A method for manufacturing a large-section thin-wall special-shaped steel shell tower segment

Abstract

The application discloses a manufacturing method of a large-section thin-wall special-shaped steel shell tower segment, which comprises the following steps: first, dividing the segment into several blocks, then manufacturing block components, setting a horizontal base line, a vertical base line and block assembly position lines on an assembly platform, and fixing supporting columns and inclined positioning supports; positioning and fixing outer wall plate units of an inclined straight wall block through the positioning supports; hoisting and fixing outer wall plate units of the remaining straight wall blocks and adjusting the perpendicularity of the outer wall plate units through the supporting columns; hoisting and fixing inner wall plate units corresponding to all the outer wall plate units and adjusting and fixing the inner wall plate units through adjusting struts, and then welding connecting angle steels between the inner wall plate units and the outer wall plate units; hoisting and fixing outer wall plate units and inner wall plate units of the remaining vertical curved wall blocks in sequence through the same method, and welding connecting angle steels between the inner wall plate units and the outer wall plate units; finally, welding blocks to form the segment. The steel shell tower segment is divided into blocks which are easy to assemble, the manufacturing process is simplified, and the production efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the field of bridge steel shell tower manufacturing technology, specifically relating to a method for manufacturing large-section thin-walled irregular steel shell tower segments. Background Technology

[0002] With the development of bridge construction technology at home and abroad, large bridge towers have evolved from the initial concrete structures to steel structures. In recent years, thin-walled steel shell composite structure towers have become a development trend. Thin-walled steel shell composite structure towers give full play to the advantages of steel and concrete, and have the characteristics of high construction efficiency and low construction cost. Summary of the Invention

[0003] To address the aforementioned problems in the existing technology, this invention provides a method for manufacturing large-section, thin-walled, irregularly shaped steel shell tower segments. The technical problem to be solved by this invention is achieved through the following technical solution:

[0004] A method for manufacturing a large-section, thin-walled, irregularly shaped steel shell tower segment includes the following steps:

[0005] Step 1: Vertically divide the segment into one inclined straight-wall block, two first vertical curved-wall blocks, at least two vertical straight-wall blocks, two second vertical curved-wall blocks, and one third vertical curved-wall block;

[0006] Step 2: Fabricate a first straight inner wall panel unit and a first straight outer wall panel unit for forming the inclined straight wall block; fabricate a first curved inner wall panel unit and a first curved outer wall panel unit for forming the first vertical curved wall block; fabricate a second straight inner wall panel unit and a second straight outer wall panel unit for forming the vertical straight wall block; fabricate a second curved inner wall panel unit and a second curved outer wall panel unit for forming the second vertical curved wall block; fabricate a third curved inner wall panel unit and a third curved outer wall panel unit for forming the third vertical curved wall block;

[0007] Step 3: Draw horizontal and vertical baselines on the assembly platform, and then use the horizontal and vertical baselines as references to draw the assembly position lines of the inclined straight wall block, the two first vertical curved wall blocks, at least two vertical straight wall blocks, two second vertical curved wall blocks and one third vertical curved wall block on the assembly platform;

[0008] Step 4: Fix several support columns and several inclined positioning brackets on the assembly platform. The support columns are arranged along the inner side of the assembly position line, and the support columns are horizontally equipped with adjusting struts. The inclined positioning brackets are arranged along the outer side of the assembly position line and are located outside the assembly position of the inclined straight wall block.

[0009] Step 5: First, hoist the first straight wall outer wall panel unit to the inside of the inclined positioning bracket, and position it with the assembly position line corresponding to the inclined straight wall block as the reference. Then, lean it against the inclined surface inside the inclined positioning bracket. Then, make precise adjustments so that the deviation between the lower end of the first straight wall outer wall panel unit and the assembly position line is ≤2mm. Then, temporarily fix it to the inclined positioning bracket with the positioning plate.

[0010] Step 6: Hoist the two second straight wall outer wall panel units to the outside of the support column respectively, and position them with the assembly position line corresponding to the vertical straight wall block as the reference. Then, adjust the verticality with the adjusting strut and temporarily weld them to the assembly platform.

