A method of manufacturing a cable machine pull rod

Abstract

This invention relates to the field of construction equipment technology for water conservancy and hydropower projects, specifically to a method for manufacturing cable crane tie rods. The method uses a tooling shaft to position the tie rod lugs during installation, with the following steps: A sealing plate is welded to a steel pipe; the steel pipe is placed on a steel platform, with one end resting on the platform and the other end suspended in the air; the lower lug is placed on a thick, leveling block, contacting the top of the steel pipe, connecting the lower lug and the steel pipe; a small leveling block is placed on the top surface of the lower lug, and then the upper lug is placed on the small leveling block; the tooling shaft passes through the shaft holes of the upper and lower lugs, connecting the upper lug to the top of the steel pipe; the other end of the steel pipe is placed on the steel platform, a new lower lug is placed, and the new lower lug is connected to the top of the other end of the steel pipe; the above steps are repeated to complete the lug installation. This invention shortens the processing cycle of the tie rod, reduces manufacturing costs, and simultaneously ensures the processing accuracy and structural performance of the tie rod.

Description

Technical Field

[0001] This invention relates to the field of construction equipment technology for water conservancy and hydropower projects, and specifically to a method for manufacturing cable winch tie rods. Background Technology

[0002] Hydropower projects are mostly built in high mountain and canyon areas with complex terrain and narrow construction sites. Long-span, high-lifting-capacity cable cranes are the core heavy equipment for the concrete pouring of hydropower station dams, the installation of metal structures and electromechanical equipment. Their installation efficiency, operational stability and construction cost directly determine the construction progress and investment control of hydropower station projects. As the core load-bearing structure of the cable crane, the towering towers at both ends need to be adapted to the requirements of rapid on-site assembly, convenient disassembly, and reusability across projects. The industry generally adopts a modular truss structure, which is mainly assembled from load-bearing columns, supporting legs, transverse beams, and load-bearing tie rods. Among them, the tie rod is a key load-bearing component that transmits loads, enhances structural rigidity, controls deformation, and ensures the overall stability of the tower. Due to the influence of the stress distribution and spatial arrangement of the truss, the design specifications of the tie rods vary greatly, with the length of a single rod mostly ranging from 3m to 15m. The main body is mostly made of seamless steel pipes or steel beams, and the two ends are hinged to the tower by pins through double ear plates. It is a slender load-bearing component with a large slenderness ratio and high requirements for the shape and position accuracy of the holes at both ends.

[0003] The current standard manufacturing process for this type of cable car tie rod in the industry involves first assembling and welding the tie rod body with the prefabricated double ear plates at both ends. After the welds pass non-destructive testing, the entire tie rod is clamped onto heavy equipment such as a large floor-type milling machine or a CNC gantry machining center. The pin holes of the double ear plates at both ends are then precision machined to meet the tolerance requirements of the design drawings.

[0004] However, the aforementioned conventional processes have many insurmountable pain points in mass production. For example, the processing cycle is long, the parallelism of processes is extremely low, there are strict constraints on the sequence of welding and finishing processes, multiple specifications of tie rods require repeated debugging of tooling and clamping and alignment, and the proportion of auxiliary time is high, making it difficult to match the tight construction schedule of hydropower projects; the dependence on heavy equipment and site is high, 15m long tie rods require matching with large-stroke heavy processing equipment, the procurement and maintenance costs are high, core equipment capacity is occupied for a long time, and the requirements for workshop space and lifting equipment are strict, which is difficult for small and medium-sized manufacturing enterprises to adapt to; the manufacturing cost is high, the cost of heavy equipment per hour is high, multiple specifications of tie rods require customized special tooling, poor versatility, welding deformation requires a large amount of machining allowance, which increases raw material loss and lengthens machining time; quality control is difficult, long tie rods are prone to bending deformation and ear plate angle deviation after welding, and are prone to bending deformation due to their own weight during clamping, affecting the machining accuracy of holes. At best, it will lead to misalignment of holes and increased assembly difficulty on site, and at worst, it will affect the structural safety of the tower and even the risk of component scrapping.

