自动化立体库货架安装规范-中英

公司内部文件自动化立体库货架安装规范AS/RS RACKING INSTALLATION GUIDE为满足公司日益增加的自动化立体仓库货架订单要求，提高我司立体仓库货架的安装精度和效率，特制定此规范。In order to meet our companys AS/RS racking installation precision and efficiency of our increased order, we formulate this guide.一、接到安装任务单，找设计人员沟通图纸内容，拿到所有图纸（包括方案图、立柱组装图、横斜撑的位置），掌握安装要点、难点，确定使用工具并准备好工具：电锤、电线、电动扳手、墨斗、常用扳手、手电钻、经纬仪、水平仪、100M钢卷尺。 Check and study all of drawing of the project. Get main design idea of the project. Master the main point and difficulties. Prepare the tools as follows: Electric hammer, electric wire, electric wrench, wrench, fountain, commonly used electric drill, theodolite, level,100M steel tape.一、 安装人员进入施工现场后，首先对地基状况、预埋件进行检测（无预埋件的仅检测地基），合格后方可安装；如不在规定范围内，必须将测量的数据传到公司，等公司给出具体解决方案后再安装。The installer should check the base situation and the Embedded parts after the installers go into the site. If the base situation and Embedded parts is qualified, the workers start to install. If not, installer should send the the date to company. After company offer some solution, then worker can install racking.注：判别条件Discriminant conditions地面平整度允许偏差：Ground flatness allowed deviation:长宽尺寸（m）Length允许偏差（mm）allowed deviation50101501515020在最大载荷下，货架基础地坪的沉降变形应小于1/1000。 Under Max load, the racking base Settlement deformation should be less than 1/1000.三、地面放样 The ground setting out1、仪器工具：经纬仪、水平仪、100M钢卷尺、墨斗等 Instrumental: theodolite, level,100M steel tape, ink and other2、取一点K为放样基准点（K为仓库的中心点），根据土建基准确定X向基准线，将经纬仪架于K点，作出X向基准线的垂线为Y向基准线，并校核两条基准线的垂直度。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的安装基准，如果现场的测量的尺寸和图纸的尺寸有误差，一定要消除误差或者把误差控制在某一个不重要的尺寸上。 To take a bit of K lofting reference point (K warehouse center point), according to the civil baseline to determine the X to baseline, a theodolite frame at K, make X to the datum line for Y to vertical datum line, and checking the two baseline verticality. With X respectively, Y to the datum line to make the track center line center line and column. Draw a line to find the shelf mounting reference, if the site measurement of size and drawing size error, must eliminate errors or error control in one important dimension.四、将水平仪置于中间的K点，进行地面水平度的测量， Put the level in the “K” point and check the flatness of the ground.逐点测量并记录货架底脚及地轨（如无需安装地轨可不测，地轨测点为地轨底板所在点）的每一点的水平标高，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节量是否一致；Measure and record the level of every point of footplate and ground rail .(Measure point of the ground rail is the shim position.) Find the peak and the lowest point.calculate the horizontal difference如不符合要求，将少量的超低点补高或超高点降低处理，直至满足要求为止。If requirements are not met, a small amount of ultra low fill high or super high reducing treatment, until satisfied.预埋已进行浇灌的以最高点为基准，其他点补高，数值偏差较大的要通知公司。Pre buried has been watered with the highest point as the reference point, the other, larger deviations to inform the companys value.注：常见柱脚固定形式在地面满足要求后处理方法Note: the common column fixed form in the ground to meet the requirements of post processing method 可调底脚 不处理，但要保证同一底脚接触面水平误差0.5mm The adjustable foot treatment, but to ensure that the same foot contact surface level error 0.5mm 膨胀螺栓 打孔放地脚螺栓（此方式采用外膨胀），垫好调节垫片，满足水平误差0.5mm；The expansion bolt hole on the bolt ( the way using external expansion ), pad adjusting gasket, satisfy the level error of 0.5mm; 采用内膨胀时边竖柱片边垫调节垫片，立柱底板满足水平误差0.5mm The expansion side vertical column side pad adjusting gasket, column bottom meet level error of 0.5mm 预埋板（焊螺栓、直接焊立柱） 保证调平板或调节螺母水平误差0.5mm the embedded plate ( welding bolt, direct welding column) ensure adjusting nut flat or horizontal error of 0.5mm 已进行二次浇灌的，补焊垫板满足水平误差0.5mm Since two time to irrigate, welding pad satisfy the level error of 0.5mm五、货架安装Installation1、货架安装前应对每一构件进行严格检查，如有变形在安装前予以矫正。 