A saddle type tower crown manufacturing process

Abstract

The application relates to a saddle-shaped tower crown manufacturing process, characterized in that the specific manufacturing process is as follows: S1, wall plate manufacturing and assembly; S2, face web plate manufacturing and assembly; S3, special-shaped rib plate manufacturing and assembly; S4, partition plate unit manufacturing and assembly; S5, bottom longitudinal rib plate setting; S6, top panel manufacturing and assembly; S7, tower crown assembly; the tower crown section adopts a modular assembly mode, each component after blanking and manufacturing is hoisted onto a jig in sequence, and assembly is performed on the jig; then, wall plates are assembled first, and then bottom panels, webs, rib plates, partition plates and top panels are assembled; according to the assembly process, the manufacturing of a half saddle-shaped tower crown can be quickly completed, the whole tower crown is divided into two sections for symmetrical manufacturing, and the components can be simultaneously processed, so that the processing efficiency and the assembly efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of bridge tower manufacturing technology, and in particular to a manufacturing process for a saddle-shaped tower crown. Background Technology

[0002] The main towers of the bridge both adopt a steel-concrete composite structure. The tower columns are divided into three sections: upper, middle, and lower. The upper tower columns are made of steel, while the middle and lower columns are made of concrete. Based on the hoisting and erection capacity requirements, the steel tower columns were re-segmented to determine the blocks to be hoisted on-site. Furthermore, when the weight and dimensions of the hoisting blocks exceeded the capacity of the cranes and flatbed trucks in the workshop, further segmentation was necessary. The overall principle was to maximize the dimensions of the individual blocks and minimize the number of blocks, based on the various constraints during the steel tower production and erection process.

[0003] The tower crown is located at the top of the bridge's steel tower structure. The fabrication and installation of the tower crown should also follow the principle of increasing the external dimensions of the sections and reducing the number of sections. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a manufacturing process for a saddle-shaped tower crown, which can solve the problems of multiple segments, redundant and complex processing and manufacturing processes, and low production efficiency in general bridge tower crowns.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a manufacturing process for a saddle-shaped tower crown, the innovation of which is as follows: the specific manufacturing process is as follows:

[0006] S1: Panel fabrication and assembly: Cut and fabricate a convex-shaped, curved panel A, and weld a rectangular panel B to the end of panel A to form a convex panel; cut and fabricate a concave-shaped, curved panel C, and weld a rectangular panel D perpendicularly to the end of panel C; then weld a panel E perpendicular to both panels C and D to the sides of panels C and D to form a concave panel; finally, embed the convex panel into the concave panel and weld it in place to form the panel.

[0007] S2: Fabrication and assembly of face and web panels: Cut the bottom face panel and a pair of web panels. The bottom face panel is set vertically on the side of the wall panel. The pair of web panels includes an arc-shaped web panel and a rectangular web panel. The rectangular web panel is set vertically at one end of the wall panel and is also perpendicular to the bottom face panel. The arc-shaped web panel is connected to one side of the rectangular web panel and is perpendicular to the bottom face panel.

[0008] S3: Fabrication and assembly of irregular ribs: Cut the first set of irregular transverse ribs according to the design requirements, and weld the first set of irregular transverse ribs vertically to the inner side of the wall panel and the inner side of the rectangular web; cut the irregular longitudinal ribs according to the design requirements, fasten the irregular longitudinal ribs onto the wall panel and mate them with the first set of irregular transverse ribs; then mate the second set of irregular transverse ribs with the irregular longitudinal ribs and set them perpendicular to the web and the inner wall of the wall panel;

[0009] S4: Fabrication and assembly of partition unit: Cut the partition according to the design requirements, and then set the side end and surface of the partition perpendicular to the second set of irregular transverse ribs, and the bottom end perpendicular to the bottom panel.

[0010] S5: Bottom longitudinal rib plate setting: Cut the bottom longitudinal rib plate according to the design requirements, then pass it through the partition unit in sequence and connect the ends to the face plate. The bottom longitudinal rib plate is welded perpendicular to the bottom panel.

[0011] S6: Fabrication and assembly of the top panel: Cut the top panel according to the design requirements, and weld the top panel to the partition unit, web plate and wall panel; finally, weld the top longitudinal rib to the back of the top panel to complete half of the manufacturing of the saddle-shaped tower crown.

[0012] S7: Assembly of the crown: Repeat steps S1-S6 to complete the production of the other half of the saddle-shaped crown, and finally weld them symmetrically to complete the production of the crown.

[0013] Furthermore, in S1, the butt weld between plate A and plate B is a full penetration weld, using a root clear weld bevel; the fillet welds between plate C, plate D, and plate E are required to be deep penetration welds, with a penetration depth of 16mm; a single-sided 40° bevel with a 2mm root bevel is used, and the back side is sealed by electric welding.

[0014] The advantages of this invention are:

[0015] 1) In this invention, the tower crown segments adopt a modular assembly method. The components that have been cut and manufactured are hoisted onto the jig in sequence and assembled on the jig. Then, the assembly starts from the wall panel, followed by the bottom panel, web panel, ribs, partitions and top panel. Following this assembly process, half of the saddle-shaped tower crown can be made quickly. The entire tower crown is divided into two segments for symmetrical manufacturing. The components can be processed in groups at the same time, which improves the processing efficiency and assembly efficiency. Attached Figure Description

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

[0017] Figure 1 This is a schematic diagram of the structure of a saddle-shaped tower crown according to the present invention.