[0005] In summary, existing conventional processes can no longer meet the core requirements of rapid construction, low-cost turnover, and high-precision manufacturing of cable cranes in current hydropower projects. Developing a low-cost manufacturing method for cable crane tie rods that can significantly shorten the processing cycle, reduce manufacturing costs, eliminate reliance on heavy equipment, and at the same time stably ensure processing accuracy and structural performance has become an urgent technical challenge to be solved in this field. Summary of the Invention

[0006] In order to solve the problems existing in the prior art, this application provides a method for manufacturing cable crane tie rods that can shorten the processing cycle and reduce manufacturing costs.

[0007] To achieve the above-mentioned technical effects, the specific technical solution of this application is as follows: A method for manufacturing a cable winch tie rod includes the following specific steps: Step S1: First, machine the tooling shaft and multiple ear plates, then pre-weld the sealing plate to both ends of the steel pipe; Step S2: Place the welded steel pipe on the steel platform, with one end of the steel pipe on the steel platform and the other end suspended in the air; Step S3: Place one ear plate on multiple blocks of equal thickness and height as the lower ear plate, and make the lower ear plate contact the top of one end of the steel pipe. Then fix the lower ear plate and the top of one end of the steel pipe in place. Step S4: Place several small equal-height blocks on the top surface of the lower ear plate, and then place another ear plate on the small equal-height blocks as the upper ear plate, and make the shaft hole of the upper ear plate correspond to the shaft hole of the lower ear plate. Step S5: Insert the tooling shaft into the shaft hole at the top of the upper ear plate and the shaft hole at the lower ear plate. At this time, fix the upper ear plate to the top of one end of the steel pipe to complete the installation of the ear plate at the top of one end of the steel pipe. Step S6: Place the other end of the steel pipe on the steel platform, place the new lower ear plate, and fix the new lower ear plate to the top of the other end of the steel pipe. Repeat steps S4 to S5 to complete the installation of the ear plate at the top of the other end of the steel pipe.

[0008] Furthermore, in step S1, the tooling shaft undergoes heat treatment to control the workpiece hardness value within the range of 217HB to 255HB.

[0009] Furthermore, multiple thick, equal-height blocks are placed at intervals on the steel platform, and are positioned above the top of one end of the steel pipe or above the top of the other end.

[0010] Furthermore, in step S2, the steel platform is 5m long and 2m wide, and a channel steel for supporting and fixing the steel pipe is placed on the top of the steel platform; the steel pipe is placed on the channel steel; multiple thickness equal height blocks are located above the top of one end of the channel steel; the thickness equal height blocks are rectangular structures, and multiple thickness equal height blocks are parallel to each other; the thickness of the thickness equal height blocks is 47mm.

[0011] Furthermore, there are two equal-height blocks, and the two equal-height blocks are leveled and fixed on the steel platform using a level.

[0012] Furthermore, in step S3, the upper ear plate and the lower ear plate are symmetrical in the horizontal direction; in step S4, the multiple small contour blocks are columnar structures; the height of the small contour blocks is 62mm.

[0013] Furthermore, there are three small contour blocks, two of which are located on both sides of the top of one end of the steel pipe, and the other small contour block is located directly above the shaft hole of the lower ear plate.

[0014] Furthermore, the specific steps for installing the ear plate in step S6, where the other end of the steel pipe is placed on the steel platform, are as follows: Step a1: Lift the tie rod and rotate it 180 degrees. Place the other end of the steel pipe in the channel steel and use a level to adjust the ear plate that has been installed at one end of the steel pipe to be horizontal. The steel pipe is then leveled using a five-ton jack. Step a2: Place the new lower ear plate on multiple thickness equal height blocks. At this time, insert the tooling shaft into the shaft hole of the new lower ear plate. Control the opening distance to be 1mm larger than the preset distance using a level. Spot weld the new lower ear plate to the top of the other end of the steel pipe. Remove the tooling shaft and repeat steps S4 to S5 to complete the installation of the ear plate at the top of the other end of the steel pipe.

