Bridge steel shell tower segment processing and assembling process

Abstract

The present application relates to a kind of bridge steel shell tower segment processing assembly process, it is characterized in that: specific processing assembly process is as follows: S1: the division of steel shell tower segment;S2: the manufacture of plate unit;S3: reinforcing steel and angle steel blanking;S4: block forming;S5: the overall butt welding of steel shell tower segment;By dividing bridge steel shell tower segment into four block structures, the required parts needed for each block are uniformly cut;Modular welding of each block structure is completed on the jig, and then the four block structures are modularly assembled on the jig;This welding method greatly improves the assembly efficiency, and each block structure can be compared and checked during synchronous processing, reducing the subsequent detection time.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of bridge steel shell tower processing and assembling, in particular to a bridge steel shell tower segment processing and assembling process. BACKGROUND

[0002] The middle and side main towers in the bridge are all of steel-concrete combined structure, and the tower column is divided into three sections of upper tower column, middle tower column and lower tower column, the upper tower column is of steel structure, and the middle and lower tower columns are of concrete structure; according to the hoisting and erecting capacity requirement, the steel tower column is re-divided into sections to determine the hoisting block in the field; in addition, when the weight and the outer shape size of the hoisting block exceed the capacity of the hoisting machine in the workshop and the capacity of the beam transportation flat car, the hoisting block needs to be re-divided. The general principle is to increase the block shape size and reduce the block quantity as much as possible according to the various limiting indexes in the steel tower production and erecting process; however, in the general steel tower section, the structure division is not conducive to the welding of the structure, the structure division quantity is large, the manufacturing is difficult, and the processing and manufacturing process is redundant due to the different sizes and structures of the parts. SUMMARY

[0003] The technical problem to be solved by the present application is to provide a bridge steel shell tower segment processing and assembling process, which can solve the problems of large section division quantity, redundant processing and manufacturing process, single manufacturing of each part and low production efficiency in the processing and manufacturing and assembling of the general steel tower section.

[0004] To solve the above technical problems, the technical scheme of the present application is as follows: a bridge steel shell tower segment processing and assembling process, the innovation point of which is as follows:

[0005] S1: division of the steel shell tower section: the steel shell tower section is in the form of a cylindrical shell structure, has inner and outer wall plates, and a steel mesh, a partition plate and a rib plate arranged between the inner and outer wall plates; the steel shell tower section is divided into a planar block, an L-shaped block and a C-shaped block; the L-shaped block has a pair of edges arranged on both sides of the planar block; the two sides of the C-shaped block are connected to the edges of the two L-shaped blocks to form the bridge steel shell tower section;

[0006] S2: manufacturing of the plate unit: the plate unit includes a wall plate, a rib plate and a partition plate; the plate material is subjected to flattening, shot blasting, paint spraying and drying on a pretreatment automatic production line; the wall plate, the rib plate and the partition plate are precisely cut by a numerical control cutting machine, and a sufficient welding shrinkage is reserved in the length and width directions of the parts by accurate calculation, and the automatic lineation and identification writing are completed at the same time of cutting; after the wall plate is cut, a semi-automatic trolley is used to cut or machine the bevel groove and the reference end groove on both sides to correct the warping deformation and the wavy deformation; after the rib plate is flattened, a semi-automatic trolley is used to cut the bevel groove to correct the straightness, and then a flat numerical control drilling machine is used to drill the hole groups at both ends;

[0007] S3: Steel bar and angle steel blanking: select the steel tower segment inside the required steel bar and angle steel, according to the quantity demand and length requirement for cutting blanking;

[0008] S4: Block forming: the block includes outer wall plate, inner wall plate, steel mesh, partition plate and stiffening angle steel; the outer wall plate and inner wall plate with rib plate welded to the block are arranged on the jig, the partition plate is welded on the inner wall plate and outer wall plate according to the marking position, after the welding of the partition plate is completed, the wall plate flatness is detected on the platform, then the shear pin assembly position line is drawn, the shear pin is welded by using stud welding machine, and the horizontal and vertical steel bars are penetrated, the steel bar binding is completed; then the stiffening angle steel is welded on the inner wall of the outer wall plate, the completed inner wall plate is buckled on the stiffening angle steel of the outer wall plate for welding to complete the block forming, and the relative position relationship of the inner and outer wall plates is ensured; the welding of the plane block, L-shaped block and C-shaped block is sequentially completed;

