Method for machining a large door shaft end column plane

Abstract

The application provides a large door shaft end column plane processing method, comprising the following steps: determining a virtual track reference surface of a floor-type boring and milling machine through three reference points, determining a door shaft end column processing reference surface, adjusting the door shaft end column so that the plane where the center roll body line is located is parallel to the virtual track reference surface, and the first processing surface is in the processing area of the floor-type boring and milling machine; processing the first processing surface using the floor-type boring and milling machine; vertically turning the door shaft end column by 180 degrees, adjusting the plane where the center roll body line is located to be parallel to the virtual track reference surface, and adjusting the second processing surface to be in the processing area of the floor-type boring and milling machine; and processing the second processing surface using the floor-type boring and milling machine. The application breaks through the dependence on large high-precision machine tools in traditional processes, provides a large door shaft end column plane processing method with low cost and easy implementation, makes the processing precision of a common floor-type boring and milling machine reach that of a gantry milling machine, supports on-site processing of super-large workpieces, and reduces the transportation cost of workpieces.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of hydraulic engineering equipment manufacturing, and particularly relates to a processing method for a large-scale gate shaft end column plane. BACKGROUND

[0002] The triangular gate is a large-scale equipment commonly used in modern hydraulic engineering, and the height of the gate is usually greater than 20 meters. The height of the end column of the gate shaft of the triangular gate is also greater than 20 meters, and each of the upper and lower end columns has an installation surface. The parallelism deviation of the two installation surfaces is required to be less than 1 mm, and the parallelism of the two installation surfaces is directly related to whether the triangular gate can be smoothly opened and closed.

[0003] In the prior art, the processing of the two large installation surfaces corresponding to the large-scale triangular gate shaft end column (length > 20 m) needs to rely on a high-precision large gantry milling machine, and the following problems exist:

[0004] 1. High equipment cost: the procurement cost of the large gantry milling machine is more than 2 million yuan, and small and medium-sized enterprises usually cannot afford it;

[0005] 2. Site limitation: the large gantry milling machine needs a special foundation and plant for processing the end column installation surface, and cannot be processed on site, so the workpiece needs to be transported between the installation site and the processing plant;

[0006] 3. Precision depends on a single factor: the large gantry milling machine itself depends on the guide rail precision, and cannot compensate for thermal deformation and gravity deformation errors. SUMMARY

[0007] An object of the present application is to provide a processing method for a large-scale gate shaft end column plane to solve at least one of the above-mentioned prior art problems.

[0008] According to one aspect of the present application, a processing method for a large-scale gate shaft end column plane is provided, wherein the large-scale gate shaft end column plane includes a first processing surface and a second processing surface located at both ends of the same side surface, and the processing method includes the following steps:

[0009] Determine the virtual track reference surface of the floor-type boring and milling machine: set a point at the front end of the front side of the guide rail of the floor-type boring and milling machine as a first reference point of the bed; set a point at the rear end of the front side of the guide rail of the bed as a second reference point; set a position on the vertical plane where the first reference point and the second reference point are located, which is one gate shaft end column length away from the first reference point, as a third reference point, and the plane where the first reference point, the second reference point and the third reference point are located constitutes the virtual track reference surface of the floor-type boring and milling machine;

[0010] Determine the door shaft end column processing reference surface: set the center roll line on the door shaft end column, the plane where the center roll line is located is parallel to the first processing surface and the second processing surface, adjust the door shaft end column so that the plane where the center roll line is located is parallel to the virtual track reference surface, and the first processing surface is in the processing area of the floor-type boring and milling machine;

[0011] Process the first processing surface using the floor-type boring and milling machine;

[0012] Vertically turn the door shaft end column by 180°, adjust the position of the door shaft end column so that the plane where the center roll line is located is parallel to the virtual track reference surface, and the second processing surface is in the processing area of the floor-type boring and milling machine;

[0013] Process the second processing surface using the floor-type boring and milling machine.

