Method for fabricating single-rotation, double-rotation, and single-arch box girder load-bearing beams

Abstract

The invention relates to a method for manufacturing a single-turn, double-turn, single-arch box-type load-bearing beam, comprising the following steps: 1. dividing a component as a whole into three sections in TKELA software and setting segmented positioning lines; 2. decomposing and unfolding each segment component into an upper wing plate, a lower wing plate, a left web plate, a right web plate and an intermediate support; cold bending after profile cutting; 3. adjusting the segment component to a top view; establishing a rectangular coordinate system, wherein the left end of the lower wing plate of the segment component falls on the Y axis and corresponds to the starting point 0 of the X axis; setting a coordinate point every 1 meter starting from the starting point O along the X axis direction; making a plurality of Y-direction constraint lines parallel to the Y axis and passing through each coordinate point of the X axis in the coordinate system, and setting the intersection of the Y-direction constraint line and the contour line of the lower wing plate of the segment component as a control point; obtaining the three-dimensional coordinates (x, y, z) of each control point in the coordinate system; fixing a welding frame according to the coordinates of each control point; 4. assembling and welding a box body and an intermediate support on the welding frame. The invention has strong segment integrity, few butt welds and high construction accuracy.

Description

Technical Field

[0001] The invention belongs to the technical field of building steel structures, and particularly relates to a method for manufacturing a single-turn, double-turn, single-arch box-shaped load-bearing beam. Background Art

[0002] Special-shaped twisted steel structures play an important role in the field of construction. They have unique shapes, excellent architectural expression, clear force characteristics, and a large overall span range. They are currently widely used in various public constructions in cities, such as airport terminals, convention and exhibition centers, and stadiums. Among them, the single-turn, double-turn, single-arch box plays an important role in the construction of Yulin Airport. The twisted box structure is complex and has a large span, making it difficult to assemble. The main body of the component is converted from a single-port box to a double-port box. The structure is special and has multiple spatial angles. Compared with traditional steel structures, it has a unique shape, complex force, difficult construction control, difficult to grasp the accuracy of the external dimensions, and poor molding effect. There are many welding sequences for the assembly of partitions in the box, and the main span is 43 meters long, so it is particularly important to study a construction technology. Summary of the invention

[0003] The technical problem to be solved by the present invention is that the existing large box beam components are divided into many sections, the welding workload is large during the butt joint construction, the assembly construction is complicated, the assembly precision requirement is high, and too many butt joint weldings make it difficult to ensure the overall quality of the box beam.

[0004] The present invention solves the above-mentioned problem by adopting the following technical solution:

[0005] A method for manufacturing a single-turn double-turn single-arch box-shaped load-bearing beam,

[0006] Step 1: In TKELA software, the component is divided into three sections and the positioning lines of the sections are set. The three sections are the left end Y-shaped section, the middle double box section and the right end Y-shaped section.

[0007] Step 2: Use CAD to split the three sections, and then decompose and unfold the components of each section. The box of each section is divided into five types of parts: upper wing plate, lower wing plate, left web plate, right web plate and middle support. The split parts are cut by CNC flame cutting machine in 1:1 profiling. After cutting, the plate rolling machine is used to cold bend according to the curvature requirements of the drawing. The curved sample is used for inspection and verification during the rolling process.

[0008] Step 3, design the welding jig of each segmented component: 1) adjust the segmented component to a top view in CAD; establish a rectangular coordinate system, the XY plane of the coordinate system is used to determine the horizontal position of the welding jig, the X axis extends along the length direction of the segmented component; the Y axis extends along the width direction of the component; the Z axis extends along the height direction of the component; 2) the left end of the lower wing plate of the segmented component falls on the Y axis and corresponds to the starting point 0 of the X axis. Starting from the starting point 0, along the X axis direction, a coordinate point is set every 1 meter from the starting point O; 3) make several Y-direction constraint lines parallel to the Y axis and passing through each coordinate point of the X axis in the coordinate system, and the intersection of the Y-direction constraint line and the contour line of the lower wing plate of the segmented component is set as a control point; measure each control point in CAD The coordinates (x, y) of the point on the XY plane; 4) In CAD, adjust the segmented component to the main view projection, lift the segmented component by 0.5 meters, make several Z-direction constraint lines parallel to the Z axis and passing through each coordinate point of the X axis in the coordinate system, measure the Z-axis value of each control point on the contour line of the lower wing plate, and obtain the three-dimensional coordinates (x, y, z) of each control point; 5) The welding cradle includes a support seat fixed to the working platform and corresponding to each control point, and the support seat is composed of two legs and a support beam; the welding cradle is fixed on the construction platform according to the plane coordinates (x, y) of each control point on the XY plane; and the positioning height of the support beam is determined by the Z-axis coordinate value; 6) Check the coordinates of each control point on the welding cradle;

