Anchorage steel open caisson intelligent building and construction method

Abstract

The invention provides an anchorage steel open caisson intelligent building and construction method, and belongs to the technical field of steel open caisson building construction, steel pretreatment, blanking, unit piece manufacturing, steel open caisson section manufacturing, steel open caisson splicing construction, splicing from the middle to the periphery when the steel open caisson is integrally spliced, a stable structure is formed in sequence, finally, closing is conducted at the four corners, and the steel open caisson is formed. And after splicing is completed, construction of the next layer is conducted, welding and coating are conducted, and construction is completed. In order to solve the problems that internal stiffening structures of cross-shaped and T-shaped sections of the project are complex and parts are prone to collision, tekla software modeling is adopted for collision inspection, whether the parts have the collision problem or not is determined, a three-dimensional diagram is adopted at the node position to indicate, the direction, the position and the part number are marked, the assembly sequence is defined, and the assembly efficiency is improved. And process animation disclosure is carried out on constructors.

Description

Technical Field

[0001] The invention relates to the technical field of steel caisson construction, and in particular to an intelligent construction method for an anchored steel caisson. Background Art

[0002] As bridge construction moves from inland to offshore, construction conditions such as deep water, soft foundation, strong wind, rapid current, waves, and strong earthquakes become more complex. The foundation of a cross-sea bridge is often located in a deep water area, with a thick cover layer of soft soil, sand, clay, and crushed (pebble) stone soil, and there may also be uneven soft (hard) interlayers distributed in the cover layer; for large-span suspension bridges and cable-stayed-suspension cooperative system bridges, in addition to bearing huge vertical forces, they also bear huge oblique tension transmitted by the main cable. The horizontal tension of the main cable of a suspension bridge with a main span of 3,000m exceeds 200,000 tons, and the main cable anchor point is high, which also increases the additional bending moment on the top surface of the anchor foundation.

[0003] The construction project of Xiamen Third East Channel starts near Xiangshan Yacht Club in Siming District of Xiamen Island. The main line goes north along the Ring Island Road to Guanyin Mountain through a tunnel, and then crosses the eastern waters of the island with a bridge to the east. The terminus is connected to the Xiang'an New Airport with an interchange. The Xiang'an branch line is built simultaneously. The total length of the route is about 19.615km, of which the main line is about 17.340km long and the total length of the Xiang'an branch line is about 2.275km. The main bridge Liuwudian Channel Bridge is a suspension bridge with a bridge length of 1948m and a main span length of 928m. The two ends of the main cable are connected and fixed to the east and west anchors. The main construction content of this project is the processing and production of the steel caisson of the east anchor.

[0004] The steel caisson reinforcement ribs of this project are dense, the spacing between the ring plates is 1-1.25m, and there are vertical connections between the ring plates, especially the T-shaped and cross-shaped segment reinforcement structures are particularly complex. The caisson is large in size and has many butt welds, making it difficult to prevent welding shrinkage and deformation. The total height of this project is 35.2m, with a length and width of 66m and 48m respectively. It is divided into seven layers from bottom to top, with a height of 5m per layer. The single-sided caisson steel shell is divided into 197 segments, and the assembly positioning accuracy is difficult to control. The internal structure of the steel caisson partition wall has no integral partition, and the overall structure is supported by angle steel, with weak structural rigidity. The steel caisson segments are easily deformed during lifting, transportation, storage and support in local positions, and the structure is easily deformed. Summary of the invention

[0005] The purpose of the present invention is to provide an intelligent construction method for an anchored steel caisson to solve the technical problems mentioned in the background technology.

[0006] (1) In view of the complex internal stiffening structure of the cross-shaped and T-shaped segments of this project, which is prone to parts collision, it is planned to use Tekla software modeling to perform collision checks to determine whether there are collision problems between parts. A three-dimensional diagram will be used at the node position to indicate the direction, position and part number, clarify the assembly sequence, and provide process animation briefings to construction personnel.

[0007] (2) In view of the problem of reduced size caused by the large number of joints in the steel caisson wall panels of this project, the welding shrinkage should be considered in advance. The corresponding welding shrinkage should be added when cutting the parts according to the plate thickness, number of reinforcements and groove form, and the secondary cutting amount should be reasonably set to ensure that the overall dimensional accuracy meets the requirements after welding.

[0008] (3) In view of the large number of sections and the large overall size of this project, which may result in the assembly accuracy not meeting the requirements, it is advisable to use the graded axis centering method to control the overall construction accuracy of the steel caisson, that is, to ensure the overall assembly accuracy of the steel caisson by controlling the axes of each level of the caisson.

[0009] (4) Use finite element calculation software to calculate the deformation of the steel caisson segment during the lifting, transportation and storage process, reasonably set temporary lifting ears and support positions, and set temporary support reinforcement when necessary based on the calculation results.

[0010] In order to achieve the above object, the technical solution adopted by the present invention is as follows:

[0011] Anchor steel caisson intelligent construction and construction method, the method comprises the following steps:

[0012] Step 1: Steel pretreatment: Before cutting and unloading the steel plate, it is processed through the pretreatment production line, shot blasting and rust removal. After the surface treatment reaches Sa3.0 level, 25-30μm inorganic zinc silicate workshop primer is sprayed. The pretreatment releases the residual stress of the steel plate during the rolling process and ensures that the flatness of the steel plate meets the requirements. At the same time, the workshop primer spraying ensures that the steel plate will not be rusted during the factory construction;

[0013] Step 2: Cutting: All plate parts are cut by CNC plasma or CNC laser cutting machine. 0-8mm welding shrinkage is reserved in the length and width direction of the wall panel unit according to the size of the plate, the number of stiffeners, and the form of the groove. 20mm secondary cutting is reserved in the length direction of the wall panel, and 50mm secondary cutting is reserved in the joint section.

[0014] Step 3: unit component production, including common parts processing, arc wall panel parts processing, truss unit 1 production, truss unit 2 production, common wall panel unit production, second section widening section wall panel unit production, third section arc section right angle unit production, cofferdam temporary internal support unit production;

[0015] Step 4: Fabrication of steel caisson segments. The steel caisson segments include cruciform segments, L-shaped segments, linear segments, and arc-shaped segments. Successively, the segment group welding jig, continuous matching fabrication of segments, fabrication of cruciform segments, fabrication of linear segments, fabrication of L-shaped segments, fabrication of arc-shaped segments, fabrication of the second cruciform segment, fabrication of the second circular segment, fabrication of the third L-shaped segment, fabrication of the third circular segment,

[0016] Step 5: Assembly construction of the steel caisson. When assembling the steel caisson as a whole, start from the middle and assemble towards the surrounding, successively forming a stable structure, and finally close the joints at the four corners. After the assembly is completed, carry out the construction of the next layer;

[0017] Step 6: Carry out welding and painting to complete the construction.

[0018] Furthermore, the specific process in Step 5 is as follows:

[0019] (1) Complete the measurement layout and pier layout as required, and use a total station to复测 the positioning line of the steel caisson and the plane position and elevation of the underlying sleeper;

[0020] (2) After the segment is transported to the lifting area, carry out segment flipping and erection. Use the main hook and auxiliary hook of a 95t crawler crane for flipping. Hang the four steel ropes of the main hook on the upper-side lifting lugs of the segment, and hang the two steel ropes of the auxiliary hook on the turnover lugs. Slowly lift the main hook while keeping the auxiliary hook stationary to complete the segment erection;

[0021] (3) After the segment is flipped and erected, hoist it into place. Coarse-position the segment through the lifting ground sample line, use a magnetic line plumb to check the verticality of the segment, and use a total station to复核 the spatial position of the upper positioning points of the segment. After meeting the requirements, add diagonal supports to fix and prevent the segment from overturning;

[0022] (4) Successively hoist the surrounding segments to form a stable structure in the shape of a "field". After hoisting adjacent segments and accurately positioning them, use an all-round welding trolley to weld the vertical welds between the segments. The welds on both side walls are welded simultaneously from bottom to top. After the welding is completed, use carbon dioxide gas shielded welding to weld the circumferential plate butt joints and other internal welds. After the vertical welds are welded, use carbon dioxide gas shielded welding to weld the bottom plate butt joints. After the overall welding of the segment is completed,复核 whether the axis deviation of the segment exceeds the allowable value, and make corrections according to the复核 results. Then hoist the next segment until all the segments in the first layer are hoisted;

[0023] (5) After the first-layer segment is hoisted and welded and inspected to be qualified, the blade angle concrete is poured. After the concrete pouring is completed, the second-layer segment is hoisted. The vertical welds of the wall panels and the ring plate welds are welded according to the welding sequence in step 4. After the vertical welds of the wall panels are welded, the horizontal welds of the first and second steel caisson ring plates are welded. The horizontal welds of the ring plates on both sides are welded by two trackless full-position crawling welding robots at the same time in the segment hoisting direction. After the welding of the inter-segment welds is completed, check whether the segment axis exceeds the allowable value, make corrections based on the review results, and then hoist the next segment until all the second-layer segments are hoisted;

[0024] (6) Repeat step (5) until all the steel caisson segments of the third section are assembled;

[0025] (7) After the first segment of the 4th floor is hoisted and accurately positioned, positioning welding is performed, and diagonal braces are added on the inner side of the segment to prevent the segment from overturning. Two trackless all-position crawling welding robots are used to perform circumferential seam welding in the segment hoisting direction at the same time; after the adjacent segments are hoisted and accurately positioned for positioning welding, and after being reinforced with diagonal braces, two omnidirectional welding trolleys are used to weld the vertical welds between the segments. The welds of the wall panels on both sides are welded from bottom to top at the same time. After welding is completed, carbon dioxide gas shielded welding is used to weld the ring plate butt joints and other internal welds. After the vertical seam welding is completed, two trackless all-position crawling welding robots are used to perform circumferential seam welding in the segment hoisting direction at the same time; the subsequent segments are installed in sequence until all the segments of the fourth steel caisson are hoisted;

[0026] (8) Remove the diagonal rod, hoist the temporary support positioning bracket, weld it, and hoist the inner support intermediate unit;

[0027] (9) Hoist the remaining steel pipes of the fourth section inner support and complete welding;

[0028] (10) The fifth section of the steel caisson is hoisted in sequence. Due to the high height, it is not possible to use the inclined support method for temporary support when hoisting the fifth section. After the section is positioned, the hook is loosened but not removed. The vertical horse plate between the sections must be increased from the original 500mm per line to 300mm per line, and the intermittent welding of the transverse seam on the outer side of the steel shell is completed after more than 50% of the hook is removed, and the next section is hoisted until the fifth section of the steel caisson is hoisted and welded. After the fifth section of the steel caisson is hoisted and welded, the inner support steel pipe is installed;

[0029] (11) Repeat step (10) to complete the hoisting of the sixth to seventh steel caisson segments;

[0030] (12) Install the truss-type internal supports in sections. First, install the long-side internal supports of the steel caisson, and then install the short-side truss-type internal supports in sections.