[0011] Step 7: Hoist the first straight inner wall panel unit to the inside of the first straight outer wall panel unit and the outside of the supporting column. After positioning it with the assembly position line corresponding to the inclined straight wall block as a reference, adjust the inclination angle with the adjusting strut. Then weld the connecting angle steel between the first straight inner wall panel unit and the first straight outer wall panel unit from bottom to top to form the inclined straight wall block. Continue to hoist the two second straight inner wall panel units to the inside of the two second straight outer wall panel units and the outside of the supporting column. After positioning them with the assembly position line corresponding to the vertical straight wall block as a reference, adjust the support with the adjusting strut. Then weld the connecting angle steel between the second straight inner wall panel unit and the second straight outer wall panel unit from bottom to top to form two vertical straight wall blocks.

[0012] Step 8: Following the method described in Step 6, hoist the two first curved wall outer wall panel units, the two second curved wall outer wall panel units, and the one third curved wall outer wall panel unit into place in sequence;

[0013] Step 9: After hoisting the two first curved wall inner wall panel units, the two second curved wall inner wall panel units, and the one third curved wall inner wall panel unit into place in sequence according to the method described in Step 7, weld the connecting angle steel between the inner wall panel unit and the outer wall panel unit from bottom to top to form two first vertical curved wall blocks, two second vertical curved wall blocks, and one third vertical curved wall block respectively.

[0014] Step 10: After all blocks have passed inspection, weld the butt joints between the blocks to form the segment.

[0015] Furthermore, vertical base points are provided on the outer and inner contour lines of the assembly position lines of all blocks, and vertical baselines are drawn on the outer walls of all plate units, with the lower end of the vertical baselines aligned with the vertical base points.

[0016] Furthermore, the adjusting strut is telescopically adjustable.

[0017] Furthermore, the inclined positioning bracket has a triangular structure, and its inner inclined surface has the same inclination as the inclined straight wall block.

[0018] Furthermore, the vertical base point is located at the midpoint between the outer and inner contour lines of the assembly position lines of all blocks, and the vertical baseline is located at the midpoint of the outer wall of all plate units.

[0019] Furthermore, in steps 8 and 9, when the deviation between the curved wall panel unit and its corresponding assembly position line is large, a thermal straightening process is used for adjustment to ensure that the deviation between the curved wall panel unit and its respective assembly position line is ≤2mm.

[0020] The beneficial effects of this invention are:

[0021] 1. By dividing the large-section thin-walled irregular steel shell tower segments into easily assembled blocks, the manufacturing process is simplified and production efficiency is improved;

[0022] 2. By optimizing the assembly sequence of plate units, the assembly quality of the blocks is ensured, and the manufacturing precision and quality of steel shell tower segments are improved, thereby solving the problem of controlling the manufacturing precision of large-section thin-walled irregular steel shell towers;

[0023] 3. This method is simple to operate, highly practical, and has proven effective in practice.

[0024] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the steel shell tower segment of the present invention;

[0026] Figure 2 This is a structural schematic diagram of the steel shell tower segment assembly platform;

[0027] Figures 3-6 This is a schematic diagram of the manufacturing process of an irregularly shaped steel shell tower segment.

[0028] Explanation of reference numerals in the attached figures:

[0029] 1- Inclined straight wall block; 2- First vertical curved wall block; 3- Vertical straight wall block; 4- Second vertical curved wall block; 5- Third vertical curved wall block; 6- Assembly platform; 7- Support column; 8- Inclined positioning bracket; 9- Vertical baseline; 1-1- First straight wall inner wall panel unit; 1-2- First straight wall outer wall panel unit; 2-1- First curved wall inner wall panel unit; 2-2- First curved wall outer wall panel unit; 3-1- Second straight wall inner wall panel unit; 3-2- Second straight wall outer wall panel unit; 4-1- Second curved wall inner wall panel unit; 4-2- Second curved wall outer wall panel unit; 5-1- Third curved wall inner wall panel unit; 5-2- Third curved wall outer wall panel unit; 6-1- Horizontal baseline; 6-2- Longitudinal baseline; 6-3- Assembly position line; 6-4- Vertical base point; 7-1- Adjusting strut. Detailed Implementation

[0030] The present invention will be further described in detail below with reference to specific embodiments, but the implementation of the present invention is not limited thereto.

