A processing technology for polygonal steel tower segments

Abstract

The present invention relates to a polygonal steel tower segment processing technology, which is characterized by: the specific manufacturing process is as follows: S1: steel tower segment division; S2: processing of plane plate units; S3: processing of diaphragm units; S4: processing of anchor boxes; S5: assembly of steel tower segments; S6: welding of steel tower segments; in the present invention, the steel tower segments are divided into two symmetrical segment units and an intermediate segment unit, and three segments are used to reduce the welding area and improve welding efficiency; the division into symmetrical structures can reduce the number of component structures to be processed and improve processing efficiency; in addition, the left segment unit and the right segment unit can be installed on the same tire frame, which reduces the production of the tire frame and saves processing time.

Description

Technical Field

[0001] The invention relates to the field of bridge steel tower segment manufacturing, and in particular to a processing technology for polygonal steel tower segments. Background Art

[0002] The bridge's central and side main towers both use a "steel-concrete" combined structure. The tower columns are divided into three sections: the upper tower column, the middle tower column, and the lower tower column. The upper tower column uses a steel structure, while the middle and lower tower columns use concrete structures. Based on the lifting and erection capacity requirements, the steel tower columns are re-segmented to determine the blocks to be hoisted on site. In addition, when the weight and external dimensions of the hoisted blocks exceed the capacity of the workshop crane and the transportation capacity of the beam flat car, they need to be subdivided. The general principle is to maximize the external dimensions of the blocks and reduce the number of blocks according to the various limiting indicators during the production and erection of the steel tower. However, when the structure is divided in the general steel tower segment, it is not conducive to structural welding. The large number of divided structures makes manufacturing difficult, and the different sizes and structures of the parts lead to redundant processing and manufacturing processes. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a polygonal steel tower segment processing technology, which can solve the problems in the processing and manufacturing of general spatial polygonal steel tower segments, such as a large number of segment divisions, redundant processing and manufacturing processes, and each component can only be manufactured individually, resulting in low production efficiency.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: a polygonal steel tower segment processing technology, the innovation of which lies in: the specific manufacturing process is as follows:

[0005] S1: Steel tower segment division: The steel tower segment consists of outer wall plates, web plates, middle web plates, diaphragms and anchor boxes; the steel tower segment is divided into left segment units, middle segment units and right segment units. The left segment units and the right segment units have the same structure and are symmetrically arranged. The middle segment units are welded between the left segment units and the right segment units to form a steel tower segment;

[0006] S2: Processing of flat plate units: The exterior wall, web, and center web plates are all flat plate units, using CNC precision cutting, with machining allowances reserved in length and width for welding shrinkage. After precision cutting, the plates are rushed and leveled, and the butt welds are beveled using a planer. Anti-deformation is pre-set before the welds are joined, weld reinforcement is ground, and post-joint welding deformation is flame trimmed. The longitudinal ribs are precisely marked on the assembly frame. The plate surface is positioned with the final assembly positioning baseline, and holes are punched to prepare for segment assembly positioning.

[0007] S3: Processing of the diaphragm unit: The main plate is precision-cut using a CNC plasma cutting machine; the stiffener and manhole guard are precision-cut using a CNC machine; the ribs are first straightened using a straightening machine and then leveled; the edges of the enclosure are processed and profiled; assembled on the frame using a CO2 semi-automatic welding machine for symmetrical welding and flame finishing; the edges are planed using a planer to ensure the straightness of the plate edges, the verticality of adjacent edges, and the overall dimensions;

[0008] S4: Anchor box processing: CNC precision cutting is performed with machining allowances. The anchor web and its upper ribs are laid out in three dimensions using a computer. A template is made according to the laid-out dimensions for marking and inspection. After cutting, the plates are leveled and the anchor web and its upper ribs are marked with machining lines using the template. The anchor web and its ribs are welded together first. The anchor pipe, its ribs, and inserts are welded together first to ensure the verticality of the anchor pipe. The stiffeners are then welded together from the inside out and flame trimmed. After the center block is trimmed, the anchor web is welded together. The anchor web unit is precisely positioned to control welding deformation. Flame trimming is performed after welding.

