A method for precise inspection and positioning installation of a marine special ship anchor machine base

Abstract

The application discloses a kind of marine special ship anchor machine base precision inspection and positioning installation method, it is related to shipbuilding technical field, for the problems such as large reference line deviation, base inspection non-quantization, component positioning inaccuracy, uneven stress in prior art, the present application calibrates the axis system theory center line by environmental temperature compensation and measurement error correction, dynamically compensates base flatness by combining welding deformation allowance, quantitatively determines the positioning coordinates and cooperation gap of stop block and chain stopper, adaptively calculates the thickness of pad and verifies the uniformity of stress, dynamically adjusts bolt tightening torque, and finally evaluates the operation state of anchor machine by quantification.The application controls reference line deviation within ±0.3mm, pad stress deviation rate ≤5%, anchor machine operation qualified rate ≥98%, realizes the precise quantification control and traceability of installation whole process, and significantly improves the operation stability and safety of anchor machine.

Description

Technical Field

[0001] This invention relates to the field of shipbuilding technology, specifically to a method for precise inspection and positioning installation of anchor winch bases for special marine engineering vessels. Background Technology

[0002] Anchor winches are core and critical equipment for mooring and anchoring operations on offshore special-purpose vessels. Their bases, serving as the mounting carrier, directly determine the operational stability and safety of the anchor winch, thus affecting the reliability of the vessel's operations at sea. Existing anchor winch base installation methods for offshore special-purpose vessels mainly suffer from the following technical problems:

[0003] Insufficient baseline positioning accuracy: The traditional string line method is often used to determine the theoretical center line of the shaft system without considering the impact of temperature fluctuations and measuring tool errors on the baseline. There is no targeted compensation mechanism, which leads to the baseline deviation often exceeding ±0.5mm, causing a chain reaction of deviations in subsequent processes.

[0004] The inspection of the base lacks quantification and compensation mechanisms: the inspection of the flatness of the base support surface and the positioning coordinates relies on manual experience judgment, without real-time detection and dynamic compensation measures. Deformation deviations are prone to occur after welding and cannot be corrected in time, resulting in uneven stress after the anchor hoist is installed.

[0005] Low positioning accuracy of stop blocks and chain stoppers: There is no precise control method for aligning the stop blocks with the running trajectory of the anchor chain and aligning the chain stoppers with the anchor chain wheel and the anchor chain cylinder. Gap control relies on manual visual inspection, which can easily cause the anchor chain to shake, wear or get stuck. The height deviation of the chain stoppers can easily cause the anchor chain to overturn.

[0006] Poor compatibility of the pad installation: The thickness of the pad is only cut according to the actual gap, without adaptive compensation based on the levelness deviation and the compression amount of the pad. Furthermore, there is no quantitative verification of the uniformity of the force on the pad, which leads to uneven force after the bolts are tightened and vibration during the operation of the anchor machine.

[0007] There are no quantitative standards for bolt tightening and adjustment: bolt tightening uses a fixed torque without dynamic compensation based on factors such as contact surface pressure, gap, and temperature, which can easily lead to bolt loosening; anchor winch adjustment only performs qualitative checks and cannot accurately identify potential faults.

[0008] Poor traceability of installation records: Measurement data, calculation results and debugging records are not systematically retained, making it impossible to accurately trace during subsequent maintenance and troubleshooting, thus increasing maintenance costs.

[0009] The aforementioned problems result in inconsistent installation quality of the anchor winch base, and the anchor winch is prone to malfunctions such as component wear, brake failure, and excessive vibration and noise during operation, which cannot meet the requirements of the harsh operating environment at sea for special marine engineering vessels. Summary of the Invention

[0010] To address the shortcomings of existing technologies, the present invention aims to provide a method for precise inspection and positioning installation of anchor winch bases for marine engineering special vessels. By providing a method for precise inspection and positioning installation of anchor winch bases for marine engineering special vessels, and through full-process quantitative control and dynamic compensation, this invention solves problems such as large baseline deviations, lack of quantitative inspection of bases, inaccurate component positioning, uneven stress, lack of standard debugging, and poor traceability of records in existing installation methods. This improves installation accuracy and efficiency, and ensures stable and reliable operation of the anchor winch.

[0011] To achieve the above objectives, the present invention provides the following technical solution:

[0012] A method for precise inspection and positioning installation of anchor winch bases for special marine engineering vessels includes the following steps:

[0013] S1: Prepare all technical data and design modification documents for anchor installation, calibrate the theoretical centerline of the shaft system by combining environmental temperature compensation and measurement error correction, complete the preliminary acceptance of the anchor base and record the data;

[0014] S2: Using the calibrated theoretical centerline of the shaft system as the sole reference, the flatness of the base support surface is tested at multiple points and dynamically compensated in combination with the welding deformation allowance. The horizontal coordinates of the base installation are calibrated, and the flatness and coordinate deviation are checked again after the base is welded and fixed.

[0015] S3: Grind and clean the base and the mounting surface of the stop block, determine the positioning coordinates of the stop block based on the actual diameter deviation of the anchor chain, and quantitatively adjust the fit clearance between the stop block and the anchor chain.

[0016] S4: Pre-treat the mating surface between the base and the anchor base, determine the actual processing thickness of the pad by combining the gap between the mating surfaces, the levelness deviation and the compression amount of the pad, and temporarily fix the pad after evenly arranging the pads and verifying the uniformity of the force.

[0017] S5: Calibrate the three-dimensional spatial coordinates of the chain catcher, and dynamically adjust the reserved gap between the anchor chain and the anchor chain tube in combination with the anchor chain length deviation and installation deviation;

[0018] S6: Use a balance hoist to lift the anchor winch to the preset position, tighten the installation bolts in a three-stage step-by-step tightening method, and check the torque of each bolt;

[0019] S7: Conduct comprehensive commissioning of the anchor winch, complete idling and loaded anchor deployment and retrieval tests, quantitatively evaluate the operating status based on the deviation rate between the actual value and the standard value of each test item, locate the unqualified items, make targeted adjustments, and then re-commission.

