Super-large-section steel tower curve cross beam section and manufacturing method thereof

Abstract

The invention discloses a super-large-section steel tower curve cross beam section and a manufacturing method thereof, and relates to the technical field of steel structure installment, the super-large-section steel tower curve cross beam section comprises two first block bodies, the opposite sides of the two first block bodies are provided with first grooves, and the grooved sides of the two first block bodies are in contact connection; the two second block bodies are arranged on the top side and the bottom side of the first block body respectively, any second block body is connected with the two first block bodies, and second grooves are formed in the two second block bodies; the longitudinal section size of the second block body is smaller than that of the first block body; and the longitudinal section size of the second groove is smaller than that of the first groove. The invention further discloses a manufacturing method of the super-large-section steel tower curve cross beam section. The technical problems that an existing steel tower curve cross beam is difficult to manufacture, and precision control is difficult are solved.

Description

Technical Field

[0001] The invention relates to the technical field of steel structure installation, and in particular to a super-large-section steel tower curved crossbeam segment and a manufacturing method thereof. Background Art

[0002] As a cable suspension system, suspension bridges have been widely used in the construction of large span bridges in recent years due to their advantages such as large span, good load-bearing capacity and beautiful bridge shape. The crossbeam plays the role of connecting the tower columns in the bridge tower structure. The traditional box-type crossbeam is too simple in shape. The curved crossbeam not only solves the force problem well, but also takes into account the aesthetics of the entire bridge, which is extremely common in steel tower structures.

[0003] There is no mature process for manufacturing curved cross beams of steel towers on the current market, and curved cross beams of steel towers are all integral parts, which is not conducive to transportation and accuracy assurance. Summary of the invention

[0004] The purpose of the present invention is to provide a super-large section steel tower curved crossbeam segment and a manufacturing method thereof, which solves the technical problems of difficulty in manufacturing and precision control of steel tower curved crossbeams in the prior art.

[0005] The embodiment of the present application discloses a super-large cross-section steel tower curved beam segment, comprising:

[0006] Two first blocks, opposite sides of the two first blocks are provided with first grooves, and the grooved sides of the two first blocks are in contact and connected;

[0007] Two second blocks, the two second blocks are respectively arranged on the top and bottom sides of the first block, and any one of the second blocks is connected to two of the first blocks, and the two second blocks are both provided with second grooves;

[0008] The longitudinal section size of the second block is smaller than that of the first block; the longitudinal section size of the second groove is smaller than that of the first groove.

[0009] The application designs the curved beam segment to be assembled into multiple blocks, which facilitates subsequent control of accuracy.

[0010] Based on the above technical solution, the embodiment of the present application can also be improved as follows:

[0011] Furthermore, the first block and the second block are both arc-shaped blocks. The beneficial effect of adopting this step is that the arc-shaped pieces facilitate the subsequent formation of a curved beam.

[0012] The present application also discloses a method for manufacturing a curved crossbeam segment of a super-large cross-section steel tower, comprising the following steps:

[0013] S1: Make multiple top plate units, web plate units, and diaphragm units;

[0014] S2: Select the assembly tire frame;

[0015] S3: welding a plurality of top plate units into a top plate multi-assembly unit, welding a plurality of web plate units into a web plate multi-assembly unit, and welding a plurality of partition plate units into a partition plate multi-assembly unit;

[0016] S4: Lay out a ground sample line on the ground, lay the web multi-assembly unit on the assembly jig, ensure that the baseline of the web multi-assembly unit is aligned with the ground sample line, and check the flatness of the web multi-assembly unit to ensure that it is ≤2mm. After passing the test, use a horse plate to fix the web multi-assembly unit and the assembly jig; after the web multi-assembly unit is positioned, correct the overall baseline and the partition position line, and check the port gap and the plate rib misalignment;

[0017] S5: Using the longitudinal baseline of the web multi-assembly unit as a reference, assembling the partition multi-assembly unit according to the partition position line, and during assembly, ensuring that the longitudinal baseline of the partition multi-assembly unit is aligned with the baseline of the web multi-assembly unit;

[0018] S6: Assemble the top plate multi-units, assemble the top plate multi-units according to the upper horizontal baseline of the web plate multi-row units, and adjust the longitudinal position according to the longitudinal baseline of the web plate multi-units to ensure that the verticality of the top and bottom plates is ≤1mm, and temporarily spot weld the top and bottom plate units and the partition plate units;

