A welding method for a single pile foundation cage

Abstract

The application discloses a welding method of a single-pile foundation sleeve cage and relates to the technical field of offshore wind power generation, which comprises the following steps: S1, welding to form small assemblies, wherein each small assembly is vertically welded by a ring beam and a plurality of support beams; S2, sequentially placing the plurality of small assemblies on a roller frame in a horizontal direction under the cooperation and fixation of a travelling crane, wherein the roller frame is an adjustable roller frame; and S3, performing welding on the small assemblies in a flat welding mode. The application effectively reduces the welding difficulty, avoids the rolling and even collapse of the ring beam on the roller frame during the assembly process, avoids repeated adjustment of the ring beam, and finally greatly improves the welding efficiency and welding precision.

Description

Technical Field

[0001] This invention relates to the field of offshore wind power generation technology, and more specifically, to a welding method for a monopile foundation cage. Background Technology

[0002] In the offshore wind power industry, the cage, a common auxiliary component of offshore wind turbine monopile foundations, is typically a cage-like ring beam structure reaching 20-30 meters in height. Traditional cage welding methods are mostly vertical welding, which presents several problems: First, it requires scaffolding for fabrication, resulting in high costs for renting steel pipes and hiring scaffolders, leading to high-altitude work costs; second, several parts require overhead welding, demanding high skill levels from welders and limiting efficiency and quality control; third, the large height and diameter of the cage ring beam assembly make indoor fabrication unsuitable, while outdoor work is significantly affected by the environment, posing numerous safety and quality risks.

[0003] Existing technologies for welding methods of monopile foundation cages, such as the assembly device for offshore wind power monopile foundation cages in patent application CN209439677U, can utilize axial adjustment mechanisms to ensure the concentricity of the cage ring beams to a certain extent, and on this basis, achieve horizontal welding of the cage. However, the welding of existing technologies is difficult, prone to welding deformation, and the ring beams are prone to rolling during assembly, which greatly affects welding efficiency and welding accuracy. At the same time, existing technologies often first unify the concentricity of each ring beam and then weld the support beams. In this case, the ring beams often need to be readjusted again when welding the support beams, which further affects welding efficiency and welding accuracy.

[0004] Therefore, a new technical solution is needed to solve the above-mentioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to provide a welding method for a single pile foundation cage, in order to solve the technical problems mentioned in the background art, such as high welding difficulty, easy welding deformation, easy rolling of the ring beam during assembly, which easily affects welding efficiency and welding accuracy, and the fact that most existing technologies require more than one adjustment of the ring beam, which further affects welding efficiency and welding accuracy.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A welding method for a cage-like structure in a monopile foundation includes the following steps:

[0008] S1. Welding to form small components, wherein each small component is formed by vertically welding a ring beam and multiple support beams on the ground or a jig.

[0009] S2. With the help of the crane, multiple small components are placed horizontally on the roller frame for assembly. The roller frames are all adjustable.

[0010] S3. The assembled small components are welded using a flat welding method. Specifically, 2 to 3 welders are arranged to perform symmetrical welding. During the symmetrical welding process, the rollers of the rotating roller frame are used to perform flat welding at the top and bottom of the joint position between each support beam and the ring beam.

[0011] S4. After welding is completed, a ring beam is concentrically welded at or near the end of the last small component to form the main body of the cage.

[0012] S5. Weld other accessories onto the main body of the cage.

[0013] Furthermore, in step S2, the specific assembly operation process is as follows: First, determine the assembly positions of the ring beams and support beams of two adjacent small components according to the drawings, and mark the ring beams. Then, rotate the rollers of the roller frame corresponding to the next small component until its ring beam rotates to the docking position with the support beam of the previous small component. Then, spot weld it at the docking position. During the assembly of two adjacent small components, a crane is required for fixation. The remaining small components are assembled as needed. Small components that have been assembled do not need to be fixed by a crane. Newly added small components need to be fixed by a crane. The concentricity of the ring beams of each small component during assembly is ensured by adjusting the height of the rollers of the roller frame.

[0014] Furthermore, the adjustable roller frame is a hydraulically jacking roller frame.

[0015] Compared with the prior art, the beneficial effects of the present invention are:

[0016] 1. In this invention, the ring beam and its matching support beam are first vertically welded into small components (single sets) before assembly welding. This solves the problem of easy welding deformation and effectively avoids repeated adjustments to the ring beam, greatly improving assembly efficiency, welding efficiency, and welding precision. Furthermore, in this invention, multiple small components are sequentially placed horizontally on an adjustable roller frame for assembly, and a crane is used for coordination and fixation. This effectively prevents the ring beam from rolling or even collapsing on the roller frame during assembly, greatly improving assembly precision and further enhancing welding efficiency and precision. In addition, the assembled small components are fixed by flat welding, effectively reducing welding difficulty and further ensuring welding efficiency and precision.

[0017] 2. In this invention, 2 to 3 welders are arranged to perform symmetrical welding, that is, 2 to 3 welders are installed to weld 2 to 3 symmetrical positions simultaneously. This not only greatly improves welding efficiency, but also further prevents welding deformation of the ring beam. On this basis, this invention uses the rollers of the rotating roller frame to perform flat welding at the top and bottom of the joint position between each support beam and the ring beam, which further ensures that the welding difficulty is reduced.