[0031] Furthermore, the ERP management system is used for intelligent management in the production of unit components in step 3. The ERP management system consists of a warehouse management system, a project management system, model visualization management, a cloud nesting system and a cloud cutting system, covering the entire production process from the arrival of raw materials to the production of steel caissons, allowing different departments and positions to work together on the same platform, reducing intermediate transmission links, sharing departmental results in real time, and mastering material inventory, production status, shipping progress, and project dynamics in real time.

[0032] Furthermore, in step 5, a three-dimensional laser scan is performed for virtual pre-assembly before assembly, and the steel caisson segments are three-dimensionally scanned. The construction error can be obtained and corrected by comparing the point cloud model generated by the scan with the theoretical model. The point cloud models of adjacent segments can also be virtually pre-assembled to understand the matching between the segments in advance, thereby guiding the assembly of the steel caisson segments.

[0033] Furthermore, in step 6, the welding is performed by automatic tracking welding using a railless full-position crawling welding robot. When the steel plate panels are assembled and reinforced in step 3, the steel plate leveling and docking and the stiffening rib assembly can be completed by utilizing codeless assembly equipment and adjusting the foot cup, the top head and the magnetic controller.

[0034] Furthermore, in step 5, the internal stiffening structure of the cross-shaped and T-shaped segments is relatively complex, and parts collision is prone to occur. It is planned to use Tekla software modeling to perform collision checks to determine whether there are collision problems among parts, and use three-dimensional diagrams at the node positions to indicate the direction, position and part number, and to clarify the assembly sequence.

[0035] Furthermore, in step 6, the problem of size reduction caused by the butt joint of the steel caisson wall panel being larger than the set value should be considered in advance. The corresponding welding shrinkage should be added when cutting the parts according to the plate thickness, number of reinforcements and groove form, and the secondary cutting amount should be set to ensure the overall size after welding.

[0036] The present invention has the following beneficial effects due to the adoption of the above technical solution:

[0037] In view of the fact that the internal stiffening structure of the cross-shaped and T-shaped segments of this project is relatively complex and parts collision is prone to occur, the present invention intends to use Tekla software modeling to perform collision checks to determine whether there are collision problems with parts, and use three-dimensional diagrams at the node positions to indicate the direction, position and part number, clarify the assembly sequence, and provide process animation briefings to construction personnel; in view of the problem that the steel caisson wall panels of this project have many joints that cause size reduction, the welding shrinkage should be considered in advance, and the corresponding welding shrinkage should be added when the parts are cut according to the plate thickness, the number of stiffeners and the groove form, and the secondary cutting amount should be reasonably set to ensure that the overall dimensional accuracy after welding meets the requirements. In view of the fact that there are many segments in this project and the overall size is large, which may cause the assembly accuracy to not meet the requirements, it is advisable to use the graded axis centering method to control the overall construction accuracy of the steel caisson, that is, to ensure the overall assembly accuracy of the steel caisson by controlling the axes of each level of the caisson. Finite element calculation software is used to calculate the deformation of the steel caisson segments during the hoisting, transportation and storage process, and temporary lifting ears and support positions are reasonably set. Temporary support reinforcement is set when necessary according to the calculation results. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 is a flow chart of the method of the present invention;

[0039] Figure 2 It is the overall flow chart of steel caisson assembly of the present invention;

[0040] Figure 3 It is a schematic diagram of the overall hoisting sequence of the present invention;

[0041] Figure 4 It is a flow chart of the welding deformation control measures of the present invention;

[0042] Figure 5 It is a flow chart of virtual pre-assembly by three-dimensional laser scanning of the present invention;

[0043] Figure 6 It is a schematic diagram of the steel caisson structure of the present invention;

[0044] Figure 7 It is a schematic diagram of the structure of the caisson cofferdam and the connected high cofferdam of the present invention; DETAILED DESCRIPTION

[0045] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and preferred embodiments. However, it should be noted that many details listed in the specification are only for the purpose of enabling the reader to have a thorough understanding of one or more aspects of the present invention, and these aspects of the present invention can be implemented even without these specific details.

[0046] like Figure 1 As shown, the intelligent construction and construction method of anchored steel caisson comprises the following steps:

[0047] Step 1: Steel pretreatment. Before cutting and unloading the steel plate, it is processed through the pretreatment production line and shot blasted to remove rust. After the surface treatment reaches Sa3.0 level, 25-30μm inorganic zinc silicate workshop primer is sprayed. The pretreatment releases the residual stress of the steel plate during the rolling process and ensures that the flatness of the steel plate meets the requirements. At the same time, the workshop primer spraying ensures that the steel plate will not be rusted during factory construction.

[0048] The components of steel caissons are divided into angle steels, plates, I-beams and H-shaped steel parts, among which angle steel parts and plates are the largest in number. The cutting of angle steel parts must not only ensure the length but also require the ends to be cut and angled. Some angle steels also require the flanges to be rounded, which makes cutting difficult. Steel plate parts mainly include ring plates, wall plates and node plates, with thickness ranging from 8 to 36 mm. The ends of I-beams and H-shaped steel parts need to be cut into interfaces that can be nested with each other, which not only requires high cutting accuracy, but also requires cutting welding grooves.

[0049] Steel plate parts are cut using a 30,000-watt digital intelligent CNC laser cutting machine. The equipment has the functions of part cutting, marking, and coding, and the maximum plate thickness is 45mm. Laser cutting has a small heat input to the steel plate, and the deformation of the cut parts is small; it has high efficiency (theoretical output 4,000t / month); high cutting accuracy (deviation is only ±0.5mm), and is the most advanced equipment for cutting steel structure parts. An information hardware module is configured on the laser cutting equipment to receive task information, and can retrieve and view cutting programs, typesetting files and other materials to improve part cutting efficiency and cutting accuracy. Based on the Internet of Things, the network management of CNC equipment, the instructions are transmitted from the Internet, and the USB disk copy is eliminated.

[0050] Steel shell parts are classified by material and plate thickness, and are automatically nested using intelligent automatic nesting software (sinoCAM), which improves material utilization, saves raw materials, and can fully dispatch various intelligent equipment in the cutting workshop; remotely control the digital intelligent laser CNC cutting machine cutting equipment, and collect equipment data such as power, gas volume, and machine tool operating status in real time; real-time monitoring of cutting progress in the event of equipment failure, real-time feedback on sorting progress, etc.

[0051] There are three processing requirements for cutting angle steel parts. The first is the wall plate angle steel, which only needs to be cut to length; the second is the truss angle steel, which not only needs to be cut to length, but also needs to be cut at the angle; the third is the partition plate angle steel, which needs to be cut to length and rounded at the same time. According to different angle steel processing requirements, different equipment can be coordinated to form an angle steel processing line to improve cutting efficiency and accuracy.

[0052] The angle steel is cut to length using a large-scale sawing machine from Kabach. This intelligent sawing machine is controlled by an advanced CNC system and can realize a fully automatic cycle from material collection and feeding to sawing. It can also automatically complete the processes of collecting the head and tail of the material and finished workpieces. The cutting angle can be from -50° to 60°. According to the angle steel specifications of this project, after repeated experiments, it was found that the efficiency is highest when 35 angle steels are cut at the same time. One cutting can be completed in 30 minutes, and the monthly production capacity can reach 1,000 tons.

[0053] Some angle steels are sawn by length in the sawing production line and transported here for angle steel cutting. The angle steel cutting process cannot be completed by ordinary sawing machines, and a large number of angle steels need to be cut in this project, so the angle steel cutting production line is activated. The angle steel is cut by a hydraulic combined punching and shearing machine. The punching and shearing machine punches and shears square steel, round steel, channel steel, I-beam and angle steel. The maximum angle steel specification that the punching and shearing machine can punch and shear is L160×14mm, which meets the use requirements of this project. The angle cutting of the punching and shearing machine can not only ensure the quality of the incision, but also greatly improve the efficiency of angle cutting. Compared with traditional sawing or flame cutting, angle steel punching can increase the construction efficiency by more than 4 times.

[0054] Angle steel rounding is cut using a fiber laser cutting machine. Fiber lasers have been a hot topic in the laser field in recent years. In the processing field, fiber lasers have a tendency to rapidly replace traditional YAG and C02 lasers. Fiber lasers have many unique advantages: good beam quality; small size, light weight, maintenance-free; simple and easy to operate with air cooling; low operating cost, can be used in industrial environments; long life, high processing accuracy, fast speed; high power conversion efficiency, can achieve intelligent, automated, flexible operation, etc.

[0055] The advantages of laser cutting machines are small thermal deformation, high cutting accuracy, low noise, no pollution, and easy automatic cutting. As an advanced manufacturing technology, laser cutting has the advantages of wide application range, flexible process, high processing accuracy, good quality, clean production process, easy to realize automation, flexibility, intelligence, and improve product quality and labor productivity.

[0056] I-beam and H-beam parts are cut and blanked by laser steel cutting machine. According to the length of the parts, the motion trajectory of the steel laser cutting machine is compiled, and the motion trajectory is parameterized according to the different cutting surfaces of different parts to ensure the cutting quality of the cutting surface. On the premise of meeting the cutting efficiency and quality, generate the programming file and import the file into the control system; start the control program, and the steel laser cutting machine will run according to the motion trajectory specified by the program; if other cutting surfaces need to be cut, all cutting surface programming will be imported into the system, and the cutting control program will be used in the system for the cutting type; and the same steel can use one program to cut multiple different cutting surfaces, which is very flexible and convenient. It can simultaneously realize a variety of cumbersome processes such as cutting, hole cutting, groove cutting, marking and marking, and opening of welding holes.

[0057] Installation of Kabach large sawing machine:

[0058] The installation steps of the Kabach sawing machine mainly include preparation work, assembly of accessories, installation of saw blades, connection of power supply and machine trial inspection.

[0059] (1) Preparation

[0060] Place the saw: Place the main body of the saw in the desired position and ensure that the ground is stable and firm. Check the hydraulic oil: Ensure that the hydraulic oil used on the saw is appropriate and sufficient, and that the sliding and rotating parts are well lubricated.

[0061] (2) Assembly accessories

[0062] Install the blade guide rail: Assemble and install the blade, guide rail, protective cover and other accessories according to the manual of the sawing machine. Install the saw belt: Unfold the saw belt, and be careful not to knock the teeth off. Then follow the specific steps to put the saw belt on the active and passive wheels, and adjust the tension to a moderate level.