[0009] Step 4: After the control points are determined, the lower wing plate of the segmented component is hoisted onto the welding frame and fixed by spot welding; after the fixation is completed, the web is hoisted and fixed, the lower chord of the web is used as the construction foundation edge line through the lower wing plate, and the upper chord is aligned and positioned by means of plumb bob ground sample control points, and a U-shaped box is obtained after all the control points are matched; the inner partition is assembled in the U-shaped box, and the inner partition also obtains horizontal and vertical positioning points according to the established three-view drawing, and the inner partition is assembled according to the relevant positioning points; finally, the upper wing plate is welded;

[0010] Step 5, after the box is assembled, assemble the middle support, a) Left end Y-shaped section and right end Y-shaped section: first select nodes on the welds between the inner web of the box body and the middle support where the Y-shaped section is converted into a double box, and measure the node coordinates; then assemble and fix each middle support to the boxes on both sides; b) Middle double box section: first locate the nodes of each middle support in the XY plane, first align the two single-port boxes horizontally, and assemble and fix the middle support to the inner web of the box body by four-way welding;

[0011] Step 6, use semi-automatic carbon dioxide gas shielded welding to complete the single-turn double-turn single-arch box welding.

[0012] Compared with the prior art, the present invention adopting the above technical solution has the following outstanding features:

[0013] The manufacturing method provided by the present invention has reduced segmentation, reduced butt welds, strong segment integrity, beautiful appearance, and easy control of construction accuracy; the present invention utilizes special jigs to assemble the segments, with high dimensional accuracy and high structural strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 The structural diagram of the box-body load-bearing beam made for the present invention;

[0015] Figure 2 This is a schematic diagram of the sectioning of the box load-bearing beam of the present invention;

[0016] Figure 3 This is the structural diagram of the first section (Y-shaped on the left end) of the present invention;

[0017] Figure 4 This is a schematic diagram of the decomposition and expansion of the left end Y-shaped segment of the present invention;

[0018] Figure 5 A schematic diagram of the control points (elevation) of the left end Y-shaped segment set for the present invention;

[0019] Figure 6 A schematic diagram (top view) of setting the control points of the left end Y-shaped segment of the present invention;

[0020] Figure 7 A schematic diagram of positioning the operating surface of the tire frame of the present invention;

[0021] Figure 8 It is a top view of the structure of the left Y-shaped tire frame of the present invention;

[0022] Fig. 9 This is a schematic diagram of fixing the lower wing plate of the left Y-shaped section of the present invention;

[0023] Fig.10 This is a structural diagram of the support seat of the present invention.

[0024] In the figure: 1. Left end Y-shaped section; 2. Middle double box section; 3. Right end Y-shaped section; 4. Positioning line; 5. Upper wing plate; 6. Lower wing plate; 7. Web plate; 8. Horizontal support; 9. Coordinate point; 10. Welding frame. DETAILED DESCRIPTION

[0025] The present invention will be further described below in conjunction with embodiments, the purpose of which is only to provide a better understanding of the content of the present invention. Therefore, the examples given do not limit the protection scope of the present invention.

[0026] This production plan involves the following aspects: 1. Production of special-shaped tire frame. 2. Positioning of single-rotation and double-rotation space nodes. 3. Overall assembly and welding of the arched box.

[0027] The single-turn double-turn single-arch box beam structure to be manufactured by the present invention is shown in FIG. Figure 1It is 43 meters long, 2.7 meters wide and 3.2 meters high. It is a box structure as a whole. The upper and lower cover plates of the box are 24mm thick, and the left and right webs are 16mm thick. There are 9 horizontal supports and 8 links in the middle part of the component, and the box is equipped with internal partitions to enhance the bending strength of the box.

[0028] In the prior art, for the above-mentioned full box components, the entire component is generally divided into five sections during production, namely, two sections for a single-port box and three sections for a double-port box. The five sections of the box are first processed separately, and then spliced ​​as a whole, so that a single component with a large span can be reduced to five segmented components with a smaller span. Since the existing production method divides large box beams into many sections, the overall welding workload during the butt joint construction is large. For such large box components, the butt welding of the box at the interface position is difficult, and the butt joint accuracy is not easy to control. A slight deviation will cause the overall size to deviate, thereby causing the component to be scrapped.

