Tooling for tower stand column manufacturing, tower stand column manufacturing method and tower assembling method

Abstract

The invention discloses a tool for manufacturing a tower stand column, a tower stand column manufacturing method and a tower assembling method. The tool comprises a bottom beam, a bottom plate connected to the bottom beam, a fixed abutting and blocking end and a movable abutting and blocking end which are oppositely placed on the bottom plate, a plurality of arc-shaped supporting plates arranged between the fixed abutting and blocking end and the movable abutting and blocking end, and supporting rods on the two sides of the arc-shaped supporting plates. A sliding block is arranged at the bottom of the movable abutting and blocking end, a sliding rail matched with the sliding block is arranged on the bottom plate, and after the column body is placed into the tool, the movable abutting and blocking end is flexibly adjusted through the sliding rail so that the flange plate and the column body can be accurately positioned and connected. The overall precision of the tower is further improved by designing a manufacturing method of the stand columns and an assembling method of the tower; high-precision production, manufacturing and assembling of the tower are achieved, rod pieces of the same model can be interchanged, the production cost is saved, and the stability and safety of the tower structure are improved.

Description

Technical Field

[0001] The invention relates to a tool for manufacturing a tower structure and a manufacturing method thereof, and in particular to a tool for manufacturing a tower column, a tower column manufacturing method and a tower assembly method. Background Art

[0002] At present, the existing tower construction methods are relatively traditional and extensive, involving land acquisition, environmental assessment, energy consumption and pollution. Traditional towers mostly use cast-in-place concrete foundations. Although the force is clear and the construction is simple, in areas with complex topography, such as hills and mountains, the construction surface of the concrete foundation has high requirements, and on-site mixing and transportation are difficult. With the society's in-depth understanding of energy conservation and emission reduction, green buildings and construction concepts, this type of tower foundation form has been difficult to adapt to the development needs of society and the industry. In order to achieve the prefabricated design and construction of the foundation, as well as convenient relocation and reuse, prefabricated steel structure towers have become a focus of the industry. However, the limitations of the manufacturing accuracy of each component of the prefabricated truss will affect the processing, installation, splicing, connection and other links of the prefabricated steel truss, thereby affecting the stability of the entire structure and the safety of the force. Summary of the invention

[0003] Purpose of the invention: The first purpose of the present invention is to provide a tooling that can improve the production and manufacturing accuracy of tower columns; the second purpose of the present invention is to provide a manufacturing method that can improve the production and manufacturing accuracy of tower columns; the third purpose of the present invention is to provide a tower assembly method that can ensure connection accuracy and improve the stability of the tower structure.

[0004] Technical solution: The tooling for manufacturing tower columns described in the present invention includes a bottom beam, a bottom plate connected to the bottom beam, a fixed stop end and a movable stop end relatively placed on the bottom plate, a plurality of arc-shaped support plates arranged between the fixed stop end and the movable stop end, and support rods on both sides of the arc-shaped support plates; wherein a sliding block is provided at the bottom of the movable stop end, and a sliding rail matching the sliding block is provided on the bottom plate.

[0005] Preferably, the fixed stopping end includes a fixed end plate, a fixed bottom plate and a first stiffening plate fixed between the fixed end plate and the fixed bottom plate; the movable stopping end includes a movable end plate, a movable bottom plate and a second stiffening plate fixed between the movable end plate and the movable bottom plate; and a plurality of end plate positioning holes are provided on the fixed end plate and the movable end plate.

[0006] The method for manufacturing a tower column welded part using the tooling of the present invention comprises the following steps:

[0007] S1: using laser cutting to produce flange plates, ear plates and reinforcing plates for assembly, wherein the flange plate is provided with flange plate positioning holes, the ear plates are provided with ear plate holes, and the flange plate is 4-5 mm thicker than the theoretical value;

[0008] S2: hoisting the column and placing it horizontally on the arc-shaped support plate in the tooling for preliminary positioning;

[0009] S3: Connect the flange plate to the fixed end plate and the movable end plate in the tooling, move the movable stop end so that the flange plate is close to the column for welding, then weld the groove angle of the column and the flange plate, weld the reinforcing plate between the column and the flange plate and the ear plate around the column to finally form a column welding part and perform one-time overall processing.

