Method of manufacturing complex small size monobloc anchor boxes

Abstract

The present application relates to a kind of complex small size single anchor box manufacturing method of step-by-step unit production and layer-by-layer advancing assembly, each part of single anchor box is composed of medium plate, wherein the stiffening thickness is 24mm, the anchor web thickness is 40mm, and the internal structure is mostly fusion welding seam and partial fusion welding seam.To ensure the assembly precision and welding quality of such anchor box, the system develops step-by-step production and layer-by-layer advancing assembly method, solves the problems of anchor box structure complexity, compact structure, small operation space, dense welding seam, high geometric dimension precision requirement and large assembly and welding difficulty in existing technology, not only realizes the welding between each part of anchor box, but also effectively guarantees the assembly quality and precision of anchor box, simultaneously realizes the welding operation of dense welding seam in compact space, and the welding quality is also guaranteed.

Description

Technical Field

[0001] This invention relates to a method for manufacturing complex small-sized single anchor boxes using step-by-step unit fabrication and layer-by-layer assembly, belonging to the field of single anchor box manufacturing for steel towers. Background Technology

[0002] The anchor box structure consists of an anchor plate, a bearing plate, an anchor web, an anchor pipe, and stiffeners. All components are made of medium-thick plates, with stiffeners measuring 24mm in thickness and the anchor web 40mm in thickness. Two layers of stiffeners are arranged around the anchor pipe, with a net dimension of approximately 80mm between stiffeners and a stiffening depth of up to 1000mm. The stiffeners are welded to adjacent components using full penetration or partial penetration welding. Due to the complex structure, compact construction, limited operating space, dense welds, and high dimensional accuracy requirements of the anchor box, assembly and welding are challenging. Furthermore, the structural dimensions of the anchor box are significantly affected by welding heat input and deformation, making manufacturing extremely difficult. Summary of the Invention

[0003] Design objective: To overcome the shortcomings of the prior art, and to design a method for manufacturing complex small-sized single anchor boxes that can achieve welding operations of parts within an ultra-compact structure, effectively ensure welding quality and assembly accuracy, and simultaneously adopt step-by-step unit fabrication and layer-by-layer assembly.

[0004] Design scheme: The anchor box consists of an anchor plate, a bearing plate, an anchor pipe, an anchor web, inner stiffeners on the anchor web, and outer stiffeners on the anchor web. The anchor box structure is as follows: Figure 1 As shown. The components of the anchor box are all medium-thick plates, with the anchor web plate being 40mm thick, and the inner and outer stiffeners of the anchor web plate being 24mm and 28mm respectively.

[0005] The anchor box's single-unit structure has many internal parts and insufficient space. A double-layer design with stiffeners around the inner side of the anchor pipe's web plate is used. These stiffeners are very close to the anchor pipe and are both fully penetrated welded to it. The minimum distance between the stiffeners around the anchor pipe is only 80mm, resulting in excessively narrow welding space and high welding difficulty. Furthermore, the connection between the anchor pipe and the bearing plate is a bevel weld. Specific dimensions are as follows... Figure 2 As shown (all dimensions in the figure are in mm).

[0006] This invention is aimed at Figure 1 , Figure 2 This study focuses on the fabrication of complex, small-sized single anchor boxes, employing a step-by-step fabrication and layer-by-layer assembly method to achieve welding operations in extremely confined spaces. The specific methods are described below: 1. Anchor Box Sub-Unit Fabrication Design: Due to the limited internal space of the anchor box, some parts are selected for priority fabrication as unit bodies during anchor box fabrication. The assembly and welding of the various parts inside the anchor box are completed in stages by disassembling the components. Because the anchor pipe and the bearing plate of the anchor box use bevel welds, and the anchor pipe and the inner reinforcement of the four surrounding anchor web plates are through-welded, the bearing plate, anchor pipe, and inner reinforcement of the anchor web plates are designated as the bearing anchor pipe reinforcement unit body. Figure 3 Fabrication. To reduce the workload of assembling the anchor box into segments and minimize welding deformation, the anchor web and part of its outer side are stiffened as anchor web stiffening unit units. Figure 4 (to assemble and manufacture.)

[0007] 2. Anchor Box Internal Stiffening Bevel Design: Due to the limited space between internal components and an effective anchor web depth of only 1m, stiffening welds are incorporated into the anchor box assembly process to ensure welding quality and sufficient welding space. Stiffening is applied around the anchor pipe and the inner side of the anchor web welded to it. The bevel orientation varies depending on the installation location. Figure 5 As shown. (A double-layer design is formed around the anchor pipe, stiffeners, and anchor webs on both sides. To meet the installation and welding operations of each layer of stiffeners and anchor webs, the bevel direction of the stiffener bevel is outward relative to the anchor pipe.)

