A process for the curved segmental construction and general assembly

Abstract

A process method for curved type segmented construction and general assembly, a guide rail is laid on a horizontal ground, a bed is arranged above the guide rail, track wheels are installed on both sides of the bed through bearings, the track wheels slide on the guide rail, slide rails with a longitudinal interval of 1m are installed on the upper surface of the bed, guide wheels are slidably connected on the slide rails, and supports with adjustable position and height are installed on the guide wheels. The fixed bed is changed into a movable bed, the secondary bed construction in the process of ship body segment general assembly is avoided, the bed support is quickly adjusted, the working efficiency is improved. The ship body segment of the reverse construction is changed into the positive construction, the overhead welding workload is reduced, the welding efficiency is improved, and the welding defects are reduced. The segment precision data is adjusted in the process of segment general assembly, the height and position of the bed support are adjusted, the use frequency of the crane is reduced. In the process of segment general assembly positioning, the movement through the travelling crane system can be realized, the process of repeated adjustment of the crane is avoided, and the segment general assembly positioning, fixation and welding work are avoided.

Description

Technical Field

[0001] This invention belongs to the field of hull construction in shipbuilding, specifically relating to a process method for curved section construction and assembly. Background Technology

[0002] In order to control welding deformation and ensure construction accuracy, the construction process of hull sections and assembly is usually carried out on jigs. According to their form, jigs can be divided into straight jigs and linear jigs. Straight jigs are used for the outer plates of straight sections, while linear jigs are used for the outer plates of curved sections.

[0003] In the frame structure, the support column is an important component. During the frame installation process, the difficult work lies in the positioning of the support column on the frame and the adjustment of the support column height. Before the support column is installed, the frame needs to be modeled to simulate the position of the support column, and at the same time, the number of columns required for each segment and the weight borne by each column need to be calculated.

[0004] For straight jigs used in flat segments, the jig fabrication process is relatively simple, as long as the supports are at the same horizontal height. However, for linear jigs, the curvature of the segment's outer surface must be fully considered. The precision requirements for support positioning and installation are extremely high, necessitating repeated adjustments to the support position and height. The support installation process must follow these steps: total station measurement of support point coordinates → support height adjustment → support welding and fixing → re-measurement of data deviations or stress deformation → secondary correction. For linear jigs, each support requires 3-5 adjustments, and each segment, depending on its volume and weight, requires approximately 20-30 supports. Therefore, the jig fabrication process involves a large amount of repetitive work, consuming significant time and labor costs.

[0005] Traditional ship hull construction methods typically include two assembly methods: the forward construction method and the reverse construction method. The forward construction method uses the outer plating of the hull sections as a base and assembles them in the order of bottom → side → deck. The reverse construction method uses the deck sections as a base and assembles them in the order of deck → side → bottom.

[0006] During the hull section manufacturing process, for sections with large outer plating shapes, a reverse construction method is typically used, employing the straight deck of the section as a template. This avoids the need to create linear templates during hull construction, saving manpower and time. However, after the hull sections are reversed, welding work during assembly will be affected. Because the sections are upside down, most flat welding will become overhead welding, resulting in lower welding efficiency, more weld defects, an increase in the number of non-destructive testing procedures, and a decline in weld quality due to repeated rework.

[0007] Traditionally, the jigs are fixed to the ground reinforcement at the construction site by welding and cannot be moved with the sections. After the hull sections are completed, the sections need to be cut off from the jigs and transported to the assembly site. At the same time, new jigs need to be made at the assembly site to support and fix the sections. Therefore, two jigs need to be built for the hull sections during the section construction stage and the section assembly stage, resulting in a lot of repetitive construction.