Shelf installation before responding to each member to carry out strict inspection, such as deformation before installation to be corrected.2、在木制的组装台上进行组装柱片，以防止喷塑层划伤；根据现场情况采用吊车、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，原则上定滑轮固定点比货架片最高点高35m），第一片吊起后要将其四周拉紧，竖起第二片后连上横梁，然后再竖第三片并挂横梁，根据设计要求安装背拉和水平拉杆，并安装天轨吊梁，调整好立柱的垂直度、横梁的水平度，满足要求后固定底脚，紧固各零部件间的连接螺栓；然后再竖柱片、挂横梁，遇到第二列背拉组时停止竖柱片，安装背拉和水平拉杆，大致调整这一区域的垂直度、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，安装剩余的天轨吊梁（此时各零部件间的连接螺栓不要紧固）。此前货架主体（除天、地轨）安装完毕后，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。之后安装天、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，每段轨道调整完毕后对焊起来。堆垛机进入货架后再按之前的顺序安装余下的货架。货架安装完毕后，全面复查各连接螺栓的紧固情况，使之均处于紧固状态。 In wooden assembling bench assembly column, in order to prevent the spray layer scratch; according to the scene with cranes, winches or methods ( such as hoisting winch or human when fixed pulley, a fixed pulley is fixed point principle than the shelf plate the highest point of high 35m ), article a lift to the around second pieces of tension, erected after the upper beam, and then third vertical slice and hanging beams, according to the design requirements of installation back pull and horizontal tie, and mounting rail crane beam, column, beam adjusting verticality levelness, meet the requirements after the fixed foot, fastening parts between the connecting bolt; then then vertical column, hanging beam, column encountered second back tension group stops when the vertical column, installation of back pull and horizontal tie, broadly tuned to this region, levelness verticality; after adjustment continue moving forward vertical column, hanging beam, and so on, until the lifting to stacking machine manufacturers requirements location, installation the remaining rail crane beam (the between each part connecting bolts do not tighten ). The shelf body ( except for days, rail ) after installation, the levelness, perpendicularity and channel direction, the vertical channel direction of straightness straightness adjusting, meet the design requirements after the shelf plate column and the connecting bolt. After installation of days, the track, before installation to the shelf body painting days, the track correction, to ensure that the correct only after install, each section of track after adjusting the butt. Stacker crane into the shelf after the press before the installation sequence the remaining shelf. Shelves after installation, a comprehensive review of all the connecting bolts fastening, which are in the fastened state.