[0014] In some embodiments, when determining the track reference surface of the floor-type boring and milling machine, a first G1 precision permanent magnet steel ruler is adsorbed to the front end of the front side of the guide rail of the floor-type boring and milling machine, a second G1 precision permanent magnet steel ruler is adsorbed to the rear end of the front side of the guide rail of the floor-type boring and milling machine, and a third G1 precision permanent magnet steel ruler is arranged behind the guide rail of the floor-type boring and milling machine at a distance of one door shaft end column length from the first permanent magnet steel ruler; adjust the position of the third permanent magnet steel ruler so that the laser plane formed by the rotation of the laser theodolite in the vertical plane is incident on the same scale of the first permanent magnet steel ruler, the second permanent magnet steel ruler and the third permanent magnet steel ruler, and then the same scale points of the first permanent magnet steel ruler, the second permanent magnet steel ruler and the third permanent magnet steel ruler are respectively the first reference point, the second reference point and the third reference point.

[0015] In some embodiments, when determining the door shaft end column processing reference surface, four roll permanent magnet steel rulers are respectively placed at the two ends of the plane with longer center roll line length on the door shaft end column, and the same end faces of the four roll permanent magnet steel rulers are all coincided with the center roll line in the same direction; adjust the position of the door shaft end column using the laser plane formed by the rotation of the laser theodolite in the vertical plane so that the points with the same scale of the four roll permanent magnet steel rulers have the same distance from the virtual track reference surface.

[0016] In some embodiments, before determining the door shaft end column processing reference surface, the door shaft end column is hoisted to the workbench of the floor-type boring and milling machine, and the lower ends of the door shaft end column are respectively supported by the first leveling tool and the second leveling tool; both the first leveling tool and the second leveling tool contain a four-degree-of-freedom fine adjustment mechanism. Thus, adjustment in two horizontal directions and two inclined directions can be realized.

[0017] In some embodiments, the present application further comprises cleaning the side surface of the guide rail of the floor-type boring and milling machine and grinding the side surface of the guide rail to a surface roughness Ra≤1.6μm before determining the virtual track reference surface of the floor-type boring and milling machine.

[0018] In some embodiments, the three-point coplanarity error of the first reference point, the second reference point and the third reference point of the present application is ≤0.2mm.

[0019] In some embodiments, the parallelism deviation of the plane where the door shaft end column center roll body line of the present application is located and the virtual track reference plane is ≤0.25mm.

[0020] In some embodiments, the step of processing the first machining surface and the second machining surface of the present application using a floor-type boring and milling machine comprises:

[0021] (1) Rough machining stage: φ160mm milling cutter is used, cutting parameters: speed 180r / min, feed 0.15mm / r, cutting depth 2mm, and 0.3mm of finishing allowance is reserved;

[0022] (2) Finishing stage: φ80mm dense-tooth milling cutter is replaced, cutting parameters: speed 600r / min, feed 0.05mm / r, cutting depth 0.3mm.

[0023] The machining method of the large door shaft end column plane of the present application breaks through the dependence of traditional process on large high-precision machine tools, and provides a low-cost and easy-to-implement large door shaft end column plane machining device. Through modular tooling and reference reconstruction technology, the ordinary floor-type boring and milling machine can reach the machining precision of the gantry milling machine. The machining of the door shaft end column flatness ≤0.3mm / 25m and the parallelism error ≤0.25mm can be realized on the ordinary floor-type boring and milling machine. The equipment modification cost is only 20,000 yuan (only the cost of adding leveling tooling), which is especially suitable for the on-site precision machining of the super-long span gate end column in water conservancy projects, supports the on-site machining of the super-large door shaft end column plane with a span of 20-40m and a weight of more than 30 tons, and reduces the transportation cost of the workpiece. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 The position relationship diagram of the floor-type boring and milling machine, the door shaft end column and the laser theodolite of the machining method of the large door shaft end column plane of an embodiment of the present application is shown.

[0025] Figure 2 The schematic diagram of the method for determining the virtual track reference plane of the floor-type boring and milling machine in the machining method of the large door shaft end column plane of an embodiment of the present application is shown.

[0026] Figure 3 The schematic diagram of the method for determining the door shaft end column machining reference plane in the machining method of the large door shaft end column plane of an embodiment of the present application is shown.

