A method for welding a large steel anchor chamber

Abstract

The application discloses a welding manufacturing method of a large steel anchor chamber, which comprises the following steps: (1), optimizing the groove form of each weld in the steel anchor chamber, determining the weld groove and processing; (2), assembling the anchor box components (6); (3), assembling the anchor box components (6) at the marked positions of the bridge middle side of the steel anchor chamber wall plate (2), and manufacturing the upper wall plate unit (13); (4), assembling the anchor box components (6) at the marked positions of the bridge middle side of the anchor chamber partition plate (5), and manufacturing the partition plate unit element (11); and (5), process welding of the steel anchor chamber assembly. By reasonably dividing the unit elements, optimizing the welding sequence, ensuring the welding quality, controlling the welding deformation and residual stress, and through the segmentation of the cable tower steel anchor chamber and the mechanical processing of the pressure bearing plate unit, the perpendicularity of the cable tower steel anchor chamber is ensured.

Description

Technical Field

[0001] This invention relates to the field of steel anchorage manufacturing technology in steel structure bridges, and in particular to a welding manufacturing method for large steel anchorages. Background Technology

[0002] The steel anchorage chamber of the pylon is a critical load-bearing component of the entire bridge, with a dense structure, limited space, and high requirements for welding quality and precision. The steel anchorage chamber is 6.0m high, 4.6m long along the bridge direction, and 2.36m wide across the bridge direction, with a single chamber weighing approximately 100t. Figures 1-3 As shown, the steel anchorage includes an upper steel box, a pressure plate 8, and pre-embedded anchors 10 embedded in the concrete tower. The upper steel box is divided into three cable chambers 1 with openings at the top in the transverse direction of the bridge. Each cable chamber 1 anchors four pairs of stay cables, and the three cable chambers 1 anchor a total of 12 pairs of stay cables. The stay cables are anchored by anchor box components 6 inside the cable chambers 1. The cable chambers 1 are rectangular. The cable chambers 1 on the outer side consist of wall plates 2 and partitions 5 arranged opposite each other on the base plate 4, and a pair of oppositely arranged web plates 3. The cable chambers 1 in the middle consist of a pair of oppositely arranged partitions 5 and a pair of oppositely arranged web plates on the base plate 4. The upper steel box extends outward from the periphery of the base plate 4. The anchor box components 6 are welded to the inner side of the wall plates 2 or partitions 5. Holes for the stay cables to pass through are opened on the web plates 3 and the base plate 4. The opening position of the holes corresponds to the setting position of the anchor box components 6. The specific setting position of the holes is determined according to the inclination angle of the stay cables. Anchoring structure 7 is welded to the base plate 4 around the bottom of the upper steel box. The upper end of the prestressed steel bolt passes through the top surface of the concrete tower column and is anchored to the base plate 4 of the upper steel box. The lower end of the prestressed steel bolt is anchored in the concrete tower column through pre-embedded anchors 10 (e.g., Figure 1 The wall panel 2 is vertically welded to the base plate 4, and the partition plates 5 are arranged in parallel along the transverse direction of the bridge and welded to the base plate 4. The web plate 3 is welded to the longitudinal sides of the partition plates 5 and wall panels 2, and the web plate 3 connects the partition plates 5 and wall panels 2 to form a cavity. Anchor box components 6 are arranged in the cavity. The anchor box components 6 are arranged in pairs symmetrically, and the two anchor box components 6 in each pair are arranged opposite each other and located on both sides of the longitudinal direction of the bridge. The anchor box components 6 on each side are arranged at intervals in the vertical direction. The main structure of the steel anchor chamber is made of Q370qD steel with a relatively thick plate, mainly including different plate thicknesses such as 30mm, 40mm, 46mm, 60mm, and 85mm.

[0003] like Figure 2 The anchor box component 6 shown mainly consists of an anchor plate 62, an anchor bearing plate 61, a force transmission web 63, and a stiffening plate 64. The anchor plate 62 is welded to one side of the anchor bearing plate 61 and has a through central hole for the cable to pass through. The force transmission web 63 is welded vertically at intervals to the other side of the anchor bearing plate 61. The stiffening plate 64 is vertically arranged along the outer wall of the force transmission web 63 and extends along the height direction of the force transmission web 63, and is arranged in parallel at intervals along the width direction of the force transmission web 63.

[0004] The steel anchor chamber of the cable tower is located on the top concrete bearing plate. The bearing plate plays a role in leveling, positioning and uniformly distributing the cable force. The flatness of the bearing plate is an important condition for ensuring the verticality of the steel anchor chamber of the cable tower.

[0005] The steel anchor chamber has a complex structure, thick plates, and dense components, and requires high manufacturing precision, which makes the welding and manufacturing of the entire product extremely difficult. Only by adopting scientific and rigorous welding processes and manufacturing methods can the entire product be manufactured.

