Manufacturing process of box type railway bridge deck steel truss girder

Abstract

The invention relates to a box type railway bridge deck steel truss girder manufacturing process. A steel truss girder comprises an upper chord member, a lower chord member and web members. The upper chord member and the lower chord member adopt box-shaped sections; the web members comprise diagonal web members and vertical members which adopt box-shaped sections; the manufacturing method is characterized by comprising the following specific manufacturing processes: S1, manufacturing an upper chord member and a lower chord member; s2, web members are manufactured; s3, assembling the steel truss girder; quality control is carried out on all production stages of the chord member and the web member, so that installation accuracy and welding quality of the chord member and the web member are improved, and welding deformation is reduced; in addition, carbon dioxide arc welding is adopted, and continuity and smoothness of welding seams are guaranteed; in addition, in the machining process of the chord member and the web member, manual lofting, scribing, cutting, repairing and polishing after cutting and other procedures are conducted, the labor intensity is reduced, the manufacturing efficiency is improved, and the precision of the steel truss can be guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of bridge processing and manufacturing, and in particular to a manufacturing process for a box-type railway bridge deck steel truss. Background Art

[0002] With the rapid development of social economy, the pressure of land transportation is becoming more and more prominent. In order to solve this pressure, the construction of a large number of railways, highways and other projects is imperative. In order to cross the rivers and lakes that the roads pass through, the use of large-span bridges is inevitable. People are also designing the structures of bridges at different distances. Steel truss structures are generally used as segmental structures of bridges. Common steel truss structures include upper chords, web members and lower chords; At present, some steel trusses adopt the upper and lower double-layer form, the sides of the upper and lower bridge decks are connected by truss plates, and the upper and lower bridge decks are laid on the T-shaped crossbeam. Since each part is manufactured separately during the manufacturing process, when assembled on the construction site, the bolt connection requires high precision, so the assembly accuracy and assembly efficiency of the entire segment of the steel truss need to be accurately controlled during the manufacturing process. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a process for manufacturing box-type railway bridge deck steel trusses, which can solve the problems of traditional box-type railway bridge deck steel truss manufacturing errors and low processing efficiency.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: a manufacturing process of a box-type railway bridge deck steel truss, the steel truss includes an upper chord, a lower chord and a web member; the upper and lower chords are both box-shaped sections; the web member includes an oblique web member and a vertical member with a box-shaped section; the innovation lies in: the specific manufacturing process is as follows: S1: Production of upper and lower chords: The chords include an upper cover plate, a lower cover plate, a vertical plate, a partition plate, a node plate and a beam joint plate; S1.1: The lower node plate unit is first welded with thick and thin plates on the horizontal frame. The center lines of the node plate, the butt plate and the center line of the connecting web member node are pre-marked, and flaw detection is carried out after welding. After the welding of the plate is completed, the longitudinal stiffening ribs are assembled and welded. CO2 gas shielded welding is used. For longer welds, the segmented back-welding method is used for welding. Local correction is performed after welding, and then positioning is carried out with the frame. S1.2: Install the internal partition of the box. When positioning and installing the partition, pay attention to its verticality with the wall panel; S1.3: After the transverse diaphragm is installed, the upper and lower cover units are hoisted. The lower cover units are pre-assembled and welded with the longitudinal stiffening ribs. When positioning the lower cover units, align the node center line and the port tongue position line, and ensure verticality; S1.4: After the lower cover plate unit is positioned properly, the upper node plate unit is hoisted onto the frame for assembly and positioning. During positioning, the node center line and the port tongue position line and verticality are determined; S1.5: After the upper node plate unit is positioned properly, the cover plate unit is hoisted for positioning. The upper cover plate unit is pre-assembled and welded with the longitudinal stiffening ribs. When positioning the upper cover plate unit, the node center line and the port tongue position line are aligned and the verticality is ensured; S1.6: After welding, the upper chord box body is partially corrected and then hoisted back onto the assembly frame for positioning. After the positioning is qualified, the beam joint plate position line is marked according to the node center and the corresponding beam joint plate web and beam joint plate node plate are installed. S1.7: The external dimensions of the upper chord box-shaped components shall be self-checked and mutually checked. After confirmation, they shall be submitted to the full-time