[0010] Preferably, the column welded part is based on the fixed end plate, and the length tolerance of the column welded part after one-time integral processing is measured to be ±0.2mm.

[0011] Preferably, the ear plates around the circumference of the column are positioned and welded with the axis determined by the end plate positioning holes as a reference.

[0012] Preferably, the two mutually perpendicular axes of the column are checked and adjusted to coincide with the axes determined by the positioning holes of the flange plate.

[0013] The method for assembling a tower using the method for manufacturing a tower column welding part of the present invention comprises the following steps:

[0014] S4: Weld the horizontal brace and the ear plate to form a combined horizontal brace, and weld the diagonal brace and the ear plate to form a combined diagonal brace. The tolerance of the ear plate holes at both ends of the combined horizontal brace and the combined diagonal brace is ±0.1mm, and the tolerance of the ear plate spacing at the end is ±0.5mm;

[0015] S5: Splice the columns, combined horizontal braces and combined diagonal braces into a single truss piece;

[0016] S6: Lay out the lines on the frame for assembling the single-piece truss and mark the central axis for setting the column;

[0017] S7: turning over the single truss piece assembled in step S7 to an upright position, aligning and positioning it according to the central axis of the tire frame in step S8, and bolting and fixing it to the tire frame;

[0018] S8: Assemble the combined horizontal braces and combined diagonal braces between the single trusses to complete the assembly of the single-segment tower;

[0019] S9: Based on the single-segment tower completed in step S8, upper tower segments are spliced ​​to finally form the tower.

[0020] Preferably, before welding the ear plates on the column in step S4, the ear plates are constrained by rigid supports.

[0021] Preferably, in step S7, the columns, the assembled horizontal braces and the assembled diagonal braces are connected in a horizontal manner by inserting ear plates into pins.

[0022] Preferably, after the lower single-segment tower is placed in step S11, the upper segment single-piece truss is hoisted, and the flange plate connecting surfaces on the upper and lower columns are bolted, and the combined horizontal braces and combined diagonal braces between the upper segment trusses are connected to complete the assembly of adjacent segments.

[0023] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages: 1. It ensures the manufacturing accuracy and connection accuracy of the tower, can realize the interchangeability between any rods of the same model and ensure the overall force and stability safety between high-precision connectors; 2. It speeds up the construction progress and saves time and cost; 3. The tower can be disassembled to achieve recycling use in multiple projects and reduce the overall cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the overall structure of a single tower segment in the present invention;

[0025] Figure 2 It is a schematic diagram of the overall structure of the tooling in the present invention;

[0026] Figure 3 It is a schematic diagram of the structure of the fixed stop end in the present invention;

[0027] Figure 4 It is a structural schematic diagram of the movable blocking end in the present invention;

[0028] Figure 5 It is a schematic diagram of the connection between the sliding block and the sliding rail in the present invention;

[0029] Figure 6 It is a schematic diagram of positioning the middle ear plate in the tooling of the present invention;

[0030] Figure 7 It is a schematic diagram of the overall structure of the combined column in the present invention;

[0031] Figure 8 It is a schematic diagram of positioning the column in the tooling of the present invention;

[0032] Fig. 9 It is a front view of the combined horizontal brace / combined diagonal brace in the present invention;

[0033] Fig.10 It is a top view of the combined horizontal brace / combined diagonal brace of the present invention;

[0034] Fig.11 It is a schematic diagram of the structure after the single-piece truss pieces of the present invention are assembled;

[0035] Fig.12 It is a schematic diagram of the structure of the tire frame in the present invention;

[0036] Fig.13 It is a schematic diagram of the connection structure between the bottom segment and the top segment in the present invention. DETAILED DESCRIPTION

[0037] The technical solution of the present invention is further described below in conjunction with the accompanying drawings.