[0063] (3) Install the saw blade

[0064] Confirm the direction: Make sure the arrow mark on the saw blade points in the direction of the sawing machine. Adjust the tension: After installing the saw blade, you need to adjust the tension of the saw blade so that it is neither too loose nor too tight.

[0065] (4) Connect the power supply

[0066] Check the power supply: Make sure the saw's power cord is properly connected and plugged into a power outlet. Turn on the power: Turn on the power switch on the electrical control box and observe whether the motor is running normally.

[0067] (5) Test machine inspection

[0068] Test run: After turning on the power, test run is usually performed three times in a row to check for any problems or abnormalities. Device inspection: Check the lifting cylinder device, clamping device, etc. to ensure flexible and reliable operation. Speed ​​adjustment: Adjust the speed knob to run at low and high speeds respectively, and repeat the test three times.

[0069] The commissioning of the Kabach sawing machine is a complex and meticulous process that requires certain steps and precautions.

[0070] (1) Preparation

[0071] Check the hydraulic oil: make sure there is enough hydraulic oil in the hydraulic oil tank, and apply a layer of engine oil to the sliding and rotating parts. Install the saw belt: install the saw belt, adjust the tensioner (turn the left handle of the saw frame) to make the saw belt tight to the appropriate degree, and adjust the travel switch contact to just touch the stop iron and be in the open state. Cooling water tank: add enough coolant, the coolant should be mixed with liquid, and replaced every two months.

[0072] (2) Electrical connection and grounding

[0073] Connect the power supply, ensure that the grounding standard is reliable, and then turn on the power switch (on the electrical control box).

[0074] (3) Test run and adjustment

[0075] Preliminary test run: Start the saw and let the saw bow drop automatically, so that the saw belt drops to 0.5-1mm below the workbench, and the limit head hits the bumper and automatically rises. When it reaches the limit position, check whether it stops automatically. Test three times in a row. Adjustment of the tensioning device: During operation, adjust the tensioning device to a relaxed state, let the travel switch contact leave the bumper, and then power off and shut down. Test three times in a row.

[0076] Speed ​​knob test: adjust the speed knob to gear 1 (low speed), then adjust the speed to gear 2 (high speed), and repeat the experiment three times. Check the clamping and releasing cylinders: Check whether they are reliable and flexible when clamping and releasing, whether they are reliable when clamping, and whether they are flexible when releasing.

[0077] (4) Specific parameter adjustment

[0078] According to the actual processing requirements, it may be necessary to adjust parameters such as sawing speed and feed speed. These parameters can usually be adjusted in the control panel or CNC system of the equipment.

[0079] (1) Preparation

[0080] Check the power supply and equipment status: Make sure the saw is powered on and check whether the power cord is normal. Also, check whether the saw's cutting blade is securely installed and whether the blade is worn. Wear personal protective equipment: Operators need to wear personal protective equipment such as safety glasses, earplugs, gloves, etc. to ensure safety during operation. Clean the work area: Make sure the work area around the saw is clean and tidy, free of debris, to avoid accidents during operation.

[0081] (2) Start-up preparation

[0082] Turn on the power switch: Turn on the power switch of the saw machine and make sure the power indicator is on, indicating that the power is normal. Adjust the cutting speed and depth: According to the hardness and thickness of the material, reasonably set the cutting speed and cutting depth of the saw machine. Check the lubrication system: Check whether the lubrication system of the saw machine is working properly, and add lubricating oil if necessary.

[0083] (3) Start cutting

[0084] Place the material: Place the metal material to be cut on the working table of the saw and secure it with a clamp.

[0085] Start the cutting switch: Turn on the cutting switch of the sawing machine and slowly lower the cutting blade to the surface of the material. Keep the sawing machine speed stable: During the cutting process, keep the sawing machine cutting speed stable to avoid being too fast or too slow.

[0086] (4) End of cutting

[0087] Turn off the saw power: After cutting, turn off the saw power and unplug it. Clean up the cutting area: Clean up the debris and chips in the cutting area to keep the work area clean and tidy.

[0088] (5) Notes

[0089] Keep your fingers away from the cutting area: During operation, avoid putting your fingers or other body parts close to the running tool to avoid danger. Pay attention to abnormal conditions: If you find abnormal sounds, odors or other abnormal conditions, stop using it immediately and check it. Regular maintenance: Regularly inspect and maintain the sawing machine to ensure the good condition of the equipment. The maintenance of the Kabach sawing machine mainly includes daily cleaning, regular inspection and replacement, and lubrication system maintenance.

[0090] (1) Daily cleaning

[0091] Cleaning of workbench and guide rails: The workbench should be cleaned frequently, especially after get off work, to facilitate the next step. Clean the guide rails and the material debris beside the guide rails to prevent the machine from getting stuck due to interference from debris during operation. Cleaning of industrial control box: Clean the industrial control box regularly, because dust is the killer of circuit boards, and only regular maintenance can ensure that the sawing machine will not be damaged.

[0092] (2) Regular inspection and replacement

[0093] Parts inspection and replacement: The parts of the sawing machine, such as saw blades, hydraulic oil, filter presses and cutters, need to be inspected and replaced regularly. The saw blades should be inspected for warping, wear and dullness, and expired or damaged saw blades should be replaced in time. Equipment status inspection: During use, you should always pay attention to the operation of the various operating parts of the sawing machine and check for abnormal sounds or vibrations. If any, find the cause and eliminate it in time.

[0094] (3) Lubrication system maintenance

[0095] Lubrication points: Lubrication should be added to the guide rail surface and lubrication points to ensure smooth operation of all parts. For CNC woodworking saws, dust should be considered during lubrication, the amount of lubrication should be appropriately reduced, and key parts such as guide rails should be kept clean and lubricated.

[0096] Steel caisson, such as Figure 6 As shown:

[0097] Steel caisson: The east anchor caisson is 25m high and is divided into 5 sections from bottom to top, each section is 5m high; the 1st to 3rd sections of the east anchor steel caisson are composed of a well wall and a partition wall. Each steel caisson has 24 well holes surrounded by the well wall and the partition wall on the plane; except for the 2nd section, the well wall is 2.0m thick, the partition wall is 1.3m thick, and the connection between the partition wall and the well wall and the partition wall is set with a 1.5m×1.5m chamfer. According to the shear force requirements of the bottom concrete, the 2nd section of the steel caisson is equipped with shear keys within the height range, the well wall is 2.0~2.6m thick, and the partition wall is 1.3~2.5m thick. The 4th to 5th sections of the east anchor steel caisson only have well walls, no partition walls, the well wall is 1.35m thick, and an opening is set at the connection with the tie beam. The inner side of the well wall is equipped with a perforated plate and shear nails to connect with the concrete top plate of the caisson. The thickness of the outer wall of the first section of the steel caisson is 36mm, and the thickness of the outer wall of the other sections is 20mm. The thickness of the inner wall, partition wall and compartment wall is 16mm. Vertical stiffening ribs are set on the wall and partition wall. The size of the vertical stiffening rib rod is ∠110×70×10mm, and the spacing is about 400mm. A horizontal ring plate is set on the wall plate every 1.0m in the first and second sections of the steel caisson along the height direction, and every 1.25m in the other sections. The horizontal ring spacing at the connection with the tie beam is appropriately adjusted. The size of the horizontal ring plate between the sections is 344×22mm, and the size of the other horizontal ring plates is 300×22mm. Horizontal trusses are set between each layer of horizontal ring plates, and the size of the horizontal truss rods is ∠140×140×12mm. Vertical trusses are set at the chamfer of the well hole of the steel caisson, and the size of the vertical truss rods is ∠140×140×12mm.

[0098] Tie beam steel shell: The tie beam adopts a steel shell concrete structure. The steel shell adopts a U-shaped section, which consists of a bottom plate and web plates on both sides. The steel shell is welded to the steel caisson. Opening plates and shear nails are set on the top surface of the bottom plate and the inner side of the web plate to connect with the tie beam concrete. The bottom plate of the tie beam steel shell is 24m wide, 1.35m high, and 29.5m long. The web plate of the tie beam steel shell is 1.35m thick and 10m high. In order to facilitate factory manufacturing, it is divided into 2 sections vertically, each section is 5m high. The size and thickness of the web plate of the tie beam steel shell and the arrangement of stiffening ribs are the same as those of the top section of the steel caisson. The upper and lower panels of the tie beam steel shell bottom plate are both 22mm thick. Transverse stiffening ribs are set on the inner side of the panels. The size of the transverse stiffening rib rod is ∠110×70×10mm, and the spacing is about 400mm. There are 17 vertical partitions arranged horizontally between the panels, with a spacing of 1.35 to 1.55m between the partitions. The outer partitions are solid web plates with a thickness of 20mm. The middle partitions are truss-type, with a 300×22mm vertical ring rib on the panel, and vertical trusses between the vertical ring ribs. The size of the vertical truss rods is ∠140×140×12mm.

[0099] Connect high cofferdam: Figure 7As shown in the figure, the height of the cofferdam is 10.2m. The cofferdam is extended by the top section of the caisson and the tie beam, and is a double-walled steel cofferdam with a thickness of 1.35m. The size and thickness of the cofferdam plate and the arrangement of stiffening ribs are the same as those of the steel caisson and the top section of the tie beam. The cofferdam is divided into two sections vertically, with the first section 5m high and the second section 5.2m high. The cofferdam is connected to the steel caisson and the steel shell of the tie beam by welding.

[0100] Steel caisson segment division: Steel caissons are divided into 94 types and 394 segments, manufactured in factories. The heaviest segment is CJB5: 16800×4797×5140 (mm), with a segment weight of 75.93 tons. The segment numbers from bottom to top are CJA, CJB, CJC, CJD, CJE, CJF, and CJG.

[0101] Step 2: Cutting. All plate parts are cut by CNC plasma or CNC laser cutting machines. A welding shrinkage of 0-8mm is reserved in the length and width directions of the wall panel unit according to the size of the panel, the number of stiffeners, and the form of the groove. A secondary cutting allowance of 20mm is reserved in the length direction of the wall panel, and a secondary cutting allowance of 50mm is reserved for the joint section.

[0102] Step 3: Production of unit components, including processing of common parts, processing of arc wall panel parts, production of truss unit 1, production of truss unit 2, production of common wall panel units, production of second-section widened segment wall panel units, production of third-section arc segment right-angle units, and production of temporary internal support units of cofferdams.

