Overall one-time total splicing manufacturing process for large sections of ultra-wide three-box separation type steel box girder

Abstract

The invention provides an overall one-time total splicing manufacturing process for a large section of an ultra-wide three-box separation type steel box girder. The overall one-time total splicing manufacturing process comprises the steps that a cross beam is positioned; the bottom plate of the middle box and the first inclined bottom plate units of the two side boxes are positioned; a side box second inclined bottom plate and a side box web unit are assembled; assembling and welding the diaphragm plate units; assembling and welding the tuyere box units; positioning, assembling and welding the first top plate unit; and other top plate units are assembled and welded. The steel box girder is integrally manufactured at a time, that is, steel box girder sections are linearly arranged on the top faces of the supporting plates of the total splicing jig frame in the longitudinal and transverse directions, and the plate units are closely attached to the steel box girder sections at a time to achieve longitudinal and transverse linear arrangement of the steel box girder. And meanwhile, steel box girder assembly and pre-assembly are completed on the same jig frame at a time, the time needed for temporary storage and reshipment of girder sections is greatly shortened, the occupied temporary storage site in a factory is reduced, the occupied amount of an overall assembly site is also reduced, meanwhile, secondary linear accurate positioning does not exist, the traditional overall assembly process of the steel box girders is met, and the quality and precision of the steel box girders are guaranteed.

Description

Technical Field

[0001] The present application relates to the technical field of steel bridge manufacturing, and in particular to a one-time overall assembly manufacturing process for large sections of ultra-wide three-box separated steel box girders. Background Art

[0002] Currently, most large steel box girders spanning rivers and seas are single-box, single-chamber, or single-box, multi-chamber structures, such as the Jintang Bridge (single-box, three-chamber structure) and the Xianxin Road Cross-River Tunnel (single-box, single-chamber structure). Split steel box girder structures have also been used in previous projects, but these were typically two-box, separated steel box girder structures, such as the completed Wuhu Second Bridge and Xihoumen Bridge, and the Huangmaohai Bridge steel box girder under construction. The cross-sectional width of single-box or separated steel box girders generally ranges from 30m to 50m, with the Lingang Bridge being the only ultra-wide design with a total width of 63m.

[0003] In existing long-span steel box girder bridges, traditional single-box steel box girder structures are typically manufactured using unit components, using a recursive assembly process. This involves dividing the traditional steel box girder structure into several plate units and blocks (primarily sealing blocks), which are then assembled, welded, and pre-assembled on a master assembly platform. Currently constructed two-box split steel box girders utilize independent manufacturing of the individual components, with the components then reassembled on a master assembly platform to complete the overall fabrication of the split steel box girder.

[0004] The production of individual units requires the arrangement of the individual production cradle and the overall assembly support cradle of the steel box girder according to the designed longitudinal and transverse lines. It also needs to be transported and placed in different sites, which occupies a large area and has a long production cycle. In addition, the secondary arrangement of the longitudinal and transverse lines and the precise positioning of the individual beam sections are also difficult. Summary of the Invention

[0005] In view of this, the purpose of this application is to provide an overall one-time assembly manufacturing process for large sections of ultra-wide three-box separated steel box girders, so as to solve the problems in the existing technology of large single-unit manufacturing site occupation, long production cycle and inaccurate secondary layout and positioning.

[0006] This application provides a one-stop overall assembly manufacturing process for large segments of ultra-wide three-box separated steel box girders, comprising the following steps: Beam positioning; Positioning of the middle box bottom plate and the first inclined bottom plate units of the side boxes on both sides; Assemble the second inclined bottom plate and web plate units of the side box; Assembly and welding of diaphragm units; Assembly and welding of nozzle box units; Positioning, assembling and welding of the first top plate unit; The remaining top plate units are welded together.

[0007] In one embodiment, the crossbeam includes a top plate and a bottom plate located on one side of the top plate, a plurality of webs are provided between the top plate and the bottom plate, parallel to the direction of the top plate, and a plurality of stiffening plates are provided between the plurality of webs.

[0008] In one embodiment, there are two cross beams, and the method for positioning the cross beams includes: simultaneously positioning the two cross beams based on the middle measurement tower reference line or the tire frame longitudinal reference line and the tire frame transverse reference line.

[0009] In one embodiment, the positioning method of the middle box floor and the first inclined floor units of the two side boxes includes: aligning the longitudinal baseline of the middle box floor unit with the longitudinal baseline of the tire frame, aligning the transverse baseline of the middle box floor unit with the transverse baseline of the tire frame, and positioning and assembling the middle box floor unit; aligning the longitudinal baseline of the first inclined floor unit of each side box with the longitudinal baseline of the tire frame, aligning the transverse baseline of the first inclined floor unit of each side box with the transverse baseline of the tire frame, and positioning and assembling the first inclined floor unit of each side box.

[0010] In one embodiment, the longitudinal baseline and transverse baseline of the positioned middle box bottom plate are used as a reference, and the second inclined bottom plate unit and the side box web plate unit on both sides of the side box are positioned, assembled and welded in sequence, and the middle box web plate units on both sides of the middle box bottom plate unit are positioned and welded using the longitudinal baseline and transverse baseline of the middle box bottom plate unit as a reference.

[0011] In one embodiment, the side box web unit is a curved plate; and / or The web element of the middle box is a curved plate.

