Intelligent construction and construction method of anchor steel caisson

Abstract

The application provides an anchorage steel caisson intelligent construction and construction method, belongs to the technical field of steel caisson construction, and relates to steel pretreatment, blanking, unit production, steel caisson segment production, steel caisson assembly construction, steel caisson overall assembly, stable structure formation, closure of four corners, next layer construction, welding and coating, and construction completion. The application is aimed at the complex internal stiffening structure of the cross-shaped and T-shaped segments of the project, and the problem of part collision. The application adopts the tekla software modeling to perform collision checking, determines whether the parts have collision problems, adopts a three-dimensional diagram at the node position, marks the direction, position and part number, makes the assembly sequence clear, and performs process animation explanation to the construction personnel.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of steel caisson construction, in particular to an intelligent construction and construction method of an anchor steel caisson. BACKGROUND

[0002] With the bridge construction from inland to the sea, the construction conditions are more complex, such as deep water, soft foundation, strong wind, rapid flow, wave, strong earthquake, etc. The foundation of the cross-sea bridge is often located in the deep water area, and there is a thick overburden layer of soft soil, sand, cohesive soil, and broken (ovoid) stone soil alternately, and there may be uneven soft (hard) interlayer distributed in the overburden layer. For long-span suspension bridges and cable-stayed-suspension cooperative system bridges, in addition to bearing huge vertical force, they also bear huge oblique tension force transmitted by the main cable. The horizontal tension force of the main cable of a 3000m-level suspension bridge exceeds 200,000 tons, and the height of the main cable anchor point is high, thereby increasing the additional bending moment of the top surface of the anchor foundation.

[0003] The third east channel in Xiamen starts from the Xiangshan Yacht Club near the Xiamen Island in Siming District, and the main line is along the tunnel along the island road to the north of Guanyin Mountain, and then crosses the east sea area of the island by bridge, and the terminal is connected to the new Xiang'an Airport, with the synchronous construction of the Xiang'an branch line, with a total length of 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 Liuwedian Channel Bridge of the main bridge is a suspension bridge with a length of 1948m and a main span length of 928m. The main cable is connected and fixed at both ends with the east and west anchorages. The main construction content of the project is the processing and manufacturing of the east anchorage steel caisson.

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

[0005] The purpose of the present application is to provide an intelligent construction and construction method of an anchor steel caisson, which solves the technical problems in the background art.

[0006] (1) For the complex internal stiffening structure of the cross-shaped and T-shaped segment of the project, part collision is prone to occur. Therefore, the tekla software is used for modeling to check the collision and determine whether the parts have collision problems. The three-dimensional diagram is used at the node position to indicate the direction, position and part number, and the assembly sequence is clear. The process animation is also introduced to the construction personnel.

[0007] (2) For the problem of size reduction caused by many butt joints of the steel caisson wall plate of the project, the welding shrinkage is considered in advance. According to the plate thickness, stiffening quantity and groove form, the corresponding welding shrinkage is added when the parts are cut, and the secondary cutting amount is reasonably set to ensure that the overall size precision after welding meets the requirements.

[0008] (3) For the case that the segment is large and the overall size is large, which may cause the assembly precision to not meet the requirements, it is appropriate to use the hierarchical axis centering method to control the overall construction precision of the steel caisson, that is, by controlling the axes of the steel caisson at all levels to ensure the overall assembly precision of the steel caisson.

[0009] (4) The deformation of the steel caisson segment during hoisting, transportation and storage is calculated by using finite element calculation software, and the temporary lifting lugs and support positions are reasonably set. Temporary support is set as necessary according to the calculation results.

[0010] In order to achieve the above purpose, the technical scheme adopted by the present application is as follows:

[0011] The intelligent construction and construction method of the anchorage steel caisson comprises the following steps:

[0012] Step 1: Steel pretreatment, before cutting and cutting of steel plate, through pretreatment production line, shot blasting and rust removal, surface treatment reaches Sa3.0 level, then sprays inorganic zinc silicate workshop primer 25-30μm, through pretreatment to release the residual stress of steel plate in the rolling process and ensure that the flatness of the steel plate meets the requirements, at the same time, through the workshop primer spraying to ensure that the steel plate is not rusted during the factory construction;

[0013] Step 2: Cutting, all plate parts are cut by numerical control plasma or numerical control laser cutting machine, the length and width direction of the wall plate unit is reserved 0-8mm welding shrinkage according to the size of the plate, the number of stiffening, the form of the groove, the length direction of the wall plate is reserved 20mm secondary cutting amount, and the closure section is reserved 50mm secondary cutting amount;

[0014] Step 3: Unit production, including ordinary part machining, circular wall plate part machining, truss piece unit 1 production, truss piece unit 2 production, ordinary wall plate unit production, second section widened segment wall plate unit production, third section circular segment right angle unit production, cofferdam temporary internal support unit production;

[0015] Step 4: Steel caisson segment manufacturing, the steel caisson segment includes cross-shaped segment, L-shaped segment, straight-shaped segment and circular arc-shaped segment, sequentially segment assembly welding jig, segment continuous matching manufacturing, cross-shaped segment manufacturing, straight-shaped segment manufacturing, L-shaped segment manufacturing, circular arc-shaped segment manufacturing, second cross-shaped segment manufacturing, second circular segment manufacturing, third L-shaped segment manufacturing, third circular segment manufacturing,

[0016] Step 5: Steel caisson assembly construction, the steel caisson is assembled from the middle to the four sides, sequentially forming a stable structure, and finally closing at the four corners. After the assembly is completed, the next layer construction is carried out.

[0017] Step 6, welding and painting are carried out, and the construction is completed.

[0018] Further, the specific process in step 5 is as follows:

[0019] (1) Complete the measurement and layout according to the requirements, and use the total station to re-measure the positioning line of the steel caisson and the plane position and elevation of the underlying cushion;

[0020] (2) After the segment is transported to the hoisting area, the segment is turned over and erected, the main hook and the auxiliary hook of the 95t crawler crane are used to turn over, the four steel wires of the main hook are hung on the upper lifting lugs of the segment, the two steel wires of the auxiliary hook are hung on the turning lugs, the main hook is slowly lifted, the auxiliary hook is kept stationary, and the segment is erected;

[0021] (3) After the segment is turned over and erected, it is hoisted into position, the segment is roughly positioned through the ground sample line, the segment verticality is inspected using a magnetic attraction type plummet, and the spatial position of the positioning point on the segment is rechecked using a total station to meet the requirements, then inclined supports are added to fix and prevent the segment from overturning;

[0022] (4) The surrounding segments are hoisted to form a cross-shaped stable structure, after the adjacent segments are hoisted and precisely positioned, a full-range welding trolley is used to weld the vertical welds between the segments, the welds on both side walls are welded from bottom to top at the same time, after the welding is completed, the butt joints of the ring plates and other internal welds are welded using carbon dioxide gas shielded welding, after the vertical welds are welded, the butt joints of the bottom plates are welded using carbon dioxide gas shielded welding, after the segment is completely welded, the segment axis deviation is rechecked to see if it exceeds the allowable value, according to the rechecking result, the next segment is hoisted until the first layer of segments is completely hoisted.

[0023] (5) After the first layer segment is hoisted, welded and completed and verified, the edge angle concrete is poured, the second layer segment is hoisted, the wall plate vertical weld and the ring plate weld are welded according to the welding sequence in step four, the wall plate vertical weld is welded, the first segment and the second segment steel caisson ring plate horizontal weld are welded, the two side ring plate horizontal welds are simultaneously welded by two trackless full-position crawling welding robots according to the segment hoisting direction, the segment axis is rechecked after the segment-to-segment weld is welded, the rechecking result is modified, then the next segment is hoisted until the second layer segment is completely hoisted;

[0024] (6) Repeat step (5) until the third segment steel caisson segment assembly construction is completed.