[0018] 3. In this invention, the first and second small components need to be fixed by a crane during assembly. The remaining small components are assembled and extended as needed. The small components that have already been assembled do not need to be fixed by a crane, while the newly added small components need to be fixed by a crane. This setting fully ensures the stability of the ring beam during assembly and improves the assembly accuracy. At the same time, it enables the operation to be carried out with a maximum of only two cranes, which effectively improves the convenience of assembly and ultimately further ensures the improvement of welding efficiency and welding accuracy.

[0019] 4. The present invention uses a hydraulic lifting assembly to form a roller frame, which effectively facilitates the welding of tapered cages and further improves its welding efficiency and welding accuracy. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the component of the present invention;

[0021] Figure 2 This is a schematic diagram illustrating the working principle of the present invention (omitting the crane and only using two small components as an example);

[0022] Figure 3 This is a schematic diagram illustrating the working principle of flat welding in this invention;

[0023] In the diagram: 1. Ring beam, 2. Support beam, 3. Roller frame;

[0024] A represents the welding position between the ring beam and the support beam in the small component; B represents the docking position between the support beam of the previous small component and the ring beam of the next small component; B1 represents the top of the docking position between the support beam of the previous small component and the ring beam of the next small component; and B2 represents the bottom of the docking position between the support beam of the previous small component and the ring beam of the next small component. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0026] Please see Figures 1-3 It illustrates a welding method for a single-pile foundation cage, comprising the following steps:

[0027] S1. Vertically weld the ring beam 1 and multiple support beams 2 onto the ground or a jig to form a small assembly (such as...). Figure 1 As shown, the welding position corresponding to ring beam 1 and support beam 2 at this time is point A).

[0028] S2. First, place the first small component horizontally on the roller frame 3 (hydraulic lifting assembly roller frame) using the crane. Then, place the second small component horizontally on another roller frame 3 using the crane and assemble it with the first small component.

[0029] During assembly, first determine the docking positions of the ring beam 1 and support beam 2 of the two small components according to the drawings (original technical drawings or process drawings decomposed from the original technical drawings). After marking the positions on the ring beam 1, with both small components being lifted by a crane, rotate the rollers of the roller frame 3 of the second small component, causing the ring beam 1 of the second small component to rotate until the ring beam 1 of the second small component rotates to the docking position with the support beam 2 of the first small component. At the docking position (e.g., Figure 2 Spot welding is used to fix the area at point B shown.

[0030] S3. Subsequent small components are spliced ​​and assembled as needed, referring to the method in step S2. The small components that have been assembled are no longer fixed by the crane, while the newly added small components are fixed by the crane. Throughout the process, the concentricity of the ring beam 1 of each small component is ensured by adjusting the height of the rollers of the roller frame 3 during assembly.

[0031] S4. When welding two adjacent small components, arrange 2 to 3 welders to weld 2 to 3 symmetrical points B at the same time. Tools such as ladders or elevated platforms can be used during welding.

[0032] During the welding process, the weld at B1 can be welded first. After the weld at B1 is completed, rotate the rollers of roller frame 3 so that B2 returns to the original position of B1, and then weld the weld at B2 (B1 and B2 can be arc-shaped or semi-circular).

[0033] S5. At the end of the last small component or near the end, a ring beam 1 is welded concentrically to form the main body of the cage.

[0034] S6. Weld other accessories (other specialized parts) onto the main body of the cage.

[0035] The welding fixtures and flux used in this invention are existing technologies and will not be described further here.

Claims

1. A welding method for a cage-like structure in a monopile foundation, characterized in that, Includes the following steps: S1. Welding forms small components, wherein each small component is vertically welded from a ring beam and multiple supporting beams; S2. With the help of the crane, multiple small components are placed horizontally on the roller frame for assembly. The roller frames are all adjustable. S3. The assembled small components are welded using a flat welding method; The specific operation process of step S2 is as follows: First, determine the assembly position of the ring beam and support beam of the two adjacent small components according to the drawings, and mark the ring beam. Then, rotate the roller of the roller frame corresponding to the next small component until its ring beam rotates to the docking position with the support beam of the previous small component. Then, spot weld it at the docking position. During the assembly of the two adjacent small components, a crane is required for fixation. The remaining small groups are assembled as needed. The small components that have been assembled do not need to be fixed by a crane. Newly added small components need to be fixed by a crane. The concentricity of the ring beams of each small component during assembly is ensured by adjusting the height of the roller of the roller frame. The specific operation process of step S3 is as follows: Arrange 2 to 3 welders to perform symmetrical welding. During the symmetrical welding process, the rollers of the rotating roller frame are used to perform flat welding at the top and bottom of the joint position between each support beam and the ring beam. The welding method also includes welding a ring beam concentrically at the end or near the end of the last small component after the assembled small components are welded to form the cage body, and welding other accessories onto the cage body.

2. The welding method for a single-pile foundation cage according to claim 1, characterized in that, In step S1, the ring beam and the support beam are welded on the ground or on the jig.

3. The welding method for a single-pile foundation cage according to claim 1, characterized in that, The adjustable roller frame is a hydraulically jacking roller frame.

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