A method for processing a space warp wallboard

Abstract

The present application belongs to the technical field of wallboard processing, and particularly relates to a space twist wallboard processing method. The technical scheme is as follows: a space twist wallboard processing method, comprising the following steps: S1: wallboard blanking: after the steel plate is blanked, the material mark and plate number mark of the main parts are transplanted, and then the wallboard is blanked; S2: wallboard bending: S21: wallboard bending processing: outer wallboard modeling unfolding, twist wallboard processing forming, outer wallboard bending; S22: outer wallboard detection: wire detection, sample detection, tooling jig detection; S23: wallboard correction: repeatedly and sequentially performing wallboard tooling jig positioning, determining wallboard correction line, wallboard flame correction, checking wallboard and tooling jig gap, until the detection is qualified; S24: wallboard acceptance. The present application provides a space twist wallboard processing method with high wallboard processing precision.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of wallboard processing, and particularly relates to a space twist wallboard processing method. BACKGROUND

[0002] At present, the pursuit of spatial curve sense gradually becomes the bridge aesthetics trend in bridge construction. In the construction process of the steel tower of a cable-stayed bridge, due to the influence of air temperature and various errors on the cable tower, necessary and effective measures need to be taken to accurately position each segment before installation, adjust the linear type, and ensure that the parameters such as perpendicularity and axis deviation meet the relevant specifications. However, since the outer wall panels of such bridge towers are all space twist curved panels, the curved surface forming has a great influence on the appearance effect of the main tower, the size of the curved wall panel changes greatly, the shape precision requirement is high, the space is required to be smooth and uniform, the production requirement is high, and the processing difficulty is great. How to form is one of the key technologies that must be solved. SUMMARY

[0003] In order to solve the above problems existing in the prior art, the purpose of the present application is to provide a space twist wallboard processing method with high wallboard processing precision.

[0004] The technical scheme adopted by the present application is as follows:

[0005] A space twist wallboard processing method, comprising the following steps:

[0006] S1: Wallboard blanking: after the steel plate is blanked, the material grade and plate number marking of the main parts are transplanted, and then the wallboard is blanked;

[0007] S2: Wallboard bending:

[0008] S21: Wallboard bending processing: outer wall panel modeling unfolding, twist wallboard processing forming, outer wall panel bending;

[0009] S22: Outer wall panel detection: wire detection, template detection, and tooling jig detection;

[0010] S23: Wallboard correction: repeatedly and sequentially positioning the wallboard on the tooling jig, determining the wallboard correction line, wallboard flame correction, and checking the gap between the wallboard and the tooling jig until the detection is qualified;

[0011] S24: Wallboard acceptance.

[0012] As a preferred scheme of the present application, in step S1, the wallboard blanking needs to meet the steel plate splicing technical requirements:

[0013] The inner and outer wall panel joint length is not less than 1000mm, and the width is not less than 200mm;

[0014] The butt welds in the longitudinal and transverse directions of the steel plate splicing joint adopt cross type intersection or T type intersection, and when the T type intersection is adopted, the distance of the intersection points is staggered by not less than 200 mm;

[0015] Before the steel plates are spliced, the part number, the appearance size and the bevel direction are checked according to the drawing, and the splicing is carried out after the confirmation of no error;

[0016] The steel plates of different thicknesses are butted, and when the thickness difference is greater than 4.0 mm, one side of the thicker plate is processed into a slope, and the slope should be 1:8, and the inner and outer wall plates are ensured to be flush outside the box;

[0017] Before assembly, the oxide scale, rust, oil stains, paint layer and other harmful substances in the to-be-welded area must be completely removed, so that the weld and the range of 30 mm wide on both sides are exposed to metal gloss;

[0018] When the width and length of a single steel plate cannot meet the requirements, the steel plates are spliced in the transverse and longitudinal directions, and the splicing of the steel plates is carried out in the order of first splicing long and then splicing wide.

[0019] As a preferred scheme of the present application, in step S1, the wall plate blanking needs to meet the lofting and marking technical requirements:

[0020] Before the steel plate blanking, the surface is shot-blasted to remove rust to reach Sa2.5 level, the surface roughness is Rz 50-80 μm, 1 pass of alcohol-soluble inorganic zinc silicate shop primer is sprayed, and the thickness is 20 μm;

[0021] Before marking, the steel quality certificate is checked, the grade, specification and quality of the steel plate are checked, and the marking is carried out after the confirmation of no error, the parts of different specifications and different materials are marked respectively, and the marking is carried out in turn according to the principle of first large and then small;

[0022] When the layout is recorded, the specifications, materials and furnace batch numbers of the marked parts are recorded, and the layout drawing and the layout part list are clearly noted, and the layout list account is well kept for reference;

[0023] When the main components of the force parts are blanked, the force direction is consistent with the rolling direction of the steel plate;

[0024] The main angle weld of the inner and outer wall plates is passed through the welding hole R50, and the rest of the positions not marked is passed through the welding hole R35;

[0025] The instruments, equipment and measuring instruments used for quality detection are verified and checked by the legal measurement institutions, and are used after being qualified.

[0026] As a preferred scheme of the present application, the wall plate blanking needs to meet the lofting and marking technical requirements, and the marking requirements of the inner and outer wall plates also include:

[0027] The wall plate number is clear and regular, and is marked by a paint pen or a spray code, and the font width is about 40 mm and the height is about 60 mm;

[0028] The wall plate number of the inner and outer wall plate is marked clearly at the joint of the four walls;

[0029] The inner and outer wall plate is marked clearly on the inner and outer surface of the box;

[0030] The partition plate and longitudinal rib positioning line of the inner and outer wall plate are marked by ink line.

