Method for installing a crane column of a crane

Abstract

The present application relates to the technical field of shipbuilding, and discloses a kind of installation method of crane column of crane.The present application obtains the three-dimensional data of hoisting column and ship deck base respectively and imports three-dimensional analysis software to carry out simulation assembly, determines reference point in simulation assembly model and sets up feature light target in the corresponding position of entity hoisting column, measures the three-dimensional position of light target in real time during hoisting and carries out dynamic comparison with the reference point of simulation assembly model, until error meets the requirement, then complete fixation;The present application transfers the precision control gravity from post-check to process prevention stage.Workers can predict installation deviation in advance and make active compensation by using digital measurement and simulation preassembly, so as to effectively avoid the accumulation of manufacturing error step by step.In dynamic environment on the ship, light target positioning technology provides guidance for terminal assembly.This real-time guidance greatly reduces the time of repeated fine-tuning on site, shortens the overall installation cycle, and reduces the cost of labor and equipment operation.

Description

Technical Field

[0001] This invention relates to the field of shipbuilding technology, and in particular to a method for installing a lifting column using a crane. Background Technology

[0002] Currently, as a key deck machinery on modern multipurpose vessels and heavy-lift vessels, the operational stability, safety, and service life of cranes directly depend on the manufacturing and installation precision of the lifting column. The lifting column is typically a large cylindrical or box-shaped welded structure, reaching heights of ten to tens of meters. It is enormous in weight, composed of multiple interconnected cylindrical sections, and ultimately requires high-precision connection to the ship's deck base and superstructure slewing mechanism via flanges or welding.

[0003] Currently, the installation process and precision control methods for lifting columns using gantry cranes, which are commonly used in the industry, have the following significant technical defects: 1. Existing precision management is typically fragmented across independent stages such as material preparation, section fabrication, and slipway installation, adhering to general shipbuilding tolerances (e.g., CB / T 3610-94 standard), lacking a systematic control logic spanning the entire product lifecycle. Measurement data at each stage (e.g., section roundness, straightness) largely relies on traditional manual paper records, failing to achieve digital transfer. This information silo leads to discontinuous transfer of precision benchmarks between stages. Tolerances from previous processes not only cannot serve as a basis for prediction and compensation in the next stage of construction but also cause errors to accumulate implicitly throughout the production chain.

[0004] 2. The core logic of existing technology is a passive trial-and-error cycle of "physical hoisting - on-site measurement - post-adjustment". For example, only after the lifting column is actually connected to the deck base is the flange gap measured with a feeler gauge or the verticality measured with a plumb bob, followed by rough physical fine-tuning using tools such as jacks and wedges. For large, heavy-load structures tens of meters high, this passive fine-tuning is time-consuming and labor-intensive, easily generates huge internal stress due to forced assembly, and has extremely poor adjustment accuracy.

[0005] 3. While traditional installation methods specify the final allowable deviation (e.g., verticality ≤ H / 1000), they are static measurements and do not fully consider the dynamic interference during the actual installation process. Examples include the shrinkage deformation due to welding heat input during hull foundation construction, the thermal expansion and contraction of the steel structure caused by diurnal temperature variations, and the structural elastic deformation of the lifting columns during hoisting. Traditional measurement methods cannot track and compensate for these dynamic effects in real time. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a lifting column installation method that combines three-dimensional simulation pre-assembly with real-time optical target positioning guidance, which effectively improves assembly accuracy and construction efficiency.

[0007] To solve the above-mentioned technical problems, the present invention provides a method for installing a lifting column, comprising the following steps: S1: After the lifting column is manufactured, measure and obtain the three-dimensional data of the lifting column; S2: During the hull construction phase, after the construction of the hull deck base is completed, the three-dimensional data of the hull deck base is measured and obtained. S3: Import the three-dimensional data of the lifting column and the three-dimensional data of the hull deck base into the three-dimensional analysis software to generate a three-dimensional model of the lifting column and a three-dimensional model of the base. Then, simulate the assembly of the three-dimensional model of the lifting column and the three-dimensional model of the base according to the assembly requirements to obtain a simulated assembly model. S4: Select multiple reference points on the lifting column model of the simulated assembly model, and then set a feature light target at the location of the lifting column corresponding to the reference points. S5: Hoist the lifting column onto the base. During this process, measure and obtain the real-time three-dimensional position of the light target. When the error between the three-dimensional position of the light target and the three-dimensional position of the corresponding reference point is within the allowable error range, complete the assembly and fixing of the lifting column and the base.