[0027] Figure 4 The enlarged schematic diagram of A in FIG. Figure 3

[0028] ​Figure 5 The structure diagram of the leveling device in the processing method of the large door shaft end column plane.

[0029] Reference signs:

[0030] 10 - door shaft end column, 11 - first processing surface, 12 - second processing surface;

[0031] 20 - floor type boring and milling machine, 21 - milling cutter head;

[0032] 30 - laser theodolite, 31 - first permanent magnet steel ruler, 32 - second permanent magnet steel ruler, 33 - third permanent magnet steel ruler;

[0033] 41 - first leveling device, 42 - support frame, 43 - second leveling device, 431 - base, 432 - jack, 433 - sliding rail, 434 - supporting plate, 435 - safety device, 436 - sliding block;

[0034] 51 - first roll permanent magnet steel ruler, 52 - second roll permanent magnet steel ruler, 53 - third roll permanent magnet steel ruler, 54 - fourth roll permanent magnet steel ruler. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings of the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work belong to the scope of protection of the present application.

[0036] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict.

[0037] Finally, it should also be noted that in this document, relationship terms such as first and second, counterclockwise and clockwise, and the like are used only to distinguish one entity or operation from another, and do not necessarily require or imply that these entities or operations exist in any such actual relationship or order. Moreover, the terms "include", "contain", not only include those elements, but also include other elements not explicitly listed or inherent to such a process, method, article or device. Without more limitations, the elements defined by the statement "include" do not exclude the existence of other same elements in the process, method, article or device including the described elements.

[0038] The present application will be further described in detail below in conjunction with the drawings.

[0039] Figure 1 The positional relationship of the floor-type boring and milling machine, the door shaft end column and the laser transit in the processing method of the large door shaft end column planar surface in an embodiment of the present application is schematically shown.

[0040] Reference Figure 1 As shown in the figure, the first processing surface 11 and the second processing surface 12 at the two ends of the large door shaft end column 10 are processed by using a common vertical floor-type boring and milling machine 20. In this embodiment, the model of the floor-type boring and milling machine used is T6215, which is a high-precision floor-type boring and milling machine mainly used for milling and boring processing of large parts, and the travel of the worktable in the X, Y and Z directions is generally about 2000mm x 1000mm x 800mm. In other embodiments, other models of floor-type boring and milling machines can also be used according to actual conditions.

[0041] One end of the door shaft end column 10 is placed on the worktable of the floor-type boring and milling machine 20, and the door shaft end column 10 is supported below by two modular leveling fixtures (the first leveling fixture 41 and the second leveling fixture 43), both of which contain four-degree-of-freedom fine adjustment mechanisms. A support frame 42 can also be used to support the lower middle part of the door shaft end column 10. The milling cutter head 21 is directly opposite the first processing surface 11 of the door shaft end column 10 to be processed.

[0042] The laser transit 30 is arranged at the front end of the position between the floor-type boring and milling machine 20 and the door shaft end column 10.

[0043] The adjustment method of the laser transit 30 is as follows:

[0044] 1. Centering: Fix one leg of the tripod, and continuously adjust the positions of the other two legs with both hands, while observing the crosshair of the optical point marker to make it align with the center of the ground point mark;

[0045] 2. Rough leveling: Extend the tripod legs to make the circular bubble centered, and roughly level the instrument;

[0046] 3. Fine leveling: Adjust the three leg screws (left thumb rule), and accurately level the instrument;

[0047] 4. Re-centering: Check the optical point marker, and if it deviates from the station mark, move the instrument to accurately center it;

[0048] 5. Re-fine leveling: Adjust the three leg screws (left thumb rule), and accurately level the instrument.

[0049] Figure 2 The method for determining the virtual track reference surface of the floor-type boring and milling machine in the processing method of the large door shaft end column planar surface in an embodiment of the present application is schematically shown.