[0031] As a preferred scheme of the present application, the wall plate blanking needs to meet the lofting and marking technical requirements and also includes the inner and outer wall plate processing allowance requirements:

[0032] The inner and outer wall plate is blanked according to the theoretical size in the transverse section, and the 5mm gap of the welding groove is used as the transverse welding shrinkage allowance;

[0033] The inner and outer wall plate is blanked according to the theoretical size in the height direction section, and the 5mm gap of the welding groove is used as the height direction welding shrinkage allowance;

[0034] When multiple segments are matched and manufactured on the same tooling, the wall plate length size of the middle segment is blanked according to the theoretical size, and a deviation of +3-5mm is allowed; the wall plate length size of the longitudinal two end segments leaves a welding and secondary cutting allowance of 30mm on the outermost side.

[0035] As a preferred scheme of the present application, the step S21 includes the following specific steps:

[0036] S211: outer wall plate modeling unfolding: the outer wall plate of the main tower is split into 3-6m unequal length processing plate pieces according to the main tower segmentation and blocking scheme, the unfolding of the bending and twisting plate is performed by using the three-dimensional model; according to the spatial coordinates of the twisting component, four edge lines of the bending and twisting component are determined, and then the wall thickness is input to automatically generate the twisting solid model and obtain any spatial coordinates on each wall plate to automatically unfold the wall plate; at the same time, the installation position line of the stiffening rib on the wall plate is generated;

[0037] S212: twisting wall plate processing and forming:

[0038] Before wall plate processing, the processing and forming bending lines and the normal control lines of assembly and the detection reference lines after forming processing are drawn on the wall plate; the processing bending lines are set every 240-500mm parallel to the end face line according to the angle of the end face line;

[0039] The wall plate forming processing is cold pressing forming by using the oil press; during wall plate processing, the round corner of the film is selected, and then the wall plate is pressed and formed according to the bending line on the wall plate; the pressing is gradually performed from one end to the other end, and the angle template is used for measurement; the pressing of the wall plate is repeatedly performed until the forming processing requirements are met;

[0040] S213: outer wall plate bending:

[0041] After the twisted outer wall panels are CNC-cut, the size, direction of the bevel and the geometric dimensions of the outer wall panels are inspected to see if they meet the specification requirements. After the inspection, the outer wall panels that pass the inspection are bent on the twisted surface. The bending process and preliminary inspection steps are as follows:

[0042] Bending line layout: Place the outer wall panel on the platform, divide the bending points into equal parts according to the length of the outer arc and the length of the inner arc according to the length of the chord. Then, use chalk or ink lines to draw the corresponding bending points of the inner and outer arcs, and mark the height difference of the Z axis relative to the 0 point. Use chalk or ink lines to draw the sample inspection lines at the upper and lower ends, as well as the positioning lines for assembling the partitions and longitudinal ribs. The positioning accuracy of the equally divided bending points should be controlled within ±2mm.

[0043] Bending equipment debugging and data input: According to the values ​​of the X / Y / Z axes of the outer wall panel's twisted surface, input the relevant data of each bending line and the angle between the upper and lower ends on the bending equipment console. The equipment must be debugged before bending;

[0044] Bending of outer wall panels: Align the bending line of the outer wall panel with the blade of the bending machine. The bending should be carried out step by step from one end to the other, and use an angle template for process measurement and control to avoid excessive pressing. Repeat the pressing of the wall panel until the basic requirements of the forming process are met.

[0045] As a preferred embodiment of the present invention, step S22 includes the following specific steps:

[0046] S221: Wire pulling detection:

[0047] Place the processed wall panels steadily without any obvious shaking;

[0048] Pad the four outermost points of the wall panel to the same elevation, and use a wire to measure the sagittal height of each point on the bending line drawn on the wall panel before forming and the horizontal line. The deviation of the sagittal height f of each point is ≤±2.0mm;

[0049] The cross intersection point and the intersection point of the cross line and the middle longitudinal line are detected. The Z coordinates of the three points are calculated according to the length ratio of the bending line closest to the detection point. If the detection point is located between two bending lines, the average Z coordinates calculated by the two bending lines are taken.

[0050] After wall panel processing, the chord length L1 / L2 / L3 / L4 ≤ ± 2.0mm, and the diagonal C1 / C2 allows a deviation of 3mm; if the inspection does not meet the above accuracy requirements, it will be pressed again and adjusted.

[0051] As a preferred embodiment of the present invention, step S22 includes the following specific steps:

[0052] S222: Sample inspection:

[0053] The sample plate is cut by laser, and is made of a color steel plate with a thickness of 1-2 mm, a width of 100-200 mm at both sides, and a length of 2.0-2.5 m. The sample plate is cut into blocks and numbered;

[0054] The sample plate is checked according to two sample plates ejected before bending, and the segmented sample plate is spliced into a straight line and a plane for detection.

[0055] The bending size deviation is detected by the fitting of the curved edges of the sample plate and the curved edges of the outer wall plate. The points with large deviations are processed again for adjustment.

[0056] As a preferred scheme of the present application, step S22 comprises the following specific steps:

[0057] S223: jig frame detection:

[0058] The height of the vertical rod is set to 0.5-1 m, the height of the inner adjusting steel pipe can be adjusted by 300-500 mm, and the height of the adjusting screw rod can be adjusted by 60 mm.