注：天地轨安装要求（具体见安装图）Note: the world rail installation requirements ( see the specific installation diagram ) 用水平仪测量每一固定点处地轨上表面的水平标高，并通过增减垫片（测量地平时，垫片应摆放好），使轨道全长的水平度在1mm内，基准按设计要求为准； Level meter for measuring a fixed point on the rail surface level, and by increasing or decreasing the gasket ( measured in peacetime, the gaskets shall be laid ), make the track length level within 1mm, according to design requirements for reference; 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； Level meter for measuring rail top surface, measuring position and adjust direction ibid., make its accuracy control in each meter0.5mm; 用经纬仪测量地轨侧面，调节使其每米1mm内，全长控制在2mm内；Surveying with theodolite to track side, adjusted its per metre 1mm, full-length control within 2mm; 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，最后紧固压板螺栓（有定位块的紧贴轻轨焊于底板上）； The rail joints according to the drawing requirements in place with high carbon steel welding rod ( KT-42E430, BJ/Twelding rod welding, after welding can also be ) with grinder grinding, the fastening clamp bolt ( with a positioning block to light rail welded on the bottom plate ); 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的打磨按以下要求进行，轨道头部下表面不必磨光，但要磨平。 Top of rail surface and the top two sides to be polished, rail head horizontal surface grinding according to the following requirements, rail head surface need not be polished, but be removed.1） 、轨道顶面的局部要求：在50mm长度内局部凹深0.1mm，用磨光设备容易作到此项要求。 The top surface of the local tracks:50mm length local concave deep 0.1mm, with polishing equipment easy to achieve this requirement.2）、轨道侧面的局部要求：在100mm长度内局部凹深0.5mm。 The track side local requirements: in the100mm length local concave deep 0.5mm.3）、总公差应符合标准FEM9.831的要求。General tolerances shall be in accordance with the FEM9.831 standard requirements.4）、熔焊接头的轨道头下表面及轨道腹板应磨得与原轮廓表面一致，以防止车轮被抬起、倾斜或 被钩绊住。Welding joint rail head surface and the rail webs shall be worn with the original contour surface, to prevent the wheels are raised, tilted or hook snagging.需打磨的范围图15 轨道的打磨 5） 、轨道顶部凸缘的下侧应平滑，无毛刺及大的凸起焊疤，以避免造成车轮运行的障 碍。在两条轨道接头处焊成的轨道腹板两侧面亦应磨平，此平面亦作为支撑轮滚动的表面。 Track to the top of the lower side of the ledge shall be smooth, no burr and raised welding scar, in order to avoid wheel running obstacle. In two rail joints welded rail web side should also be removed, the plane also as a supporting wheel rolling surface.6）、天轨对接处尽量贴合或按图纸就位，调整好垂直及水平弯曲允许偏差后采用对焊方法焊接，角钢天轨还应在天轨上表面焊接连接板，焊后打磨。 Rail joint drawings or to engage in place, adjust the vertical and horizontal bending tolerance after the introduction of butt welding method welding, steel rail should also in the days of rail surface welded with a connecting plate, welding after grinding.六、安装过程中需注意以下事项：The installation process should pay attention to the following matters:1、所有螺栓和连接面要除锈；天、地轨的对接焊缝必须平整光滑，焊缝不允许突出轨道表面，以免影响堆垛机运行。 All bolts and connecting surface to rust; day, rail butt weld shall be smooth, not allowed to highlight the weld surface of the rail, so as not to affect the stacking machine operation.2、化学螺栓的安装Chemical bolt installation2.1、 作业前准备 Preparation before operation 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）一般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分。CChemical bolt by chemical hose, spiral pipe, washer and nut, screw, washer, nut ( six ) generally have galvanized steel and galvanized steel pipe two, pharmaceutical chemicals reaction resin, curing agent and stone particles composition. 2.1.2、钻机及钻头在打孔时，要使用与锚栓匹配的自动保障孔深的钻机和钻头。钻孔深度由设计师根据使用要求和设计规范确定。Drill and drill in drilling, to use with anchor bolt matching automatic security hole deep drilling rig and drill bit. Drilling depth by the designer according to the use requirements and design specifications to determine. 2.1.3、吸尘器、弹性毛刷、木箱（300*200*200），用于安装螺栓前清理孔中的混凝土粉尘。Vacuum cleaner, elastic brush, wooden box (300*200*200), for mounting bolts concrete dust cleaning before Kong Zhong. 