[0015] Furthermore, the error in adjusting the top surface of the ear plate horizontally in step a1 is less than 0.5 mm.

[0016] Furthermore, in steps S3 to S6, the ear plate and the steel pipe are connected by spot welding; in step S5, multiple fixing components for reinforcement and support are connected between the outer side of the upper ear plate and the outer side of the lower ear plate; after the ear plate is spot welded to the top of one end of the steel pipe in step S5, the ear plate is welded, and after the ear plate welding is completed and cooled, the tooling shaft is removed and the fixing components are removed.

[0017] Based on the above technical solution, the beneficial effects of this application are as follows: 1. This invention simplifies the installation process by first machining multiple ear plates and tooling shafts, and using thick and small equal-height blocks and steel platforms. All of these can be manufactured in a regular machining workshop without the need for special equipment. It also achieves high-precision control of the ear plate coaxiality, opening size, and levelness in all dimensions, thereby significantly shortening the processing cycle, reducing manufacturing costs, eliminating reliance on heavy equipment, and ensuring the machining accuracy and structural performance of the tie rod.

[0018] 2. This invention uses a tooling shaft to weld the tie rod ear plates. During the welding process, the tooling shaft is simultaneously inserted into the shaft holes of the upper and lower ear plates to form rigid positioning. This solves the technical problem of large coaxiality deviation caused by traditional scribing positioning or visual alignment. It avoids the failure of the pin to be inserted, rotation jamming, or uneven force due to large coaxiality deviation in the later stage, thus ensuring the machining accuracy and structural performance of the tie rod.

[0019] 3. By using a small equal-height block with a height of 62mm and a thick equal-height block with a thickness of 47mm, this invention controls the distance between the upper and lower ear plates, as well as the height of the lower ear plate, ensuring the stability and precision of the tie rod welding process and greatly reducing the installation error of the tie rod.

[0020] 4. By using thick, level blocks, a level, and a five-ton jack, this invention ensures that the levelness and parallelism of both end plates meet high precision requirements, resulting in uniform force distribution during use and preventing damage caused by uneven load.

[0021] 5. By using thick equal-height blocks, small equal-height blocks, and tooling shafts, the present invention forms an integral rigid fixation for the upper and lower ear plates. The tooling shaft is removed after the ear plates are welded and completely cooled, allowing the welding stress to be released slowly under constraint, which greatly reduces residual deformation and significantly reduces the workload of post-weld correction of the ear plates. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure during installation of the present invention; Figure 2 This is a schematic diagram of the structure for installing the lower side ear plate of the present invention; Figure 3 This is a schematic diagram of the structure after the ear plate of the present invention is installed; Figure 4 This is a schematic diagram of the product shaft structure of the present invention; Figure 5 This is a schematic diagram of the tooling shaft structure of the present invention; Figure 6 This is a schematic diagram of the steel pipe structure after the sealing plate is installed; Figure 7 This is a schematic diagram of the structure of the present invention when adjusting the horizontal and opening positions.

[0023] In the attached diagram: 1-steel pipe; 2-channel steel; 3-thickness equal-height block; 4-ear plate; 5-small equal-height block; 6-sealing plate; 7-tool shaft; 8-fixed component; 9-jack. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this application, but not all embodiments.