[0059] The jig frame is set on the concrete ground, and the whole steel plate or board is laid on the concrete ground to meet the width of the jig vertical rod.

[0060] The jig vertical rod and the steel plate laid on the ground need to be welded firmly, the longitudinal spacing of the vertical rod is 500 mm, the transverse spacing is 1000 mm, and the horizontal and vertical supports are connected by angle steel.

[0061] After the jig frame is set, the overall line height is measured to ensure that the line type is consistent with the drawing and completely correct, and then the wall plate detection is performed. When detecting a different wall plate, the height of the jig vertical rod is adjusted to ensure that it is consistent with the twisted curve of the wall plate.

[0062] The wall plate is placed on the jig, and the gap between the wall plate and the jig is checked. The gap between the wall plate and the screw rod is allowed to deviate by ±2 mm.

[0063] As a preferred scheme of the present application, in step S23, the wall plate correction needs to meet the technical points of flame heating correction of the wall plate:

[0064] The flame temperature during bending heating should be controlled at 600-800℃, and repeated heating at the same position should be avoided, and over-heating should be strictly prohibited.

[0065] During bending heating, the flame baking position of each heating area of the wall plate is at least spaced by 100-200 mm, and the front and rear heating should not be performed at the same position.

[0066] During bending heating, the wall plate is cooled freely in the air. If external force needs to be applied, it should be uniformly applied.

[0067] The bent wall plate is placed on a tool jig frame to be corrected, the gap between the outer wall plate and the tool is checked, and the correction principle is from the middle to the four corners.

[0068] The correction line is confirmed: according to the longitudinal, transverse or oblique gap of the tool, the maximum gap line and the middle are taken as the starting line, and the gap is gradually corrected to the smaller edge.

[0069] The beneficial effects of the present application are:

[0070] 1. The space twist wall plate processing method of the present application can improve the wall plate processing precision by 96%.

[0071] 2. The detection method of the space twist plate by using the pull line can only reflect the macro control in the processing process, and is a most effective method for the rapid and simple processing process, but cannot fundamentally guarantee the actual processing precision requirement of the wall plate. Therefore, in order to guarantee the assembly precision of the bent twist plate component during assembly, the wall plate must also be detected in detail before assembly. The detection is carried out by using a special jig frame for comprehensive detection. The jig frame is set up according to the actual twist line of each wall plate in 1:1, and the twist surface of the wall plate is truly displayed. When detecting, the processed wall plate is only placed on the jig frame of the wall plate, and whether the wall plate is in point fit with the jig frame can be directly observed.

[0072] 3. The general space curved surface steel plate processing loss rate is 20%, and through three-dimensional entity modeling, deepening detailed drawing and fixed size procurement, the actual processing loss rate is 15%. BRIEF DESCRIPTION OF DRAWINGS

[0073] Figure 1 is a material mark position diagram;

[0074] Figure 2 is a polishing range diagram of the welding area;

[0075] Figure 3 is a steel plate splicing and seam welding sequence example diagram;

[0076] Figure 4 is a steel plate factory butt joint groove diagram;

[0077] Figure 5 is a wall plate site butt joint groove diagram;

[0078] Figure 6 is an inner and outer wall plate marking diagram;

[0079] Figure 7 is a wall plate length direction plus allowance diagram;

[0080] Figure 8 is a wall plate height and longitudinal processing allowance diagram;

[0081] Figure 9 is a schematic diagram of the wallboard transverse machining allowance;

[0082] Figure 10 is a model diagram of the outer wallboard segment of the main tower;

[0083] Figure 11 is a curved line model diagram of the outer wallboard segment of the main tower;

[0084] Figure 12 is a curved machining size diagram of the outer wallboard segment of the main tower;

[0085] Figure 13 is a schematic diagram of the outer wallboard bending line and inspection line;

[0086] Figure 14 is a schematic diagram of the outer wallboard twisted surface space coordinates;

[0087] Figure 15 is a schematic diagram of the two-end included angle degree marking number;

[0088] Figure 16 is a schematic diagram of the outer wallboard longitudinal and transverse and cross detection points;

[0089] Figure 17 is a schematic diagram of the wallboard machining detection;

[0090] Figure 18 is a schematic diagram of the wallboard template inspection line and template;

[0091] Figure 19 is a schematic diagram of the tooling vertical rod;

[0092] Figure 20 is a three-dimensional schematic diagram of the detection jig frame;

[0093] Figure 21 is a three-dimensional schematic diagram of the wallboard after machining and forming and the detection jig frame;

[0094] Figure 22 is a schematic diagram of the wallboard horizontal height inspection; DETAILED DESCRIPTION

[0095] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme of the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some embodiments of the present application, but not all the embodiments. The components of the embodiments of the present application described and shown in the drawings can be arranged and designed in various different configurations.

[0096] 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 claimed invention, 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 inventive effort are within the scope of protection of the present invention. It should be noted that the embodiments of the present invention and the features therein may be combined with each other unless there is a conflict.

[0097] The method for processing the spatial distortion wall panel of this embodiment includes the following steps:

[0098] 1. Wall panel cutting process

[0099] 1. Material Marker Transplantation

[0100] 1) After cutting the steel plate, the material brand and plate number markings should be transplanted to the main parts to facilitate material tracking. The material (including residual material) stacking area should be marked with a sign indicating the project name, specification, material, batch number, Z-axis performance and plate thickness deviation (N type / C type).