[0006] In the existing technology, two steel anchor chambers for the pylons are set on each side of the centerline in the longitudinal direction of the bridge. The anchor chamber walls are parallel to the centerline. The side facing the centerline is the bridge center side (QZ side), and the side facing away from the centerline is the non-bridge center side. The side where the two steel anchor chambers of the pylons face each other on the centerline side is the mid-span side (KZ side), and the side where the two steel anchor chambers of the pylons face away from each other on the centerline side is the non-mid-span side. Summary of the Invention

[0007] This invention provides a method for manufacturing large steel anchor chambers, which solves the technical problems of difficulty in welding large steel anchor chambers, difficulty in controlling deformation, and difficulty in controlling welding quality in the prior art.

[0008] In light of the structural characteristics of the cable tower's steel anchor chamber, its manufacturing process will proceed through five stages: parts cutting, machining, component welding, unit welding, and assembly. By rationally dividing the unit components and optimizing the welding sequence, welding quality will be ensured, and welding deformation and residual stress will be controlled. Furthermore, the verticality of the cable tower's steel anchor chamber will be ensured through segmented machining of the steel anchor chamber and the pressure plate unit.

[0009] The technical solution of this invention is as follows: a welding manufacturing method for a large steel anchor chamber, the steel anchor chamber comprising wall plates, web plates, bottom plates, partition plates, anchor box components, and anchoring structures, the anchor box components comprising an anchor bearing plate, an anchor pad plate, a force-transmitting web plate, and a stiffening plate, wherein a cable tower steel anchor chamber embedded component is also installed at the lower part of the bottom plate, the cable tower steel anchor chamber embedded component comprising a bearing plate (40mm), a PBL shear connector, and embedded anchors; the welding manufacturing method for the large steel anchor chamber comprises the following steps:

[0010] (1) Optimize the bevel form of each weld in the steel anchor chamber, determine the weld bevel and process it;

[0011] (2) Assemble and weld anchor box components;

[0012] (3) Weld anchor box components at the positions marked on the bridge side of the wall panel to manufacture the upper wall panel unit;

[0013] (4) Weld anchor box components at the marked positions on the bridge side of the diaphragm to manufacture diaphragm unit components;

[0014] (5) Welding process of steel anchor chamber assembly, including:

[0015] Two partition unit pieces are stacked one on top of the first partition unit piece, and the upper partition unit piece is stacked on top of the uppermost partition unit piece.

[0016] Complete the welding of the partition unit to the lower wall panel or partition unit, and complete the welding of the upper wall panel unit to the lower partition unit.

[0017] Welding base plate;

[0018] Welding the web plate;

[0019] Flip the steel anchor chamber so that the upper opening of the steel anchor chamber faces upward. Weld the anchoring structure on the upper surface of the base plate and weld the PBL shear connector and bearing plate on the lower surface of the base plate.

[0020] The process of sequentially stacking two partition unit components on the first wall panel, and then stacking an upper wall panel unit on top of the uppermost partition unit component, includes:

[0021] (51) First, lay the first wall panel flat with the middle side of the bridge facing up, and weld the steel liner at the location where the anchor box component is set to manufacture the lower wall panel unit.

[0022] (52) The non-bridge middle side of the welded anchor box component of the diaphragm unit is facing the lower wall panel unit, so that the anchor box component is aligned with the steel liner. The steel liner is welded on the bridge middle side of the diaphragm unit according to the position where the anchor box component is set.

[0023] (53) Repeat step (52) to position another partition unit on the partition unit;

[0024] (54) Repeat step (52) and position the upper wall panel unit above;

[0025] The process of completing the welding of the partition unit to the lower wall panel or partition unit, and the process of completing the welding of the upper wall panel unit to the lower partition unit, includes:

[0026] (55) Weld the fillet weld between the anchor box component and the bridge center side of the wall panel or partition, and perform flaw detection;

[0027] (56) Weld anchor plates onto anchor box components and inspect the welds;

[0028] The assembly of the base plate includes (57), clamping the base plate and the anchor bearing plate at the lower end of the steel anchor chamber with a clamp, positioning the base plate, welding the fillet weld between the force transmission web and stiffening plate and the base plate, and welding the flat fillet weld between the wall plate or partition and the base plate located on the middle side of the bridge.

[0029] The assembly and welding of the web plate includes: (58) assembling the web plates on both sides of the steel anchor chamber, rotating the steel anchor chamber 90° so that the middle side of the steel anchor chamber is laid flat, welding the fillet weld between the web plate and the wall plate or partition plate, and welding the fillet weld between the web plate and the bottom plate located on the middle side.

[0030] (59) Flip the steel anchor chamber 90° so that the back of the steel anchor chamber on the bridge center side is flat and facing upward, and weld the fillet weld between the wall plate or partition and the bottom plate on the non-bridge center side.

[0031] (60) Flip the steel anchor chamber 90° so that the back side of the mid-span side of the steel anchor chamber is flat and facing upward. Weld the fillet weld between the web plate and the wall plate or partition plate, and weld the fillet weld between the web plate and the bottom plate located on the non-mid-span side.