[0025] Example 1 like Figure 1 As shown, a method for manufacturing a cable crane tie rod includes the following specific steps: Step S1: As Figure 5 and Figure 6 As shown, tooling shaft 7 and multiple ear plates 4 are first machined, and then sealing plates 6 are pre-welded to both ends of steel pipe 1. The purpose of pre-welding sealing plates 6 is to reduce the impact on the opening size of ear plates 4. Step S2: Place the welded steel pipe 1 on the steel platform, with one end of the steel pipe 1 on the steel platform and the other end suspended in the air; Step S3: Place an ear plate 4 on multiple thick and equal-height blocks 3 as the lower ear plate, and make the lower ear plate contact the top of one end of the steel pipe 1. Then fix the lower ear plate and the top of one end of the steel pipe 1 in a fixed connection. Step S4: As Figure 2 As shown, multiple small equal-height blocks 5 are placed on the top surface of the lower ear plate, and another ear plate 4 is placed on the small equal-height blocks 5 as the upper ear plate, with the shaft hole of the upper ear plate corresponding to the shaft hole of the lower ear plate. Step S5: Insert the tooling shaft 7 into the shaft hole at the top of the upper ear plate and the shaft hole in the lower ear plate. At this time, fix the upper ear plate to the top of one end of the steel pipe 1 to complete the installation of the ear plate 4 at the top of one end of the steel pipe 1. The purpose of inserting the tooling shaft 7 into the shaft holes at the top of the side ear plate 4 and the lower ear plate is to control the concentricity of the holes and shafts of the upper and lower ear plates, so as to ensure that the shaft can be easily inserted when installing the product shaft later. Because there is a bevel around the weld between the ear plate 4 and the steel pipe 1, the opening between the upper and lower ear plates may increase after welding, causing the axes of the two holes to not coincide, resulting in the tooling shaft 7 getting stuck and unable to be removed. The specific solution is to use flame straightening to heat the root of the inner weld of the upper and lower ear plates with a heat gun. After cooling, the opening between the upper and lower ear plates will decrease until the size is consistent with the opening before welding. At this time, it indicates that the axes coincide. Then, use a hammer to tap the tooling shaft 7 to make the tooling shaft 7 exit the shaft hole. Step S6: As Figure 3As shown, place the other end of the steel pipe 1 on the steel platform, place the new lower ear plate, and fix the new lower ear plate to the top of the other end of the steel pipe 1. Then repeat steps S4 to S5 to complete the installation of the ear plate 4 at the top of the other end of the steel pipe 1. After installation, the center line of the gap between the upper ear plate and the lower ear plate should coincide with the center line of the steel pipe 1.

[0026] Example 2 Based on Example 1, in step S1, the tooling shaft 7 undergoes heat treatment to control the workpiece hardness range to 217HB to 255HB; in step S1, a product shaft is also machined for trial insertion of all ear plates 4 after step S6; the product shaft undergoes heat treatment to control the workpiece hardness range to 217HB to 255HB, and is plated with hard chrome; the thickness of the hard chrome is controlled to be 0.03mm to 0.05mm; the dimensional tolerance of the product shaft is 0.05mm smaller than that of the tooling shaft 7. The purpose of designing the dimensional tolerance of the product shaft to be smaller than that of the tooling shaft 7 is to ensure that the tooling shaft 7 can be inserted, and that the product shaft can also be inserted subsequently; Figure 4 As shown, the product shaft is provided with a stop plate groove to lock the stop plate on the cable machine. Multiple thick, equal-height blocks 3 are placed at intervals on the steel platform, and are located above the top of one end or the top of the other end of the steel pipe 1.

[0027] In step S2, the steel platform is 5m long and 2m wide, and a channel steel 2 for supporting and fixing the steel pipe 1 is placed on the top of the steel platform; the steel pipe 1 is placed on the channel steel 2; multiple thick equal height blocks 3 are located above the top of one end of the channel steel 2; the thick equal height blocks 3 are rectangular structures, and the multiple thick equal height blocks 3 are parallel to each other; the thickness of the thick equal height blocks 3 is 47mm, and the thickness of the equal height blocks is determined by the plane from the lower ear plate to the platform; there are two thick equal height blocks 3, and the two thick equal height blocks 3 are leveled and fixed on the steel platform by a level.