[0031] Please see Figures 1-6 This invention provides a method for manufacturing a large-section, thin-walled, irregularly shaped steel shell tower segment. The outer wall plate of the irregularly shaped steel shell tower segment has a thickness of 16–40 mm, an inner wall plate thickness of 8–10 mm, and a cross-sectional dimension of 10 m × 10 m. The method specifically includes the following steps:

[0032] Step 1: Vertically divide the steel shell tower segment into one inclined straight-wall block 1, two first vertical curved-wall blocks 2, two vertical straight-wall blocks 3, two second vertical curved-wall blocks 4, and one third vertical curved-wall block 5;

[0033] Step 2: Fabricate the first straight inner wall panel unit 1-1 and the first straight outer wall panel unit 1-2 for forming the inclined straight wall block 1; fabricate the first curved inner wall panel unit 2-1 and the first curved outer wall panel unit 2-2 for forming the first vertical curved wall block 2; fabricate the second straight inner wall panel unit 3-1 and the second straight outer wall panel unit 3-2 for forming the vertical straight wall block 3; fabricate the second curved inner wall panel unit 4-1 and the second curved outer wall panel unit 4-2 for forming the second vertical curved wall block 4; fabricate the third curved inner wall panel unit 5-1 and the third curved outer wall panel unit 5-2 for forming the third vertical curved wall block 5;

[0034] Step 3: Draw horizontal baseline 6-1 and vertical baseline 6-2 on the assembly platform 6, and then draw the assembly position lines 6-3 of the inclined straight wall block 1, two first vertical curved wall blocks 2, at least two vertical straight wall blocks 3, two second vertical curved wall blocks 4 and one third vertical curved wall block 5 on the assembly platform 6 using the horizontal baseline 6-1 and vertical baseline 6-2 as references.

[0035] Step 4: Fix several support columns 7 and several inclined positioning brackets 8 on the assembly platform 6. The support columns 7 are arranged along the inner side of the assembly position line 6-3, and an adjusting strut 7-1 is horizontally arranged on the support columns 7. The adjusting strut 7-1 is telescopic and adjustable, and the angle of the inner wall panel unit and the outer wall panel unit can be adjusted simultaneously. The telescopic structure of the adjusting strut 7-1 is a common structure, and will not be described in detail here. The inclined positioning brackets 8 are arranged along the outer side of the assembly position line 6-3 and are located outside the assembly position of the inclined straight wall block 1.

[0036] The installation height of the adjusting strut 7-1 is 1 / 3 of the height of the supporting column 7, ensuring that the angles of the inner wall panel unit and the outer wall panel unit can be precisely adjusted and stably supported.

[0037] The inclined positioning bracket has a triangular structure, and its inner inclined surface has the same inclination as the inclined straight wall block 1, thereby ensuring the installation accuracy of the inclined straight wall block 1.

[0038] Step 5: First, hoist the first straight wall outer wall panel unit 1-2 to the inside of the inclined positioning bracket 8, and position it with the assembly position line corresponding to the inclined straight wall block 1 as a reference. Then, lean it against the inclined surface inside the inclined positioning bracket 8. Then, make precise adjustments so that the deviation between the lower end of the first straight wall outer wall panel unit 1-2 and the assembly position line is ≤2mm. Then check the gap between the first straight wall outer wall panel unit 1-2 and the inclined positioning bracket 8. When the gap is ≤2mm, temporarily fix the first straight wall outer wall panel unit 1-2 to the inclined positioning bracket 8 through the positioning plate.

[0039] Step 6: Hoist the two second straight wall outer wall panel units 3-2 to the outside of the support column 7 respectively, and position them with the assembly position line corresponding to the vertical straight wall block 3 as the reference. Then, adjust the verticality with the adjusting support rod 7-1 and temporarily weld them to the assembly platform 6. Temporarily connect the two adjacent second straight wall outer wall panel units 3-2 with a board. Support the panel unit with a steel wire rope, one end of which is fixed to a hook on the chain hoist and the other end is fixed to the second straight wall outer wall panel unit 3-2.

[0040] Step 7: Hoist the first straight inner wall panel unit 1-1 to the inside of the first straight outer wall panel unit 1-2 and the outside of the support column 7. After positioning it with the assembly position line corresponding to the inclined straight wall block 1 as a reference, adjust the tilt angle with the adjusting support rod 7-1, then fix the adjusting support rod 7-1 to the first straight inner wall panel unit 1-1, and spot weld the first straight inner wall panel unit 1-1 to the assembly platform. Then weld the connecting angle steel between the first straight inner wall panel unit 1-1 and the first straight outer wall panel unit 1-2 from bottom to top to form the inclined straight wall block 1.