[0009] S5: Data measurement: the accuracy measurement, inclination measurement and up and down port size measurement of the horizontal and vertical baseline of the formed block are performed to control the block structure within the qualified size range;

[0010] S6: Overall welding of steel shell tower segment: set up the assembly jig, set up the longitudinal and horizontal positioning baseline of the steel tower segment on the jig; the plane block is positioned on the jig based on the horizontal and vertical baseline of the jig; the temporary process support is positioned on the outer wall plate of the plane block based on the horizontal and vertical baseline and elevation benchmark of the jig; the L-shaped block is welded on both sides of the plane block based on the horizontal and vertical baseline of the jig, the matching accuracy between the L-shaped block and the plane block is ensured, and the opening size above the L-shaped block and the block perpendicularity are mainly controlled; the C-shaped block is welded on the top end of the L-shaped block based on the horizontal and vertical baseline of the jig, the matching accuracy of the C-shaped block with the plane block and the L-shaped block is ensured, and the segment box size, segment matching accuracy are mainly controlled, after the qualification, the reserved amount is cut by marking, and the welding of the bridge steel shell tower segment is completed;

[0011] S7: Size re-measurement: after the overall welding of the steel shell tower segment is completed, the horizontal and vertical baseline and inclination of the steel shell tower are re-measured, and the size of the upper and lower ports is re-measured; to control the overall welded steel shell tower structure within the qualified size range;

[0012] S8: Steel shell tower pre-assembly: the steel shell tower segment is pre-assembled in the factory area, the steel shell tower is placed according to the assembly position, the pre-assembly effect of the steel shell tower segment is detected by cooperating with the lifting appliance equipment and the jig.

[0013] Further, the block is accurately positioned on the jig with the level and the theodolite before pre-assembly, the C-shaped block is detected to be qualified before assembly, and the block wall plate edge misalignment is checked after pre-assembly.

[0014] Further, the steel shell tower segment is arranged and welded with adjusting brackets and guide blocks on the inner and outer wall plates when assembled, and the temporary matching parts are assembled and welded when three-dimensionally assembled, so as to ensure that the steel tower segment is precisely erected at the bridge site.

[0015] The present application has the advantages of:

[0016] 1) In the present application, the bridge steel shell tower segment is divided into four block structures, the required parts for each block structure are uniformly cut, the modular assembly and welding of the block structures are completed on a jig, and the four block structures are modularly assembled and welded on the jig. This assembly and welding method greatly improves the assembly efficiency, and the mutual comparison and verification process can be realized during the synchronous processing of the block structures, thereby reducing the subsequent detection time. BRIEF DESCRIPTION OF DRAWINGS

[0017] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] Fig. 1 A bridge steel shell tower segment processing and assembly process diagram is provided.

[0019] Figs. 2-3 A bridge steel shell tower segment processing and assembly process planar block assembly and welding state diagram is provided.

[0020] Figs. 4-5 A bridge steel shell tower segment processing and assembly process overall assembly and welding state diagram is provided. EMBODIMENT

[0021] To make the purpose, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. The components of the embodiments of the present application described and shown in the accompanying drawings can be arranged and designed in various different configurations.

[0022] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but only represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor are within the scope of protection of the present application.

[0023] As Figs. 1-5 shown in a bridge steel shell tower segment processing and assembly process, the specific processing and assembly process is as follows:

[0024] S1: Steel shell tower segment division: the steel shell tower segment is in the form of a cylindrical shell structure, has inner and outer wall plates, and a reinforcement mesh, a partition plate and a rib plate arranged between the inner and outer wall plates; the steel shell tower segment is divided into planar blocks, L-shaped blocks and C-shaped blocks; the L-shaped blocks have a pair of blocks arranged on both sides of the planar blocks; the two sides of the C-shaped blocks are connected to the edges of the two L-shaped blocks to form a bridge steel shell tower segment;

[0025] S2: Manufacture of plate units: the plate units include wall plates, rib plates and partition plates; plate materials are leveled, shot blasted, painted and dried by a pretreatment automatic production line; the wall plates, rib plates and partition plates are precisely cut by a numerical control cutting machine; sufficient welding shrinkage is reserved in the length and width directions of the parts by accurate calculation; automatic line marking and identification writing are completed during cutting; after the wall plates are cut, a semi-automatic trolley is used to cut or machine the bevel groove and the reference end head bevel groove on both sides to correct warping deformation and wave deformation; after the rib plates are leveled, a semi-automatic trolley is used to cut the bevel groove to correct straightness, and then a flat numerical control drilling machine is used to drill the hole groups at both ends;

