Manufacturing process of gantry crane rigid leg

Abstract

The present application relates to gantry crane manufacturing field, disclose a kind of manufacturing process of gantry crane rigid leg, comprising the following steps: step one, fish tail section segmented production, A1, fish tail bottom plane segmented production, A2, partition and T row welding, A3, floor and side plate plane segmented hoisting, A4, top middle plane segmented hoisting, A5, ear plate assembly welding, step two, rigid leg vertical segmented production, B1, production plane jig frame;B2, rigid leg bottom plane segmented positioning, B3, side plane segmented hoisting, B4, the other side plane segmented hoisting, B5, top plane segmented hoisting, step three, rigid leg folding, C1, folding sequence as follows: first, rigid leg vertical segmented G2 and G3 are folded into G23, and rigid leg vertical segmented G4 and G5 are folded into G45;Then fish tail section G1, G23 and G45 three large segments are folded, and segmented positioning is carried out using flat car.The present application improves welding accuracy and reduces overall project cost.

Description

Technical Field

[0001] This invention relates to the field of gantry crane construction, specifically to a manufacturing process for the rigid legs of a gantry crane. Background Technology

[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 objects. The outriggers, as key components, play a crucial role in balancing and stabilizing the crane. Based on their structure and function, gantry crane outriggers can be divided into two types: rigid outriggers and flexible outriggers. Rigid outriggers employ a box-shaped structure, and their four long weld seams are prone to shrinkage deformation during welding, resulting in lower welding precision.

[0003] A relevant reference, CN110104546A, discloses a method for constructing a rigid leg for a gantry crane. This method divides the rigid leg into a column structure and a fishtail beam structure. First, the column structure and fishtail beam structure are fabricated as intermediate components. During fabrication, the trimming amount at the top of the column structure is determined based on the angular dimensions of the main beam and the overall rigid leg assembly. Then, these two intermediate components are spliced ​​together. Finally, a saddle is spliced ​​and connected to the lower end of the fishtail beam structure to form the rigid leg. However, the splicing of the intermediate components of the column box girder and the fishtail beam 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 that improves welding accuracy and reduces the overall cost of the project.

[0005] To solve the above technical problems, the present invention provides a manufacturing process for the rigid leg of a gantry crane, comprising the following steps:

[0006] Step 1: Segmenting the fish tail section

[0007] A1. Segmented construction of the fishtail bottom plane

[0008] The process involves preparing the jig, assembling the plates, performing single-sided submerged arc welding, flipping the other side for submerged arc welding, and then installing and welding the longitudinal ribs.

[0009] A2. Welding of partitions and T-shaped blocks

[0010] The partition and T-shaped pre-assembly groups were carried out in sequence, followed by hoisting and welding of the partition and T-shaped groups, and the profiles were fitted at the joints of the sections.

[0011] A3. Segmented hoisting of the base plate and side plates

[0012] A4. Segmented hoisting of the top and middle plan

[0013] The process of sequentially slicing the central plane of the suspended ceiling into sections, welding the internal and external parts of the three-dimensional sections, and marking the horizontal center line is carried out.

[0014] A5. Ear plate assembly welding

[0015] Step 2: Construction of rigid leg segments

[0016] The manufacturing steps for rigid leg sections G2, G3, G4, and G5 are the same:

[0017] B1. Construct a flat jig using angle iron or round benches.

[0018] B2. Rigid Leg Bottom Plane Segmentation Positioning

[0019] The rigid leg base planes are hoisted onto the jig segment by segment using double hooks; the fit between the jig segment and the rigid leg base plane is checked; the peripheral jig segment is welded and fixed to the rigid leg base plane.

[0020] B3. Side-plane segmented hoisting

[0021] The following steps were performed sequentially: side plane segmented tilting and hoisting at 90 degrees; installation of process diagonal bracing; corner joint assembly and positioning; and scaffolding erection.

[0022] B4. Segmented hoisting on the other side of the plane

[0023] B5. Segmented hoisting of the top plane

[0024] Step 3: Close the rigid legs

[0025] C1. The closing sequence is as follows:

[0026] First, combine rigid leg segments G2 and G3 into G23, and combine rigid leg segments G4 and G5 into G45.

[0027] Then the three major sections, G1, G23 and G45, of the fishtail section are joined together, and each section is positioned using a flatbed truck.

