Efficient bulk carrier side tank general assembly method

Abstract

The application discloses a kind of bulk carrier side cabin high-efficiency total assembly method, comprising the following steps: S1, segmented production and transportation;Combined with the structure form of ship side cabin section, build lower fetus in large assembly site, then transport segmented to the uncovered area of folding and loading crane by flatbed transport vehicle;S2, segmented total assembly and outfitting;The above-mentioned segmented total assembly is positioned by three-dimensional adjusting machine, and total assembly is welded, outfitting operation is carried out by erecting scaffold construction platform;S3, section overall painting;After the above-mentioned segmented total assembly, double-car transportation is carried out to painting plant by flatbed transport vehicle, and overall painting is carried out, sanding and painting;S4, section overall loading and transportation;Double-car transportation is carried out to folding and loading site by flatbed transport vehicle, and folding and loading are carried out to section turning over.The application optimizes construction procedure, effectively shortens the hoisting time of sub-section, reduces the use time of gantry crane, occupies low crane resource;Operation difficulty is reduced, and construction quality is improved;Efficiency of segmented loading is effectively improved, and shipbuilding dock period is shortened.

Description

Technical Field

[0001] This invention relates to the field of shipbuilding technology, specifically to a method for efficient assembly of side tanks in bulk carriers. Background Technology

[0002] Ballast tanks on bulk carriers are divided into top ballast tanks and bottom ballast tanks. Taking a 210,000 deadweight ton bulk carrier as an example, a single ballast tank is approximately 29 meters long and 15 meters wide, with a structural weight of approximately 500 tons. Due to limitations in lifting and transportation equipment and shipyard road transport, the ballast tanks cannot be directly constructed as a complete structure. Shipyards typically adopt a "divide and conquer" approach, dividing the ballast tanks into several relatively small structural sections for construction. After the sections are outfitted and painted, they are assembled in a dedicated area (i.e., the sections are assembled into a complete unit), involving numerous processes. The aforementioned sections are assembled in a dedicated site using the outer side plating as a base, with the top and bottom side tanks assembled vertically. However, the transport posture of the sections differs from that of the final assembly. This necessitates not only preparing new support equipment but also using cranes for tilting and adjustment. Furthermore, the scaffolding used for section painting and final assembly is not interchangeable, requiring repeated erection and dismantling. This not only results in heavy pre-construction preparations but also a significant dependence on site resources, especially crane resources, leading to substantial long-term occupation. Since site resources are fixed and cannot match the assembly requirements, once crane resources are fully utilized, the assembly efficiency of the side tank sections will be difficult to further improve, impacting the ship's overall efficiency and consequently extending the shipbuilding dock period. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a method for efficient assembly of side tanks on bulk carriers.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0005] A method for efficient assembly of side tanks on bulk carriers includes the following steps:

[0006] S1. Segmented fabrication and transportation: Based on the structural form of the ship's side compartment, the lower section is constructed in the large assembly site. Then, using the wide and flat surface as the lower section, the segments are transported by flatbed truck to the area not covered by the assembly crane.

[0007] S2. Segment assembly and outfitting: The above segments are assembled and positioned using a three-dimensional adjustment machine, and a scaffolding construction platform is erected for welding of the assembly seams and outfitting operations.

[0008] S3, Overall painting of the entire section; After the above sections are assembled, they are transported to the painting plant by two flatbed trucks for overall painting, sandblasting and spraying.

[0009] S4. The entire section is transported as a whole; it is transported to the assembly site by two flatbed trucks, and the entire section is turned over for assembly.

[0010] Furthermore: In step S1, the ship's side compartments are divided into top side compartments and bottom side compartments, both designed as ballast tanks, which are single-hull triangular structures with outward-extending sides; the top side compartment includes a deck, ramp plates, and outer side plates, and its deck surface is a flat surface. During the manufacturing and transportation of the top side compartment, its deck surface is used as the construction base surface, that is, the deck is used as the base. The bottom side compartment includes an outer bottom plate, outer side plates, and ramp plate structures, and its outer side plates are larger in size. During the manufacturing and transportation of the bottom side compartment, its outer side plates are used as the working base surface.

[0011] Furthermore, after the sectional assembly in step S2, the weight and center of gravity of the sectional section are determined according to the sectional structure of the ship side compartment in step S1. The weight of the sectional section shall not exceed the load capacity of the hoisting and turning, and shall also be less than the maximum load capacity of the flatbed transport vehicle. The lifting points of the hoisting crane are arranged according to the center of gravity of the sectional section to avoid uneven load on the weighing.

[0012] Furthermore, the segmented mounting and positioning assembly in step S2 includes the preparation of the overall assembly support fixtures, the preparation of the three-dimensional adjustment machine, and the construction platform equipment. The preparation of the overall assembly support fixtures involves placing the support fixtures at the overall assembly site according to the overall assembly fixture layout diagram. The preparation of the three-dimensional adjustment machine requires preparing a sufficient number of three-dimensional adjustment machines to adjust the posture of the segmented structure. The construction platform is erected according to the overall assembly scaffolding plan, and then the adjusted segmented structure is sealed and fixed by welding.