inspector for acceptance. After passing the inspection, welding can be carried out. When welding the inner partition and the box body surface and belly plate, in order to effectively reduce the overall welding deformation, CO2 gas shielded welding shall be adopted and even number of welders shall be used for symmetrical welding to ensure the welding quality. The main welds at the four corners of the main body shall be welded by submerged arc automatic welding, and the welds shall be cleaned and inspected after welding. S1.8: After the box body is welded, necessary corrections are made. If qualified, the chord allowance line is drawn based on the vertical center line of the component and the center line of the node plate. After the line is drawn, the end milling platform is hoisted and the left and right sides of the box body are end milled to ensure that the verticality error between the end face of the component and the center line of the body is not greater than B / 1500; S1.9: After the left and right end surfaces of the chord are machined, the metal processing personnel will re-check and accept the overall center line of the chord and the end drilling datum; after passing the inspection, a double-sided mobile occupancy bed will be used to occupy the high bolt hole groups at the two ends of the chord. In the case of one clamping, the high bolt hole groups on the two sides will be completed, and then the secondary positioning clamping will be performed to complete the occupancy of the high bolt hole groups on the other sides to ensure the hole making accuracy of the rod; S2: Production of belly bar: S2.1: The steel plate is leveled with a leveling machine before cutting to prevent unevenness of the steel plate from affecting the quality; parts are cut by CNC precision cutting, butt grooves are cut by semi-automatic precision cutting, and secondary leveling is performed after cutting; the two long sides of the web are planed; the excess height of the spliced ​​weld is leveled with a belt grinder; S2.2: Fabricate the web unit in advance, and use self-made professional tooling to assemble the longitudinal stiffener and web into a T-shaped component; use fine wire submerged arc welding or CO2 gas shielded automatic welding, and correct the lateral bending and angular deformation; use anti-deformation welding to control the flatness and curvature of the plate; use double-sided welding to ensure the verticality of the rib plate; S2.3: Lift the box-type bottom plate onto the assembly frame, align the center of the bottom plate with the center line of the ground, align the bottom plate port with the ground line, and spot weld the bottom plate firmly after the positioning is qualified; S2.4: The diaphragms are hoisted onto the assembly frame for positioning and assembly. The diaphragms are milled around the edges before positioning and assembly to serve as the inner tube positioning reference of the box-type component. The diaphragms are assembled on the structural positioning line on the bottom plate component of the box-type component assembly machine, and the verticality of the diaphragms is ensured. S2.5: After the diaphragm is assembled, the webs on both sides are positioned and assembled in sequence; after the webs on both sides are positioned, the three sides of the diaphragm are welded by CO2 gas shielded semi-automatic welding; S2.6: After the welding of the diaphragm is completed, the supervisor shall inspect and approve the concealed welds inside the box, and repair and paint the damaged parts of the workshop primer; then install the upper cover plate, preheat it according to the plate thickness and process requirements, use CO2 gas shielded semi-automatic welding to weld the fillet welds inside the box, and then symmetrically weld the four outer corner welds in sequence on the gantry submerged arc automatic welding machine on the box component production line. After welding, grind the welds and perform non-destructive testing on the welds, and submit them for inspection after correction; S2.7: After the inspection is qualified, the box-type components shall be machined at the two ends by using special end milling equipment; after the end milling is qualified, the components shall be numbered, and the positioning marks and other symbols shall be marked at the designated positions according to the process regulations; S2.8: Hole making: After the box-type web is manufactured and welded, a CNC drilling machine is used to make the hole groups at the ends of the web; S3: Assembly of steel trusses: The internal chords and diagonal webs of the steel trusses are welded together, the chords between two adjacent steel trusses are connected by high-strength bolts, and the diagonal webs between the steel trusses are divided into two and connected by high-strength bolts.

[0005] The advantages of the present invention are: 1) In the present invention, quality control is performed on each stage of the production of the chord and the web, thereby improving the accuracy of the installation of the chord and the web and the quality of welding, and reducing welding deformation; in addition, carbon dioxide gas shielded welding is used to ensure the continuity and smoothness of the weld; in addition, in the processing of the chord and the web, manual lofting, marking, cutting, repair and polishing after cutting are performed, which reduces labor intensity, improves production efficiency, and can also ensure the accuracy of the steel truss. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0007] Figure 1 The present invention is a diagram showing the assembly state of a box-type railway bridge deck steel truss.

