Method for manufacturing a pile holder

Abstract

The application relates to a method for manufacturing a fixed pile frame, which comprises the following steps: prefabricating an upper fixed pile frame; prefabricating a lower fixed pile frame; machining the lower fixed pile frame by using a portable machining device, so that the lower ends of two side faces of a lower installation channel become inclined planes which are gradually expanded in a vertically downward direction; simulating loading of the lower fixed pile frame; hoisting the upper fixed pile frame and welding the upper fixed pile frame and the lower fixed pile frame into an integrated body, while ensuring that the center lines of the upper installation channel and the lower installation channel coincide; measuring and mapping the distance and the angle of the two side faces of the lower installation channel relative to the center line of a pile leg rack, and machining a gasket and an arc-shaped wear-resistant plate according to the measurement and mapping results; and welding the gasket and the arc-shaped wear-resistant plate to the inclined planes in sequence, so that the lower ends of the two side faces of the lower installation channel form arc surfaces which are convex towards the center line of the lower installation channel. The method realizes ideal design of a lower opening curved surface of the fixed pile frame without increasing machining cost of the fixed pile frame, and effectively solves the problem of stress concentration of a pile leg.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of ship and ocean engineering technology, in particular to a method for manufacturing a fixed pile frame. BACKGROUND

[0002] The lifting system of a conventional offshore wind power installation vessel is composed of a pile shoe, a pile leg, an upper and lower fixed pile frame, and a complete set of gear box device and its electric control and sensing system, etc. The main function of the fixed pile frame itself, in addition to bearing the weight of the lifting gear box device, is to bear the weight of the offshore lifting pile shoe and pile leg during ship operation, and to bear the super high load such as the overall weight of the ship during operation, the dynamic load of construction, the inertial load, and the wind and wave load, etc. Therefore, the upper and lower fixed pile frames have the characteristics of large structure size and high structure strength requirement.

[0003] During ship operation, the lifting system lifts the ship to the water surface through the gear box on the fixed pile frame, and the entire pile leg is confined inside the fixed pile frame, i.e. the overall freedom of the ship is limited by the fixed pile frame. Generally, the lower wear-resistant base plate of the fixed pile frame is designed as parallel surfaces, but this will cause the problem of stress concentration of the pile leg. Due to the influence of various loads during offshore operation of the ship, the sharp corner hard point contact of the pile leg inside the fixed pile frame is extremely disadvantageous, so the size of the related materials such as the pile leg rack plate and the fixed pile frame structure is increased, and the material grade is improved to achieve higher strength requirement.

[0004] Alternatively, a solution is to design the lower wear-resistant base plate of the fixed pile frame as a circular arc surface. However, the overall curved surface of the lower fixed pile frame must be machined by a large machine tool, which has a long cycle and high cost. Since the lower fixed pile frame is one of the basic operations of the lifting system, if the machining cycle is too long, it will cause the lag of the overall lifting system construction progress, and even delay the entire project schedule. SUMMARY

[0005] An object of the present application is to solve the problems existing in the prior art, and to provide a method for manufacturing a fixed pile frame. To solve the above technical problems, the present application adopts the following technical solutions:

[0006] A method for manufacturing a fixed pile frame, the fixed pile frame comprising:

[0007] an upper fixed pile frame, the center of which is provided with an upper installation passage;

[0008] a lower fixed pile frame connected to the lower end of the upper fixed pile frame, the center of which is provided with a lower installation passage, and the lower end of the lower installation passage is formed as an arc surface protruding towards the center line of the lower installation passage;

[0009] The method comprises:

[0010] preparing the upper fixed pile frame;

[0011] The prefabricated lower pile holder;

[0012] The portable machining equipment is used to machine the lower pile holder, so that the lower ends of the two sides of the lower installation channel become inclined planes which gradually expand in the vertically downward direction;

[0013] After the segmented enclosure is folded, the lower pile holder is simulated and loaded;

[0014] After the folding and installation precision of the lower pile holder is qualified, the upper pile holder is hoisted and welded with the lower pile holder to form an integrated whole, while ensuring that the center lines of the upper installation channel and the lower installation channel coincide;

[0015] The distance and angle of the two sides of the lower installation channel relative to the center line of the pile leg rack are measured and plotted, and the gusset plate and the arc-shaped wear plate are machined according to the measurement results, and the gusset plate and the arc-shaped wear plate are welded to the inclined planes in sequence, so that the lower ends of the two sides of the lower installation channel form an arc surface which protrudes towards the center line of the lower installation channel.