[0025] (7) The first segment of the fourth layer is hoisted and precisely positioned, then the positioning welding is performed, the inclined support is added inside the segment to prevent the segment from overturning, the two trackless full-position crawling welding robots are simultaneously used to perform the girth weld according to the segment hoisting direction, the adjacent segment is hoisted and precisely positioned, then the positioning welding is performed, the inclined support is added for reinforcement, then the two full-position welding trolleys are used to perform the segment-to-segment vertical weld, the two side wall plate welds are simultaneously welded from bottom to top, the carbon dioxide gas shielded welding is used to weld the ring plate butt joint and other internal welds after the vertical weld is welded, the two trackless full-position crawling welding robots are simultaneously used to perform the girth weld according to the segment hoisting direction after the vertical weld is welded, then the subsequent segments are sequentially installed until the fourth segment steel caisson segment is completely hoisted.

[0026] (8) The inclined rods are removed, the temporary support positioning bracket is hoisted, welded and fixed, and the inner support middle unit is hoisted.

[0027] (9) The remaining steel pipes of the fourth segment inner support are hoisted and welded.

[0028] (10) The fifth segment of the steel caisson is sequentially hoisted, the segment positioning is completed, then the hooks are loosened but not removed, the segment-to-segment vertical plate is increased from 500mm per row to 300mm per row, the steel shell outside horizontal joint is intermittently welded to more than 50%, then the hooks are removed, the next segment is hoisted, until the fifth segment steel caisson is completely hoisted, the inner support steel pipe is installed after the fifth segment steel caisson is hoisted and welded.

[0029] (11) Repeat step (10) to complete the sixth to seventh segment steel caisson segment hoisting.

[0030] (12) The segmented hoisting truss type inner support is hoisted, the long side inner support of the steel caisson is hoisted first, then the short side truss type inner support is hoisted.

[0031] Further, the unit element manufacturing in step 3 is intelligently managed by adopting an ERP management system, the ERP management system is composed of a warehouse management system, a project management system, model visualization management, cloud material and cloud cutting system, covers the whole production process from raw material arrival to steel caisson manufacturing, makes different departments and posts work collaboratively on the same platform, reduces intermediate transmission links, shares department achievements in real time, and realizes real-time control of material inventory, production status, shipping progress and project dynamics.

[0032] Further, in step 5, virtual pre-assembly is carried out by three-dimensional laser scanning before assembly, the steel caisson segment is scanned in three dimensions, the construction error can be obtained by comparing the point cloud model generated by scanning with the theoretical model, and the error can be corrected, and the matching between adjacent segments can be known in advance by virtual pre-assembly of the point cloud models of adjacent segments, to guide the assembly of the steel caisson segment.

[0033] Further, in step 6, the welding is carried out by adopting a guide rail-free full-position crawling welding robot for automatic tracking welding, and in step 3, the steel plate is assembled and stiffened by using a code-free assembly device, adjusting the foot cup, top head and magnetic force controller, so as to complete the work of steel plate leveling butt joint and stiffening rib assembly.

[0034] Further, in step 5, the internal stiffening structure of the cross-shaped and T-shaped segments is relatively complex, and the problem of part collision is prone to occur, the tekla software is used for modeling to check the collision, to determine whether the parts have collision problems, and a three-dimensional diagram is used at the node position to mark the direction, position and part number, and the assembly sequence is clear.

[0035] Further, in step 6, the size reduction problem caused by the steel caisson wall plate butt joint seam being greater than the set value, the welding shrinkage amount is considered in advance, the corresponding welding shrinkage amount is added to the part blanking according to the plate thickness, the stiffening number and the groove form, and the secondary cutting amount is set to ensure the overall size after welding.

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

[0037] The present application aims at the problem that the internal stiffening structure of the cross-shaped and T-shaped segment of the project is relatively complex and is prone to part collision, proposes to adopt the tekla software modeling to carry out collision checking to determine whether the parts exist collision problems, and adopts three-dimensional diagram at the node position to indicate the direction, position and part number, and clear the assembly sequence, and carries out process animation to the construction personnel; aiming at the problem that the steel caisson wall plate of the project has many butt joints causing size reduction, the welding shrinkage should be considered in advance, the corresponding welding shrinkage is added when the parts are cut according to the thickness, stiffening quantity and groove form, and the secondary cutting amount is reasonably set to ensure that the overall size precision after welding meets the requirements, aiming at the problem that the segment of the project is relatively large, the overall size is relatively large, which may cause that the assembly precision does not meet the requirements, the hierarchical axis centering method is preferably adopted to control the overall construction precision of the steel caisson, that is, the overall assembly precision of the steel caisson is ensured by controlling the hierarchical axis of the caisson BRIEF DESCRIPTION OF DRAWINGS

[0038] Figure 1 is a method flowchart of the present application;

[0039] Figure 2 is a steel caisson assembly overall flowchart of the present application;

[0040] Figure 3 is an overall hoisting sequence schematic diagram of the present application;

[0041] Figure 4 is a welding deformation control measure flowchart of the present application;

[0042] Figure 5 is a three-dimensional laser scanning virtual pre-assembly flowchart of the present application;

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

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

[0045] In order to make the purpose, technical scheme and advantages of the present application more clear and explicit, the following preferred embodiments are given with reference to the drawings, and the present application is further described in detail. However, it should be noted that many details in the description are only for the reader to have a thorough understanding of one or more aspects of the present application, and the aspects of the present application can be realized even without these specific details.

[0046] As shown in Figure 1 , the anchorage steel caisson intelligent construction and construction method, the method comprises the following steps:

[0047] Step 1: Steel pretreatment, before cutting the steel plate, it is processed by the pretreatment production line, shot blasting and rust removal, the surface treatment reaches Sa3.0 level, then spray inorganic zinc silicate shop primer 25-30 μm, through the pretreatment to release the residual stress of the steel plate in the rolling process and ensure the flatness of the steel plate to meet the requirements, at the same time, through the shop primer spraying to ensure that the steel plate is not rusted during the factory construction.

[0048] The steel caisson component parts are divided into angle steel, plate, I-beam and H-beam steel parts, among which the angle steel parts and plates are the largest in quantity. The length of the angle steel parts must be ensured during cutting, and the end of the part must be cut and angled. Some angle steels also need to be cut round the flange. The plate parts mainly include ring plates, wall plates and node plates, with thickness of 8-36 mm. The end of the I-beam and H-beam parts needs to be cut into interfaces that can be nested with each other, which not only requires high cutting precision, but also needs to cut out the welding groove.

[0049] The plate parts are cut by a set of 30,000-watt digital intelligent numerical control laser cutting machine, which has the functions of part cutting, marking and code printing, and the maximum plate thickness for cutting is 45 mm. Laser cutting has small heat input and small deformation of the cut parts, high efficiency (theoretical output 4000 t / month), and high cutting precision (deviation only ±0.5 mm), which is the most advanced equipment for cutting steel structure parts. Information hardware modules are configured on the laser cutting equipment to receive task information and access and view cutting programs, layout files and other data to improve the cutting efficiency and precision of parts. Based on the internet of things, the numerical control equipment is connected to the network, and the instructions are transmitted from the network to avoid U disk copying.

[0050] The steel shell parts are classified according to material and thickness, and automatic nesting software (sinoCAM) is used for automatic nesting to improve material utilization and save raw materials. The intelligent equipment in the cutting workshop can be fully dispatched, and the remote control digital intelligent laser numerical control cutting machine can be used to collect real-time data such as power, gas quantity and machine tool running state. The cutting progress, sorting progress and other functions are real-time feedback.

[0051] The angle steel parts can be divided into three kinds of processing requirements. The first kind is wall plate angle steel, which only needs to be cut to length. The second kind is truss piece angle steel, which needs to be cut to length and angled. The third kind is 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 combined to form an angle steel processing line to improve the cutting efficiency and precision.

[0052] The angle steel cutting is processed by using the Cabah large sawing machine. The intelligent sawing machine is controlled by using the advanced numerical control system, and can realize the full-automatic circulation from the material taking from the storage rack, the feeding to the sawing completion, and the automatic completion of the processes such as the collection of the material head and tail and the finished workpiece. The cutting angle can be from-50° to 60°. According to the angle steel specifications of the project, through repeated experiments, it is obtained that the efficiency is the highest when the number of simultaneously cut angle steels is 35, and one cutting can be completed in 30 minutes, and the monthly production capacity can reach 1000 tons.