[0019] S 7: After welding, flaw detection is performed to correct welding deformation and form a block;

[0020] S8: repeating steps S4-S7 to complete the assembly of the remaining three blocks, and dividing the four blocks into two first blocks and two second blocks according to the different areas of the longitudinal sections;

[0021] S9: Select a pre-assembled tire frame and assemble the two first blocks. During the assembly process, ensure that the baselines of the two first blocks coincide, and then perform spot welding and temporary fixing with a stacking plate;

[0022] S10: welding the butt weld between the two first blocks to ensure that the two first blocks are welded into a whole;

[0023] S11: Taking the two first blocks as reference, assembling the two second blocks respectively, and setting round tube fixtures at the ends of the second blocks;

[0024] S12: Weld the butt welds between the second block and the first block respectively, perform flaw detection after welding to ensure that the four blocks are welded into a whole segment and complete the processing.

[0025] Based on the above technical solution, the embodiment of the present application can also be improved as follows:

[0026] Furthermore, the step S3 also includes the following contents:

[0027] After welding is completed, the welding deformation is trimmed to ensure that the flatness of the top plate multi-assembly unit, the web plate multi-assembly unit and the partition plate multi-assembly unit is ≤1.0mm / m. After passing the test, proceed to step S4.

[0028] Furthermore, the step S5 also includes the following steps: spot fixing the support of the assembled tire frame and the web multi-assembly unit, the point fixing position is above the center of gravity of the partition unit, and each partition unit has no less than 3 supports. The beneficial effect of adopting this step is that the stability of subsequent welding can be improved by point fixing.

[0029] Furthermore, the step S7 also includes the following steps: flame cutting the grooves at both ends of the web and the top and bottom plates based on the longitudinal baseline of the block, grinding the cuts and trimming deformation.

[0030] Furthermore, the diameter of the round tube tooling is not less than 100 mm.

[0031] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages:

[0032] 1. The present application discloses a curved crossbeam segment of a super-large cross-section steel tower, which is first manufactured into corresponding blocks and then assembled, so as to better achieve precision control.

[0033] 2. The present application also discloses a method for manufacturing curved crossbeam segments of super-large cross-section steel towers, which not only ensures the construction quality, reduces the total assembly time, speeds up the construction progress, but also helps to reduce the safety risks of construction personnel working at high altitudes and reduce the time of high altitude operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0035] Figure 1 It is a structural schematic diagram of a curved crossbeam segment of a super-large cross-section steel tower according to a specific embodiment of the present invention;

[0036] Figure 2 It is a schematic flow chart of a method for manufacturing a curved crossbeam segment of a super-large cross-section steel tower according to a specific embodiment of the present invention;

[0037] Figure 3A structural schematic diagram of a product made by a method for making a curved crossbeam segment of a super-large cross-section steel tower according to a specific embodiment of the present invention

[0038] 1-first block; 2-first groove; 3-second block; 4-second groove; DETAILED DESCRIPTION

[0039] The following embodiments of the technical solution of the present invention are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore only used as examples, and cannot be used to limit the protection scope of the present invention.

[0040] It should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should have the common meanings understood by those skilled in the art to which the present invention belongs.

[0041] In this application, unless otherwise clearly specified and limited, the terms "installation", "connection", "fixation" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] In order to better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0043] Embodiment 1:

[0044] like Figure 1 As shown, the present application discloses an ultra-large section steel tower curved beam segment. Compared with the existing beam segments, the present application divides the beam segment into multiple box chambers, and then adopts a horizontal overall assembly method, which is convenient for improving the construction quality, while also ensuring the actual processing accuracy, reducing the overall assembly time, speeding up the construction progress, and helping to reduce the safety risks of construction personnel working at high altitudes and reduce the time of high altitude operations.

[0045] The specific structure of the embodiment of the present application includes:

[0046] Two first blocks 1, opposite sides of the two first blocks 1 are provided with first grooves 2, and the grooved sides of the two first blocks 1 are in contact and connected, wherein each first block 1 is composed of an arc top plate, an arc bottom plate, an arc stiffening rib, a horizontal stiffening rib, a partition, an arc web plate, a saber-bend stiffening rib, and a T-shaped stiffening rib, so as to ensure the strength of the first block 1 after welding;

[0047] Two second blocks 3, the two second blocks 3 are respectively arranged on the top and bottom sides of the first block 1, and any second block 3 is connected to the two first blocks 1, and the two second blocks 3 are provided with second grooves 4 inside. The first groove 2 and the second groove 4 are provided in the present application to ensure strength while saving materials. At the same time, the second block 3 of the present application is composed of an arc top plate, an arc stiffening rib, an arc web, a saber-bend stiffening rib, a partition, and a horizontal stiffening rib. Compared with the first block 1, only the structure of the stiffening rib is different;

[0048] The longitudinal section size of the second block 3 is smaller than that of the first block 1 ; the longitudinal section size of the second groove 4 is smaller than that of the first groove 2 . Compared with the first block 1 , the size of the second block 3 is smaller.