[0016] In one of the embodiments, the lower pile holder includes a left guide base plate and a right guide base plate which form the lower installation channel, and the step of machining the lower pile holder by using the portable machining equipment specifically includes:

[0017] The left guide base plate and the right guide base plate are machined by using the portable machining equipment, so that the inner side of the lower end of the left guide base plate becomes an inclined plane which gradually expands in the vertically downward direction, and the inner side of the lower end of the right guide base plate becomes an inclined plane which gradually expands in the vertically downward direction.

[0018] In one of the embodiments, in the step of machining the left guide base plate and the right guide base plate by using the portable machining equipment, the flatness of the left guide base plate is ensured to be within 0.2mm, and the flatness of the right guide base plate is ensured to be within 0.2mm.

[0019] In one of the embodiments, the left guide base plate has a machining amount not less than 5mm and a strength redundancy amount not less than 5mm, and the right guide base plate has a machining amount not less than 5mm and a strength redundancy amount not less than 5mm.

[0020] In one of the embodiments, the surface of the gusset plate opposite to the inclined plane is a plane parallel to the inclined plane, and the surface of the gusset plate opposite to the arc-shaped wear plate is an arc surface parallel to the arc-shaped wear plate.

[0021] In one of the embodiments, the arc-shaped wear plate is a convex arc-shaped plate which protrudes towards the center line of the lower installation channel, and the precision of the arc-shaped wear plate is controlled within 539.2±1mm from the center line of the pile leg rack.

[0022] In one of the embodiments, the slope of the inclined plane is 1:75.

[0023] In one of the embodiments, the welding process is plug welding in the step of sequentially welding the backing plate and the arc-shaped wear plate to the inclined plane.

[0024] In one of the embodiments, the step of simulating the mounting of the lower pile holder includes:

[0025] In the well area of the platform, the installation position of the lower pile holder is measured and found out;

[0026] Three lower pile holders are respectively hoisted above the well area, each lower pile holder is positioned and folded to the platform.

[0027] In one of the embodiments, after the step of hoisting the upper pile holder and folding it with the lower pile holder, it further includes:

[0028] After the folding and installation precision of each upper pile holder is qualified, a support structure is welded between adjacent upper pile holders;

[0029] The support structure includes a cross beam connecting the top ends of two adjacent upper pile holders, and a support frame connected below each cross beam and connected with two adjacent upper pile holders.

[0030] From the above technical solution, the present application has at least the following advantages and positive effects:

[0031] The manufacturing method of the pile holder provided by the present application optimizes the structure of the pile holder and its manufacturing method, realizes the ideal design of the lower curved surface of the pile holder without increasing the machining cost of the pile holder, solves the problem of stress concentration of the pile leg caused by the sharp corner hard point of the conventional lower pile holder. The method effectively improves the production efficiency, shortens the production cycle, ensures the safety and applicability of the wind power installation ship lifting system, and reduces the construction cost.

[0032] Specifically, by respectively designing and processing the inclined straight surface structure of the lower end of the lower pile holder, the semi-curved surface structure of the backing plate and the full-curved surface structure of the arc-shaped wear plate, portable machining is realized on site, which greatly reduces the overall project construction cost and construction period. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 is a flowchart of the manufacturing method of the pile holder of the embodiment of the present application.

[0034] Figure 2 is a structural schematic diagram of the pile holder in the method of the embodiment of the present application.

[0035] Figure 3 is Figure 2 the upper holder main body manufacturing process of the upper pile holder in the structure shown.

[0036] Figure 4 is Figure 2 is a structural schematic diagram of the upper pile fixing frame in the structure shown in

[0037] Figure 5 is Figure 2 is a schematic diagram of the lower frame body manufacturing process of the lower pile fixing frame in the structure shown in

[0038] Figure 6 is Figure 2 is a structural schematic diagram of the lower pile fixing frame in the structure shown in

[0039] Figure 7 is a schematic diagram of the pile fixing frame and the pile leg arrangement in the well in the embodiment of the application.

[0040] Figure 8 is a schematic diagram of the pile fixing frame folding installation in the embodiment of the application.

[0041] Figure 9 is a structural schematic diagram of the pile fixing frame and the pile leg rack fitting installation in the embodiment of the application.