[0032] Further, step (1) includes: cutting the edge of the force-transmitting web that contacts the wall panel or partition into a 45° bevel;

[0033] The edge of the anchor bearing plate that contacts the wall panel or partition is cut into a 45° bevel.

[0034] Cut the edge of the wall panel or partition that contacts the base plate into a 45° bevel, centered on the edge centerline and 0.5P away from both sides of the edge centerline;

[0035] The edge of the PBL shear connector that contacts the bearing plate is cut into a 45° bevel with the center line of the edge as the center and a distance of 0.5P on both sides of the center line of the edge.

[0036] The edge of the wall panel that is not in contact with the middle side of the web is cut into a 45° bevel.

[0037] The edge of the wall panel that contacts the middle side of the web bridge is cut into a bevel of 20.556°.

[0038] The edge of the web plate that contacts the wall plate at the middle side of the bridge is cut into a bevel of 20.556°.

[0039] The edge of the force-transmitting web that contacts the stiffening plate or the bottom plate is cut into a 45° bevel from a distance P near the tip of the bottom plate.

[0040] Further, step (2) includes: first completing the fillet weld between the force transmission web and the anchor bearing plate, and then completing the fillet weld between the stiffening plate and the anchor bearing plate.

[0041] Furthermore, steps (3) and (4) include:

[0042] First, perform a root pass welding on the anchor bearing plate and the wall panel or partition. The uncut side of the anchor bearing plate is spot welded to the wall panel or partition through a steel gasket, so that the anchor bearing plate is separated from the wall panel or partition by a distance P. The cut side of the anchor bearing plate faces the outside of the steel anchor box component.

[0043] Then, symmetrically weld the fillet welds between the force transmission web and the wall plate or partition plate. Spot weld the uncut side of the edge of the force transmission web with the bevel to the wall plate or partition plate through a steel backing, so that the force transmission web is separated from the wall plate or partition plate by a distance P. The cut side of the force transmission web faces the outside of the steel anchor box component.

[0044] Then weld the fillet weld between the stiffening plate and the anchor bearing plate.

[0045] Furthermore, the uncut side of the wall panel is spot-welded to the web plate with a steel backing, so that the wall panel is separated from the web plate by a distance P, and the cut side of the wall panel faces the middle side of the steel anchor chamber.

[0046] Furthermore, in steps (2) to (5), CO2 gas shielded welding is used for the root pass and submerged arc welding is used for welding. The weld is welded in layers and passes intermittently. Each weld fills 1 / 3 to 1 / 2 of the weld amount, and the interpass temperature is strictly controlled. The same type of weld is welded multiple times and alternately.

[0047] Implementation effect

[0048] This welding method yielded significant economic benefits.

[0049] 1. By adopting the concept of breaking down the whole into parts, the steel anchor chamber wall panel is divided into three pieces and embedded between the partitions, thereby transforming the weld seam in the closed and narrow space into an outward weld seam, which greatly reduces the difficulty of the welding operation and ensures the quality and precision requirements from the side.

[0050] 2. The specific application of submerged arc welding on the cover surface improves welding efficiency while ensuring the appearance of the weld. In addition, the expanded application of gas shielded welding for filling reduces the overall deformation of the steel anchor chamber.

[0051] 3. Considering the structural characteristics of the cable tower's steel anchor chamber, its manufacturing process will proceed through five stages: parts cutting, machining, component welding, unit welding, and assembly. By optimizing the welding sequence, welding quality is ensured, and welding deformation and residual stress are controlled. Furthermore, the verticality of the cable tower's steel anchor chamber is ensured through segmented machining of the steel anchor chamber and the pressure plate units, achieving high quality standards. Attached Figure Description

[0052] Figure 1 This is a structural schematic diagram of the steel anchor chamber structure of the cable tower;

[0053] Figure 2This is a schematic diagram of the anchor box component structure;

[0054] Figure 3 A schematic diagram of the welding process for anchor box components;

[0055] Figure 4 A schematic diagram showing the welding of the anchor box components to the anchor chamber wall panel (partition);

[0056] Figure 5 For the steel anchor chamber assembly welding process;

[0057] Figure 6 Flowchart for anchor box component manufacturing;

[0058] Figure 7 Flowchart for anchor box component manufacturing;

[0059] Figure 8 This is a structural schematic diagram of the partition unit;

[0060] Figure 9 This is a structural schematic diagram of the upper and lower wall panel unit components;

[0061] Figure 10 Anchor chamber structure and assembly flowchart;

[0062] Figure 11 Flowchart for assembling anchor chamber wall panels and partitions;

[0063] Figure 12 Flowchart for assembling the anchor chamber web and anchor chamber floor;

[0064] Figure 13 This is a flowchart of the assembly process for the pressure plate and anchor chamber structure. Detailed Implementation

[0065] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other. The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0066] In the following embodiments, the anchor chamber wall plate 2 is also referred to as wall plate 2, the anchor chamber web plate 3 is also referred to as web plate 3, the anchor chamber bottom plate 4 is also referred to as bottom plate 4, and the anchor chamber partition plate 5 is also referred to as partition plate 5.