[0050] Reference Figure 2As shown, the method for determining the virtual rail reference plane of the floor-type boring and milling machine 20 comprises the following steps:

[0051] The first permanent magnetic steel ruler 31 of G1 accuracy is adsorbed to the front end of the front side of the guide rail of the floor-type boring and milling machine 20, the second permanent magnetic steel ruler 32 of G1 accuracy is adsorbed to the rear end of the front side of the guide rail of the floor-type boring and milling machine 20, and the third permanent magnetic steel ruler 33 of G1 accuracy can be adsorbed on a placing table, and the placing table is placed at the rear end of the guide rail of the floor-type boring and milling machine 20 and at a position about one door shaft end column 10 length away from the first permanent magnetic steel ruler 31. This distance does not have to be very accurate, and for a 20-meter-long door shaft end column 10, the error can be about 0.5-1 meter.

[0052] The X / Y / Z three directions of the laser theodolite 30 are adjusted, the laser emitted by the laser theodolite 30 is irradiated on the same scale of the first permanent magnetic steel ruler 31 and the second permanent magnetic steel ruler 32, then the X / Y directions are kept unchanged, the Z direction is adjusted, the laser plane formed by the laser theodolite 30 on the vertical plane is irradiated on the third permanent magnetic steel ruler 33, the position of the placing table is adjusted so that the laser is irradiated on the same scale of the third permanent magnetic steel ruler 33 as that of the first permanent magnetic steel ruler 31 and the second permanent magnetic steel ruler 32, and then the same scale points of the first permanent magnetic steel ruler 31, the second permanent magnetic steel ruler 32 and the third permanent magnetic steel ruler 33 irradiated by the laser are respectively the first reference point, the second reference point and the third reference point. The plane where the first reference point, the second reference point and the third reference point are located is the virtual rail reference plane of the floor-type boring and milling machine 20.

[0053] The first permanent magnetic steel ruler 31, the second permanent magnetic steel ruler 32 and the third permanent magnetic steel ruler 33 are the same permanent magnetic steel ruler. The three-point coplanar error of the first reference point, the second reference point and the third reference point is ≤0.2 mm.

[0054] Before determining the virtual rail reference plane of the floor-type boring and milling machine 20, the guide rail side of the floor-type boring and milling machine 20 can be cleaned, and the guide rail side can be ground to a surface roughness Ra≤1.6 μm.

[0055] Figure 3 and Figure 4 The method for determining the door shaft end column machining reference plane in the method for machining the large door shaft end column plane is schematically shown.

[0056] Reference Figure 3 and Figure 4 As shown, first, the center roll body line (dotted line in the figure) is set on the door shaft end column 10, the first machining surface 11 and the second machining surface 2 are placed parallel to the ground, the level scanner is kept unchanged in the vertical direction and only moves in the horizontal direction, and one point is selected on each surface of the door shaft end column 10, and there are four points in total. A line is drawn around the door shaft end column 10 along the four points, which is the center roll body line of the door shaft end column 10, and the center roll body lines on the four surfaces of the door shaft end column 10 are in the same horizontal plane.

[0057] The door shaft end column 10 is hoisted to the workbench of the floor-type boring and milling machine, and the two ends of the door shaft end column 10 are respectively supported by the first leveling tool 41 and the second leveling tool 43, and the first leveling tool 41 and the second leveling tool 43 are both provided with a four-degree-of-freedom fine adjustment mechanism. The middle part of the door shaft end column 10 can be supported by the support frame 42.

[0058] Four roll body permanent magnet steel rulers (the first roll body permanent magnet steel ruler 51, the second roll body permanent magnet steel ruler 52, the third roll body permanent magnet steel ruler 53, and the fourth roll body permanent magnet steel ruler 54) are respectively arranged at the two ends of the plane with a longer center roll body line length on the door shaft end column 10, and the same end faces of the four roll body permanent magnet steel rulers (the first roll body permanent magnet steel ruler 51, the second roll body permanent magnet steel ruler 52, the third roll body permanent magnet steel ruler 53, and the fourth roll body permanent magnet steel ruler 54) are coincided with the center roll body line in the same direction, and the free ends of the roll body permanent magnet steel rulers (the first roll body permanent magnet steel ruler 51, the second roll body permanent magnet steel ruler 52, the third roll body permanent magnet steel ruler 53, and the fourth roll body permanent magnet steel ruler 54) are directed to the floor-type boring and milling machine 20, as shown in Figure 3 and 4 .