[0049] Specifically, the first block 1 and the second block 2 are both arc-shaped blocks, so that after being spliced, a curved beam segment can be formed.

[0050] The two first blocks in this application are manufactured with the web facing downward, i.e., the multiple web units are used as the base, so that the difficulty of making the frame can be reduced by slightly modifying the existing frame tooling on site; secondly, this application successfully reduces the height of the two first blocks to about 5m (the original whole block was 10m), reducing the construction difficulty and safety risks (climbing work and scaffolding erection). The two first blocks are butt-jointed up and down, and then the two second blocks are butt-jointed from the side, which greatly reduces the welding difficulty (basically horizontal and vertical welding, thus avoiding overhead welding, reducing the welding difficulty and effectively ensuring the welding quality of the entire section). Finally, the split production can smoothly enter the sandblasting and painting workshop, and at the same time facilitate the turning over of the block production and the transportation on site, making full use of the existing tooling on site and reducing the number of newly manufactured tooling.

[0051] Embodiment 2:

[0052] Based on Example 1, Figure 2-3 As shown, the embodiment of the present application discloses a method for manufacturing a curved crossbeam segment of a super-large cross-section steel tower, comprising the following steps:

[0053] S1: Make multiple top plate units, web plate units, and diaphragm units;

[0054] When the top plate unit is manufactured, a laser machine is used to mark the inner and outer skin baselines and the stiffening rib assembly positions on the arc top plate, and saber-bend stiffening ribs are manufactured at the same time. The saber-bend stiffening ribs are then installed on the side of the arc top plate. During installation, the gap between the saber-bend stiffening ribs and the plate surface of the arc top plate is ensured to be no greater than 0.5 mm. Then electric welding is performed, and the verticality of the saber-bend stiffening ribs is controlled to be no greater than 1 mm to complete the manufacture of the top plate unit. When the tire frame is selected, a level is used to place the elevation of the tooth plate on the tire frame, thereby ejecting the camber value of the top plate unit. At the same time, a group of tooth plates is arranged on the tire frame every 1 meter, and it is ensured that the saber height value of each group of tooth plates reaches the theoretical design value.

[0055] When the web unit is manufactured, the arc-shaped web is placed on the tire frame, and then the arc-shaped stiffening ribs or horizontal stiffening ribs are assembled, and finally welded and fixed to complete the manufacture of the web unit; when the arc-shaped stiffening ribs or horizontal stiffening ribs are assembled, the gap between the arc-shaped stiffening ribs or horizontal stiffening ribs and the arc-shaped web is ensured to be ≤0.5mm, and the gap between the arc-shaped stiffening ribs or horizontal stiffening ribs and the arc-shaped web is ≤1.0mm, and spot welding is performed after precise positioning to control the verticality of the plate ribs to be ≤1mm;

[0056] When the partition unit is manufactured, the partition is placed on the tire frame, and then the horizontal stiffening ribs are assembled, and finally welded and fixed to complete the manufacture of the web unit. At the same time, when the horizontal stiffening ribs are assembled, the gap between the horizontal stiffening ribs and the arc-shaped web is ≤0.5mm, and the gap in the local area is ≤1.0mm. After precise positioning, spot welding is performed to control the verticality of the plate ribs to ≤1mm; when the horizontal stiffening ribs in the web unit and the partition unit are assembled, the angle plate of the tire frame is used to control the assembly accuracy of the horizontal stiffening and the corresponding panel;

[0057] In step S1, the accuracy of the plate unit is the basis for the subsequent block production. From the beginning of cutting the steel plate, especially the curvature of the top plate unit will affect the appearance of the overall segment and bridge position in the later stage, as well as whether it is consistent with the design drawings.

[0058] S2: Use an assembly frame; the assembly frame consists of a base plate, a support plate and a pressure plate, in which the elevation of the tooth plate changes linearly from south to north and from east to west. It is released using a total station, and the tooth plate and the web unit are kept in close contact during the manufacturing process; that is, according to the data fed back from the design drawings, the tooth plate (height change) on the special frame can be used to effectively ensure the manufacturing line shape (variable cross-section) of the entire segment.