[0020] Furthermore, in step S1, the calibration operation of the theoretical centerline of the shaft system is as follows:

[0021] S11: Adjust the ambient temperature to 18-22℃, and control the temperature change rate to ≤1.5℃ / h;

[0022] S12: Use a calibrated total station to collect the actual measured length of the theoretical centerline of the axis system, and record the inherent error of the measuring tool and the actual ambient temperature;

[0023] S13: Taking into account the difference between the actual measured length and the theoretical length of the shaft system centerline, the inherent error of the measuring tool, and the deviation of the ambient temperature from the 20℃ standard temperature, calculate the final deviation of the baseline.

[0024] S14: If the final deviation of the baseline exceeds ±0.3mm, adjust the position of the baseline and repeat the measurement and calculation until the deviation is ≤±0.3mm in 3 consecutive re-verifications.

[0025] Furthermore, in step S2, the detection and compensation operation for the flatness of the base support surface is as follows:

[0026] S21: Select no less than 10 measurement points evenly on the base support surface, collect height data of each measurement point, and determine the maximum height difference, minimum height difference, and average height deviation of the measurement points;

[0027] S22: Taking into account the ratio of the maximum height difference of the base support surface to the length of the measurement area, the average height deviation of the measurement points, and the allowable amount for welding deformation, calculate the overall flatness deviation;

[0028] S23: If the overall flatness deviation exceeds 0.3mm / m, a combination of local grinding of the raised parts and fine-tuning pads to compensate for the recessed parts shall be used to correct it until the overall flatness deviation is ≤0.3mm / m;

[0029] Furthermore, in step S2, the calibration process for the horizontal coordinates of the base is as follows: determine the theoretical horizontal coordinates of the base according to the layout diagram of the mooring and towing equipment, calculate the horizontal deviation between the actual coordinates and the theoretical coordinates, and ensure that the deviations in both horizontal directions are ≤ ±0.5mm; after welding and fixing, stand for 30 minutes for re-inspection, and the flatness re-inspection measurement deviation is ≤ ±0.05mm / m, and the coordinate deviation is ≤ ±0.03mm.

[0030] Furthermore, in step S3, the process for determining the positioning coordinates of the stop block is as follows: determine its theoretical coordinates based on the design parameters of the anchor chain's running trajectory, superimpose the compensation amount dynamically adjusted according to the deviation between the actual diameter and the theoretical diameter of the anchor chain, and calculate the actual positioning coordinates of the stop block. The compensation amount ranges from 0.1 to 0.2 mm. After adjusting the perpendicularity deviation between the stop block and the drum axis to ≤0.1°, spot weld it for temporary fixation.

[0031] The adjustment process for the fit clearance between the stop block and the anchor chain is as follows: Measure the deviation between the actual diameter and the theoretical diameter of the anchor chain and the grinding deviation of the stop surface. Taking into account the standard fit clearance, the anchor chain diameter deviation, and the grinding deviation of the stop surface, calculate the actual fit clearance. The standard fit clearance ranges from 0.5 to 1 mm. Fine-tune the position of the stop block so that the actual fit clearance is within the range of 0.5 to 1 mm.

[0032] Furthermore, in step S4, the process for determining the actual processing thickness of the pad block is as follows: measure the actual gap and longitudinal and transverse horizontal deviations of the mating surfaces of the base and the anchor base, and comprehensively consider the actual gap of the mating surfaces, the longitudinal and transverse horizontal deviations, and the reserved value of the pad block compression amount to calculate the actual processing thickness of the pad block; the thickness deviation of the pad block after processing is ≤ ±0.02mm, the single layer thickness is ≥8mm, and when multiple layers are stacked, the number of layers is ≤3 and the material is consistent with the base.

[0033] Furthermore, in step S4, the operation procedure for paving block arrangement and stress verification is as follows:

[0034] S41: Arrange the pads evenly according to the design points. The distance between the center of each group of pads and the bolt hole of the anchor base is ≥50mm. When multiple layers are stacked, the misalignment angle is ≥90° and there are no through gaps.

[0035] S42: The longitudinal and transverse horizontal levelness of the anchor winch base is ≤0.03mm / m, and the contact gap between the pad block and the base and anchor winch base is ≤0.1mm;

[0036] S43: Calculate the average force on a single set of blocks based on the weight of the anchor winch, the rated load, and the number of blocks. Then, calculate the force deviation rate based on the difference between the maximum force and the average force on a single set of blocks, ensuring that the force deviation rate is ≤5%.

[0037] Furthermore, in step S5, the calibration process for the three-dimensional coordinates of the chain catcher is as follows: determine the theoretical three-dimensional coordinates of the chain catcher according to the drawings, use a total station to detect the actual three-dimensional coordinates and calculate the comprehensive deviation in the horizontal direction and the deviation in the vertical direction, ensuring that the comprehensive deviation in the horizontal direction is ≤ ±0.3mm and the deviation in the vertical direction is ≤ ±0.2mm, so that the groove of the chain catcher is precisely located on the line connecting the anchor chain wheel and the anchor chain cylinder of the anchor winch.

[0038] The adjustment process for the reserved gap between the anchor chain and the anchor chain canister is as follows: Measure the deviation between the actual length and the theoretical length of the anchor chain and the installation deviation of the chain catcher. Taking into account the standard reserved gap, the anchor chain length deviation, and the chain catcher installation deviation, calculate the actual reserved gap. The standard reserved gap is 5mm. Adjust the height of the chain catcher so that the gap between the anchor chain and the opening of the anchor chain canister after the anchor chain is tightened is 5±0.5mm.

[0039] Furthermore, in step S6, the three-stage step-by-step tightening method is as follows: the first stage tightens to 380 N·m with an interval of 25 s; the second stage tightens to 570 N·m with an interval of 25 s; the third stage tightens to the calculated actual tightening torque. After tightening is completed, a torque tester is used to check the torque of each piece and record the data.

[0040] Furthermore, in step S7, the process for quantitatively evaluating the anchor winch operating status is as follows: compile the actual test values ​​and corresponding standard values ​​of each commissioning item, calculate the overall pass rate of the anchor winch operating status based on the deviation rate between the actual value and the standard value of each test item, and determine the rectification direction of the non-conforming items through the test item with the largest positioning deviation.