[0012] In one embodiment, before assembling the diaphragm unit, a level is placed on the plane of the middle box bottom plate to measure the elevation of the middle box bottom plate surface at the location of the diaphragm. The relative elevation difference at the same diaphragm is ≯2mm, and the relative elevation difference at different diaphragms in the same section of steel box girder is ≯4mm.

[0013] In one embodiment, the longitudinal baseline of the middle box bottom plate is used as a reference, and the position line of the middle box transverse partition plate is aligned to position and assemble the side box transverse partition plate units on both sides; and / or The nozzle box unit is assembled based on the horizontal baseline of the side box bottom plate and the corresponding 2# side measuring tower baseline. The misalignment between the bottom plate of the nozzle box and the second inclined bottom plate of the corresponding side box is ≤2mm; the misalignment between the partition of the nozzle box and the horizontal partition of the corresponding side box is ≤2mm; and / or Using the 1# side measurement tower baseline and the middle measurement tower baseline as references, locate the horizontal position of the first top plate unit of the side box and the first top plate unit of the middle box. Use the method of hanging a plumb line to align the horizontal baseline of the first top plate unit of the middle box with the horizontal baseline of the middle box bottom plate to locate the longitudinal position of the first top plate unit of the middle box. Use the method of hanging a plumb line to align the horizontal baseline of the first top plate unit of the side box with the horizontal baseline of the first inclined bottom plate of the side box to locate the longitudinal position of the first top plate unit of the side box; and / or Use the horizontal baseline of the first top plate unit of the middle box and the baseline of the middle measuring tower to locate the top plate units on both sides of the first top plate unit of the middle box. Repeat the above steps and use the horizontal baseline of the first top plate unit of the side box and the baseline of the 1# side measuring tower to locate the top plate units on both sides of the first top plate unit of the side box to complete the assembly.

[0014] In one embodiment, the center line of the plate thickness of the middle box partition is aligned with the position line of the middle box partition, the verticality of the middle box partition and the middle box bottom plate is controlled, the distance between the vertical baseline of the middle box partition and the baseline of the 1# side measuring tower is controlled, and the top surface elevation of the horizontal reinforcement on the middle box partition is controlled at the same time, so as to accurately position the middle box partition, and the side box partition units are positioned in turn.

[0015] In one embodiment, the process further comprises assembling and welding the anchor box units in the suspension cable area, and positioning and assembling the anchor box units in the suspension cable area based on the assembly position line of the anchor box units.

[0016] This application is a one-time production of the entire structure, that is, the longitudinal and transverse design lines of the steel box girder segments are arranged on the top surface of the support plate of the assembly cradle, and the longitudinal and transverse line settings of the steel box girder are achieved in one go by closely fitting the plate units with it. At the same time, the assembly and pre-assembly of the steel box girder are completed in one go on the same cradle, which greatly shortens the time required for temporary storage and transportation of the beam segments, reduces the occupation of temporary storage space within the factory, and also reduces the occupation of the assembly site. At the same time, there is no secondary precise positioning of the line shape, which is also in line with the traditional assembly process of steel box girders, and the quality and accuracy of the steel box girder are relatively guaranteed. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings of the embodiments. Obviously, the drawings described below only relate to some embodiments of the present application and are not intended to limit the present application. Figure 1 This is a diagram showing the positioning of the beams in the embodiment of the present application; Figure 2 This is a positioning diagram of the first inclined bottom plate and the middle box bottom plate of the side box embodiment of the present application; Figure 3 This is a diagram of the second inclined bottom plate, side box web and middle box web of the embodiment of the present application; Figure 4 This is an assembly diagram of the side box bulkhead and the middle box bulkhead according to the embodiment of the present application; Figure 5 This is a diagram showing the positioning of the nozzle box according to an embodiment of the present application; Figure 6 This is a positioning diagram of the first top plate of the side box and the first top plate of the middle box in the embodiment of the present application; Figure 7 This is a diagram showing the positioning of the remaining top plates of the side boxes and the middle box according to an embodiment of the present application; Figure 8 This is a positioning diagram of the anchor box unit in the suspension cable area of the embodiment of the present application; Figure 9 This is a schematic diagram of the beam structure of an embodiment of the present application; Figure 10 This is another structural diagram of the beam according to an embodiment of the present application; Figure 11 This is a schematic diagram of the curved plate structure of an embodiment of the present application; Figure 12 This is a schematic diagram of the line drawing of the curved plate according to an embodiment of the present application; Figure 13 This is a side view of the curved plate according to an embodiment of the present application; Figure 14 A side view of another curved plate according to an embodiment of the present application; Figure 15 This is a structural diagram of the positioning inspection template of the embodiment of the present application. DETAILED DESCRIPTION

[0018] The following will be combined with the accompanying drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0019] In the description of the present application, it should be understood that the terms "length", "width", "thickness", "up", "down", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a unique orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first" and "second" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance or indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more features. In the description of the present application, "multiple" means two or more, unless otherwise clearly and specifically defined.

[0020] In the application, the word "exemplary" is used to mean "serving as an example, illustration, or description." Any embodiment described in this application as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. The following description is given to enable any person skilled in the art to implement and use the present application. In the following description, details are listed for the purpose of explanation. It should be understood that one of ordinary skill in the art can recognize that the present application can be implemented without using these specific details. In other instances, known structures and processes are not described in detail to avoid obscuring the description of the present application with unnecessary detail. Therefore, the present application is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles disclosed herein.