[0008] As a preferred embodiment of the present invention, in S1, the column body and column head of the lifting column are first manufactured in sections, and then the column body and the column head are assembled to form the lifting column.

[0009] As a preferred embodiment of the present invention, after the column body is manufactured, the actual size of the upper opening of the column body is measured and obtained. During the manufacturing process of the column head, the lower opening of the column head is manufactured according to the actual size of the upper opening of the column body.

[0010] As a preferred embodiment of the present invention, the deviation between the size of the lower opening of the column head and the actual size of the upper opening of the column body is ≤ ±2mm.

[0011] As a preferred embodiment of the present invention, a plurality of horizontally fixed optical targets are embedded on the flange surface of the column head. During the assembly process of the column head and the column body, the relative height difference of the plurality of horizontally fixed optical targets is measured to monitor the levelness of the flange surface of the column head.

[0012] As a preferred embodiment of the present invention, in S1, compared with the design value, the height deviation of the lifting column is ≤ ±4mm, the width deviation of the lifting column is ≤ ±2mm, the levelness of the flange surface of the column head is ≤ 2mm, and the misalignment of the closing joint between the column head and the column body is ≤ ±3mm.

[0013] As a preferred embodiment of the present invention, a height reference line, a first longitudinal reference line, and a first transverse reference line are drawn on the side wall of the column body, and a second longitudinal reference line and a second transverse reference line are drawn on the side wall of the column head; during the assembly process of the column body and the column head, the first longitudinal reference line is aligned with the second longitudinal reference line, and the first transverse reference line is aligned with the second transverse reference line, and the height of the column head during positioning is detected with the height reference line as a reference.

[0014] As a preferred embodiment of the present invention, in S5, a spatial rectangular coordinate system is established in the three-dimensional analysis software with a certain point of the three-dimensional model of the base as the origin, and the coordinates of the reference point in the spatial rectangular coordinate system are obtained; during the hoisting of the lifting column, the point corresponding to the origin of the spatial rectangular coordinate system is set as the measurement zero point, the distance between the light target and the measurement zero point is measured, and the obtained measurement value is imported into the three-dimensional analysis software to obtain the real-time coordinates of the light target in the spatial rectangular coordinate system. When the difference between the real-time coordinates of the light target in the spatial rectangular coordinate system and the coordinates of the corresponding reference point is less than or equal to the allowable error value, the assembly and fixing of the lifting column and the base are completed.

[0015] This invention discloses an installation method for a lifting column using a crane. Compared with existing technologies, its advantages are as follows: This invention acquires three-dimensional data of the lifting column and the ship's deck base separately and imports them into three-dimensional analysis software for simulated assembly. A reference point is determined in the simulated assembly model, and a characteristic optical target is set at the corresponding position of the physical lifting column. During the lifting process, the three-dimensional position of the optical target is measured in real time and dynamically compared with the reference point of the simulated assembly model until the error meets the requirements before fixing is completed. This invention, through three-dimensional simulation pre-assembly and real-time optical target positioning guidance, can effectively improve assembly accuracy and construction efficiency. Attached Figure Description

[0016] Figure 1 This is a structural diagram of the lifting column of the present invention; Figure 2 This is a structural diagram simulating the assembly of the three-dimensional model of the lifting column and the three-dimensional model of the base of the present invention; Figure 3 Structural diagram of the lifting column of the present invention during hoisting; In the figure, there is a lifting column 1; a column body 11; a column head 12; a 3D model of the lifting column 2; a 3D model of the base 3; and a feature light target 4. Detailed Implementation

[0017] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0018] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., used to indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0019] like Figure 1-3 As shown, a preferred embodiment of the present invention provides a method for installing a lifting column using a crane, comprising the following steps: S1: After completing the fabrication of lifting column 1, the three-dimensional data of the lifting column is measured and acquired. For example, a 3D laser scanner is used to scan the lifting column to obtain a 3D point cloud model of the lifting column. The 3D point cloud model contains a large number of surface coordinate points. The measuring equipment records the actual shape of the lifting column through these points. The staff uses this data to understand the manufacturing deviations of the object. This helps in the subsequent reconstruction of the real component in virtual space.

[0020] S2: During the hull construction phase, after the hull deck base is constructed, its three-dimensional data is measured and acquired. The base is prone to shrinkage or deformation during welding. Surveyors collect the actual three-dimensional dimensions of the base. The system uses these actual dimensions as the basis for subsequent comparisons. This avoids significant discrepancies between the design drawings and the actual structure on site.