[0038] The tower frame of the present invention adopts a steel truss structure, and the column preferably adopts 4 round steel pipes, and the round steel pipe preferably has a diameter of 700mmx20mm. The columns are connected into a whole by combined horizontal braces and combined diagonal braces. The horizontal braces and the diagonal braces are preferably made of square steel pipes with a specification of 180mmx12mm. The combined horizontal braces and the combined diagonal braces are connected to the columns by inserting the pins through the ear plates. The flange plates and the ear plates are preferably 28mm thick, and the pins are preferably 50mm in diameter. Fig.10 As shown, the tower segments are connected by bolting through flange plates, the contact surface of the flange plates is not less than 95%, and the bolt connection pass rate is 100%. The single-layer segment is preferably 5535 mm in height.

[0039] The manufacturing and assembly method of the tower column tooling includes the following steps:

[0040] (1) The fixed stopper end G1 and the movable stopper end H1 are welded and then machined by integral milling machine;

[0041] (2) The end plate positioning holes on the fixed end plate G11 and the movable end plate H11 are CNC drilled, and the hole diameter is 5 mm smaller than the theoretical hole;

[0042] (3) The fixed end plate G11 and the movable end plate H11 are perpendicular to the ground, the end surface positioning holes of the fixed stop end and the movable stop end are aligned with each other, and the end plate positioning holes are symmetrically arranged along the vertical and horizontal center lines of the columns that are perpendicular to each other, and the deviation requirement is ≤0.5mm;

[0043] (4) Check the flatness of the top surface of the slide rail (H15) and its straightness in the longitudinal direction.

[0044] The specific steps of the method for manufacturing column welding parts are as follows:

[0045] First, the column 1 is made of round steel pipe, which is sawed and cut. A semi-automatic trolley and a roller frame are used to roll flame cut the welding groove between the end of the column 1 and the flange plate 4 to ensure that the cutting size of the groove is consistent. The flange plate 4, the ear plate 5, and the reinforcement plate are all cut by laser. The flange plate 4 is preferably set to a thickened steel plate with a thickness 4-5mm thicker than the theoretical value for subsequent overall machining. Use the tooling to weld and assemble the column 1, flange plate 4 and ear plate 5. The specific assembly steps are as follows: slide the movable stop end H1 along the slide rail H15 for a distance, and use the end plate positioning holes on the fixed end plate G11 and the movable end plate H11 to position the flange plate 4. When positioning, use the positioning pin to position and ensure that the flange plate 4 is in close contact with the tooling end plate; hoist the column 1 into the tooling, and use the arc support plate C1 to support rough positioning, and then accurately adjust the spatial position of the column 1, and make the two mutually perpendicular axes of the column 1 coincide with the axes determined by the flange plate positioning holes respectively, and fine-tune the movable stop end H1 along the slide rail H15 to close to the end of the column, and assemble the flange plate (4) close to the column (1) by positioning welding, and measure the total length of the column with the fixed stop end G1 as the reference, and ensure that the total length is within On the basis of the theoretical length L, a welding shrinkage of 4 to 6 mm is added between the flange plate 4 and the column 1, so that the tolerance of the column welded part after one-time integral processing is ±2 mm; positioning welding is performed on the flange plate 4 and the circumference positioning weld of the column 1, and the flange plate 4 and the reinforcing plate of the circumference of the column 1 are assembled; the circumference ear plate 5 is positioned and assembled based on the axis determined by the positioning holes of the fixed end plate G11 and the movable end plate H11 in the tooling, and an ear plate hole is provided on the ear plate 5. The center position of the ear plate hole is 1 mm away from the column positioning axis compared to the theoretical value. The welding shrinkage; after the flange plate 5, the ear plate 6 and the column 1 are assembled and welded, a column welded part is formed. At this time, the positioning pins on the flange plate 4 and the tooling stop end plate are removed, and the movable stop end H1 is moved a certain distance along the slide rail H15 and then lifted away from the column welded part. The column welding parts are hoisted above the roller frame, and the rollers on the roller frame are driven by the motor to roll, so as to realize the rotation of the column welding parts, and the groove welds between the flange plate 4, the ear plate 5 and the column 1 are performed. Before welding, a rigid support constraint is added between the ear plates 5. The rigid support constraint is preferably positioned using a commonly used positioning plate to prevent deformation during welding. During the welding process, multi-layer and multi-pass welding is required to control welding deformation; the overall machining of the column is preferably processed by an overall one-time CNC machining process, such as Figure 6 As shown, the control requirements during machining are as follows: first, mill the flange surfaces at both ends of the column, control the length spacing deviation between the flange plate surfaces at both ends to not exceed ±0.2mm, and the flange surface flatness to not exceed 0.1mm; drill bolt holes around the flange plate, including the positioning holes reserved during drilling, control the bolt hole spacing and the spacing tolerance with the center line of the column to meet ±0.1mm; use the expansion milling machine to process the ear plate holes, control the ear plate hole spacing tolerance from the center line of the column to meet ±0.1mm, and the ear plate hole diameter tolerance is +0.2~0.3mm.