[0053] Some angle steels are transported here for angle cutting processing after being sawed according to the length on the sawing production line. The ordinary sawing machine cannot complete the angle cutting process, and the angle steel cutting production line is started in the project, and the angle steel is cut by using the hydraulic combined punching shear machine. The punching shear machine punches and shears the square steel, round steel, channel steel, I-beam and angle steel, and the maximum angle steel specification that can be punched and sheared by the punching shear machine is L160x14mm, which meets the use requirements of the project. The punching shear machine can not only ensure the cutting quality, but also can greatly improve the cutting efficiency. Compared with the traditional sawing or flame cutting, the angle steel punching can improve the construction efficiency by more than 4 times.

[0054] The angle steel round cutting is carried out by using the fiber laser cutting machine. The fiber laser is a hot spot in the laser field in recent years, and the fiber laser has the trend of rapidly replacing the traditional YAG and CO2 lasers in the processing field. The fiber laser has many unique advantages: good beam quality; small size, light weight and maintenance-free; air cooling is simple and easy to operate; low operating cost, can be used in industrial environment; long service life, high processing precision, high speed; high electric energy conversion efficiency, can realize intelligentization, automation, flexibility operation, etc.

[0055] The advantage of the laser cutting machine is small thermal deformation, high cutting precision, small noise, no pollution, easy to realize automatic cutting. Laser cutting as an advanced manufacturing technology has the advantages of wide application range, flexible process, high processing precision, good quality, clean production process, easy to realize automation, flexibility, intelligence and improve product quality, labor productivity, etc.

[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 laser steel cutting machine is programmed, and the motion trajectory is parameterized set according to the different cutting surfaces of different parts to ensure the cutting quality of the cutting surface. Under the premise of meeting the cutting efficiency and quality, the programming file is generated and imported into the control system; start the control program, the laser steel cutting machine will run according to the programmed motion trajectory; if other cutting surfaces need to be cut, all cutting surfaces are programmed and imported into the system, and which cutting control program is used in the system; and the same steel can be used to cut out multiple different cutting surfaces, which is very flexible and convenient. It can simultaneously realize cutting, hole cutting, bevel cutting, marking, line cutting, opening welding hole and other complex processes.

[0057] Installation of Kabah large sawing machine:

[0058] The installation steps of Kabah sawing machine mainly include preparation, assembly of parts, installation of saw blade, connection of power supply and machine test.

[0059] (1) Preparation

[0060] Place the sawing machine: Place the main body of the sawing machine in the desired position and make sure the ground is stable and firm. Check the hydraulic oil: make sure the hydraulic oil used in the sawing machine is appropriate and sufficient, and the sliding and rotating parts are well lubricated.

[0061] (2) Assembly of parts

[0062] Install the blade guide rail: according to the instruction manual of the sawing machine, assemble and install the blade, guide rail, protective cover and other parts. Install the saw belt: unfold the saw belt, pay attention to avoid tooth collision and damage the saw teeth. Then according to the specific steps, put the saw belt on the main and passive wheels, and adjust the tension to appropriate degree.

[0063] (3) Installation of saw blade

[0064] Confirm the direction: make sure the arrow mark on the saw blade points to the direction of the sawing machine. Adjust the tension: after installing the saw blade, adjust the tension of the saw blade to make it neither too loose nor too tight.

[0065] (4) Connection of power supply

[0066] Check the power supply: make sure the power cord of the sawing machine is connected correctly and plugged into the power socket. Turn on the power supply: turn on the power switch on the electrical control box and observe whether the motor is running normally.

[0067] (5) Machine test

[0068] Trial operation: After turning on the power, perform trial operation, usually three consecutive trials to check for any problems or abnormalities. Check the device: Check the lifting cylinder device, clamping device, etc., to ensure smooth and reliable operation. Adjust the speed: Adjust the speed knob and run at low and high speeds, respectively, and repeat the experiment three times.

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

[0070] (1) Preparation

[0071] Check the hydraulic oil: Ensure that the hydraulic oil tank has sufficient hydraulic oil, and apply a layer of oil to the sliding and rotating parts. Install the saw belt: Install the saw belt and adjust the tensioning device (turn the left handle of the saw frame) to tighten the saw belt to the appropriate level, and adjust the travel switch contacts to just touch the stopper, in the open state. Coolant tank: Add enough coolant, which should be mixed with liquid, and replace it every two months.

[0072] (2) Electrical connection and grounding

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

[0074] (3) Trial operation and adjustment

[0075] Initial trial operation: Start the saw and let the saw bow automatically lower, allowing the saw belt to drop 0.5-1mm below the workbench. The limit switch contacts will automatically rise when they hit the stopper, and the machine will automatically stop at the limit position. Repeat the experiment three times. Adjust the tensioning device: During operation, adjust the tensioning device to a relaxed state, allowing the travel switch contacts to move away from the stopper and turn off the power. Repeat the experiment three times.

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

[0077] (4) Specific parameter adjustment

[0078] According to actual processing needs, you may need to adjust the sawing speed, feed speed, etc. These parameters can usually be adjusted on the control panel or numerical control system of the equipment.

[0079] (1) Preparation

[0080] Check the power supply and equipment status: Ensure that the saw bed's power supply is turned on and check if the power cord is normal. At the same time, check if the cutting blade of the saw bed is installed firmly and if the blade is worn out. Wear personal protective equipment: The operator needs to wear safety glasses, earplugs, gloves and other personal protective equipment to ensure safety during operation. Clean the work area: Ensure that the work area around the saw bed is clean and tidy, and there is no 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 bed and make sure the power indicator light is on, indicating that the power is normal. Adjust the cutting speed and depth: According to the hardness and thickness of the material, set the cutting speed and cutting depth of the saw bed reasonably. Check the lubrication system: Check if the lubrication system of the saw bed 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 workbench of the saw bed and use the clamp to fix it.

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

[0086] (4) End cutting

[0087] Turn off the saw bed power: After cutting is completed, turn off the power of the saw bed and pull out the plug. Clean the cutting area: Clean the debris and scraps in the cutting area to keep the work area clean and tidy.

[0088] (5) Matters needing attention

[0089] Avoid placing fingers near the cutting area: During operation, avoid placing fingers or other body parts near the running cutter to avoid danger. Pay attention to abnormal situations: If you find abnormal sound, odor or other abnormal situations, stop using immediately and check. Regular maintenance: Regularly check and maintain the saw bed to ensure the good condition of the equipment. The maintenance of Cabah saw bed mainly includes daily cleaning, regular inspection and replacement, and lubrication system maintenance.

[0090] (1) Daily cleaning

[0091] Workbench and guide rail cleaning: The workbench should be cleaned regularly, especially after work, the workbench should be cleaned in time, to provide convenience for the next step. Clean the guide rail and the material debris beside the guide rail to prevent the machine from being stuck due to debris interference during operation. Industrial control box cleaning: Clean the industrial control box regularly, because dust is the killer of circuit board, only regular maintenance can ensure that the sawing machine will not be damaged.

[0092] (2) Regular inspection and replacement

[0093] Part inspection and replacement: The parts of the sawing machine such as saw blade, hydraulic oil, filter press and tool need regular inspection and replacement. The saw blade should be checked for its warping, wear and passivation, and the expired or damaged saw blade should be replaced in time. Equipment state inspection: During use, the running condition of each running part of the sawing machine should be observed at any time, and the abnormal sound or vibration should be checked and eliminated in time if any.

[0094] (3) Lubrication system maintenance

[0095] Lubrication point lubrication: The guide rail surface and lubrication point should be lubricated enough to ensure smooth operation of each part. For numerical control woodworking sawing machine, dust condition should be considered when lubricating, lubrication amount should be appropriately reduced, and cleanliness and lubrication of key parts such as guide rail should be ensured.