[0008] The research object of this invention patent is to improve work efficiency, reduce the repetitive construction of jigs, and provide a movable and reusable jig that ensures that the position and horizontal height of the jig support can be freely adjusted. Summary of the Invention

[0009] To address the aforementioned problems, this invention provides a process for constructing and assembling curved sections, aiming to avoid secondary jig construction during the assembly of hull sections, while simultaneously enabling rapid adjustment of jig supports and improving work efficiency. The technical solution adopted is as follows:

[0010] A process for constructing and assembling curved sections includes a hull section construction stage and a hull section assembly stage. The specific operations of the hull section construction stage are as follows:

[0011] S1: A guide rail is laid on a horizontal ground. A tire body is set on top of the guide rail. The track wheels are installed on both sides of the tire body through bearings. The track wheels slide on the guide rail. A slide rail with a longitudinal spacing of 1m is installed on the upper surface of the tire body. Guide wheels are slidably connected on the slide rail. The guide wheels are equipped with pillars whose position and height can be adjusted.

[0012] S2: Make a baseline parallel to the guide rail 3 meters away from the edge of the hull body on the outside of the guide rail at the segmented construction site. This baseline will serve as the width reference during the segmented construction of the hull. At the same time, set a length reference point on the baseline to serve as the length reference point during the segmented construction of the hull.

[0013] S3: Using a total station, establish a three-dimensional coordinate system with the baseline X as the reference. Draw the longitudinal network lines B and C of the segment and the center line A of the hull on the jig. Use the reference point M or N in the length direction on the baseline as the reference to determine the position of the transverse network line of the hull. Draw the transverse network line F of the hull segment on the jig. Draw the plate opening lines D and E of the hull segment in the same way.

[0014] S4: Based on the hull section jig drawing and assembly drawing, determine the jig supports required for each section, and complete the position positioning and horizontal height adjustment of the supports.

[0015] S5: Complete the cutting of the outer plate parts, and calculate the distances from the hull network line, center line, plate opening line to the same edge of the part based on the theoretical data of the hull section assembly drawing.

[0016] S6: When assembling hull parts, according to the data calculated in step S5, the parts are placed on the jig support pillars corresponding to the network lines, center lines, and plate opening lines drawn on the jig in step S3, and the segmented parts are fixed by the electro-permanent magnet device on the support pillar.

[0017] S7: Following the above steps, the outer hull plate parts are installed sequentially. After the outer hull plate of the hull section is assembled, the other parts of the hull section are assembled until the entire section is completed, preparing for the overall assembly of the sections.

[0018] The specific operations for the hull section assembly stage are as follows:

[0019] F1: The driving system starts, moves the segments until the tire carrier James's buckle is fully engaged, the driving tire body is engaged, and the driving tire carrier brakes to fix the two segments.

[0020] F2: By adjusting the height and position of the support pillars, the alignment deviation of the segment network lines and center lines caused by welding shrinkage and assembly errors during the segment manufacturing process can be adjusted.

[0021] F3: By adjusting the position and horizontal height of the support pillars, the overall accuracy data of the segment is adjusted, while fully considering the alignment of the overall assembly structure, so that all data of the segment meet the requirements and the overall assembly positioning is completed.

[0022] Furthermore, in step S3, using a total station with points r and s on the baseline X drawn in step S2 as reference points, a three-dimensional coordinate system is established. Points j and k with the same y-value in the three-dimensional coordinate system are measured on the hull body near its center. Points j and k are connected using a chalk line, and the straight line formed is the centerline of the hull section. Again, a three-dimensional coordinate system is established with points r and s on the baseline as reference points, and the longitudinal network line data is drawn on the hull body according to the design drawings. Points u and v with the same y-value in the three-dimensional coordinate system are connected using a chalk line to form a longitudinal network line B. The longitudinal network line C is drawn in the same way. Using a total station, the distance from the reference point r in the length direction is measured in the current coordinate system. Based on the distance from the reference point r in the length direction of the transverse network line in the design drawings, the x-coordinate value in the three-dimensional coordinate system of the transverse network line of the hull section is calculated. Points g and h with the same x-coordinate in the three-dimensional coordinate system are drawn on the jig. Points g and h are connected using a chalk line to form a transverse network line F.