[0042] Figure 10 is Figure 9 is an enlarged schematic diagram at A in the structure shown in

[0043] The reference signs are explained as follows:

[0044] 10-well; 20-pile leg rack; 30-pile fixing frame;

[0045] 100-upper pile fixing frame; 110-upper installation channel; 120-upper frame body; 121-middle plate component; 1211-horizontal and vertical structural component; 122-tail plate component; 123-stop block; 124-combination; 1241-large shaft sleeve; 1242-small bearing seat; 125-left side combination; 126-right side combination; 127-guiding plate combination;

[0046] 130-upper guiding base plate; 140-gear sleeve;

[0047] 200-lower pile fixing frame; 201-lower frame body; 202-middle plate combination; 203-tail plate; 204-left front plate combination; 205-right front plate combination;

[0048] 210-lower installation channel; 211-inclined plane; 220-left guiding base plate; 230-right guiding base plate; 240-pad plate; 250-arc-shaped wear-resistant plate;

[0049] 300-supporting structure; 310-cross beam; 320-supporting frame. DETAILED DESCRIPTION

[0050] The features and advantages of the present application will be more fully apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0051] In the description of the present application, it should be understood that the indication of direction or positional relationship (such as up, down, left, right, front and back, etc.) in the embodiments shown in the drawings is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element indicated must have a particular orientation, be constructed and operated in a particular orientation. When the positions of these elements are changed, the indications of these directions are also changed accordingly.

[0052] In addition, the terms "first", "second" are only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first", "second" can explicitly or implicitly include one or more of the features. In the description of the present application, the meaning of "a plurality of" is two or more, unless otherwise specifically limited.

[0053] The manufacturing method of the pile fixing frame of the present application fundamentally changes the structure cost and safety of the lifting system by optimizing the design of the pile fixing frame structure and the manufacturing method thereof. Through the optimization of the structure design of the pile fixing frame 30, especially the lower pile fixing frame 200, the lower opening curved surface machining can be realized by on-site machining, which greatly reduces the machining cost, and at the same time solves the problem of stress concentration of the pile leg caused by the sharp corner hard point existing in the conventional lower pile fixing frame.

[0054] Please refer to Figure 1 The manufacturing method of the pile fixing frame 30 of the embodiment of the present application includes:

[0055] S10, prefabricating the upper pile fixing frame 100.

[0056] S20, prefabricating the lower pile fixing frame 200.

[0057] S30, using a portable machining device to machine the lower pile fixing frame 200, so that the lower end two sides of the lower installation channel 210 become inclined planes 211 which gradually expand in the vertical downward direction.

[0058] S40, after the segmented cofferdams are folded, the lower pile fixing frame 200 is simulated and loaded.

[0059] S50, after the lower pile frame 200 is closed and installed with qualified precision, hoist the upper pile frame 100 and weld it with the lower pile frame 200 to form an integrated body, and ensure that the center lines of the upper installation channel 110 and the lower installation channel 210 coincide.

[0060] S60, measure and plot the distance and angle of the two side surfaces of the lower installation channel 210 relative to the center line of the pile leg rack 20, and process the gusset plate 240 and the arc-shaped wear plate 250 according to the measurement results, and weld the gusset plate 240 and the arc-shaped wear plate 250 to the inclined plane 211 in sequence, so that the lower ends of the two side surfaces of the lower installation channel 210 form an arc surface protruding towards the center line of the lower installation channel 210.

[0061] In combination Figure 2 As shown in the drawings, the pile frame 30 includes an upper pile frame 100 and a lower pile frame 200. The center of the upper pile frame 100 is provided with an upper installation channel 110. The lower end of the lower pile frame 200 is connected to the upper pile frame 100, and the center of the lower pile frame 200 is provided with a lower installation channel 210. The lower ends of the two side surfaces of the lower installation channel 210 form an arc surface protruding towards the center line of the lower installation channel 210. It can be understood that in the present embodiment, the upper installation channel 110 and the lower installation channel 210 form an installation channel for accommodating and installing the pile leg rack 20.

[0062] In detail, as shown in the drawings Figure 3 and Figure 4 The upper pile frame 100 includes an upper frame body 120, an upper guide base plate 130 formed on both sides of the upper installation channel 110 and located on both sides of the upper frame body 120, and a plurality of gear sleeves 140 located on both sides of the upper installation channel 110.

[0063] As shown in the drawings Figure 3 In step S10, the prefabricated upper pile frame 100 specifically refers to the prefabricated upper frame body 120, which can be completed by using a large-scale numerical control machine tool in a machining workshop. The general process includes:

[0064] The middle plate member 121 and the tail plate member 122 are built: the middle plate member 121 is used as a mold, and after the precision is qualified, the structure position line is surveyed, and the horizontal and vertical structural members 1211 between the middle plate and the tail plate are assembled and welded. After welding, the overall flatness deviation is not more than 3mm, and the welding sequence is symmetrically welded from the middle to the periphery. At the same time, the tail plate member 122 is used as a mold, and the middle stop block 123 and the two side stop blocks 123 are assembled and welded, and after the welding is completed, the straightness deviation of a single stop block is not more than 2mm, the stop block 123 is not more than 3mm from the middle deviation, and the overall tail plate member 122 is not more than 3mm. After the welding quality and precision quality inspection are qualified, the middle plate member 121 and the tail plate member 122 can flow into the next process.

