Assembly line manufacturing method for plane segmentation

Abstract

The invention relates to the technical field of ship plane segmentation, and discloses a plane segmentation assembly line manufacturing method which comprises the following steps: step 1, main board splicing operation; step 2, SAW welding and fixing; step 3, carrying out segmented turning-over operation; step 4, configuring and scribing a longitudinal bone; 5, longitudinal installation operation is carried out; step 6, longitudinal welding operation; 7, conveying to a jig frame section by section; 8, pulling-in operation of the inner structural material is carried out; ninthly, inner structural material assembling work is conducted; 10, welding operation is conducted on the inner structural material; step 11, checking and repairing operation; step 12, pre-outfitting operation is carried out; and step 13, carrying out subsection transportation operation. The flow from one station to the next station is segmented according to the fixed rhythm, so that the waiting time in the traditional fixed station production is eliminated, and the production process is smooth; the labor investment is effectively reduced; the conveying efficiency is effectively improved through the conveying trolley and the plate chain conveying device, conveying is carried out according to a specific rail, the problem of conveying errors is avoided, and the conveying accuracy is improved.

Description

Technical Field

[0001] This invention relates to the field of ship planar section technology, specifically a method for automated manufacturing of planar sections. Background Technology

[0002] In shipbuilding, apart from a portion of the structure, the rest are flat parts. These flat parts need to be transported and welded. In the past, welding required manual handling, which was not only time-consuming and labor-intensive, but also caused problems such as transportation errors, affecting the installation schedule.

[0003] Document CN 112408190 A discloses a method for manufacturing a planar segmented assembly line, including segmented lifting beams and lifting devices; the segmented lifting beams are configured in pairs; the lifting devices are configured in pairs; the lifting devices are arranged opposite each other on both sides of the assembly line working area; the segmented lifting beams, under the action of hoisting equipment, are detachably mounted on top of the pair of opposite lifting devices in the horizontal frame assembly line working area; the segmented lifting beams move up and down under the drive of the lifting devices. When this assembly line is in use, there are no transport trolleys, tracks, and corresponding plate chain conveying devices to help transport the planar plates, affecting the overall work efficiency.

[0004] Therefore, a new technical solution is needed to solve the above-mentioned technical problems. Summary of the Invention

[0005] To address the aforementioned problems, this invention discloses a planar segmented assembly line manufacturing method, which allows products to flow from one workstation to the next at a fixed pace, eliminating waiting time in traditional fixed-workstation production and ensuring a smooth production process; it can effectively reduce manual labor input and improve production efficiency.

[0006] The technical solution of this invention is: a planar segmented assembly line manufacturing method, comprising the following steps: Step 1, Mainboard assembly operation: The steel plate transport trolley transports the steel plates to be assembled to the vicinity of the "steel plate pre-assembly welding station" at the front of the assembly line, where the electromagnetic crane in the workshop lifts the steel plates onto the steel platform; Step 2, SAW welding and fixing: The spliced ​​steel plates are transferred to the SAW welding station on the front of the steel platform by the plate chain conveyor device and the welding suspension device is started to weld and fix the splice to enhance the stability of the main board structure. Step 3, Segmented Turning Operation: The main board after SAW welding is sent to the turning station of the steel platform by the plate chain conveyor to complete the segmented turning and adjust the segmented posture in order to facilitate the precise operation of subsequent longitudinal bone related processes. Step 4, longitudinal rib configuration marking: After being turned over and adjusted, the segments are transported to the longitudinal rib configuration marking station on the steel platform. According to production requirements, longitudinal rib installation marking lines are marked at the designated positions of the segments to clarify the installation positions of the longitudinal ribs. Step 5, longitudinal rib installation: The marked steel plates are transferred to the longitudinal rib installation station on the steel platform. According to the markings, the longitudinal ribs are precisely installed in the corresponding positions of the sections to ensure the installation accuracy of the longitudinal ribs. Step 6, longitudinal bone welding operation: After the longitudinal bone is installed, the sections are transported to the longitudinal bone welding station on the steel platform. The welding suspension device is started to weld the connection between the longitudinal bone and the main board to complete the longitudinal bone fixation. During the welding process, the electrical control system controls the line to ensure work efficiency. Step 7, Segmented transport to the jig: The segments with completed longitudinal reinforcement welding are smoothly transported to the jig area via a plate chain conveyor or a transfer trolley, and then proceed to the subsequent internal structure material processing and pre-outfitting stages. Step 8, Internal structure material pulling in: The internal structure material pulling in operation is carried out in sections. The internal structure material is pulled into the designated area of ​​each section with the help of the relevant conveying mechanism to prepare for the internal structure material assembly. Step 9, Internal structure assembly: Pull in the internal structure segments and transport them sequentially to the internal structure assembly station of the jig according to the assembly line. Assemble the segments and internal structure to ensure that the internal structure and the segment structure fit tightly. Step 10, Internal Component Welding: The assembled sections are transferred to the welding station of the jig, the welding suspension device is activated, and the connection between the sections and the internal components is welded at the internal component welding station to strengthen the overall structural strength; welding defects must be avoided during the welding process to ensure welding quality. Step 11, Inspection and Repair Work: The sections with completed internal structure welding are transported to the inspection and repair station of the jig. The staff conducts a comprehensive inspection of the assembly accuracy and welding quality of the sections. If assembly deviations or welding cracks are found, they are repaired and adjusted in time to ensure that the sections meet the production standards. Step 12, Pre-outfitting operation: The inspected and repaired sections are transported to the pre-outfitting station of the jig. According to the hull production requirements, pre-outfitting operations are carried out on the sections, and relevant outfitting components are installed to lay the foundation for the subsequent hull assembly. Step 13, Segmented Transport Operation: The pre-outfitted segments are transported to the two transport and lifting stations of the jig. The hydraulic lifting device is started to lift the segments smoothly, ensuring that there is no jamming or delay during the lifting process. Then, the lifted segments are transported out of the production line by the transport trolley. At this point, the complete production process of the planar segmented production line manufacturing method is completed.