[0067] Example 1

[0068] A method for welding and manufacturing a large steel anchor chamber, with a brief description of the main implementation steps and scheme:

[0069] 1. Machining the welding bevel

[0070] The study investigated the weldability of existing welding processes and optimized the bevel forms of each joint inside the steel anchor chamber according to Table 1. The aim was to achieve symmetrical weld joint bevels, minimize weld volume, reduce post-weld shrinkage and deformation, and result in aesthetically pleasing weld formations. The optimized bevel forms of the main weld seams of each joint inside the steel anchor chamber are as follows:

[0071] The edge of the force transmission web 63 that contacts the anchor chamber wall 2 or partition 5 is cut into a 45° bevel. The uncut side of the force transmission web 63 is spot-welded to the top of the anchor chamber wall 2 or partition 5 through a steel liner, so that the force transmission web 63 is separated from the anchor chamber wall 2 or partition 5 by a distance P. The cut side of the force transmission web 63 faces the outside of the steel anchor box component 6.

[0072] The edge of the anchor bearing plate 61 that contacts the anchor chamber wall plate 2 or partition plate 5 is cut into a 45° bevel. The uncut side of the anchor bearing plate 61 is spot-welded to the anchor chamber wall plate 2 or partition plate 5 through a steel gasket, so that the anchor bearing plate 61 is separated from the anchor chamber wall plate 2 or partition plate 5 by a distance P. The cut side of the anchor bearing plate 61 faces the outside of the steel anchor box component 6.

[0073] The edge of the anchor chamber wall panel 2 or partition 5 that contacts the bottom plate 4 is cut into a 45° bevel with the center line of the edge as the center and a distance of 0.5P on both sides of the center line of the edge.

[0074] The edge of the PBL shear connector 9 that contacts the bearing plate 8 is cut into a 45° bevel with the center line of the edge as the center and a distance of 0.5P on both sides of the center line of the edge.

[0075] The edge (non-middle side) where the anchor chamber wall plate 2 contacts the anchor chamber web plate 3 is cut into a 45° bevel. The uncut side of the anchor chamber wall plate 2 is spot-welded to the anchor chamber web plate 3 through a steel liner, so that the anchor chamber wall plate 2 and the anchor chamber web plate 3 are separated by a distance P. The cut side of the anchor chamber wall plate 2 faces the outside of the steel anchor.

[0076] The edge of the wall plate 2 that contacts the middle side of the web plate 3 is cut into a bevel of 20.556°; the edge of the middle side of the web plate 3 that contacts the wall plate 2 is cut into a bevel of 20.556°; the uncut side of the anchor chamber wall plate 2 is spot welded to the anchor chamber web plate 3 through a steel liner, so that the anchor chamber wall plate 2 and the anchor chamber web plate 3 are separated by a distance P, and the cut side of the anchor chamber wall plate 2 faces the outside of the steel anchor.

[0077] The edge of the force-transmitting web 63 that contacts the base plate 4 is cut into a 45° bevel from a distance P near the tip of the base plate 4.

[0078] The edge of the stiffening plate 64 that contacts the base plate 4 is cut into a 45° bevel from a distance P near the tip of the base plate 4.

[0079] Table 1. Groove type and dimensions of main welds

[0080]

[0081] 2. Assemble and weld anchor box components

[0082] The force-transmitting web 63 and the anchor bearing plate 61 are assembled into a component on a specialized assembly platform. The fillet weld between the force-transmitting web 63 and the anchor bearing plate 61 is a partial penetration weld (weld No. I), and rigid fixation is achieved using supports before welding. Semi-automatic CO2 gas shielded welding with flux-cored wire is used for welding. Due to the large thickness of the anchor box, all welds must be welded in layers and passes, with strict control of interpass temperature. Welds of the same type are performed multiple times, alternating between passes (the amount of material welded each time should be controlled to 1 / 3 to 1 / 2 of the filler material for that weld). The fillet weld between the force-transmitting web 63 and the anchor bearing plate 61 is welded first. Figure 3 In the middle welding sequence I), the fillet weld between the stiffening plate 64 and the anchor bearing plate 61 is then welded. Figure 3 (Welding sequence II).

[0083] 3. Anchor box components are welded to wall panels and partitions.

[0084] Anchor box component 6 is welded to wall plate 2 and partition plate 5 on a special flat jig. The welding is performed using flux-cored wire CO2 semi-automatic gas shielded welding. First, the anchor bearing plate 61 and anchor chamber wall plate 2 (or partition plate 5) are welded together. Then, the fillet welds between the force transmission web plate 63 and anchor chamber wall plate 2 (or partition plate 5) are symmetrically welded (in stages, intermittently welding 1 / 3 to 1 / 2 of the fillet material for each weld, carefully controlling the interpass temperature). Finally, the fillet welds between the anchor bearing plate 61 and anchor chamber wall plate 2 (or partition plate 5) are welded. Care must be taken to control the interpass temperature during this step.