[0021] See Figure 1 The embodiment of the present application provides a one-time overall assembly manufacturing process for large segments of an ultra-wide three-box separated steel box girder, comprising the following steps: S1, beam positioning; S2, positioning the middle box bottom plate and the first inclined bottom plate units of the side boxes on both sides; S3, assembling the second inclined bottom plate and web plate unit of the side box; S4, assembly and welding of diaphragm units; S5. Assembly and welding of nozzle box unit; S6. Positioning, assembling and welding of the first top plate unit; S7. Weld the remaining top plate units.

[0022] In this application, the web units of the middle box and side boxes both adopt an arc-shaped cross-section design, which is also the first application in the field of steel box girder processing; the crossbeam and the independent box body are designed with no joint components, and the arc-shaped section is directly welded to the independent box web, which is also the first time it has been used in a separated steel box girder structure, with a novel structure and beautiful appearance.

[0023] This invention, targeting three-box separated, ultra-wide, large-segment steel box girder structures, innovatively proposes a method for the one-step assembly of separated, large-segment steel box girders. This manufacturing method creatively integrates the manufacturing technologies of single-box and split-box girders, offering a one-step, in-situ assembly process for single-unit assemblies. Furthermore, based on the structural characteristics of the steel beam, a multi-unit assembly and reassembly process is also proposed. The purpose of this manufacturing technology is to develop a set of independent, in-situ assembly technologies suitable for three-box separated steel box girder structures, ensuring that the manufacturing precision of ultra-wide, ultra-high, large-segment steel box girders meets design requirements while minimizing welding deformation.

[0024] The present invention uses an overall one-time manufacturing process for in-situ assembly of single units, which sets the horizontal and vertical linear shapes of the steel box beam at one time through the top elevation of the support plate of the tire frame, including the linear shapes of the middle box, side boxes and crossbeam. The curvature of the arc area of the web of the crossbeam is also adjusted according to the design value of the horizontal linear shape, so that when the steel box beam is assembled, the arc of the arc web of the crossbeam can be used as the outer support of the arc web of the middle box and the side box, and as an auxiliary positioning of the outer tire. At this time, the middle box and the side box are not welded into a whole, and they can be properly fine-tuned during the process of fitting with the web of the crossbeam. For example, flame correction can be used to improve the local closeness of the places that do not meet the requirements, which effectively solves the assembly problem of the arc overlap between the middle box, side box and crossbeam without crossbeam joint structure described in the present invention.

[0025] The manufacturing process described in the present invention lists the crossbeam and the nozzle box as block units and manufactures them separately. On the one hand, the welding deformation distribution is decomposed and digested into plate units and blocks to reduce the impact of welding deformation on the manufacturing of the entire box; on the other hand, the crossbeam as a whole participates in the overall assembly of the beam section. Its arc-shaped interface can be used as the assembly and positioning outer tire of the arc-shaped web of the middle box and the side box. While assisting the positioning of the plate unit, it can also form a constraint control to ensure the size of the arc area. Finally, the nozzle box structure includes the nozzle and the anchor box structure. Separating these two parts separately for unit and block manufacturing is beneficial to controlling the assembly accuracy of the anchor box and reducing the impact of welding deformation on the position and angle of the anchor box.

[0026] The overall one-time manufacturing process of the in-situ assembly of the monomer organization described in the present invention uses the longitudinal and transverse baselines of the assembly frame as the control reference, and the beam block as the monomer reference and embedded outer tire to complete the assembly of the middle box and the side box. Compared with the monomer production, this process is more integrated in the reset assembly process, and real-time monitoring and adjustment of the entire cross-section size can be achieved during the assembly process, which is more beneficial to the size and precision control of the steel box girder production.

[0027] In S1: See also Figure 9 and Figure 10 In some embodiments, the crossbeam includes a top plate and a bottom plate located on one side of the top plate, and a plurality of webs are arranged between the top plate and the bottom plate, parallel to the direction of the top plate, and a plurality of stiffening plates are arranged between the plurality of webs.

[0028] Furthermore, there are two cross beams, and the method for positioning the cross beams includes: simultaneously positioning the two cross beams based on the middle measuring tower reference line or the tire frame longitudinal reference line and the tire frame transverse reference line.

[0029] It can be understood that each segment of the three-box separated steel box girder is provided with 4 or 2 cross beams depending on its length.

[0030] It can also be understood that each section of the three-box separated steel box girder has 2 or 4 cross beams, and the overall assembly of the steel box girder is carried out in one round, so the cross beam positioning in this application refers to the first cross beam (2) of the cross bridge of the first section of the steel box girder in this round.

[0031] It can also be understood that the total assembly frame is composed of columns and longitudinal beams and transverse beams above the columns. In order to fit the longitudinal and transverse lines of the steel box beam, corresponding steel box beam supports are provided above the longitudinal and transverse beams of the total assembly frame.

[0032] In S2: See also Figure 2 In some embodiments, the first inclined bottom plate of the side box is the middle inclined bottom plate of the side box.

[0033] Furthermore, the positioning method of the middle box bottom plate and the first inclined bottom plate units of the two side boxes includes: aligning the longitudinal baseline of the middle box bottom plate unit with the longitudinal baseline of the tire frame, aligning the transverse baseline of the middle box bottom plate unit with the transverse baseline of the tire frame, and positioning and assembling the middle box bottom plate unit; aligning the longitudinal baseline of the first inclined bottom plate unit of each side box with the longitudinal baseline of the tire frame, aligning the transverse baseline of the first inclined bottom plate unit of each side box with the transverse baseline of the tire frame, and positioning and assembling the first inclined bottom plate unit of each side box.