[0103] The processing of steel caissons attempts to use the ERP management system for intelligent management. The system is mainly composed of a warehouse management system, a project management system, model visualization management, cloud nesting and cloud cutting systems, etc. It can cover the entire production process from the arrival of raw materials to the production of steel caissons. It allows different departments and positions to work together on the same platform, reduce intermediate transmission links, share departmental results in real time, and grasp material inventory, production status, shipping progress, and project dynamics in real time.

[0104] The WMS warehouse management system has the characteristics of fast warehousing and outgoing, dual warehouse management, barcode application, inventory sharing, and rapid cost statistics. The system has complete subject configuration and can quickly handle the incoming and outgoing of materials without too much operation. The project warehouse and the public warehouse are strictly distinguished, which can ensure that project materials are exclusive and dedicated, and can also ensure the normal outgoing of other projects without interfering with each other, independent accounting, and clear accounts. At the same time, the system barcodes materials to facilitate inventory and tracking of materials, realizing true intensive material management.

[0105] The PMIS project management system does not need to fill out cumbersome process transfer forms. The EPR intelligent management system automatically determines the processing process of the component according to the component category, and automatically transfers to the next process after the previous process is completed. Combined with the one-item-one-code error prevention and correction rule, it ensures that each product process not only achieves high-efficiency flow, but also prevents any wrong or missing parts from occurring.

[0106] CAM+CNC cloud cutting system, the traditional transmission of CNC cutting data requires the use of a USB flash drive to copy the cutting instructions to the CNC cutting machine. Now through the cloud cutting system, the cutting machine can be slightly modified to complete the remote transmission of CNC codes. At the same time, workers can work according to the cutting instructions, which can not only improve efficiency but also reduce the error rate.

[0107] The visual model, through the reading, classification and sharing of "one model to the end", realizes the high integration of in-depth drawings and models, making it "simplified" for the project participating departments to look through drawings and check lists. Click the component number, and the 3D graphics and 2D drawings will be immediately presented, showing the relative relationship of the 3D model geometric components in space, while showing the 2D graphics expressing the detailed structure and marked dimensions. "The complementary display of numbers, drawings and models allows non-professionals to easily check and compare. It realizes the integration of design, production and installation.

[0108] This project uses Tekla Structures for BIM modeling, establishes a BIM solid model at a 1:1 ratio, and conducts digital process layout, layout, and welding design based on the BIM model. At the same time, it provides various data such as component lists, part numbers, and material procurement lists to support the project's digital process design, scientific scheduling, production progress, and information management.

[0109] Based on the in-depth model data of BIM, the parts cutting files are exported from the model, and Tekla Structures BIM modeling software is used for lofting and welding process design.

[0110] SmartNest automatic nesting software can automatically group materials according to project, model, material, plate thickness, and processing method. It is suitable for picking up materials in batches or for construction while drawing, picking up materials, and unloading materials, shortening the time for manual material verification and planning.

[0111] SmartNest automatic nesting software is used to layout and nest steel plates, automatically calculate the optimal size within the specified range, and achieve the highest material utilization and the most economical purchase batch, which is suitable for rapid material delivery. At the same time, according to different processing equipment process parameters and cost sharing methods, the software generates the cost of cutting materials at the same time as the layout is completed, which is used for project budgeting or outsourcing cost estimation. The software integrates multiple processes such as drawing conversion, material budgeting, plan management, automatic layout, process optimization, cost forecasting, surplus material management, and production control.

[0112] Backpack portable laser rust removal equipment

[0113] The relatively fluffy rust layer on the surface of the object is physically blasted and cracked, and the high-speed spot moves to form a plume to discharge the cleaning debris to complete the cleaning. At the same time, the high-energy pulse laser is focused on the surface of the object to be cleaned, and the irregular structures such as dirty rust and dark surfaces absorb the laser energy and the plasma energy formed on the metal surface, and are instantly vaporized and separated from the parent material.

[0114] The backpack portable laser cleaning machine integrates light size, easy operation, efficient cleaning, non-contact and pollution-free. It is used to clean rust on cast iron and carbon steel plates, oil on stainless steel and mold gears, and oxides on aluminum plates and stainless steel paint. The cleaning effect is smooth and does not damage the parent material.

[0115] This equipment is mainly used in the dock assembly site. During the on-site assembly, the steel caisson is in a vertical state. The interface weld position is not convenient for large-scale sandblasting and does not meet environmental protection requirements. Using a portable laser rust remover to remove rust from the weld position has high rust removal efficiency and improves construction efficiency. On the other hand, it can meet the environmental and water protection requirements of on-site construction, and at the same time, it can realize the application of new technologies in steel structure products and promote the application of new technologies and new processes.

[0116] Stationary welding robot

[0117] Firstly, the motion trajectory of the welding robot is calculated according to the single weld in the steel caisson. The motion trajectory is parameterized according to the connection method between different components to ensure the welding quality. The parameterized trajectories are combined in order to minimize the welding deformation while meeting the welding quality of a single weld. Finally, the control program is written.

[0118] Input the control program into the robot's controller and start the control program. The robot will then complete the actions specified by the program step by step. If the task changes, you only need to modify or rewrite the control program.

[0119] In this project, welding robots are mainly used for the welding of ring plate units. The angles of the angle steels of the ring plate units are different, which makes it inconvenient to use semi-automatic welding equipment, and the weld length is relatively short. The general structure of the ring plate units is basically the same. The application of welding robots can maximize the construction efficiency.

[0120] Fiber laser steel cutting machine

[0121] Fiber lasers have been a hot topic in the laser field in recent years. In the field of processing, fiber lasers have a tendency to rapidly replace traditional YAG and C02 lasers. Fiber lasers have many unique advantages: good beam quality; small size, light weight, maintenance-free; simple and easy to operate with air cooling; low operating cost, can be used in industrial environments; long life, high processing precision, fast speed; high power conversion efficiency, can realize intelligent, automated, flexible operation, etc.

[0122] The advantages of laser cutting machines are: small thermal deformation, high cutting accuracy, low noise, no pollution, and easy automatic cutting. As an advanced manufacturing technology, laser cutting has the advantages of wide application range, flexible process, high processing accuracy, good quality, clean production process, easy to realize automation, flexibility, intelligence, and improve product quality and labor productivity.

[0123] The angle steels of the ring plate unit and the wall plate unit connected to the partition plate in this project need to be cut and cut. Conventional steel equipment can only process angle steels at a single angle, which is inefficient and requires improved cutting accuracy. The application of laser steel cutting machine can ensure the cutting quality of angle steel and improve construction efficiency.

[0124] Magnetic codeless assembly equipment

[0125] When assembling and reinforcing steel plates or plate units, the leveling and docking of steel plates and the assembly of stiffening ribs can be completed by using the codeless assembly equipment and adjusting the foot cup, the top head and the magnetic controller. Codeless assembly equipment replaces the traditional welding code plate assembly, and there is no damage to the parent material caused by hammer marks, iron tips and code points. There is no need to grind weld scars or repair welding. It can be operated by one person, has light weight, high safety factor, simple and fast operation, simple maintenance, cost saving, and green environmental protection.

[0126] The equipment is intended to be used in the assembly process of the wall panel units of this project. It can improve the construction efficiency while meeting the requirements for angle steel assembly accuracy.

[0127] Railless all-position crawling welding robot

[0128] The whole set of equipment adopts a wheel-crawler crawling structure, and the equipped visual tracking system allows the robot to crawl freely on vertical surfaces or curved surfaces without tracks, and realizes autonomous tracking of welds; at the same time, the high-dynamic industrial camera adopted can realize the operator's real-time monitoring of the molten pool, and the remote monitoring distance can reach 15 meters. In addition, the equipment adopts a removable ceramic liner pasted on the back, which can realize single-sided welding and double-sided forming of the weld, ensuring stable welding quality and beautiful forming. It is especially suitable for the assembly and installation of steel structures with complex structures and large welding volume, such as steel linings.

[0129] During the on-site assembly of the steel caisson, the butt welds of the outer wall panels have both vertical and horizontal welding positions. The magnetic welding robot is not affected by the welding position and can meet the welding requirements of both vertical and horizontal welding positions. It is easy to operate and one person can operate multiple machines at the same time, which improves construction efficiency. Compared with manual welding, the welding parameters of the machine welding method are more stable, and the physical quality and appearance quality of the weld are guaranteed.

[0130] 3D laser scanning virtual pre-assembly

[0131] The steel caisson of the East Anchor of Xiamen's Third East Channel has the characteristics of large volume, multiple segments, and multiple processes. It requires high construction control precision, is difficult to control, and is difficult to pre-assemble. In this regard, this project introduces 3D laser scanner automatic measurement technology to perform 3D scanning on some steel caisson segments. It can not only obtain construction errors and make corrections by comparing the point cloud model generated by the scan with the theoretical model, but also understand the matching between segments in advance by virtually pre-assembling the point cloud models of adjacent segments, and guide the assembly of steel caisson segments.

[0132] Due to the disadvantage of 3D scanning technology, which requires a lot of data collection and processing, this project mainly scans arc segments that are more difficult to make, generates scanning data and performs virtual pre-assembly. The combination of physical assembly and virtual pre-assembly verifies the assembly quality of virtual pre-assembly on the one hand, and the assembly quality of physical assembly on the other hand. Figure 5 shown.

[0133] Processing of common parts: 1. Cutting: plate parts are cut by CNC plasma cutting or CNC laser cutting machine; angle steel parts are cut and angled at one or both ends by sawing machine, fiber laser cutting machine or multi-function punching and shearing machine; 2. Correction: correct part deformation; 3. Wall panel parts splicing: the width of the wall panel parts is wide, and it is necessary to splice them. When splicing, the horizontal and vertical baselines must be aligned to prevent the wrong edges from being spliced; 4. Welding: submerged arc automatic welding is used to weld the joints of the spliced ​​parts; 5. Correction: correct welding deformation; 6. Non-destructive testing: ultrasonic testing of the weld 24 hours after welding is completed; 7. Marking: mark the splicing direction, number and reference information, etc.

[0134] Processing of arc wall panel parts: 1. Cutting: CNC plasma cutting is used to cut the wall panel parts at the rounded corners; 2. Correction: correction of part deformation; 3. Arc processing uses a hydraulic plate rolling machine to process the arc wall panels, and the processing accuracy is controlled by measurement and special arc templates; 4. Marking: marking direction, number and reference information, etc.

[0135] Production of truss unit 1: 1. Position the ring plates on both sides of the upper tire on a special non-marking tire frame and perform positioning welding; 2. Assemble the angle steel according to the angle steel installation limit block; 3. Weld the weld between the angle steel stiffening rib and the ring plate (welding is carried out using an intelligent welding robot); 4. Mark the unit number, direction and reference information.