[0028] By adopting the above technical solution, the welding process involves assembling G2 and G3 sections, G4 and G5 sections, and then assembling the three major fishtail sections G1, G23, and G45 in a step-by-step manner. Errors are promptly identified and corrected during each small assembly process, improving welding precision. Using flatbed trucks for segment positioning avoids frequent hoisting and positioning operations with large lifting equipment. Especially when there is no lifting equipment available at the large assembly site, the flatbed truck positioning method directly saves the cost of renting or using crawler cranes and other lifting equipment, reducing the overall project cost. The entire manufacturing process is divided into three main steps: fishtail section fabrication, rigid leg erection section fabrication, and rigid leg assembly. Each major step is further subdivided into several smaller steps, creating a clear hierarchy that facilitates orderly operation by workers, ensuring a smooth manufacturing process and effectively improving production efficiency.

[0029] Preferably, the fish tail section is manufactured in segments, and in step two, during the assembly and welding of the partition and T-shaped plate, the length of the patch section is 400mm.

[0030] By adopting the above technical solution, the 400mm patching section accurately fills the gap between the segments, ensuring structural integrity.

[0031] Preferably, in the segmented fabrication of the fishtail section, during the segmented hoisting of the bottom plate and side plate in step three, the following steps are performed in sequence: hoisting the top inclined plane segment, hoisting the bottom plate, hoisting the internal inclined bracing, hoisting the side plate segment, welding the internal auxiliary steel, and welding the elevator shaft frame and electrical support.

[0032] By adopting the above technical solution, component hoisting allows for independent correction of each component, such as verticality and horizontality, ensuring that the installation accuracy meets the specifications.

[0033] Preferably, the fishtail section is manufactured in segments. In step five, during the assembly and welding of the ear plate components, the ear plate components are pre-assembled, the anti-shear blocks are installed, the ear plate components are welded, the horizontal center line is marked, and the segment completion inspection is carried out in sequence.

[0034] By adopting the above technical solution, the ear plates can be directly welded without traditional machining, which effectively saves production and manufacturing costs. The installation of the shear blocks effectively transmits shear force, prevents welding displacement, and improves structural stability.

[0035] Preferably, in the rigid leg segment fabrication, during the other side plane segment hoisting in step four, the other side plane segment is turned 90 degrees and hoisted in sequence, process diagonal bracing is installed, corner joint assembly and positioning is performed, internal auxiliary steel is installed, and scaffolding is erected.

[0036] By adopting the above technical solutions, the process bracing reduces the relative displacement between segments, ensuring the overall rigidity of the structure during hoisting. The five small steps are implemented in a coordinated manner to improve structural stability, increase construction efficiency, and ensure controllable quality.

[0037] Preferably, the rigid leg is made in sections. In step five, the top plane is hoisted in sections by turning the top plane sections 180 degrees and then hoisting them with double hooks; corner joints are assembled and positioned; and edge protection railings are installed.

[0038] By adopting the above technical solution, the top section is flipped 180 degrees on the ground, avoiding the complex operation of high-altitude flipping, reducing the risk of high-altitude operations, and installing edge guardrails to prevent the top section from falling, ensuring the personal safety of construction personnel. The three small steps are implemented one by one, and precise assembly positioning and edge guardrail protection are used to ensure the structural stability during hoisting.

[0039] Preferably, the rigid leg closing also includes the following steps:

[0040] C2. Inclined ladders and elevator shafts are pre-installed within the rigid leg sections and welded at the joints;

[0041] C3. Scaffolding with inner and outer joints at the circumferential seam;

[0042] C4. Elevator tracks, cable trays, and cables are laid inside the rigid legs;

[0043] C5. Install driver's cab platform and lighting platform;

[0044] C6. After the overall welding is completed and inspected and approved, the main hinge point is machined.

[0045] By adopting the above technical solution, the inclined ladder and elevator shaft are pre-installed within the rigid leg sections, providing convenient access for construction personnel and reducing the workload and risks of constructing temporary access at high altitudes. The installation of elevator tracks, cable trays, and cables inside the rigid legs is carried out simultaneously during the assembly process, ensuring accurate positioning and secure fixing of these internal facilities. This avoids installation quality problems caused by space constraints or construction difficulties during later individual installations.

[0046] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0047] 1. This invention allows for the simultaneous closure of G4 and G5 while G2 and G3 are being joined, shortening the overall construction cycle and improving construction efficiency. By employing a step-by-step closure method—closing G2 and G3, then G4 and G5, followed by the closure of the three large fishtail sections G1, G23, and G45—errors can be detected and corrected promptly during each small closure process, thus improving welding precision.

[0048] 2. This invention employs flatbed truck positioning for segmentation, avoiding frequent hoisting and positioning operations using large lifting equipment. Especially in situations where there is no lifting equipment available at large assembly sites, the flatbed truck positioning method directly saves on the cost of renting or using crawler cranes and other lifting equipment, thus reducing the overall project cost.

