自动化立体库货架安装规范中英.docx

自动化立体库货架安装规范中英.docx

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自动化立体库货架安装规范中英

自动化立体库货架安装规范

AS/RSRACKINGINSTALLATIONGUIDE

为满足企业日益增加自动化立体仓库货架订单要求,提升本企业立体仓库货架安装精度和效率,特制订此规范。

Inordertomeetourcompany’sAS/RSrackinginstallationprecisionandefficiencyofourincreasedorder,weformulatethisguide.

一、接到安装任务单,找设计人员沟通图纸内容,拿到全部图纸（包含方案图、立柱组装图、横斜撑位置）,掌握安装关键点、难点,确定使用工具并准备好工具:

电锤、电线、电动扳手、墨斗、常见扳手、手电钻、经纬仪、水平仪、100M钢卷尺。

Checkandstudyallofdrawingoftheproject.Getmaindesignideaoftheproject.Masterthemainpointanddifficulties.Preparethetoolsasfollows:

Electrichammer,electricwire,electricwrench,wrench,fountain,commonlyusedelectricdrill,theodolite,level,100Msteeltape.

一、安装人员进入施工现场后,首先对地基情况、预埋件进行检测（无预埋件仅检测地基）,合格后方可安装;如不在要求范围内,必需将测量数据传到企业,等企业给出具体处理方案后再安装。

TheinstallershouldcheckthebasesituationandtheEmbeddedpartsaftertheinstallersgointothesite.IfthebasesituationandEmbeddedpartsisqualified,theworkersstarttoinstall.Ifnot,installershouldsendthethedatetocompany.Aftercompanyoffersomesolution,thenworkercaninstallracking.

注:

判别条件Discriminantconditions

①地面平整度许可偏差:

Groundflatnessalloweddeviation:

长宽尺寸（m）Length

许可偏差（mm）alloweddeviation

≤50

±10

≤150

±15

＞150

±20

②在最大载荷下,货架基础地坪沉降变形应小于1/1000。

UnderMaxload,therackingbaseSettlementdeformationshouldbelessthan1/1000.

三、地面放样Thegroundsettingout

1、仪器工具:

经纬仪、水平仪、100M钢卷尺、墨斗等

Instrumental:

theodolite,level,100Msteeltape,inkandother

2、取一点K为放样基准点（K为仓库中心点）,依据土建基正确定X向基准线,将经纬仪架于K点,作出X向基准线垂线为Y向基准线,并校核两条基准线垂直度。

分别以X向、Y向基准线作出轨道中心线和柱脚中心线。

画线前一定要找到货架安装基准,假如现场测量尺寸和图纸尺寸有误差,一定要消除误差或者把误差控制在某一个不关键尺寸上。

TotakeabitofKloftingreferencepoint（Kwarehousecenterpoint）,accordingtothecivilbaselinetodeterminetheXtobaseline,atheodoliteframeatK,makeXtothedatumlineforYtoverticaldatumline,andcheckingthetwobaselineverticality.WithXrespectively,Ytothedatumlinetomakethetrackcenterlinecenterlineandcolumn.Drawalinetofindtheshelfmountingreference,ifthesitemeasurementofsizeanddrawingsizeerror,musteliminateerrorsorerrorcontrolinoneimportantdimension.

四、将水平仪置于中间K点,进行地面水平度测量,

Putthelevelinthe“K”pointandchecktheflatnessoftheground.

逐点测量并统计货架底脚及地轨（如无需安装地轨可不测,地轨测点为地轨底板所在点）每一点水平标高,分析出最高点和最低点,算出地平差量,并验证此差值与设计最大调整量是否一致;

Measureandrecordthelevelofeverypointoffootplateandgroundrail.（Measurepointofthegroundrailistheshimposition.）

Findthepeakandthelowestpoint.

calculatethehorizontaldifference

如不符合要求,将少许超低点补高或超高点降低处理,直至满足要求为止。

Ifrequirementsarenotmet,asmallamountofultralowfillhighorsuperhighreducingtreatment,untilsatisfied.

预埋已进行浇灌以最高点为基准,其她点补高,数值偏差较大要通知企业。

Preburiedhasbeenwateredwiththehighestpointasthereferencepoint,theother,largerdeviationstoinformthecompany'svalue.