[0021] S3: Import the 3D data of the lifting column and the 3D data of the hull deck base into the 3D analysis software to generate the 3D model 2 of the lifting column and the 3D model 3 of the base. Then, simulate the assembly of the 3D model of the lifting column and the 3D model of the base according to the assembly requirements to obtain the simulated assembly model. It can be understood that the simulated assembly model meets the assembly requirements and is in a good matching state.

[0022] Specifically, the collected 3D point cloud data or feature line and surface data of the lifting column are imported into professional 3D measurement and analysis software. In the software's virtual space, using the ship's coordinate system as a reference, the data is mapped to the 3D model of the base and the lifting column model respectively. Based on the assembly requirements of the design drawings (such as the horizontality of the column head flange, the overall verticality of the lifting column, the installation height of the lifting column, positioning dimensions, etc.), virtual assembly simulation is performed in the software. The software analyzes, calculates, and optimizes the optimal relative position to meet all design accuracy requirements. An installation operation guidance package is generated: based on the simulation pre-assembly results, a digital operation guidance document containing the following information is generated: positioning values ​​in the height, length, and width directions of the lifting column; trimming amount of the lower structure of the lifting column; and horizontality data of the lifting column flange surface, etc.

[0023] S4: Select multiple reference points on the lifting column model of the simulated assembly model, and then set the feature light target 4 at the location corresponding to the lifting column and the reference points.

[0024] Specifically, after achieving a satisfactory matching state, multiple feature reference points (generally selected in the flange face, height direction, length direction, and width direction) are established in the simulated assembly model. The selection principles for these reference points are: Physical accessibility: their location on the corresponding physical component is clear, easily identifiable, and accessible. Measurement stability: they are located in structurally stable areas that are not easily deformed or obstructed. Representativeness: they effectively reflect the spatial position and orientation of the segment in the matched state. Then, optical reflective target spheres (or prisms) are firmly attached as feature light targets at the corresponding physical locations of the actual lifting column and base in the simulated assembly model. A one-to-one correspondence is established between the center coordinates of each light target (in its respective segment's local coordinate system) and the coordinates of the selected reference points on the virtual model in the simulated pre-assembly. This step ensures that the virtual "matching state" is physically marked on the lifting component.

[0025] S5: Hoist the lifting column onto the base. During this process, measure and obtain the real-time three-dimensional position of the optical target. When the error between the three-dimensional position of the optical target and the three-dimensional position of its corresponding reference point is within the allowable error range, complete the assembly and fixing of the lifting column and the base.

[0026] Specifically, the lifting column is hoisted onto the base. Measuring equipment (such as a total station) is set up at stable locations around the hoisting area, and a unified coordinate system for the hoisting site is established. The total station only needs to measure the real-time three-dimensional coordinates of the optical targets already fixed on the lifting column. Based on the data from the simulated assembly model, the calculation software (which can be integrated with the total station or run independently) calculates the actual attitude of the lifting column in the field coordinate system in real time. Simultaneously, the software calls upon the theoretical relative positional relationship between the base and the lifting column in the simulated assembly model. Combining the actual attitude of the lifting column and the theoretical relative relationship, the software inversely calculates the theoretical field coordinate values ​​that each feature optical target should appear in under the "matching state" in the simulated assembly model.

[0027] The lifting column is slowly moved to its docking point with the base. During this process, the total station tracks the actual coordinates of the feature targets on the lifting column in real time and compares them with the calculated theoretical coordinate values. The software interface dynamically displays the three-dimensional position deviation and attitude angle deviation of each feature target. Based on this precise deviation guidance, the crane operator fine-tunes the position and attitude of the lifting column until the actual measured values ​​of all feature targets are within the allowable error tolerance range. At this point, it indicates that the lifting column has been restored to the "matching state" simulated by the software and can be assembled and fixed. After the lifting column is installed, compared with the design values, the height deviation of the lifting column is ≤ ±4mm, the length and width deviations are ≤ ±2mm respectively, the horizontality of the column head flange surface is ≤ 2mm, and the verticality of the column body is ≤ 0.1%h.