[0018] Figures 2 to 8 This is an assembly diagram illustrating the manufacturing process of a saddle-shaped tower crown according to the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0020] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0021] like Figures 1 to 8 The manufacturing process of a saddle-shaped tower crown shown is as follows:

[0022] S1: Panel fabrication and assembly: Cut and fabricate a convex-shaped, curved panel A, and weld a rectangular panel B to the end of panel A to form a convex panel; cut and fabricate a concave-shaped, curved panel C, and weld a rectangular panel D perpendicularly to the end of panel C; then weld a panel E perpendicular to both panels C and D to the sides of panels C and D to form a concave panel; finally, embed the convex panel into the concave panel and weld it in place to form the panel.

[0023] S2: Fabrication and assembly of face and web panels: Cut the bottom face panel and a pair of web panels. The bottom face panel is set vertically on the side of the wall panel. The pair of web panels includes an arc-shaped web panel and a rectangular web panel. The rectangular web panel is set vertically at one end of the wall panel and is also perpendicular to the bottom face panel. The arc-shaped web panel is connected to one side of the rectangular web panel and is perpendicular to the bottom face panel.

[0024] S3: Fabrication and assembly of irregular ribs: Cut the first set of irregular transverse ribs according to the design requirements, and weld the first set of irregular transverse ribs vertically to the inner side of the wall panel and the inner side of the rectangular web; cut the irregular longitudinal ribs according to the design requirements, fasten the irregular longitudinal ribs onto the wall panel and mate them with the first set of irregular transverse ribs; then mate the second set of irregular transverse ribs with the irregular longitudinal ribs and set them perpendicular to the web and the inner wall of the wall panel;

[0025] S4: Fabrication and assembly of partition unit: Cut the partition according to the design requirements, and then set the side end and surface of the partition perpendicular to the second set of irregular transverse ribs, and the bottom end perpendicular to the bottom panel.

[0026] S5: Bottom longitudinal rib plate setting: Cut the bottom longitudinal rib plate according to the design requirements, then pass it through the partition unit in sequence and connect the ends to the face plate. The bottom longitudinal rib plate is welded perpendicular to the bottom panel.

[0027] S6: Fabrication and assembly of the top panel: Cut the top panel according to the design requirements, and weld the top panel to the partition unit, web plate and wall panel; finally, weld the top longitudinal rib to the back of the top panel to complete half of the manufacturing of the saddle-shaped tower crown.

[0028] S7: Assembly of the crown: Repeat steps S1-S6 to complete the production of the other half of the saddle-shaped crown, and finally weld them symmetrically to complete the production of the crown.

[0029] The butt weld between plate A and plate B in S1 is a full penetration weld, using a root clearing weld bevel. The fillet welds between plates C, D, and E are required to be deep penetration welds, with a penetration depth of 16mm. A single-sided 40° bevel with a 2mm root bevel is used, and the back side is sealed by electric welding.

[0030] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a saddle-shaped tower crown, characterized in that: The specific manufacturing process is as follows: S1: Panel fabrication and assembly: Cut and fabricate a convex-shaped, curved panel A, and weld a rectangular panel B to the end of panel A to form a convex panel; cut and fabricate a concave-shaped, curved panel C, and weld a rectangular panel D perpendicularly to the end of panel C; then weld a panel E perpendicular to both panels C and D to the sides of panels C and D to form a concave panel; finally, embed the convex panel into the concave panel and weld it in place to form the panel. S2: Fabrication and assembly of face and web panels: Cut the bottom face panel and a pair of web panels. The bottom face panel is set vertically on the side of the wall panel. The pair of web panels includes an arc-shaped web panel and a rectangular web panel. The rectangular web panel is set vertically at one end of the wall panel and is also perpendicular to the bottom face panel. The arc-shaped web panel is connected to one side of the rectangular web panel and is perpendicular to the bottom face panel. S3: Fabrication and assembly of irregular ribs: Cut the first set of irregular transverse ribs according to the design requirements, and weld the first set of irregular transverse ribs vertically to the inner side of the wall panel and the inner side of the rectangular web; cut the irregular longitudinal ribs according to the design requirements, fasten the irregular longitudinal ribs onto the wall panel and mate them with the first set of irregular transverse ribs; then mate the second set of irregular transverse ribs with the irregular longitudinal ribs and set them perpendicular to the web and the inner wall of the wall panel; S4: Fabrication and assembly of partition unit: Cut the partition according to the design requirements, and then set the side end and surface of the partition perpendicular to the second set of irregular transverse ribs, and the bottom end perpendicular to the bottom panel. S5: Bottom longitudinal rib plate setting: Cut the bottom longitudinal rib plate according to the design requirements, then pass it through the partition unit in sequence and connect the ends to the face plate. The bottom longitudinal rib plate is welded perpendicular to the bottom panel. S6: Fabrication and assembly of the top panel: Cut the top panel according to the design requirements, and weld the top panel to the partition unit, web plate and wall panel; finally, weld the top longitudinal rib to the back of the top panel to complete half of the manufacturing of the saddle-shaped tower crown. S7: Assembly of the crown: Repeat steps S1-S6 to complete the production of the other half of the saddle-shaped crown, and finally weld them symmetrically to complete the production of the crown.

2. The manufacturing process of a saddle-shaped tower crown according to claim 1, characterized in that: The butt weld between plate A and plate B in S1 is a full penetration weld, using a root clear weld bevel. The fillet welds between plates C, D, and E are required to be deep penetration welds, with a penetration depth of 16mm. A single-sided 40° bevel with a 2mm root bevel is used, and the back side is sealed by electric welding.

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