[0136] Production of truss unit 2: 1. Positioning on the tire. The truss ring plate and node plate are positioned on a special codeless assembly tire frame and fixed to the tire frame with a limit plate; 2. Assemble the transverse stiffening plates and stiffening ribs first according to the position of the positioning blocks, and then assemble the longitudinal stiffening plates and stiffening ribs, and perform positioning welding; 3. Turn over, assemble the transverse and longitudinal stiffening plates and stiffening ribs on the other side after turning over, and perform positioning welding; 4. Welding, weld the welds between the angle steel stiffening ribs and the ring plate and node plate (welding is carried out using an intelligent welding robot); 5. Correction, correct welding deformation; 6. Marking, mark the unit number, direction and reference information.

[0137] Production of ordinary wall panel units: 1. Grinding and marking: use an automatic sanding machine to grind the welding area and mark the position lines of the stiffening angle steel and the truss piece; 2. Assemble the stiffening angle steel according to the line; 3. Weld the weld between the stiffening angle steel and the wall panel on a special anti-deformation frame; 4. Correction: use flame to correct welding deformation; 5. Marking: mark the unit number, direction and reference information, etc.

[0138] Production of the second section widened segment wall panel unit: 1. Grinding and marking, use an automatic sanding machine to grind the welding area and mark the position lines of the stiffening angle steel and the truss piece; 2. Assemble the stiffening angle steel, assemble the stiffening angle steel along the line; 3. Welding, weld the weld between the stiffening angle steel and the wall panel on a special anti-deformation frame; 4. Correction, correct the welding deformation. 5. Ring plate assembly: assemble the ring plate according to the line; 6. Welding: weld the ring plate and the wall plate, and the ring plate and the angle steel by using carbon dioxide gas shielded welding; 7. Correction: correct welding deformation; 8. Assembly: assemble the partition plate parts according to the line, place the inclined wall plate parts against the tire frame positioning baffle, accurately adjust the position and angle of the inclined wall plate, and perform positioning welding; assemble the remaining angle steel reinforcements according to the line; 9. Welding: weld the inclined wall plate and the welds between the partition plate and the wall plate, and weld the angle steel and the angle steel stiffening ribs by using carbon dioxide gas shielded welding; 10. Correction: correct welding deformation; 11. Assembly: assemble the triangle stiffeners and the corresponding angle steels according to the line, and perform positioning welding. 12. Welding: weld the welds of the triangle plate and the angle steel by using carbon dioxide gas shielded welding; 13. Correction: correct welding deformation; 14. Identification: identify the unit number, direction and reference information, etc.

[0139] The third section of the arc segment right angle unit production: 1. Grinding and marking, use an automatic sanding machine to grind the welding area, mark the position line of the stiffening angle steel and the truss position line; 2. Assemble the stiffening angle steel, assemble the stiffening angle steel according to the line; 3. Weld, weld the weld between the stiffening angle steel and the ring plate; 4. Correction, correct welding deformation; 5. Assemble, follow the line of the wall panel units on both sides; 6. Weld, use carbon dioxide gas shielded welding to weld the welds between the ring plate and the wall plate, and the ring plate and the angle steel; 7. Correction, correct welding deformation; 8. Assemble, assemble the upper side ring plate unit according to the line, and perform positioning welding. 9. Weld, use carbon dioxide gas shielded welding to weld the weld between the ring plate and the wall plate; 10. Correction, correct welding deformation; 11. Marking: mark the unit number, direction and reference information, etc.

[0140] Production of temporary internal support units of cofferdams: 1. Pier layout, temporary pier measurement and layout, and temporary pier layout; 2. Assembly, positioning of steel pipes, and then subsequent vertical support positioning. Steel pipes are positioned, and then subsequent vertical support positioning is completed in sequence. 3. Assembly: To prevent welding shrinkage and deformation, anti-deformation supports and vertical temporary supports are pre-arranged; weld the vertical support and the steel pipe, and repair the welding deformation; 4. Marking, removal of temporary anti-deformation pipes, correction, marking direction; positioning of the truss unit at the intersection line on the other side, spot welding and fixing, to prevent welding shrinkage and deformation, anti-deformation supports are pre-arranged; weld the vertical support and the steel pipe, and repair the welding deformation; 5. Marking, removal of temporary anti-deformation pipes, correction, marking direction.

[0141] Unit component manufacturing requirements: (1) Cutting, a. Cutting accuracy requirements must be strictly implemented in accordance with the requirements of the process drawings. b. To ensure the quality of part processing, a cutting test should be carried out before the first cutting to ensure cutting accuracy and quality. c. After the parts are cut, the cutting edges need to be cleaned and polished, and defects such as pits caused during cutting should be repaired and polished. d. Parts should preferably be cut by CNC plasma or laser cutting. e. When cutting, each segment should reserve a matching amount (length, height), and before cutting, the matching should be carried out according to the measurement and 3D laser scanning data. f. After cutting, the end of the cut material should be marked with the number, specification, material, etc. At the same time, the specification, furnace batch number, material, steel plate number, etc. should be marked on the remaining material, and the number should be marked in the thickness direction of the end plate. g. Angle steel is cut by sawing machine, and the length tolerance is ±3mm. (2) Correction, a. Before correcting the parts, remove the burrs and slag on the cutting edge. There should be no obvious dents or other damage on the surface of the corrected parts. b. The temperature of hot straightening is controlled at 700-800℃. After straightening, the parts are slowly cooled with air. Before they reach room temperature, they must not be hammered or quenched with water. (3) Assembly of unit components: a. Before assembly, you must be familiar with the drawings and process documents, carefully check each component, and assemble it only after confirming that it meets the drawings and process requirements. b. Assembly should be carried out on a platform. Assemble the stiffening angle steel according to the line, and control the deviation within the range allowed by the specification; when assembling the rib plate, it should be tightened against the main board before positioning welding. The positioning welding interval is 400-600mm and the length is 50-100mm. Control the verticality deviation of the rib plate to be no more than 1mm.

[0142] (4) Unit component welding, a. Welding method: The steel plate butt joint adopts a single-sided welding and double-sided forming process: open a V-shaped groove, paste a ceramic liner on the back, CO2 gas shielded welding for base and filling, and submerged arc automatic welding for covering; other structural welding is determined according to the design drawings and welding process instructions. The welding of the wall panel unit must be carried out on a special anti-deformation flip frame using a semi-automatic welding trolley. The welding of the truss unit is carried out on the platform using a welding robot. b. Process assurance measures, ① Strictly abide by the welding process and do not change the process without authorization. ② Avoid manual welding in all positions where machine welding can be used.

[0143] Step 4: Fabrication of steel caisson segments. Steel caisson segments include cross-shaped segments, L-shaped segments, straight-shaped segments, and arc-shaped segments.

[0144] Segment welding frame: The steel caisson segment welding frame is made of Q235B material, and the frame columns, crossbeams and longitudinal beams are all made of ∠110×70×10 angle steel. In order to ensure the manufacturing accuracy of the steel caisson, the quality requirements of the frame setting must have sufficient rigidity to ensure that the steel caisson blocks are not deformed during welding. The frame plane deviation is no more than 2mm. The frame is equipped with a wall panel positioning device and measurement observation points to ensure the accuracy of the geometric dimensions. Each unit component is assembled and welded on the segment manufacturing frame to produce a steel caisson segment, and the segment is marked and numbered and transported to the storage area for storage.

[0145] Continuous matching of segments: To ensure the segment size accuracy and assembly accuracy, continuous matching is used as much as possible during segment production. The outer wall segments and the middle segments can be produced by continuous matching, and some segments that cannot be produced by continuous matching are verified by virtual pre-assembly process.

[0146] Manufacturing of cross-shaped segments: 1. Positioning of wall panel units; 2. Assembling truss units. Assemble the first truss unit along the line, accurately adjust the verticality, add diagonal braces and then perform tack welding; 3. Assemble the bulk parts between truss units. Assemble the subsequent truss units along the line and assemble the bulk parts between the truss units in sequence; 4. Weld the welds between trusses and wall panels, and between trusses and bulk parts; 5. Correction, correction of welding deformation; 6. Assemble the wall panel units on both sides. Assemble the wall panel units on both sides along the line, accurately adjust the positions of the wall panels on both sides, add temporary supports to fix and perform tack welding; 7. Welding, welding the welds between the wall panels on both sides and the truss ring plates; 8. Correction, correction of welding deformation; 9. Assemble the upper wall panel units. Assemble the upper wall panel units along the line, accurately adjust the positions of the wall panels, and perform tack welding; 10. Welding, welding the welds between the wall panels and the truss ring plates; 11. Correction, correction of welding deformation; 12. On the cross joint 1. After the cross-shaped segment joint is made, it is placed on a special assembly frame as a whole and fixed after precise positioning; 13. Assembly, assemble the wall panels on both sides of the joint and perform positioning welding; 14. Welding, weld the butt welds between the wall panels; 15. Correction, correct welding deformation; 16. Assembly, assemble the truss units, bottom plate units and joint wall panel units on both sides in line in turn, accurately adjust and add temporary support before performing positioning welding; 17. Welding, weld the welds between the ring plate wall panels; 18. Correct welding deformation; 19. Assembly, assemble the upper side wall panel units in line, accurately adjust and perform positioning welding; 20. Welding, weld the welds between the ring plate wall panels; 21. Correction, correct welding deformation; 22. Non-destructive testing, perform welding non-destructive testing 24 hours after welding is completed; 23. Marking, mark the segment number, direction and reference information, etc.; 24. Segment unloading, segment unloading enters the next process.

[0147] I-shaped segment manufacturing: 1. Wall panel upper tire, wall panel unit upper tire positioning; 2. Assemble truss unit, assemble inner truss unit according to the line, add temporary support after precise positioning and perform positioning welding; 3. Assemble bulkhead board, assemble bulkhead board according to the line and perform positioning welding; 4. Assemble, assemble the truss unit on the other side according to the line, add temporary support after precise positioning and perform positioning welding; 5. Assemble, assemble the wall panel unit on the other side according to the line, add temporary support after precise positioning and perform positioning welding; 6. Assemble, assemble interlayer truss unit according to the line, add temporary support after precise positioning and perform positioning welding; 7. Assemble, assemble bottom plate unit, add temporary support after precise positioning and perform positioning welding; 8. Welding, weld the fillet welds of bulkhead board and wall panel unit in sequence, Fillet welds between bulkhead plate and bottom plate unit, fillet welds between wall plate and bottom plate unit, fillet welds between truss ring plate and wall plate unit, fillet welds between ring plate and bulkhead plate; 9. Correction, correction of welding deformation; 10. Assembly, assembling the bottom plate blade foot position web and stiffener, and positioning welding after precise positioning; 11. Welding, using CO2 gas shielded welding to weld in sequence: fillet welds between blade foot web and bottom plate, fillet welds between blade foot stiffener and bottom plate, fillet welds between blade foot stiffener and blade foot web; 12. Correction, correction of welding deformation; 13. Non-destructive testing, non-destructive testing of welding is carried out 24 hours after welding is completed; 14. Identification, identification of segment number, direction and reference information, etc.; 15. Unloading of segments, the next process is entered.