[0007] Preferably, in step 1, the steel platform is equipped with a steel plate lateral adjustment device and a longitudinal adjustment device, and the steel plate is transported to the SAW welding station by lifting rollers and a plate chain conveyor.

[0008] Preferably, the workstation in step 4 is marked manually, and the steel platform is equipped with lifting rollers.

[0009] Preferably, the weight of the longitudinal skeleton in step 6 does not exceed 150t, and there are two longitudinal skeleton welding stations. The plate chain conveyor of one longitudinal skeleton welding station extends to one-quarter to one-third of the length of the station, and the other longitudinal skeleton welding station extends all the way to the lifting station.

[0010] Preferably, each workstation in steps 8, 9, 10, 11, and 12 is equipped with an electric hoist and a welding machine.

[0011] Preferably, step 10 includes three welding stations equipped with suspended beams, each suspended beam having a welding machine located on both sides of the beam.

[0012] Preferably, in step 13, the hydraulic lifting device has a cylinder lifting force greater than 70t, a total lifting force of 560t, a cylinder diameter of 250mm, and a telescopic speed of 300-340mm / min.

[0013] Preferably, the plate chain conveyor is used to transport the steel plate from the previous station to the front SAW welding station, and from the front SAW welding station to the steel plate flipping welding station. Another plate chain conveyor takes over and transports the steel plate from the steel plate welding station to the next station.

[0014] The advantages of this invention are: 1. This invention segments the flow from one workstation to the next according to a fixed rhythm, eliminating the waiting time in traditional fixed-workstation production, and making the production process smooth; it can effectively reduce the input of manpower and improve production efficiency.

[0015] 2. This invention can effectively improve transportation efficiency by using a transport trolley and a plate chain conveyor, and by transporting along a specific track, it ensures that no transportation errors occur, thereby improving the accuracy of transportation and increasing work efficiency.

[0016] 3. This invention improves mechanization efficiency, reduces manual labor, and enhances safety while lowering labor costs. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the process of the present invention; Figure 2 This is a schematic diagram of the plate chain conveyor and transport trolley of the present invention.

