A method for manufacturing a segmented octagonal space structure steel tower diaphragm

Abstract

The application relates to a whole-to-part octagonal space structure steel tower partition plate manufacturing method for the production and manufacturing of complex octagonal variable cross-section space structure steel tower partition plates, the whole tower adopts CATIA three-dimensional overall modeling, then the steel tower inner partition plates are scientifically and reasonably divided into blocks according to the assembly sequence of each wall plate unit designed, and are divided onto corresponding wall plate units as small transverse ribs of the wall plate units, the space transverse rib wall plate unit is assembled through laser double-line marking, reference line alignment and design of an installation space angle sample, the space positioning of the small transverse rib and the wall plate unit is accurately controlled, and finally the partition plate can be restored only by accurately controlling the angle and position of the wall plate unit during segment assembly. Advantages: the partition plate manufacturing method can fully solve the difficulties in the manufacturing of the complex space variable cross-section steel tower partition plate, the production efficiency is improved, and the method can be well referenced for subsequent similar steel bridge manufacturing.

Description

Technical Field

[0001] This invention relates to a method for manufacturing octagonal spatial structure steel tower partitions by breaking them down into smaller parts, which is used for the production and manufacturing of complex octagonal variable cross-section spatial structure steel tower partitions and belongs to the field of steel bridge manufacturing technology. Background Technology

[0002] Traditional steel towers consist of wall panel units and diaphragm units. The stiffeners on the wall panel units are perpendicular to the panel itself, and the diaphragm units are typically fabricated and installed as a single piece, making their manufacturing relatively simple. However, this approach cannot meet the demands of urbanization, which requires urban steel bridges with increasingly diverse cross-sectional shapes. These diverse cross-sectional shapes present challenges such as complex spatial angles, high manufacturing precision requirements, and significant manufacturing difficulties.

[0003] If the complex octagonal variable cross-section spatial angle structure steel tower diaphragms are manufactured separately using traditional whole diaphragms, although the diaphragm unit is a single piece and does not need to be manufactured separately, the following problems exist: First, the diaphragm has an irregular, porous structure, and the whole-piece manufacturing results in high material consumption, low utilization rate, significant waste, and high cost; second, the steel tower has an octagonal spatial structure, and during segment assembly, each diaphragm requires the design and installation of different control fixtures to position its spatial attitude and location, which is difficult to position and consumes a large amount of fixture materials; third, the steel tower has an octagonal variable cross-section and a complex spatial structure, and the steel tower diaphragm... The large spatial angle between the plate and the wall panel, coupled with the limited space for assembly and welding, makes it difficult to guarantee the positional accuracy and welding quality of the partition and wall panel during segment assembly, and poses certain safety hazards. Fourth, during segment assembly, the longitudinal stiffening ribs on the wall panel unit need to pass through the stiffening holes on the partition. Due to the spatial structure of the steel tower, interference occurs, and the longitudinal stiffening ribs on the wall panel unit cannot pass through the stiffening holes on the partition smoothly. Therefore, the longitudinal stiffening ribs on the wall panel unit need to be broken at the partition position, and a large number of interlocking structures need to be added. Fifth, there are partition units that are manufactured and assembled separately, resulting in a large number of plate units manufactured and high labor and material consumption costs.

[0004] These problems will greatly affect the steel tower manufacturing schedule, resulting in high consumption of labor and materials, high costs, and difficulty in controlling the manufacturing precision of the steel tower. Summary of the Invention

[0005] Design objective: To overcome the shortcomings of the prior art, this paper proposes a method for manufacturing octagonal spatial structure steel tower partitions by breaking them down into smaller parts. Specifically, the entire partition within a steel tower segment is scientifically and rationally divided into smaller pieces, which serve as small transverse ribs for the wall panel units. These smaller pieces are manufactured together with the wall panel units. During the assembly of the steel tower segments, the partitions are restored by precisely positioning and assembling the wall panel units. This method can effectively solve the manufacturing challenges of complex steel tower structures and improve production efficiency.