[0148] L-shaped segment manufacturing: 1. Wall panel upper part, wall panel unit upper part positioning; 2. Assembly, assemble truss unit according to the line, add temporary support after precise positioning and perform positioning welding; 3. Assembly, assemble the partition plate unit according to the line, add temporary support after precise positioning and perform positioning welding; 4. Assembly, assemble the truss on the other side according to the line, perform positioning welding after precise positioning; 5. Assembly, assemble the bottom plate unit according to the line, add temporary support after precise positioning and perform positioning welding; 6. Assembly, assemble the truss unit at the T-joint position according to the line, add temporary support after precise positioning and perform positioning welding; 7. Assembly, assemble the bulk parts between the T-joint trusses, perform positioning welding after precise positioning; 8. Assembly, assemble the upper side according to the line For the wall panel unit, tack welding shall be performed after precise positioning; 9. Assembly, assemble the interlayer truss units along the line, and tack welding shall be performed after precise positioning; 10. Welding, use CO2 gas shielded welding to weld the wall panel unit and the ring plate unit, the welds between the bottom plate unit and the wall panel, and the vertical connection parts of the truss unit at the T-joint position; 11. Correction, correct welding deformation; 12. Assembly, assemble the bottom plate blade foot and stiffen it, and complete the welding after precise positioning; 13. Correction, correct welding deformation; 14. Non-destructive testing, perform welding non-destructive testing 24 hours after welding is completed; 15. Marking, mark the segment number, direction and reference information, etc.; 16. Remove the segment, and enter the next process.

[0149] Arc segment manufacturing: 1. Put the wall panels on the frame, the two arc segment wall panels are placed on the frame for positioning, and fixed to the frame; 2. Welding, welding the weld between the two arc segment wall panels; 3. Correction, correct the welding deformation, and use the ring plate as a template to check whether the curvature of the wall panel meets the requirements; 4. Assemble, assemble the ring plate and the wall panel angle steel at the same time, and perform positioning welding after assembly; 5. Welding, welding the weld between the wall panel and the angle steel and the ring plate; 6. Correction, correct welding deformation; 7. Assemble, accurately position the single-side angle steel of the ring plate according to the line, assemble the temporary support (red parts) on the other side, and fix it with spot welding, 8. Assemble, assemble the inner arc side wall panel unit (the inner arc side ring plate is pre-welded to the wall panel), after precise positioning, Perform tack welding; 9. Replace temporary support, remove internal temporary support pipe, replace the removed position with angle steel, and perform tack welding; 10. Assemble, assemble the end arc trusses, accurately position them, and perform tack welding; 11. Assemble, assemble the bottom plate unit, accurately position them, and perform tack welding; 12. Weld, use CO2 gas shielded welding to weld the welds between the angle steel and the ring plate, as well as the corner welds between the wall plate and the bottom plate unit; 13. Correction, correct welding deformation; 14. Assemble, assemble the bottom plate blade foot stiffener, accurately position it, and complete the welding; 15. Correction, correct welding deformation; 16. Marking, mark the segment number, direction and reference information, etc.; 17. Remove the segment, and enter the next process.

[0150] Manufacturing of the second cross-shaped segment: 1. Positioning the wall panel unit; 2. Assembling the truss unit, assemble the first truss unit according to the line, accurately adjust the verticality, add diagonal braces and then perform positioning welding; 3. Assembling the bulk parts between the truss units, assemble the subsequent truss units according to the line and assemble the bulk parts between the truss units in sequence; 4. Welding, welding the welds between the truss unit and the wall panel, and between the truss unit and the bulk parts; 5. Correction, correction of welding deformation; 6. Assembling the wall panel units on both sides, assemble the wall panel units on both sides according to the line, accurately adjust the position of the wall panels on both sides, add temporary supports to fix and perform positioning welding; 7. Welding the welds between the wall panels on both sides and the truss ring plate; 8. Correction, correction of welding deformation; 9. Assembling the upper wall panel unit, assemble the upper wall panel unit according to the line, accurately adjust the position of the wall panel, and perform positioning welding; 10. Welding, welding the welds between the wall panel and the truss ring plate; 11. Correction, correction of welding deformation; 12. Cross joint installation. After the cross segment joint is made, it is placed on a special assembly frame as a whole and fixed after precise positioning. 13. Assemble the wall panels on both sides of the assembly joint and perform positioning welding. 14. Weld. Weld the butt welds between the wall panels. 15. Correct. Correct the welding deformation. 16. Assemble. Assemble the truss units and partition plate units on both sides in line in turn, and perform positioning welding after precise adjustment and temporary support. 17. Weld. Weld the welds between the ring plate wall panels. 18. Correct. Correct the welding deformation. 19. Assemble. Assemble the upper side wall panel units in line, and perform positioning welding after precise adjustment. 20. Weld. Weld the welds between the ring plate wall panels. 21. Correct. Correct the welding deformation. 22. Non-destructive testing. Perform welding non-destructive testing 24 hours after welding is completed. 23. Mark. Mark the segment number, direction and reference information, etc. 24. Remove the segment. The segment is removed and enters the next process.

[0151] The second circular segment manufacturing: 1. Position the outer arc wall panel upper part of the wall panel and fix it with the frame; 2. Assemble, now place the angle steel in the corresponding position of the wall panel according to the line, fix the two ends with temporary ring plates (make an extra ring plate part at this position as a template), assemble the truss unit and the bottom plate unit according to the line, accurately position the angle steel and the truss unit, add temporary support and perform positioning welding; 3. Weld, use CO2 gas shielded welding to weld the welds between the truss unit ring plate, angle steel and wall panel; 4. Correction, correct welding deformation; 5. Assemble, assemble the inner arc side wall panel (angle steel) according to the line The stiffener is pre-placed in the ring plate stiffening groove), and after precise positioning, positioning welding is performed; 6. Welding, using CO2 gas shielded welding to weld the weld between the inner arc wall plate unit and the angle steel stiffener rib; 7. Correction, correction of welding deformation; 8. Assembly, assemble the top truss unit according to the line, and perform positioning welding after precise positioning; 9. Welding, using CO2 gas shielded welding to weld the weld between the ring plate and the wall plate of the top truss unit; 10. Correction, correction of welding deformation; 11. Marking, marking the segment number, direction and reference information, etc.; 12. Segment removal, the segment is removed and enters the next process.

[0152] The third section of L-shaped segment manufacturing: 1. Wall panel upper tire, wall panel unit upper tire positioning; 2. Assemble the truss unit and the partition plate unit according to the line, add temporary support after precise positioning and perform positioning welding; 3. Welding, use CO2 gas shielded welding to weld the weld between the truss unit ring plate and the wall panel; 4. Correction, correct welding deformation; 5. Assemble, assemble the inner wall panel unit according to the line, and perform positioning welding after precise positioning; 6. Welding, use CO2 gas shielded welding to weld the weld between the truss unit ring plate and the wall panel; 7. Correction, correct welding deformation; 8. Non-destructive testing, carry out welding non-destructive testing 24 hours after welding is completed; 9. Marking, mark the segment number, direction and reference information, etc.; 10. Segment lower tire, the segment lower tire enters the painting process; 11. Marking, transplant segment information.

[0153] The third section of circular segment manufacturing: 1. Wall panel upper tire, the inner wall panel unit of the arc is positioned on the tire and fixed with the tire frame; 2. Assembly, the internal angle steel of the wall panel is assembled according to the line; 3. Assembly, the outer arc wall panel unit is accurately positioned on the tire and fixed by spot welding; 4. Welding, CO2 gas shielded welding is used to weld the weld between the angle steel and the ring plate; 6. Correction, correction of welding deformation; 7. Assembly, assemble the right-angle unit according to the line (first weld the right-angle position components into a whole, and then participate in the overall assembly of the segment), and perform positioning welding after accurate positioning; 9. Welding, CO2 gas shielded welding is used to weld the straight Corner units and welds between outer wall reinforcement components and wall panels, truss units; 10. Correction, correction of welding deformation; 11. Assembly, assemble the back corbel along the line, and perform positioning welding after precise positioning; 12. Welding, use CO2 gas shielded welding for corbel and arc fillet welds, as well as the internal fillet welds of the corbel; 13. Correction, correction of welding deformation; 14. Non-destructive testing, non-destructive testing of welding is carried out 24 hours after welding is completed; 15. Identification, identification of segment number, direction and reference information, etc.; 16. Segment removal, the segment removal enters the painting process; 17. Identification, transplant segment information.

[0154] Assembled piers and gantry crane foundation: The gantry crane foundation should be a concrete foundation with tracks on top. The foundation is 260m long, 0.6m wide and 0.3m high. The foundation is cast with C35 concrete. The longitudinal steel bars and stirrups are arranged inside the foundation. The steel bars are all φ12mm threaded steel bars. φ20mm elbow anchor bolts are embedded inside the foundation to fix the tracks and foundation to meet the use requirements of the gantry crane. The assembled pier is made of φ325×8 steel pipes.

[0155] Step 5: Steel caisson assembly construction. When assembling the steel caisson as a whole, assemble from the middle to the surrounding areas to form a stable structure in sequence, and finally close the four corners. After the assembly is completed, proceed to the next layer of construction. Figure 2-3 As shown, the specific process is as follows:

[0156] (1) Complete the measurement layout and pier layout as required, and use a total station to复测 the positioning line of the steel caisson and the plane position and elevation of the underlying sleeper blocks.

[0157] (2) After the segment is transported to the hoisting area, perform segment flipping and erection. Use the main hook and auxiliary hook of a 95t crawler crane for flipping. Hang the four steel ropes of the main hook on the upper-side hoisting lugs of the segment, and hang the two steel ropes of the auxiliary hook on the turning lugs. Slowly lift the main hook while keeping the auxiliary hook stationary to complete the segment erection.

[0158] (3) After the segment is flipped and erected, hoist it into place. Coarse-position the segment through the ground hoisting line, use a magnetic plumb bob to check the verticality of the segment, and use a total station to复核 the spatial position of the upper positioning points of the segment. After meeting the requirements, add diagonal braces to fix and prevent the segment from overturning.

