Manufacturing method of super-large-diameter thick-wall round pipe

Abstract

The invention discloses a manufacturing method of a super-large-diameter thick-wall round pipe. The manufacturing method comprises the steps that the round pipe is divided into blocks in the length direction; blanking the circular tube wall plate; a round tube is curled, and a tube plate associated positioning tool is adopted to support the end opening of the round tube; welding the curled round pipe, positioning and welding a longitudinal butt welding seam of the round pipe after pipe reeling is completed, and then moving the round pipe to a roller frame for longitudinal seam welding; the round pipes are lengthened on an assembling machine, and longitudinal welding seams of the adjacent round pipe sections are staggered by at least 1 / 32 arc; and welding the T ribs, the annular plates and the shear nails. According to the invention, the automatic welding of the arc welding seam is realized, the nondestructive testing acceptance requirement is met, the welding seam quality of the circular tube longitudinal seam is better controlled, and the manual welding cost is reduced; the special steel pipe assembling machine is adopted for lengthening the steel pipes, the round pipes are adjusted through longitudinal and vertical movement of the roller carriers on the rails of the assembling machine, matching and butt joint of steel pipe connectors are facilitated, the matching precision of the butt joint end faces of the steel pipes is effectively controlled, and the construction efficiency is improved.

Description

Technical Field

[0001] The invention relates to a method for manufacturing a round tube, in particular to a method for manufacturing an ultra-large diameter thick-walled round tube. Background Art

[0002] In the field of modern engineering, the demand for ultra-large diameter thick-walled round tubes is increasing day by day. They play an indispensable role in large-scale building structures, bridges, marine engineering, heavy machinery and other fields. However, it is not easy to make such round tubes. It requires a combination of advanced technology, exquisite craftsmanship and strict quality control. Traditional round tube manufacturing methods mainly include forging, casting, rolling and welding. In production, different manufacturing methods need to be selected according to the usage scenarios and the properties of the round tube to ensure the final product quality. The diameter of the ultra-large diameter thick-walled round tube reaches 3.6m, the length is 13.5m, and the wall thickness is 30mm. This type of large-diameter thick-walled round tube is generally manufactured by coil welding. However, this type of ultra-large diameter thick-walled round tube is large in size and heavy in weight. The traditional round tube welding and extension method, that is, assembling and welding two round tubes on a tire frame, requires a lot of manpower and material resources. At the same time, the welding quality, roundness and concentricity of the round tube cannot be guaranteed; and the round tube has high rigidity after rolling and is not easy to adjust at the interface. Therefore, the roundness size accuracy control of the round tube, the port matching accuracy control of the extended round tube and the weld quality are manufacturing difficulties. Summary of the invention

[0003] Purpose of the invention: The purpose of the invention is to propose a method for manufacturing ultra-large diameter thick-walled round tubes to achieve factory manufacturing of the structural round tube units, improve production efficiency and ensure construction quality.

[0004] Technical solution: The present invention comprises the following steps: dividing the round tube into blocks in the length direction; cutting the round tube wall plate; curling the round tube, and supporting the round tube port with the tube plate associated positioning tooling; welding the curled round tube, positioning welding the longitudinal butt weld of the round tube after the tube is rolled, and then moving the round tube to the roller frame for longitudinal seam welding; extending the round tube on the assembly machine, and staggering the longitudinal welds of adjacent round tube segments by at least 1 / 32 of the arc; welding T-ribs, ring plates, and shear nails.

[0005] When dividing the circular tube in the length direction, the position of the ring plate is avoided, and the length of a single circular tube is controlled to be about 3.5m.

[0006] The single circular tube comprises a circular tube wall plate, and T-ribs, annular stiffeners, tension plates and shear nails are arranged inside the circular tube wall plate.

[0007] After the round tube is curled, it is ensured that the ovality error is controlled within ±2mm.