[0034] It can be understood that the focus should be on the unevenness and elevation of the four corners of the middle box bottom plate unit, and the inclination angle of the first inclined bottom plate unit of the side box should also be paid attention to.

[0035] In the S3: See also Figure 3 In some embodiments, the longitudinal baseline and transverse baseline of the positioned middle box bottom plate are used as references to sequentially position and assemble the second inclined bottom plate unit and the side box web plate unit on both sides of the side box for welding, and the longitudinal baseline and transverse baseline of the middle box bottom plate unit are used as references to position and weld the middle box web plate units on both sides of the middle box bottom plate unit.

[0036] Furthermore, the side box web unit is an arc-shaped plate.

[0037] Furthermore, the middle box web unit is a curved plate.

[0038] See Figure 11 , further, the arc-shaped plate includes: The plate is arc-shaped and has an inner side surface; Plate ribs are sequentially arranged on the inner side surface of the plate along the length direction of the plate; The plate connecting piece has a first side and a second side, wherein the first side is provided with a first groove matched with the plate rib.

[0039] It's understandable that due to the curved shape of the panel, there's an angular relationship between the ribs, and the rib spacing decreases from the base to the free end, with the reduction proportional to the radius of the curved panel. The selection range and form of the connecting plate a must be determined based on the curvature and the installation conditions of the connecting plate a (the connecting plate assembly).

[0040] The curved plate of the present application is a unit. Specifically, the present application manufactures the plate, plate ribs and plate joint parts together as a unit body, which increases the streamline of the steel box, reduces the effect of the lateral wind force on the bridge, reduces the wind vibration effect, and at the same time improves the aesthetic design of the structure itself.

[0041] In some embodiments, the plate rib and the first groove are fixed by welding.

[0042] Furthermore, the plate rib and the first groove are connected by single-side welding.

[0043] In some embodiments, the connecting plate assembly includes a connecting plate a, which is arranged on the inner side surface of the plate in sequence along the width direction of the plate. The connecting plate a has the first side and the second side arranged opposite to each other, the first side is provided with a first groove matching the plate rib, and the second side is provided with a flange plate.

[0044] Furthermore, the flange plate is fixed to the center line position of the second side of the connecting plate a along the length direction.

[0045] See Figures 11 to 15 , an embodiment of the present application also provides a method for manufacturing a curved plate, which can be used to manufacture the curved plate of the aforementioned embodiment.

[0046] See Figure 12 In some embodiments, the manufacturing method includes: S01. Provide panels; S02. Draw the horizontal baseline, vertical baseline, plate rib position line, plate joint position line and arc bending guide line on the plate; S03, pressing the plate into a curved plate along the curved bending guide line; S04. Weld the plate ribs according to the plate rib position lines; S05. Assemble the connecting plate parts and weld them.

[0047] In order to ensure the size and accuracy of the circumferential groove of the curved plate, the present application adopts the method of cutting the plate with the net size + process quantity when cutting the plate, thereby changing the post-trimming process of the plate unit production; when marking the plate, a high-precision laser marking machine is used to replace manual marking to improve the marking accuracy; the marking type is based on the horizontal baseline, vertical baseline, plate rib position line and plate joint position line, and an arc bending guide line is added to assist in the profiling and profiling position inspection of the curved plate; in order to improve the assembly accuracy of the plate rib, the original plate rib position line is marked according to the center line of the plate rib thickness, and adjusted to the plate skin line on one side or both sides of the plate rib, thereby reducing the deviation of the plate rib assembly alignment and realizing one-side reference control or two-way control; the traditional plate unit can measure the vertical relationship between the plate rib and the panel by a protractor, and the present application adopts a positioning inspection template for the curved plate design to control the plate rib angle and realize the centripetal (center of the circle) assembly of each plate rib; the flatness of the traditional plate unit panel can be detected and controlled by a long plate ruler, and the present invention adopts an internal and external double-sided template for the arc surface design to assist in checking the curvature effect, providing an intuitive basis for the correction of the plate unit. This application mainly realizes the manufacturing precision control of multi-curvature combined arc plate units from the aspects of curvature control, plate rib spacing and angle, and welding deformation.

[0048] The arc-shaped plate of the present application is a unit. The present application manufactures the plate, plate ribs and plate joint parts together as a unit body. The present application assembles the plate ribs for the first time after the plate is bent.

[0049] In the S01: In some embodiments, the plate is a rectangular parallelepiped structure.

[0050] Furthermore, the plate is a steel plate.

[0051] In some embodiments, the flatness of the plate surface is ≤1 mm / m.

[0052] In some embodiments, the straightness of the plate edge is ≤1 mm / m.

[0053] In some embodiments, the plate is first milled straight around its periphery, and then grooves are machined around the periphery of the plate.

[0054] It can be understood that the plate is milled straight all around to ensure that the straightness of all sides of the plate is ≤1mm / m. At a distance of 50mm from the edge of the plate, the groove processing alignment line is drawn to accurately locate the position of the processing head or cutting nozzle. According to the processing groove size, such as 45° single V groove or 40° single V groove, the corresponding groove size is processed by adjusting the cutting head angle, thereby realizing groove processing accuracy control and avoiding grooves of different depths and sizes that affect welding quality.