[0023] Furthermore, in the aforementioned process of constructing and assembling curved sections, the tracks laid on the horizontal ground are arranged in a grid pattern.

[0024] Furthermore, in the aforementioned process of constructing and assembling curved sections, the Janus buckle is located at the end of the body along its length.

[0025] Furthermore, in the aforementioned process of constructing and assembling curved sections, multiple guide wheels are slidably connected on the slide rail.

[0026] Furthermore, in the above-mentioned process of constructing and assembling curved sections, the guide wheel is square, the support column is equipped with a hydraulic device, and the hydraulic cylinder is inserted into the guide wheel from the top of the guide wheel for fixation.

[0027] Furthermore, in the aforementioned process of constructing and assembling curved sections, two track wheels are provided on each side of the body.

[0028] Furthermore, in the above-mentioned process of constructing and assembling curved sections, the edge of the plate opening is 3mm from the body edge.

[0029] In the current segmented construction phase, supports are welded to the reinforcing bars at the construction site, with a 1m distance between the supports, forming a jig for the segmented construction process. A center line is marked on the jig. The support height is adjusted according to the jig drawing and segmented assembly drawing. The support height is fixed in increments; for height values ​​between two increments that cannot be adjusted, threaded pipes are welded to the upper end of the supports to allow for fine-tuning of the jig support height. The outer plates located on the jig centerline of the segmented structure are transported to the jig supports. Referring to the jig centerline, the segmented outer plates are welded and positioned on the jig supports. After the segmented outer plates on the jig centerline are welded, other components of the segmented outer plates are assembled on the jig using the segmented outer plates on the jig centerline as a reference. After the segmented outer plates are assembled, the internal structure of the segment is assembled. According to the segmented transportation plan and segmented assembly drawing, lifting lugs are welded at the corresponding positions in the segment, and the lifting lug welds are inspected using magnetic particle and ultrasonic non-destructive testing. After the segmented assembly and welding are completed, the segments are cut off from the jig support, and the outer surface of the segments is treated as follows: residual weld metal on the segments is gouged and ground, damaged base material areas caused by welding on the segments are repaired by welding, and the repaired weld areas are inspected for defects.

[0030] During the sectional assembly stage, supports are welded onto the reinforcing bars at the sectional assembly site, with a spacing of 1m between supports. The number and coverage of these supports should be sufficient for both sections during the assembly process, and a center line should be marked on the center line. A crane is used to move the reference section onto the center line supports. Based on the section's assembly drawing, the center line, and the center line, the section's position on the center line is determined. Using a point on the section as a horizontal reference, a total station or level is used to assist in measuring and adjusting the section's level. During adjustment, a point on the section structure is used as the overall horizontal reference point for the section. The total station or level is used to measure the horizontal height of other locations on the section, and the current height value is calculated based on the assembly drawing. For adjustments to sections with out-of-tolerance levels, the section is lifted by a crane, raising or lowering the support height. The section is then placed back on the support, and the horizontal height of the out-of-tolerance locations is measured again. This adjustment process is repeated until the horizontal height of every part of the section meets the requirements, thus completing the section's level adjustment. The assembly of the main assembly segments is achieved by using a crane to move the segments onto the support frame, aligning the assembly opening of each segment with the opening of the reference segment. The level of each segment is then adjusted, using the horizontal reference point as its horizontal benchmark. The overall accuracy data and structural alignment of the assembly segments are adjusted. Using measuring tools such as a total station, the length, width, and other overall dimensions of each segment are measured during assembly. Based on the structural alignment, level, and gaps at the assembly openings of each segment, the position and level of the segment are adjusted again using a crane, ensuring that all data for each segment meets the corresponding process requirements, thus completing the precision positioning of the assembly segments.