[0085] A dedicated flat frame is a support structure or platform used to ensure that the anchor box component 6, wall panel 2, and partition 5 are in a horizontal position.

[0086] In this step, the anchor box component 6 is first welded to the anchor chamber wall plate 2 and the partition plate 5, so that the welds of the anchor chamber wall plate 2, the partition plate 5 and the force transmission web plate 63 can be welded when they are in a horizontal position, ensuring that the welds are evenly filled and fully penetrated. In this step, the welds of the anchor chamber wall plate 2, the partition plate 5 and the force transmission web plate 63 are transformed into outward welds, reducing the difficulty of the welding operation.

[0087] 4. Welding process of steel anchor chamber assembly

[0088] The steel anchor chamber assembly is carried out on a special assembly jig, and CO2 gas shielded welding is mainly used for welding. The welds on the two sides of the anchor chamber wall plate can be welded by CO2 gas shielded welding for the root pass and submerged arc automatic welding after the turn-over.

[0089] The welding steps include:

[0090] Step 41. First, locate the anchor chamber wall plate 2, and weld the steel liner at the location where the anchor box component 6 is set;

[0091] Step 42. Next, align the side of the partition plate 5 with the welded anchor box component 6 facing the anchor chamber wall plate 2, so that the anchor box component 6 is aligned with the steel liner. Weld the steel liner on the back of the partition plate 5 according to the position where the anchor box component 6 is set.

[0092] Step 43. Repeat step 42 to position the partition 5 of the welded anchor box component 6 in sequence;

[0093] Step 44. Repeat step 42 to position the anchor chamber wall plate 2 of the welded anchor box component 6 above;

[0094] Step 45. Complete the fillet weld between the anchor box component 6 and the anchor chamber wall plate 2 (partition 5) (see Step 2 for welding sequence);

[0095] Step 46. Install and weld 80mm anchor plates 62 on the anchor box components (before installation and welding, flaw detection should be completed for the fillet welds between the anchor box bearing plates 61 and the anchor chamber wall plates 2 and partition plates 5).

[0096] Step 47. Assemble the anchor chamber bottom plate;

[0097] Step 48. Weld the fillet weld between the anchor box force transmission web 63 and stiffening plate 64 and the anchor chamber bottom plate 4;

[0098] Step 49. Weld the fillet weld between the anchor chamber wall plate 2 (partition 5) and the bottom plate 4;

[0099] Step 50. Assemble the web plate;

[0100] Step 51. After turning over 90°, use CO2 gas shielded welding for the root pass and submerged arc automatic welding to weld the fillet weld between the anchor chamber web plate 3 and the anchor chamber wall plate 2 (partition 5). Use CO2 gas shielded welding to weld the flat fillet weld between the anchor chamber web plate 3 and the bottom plate 4.

[0101] Step 52. Turn the plate over 90° and weld the fillet weld between the anchor chamber wall plate 2 (partition 5) and the bottom plate 4;

[0102] Step 53. Turn over 90°, use CO2 gas shielded welding for the root pass and submerged arc automatic welding to weld the fillet weld between the anchor chamber web plate 3 and the anchor chamber wall plate 2 (partition 5), and use CO2 gas shielded welding to weld the flat fillet weld between the anchor chamber web plate 3 and the bottom plate 4.

[0103] Step 54. Weld the anchoring structure 7, PBL shear connector 9 and bearing plate 8 (unless otherwise specified, CO2 gas shielded welding shall be used).

[0104] Steps 41 and 42 transform the weld between the anchor box component 6 in the partition 5 of the welded anchor box component 6 or the steel lining on the lower wall plate 2 or partition 5 into a flat weld instead of an overhead weld, so that the weld is filled evenly and penetrated, and the weld faces outward, reducing the difficulty of the welding operation.

[0105] In the existing technology, the welding of the steel anchor chamber involves first welding the partition plate 5, web plate 3, and wall plate 2 to form the upper steel box, and then welding the anchor box component 6. This process can only be carried out in a closed and narrow space. When the weld between the force-transmitting web plate 63 of the anchor box component 6 and the partition plate 5 and web plate 3 cools, it is prone to shrinkage. The web plate 3 and these welds exert stress on each other, causing the web plate 3 of the upper steel box structure to deform. It also causes residual tensile stress in the weld between the force-transmitting web plate 63 and the partition plate 5 and web plate 3, which affects the structural strength.

[0106] In step 4 of the present invention, the web of the steel anchor chamber is divided into three pieces and embedded between the anchor chambers. The web 3 is welded after the weld between the anchor box component 6 and the partition plate 5 and the web 3 has cooled. This avoids the whole web 3 from exerting tensile stress on the weld between the force-transmitting web 63 of the anchor box component 6 and the partition plate 5 and the web 3.

[0107] In step 4 of this invention, the bottom plate 4 is welded first, and then the web plate 3 is welded. This avoids the problem in the prior art where the welding of the bottom plate 4 and the anchor box component 6 can only be carried out in a closed and narrow space when the web plate is welded first to assemble the upper steel box and then the anchor box component 6 and the bottom plate 4 are welded.