[0159] (4) Hoist the surrounding segments in sequence to form a cross-shaped stable structure. After hoisting adjacent segments and accurately positioning them, use an all-round welding trolley to weld the vertical welds between the segments. The welds on both side walls are welded simultaneously from bottom to top. After welding is completed, use CO₂ gas shielded welding to weld the butt joints of the ring plates and other internal welds. After the vertical welds are welded, use CO₂ gas shielded welding to weld the butt joints of the bottom plates. After the overall welding of the segment is completed,复核 whether the axis deviation of the segment exceeds the allowable value, and make corrections according to the复核 results. Then hoist the next segment until all the segments of the first layer are hoisted.

[0160] (5) After the hoisting and welding of the first-layer segments are completed and inspected to be qualified, pour the concrete of the cutting edge. After the concrete pouring is completed, hoist the second-layer segments, and weld the vertical welds of the wall plates and the ring plate welds according to the welding sequence in step (4). After the vertical welds of the wall plates are welded, weld the transverse welds of the ring plates between the first and second steel caissons. The two transverse welds of the ring plates on both sides are welded simultaneously by two trackless all-position crawling welding robots in the segment hoisting direction. After the welds between the segments are welded,复核 whether the axis of the segment exceeds the allowable value, and make corrections according to the复核 results. Then hoist the next segment until all the segments of the second layer are hoisted.

[0161] (6) Repeat step (5) until the assembly construction of all the steel caisson segments of the third section is completed.

[0162] (7) After the first segment of the 4th floor is hoisted and accurately positioned, positioning welding is performed, and diagonal braces are added on the inner side of the segment to prevent the segment from overturning. Two trackless all-position crawling welding robots are used to perform circumferential seam welding in the segment hoisting direction at the same time; after the adjacent segments are hoisted and accurately positioned for positioning welding, and after being reinforced with diagonal braces, two omnidirectional welding trolleys are used to weld the vertical welds between the segments. The welds of the wall panels on both sides are welded from bottom to top at the same time. After welding is completed, carbon dioxide gas shielded welding is used to weld the ring plate butt joints and other internal welds. After the vertical seam welding is completed, two trackless all-position crawling welding robots are used to perform circumferential seam welding in the segment hoisting direction at the same time; the subsequent segments are installed in sequence until all the segments of the fourth steel caisson are hoisted;

[0163] (8) Remove the diagonal rod, hoist the temporary support positioning bracket, weld it, and hoist the inner support intermediate unit;

[0164] (9) Hoist the remaining steel pipes of the fourth section inner support and complete welding;

[0165] (10) The fifth section of the steel caisson is hoisted in sequence. Due to the high height, it is not possible to use the inclined support method for temporary support when hoisting the fifth section. After the section is positioned, the hook is loosened but not removed. The vertical horse plate between the sections must be increased from the original 500mm per line to 300mm per line, and the intermittent welding of the transverse seam on the outer side of the steel shell is completed after more than 50% of the hook is removed, and the next section is hoisted until the fifth section of the steel caisson is hoisted and welded. After the fifth section of the steel caisson is hoisted and welded, the inner support steel pipe is installed;

[0166] (11) Repeat step (10) to complete the hoisting of the sixth to seventh steel caisson segments;

[0167] (12) Install the truss-type internal supports in sections. First, install the long-side internal supports of the steel caisson, and then install the short-side truss-type internal supports in sections.

[0168] Step 6: Welding and painting.

[0169] Characteristics of steel caisson welding: (1) The wall panel unit stiffening angle steel is dense and the wall panel is thin, so controlling welding deformation is the key during welding. (2) The cross-shaped and L-shaped node position ring plates and supporting angle steels form truss partitions, and the internal space is small, making assembly welding difficult. (3) The Quanzhou assembly base is located in a coastal environment with frequent strong winds, so wind protection is required during welding.

[0170] Principles for selecting welding schemes: Based on the characteristics and quality requirements of this project, the basic principle for determining the welding process scheme is: Under the premise of ensuring welding quality, try to use welding processes with small welding deformation and small weld shrinkage. The wall panel unit adopts an anti-deformation automatic welding machine for assembly welding, and the truss unit adopts an intelligent welding robot. Various types of automation and intelligent welding equipment are used to ensure welding quality and improve production efficiency.

[0171] (1) The welding method is mainly automatic welding to ensure the stability of welding quality. Select welding materials that match the parent material, control the diffusible hydrogen content in the weld, and ensure that all indicators of the weld meet the design requirements.

[0172] (2) Some of the angle steels between the truss units are used as buffer parts, and the angle steels at the node positions are welded by retreating.

[0173] (3) Prepare a comprehensive and reasonable welding process assessment test plan based on the structural characteristics to determine the appropriate groove form, welding method, welding equipment, welding materials, preheating temperature, interlayer temperature and process parameters, etc. After the review is passed, it will serve as the basis for preparing the welding process documents.

[0174] Welding process requirements: 1. Welding environment requirements

[0175] The welding environment must meet the following requirements: (1) Wind speed: The wind speed during gas shielded welding shall not exceed 2m / s; (2) Relative humidity shall not exceed 80%; (3) The temperature of the weldment shall not be lower than 5°C; When the working environment exceeds the following conditions, necessary preventive measures must be taken before work can be carried out.

[0176] 2. Preparation before welding: (1) Welders participating in the welding construction of this project should have corresponding welding qualification certificates and work within the validity period; (2) The welding process assessment has passed the review and the welding process documents have been compiled and issued; (3) Before welding, the welding process technology is explained to the relevant personnel and they are tested. Only those who pass the test can take up their posts; (4) The welding materials are baked according to the specifications and issued, used and recycled according to the welding material management system; (5) Before welding, rust, oil stains, oxides, etc. on the groove surface and both sides of the groove must be thoroughly cleaned, and both sides of the groove must be cleaned; (6) When the welding environment is not available, appropriate measures must be taken; (7) The welding equipment must be debugged before welding.

[0177] 3. Requirements for tack welding: (1) The welding materials used for tack welding should match the workpiece to be welded; (2) The tack weld should be kept uniform, and the weld leg size and weld length should be in accordance with the requirements of the process documents. The surface of the tack weld is not allowed to have defects such as cracks and lack of fusion; (3) The tack weld should be more than 30 mm away from the end of the workpiece, and its length should be 50 to 100 mm; the spacing should be 400 to 600 mm; the weld leg size of the tack weld should not be greater than 1 / 2 of the designed weld leg size.

[0178] 4. Requirements during welding: (1) The welder must strictly follow the requirements of the welding process documents. When welding multiple layers and multiple passes, the joints should be staggered, and the coating and spatter of the upper layer should be cleaned before the subsequent welds can be welded; (2) The arc starter plate and arc extinguishing plate should be installed at the end of the butt weld using submerged arc welding. After welding, the arc starter and arc extinguishing plates are not allowed to be removed by hammering or other methods. Flame cutting should be used, and a 1-3mm margin should be left. The plates should be ground with a grinder until they are flush with the parent material; (3) When preheating is required, welding is allowed only after preheating according to the process requirements. The preheating range shall not be less than 100mm on both sides of the weld. The temperature measurement point is on the back of the heated side, 50mm away from the weld. During the welding process, the layer temperature shall not be lower than the preheating temperature. Each weld should be welded in one go as much as possible. When welding is interrupted, appropriate slow cooling measures should be taken. When re-welding, it can only be carried out after preheating as required; (4) When CO2 gas shielded welding is used on site, strict and reliable wind and rain protection measures must be taken, and the purity of CO2 gas must not be lower than 99.5% (5) For welds that require root cleaning by gas gouging, the root defects of the front weld must be completely removed, the depth and width of the gas gouging must be uniform, and the root should have at least an arc of R ≥ 6mm; (6) If major welding quality problems are found during welding, welding must be stopped immediately and reported to the welding engineer and the supervising engineer. Welding can only be continued after the cause of the problem is found and preventive measures and solutions are proposed.

[0179] 5. Control of overhead welds in the factory: (1) The overhead welds of the factory segments are the fillet welds between the wall panels and the ring panels. The space between the two layers of wall panels and the trusses is large, so welders can easily complete the overhead welding task; (2) When welding overhead welds, welding must be carried out strictly in accordance with the welding parameters evaluated by the welding process to ensure welding quality; (3) Detailed technical instructions are provided to the welders of overhead welds; (4) Overhead weld welders must hold a welder certificate and pass the welder examination for this project before they can start welding. According to the design drawings and manufacturing process of the steel caisson, the main types of welds in this project are butt welds and T-type fillet welds, which are mainly the butt welds of the bottom plate / wall panel, the fillet welds of the wall panel and the ring panel, and the fillet welds of the angle steel and the ring panel. Controlling welding deformation mainly involves setting pre-deformation, adjusting the welding sequence and welding direction, and rigid constraints to control deformation, such as Figure 4 shown.

[0180] In order to ensure the quality of welding and ensure that the various properties of the welded joints meet the design requirements, strict control will be exercised in terms of people, machines, materials, methods, and environment to ensure the quality of welding. When welding the weld, windproof measures such as wind shields will be added. When the ambient humidity is too high, preheating before welding and adding rain shelters and other moisture-proof measures will be carried out.

[0181] Inspection and welding records:

[0182] (1) Visual inspection of welds: all welds shall be visually inspected after the weld metal has cooled, and inspection records shall be filled in. All welds shall be free of welding defects such as cracks, lack of fusion, weld bumps, slag inclusions, unfilled arc pits and leaks. Welded components that fail the visual inspection shall not enter the next process until they are processed and meet the requirements. (2) Non-destructive testing: non-destructive testing personnel shall have Grade II or above qualifications, and non-destructive testing supervisors shall have Grade III qualifications. Non-destructive testing personnel must be approved and filed by the supervising engineer before they can go to work. (3) Welding records: all welds shall be registered by the welders, and the welders can be traced. Welders with irregular welding shall be found in time, and training shall be conducted. Welders who fail to weld again shall be dismissed.

[0183] Steel caisson assembly welding protection measures, due to welding environment requirements, generally stop construction in rainy days, if the progress requires rush work, in addition to local heating and wind protection, the entire weld must be placed under the protection of an effective wind and rain shelter before construction. When welding the vertical welds of the wall panels on site, set up magnetic windshield strips on the outside of the cage for protection.

