An assembling process of a variable cross-section back-shaped steel shell concrete combined steel tower

Abstract

The application relates to a variable cross-section back-shaped steel shell concrete combined steel tower assembling process, and the specific processing and assembling process is as follows: S1, division of a steel shell tower section; S2, manufacturing of a plate unit; S3, blanking of steel bars and angle steels; S4, block forming; S5, integral butt welding of the steel shell tower section; the bridge steel shell tower section is divided into four block structures, the required parts of each block structure are uniformly cut; the modularization of the block structures is completed on a jig frame, and then the four block structures are modularly assembled and welded on the jig frame; the assembling and welding mode greatly improves the assembling efficiency, and the mutual comparison and checking process of the block structures can be realized in the synchronous processing process, so that the subsequent detection time is reduced.

Description

Technical Field

[0001] This invention relates to the field of bridge steel shell tower processing and assembly technology, and in particular to an assembly process for a variable cross-section U-shaped steel shell concrete composite steel tower. Background Technology

[0002] The main towers of the bridge both adopt a steel-concrete composite structure. The tower columns are divided into three sections: upper, middle, and lower. The upper tower columns are made of steel, while the middle and lower tower columns are made of concrete. Based on the hoisting and erection capacity requirements, the steel tower columns were re-segmented to determine the blocks to be hoisted on-site. Furthermore, when the weight and dimensions of the hoisting blocks exceeded the capacity of the cranes and flatbed trucks in the workshop, further segmentation was necessary. The general principle was to maximize the dimensions of the segments and minimize the number of segments, based on the various constraints during the steel tower production and erection process. However, structural segmentation in general steel tower sections is not conducive to welding, and the large number of segments makes manufacturing difficult. Moreover, the varying sizes and structures of the components lead to redundant processing and manufacturing processes. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an assembly process for a variable cross-section U-shaped steel shell concrete composite steel tower, which can solve the problems of large number of segments, redundant processing and manufacturing processes, and low production efficiency in the general processing, manufacturing and assembly of steel tower segments.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention is: an assembly process for a variable cross-section U-shaped steel shell concrete composite steel tower, the innovation of which lies in the following specific processing and assembly process:

[0005] S1: Division of Steel Shell Tower Segments: The steel shell tower segments have a columnar shell structure, with inner and outer wall panels, as well as steel mesh, partitions, and ribs set between the inner and outer wall panels; the steel shell tower segments are divided into planar blocks, L-shaped blocks, and C-shaped blocks; the L-shaped blocks have a pair set 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;

[0006] S2: Manufacturing of Plate Units: Plate units include wall panels, ribs, and partitions; the sheet metal is pre-treated using an automated production line for leveling, shot blasting, painting, and drying; the wall panels, ribs, and partitions are precisely cut using a CNC cutting machine, with sufficient welding shrinkage allowance reserved in the length and width directions of the parts through precise calculations, and automatic scribing and marking are completed simultaneously during cutting; after the wall panels are cut, the bevels on both sides and the reference end are cut or machined using a semi-automatic trolley to correct warping and wavy deformation; after the ribs are cut and leveled, the bevels on both sides are cut using a semi-automatic trolley to correct straightness, and then the holes at both ends are drilled using a flat CNC drilling machine;

[0007] S3: Reinforcing steel and angle steel cutting: Select the reinforcing steel and angle steel required for the inside of the steel tower segment, and cut them according to the quantity and length requirements;

[0008] S4: Block Forming: The block consists of outer wall panels, inner wall panels, reinforcing mesh, partitions, and stiffening angle steel. The outer and inner wall panels, with welded ribs, are placed on a jig. Partitions are welded to the inner and outer wall panels according to the marked positions. After welding the partitions, the panels are straightened and their flatness is checked on a platform. Shear stud assembly lines are then marked, and shear studs are welded using a stud welding machine. Horizontal and longitudinal reinforcing bars are then inserted, and the reinforcing bars are tied. Stiffening angle steel is then welded to the inner wall of the outer wall panel. The assembled inner wall panel is then attached to the stiffening angle steel on the outer wall panel and welded to complete the block forming, ensuring the relative positional relationship between the inner and outer wall panels. The assembly and welding of planar blocks, L-shaped blocks, and C-shaped blocks are completed sequentially.