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

[0097] Steel caissons: The east anchor caisson is 25m high and divided into 5 sections from bottom to top, each 5m high. Sections 1-3 of the east anchor steel caisson consist of caisson walls and partition walls. Each steel caisson has 24 openings enclosed by the caisson walls and partition walls on its plane. Except for sections 2, the caisson walls are 2.0m thick, the partition walls are 1.3m thick, and 1.5m x 1.5m chamfers are provided at the connections between the partition walls and the caisson walls, and between the partition walls themselves. Section 2 of the steel caisson has shear keys within its height range to meet the shear resistance requirements of the bottom concrete. The caisson walls are 2.0-2.6m thick, and the partition walls are 1.3-2.5m thick. Sections 4-5 of the east anchor steel caisson only have caisson walls, without partition walls. The caisson walls are 1.35m thick, and openings are provided at the connection with the tie beams. Perforated plates and shear studs are installed on the inner side of the caisson walls to connect with the concrete top slab of the caisson. The outer wall panel thickness of the first section of the steel caisson is 36mm, while the outer wall panel thickness of the remaining sections is 20mm. The inner wall panel, partition wall panel, and compartment panel are all 16mm thick. Vertical stiffening ribs are installed on the caisson wall and partition wall panels, with the rib members measuring ∠110×70×10mm and spaced approximately 400mm apart. Along the height direction, the first and second sections of the steel caisson have a horizontal ring plate installed on the wall panel every 1.0m, and the remaining sections every 1.25m. The spacing of the horizontal ring plates at the connection with the tie beams is adjusted appropriately. The horizontal ring plate dimensions between sections are 344×22mm, and the dimensions of the remaining horizontal ring plates are 300×22mm. Horizontal trusses are installed between each layer of horizontal ring plates, with the horizontal truss members measuring ∠140×140×12mm. Vertical trusses are installed at the chamfered corners of the caisson openings, with the vertical truss members measuring ∠140×140×12mm.

[0098] Tie Beam Steel Shell: The tie beam adopts a steel-concrete shell structure with a U-shaped cross-section, consisting of a bottom plate and two side webs. The steel shell is welded to the steel caisson. Perforated plates and shear studs are installed on the top surface of the bottom plate and the inner side of the webs 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 webs of the tie beam steel shell are 1.35m thick and 10m high. For ease of factory manufacturing, it is vertically divided into two sections, each 5m high. The dimensions and thickness of the web plates of the tie beam steel shell, as well as the arrangement of the stiffening ribs, are the same as those of the top section of the steel caisson. The upper and lower panels of the bottom plate of the tie beam steel shell are both 22mm thick. Transverse stiffening ribs are installed on the inner side of the panels. The dimensions of the transverse stiffening ribs are ∠110×70×10mm, with a spacing of approximately 400mm. Seventeen vertical partitions are arranged horizontally between the panels, with a spacing of 1.35–1.55 m. The outer partitions are solid web plates with a thickness of 20 mm. The middle partitions are truss-type, with a 300×22 mm vertical ring rib on the panel. Vertical trusses are set between the vertical ring ribs, and the dimensions of the vertical truss members are ∠140×140×12 mm.

[0099] Connecting to a high cofferdam: such as Figure 7The height of the connecting cofferdam is 10.2 m. The connecting cofferdam is a double-wall steel cofferdam with a thickness of 1.35 m, which is extended by a caisson and a top segment of a tie beam. The size and thickness of the cofferdam plate and the arrangement of the stiffening ribs are the same as those of the steel caisson and the top segment of the tie beam. The cofferdam is vertically divided into two segments, with the first segment having a height of 5 m and the second segment having a height of 5.2 m. The cofferdam is connected to the steel caisson and the steel shell of the tie beam by welding.

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

[0101] Step 2: Cutting, all plate parts are cut by numerical control plasma or numerical control laser cutting machine. The length and width directions of the wall plate unit are reserved with 0-8 mm welding shrinkage according to the size of the plate, the number of stiffeners, and the type of bevel. The length direction of the wall plate is reserved with 20 mm secondary cutting amount, and the closure section is reserved with 50 mm secondary cutting amount.

[0102] Step 3: Unit production, including ordinary part processing, circular wall plate part processing, truss piece unit 1 production, truss piece unit 2 production, ordinary wall plate unit production, second segment widened segment wall plate unit production, third segment circular segment right-angle unit production, and temporary internal support unit production of the cofferdam.

[0103] The steel caisson processing attempts to use an ERP management system for intelligent management. This system mainly consists of warehouse management system, project management system, model visualization management, cloud nesting, and cloud cutting system, etc. It can cover the entire production process from raw material arrival to steel caisson production. It allows different departments and positions to work collaboratively on the same platform, reduces intermediate transmission links, shares departmental results in real time, and keeps track of material inventory, production status, shipping progress, and project dynamics in real time.

[0104] The WMS warehouse management system has the characteristics of fast warehouse entry and exit, double-warehouse management, barcode application, inventory sharing, and fast cost statistics. This system has complete subject configuration, and can quickly handle material entry and exit without too much operation. The project warehouse and the public warehouse are strictly separated, ensuring that project materials are exclusive and dedicated, and that other projects can normally exit without interference, independent accounting, and clear accounts. At the same time, the system uses material barcodes, making it easy to count and track materials, and achieving true material intensive management.

[0105] PMIS project management system, without filling out the cumbersome process flow, EPR intelligent management system automatically according to the component category, automatic judgment of the processing procedure, after the completion of the previous process, automatically flow to the next process; with a material code error correction rules, to ensure that each product process not only to achieve high efficiency flow, and will not appear any wrong and missing pieces.

[0106] CAM+CNC cloud cutting system, the traditional transmission CNC cutting data, need to use U disk to copy the cutting instructions to the numerical control cutting machine, now through the cloud cutting system, cutting machine slightly modified, can complete the remote transmission of CNC code. At the same time, workers according to the cutting instruction operation, not only can improve the efficiency, but also can reduce the error rate.

[0107] Visual model, through the "one model to the end" reading, classification and sharing application, to realize the deepening of the high integration of drawing and model, let the project departments read the drawing and check the list of work "simplify" click component number, three-dimensional graphics and two-dimensional drawing is presented, on the one hand to show the relative relationship of three-dimensional model geometry components in space, on the other hand to show the two-dimensional graphic expression of detail structure and dimension. "The number, figure, model complementary each other, let non professional personnel also can easily check and contrast. Realize the integration of design, production and installation.

[0108] This project through Tekla Structures BIM modeling, according to 1:1 scale to establish BIM entity model, based on BIM model to carry out digital process lofting, layout and welding design; At the same time, provide component list, part number, material procurement list and other types of data, support project digital process design, scientific production scheduling, production progress and information management.

[0109] Based on the deepening of BIM model data, from the model to export parts of the file, using Tekla Structures BIM modeling software lofting and welding process design.

[0110] SmartNest automatic nesting software can be grouped according to the project, model, material, thickness, processing mode technology, suitable for whole batch of material or one side out of the picture, one side of the material, one side of the construction of the situation, shorten the time of manual check material and make plan.

[0111] The steel plate layout and nesting are performed by the SmartNest automatic nesting software, the optimal size is automatically calculated in a specified range, the material utilization rate is the highest, and the most economical procurement batch is suitable for rapid material submission. Meanwhile, according to different processing equipment process parameters and cost allocation modes, the nesting cost is generated at the same time when the nesting is completed, and is used for project budget or outsourcing cost estimation. The software integrates drawing conversion, material budget, plan management, automatic nesting, process optimization, cost prediction, excess material management, production control and other processes.

[0112] Backpack portable laser rust removal equipment

[0113] The relatively fluffy rust layer on the surface of the object is cracked in a physical blasting manner, and the cleaning debris is discharged by forming a plume through high-speed spot movement to complete cleaning. At the same time, the high-energy pulsed laser is focused on the surface of the cleaning object, and the irregular structures and dark surfaces such as dirt and rust absorb the laser energy and the plasma energy formed by the metal surface, which is instantaneously vaporized and separated from the base material.