2.2 、质量要求 Quality requirements 2.2.1、为了充分发挥一个锚栓的最大承载能力，必须保障一定的间距、边距、构件厚度，数据以厂家提供的技术参数为准。In order to give full play to an anchor bolt is the maximum bearing capacity, must guarantee a certain spacing, distance, thickness, data for manufacturers to provide technical parameters for. 2.2.2、钻孔的孔径遵照规范或产品说明书。Drilling diameter according to the specifications or product specification. 2.2.3、在施工前，应遵照规范对施工的化学螺栓进行拉拔试验，拉拔试验的力遵照规范或产品说明书规定。Before the construction, should be in accordance with the norms of construction chemical bolt pullout test, pullout test force according to the specifications or product specification 2.3、工艺流程：Technological process钻孔清孔置入药剂管钻入螺栓凝胶过程硬化过程固定物体。Drillinghole cleaningchemical tube placementdrill into the bolt Gel process Hardening processFixed object2.3.1、钻孔： 先根据设计要求，按图纸间距（相邻锚栓轴线间的距离）、边距（锚栓轴线至构件自由边缘的距离）定好位置，在基材上钻孔，按设计螺栓型号，根据螺栓的安装参数表确定孔径、孔深，由锚栓类型及尺寸来决定需要的钻孔深度，除少数例外情况，一般大于锚固深度（从锚固基础结构表面到螺杆底端的距离，是影响其承载力的重要参数）。螺杆型号的选择要满足锚固厚度的要求，锚固厚度等于被锚固物体的厚度（包含装饰层厚度）。与化学螺栓有关的参数，安装参数如表1，供安装参考。 According to the design requirements, drawings by spacing ( the distance between adjacent anchor axis ), the margins (anchor axis to the member free edge distance ) set the position on a substrate, drilling, according to the design of bolt models, according to the bolt installation parameters determine the aperture, deep, by anchor bolt type and size to decide need to drill hole depth, with a few exceptions, is generally greater than the anchoring depth ( from anchorage foundation structure surface to screw the bottom end of the range, is the important parameter influencing their bearing capacity ). Screw type choice to meet the requirements of the anchorage anchorage thickness, thickness equal to the anchored object thickness ( containing the decorative layer thickness). And chemical bolts related parameters, installation parameters as shown in Table 1, for installation reference.表1 化学螺栓安装参数型号 M8 M10 M12 M16 M20 M24 M30 螺杆直径(mm) M8 M10 M12 M16 M20 M24 M30 螺杆全长L(mm) 110130160190260300380钻孔直径DB(mm) 10121418252835埋设深度T(mm) 8090110125170210280固定物厚度Smax(mm) 14202535656570最小基材厚度D(mm) 130140160175220260330最大扭紧扭距Mp(Nm) 10204080150200400如有需要可根据要求增加孔深以增大强度 单个锚栓平均破坏载荷（KN）型号M8M10M12M16M20M24M30拉拔力C30砼5.8级镀锌螺杆1831.845.772.6110.6155.3240.7A4不锈钢22.334.556.172.6128.9158.6-剪力C30砼5.8级镀锌螺杆11.418.226.548.575.2110173.2A4不锈钢15.424.335.365.8102.9105.6-单个锚栓设计载荷（KN）型号M8M10M12M16M20M24M30拉拔力C30砼5.8级镀锌螺杆7.512.5192942.559.789A4不锈钢7.512.5192942.559.7-剪力C30砼5.8级镀锌螺杆7.712.117.733.051.474.2117.8A4不锈钢8.313.119.035.355.273.2- 以上镀锌螺杆要求: 、5.8级符合ISO-898TI 、最低破坏强度.50Kg/mm2 、屈服强度.40Kg/mm2 、镀锌厚度.最少5m 设计载荷按：镀锌螺杆拉拔力安全系数2.4-2.7，剪切力安全系数1.4-1.5；不锈钢螺杆拉拔力安全系数2.5-3.0，剪切力安全系数1.4-1.8。Galvanized screw requirements above:l In5.8, with ISO-898TIl The minimum breaking strength, .50Kg/mm2, l the yield strength of.40Kg/mm2l galvanized thickness of at least 5 m.Design load press: galvanized screw pullout safety coefficient 2.4-2.7, shear safety factor 1.4-1.5; no Stainless steel screw pullout safety coefficient 2.5-3.0, shear safety factor 1.4-1.8. 2.3.2、清孔 Clean the hole （1） 用压缩气体吹尽孔内粉屑。Use compressed gas to blow off dust as hole. （2） 用毛刷将孔內壁附着的粉屑清除。Brush the dust attached on the inner wall of the hole clearance. （3） 一二步骤反复多次，最大限度清尽孔内粉屑。 Repeat the (1) and (2), Maximum clear as hole powder. 注意：note:a为了防止固着强度降低，请一定要清扫孔內。