[0013] Furthermore, in step S3, the overall painting process involves keeping the segmented assembly structure unchanged and using the deck as the base for transportation and spraying operations.

[0014] Furthermore, in step S4, the overall section turning is carried out using a gantry crane, wherein the top side compartment is turned 180°.

[0015] Compared with the prior art, the present invention has the following beneficial effects: by optimizing the construction process, the present invention effectively shortens the hoisting time of the main sections, reduces the usage time of the 600T gantry crane, and has low crane resource occupation; the operation difficulty is reduced, the construction quality is improved, repetitive operations are avoided, the efficiency of section mounting is effectively improved, and the shipbuilding dock period is shortened. Attached Figure Description

[0016] Figure 1 This invention relates to a comparison diagram of the construction process flow and existing processes;

[0017] Figure 2 This is a schematic diagram showing the selection of the base surface for the bulk carrier side tank assembly in the construction process of this invention;

[0018] Figure 3This is a schematic diagram illustrating the verification of the center of gravity position of the top side tank section of the bulk carrier in this invention;

[0019] Figure 4 This is a schematic diagram illustrating the verification of the center of gravity position of the bottom side tank section of a bulk carrier in this invention;

[0020] Figure 5 This is a schematic diagram of the bulk carrier side hold section transportation scheme in this invention;

[0021] Figure 6 This is a schematic diagram of the overall transportation scheme for the side hold section of a bulk carrier in this invention;

[0022] Figure 7 This is a tooling layout diagram for the off-site assembly of the bulk carrier side hold sections in this invention;

[0023] In the diagram: 01 refers to the top side compartment, and 02 refers to the bottom side compartment;

[0024] 1. Deck, 2. Side plating, 3. Ramp plate, 4. Bottom plating, 5. Side plating, 6. Ramp plate, 7. Flatbed transport vehicle, 8. Overall center of gravity, 9. Sub-section center of gravity. Detailed Implementation

[0025] It should be noted that in the description of this invention, terms such as "upper," "lower," "top," "bottom," and "outer side" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are only used to facilitate the description of the structural relationship between the components in this invention and do not specifically mean that any component in this invention must have a specific orientation, be constructed and operated in a specific orientation, or be construed as a limitation of this invention.

[0026] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings:

[0027] like Figure 1 As shown, a highly efficient assembly method for ballast tank side holds of bulk carriers optimizes the segmented construction process by studying the outfitting, painting, assembly, and transportation operations of ballast tank structures. Compared with existing segmented construction processes, it reduces two process steps, specifically including the following steps:

[0028] S1. Segmented fabrication and transportation. First, based on the overall structural form of the bulk carrier's side holds, the lower sections are constructed in the large assembly area; the side holds can be divided into top side holds and bottom side holds, both being single-hull triangular structures with projecting sides, such as... Figure 2As shown, the top side compartment includes a deck 1, side outer plating 2, and a ramp 3. The deck surface is a flat area with a large area; therefore, deck 1 is used as the construction base surface during the fabrication and transportation of the top side compartment. The bottom side compartment includes an outer bottom plating 4, side outer plating 5, and a ramp 6. The side outer plating 5 is larger and flat; therefore, it is used as the working base surface during the fabrication and transportation of the bottom side compartment. When fabricating the above structure in sections, refer to... Figure 3 and Figure 4 As shown, it is necessary to verify and analyze whether the weight of the above-mentioned segments and the total weight, and the positions of the segment center of gravity 9 and the total weight of the total weight 8, meet the lifting capacity of the crane and the transportation capacity of the flatbed transport vehicle 7. The weight of the total segment should not exceed the lifting and turning load capacity, and should also be less than the maximum load capacity of the flatbed transport vehicle 7. Determine the feasible range for off-site assembly and overall transfer of the total segment. Subsequently, using the above-determined construction base as a base, the completed segments are transported by the flatbed transport vehicle 7 to the area not covered by the assembly crane. The transportation plan is as follows: Figure 5 As shown, the off-site assembly site, which is the area not covered by the cranes used for assembly, can be selected at a location where the foundation bearing capacity is sufficient to support the strength of the ship's structure. There are no special requirements for crane resources, such as the original segmented outfitting site.

[0029] S2. Segment Assembly and Outfitting. Prepare a sufficient number of 3D adjustment machines and place them in designated positions according to the 3D adjustment machine layout diagram, prioritizing locations with strong structural features. Based on the segment assembly base surface determined above, construction personnel will use the 3D adjustment machines to mount, adjust, and position the segments completed in step S1, minimizing the use of cranes during segment assembly. Prepare assembly support fixtures at the off-site assembly site and place them according to the assembly fixture layout diagram, avoiding the transport area of ​​the flatbed transport vehicle 7. See [link to relevant documentation]. Figure 7 This ensures that the supporting equipment for the sub-sections and main sections is consistent with the supporting equipment for the main assembly; the scaffolding construction platform is erected according to the main assembly scaffolding plan to achieve platform universality, and the main assembly seam welding and outfitting operations are carried out on the adjusted and positioned sub-sections.