[0041] Compared with the prior art, the beneficial effects of the present invention are:

[0042] The accuracy of baseline positioning is significantly improved: through environmental temperature compensation and measurement error correction, the baseline deviation is controlled within ±0.3mm, laying a precise foundation for subsequent processes;

[0043] The base inspection achieves quantitative and dynamic compensation: through multi-point detection and welding deformation allowance compensation, it is ensured that the flatness of the base is ≤0.3mm / m and the coordinate deviation after welding is ≤±0.03mm;

[0044] The positioning accuracy of components has been greatly improved: the positioning deviations of the stop block and the chain stop are controlled within 0.2mm and 0.3mm respectively, and the fit gap is precisely controllable, avoiding problems such as anchor chain jamming, wear and overturning;

[0045] The installation compatibility and stress uniformity of the pad blocks meet the standards: the thickness of the pad blocks is self-adaptive and the stress deviation rate is ≤5%, which reduces the vibration of the anchor winch and extends the service life of the equipment;

[0046] Improved bolt tightening reliability and commissioning safety: Dynamic bolt torque compensation to avoid potential loosening; Quantitative assessment of anchor winch operation status with a pass rate of ≥98%, accurately identifying potential faults;

[0047] Achieve full-process traceability: Complete installation records facilitate subsequent maintenance and troubleshooting, reducing maintenance costs;

[0048] High degree of standardization: Clear operational specifications and deviation control standards for each step, which are replicable and scalable, ensuring consistent installation quality. Attached Figure Description

[0049] Figure 1 This is a flowchart of a method for precise inspection and positioning installation of anchor winch bases for special marine vessels, as described in this invention. Detailed Implementation

[0050] The technical solutions of the present invention will now be described in detail with reference to the accompanying drawings.

[0051] like Figure 1 As shown, this invention discloses a method for precise inspection and positioning installation of anchor winch bases for special offshore vessels. It is applicable to the installation of anchor winches and windlasses on 70MOCV vessels (Project No. HYM25001, Honghua Map No. HYM25001-DOP-CW-W508), strictly adhering to the requirements of the *China Shipbuilding Quality Standard—CSQS*, *Rules for Classification and Construction of Steel Seagoing Ships*, CB / T3606-93 *Installation Quality of Mechanical and Electrical Equipment*, and Design Modification Notification M-MN-002P (2026.1.14). This embodiment clarifies the deviation calculation and compensation logic for each stage through quantitative formula functions, fully connecting the entire process from benchmark calibration to acceptance and archiving. Those skilled in the art can completely reproduce this invention based on this embodiment.

[0052] A method for precise inspection and positioning installation of anchor winch bases for special marine engineering vessels includes the following steps:

[0053] S1: Prepare all technical data and design modification documents for anchor installation, calibrate the theoretical centerline of the shaft system by combining environmental temperature compensation and measurement error correction, complete the preliminary acceptance of the anchor base and record the data;

[0054] Furthermore, in step S1, the calibration operation of the theoretical centerline of the shaft system is as follows:

[0055] S11: Adjust the ambient temperature to 18-22℃, and control the temperature change rate to ≤1.5℃ / h;

[0056] S12: Use a calibrated total station to collect the actual measured length of the theoretical centerline of the axis system, and record the inherent error of the measuring tool and the actual ambient temperature;

[0057] S13: Taking into account the difference between the actual measured length and the theoretical length of the shaft system centerline, the inherent error of the measuring tool, and the deviation of the ambient temperature from the 20℃ standard temperature, calculate the final deviation of the baseline.

[0058] S14: If the final deviation of the baseline exceeds ±0.3mm, adjust the position of the baseline and repeat the measurement and calculation until the deviation is ≤±0.3mm in 3 consecutive re-verifications.

[0059] Furthermore, in another embodiment of the invention;

[0060] Prepare the following documents: anchor winch installation drawing (ST0053-250-01), mooring and towing equipment layout drawing (P-2385-F04), equipment manufacturer's certificate of conformity, installation instructions, and design modification notice M-MN-002P. Pay particular attention to any new requirements in the notice regarding shim placement and bolt tightening. Organize a technical briefing for at least three personnel with more than three years of experience in marine electromechanical installation, clarifying deviation control thresholds, calculation methods, and data recording requirements for each stage.

[0061] Prepare a complete set of measuring instruments that have been verified by a national legal metrology institution and are within their validity period, including a total station (angle measurement accuracy ≤ ±1″, distance measurement accuracy ≤ ±2mm + 2ppm×D), an electronic level (accuracy ≤ ±0.01mm / m), a feeler gauge (accuracy 0.01mm), a torque meter (accuracy ≤ ±1%), a pressure sensor (accuracy ≤ ±0.5%FS), and a surface roughness tester (accuracy ≤ ±0.1μm). Zero-point calibration must be performed on all tools before use, and the calibration data must be recorded and archived.

[0062] This step, through environmental control and multi-factor deviation compensation, keeps the baseline deviation within ±0.3mm, providing a unique benchmark for all subsequent processes.

[0063] 1. Environmental control measures include closing ventilation openings in the work area, using air conditioning to stabilize the ambient temperature at 18-22℃, continuously monitoring for 2 hours to ensure that the temperature change rate is ≤1.5℃ / h, and avoiding temperature stress that could cause deformation of the hull structure and affect the accuracy of the baseline.

[0064] 2. Data acquisition involved using a total station to mark reference points at both ends of the axis system and collecting the actual measured length between the two points. Record the inherent error of the measuring tool (≤±0.05mm) and real-time ambient temperature .

[0065] 3. Calculation of final deviation from baseline:

[0066] ;

[0067] In the formula, The final deviation from the baseline is expressed in mm. The actual measured length of the theoretical centerline of the shaft system, in mm; The design length of the theoretical centerline of the shaft system, in mm; The measurement tool has inherent error; the unit is mm. Let be the coefficient of linear expansion of steel, taken as... ; This represents the deviation of the actual ambient temperature from the standard temperature by 20°C, expressed in °C. .