[0026] S3: Steel bar and angle steel cutting: select the steel bars and angle steels required inside the steel tower segment, and cut them according to the quantity and length requirements;

[0027] S4: Block forming: the blocks include outer wall plates, inner wall plates, reinforcement meshes, partition plates and stiffening angle steels; the outer wall plates and inner wall plates of the blocks with rib plates are arranged on a jig, the partition plates are welded to the inner and outer wall plates according to the marking positions, the wall plate flatness is corrected and detected on the platform after the welding of the partition plates is completed, then the shear stud assembly position line is marked, the shear studs are welded by a stud welding machine, and the horizontal and vertical steel bars are inserted, and the steel bar binding is completed; then the stiffening angle steels are welded to the inner wall of the outer wall plates, the completed and welded inner wall plates are buckled on the stiffening angle steels of the outer wall plates for welding to complete the block forming and ensure the relative position relationship between the inner and outer wall plates; the welding and assembly of the planar blocks, L-shaped blocks and C-shaped blocks are sequentially completed;

[0028] S5: Data measurement: the horizontal and vertical baselines of the formed blocks are measured for accuracy, the inclination is measured, and the upper and lower port sizes are measured to control the block structure within the qualified size range;

[0029] S6: The overall butt welding of the steel shell tower segment: set up an assembling jig, set up the longitudinal and transverse positioning base lines of the steel tower segment on the jig; position the planar blocks on the jig with the longitudinal and transverse base lines of the jig as the reference; loft the temporary process support on the outer wall plate of the planar blocks with the longitudinal and transverse base lines of the jig and the elevation leveling points as the reference; weld the L-shaped blocks on both sides of the planar blocks with the longitudinal and transverse base lines of the jig as the reference, ensure the matching precision between the L-shaped blocks and the planar blocks, and focus on controlling the opening size of the L-shaped blocks and the perpendicularity of the blocks; weld the C-shaped blocks on the top end of the L-shaped blocks with the longitudinal and transverse base lines of the jig as the reference, ensure the matching precision of the C-shaped blocks and the planar blocks and the L-shaped blocks, and focus on controlling the box opening size of the steel shell tower segment and the matching precision between the segments, mark and cut the reserved amount after passing the inspection, and complete the butt welding of the bridge steel shell tower segment;

[0030] S7: Size re-measurement: after the overall butt welding of the steel shell tower segment is completed, re-measure the longitudinal and transverse base lines and the inclination angle of the steel shell tower, and re-measure the size of the upper and lower ports; so as to control the size of the overall butt welded steel shell tower structure within the qualified range;

[0031] S8: Steel shell tower pre-assembly: the steel shell tower segment is pre-assembled in the factory area, the steel shell tower is placed according to the assembly position, the pre-assembly is carried out by cooperating with the lifting appliance equipment and the jig, and the pre-assembly effect between the steel shell tower segments is detected.

[0032] The C-shaped blocks are accurately positioned on the jig by cooperating with the level and the theodolite before the block pre-assembly, the pre-assembly is carried out after the C-shaped blocks pass the inspection, and the misalignment of the wall plates of the front and rear blocks is checked after the pre-assembly is completed.

[0033] The adjusting brackets and guide blocks are arranged and welded on the inner and outer wall plates during the assembly of the steel shell tower segment, the temporary matching parts are assembled and welded during the three-dimensional assembly, and the steel tower segment is accurately erected at the bridge site.

