Bridge floor transverse and longitudinal pre-camber steel beam manufacturing process

Abstract

The invention relates to a bridge floor transverse and longitudinal pre-camber steel beam manufacturing process. The manufacturing process is characterized by comprising the following specific manufacturing processes: S1, blanking and welding of a bottom plate; s2, blanking and welding of the side plates; s3, blanking and welding of the bridge deck slab; s4, blanking of the partition plate; s5, assembling the steel beams; s6, the pre-camber is monitored; s7, measuring a steel beam; blanking precision of each unit of a bridge deck transverse and longitudinal pre-camber steel beam is controlled, a bridge deck slab unit is tailor-welded on a pre-camber jig frame, the whole steel beam is welded in an inverted mode so as to reduce deformation of the bridge deck slab in the structure of tailor-welded steel beams, and the camber camber precision of the whole steel beam is guaranteed; besides, by arranging a three-dimensional measurement control network, all measurement points of the jig frame and the segments are directly and accurately monitored through the measurement control network, so that accumulative measurement errors are avoided, and the assembly precision is improved; and meanwhile, the welding quality is controlled in the splicing process, and welding deformation is reduced to ensure the size of the steel beam.

Description

Technical Field

[0001] The invention relates to the technical field of bridge construction, and in particular to a process for manufacturing transverse and longitudinal pre-cambered steel beams for bridge decks. Background Art

[0002] The structure of a large-segment continuous steel truss bridge deck is complex and the main beam is rigid. Especially after the integral node technology is adopted, once the assembly line is deviated, adjustment will be very difficult. In order to control the deflection of the steel truss bridge deck under the action of constant load, how to ensure the factory pre-camber of the steel truss and how to control it during the manufacturing and assembly process has become a major difficulty; therefore, a bridge deck transverse and longitudinal pre-camber steel beam manufacturing process is needed to meet the pre-camber requirements of large-segment steel truss beams. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a process for manufacturing transverse and longitudinal pre-camber steel beams for bridge decks, which can solve the problem that the pre-camber processing of traditional transverse and longitudinal pre-camber steel beams for bridge decks is difficult to ensure and the control is difficult during the manufacturing and assembly process.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: a bridge deck transverse and longitudinal pre-camber steel beam manufacturing process, the innovation of which is: the specific manufacturing process is as follows: S1: Cutting and welding of the bottom plate: Cut the bottom plate unit according to the set size, weld the bottom plate unit on a dedicated tire frame, and ensure the welding accuracy of the inclination angle of the bottom plate unit near the end; S2: Cutting and welding of side panels: Cut the side panel units according to the set size, and ensure the slope of the side that needs to be pre-arched during cutting; then assemble and weld the side panel units on the tire frame; S3: Cutting and welding of bridge deck: Cut the deck unit according to the set size, and place the deck unit on the pre-arch frame for welding to ensure the pre-arch degree of the deck unit after assembly and welding; S4: Cutting of the partition: cutting and cutting according to the size of the partition unit at the location for later use; S5: Assembly of steel beams: The steel beams are welded in an inverted manner. The bridge deck is placed on the pre-arched frame. The diaphragm unit is first welded to the panel unit according to the set position; then the side panels with diaphragm unit embedding grooves are welded to both sides of the diaphragm unit and the diaphragm unit is embedded in the diaphragm unit embedding grooves. The bottom end of the side panel is welded to the back of the bridge deck; finally, the bottom plate is welded to the top of the diaphragm and the side panel, and finally the bridge deck is turned over to realize the production of the transverse and longitudinal pre-arched steel beams; S6: Monitoring of pre-camber: Construct a three-dimensional measurement control network including a leveling network, a plane linear control network and a total station measurement base station; use a total station and a theodolite to directly and accurately monitor all measurement points of the tire frame and segments through the measurement control network to avoid cumulative measurement errors; the assembly camber value is determined according to the drawings, and the camber is adjusted by the elevation of the pads and adjustment blocks on the load-bearing piers, and is measured and controlled using high-precision levels and leveling control points.

[0005] S7: Measurement of steel beams: The measurement of the assembly length, inter-node length, lateral bend, axis and anchor point spacing of the steel beams. The measuring points are arranged on the center line of the main truss. The three-dimensional coordinates of each point are measured using a total station to ensure the accuracy of the geometric dimensions of the entire steel beam assembly. After the steel beam is assembled, the bridge deck node elevation is measured using a precision level. The camber and panel slope of the entire steel beam are measured to form a complete set of accurate assembly data to ensure that the camber value is within the requirements of the manufacturing acceptance rules.