[0009] S5: Overall welding of steel shell tower segments: Set up an assembly jig and set longitudinal and transverse positioning baselines for the steel tower segments on the jig; use the longitudinal and transverse baselines of the jig as a reference to position the planar blocks on the jig; use the longitudinal and transverse baselines of the jig and elevation level points as references to lay out and position temporary process supports on the outer wall panels of the planar blocks; use the longitudinal and transverse baselines of the jig as a reference to weld L-shaped blocks on both sides of the planar blocks, ensuring the matching accuracy between the L-shaped blocks and the planar blocks, focusing on controlling the opening size of the L-shaped blocks and the verticality of the blocks; use the longitudinal and transverse baselines of the jig as a reference to weld C-shaped blocks on the top of the L-shaped blocks, ensuring the matching accuracy between the C-shaped blocks and the planar blocks and the L-shaped blocks, focusing on controlling the box opening size of the steel shell tower segments and the matching accuracy between segments. After passing the test, mark and cut the reserved allowance to complete the welding of the bridge steel shell tower segments.

[0010] Furthermore, before the blocks are pre-assembled, they are accurately positioned on the jig using a level and a theodolite. The C-shaped blocks are then assembled only after they are deemed qualified. After the pre-assembly is completed, the misalignment of the front and rear block wall panels is checked.

[0011] Furthermore, during the assembly of the steel tower segments, brackets and guide blocks are arranged and welded on the inner and outer wall panels. Temporary matching parts are assembled and welded during three-dimensional assembly to ensure that the steel tower segments are accurately erected at the bridge site.

[0012] The advantages of this invention are:

[0013] 1) In this invention, the steel shell tower of the bridge is divided into four block structures. The required components for each block are uniformly cut and prepared. The modular welding of each block structure is completed on the jig, and then the four block structures are modularly assembled and welded on the jig. This welding method greatly improves the assembly efficiency. At the same time, the block structures can be compared and verified with each other during the synchronous processing, reducing the subsequent inspection time. Attached Figure Description

[0014] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0015] Figure 1 This is a flowchart illustrating the assembly process of a variable cross-section U-shaped steel-concrete composite steel tower according to the present invention.

[0016] Figures 2 to 3 This is a planar block assembly and welding diagram of the assembly process of a variable cross-section U-shaped steel shell concrete composite steel tower according to the present invention.

[0017] Figures 4 to 5 This is an overall welding diagram illustrating the assembly process of a variable cross-section U-shaped steel-concrete composite steel tower according to the present invention. Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0019] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0020] like Figures 1 to 5 The assembly process of a variable cross-section U-shaped steel-shell concrete composite steel tower shown is as follows:

[0021] S1: Division of Steel Shell Tower Segments: The steel shell tower segments have a columnar shell structure, with inner and outer wall panels, as well as steel mesh, partitions, and ribs set between the inner and outer wall panels; the steel shell tower segments are divided into planar blocks, L-shaped blocks, and C-shaped blocks; the L-shaped blocks have a pair set 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;

[0022] S2: Manufacturing of Plate Units: Plate units include wall panels, ribs, and partitions; the sheet metal is pre-treated using an automated production line for leveling, shot blasting, painting, and drying; the wall panels, ribs, and partitions are precisely cut using a CNC cutting machine, with sufficient welding shrinkage allowance reserved in the length and width directions of the parts through precise calculations, and automatic scribing and marking are completed simultaneously during cutting; after the wall panels are cut, the bevels on both sides and the reference end are cut or machined using a semi-automatic trolley to correct warping and wavy deformation; after the ribs are cut and leveled, the bevels on both sides are cut using a semi-automatic trolley to correct straightness, and then the holes at both ends are drilled using a flat CNC drilling machine;

[0023] S3: Reinforcing steel and angle steel cutting: Select the reinforcing steel and angle steel required for the inside of the steel tower segment, and cut them according to the quantity and length requirements;

[0024] S4: Block Forming: The block consists of outer wall panels, inner wall panels, reinforcing mesh, partitions, and stiffening angle steel. The outer and inner wall panels, with welded ribs, are placed on a jig. Partitions are welded to the inner and outer wall panels according to the marked positions. After welding the partitions, the panels are straightened and their flatness is checked on a platform. Shear stud assembly lines are then marked, and shear studs are welded using a stud welding machine. Horizontal and longitudinal reinforcing bars are then inserted, and the reinforcing bars are tied. Stiffening angle steel is then welded to the inner wall of the outer wall panel. The assembled inner wall panel is then attached to the stiffening angle steel on the outer wall panel and welded to complete the block forming, ensuring the relative positional relationship between the inner and outer wall panels. The assembly and welding of planar blocks, L-shaped blocks, and C-shaped blocks are completed sequentially.