[0008] Figure 2 The present invention provides a chord manufacturing state diagram of a box-type railway bridge deck steel truss girder.

[0009] Figure 3 The present invention provides a state diagram of the web member production of a box-type railway bridge deck steel truss. DETAILED DESCRIPTION

[0010] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0011] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0012] like Figures 1 to 3 A manufacturing process of a box-type railway bridge deck steel truss is shown, the steel truss includes an upper chord, a lower chord and a web member; the upper and lower chords are both box-shaped sections; the web member includes an oblique web member and a vertical member with a box-shaped section; the specific manufacturing process is as follows: S1: Production of upper and lower chords: The chords include an upper cover plate, a lower cover plate, a vertical plate, a partition plate, a node plate and a beam joint plate; S1.1: The lower node plate unit is first welded with thick and thin plates on the horizontal frame. The center lines of the node plate, the butt plate and the center line of the connecting web member node are pre-marked, and flaw detection is carried out after welding. After the welding of the plate is completed, the longitudinal stiffening ribs are assembled and welded. CO2 gas shielded welding is used. For longer welds, the segmented back-welding method is used for welding. Local correction is performed after welding, and then positioning is carried out with the frame. S1.2: Install the internal partition of the box. When positioning and installing the partition, pay attention to its verticality with the wall panel; S1.3: After the transverse diaphragm is installed, the upper and lower cover units are hoisted. The lower cover units are pre-assembled and welded with the longitudinal stiffening ribs. When positioning the lower cover units, align the node center line and the port tongue position line, and ensure verticality; S1.4: After the lower cover plate unit is positioned properly, the upper node plate unit is hoisted onto the frame for assembly and positioning. During positioning, the node center line and the port tongue position line and verticality are determined; S1.5: After the upper node plate unit is positioned properly, the cover plate unit is hoisted for positioning. The upper cover plate unit is pre-assembled and welded with the longitudinal stiffening ribs. When positioning the upper cover plate unit, the node center line and the port tongue position line are aligned and the verticality is ensured; S1.6: After welding, the upper chord box body is partially corrected and then hoisted back onto the assembly frame for positioning. After the positioning is qualified, the beam joint plate position line is marked according to the node center and the corresponding beam joint plate web and beam joint plate node plate are installed. S1.7: The external dimensions of the upper chord box-shaped components shall be self-checked and mutually checked. After confirmation, they shall be submitted to the full-time inspector for acceptance. After passing the inspection, welding can be carried out. When welding the inner partition and the box body surface and belly plate, in order to effectively reduce the overall welding deformation, CO2 gas shielded welding shall be adopted and even number of welders shall be used for symmetrical welding to ensure the welding quality. The main welds at the four corners of the main body shall be welded by submerged arc automatic welding, and the welds shall be cleaned and inspected after welding. S1.8: After the box body is welded, necessary corrections are made. If qualified, the chord allowance line is drawn based on the vertical center line of the component and the center line of the node plate. After the line is drawn, the end milling platform is hoisted and the left and right sides of the box body are end milled to ensure that