[0101] 2) Material marking transplant content

[0102] ① Parts transplant material, furnace batch number, and Class C deviation; (spray code according to self-numbering and keep records)

[0103] ② Thickness, material, furnace batch number, Class C deviation, and Z-direction performance of the remaining material transplanted.

[0104] 3) Parts and components, and residual material markings and transplants shall be marked with mechanical guns. It is strictly forbidden to use sharp tools such as files, punches, and sample punches to print steel stamp numbers.

[0105] 4) Material marking transplantation scope: All inner and outer wall panels and remaining materials are transplanted.

[0106] 5) Material marking position such as Figure 1 As shown, the material marking position is 200 to 300 mm away from the two side plate edges. If the material marking coincides with the component rib plate, the material marking number can be appropriately shifted.

[0107] 2. Technical requirements for blanking process

[0108] 1) Technical requirements for steel plate splicing

[0109] ① The length of the inner and outer wall panels should not be less than 1000mm, and the width should not be less than 200mm.

[0110] ②For steel plate splicing joints, the butt welds in the longitudinal and transverse directions can adopt cross-shaped or T-shaped cross-shaped welds (except for on-site butt joints, cross-shaped welds should be avoided in factory splicing joints). When using T-shaped cross-shaped welds, the distance between the intersection points shall not be less than 200mm.

[0111] ③ Before splicing steel plates, the part number, external dimensions and groove direction must be checked according to the drawings, and splicing can only be carried out after confirmation.

[0112] ④ When steel plates of different thickness are butted together, if the thickness difference is greater than 4.0mm, the thicker plate should be processed into a slope with a slope of 1:8. The inner and outer wall panels should be flush with the outside of the box.

[0113] ⑤ Before assembly, the oxide scale, rust, oil, paint and other harmful substances in the area to be welded must be thoroughly removed, so that the weld and the 30mm wide area on both sides are exposed to the metallic luster. Figure 2 shown.

[0114] ⑥ When the width and length of a single steel plate cannot meet the requirements, the steel plate needs to be spliced ​​horizontally and vertically. In order to reduce the deformation of the flatness of the steel plate after welding, the order of "joining the length first and then the width" should be adopted, that is, welding the horizontal seam first and then the vertical seam, see Figure 3 shown.

[0115] 2) Technical requirements for splicing groove

[0116] ① Butt bevel of steel plate in factory, see Figure 4 .

[0117] ② On-site bevel joints of inner and outer wall panels, see Figure 5 .

[0118] 3) Laying out and numbering materials

[0119] Before cutting, construction team members should familiarize themselves with the construction drawings and detailed breakdown drawings, carefully read the construction plan, process documents, and design specifications, and carefully check the dimensions and bevel directions between the drawings. Pay special attention to the correspondence between the connection points, connection methods, connection bevels, and dimensions of each component. If any questions arise, contact the manufacturer's process technicians immediately for resolution and do not make any changes on your own.

[0120] ① The steel plate should be pretreated before cutting, that is, the surface should be shot blasted to Sa2.5 level and the surface roughness should be Rz50~80μm, and then sprayed with a coat of alcohol-soluble inorganic zinc silicate workshop primer with a thickness of 20μm.

[0121] ② Before numbering, the steel material certificate should be checked to check the brand, specification and quality of the steel plate. Numbering can only be done after confirmation. Parts of different specifications and materials should be numbered separately. Numbering should be done in the order of large parts first and small parts later.

[0122] ③ When typeset, technicians must record the specifications, materials, and batch numbers of the parts, make clear notes on the typeset drawing and typeset parts list, and keep a record of the typeset list for future reference.

[0123] ④When the force-bearing parts of the main components are cut, the force direction should be consistent with the rolling direction of the steel plate.

[0124] ⑤The R50 welding hole is used at the main angle weld of the inner and outer wall plates, and the R35 welding hole is used at the other positions.

[0125] ⑥The inner and outer wall plates are marked as shown in Figure 6 .

[0126] The wall plate number must be clear and regular, marked with a paint pen or a spray code, with a font width of about 40 mm and a height of about 60 mm.

[0127] The wall plate number of the inner and outer wall plates must be clearly marked at the four corners.

[0128] The inner and outer wall plates must be clearly marked inside and outside the box.

[0129] The partition and longitudinal rib positioning lines of the inner and outer wall plates are marked with ink lines.

[0130] ⑦The inner and outer wall plates are marked as shown in Figures 7-9 .

[0131] A The inner and outer wall plates are cut according to the theoretical size, and the 5mm gap of the welding groove is used as the shrinkage allowance for transverse welding.

[0132] B The inner and outer wall plates are cut according to the theoretical size in the height direction, and the 5mm gap of the welding groove is used as the shrinkage allowance for height direction welding.

[0133] C When multiple segments are matched and manufactured on the same tooling, the wall plate length of the middle segment is cut according to the theoretical size, with no negative deviation allowed and +3+5mm allowed. The wall plate length of the longitudinal two end segments has a welding and secondary cutting allowance of 30mm on the outermost side (relative to the same tooling with multiple segments).

[0134] ⑧The instruments, equipment and measuring instruments used for quality detection should be verified and calibrated by the legal measuring agency, and can be used only after passing the verification. A 20-meter steel tape must be kept as the master version after passing the third-party detection, and other steel tapes should be compared with the master version steel tape regularly. The steel tape with a 20-meter length deviation of more than ±2mm is discarded.