[0006] Furthermore, the bottom plate unit, bridge deck unit, side plate unit and partition plate unit all need to be measured in size and marked in position after cutting and blanking.

[0007] Furthermore, in the assembly of the S5 steel beam, the weld is a full penetration weld, and the reserved amount is monitored and tracked at any time for feedback and trimming. Senior welders and robots are used to weld the welds to ensure the first-time pass rate of the welds. The welding process is strictly carried out in accordance with the welding parameters specified in the welding process, and a welding method with low line energy is used. Multi-layer and multi-pass welding must be performed symmetrically on both sides. Welding deformation is reduced to ensure the size of the steel beam.

[0008] Furthermore, S5: During the assembly of the steel beam: During the assembly, the horizontal line below each part is used as a reference to ensure the horizontal heights of the middle point and the end points on the same steel beam.

[0009] The advantages of the present invention are: 1) In the present invention, the bridge deck units are welded on the pre-arch frame by controlling the cutting accuracy of each unit of the transverse and longitudinal pre-arch steel beams of the bridge deck. The entire steel beam is welded in an inverted manner to reduce the deformation of the bridge deck in the structure of the welded steel beam, thereby ensuring the arching accuracy of the entire steel beam. In addition, by arranging a three-dimensional measurement control network, all measurement points of the frame and the segment are directly and accurately monitored through the measurement control network to avoid cumulative measurement errors and improve assembly accuracy. At the same time, the quality of welding is controlled during the assembly process to reduce welding deformation to ensure the size of the steel beam. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0011] Figure 1The present invention is a flow chart of the manufacturing process of a bridge deck transverse and longitudinal pre-camber steel beam.

[0012] Figure 2 The present invention is a structural schematic diagram of a transverse and longitudinal pre-cambered steel beam of a bridge deck system. DETAILED DESCRIPTION

[0013] 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.

[0014] 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.

[0015] like Figure 1 Figure 2 A bridge deck transverse and longitudinal pre-camber steel beam manufacturing process is shown, and the specific manufacturing process is as follows: S1: Cutting and welding of the bottom plate: Cut the bottom plate unit according to the set size, weld the bottom plate unit on a dedicated tire frame, and ensure the welding accuracy of the inclination angle of the bottom plate unit near the end; S2: Cutting and welding of side panels: Cut the side panel units according to the set size, and ensure the slope of the side that needs to be pre-arched during cutting; then assemble and weld the side panel units on the tire frame; S3: Cutting and welding of bridge deck: Cut the deck unit according to the set size, and place the deck unit on the pre-arch frame for welding to ensure the pre-arch degree of the deck unit after assembly and welding; S4: Cutting of the partition: cutting and cutting according to the size of the partition unit at the location for later use; S5: Assembly of steel beams: The steel beams are welded in an inverted manner. The bridge deck is placed on the pre-arched frame. The diaphragm unit is first welded to the panel unit according to the set position; then the side panels with diaphragm unit embedding grooves are welded to both sides of the diaphragm unit and the diaphragm unit is embedded in the diaphragm unit embedding grooves. The bottom end of the side panel is welded to the back of the bridge deck; finally, the bottom plate is welded to the top of the diaphragm and the side panel, and finally the bridge deck is turned over to realize the production of the transverse and longitudinal pre-arched steel beams; S6: Monitoring of pre-camber: Construct a three-dimensional measurement control network including a leveling network, a plane linear control network and a total station measurement base station; use a total station and a theodolite to directly and accurately monitor all measurement points of the tire frame and segments through the measurement control network to avoid cumulative measurement errors; the assembly camber value is determined according to the drawings, and the camber is adjusted by the elevation of the pads and adjustment blocks on the load-bearing piers, and is measured and controlled using high-precision levels and leveling control points.

[0016] S7: Measurement of steel beams: The measurement of the assembly length, inter-node length, lateral bend, axis and anchor point spacing of the steel beams. The measuring points are arranged on the center line of the main truss. The three-dimensional coordinates of each point are measured using a total station to ensure the accuracy of the geometric dimensions of the entire steel beam assembly. After the steel beam is assembled, the bridge deck node elevation is measured using a precision level. The camber and panel slope of the entire steel beam are measured to form a complete set of accurate assembly data to ensure that the camber value is within the requirements of the manufacturing acceptance rules.