[0065] The combination 124 is built: the qualified tail plate 122 is accurately buckled on the middle plate 121 and its horizontal and vertical structure 1211, and after accurate positioning, it is sealed and welded for reinforcement, and welding is performed to form the combination 124, and the welding sequence is symmetric welding from the middle to the outside. After welding, the flatness deviation of the tail plate 122 is not more than 3mm. After welding, the combination 124 is turned over as a whole, and the sealing is accurately positioned. After sealing, the large shaft sleeve 1241 and the reinforcing elbow plate are installed; the position deviation of each large shaft sleeve 1241 before welding should be not more than 2mm from the theoretical position, and the deviation after welding should be not more than 3mm. After welding, the precision and weld quality detection are completed, and only after the detection is qualified, it can flow into the next process.

[0066] The left combination 125, the right combination 126 and the guide plate combination 127 are manufactured: the left combination 125 and the right combination 126 are respectively assembled and welded with the inner T-shaped structure small assembly and the inclined outer plate with the front plate as the tail, and after welding is completed, it should be shaped. The flatness deviation of the front plate is not more than 3mm, and the flatness of the lower port of the T-shaped structure is not more than 2mm. The guide plate combination 127 is composed of an upper guide base plate 130 and an attached reinforcing part on the back, and after the welding is completed, the flatness of the upper guide base plate 130 is not more than 2mm.

[0067] After the left combination 125, the right combination 126 and the guide plate combination 127 are manufactured and welded and the precision inspection is qualified, they are assembled and welded on the combination 124, and the welding sequence is symmetric welding from the middle to the outside. After the welding inspection is qualified, the small bearing seat 1242 is installed, and the whole welding is carried out. Among them, the small bearing seat 1242, the aforementioned large shaft sleeve 1241, and the shaft hole of the tail plate 122 are used to form the gear sleeve 140 located on both sides of the upper installation channel 110. The concentricity deviation of the small bearing seat 1242 and the large shaft sleeve 1241, the shaft hole of the tail plate 122, the layer height deviation, the position deviation of each sleeve axis, and the flatness deviation of the rear brake block on the tail plate 122 are all controlled within 3mm.

[0068] It should be noted that when the upper pile frame 100 is built, the distance between the upper guide base plate 130 on both sides and the center line of the pile leg rack 20 should be controlled, and the position and flatness of the middle stop block 123 and the stop block 123 on both sides should be controlled. After the whole structure of the upper pile frame 100 is welded, it should be ensured that there is a machining allowance for the above-mentioned key machining parts.

[0069] Please refer to Figure 5 and Figure 6 It is shown that the lower pile frame 200 includes a lower frame body 201, and a left guide base plate 220 and a right guide base plate 230 capable of forming a lower installation channel 210.

[0070] Please refer to Figure 5In step S20, the prefabricated lower pile frame 200 specifically refers to a prefabricated lower frame body 201, which can be completed by using large-scale numerical control machine tools in a machining workshop. The general process includes:

[0071] The middle plate assembly 202 is built: the middle plate is used as a template, and the center line and the horizontal and vertical structure lines are drawn. The horizontal and vertical structures are assembled and welded on the middle plate to form the middle plate assembly 202, and the welding and precision inspection are completed.

[0072] The middle plate assembly 202 is built with the tail plate 203: after the middle plate assembly 202 is welded and inspected, it is turned over and buckled on the tail plate 203. The tail plate 203 also has structure position lines drawn, and after the middle plate assembly 202 is welded with the tail plate 203, the weld and precision inspection are completed.

[0073] The left front plate assembly 204 and the right front plate assembly 205 are made: the front plate is used as a template, and the horizontal and vertical structures, wear-resistant base plate structures, and vertical outer side plate structures on the front plate are assembled and welded to form the left front plate assembly 204 and the right front plate assembly 205, respectively.

[0074] After the left front plate assembly 204 and the right front plate assembly 205 are made and inspected, they are turned over and buckled on the tail plate 203 with the middle plate assembly 202, and the positioning position is determined according to the positioning and optimization of the middle plate. In this process, several I-beams can be used for strong support to fix the left front plate assembly 204 and the right front plate assembly 205 after positioning, to avoid displacement and deformation during welding. After the above steps, the lower frame body 201 of the lower pile frame 200 can be made.