[0114] The backpack portable laser cleaning machine integrates light volume, simple operation, high-efficiency cleaning, non-contact, and pollution-free, and is used for rust cleaning of cast iron and carbon steel plates, oil stain cleaning of stainless steel, mold gears, oxide cleaning of aluminum plates and stainless steel baking paint, and the cleaning effect is clean and does not damage the base material.

[0115] The device is mainly applied to the dock assembly site. When the site is assembled, the steel caisson is in a vertical assembly state, and the interface weld position is not convenient for large-area sand blasting and does not meet the environmental protection requirements. The portable laser rust removal instrument is used for rust removal at the weld position, which can improve the construction efficiency on the one hand, and meet the on-site construction environmental protection requirements on the other hand, and can realize the application of new technology in steel structure products and promote the application of new technology and new process.

[0116] Fixed welding robot

[0117] Firstly, the motion trajectory of the welding robot is calculated according to a single weld in the steel caisson, the motion trajectory is parameterized set according to the connection mode between different components to ensure the welding quality, the parameterized trajectories are sequentially combined, the welding deformation is minimized under the premise of meeting the welding quality of a single weld, and finally the control program is written.

[0118] The control program is input to the controller of the robot, the control program is started, and the robot completes the task step by step according to the action specified in the program. If the task is changed, the control program needs to be modified or rewritten.

[0119] The welding robot is mainly applied to the welding of the ring plate unit in the project. The angle steels of the ring plate unit have different angles, and it is inconvenient to use a semi-automatic welding device, and the length of the weld is relatively short. The ring plate units have basically the same structure, and the application of the welding robot can maximize the construction efficiency.

[0120] Optical fiber laser type steel cutting machine

[0121] Optical fiber laser is a hot spot in the field of laser in recent years. In the processing field, optical fiber laser has a trend of rapidly replacing traditional YAG and CO2 lasers. Optical fiber laser has many unique advantages: good beam quality; small size, light weight, maintenance free; air cooling is simple and easy to operate; low operating cost, can be used in industrial environment; long service life, high processing precision, high speed; high power conversion efficiency, can realize intelligentization, automation, flexibility operation, etc.

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

[0123] The angle steel of the ring plate unit and the wall plate unit connected with the partition plate in the project needs to be cut and arc operated. The conventional type steel equipment can only process angle steel with single root and single angle, the working efficiency is low, and the cutting precision needs to be improved. The application of laser type steel cutting machine can ensure the cutting quality of angle steel and improve the construction efficiency.

[0124] Magnetic non-code assembly equipment

[0125] When assembling the steel plate or plate unit, the non-code assembly equipment is used to adjust the foot cup, top head and magnetic force controller, so that the steel plate leveling butt joint, stiffening rib assembly and other work can be completed. The non-code assembly equipment replaces the traditional welding code plate assembly, and there is no damage to the base metal caused by hammer marks, iron spikes and code points. It can be operated by a single person, has light self weight, high safety factor, simple and fast operation, simple maintenance, cost saving and green environmental protection.

[0126] The equipment is used for the assembly process of the wall plate unit in the project, which can improve the construction efficiency and meet the requirements of angle steel assembly precision.

[0127] Non-rail full-position climbing welding robot

[0128] The whole set of equipment adopts wheel-track type crawling structure, and the visual tracking system provided can enable the robot to freely crawl on vertical or curved surfaces without track, and realize autonomous tracking of the weld; meanwhile, the high dynamic industrial camera adopted can realize real-time monitoring of the operator on the molten pool, and the remote monitoring distance can reach 15 meters. In addition, the equipment adopts detachable ceramic lining pasted on the back, can realize single-sided welding and double-sided forming of the weld, ensures stable welding quality and beautiful forming, and is especially suitable for assembly and installation of steel structures such as steel lining which has complex structure and large welding amount.

[0129] During the on-site assembly of the steel caisson, the butt weld of the outer wall plate exists in the vertical welding position and the horizontal welding position at the same time. The magnetic attraction type welding robot is not affected by the welding position, and can simultaneously meet the welding requirements of the vertical welding position and the horizontal welding position, and is convenient to operate. One person can operate multiple groups of machines at the same time, which improves the 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] Three-dimensional laser scanning virtual pre-assembly

[0131] The third east channel east anchor caisson steel caisson in Xiamen has the characteristics of large volume, many segments, many processes, etc., and has high construction control precision requirements, large construction control difficulty, and large pre-assembly difficulty. In view of this, the project introduces three-dimensional laser scanner automatic measurement technology to perform three-dimensional scanning on part of the steel caisson segments. The construction error can be obtained by comparing the point cloud model generated by scanning with the theoretical model, and the error can be corrected. The matching between adjacent segments can be known in advance by performing virtual pre-assembly on the point cloud models of adjacent segments, thereby guiding the assembly of the steel caisson segments.

[0132] Limited by the shortcomings of large data collection and processing workload of three-dimensional scanning technology, the project mainly scans the circular arc segments which are difficult to manufacture, generates scanning data and performs virtual pre-assembly. The assembly quality of virtual pre-assembly is verified on one hand, and the assembly quality of physical assembly is verified on the other hand, as shown in Figure 5 .

[0133] General part processing: 1. Cutting, plate parts are cut by numerical control plasma cutting or numerical control laser cutting machine; angle steel parts are cut by sawing machine, fiber laser cutting machine or multi-functional punching and shearing machine to cut the limbs and angles at one end or both ends of the angle steel; 2. Correction: correct the deformation of the parts; 3. Wall plate part splicing: the wall plate part width is wide, and splicing is needed. The horizontal and vertical baselines need to be aligned during splicing to prevent misalignment; 4. Welding: use submerged arc automatic welding to weld the spliced parts; 5. Correction: correct the welding deformation; 6. Non-destructive testing: perform ultrasonic flaw detection on the weld after 24 hours of welding; 7. Marking: mark the splicing direction, number and reference information, etc.

[0134] Circular-arc wall plate part processing: 1. blanking, the circular-arc wall plate part is blanked by numerical control plasma cutting; 2. correction, correcting the deformation of the part; 3. circular-arc processing, the circular-arc wall plate is processed by a hydraulic plate rolling machine, and the processing precision is controlled by measurement and a special arc-shaped reference; 4. marking, marking the direction, number and reference information, etc.

[0135] Truss piece unit 1 manufacturing: 1. positioning the upper tire, the two side ring plates are positioned on a special non-drawing tire frame, and positioning welding is performed; 2. assembly, assembling the angle steel according to the limiting block; 3. welding, welding the angle steel stiffener and the inter-ring plate weld (using an intelligent welding robot for welding); 4. marking, marking the unit number, direction and reference information.

[0136] Truss piece unit 2 manufacturing: 1. positioning the upper tire, the truss ring plate and the node plate are positioned on a special non-coding assembly tire frame, and are fixed with the limiting plate and the tire frame; 2. assembly, assembling the horizontal stiffener and the stiffener first, and then assembling the vertical stiffener and the stiffener according to the position of the limiting block, and performing positioning welding; 3. turning over, assembling the other side horizontal and vertical stiffeners and stiffeners after turning over, and performing positioning welding; 4. welding, welding the angle steel stiffener and the inter-ring plate, node plate weld (using an intelligent welding robot for welding); 5. correction, correcting the welding deformation; 6. marking, marking the unit number, direction and reference information.

[0137] Ordinary wall plate unit manufacturing: 1. polishing and marking, polishing the welding area by using an automatic sanding machine, and marking the position line of the stiffening angle steel and the position line of the truss; 2. assembling the stiffening angle steel, assembling the stiffening angle steel according to the line; 3. welding, welding the inter-wall plate weld of the stiffening angle steel on the special reverse deformation tire frame; 4. correction, correcting the welding deformation by using a flame; 5. marking, marking the unit number, direction and reference information, etc.