注:

常见柱脚固定形式在地面满足要求后处理方法

Note:

thecommoncolumnfixedforminthegroundtomeettherequirementsofpostprocessingmethod

1可调底脚不处理,但要确保同一底脚接触面水平误差±0.5mm

Theadjustablefoottreatment,buttoensurethatthesamefootcontactsurfacelevelerror±0.5mm

2膨胀螺栓打孔放地脚螺栓（此方法采取外膨胀）,垫好调整垫片,满足水平误差±0.5mm;

Theexpansionboltholeonthebolt（thewayusingexternalexpansion）,padadjustinggasket,satisfythelevelerrorof±0.5mm;

采取内膨胀时边竖柱片边垫调整垫片,立柱底板满足水平误差±0.5mm

Theexpansionsideverticalcolumnsidepadadjustinggasket,columnbottommeetlevelerrorof±0.5mm

3预埋板（焊螺栓、直接焊立柱）确保调平板或调整螺母水平误差±0.5mm

theembeddedplate（weldingbolt,directweldingcolumn）ensureadjustingnutflatorhorizontalerrorof±0.5mm

4已进行二次浇灌,补焊垫板满足水平误差±0.5mm

Sincetwotimetoirrigate,weldingpadsatisfythelevelerrorof±0.5mm

五、货架安装Installation

1、货架安装前应对每一构件进行严格检验,如有变形在安装前给予矫正。

Shelfinstallationbeforerespondingtoeachmembertocarryoutstrictinspection,suchasdeformationbeforeinstallationtobecorrected.

2、在木制组装台上进行组装柱片,以预防喷塑层划伤;依据现场情况采取吊车、卷扬机或人等方法进行吊装（如用卷扬机或人力时固定定滑轮,标准上定滑轮固定点比货架片最高点高3~5m）,第一片吊起后要将其四面拉紧,竖起第二片后连上横梁,然后再竖第三片并挂横梁,依据设计要求安装背拉和水平拉杆,并安装天轨吊梁,调整好立柱垂直度、横梁水平度,满足要求后固定底脚,紧固各零部件间连接螺栓;然后再竖柱片、挂横梁,碰到第二列背拉组时停止竖柱片,安装背拉和水平拉杆,大致调整这一区域垂直度、水平度;调整好后继续往前推进竖柱片、挂横梁,依次类推,直至吊装至堆垛机厂家要求位置,安装剩下天轨吊梁（此时各零部件间连接螺栓不要紧固）。

以前货架主体（除天、地轨）安装完成后,对水平度、垂直度及通道方向直线度、垂直通道方向直线度进行调整,满足设计要求后将货架片柱脚及各连接螺栓紧固。

以后安装天、地轨,在安装前以货架主体画天、地轨校正线,确保无误后才开始安装,每段轨道调整完成后对焊起来。

堆垛机进入货架后再按之前次序安装余下货架。

货架安装完成后,全方面复查各连接螺栓紧固情况,使之均处于紧固状态。

Inwoodenassemblingbenchassemblycolumn,inordertopreventthespraylayerscratch;accordingtothescenewithcranes,winchesormethods（suchashoistingwinchorhumanwhenfixedpulley,afixedpulleyisfixedpointprinciplethantheshelfplatethehighestpointofhigh3~5m）,articlealifttothearoundsecondpiecesoftension,erectedaftertheupperbeam,andthenthirdverticalsliceandhangingbeams,accordingtothedesignrequirementsofinstallationbackpullandhorizontaltie,andmountingrailcranebeam,column,beamadjustingverticalitylevelness,meettherequirementsafterthefixedfoot,fasteningpartsbetweentheconnectingbolt;thenthenverticalcolumn,hangingbeam,columnencounteredsecondbacktensiongroupstopswhentheverticalcolumn,installationofbackpullandhorizontaltie,broadlytunedtothisregion,levelnessverticality;afteradjustmentcontinuemovingforwardverticalcolumn,hangingbeam,andsoon,untiltheliftingtostackingmachinemanufacturersrequirementslocation,installationtheremainingrailcranebeam（thebetweeneachpartconnectingboltsdonottighten）.Theshelfbody（exceptfordays,rail）afterinstallation,thelevelness,perpendicularityandchanneldirection,theverticalchanneldirectionofstraightnessstraightnessadjusting,meetthedesignrequirementsaftertheshelfplatecolumnandtheconnectingbolt.Afterinstallationofdays,thetrack,beforeinstallationtotheshelfbodypaintingdays,thetrackcorrection,toensurethatthecorrectonlyafterinstall,eachsectionoftrackafteradjustingthebutt.Stackercraneintotheshelfafterthepressbeforetheinstallationsequencetheremainingshelf.Shelvesafterinstallation,acomprehensivereviewofalltheconnectingboltsfastening,whichareinthefastenedstate.