[0135] 4) Cutting, repairing

[0136] ① The inner and outer wall plates are cut by precision (numerical control, automatic, semi-automatic) flame cutting, and manual cutting is prohibited in principle.

[0137] ② The cutting nozzle number (i.e. the cutting oxygen hole diameter) should be determined according to the thickness of the cutting workpiece, and usually can be selected according to the manufacturer's instruction. The conventional cutting nozzle number should be selected according to Table 1.

[0138] Table 1 Precision cutting parameter selection reference table

[0139]

[0140]

[0141] ③ Selection of torch back rake angle: The torch back rake angle can be selected according to Table 2 corresponding to the thickness of the plate being cut.

[0142] Table 2 Torch back rake angle reference table

[0143] No. Plate thickness (mm) Torch inclination angle 1 <10 30～35° 2 10～20 20～25° 3 20～30 5～15° 4 30 Generally no inclination angle

[0144] ④ Determination of kerf compensation: The kerf compensation should be determined according to the selected nozzle number, see Table 3.

[0145] Table 3 Kerf compensation reference table

[0146] No. Nozzle number Cutting gap compensation (mm) 1 1 2.3 2 2 2.8 3 3 3.3 4 4 3.8

[0147] ⑤ When precision cutting is used, the cutting surface quality should meet the requirements of Table 4.

[0148] Table 4 Precision cutting edge surface quality requirements

[0149]

[0150]

[0151] ⑥ Grinding after cutting

[0152] a) When the depth of the pitting or damage on the local surface of the steel is 0.3-1 mm, it can be ground smooth; when the depth exceeds 1 mm, it should be ground smooth after repair welding.

[0153] b) When the depth of the interlayer defect on the local edge of the steel does not exceed 5 mm, the crack can be removed first and then repaired and ground.

[0154] c) When the depth of the kerf or crater on the gas cutting edge is less than 2 mm, it can be ground smooth; when the depth exceeds 2 mm, it should be repaired and ground smooth after chamfering.

[0155] d) Repairing pits and craters should strictly follow the welding process requirements.

[0156] II. Wall plate bending

[0157] 1. Wall plate bending processing

[0158] 1) Outer wall plate modeling unfolding

[0159] The outer wall plate of the main tower is a spatial twist plate with a relatively large bending and twisting rate. In order to control the layout and cutting precision, the unfolding of the wall plate is particularly important. According to the segmented and blocked scheme of the main tower, the outer wall plate of the main tower is split into processing plates with lengths of 3m to 6m. The three-dimensional model and related software can well meet the unfolding of the bending and twisting plate. According to the spatial coordinates of the twisted component, the four edges of the bending and twisting component are determined, and the wall thickness is inputted, so that the twisted entity model is automatically generated, thereby obtaining any spatial coordinates on each wall plate, automatically unfolding the wall plate, and generating the installation position line of the stiffening rib on the wall plate. Thus, the linear data of the unfolded wall plate can be obtained, and the cutting data of the wall plate is inputted into the flame numerical control cutting machine for cutting and cutting of the wall plate. Figures 10-12

[0160] 2) Twisted wall plate processing and forming

[0161] ① Before the wall plate is processed, the processing and forming bending lines and the normal control lines for assembly (partition, longitudinal rib) and the detection reference lines after forming processing (sample inspection line) must be drawn on the wall plate. The processing bending lines are set every 240-500mm according to the angle of the end face line of the wall plate (bending line spacing B = t*10+30, t is the thickness of the wall plate, and the end face line is divided equally). The processing bending lines must ensure accurate positioning.

[0162] ② The wall plate forming processing should be given priority to cold pressing processing and forming by using an oil press. When the wall plate is processed, a proper round corner should be selected to avoid obvious indentation on the surface of the wall plate. Then the wall plate is pressed and formed according to the bending lines on the wall plate. The pressing should be performed gradually from one end to the other end, and an angle sample is used for measurement to avoid over-pressing. The wall plate is repeatedly pressed in this way until the forming processing requirement is met.

[0163] 3) Bending of outer wall plate

[0164] After the numerical control cutting of the twisted outer wall plate, the size, direction and geometric dimensions of the outer wall plate are detected to see whether they meet the specification requirements. Only the outer wall plate that meets the requirements can be bent. The bending process and preliminary detection steps are as follows:

[0165] ① Bending line layout: place the outer wall plate on the platform, divide the bending points of the outer arc (upper) according to the arc length, and divide the bending points of the inner arc (lower) according to the divided chord length. Then, the corresponding divided bending points of the inner and outer arcs are popped out with chalk or ink line, and the height difference of the Z axis relative to the 0 point is marked. The sample inspection line and the positioning line for assembling the partition and longitudinal rib are also popped out with chalk or ink line at the upper and lower ends. The positioning accuracy of the divided bending points is controlled within ±2mm. Figure 13

[0166] ② Bending equipment debugging and data input: according to the values of the X / Y / Z axes of the outer wall plate twist surface given in the detailed drawing (see Figure 14 ​​), input the relevant data of each bending line (the bending length of the arc-shaped wallboard needs to input the actual length of each bending line) and the clamping angle of the upper and lower ends on the bending equipment console, and the clamping angle of the upper and lower ends of the wallboard (the angle is accurate to two decimal places) is shown in the schematic Figure 15 The equipment needs to be debugged before bending.

[0167] ③Bending of outer wallboard: align the bending line of the outer wallboard with the cutting edge of the bending machine, and bend from one end to the other end step by step, and use the angle template for process measurement control to avoid excessive pressing. Repeat the pressing process on the wallboard until the basic requirements of forming processing are met.