[0006] Design Scheme: To achieve the aforementioned design objectives, this invention, through in-depth analysis of the structural and construction characteristics of a complex octagonal variable cross-section spatial angle steel tower and its partitions, proposes to scientifically and rationally divide the entire partition within the steel tower into smaller pieces according to the assembly sequence of the steel tower segments. These smaller pieces serve as small transverse ribs for the wall panel units. During the wall panel unit assembly, these ribs are directly assembled onto the wall panel units. During the segment assembly, the partitions are restored by precisely positioning and assembling the wall panel units. Specifically, the entire tower is modeled using CATIA 3D. The partitions within the steel tower are then scientifically and rationally divided into blocks according to the designed assembly sequence of each wall panel unit, and these blocks are assigned to the corresponding wall panel units as small transverse ribs. During the assembly of the spatial transverse rib wall panel units, laser double-sided scribing, baseline alignment, and the design and installation of spatial angle templates allow for precise control of the spatial positioning of the assembled small transverse ribs and wall panel units. Finally, during segment assembly, the partitions are restored simply by precisely controlling the angle and position of the wall panel units.

[0007] Compared with the prior art, this invention has the following advantages: First, by dividing the partition into small horizontal ribs, it avoids the disadvantages of high material consumption and high cost when manufacturing partitions with irregular holes as a whole, thus improving material utilization. Second, by pre-dividing the partition into small horizontal ribs and assembling them onto the wall panel unit, it avoids and solves the problem of the traditional method of designing and installing a large number of tooling fixtures to position the spatial posture and position of the partition during the assembly of steel tower segments, which is difficult to position and consumes a lot of materials. Third, it avoids the difficult problem of assembling and welding the partition and wall panel of the complex octagonal variable cross-section spatial structure steel tower under conditions of large spatial angles, narrow working space, and certain safety hazards. Fourth, it effectively avoids the problem of interference between the longitudinal stiffening ribs on the wall panel unit and the stiffening holes on the partition during segment assembly. Fifth, there are no separately manufactured and assembled partition units during the manufacturing of steel tower plate units and segment assembly, resulting in fewer plate units and greatly improving the efficiency and accuracy of segment manufacturing. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the segment elevation.

[0009] Figure 2 This is a schematic diagram of the horizontal cross-section of the segment elevation.

[0010] Figure 3 This is a schematic diagram of a spatial transverse ribbed wall panel unit.

[0011] Figure 4 This is a schematic diagram of the manufacturing method for an octagonal variable cross-section spatial structure steel tower. Implementation

[0012] Example 1: Refer to Appendix Figure 1-4A method for manufacturing partitions in an octagonal spatial structure steel tower: The central axis of the steel tower is in space, with an angle of 62.2° to the longitudinal projection of the bridge and an angle of 76.8° to the transverse projection of the bridge. The tower column axis is 87.445m long, and the cross-section gradually changes from 5.2m x 8.5m to 3.2m x 4m. A partition is horizontally arranged every 2m in height inside the steel tower.

[0013] (1) The steel tower is modeled in three dimensions using CATIA. Currently, CATIA modeling is a well-known technology for complex structures. It can simulate reality in advance and intuitively grasp the internal structure of the steel tower, effectively control the accuracy in actual manufacturing, avoid spatial interference, and comprehensively improve production efficiency and ensure manufacturing accuracy. When modeling, the specific modeling method is limited by the CATIA modeling software. The method and steps are relatively conventional. Usually, the structural dimension data shown in the design drawing is used as the basis. First, the central axis baseline of the steel tower is established. Then, the corresponding steel tower cross sections at different heights are established based on the central axis. Next, all tower walls are fitted to form the outline model of the entire steel tower. Finally, partitions and horizontal and vertical stiffening are established inside it. The steel tower model is then completed.

[0014] (2) The steel tower transverse ribs (diaphragms) are divided into 12 small transverse ribs. The shape of the small ribs should take into full account the assembly and restoration sequence of the diaphragms. The principle of assembling the small ribs one after another is to avoid interfering with the assembly of the small ribs one after another. The joints of the small ribs should be selected as short as possible and at the center of the arc.