[0068] 4. Deviation correction is as follows: Fine-tune the positions of the first and last reference points, repeat the measurement and calculation until the deviation is ≤ ±0.3mm in three consecutive verifications. Mark the final reference line on the deck with a screed, paint it with red paint for protection, and label it with the reference number.

[0069] Inspect the appearance of the base to confirm there are no welding defects such as cracks, porosity, or slag inclusions, and no residual deformation after heat straightening. Use an electronic level to preliminarily check the original flatness of the base support surface to ensure it is ≤0.5mm / m; use a steel tape measure to check the dimensional deviation of the base to be ≤±1mm. After acceptance, fill in the "Base Preliminary Acceptance Record Form" and hand it over to the next process.

[0070] S2: Using the calibrated theoretical centerline of the shaft system as the sole reference, the flatness of the base support surface is tested at multiple points and dynamically compensated in combination with the welding deformation allowance. The horizontal coordinates of the base installation are calibrated, and the flatness and coordinate deviation are checked again after the base is welded and fixed.

[0071] Furthermore, in step S2, the detection and compensation operation for the flatness of the base support surface is as follows:

[0072] S21: Select no less than 10 measurement points evenly on the base support surface, collect height data of each measurement point, and determine the maximum height difference, minimum height difference, and average height deviation of the measurement points;

[0073] S22: Taking into account the ratio of the maximum height difference of the base support surface to the length of the measurement area, the average height deviation of the measurement points, and the allowable amount for welding deformation, calculate the overall flatness deviation;

[0074] S23: If the overall flatness deviation exceeds 0.3mm / m, a combination of local grinding of the raised parts and fine-tuning pads to compensate for the recessed parts shall be used to correct it until the overall flatness deviation is ≤0.3mm / m;

[0075] Furthermore, in step S2, the calibration process for the horizontal coordinates of the base is as follows: determine the theoretical horizontal coordinates of the base according to the layout diagram of the mooring and towing equipment, calculate the horizontal deviation between the actual coordinates and the theoretical coordinates, and ensure that the deviations in both horizontal directions are ≤ ±0.5mm; after welding and fixing, stand for 30 minutes for re-inspection, and the flatness re-inspection measurement deviation is ≤ ±0.05mm / m, and the coordinate deviation is ≤ ±0.03mm.

[0076] Furthermore, in another embodiment of the invention;

[0077] Using the theoretical centerline of the shaft system calibrated in step 1 as the sole reference, all inspection and measurement are performed using an optical instrument method, replacing the traditional string method and eliminating measurement errors caused by string tension and sag.

[0078] 1. Data acquisition involves selecting at least 10 measurement points evenly on the base support surface using a grid method (at least 2 points per meter along the long side, and full coverage along the short side). An electronic level is used to collect the height data of each measurement point relative to the reference plane to determine the maximum height. Minimum height and the average height deviation of the measurement points .

[0079] 2. Calculation of overall flatness deviation:

[0080] ;

[0081] In the formula, The flatness deviation is expressed in mm / m. The maximum height of the measurement point, in mm; Minimum height of the measurement point, in mm; The measurement is for the diagonal length of the area, in meters (m). The average height deviation weighting coefficient is set to 0.8. The average height deviation of the measurement points, in mm; To allow for welding deformation, a tolerance of 0.03 mm / m is set.

[0082] 3. Deviation compensation is if For protruding areas, use an angle grinder with 80# sandpaper to gradually polish, with each polishing layer ≤0.05mm; for recessed areas, use a thin copper sheet with a thickness of 0.1-0.2mm for temporary compensation. After polishing, remeasure and calculate until... .

[0083] Base installation horizontal coordinate calibration

[0084] 1. Determine the theoretical coordinates of the base center based on the mooring and towing equipment layout diagram (P-2385-F04). .

[0085] 2. Use a total station to measure the actual coordinates of the base center. The horizontal coordinate deviation is calculated as follows:

[0086] ;

[0087] In the formula, X-axis coordinate deviation, in mm; This represents the Y-axis coordinate deviation, in mm.

[0088] 3. Deviation adjustment to if or The base position should be slowly adjusted using the dedicated fine-tuning jack at the bottom. Do not strike the base with a hammer to avoid plastic deformation. After adjustment, remeasure until the deviation meets the standard.

[0089] The base and deck were welded and fixed using a symmetrical segmented welding method. The welding parameters were: welding current 120-150A, welding voltage 22-26V, welding speed 8-10cm / min, and φ3.2mm E4303 welding rods. After welding, the base was allowed to stand for 30 minutes to allow for full stress release. The flatness and center coordinates of the base support surface were then re-measured to ensure that the flatness deviation was ≤±0.05mm / m and the coordinate deviation was ≤±0.03mm. The welding parameters and re-measurement data were recorded.

[0090] S3: Grind and clean the base and the mounting surface of the stop block, determine the positioning coordinates of the stop block based on the actual diameter deviation of the anchor chain, and quantitatively adjust the fit clearance between the stop block and the anchor chain.

[0091] Furthermore, in step S3, the process for determining the positioning coordinates of the stop block is as follows: determine its theoretical coordinates based on the design parameters of the anchor chain's running trajectory, superimpose the compensation amount dynamically adjusted according to the deviation between the actual diameter and the theoretical diameter of the anchor chain, and calculate the actual positioning coordinates of the stop block. The compensation amount ranges from 0.1 to 0.2 mm. After adjusting the perpendicularity deviation between the stop block and the drum axis to ≤0.1°, spot weld it for temporary fixation.

[0092] The adjustment process for the fit clearance between the stop block and the anchor chain is as follows: Measure the deviation between the actual diameter and the theoretical diameter of the anchor chain and the grinding deviation of the stop surface. Taking into account the standard fit clearance, the anchor chain diameter deviation, and the grinding deviation of the stop surface, calculate the actual fit clearance. The standard fit clearance ranges from 0.5 to 1 mm. Fine-tune the position of the stop block so that the actual fit clearance is within the range of 0.5 to 1 mm.