[0184] Welding precautions

[0185] (1) The weld seams of steel caissons shall be inspected for flaws 24 hours after welding is completed; (2) Before use, welding wires and fluxes shall be baked and stored in strict accordance with the provisions of the product manual. Inspection quantity: All inspections. Inspection method: Check the quality certificate and baking records. (3) Welders must pass the examination and obtain a certificate of qualification. Certified welders must weld within the items they have passed the examination and within their approved scope. Inspection quantity: All inspections. Inspection method: Check the welder's certificate of qualification and its approved scope and validity period. (4) The welding environment on site shall comply with the following regulations: wind speed < level 5, temperature ≥ 5℃, humidity ≤ 80%, and outdoor welding is not allowed on rainy days. If the above environmental requirements are exceeded, measures shall be taken to ensure that welding can be carried out only when the quality of the weld can be guaranteed. (5) When gas shielded welding is used for steel caisson sections, ventilation protection measures must be taken and the operator must wear an oxygen-permeable protective mask. (6) All welds must be non-destructively tested according to design requirements.

[0186] Painting process

[0187] 1. Pre-painting workshop primer, before unloading, the plates and steel sections are shot blasted, sprayed with workshop primer, and dried on the pre-treatment production line. 2. Segment painting, surface treatment and spraying operations are all carried out in a special painting workshop, and the temperature and humidity in the painting room should meet the requirements of the corresponding specifications. The painting operation procedure should follow the operation sequence of "edge grinding → degreasing and dirt removal → sandblasting → cleaning → spraying". 3. Re-painting, grind the reserved parts and damaged parts of the segment assembly weld to make their rust removal level and surface roughness meet the requirements of the specifications, and apply re-paint layer by layer by brushing according to the coating system.

[0188] Segment transportation and storage: According to the construction process and construction plan of the steel caisson for the east anchor of the A1 section of the Xiamen Third Channel, the steel caisson will be temporarily stored after being manufactured at the manufacturing and processing base. The steel caisson will be transported according to the construction schedule and transported to the Quanzhou processing base for overall assembly. The height of the second cross-shaped segment is 4.8m and cannot be transported as a whole by land. Therefore, the second cross-shaped segment needs to be made into segments with the two sides of the straight part, and the cross joints are made into plate units for transportation. After being transported to the dock, they are assembled into segments at the dock. The caisson segments are transported by road. The company will select transportation units with sufficient transportation capacity, good reputation and long-term cooperation with the company to undertake the transportation of steel structures.

[0189] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. Intelligent construction and construction method of anchored steel caisson, characterized by: The method includes the following steps: Step 1: Steel pretreatment. Before cutting and blanking the steel plate, shot blasting and rust removal are carried out through a pretreatment production line. After the surface treatment reaches Sa3.0 level, an inorganic zinc silicate shop primer with a thickness of 25 - 30μm is sprayed. The residual stress in the steel plate during the rolling process is released through pretreatment, and the flatness of the steel plate is ensured to meet the requirements. At the same time, the steel plate is protected from rust during the factory construction period by spraying the shop primer. Step 2: Blanking. All sheet metal parts are blanked using a CNC plasma or CNC laser cutting machine. For the length and width directions of the wall panel units, a welding shrinkage allowance of 0 - 8mm is reserved according to the sheet size, the number of stiffeners, and the groove form. A secondary cutting allowance of 20mm is reserved in the length direction of the wall panel, and a secondary cutting allowance of 50mm is reserved for the closure section. Step 3: Unit component manufacturing, including the processing of ordinary parts, the processing of arc wall panel parts, the manufacturing of truss unit 1, the manufacturing of truss unit 2, the manufacturing of ordinary wall panel units, the manufacturing of the second widened section wall panel units, the manufacturing of the third arc section right-angle units, and the manufacturing of the cofferdam temporary internal support units. Step 4: Steel caisson section manufacturing. The steel caisson sections include cruciform sections, L-shaped sections, straight sections, and circular arc sections. In sequence, the section group welding jig, continuous matching manufacturing of sections, manufacturing of cruciform sections, manufacturing of straight sections, manufacturing of L-shaped sections, manufacturing of circular arc sections, manufacturing of the second cruciform section, manufacturing of the second circular section, manufacturing of the third L-shaped section, and manufacturing of the third circular section. Step 5: Steel caisson assembly construction. When the steel caisson is assembled integrally, it is assembled from the middle to the surrounding, forming a stable structure in sequence, and finally closing at the four corners. After the assembly is completed, the next layer of construction is carried out. Step 6: Welding and painting are carried out to complete the construction.

2. The intelligent construction and construction method of anchored steel caisson according to claim 1 is characterized by: The specific process in Step 5 is as follows: (1) Complete the measurement layout and pier layout as required, and use a total station to复测 the positioning line of the steel caisson and the plane position and elevation of the underlying bearing blocks. (2) After the section is transported to the lifting area, the section is flipped and erected. A 95t crawler crane's main hook and auxiliary hook are used for flipping. The four steel wire ropes of the main hook are hung on the upper-side lifting lugs of the section, and the two steel wire ropes of the auxiliary hook are hung on the turning lugs. Slowly lift the main hook while keeping the auxiliary hook stationary to complete the section erection. (3) After the section is flipped and erected, it is hoisted into place. Coarse positioning of the section is carried out through the lifting ground line. A magnetic plumb bob is used to check the verticality of the section. After using a total station to复核 that the spatial position of the upper positioning points of the section meets the requirements, diagonal braces are added to fix and prevent the section from overturning. (4) Hoist the surrounding sections in sequence to form a stable structure in the shape of a "field". After hoisting adjacent sections and accurately positioning them, an all-round welding trolley is used to weld the vertical welds between the sections. The welds on both side walls are welded simultaneously from bottom to top. After the welding is completed, a carbon dioxide gas shielded welding is used to weld the circumferential plate butt joints and other internal welds. After the vertical welds are welded, a carbon dioxide gas shielded welding is used to weld the bottom plate butt joints. After the overall welding of the section is completed, check whether the axis deviation of the section exceeds the allowable value, and make corrections according to the check results. Then hoist the next section until all the first-layer sections are hoisted. (5) After the first-layer segment is hoisted and welded and inspected to be qualified, the blade angle concrete is poured. After the concrete pouring is completed, the second-layer segment is hoisted. The vertical welds of the wall panels and the ring plate welds are welded according to the welding sequence in step 4. After the vertical welds of the wall panels are welded, the horizontal welds of the first and second steel caisson ring plates are welded. The horizontal welds of the ring plates on both sides are welded by two trackless full-position crawling welding robots at the same time in the segment hoisting direction. After the welding of the inter-segment welds is completed, check whether the segment axis exceeds the allowable value, make corrections based on the review results, and then hoist the next segment until all the second-layer segments are hoisted; (6) Repeat step (5) until all the steel caisson segments of the third section are assembled; (7) After the first segment of the 4th floor is hoisted and accurately positioned, positioning welding is performed, and diagonal braces are added on the inner side of the segment to prevent the segment from overturning. Two trackless all-position crawling welding robots are used to perform circumferential seam welding in the segment hoisting direction at the same time; after the adjacent segments are hoisted and accurately positioned for positioning welding, and after being reinforced with diagonal braces, two omnidirectional welding trolleys are used to weld the vertical welds between the segments. The welds of the wall panels on both sides are welded from bottom to top at the same time. After welding is completed, carbon dioxide gas shielded welding is used to weld the ring plate butt joints and other internal welds. After the vertical seam welding is completed, two trackless all-position crawling welding robots are used to perform circumferential seam welding in the segment hoisting direction at the same time; the subsequent segments are installed in sequence until all the segments of the fourth steel caisson are hoisted; (8) Remove the diagonal rod, hoist the temporary support positioning bracket, weld it, and hoist the inner support intermediate unit; (9) Hoist the remaining steel pipes of the fourth section inner support and complete welding; (10) The fifth section of the steel caisson is hoisted in sequence. Due to the high height, it is not possible to use the inclined support method for temporary support when hoisting the fifth section. After the section is positioned, the hook is loosened but not removed. The vertical horse plate between the sections must be increased from the original 500mm per line to 300mm per line, and the intermittent welding of the transverse seam on the outer side of the steel shell is completed after more than 50% of the hook is removed, and the next section is hoisted until the fifth section of the steel caisson is hoisted and welded. After the fifth section of the steel caisson is hoisted and welded, the inner support steel pipe is installed; (11) Repeat step (10) to complete the hoisting of the sixth to seventh steel caisson segments; (12) Install the truss-type internal supports in sections. First, install the long-side internal supports of the steel caisson, and then install the short-side truss-type internal supports in sections.

3. The intelligent construction and construction method of anchored steel caisson according to claim 1 is characterized by: The ERP management system is used for intelligent management in the unit component production of step 3. The ERP management system consists of a warehouse management system, a project management system, model visualization management, a cloud nesting system and a cloud cutting system. It covers the entire production process from the arrival of raw materials to the production of steel caissons, allowing different departments and positions to work together on the same platform, reducing intermediate transmission links, sharing departmental results in real time, and keeping track of material inventory, production status, shipping progress, and project dynamics in real time.

4. The intelligent construction and construction method of anchored steel caisson according to claim 1 is characterized by: In step 5, a three-dimensional laser scan is performed for virtual pre-assembly before assembly. The steel caisson segments are three-dimensionally scanned. The construction error can be obtained and corrected by comparing the point cloud model generated by the scan with the theoretical model. The point cloud models of adjacent segments can also be virtually pre-assembled to understand the matching between the segments in advance and guide the assembly of the steel caisson segments.

5. The intelligent construction and construction method of anchored steel caisson according to claim 1 is characterized by: In step 6, the welding is performed by automatic tracking welding using a railless full-position crawling welding robot. When the steel plate panels are assembled and reinforced in step 3, the steel plate leveling and docking and the stiffening rib assembly can be completed by utilizing codeless assembly equipment and adjusting the foot cup, the top head and the magnetic controller.

6. The intelligent construction and construction method of anchored steel caisson according to claim 1 is characterized by: In step 5, the internal stiffening structure of the cross-shaped and T-shaped segments is relatively complex, and parts collision is prone to occur. It is planned to use Tekla software modeling to perform collision checks to determine whether there are collision problems between parts, and use three-dimensional diagrams at the node positions to indicate the direction, position and part number to clarify the assembly sequence.

7. The intelligent construction and construction method of anchored steel caisson according to claim 1 is characterized by: In step 6, the problem of size reduction caused by the butt joint of the steel caisson wall panel being larger than the set value should be solved by considering the welding shrinkage in advance. According to the plate thickness, number of reinforcements and groove form, the corresponding welding shrinkage should be added when cutting the parts, and the secondary cutting amount should be set to ensure the overall size after welding.

Images