the verticality error between the end face of the component and the center line of the body is not greater than B / 1500; S1.9: After the left and right end surfaces of the chord are machined, the metal processing personnel will re-check and accept the overall center line of the chord and the end drilling datum; after passing the inspection, a double-sided mobile occupancy bed will be used to occupy the high bolt hole groups at the two ends of the chord. In the case of one clamping, the high bolt hole groups on the two sides will be completed, and then the secondary positioning clamping will be performed to complete the occupancy of the high bolt hole groups on the other sides to ensure the hole making accuracy of the rod; S2: Production of belly bar: S2.1: The steel plate is leveled with a leveling machine before cutting to prevent unevenness of the steel plate from affecting the quality; parts are cut by CNC precision cutting, butt grooves are cut by semi-automatic precision cutting, and secondary leveling is performed after cutting; the two long sides of the web are planed; the excess height of the spliced ​​weld is leveled with a belt grinder; S2.2: Fabricate the web unit in advance, and use self-made professional tooling to assemble the longitudinal stiffener and web into a T-shaped component; use fine wire submerged arc welding or CO2 gas shielded automatic welding, and correct the lateral bending and angular deformation; use anti-deformation welding to control the flatness and curvature of the plate; use double-sided welding to ensure the verticality of the rib plate; S2.3: Lift the box-type bottom plate onto the assembly frame, align the center of the bottom plate with the center line of the ground, align the bottom plate port with the ground line, and spot weld the bottom plate firmly after the positioning is qualified; S2.4: The diaphragms are hoisted onto the assembly frame for positioning and assembly. The diaphragms are milled around the edges before positioning and assembly to serve as the inner tube positioning reference of the box-type component. The diaphragms are assembled on the structural positioning line on the bottom plate component of the box-type component assembly machine, and the verticality of the diaphragms is ensured. S2.5: After the diaphragm is assembled, the webs on both sides are positioned and assembled in sequence; after the webs on both sides are positioned, the three sides of the diaphragm are welded by CO2 gas shielded semi-automatic welding; S2.6: After the welding of the diaphragm is completed, the supervisor shall inspect and approve the concealed welds inside the box, and repair and paint the damaged parts of the workshop primer; then install the upper cover plate, preheat it according to the plate thickness and process requirements, use CO2 gas shielded semi-automatic welding to weld the fillet welds inside the box, and then symmetrically weld the four outer corner welds in sequence on the gantry submerged arc automatic welding machine on the box component production line. After welding, grind the welds and perform non-destructive testing on the welds, and submit them for inspection after correction; S2.7: After the inspection is qualified, the box-type components shall be machined at the two ends by using special end milling equipment; after the end milling is qualified, the components shall be numbered, and the positioning marks and other symbols shall be marked at the designated positions according to the process regulations; S2.8: Hole making: After the box-type web is manufactured and welded, a CNC drilling machine is used to make the hole groups at the ends of the web; S3: Assembly of steel trusses: The internal chords and diagonal webs of the steel trusses are welded together, the chords between two adjacent steel trusses are connected by high-strength bolts, and the diagonal webs between the steel trusses are divided into two and connected by high-strength bolts.