[0059] S 3: On the platform, weld the top plate multiple units, web plate multiple units and partition plate multiple units based on the vertical and horizontal baselines, trim the welding deformation to ensure that the flatness of the top plate multiple units, web plate multiple units and partition plate multiple units is ≤1.0mm / m; assemble the same type of plate units before block production to reduce the number of plate unit hoisting, reduce labor costs, and reduce construction difficulty (the welding of plate units in the block box is limited by space and welding difficulty, etc.), and use special fixtures to hoist the welded multi-plate units onto the tire frame for block production;

[0060] S4: Lay out a ground sample line on the ground, lay the web multi-assembly unit on the assembly jig, ensure that the baseline of the web multi-assembly unit is aligned with the ground sample line, and check the flatness of the web multi-assembly unit to ensure that it is ≤2mm. After passing the test, use a horse plate to fix the web multi-assembly unit and the assembly jig; after the web multi-assembly unit is positioned, correct the overall baseline and the partition position line, and check the port gap and the plate rib misalignment;

[0061] S5: Using the longitudinal baseline of the web multi-assembly unit as a reference, assembling the partition multi-assembly unit according to the partition position line, and during assembly, ensuring that the longitudinal baseline of the partition multi-assembly unit is aligned with the baseline of the web multi-assembly unit;

[0062] When supporting, the support of the assembly tire frame is point-fixed with the web multi-piece unit, and the point-fixed position is above the center of gravity of the partition unit, and each partition unit is supported at no less than 3 points;

[0063] During assembly, ensure that the verticality of the partition unit is ≤1mm to ensure that the test is qualified. If qualified, proceed to the next step S6;

[0064] S6: Assemble the top plate multi-units, assemble the top plate multi-units according to the upper horizontal baseline of the web plate multi-row units, and adjust the longitudinal position according to the longitudinal baseline of the web plate multi-units to ensure that the verticality of the top and bottom plates is ≤1mm, and temporarily spot weld the top and bottom plate units and the partition plate units; further explanation is given for steps S5 and S6. Since the longitudinal baseline of the partition plate multi-units and the baseline of the web plate multi-units are on the same plane when the plate units are manufactured, the baselines of these two types of plate units are aligned when the blocks are manufactured, which can ensure that the partition plate multi-units are in the correct installation position, and then the baseline of the partition plate multi-units and the baseline of the top and bottom plate multi-units are on the same plane, thereby ensuring that the subsequent top and bottom plate multi-units are in the correct installation position;

[0065] S 7: After welding, flaw detection is carried out to trim welding deformation and form a block; when trimming welding deformation, the specific deviations of the block box opening size and diagonal difference are as follows: its length, width and height requirements are ±2m, the box opening diagonal deviation is allowed to be 1.5mm, and the box side bend and distortion shall not exceed 3mm;

[0066] At the same time, the grooves at both ends of the web and top and bottom plates are cut with flames based on the longitudinal baseline of the block, and the cuts are polished and the deformation is corrected;

[0067] S8: repeating steps S4-S7 to complete the assembly of the remaining three blocks, and dividing the four blocks into two first blocks and two second blocks according to the different areas of the longitudinal sections, wherein the first block and the second block are the first block and the second block described in specific embodiment 1;

[0068] S9: Use a pre-assembled frame to assemble the two first blocks. During the assembly process, ensure that the baselines of the two first blocks coincide, and then perform spot welding and temporary fixing with stacking plates. The pre-assembled frame is mainly composed of multi-faceted support stools and support plates. The multi-faceted support stools are arranged at the intersection of the cross diaphragm and the web of the middle beam block, and the support plates are placed on the support stools. To facilitate segment measurement, the support plates are cut on site according to the actual elevation difference in the parameter table;

[0069] S10: welding the butt weld between the two first blocks to ensure that the two first blocks are welded into a whole;

[0070] S11: Taking the two first blocks as reference, assembling the two second blocks respectively, and providing a round tube fixture at the end of the second block, wherein the diameter of the round tube fixture is not less than 100 mm;

[0071] S12: Weld the butt welds between the second block and the first block respectively, perform flaw detection after welding to ensure that the four blocks are welded into a whole segment and complete the processing.