[0168] 2. Detection of outer wallboard

[0169] After bending and forming, the wallboard is detected using the template and the tension line, and then the wallboard is detected using the tooling jig.

[0170] 1) Tension line detection

[0171] ① Place the processed wallboard steadily without obvious shaking.

[0172] ② Pad the four outermost points of the wallboard to the same height (pad the height difference of the four points to zero), and use the tension line to measure the vector height of each point of the bending line drawn before forming processing on the wallboard (the four edges in the vertical and horizontal directions). The vector height f of each point deviates by ≤±2.0mm. As shown in the figure. Figure 16

[0173] ③ The cross intersection point and the intersection point of the cross line and the middle longitudinal line must be detected (3 points), and the Z-direction coordinate value of the 3 points is calculated according to the length proportion of the nearest bending line of the detection point. If the detection point is located in the middle of two bending lines, the average value of the Z-direction coordinates calculated from the two bending lines can be taken.

[0174] ④ The chord length L1 / L2 / L3 / L4 of the wallboard after processing is ≤±2.0mm, and the diagonal line C1 / C2 is allowed to deviate by 3mm. If the detection does not meet the above accuracy requirements, the pressing processing should be performed again for adjustment to ensure that the curved surface basically maintains consistency with the designed curved surface, thereby ensuring the processing accuracy. As shown in the figure. Figure 17

[0175] 2) Template detection

[0176] ① The template is cut by laser cutting, with a thickness of 1-2mm color steel plate, a width of 100-200mm on both sides, and a length of 2.0-2.5m according to the length for easy detection during the bending process (determined according to the size of the arc). The template is cut into blocks and needs to be numbered, such as: TJB-9W2-W(N)-1-3, TJB-9W2 is the number of outer wallboard, W is the outer arc, N is the inner arc, and 1-3 is the number of outer arc or inner arc templates (the template number is coded from left to right).​​Figure 18 As shown.

[0177] ②According to the 2 sample lines ejected before bending to check the detection, the overall detection needs to splice the segmented sample into a straight line and a plane for detection.

[0178] ③The bending size deviation is detected by the fitting of the sample curve edge and the outer wall plate peripheral curve edge. For the points with large deviation, re-pressing processing is performed for adjustment to ensure that the curved surface is basically consistent with the designed curved surface, thereby ensuring the processing precision.

[0179] 3) Tool jig detection

[0180] ①The height of the stand is set to 0.5-1m, the inner adjusting steel pipe can adjust the height by 300-500mm, and the adjusting screw rod can adjust the height by 60mm. For example, Figure 19 As shown.

[0181] ②The tool jig is erected on the concrete floor. The overall steel plate or board is laid on the concrete floor to meet the tool stand width, and the maximum area of the site required is 9m*15m.

[0182] ③The tool stand and the ground laid steel plate need to be welded firmly. The longitudinal spacing of the stand is 500mm (bending arc direction), and the transverse spacing is 1000mm (knife line direction). The horizontal and vertical supports are connected by angle steel to form a whole stable tool.

[0183] ④After the tool jig is erected, the overall line height must be measured by professional measurement personnel to ensure that the line type is consistent with the drawing and completely correct before the wallboard detection. When detecting each different wallboard, the height of the tool stand must be adjusted to ensure that it is consistent with the twist curve of the wallboard.

[0184] ⑤Place the wallboard on the tool and check the gap between the wallboard and the tool. The allowable deviation of the gap between the wallboard and the screw rod is ±2mm. For example, Figure 20 and Figure 21 As shown.

[0185] 3. Wallboard correction

[0186] After the wallboard is bent by the heavy oil press, it is initially detected by the sample and the detection line. If the wallboard formed by the processing precision cannot meet the assembly requirements, the oil press must be re-used for local accurate control to accurately ensure the processing precision of the wallboard. For local problems that cannot be controlled locally by the heavy oil press, flame processing is used. The wallboard correction process is as follows: wallboard tool jig positioning → determining wallboard correction line → wallboard flame correction → checking the gap between the wallboard and the tool jig → repeating the above steps until the detection is qualified.

[0187] Technical points of wallboard flame heating correction:

[0188] 1) The flame temperature should be controlled at 600-800℃ during bending heating, and the same part should not be repeatedly heated, and overburning is strictly prohibited.

[0189] 2) During bending heating, the flame baking part of the wallboard heating area should not be too close, and should be at least 100-200mm apart, and the front and rear heating should not be performed at the same part.

[0190] 3) During bending heating, water should not be used for rapid cooling, and the wallboard should be slowly formed by uniformly applying external force, and the steel material should not be hammered.

[0191] 4) The wallboard after bending is placed on the tool jig frame for correction, the gap between the outer wallboard and the tool is checked, and the correction principle is from the middle to the four corners.

[0192] 5) Correction line confirmation: according to the longitudinal, transverse or oblique gap of the tool, the correction line is selected, and the principle is to take the maximum gap line and the middle as the starting line, and gradually correct to the smaller gap and the edge, and the correction line is not necessarily the full length of the wallboard width, and the wallboard correction can be locally performed. For example, as shown in the figure. Figure 22

[0193] 4, wallboard acceptance

[0194] After the wallboard is flame corrected on the tool jig frame, the sample plate, the line and the tool gap are checked, and finally the gap between the outer wallboard and the tool is used as the standard, the gap between the wallboard and the screw rod is controlled within 2mm, and the level meter is used to measure whether the Z-direction elevation value of each tool point reaches the acceptance standard, and the tool gap and the wallboard distortion elevation are simultaneously accepted. The distorted wallboard is qualified only when the tool gap and the wallboard distortion elevation are simultaneously accepted.