[0013] Those skilled in the art should understand that the present invention is not limited to the above-mentioned embodiments. The above-mentioned embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may be subject to various changes and improvements, and these changes and improvements shall all fall within the scope of the present invention claimed for protection.

Claims

1. A process for manufacturing a box-type railway bridge deck steel truss, the steel truss comprising an upper chord, a lower chord and a web member; the upper and lower chord members both adopt a box-type section; the web member comprises an oblique web member and a vertical member adopting a box-type section; the feature is: The specific production process is as follows: S1: Production of upper and lower chords: The chords include an upper cover plate, a lower cover plate, a vertical plate, a partition plate, a node plate and a beam joint plate; S1.1: The lower node plate unit is first welded with thick and thin plates on the horizontal frame. The center lines of the node plate, the butt plate and the center line of the connecting web member node are pre-marked, and flaw detection is carried out after welding. After the welding of the plate is completed, the longitudinal stiffening ribs are assembled and welded. CO2 gas shielded welding is used. For longer welds, the segmented back-welding method is used for welding. Local correction is performed after welding, and then positioning is carried out with the frame. S1.2: Install the internal partition of the box. Pay attention to the verticality of the partition with the wall panel when positioning and installing it; S1.3: After the transverse diaphragm is installed, the upper and lower cover units are hoisted. The lower cover units are pre-assembled and welded with the longitudinal stiffening ribs. When positioning the lower cover units, align the node center line and the port tongue position line, and ensure verticality; S1.4: After the lower cover plate unit is positioned properly, the upper node plate unit is hoisted onto the frame for assembly and positioning. During positioning, the node center line and the port tongue position line and verticality are determined; S1.5: After the upper node plate unit is positioned properly, the cover plate unit is hoisted for positioning. The upper cover plate unit is pre-assembled and welded with the longitudinal stiffening ribs. When positioning the upper cover plate unit, the node center line and the port tongue position line are aligned and the verticality is ensured; S1.6: After welding, the upper chord box body is partially corrected and then hoisted back onto the assembly frame for positioning. After the positioning is qualified, the beam joint plate position line is marked according to the node center and the corresponding beam joint plate web and beam joint plate node plate are installed. S1.7: The external dimensions of the upper chord box-shaped components shall be self-checked and mutually checked. After confirmation, they shall be submitted to the full-time inspector for acceptance. After passing the inspection, welding can be carried out. When welding the inner partition and the box body surface and belly plate, in order to effectively reduce the overall welding deformation, CO2 gas shielded welding shall be adopted and even number of welders shall be used for symmetrical welding to ensure the welding quality. The main welds at the four corners of the main body shall be welded by submerged arc automatic welding, and the welds shall be cleaned and inspected after welding. S1.8: After the box body is welded, necessary corrections are made. If qualified, the chord allowance line is drawn based on the vertical center line of the component and the center line of the node plate. After the line is drawn, the end milling platform is hoisted and the left and right sides of the box body are end milled to ensure that the verticality error between the end face of the component and the center line of the body is not greater than B / 1500; S1.9: After the left and right end surfaces of the chord are machined, the metal processing personnel will re-check and accept the overall center line of the chord and the end drilling datum; after passing the inspection, a double-sided mobile occupancy bed will be used to occupy the high bolt hole groups at the two ends of the chord. In the case of one clamping, the high bolt hole groups on the two sides will be completed, and then the secondary positioning clamping will be performed to complete the occupancy of the high bolt hole groups on the other sides to ensure the hole making accuracy of the rod; S2: Production of belly bar: S2.1: The steel plate is leveled with a leveling machine before cutting to prevent unevenness of the steel plate from affecting the quality; parts are cut by CNC precision cutting, butt grooves are cut by semi-automatic precision cutting, and secondary leveling is performed after cutting; the two long sides of the web are planed; the excess height of the spliced ​​weld is leveled with a belt grinder; S2.2: Fabricate the web unit in advance, and use self-made professional tooling to assemble the longitudinal stiffener and web into a T-shaped component; use fine wire submerged arc welding or CO2 gas shielded automatic welding, and correct the lateral bending and angular deformation; use anti-deformation welding to control the flatness and curvature of the plate; use double-sided welding to ensure the verticality of the rib plate; S2.3: Lift the box-type bottom plate onto the assembly frame, align the center of the bottom plate with the center line of the ground, align the bottom plate port with the ground line, and spot weld the bottom plate firmly after the positioning is qualified; S2.4: The diaphragms are hoisted onto the assembly frame for positioning and assembly. The diaphragms are milled around the edges before positioning and assembly to serve as the inner tube positioning reference of the box-type component. The diaphragms are assembled on the structural positioning line on the bottom plate component of the box-type component assembly machine, and the verticality of the diaphragms is ensured. S2.5: After the diaphragm is assembled, the webs on both sides are positioned and assembled in sequence; after the webs on both sides are positioned, the three sides of the diaphragm are welded by CO2 gas shielded semi-automatic welding; S2.6: After the welding of the diaphragm is completed, the supervisor shall inspect and approve the concealed welds inside the box, and repair and paint the damaged parts of the workshop primer; then install the upper cover plate, preheat it according to the plate thickness and process requirements, use CO2 gas shielded semi-automatic welding to weld the fillet welds inside the box, and then symmetrically weld the four outer corner welds in sequence on the gantry submerged arc automatic welding machine on the box component production line. After welding, grind the welds and perform non-destructive testing on the welds, and submit them for inspection after correction; S2.7: After the inspection is qualified, the box-type components shall be machined at the two ends by using special end milling equipment; after the end milling is qualified, the components shall be numbered, and the positioning marks and other symbols shall be marked at the designated positions according to the process regulations; S2.8: Hole making: After the box-type web is manufactured and welded, a CNC drilling machine is used to make the hole groups at the ends of the web; S3: Assembly of steel trusses: The internal chords and diagonal webs of the steel trusses are welded together, the chords between two adjacent steel trusses are connected by high-strength bolts, and the diagonal webs between the steel trusses are divided into two and connected by high-strength bolts.

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