[0108] Furthermore, in the existing technology, when assembling the upper steel box and then welding the anchor box component 6 inside the upper steel box, the weld shrinks as it cools, putting tension on the partition plate 5 and the wall plate 2, causing them to bend and deform, thus affecting the verticality of the upper steel box. In contrast, in this invention, when the anchor box component 6 is welded onto the wall plate 2 on the partition plate 5 in sections, a dedicated assembly jig can be used to ensure that the wall plate 2 and partition plate 5 remain horizontal and flat, guaranteeing the verticality of the upper steel box.

[0109] Example 2

[0110] A method for welding and manufacturing a large steel anchor chamber, such as Figures 7-13 A brief description of the main implementation steps and plan:

[0111] 1. Anchor box component manufacturing, such as Figure 7 :

[0112] 1) Stiffening plates 64 are welded at equal intervals on one side of the force-transmitting web 63 to form anchor box parts. The force-transmitting surface of the anchor box parts is machined and inspected. The force-transmitting surface refers to the contact surface between the force-transmitting web 63 and the bearing plate 61. It is tightened by gravity and clamps. The contact surface is made smooth and flat by machining before assembly and tightening, so that the force is evenly and evenly transmitted to the structure.

[0113] 2) Weld the anchor box parts onto the anchor bearing plate 61 according to the drawings, ensuring the perpendicularity between the force transmission web 63 and the anchor bearing plate 61. The weld between the force transmission web 63 and the anchor bearing plate 61 should be tightened before welding.

[0114] 3) Inspect the welding and assembly; once qualified, transfer the components to the storage area.

[0115] 2. Manufacturing of partition unit 11, such as Figure 8 :

[0116] After the partition plate 5 passes inspection and is marked with lines, position the anchor box component 6 on the marked positioning lines. Check the dimensions of the anchor box component 6 and its positioning, and weld it after passing inspection.

[0117] 3. Manufacturing of wall panel units, such as Figure 9 :

[0118] After the anchor chamber wall panel 2 passes the inspection and is marked with lines, the anchor box parts N4 and the anchor chamber stiffeners N16 and N17 are welded to one side of the anchor chamber wall panel 2 according to the marked lines to form the lower wall panel unit 12.

[0119] After the anchor chamber wall panel 2 passes the inspection and is marked with lines, the anchor box component 6 is welded to one side of the anchor chamber wall panel 2 according to the marked lines to form the upper wall panel unit 13.

[0120] When welding the partition plate unit 11 and the lower wall plate unit 12, strictly follow the process requirements. The main manufacturing process is as follows: mark the anchor point positioning points on the partition plate 5 and the wall plate 2; mark the positioning line of the anchor bearing plate 61 and the positioning inspection line of the anchor box parts; weld the anchor box part 6 to the partition plate 5 according to the positioning lines; check the dimensions of the anchor box part 6 and the positioning; report the inspection; remove the anchor pad plate and weld it.

[0121] The anchor box anchor point positioning and anchor box component positioning status were checked using a level, laser tracking measuring instrument and laser theodolite.

[0122] 4. Assembly of the steel anchor chamber of the cable tower

[0123] The steel anchor chambers of the pylon are box-type structures, with each chamber manufactured and assembled separately. The chambers are assembled on a horizontal assembly jig using a horizontal assembly method. The structural form and assembly process are as follows: Figure 10 As shown:

[0124] The steel anchor box of the cable tower is assembled in sections using a horizontal mounting method, and the assembly process is as follows: Figures 11-13 :

[0125] 1) Position the bottom wall panel unit 12, and position the first layer wall panel unit 12 on the jig according to the landmark points.

[0126] 2) Assemble partition unit 11. After partition unit 11 is flipped over, it is positioned on the first layer lower wall panel unit 12. During positioning, the center line, the reference port line and the ground line of the jig are aligned. Use a level, laser tracking measuring instrument and laser theodolite to check the anchor point positioning of the anchor box and the angle of the anchor plate. If there is an error with the theoretical installation line, communicate with the process engineer in time.

[0127] 3) Following step 3, weld the anchor box part N4 and the anchor chamber stiffeners N16 and N17 onto the back of the first layer partition unit 11 according to the marked lines.

[0128] 4) Assemble the two-layer partition unit 11 according to steps 2) to 3). Then assemble the upper wall panel unit 13 on the second-layer partition unit 11. To prevent deformation, use positioning clamps for port support. Weld after each anchor point positioning dimension has passed inspection.

[0129] Fillet welds are made between the anchor box component 6 and the anchor chamber wall plate 2 (partition 5), and welds are made between the anchor box stiffening plate 64 and the anchor under bearing plate 61.

[0130] After the weld flaw detection is qualified, the positioning anchor plate 62 is installed, and welding is carried out after the inspection is qualified.