[0028] This invention acquires 3D data of the lifting column and the ship's deck base separately, imports it into 3D analysis software for simulated assembly, determines reference points in the simulated assembly model, and sets characteristic optical targets at corresponding positions on the physical lifting column. During hoisting, the 3D position of the optical targets is measured in real time and dynamically compared with the reference points in the simulated assembly model until the error meets the requirements before fixing. This method shifts the focus of precision control from post-construction verification to process prevention. Using digital measurement and simulated pre-assembly, workers can predict installation deviations in advance and proactively compensate, effectively preventing the accumulation of manufacturing errors. In the dynamic environment of the ship, optical target positioning technology provides guidance for final assembly. This real-time guidance significantly reduces the time spent on repeated fine-tuning on-site, shortens the overall installation cycle, and reduces labor and equipment operating costs. Simultaneously, the measurement system maintains a digital record of the entire process, constructing a complete precision data chain. Managers can use this data chain to clearly trace the quality status of each production stage.

[0029] For example, in S1, the column body and column head of the lifting column are first manufactured in sections, and then the column body and column head are assembled to form the lifting column. Manufacturing the column body and column head separately reduces the difficulty of manufacturing in a single operation. The column body is generally a slender cylindrical structure, while the column head has flanges and reinforcing ribs. Manufacturing them separately makes it easier to control the shape accuracy of each part individually. Finally, the two are assembled into a single lifting column. The assembly process also requires measurement and adjustment.

[0030] For example, after the column body is fabricated, the actual dimensions of the top opening are measured. During the fabrication of the column head, the bottom opening of the column head is fabricated based on these actual dimensions. After the column body is completed, the actual dimensions of its top opening may slightly differ from the design value. The operator measures this actual dimension and then uses it as the machining target for the bottom opening of the column head. This ensures that the bottom opening of the column head precisely matches the top opening of the column body, reducing the amount of trimming work during assembly. The deviation between the dimensions of the bottom opening of the column head and the actual dimensions of the top opening of the column body should be ≤ ±2mm. This deviation range ensures minimal misalignment at the interface when the column head and column body are assembled. Minimal misalignment is beneficial for subsequent welding quality.

[0031] For example, multiple horizontally fixed optical targets are embedded on the flange surface of the column head. During the assembly of the column head and the column body, the relative height difference of these targets is measured to monitor the levelness of the flange surface. Because the column head is relatively high (generally around 9 meters), measuring the flange surface is difficult; therefore, optical targets are pre-embedded on the flange surface. These horizontally fixed optical targets provide level measurement during the assembly and shipboard loading phases. Operators pre-embed three or four optical targets on the flange surface. The installation positions of these targets form a horizontal plane. During assembly, operators use a level or total station to measure the elevation of these targets and calculate the elevation difference between the highest and lowest points. This difference is the levelness deviation of the flange surface. If the deviation is too large, operators can correct it by adjusting the position of the column head or adding shims. Pre-embedded optical targets avoid errors caused by re-laying points for each measurement.

[0032] For example, in S1, compared with the design values, the height deviation of the lifting column is ≤ ±4mm, the width deviation is ≤ ±2mm, the levelness of the flange face of the column head is ≤ 2mm, and the misalignment of the joint between the column head and the column body is ≤ ±3mm. Ensuring the geometric accuracy of the lifting column itself lays the foundation for subsequent docking with the base.

[0033] For example, a height reference line, a first longitudinal reference line, and a first transverse reference line are drawn on the side wall of the column. It can be understood that the height reference line is set horizontally, the first longitudinal reference line is the perpendicular bisector of the longitudinal side of the column, and the first transverse reference line is the perpendicular bisector of the transverse side of the column. A second longitudinal reference line and a second transverse reference line are drawn on the side wall of the column head. The second longitudinal reference line is the perpendicular bisector of the longitudinal side of the column head, and the second transverse reference line is the perpendicular bisector of the transverse side of the column head. During the assembly of the column and the column head, the first longitudinal reference line is aligned with the second longitudinal reference line, and the first transverse reference line is aligned with the second transverse reference line. The height of the column head during positioning is detected with the height reference line as the reference.