[0059] The laser plane formed by the laser theodolite 30 rotating in the vertical plane is used to adjust the position of the door shaft end column 10 by using the first leveling tool 41 and the second leveling tool 43, so that the laser plane irradiates the same scale points of the four roll body permanent magnet steel rulers (the first roll body permanent magnet steel ruler 51, the second roll body permanent magnet steel ruler 52, the third roll body permanent magnet steel ruler 53, and the fourth roll body permanent magnet steel ruler 54), and the distances between the four scale points and the virtual track reference plane are equal, that is, the plane where the center roll body line of the door shaft end column 10 is located is parallel to the virtual track reference plane (the plane where the first reference point, the second reference point, and the third reference point are located) of the floor-type boring and milling machine 20, and parallel to the milling cutter disc 21 machining surface, and the first machining surface 11 is located in the machining area of the floor-type boring and milling machine 20.

[0060] The machining of the first machining surface 11 of the door shaft end column 10 by using the floor-type boring and milling machine can include the following steps:

[0061] (1) Rough machining stage: φ160mm milling cutter disc (APKT diamond milling cutter blade) is adopted, and the cutting parameters are as follows: rotation speed 180r / min, feed 0.15mm / r, cutting depth 2mm, and 0.3mm reserved for fine machining allowance;

[0062] (2) Fine machining stage: φ80mm dense-tooth milling cutter disc (PCD diamond milling cutter blade) is replaced, and the cutting parameters are as follows: rotation speed 600r / min, feed 0.05mm / r, and cutting depth 0.3mm.

[0063] After the first machining surface 11 of the door shaft end column 10 is machined, it is parallel to the guide rail of the floor-type boring and milling machine 20, and the parallelism deviation is ≤0.25mm.

[0064] When the first machining surface 11 is machined, the door shaft end column 10 is vertically flipped by 180° using a crane, and the two ends of the door shaft end column 10 are respectively placed on the first leveling tool 41 and the second leveling tool 43. The position of the door shaft end column 10 is adjusted again according to the above method by adjusting the first leveling tool 41 and the second leveling tool 43, so that the plane where the center roll body line of the door shaft end column 10 is located is parallel to the virtual track reference surface of the floor-type boring and milling machine 20, and parallel to the machining surface of the milling cutter 21, and the second machining surface 12 is in the machining area of the floor-type boring and milling machine 20.

[0065] The second machining surface 12 is machined again according to the above steps using the floor-type boring and milling machine 20.

[0066] Finally, whether the parallelism of the first machining surface 11 and the second machining surface 12 of the door shaft end column 10 that have been machined is within the allowable tolerance range of less than 1mm can be checked by using a theodolite.

[0067] Figure 5 The structure of the leveling tool in the machining method of the large door shaft end column plane according to an embodiment of the present application is schematically shown.

[0068] Reference Figure 5 As shown, the leveling tool includes a base 431, a sliding rail 433, a jack 432, a supporting plate 434, a safety device 435 and a sliding block 436.

[0069] The sliding rail 433 is arranged on the upper surface of the base 431. The sliding block 436 is adapted to the sliding rail 433, and the sliding block 436 is installed on the sliding rail 433. Four jacks 432 are respectively arranged on the four corners of the upper surface of the sliding block 436, and a safety device 435 is arranged between the two jacks 432. The supporting plate 434 is arranged above the jacks 432.

[0070] The supporting plate 434 can be moved in the X and Z directions by adjusting the jacks 432 and the sliding block 436, and the jacks 432 can be adjusted separately. After the position adjustment of the door shaft end column 10 is completed, the safety device 435 is placed between the two jacks 432, which can prevent the jacks from failing and the door shaft end column 10 from tilting and moving during machining.

[0071] The above only describes some embodiments of the present application. Those skilled in the art can make several modifications and improvements without departing from the inventive concept, which are all within the protection scope of the present application.

