起重机制造的工艺流程
Crane manufacturing process
我们公司主要生产桥、门式起重机，具有自行设计、研制能力和制造加工能力；我们的产品涉及到冶金、水工、电站、化工、造纸、造船、航空、航天、港口等行业，目前制造的起重机最大起重量为500t，最大起升高度达400米。
Our company mainly produces bridge, gantry crane, with our own design, development capabilities, manufacturing and processing capacity; of our products related to metallurgy, hydraulic, power, chemical industry, papermaking, shipbuilding, aviation, space, ports and other industries, the current manufacturing maximum starting weight of the crane 500t, maximum lifting height of up to 400 meters.
在结构件制造方面，本公司具有较强的制造能力；有年处理能力达5万吨以上，具开卷、校平、剪切、抛丸、喷漆、烘干能力的预处理生产线一条；有数控切割设备5台；（6000X50000）；半自动切割60多台，CO2气体保护焊，埋弧自动焊（平、角焊）200多台；其他焊机300多台。有各种剪板机，校平机、折弯机、卷板机等各种大型加工设备。这些设备为提高结构件的制造能力提供了有力的保证。
In the structural parts manufacturing, our company has strong manufacturing capacity; have capacity of more than 5 million tons in a year, with open-book, school level, shearing, shot blasting, painting, drying capacity of a pre-processing production line; a numerical cutting equipment 5 sets; semi-automatic cutting more than 60 units, CO2 gas shielded welding, submerged arc welding (flat, angle welding) more than 200 units; other welding more than 300 units. A variety of shears, school-level machine, bending machine, rolling machine and other large-scale processing equipment. These devices to improve the structural parts of the manufacturing capacity to provide a strong guarantee.
在机械加工方面，本公司的设备加工能力在长垣地区可以说是领先的，我们有16米的落地铣镗床，即将到厂的m=28，最大加工直径φ3150的大型滚齿机和大型立式车床，数控重型卧式车床、各种卧式镗床，立式铣加工中心等精、大、稀设备，为我们公司加工各种大型、高精度的零件提供了设备保证
In mechanical processing, the processing capacity of the company's equipment can be
said in the Changyuan region's leading, we have 16 meters of floor milling and boring machine, upcoming visit to the factory m = 28, maximum machining diameter of φ3150 large-scale and large vertical lathe hobbing machine , CNC heavy duty horizontal lathe, all kinds of horizontal boring machine, vertical machining centers, precision milling, large, rare equipment for our processing of all kinds of large-scale, high-precision parts provided with equipment to ensure
机械产品生产过程是指从原材料到机械产品出厂的全部生产过程。它既包括：毛坯的制造、机械加工、热处理、装配、检验、试车、油漆等主要生产过程；还包括包装、运输等辅助过程。
其生产过程可以由一个工厂完成，也可以由多个工厂完成。我们公司除了大型结构件，部分机械
加工零件由本公司制造外，有一部分零部件由外协厂加工制造。主要是我们的生产能力不能满足。Mechanical product refers to the production process from raw material to the entire machinery factory production process. It includes: blank manufacturing, machining, heat treatment, assembly, inspection, testing, painting and other major production process; also includes the packaging, transportation and other auxiliary processes. Its production process can be completed by a factory, you can also be completed by a number of factories. In addition to our large-scale structural parts, some machining parts manufactured by the company, there are some parts from the outside co-processing and manufacturing plants, mainly because our production capacity needs to be improved.
下面就我们公司起重机生产的主要工艺流程作一介绍，在介绍工艺流程的同时，把每道工艺过程中所涉及到的设备作一些介绍，让大家对我们的设备能力有一个初步了解。Now I'll briefly introduce process of making the crane, at the same time, you may have a preliminary understanding of our equipment.
先介绍起重机制造的总工艺流程，然后再逐一介绍每道工序的详细情况。
我们的起重机由金属结构件、机加工件、外购件、外协件及电气几大部分组成，其工艺流程见工
艺流程方框图：
起重机由金属结构件（主梁、端梁、平台及梯子栏杆、小车架，等）、机加工件；外购件（轴承，紧固件，标准件等），外协件（因本公司设备或生产能力原因，委托外单位加工的零部件：如吊钩）经过装配而成产品。Crane from the metal structure (the main beams, side beams, platform and ladder railings, small frame, etc.), machining
parts; purchased parts (bearings, fasteners, standard parts, etc.) and spare parts (due to our equipment or capacity reasons, the commission units processing components: If the hook) made through the assembled product.