[0075] It can be understood that the wear-resistant base plate structures of the left front plate assembly 204 and the right front plate assembly 205 are used to form the left and right sides of the lower installation channel 210. That is, the wear-resistant base plate of the left front plate assembly 204 is the aforementioned left guide base plate 220, and the wear-resistant base plate of the right front plate assembly 205 is the aforementioned right guide base plate 230.

[0076] In addition, during the steps of making the lower pile frame 200, the flatness of the left guide base plate 220 and the right guide base plate 230, as well as the overall size of the parts, need to be controlled. And ensure that the wear-resistant base plate structures of the left front plate assembly 204 and the right front plate assembly 205 have a certain amount of machining and strength redundancy. For example, ensure that the left guide base plate 220 has a machining amount of not less than 5mm and a strength redundancy of not less than 5mm, and ensure that the right guide base plate 230 has a machining amount of not less than 5mm and a strength redundancy of not less than 5mm.

[0077] In step S30, the portable machining equipment can be a portable grinding machine, a cutting machine, a rounding machine, etc., which can be selected according to the structure to be machined.

[0078] It should be noted that, as shown in Figure 5 When the lower pile frame 200 is basically completed, the several I-shaped steel supports between the left front plate assembly 204 and the right front plate assembly 205 need to be removed. Then, the portable machining equipment is used to machine the wear-resistant base plate structure in the left front plate assembly 204 and the right front plate assembly 205. That is, the left guide base plate 220 and the right guide base plate 230 are machined respectively, so that the lower ends of the two sides of the lower mounting channel 210 can become inclined planes 211 that gradually expand in the vertically downward direction.

[0079] Specifically, the left guide base plate 220 and the right guide base plate 230 are machined by using the portable machining equipment, so that the lower end of the left guide base plate 220 becomes an inclined plane 211 that gradually expands in the vertically downward direction, and the lower end of the right guide base plate 230 also becomes an inclined plane 211 that gradually expands in the vertically downward direction. At this time, the lower end of the lower mounting channel 210 of the lower pile frame 200 is roughly in the shape of a "bell mouth", and the lower ends of the left guide base plate 220 and the right guide base plate 230 on both sides of the lower mounting channel 210 are both outwardly expanding inclined planes 211. In this embodiment, the inclination of the inclined plane 211 at the lower end of the left guide base plate 220 can be 1:75, and the inclination of the inclined plane 211 at the lower end of the right guide base plate 230 can also be 1:75.

[0080] In this step, the overall flatness of the left guide base plate 220 needs to be ensured to be within 0.2mm, and the overall flatness of the right guide base plate 230 needs to be ensured to be within 0.2mm.

[0081] In this embodiment, the overall machining of the lower pile frame 200 can be completed by using portable machining equipment on site. When the lower pile frame 200 is machined, the distance between the left guide base plate 220 and the inclined plane 211 thereon and the right guide base plate 230 and the inclined plane 211 thereon on both sides relative to the center line of the pile leg rack 20 needs to be controlled.

[0082] In the present application, the portable machining equipment can also be used to machine the relevant structural parts of the upper pile holder 100, such as the upper guide base plate 130, the stop block, and each gear sleeve 140 of the upper pile holder 100. In the machining process, the machining accuracy of each structure needs to be ensured, such as controlling the distance between the two side upper guide base plates 130 and the center line of the pile leg rack 20. For example, the distance between the left gear sleeve 140 and the right gear sleeve 140 is within 815.2±0.07mm, the distance between the upper and lower sleeves is within 1310±0.2mm, and the concentricity of each is within 0.2mm.

[0083] In addition, the portable machining equipment can also be used to individually machine the wear plate structure and baffle structure that need to be installed on each guide base plate.

[0084] In the present application, when machining the upper guide base plate 130 of the upper pile holder 100 and the left and right guide base plates 220 and 230 of the lower pile holder 200, bolt holes will be machined on each guide base plate for installing the respective wear plate structure.

[0085] In the present application, when machining the two side upper guide base plates 130 of the upper pile holder 100 and the left and right guide base plates 220 and 230 of the lower pile holder 200, the distance between each guide base plate and the center line of the pile leg rack 20 after machining needs to be controlled.

[0086] Referring to Figure 1 As shown in the figure, the specific steps of simulating the mounting of the lower pile holder 200 in step S40 are as follows:

[0087] First, cut off the rough material inserted into the position of the lower pile holder 200 in the surrounding well 10.