[0031] This invention can replace crane adjustment of segments. Traditionally, segment group data adjustment is achieved by raising and lowering the crane hook to move the segments. Since the crane only has three hooks, the position of the hooks connecting the segments needs to fully consider the weight, structure, and volume of the segments. Therefore, the process of adjusting the precision data of the segments by hooks is relatively complex, requiring the simultaneous operation of all three hooks. Adjusting the data at a certain position of a segment requires multiple raising and lowering of the crane hooks. This invention can precisely adjust the position and height of one or more supports to complete the precision data adjustment. The adjustment position is accurate, and the adjustment method is efficient and convenient.

[0032] This invention converts reverse-engineered hull sections into forward-engineered sections, reducing overhead welding workload and thus improving welding efficiency and reducing welding defects. The jig supports can move and be fixed on tracks, and their height is adjustable, suitable for different types of sections, and reusable. During section assembly, section accuracy data can be adjusted by changing the height and position of the jig supports, reducing crane usage frequency. Section assembly positioning can be achieved through movement using the overhead crane system, eliminating the need for repeated crane adjustments, simplifying operation and improving work efficiency. During section assembly positioning, the jig supports can be fixed using James Clerk locking mechanisms, eliminating the need for welding work for section assembly positioning and fixing. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the driving system;

[0034] Figure 2 This is a schematic diagram of the tire body for the vehicle's driving system.

[0035] Figure 3 This is a schematic diagram of the tire body for the vehicle's driving system.

[0036] Figure 4 This is a schematic diagram of the assembly process for the segmented outer panels;

[0037] Figure 5 This is a schematic diagram of the internal structure of the assembly section;

[0038] Figure 6 This is a schematic diagram of the segmented overall process;

[0039] Among them, 1-guide rail, 2-body, 3-track wheel, 4-slide rail, 5-guide wheel, 6-support column, 7-Jan's buckle, A-hull centerline, B-hull section longitudinal grid line, C-hull section transverse grid line, D-hull section plate edge line, E-hull section plate edge line, F-hull section transverse grid line, X-construction site baseline, M-front and rear reference points on the baseline, N-front and rear reference points on the baseline, a-distance from the edge of the outer plate of the hull section to the centerline of the hull section, f-distance from the outer plate of the hull section to the transverse grid line of the hull section. Detailed Implementation

[0040] The present invention will be described in detail with reference to specific embodiments.

[0041] A new process for constructing and assembling curved sections involves changing the section construction steps, eliminating the splicing of outer plates for each section, and directly assembling the outer plate parts of the hull sections onto a jig. Using the section grid lines and center lines on the jig as a reference, and referring to the part positions in the assembly drawing, the hull parts are positioned on the jig. After the hull sections are constructed, the gantry crane system is activated to move the sections, and two sections are fixed using James Bond buckles. A 6mm gap is reserved at the hull section assembly opening. By adjusting the position and height of the support pillars, the overall accuracy data, grid line alignment, and structural alignment of the sections are completed. Subsequently, the sections are assembled and welded.

[0042] 1. Hull section construction stage

[0043] S1: As Figure 1 As shown, the track in the crane system is laid on the horizontal ground of the construction site. The wheels are mounted on the tire body through bearings and can roll on the track to move the position of the tire frame, thereby realizing the segmented position movement. The tire body is a horizontal steel platform, and its upper surface is equipped with tracks of the same horizontal height, with a guide rail spacing of 1m. Guide wheels are installed on the track, and the guide wheels are connected to the guide rails through bearings, allowing them to move on the tire body track. Supports are fixed on the guide wheels, and the supports are equipped with hydraulic adjustment devices to adjust the horizontal height of the supports.

[0044] The driving system is equipped with an electric power system, which can provide power for the movement of the overall tire frame and the guide wheels. At the same time, the driving system is also equipped with an electromagnetic braking system, which can brake the moving tire frame and guide wheels, and at the same time fix the position of the tire frame and guide wheels.

[0045] S2: As Figure 2 As shown, a baseline X is drawn at the construction site for segmented construction. The baseline X serves as the reference for the width direction of the segment, and two reference points r and s are set on the baseline X for the length direction of the hull.