起重机工艺流程图
金属结构件
厂内流程出厂后流程
一结构件生产工艺流程Production process for current each structure:
1.来料检查：是指对进厂的材料（包括钢材及焊接材料），质管部门检查是否有制造厂的合格证明书，并根据其合格证明书按照国家标准及公司规定验收核准，必要时要进行复验，对其进行化学成分和机械强度等项进行抽样检查，是否达到国家标准和企业的有关要求；
Inspection of the incoming material: it means that quality inspection department will check if the incoming materials (including steel, welding material) have certifications, verify them in accordance with the national standard and company. Recheck if necessary, conduct random inspection chemical composition and mechanical strength will be inspected by random samples to see whether
1.1钢材 Steel
本公司金属结构件常用钢材
Commonly used steel of our company 表1 table one
钢材牌号表示：Q—钢材屈服强度“屈”的拼音首位字母：235—屈服点（强度），
单位MPa（兆帕）；A、B、C、D-质量等级；F—沸腾钢（脱氧方法） b—半镇静钢 Z—镇静钢（可省略）TZ—特殊镇静钢（可省略）。Steel mark:Q-yield point of steel; 235- yield point strength, unit (MPa); A、B、C、D-quality grade; F— boiling steel (method of deoxidation) b— semi-deoxidized steel Z—killed steel（can be omitted）TZ—special killed steel (can be omitted）.
45（35）—含碳量（万分之几）
45（35）—carbon content(? in ten thousand)
1.2焊接材料 welding material
1.2.1 焊条型号和规格 model and specification of welding rod
焊条型号（碳钢焊条） welding rod model (Carbon steel, welding rod) E4303 (J422) E4316 (J426) E5003 (J502) E5015 (J507) E5016 (J506)
以E5016为例，说明各项字母和数字代表的意义：(E—焊条，50—熔敷金属抗拉强度最小值500MPa，1—焊条适用的焊接位置：0，1表示焊条适用于全位置（平、立、仰、横），6—药皮类型
Take E5016 as an example, describe meaning of each letter and figure: (E--welding nod, 50- min. tensile strength of deposited metal is 500MPa, 1--suitable location for welding nod: 0，1 means it’s suitable for all positions (horizontal, vertical, upward and side-wards), 6- type of the cover.
特点： E4303, E5003熔渣流动性好，脱渣容易，电弧稳定，熔深适中，飞溅少，焊波整齐，适用于全位置焊接，主要焊接较重要的低碳钢结构。
Features: E4303, E5003 slag with good fluidity, removal of slag layer is easy, electric arc is stable, moderate depth of fusion, less splash, weld ripples in good order, suitable for welding on all positions, mainly used for welding of important low-carbon steel structure.
E4316 、E5016电弧稳定，工艺性能一般，适用于全位置焊接。这类焊条的熔敷金属具有良好的抗裂性能和力学性能，主要焊接重要的低碳钢结构，也可焊接与焊条强度相当的低合金钢结构。
E4316, E5016 arc are stable, process performance is general and suitable for welding on all positions. Deposited metal of such welding nod
has good crack resistance and mechanical property, mainly used for welding of important low-carbon steel structure, and also for welding of low-carbon steel structure that has similar strength.
焊条规格：φ2.5-φ5
Specification of welding nod: φ2.5-φ5
1.2.2焊丝型号和规格 model and specification of welding wire
焊丝型号：
埋弧自动焊焊丝：H08A H08MnA H08Mn2Si H10Mn2（原型号）
气保焊：实心焊丝：ER50-6 ER49-1 （ER—焊丝， 50—熔敷金属抗拉强度最小值500MPa 6—焊丝化学成分分类代号）
Model of welding wire：
Automatic submerged-arc welding wire: H08A H08MnA H08Mn2Si H10Mn2 (Original Code).
Gas Shielded Welding: solid wire: ER50-6 ER49-1 (ER—welding wire, 50— min. tensile strength of deposited metal is 500MPa, 6—code of chemical composition of welding wire)
药芯焊丝EF flux-cored wire
焊丝规格specification of welding wire：1.2，φ2.0，φ3.0，φ3.2，φ4.0，2.钢材表面的预处理Pretreatment of steel surface：
钢材在下料前，表面必须经过喷丸或抛丸除锈处理，其重要构件表面达到GB8923中的Sa2.5级；一般件达到Sa3级。除锈后，应立即喷涂防锈底漆 Before cutting of the steel, shot and ball blasted, surface of important parts reach degree Sa2.5 of GB8923 standard. After removing the rust, paint anti-corrosive primer at once.