[0034] For example, in S5, in the 3D analysis software, a spatial rectangular coordinate system is established with a certain point on the 3D model of the base as the origin, and the coordinates X, Y, and Z of the reference point in the spatial rectangular coordinate system are obtained. During the hoisting of the lifting column, the point corresponding to the origin of the spatial rectangular coordinate system is set as the measurement zero point. The distance between the optical target and the measurement zero point is measured, and the obtained measurement value is imported into the 3D analysis software to obtain the real-time coordinates of the optical target in the spatial rectangular coordinate system. The assembly and fixing of the lifting column and the base is completed when the difference (ΔX, ΔY, ΔZ) between the real-time coordinates of the optical target in the spatial rectangular coordinate system and the coordinates of its corresponding reference point is less than or equal to the allowable error value. The operator selects a feature point on the 3D model of the base as the origin of the coordinate system in the 3D analysis software. The software automatically calculates the coordinates of each reference point relative to this origin. During hoisting, the operator aligns the zero point of the total station with the corresponding physical feature point on the base. The total station directly measures the distance and angle from the optical target to this zero point. The total station imports this data into the software. The software calculates the real-time coordinates of the optical target in the same spatial rectangular coordinate system. The software subtracts the real-time coordinates from the previously saved reference point coordinates item by item to obtain the difference. When the absolute value of all differences is not greater than the allowable error, the operator can proceed with the fixing. This coordinate transformation method based on a unified origin reduces the cumulative error caused by multiple coordinate system conversions.

[0035] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present invention, and these improvements and substitutions should also be considered within the scope of protection of the present invention.

Claims

1. A method for installing a lifting column using a crane, characterized in that: Includes the following steps: S1: After the lifting column is manufactured, measure and obtain the three-dimensional data of the lifting column; S2: During the hull construction phase, after the construction of the hull deck base is completed, the three-dimensional data of the hull deck base is measured and obtained. S3: Import the three-dimensional data of the lifting column and the three-dimensional data of the hull deck base into the three-dimensional analysis software to generate a three-dimensional model of the lifting column and a three-dimensional model of the base. Then, simulate the assembly of the three-dimensional model of the lifting column and the three-dimensional model of the base according to the assembly requirements to obtain a simulated assembly model. S4: Select multiple reference points on the lifting column model of the simulated assembly model, and then set a feature light target at the location of the lifting column corresponding to the reference points. S5: Hoist the lifting column onto the base. During this process, measure and obtain the real-time three-dimensional position of the light target. When the error between the three-dimensional position of the light target and the three-dimensional position of the corresponding reference point is within the allowable error range, complete the assembly and fixing of the lifting column and the base.

2. The installation method of the lifting column by the crane according to claim 1, characterized in that: In S1, the column body and column head of the lifting column are manufactured in sections, and then the column body and column head are assembled to form the lifting column.

3. The installation method of the lifting column by the crane according to claim 2, characterized in that: After the column is made, the actual size of the top opening of the column is measured. During the making of the column head, the bottom opening of the column head is made according to the actual size of the top opening of the column.

4. The installation method of the lifting column by the crane according to claim 3, characterized in that: The deviation between the size of the lower opening of the column head and the actual size of the upper opening of the column body is ≤ ±2mm.

5. The installation method of the lifting column by the crane according to claim 2, characterized in that: Multiple horizontally fixed optical targets are embedded on the flange surface of the column head. During the assembly process of the column head and the column body, the relative height difference of the multiple horizontally fixed optical targets is measured to monitor the levelness of the flange surface of the column head.

6. The installation method of the lifting column by the crane according to claim 2, characterized in that: In S1, compared with the design value, the height deviation of the lifting column is ≤ ±4mm, the width deviation of the lifting column is ≤ ±2mm, the levelness of the flange surface of the column head is ≤ 2mm, and the misalignment of the closing joint between the column head and the column body is ≤ ±3mm.

7. The installation method of the lifting column by the crane according to claim 2, characterized in that: Draw a height reference line, a first longitudinal reference line, and a first transverse reference line on the side wall of the column, and draw a second longitudinal reference line and a second transverse reference line on the side wall of the column head. During the assembly process of the column body and the column head, the first longitudinal reference line is aligned with the second longitudinal reference line, and the first transverse reference line is aligned with the second transverse reference line. The height of the column head during positioning is detected with the height reference line as the reference.

8. The installation method of the lifting column of the crane according to claim 1, characterized in that: In S5, in the 3D analysis software, a spatial rectangular coordinate system is established with a certain point of the 3D model of the base as the origin, and the coordinates of the reference point in the spatial rectangular coordinate system are obtained. During the hoisting of the lifting column, the point corresponding to the origin of the spatial rectangular coordinate system is set as the measurement zero point, the distance between the light target and the measurement zero point is measured, and the obtained measurement value is imported into the 3D analysis software to obtain the real-time coordinates of the light target in the spatial rectangular coordinate system. When the difference between the real-time coordinates of the light target in the spatial rectangular coordinate system and the coordinates of the corresponding reference point is less than or equal to the allowable error value, the assembly and fixing of the lifting column and the base are completed.

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