[0138] Second section of the widened section wallboard unit production: 1, grinding line, using automatic belt sander grinding welding area, draw stiffener position line, gusset position line; 2, stiffener assembly, according to line assembly stiffener; 3, welding, welding stiffener and wallboard between the weld; 4, correction, correction of welding deformation. 5, ring plate assembly, according to line assembly ring plate; 6, welding, using carbon dioxide gas shielded welding ring plate and wallboard, ring plate and angle steel between the weld; 7, correction, correction of welding deformation; 8, assembly, according to line assembly partition plate parts, the inclined wallboard parts close to the jig positioning stop plate, accurate adjustment of the inclined wallboard position and angle, the positioning of the welding; according to line assembly the rest of the angle steel stiffening; 9, welding, using carbon dioxide gas shielded welding inclined wallboard and partition plate and wallboard between the weld, welding angle steel and angle steel stiffening rib weld; 10, correction, correction of welding deformation; 11, assembly, according to line assembly triangular stiffening and corresponding angle steel, the positioning of the welding. 12, welding, using carbon dioxide gas shielded welding triangular plate and angle steel weld; 13, correction, correction of welding deformation; 14, identification: identification unit number, direction and reference information, etc.

[0139] Third section of the circular segment right angle unit production: 1, grinding line, using automatic belt sander grinding welding area, draw stiffener position line, gusset position line; 2, stiffener assembly, according to line assembly stiffener; 3, welding, welding stiffener and ring plate between the weld; 4, correction, correction of welding deformation; 5, assembly, according to line both sides wallboard unit; 6, welding, using carbon dioxide gas shielded welding ring plate and wallboard, ring plate and angle steel between the weld; 7, correction, correction of welding deformation; 8, assembly, according to line assembly upper ring plate unit, the positioning of the welding. 9, welding, using carbon dioxide gas shielded welding ring plate and wallboard between the weld; 10, correction, correction of welding deformation; 11, identification: identification unit number, direction and reference information, etc.

[0140] Cofferdam temporary internal support unit production: 1. Support layout temporary support measurement lofting, layout temporary support; 2. Assembly: steel pipe on the jig positioning, then sequentially complete the subsequent vertical support on the jig positioning. Steel pipe on the jig positioning, then sequentially complete the subsequent vertical support on the jig positioning. 3. Assembly: to prevent welding shrinkage deformation, pre arrangement of anti deformation support and vertical temporary support; welding vertical support and steel pipe between the overhead weld, trimming welding deformation; 4. Identification, remove the temporary anti deformation pipe, correction, identification direction; the other side of the intersection line gusset unit on the jig positioning, spot welding fixed, to prevent welding shrinkage deformation, pre arrangement of anti deformation support; welding vertical support and steel pipe between the overhead weld, trimming welding deformation; 5. Identification remove the temporary anti deformation pipe, correction, identification direction.

[0141] Unit production requirements: (1) blanking, a. The blanking accuracy shall be strictly in accordance with the contents specified in the process drawing. b. To ensure the quality of the parts processing, the first time blanking shall be carried out cutting test to ensure the cutting accuracy and quality. c. The cutting edge shall be cleaned and polished after the cutting of the parts, and the defects such as collapse caused by cutting shall be repaired and polished. d. The parts shall preferentially use numerical control plasma or laser cutting. e. When blanking, the cutting amount (length, height) of each section shall be reserved, and the cutting shall be carried out according to the measurement and three-dimensional laser scanning data before the blanking. f. The end of the blanking shall be marked with the number, specification, material, etc., and the specification, furnace batch number, material, steel plate number, etc. shall be marked on the excess material, and the number shall be marked in the thickness direction of the end plate. g. The angle steel shall be sawn by sawing machine, and the length tolerance is ±3mm. (2) Correction, a. The burrs and slag on the edge of the blanking shall be removed before the correction of the parts, and the surface of the corrected parts shall not have obvious indentation and other damage. b. The temperature of the hot correction shall be controlled at 700-800℃, and the parts after correction shall be slowly cooled with air, and shall not be hammered or rapidly cooled with water before the temperature is reduced to room temperature. (3) Unit assembly: a. The assembly shall be carried out on the platform, and the stiffening angle steel shall be assembled according to the line, and the deviation shall be controlled within the allowable range specified in the specification; when assembling the rib plate, the rib plate shall be tightly contacted with the main plate before positioning welding, the interval of the positioning welding is 400-600mm, and the length is 50-100mm. The perpendicularity deviation of the rib plate shall be not more than 1mm.

[0142] (4) Unit welding, a. Welding method: the butt joint of the steel plate adopts single-sided welding and double-sided forming process: V-shaped groove is opened, the reverse side is pasted with ceramic liner, CO2 gas shielded welding is used for bottoming and filling, and automatic submerged arc welding is used for covering; the welding of other structures is determined according to the design drawing and welding process guide book. The welding of the wall plate unit shall be carried out on the special reverse deformation turnover jig using semi-automatic welding trolley. The welding of the truss piece unit shall be carried out on the platform using welding robot. b. Process guarantee measures: ①Strictly follow the welding process, and do not change the process arbitrarily. ②Avoid manual welding for the positions that can be welded by machine.

[0143] Step 4: Steel caisson section production, the steel caisson section includes cross-shaped section, L-shaped section, one-character-shaped section and circular arc-shaped section,

[0144] Segment group welding jig: steel caisson segment group welding jig, the material of the jig is Q235B, the upright column, crossbeam and longitudinal beam of the jig are all ∠110x70x10 angle steel. In order to ensure the manufacturing precision of the steel caisson, the quality requirement of the jig must have enough rigidity to ensure that the segment welding does not deform. The plane deviation of the jig is not more than 2mm. The jig is provided with wallboard positioning device and measurement observation point to ensure the accuracy of the geometric size. Each unit is assembled and welded into a steel caisson segment on the segment manufacturing jig, and the segment is marked and numbered, and then transported to the storage area for storage.

[0145] Segment continuous matching manufacturing: in order to ensure the segment size precision and assembly precision, continuous matching manufacturing is adopted as far as possible. The outer wall segment and the middle segment can be continuously matched and manufactured, and the segments that cannot be continuously matched and manufactured are verified by virtual pre-assembly process.

[0146] Cross-shaped segment manufacturing: 1, wallboard unit upper jig positioning; 2, assemble the first piece of truss unit according to the line, accurately adjust the verticality, add inclined support and then apply positioning welding; 3, assemble the subsequent truss units according to the line and assemble the scattered parts between the truss units in turn; 4, weld the weld between the truss and the wallboard, and the weld between the truss and the scattered parts; 5, correct, correct the welding deformation; 6, assemble the two side wallboard units according to the line, accurately adjust the position of the two side wallboards, add temporary support and apply positioning welding; 7, weld, weld the weld between the two side wallboards and the truss ring plate; 8, correct, correct the welding deformation; 9, assemble the upper side wallboard unit according to the line, accurately adjust the position of the wallboard and apply positioning welding; 10, weld, weld the weld between the wallboard and the truss ring plate; 11, correct, correct the welding deformation; 12, cross joint upper jig, after the completion of the cross joint manufacturing of the cross-shaped segment, the whole is placed on the special total assembly jig, accurately positioned and fixed; 13, assemble, assemble the two side wallboards of the joint and apply positioning welding; 14, weld, weld the butt weld between the wallboards; 15, correct, correct the welding deformation; 16, assemble, assemble the two side truss units, the bottom plate unit and the joint wallboard unit according to the line, accurately adjust and add temporary support and then apply positioning welding; 17, weld, weld the weld between the ring plate wallboards; 18, correct the welding deformation; 19, assemble, assemble the upper side wallboard unit according to the line and apply positioning welding after accurate adjustment; 20, weld, weld the weld between the ring plate wallboards; 21, correct, correct the welding deformation; 22, nondestructive testing, perform welding nondestructive testing 24 hours after welding; 23, mark, mark the segment number, direction and reference information; 24, segment lower jig, the segment is lowered into the next process.