[0131] 5) Install and weld the base plate 4. Clamp the base plate 4 and the anchor bearing plate 61 with C-clamps, and position the base plate 4 according to the ground line. Before welding, use positioning clamps to support the anchor chamber wall plate 2 and the partition plate 5.

[0132] Fillet welds are made between the anchor box force-transmitting web plate 63 and stiffening plate 64 and the bottom plate 4. Flat fillet welds are made between the anchor chamber wall plate 2 (partition 5) and the bottom plate 4. (Non-bridge mid-side overhead welds will be welded after subsequent overturning.)

[0133] 6) Assemble the web plates 3 of the anchor chambers on both sides, and proceed to the next process after passing the inspection.

[0134] 7) Turn the anchor chamber 3 over 90° and weld the web plate 3 of the mid-span side anchor chamber. Use CO2 gas shielded welding for the root pass and submerged arc automatic welding to weld the fillet weld between the anchor chamber web plate 3 and the anchor chamber wall plate 2 (partition 5). Use CO2 gas shielded welding to weld the flat fillet weld between the anchor chamber web plate 3 and the bottom plate 4.

[0135] 8) Turn the plate 90° over and weld the weld seam of the non-bridge middle side bottom plate 4, and weld the fillet weld seam between the anchor chamber wall plate 2 (partition plate 5) and the bottom plate 4.

[0136] 9) Turn the anchor chamber 3 over 90° and weld the non-mid span side anchor chamber web plate 3. Use CO2 gas shielded welding for the root pass and submerged arc automatic welding to weld the fillet weld between the anchor chamber web plate 3 and the anchor chamber wall plate 2 (partition 5). Use CO2 gas shielded welding to weld the flat fillet weld between the anchor chamber web plate 3 and the bottom plate 4.

[0137] 10) Assemble the anchoring structure 7, hoist the anchor chamber segment into place, and then assemble the anchoring structure 7.

[0138] 7. Anchoring structure is welded using CO2 gas shielded welding.

[0139] 11) Check the geometric dimensions of the anchor chamber and the allowance for cutting the port, and mark it according to the drawing requirements.

[0140] 12) Install and weld the pressure plate 8. After the pressure plate 8 is marked and inspected and approved, install and weld the PBL shear connector 9 onto the pressure plate 8 according to the lines.

[0141] 7. Anchoring structure is welded using CO2 gas shielded welding.

Claims

1. A welding manufacturing method for a large steel anchor chamber, the steel anchor chamber comprising a wall plate (2), a web plate (3), a bottom plate (4), a partition plate (5), an anchor box component (6), and an anchoring structure (7), the anchor box component (6) comprising an anchor bearing plate (61), an anchor pad plate (62), a force transmission web plate (63), and a stiffening plate (64), wherein the bottom plate (4) is further provided with a pre-embedded component for the steel anchor chamber of the cable tower, the pre-embedded component for the steel anchor chamber of the cable tower comprising a bearing plate (8), a PBL shear connector (9), and a pre-embedded anchor (10); characterized in that, The welding manufacturing method of the large steel anchor chamber includes the following steps: (1) Optimize the bevel form of each weld in the steel anchor chamber, determine the weld bevel and process it; (2) Assemble and weld anchor box components (6); (3) Weld the anchor box component (6) at the position marked on the bridge side of the wall panel (2) to manufacture the upper wall panel unit (13). (4) Weld the anchor box component (6) at the position marked on the bridge side of the diaphragm (5) to manufacture the diaphragm unit (11). (5) Welding process of steel anchor chamber assembly, including: Two partition unit pieces (11) are stacked one after another on the first wall panel (2), and an upper wall panel unit (13) is stacked on top of the uppermost partition unit piece (11). Complete the welding of the partition unit (11) to the adjacent first wall panel (2) or the adjacent partition unit (11), and complete the welding of the upper wall panel unit (13) to the adjacent partition unit (11). Welding base plate (4); Welding the web plate (3); Flip the steel anchor chamber so that the upper opening of the steel anchor chamber faces upward. Weld the anchoring structure (7) on the upper surface of the base plate (4) and weld the PBL shear connector (9) and the bearing plate (8) on the lower surface of the base plate (4). The welding base plate (4) includes: (57) Clamp the bottom plate (4) and the anchor bearing plate (61) at the lower end of the steel anchor chamber with a clamp to position the bottom plate (4), weld the fillet weld between the force transmission web plate (63) and the stiffening plate (64) and the bottom plate (4), and weld the flat fillet weld between the wall plate (2) or partition plate (5) and the bottom plate (4) located on the middle side of the bridge. The welded web (3) includes: (58) Assemble the web plates (3) on both sides of the steel anchor chamber, rotate the steel anchor chamber 90° so that the middle side of the steel anchor chamber is flat, weld the fillet weld between the web plate (3) and the wall plate (2) or the partition plate (5), and weld the fillet weld between the web plate (3) and the bottom plate (4) located on the middle side. (59) Flip the steel anchor chamber 90° so that the back of the steel anchor chamber on the bridge center side is flat and facing upward, and weld the fillet weld between the wall plate (2) or partition plate (5) and the bottom plate (4) on the non-bridge center side. (60) Flip the steel anchor chamber 90° so that the back side of the steel anchor chamber on the mid-span side is flat and facing upward. Weld the fillet weld between the web plate (3) and the wall plate (2) or the partition plate (5). Weld the fillet weld between the web plate (3) and the bottom plate (4) on the non-mid-span side.