[0055] In the S02: See Figure 12In some embodiments, a high-precision laser marking machine is used to mark horizontal baselines, vertical baselines, plate rib position lines, plate joint position lines and arc bending guide lines on the plate.

[0056] It can be understood that the horizontal baseline and the longitudinal baseline will be preserved as the benchmark of the unit element until the overall assembly of the steel box girder segment. The longitudinal and transverse control of the plate unit manufacturing process is based on the horizontal baseline and the longitudinal baseline. When the steel box girder segment is assembled, the spacing between the horizontal and longitudinal baselines of adjacent plates is used to control the assembly position of the plate elements, assist in the positioning of the plate elements, and realize the assembly dimensional accuracy control of the steel box girder at the same time.

[0057] In some embodiments, the longitudinal base line is located at the center of the panel along the length direction of the panel.

[0058] In some embodiments, along the width direction of the plate, the transverse base line is located at the center of the plate or at one side of the center of the plate.

[0059] In some embodiments, a plurality of the plate rib position lines are arranged in sequence and spaced apart along the length direction of the plate.

[0060] In some embodiments, a plurality of the plate connecting position lines are sequentially spaced apart along the width direction of the plate.

[0061] In some embodiments, the arc-shaped bending guide lines are arranged at equal intervals along the length of the plate, and the distance between adjacent arc-shaped bending guide lines is less than 100 mm, for example, 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 99 mm, etc. This distance range is conducive to increasing the indentation density.

[0062] It can be understood that the plate is first bent through the arc bending guide line and then the plate rib is installed through the plate rib position line.

[0063] In said S03: See Figure 11 、 Figure 13 and Figure 14 In some embodiments, a press is used to press the plate into an arc-shaped plate along an arc-shaped bending guide line.

[0064] Furthermore, the press includes an upper die and a lower die, the upper die adopts an R150 die head, and the upper die and the lower die cooperate to complete the pressing.

[0065] It can be understood that during the pressing process, the indentation density is increased by encrypting the arc guide lines, and the pressure areas of the plate are cross-propelled to avoid hard bends or obvious straight sections on the plate surface during the bending process.

[0066] Furthermore, during the pressing process, a positioning inspection template is used to track and inspect the arc size after each pressing. If the arc size does not meet the requirements, the press is used to re-press until the arc size meets the requirements.

[0067] It can be understood that each embossing is the arc formed by each plate pressed down by the press.

[0068] It can be understood that the inspection reference edge of the arc inspection template is designed according to the radius size of the arc plate to be inspected. During the inspection process, the inspection reference edge is placed close to the inner skin of the arc plate to check the gap between the template reference edge and the inner skin of the arc plate. When the gap is ≤1mm, it can be determined that the arc pressing size at that location meets the requirements. When the gap is greater than 1mm, it can be determined to be unqualified. During the inspection process, the template position is moved and the arc size of any position of the arc plate is checked multiple times. If it does not meet the requirements, re-pressing is performed. Generally, each position is pressed at least twice.

[0069] In some embodiments, when the curved plate is pressed, a reverse deformation amount is preset.

[0070] It can be understood that the amount of reverse deformation is set according to the chord length of the arc plate + 1mm~2mm, and the production process is adjusted in time according to the actual measurement situation.

[0071] It can be understood that after the arc plate is press-formed, the plate rib assembly and welding operations will continue. At the same time, flame correction is required to reduce the influence of welding deformation on the dimensional accuracy of the arc plate unit. Therefore, when the arc plate is pressed, it is necessary to preset the reverse deformation amount according to the arc radius of the pressed arc plate and the thickness of the plate. Since the plate ribs are evenly arranged on the inner side of the arc plate, the arc plate will tend to retract due to the heat on the inner side during welding, that is, the arc opening will shrink. Therefore, during the arc plate pressing process, the arc plate opening size is appropriately relaxed to compensate for the steel plate press rebound amount and welding shrinkage amount. Here, the reverse deformation amount should be remeasured and tracked during the production process and adjusted when necessary.

[0072] It can also be understood that during the arc-shaped plate pressing process, the arc-pressing and pushing operation of the arc-shaped plate is completed by the CNC front pushing shaft and CNC rear stop frame of the press, realizing the forward pushing and backward feeding (CNC) operation, ensuring that each line is accurate, ensuring that the inner and outer arcs of the arc-shaped plate are smooth, and using a non-indentation lower die to press to ensure that there is no obvious indentation on the outer arc.

[0073] In said S04: See Figure 15 In some embodiments, the plate skin line on one side or both sides of the plate rib is extended into the curved plate to form a plate rib position line.

[0074] It can be understood that rib position lines are drawn along the length direction of the arc-shaped plate, and each rib position line is connected to the plate skin lines on one side or both sides of the corresponding rib.

[0075] Furthermore, the plate skin of the plate rib is close to the plate rib position line, and the plate thickness surface of the plate rib is close to the inner side surface of the curved plate.

[0076] It can be understood that the plate skin is the thick surface of the plate rib.

[0077] Furthermore, after welding, a positioning inspection template is used to check the assembly effect of the plate ribs.

[0078] It can be understood that spot welding is used for welding, and the positions of plate rib ports and connecting plate parts are avoided during spot welding, because patch welding is required later.