[0009] S5: Assembly of steel tower segments:

[0010] S5.1: Assembly of the left and right segment units: Accurately mark the positioning lines for the outer wall plates and transverse diaphragms on the tire frame, and assemble the transverse diaphragms and middle web plates in sequence; assemble the lower web plates, and mark the assembly lines for the diaphragms and anchor boxes on the web plates; then assemble the anchor boxes and corresponding transverse diaphragms on the lower web plates; assemble the upper web plates, and mark the assembly lines for the diaphragms and middle web plates on the web plates, and assemble the transverse diaphragms and middle web plates in sequence; finally, assemble the outer wall plates on both sides and the upper wall plates to form the left segment unit. The right segment unit is assembled in the same manner as the left segment unit.

[0011] S5.2: Assembly of the intermediate segment unit: Accurately mark the positioning lines for the outer wall panels and diaphragms on the tire frame, and assemble the diaphragm and middle web panels in sequence; assemble the lower web panels, and mark the diaphragm and anchor box assembly lines on the web panels; then assemble the anchor box and corresponding diaphragms on the lower web panels; assemble the upper web panels, and mark the diaphragm and middle web assembly lines on the web panels; assemble the diaphragms and middle web panels in sequence, and finally assemble the outer wall panels on both sides to form the intermediate segment unit;

[0012] S6: Welding of steel tower segments: The welding of the middle segment unit, the left segment unit and the right segment unit follows the principle of welding inside first and outside later, bottom first and top later, and symmetrically from the center to both sides, and adopts CO2 welding method; when welding, process partitions are used at the segment ports to ensure the external dimensions and matching accuracy of the adjacent segment interfaces.

[0013] Furthermore, the welding of the steel tower segment in S6 must be carried out when the welding environment temperature is above 5°C and the relative humidity is below 80%; if the plate thickness is greater than 24mm, it should be preheated to 80-120°C within the range of 50-80mm of the seam.

[0014] The advantages of the present invention are:

[0015] 1) In the present invention, the steel tower segment is divided into two symmetrical segment units and an intermediate segment unit, and three segments are used to reduce the welding area and improve welding efficiency. The symmetrical structure can reduce the number of processed component structures and improve processing efficiency. In addition, the left segment unit and the right segment unit can be installed on the same tire frame, which reduces the production of the tire frame and saves processing time. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0017] Figure 1 The present invention is a flowchart of a polygonal steel tower segment processing process.

[0018] Figures 2 to 8 This is a forming state diagram of the left segment unit of a polygonal steel tower segment processing technology of the present invention.

[0019] Figures 9 to 14 This is a forming state diagram of the middle segment unit of a polygonal steel tower segment processing technology of the present invention.

[0020] Figure 15 The figure is a schematic diagram of the overall structure of a steel tower segment according to a processing technology for polygonal steel tower segments of the present invention. Implementation Method

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0022] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0023] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0024] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" and the like indicate positions or locations based on the positions shown in the accompanying drawings, or the positions or locations in which the inventive product is typically placed when in use. These terms are intended solely to facilitate the description of the present invention and to simplify the description, and are not intended to indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third," etc., are used solely to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0025] Furthermore, terms such as "horizontal" and "vertical" do not necessarily mean that a component must be absolutely horizontal or overhanging, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0026] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0027] like Figures 1 to 15 The processing technology of a polygonal steel tower segment is shown in the figure. The specific manufacturing process is as follows:

[0028] S1: Steel tower segment division: The steel tower segment consists of outer wall plates, web plates, middle web plates, transverse diaphragms and anchor boxes; the steel tower segment is divided into left segment unit, middle segment unit and right segment unit, and the left segment unit and the right segment unit have the same structure and are symmetrically arranged. The middle segment unit is welded between the left segment unit and the right segment unit to form a steel tower segment.