Claims

1. A method of processing a large door shaft end column plane, wherein the large door shaft end column plane includes a first processing surface and a second processing surface at both ends of the same side thereof, characterized by, The processing method comprises the following steps: Determine the virtual rail reference plane of the floor-type boring and milling machine independent of the accuracy of its own guide rail: set a point at the front end of the front side of the guide rail of the floor-type boring and milling machine as a first reference point; set a point at the rear end of the front side of the guide rail of the floor-type boring and milling machine as a second reference point; set a point on the vertical plane where the first reference point and the second reference point are located, at a distance of one door shaft end column length from the first reference point, as a third reference point, and the plane where the first reference point, the second reference point and the third reference point are located constitutes the virtual rail reference plane of the floor-type boring and milling machine; Determine the door shaft end column processing reference plane: set a center roll body line on the door shaft end column, the plane where the center roll body line is located is parallel to the first processing surface and the second processing surface, adjust the position of the door shaft end column so that the plane where the center roll body line is located is parallel to the virtual rail reference plane, and the first processing surface is located in the processing area of the floor-type boring and milling machine; Process the first processing surface using the floor-type boring and milling machine; Vertically turn the door shaft end column by 180°, adjust the position of the door shaft end column so that the plane where the center roll body line is located is parallel to the virtual rail reference plane, and the second processing surface is located in the processing area of the floor-type boring and milling machine; Process the second processing surface using the floor-type boring and milling machine; Before determining the door shaft end column processing reference plane, hoist the door shaft end column to the workbench of the floor-type boring and milling machine, and support the two ends of the door shaft end column by the first leveling tool and the second leveling tool respectively; Both the first leveling tool and the second leveling tool contain a four-degree-of-freedom fine adjustment mechanism for compensating for the deflection deformation of the large door shaft end column, and ensuring that the parallelism deviation of the plane where the center roll body line of the door shaft end column is located and the virtual rail reference plane is ≤0.25mm.

2. The method of claim 1, wherein When determining the rail reference plane of the floor-type boring and milling machine, adsorb a first permanent magnetic steel ruler of G1 accuracy to the front end of the front side of the guide rail of the floor-type boring and milling machine, adsorb a second permanent magnetic steel ruler of G1 accuracy to the rear end of the front side of the guide rail of the floor-type boring and milling machine, and set a third permanent magnetic steel ruler of G1 accuracy at a position behind the guide rail of the floor-type boring and milling machine, at a distance of one door shaft end column length from the first permanent magnetic steel ruler; Adjust the position of the third permanent magnetic steel ruler so that the laser plane formed by the laser theodolite rotating on the vertical plane is irradiated on the same scale of the first permanent magnetic steel ruler, the second permanent magnetic steel ruler and the third permanent magnetic steel ruler, and then the same scale points of the first permanent magnetic steel ruler, the second permanent magnetic steel ruler and the third permanent magnetic steel ruler are the first reference point, the second reference point and the third reference point respectively.

3. The method of claim 1 wherein, When determining the door shaft end column processing reference plane, place four roll body permanent magnetic steel rulers at the two ends of the plane where the center roll body line of the door shaft end column is longer, and the same end faces of the four roll body permanent magnetic steel rulers are all coincided with the center roll body line in the same direction; Adjust the position of the door shaft end column by using the laser plane formed by the laser theodolite rotating on the vertical plane, so that the points with the same scale of the four roll body permanent magnetic steel rulers are at the same distance from the virtual rail reference plane.

4. The method of claim 1 wherein, It also comprises cleaning the side of the guide rail of the floor-type boring and milling machine before determining the virtual rail reference plane of the floor-type boring and milling machine, and grinding the side of the guide rail to a surface roughness Ra≤1.6μm.

5. The method of claim 1 wherein, The three-point coplanarity error of the first reference point, the second reference point and the third reference point is ≤0.2mm.

6. The method of processing according to any one of claims 1-5, wherein, The step of processing the first processing surface and the second processing surface using a floor-type boring and milling machine comprises: (1) rough processing stage: φ160mm milling cutter is adopted, cutting parameters: speed 180r / min, feed 0.15mm / r, cutting depth 2mm, and a finishing allowance of 0.3mm is reserved; (2) finishing stage: φ80mm dense-tooth milling cutter is replaced, cutting parameters: speed 600r / min, feed 0.05mm / r, cutting depth 0.3mm.

Images