[0088] Then, measure the installation position of the lower pile holder 200 in the surrounding well 10 area of the platform.

[0089] After that, hoist the three lower pile holders 200 above the surrounding well 10 area, position each lower pile holder 200, and fold the lower pile holders 200 to the platform.

[0090] As Figure 7 shown, the three pile holders 30 are evenly distributed with the center of the surrounding well as the center and 120° as the central angle. Between the mounting of each lower pile holder 200, the position of each lower pile holder 200 needs to be measured and determined.

[0091] It should be noted that when hoisting and folding the lower pile holder 200, the distance and angle of the three lower pile holders 200 of the same pile leg relative to the center of the pile leg (i.e. the center of the surrounding well) need to be controlled accurately, and the distance from each guide base plate of the upper pile holder 100 and the lower pile holder 200 to the center line of the pile leg rack 20 needs to be accurate.

[0092] In addition, the horizontal degree of the three lower pile jacks 200 should be controlled. In detail, after the welding post-installation precision of the lower pile jack 200 is detected to be qualified, the simulation loading of the upper pile jack 100 can be performed. According to the simulation loading data, the upper horizontal degree of the lower pile jack 200 is trimmed.

[0093] Referring to Figure 1 As shown in FIG. 5, after the folding installation precision of the lower pile jack 200 is qualified, each upper pile jack 100 can be hoisted and folded with the corresponding lower pile jack 200.

[0094] In this step, the center lines of the upper installation channel 110 and the lower installation channel 210 should be overlapped. That is, the distance and angle of the upper pile jack 100 and the lower pile jack 200 relative to the center of the pile leg should be accurate, and the distance from each guide base plate of the upper pile jack 100 and the lower pile jack 200 to the center line of the pile leg rack 20 should be accurate.

[0095] In addition, the horizontal reference of the lower pile jack 200 trimmed according to the simulation folding data should be positioned to the horizontal height of the three upper pile jacks 100. After the above precisions are qualified, the upper pile jack 100 is reinforced and welded, and the folding joint of the upper pile jack 100 and the lower pile jack 200 is completed.

[0096] Further, after the step of hoisting the upper pile jack 100 and folding it with the lower pile jack 200, it further includes:

[0097] After the folding installation precision of each upper pile jack 100 is qualified, the support structure 300 is welded between the adjacent upper pile jacks 100.

[0098] In detail, as Figure 8 shown in FIG. 6, the support structure 300 includes a cross beam 310 connected to the top ends of the two adjacent upper pile jacks 100, and a support frame 320 connected below each cross beam 310 and connected to the two adjacent upper pile jacks 100. By designing and installing the support structure 300, the stability of the whole pile jack 30 can be improved.

[0099] Referring to Figure 1 , the manufacturing method of the present application needs to measure and draw the distance and angle of each guide base plate of the lower pile jack 200 relative to the center line of the pile leg rack 20 after the folding of the upper pile jack 100 and the lower pile jack 200 is completed, and process the gusset plate 240 and the arc-shaped wear plate 250 according to the measurement results. It should be noted that since the present application mainly explains the forming and manufacturing of the lower port curved surface of the pile jack 30, the gusset plate 240 and the arc-shaped wear plate 250 in this embodiment only refer to the gusset plate structure and the wear plate structure installed at the lower end of the lower pile jack 200.

[0100] It is understood that in this application, after the upper pile frame 100 and the lower pile frame 200 are joined together, it is necessary to measure the distance and angle of each guide base plate of the upper pile frame 100 relative to the center line of the pile leg rack 20. Finally, based on these measurement results, the pad structure and wear-resistant plate structure on the upper guide base plate 130 of the upper pile frame 100, as well as the pad structure and wear-resistant plate structure required for the left guide base plate 220 and right guide base plate 230 of the lower pile frame 200, excluding the inclined plane 211, are processed. Furthermore, during processing and installation, the accuracy of these pad structures and wear-resistant plate structures must be controlled to ensure they are parallel to the center line of the pile leg rack 20; details will not be elaborated further here.

[0101] Combination Figure 9 and Figure 10 As shown, the pad 240 in this embodiment has a roughly semi-circular cross-section. Specifically, the surface of the pad 240 opposite to the inclined plane 211 is a plane parallel to the inclined plane 211, and the surface of the pad 240 opposite to the arc-shaped wear-resistant plate 250 is an arc surface parallel to the arc-shaped wear-resistant plate 250.