[0029] The manufacturing method of the above-mentioned single-turn double-turn single-arch box girder provided by the present invention is:

[0030] Step 1: Divide the 43-meter component into three sections and set the segment positioning line 4 (such as Figure 1 ), component No. 1 is the left end Y-shaped section 1, which is 14 meters long and 2.7 meters wide; component No. 2 is the middle double-box section 2, which is 15 meters long and 2.6 meters wide; component No. 3 is the right end Y-shaped section 3, which is 14 meters long and 2.7 meters wide.

[0031] Step 2: Use CAD to separate the three sections, and then decompose and expand each section (see Figure 2 ), each segmented component box is divided into five parts: upper wing plate 5, lower wing plate 6, left web plate, right web plate and middle support 8 (see Figure 3 , Figure 4 ); The split parts are cut into 1:1 shapes using a CNC flame cutting machine. After cutting, they are cold-bent using a plate rolling machine according to the curvature requirements of the drawing. During the rolling process, a curved sample is used for inspection and verification.

[0032] Step 3, designing the welding frame 10 of each segmented component:

[0033] 1) Adjust the segmented component to a top view in CAD and establish a rectangular coordinate system. Take the left end Y-shaped segment as an example. Figure 5 , Figure 6 The XY plane of the coordinate system is used to determine the horizontal position of the welding jig 10. The X-axis extends along the length direction of the segmented component, and the X-axis is used to determine the longitudinal position of the welding jig 10; the Y-axis extends along the width direction of the component, and the Y-axis is used to determine the lateral position of the welding jig 10; the Z-axis extends along the height direction of the component; and the Z-axis is used to determine the vertical height of the welding jig 10.

[0034] 2) The left end of the lower wing plate 6 of the segmented component falls on the Y axis and corresponds to the starting point 0 of the X axis. Starting from the starting point O, a coordinate point is set every 1 meter along the X axis direction.

[0035] 3) In the coordinate system, make several Y-axis constraint lines parallel to the Y-axis and passing through each coordinate point of the X-axis respectively. The intersection of the Y-axis constraint line and the contour line of the lower wing plate 6 of the segmented component is set as the control point 9; the plumb point on the web 7 corresponding to the control point 9 on the contour line of the lower wing plate 6 is also set as the control point 9; measure the coordinates (x, y) of each control point 9 on the XY plane in CAD.

[0036] 4) In CAD, adjust the segmented component to the main view projection and lift the segmented component by 0.5 meters; make several Z-direction constraint lines parallel to the Z axis and passing through each coordinate point of the X axis in the coordinate system, measure the Z-axis value of each control point 9 on the contour line of the lower wing plate 6, and obtain the three-dimensional coordinates (x, y, z) of each control point 9.

[0037] 5) See Fig. 9 , Fig.10 The welding frame 10 includes a support base fixed to the working platform and corresponding to each control point 9, and the support base is composed of two legs and a support beam. Both the legs and the support beam are made of [18 channel steel. The welding frame 10 is fixed on the construction platform according to the plane coordinates (x, y) of each control point 9 on the XY plane; and the Z-axis coordinate value is used to determine the positioning height of the support beam.

[0038] 6) Review the coordinates of each control point 9 on the welding frame 10.

[0039] See also Figure 8 The welding jig 10 for the left end Y-shaped segment 1 is a Y-shaped jig style (see Figure 7 , Figure 8 , Fig. 9 ); The welding tire frame 10 for the middle double box section 2 will be two straight lines parallel to each other.

[0040] Step 4, after determining the control point 9, hoist the lower wing plate 6 of the segmented component onto the welding frame 10 and fix it by spot welding; after the fixation is completed, assemble the web 7 according to the contour line of the lower wing plate 6, the lower chord of the web 7 passes through the lower wing plate 6 as the construction foundation edge line, and the upper chord is aligned and positioned by means of a plumb bob ground sample control point; after the positioning of the web 7 on one side is completed, the web on the other side is positioned according to the cross-sectional size of the box body with the web as a reference; a U-shaped box body is obtained after all the control points 9 are matched; assemble the inner partition in the U-shaped box body according to the size requirements of the drawing, and after the welding of the inner partition is completed, the upper wing plate 5 is assembled according to the upper edge of the web 7.