[0025] S5: Overall welding of steel shell tower segments: Set up an assembly jig and set longitudinal and transverse positioning baselines for the steel tower segments on the jig; use the longitudinal and transverse baselines of the jig as a reference to position the planar blocks on the jig; use the longitudinal and transverse baselines of the jig and elevation level points as references to lay out and position temporary process supports on the outer wall panels of the planar blocks; use the longitudinal and transverse baselines of the jig as a reference to weld L-shaped blocks on both sides of the planar blocks, ensuring the matching accuracy between the L-shaped blocks and the planar blocks, focusing on controlling the opening size of the L-shaped blocks and the verticality of the blocks; use the longitudinal and transverse baselines of the jig as a reference to weld C-shaped blocks on the top of the L-shaped blocks, ensuring the matching accuracy between the C-shaped blocks and the planar blocks and the L-shaped blocks, focusing on controlling the box opening size of the steel shell tower segments and the matching accuracy between segments. After passing the test, mark and cut the reserved allowance to complete the welding of the bridge steel shell tower segments.

[0026] Before pre-assembly of the blocks, accurate positioning is carried out on the jig with the help of a level and theodolite. After the C-shaped blocks are inspected and found to be qualified, they are then assembled. After the pre-assembly is completed, the misalignment of the front and rear block wall panels is checked.

[0027] During the assembly of steel tower segments, brackets and guide blocks are arranged and welded on the inner and outer wall panels. Temporary matching parts are assembled and welded during three-dimensional assembly to ensure that the steel tower segments are accurately erected at the bridge site.

[0028] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. An assembly process for a variable cross-section U-shaped steel-shell concrete composite steel tower, characterized in that: The specific processing and assembly techniques are as follows: S1: Division of Steel Shell Tower Segments: The steel shell tower segments have a columnar shell structure, with inner and outer wall panels, as well as steel mesh, partitions, and ribs set between the inner and outer wall panels; the steel shell tower segments are divided into planar blocks, L-shaped blocks, and C-shaped blocks; the L-shaped blocks have a pair set 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 Units: Plate units include wall panels, ribs, and partitions; the sheet metal is pre-treated using an automated production line for leveling, shot blasting, painting, and drying; the wall panels, ribs, and partitions are precisely cut using a CNC cutting machine, with sufficient welding shrinkage allowance reserved in the length and width directions of the parts through precise calculations, and automatic scribing and marking are completed simultaneously during cutting; after the wall panels are cut, the bevels on both sides and the reference end are cut or machined using a semi-automatic trolley to correct warping and wavy deformation; after the ribs are cut and leveled, the bevels on both sides are cut using a semi-automatic trolley to correct straightness, and then the holes at both ends are drilled using a flat CNC drilling machine; S3: Reinforcing steel and angle steel cutting: Select the reinforcing steel and angle steel required for the inside of the steel tower segment, and cut them according to the quantity and length requirements; S4: Block Forming: The block consists of outer wall panels, inner wall panels, reinforcing mesh, partitions, and stiffening angle steel. The outer and inner wall panels, with welded ribs, are placed on a jig. Partitions are welded to the inner and outer wall panels according to the marked positions. After welding the partitions, the panels are straightened and their flatness is checked on a platform. Shear stud assembly lines are then marked, and shear studs are welded using a stud welding machine. Horizontal and longitudinal reinforcing bars are then inserted, and the reinforcing bars are tied. Stiffening angle steel is then welded to the inner wall of the outer wall panel. The assembled inner wall panel is then attached to the stiffening angle steel on the outer wall panel and welded to complete the block forming, ensuring the relative positional relationship between the inner and outer wall panels. The assembly and welding of planar blocks, L-shaped blocks, and C-shaped blocks are completed sequentially. S5: Overall welding of steel shell tower segments: Set up an assembly jig and set longitudinal and transverse positioning baselines for the steel tower segments on the jig; use the longitudinal and transverse baselines of the jig as a reference to position the planar blocks on the jig; use the longitudinal and transverse baselines of the jig and elevation level points as references to lay out and position temporary process supports on the outer wall panels of the planar blocks; use the longitudinal and transverse baselines of the jig as a reference to weld L-shaped blocks on both sides of the planar blocks, ensuring the matching accuracy between the L-shaped blocks and the planar blocks, focusing on controlling the opening size of the L-shaped blocks and the verticality of the blocks; use the longitudinal and transverse baselines of the jig as a reference to weld C-shaped blocks on the top of the L-shaped blocks, ensuring the matching accuracy between the C-shaped blocks and the planar blocks and the L-shaped blocks, focusing on controlling the box opening size of the steel shell tower segments and the matching accuracy between segments; after passing the test, mark and cut the reserved allowance to complete the welding of the bridge steel shell tower segments; Before the blocks are pre-assembled, they are accurately positioned on the jig with the help of a level and a theodolite. The C-shaped blocks are then assembled after they are found to be qualified. After the pre-assembly is completed, the misalignment of the front and rear block wall panels is checked. During the assembly of the steel tower segments, brackets and guide blocks are arranged and welded on the inner and outer wall panels. Temporary matching parts are assembled and welded during three-dimensional assembly to ensure that the steel tower segments are accurately erected at the bridge site.

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