[0147] Manufacturing of the L-shaped segment: 1. Wallboard upper tire, wallboard unit upper tire positioning; 2. Assembly, assemble the stringer unit, accurately position after adding temporary support and applying positioning welding; 3. Assembly, assemble the stringer unit according to the line, accurately position after adding temporary support and applying positioning welding; 4. Assembly, assemble the other side stringer according to the line, accurately position after applying positioning welding; 5. Assembly, assemble the bottom plate unit according to the line, accurately position after adding temporary support and applying positioning welding; 6. Assembly, assemble the T-shaped joint position stringer unit according to the line, accurately position after adding temporary support and applying positioning welding; 7. Assembly, assemble the T-shaped joint between the loose pieces, accurately position after applying positioning welding; 8. Assembly, assemble the upper side wallboard unit according to the line, accurately position after applying positioning welding; 9. Assembly, assemble the interlayer stringer unit according to the line, accurately position after applying positioning welding; 10. Welding, weld the wallboard unit and ring plate unit, the bottom plate unit and the wallboard, the T-shaped joint position stringer unit vertical connection loose piece by using CO2 gas shielded welding; 11. Correction, correct the welding deformation; 12. Assembly, assemble the bottom plate blade foot stiffener, accurately position after completing welding; 13. Correction, correct the welding deformation; 14. Non-destructive testing, perform welding non-destructive testing after 24 hours of welding completion; 15. Identification, identify the segment number, direction and reference information, etc.; 16. Segment down tire, segment down tire into the next process.

[0148] Manufacturing of the L-shaped segment: 1. Wallboard upper tire, wallboard unit upper tire positioning; 2. Assembly, assemble the stringer unit, accurately position after adding temporary support and applying positioning welding; 3. Assembly, assemble the stringer unit according to the line, accurately position after adding temporary support and applying positioning welding; 4. Assembly, assemble the other side stringer according to the line, accurately position after applying positioning welding; 5. Assembly, assemble the bottom plate unit according to the line, accurately position after adding temporary support and applying positioning welding; 6. Assembly, assemble the T-shaped joint position stringer unit according to the line, accurately position after adding temporary support and applying positioning welding; 7. Assembly, assemble the T-shaped joint between the loose pieces, accurately position after applying positioning welding; 8. Assembly, assemble the upper side wallboard unit according to the line, accurately position after applying positioning welding; 9. Assembly, assemble the interlayer stringer unit according to the line, accurately position after applying positioning welding; 10. Welding, weld the wallboard unit and ring plate unit, the bottom plate unit and the wallboard, the T-shaped joint position stringer unit vertical connection loose piece by using CO2 gas shielded welding; 11. Correction, correct the welding deformation; 12. Assembly, assemble the bottom plate blade foot stiffener, accurately position after completing welding; 13. Correction, correct the welding deformation; 14. Non-destructive testing, perform welding non-destructive testing after 24 hours of welding completion; 15. Identification, identify the segment number, direction and reference information, etc.; 16. Segment down tire, segment down tire into the next process.

[0149] Arc segment manufacturing: 1. Wall plate on the tire, two arc segment wall plates are respectively positioned on the tire and fixed with the tire frame; 2. Welding, welding the weld between the two arc segment wall plates; 3. Correction, correcting the welding deformation, and using a ring plate as a template to check whether the wall plate curvature meets the requirements; 4. Assembly, simultaneously assembling the ring plate and the wall plate angle steel, and performing positioning welding after assembly; 5. Welding, welding the weld between the wall plate and the angle steel and the ring plate; 6. Correction, correcting the welding deformation; 7. Assembly, positioning the ring plate single-side angle steel according to the line, and assembling a temporary support (red part) on the other side, and performing spot welding; 8. Assembly, assembling the inner arc side wall plate unit (the inner arc side ring plate is pre-welded with the wall plate), and performing positioning welding after accurate positioning; 9. Replace the temporary support, remove the internal temporary support pipe, and replace it with an angle steel at the position, and perform positioning welding; 10. Assembly, assembling the end arc truss piece, and performing positioning welding after accurate positioning; 11. Assembly, assembling the bottom plate unit, and performing positioning welding after accurate positioning; 12. Welding, welding the weld between the angle steel and the ring plate, and the fillet weld between the wall plate and the bottom plate unit by using CO2 gas shielded welding; 13. Correction, correcting the welding deformation; 14. Assembly, assembling the bottom plate blade foot stiffener, and completing the welding after accurate positioning; 15. Correction, correcting the welding deformation; 16. Marking, marking the segment number, direction and reference information, etc.; 17. Segment tire removal, segment tire removal into the next process.

[0150] Second section cross section segment manufacturing: 1, wallboard unit on the positioning of the tire; 2, assembling truss piece unit, according to the line assembly first piece truss piece unit, accurate adjustment of verticality, after adding inclined support to apply positioning welding; 3, assembling truss piece unit between bulk piece according to the line assembly subsequent truss piece unit and in turn assemble bulk piece between truss piece unit; 4, welding, welding truss piece unit and wallboard, truss piece unit and bulk piece between the weld; 5, correction, correction of welding deformation; 6, assembling two side wallboard unit, according to the line assembly two side wallboard unit, accurate adjustment of the position of two side wallboard, add temporary support member fixed and apply positioning welding; 7, welding welding between two side wallboard and truss ring plate; 8, correction, correction of welding deformation; 9, assembling upper side wallboard unit, according to the line assembly upper side wallboard unit, accurate adjustment of wallboard position, apply positioning welding; 10, welding, welding between wallboard and truss ring plate; 11, correction, correction of welding deformation; 12, cross joint on the tire, after the completion of cross joint section joint, the whole is placed on the special total assembly jig, accurate positioning and fixed; 13, assembling assembling joint two side wallboard, apply positioning welding; 14, welding, welding between wallboard butt weld; 15, correction, correction of welding deformation; 16, assembling, in turn according to the line assembly two side truss piece unit, accurate adjustment and add temporary support after applying positioning welding; 17, welding, welding between ring plate wallboard; 18, correction, correction of welding deformation; 19, assembling, according to the line assembly upper side wallboard unit, accurate adjustment after applying positioning welding; 20, welding, welding between ring plate wallboard; 21, correction, correction of welding deformation; 22, nondestructive testing, after 24h welding nondestructive testing; 23, mark, mark section number, direction and reference information; 24, section down the tire, section down the tire into the next process.

[0151] Second section circular segment manufacturing: 1, wallboard on the tire outer arc wallboard on the tire positioning, and fixed with jig; 2, assembling, now according to the line placing angle steel in corresponding position of wallboard, both ends are fixed with temporary ring plate (the position ring plate part makes a piece as template), according to the line assembly truss piece unit, bottom plate unit, accurate positioning angle steel and truss piece unit after adding temporary support and applying positioning welding; 3, welding, using CO2 gas shielded welding welding between truss piece unit ring plate, angle steel and wallboard; 4, correction, correction of welding deformation; 5, assembling, according to the line assembly inner arc side wallboard (angle steel stiffening rib is placed in ring plate stiffening groove in advance), accurate positioning, apply positioning welding; 6, welding, using CO2 gas shielded welding welding between inner arc wallboard unit and angle steel stiffening rib; 7, correction, correction of welding deformation; 8, assembling, according to the line assembly top truss piece unit, accurate positioning after applying positioning welding; 9, welding, using CO2 gas shielded welding welding between top truss piece unit ring plate and wallboard; 10, correction, correction of welding deformation; 11, mark, mark section number, direction and reference information; 12, section down the tire, section down the tire into the next process.

[0152] Third section L-shaped segment manufacturing: 1, wall plate on the tire, wall plate unit on the tire positioning; 2, assembly according to line assembly truss piece unit and partition board unit, accurate positioning after adding temporary support and apply positioning welding; 3, welding, CO2 gas shielded welding is used to weld the weld between the ring plate and the wall plate; 4, correction, correct the welding deformation; 5, assembly, according to line assembly inside wall plate unit, accurate positioning after applying positioning welding; 6, welding, CO2 gas shielded welding is used to weld the weld between the ring plate and the wall plate; 7, correction, correct the welding deformation; 8, nondestructive testing, welding nondestructive testing is carried out after 24 hours of welding; 9, mark, mark the segment number, direction and reference information; 10, segment down tire, segment down tire into the coating process; 11, mark, transplant segment information.