[0018] The following are the station locations: 1. Steel plate pre-assembly welding station; 2. SAW welding station; 3. Turning station; 4. Longitudinal frame configuration marking station; 5. Longitudinal frame installation station; 6. Longitudinal frame welding station; 7. Internal structure material pulling station; 8. Internal structure material assembly station; 9. Internal structure material welding station; 10. Inspection and repair station; 11. Pre-outfitting station; 12. Transport and lifting station; 13. Plate chain conveyor device; 14. Transport trolley. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0020] like Figure 1-2 As shown, the planar segmented assembly line manufacturing method includes the following steps: Step 1, Mainboard assembly operation: The steel plate transport trolley 12 transports the steel plates to be assembled to the vicinity of the first station of the assembly line, "steel plate pre-assembly welding station 1". The electromagnetic crane in the workshop lifts the steel plates onto the steel platform. The steel platform is equipped with a steel plate lateral adjustment device and a longitudinal adjustment device. The steel plates are transported to the SAW welding station 2 by lifting rollers and plate chain conveyor. Step 2, SAW welding and fixing: The spliced ​​steel plates are transferred to the front SAW welding station 2 of the steel platform by the plate chain conveyor 13 and the welding suspension device is started to weld and fix the splice to enhance the stability of the main board structure. Step 3, segmented turning operation: The main board after SAW welding is sent to the turning station of the steel platform by the plate chain conveyor 13 to complete the segmented turning and adjust the segmented posture in order to ensure the precise operation of subsequent longitudinal bone related processes. Step 4, longitudinal rib configuration marking: After being turned over and adjusted, the segments are conveyed to the longitudinal rib configuration marking station 4 on the steel platform. The marking is done manually. The steel platform is equipped with lifting rollers. According to the production requirements, the longitudinal rib installation marking lines are marked at the designated positions of the segments to clarify the installation positions of the longitudinal ribs. Step 5, longitudinal rib installation: The marked steel plates are transferred to the longitudinal rib installation station 5 on the steel platform. According to the markings, the longitudinal ribs are precisely installed in the corresponding positions of the segments to ensure the installation accuracy of the longitudinal ribs. Step 6, longitudinal bone welding operation: After the longitudinal bone is installed, the segment is transported to the longitudinal bone welding station 6 on the steel platform. The welding suspension device is started to weld the connection between the longitudinal bone and the main board to complete the longitudinal bone fixation. During the welding process, the line is controlled by the electrical control system to ensure work efficiency. The weight including the longitudinal bone does not exceed 150t. There are 2 longitudinal bone welding stations. The plate chain conveyor 13 of one longitudinal bone welding station extends to one-quarter to one-third of the length of the station. The other longitudinal bone welding station extends all the way to the lifting station. Step 7, Segmented transport to the jig: The segments with completed longitudinal reinforcement welding are smoothly transported to the jig area via the plate chain conveyor 13 or the transfer trolley, and then proceed to the subsequent internal structure material processing and pre-outfitting stages. Step 8, Internal structure material pulling in: The internal structure material pulling in operation is carried out in sections at the internal structure material pulling in station 7 of the jig. With the help of relevant conveying mechanisms, the internal structure material is pulled into the designated area of ​​the section to prepare for internal structure material assembly. Step 9, Internal structure assembly: Pull in the internal structure segments and transport them sequentially to the internal structure assembly station 8 of the jig according to the assembly line. Assemble the segments and internal structure to ensure that the internal structure and the segment structure fit tightly. Step 10, Welding of internal components: The assembled sections are transferred to the welding station of the jig. The welding suspension device is started, and the connection between the sections and the internal components is welded at the internal component welding station 9 to strengthen the overall structural strength. Welding defects must be avoided during the welding process to ensure welding quality. Three welding stations are set up, and suspension beams are configured. Each suspension beam is equipped with a welding machine, which is located on both sides of the beam. Step 11, Inspection and Repair Work: The sections with completed internal structure welding are transported to the inspection and repair station 10 of the jig. The staff conducts a comprehensive inspection of the assembly accuracy and welding quality of the sections. If assembly deviations or welding cracks are found, they are repaired and adjusted in time to ensure that the sections meet the production standards. Step 12, Pre-outfitting operation: The inspected and repaired sections are transported to the pre-outfitting station 11 of the jig. According to the hull production requirements, pre-outfitting operations are carried out on the sections, and relevant outfitting components are installed to lay the foundation for the subsequent hull assembly. Electric hoists and welding machines are installed at each workstation in steps 8, 9, 10, 11, and 12. Step 13, Segmented Transport Operation: The pre-outfitted segments are transported to the two transport and lifting stations 14 of the jig. The hydraulic lifting device is started to lift the segments smoothly, ensuring that there is no jamming or delay during the lifting process. Then, the lifting segment is transported out of the assembly line by the transport trolley 12. At this point, the complete production process of the assembly line manufacturing method of planar segments is completed. In step 13, the hydraulic lifting device has a cylinder lifting force of more than 70t, a total lifting force of 560t, a cylinder diameter of 250mm, and a telescopic speed of 300-340mm / min.

[0021] The plate chain conveyor 13 transports the steel plate from the previous station to the front SAW welding station 2, and from the front SAW welding station 2 to the steel plate turning welding station. Another plate chain conveyor 13 takes over and transports the steel plate from the steel plate welding station to the next station.

[0022] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention; the objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments, and any modifications or variations of the embodiments of the present invention may be made without departing from the stated principles.