2. The welding manufacturing method for a large steel anchor chamber according to claim 1, characterized in that, Step (1) includes: cutting the edge of the force-transmitting web (63) that contacts the wall panel (2) or partition (5) into a 45° bevel; The edge of the anchor bearing plate (61) that contacts the wall panel (2) or partition (5) is cut into a 45° bevel. Cut the edge of the wall panel (2) or partition (5) that contacts the bottom plate (4) into a 45° bevel with the center line of the edge as the center and a distance of 0.5P on both sides of the center line of the edge; The edge of the PBL shear connector (9) that contacts the bearing plate (8) is cut into a 45° bevel with the center line of the edge as the center and a distance of 0.5P on both sides of the center line of the edge; The edge of the wall panel (2) that is not in contact with the web panel (3) on the non-bridge side is cut into a 45° bevel. The edge of the wall panel (2) that contacts the middle side of the web plate (3) is cut into a bevel of 20.556°. The edge of the web (3) that contacts the wall plate (2) at the middle side of the bridge is cut into a bevel of 20.556°. The edge of the force-transmitting web (63) that contacts the stiffening plate (64) or the bottom plate (4) is cut into a 45° bevel from a distance P near the tip of the bottom plate (4).

3. The welding manufacturing method for a large steel anchor chamber according to claim 2, characterized in that, Step (2) includes: first completing the fillet weld between the force transmission web (63) and the anchor bearing plate (61), and then completing the fillet weld between the stiffening plate (64) and the anchor bearing plate (61).

4. The welding manufacturing method for a large steel anchor chamber according to claim 3, characterized in that, Steps (3) and (4) include: First, the anchor bearing plate (61) is welded to the wall panel (2) or partition (5). The uncut side of the anchor bearing plate (61) is spot welded to the wall panel (2) or partition (5) through a steel liner, so that the anchor bearing plate (61) is separated from the wall panel (2) or partition (5) by a distance P. The cut side of the anchor bearing plate (61) faces the outside of the steel anchor box component (6). Then, symmetrically weld the fillet weld between the force transmission web (63) and the wall plate (2) or partition plate (5), and spot weld the uncut side of the edge of the force transmission web (63) with the bevel to the wall plate (2) or partition plate (5) through the steel backing, so that the force transmission web (63) is separated from the wall plate (2) or partition plate (5) by a distance P, and the cut side of the force transmission web (63) faces the outside of the steel anchor box component (6); Then weld the fillet weld between the stiffening plate (64) and the anchor bearing plate (61).

5. The welding manufacturing method for a large steel anchor chamber according to claim 4, characterized in that, The uncut side of the edge of the wall panel (2) is spot welded to the web plate (3) through a steel liner, so that the wall panel (2) and the web plate (3) are separated by a distance P. The cut side of the wall panel (2) faces the middle side of the steel anchor chamber.

6. The welding manufacturing method for a large steel anchor chamber according to claim 5, characterized in that, The process of stacking two partition unit components (11) sequentially on the first wall panel (2) and stacking an upper wall panel unit (13) on top of the uppermost partition unit component (11) includes: (51) First, lay the first wall panel (2) flat, with the middle side of the bridge facing upwards, and weld the steel liner at the position where the anchor box component (6) is set to manufacture the lower wall panel unit (12). (52) Weld the non-bridge middle side of the anchor box component (6) of the partition unit (11) toward the lower wall panel unit (12) so that the anchor box component (6) is aligned with the steel liner. Weld the steel liner on the bridge middle side of the partition unit (11) at the position where the anchor box component (6) is set. (53) Repeat step (52) to position another layer of partition unit (11) on partition unit (11). (54) Repeat step (52) and position the upper wall panel unit (13) above.

7. The welding manufacturing method for a large steel anchor chamber according to claim 6, characterized in that, The completion of the welding of the partition unit (11) to the adjacent first wall panel (2) or the adjacent partition unit (11), and the completion of the welding of the upper wall panel unit (13) to the adjacent partition unit (11) include: (55) Weld the fillet weld between the anchor box component (6) and the wall panel (2) or the diaphragm (5) on the bridge side, and perform flaw detection; (56) Weld anchor plate (62) onto anchor box component (6) and inspect the weld.

8. A welding manufacturing method for a large steel anchor chamber according to any one of claims 1 to 7, characterized in that, In steps (2) to (5), CO2 gas shielded welding and submerged arc welding are used for the welding of the root pass and the welding is carried out in layers and intermittent welding. Each time, 1 / 3 to 1 / 2 of the filler volume of the weld is welded, and the interpass temperature is strictly controlled. The same type of weld is welded in multiple alternating layers.

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