注:

天地轨安装要求（具体见安装图）

Note:

theworldrailinstallationrequirements（seethespecificinstallationdiagram）

1用水平仪测量每一固定点处地轨上表面水平标高,并经过增减垫片（测量地平时,垫片应摆放好）,使轨道全长水平度在±1mm内,基准按设计要求为准;

Levelmeterformeasuringafixedpointontherailsurfacelevel,andbyincreasingordecreasingthegasket（measuredinpeacetime,thegasketsshallbelaid）,makethetracklengthlevelwithin±1mm,accordingtodesignrequirementsforreference;

2用水平仪测量地轨顶面,测量位置和调整方向同上,使其精度控制在每米±0.5mm内;

Levelmeterformeasuringrailtopsurface,measuringpositionandadjustdirectionibid.,makeitsaccuracycontrolineachmeter±0.5mm;

3用经纬仪测量地轨侧面,调整使其每米±1mm内,全长控制在±2mm内;

Surveyingwiththeodolitetotrackside,adjusteditspermetre±1mm,full-lengthcontrolwithin±2mm;

4地轨接头处按图纸要求就位后用高碳钢焊条（KT-42E430,BJ/T4747,506焊条亦可）对焊,焊后用磨光机打磨,最终紧固压板螺栓（有定位块紧贴轻轨焊于底板上）;

Therailjointsaccordingtothedrawingrequirementsinplacewithhighcarbonsteelweldingrod（KT-42E430,BJ/T4747506weldingrodwelding,afterweldingcanalsobe）withgrindergrinding,thefasteningclampbolt（withapositioningblocktolightrailweldedonthebottomplate）;

5轨道顶部表面及顶部两个侧面要打磨光,轨道头部横向外轮廓表面打磨按以下要求进行,轨道头部下表面无须磨光,但要磨平。

Topofrailsurfaceandthetoptwosidestobepolished,railheadhorizontalsurfacegrindingaccordingtothefollowingrequirements,railheadsurfaceneednotbepolished,butberemoved.

1）、轨道顶面局部要求:

在±50mm长度内局部凹深≤0.1mm,用磨光设备轻易作到此项要求。

Thetopsurfaceofthelocaltracks:

±50mmlengthlocalconcavedeep≤0.1mm,withpolishingequipmenteasytoachievethisrequirement.

2）、轨道侧面局部要求:

在±100mm长度内局部凹深≤0.5mm。

Thetracksidelocalrequirements:

inthe±100mmlengthlocalconcavedeep≤0.5mm.

3）、总公差应符合标准FEM9.831要求。

GeneraltolerancesshallbeinaccordancewiththeFEM9.831standardrequirements.

4）、熔焊接头轨道头下表面及轨道腹板应磨得与原轮廓表面一致,以预防车轮被抬起、倾斜或被钩绊住。

Weldingjointrailheadsurfaceandtherailwebsshallbewornwiththeoriginalcontoursurface,topreventthewheelsareraised,tiltedorhooksnagging.

图15轨道打磨

5）、轨道顶部凸缘下侧应平滑,无毛刺及大凸起焊疤,以避免造成车轮运行障碍。

在两条轨道接头处焊成轨道腹板两侧面亦应磨平,此平面亦作为支撑轮滚动表面。

Tracktothetopofthelowersideoftheledgeshallbesmooth,noburrandraisedweldingscar,inordertoavoidwheelrunningobstacle.Intworailjointsweldedrailwebsideshouldalsoberemoved,theplanealsoasasupportingwheelrollingsurface.

6）、天轨对接处尽可能贴合或按图纸就位,调整好垂直及水平弯曲许可偏差后采取对焊方法焊接,角钢天轨还应在天轨上表面焊接连接板,焊后打磨。

Railjointdrawingsortoengageinplace,adjusttheverticalandhorizontalbendingtoleranceaftertheintroductionofbuttweldingmethodwelding,steelrailshouldalsointhedaysofrailsurfaceweldedwithaconnectingplate,weldingaftergrinding.

六、安装过程中需注意以下事项:

Theinstallationprocessshouldpayattentiontothefollowingmatters:

1、全部螺栓和连接面要除锈;天、地轨对接焊缝必需平整光滑,焊缝不许可突出轨道表面,以免影响堆垛机运行。

Allboltsandconnectingsurfacetorust;day,railbuttweldshallbesmooth,notallowedtohighlighttheweldsurfaceoftherail,soasnottoaffectthestackingmachineoperation.

2、化学螺栓安装Chemicalboltinstallation

2.1、作业前准备Preparationbeforeoperation

2.1.1、化学螺栓由化学胶管、螺管、垫圈及螺母组成,螺杆、垫圈、螺母（六角）通常有镀锌钢和不镀锌钢两种,药剂管内药剂有反应树脂、固化剂和石颗粒等成份。

C

Chemicalboltbychemicalhose,spiralpipe,washerandnut,screw,washer,nut（six）generallyhavegalvanizedsteelandgalvanizedsteelpipetwo,pharmaceuticalchemicalsreactionresin,curingagentandstoneparticlescomposition.

2.1.2、钻机及钻头在打孔时,要使用与锚栓匹配自动保障孔深钻机和钻头。

钻孔深度由设计师依据使用要求和设计规范确定。

Drillanddrillindrilling,tousewithanchorboltmatchingautomaticsecurityholedeepdrillingriganddrillbit.Drillingdepthb