[0046] S3: As Figure 2As shown, using a total station, a three-dimensional coordinate system is established with points r and s on the baseline X drawn in step S2 as reference points. Points j and k with the same y-value in the three-dimensional coordinate system are measured on the hull body near its center. Points j and k are connected using a chalk line; the straight line formed is the centerline of the hull section. Again, a three-dimensional coordinate system is established with points r and s on the baseline as reference points. Based on the longitudinal grid line data in the design drawings, points u and v with the same y-value in the three-dimensional coordinate system are drawn on the hull body. Point u is connected using a chalk line. Connect point v to form longitudinal network line B, and draw longitudinal network line C in the same way. Use a total station to measure the distance from the reference point r in the length direction in the current coordinate system. Calculate the x-coordinate value of the transverse network line in the three-dimensional coordinate system of the hull section based on the distance from the reference point r in the length direction of the transverse network line in the design drawings. Draw points g and h with the same x-coordinate in the three-dimensional coordinate system on the jig. Connect points g and h with a chalk line to form transverse network line F. The distance between the plate edge line and the edge of the jig should be 3mm.

[0047] S4: As Figure 1 As shown, the support column can move on the slide rail. The position of the support column for supporting the outer plate K of the ship is determined according to the jig drawing. The support column is moved into place with the network line and center line drawn on the jig in step S3 as the reference. The support column is fixed in the current position by the electromagnetic braking system. The horizontal height of the support column is determined according to the ship assembly drawing. The horizontal height of the support column is adjusted by the hydraulic device of the support column.

[0048] S5: As Figure 3 As shown, after the segmented outer plate part K is cut, the distance f from the transverse grid line F and the distance a from the center line A of the outer plate part K are calculated with reference to the hull segment assembly drawing.

[0049] S6: As Figure 4 As shown, when assembling the outer hull plate component K onto the tire, the length direction of the outer hull plate component K is located using the transverse grid line F of the tire as a reference, and the width direction of the segmented outer hull plate component K is located using the longitudinal grid line on the tire. The segmented outer hull plate component K is then assembled onto the tire and fixed using a support electro-permanent magnet device.

[0050] S7: As Figure 5 The segmented outer panel parts are installed sequentially according to step S5. After the segmented outer panel is formed, the internal structure of the segment is assembled. The segmented assembly and welding are completed, preparing for the overall segment assembly.

[0051] 2. Hull Section Assembly Stage

[0052] F1: As Figure 6As shown, segment P is the reference segment of the overall group, and segment Q is the segment of the overall group. The trolley system is started, and the segment is moved until the James fastener on the tire body is closed. The electromagnetic braking system of the trolley system brakes the track wheel, the trolley system is fixed, and the tire body is connected. In step S3 of the segment construction process, the distance between the edge of the tire frame plate and the edge of the tire body is 3mm. Therefore, after the segment group is positioned, the gap between the segment group is guaranteed to be 6mm.

[0053] F2: Check the alignment of the grid lines and center lines of the baseline segments and the main group. Adjust the height and position of the support pillars to ensure that the alignment of the grid lines and center lines is ≤2mm.

[0054] F3: In response to changes in the overall data of the sections during the segmented construction process, after completing step S2, the overall assembly seam and structural alignment between the hull sections are measured. If the overall assembly seam of the section is within 4-10mm and the structural alignment deviation is less than 1 / 3 of the plate thickness, the overall assembly and welding of the section can be carried out. If the overall assembly seam and structural alignment deviation of the section are large, the height and position of the support pillars need to be adjusted again until the overall assembly seam and structural alignment of the section meet the relevant process requirements before the assembly and welding of the section can be carried out.