[0079] Furthermore, the positioning inspection template includes a first side and a second side arranged opposite to each other, the first side is provided with a second groove that matches the cross-section of the plate rib, the opening of the second groove is located on the first side, and the second groove extends along one side toward the second side. The number of second grooves is the same as the number of plate ribs, one side of the second groove is the plate rib reference edge, the first side is the inner arc reference edge and is arc-shaped, and the inner arc reference edge matches the inner curved surface of the arc plate; at least one elongated hand hole is provided on the side close to the second side, and weight reduction holes are also provided on the positioning inspection template between the second grooves.

[0080] Furthermore, the inclination of each plate rib reference edge is different, and the other side of the second groove is inclined away from the side corresponding to the plate rib reference edge so as to fit with the corresponding plate rib.

[0081] The inclination of each plate rib reference edge in the present application is different, the purpose of which is to facilitate the fit with the corresponding plate rib, and to judge whether the plate rib assembly angle is in place by whether there is a gap between the plate rib reference edge and the plate rib; the other side of the second groove is inclined away from the side corresponding to the plate rib reference edge, the purpose of which is to facilitate the placement of the positioning inspection template in place (to facilitate the fit with the corresponding plate rib), and also reduce the net area of the positioning inspection template, which can reduce the weight of the positioning inspection template and facilitate the holding operation during use.

[0082] The curved plate of the present application is a multi-curvature curved plate, and its curvature can be changed freely; the plate ribs are plate-like structures.

[0083] In some embodiments, the inclination direction of each rib is different.

[0084] Exemplarily, the curved plate is a circular arc plate.

[0085] It can be understood that the weight-reducing holes can be of regular shape or irregular shape.

[0086] Furthermore, the second groove of the positioning inspection template is matched with the corresponding plate rib, and the inner arc reference edge is matched with the inner curved surface of the arc plate. Then, multiple plate rib reference edges are pressed against the plate skin of the plate rib at the same time, and the degree of fit between each plate rib surface and the plate rib reference edge is checked. If it is not perfectly fitted, adjust it to be perfectly fitted and then perform spot welding to fix it. After the plate rib is spot welded, the plate rib assembly effect of the arc plate along the length direction is checked by moving the positioning inspection template. The focus should be on controlling the position of the plate rib root, the plate rib angle and the spacing between the free ends of the plate rib. The inspection process must always ensure that the inner arc reference edge and the plate rib reference edge are perfectly fitted to complete the plate rib welding operation.

[0087] It can be understood that the plate rib surface is the surface on both sides of the plate rib width direction.

[0088] It can be understood that the focus should be on controlling the root position of the plate rib, that is, the outer skin line on both sides of the plate rib is accurately aligned with the plate rib position line, where the root position of the plate rib is the position where the outer skin line of the plate rib contacts the inner arc surface of the arc plate, and welding is welding on both sides of the plate rib thickness surface.

[0089] It can also be understood that the rib angle and the distance between the free ends of the ribs are formed because the ribs are welded to the inner side of the curved panel and the ribs are arranged centripetally, so a natural angle is formed between the ribs, namely the rib angle. At the free end of the ribs, that is, the width side that is not welded, there will be a size between the ribs, namely the distance between the free ends of the ribs.

[0090] It can be understood that the centripetal (center of the arc plate) arrangement of the plate ribs can be achieved with the help of the positioning inspection template to assist in control.

[0091] In said S05: In some embodiments, the connecting plate assembly includes a connecting plate a, which is arranged on the inner side surface of the plate in sequence along the width direction of the plate, and the connecting plate a has a first side and a second side arranged opposite to each other, and the first side is provided with a first groove matching the plate rib; the second side is provided with a flange plate, and the flange plate is fixed to the center line position of the second side of the connecting plate a along the length direction.

[0092] Furthermore, the assembly of the connecting plate assembly includes connecting the plate rib and the first groove by single-side welding; and directly welding the connecting plate a and the flange plate.

[0093] It can be understood that the longitudinal center line of the connecting plate a close to the flange plate is aligned with the longitudinal center line of the flange plate, and the thickness center line of the connecting plate a is aligned with the width center line of the flange plate.

[0094] It can be understood that the focus is on controlling the verticality of the connecting plate a and the flange plate. During the assembly process, a square is used to check whether the angle between the connecting plate a and the flange plate is vertical. If it is not vertical, fine-tune it.

[0095] In some embodiments, welding the plate assembly includes welding the flange plate to the second side surface.

[0096] It can be understood that the position of the positioning and assembly of the connecting plate assembly and the verticality of the connecting plate and the arc plate are checked to complete the connecting plate welding.

[0097] It can be understood that the flame correction method is used to correct the welding deformation of the curved plate unit. Specifically, the curved plate is locally heated through the fire adjustment process, and then the local plate surface undergoes slight changes due to shrinkage to adjust the local deformation. The curvature of the curved plate, especially the position of the two ends, the position and angle of the plate ribs are checked, and special attention is paid to the end and the plate connection position.

[0098] In said S4: See also Figure 4 In some embodiments, before assembling the diaphragm unit, a level is placed on the plane of the middle box bottom plate to measure the elevation of the middle box bottom plate surface at the location of the diaphragm. The relative elevation difference at the same diaphragm is ≯2mm, and the relative elevation difference at different diaphragms of the same section of steel box girder is ≯4mm.