[0041] Continue to hoist the two second straight wall inner wall panel units 3-1 to the inner side of the two second straight wall outer wall panel units 3-2 and the outer side of the support column 7, and position them with the assembly position line corresponding to the vertical straight wall block 3 as a reference. Then, adjust the verticality with the adjusting support rod 7-1, fix the adjusting support rod 7-1 to the second straight wall inner wall panel unit 3-1, and spot weld the second straight wall inner wall panel unit 3-1 to the assembly platform. Then, weld the connecting angle steel between the second straight wall inner wall panel unit 3-1 and the second straight wall outer wall panel unit 3-2 from bottom to top to form two vertical straight wall blocks 3 respectively.

[0042] Step 8: Following the method described in Step 6, hoist the two first curved wall outer wall panel units 2-2, the two second curved wall outer wall panel units 4-2, and the third curved wall outer wall panel unit 5-2 into place and spot weld them to the assembly platform;

[0043] Step 9: Following the method described in Step 7, hoist and fix the two first curved wall inner wall panel units 2-1, the two second curved wall inner wall panel units 4-1, and the third curved wall inner wall panel unit 5-1 into place. Then, weld the connecting angle steel between the inner wall panel unit and the outer wall panel unit from bottom to top to form two first vertical curved wall blocks 2, two second vertical curved wall blocks 4, and one third vertical curved wall block 5, respectively.

[0044] In steps 8 and 9, when the local position of the curved wall panel unit deviates significantly from the corresponding assembly position line, a thermal straightening process is used for adjustment to ensure that the deviation between the curved wall panel unit and its respective assembly position line is ≤2mm, thus ensuring the manufacturing accuracy of the steel shell tower segment.

[0045] Step 10: Inspect the port dimensions, verticality, and steel plate misalignment of all blocks. After all blocks pass the inspection, weld the butt joints between the blocks to form the steel shell tower segment.

[0046] Furthermore, vertical base points 6-4 are provided on the outer and inner contour lines of the assembly position lines 6-3 of all blocks, and the vertical base points 6-4 are located at the middle position of the outer and inner contour lines of the assembly position lines of the blocks. Vertical baselines 9 are drawn on the outer walls of all plate units, and the vertical baselines 9 are located at the middle position of the outer walls of all plate units, and the lower end of the vertical baselines is aligned with the vertical base points 6-4, thereby facilitating the rapid positioning of the plate units of each block.

[0047] The assembly scheme and assembly sequence designed by the embodiments of the present invention solve the problem of manufacturing precision control of large cross-section thin-walled irregular steel shell towers, thereby improving the manufacturing precision and quality of irregular steel shell towers.