[0049] 3. This invention divides the entire manufacturing process into three major steps: segmented fabrication of the fishtail section, segmented fabrication of the rigid legs, and assembly of the rigid legs. Each major step is further subdivided into several smaller steps, with clear hierarchical distinctions. This facilitates orderly operation by staff, ensuring a smooth manufacturing process and effectively improving production efficiency.

[0050] 4. In the segmented fabrication of the bottom plane of the fish tail section, this invention adopts a method of single-sided submerged arc welding after splicing plates, followed by flipping and submerged arc welding on the other side. This method makes the weld uniform and firm, reduces the occurrence of welding defects, improves welding quality, and increases the strength and stability of the structure. Attached Figure Description

[0051] Figure 1 This is a structural diagram of the present invention;

[0052] Figure 2 This is a schematic diagram of step A1 in the process of segmenting the fish tail section according to the present invention;

[0053] Figure 3 This is a schematic diagram of step A2 in the process of segmenting the fish tail section according to the present invention;

[0054] Figure 4 A3 is a schematic diagram of the fish tail segment manufacturing process of the present invention;

[0055] Figure 5 A4 is a schematic diagram of the fish tail segment manufacturing process of the present invention;

[0056] Figure 6 A5 is a schematic diagram of the fish tail segment manufacturing process of the present invention;

[0057] Figure 7 This is a schematic diagram of step B1 in the manufacturing process of the rigid leg segment of the present invention;

[0058] Figure 8 This is a schematic diagram of step B2 in the manufacturing process of the rigid leg segment of the present invention;

[0059] Figure 9 This is a schematic diagram of step B3 in the manufacturing process of the rigid leg segment of the present invention;

[0060] Figure 10 This is a schematic diagram of step B4 in the manufacturing process of the rigid leg segment of the present invention;

[0061] Figure 11 This is a schematic diagram of step B5 in the manufacturing process of the rigid leg segment of the present invention.

[0062] Drawing numbers: 1. Fishtail bottom plane segment, 2. Partition plate, 3. T-row, 4. Bottom plate, 5. Diagonal brace, 6. Side plate plane segment, 7. Top center plane segment, 8. Shear block, 9. Rigid leg bottom plane segment, 10. Side plane segment, 11. Top plane segment, 12. Ear plate assembly. Detailed Implementation

[0063] A manufacturing process for a rigid leg of a gantry crane includes the following steps:

[0064] Step 1: Segmenting the fish tail section

[0065] A1, such as Figure 2 Fish tail bottom plane segment 1 construction

[0066] 1. Prepare the tire frame;

[0067] 2. Panel assembly → Single-sided submerged arc welding;

[0068] 3. Flip over and submerged arc welding on the other side;

[0069] 3. Install and weld longitudinal reinforcement bars.

[0070] By employing a method of single-sided submerged arc welding after panel assembly, followed by flipping and submerged arc welding on the other side, the weld seam becomes uniform and strong, reducing welding defects, improving welding quality, and increasing the strength and stability of the structure.

[0071] A2, such as Figure 3 Partition plate and T-bar assembly welding

[0072] 1. Partition; 2. T-row; 3. Advance team;

[0073] 2. Installation of partitions and T-shaped panels;

[0074] 3. Welding;

[0075] 4. A 400mm long patch section is made at the joint of the segments (not shown in the figure). The 400mm patch section precisely fills the gap between the segments to ensure structural integrity.

[0076] A3, such as Figure 4 The bottom plate and side plates are hoisted in sections.

[0077] 1. Segmentation of the inclined plane of the suspended ceiling;

[0078] 2. Lifting base plate 4;

[0079] 3. Internal diagonal bracing 5 is hoisted;

[0080] 4. The side panel is divided into 6 sections for hoisting;

[0081] 5. Internal auxiliary steel assembly and welding;

[0082] 6. Elevator shaft frame and electrical support assembly and welding.

[0083] Component hoisting allows for independent calibration of each component, such as verticality and horizontality, ensuring that the installation accuracy meets specifications.

[0084] A4, such as Figure 5 Segmented hoisting of the top and middle plan

[0085] 1. The central section of the suspended ceiling is divided into 7 segments;

[0086] 2. Three-dimensional segmented internal welding;

[0087] 3. External welding;

[0088] 4. Welding inspection passed;

[0089] 5. Draw the horizontal center line.

[0090] A5, such as Figure 6 Ear plate assembly welding

[0091] 1. Earplate assembly pilot group;

[0092] 2. Installation of anti-shear block 8: One side of anti-shear block 8 is welded to the base plate 4, and the other side is welded to the ear plate assembly 12.