[0099] It can be understood that the top surface of the diaphragm is a slope, and the 2% transverse slope is superimposed on the transverse manufacturing camber value. What is measured here is, for example, taking the transverse center line of the bridge as the reference, deviating a value to the left and right, measuring the elevation of the top surface of each beam where this offset falls, and controlling the relative height difference of different diaphragms at this position to be ≯4mm.

[0100] In some embodiments, the longitudinal baseline of the middle box bottom plate is used as a reference, and the position line of the middle box transverse partition plate is aligned to position and assemble the side box transverse partition plate units on both sides.

[0101] Furthermore, align the center line of the plate thickness of the middle box partition with the position line of the middle box partition, control the verticality of the middle box partition and the middle box bottom plate, control the distance between the vertical baseline of the middle box partition and the baseline of the 1# side measuring tower, and at the same time control the top surface elevation of the horizontal reinforcement on the middle box partition, so as to accurately position the middle box partition, and locate the side box partition units by analogy.

[0102] It can be understood that the focus is on controlling the verticality of the diaphragm and the middle box bottom plate, the relative height difference of the elevation base of the diaphragm unit component, and the verticality of the diaphragm and the middle box bottom plate is measured by a large angle square or detected by a plumb bob during the assembly process; the elevation detection is controlled by measuring the elevation value of the fixed position of the upper edge of the diaphragm through a total station.

[0103] In said S5: See also Figure 5In some embodiments, the nozzle box unit is assembled based on the horizontal baseline of the side box bottom plate and the corresponding 2# side measuring tower baseline, and the misalignment between the bottom plate of the nozzle box and the second inclined bottom plate of the corresponding side box is ≤2mm; the misalignment between the partition of the nozzle box and the horizontal partition of the corresponding side box is ≤2mm.

[0104] It can be understood that the horizontal baseline of the three-box separated steel box girder is a system line that runs through the entire horizontal direction of the three-box separated steel box girder to form a circle, so aligning the horizontal baseline of the nozzle box with the horizontal baseline of the side box can control the longitudinal position of the nozzle box; the position set by the 2# side measuring tower is consistent with the longitudinal baseline of the top plate of the nozzle box, so the transverse position of the nozzle box is located with the 2# side measuring tower baseline; a support plate is provided on the oblique support of the tire frame, and the elevation of the top surface of the support plate is set according to the longitudinal and transverse manufacturing lines of the three-box separated steel box girder. At the same time, the alignment of the top and bottom plates of the nozzle box with the top and bottom plates of the side box can show whether their height direction is placed in place.

[0105] In said S6: See also Figure 6 In some embodiments, the lateral positions of the first top plate unit of the side box and the first top plate unit of the middle box are positioned based on the 1# side measurement tower baseline and the middle measurement tower baseline. The horizontal baseline of the first top plate unit of the middle box is aligned with the horizontal baseline of the middle box bottom plate by using the hanging plumb line method to locate the longitudinal position of the first top plate unit of the middle box; the horizontal baseline of the first top plate unit of the side box is aligned with the horizontal baseline of the first inclined bottom plate of the side box by using the hanging plumb line method to locate the longitudinal position of the first top plate unit of the side box.

[0106] It can be understood that during assembly, the longitudinal and transverse baseline alignment deviations of the first top plate units of the middle box and the side box should be controlled to be ≤1mm.

[0107] In the S7: See also Figure 7 In some embodiments, the top plate units on both sides of the first top plate unit of the middle box are positioned using the horizontal baseline of the first top plate unit of the middle box and the baseline of the middle measuring tower. Repeat the above steps and use the horizontal baseline of the first top plate unit of the side box and the baseline of the 1# side measuring tower as the basis to position the top plate units on both sides of the first top plate unit of the side box to complete the assembly.

[0108] It can be understood that the horizontal baseline alignment deviation of other top plate units is ≤1mm, and the longitudinal baseline spacing between other top plate units is controlled as "set +2mm" to reserve shrinkage for welding shrinkage. The longitudinal and transverse top surface elevation deviations of other top plate units are controlled within 3mm.

[0109] In some embodiments, the process further comprises assembling welding of the anchor box unit in the catenary area.

[0110] See also Figure 8 Furthermore, the anchor box unit in the suspension area is positioned and assembled based on the anchor box unit assembly position line.

[0111] It can be understood that the alignment deviation between the baseline of the anchor box unit and the longitudinal and transverse baseline of the beam top plate is ±2mm, the longitudinal misalignment of the anchor box units on both sides is ±2mm, the height difference of the anchor box units is ±4mm, and the angle deviation of the box units is ≤0.1°.

[0112] In this application: The vertical center line of the first inclined bottom plate of the side box is the 1# side measuring tower baseline, and there are two 1# side measuring tower baselines; the vertical center line of the nozzle box is the 2# side measuring tower baseline, and there are two 2# side measuring tower baselines; the longitudinal baseline of the tire frame is the middle measuring tower baseline.

[0113] The basic concepts have been described above. It will be apparent to those skilled in the art that the detailed disclosure above is merely illustrative and does not limit the present application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and amendments to the present application. Such modifications, improvements, and amendments are suggested in the present application and remain within the spirit and scope of the exemplary embodiments of the present application.

[0114] At the same time, this application uses specific terms to describe the embodiments of this application. For example, "one embodiment," "an embodiment," and / or "some embodiments" refer to a certain feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that "one embodiment," "an embodiment," or "an alternative embodiment" mentioned twice or multiple times in different locations in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this application may be appropriately combined.