[0029] S2: Processing of flat plate units: The outer wall plates, web plates and middle web plates are all flat plate units, which are cut by CNC precision cutting, and the length and width directions are reserved for welding shrinkage machine processing allowances; after precision cutting, the plates are rushed and leveled, and the butt joint weld grooves are planed by a planer. Before the splicing welds, the anti-deformation is preset, the weld excess height is scraped and ground, and the welding deformation after the splicing is flame trimmed; the longitudinal ribs are accurately marked on the assembly frame; the plate surface is placed with the assembly positioning baseline, and the proofing is punched to prepare for the segment assembly positioning.

[0030] S3: Processing of diaphragm units: the main board is precision-cut by a CNC plasma cutting machine; the stiffening plate and manhole guard are precision-cut by a CNC; the ribs are first straightened by a straightening machine and then leveled; the edges of the enclosure are processed and profiled; they are assembled on the frame using a CO2 semi-automatic welding machine for symmetrical welding and flame finishing; the perimeter is planed with a planer to ensure the straightness of the plate edges, the verticality of adjacent edges and the overall dimensions.

[0031] S4: Processing of anchor box: CNC precision cutting with machining allowance, three-dimensional lofting of anchor web and upper ribs by computer, and production of templates according to the lofting dimensions for marking and inspection; after cutting, the plates are leveled, and machining lines are marked on the anchor web and upper ribs using templates; the anchor web and its ribs are welded first, and the anchor pipe, its ribs and inserts are welded first during subsequent welding to ensure the verticality of the anchor pipe, and then the stiffeners are welded from the inside out and flame trimmed; after the center block is trimmed, the anchor web is welded, the anchor web unit is accurately positioned, welding deformation is controlled, and flame trimming is performed after welding.

[0032] S5: Assembly of steel tower segments:

[0033] S5.1: Assembly of the left and right segment units: Accurately mark the positioning lines for the outer wall plates and transverse diaphragms on the tire frame, and assemble the transverse diaphragms and middle web plates in sequence; assemble the lower web plates, and mark the assembly lines for the diaphragms and anchor boxes on the web plates; then assemble the anchor boxes and corresponding transverse diaphragms on the lower web plates; assemble the upper web plates, and mark the assembly lines for the diaphragms and middle web plates on the web plates, and assemble the transverse diaphragms and middle web plates in sequence; finally, assemble the outer wall plates on both sides and the upper wall plates to form the left segment unit. The right segment unit is assembled in the same manner as the left segment unit.

[0034] S5.2: Assembly of the intermediate segment unit: Accurately mark the positioning lines for the outer wall panels and diaphragms on the tire frame, and assemble the diaphragm and middle web panels in sequence; assemble the lower web panels, and mark the diaphragm and anchor box assembly lines on the web panels; then assemble the anchor box and corresponding diaphragms on the lower web panels; assemble the upper web panels, and mark the diaphragm and middle web assembly lines on the web panels; assemble the diaphragms and middle web panels in sequence, and finally assemble the outer wall panels on both sides to form the intermediate segment unit;

[0035] S6: Welding of steel tower segments: The welding of the middle segment unit, the left segment unit and the right segment unit follows the principle of welding inside first and outside later, bottom first and top later, and symmetrically from the center to both sides, and adopts CO2 welding method; when welding, process partitions are used at the segment ports to ensure the external dimensions and matching accuracy of the adjacent segment interfaces.

[0036] The welding of S6 steel tower segments must be carried out when the welding environment temperature is above 5°C and the relative humidity is below 80%. If the plate thickness is greater than 24mm, it should be preheated to 80-120°C within the range of 50-80mm of the seam.