[0008] The tube sheet associated positioning tooling includes an inner circle arranged concentrically with the circular tube, a plurality of radial supports radiating radially from the outer side of the inner circle, transverse supports are respectively connected between adjacent radial supports, a fixing plate is installed at the end of each radial support, the plurality of fixing plates are located on the same circle, and each fixing plate is in contact with the inner wall of the circular tube.

[0009] When the longitudinal seam is welded, the weld adopts an X-shaped groove type, and submerged arc welding is used to weld the longitudinal butt weld.

[0010] When the longitudinal seam is welded, the longitudinal seam is first rolled to the bottom by a roller frame, and after the inner groove is welded in a horizontal position, the longitudinal seam is rolled to the top by a roller frame, and the outer weld is welded in a horizontal position.

[0011] The assembling machine includes a longitudinally arranged track, on which a plurality of groups of roller frames are slidably installed, and circular tube segments are placed between adjacent roller frames. Each group of roller frames includes rollers arranged in pairs, and the rollers are driven to rotate by a motor. The height of the rollers under the first circular tube segment is fixed, and hydraulic rods are installed on the roller bases under the remaining circular tube segments to adjust the roller height.

[0012] When welding the T-ribs, the T-ribs are installed every 90° based on the longitudinal butt weld of the round tube.

[0013] The welding of T-ribs, ring plates and shear nails is specifically as follows: assembling and welding the T-ribs and ring plates inside the round tube on a roller frame platform, ensuring that the upper and lower steel bar holes of the ring plate are connected, repairing the welding deformation of the round tube unit, assembling and welding the shear nails, repairing the welding deformation, and rolling the round tube assembly again with a roller frame.

[0014] Beneficial effects: The present invention has the following advantages:

[0015] (1) The present invention realizes the automatic welding of arc welds, which not only meets the requirements of non-destructive testing and acceptance, but also better controls the weld quality of the longitudinal seam of the round tube and reduces the cost of manual welding;

[0016] (2) A special steel pipe assembly machine is used to extend the steel pipes. The round pipes are adjusted by the longitudinal and up and down movement of the roller frame on the assembly machine track, which facilitates the matching and docking of the steel pipe interfaces and effectively controls the matching accuracy of the butt end faces of the steel pipes. The operation is simple and convenient, which can significantly improve the construction efficiency.

[0017] (3) By designing a special tube sheet associated positioning tool for extra-large diameter round tubes, the steel tube port is supported to effectively prevent deformation at the round tube interface. At the same time, the tool can accurately identify the center of the round tube to ensure the precise positioning of the round tube in the subsequent steel tower block. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a cross-sectional view of a circular tube of the present invention;

[0019] Figure 2 This is a front view of the interior of a circular tube of the present invention;

[0020] Figure 3 This is a diagram of the arrangement of the circular tube section shear nails of the present invention;

[0021] Figure 4 This is a main view of the shear nail arrangement diagram of the circular tube of the present invention;

[0022] Figure 5 It is a schematic diagram of the block division of the circular tube wall panel of the present invention;

[0023] Figure 6 It is a schematic diagram of the associated positioning tooling of the present invention;

[0024] Figure 7 This is a schematic diagram of the installation of the associated tooling for the round tube box opening of the present invention;

[0025] Figure 8 It is a schematic diagram of placing a round tube on a special roller frame of the present invention;

[0026] Fig. 9 It is a schematic diagram of the round tube teaming machine of the present invention;

[0027] Fig.10 It is a schematic diagram of placing the round tube of the present invention on the teaming machine. DETAILED DESCRIPTION

[0028] The present invention will be further described below in conjunction with the accompanying drawings.

[0029] The method for manufacturing an ultra-large diameter thick-walled round tube of the present invention comprises the following steps:

[0030] S1. Divide the length of the round tube into blocks

[0031] The length of the round tube is divided into blocks within the maximum processing capacity of the coiling equipment to minimize the circumferential seam butt joint and control the length of a single round tube to about 3.5m. Figure 1 to Figure 4 As shown, it includes a circular tube wall plate 1, which is provided with T ribs 2, annular stiffeners 3, tension plates 4 and shear nails 5. The block position needs to avoid the ring plate position to prevent weld overlap. When the annular seam 6 is butt-jointed, it is ensured that the longitudinal welds 7 of the adjacent segment circular tubes are not on the same straight line, and are staggered by at least 1 / 32 of the arc. After the requirements are met, the annular seams 6 between the segments are welded. The block scheme of the circular tube wall plate is as follows Figure 5 As shown, L≥1 / 32 arc, and L is the staggered distance between the longitudinal welds 7 of adjacent segment circular tubes.