[0028] In step S3, the upper and lower ear plates are symmetrical in the horizontal direction; in step S4, the multiple small contour blocks 5 are columnar structures; the height of the small contour block 5 is 62mm. The reason for setting it to 62mm is that the actual opening after the upper and lower ear plates are welded is 60mm, and the tolerance is 1mm. Therefore, the positive tolerance of the size before welding plus 1mm is the welding shrinkage; there are three small contour blocks 5, two of which are located on both sides of the top of one end of the steel pipe 1, and the other small contour block 5 is located directly above the shaft hole of the lower ear plate.

[0029] Example 3 Based on Example 2, such as Figure 7 As shown, the specific steps for installing the ear plate 4 by placing the other end of the steel pipe 1 on the steel platform in step S6 are as follows: Step a1: Lift the tie rod and rotate it 180 degrees. Place the other end of the steel pipe 1 in the channel steel 2. Use a level to adjust the ear plate 4, which has been installed at one end of the steel pipe 1, to be horizontal, ensuring that both ends of the steel pipe 1 and the ear plate 4 are horizontal and parallel to the ground. The steel pipe 1 is horizontally adjusted using a five-ton jack 9. The error in the horizontal adjustment of the top surface of the ear plate 4 in step a1 is less than 0.5mm. Step a2: Place the new lower ear plate on multiple thickness equal height blocks 3. At this time, insert the tooling shaft 7 into the shaft hole of the new lower ear plate. Control the opening distance to be 1mm larger than the preset distance by using a level. Spot weld the new lower ear plate to the top of the other end of the steel pipe 1. Remove the tooling shaft 7 and repeat steps S4 to S5 to complete the installation of the ear plate 4 at the top of the other end of the steel pipe 1.

[0030] In steps S3 to S6, the ear plate 4 and the steel pipe 1 are connected by spot welding. In step S5, multiple fixing components 8 for reinforcement and support are connected between the outer side of the upper ear plate and the outer side of the lower ear plate. The fixing components 8 are directly welded between the outer side of the upper ear plate and the outer side of the lower ear plate to control the free shrinkage of the ear plate 4 during welding, reduce welding deformation, and reduce the amount of post-weld repair work. It is estimated that the opening of the ear plate 4 will increase by 2 to 3 mm after adding the fixing components 8, and may increase by 5 to 6 mm if not added. After the ear plate 4 and the top of one end of the steel pipe 1 are spot welded together in step S5, after the ear plate 4 and the steel pipe 1 are welded and completely cooled, the tooling shaft 7 is taken out and the fixing components 8 are removed.

[0031] The above description is a detailed description of the preferred embodiments of this application. However, the embodiments are not intended to limit the scope of this patent application. All equivalent changes or modifications made under the technical spirit of this application should fall within the patent scope covered by this application.

Claims

1. A method for manufacturing a cable winch tie rod, characterized in that, The specific methods and steps include the following: Step S1: First, process the tooling shaft (7) and multiple ear plates (4), and then pre-weld the sealing plate (6) to both ends of the steel pipe (1); Step S2: Place the welded steel pipe (1) on the steel platform, so that one end of the steel pipe (1) is placed on the steel platform and the other end is suspended in the air; Step S3: Place an ear plate (4) on multiple thick and high blocks (3) as the lower ear plate, and make the lower ear plate contact the top of one end of the steel pipe (1), and then fix the lower ear plate and the top of one end of the steel pipe (1) in a fixed connection. Step S4: Place multiple small equal-height blocks (5) on the top surface of the lower ear plate, and then place another ear plate (4) on the small equal-height blocks (5) as the upper ear plate, and make the shaft hole of the upper ear plate correspond to the shaft hole of the lower ear plate. Step S5: Insert the tooling shaft (7) into the shaft hole at the top of the upper ear plate and the shaft hole at the lower ear plate. At this time, fix the upper ear plate to the top of one end of the steel pipe (1) to complete the installation of the ear plate (4) at the top of one end of the steel pipe (1). Step S6: Place the other end of the steel pipe (1) on the steel platform, place the new lower ear plate, and fix the new lower ear plate to the top of the other end of the steel pipe (1). Repeat steps S4 to S5 to complete the installation of the ear plate (4) at the top of the other end of the steel pipe (1).