[0015] (3) Blanking and laser scribing of plate unit parts: The accurate contour data of each part is exported from the CATIA model, and then the contour data is entered into the CNC blanking machine for CNC blanking. Finally, it must be ensured that the solid contour deviation of the plate unit part |actual-theoretical| ≤ 0.5mm;

[0016] Laser scribing technology has only recently begun to be applied to the manufacturing of large-scale, complex steel structures. Because laser scribing equipment is expensive, it is not currently used in the manufacturing of conventional bridge steel structures and has not been widely adopted. The assembly position lines of steel plates are still mainly drawn manually using traditional methods. The process involves placing the steel plate on a laser scribing machine, programming the required position lines of the steel plate and inputting them into the computer, and then the computer automatically scribing the lines according to the program.

[0017] (4) Assembly of wall panel units (design and install horizontal ribs and wall panel angle templates). On the wall panel parts, use the horizontal rib position line as a reference to fix the angle template in advance to ensure that the angle template is accurately positioned and firmly fixed. Then assemble and position the horizontal ribs along the horizontal rib position line on the wall panel, and control the spatial assembly angle through the angle template.

[0018] (5) Assembly of transverse rib wall panel units in each space of the steel tower (on the horizontal assembly platform, according to the tilt direction of the spatial steel tower structure, select the outer wall panel unit that tilts outward and assemble each wall panel unit in a staggered manner in sequence). Figure 1 (Assemble from right to left) During the process, reliable supports must be installed immediately after each wall panel unit is in place.

[0019] (6) Steel tower partition manufacturing completed (After the assembly and welding of each space transverse rib wall panel unit of the steel tower is completed, each small transverse rib is restored to the steel tower partition, forming a whole large partition, that is, the steel tower partition manufacturing is completed. The flatness of the entire steel plate of the steel tower is ≤1mm, the misalignment at each joint is ≤0.5mm, and the deviation of the partition outline dimension is ≤1mm).

[0020] It should be understood that although the above embodiments provide a relatively detailed textual description of the design concept of the present invention, these textual descriptions are merely simple textual descriptions of the design concept of the present invention, and not limitations on the design concept of the present invention. Any combination, addition, or modification that does not exceed the design concept of the present invention falls within the protection scope of the present invention.

Claims

1. A method for manufacturing octagonal spatial structure steel tower partitions by breaking them down into smaller parts, characterized by: The central axis of the steel tower is at an angle of 62.2° with the longitudinal projection of the bridge and 76.8° with the transverse projection of the bridge. The tower column is 87.445m long, and the cross-section gradually changes from 5.2m x 8.5m to 3.2m x 4m. A partition is horizontally installed every 2m in height inside the steel tower. The entire tower is modeled in 3D using CATIA. Then, the partitions inside the steel tower are scientifically and rationally divided into blocks according to the assembly sequence of the designed wall panel units, and assigned to the corresponding wall panel units as small transverse ribs of the wall panel units. When assembling the spatial transverse rib wall panel unit, laser double-sided scribing, baseline alignment, and design and installation of spatial angle templates are used to precisely control the spatial positioning of the small transverse ribs and wall panel units. Finally, during segment assembly, the partition can be restored simply by precisely controlling the angle and position of the wall panel unit.

2. The method for manufacturing octagonal spatial structure steel tower partitions according to claim 1, characterized in that: The steel tower was modeled in 3D using CATIA. Based on its own structural characteristics, the manufacturing and assembly process was designed, and a scientific and reasonable partition block scheme was designed. All parts of the plate unit are cut using CNC cutting, including all parts of the steel tower for both the outer and inner wall plate units; When assembling the wall panel units, laser double-sided scribing technology is used, and a space angle template for the horizontal ribs is designed and installed. The assembly angle of each wall panel and the horizontal rib is obtained in advance in the model. Then, based on the different angle relationships between the horizontal ribs and the wall panel units, a specific triangular template is made to control the assembly angle between the horizontal ribs and the wall panels. When assembling steel tower segments, the misalignment between adjacent interfaces of the transverse ribs on the wall panel unit should be ≤0.5mm.

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