section 11 180 degrees and then hoist it with double hooks; 2. Assembly and positioning of corner joints; 3. Railing protection for edge work.

[0052] Turn the top section 180 degrees on the ground to avoid the complicated operation of high-altitude flipping and reduce the risk of high-altitude operations. Install edge working railings to prevent the top plane section from falling and ensure the personal safety of construction workers. The three small steps are implemented one by one, using precise assembly positioning and edge working railing protection to ensure structural stability during the lifting process.

[0053] Step 3: Close the rigid legs 1. The tire frame is similar to the rigid leg tire frame; 2. Tire frame height 2000; 3. The layout of the tire frame takes into account the rigid leg segmentation of the flatbed truck positioning without obstacles on site; 4. Closing order: First, the rigid leg segment G2 and the rigid leg segment G3 are combined into G23, and the rigid leg segment G4 and the rigid leg segment G5 are combined into G45; Then the three large segments of the fishtail segment G1, G23 and G45 are closed, as shown in the following example: Figure 1Each section is positioned and loaded on a flatbed truck; there is no lifting equipment at the large assembly site, so the flatbed truck is used for positioning, saving the cost of crawler cranes. This achieves the goal of reasonable process design in terms of cost control.

[0054] 5. The inclined ladder and elevator shaft are pre-installed in the rigid leg section and welded at the joint; the inclined ladder and elevator shaft are pre-installed in the rigid leg section, providing construction workers with convenient up and down passages, reducing the workload and risks of building temporary passages at high altitudes.

[0055] 6. Partner scaffolding inside and outside the annular joint; 7. The elevator tracks, cable trays and cables inside the rigid legs have been laid. The work of laying the elevator tracks, cable trays and cables inside the rigid legs is carried out simultaneously during the closing process, ensuring that the installation positions of these internal facilities are accurate and firmly fixed, avoiding installation quality problems caused by limited space or difficult construction during the later separate installation.

[0056] 8. Installation of cab platform and lighting platform; 9. After the overall welding is completed and inspected and qualified, the main hinge point is processed.

[0057] This application divides the entire manufacturing process into three major steps: segmented production of the fishtail segment, segmented production of the rigid leg, and closure of the rigid leg. Each major step is further subdivided into multiple specific small steps with clear levels, which makes it easier for staff to operate in an orderly manner according to the process, so that the manufacturing process proceeds in an orderly manner and effectively improves production efficiency. The use of flatbed trucks for segmented positioning avoids the use of large lifting equipment for frequent lifting and positioning operations. Especially when there is no lifting equipment at the large closure site, the flatbed truck positioning method directly saves the cost of renting or calling crawler cranes and other lifting equipment, reducing the overall cost of the project. While closing G2 and G3, G4 and G5 can be closed at the same time, shortening the overall construction period and improving construction efficiency. By closing G2 and G3, closing G4 and G5, and then closing the three large segments of the fishtail segment G1, G23 and G45, and closing them step by step, errors can be discovered and corrected in a timely manner during each small closing process, thereby improving welding accuracy.

[0058] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a gantry crane rigid leg, characterized by: The steps include: Step 1: Make the fishtail segment A1. Segmented production of the fishtail bottom plane Carry out the following steps: preparation of the tire frame, assembly of the plates, submerged arc welding on one side, turning over and submerged arc welding on the other side, and installation and welding of the longitudinal reinforcement; A2. Partition and T-row welding Carry out the partition and T-row advance group in sequence, hoist the partition and T-row, weld them, and make patching sections at the joints of the sections; A3. Bottom plate and side plate flat section lifting A4. Sectional hoisting of the top middle plane Carry out the plane segmentation of the middle part of the hoisting top, the internal and external welding of the three-dimensional segmentation, and the marking of the horizontal center line in sequence; A5. Assembly and welding of ear plate components Step 2: Make the rigid leg sections The manufacturing steps of rigid leg stand segment G2, rigid leg stand segment G3, rigid leg stand segment G4 and rigid leg stand segment G5 are the same: B1. Use angle steel or round stool to make a flat tire frame B2, rigid leg bottom plane segment positioning Use double hooks to lift the rigid leg bottom plane segments onto the tire frame; check the fit between the flat tire frame and the rigid leg bottom plane segments; weld and fix the peripheral tire frame and the rigid leg bottom plane segments; B3. Side plane segmented lifting Carry out the side plane section turning 90 degrees for hoisting in sequence; install the process diagonal brace; assemble and position the corner joints; and build the scaffolding; B4, hoisting in sections on the other side B5. Top plane segmented lifting Step 3: Close the rigid legs C1. The closing order is as follows: First, combine the rigid leg segments G2 and G3 into G23, and combine the rigid leg segments G4 and G5 into G45; Then the three large sections of the fishtail segment G1, G23 and G45 are put together, and the sections are positioned using a flatbed truck.

2. The manufacturing process of a gantry crane rigid leg according to claim 1, characterized in that: The fishtail section is manufactured in sections. In step 2, the partition and T-row assembly and welding, the length of the patching section is 400 mm.

3. The manufacturing process of the rigid leg of a gantry crane according to claim 1, characterized in that: The fishtail section is manufactured in sections. In step three, the bottom plate and side plate plane sections are hoisted in sections, which includes hoisting the top inclined plane section, hoisting the bottom plate, hoisting the internal diagonal brace, hoisting the side plate plane section, welding the internal auxiliary steel, and welding the elevator shaft frame and electrical bracket.

4. The manufacturing process of a gantry crane rigid leg according to claim 1, characterized in that: The fishtail section is manufactured in sections. In the step five ear plate assembly welding, the ear plate assembly advance group, shear block installation, ear plate assembly welding, horizontal center line marking, and section completion inspection are carried out in sequence.

5. The manufacturing process of the rigid leg of a gantry crane according to claim 1, characterized in that: The rigid leg stand segments are manufactured, and in step four, the other side plane segments are hoisted, and the other side plane segments are turned over 90 degrees for hoisting, the process diagonal braces are installed, the corner joints are assembled and positioned, the internal auxiliary steel is installed, and the scaffolding is built.

6. The manufacturing process of a gantry crane rigid leg according to claim 1, characterized in that: In the production of the rigid leg sections, in step five, the top plane sections are hoisted, and the top plane sections are turned 180 degrees and then hoisted with double hooks, the corner joints are assembled and positioned, and the edge work railings are protected.

7. The manufacturing process of a gantry crane rigid leg according to claim 1, characterized in that: The rigid legs are folded, further comprising the following steps: C2, Inclined ladders and elevator shafts are pre-installed in the rigid leg sections and welded at the joints; C3, internal and external partner scaffolding at the annular joint; C4. Elevator tracks, cable trays and cables are laid inside the rigid legs.

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