[0032] S2. Cutting of round tube wall panels

[0033] A gantry flame cutting machine is used for cutting and two short side bevels are precisely cut. A special steel sample rod is used to mark and cut the head, and the slit compensation amount is selected according to the plate thickness and cutting nozzle model to ensure the dimensional accuracy of the cutting before the steel plate is rolled; according to the dimensional deviation of the first batch of round tubes after welding, the single plate cutting size of the round tube is adjusted to ensure that the diameter of each point of the round tube after rolling is within the range of ±2mm required by the drawing.

[0034] S3, round tube curling production

[0035] A plate rolling machine is used to roll the tube with the length of the tube as the circumference, and the tube rolling process requires one-time forming. In order to ensure the arc of the longitudinal weld position of the tube, a steel plate bending device is used to pre-bend the joint using a rolling head device before rolling. A special tube rolling machine for extra-large diameter tubes is used to roll the tube, and a reasonable tube rolling process is formulated to ensure the same-direction deviation of the contour size after the tube is rolled; the deformation of a single tube is subjected to force analysis by computer, and the theoretical diameter values ​​of the tube at 0°, 45° and 90° positions after deformation under the action of its own weight are calculated, so as to facilitate the detection of the ovality of the single tube after rolling. After the tube is rolled, the ovality error is ensured to be controlled within ±2mm; design special tube plate associated positioning tooling for extra-large diameter tubes, such as Figure 6 As shown, the end of the round tube is supported, such as Figure 7 As shown, deformation of the round tube interface is prevented.

[0036] like Figure 6 As shown, the associated positioning tooling includes an inner circle arranged concentrically with the circular tube, and multiple radial supports are radiated radially from the outer side of the inner circle. Transverse supports are respectively connected between adjacent radial supports. A fixing plate is installed at the end of each radial support. Multiple fixing plates are located on the same circle, and each fixing plate is fitted with the inner wall of the circular tube, such as Figure 7 As shown, the round tube port is supported to prevent deformation of the round tube interface.

[0037] S4, welded curled round tube

[0038] After the tube is rolled, the longitudinal butt weld of the round tube is positioned on the plate rolling machine, and then the round tube is lifted off the plate rolling machine and placed on the roller frame for longitudinal seam welding. Figure 8 As shown, the weld adopts X-shaped groove type, and the longitudinal butt weld is welded by submerged arc welding. First, the longitudinal seam is rolled to the bottom by a roller frame, and the inner groove is welded in a flat position. Then, the longitudinal seam is rolled to the top by a roller frame, the root is cleaned by air planing, and the outer weld is welded in a flat position.

[0039] S5, round tube extension

[0040] The round tube is connected on the assembly machine. Fig. 9 and Fig.10As shown, the assembling machine includes two longitudinal tracks, on which multiple groups of roller frames are slidably installed, and round pipe segments are placed between adjacent roller frames. A motor is installed on each group of roller frames, and the motor starts to drive the roller frames to move longitudinally along the tracks. Each group of roller frames includes rollers arranged in pairs, and the rollers are driven to rotate by the motor. Except for the roller frame supporting the first section of the round pipe, hydraulic rods are installed on the roller bases of the other roller frames. The roller height is adjusted by retracting the hydraulic rods, which facilitates the matching and docking of the round pipe interfaces.

[0041] Place the 3.5m short round tube on the round tube assembly machine for lengthening, and continuously match the short round tubes. Adjust the assembly accuracy of the round tube interface, and make the longitudinal welds of adjacent short round tubes not on the same straight line, staggered by at least 1 / 32 arc, and weld the annular seam between segments after meeting the requirements. The weld adopts X-shaped groove type, and the transverse butt weld is welded by submerged arc welding.