[0072] In the description of the present invention, a large number of specific details are described. However, it is understood that embodiments of the present invention can be practiced without these specific details. In some instances, well-known methods, structures and techniques are not shown in detail so as not to obscure the understanding of this description.

[0073] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0074] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein by equivalents. These modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be included in the scope of the claims and specification of the present invention.

Claims

1. A curved crossbeam segment of a super-large cross-section steel tower, characterized in that: include: Two first blocks, opposite sides of the two first blocks are provided with first grooves, and the grooved sides of the two first blocks are in contact and connected; Two second blocks, the two second blocks are respectively arranged on the top and bottom sides of the first block, and any one of the second blocks is connected to two of the first blocks, and the two second blocks are both provided with second grooves; The longitudinal section size of the second block is smaller than that of the first block; the longitudinal section size of the second groove is smaller than that of the first groove.

2. The ultra-large section steel tower curved beam segment according to claim 1, characterized in that: The first block and the second block are both arc-shaped blocks.

3. A method for manufacturing a curved crossbeam segment of a super-large cross-section steel tower, characterized in that: The following steps are involved: S1: Make multiple top plate units, web plate units, and diaphragm units; S2: Select the assembly tire frame; S3: welding a plurality of top plate units into a top plate multi-assembly unit, welding a plurality of web plate units into a web plate multi-assembly unit, and welding a plurality of partition plate units into a partition plate multi-assembly unit; S4: Lay out a ground sample line on the ground, lay the web multi-assembly unit on the assembly jig, ensure that the baseline of the web multi-assembly unit is aligned with the ground sample line, and check the flatness of the web multi-assembly unit to ensure that it is ≤2mm. After passing the test, use a horse plate to fix the web multi-assembly unit and the assembly jig; After the web plate multi-unit is positioned, correct the overall baseline and the partition plate position line, and check the port gap and plate rib misalignment; S5: Using the longitudinal baseline of the web multi-assembly unit as a reference, assembling the partition multi-assembly unit according to the partition position line, and during assembly, ensuring that the longitudinal baseline of the partition multi-assembly unit is aligned with the baseline of the web multi-assembly unit; S6: Assemble the top plate multi-units, assemble the top plate multi-units according to the upper horizontal baseline of the web plate multi-row units, and adjust the longitudinal position according to the longitudinal baseline of the web plate multi-units to ensure that the verticality of the top and bottom plates is ≤1mm, and temporarily spot weld the top and bottom plate units and the partition plate units; S 7: After welding, flaw detection is performed to correct welding deformation and form a block; S8: repeating steps S4-S7 to complete the assembly of the remaining three blocks, and dividing the four blocks into two first blocks and two second blocks according to the different areas of the longitudinal sections; S9: Select a pre-assembled tire frame and assemble the two first blocks. During the assembly process, ensure that the baselines of the two first blocks coincide, and then perform spot welding and temporary fixing with a stacking plate; S10: welding the butt weld between the two first blocks to ensure that the two first blocks are welded into a whole; S11: Taking the two first blocks as reference, assembling the two second blocks respectively, and setting round tube fixtures at the ends of the second blocks; S12: Weld the butt welds between the second block and the first block respectively, perform flaw detection after welding to ensure that the four blocks are welded into a whole segment and complete the processing.

4. The method according to claim 3, characterized in that: The step S3 also includes the following contents: After welding is completed, the welding deformation is trimmed to ensure that the flatness of the top plate multi-assembly unit, the web plate multi-assembly unit and the partition plate multi-assembly unit is ≤1.0mm / m. After passing the test, proceed to step S4.

5. The manufacturing method according to claim 3, characterized in that: The step S5 also includes the following steps: point-fixing the support of the assembled tire frame and the web multi-piece unit, the point-fixing position is above the center of gravity of the partition unit, and each partition unit has no less than 3 supports.

6. The method according to claim 4, characterized in that: The step S7 also includes the following steps: when correcting welding deformation, ensure that the specific deviations of the block box opening size and diagonal difference are as follows: its length, width and height requirements are ±2m, the box opening diagonal deviation is allowed to be 1.5mm, and the box lateral bending and twisting do not exceed 3mm.

7. The manufacturing method according to claim 6, characterized in that: The step S7 also includes the following steps: flame cutting the grooves at both ends of the web and the top and bottom plates based on the longitudinal baseline of the block, grinding the cuts and trimming the deformation.

8. The manufacturing method according to claim 3, characterized in that: The diameter of the round tube tooling is not less than 100 mm.

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