[0046] Steps for manufacturing the diagonal brace and the transverse brace: the diagonal brace 3 and the transverse brace 2 are cut by rectangular tube sawing to control the length dimension, the ear plates connected to the transverse brace 2 and the diagonal brace 3 are cut by CNC, and the ear plate 5 is cut 6mm smaller than the theoretical aperture for subsequent machining. The manufacturing process steps are as follows: assemble and weld the ear plates 5 at both ends of the diagonal brace 3 and the transverse brace 2 and the rectangular tube groove welds, control the spacing tolerance between the ear plates at the same end within ±0.5mm, and the spacing between the ear plate holes at both ends is ±2.0mm; Figure 8 and Fig. 9 As shown, the ear plate holes at both ends of the diagonal brace 3 and the horizontal brace 2 are integrally CNC-machined, and the spacing tolerance of the ear plate holes at both ends is controlled to meet ±0.1mm. The ear plate hole diameter is preferably 50mm, with a tolerance of +0.2 to 0.3mm. The corresponding pin shaft diameter is preferably 50mm, and the machining tolerance is controlled within -0.3 to -0.2mm.

[0047] Pre-assembly and assembly of tower segments: In the pre-assembly stage, the same rods are randomly selected for assembly to test whether the assembly accuracy meets the requirements of finished product assembly, and to achieve the arbitrary interchange of rods of the same model. The specific assembly process is as follows: assemble the lower segment, use a horizontal body to assemble the two side columns and the combined horizontal braces and combined diagonal braces between them into a single truss; make an assembly frame, such as Fig.11 As shown, lay out the line on the tire frame, mark the central axis of the four columns, turn over the assembled single truss, align and position it according to the line, and bolt it to the tire frame. Assemble the combined horizontal brace and combined diagonal brace between the two trusses to complete the assembly of the single segment; hoist the single truss of the upper segment, bolt the bolts on the flange plate connection surface, support the diagonal brace and horizontal brace to prevent tipping, and finally connect the combined horizontal brace and combined diagonal brace between the two trusses of the upper segment to complete the pre-assembly of adjacent segments.

Claims

1. A tool for manufacturing a tower column, characterized in that: The invention comprises a bottom beam (Z1), a bottom plate (D1) connected to the bottom beam (Z1), a fixed stop end (G1) and a movable stop end (H1) placed on the bottom plate (D1) relative to each other, a plurality of arc-shaped support plates (C1) arranged between the fixed stop end (G1) and the movable stop end (H1), and support rods (L1) on both sides of the arc-shaped support plates (C1); wherein a sliding block (H14) is provided at the bottom of the movable stop end (H1), and a sliding rail (H15) matched with the sliding block (H14) is provided on the bottom plate (D1).