[0195] The present application is not limited to the above-mentioned optional embodiments, and anyone can derive other various forms of products under the inspiration of the present application, but regardless of any changes in shape or structure, any technical solution falling within the scope defined by the claims of the present application falls within the protection scope of the present application.​

Claims

1. A method for processing a spatially distorted wall panel, characterized in that: The following steps are involved: S1: Wall panel cutting: After cutting the steel plate, the material brand and plate number markings of the main parts are transplanted, and then the wall panel cutting is carried out; S2: Siding bending: S21: Wall panel bending processing: modeling and unfolding of outer wall panels, processing and forming of twisted wall panels, and bending of outer wall panels; S22: External wall panel inspection: wire drawing inspection, sample inspection, tooling frame inspection; S23: Siding Correction: Repeat the following steps: positioning the tooling frame on the siding, determining the siding correction line, flame correcting the siding, and checking the gap between the siding and the tooling frame until the test is qualified. S24: Siding acceptance; Step S21 includes the following specific steps: S211: Exterior wall panel modeling and development: According to the main tower segmentation and block plan, the main tower exterior wall panels are split into processed panels of varying lengths of 3 to 6 meters. The bent and twisted panels are then unfolded using a 3D model. Based on the spatial coordinates of the twisted components, the four edge lines of the bent and twisted components are determined. The wall thickness is then input to automatically generate a twisted solid model. The arbitrary spatial coordinates of each panel are obtained, and the panels are automatically unfolded. Simultaneously, the installation position lines of the stiffeners on the panels are generated. S212: Twisted wall panel forming: Before the wall panel is processed, the processing bending line, the assembly normal control line and the inspection reference line after the forming process are drawn on the wall panel. The processing bending line is set according to the linear angle of the wall panel end face and is parallel to the linear shape of the end face every 240 to 500 mm. The wall panel forming process adopts the hydraulic press to carry out cold pressing. When processing the wall panel, the fillet of the pressing film is selected, and then the wall panel is pressed according to the bending line. The pressing is carried out step by step from one end to the other end, and the angle template is used for measurement. The wall panel is pressed repeatedly until the forming requirements are met. S213: External wall panel bending: After the twisted outer wall panels are CNC-cut, the size, direction of the bevel and the geometric dimensions of the outer wall panels are inspected to see if they meet the specification requirements. After the inspection, the outer wall panels that have passed the inspection are bent on the twisted surface. The bending process and preliminary inspection steps are as follows: Bending line layout: Place the outer wall panel on the platform, divide the bending points into equal parts according to the length of the outer arc according to the expanded drawing of the outer wall panel, and divide the bending points of the inner arc into equal parts according to the length of the equal chord. Then, use chalk or ink lines to draw the corresponding equally divided bending points of the inner and outer arcs, and mark the height difference of the Z axis relative to the 0 point. Use chalk or ink lines to draw the sample inspection lines at the upper and lower ends, as well as the positioning lines for assembling the partitions and longitudinal ribs. The positioning accuracy of the equally divided bending points should be controlled within ±2mm. Bending equipment debugging and data input: According to the values ​​of the X / Y / Z axes of the outer wall panel's twisted surface, input the relevant data of each bending line and the angle between the upper and lower ends on the bending equipment console. The equipment must be debugged before bending; Bending of outer wall panels: Align the bending line of the outer wall panel with the blade of the bending machine. The bending should be carried out step by step from one end to the other, and use an angle template for process measurement and control to avoid excessive pressing. Repeat the pressing of the wall panel until the basic requirements of the forming process are met.

2. A method for processing a spatially distorted wall panel according to claim 1, characterized in that: In step S1, the wall panel cutting must meet the technical requirements of steel plate splicing: The length of the inner and outer wall panels shall not be less than 1000mm, and the width shall not be less than 200mm; The butt welds in the longitudinal and transverse directions of the steel plate splicing joints shall adopt cross-shaped or T-shaped cross-shaped welds. When T-shaped cross-shaped welds are used, the distance between the intersection points shall be staggered by not less than 200mm. Before splicing steel plates, check the part numbers, dimensions and groove directions according to the drawings, and splice after confirming that they are correct; When steel plates of different thickness are butted together, if the thickness difference is greater than 4.0mm, one side of the thicker plate should be processed into a slope with a slope of 1:

8. The inner and outer wall panels should be kept flush with the outside of the box. Before assembly, the oxide scale, rust, oil stains, and harmful paint substances in the area to be welded must be thoroughly removed, so that the weld and the 30mm wide area on both sides can reveal the metallic luster; When the width and length of a single steel plate cannot meet the requirements, the steel plates are spliced ​​horizontally and vertically; when splicing steel plates, the order of splicing the length first and then the width is adopted.