Claims

1. The overall one-time assembly manufacturing process of large sections of ultra-wide three-box separated steel box girders is characterized by: The steps include: Beam positioning; Positioning of the middle box bottom plate and the first inclined bottom plate units of the side boxes on both sides; Assemble the second inclined bottom plate and web plate units of the side box; Assembly and welding of diaphragm units; Assembly and welding of nozzle box units; Positioning, assembling and welding of the first top plate unit; The remaining top plate units are welded together.

2. The overall one-time assembly manufacturing process for large sections of ultra-wide three-box separated steel box beams according to claim 1 is characterized in that: The crossbeam includes a top plate and a bottom plate located on one side of the top plate. A plurality of webs are arranged between the top plate and the bottom plate, parallel to the direction of the top plate, and a plurality of stiffening plates are arranged between the plurality of webs.

3. The overall one-time assembly manufacturing process for large sections of ultra-wide three-box separated steel box beams according to claim 2 is characterized in that: There are two cross beams, and the positioning method of the cross beams includes: positioning the two cross beams simultaneously based on the middle measuring tower reference line or the tire frame longitudinal reference line and the tire frame transverse reference line.

4. The overall one-time assembly manufacturing process for large segments of ultra-wide three-box separated steel box girders according to claim 1 is characterized in that: The positioning method of the middle box bottom plate and the first inclined bottom plate units of the side boxes on both sides includes: aligning the longitudinal baseline of the middle box bottom plate unit with the longitudinal baseline of the tire frame, aligning the transverse baseline of the middle box bottom plate unit with the transverse baseline of the tire frame, and positioning and assembling the middle box bottom plate unit; aligning the longitudinal baseline of the first inclined bottom plate unit of each side box with the longitudinal baseline of the tire frame, aligning the transverse baseline of the first inclined bottom plate unit of each side box with the transverse baseline of the tire frame, and positioning and assembling the first inclined bottom plate unit of each side box.

5. The one-step overall assembly manufacturing process for large sections of ultra-wide three-box separated steel box girders according to claim 1 is characterized in that: Taking the longitudinal baseline and transverse baseline of the positioned middle box bottom plate as the reference, the second inclined bottom plate unit and the side box web unit on both sides of the side box are positioned and assembled in sequence for welding, and the middle box web units on both sides of the middle box bottom plate unit are positioned and welded using the longitudinal baseline and transverse baseline of the middle box bottom plate unit as the reference.

6. The one-step overall assembly manufacturing process for large sections of ultra-wide three-box separated steel box girders according to claim 5 is characterized in that: The side box web element is a curved plate; and / or The web element of the middle box is a curved plate.

7. The one-step assembly manufacturing process for large segments of ultra-wide three-box separated steel box girders according to claim 1 is characterized in that: Before assembling the diaphragm unit, place the level on the plane of the middle box bottom plate and measure the elevation of the middle box bottom plate where the diaphragm is located. The relative elevation difference at the same diaphragm is ≯2mm, and the relative elevation difference at different diaphragms of the same section of steel box girder is ≯4mm.

8. The one-step overall assembly manufacturing process for large sections of ultra-wide three-box separated steel box girders according to claim 1 is characterized in that: Using the longitudinal baseline of the middle box bottom plate as a reference, align the position line of the middle box transverse partition plate and assemble the side box transverse partition plate units on both sides; and / or The nozzle box unit is assembled based on the horizontal baseline of the side box bottom plate and the corresponding 2# side measuring tower baseline. The misalignment between the bottom plate of the nozzle box and the second inclined bottom plate of the corresponding side box is ≤2mm; the misalignment between the partition of the nozzle box and the horizontal partition of the corresponding side box is ≤2mm; and / or Using the 1# side measurement tower baseline and the middle measurement tower baseline as references, locate the horizontal position of the first top plate unit of the side box and the first top plate unit of the middle box. Use the method of hanging a plumb line to align the horizontal baseline of the first top plate unit of the middle box with the horizontal baseline of the middle box bottom plate to locate the longitudinal position of the first top plate unit of the middle box. Use the method of hanging a plumb line to align the horizontal baseline of the first top plate unit of the side box with the horizontal baseline of the first inclined bottom plate of the side box to locate the longitudinal position of the first top plate unit of the side box; and / or Use the horizontal baseline of the first top plate unit of the middle box and the baseline of the middle measuring tower to locate the top plate units on both sides of the first top plate unit of the middle box. Repeat the above steps and use the horizontal baseline of the first top plate unit of the side box and the baseline of the 1# side measuring tower to locate the top plate units on both sides of the first top plate unit of the side box to complete the assembly.

9. The one-step overall assembly manufacturing process for large sections of ultra-wide three-box separated steel box girders according to claim 8 is characterized in that: Align the center line of the plate thickness of the middle box partition with the position line of the middle box partition, control the verticality of the middle box partition and the middle box bottom plate, control the distance between the vertical baseline of the middle box partition and the baseline of the 1# side measuring tower, and control the top surface elevation of the horizontal reinforcement on the middle box partition to accurately position the middle box partition, and similarly position the side box partition units on both sides.

10. The one-step overall assembly manufacturing process for large segments of ultra-wide three-box separated steel box girders according to claim 1 is characterized in that: The process also includes assembling and welding the anchor box unit in the suspension cable area, and positioning and assembling the anchor box unit in the suspension cable area based on the assembly position line of the anchor box unit.

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