[0008] 3. Anchor Box Assembly Sequence Design: Based on the structural characteristics of the anchor box, the anchor box is fabricated using a progressive assembly method from the inside out. Assembly begins with the stiffeners connected to the anchor pipe, followed by the first layer of stiffeners surrounding the anchor pipe, and finally the second layer of stiffeners surrounding the anchor pipe. (See attached diagram.) Figure 6 .

[0009] Compared with the prior art, the present invention has two advantages: First, it solves the problem of difficult assembly and welding of multiple stiffening processes in ultra-small spaces by using a process of modular manufacturing and layer-by-layer assembly, which effectively ensures welding quality and makes the anchor box assembly accuracy meet the design requirements; Second, it improves production efficiency. Attached Figure Description

[0010] Figure 1 These are side view, front view, and three-dimensional schematic diagrams of the anchor box structure.

[0011] Figure 2 This is a schematic diagram showing the relationship between the internal space of the anchor box and the welding.

[0012] Figure 3 Schematic diagram of a pressure-bearing anchor pipe stiffening unit.

[0013] Figure 4 This is a schematic diagram of the anchor web stiffener unit.

[0014] Figure 5 This is a schematic diagram of the stiffening bevel inside the anchor box.

[0015] Figure 6is a schematic diagram of the anchor box assembly sequence.

[0016] Figure 7 is a schematic diagram of overall manufacturing (1) of the anchor box.

[0017] Figure 8 is a schematic diagram of overall manufacturing (2) of the anchor box.

[0018] Figure 9 is a schematic diagram of overall manufacturing (3) of the anchor box.

[0019] Figure 10 is a schematic diagram of overall manufacturing (4) of the anchor box.

[0020] Figure 11 is a schematic diagram of overall manufacturing (5) of the anchor box.

[0021] Figure 12 is a schematic diagram of overall manufacturing (6) of the anchor box. DETAILED DESCRIPTION

[0022] Example 1: Referring to the accompanying Figure 1-6 . A complex small-size single anchor box, composed of anchor plate 1, bearing plate 2, anchor pipe 3, anchor web 4, inner stiffeners 5 of the anchor web, and outer stiffeners 6 of the anchor web; the anchor plate 1 is connected to one end of the anchor pipe 3, the hole center of the anchor pipe 3 is aligned with the hole center of the anchor hole of the bearing plate 2 for welding connection, the inner stiffeners 5 of the anchor web are located around the anchor pipe 3, and part of the outer stiffeners 6 of the anchor web are welded with the anchor web 4 into a whole. The flatness of the plate surface of the bearing plate 2 shall be controlled within 1 mm / m (according to the relevant specification requirements for steel structures, the plate surface flatness of general components needs to be controlled within this range to be qualified). The flatness of the plate surface of the anchor web 4 is controlled within 1 mm / m (according to the relevant specification requirements for steel structures, the plate surface flatness of general components needs to be controlled within this range to be qualified).

[0023] The anchor web is only a component inside the anchor box, that is 4 in the figure, and there is only one plate.

[0024] Example 2: On the basis of Example 1, a manufacturing method for a complex small-size single anchor box, Manufacturing method for anchor box unit: (1) Manufacturing of the assembly of anchor pipe 3 and bearing plate 2: the assembly of anchor pipe 3 and bearing plate 2 is composed of anchor pipe 3, bearing plate 2 and the inner stiffeners 5 of the anchor web welded around the anchor pipe.

[0025] (2) Mark the cutting position line on the anchor pipe 3 according to the design size, and perform cutting blanking by sawing; (3) Process a circumferential groove on the welding side of the anchor pipe 2 and the bearing plate 2 by a pipe cutting machine; (4) The bearing plate 2 and the inner stiffeners 5 of the anchor web are cut and blanked by numerical control, and the anchor hole of the bearing plate 2 is cut out together; (5) The flatness of the bearing plate 2 must be controlled within 1mm / m. The longitudinal and transverse baselines of the bearing plate are drawn with the center of the anchor hole as the reference. (6) The reinforcement 5 around the anchor pipe 3 is processed according to the bevel direction and bevel size given in the scheme; (7) Lay the pressure plate 2 flat on the assembly platform, align the center of the anchor pipe 3 with the center of the anchor hole of the pressure plate 2, control the perpendicularity of the anchor pipe 3 and the pressure plate 2, and position and assemble the anchor pipe 3 and the pressure plate 2. (8) Position and assemble the stiffeners 5 around the anchor pipe 3 with the longitudinal and transverse reference lines on the pressure plate 2 as references, and focus on controlling the perpendicularity of the stiffeners 5 to the pressure plate 2.

[0026] 2) Fabrication of the anchor web 4 and the outer stiffener 6 of part of the anchor web: The anchor web 4 and the outer stiffener 6 of part of the anchor web are first assembled into a whole and used in the fabrication of the anchor box. This helps to eliminate some welding deformation, reduce the amount of work during the fabrication of the anchor box, and improve efficiency.