[0093] Furthermore, in another embodiment of the invention;

[0094] The mounting surfaces of the base and stop block were sanded using an angle grinder with 120# sandpaper to remove rust, welding slag, oil, and burrs. After sanding, they were wiped clean with anhydrous ethanol. A roughness tester was used to check the surface roughness to ensure... There should be no fewer than 3 detection points, and the average value should be taken as the final result.

[0095] 1. Determine the theoretical coordinates of the anchor chain centerline based on the anchor chain running trajectory design parameters. .

[0096] 2. Measure the actual diameter of the anchor chain. Calculate the anchor chain diameter deviation ( (Design diameter for anchor chain).

[0097] 3. The actual positioning coordinates of the stop block are calculated as follows:

[0098] ;

[0099] In the formula, , The actual coordinates of the stop block's positioning center, in mm; , These are the theoretical coordinates of the anchor chain centerline, in mm; , This is a dynamic compensation value, ranging from 0.1 to 0.2 mm. Take the upper limit at any time. Take the lower limit.

[0100] 4. Adjust the angle of the stop block, use a right-angle ruler to check the perpendicularity of the stop block to the drum axis, and ensure that the perpendicularity deviation is ≤0.1°. Mark the positioning line with a scriber according to the calculated positioning coordinates, and temporarily fix the stop block by spot welding. The length of the weld point is ≤10mm.

[0101] Quantitative adjustment of the gap between the stop block and the anchor chain

[0102] 1. Data acquisition is for measuring the diameter deviation of the anchor chain. The grinding deviation of the stop surface was checked using a feeler gauge. (≤±0.05mm).

[0103] 2. The actual fit clearance is calculated as follows:

[0104] ;

[0105] In the formula, The actual clearance between the stop block and the anchor chain, in mm; The standard fit clearance ranges from 0.5 to 1 mm. The deviation compensation coefficient is set to 0.9. This refers to the anchor chain diameter deviation, in mm. The grinding deviation of the stop surface is expressed in mm.

[0106] 3. Adjust the gap to if If the gap exceeds 0.5-1mm, fine-tune the position of the stop block. After adjustment, use a feeler gauge to check the gap every 100mm along the entire length of the stop surface to ensure that the gap is uniform and within the standard range. Record the final gap data.

[0107] S4: Pre-treat the mating surface between the base and the anchor base, determine the actual processing thickness of the pad by combining the gap between the mating surfaces, the levelness deviation and the compression amount of the pad, and temporarily fix the pad after evenly arranging the pads and verifying the uniformity of the force.

[0108] Furthermore, in step S4, the process for determining the actual processing thickness of the pad block is as follows: measure the actual gap and longitudinal and transverse horizontal deviations of the mating surfaces of the base and the anchor base, and comprehensively consider the actual gap of the mating surfaces, the longitudinal and transverse horizontal deviations, and the reserved value of the pad block compression amount to calculate the actual processing thickness of the pad block; the thickness deviation of the pad block after processing is ≤ ±0.02mm, the single layer thickness is ≥8mm, and when multiple layers are stacked, the number of layers is ≤3 and the material is consistent with the base.

[0109] Furthermore, in step S4, the operation procedure for paving block arrangement and stress verification is as follows:

[0110] S41: Arrange the pads evenly according to the design points. The distance between the center of each group of pads and the bolt hole of the anchor base is ≥50mm. When multiple layers are stacked, the misalignment angle is ≥90° and there are no through gaps.

[0111] S42: The longitudinal and transverse horizontal levelness of the anchor winch base is ≤0.03mm / m, and the contact gap between the pad block and the base and anchor winch base is ≤0.1mm;

[0112] S43: Calculate the average force on a single set of blocks based on the weight of the anchor winch, the rated load, and the number of blocks. Then, calculate the force deviation rate based on the difference between the maximum force and the average force on a single set of blocks, ensuring that the force deviation rate is ≤5%.

[0113] Furthermore, in another embodiment of the invention;

[0114] 4.1 Pretreatment of bonding surfaces

[0115] Grind the mating surfaces of the base and the anchor base to remove oxide scale and oil stains, and check the roughness. The initial gap between the mating surfaces was measured using a feeler gauge. One point was measured at the corresponding position of each pad, and the gap data at each point was recorded.

[0116] 4.2 Adaptive Calculation and Machining of Pad Thickness

[0117] 1. Data acquisition involved measuring the actual gap between the mating surfaces of the base and the anchor winch base using a feeler gauge. An electronic level was used to check the longitudinal and transverse levelness deviations of the anchor winch base. (≤0.03mm / m).

[0118] 2. The actual machining thickness of the pad block is calculated as follows:

[0119] ;

[0120] In the formula, The actual machining thickness of the pad block is in mm; The actual gap between the mating surfaces is in mm. The levelness compensation coefficient is set to 1.05. The horizontal and longitudinal deviations of the anchor winch base are expressed in mm. The allowance for the compression of the pad is set at 0.02 mm.

[0121] 3. The pad blocks are processed using wire cutting technology, and the material is the same Q235 steel as the base. After processing, the upper and lower surfaces of the pad blocks are ground with a surface grinder, and the thickness deviation is checked to be ≤±0.02mm; the thickness of a single layer pad block is ≥8mm, and when multiple layers are stacked, the number of layers is ≤3, and adjacent pad blocks are staggered by 90° and there are no through gaps.

[0122] 4.3 Verification of pad block arrangement and stress uniformity

[0123] 1. Arrange the pads evenly according to the design points, ensuring that the distance between the center of each group of pads and the bolt hole of the anchor base is ≥50mm, and that the contact surfaces of the multi-layer pads are tightly fitted without any looseness.

[0124] 2. Use an electronic level to calibrate the longitudinal and transverse levelness of the anchor winch base, and adjust the thickness of the shims to ensure that the levelness is ≤0.03mm / m; use a feeler gauge to check the fit gap between the shims and the base and anchor winch base to ensure that it is ≤0.1mm.