Claims

1. A planar segmented assembly line manufacturing method, characterized in that, Includes the following steps: Step 1, Mainboard assembly operation: The steel plate transport trolley transports the steel plates that need to be assembled to the vicinity of the "steel plate pre-assembly welding station" at the front of the assembly line, where the electromagnetic crane in the workshop lifts the steel plates to the assembly station; Step 2, SAW welding and fixing: The spliced ​​steel plates are transferred to the SAW welding station via a plate chain conveyor. The welding suspension device is activated to weld and fix the spliced ​​joints, thereby enhancing the stability of the main plate structure. Step 3, Segmented Turning Operation: The main board after SAW welding is sent to the turning station by the plate chain conveyor to complete the segmented turning and adjust the segmented posture to facilitate the precise operation of subsequent longitudinal bone related processes; Step 4, longitudinal rib configuration marking: After being turned over and adjusted, the segments are transported to the longitudinal rib configuration marking station on the steel platform. According to production requirements, longitudinal rib installation marking lines are marked at the designated positions of the segments to clarify the installation positions of the longitudinal ribs. Step 5, longitudinal rib installation: The marked steel plates are transferred to the longitudinal rib installation station on the steel platform. According to the markings, the longitudinal ribs are precisely installed in the corresponding positions of the sections to ensure the installation accuracy of the longitudinal ribs. Step 6, longitudinal bone welding operation: After the longitudinal bones are installed, the sections are transported to the longitudinal bone welding station on the steel platform. The automatic longitudinal bone welding equipment is started to weld the connection between the longitudinal bone and the main board, thus fixing the longitudinal bone. During the welding process, the electrical control system controls the line to ensure work efficiency. Step 7, Segmented transport to the jig: The segments with completed longitudinal reinforcement welding are smoothly transported to the jig area by a transfer cart, and then proceed to the subsequent internal structure material processing and pre-outfitting stages; Step 8, Internal structure material pulling in: The internal structure material pulling in operation is carried out in sections at the internal structure material pulling in station of the jig. With the help of a winch, the internal structure material is pulled in sections into the designated area to prepare for internal structure material assembly. Step 9, Internal structure assembly: Pull in the internal structure segments and transport them sequentially to the internal structure assembly station of the jig according to the assembly line. Assemble the segments and internal structure to ensure that the internal structure and the segment structure fit tightly. Step 10, Internal Component Welding: The assembled sections are transferred to the welding station of the jig, the welding suspension device is activated, and the connection between the sections and the internal components is welded at the internal component welding station to strengthen the overall structural strength; welding defects must be avoided during the welding process to ensure welding quality. Step 11, Inspection and Repair Work: The sections with completed internal structure welding are transported to the inspection and repair station of the jig. The staff conducts a comprehensive inspection of the assembly accuracy and welding quality of the sections. If assembly deviations or welding cracks are found, they are repaired and adjusted in time to ensure that the sections meet the production standards. Step 12, Pre-outfitting operation: The inspected and repaired sections are transported to the pre-outfitting station of the jig. According to the hull production requirements, pre-outfitting operations are carried out on the sections, and relevant outfitting components are installed to lay the foundation for the subsequent hull assembly. Step 13, Segmented Transport Operation: The pre-outfitted segments are transported to the two transport and lifting stations of the jig. The hydraulic lifting device is started to lift the segments smoothly, ensuring that there is no jamming or delay during the lifting process. Then, the lifted segments are transported out of the production line by a transport flatbed truck. At this point, the complete production process of the planar segmented production line manufacturing method is completed.

2. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: In step 1, the steel platform is equipped with a steel plate lateral adjustment device and a longitudinal adjustment device. The steel plate is transported to the SAW welding station by lifting rollers and a plate chain conveyor.

3. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: In step 4, the workstation is marked manually, and the steel platform is equipped with lifting rollers.

4. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: In step 6, the weight of the longitudinal ribs does not exceed 150t. There are two longitudinal rib welding stations. The plate chain conveyor of one longitudinal rib welding station extends to one-quarter to one-third of the length of the station, and the other longitudinal rib welding station extends all the way to the lifting station.

5. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: Each workstation in steps 8, 9, 10, 11, and 12 is equipped with an electric chain hoist and a welding machine.

6. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: In step 10, there are 3 welding stations, each equipped with a suspended beam. Each suspended beam is equipped with a welding machine, which is located on both sides of the beam.

7. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: In step 13, the hydraulic lifting device has a cylinder lifting force greater than 70t, a total lifting force of 560t, a cylinder diameter of 250mm, and a telescopic speed of 300-340mm / min.

8. The planar segmented assembly line manufacturing method according to claim 1, characterized in that: The plate chain conveyor device transports the steel plate from the previous station to the front SAW welding station, and from the front SAW welding station to the steel plate flipping welding station. Another plate chain conveyor device takes over and transports the steel plate from the steel plate welding station to the next station.

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