[0027] (1) The anchor web 4 and the outer stiffener 6 of the anchor web are respectively cut by CNC precision cutting, and the flatness of the plate surface is controlled within 1mm / m. (2) Draw longitudinal and transverse baselines on the anchor web 4, and draw the assembly position lines of the outer stiffener 6 based on them; (3) Assemble the outer stiffener-6 of the anchor web according to the line positioning, and focus on controlling the stiffener spacing and the perpendicularity of the stiffener to the anchor web-4.

[0028] 3) Overall fabrication of anchor boxes: When fabricating anchor boxes as a whole, a manufacturing process combining unit fabrication and layer-by-layer assembly is adopted. The internal parts of the anchor box are assembled and welded in stages to achieve overall fabrication of the anchor box, so that the quality of the welds and the overall precision are effectively controlled and guaranteed.

[0029] (1) Place the anchor pipe 3 and the bearing plate 2 assembly on the special assembly platform, with the anchor pipe facing upwards. Figure 7 ; (2) Using the longitudinal baseline of bearing plate-2 as a reference, draw the assembly position line of the anchor web assembly, and assemble the anchor web assembly according to the line. See Figure 8 ; (3) Using the longitudinal and transverse baselines of the bearing plate-2 as a reference, mark the assembly position lines for the first layer of stiffening, position and assemble the first layer of stiffening for flat welding, focusing on controlling the perpendicularity of the stiffening to the bearing plate-2 and controlling welding deformation, see Figure 9 .

[0030] (4) Align the center line of the stiffening plate and the inner stiffening position line of the anchor web plate, assemble the short stiffening between the inner stiffening and the anchor web plate, focusing on controlling the alignment of the center lines of the stiffening plates on both sides and the perpendicularity of the stiffening to the bearing plate, see Figure 10 .

[0031] (5) Position and assemble the outermost stiffener according to the assembly position lines on the bearing plate and the anchor web, focusing on controlling the alignment of the center line of the stiffener plate thickness and the perpendicularity of the stiffener to the bearing plate and the anchor web. See Figure 11 .

[0032] (6) Assemble the stiffening plate according to the stiffening assembly position line on the outer side of the anchor web, see Figure 12 .

[0033] (7) Process the bearing plate surface as a whole, assemble the anchor plate, and process the anchor holes as a whole.

[0034] It should be understood that although the above embodiments provide a relatively detailed textual description of the design concept of the present invention, these textual descriptions are merely simple textual descriptions of the design concept of the present invention, and not limitations on the design concept of the present invention. Any combination, addition, or modification that does not exceed the design concept of the present invention falls within the protection scope of the present invention.

Claims

1. A method for manufacturing complex, small-sized single anchor boxes, characterized by: The complex small-sized single anchor box is composed of an anchor plate (1), a pressure plate (2), an anchor pipe (3), an anchor web (4), an inner stiffener (5) on the anchor web, and an outer stiffener (6) on the anchor web. The anchor plate (1) is connected to one end of the anchor pipe (3), and the center of the hole of the anchor pipe (3) is aligned with the center of the anchor hole of the pressure plate (2) and welded together. The inner stiffener (5) on the anchor web is located around the anchor pipe (3), and part of the outer stiffener (6) on the anchor web is welded to the anchor web (4) to form a whole. Its complex small-sized single anchor box manufacturing method: 1) Place the anchor pipe (3) and the bearing plate (2) assembly on a special assembly platform with the anchor pipe facing upwards; 2) Draw the assembly position line of the anchor web assembly based on the longitudinal baseline of the bearing plate (2), and assemble the anchor web assembly according to the line; 3) Using the longitudinal and transverse baselines of the bearing plate (2) as a reference, draw the first layer stiffening assembly position line, position and assemble the first layer stiffening and weld it, control the perpendicularity of the stiffening to the bearing plate (2), control the welding deformation to be less than 1mm / m, and control the flatness of the anchor web plate after welding to be within 1mm / m. 4) Align the center line of the stiffening plate and the inner stiffening position line of the anchor web plate, assemble the short stiffening between the inner stiffening and the anchor web plate, and control the alignment of the center lines of the stiffening plates on both sides and the perpendicularity of the stiffening to the bearing plate. 5) Align the assembly position lines on the bearing plate and the anchor web with the assembly position lines, position and assemble the outermost stiffener, and control the alignment of the center line of the stiffener plate thickness and the perpendicularity of the stiffener to the bearing plate and the anchor web. 6) Assemble the stiffening plate according to the stiffening assembly position line on the outer side of the anchor web; 7) Process the bearing plate surface as a whole, assemble the anchor plate, and process the anchor holes as a whole.

2. The method of claim 1, wherein: The flatness of the bearing plate (2) must be controlled within 1mm / m.

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