[0042] S6, welded T ribs, ring plates, shear studs

[0043] Taking the longitudinal butt weld of the round tube as the reference, four longitudinal baselines are drawn at 90° intervals as the T-rib installation reference lines. The circumferential reference lines of the round tube are drawn as the parts assembly reference lines. The circumferential reference lines are used to draw the alignment lines between the round tube and the block.

[0044] On the roller frame platform, weld the T-ribs and steel ring plates inside the round tube to ensure that the upper and lower steel holes of the ring plates are connected. Repair the welding deformation of the round tube unit, weld the shear nails, repair the welding deformation, and use the roller frame to roll the round tube assembly again.

[0045] Process addition and beveling of the cylindrical edge at the bottom of the flame cutting tower.

[0046] Test the ovality and straightness of the round tube, the ovality is ≤2mm, and the longitudinal centerline lateral bend is ≤3mm. After passing the test, participate in the block production.

Claims

1. A method for manufacturing an ultra-large diameter thick-walled round tube, characterized in that: The following steps are involved: Divide the round tube into blocks along the length direction; cut the round tube wall panels; The round tube is rolled and the tube-sheet-related positioning tooling is used to support the tube port; the rolled round tube is welded, and after the tube is rolled, the longitudinal butt weld of the round tube is positioned and welded, and then the round tube is moved to the roller frame for longitudinal seam welding; the round tube is extended on the assembly machine, and the longitudinal welds of adjacent round tube segments are staggered by at least 1 / 32 of the arc; T-ribs, ring plates, and shear studs are welded.

2. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 1, characterized in that: When dividing the circular tube in the length direction, the position of the ring plate is avoided, and the length of a single circular tube is controlled to be about 3.5m.

3. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 2, characterized in that: The single circular tube comprises a circular tube wall plate, and T-ribs, annular stiffeners, tension plates and shear nails are arranged inside the circular tube wall plate.

4. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 1, characterized in that: After the round tube is curled, it is ensured that the ovality error is controlled within ±2mm.

5. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 1, characterized in that: The tube sheet associated positioning tooling includes an inner circle arranged concentrically with the circular tube, a plurality of radial supports radiating radially from the outer side of the inner circle, transverse supports are respectively connected between adjacent radial supports, a fixing plate is installed at the end of each radial support, the plurality of fixing plates are located on the same circle, and each fixing plate is in contact with the inner wall of the circular tube.

6. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 1, characterized in that: When the longitudinal seam is welded, the weld adopts an X-shaped groove type, and submerged arc welding is used to weld the longitudinal butt weld.

7. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 6, characterized in that: When the longitudinal seam is welded, the longitudinal seam is first rolled to the bottom by a roller frame, and after the inner groove is welded in a horizontal position, the longitudinal seam is rolled to the top by a roller frame, and the outer weld is welded in a horizontal position.

8. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 1, characterized in that: The assembling machine includes tracks arranged in pairs, on which multiple groups of roller frames are slidably installed, and circular pipe segments are placed between adjacent roller frames. Each group of roller frames includes rollers arranged in pairs, and the rollers are driven to rotate by a motor. The height of the rollers under the first circular pipe segment is fixed, and hydraulic rods are installed on the roller bases under the remaining circular pipe segments.

9. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 1, characterized in that: When welding the T-ribs, the T-ribs are installed every 90° based on the longitudinal butt weld of the round tube.

10. The method for manufacturing an ultra-large diameter thick-walled round tube according to claim 9, characterized in that: The welding of T-ribs, ring plates and shear nails is specifically as follows: assembling and welding the T-ribs and ring plates inside the round tube on a roller frame platform, ensuring that the upper and lower steel bar holes of the ring plate are connected, repairing the welding deformation of the round tube unit, assembling and welding the shear nails, repairing the welding deformation, and rolling the round tube assembly again with a roller frame.

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