Claims

1. A process for constructing and assembling curved sections, characterized in that, The process includes the hull section construction phase and the hull section assembly phase. The specific operations for the hull section construction phase are as follows: S1: A guide rail is laid on a horizontal ground. A tire body is set above the guide rail. The track wheels are installed on both sides of the tire body through bearings. The track wheels roll on the guide rail. A slide rail with a longitudinal spacing of 1m is installed on the upper surface of the tire body. Guide wheels are slidably connected on the slide rail. The guide wheels are equipped with pillars whose position and height can be adjusted. S2: Make a baseline parallel to the guide rail outside the section construction site as the width reference during the section construction process. At the same time, set a length reference point on the baseline as the length reference point during the section construction process. S3: Using a total station, establish a three-dimensional coordinate system based on the baseline drawn in step S2. Make longitudinal network lines and center lines on the tire body, and then locate the transverse network lines using the reference points in the length direction on the baseline. S4: The support column slides on the slide rail via the guide wheel. The position of the support column for supporting the outer plate K of the ship is determined according to the jig drawing. The support column is moved into place with the network line and center line drawn on the jig in step S3 as the reference. An electromagnetic braking system is fixed at the top of the support column. The support column is fixed in the current position by the electromagnetic braking system. The horizontal height of the support column is determined according to the hull assembly drawing. The horizontal height of the support column is adjusted by the hydraulic device of the support column. S5: Complete the cutting of the outer plate parts, and calculate the distances from the hull grid line, center line, plate opening line to the same edge of the part based on the theoretical data of the hull section assembly drawing; S6: When assembling hull parts, according to the data calculated in step S5, the parts are placed on the jig support pillars corresponding to the network lines, center lines and plate opening lines drawn on the jig in step S3, and the segmented parts are fixed by the electro-permanent magnet device on the support pillars. S7: Following the above steps, the outer plate parts of the hull are installed in sequence. After the outer plate of the hull section is assembled, the other parts of the hull section are assembled until the entire section is completed, preparing for the overall assembly of the section. The specific operations for the hull section assembly stage are as follows: F1: The driving system starts, moves the segments until the Jansers of the adjacent tires are fully engaged, and the driving tire frame brakes to fix the two segments in place; F2: By adjusting the height and position of the support column, the alignment deviation of the segment network line and center line caused by welding shrinkage and assembly errors during the segment manufacturing process is adjusted; F3: By adjusting the position and horizontal height of the support pillars, the overall accuracy data of the segment is adjusted, while fully considering the alignment of the overall assembly structure, so that all data of the segment meet the requirements and the overall assembly positioning is completed.

2. The process method according to claim 1, characterized in that, In step S3, using a total station, a three-dimensional coordinate system is established with points r and s on the baseline X drawn in step S2 as reference points. Points j and k with the same y-value in the three-dimensional coordinate system are measured on the hull body near the center of the hull. Points j and k are connected using a chalk line, and the straight line formed is the center line of the hull section. A three-dimensional coordinate system is established again with points r and s on the baseline as reference points. Points u and v with the same y-value in the three-dimensional coordinate system are drawn on the hull body according to the longitudinal network line data in the design drawings. Points u and v are connected using a chalk line to form longitudinal network line B. Longitudinal network line C is drawn in the same way. Using a total station, the distance from the reference point r in the length direction is measured in the current coordinate system. Based on the distance from the reference point r in the length direction of the transverse network line in the design drawings, the x-coordinate value in the three-dimensional coordinate system of the transverse network line of the hull section is calculated. Points g and h with the same x-coordinate in the three-dimensional coordinate system are drawn on the hull body. Points g and h are connected using a chalk line to form transverse network line F.

3. The process method according to claim 1, characterized in that, The guide rails laid on the horizontal ground are arranged in a grid pattern.

4. The process method according to claim 1, characterized in that, The Jans buckle is located at the end of the tire body along its length.

5. The process method according to claim 1, characterized in that, Multiple guide wheels are slidably connected on the slide rail.

6. A process method according to claim 1 or 4, characterized in that, The guide wheel is square, and the support column is equipped with a hydraulic device. The hydraulic cylinder is inserted into the guide wheel from the top and fixed in place.

7. The process method according to claim 1, characterized in that, Two track wheels are provided on each side of the tire body.

8. The process method according to claim 1, characterized in that, The bead line is 3mm from the edge of the tire body.

Images