2. The method for manufacturing a cable crane tie rod according to claim 1, characterized in that: In step S1, the tooling shaft (7) undergoes heat treatment to control the workpiece hardness value range from 217HB to 255HB.

3. The method for manufacturing a cable crane tie rod according to claim 1, characterized in that: Multiple thick, equal-height blocks (3) are placed at intervals on the steel platform and are located above the top of one end or the top of the other end of the steel pipe (1).

4. The method for manufacturing a cable crane tie rod according to claim 3, characterized in that: In step S2, the steel platform is 5m long and 2m wide, and a channel steel (2) for supporting and fixing the steel pipe (1) is placed on the top of the steel platform; the steel pipe (1) is placed on the channel steel (2); multiple equal-height blocks (3) are located above the top of one end of the channel steel (2); the equal-height blocks (3) are rectangular structures, and multiple equal-height blocks (3) are parallel to each other; the thickness of the equal-height blocks (3) is 47mm.

5. A method for manufacturing a cable crane tie rod according to claim 4, characterized in that: There are two equal-height blocks (3), and the two equal-height blocks (3) are leveled and fixed on the steel platform by a level.

6. The method for manufacturing a cable crane tie rod according to claim 1, characterized in that: In step S3, the upper ear plate and the lower ear plate are symmetrical in the horizontal direction; in step S4, the multiple small contour blocks (5) are columnar structures; the height of the small contour blocks (5) is 62mm.

7. A method for manufacturing a cable crane tie rod according to claim 6, characterized in that: There are three small contour blocks (5), two of which are located on the top of one end of the steel pipe (1) on both sides, and the other small contour block (5) is located directly above the shaft hole of the lower ear plate.

8. A method for manufacturing a cable crane tie rod according to claim 7, characterized in that: The specific steps for installing the ear plate (4) by placing the other end of the steel pipe (1) on the steel platform in step S6 are as follows: Step a1: Lift the tie rod and rotate it 180 degrees. Place the other end of the steel pipe (1) in the channel steel (2). Use a level to adjust the ear plate (4) that has been installed at one end of the steel pipe (1) to be horizontal. The steel pipe (1) is then leveled by a five-ton jack (9). Step a2: Place the new lower ear plate on multiple thickness equal height blocks (3). At this time, insert the tooling shaft (7) into the shaft hole of the new lower ear plate. Control the opening distance to be 1mm larger than the preset distance by using a level instrument. Spot weld the new lower ear plate to the top of the other end of the steel pipe (1). Remove the tooling shaft (7) and repeat steps S4 to S5 to complete the installation of the ear plate (4) at the top of the other end of the steel pipe (1).

9. A method for manufacturing a cable crane tie rod according to claim 8, characterized in that: The error in adjusting the top surface of the ear plate (4) in step a1 is less than 0.5 mm.

10. A method for manufacturing a cable winch tie rod according to claim 9, characterized in that: In steps S3 to S6, the ear plate (4) and the steel pipe (1) are connected by spot welding. In step S5, multiple fixing parts (8) for reinforcement and support are connected between the outer side of the upper ear plate and the outer side of the lower ear plate. After the top of the ear plate (4) and the steel pipe (1) are spot welded together in step S5, the ear plate (4) and the steel pipe (1) are cooled down. Then the tooling shaft (7) is taken out and the fixing parts (8) are removed.

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