2. The tooling for manufacturing a tower column according to claim 1, characterized in that: The fixed abutting end (G1) comprises a fixed end plate (G11), a fixed bottom plate (G13) and a first stiffening plate (G12) fixed between the fixed end plate (G11) and the fixed bottom plate (G13); the movable abutting end (H1) comprises a movable end plate (H11), a movable bottom plate (H13) and a second stiffening plate (H12) fixed between the movable end plate (H11) and the movable bottom plate (H13); a plurality of end plate positioning holes are provided on the fixed end plate (G11) and the movable end plate (H11).

3. A method for manufacturing a tower column welded part using the tooling according to claim 1 or 2, characterized in that: The steps include: S1: using laser cutting to produce a flange plate (4), an ear plate (5) and a reinforcing plate for assembly, wherein the flange plate (4) is provided with a flange plate positioning hole, and the ear plate (5) is provided with an ear plate hole, wherein the flange plate (4) is 4-5 mm thicker than the theoretical value; S2: hoisting the column (1) and placing it horizontally on the arc-shaped support plate (C1) in the tooling for preliminary positioning; S3: Connect the flange plate (4) to the fixed end plate (G11) and the movable end plate (H11) in the tooling, move the movable stop end (H1) so that the flange plate (4) is close to the column (1) for positioning welding assembly, and then weld the groove angle around the column (1) and the flange plate (4), weld the reinforcing plate between the column (1) and the flange plate (4) and the ear plate (5) around the column (1) to finally form a column welding part and then perform one-time overall processing.

4. A method for manufacturing a tower column welded part according to claim 3, characterized in that: The column welded part is measured with the fixed end plate (G11) as a reference, and the length tolerance of the column welded part after one-time integral processing is ±0.2mm. The one-time integral processing includes the processing of the flange surfaces and ear plate holes at both ends of the column welded part. The spacing tolerance between the ear plate hole centers and the ear plate hole to the machined surface of the end flange plate (4) is ±0.1mm.

5. A method for manufacturing a tower column welded part according to claims 1 and 4, characterized in that: The lug plates (5) around the circumference of the column (1) are positioned and welded using the axis determined by the end plate positioning holes as a reference.

6. A method for manufacturing a tower column welded part according to claim 4, characterized in that: Check and adjust the two mutually perpendicular axes of the column (1) to coincide with the axes determined by the positioning holes of the flange plate.

7. A method for assembling a tower using the column welded parts manufactured by the method of claim 3, characterized in that: The steps include: S4: Weld the horizontal brace (2) and the ear plate (5) to form a combined horizontal brace, and weld the diagonal brace (3) and the ear plate (5) to form a combined diagonal brace. The tolerance of the distance between the ear plates at both ends of the combined horizontal brace and the combined diagonal brace is ±0.1 mm, and the tolerance of the distance between the ear plates at the end is ±0.5 mm. S5: Splice the columns, combined horizontal braces and combined diagonal braces into a single truss piece; S6: Lay out the lines on the frame for assembling the single-piece truss and mark the central axis for setting the column; S7: turning over the single truss piece assembled in step S6 to an upright position, aligning and positioning it according to the central axis of the tire frame in step S8, and bolting and fixing it to the tire frame; S8: Assemble the combined horizontal braces and combined diagonal braces between the single trusses to complete the assembly of the single-segment tower; S9: Based on the single-segment tower completed in step S8, upper tower segments are spliced ​​to finally form the tower.

8. A method for assembling a tower according to claim 7, characterized in that: Before welding the ear plates (5) on the column (1) in step S4, the ear plates (5) are constrained by rigid supports.

9. A method for assembling a tower according to claim 6, characterized in that: In step S7, the vertical column, the assembled horizontal brace and the assembled diagonal brace are connected horizontally by inserting the ear plate (5) into the pin shaft (6).

10. A method for assembling a tower according to claim 6, characterized in that: In step S11, after the lower single-segment tower is placed, the upper segment single-piece truss is hoisted, the flange plate connecting surfaces on the upper and lower columns are bolted, and the combined horizontal braces and combined diagonal braces between the upper segment trusses are connected to complete the assembly of adjacent segments.

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