[0093] 3. Welding of ear plate assembly;

[0094] 4. Draw the horizontal center line;

[0095] 5. Sectional completion inspection.

[0096] The ear plates are directly welded without traditional machining, effectively saving production and manufacturing costs. The installation of shear blocks effectively transmits shear force, prevents weld displacement, and improves structural stability.

[0097] Step 2: Construction of rigid leg segments

[0098] The manufacturing steps for rigid leg sections G2, G3, G4, and G5 are the same:

[0099] B1, such as Figure 7 Frame fabrication

[0100] 1. Construct a flat jig using angle iron or round benches;

[0101] 2. The frame is firmly fixed to the ground;

[0102] 3. The levelness of the tire frame passed the inspection.

[0103] B2, such as Figure 8 Rigid leg bottom plane segmented positioning

[0104] 1. The rigid leg bottom plane is lifted into 9 sections by double hooks and placed onto the jig.

[0105] 2. Check the fit between the jig frame and the rigid leg bottom plane segment 9;

[0106] 3. Weld the peripheral frame to the rigid leg bottom plane in sections 9 and fix them in place.

[0107] B3, such as Figure 9 Side-plane segmented hoisting

[0108] 1. Side plane segmented, 10 sections, tilted 90 degrees for hoisting;

[0109] 2. Installation of process diagonal bracing;

[0110] 3. Corner joint assembly and positioning;

[0111] 4. Scaffolding erection.

[0112] B4, such as Figure 10 The other side is installed in sections.

[0113] 1. The other side of the plane is divided into 10 sections, rotated 90 degrees, and hoisted.

[0114] 2. Installation of process diagonal bracing; process diagonal bracing reduces relative displacement between sections and ensures the overall rigidity of the structure during hoisting.

[0115] 3. Corner joint assembly and positioning;

[0116] 4. Internal auxiliary steel installation; including elevator shaft, electrical support, inclined ladder, and platform;

[0117] 5. Scaffolding erection.

[0118] Five small steps were implemented in a coordinated manner to improve structural stability, ensure efficient construction, and maintain controllable quality. The elevator shaft, electrical support, inclined ladder, and platform were pre-installed inside the rigid legs to avoid conflicts during later high-altitude operations and shorten the overall construction period.

[0119] B5, such as Figure 11 Segmented hoisting of the top plane

[0120] 1. After the top plane is divided into 11 sections, it is flipped 180 degrees and then hoisted with double hooks;

[0121] 2. Corner joint assembly and positioning;

[0122] 3. Edge protection railings for working near the edge.

[0123] The top section was flipped 180 degrees on the ground to avoid the complex operation of high-altitude flipping, reduce the risk of high-altitude work, and install edge guardrails to prevent the top section from falling and ensure the personal safety of construction personnel. The three small steps were implemented one by one, and precise assembly positioning and edge guardrail protection were used to ensure the structural stability during hoisting.

[0124] Step 3: Close the rigid legs

[0125] 1. The construction of the jig is similar to that of a rigid leg jig;

[0126] 2. The height of the tire frame is 2000 mm.

[0127] 3. The layout of the jig frame takes into account the segmented rigid legs for positioning the flatbed truck, which is not designed to prevent obstacles on site.

[0128] 4. Assembly sequence:

[0129] First, combine rigid leg segments G2 and G3 into G23, and combine rigid leg segments G4 and G5 into G45.

[0130] Then the three major segments of the fishtail section, G1, G23, and G45, come together, as follows: Figure 1Each section was positioned using flatbed trucks, and each section was loaded onto flatbed trucks. Since there were no lifting equipment at the large assembly site, flatbed trucks were used directly for positioning, saving the cost of hiring crawler cranes. This achieved the goal of making the process design reasonable in terms of cost control.

[0131] 5. The inclined ladder and elevator shaft are pre-installed within the rigid leg sections and welded at the joint; the pre-installation of the inclined ladder and elevator shaft within the rigid leg sections provides a convenient access for construction personnel, reducing the workload and risks of building temporary access at high altitudes.

[0132] 6. Scaffolding with internal and external supports at the circumferential joint;

[0133] 7. The elevator track, cable tray, and cable laying inside the rigid leg are completed. The laying of elevator track, cable tray, and cable inside the rigid leg is carried out simultaneously during the closing process to ensure that the installation position of these internal facilities is accurate and firmly fixed, avoiding installation quality problems caused by space constraints or construction difficulties when installing them separately later.

[0134] 8. Installation of driver's cab platform and lighting platform;

[0135] 9. After the overall welding is completed and inspected and approved, the main hinge point is machined.