[0037] Those skilled in the art will appreciate that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A polygonal steel tower segment processing process, characterized by: The specific manufacturing process is as follows: S1: Steel tower segment division: The steel tower segment consists of outer wall plates, web plates, middle web plates, diaphragms and anchor boxes; the steel tower segment is divided into left segment units, middle segment units and right segment units. The left segment units and the right segment units have the same structure and are symmetrically arranged. The middle segment units are welded between the left segment units and the right segment units to form a steel tower segment; S2: Processing of flat plate units: The exterior wall, web, and center web plates are all flat plate units, using CNC precision cutting. Welding shrinkage and machining allowances are reserved in the length and width directions. After precision cutting, the plates are rushed and leveled. A planer is used to bevel the butt welds. Pre-deformation is preset before the welds are joined, and the weld reinforcement is ground. Post-joint welding deformation is flame trimmed. The longitudinal ribs are precisely marked on the assembly frame. The assembly positioning baseline is set on the plate surface, and holes are punched to prepare for segment assembly and positioning. S3: Processing of the diaphragm unit: The main plate is precision-cut using a CNC plasma cutting machine; the stiffener and manhole guard are precision-cut using a CNC machine; the ribs are first straightened using a straightening machine and then leveled; the edges of the enclosure are processed and profiled; assembled on the frame using a CO2 semi-automatic welding machine for symmetrical welding and flame finishing; the edges are planed using a planer to ensure the straightness of the plate edges, the verticality of adjacent edges, and the overall dimensions; S4: Anchor box processing: CNC precision cutting is performed with machining allowances. The anchor web and its upper ribs are laid out in three dimensions using a computer. A template is made according to the laid-out dimensions for marking and inspection. After cutting, the plates are leveled and the anchor web and its upper ribs are marked with machining lines using the template. The anchor web and its ribs are welded together first. The anchor pipe, its ribs, and inserts are welded together first to ensure the verticality of the anchor pipe. The stiffeners are then welded together from the inside out and flame trimmed. After the center block is trimmed, the anchor web is welded together. The anchor web unit is precisely positioned to control welding deformation. Flame trimming is performed after welding. S5: Assembly of steel tower segments: S5.1: Assembly of the left and right segment units: Accurately mark the positioning lines for the outer wall plates and transverse diaphragms on the tire frame, and assemble the transverse diaphragms and middle web plates in sequence; assemble the lower web plates and mark the assembly lines for the diaphragms and anchor boxes on the web plates; then assemble the anchor boxes and corresponding transverse diaphragms on the lower web plates; assemble the upper web plates and mark the assembly lines for the diaphragms and middle web plates on the web plates, and then assemble the transverse diaphragms and middle web plates in sequence; finally, assemble the outer wall plates on both sides and the upper wall plates to form the left segment unit. The right segment unit is assembled in the same manner as the left segment unit. S5.2: Assembly of the intermediate segment unit: Accurately mark the positioning lines for the outer wall panels and diaphragms on the tire frame, and assemble the diaphragm and middle web panels in sequence; assemble the lower web panels and mark the diaphragm and anchor box assembly lines on the web panels; then assemble the anchor box and corresponding diaphragms on the lower web panels; assemble the upper web panels and mark the diaphragm and middle web assembly lines on the web panels; assemble the diaphragms and middle web panels in sequence, and finally assemble the outer wall panels on both sides to form the intermediate segment unit; S6: Welding of steel tower segments: The welding of the middle segment unit, the left segment unit and the right segment unit follows the principle of welding inside first and outside later, bottom first and top later, and symmetrically from the center to both sides, and adopts CO2 welding method; when welding, process partitions are used at the segment ports to ensure the external dimensions and matching accuracy of the adjacent segment interfaces.

2. A polygonal steel tower segment processing process according to claim 1, characterized in that: The welding of the steel tower segments in S6 must be carried out when the welding environment temperature is above 5°C and the relative humidity is below 80%. If the plate thickness is greater than 24mm, it should be preheated to 80-120°C within the range of 50-80mm of the seam.

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