In order to prevent the fixation strength reducing, please be sure to clean the hole.b因为压缩气体只能吹尽孔内浮灰，很难将孔内壁附着的粉屑清除，所以 请务必使用毛刷。Because the compressed gas can flow as hole floating dust, is difficult to be attached on the inner wall of the dust removal hole, so be sure to use the brush. 2.3.3、植入药剂管Implantation agent tube 将药剂管插入洁净的孔中，插入时保证树脂在手温条件下能像蜂蜜一样流动，方可使用药剂管。Chemical tube inserted into the clean hole, insert that resin in hand temperature conditions like honey flow, can use agent tube. 2.3.4、钻入螺栓Drilling bolts 2.3.4.1、用电钻旋入螺杆，直至药剂流出为止。With the electric drill is screwed into the screw, until the drug efflux. 2.3.4.2、电钻使用专用配套电钻（具备钻孔和旋入螺杆的双重功能），钻速为750nmin。Electric drill used for supporting electric drill ( with drilling and screwing screw double function ), drilling speed is 750N / min. 2.3.4.3、螺栓旋入，药剂管破碎，树脂。固化剂和石英颗粒混合，并填充锚栓与孔壁之间的孔隙。Bolt is screwed into the pipe broken, agent, resin. Curing agent and quartz particles mixing, and fills the anchor bolt and the hole wall between the pore. 2.3.4.4、药剂管插入洁净的湿孔时，孔内水必须排出钻孔，但凝胶过程及硬化过程的等待时间必须加倍。Reagent tube is inserted into the clean wet hole, pore water must drain hole, but gelation process and hardening process of waiting time must redouble. 2.3.5、凝胶过程Gel process 保持安装工具不动（凝胶时间不低于表2 相关时间）。Keep the installation tool does not move ( gel time of not less than the time of sheet 2 ). 2.3.6、硬化过程Hardening process 取下安装工具静待药剂硬化（硬化时间不低于表2 相关时间要求）。Remove the mounting tool for chemical hardening ( hardening time of not less than the time required of sheet 2).表2 化学反应时间化学反应时间温度（）凝胶时间（min）硬化时间（min）-5-0603000-103060102020302040820 2.3.7、固定物体Fixed object 待药剂完全硬化后，加上垫圈及六角螺母固定物体。To be completely after hardening agent, plus a washer and nut six angle fixed object.影响因素 2.4、 施工要求及注意点Construction requirement and points for attention 2.4.1、施工要求Construction requirement 7.4.1.1、施工时，根据施工部位组织劳动力。如在地面操作时，施工量不大时，配人打孔，人清孔，然后2人安装便可以。During construction, according to the construction site organization of labor. As in ground operations, construction quantity, with1hole,1hole cleaning, and the 2installation can. 2.4.1.2、当锚固对象较大时，并且在高空操作时，每台钻配2人打孔（1人钻孔，人辅助），人清孔。其他辅助工人根据锚固对象尺寸、重量、环境的具体情况确定数量。钻机的数量根据工作量及进度要求考虑班数。When the anchor object is large, and in high altitude operation, each with2bench drill hole (1holes,1assisted ),1hole cleaning. Other auxiliary workers according to the anchor object size, weight, environmental circumstances to determine the number of. Rig number according to the workload and schedule considering the number of classes. 2.4.2、注意点points for attention 2.4.2.1、钻机防止漏电事故，机具操作严格按操作规程作业。Drill to prevent leakage accident, equipment operation in strict accordance with the operation procedures. 2.4.2.2、需搭设脚手架操作时，应按合格方案搭设和使用。Need scaffold operation, shall be qualified plan erection and use. 2.4.2.3、要求严格执行现场有关操作规程和安全管理规定。Demanding the implementation of the operation procedures and safety management regulations.七、对安装调试完毕后的货架进行全面检查，包括螺栓、花篮盘的紧固，水平度、垂直度的数据收集；对喷塑层破损处进行补漆。The installation is completed after the shelves to conduct a comprehensive inspection, including bolts, flower basket plate fastening, levelness, perpendicularity data collection; the spray layer damage repair paint.注：货架交验精度要求Note: shelves inspection accuracy requirements 每一货架片沿巷道长度和宽度方向的垂直极限偏差为10mm；Each shelf along the tunnel length and width direction vertical limit deviation of 10mm 货架同层横梁高度偏差为5mm，同层横梁靠堆垛机一侧的高度应不低于另一侧，