[0030] S3. Overall Section Painting. After the above-mentioned section assembly, the sections are transported longitudinally in pairs by flatbed trucks (7) to the painting workshop for overall painting, sandblasting, and spraying. Throughout the process, the above-mentioned construction base surface is used as the reference. The order of section painting operations is determined according to the dimensions of the overall section and the painting workshop. Under the premise that the painting workshop can meet the overall section construction, it is determined that the sections are assembled first and then painted, and the painting construction plan is adjusted accordingly. This operation process can effectively avoid paint damage caused by painting before overall assembly, avoid subsequent overall assembly paint touch-up, and avoid repeated construction.

[0031] S4. Overall loading and transportation of the entire section; after the above painting operations are completed, the sections are transported to the assembly and loading site by two flatbed trucks in series. Figure 6As shown; then, using a gantry crane and the lifting points of the crane hooks arranged according to the center of gravity 8 of the main section, the main section is turned over to avoid load deviation of each hook; after the main section is turned over, the assembly operation is carried out, which can be done using the existing assembly scheme. At this point, the assembly operation process of the bulk carrier side tank main section is completed.

[0032] The segmented transportation plan in step S1 above should be based on the overall transportation direction of the final section, and the overall section transfer plan should be designed first.

[0033] Throughout the process, it is also necessary to design the overall assembly seam welding method and welding bevel scheme. The welding method should prioritize the application of efficient welding methods such as automatic welding.

[0034] By using the above construction process to assemble the ship's side compartments, the time required for gantry crane use can be effectively reduced. For example, in the prior art, it takes about 4 hours to turn a single section of the gantry crane 180°, and about 0.5 hours to lift the entire section after merging two sections, for a total of 8.5 hours. In contrast, in this invention, the merging of the entire section in the early stage does not require the use of gantry crane time. Only the section is turned over and merged at the end, which takes about 3 hours. This effectively improves the ship's loading efficiency and shortens the ship's docking period.

[0035] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A method for efficient assembly of side holds on a bulk carrier, characterized in that, Includes the following steps: S1. Segmented fabrication and transportation: Combining the structural form of the ship's side compartment, the lower section is built in the large assembly site, and then the segments are transported to the area not covered by the assembly crane using a flatbed truck with a wide and flat surface as the lower section. S2, Segment assembly and outfitting; The above segments are assembled and positioned using a three-dimensional adjustment machine, and a scaffolding construction platform is erected for welding of the assembly joints and outfitting operations; S3, Overall painting of the entire section; After the above sections are assembled, they are transported to the painting workshop by two flatbed trucks for overall painting, sandblasting and spraying. S4. The entire section is transported as a whole; it is transported to the assembly and loading site by two flatbed trucks, and the entire section is turned over for assembly and loading. In step S1, the ship's side compartments are divided into top side compartments and bottom side compartments, both designed as ballast tanks with a single-hull triangular outward-extending structure. The top side compartment includes a deck, ramp plates, and outer side plates, with a flat deck surface. The deck surface serves as the construction base during the fabrication and transportation of the top side compartment. The bottom side compartment includes an outer bottom plate, outer side plates, and ramp plate structure, with the outer side plates being larger. The outer side plates serve as the working base during the fabrication and transportation of the bottom side compartment. After the sectional assembly in step S2, the weight and center of gravity of the sectional section are determined according to the sectional structure of the ship side compartment in step S1. The weight of the sectional section shall not exceed the load capacity of the hoisting and turning, and shall also be less than the maximum load capacity of the flatbed transport vehicle. The lifting points of the hoisting crane shall be arranged according to the center of gravity of the sectional section to avoid uneven load on the weighing. The segmented mounting and positioning assembly in step S2 includes the preparation of the overall support tooling, the preparation of the three-dimensional adjustment machine, and the construction platform equipment. The preparation of the overall support tooling involves placing the support tooling at the overall assembly site according to the overall tooling layout diagram. The preparation of the three-dimensional adjustment machine requires a sufficient number of three-dimensional adjustment machines to adjust the posture of the segmented structure. The construction platform is erected according to the overall scaffolding plan, and then the adjusted segmented structure is sealed and fixed by welding.

2. The efficient assembly method for side tanks of a bulk carrier according to claim 1, characterized in that: In step S3, the overall painting process is carried out without changing the segmented assembly structure. The deck is used as the base for transportation and spraying operations.

3. The efficient assembly method for side tanks of a bulk carrier according to claim 1, characterized in that: In step S4, the overall section is turned over using a gantry crane, with the top side compartment turning 180°.

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