起重机制造工艺流程.docx

1、起重机制造工艺流程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 product

2、s 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

3、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,

4、 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 va

5、riety 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3150的大型滚齿机和大型立式车床，

6、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 companys equipment can be said in the Changyuan regions leading, we have 16 meters of floor milling and boring machine, upcoming visit to the factory m = 28, maximum machining diameter o

7、f 3150 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

8、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 i

9、ncludes: 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

10、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

11、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 Ill 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

12、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 uni

13、ts processing components: If the hook) made through the assembled product.起重机工艺流程图 金属结构件来料检验化学成分、机械性能预处理喷丸喷底漆号料下 料数控、剪切、半自动切割 板料拼接埋弧自动焊探伤板料校平辊式校平机二次划线下料自动切割组装（点装）气保焊、手工焊 焊接探伤检查超声波装配（汇装）桥架、小车总装检验 机械加工件 （不经热处理毛 坯（铸、锻件）（焊接件）圆钢件（锯床下料）金属切削加工车、铣、刨、磨、镗钻、插、拉、齿加工、热处理（调质、淬火、回火、正火）精加工部件装配冷装 热装车轮，台车架，卷筒外购件电机、减速

14、器、轴承、标准紧固件等外协件 非本厂加工的零部件 电器组装 试车安装发运检验 油漆 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 de

15、partment 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

16、 see whether 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 种 steel强度等级s(MPa)（屈服点）Strength grade s (MPa) (yield point)牌 号mark普遍碳素结构钢Universal carbon structural steel185-235（钢材厚度越厚，s越小）185-235(the thicker the plate, the smaller the s)Q235A Q235A.FQ235B 20 优质碳素结构钢improved carbon

17、 structural steel315-355 (GB/T699)35 45低合金结构钢low-alloy structural steel275-345（GB/T1591-1994）Q345A Q345B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;

18、 F boiling steel (method of deoxidation) b semi-deoxidized steel Zkilled steel（can be omitted）TZspecial killed steel (can be omitted）.45（35）含碳量（万分之几）45（35）carbon content(? in ten thousand)焊接材料 welding material 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,

19、 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 i

20、s 500MPa, 1-suitable location for welding nod: 0，1 means its 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 e

21、asy, 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, E50

22、16 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

23、 has similar strength.焊条规格：5 Specification of welding nod: 5 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 H08Mn2

24、Si H10Mn2 (Original Code).Gas Shielded Welding: solid wire: ER50-6 ER49-1 (ERwelding wire, 50 min. tensile strength of deposited metal is 500MPa, 6code of chemical composition of welding wire) 药芯焊丝EF flux-cored wire 焊丝规格specification of welding wire：1.2，2.0，3.0，3.2，4.0，2.钢材表面的预处理Pretreatment of stee

25、l 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，（T

26、DT44-10X2200）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2000mm200mm钢材或高1800mm1200mm以内的结构件。Shot blasting treatment: treat 2000mm200mm(width) steel plate or structure no larger than 1800mm1200mm. pr

27、imer 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.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

28、 used on the basics of different final coat (see table one). Table 2产品使用环境Operating environment适用环境Application environment 涂层厚度coating thickness（m）推荐涂料品种 recommended paint varieties 底 漆厚 度primer thickness 涂层总厚度 total thickness一般使用环境general environment内陆地区一般环境下作业的产品 products used in inland area 25-35

29、75-105底漆：铁红醇酸底漆 红丹醇酸防锈漆C53-1铁红环氧酯底漆H06-2面漆：各色醇酸磁漆C04-2，C04-42Primer:red iron oxide alkyd primer C06-1, C.6-11Red Lead Alkyd antirust paint C53-1Iron oxide red epoxy ester primer H06-2finishing coat:Colored alkyd enamel C04-2, C04-42沿海地区及腐蚀性较强环境 coastal and highly corrosive areas含盐雾的沿海港口，有一定腐蚀的工业大气等地

30、区作业的产品With salt-fog in coastal areas, industrial atmosphere with corrosion50-100150-220底漆：环氧富锌底漆H06-4 铁红环氧酯底漆H06-2 红丹环氧酯防锈漆 ，云铁环氧防锈漆H53-1锌黄、铁红过氯乙烯底漆G06-4面漆：氯化橡胶漆、环氧树酯磁漆、丙烯酸磁漆，过氯乙烯磁漆Primer：epoxy zinc-rich primer H06-4iron red epoxy ester primer H06-2, hongdan epoxy ester antirust paint, epoxy mio pai

31、nt H53-1, zinc yellow & red iron oxide ethylene perchloride primer G06-4.Finishing coat:chlorinated rubber paint, epoxy polymer enamel, acrylic enamel, vinyl perchloride enamel, 高温环境 hot environment各种高温环境下作业的产品products used in hot environment 25-5050-85无机硅酸锌底漆（400）W61-32铝粉有机硅耐热漆（300-350）W61-42有机硅耐热漆（300W61-37有机硅耐热漆（300-400. inorganic zinc silicate primer （4