[0048] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A method for manufacturing a large-section, thin-walled, irregularly shaped steel shell tower segment, characterized in that, Includes the following steps: Step 1: Vertically divide the segment into one inclined straight wall block (1), two first vertical curved wall blocks (2), at least two vertical straight wall blocks (3), two second vertical curved wall blocks (4) and one third vertical curved wall block (5); Step 2: Fabricate the first straight wall inner wall panel unit (1-1) and the first straight wall outer wall panel unit (1-2) for forming the inclined straight wall block (1); fabricate the first curved wall inner wall panel unit (2-1) and the first curved wall outer wall panel unit (2-2) for forming the first vertical curved wall block (2); fabricate the second straight wall inner wall panel unit (3-1) and the second straight wall outer wall panel unit (3-2) for forming the vertical straight wall block (3); fabricate the second curved wall inner wall panel unit (4-1) and the second curved wall outer wall panel unit (4-2) for forming the second vertical curved wall block (4); fabricate the third curved wall inner wall panel unit (5-1) and the third curved wall outer wall panel unit (5-2) for forming the third vertical curved wall block (5); Step 3: Draw horizontal baseline (6-1) and vertical baseline (6-2) on the assembly platform (6), and then draw the assembly position lines (6-3) of the inclined straight wall block (1), two first vertical curved wall blocks (2), at least two vertical straight wall blocks (3), two second vertical curved wall blocks (4) and one third vertical curved wall block (5) on the assembly platform (6) based on the horizontal baseline (6-1) and vertical baseline (6-2). Step 4: Fix several support columns (7) and several inclined positioning brackets (8) on the assembly platform (6). The support columns (7) are arranged along the inner side of the assembly position line (6-3), and an adjusting strut (7-1) is horizontally arranged on the support columns (7). The inclined positioning brackets (8) are arranged along the outer side of the assembly position line (6-3) and are located outside the assembly position of the inclined straight wall block (1). Step 5: First, hoist the first straight wall outer wall panel unit (1-2) to the inside of the inclined positioning bracket (8), and position it with the assembly position line corresponding to the inclined straight wall block (1) as the reference. Then, lean it against the inclined surface inside the inclined positioning bracket (8) and make precise adjustments so that the lower end of the first straight wall outer wall panel unit (1-2) deviates from the assembly position line by ≤2mm. Then, temporarily fix it to the inclined positioning bracket (8) with the positioning plate. Step 6: Hoist the two second straight wall outer wall panel units (3-2) to the outside of the support column (7), and position them with the assembly position line corresponding to the vertical straight wall block (3) as the reference. Then, adjust the verticality with the adjusting support rod (7-1) and temporarily weld them to the assembly platform (6). Step 7: Hoist the first straight inner wall panel unit (1-1) to the inside of the first straight outer wall panel unit (1-2) and the outside of the supporting column (7), and position it using the assembly position line corresponding to the inclined straight wall block (1) as a reference. Then, adjust the tilt angle using the adjusting strut (7-1), and weld the connecting angle steel between the first straight inner wall panel unit (1-1) and the first straight outer wall panel unit (1-2) from bottom to top to form the inclined straight wall block (1); Continue Two second straight wall inner wall panel units (3-1) are hoisted to the inner side of two second straight wall outer wall panel units (3-2) and the outer side of the support column (7). After positioning with the assembly position line corresponding to the vertical straight wall block (3) as the reference, the support is adjusted by the adjusting strut (7-1). Then, the connecting angle steel between the second straight wall inner wall panel unit (3-1) and the second straight wall outer wall panel unit (3-2) is welded from bottom to top to form two vertical straight wall blocks (3). Step 8: Following the method described in Step 6, hoist the two first curved wall outer wall panel units (2-2), the two second curved wall outer wall panel units (4-2), and the one third curved wall outer wall panel unit (5-2) into place in sequence; Step 9: After hoisting the two first curved wall inner wall panel units (2-1), the two second curved wall inner wall panel units (4-1), and the third curved wall inner wall panel unit (5-1) into place in sequence according to the method described in Step 7, weld the connecting angle steel between the inner wall panel unit and the outer wall panel unit from bottom to top to form two first vertical curved wall blocks (2), two second vertical curved wall blocks (4), and one third vertical curved wall block (5). Step 10: After all blocks have passed inspection, weld the butt joints between the blocks to form the segment.

2. The method for manufacturing large-section thin-walled irregular-shaped steel shell tower segments according to claim 1, characterized in that, Vertical base points (6-4) are provided on the outer and inner contour lines of the assembly position lines (6-3) of all blocks. Vertical baselines (9) are drawn on the outer walls of all plate units, and the lower end of the vertical baselines (9) is aligned with the vertical base points (6-4).

3. The method for manufacturing large-section thin-walled irregular-shaped steel shell tower segments according to claim 1, characterized in that, The adjustable support rod (7-1) is telescopic and adjustable.

4. The method for manufacturing large-section thin-walled irregular-shaped steel shell tower segments according to claim 1, characterized in that, The inclined positioning bracket (8) has a triangular structure, and its inner inclined surface has the same inclination as the inclined straight wall block (1).

5. The method for manufacturing large-section thin-walled irregular-shaped steel shell tower segments according to claim 2, characterized in that, The vertical base point (6-4) is located at the midpoint between the outer contour line and the inner contour line of the assembly position line (6-3) of all blocks, and the vertical baseline (9) is located at the midpoint of the outer wall of all plate units.

6. The method for manufacturing large-section thin-walled irregular-shaped steel shell tower segments according to any one of claims 1-5, characterized in that, In steps 8 and 9, when the deviation between the curved wall panel unit and the corresponding assembly position line is large, a thermal straightening process is used to adjust it to ensure that the deviation between the curved wall panel unit and its respective assembly position line is ≤2mm.

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