[0102] The arc-shaped wear-resistant plate 250 is a convex arc-shaped plate that protrudes towards the center line of the lower installation channel 210. The arc-shaped wear-resistant plate 250 can fully contact the arc surface of the pad 240, and the side of the arc-shaped wear-resistant plate 250 near the pile leg rack 20 is also curved, so that the lower end of the lower installation channel 210 is roughly in the shape of a "trumpet".

[0103] In one embodiment, the accuracy of the arc-shaped wear-resistant plate 250 is preferably controlled within 539.2 ± 1 mm from the center line of the pile leg rack 20.

[0104] After the pad 240 and the arc-shaped wear-resistant plate 250 are processed, the pad 240 and the arc-shaped wear-resistant plate 250 are welded to the inclined plane 211 of the left guide base plate 220 and the right guide base plate 230 in sequence, so that the two sides of the lower end of the lower mounting channel 210 form an arc surface that protrudes towards the center line of the lower mounting channel 210.

[0105] In the step of sequentially welding the pad 240 and the arc-shaped wear-resistant plate 250 to the inclined plane 211, the welding process is plug welding. Specifically, the pad 240 is provided with plug welding holes for welding the pad 240 to the left guide base plate 220 and the right guide base plate 230. The outer ring of the pad 240 is also welded to the left guide base plate 220 and the right guide base plate 230.

[0106] like Figure 9 As shown, the two sides of the lower mounting channel 210, except for the arc-shaped part at the lower end A, are all parallel to the center line of the pile leg rack 20.

[0107] In the present application, after the step of hoisting the upper pile holder 100 and closing it with the lower pile holder 200, the following steps can also be included:

[0108] After the installation of the guide plate base plate, the wear-resistant plate structure of the upper pile holder 100 and the lower pile holder 200, and the mat plate 240 and the arc-shaped wear-resistant plate 250 at the lower end of the lower pile holder 200, the overall precision of the pile holder 30 is detected, and after passing the detection, the pile leg sections are closed. Specifically, the relative position precision of each three groups of lifting systems including the upper pile holder 100 and the lower pile holder 200 is detected. After the precision is qualified, the closing operation of the platform pile leg can be performed.

[0109] According to the above technical solution, the manufacturing method of the pile holder 30 of the embodiment of the present application has at least the following beneficial effects:

[0110] The manufacturing method of the pile holder of the embodiment of the present application optimizes the structure of the pile holder 30 and its manufacturing method, realizes the ideal design of the lower curved surface of the pile holder 30 without increasing the machining cost of the pile holder 30, effectively improves the production efficiency, shortens the production cycle, ensures the safety and applicability of the lifting system of the wind power installation ship, and reduces the construction cost.

[0111] The manufacturing method of the pile holder of the present application effectively solves the problem that when the lower opening of the pile holder is designed as a plane in the prior art, stress concentration areas are prone to occur, the relevant structure size needs to be increased and the material grade needs to be improved, thereby greatly increasing the construction cost. At the same time, it also solves the problem that in the prior art, in order to reduce stress concentration, the lower opening of the pile holder is designed as a curved surface, which requires the use of a large machine tool to complete the overall machining of the lower curved surface, resulting in a long cycle and high cost.

[0112] Specifically, by respectively designing the inclined straight surface structure at the lower end of the lower pile holder 200, the semi-curved surface structure of the mat plate 240, and the full-curved surface structure of the arc-shaped wear-resistant plate 250, a high-precision and high-strength design and installation method of the lower curved surface of the pile holder 30 is realized without increasing the machining cost of the lower pile holder 200.

[0113] Moreover, the inclined straight surface structure at the lower end of the lower pile holder 200, the semi-curved surface structure of the mat plate 240, and the full-curved surface structure of the arc-shaped wear-resistant plate 250 can be machined by using a portable machining method on site, which greatly saves the high machining cost that can only be completed by large-scale numerical control machine tools.

[0114] The lower pile frame 200 is designed with a semi-curved pad plate 240 at the lower end, and the design and installation scheme of a circular arc wear-resistant plate 250 can realize the advantages of low-cost single-piece machining, high strength, and quality safety and reliability. The machining data feedback of the pad plate 240 and the wear-resistant plate 250 can be completed by using a conventional total station and analysis software, realizing fast, simple and efficient high-precision construction and installation of the lower pile frame 200. The scheme can greatly reduce the overall machining cost and production and installation cycle of the lower pile frame 200, and effectively solve the problem of stress concentration of the pile leg caused by the sharp corner hard point of the conventional lower pile frame 200.