[0017] The bottom plate unit, bridge deck unit, side plate unit and partition plate unit all need to be measured in size and marked in position after cutting.

[0018] During the assembly of S5 steel beams, the welds are full penetration welds. The reserved amount is adjusted by real-time monitoring, tracking and feedback. Senior welders and robots are used to weld the welds to ensure the first-time pass rate of the welds. The welding process is strictly carried out in accordance with the welding parameters specified in the welding process, and a welding method with low line energy is used. Multi-layer and multi-pass welding must be performed symmetrically on both sides. Welding deformation is reduced to ensure the size of the steel beam.

[0019] S5: During assembly of steel beams: During assembly, the horizontal line below each part is used as the reference to ensure the horizontal heights of the middle point and end points of the same steel beam.

[0020] 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 bridge deck transverse and longitudinal pre-camber steel beam, characterized in that: The specific production process is as follows: S1: Cutting and welding of the bottom plate: Cut the bottom plate unit according to the set size, weld the bottom plate unit on a dedicated tire frame, and ensure the welding accuracy of the inclination angle of the bottom plate unit near the end; S2: Cutting and welding of side panels: Cut the side panel units according to the set size, and ensure the slope of the side that needs to be pre-arched during cutting; then assemble and weld the side panel units on the tire frame; S3: Cutting and welding of bridge deck: Cut the deck unit according to the set size, and place the deck unit on the pre-arch frame for welding to ensure the pre-arch degree of the deck unit after assembly welding; S4: Cutting of the partition: cutting and cutting according to the size of the partition unit at the location for later use; S5: Assembly of steel beams: The steel beams are welded in an inverted manner. The bridge deck is placed on the pre-arched frame. The diaphragm unit is first welded to the panel unit according to the set position; then the side panels with diaphragm unit embedding grooves are welded to both sides of the diaphragm unit and the diaphragm unit is embedded in the diaphragm unit embedding grooves. The bottom end of the side panel is welded to the back of the bridge deck; finally, the bottom plate is welded to the top of the diaphragm and the side panel, and finally the bridge deck is turned over to realize the production of the transverse and longitudinal pre-arched steel beams; S6: Monitoring of pre-camber: Construct a three-dimensional measurement control network including a leveling network, a plane linear control network and a total station measurement base station; use a total station and a theodolite to directly and accurately monitor all measurement points of the tire frame and segments through the measurement control network to avoid cumulative measurement errors; the assembly camber value is determined according to the drawings, and the camber is adjusted by the elevation of the pads and adjustment blocks on the load-bearing piers, and is measured and controlled using high-precision levels and leveling control points. 2.S7: Measurement of steel beams: The assembly length, inter-node length, lateral bend, axis and anchor point spacing of the steel beams are measured. The measuring points are arranged on the center line of the main truss. The three-dimensional coordinates of each point are measured using a total station to ensure the geometric dimensional accuracy of the entire steel beam assembly. After the steel beams are assembled, the bridge deck node elevations are measured using a precision level. The camber and panel slope of the entire steel beam are measured to form a complete set of accurate assembly data to ensure that the camber value is within the requirements of the manufacturing acceptance rules.

3. The process for manufacturing a bridge deck transverse and longitudinal pre-camber steel beam according to claim 1, characterized in that: The bottom plate unit, bridge deck unit, side plate unit and partition plate unit all need to be measured in size and marked in position after cutting.

4. The process for manufacturing a bridge deck transverse and longitudinal pre-camber steel beam according to claim 1, characterized in that: In the assembly of the S5 steel beam, the weld is a full penetration weld, and the reserved amount is adjusted by real-time monitoring, tracking and feedback. Senior welders and robots are used to weld the welds to ensure the first-time pass rate of the welds. The welding process is strictly carried out in accordance with the welding parameters specified in the welding process, and a welding method with low line energy is used. Multi-layer and multi-pass welding must be performed symmetrically on both sides. Welding deformation is reduced to ensure the size of the steel beam.

5. The process for manufacturing a bridge deck transverse and longitudinal pre-camber steel beam according to claim 1, characterized in that: S5: During the assembly of the steel beam: During the assembly, the horizontal line below each part is used as the reference to ensure the horizontal heights of the middle point and the end point of the same steel beam.

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