[0125] 3. Verification of uniformity of force distribution on the pad blocks

[0126] The average force on a single set of pad blocks is calculated as follows:

[0127] ;

[0128] In the formula, The average force on a single set of pad blocks is expressed in N. The anchor winch's own weight is expressed in nanometers (N). The rated load of the anchor winch is in N; This represents the total number of sets of pad blocks.

[0129] Distributed pressure sensors were used to measure the actual force on each pad group to determine the maximum force. The calculated force deviation rate is:

[0130] ;

[0131] In the formula, The stress deviation rate of the pad block is expressed in % (%). This represents the maximum force on a single block, expressed in N (unit: N).

[0132] like Fine-tune the thickness or position of the corresponding pads until the stress deviation rate meets the standard. After meeting the standard, temporarily fix the pads by spot welding, with a weld spacing of 50-80mm and a weld height ≤3mm.

[0133] S5: Calibrate the three-dimensional spatial coordinates of the chain catcher, and dynamically adjust the reserved gap between the anchor chain and the anchor chain tube in combination with the anchor chain length deviation and installation deviation;

[0134] Furthermore, in step S5, the calibration process for the three-dimensional coordinates of the chain catcher is as follows: determine the theoretical three-dimensional coordinates of the chain catcher according to the drawings, use a total station to detect the actual three-dimensional coordinates and calculate the comprehensive deviation in the horizontal direction and the deviation in the vertical direction, ensuring that the comprehensive deviation in the horizontal direction is ≤ ±0.3mm and the deviation in the vertical direction is ≤ ±0.2mm, so that the groove of the chain catcher is precisely located on the line connecting the anchor chain wheel and the anchor chain cylinder of the anchor winch.

[0135] The adjustment process for the reserved gap between the anchor chain and the anchor chain canister is as follows: Measure the deviation between the actual length and the theoretical length of the anchor chain and the installation deviation of the chain catcher. Taking into account the standard reserved gap, the anchor chain length deviation, and the chain catcher installation deviation, calculate the actual reserved gap. The standard reserved gap is 5mm. Adjust the height of the chain catcher so that the gap between the anchor chain and the opening of the anchor chain canister after the anchor chain is tightened is 5±0.5mm.

[0136] Furthermore, in another embodiment of the invention;

[0137] 5.1 Three-dimensional coordinate calibration of the chain stop

[0138] 1. Determine the theoretical three-dimensional coordinates of the center of the chain catcher groove based on the drawings. Ensure that the center of the groove is located on the line connecting the anchor winch sprocket and the anchor chain cylinder.

[0139] 2. Use a total station to determine the actual three-dimensional coordinates of the center of the chain stop groove. The horizontal and vertical deviations are calculated as follows:

[0140] ;

[0141] In the formula, This represents the overall horizontal deviation, in mm. This refers to the deviation in the height direction, in mm. , , unit mm.

[0142] 3. Deviation adjustment to if or The position of the chain catcher is finely adjusted using a jack, prioritizing horizontal alignment before adjusting the height. After adjustment, the alignment is retested until the deviation meets the standard.

[0143] 5.2 Dynamic adjustment of the reserved gap between the anchor chain and the anchor chain tube

[0144] 1. Data acquisition involves measuring the actual total length of the anchor chain. Calculate the anchor chain length deviation ( (Design length for anchor chain); Check chain stop installation deviation. (≤0.2mm).

[0145] 2. The actual clearance is calculated as follows:

[0146] ;

[0147] In the formula, The actual clearance reserved between the anchor chain and the anchor chain cylinder opening after the anchor chain is tightened, in mm; The deviation compensation coefficient is set to 0.5. This refers to the anchor chain length deviation, in mm. The measurement for chain stop installation deviation is in mm.

[0148] 3. Adjust the height according to the calculation. Fine-tune the height of the chain catcher, and then manually pull the anchor chain three times to confirm that there is no jamming, shaking, or overturning, and that the gap between the anchor chain and the anchor chain cylinder opening after tightening is 5±0.5mm. Record the final gap data.

[0149] S6: Use a balance hoist to lift the anchor winch to the preset position, tighten the installation bolts in a three-stage step-by-step tightening method, and check the torque of each bolt;

[0150] Furthermore, in step S6, the three-stage step-by-step tightening method is as follows: the first stage tightens to 380 N·m with an interval of 25 s; the second stage tightens to 570 N·m with an interval of 25 s; the third stage tightens to the calculated actual tightening torque. After tightening is completed, a torque tester is used to check the torque of each piece and record the data.

[0151] Furthermore, in another embodiment of the invention;

[0152] 6.1 Anchor winch hoisting

[0153] The anchor winch was slowly hoisted to the preset position using a four-point balancing hoist, maintaining its horizontal position with an inclination ≤0.1° during the hoisting process. The height and angle of the hoist were adjusted to ensure the anchor winch base was fully engaged with the pads, with no suspension. After hoisting, the hoist was removed, and the longitudinal and transverse horizontal levelness of the anchor winch base was checked to ensure it still met the requirement of ≤0.03mm / m.

[0154] 6.2 Dynamic Calculation of Bolt Tightening Torque

[0155] 1. Data acquisition involves using pressure sensors to detect the pressure deviation between the contact surfaces of the base and the anchor winch base. (The difference between actual pressure and theoretical pressure); the deviation between the actual gap and the standard gap (≤0.1mm) of the mating surfaces is measured using a feeler gauge. Record the ambient temperature during tightening. .

[0156] 2. The actual tightening torque is calculated as follows:

[0157] ;

[0158] In the formula, The actual tightening torque of a single bolt is expressed in N·m. The theoretical tightening torque for bolts is 760 N·m for M27 bolts; The pressure deviation compensation coefficient is set to 0.015. The pressure deviation at the bonding surface is expressed in MPa. The clearance deviation compensation coefficient is set to 0.02. The deviation of the mating surface gap is expressed in mm. The temperature compensation coefficient is set to 0.005 / ℃. The deviation of the actual temperature from 20℃ is expressed in ℃.

[0159] 3. Ensure the calculations are accurate. and The deviation should be ≤±5%. If it exceeds the range, re-check the condition of the bonding surface and adjust it.