[0041] Step 5, assemble the middle support 8 after the box is assembled, a) Left end Y-shaped segment 1 and right end Y-shaped segment 3: first select nodes on the welds between the inner web of the box body where the Y-shaped segment is converted into a double box and the middle support 8, and measure the node coordinates; then assemble and fix each middle support 8 to the boxes on both sides; b) Middle double box segment 2: first locate the nodes of each middle support 8 in the XY plane, first align the two single-mouth boxes horizontally, and assemble and fix the middle support 8 to the inner web 7 of the box body by four-way welding.

[0042] Step 6, use semi-automatic carbon dioxide gas shielded welding to complete the single-turn double-turn single-arch box welding. The single-turn double-turn single-arch box is a multi-angle spatial structure, which cannot be welded by submerged arc automatic welding. Semi-automatic carbon dioxide gas shielded welding can achieve continuous welding, without frequent replacement of welding materials, construction speed, and good weld formation. After multiple flips, multi-layer and multi-pass welding, the single-turn double-turn single-arch box welding is completed.

[0043] The above description is only a preferred feasible embodiment of the present invention, and does not limit the scope of rights of the present invention. All equivalent changes made using the contents of the present specification and its drawings are included in the scope of rights of the present invention.

Claims

1. A method for manufacturing a single-turn double-turn single-arch box-shaped load-bearing beam, characterized in that: The steps are as follows Step 1: In TKELA software, the component is divided into three sections and the positioning lines of the sections are set. The three sections are the left end Y-shaped section, the middle double box section and the right end Y-shaped section. Step 2: Use CAD to split the three sections, and then decompose and unfold the components of each section. The box of each section is divided into five types of parts: upper wing plate, lower wing plate, left web plate, right web plate and middle support. The split parts are cut by CNC flame cutting machine in 1:1 profiling. After cutting, the plate rolling machine is used to cold bend according to the curvature requirements of the drawing. The curved sample is used for inspection and verification during the rolling process. Step 3, designing the welding frame of each segmented component: 1) adjusting the segmented component to a top view in CAD; A rectangular coordinate system is established, wherein the XY plane of the coordinate system is used to determine the horizontal position of the welding frame, the X axis extends along the length direction of the segmented component, and the Y axis extends along the width direction of the component; The Z axis extends along the height direction of the component; 2) The left end of the lower wing plate of the segmented component falls on the Y axis and corresponds to the starting point 0 of the X axis. Starting from the starting point 0, along the X axis direction, a coordinate point is set every 1 meter from the starting point O; 3) In the coordinate system, make several Y-direction constraint lines parallel to the Y axis and passing through each coordinate point of the X axis respectively. The intersection of the Y-direction constraint line and the contour line of the lower wing plate of the segmented component is set as the control point; measure the coordinates (x, y) of each control point on the XY plane in CAD; 4) In CAD, adjust the segmented component to the main view projection and lift the segmented component by 0. 5 meters, make several Z-direction constraint lines parallel to the Z axis and passing through each coordinate point of the X axis in the coordinate system, measure the Z-axis value of each control point on the contour line of the lower wing plate, and obtain the three-dimensional coordinates (x, y, z) of each control point; 5) The welding cradle includes a support seat fixed to the working platform and corresponding to each control point, and the support seat is composed of two legs and a support beam; the welding cradle is fixed on the construction platform according to the plane coordinates (x, y) of each control point on the XY plane; and the positioning height of the support beam is determined by the Z-axis coordinate value; 6) Check the coordinates of each control point on the welding cradle; Step 4: After the control points are determined, the lower wing plate of the segmented component is hoisted onto the welding frame and fixed by spot welding; after the fixation is completed, the web is hoisted and fixed, the lower chord of the web is used as the construction foundation edge line through the lower wing plate, and the upper chord is aligned and positioned by means of plumb bob ground sample control points, and a U-shaped box is obtained after all the control points are matched; the inner partition is assembled in the U-shaped box, and the inner partition also obtains horizontal and vertical positioning points according to the established three-view drawing, and the inner partition is assembled according to the relevant positioning points; finally, the upper wing plate is welded; Step 5, after the box is assembled, assemble the middle support, a) Left end Y-shaped section and right end Y-shaped section: first select nodes on the welds between the inner web of the box body and the middle support where the Y-shaped section is converted into a double box, and measure the node coordinates; then assemble and fix each middle support to the boxes on both sides; b) Middle double box section: first locate the nodes of each middle support in the XY plane, first align the two single-port boxes horizontally, and assemble and fix the middle support to the inner web of the box body by four-way welding; Step 6, use semi-automatic carbon dioxide gas shielded welding to complete the single-turn double-turn single-arch box welding.

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