预处理设备Pretreatment equipment：
（1）开卷、校平、剪切生产线，（TDT44-10X2200）
Unreeling, leveling, shear production line.
（2）预处理（抛丸、喷漆、烘干一条线）QXY3000
Pretreatment (shot blast, paint, and drying as one line) QXY3000.
（3）抛丸处理：可处理宽2000mm×200mm钢材或高1800mm×1200mm以内的结构件。Shot blasting treatment: treat 2000mm×200mm(width) steel plate or structure
no larger than 1800mm×1200mm.
3.喷涂底漆 primer painting
底漆喷涂应在抛丸处理后，立即进行；否则，钢板表面生锈。Primer spray will be painted immediately after shot blast to avoid rust of the surface.
3.1底漆的种类：根据产品使用环境不同，所使用的油漆品种也不同，根据不同的面
漆品种，应使用不同的底漆（见表1）
Type of prime coat: Different paint will be used according to different environment, and also different primer will be used on the basics of different final coat (see table one). Table 2
油漆品种由工艺部油漆工艺员根据合同要求，制定油漆工艺（含油漆品种、颜色、数量、底、面漆涂层厚度等内容）。
Painting craft (including type of paint, color, quantity, thickness of primer and finish coat, etc.) will be made according to contract.
4.号料：根据图样，或利用样板、样杆等直接在材料上划出构件形状和加工界线。Marking off: mark the shape and processing lines on plate with sample plate, handrail or diagram.
5.下料Plate-cutting：
5.1 下料方法：数控切割下料、半自动切割下料、剪切下料、锯切下料。
下料方法的界定由工艺部下料工艺员决定，编制下料工艺卡，对林对数控切割下料件进行编程，编程序号。Cutting method: CNC cutting, semi-automatic cutting, shearing and sawing. Processing department will choose the appropriate cutting method, draw up procedure card, put in program and number.
5.2各种下料方法适用范围 Scope of application for each cutting method: 数控切割下料：形状比较复杂板件，如筋板、异形件等。
半自动切割下料：大型件，且切割边为直线。如主梁腹板拼接后，需用半自动切割进行下料。
剪切下料；对于形状简单的薄板、中板（12mm以下），剪切边为直线的零件。
带锯床：主要用于型材下料（圆钢，及其他型钢）
CNC cutting: plate with complex shape, such as gusset plate,special parts, etc.
Semi-automatic cutting: large parts, edge is in straight line. For example, after connection of main girder web plate, cut it with semi-automatic machine.
5.3下料设备 Cutting Equipment
表 table 3
6. 板料拼接：有些零件（如主梁腹板）需要由多块板料进行拼接而成。
拼接时，应根据零件尺寸，进行号料，按照有关工艺要求进行拼接。焊缝用半自动割刀根据工艺要求开坡口，用埋弧自动焊进行焊接。
Plate connection: some parts (such as web plate of main girder) will be connected by several plates. Plates will be connected according to size, mark and process requirements. Weld will be bevel cut by semi-automatic cutter and then treated by automatic submerged-arc welding.
7.探伤检查：对接焊缝属重要焊缝，根据要求，应进行无损探伤，射线探伤时应不
低于GB3323中规定的Ⅱ级，超声波探伤时应不低于JB1152中规定的Ⅰ级。对不合格的地方，用碳弧气刨刨掉，并进行清根后，再进行焊接。
设备：TF-3125 X射线探伤仪。
Flaw detection: butt weld seam will be detected according to requirements because of its importance, grade is no lower than II regulated in GB3323, when detected by ray, and shall be no less than Ⅰ regulated in JB1152 when detected by ultrasonic. For unqualified parts, shaved by carbon arc gouging, re-weld after cleaning.
8.校平：板料拼接后，应进行校平，
方法：（1）机械校平：设备：辊式板材矫平机 W43Q-32X2500
（2）火焰矫正
（3）手工矫正
要求：校平后的平面度≤1/1000
Leveling: level the plate after connecting,
Method: （1）Mechanical leveling: equipment: roller plate leveler W43Q-32X2500
（2）flame straightening
（3）manual correction
9.二次划线，下料：
钢板拼接后，经过探伤检验、校平后，按照所需要的形状、尺寸划出切割线（号料），然后用半自动切割机沿切割线割出，并按要求割出焊接坡口。
Secondary mark, cutting:
After connecting, detection and leveling, draw cutting lines (marking off)
according to the required shape, size, cut them with semi-automatic cutting machine.