[0160] 6.3 Three-level step-by-step tightening and verification

[0161] Tighten all M27 mounting bolts using a diagonal, crisscrossing tightening sequence and a three-stage, step-by-step tightening method:

[0162] 1. The first level is to tighten to That is, 380 N·m, with a 25-second interval after each bolt is tightened to ensure that the bolts are initially subjected to uniform force;

[0163] 2. The second stage is to tighten to That is, 570 N·m, with a 25-second interval to avoid sudden changes in bolt force;

[0164] 3. The third level is to tighten to the calculated value. After tightening, let it stand for 10 minutes, then use a torque tester to check the torque of each bolt. If the torque decreases by more than 5%, retighten it to the required value. Record the final tightening torque data for each bolt.

[0165] S7: Conduct comprehensive commissioning of the anchor winch, complete idling and loaded anchor deployment and retrieval tests, quantitatively evaluate the operating status based on the deviation rate between the actual value and the standard value of each test item, locate the unqualified items, make targeted adjustments, and then re-commission.

[0166] Furthermore, in step S7, the process for quantitatively evaluating the anchor winch operating status is as follows: compile the actual test values ​​and corresponding standard values ​​of each commissioning item, calculate the overall pass rate of the anchor winch operating status based on the deviation rate between the actual value and the standard value of each test item, and determine the rectification direction of the non-conforming items through the test item with the largest positioning deviation.

[0167] Furthermore, in another embodiment of the invention;

[0168] 7.1 Debugging Preparation

[0169] Check the connections of all components of the anchor winch, confirming that the bolts are properly tightened, the stop block and chain stop are accurately positioned, and the anchor chain is installed in place; start the anchor winch control system, check that the circuit and hydraulic system are operating normally, with no leaks or alarms; check that the hydraulic system oil level in the tank is in the middle of the scale.

[0170] 7.2 Core Experiments Conducted

[0171] 1. The no-load test involves running the anchor winch unloaded for 30 minutes at 80% of the manufacturer's rated speed. Every 5 minutes, the surface temperature of the anchor winch housing, the vibration speed of the bearing housing, and the noise should be checked and the test data recorded. Check all rotating parts for any jamming or abnormal noise.

[0172] 2. The anchor raising and lowering test under load involves running the anchor winch under rated load for 20 minutes, checking the meshing of the anchor chain wheel and the anchor chain, and recording the number of chain jumps (≤1 time / full range); testing the braking performance of the braking device and recording the braking distance (≤0.5m); and checking the fit between the anchor claw and the anchor hole to ensure a tight fit.

[0173] 3. Auxiliary tests include chain stopper operation test and anchor chain flushing device operation test; additional oil temperature monitoring is conducted on the hydraulic anchor winch to ensure that the oil temperature is controlled within the range of 35-55℃.

[0174] 7.3 Quantitative Assessment of Operational Status

[0175] 1. Compile the actual test values ​​for all debugging items. and corresponding standard values The testing items include surface temperature, vibration velocity, noise, braking distance, chain skipping frequency, oil temperature, etc. item.

[0176] 2. The overall pass rate for anchor winch operation is calculated as follows:

[0177] ;

[0178] In the formula, The overall operational qualification rate is expressed in % (%). For the first The actual value of the item test; For the first The standard value for the test item.

[0179] 3. Identification and rectification of non-conformities:

[0180] like The test was deemed successful because there were no abnormal heating (surface temperature ≤60℃), abnormal vibration (vibration velocity ≤2.8mm / s), abnormal noise, or jamming.

[0181] like Calculate the absolute value of the deviation for each test item using the formula. For items with the largest positioning deviations, targeted rectification should be carried out (such as adjusting bolt torque, stop block clearance, chain stop height, etc.). After rectification, re-adjustment should be performed until it meets the requirements. Record the debugging data, evaluation results, and troubleshooting details.

[0182] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. These embodiments are merely descriptions of preferred embodiments and are not intended to limit the scope or concept of the invention. The specific technical features described in the above embodiments can be combined in any suitable manner without contradiction. Such combinations, as long as they do not violate the spirit of the present invention, should also be considered as part of this disclosure. To avoid unnecessary repetition, the present invention will not further describe the various possible combinations.

[0183] This invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of this invention and without departing from the design idea of ​​this invention, all modifications and improvements made by those skilled in the art to the technical solutions of this invention should fall within the protection scope of this invention. The technical content for which protection is sought in this invention has been fully described in the claims.

Claims

1. A method for precise inspection and positioning installation of anchor winch bases for special marine engineering vessels, characterized in that, Includes the following steps: S1: Prepare all technical data and design modification documents for anchor installation, calibrate the theoretical centerline of the shaft system by combining environmental temperature compensation and measurement error correction, complete the preliminary acceptance of the anchor base and record the data; S2: Using the calibrated theoretical centerline of the shaft system as the sole reference, the flatness of the base support surface is tested at multiple points and dynamically compensated in combination with the welding deformation allowance. The horizontal coordinates of the base installation are calibrated, and the flatness and coordinate deviation are checked again after the base is welded and fixed. S3: Grind and clean the base and the mounting surface of the stop block, determine the positioning coordinates of the stop block based on the actual diameter deviation of the anchor chain, and quantitatively adjust the fit clearance between the stop block and the anchor chain. S4: Pre-treat the mating surface between the base and the anchor base, determine the actual processing thickness of the pad by combining the gap between the mating surfaces, the levelness deviation and the compression amount of the pad, and temporarily fix the pad after evenly arranging the pads and verifying the uniformity of the force. S5: Calibrate the three-dimensional spatial coordinates of the chain catcher, and dynamically adjust the reserved gap between the anchor chain and the anchor chain tube in combination with the anchor chain length deviation and installation deviation; S6: Use a balance hoist to lift the anchor winch to the preset position, tighten the installation bolts in a three-stage step-by-step tightening method, and check the torque of each bolt; S7: Conduct comprehensive commissioning of the anchor winch, complete idling and loaded anchor deployment and retrieval tests, quantitatively evaluate the operating status based on the deviation rate between the actual value and the standard value of each test item, locate the unqualified items, make targeted adjustments, and then re-commission.

2. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S1, the calibration operation of the theoretical centerline of the shaft system is as follows: S11: Adjust the ambient temperature to 18-22℃, and control the temperature change rate to ≤1.5℃ / h; S12: Use a calibrated total station to collect the actual measured length of the theoretical centerline of the axis system, and record the inherent error of the measuring tool and the actual ambient temperature; S13: Taking into account the difference between the actual measured length and the theoretical length of the shaft system centerline, the inherent error of the measuring tool, and the deviation of the ambient temperature from the 20℃ standard temperature, calculate the final deviation of the baseline. S14: If the final deviation of the baseline exceeds ±0.3mm, adjust the position of the baseline and repeat the measurement and calculation until the deviation is ≤±0.3mm in 3 consecutive re-verifications.

3. The method for precise inspection and positioning installation of anchor winch bases for marine special vessels according to claim 1, characterized in that, In step S2, the detection and compensation operation for the flatness of the base support surface is as follows: S21: Select no less than 10 measurement points evenly on the base support surface, collect height data of each measurement point, and determine the maximum height difference, minimum height difference, and average height deviation of the measurement points; S22: Taking into account the ratio of the maximum height difference of the base support surface to the length of the measurement area, the average height deviation of the measurement points, and the allowable amount for welding deformation, calculate the overall flatness deviation; S23: If the overall flatness deviation exceeds 0.3mm / m, a combination of local grinding of the raised parts and fine-tuning pads to compensate for the recessed parts shall be used to correct it until the overall flatness deviation is ≤0.3mm / m.

4. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S2, the calibration process for the horizontal coordinates of the base is as follows: determine the theoretical horizontal coordinates of the base according to the layout diagram of the mooring and towing equipment, calculate the horizontal deviation between the actual coordinates and the theoretical coordinates, and ensure that the deviations in both horizontal directions are ≤ ±0.5mm; after welding and fixing, let it stand for 30 minutes for re-inspection, and the flatness re-inspection measurement deviation is ≤ ±0.05mm / m, and the coordinate deviation is ≤ ±0.03mm.

5. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S3, the process for determining the positioning coordinates of the stop block is as follows: determine its theoretical coordinates based on the design parameters of the anchor chain's running trajectory, superimpose the compensation amount dynamically adjusted according to the deviation between the actual diameter and the theoretical diameter of the anchor chain, and calculate the actual positioning coordinates of the stop block. The compensation amount ranges from 0.1 to 0.2 mm. After adjusting the perpendicularity deviation between the stop block and the drum axis to ≤0.1°, spot weld it for temporary fixation. The adjustment process for the fit clearance between the stop block and the anchor chain is as follows: Measure the deviation between the actual diameter and the theoretical diameter of the anchor chain and the grinding deviation of the stop surface. Taking into account the standard fit clearance, the anchor chain diameter deviation, and the grinding deviation of the stop surface, calculate the actual fit clearance. The standard fit clearance ranges from 0.5 to 1 mm. Fine-tune the position of the stop block so that the actual fit clearance is within the range of 0.5 to 1 mm.

6. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S4, the process for determining the actual processing thickness of the pad block is as follows: measure the actual gap and longitudinal and transverse horizontal deviation of the mating surface between the base and the anchor base, and comprehensively consider the actual gap of the mating surface, the longitudinal and transverse horizontal deviation, and the reserved value of the pad block compression amount to calculate the actual processing thickness of the pad block; the thickness deviation of the pad block after processing is ≤ ±0.02mm, the single layer thickness is ≥8mm, and when multiple layers are stacked, the number of layers is ≤3 and the material is consistent with the base.

7. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S4, the operation procedure for arranging the pads and verifying the stress is as follows: S41: Arrange the pads evenly according to the design points. The distance between the center of each group of pads and the bolt hole of the anchor base is ≥50mm. When multiple layers are stacked, the misalignment angle is ≥90° and there are no through gaps. S42: The longitudinal and transverse horizontal levelness of the anchor winch base is ≤0.03mm / m, and the contact gap between the pad block and the base and anchor winch base is ≤0.1mm; S43: Calculate the average force on a single set of blocks based on the weight of the anchor winch, the rated load, and the number of blocks. Then, calculate the force deviation rate based on the difference between the maximum force and the average force on a single set of blocks, ensuring that the force deviation rate is ≤5%.

8. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S5, the calibration process for the three-dimensional coordinates of the chain catcher is as follows: determine the theoretical three-dimensional coordinates of the chain catcher according to the drawings, use a total station to detect the actual three-dimensional coordinates and calculate the comprehensive deviation in the horizontal direction and the deviation in the vertical direction, ensuring that the comprehensive deviation in the horizontal direction is ≤ ±0.3mm and the deviation in the vertical direction is ≤ ±0.2mm, so that the groove of the chain catcher is precisely on the line connecting the anchor chain wheel and the anchor chain cylinder of the anchor winch. The adjustment process for the reserved gap between the anchor chain and the anchor chain canister is as follows: Measure the deviation between the actual length and the theoretical length of the anchor chain and the installation deviation of the chain catcher. Taking into account the standard reserved gap, the anchor chain length deviation, and the chain catcher installation deviation, calculate the actual reserved gap. The standard reserved gap is 5mm. Adjust the height of the chain catcher so that the gap between the anchor chain and the opening of the anchor chain canister after the anchor chain is tightened is 5±0.5mm.

9. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S6, the three-stage tightening method is as follows: the first stage is tightened to 380 N·m with an interval of 25 s; the second stage is tightened to 570 N·m with an interval of 25 s; the third stage is tightened to the calculated actual tightening torque. After tightening, the torque is checked one by one using a torque tester and the data is recorded.

10. The method for precise inspection and positioning installation of anchor winch base for marine special vessels according to claim 1, characterized in that, In step S7, the process for quantitatively evaluating the anchor winch operating status is as follows: compile the actual test values ​​and corresponding standard values ​​of each commissioning item, calculate the overall pass rate of the anchor winch operating status based on the deviation rate between the actual value and the standard value of each test item, and determine the rectification direction of the non-conforming items through the test item with the largest positioning deviation.

Images