[0115] The above embodiments are only illustrative of the structure, and the structures in the embodiments are not fixedly combined. In the absence of structural conflicts, the structures in the embodiments can be arbitrarily combined.

[0116] Although the present application has been described with reference to several exemplary embodiments, it is understood that the terms used are illustrative and exemplary, rather than restrictive. Since the present application can be embodied in various forms without departing from the spirit or essential characteristics thereof, it is understood that the above-described embodiments are not limited to any of the aforementioned details, but are to be construed broadly within the spirit and scope of the appended claims, and all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore to be embraced by the claims.

Claims

1. A method of making a pile holder, characterized by, The solid pile frame comprises: an upper solid pile frame, the center of which is provided with an upper mounting channel; a lower solid pile frame connected to the lower end of the upper solid pile frame, the center of which is provided with a lower mounting channel, the lower end of which is formed into an arc surface protruding towards the center line of the lower mounting channel; the manufacturing method comprises: preparing the upper solid pile frame; preparing the lower solid pile frame; processing the lower solid pile frame with a portable machining device to make the lower end of the lower mounting channel into an inclined plane gradually expanding in the vertically downward direction; simulating the loading of the lower solid pile frame after the segmental closure of the cofferdam; after the lower solid pile frame is closed and installed with precision, hoisting the upper solid pile frame and welding it with the lower solid pile frame into an integrated whole, while ensuring that the center lines of the upper mounting channel and the lower mounting channel coincide; measuring and mapping the distance and angle of the two side surfaces of the lower mounting channel relative to the center line of the pile leg rack, and processing the gasket and the arc-shaped wear plate according to the mapping results, and welding the gasket and the arc-shaped wear plate onto the inclined plane in sequence, so that the lower end of the lower mounting channel forms an arc surface protruding towards the center line of the lower mounting channel.

2. The method of claim 1, wherein, The lower solid pile frame comprises a left guide base plate and a right guide base plate forming the lower mounting channel, and the step of processing the lower solid pile frame with a portable machining device comprises: processing the left guide base plate and the right guide base plate with the portable machining device to make the inner side of the lower end of the left guide base plate into an inclined plane gradually expanding in the vertically downward direction, and to make the inner side of the lower end of the right guide base plate into an inclined plane gradually expanding in the vertically downward direction.

3. The method of claim 2, wherein the step of forming the solid pile frame comprises the step of: In the step of processing the left guide base plate and the right guide base plate with the portable machining device, the flatness of the left guide base plate is ensured to be within 0.2 mm, and the flatness of the right guide base plate is ensured to be within 0.2 mm.

4. The method of claim 2, wherein the step of forming the solid pile frame comprises the step of: The left guide base plate has a machining amount of not less than 5 mm and a strength redundancy amount of not less than 5 mm, and the right guide base plate has a machining amount of not less than 5 mm and a strength redundancy amount of not less than 5 mm.

5. The method of claim 1, wherein the step of forming the solid pile frame comprises the step of: The surface of the gasket opposite to the inclined plane is a plane parallel to the inclined plane, and the surface of the gasket opposite to the arc-shaped wear plate is an arc surface parallel to the arc-shaped wear plate. ​ 6. The method of claim 1, wherein the step of forming the solid pile frame comprises the step of: The arc-shaped wear plate is a convex arc-shaped plate protruding towards the center line of the lower mounting channel, and the precision of the arc-shaped wear plate is controlled within 539.2±1 mm from the center line of the pile leg rack.

7. The method of claim 1, wherein the step of forming the solid pile frame comprises the step of: The inclination of the inclined plane is 1:

75. ​ 8. The method of claim 1, wherein the step of forming the solid pile frame comprises the step of: In the step of welding the gasket and the arc-shaped wear plate onto the inclined plane in sequence, the welding process is plug welding. ​ 9. The method of claim 1, wherein the step of forming the solid pile frame comprises the step of: The step of simulating the loading of the lower solid pile frame comprises: ​ measuring and finding the installation position of the lower solid pile frame in the cofferdam area of the platform; hoisting three lower solid pile frames above the cofferdam area respectively, positioning each lower solid pile frame and closing each lower solid pile frame to the platform.

10. The method of claim 1, wherein, After the step of hoisting the upper solid pile frame and closing it with the lower solid pile frame, it further comprises: After the upper fixed pile frame is assembled and folded with high precision, a support structure is welded between the adjacent upper fixed pile frames; The support structure comprises a crossbeam connecting the top ends of two adjacent upper fixed pile frames, and a support frame connected below each crossbeam and connected with two adjacent upper fixed pile frames.

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