3. The method for processing a spatially distorted wall panel according to claim 1, characterized in that: In step S1, the wall panel cutting must meet the technical requirements of layout and numbering: Before cutting the steel plate, the surface is shot blasted to Sa2.5 level, the surface roughness is Rz50~80μm, and one coat of alcohol-soluble inorganic zinc silicate shop primer is sprayed with a thickness of 20μm; Before numbering, check the steel material certificate, check the brand, specification and quality of the steel plate, and number the material after confirming that everything is correct. Number the parts of different specifications and materials separately, and number the parts in order of the large ones first and the small ones later. When typesetting, record the specifications, materials, and batch numbers of the parts, make clear notes on the typesetting drawing and typesetting parts list, and keep a record of the typesetting list for future reference; When cutting the load-bearing parts of the main components, make sure that their load direction is consistent with the rolling direction of the steel plate; The main welds of the inner and outer wall panels are welded with R50 holes, and the other unspecified parts are welded with R35 holes; The instruments, equipment and measuring instruments used for quality inspection shall be verified and calibrated by the statutory metrology institutions and shall be used only after passing the inspection.

4. A method for processing a spatially distorted wall panel according to claim 3, characterized in that: The siding cutting must meet the technical requirements for layout and numbering, including the marking requirements for internal and external siding panels: The wall panels are clearly and neatly numbered, marked with a paint pen or inkjet printer, with a font width of 40mm and a height of 60mm; The numbers of the four connecting wall panels of the inner and outer wall panels are clearly marked; The outside of the inner and outer siding boxes are clearly marked; The partition and longitudinal rib positioning lines of the inner and outer wall panels are marked with ink lines.

5. The method for processing a spatially distorted wall panel according to claim 3, characterized in that: The wall panel cutting must meet the technical requirements of layout and numbering, including the requirements for the processing allowance of the inner and outer wall panels: The inner and outer wall panels are cut into sections according to the theoretical size, and a 5mm gap is left at the on-site welding groove as a shrinkage allowance for horizontal welding. The inner and outer wall panels are cut in sections according to the theoretical size in the height direction, and a 5mm gap is left at the on-site welding groove as a shrinkage allowance in the height direction; When multiple segments are matched and manufactured on the same tooling, the wall panel length of the middle segment is cut according to the theoretical size, with an allowable deviation of +3 to 5 mm; the wall panel length of the longitudinal end segments leaves a welding and secondary cutting allowance of 30 mm each on the outermost side.

6. The method for processing a spatially distorted wall panel according to claim 1, characterized in that: Step S22 includes the following specific steps: S221: Wire pulling detection: Place the processed wall panels steadily without any obvious shaking; Pad the four outermost points of the wall panel to the same elevation, and use a wire to measure the sagittal height of each point on the bending line drawn on the wall panel before forming and the horizontal line. The deviation of the sagittal height f of each point is ≤±2.0mm; The cross intersection point and the intersection point of the cross line and the middle longitudinal line are detected. The Z coordinates of the three points are calculated according to the length ratio of the bending line closest to the detection point. If the detection point is located between two bending lines, the average Z coordinates calculated by the two bending lines are taken. After wall panel processing, the chord length L1 / L2 / L3 / L4 ≤ ± 2.0mm, and the diagonal C1 / C2 allows a deviation of 3mm; if the inspection does not meet the above accuracy requirements, it will be pressed again and adjusted.

7. A method for processing a spatially distorted wall panel according to claim 6, characterized in that: Step S22 includes the following specific steps: S222: Sample inspection: The sample is made of laser-cut, 1-2mm thick color steel plate, 100-200mm wide on both sides, and 2.0-2.5m long. The sample is numbered after being cut into pieces. Test according to the two sample inspection lines that pop up before bending. For overall testing, the segmented sample needs to be spliced ​​into a straight line and a plane for testing; The bending size deviation is detected by the fit between the curved edge of the sample and the curved edge of the outer wall panel. The points with large deviations are pressed again for adjustment.

8. The method for processing a spatially distorted wall panel according to claim 7, characterized in that: Step S22 includes the following specific steps: S223: Tooling tire frame inspection: The height of the pole is set to 0.5~1m, the inner adjusting steel pipe can adjust the height to 300~500mm, and the adjusting screw can adjust the height to 60mm; The tooling frame is erected on the concrete floor, and the concrete floor is entirely paved with steel plates or slats to meet the width of the tooling poles; The tooling poles and the steel plates on the ground must be welded firmly. The vertical spacing of the poles is 500mm and the horizontal spacing is 1000mm. The tooling poles are connected with horizontal and vertical support by angle steel in the horizontal and vertical directions. After the tooling frame is set up, measure the overall connection line elevation to ensure that the line shape is consistent with the drawing and completely correct before testing the wall panels. When testing each different wall panel, adjust the height of the tooling pole to ensure that it is consistent with the distortion line shape of the tested wall panel. Place the wall panel on the fixture and check the gap between the wall panel and the fixture. The allowable deviation of the gap between the wall panel and the screw is ±2mm.

9. The method for processing a spatially distorted wall panel according to claim 1, characterized in that: In step S23, the wall panel correction must meet the technical requirements of wall panel flame heating correction: When bending and heating, the flame temperature should be controlled at 600-800℃, and repeated heating of the same part should not be done multiple times. Over-burning is strictly prohibited. During bending heating, the interval between the flame baking parts of each heating area of ​​the wall panel shall be at least 100-200mm, and the front and back heating shall not be performed on the same part; When bending and heating, cool freely in the air; if external force is required, apply it evenly; Place the bent wall panel on the tooling frame for correction, check the gap between the outer wall panel and the tooling, and correct it from the middle to the surrounding areas; Correction line confirmation: Select the correction line according to the longitudinal, transverse or oblique gap of the tooling, starting with the maximum gap line and the middle, and gradually correct towards the smaller gaps and edges.

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