[0034] Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, the above-mentioned embodiments and descriptions in the specification are only to illustrate the principles of the present application, various changes and improvements can be made without departing from the spirit and scope of the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A process for the fabrication and assembly of bridge steel shell tower segments, characterized in that: The specific processing and assembling process is as follows: S1: division of steel shell tower segment: the steel shell tower segment is in the form of a cylindrical shell structure, has inner wall plates and outer wall plates, and a steel mesh, a partition plate and a rib plate arranged between the inner wall plates and the outer wall plates; the steel shell tower segment is divided into planar blocks, L-shaped blocks and C-shaped blocks; the L-shaped blocks are provided in pairs on both sides of the planar blocks; the C-shaped blocks are connected to the edges of the two L-shaped blocks on both sides to form a bridge steel shell tower segment; S2: manufacturing of plate unit: the plate unit includes wall plates, rib plates and partition plates; the plate material is subjected to flattening, shot blasting, paint spraying and drying on a pretreatment automatic production line; the wall plates, rib plates and partition plates are precisely cut by a numerical control cutting machine; by accurate calculation, sufficient welding shrinkage is reserved in the length and width directions of the parts; automatic scribing and marking are completed during cutting; after the wall plates are cut, a semi-automatic trolley is used to cut or machine the bevel groove and the reference end groove on both sides to correct warping and wavy deformation; after the rib plates are flattened, a semi-automatic trolley is used to cut the bevel groove to correct straightness, and then a flat numerical control drilling machine is used to drill the hole groups at both ends; S3: steel bar and angle steel cutting: select the steel bars and angle steels required inside the steel shell tower segment, and cut and cut them according to the quantity and length requirements; S4: block forming: the block includes outer wall plates, inner wall plates, steel mesh, partition plates and stiffening angle steels; the outer wall plates and the inner wall plates of the block with rib plates are arranged on the jig, the partition plates are welded on the inner wall plates and the outer wall plates according to the scribed positions, the wall plate flatness is corrected and detected on the platform after the welding of the partition plates is completed, then the shear pin assembly position line is scribed, the shear pin is welded by a stud welding machine, and the horizontal and vertical steel bars are inserted, and the steel bar binding is completed; then the stiffening angle steels are welded on the inner wall of the outer wall plate, the completed and welded inner wall plate is buckled on the stiffening angle steels on the outer wall plate to complete the block forming, and the relative position relationship between the inner and outer wall plates is ensured; the welding and assembly of the planar blocks, the L-shaped blocks and the C-shaped blocks are sequentially completed; S5: data measurement: the accuracy of the horizontal and vertical base lines of the formed block is measured, the inclination is measured, and the size of the upper and lower ports is measured to control the block structure within the qualified size range; S6: overall welding of steel shell tower segment: set up an assembling jig, and set up the longitudinal and transverse positioning base lines of the steel shell tower segment on the jig; position the planar block on the jig with the longitudinal and transverse base lines of the jig as the reference; position the temporary process support on the outer wall plate of the planar block with the longitudinal and transverse base lines of the jig and the elevation level point as the reference; weld and assemble the L-shaped blocks on both sides of the planar block with the longitudinal and transverse base lines of the jig as the reference, ensure the matching accuracy between the L-shaped blocks and the planar blocks, and focus on controlling the opening size of the L-shaped blocks and the perpendicularity of the blocks; weld and assemble the C-shaped blocks at the top of the L-shaped blocks with the longitudinal and transverse base lines of the jig as the reference, ensure the matching accuracy of the C-shaped blocks and the planar blocks and the L-shaped blocks, focus on controlling the box opening size of the steel shell tower segment and the matching accuracy between the segments, mark and cut the reserved amount after passing the inspection, and complete the welding of the bridge steel shell tower segment. S7: Size retest: after the completion of the overall butt welding of the steel shell tower segment, the horizontal, vertical baseline and inclination of the steel shell tower segment are retested, and the size of the upper and lower ports is retested; to control the overall butt welded steel shell tower segment within the qualified size range; S8: Steel shell tower pre-assembly: the steel shell tower segment is pre-assembled in the factory area, the steel shell tower is placed according to the assembly position, and the pre-assembly is carried out by cooperating with the lifting appliance equipment and the jig frame. The pre-assembly effect of the steel shell tower segment is detected.

2. A process for the fabrication and assembly of bridge steel shell tower segments according to claim 1, characterized in that: The block is accurately positioned on the jig frame with the cooperation of the level and the theodolite before the block is pre-assembled. The C-shaped block is detected to be qualified before assembly. The edge misalignment of the front and rear block wall plates is checked after the pre-assembly is completed.

3. A process for assembling a bridge steel shell tower segment according to claim 1, characterized in that: The steel shell tower segment is arranged and welded with adjusting brackets and guide blocks on the inner and outer wall plates during assembly. The temporary matching parts are assembled and welded during three-dimensional assembly to ensure that the steel shell tower segment is accurately erected at the bridge site.

Images