[0136] This application divides the entire manufacturing process into three main steps: segmented fabrication of the fishtail section, segmented fabrication of the rigid legs, and assembly of the rigid legs. Each major step is further subdivided into several smaller steps, creating a clear hierarchy that facilitates orderly operation by staff, ensuring a smooth manufacturing process and effectively improving production efficiency. The use of flatbed trucks for segmented positioning avoids the need for frequent hoisting and positioning operations with large lifting equipment. Especially when there is no lifting equipment available at the large assembly site, the flatbed truck positioning method directly saves on the cost of renting or using crawler cranes and other lifting equipment, reducing the overall project cost. While assembling G2 and G3, the assembly of G4 and G5 can be carried out simultaneously, shortening the overall construction cycle and improving construction efficiency. By employing a step-by-step assembly method—assembling G2 and G3, then G4 and G5, followed by the assembly of the three major fishtail sections G1, G23, and G45—errors can be detected and corrected promptly during each small assembly process, improving welding precision.

[0137] 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 manufacturing process for the rigid legs of a gantry crane, characterized in that: Includes the following steps: Step 1: Segmenting the fish tail section A1. Segmented construction of the fishtail bottom plane The process involves preparing the jig, assembling the plates, performing single-sided submerged arc welding, flipping the other side for submerged arc welding, and then installing and welding the longitudinal ribs. A2. Welding of partitions and T-shaped blocks The partition and T-shaped pre-assembly groups were carried out in sequence, followed by hoisting and welding of the partition and T-shaped groups, and the profiles were fitted at the joints of the sections. A3. Segmented hoisting of the base plate and side plates A4. Segmented hoisting of the top and middle plan The process of sequentially slicing the central plane of the suspended ceiling into sections, welding the internal and external parts of the three-dimensional sections, and marking the horizontal center line is carried out. A5. Ear plate assembly welding Step 2: Construction of rigid leg segments The manufacturing steps for rigid leg sections G2, G3, G4, and G5 are the same: B1. Construct a flat jig using angle iron or round benches. B2. Rigid Leg Bottom Plane Segmentation Positioning The rigid leg base planes are hoisted onto the jig segment by segment using double hooks; the fit between the jig segment and the rigid leg base plane is checked; the peripheral jig segment is welded and fixed to the rigid leg base plane. B3. Side-plane segmented hoisting The following steps were performed sequentially: side plane segmented tilting and hoisting at 90 degrees; installation of process diagonal bracing; corner joint assembly and positioning; and scaffolding erection. B4. Segmented hoisting on the other side of the plane B5. Segmented hoisting of the top plane Step 3: Close the rigid legs C1. The closing sequence is as follows: First, combine rigid leg segments G2 and G3 into G23, and combine rigid leg segments G4 and G5 into G45. Then the three major sections of the fishtail section, G1, G23 and G45, are joined together, and each section is positioned using a flatbed truck. The fishtail section is fabricated in sections. In step A3, the bottom plate and side plate are hoisted in sections, and the top inclined plane is hoisted in sequence, followed by the bottom plate, the internal inclined bracing, the side plate, the internal auxiliary steel, and the elevator shaft frame and electrical support. The fishtail section is manufactured in sections. In step A5, the ear plate assembly is assembled and welded. The ear plate assembly is pre-assembled, the anti-shear block is installed, the ear plate assembly is welded, the horizontal center line is marked, and the section completion inspection is carried out in sequence. In the fabrication of the rigid leg sections, during the hoisting of the other side plane section in step B4, the other side plane section is turned 90 degrees and hoisted in sequence, the process diagonal bracing is installed, the corner joint is assembled and positioned, the internal auxiliary steel is installed, and the scaffolding is erected.

2. The manufacturing process of a rigid leg for a gantry crane according to claim 1, characterized in that: The fish tail section is manufactured in sections. In step A2, during the assembly and welding of the partition plate and T-shaped plate, the length of the patch section is 400mm.

3. The manufacturing process of a rigid leg for a gantry crane according to claim 1, characterized in that: In the fabrication of the rigid leg sections, during step B5, the top plane section is hoisted by flipping the top plane section 180 degrees and then hoisting it with double hooks, assembling and positioning the corner joints, and protecting the edge of the work area with railings.

4. The manufacturing process of a rigid leg for a gantry crane according to claim 1, characterized in that: The closing of the rigid legs also includes the following steps: C2. Inclined ladders and elevator shafts are pre-installed in rigid leg segments G2, G3, G4, and G5, and welded at the joint. C3. Scaffolding with inner and outer joints at the circumferential seam; C4. The rigid legs are equipped with elevator tracks, cable trays, and cables.

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