10.组装 Assembly：
金属结构部件所有板料及型材备齐后，即可进行组装。组装指焊接前的组对和装配。即将各板料、型材组装成架。各零件之间用手工焊或气保焊进行点固焊，（定位焊），根据不同板厚，点固焊缝长度也不一样，板料越厚，点固焊缝越长，约10-60范围内。点固焊接间距约100-300，板料约厚，间距越小。点固焊一定要点焊牢固。
以主梁为例，部件装配大致程序如下
1.搭建平台：组装必须在平台上进行；平台要求：平面度≤1/1000
2.腹板平放在平台上，点装纵筋角钢，并焊接，一般为双面交错断续焊；
3.上盖板平铺在平台上，划出各筋板、腹板位置线
4.在上盖板上按线点焊装大筋板；采用手工焊或CO2保护焊点焊。
5.在上盖板上点装主副腹板，成π形梁；
6.焊接内部焊缝，（筋板与腹板、盖板）；（气保焊），并涂喷防锈底漆。
7.下盖板在平台上划线后，π形梁吊放在下盖板上；焊内部未焊接焊缝。
8.焊接四条主焊缝（埋弧自动焊）及其他可见焊缝（气保焊）。
9.校正，时效。对于大型构件，一般采用振动时效。
主梁制成后，应保证主梁有0.9-1.4S/1000的拱度。（S—跨度）
Take main girder as an example, assembly procedure as follows:
1. Build platform: assemble it on the platform, flatness no more than 1
/ 1000
2. Web plate will be put on the platform, weld longitudinal reinforcement
angle, generally it’s double-staggered intermittent welding;
3. Cover-Plate will be tiled on the platform, mark the position of rib
and web plate.
4. Weld the ribs according to dot line on plate, apply manual and CO2 spot
welding;
5. Weld main and aux web plate on cover plate which will be "π" shape
beam.
6. Weld seams inside, (ribs, web and cover plate); (gas-welding), then
paint antirust primer;
7. After marking on platform, put “n”shape girder on lower plate; weld
seams inside;
8. Weld four main seams (automatic submerged-arc welding) and other seams
(gas protection welding).
9. Correction, limitation. Generally VSR will be used for large components,
camber of main girder shall be 0.9-1.4S/1000 (S stands for span).
11.探伤、检查
对主要焊缝进行超声波探伤检查，腹板与盖板的四条长焊缝，应达到GB/T12469中规定的缺陷分级Ⅱ级标准。结构尺寸达到图纸要求，拱度在规定的范围内。
12.装配（汇装）Assembly (assemblage)
汇装就是将各部件按要求组装在一起，组装成大部件；组装时，应按照有关要求进行组装。如主梁，端梁汇装成桥架时，须保证两轨道中心距离（轨距），桥架对角线长度误差等。大小车运行机构的装配时，保证车轮安装相互位置，如车轮的垂直偏斜、水平偏斜、同位差等；起升卷筒的装配要进行校线，卷筒轴线的偏移、齿轮侧隙，联轴器水平位移、角位移等等。Assemblage means assemble each part according to requirements. When main girder and end carriage are connected into bridge, assure that distance between center of two track and length tolerance of bridge diagonal line meets requirements. When assemble LT and CT mechanisms,
二. 机加工件生产工艺流程
1. 毛坯：机加工件的毛坯主要有铸钢件（ZG270-500，ZG340-640等）,铸铁件
（HT、Q T），焊接件（钢板和焊接件），圆钢件（用锯床下料）。
Production process of machining parts
Rough parts: they mainly include cast steel (ZG270-500，ZG340-640 etc.), iron casting (HT, QT), welding (steel plate and welding parts), round steel parts (cut by saw machine.
2 .机械加工：机械加工是指对机械产品中的零件采用各种加工方法（车、铣、
刨、磨、镗、钻、插等）来改变毛坯的形状、尺寸、表面粗糙度等，使之成为合格零件的过程。
Machining: it means machine mechanical components in different method (milling, planing, grinding, boring, drilling, insertion, etc.) to change shape, size, surface roughness of them into qualified ones. 2.1 加工设备processing equipment ：表 table 4