[0153] Third section circular segment manufacturing: 1, wall plate on the tire, arc inside wall plate unit on the tire positioning, and fixed with the tire frame; 2, assembly, accurate positioning according to line assembly wall plate internal angle steel; 3, assembly, outer arc wall plate unit on the tire accurate positioning, spot welding fixed; 4, welding, CO2 gas shielded welding is used to weld the weld between the angle steel and the ring plate; 6, correction, correct the welding deformation; 7, assembly, according to line assembly right angle unit, (firstly, the right angle position component is assembled into a whole, and then participates in the total segment assembly), accurate positioning after applying positioning welding; 9, welding, CO2 gas shielded welding is used to weld the weld between the right angle unit and the wall plate, and the weld between the outer wall reinforcing assembly and the wall plate and truss piece unit; 10, correction, correct the welding deformation; 11, assembly, according to line assembly reverse bracket, accurate positioning after applying positioning welding; 12, welding, CO2 gas shielded welding is used to weld the weld between the bracket and the arc angle, and the internal weld of the bracket; 13, correction, correct the welding deformation; 14, nondestructive testing, welding nondestructive testing is carried out after 24 hours of welding; 15, mark, mark the segment number, direction and reference information; 16, segment down tire, segment down tire into the coating process; 17, mark, transplant segment information.

[0154] Gantry crane foundation: the gantry crane foundation is preferably made of concrete foundation, on which a track is laid, the foundation is 260m long, 0.6m wide and 0.3m high, the foundation is made of C35 concrete, longitudinal steel bars and stirrups are arranged inside the foundation, the steel bars are all φ12mm threaded steel, φ20mm elbow anchors are pre-buried inside the foundation for fixing the track and the foundation, which meets the requirements of the gantry crane.

[0155] Step 5: steel caisson assembly construction, the steel caisson is assembled from the middle to the periphery, and a stable structure is formed in sequence, and finally the four corners are closed, after the assembly is completed, the next layer construction is carried out. Figures 2-3 As shown in the figure, the specific process is as follows:

[0156] (1) Complete the surveying and setting out, and the pier layout as required. Use a total station to re-measure the positioning line of the steel caisson and the plane position and elevation of the wooden blocks below.

[0157] (2) After the segment is transferred to the hoisting area, the segment is flipped and erected. The main hook and auxiliary hook of a 95t crawler crane are used for flipping. The four wire ropes of the main hook are hung on the hoisting lugs on the upper side of the segment, and the two wire ropes of the auxiliary hook are hung on the turning lugs. The main hook is slowly lifted while the auxiliary hook remains stationary to complete the segment erection.

[0158] (3) After the segment is flipped and erected, it is hoisted into place. The segment is roughly positioned by the ground line. The verticality of the segment is checked by the magnetic plumb line. The spatial position of the positioning point on the segment is verified by the total station. After the requirements are met, the segment is fixed by the inclined support to prevent it from overturning.

[0159] (4) The surrounding segments are hoisted in sequence to form a stable grid-shaped structure. After hoisting and accurately positioning the adjacent segments, the vertical welds between the segments are welded using an all-round welding trolley. The welds of the two side wall panels are welded simultaneously from bottom to top. After the welding is completed, the ring plate butt joint and other internal welds are welded using carbon dioxide gas shielded welding. After the vertical welds are completed, the bottom plate butt joint is welded using carbon dioxide gas shielded welding. After the overall welding of the segments is completed, the segment axis deviation is checked to see if it exceeds the allowable value. Correction is made according to the check results. Then the next segment is hoisted until all the segments of the first layer are hoisted.

[0160] (5) After the first layer of segments is hoisted, welded and inspected, the corner concrete is poured. After the concrete is poured, the second layer of segments is hoisted. The vertical welds of the wall panels and the welds of the ring plates are welded in the welding sequence in step four. After the vertical welds of the wall panels are welded, the transverse welds of the first and second steel caisson ring plates are welded. The transverse welds of the ring plates on both sides are welded simultaneously by two trackless all-position crawling welding robots in the direction of segment hoisting. After the welds between segments are completed, the segment axis is checked to see if it exceeds the allowable value. The correction is made according to the check. Then the next segment is hoisted until all the second layer of segments are hoisted.

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

[0162] (7) After the first section of the fourth layer is hoisted and precisely positioned, the positioning welding is applied, and the diagonal support is added inside the section to prevent the section from overturning. Two trackless full-position climbing welding robots are used to perform the girth welding in the direction of the section hoisting. The adjacent section is hoisted and precisely positioned, and the positioning welding is applied after the diagonal support is added. Then, two full-position welding trolleys are used to perform the vertical welding between the sections. The welding of the two side wall plates is performed from bottom to top at the same time. After the vertical welding is completed, the carbon dioxide gas shielded welding is used to weld the girth plate butt joints and other internal welds. After the vertical welding is completed, two trackless full-position climbing welding robots are used to perform the girth welding in the direction of the section hoisting. The subsequent sections are installed in sequence until the hoisting of the fourth section of the steel caisson is completed.

[0163] (8) The diagonal rods are removed, and the temporary support positioning bracket is hoisted and welded. The inner support middle unit is hoisted.

[0164] (9) The remaining steel pipes of the fourth section of the inner support are hoisted and welded.

[0165] (10) The fifth section of the steel caisson is hoisted in sequence. Due to the high height, the diagonal support method cannot be used for temporary support. After the positioning of the section is completed, the hook is loosened but not removed. The vertical plate between the sections is increased from 500mm per row to 300mm per row. After the intermittent welding of the outer lateral joints of the steel shell is completed by more than 50%, the hook is removed, and the hoisting of the next section is performed. This process is repeated until the hoisting of the fifth section of the steel caisson is completed. After the hoisting and welding of the fifth section of the steel caisson are completed, the inner support steel pipes are installed.

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

[0167] (12) The segmented truss-type inner support is hoisted. The long-side inner support of the steel caisson is hoisted first, and then the short-side truss-type inner support is hoisted in segments.

[0168] Step 6: Welding and painting are performed.

[0169] The welding characteristics of the steel caisson are as follows: (1) The wall plate unit has dense stiffening angle steel, and the wall plate is thin. Controlling the welding deformation during welding is the key. (2) The cross-shaped and L-shaped node position ring plate and support angle steel form a truss partition. The internal space is small, and the assembly welding is difficult. (3) The assembly base in Quanzhou is located in a coastal environment with more strong winds. Windproof is required during welding.

[0170] The selection principle of the welding scheme is as follows: According to the characteristics and quality requirements of the project, the basic principle for determining the welding process scheme is to use welding processes with small welding deformation and small weld shrinkage as much as possible under the premise of ensuring welding quality. The wall plate unit is assembled and welded by a reverse deformation automatic welding machine, and the truss piece unit is welded by an intelligent welding robot. The welding quality and production efficiency are ensured and improved through various automatic and intelligent welding equipment.

[0171] (1) Welding method is mainly automatic welding to ensure the stability of welding quality. Select the welding material matched with the base material, control the content of diffusible hydrogen in the weld to ensure that all indicators of the weld meet the design requirements.

[0172] (2) Part of the angle steel between the truss piece units is used as a buffer piece, and the node position angle steel is assembled and welded by disassembling.

[0173] (3) A comprehensive and reasonable welding procedure qualification test scheme is prepared according to the structural characteristics to determine the appropriate groove form, welding method, welding equipment, welding material, preheating temperature, interpass temperature and process parameters, etc. After the review, it is used as the basis for the preparation of welding procedure documents.

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

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

[0176] 2. Welding preparation: (1) Welders participating in the welding construction of this project shall have corresponding welding qualification certificate and work within the valid period; (2) The welding procedure qualification has passed the review, and the welding procedure document has been prepared and issued; (3) Welding technology is introduced to relevant personnel before welding and examination, and only those who pass the examination can work; (4) Welding materials are baked according to the requirements of the specification, and are issued, used and recovered according to the welding material management system; (5) The rust, oil stains, oxides and other impurities on the groove face and both sides of the groove shall be thoroughly cleaned, and both sides of the groove shall be cleaned; (6) When the welding environment is not available, appropriate measures shall be taken; (7) Welding equipment and other equipment are debugged before welding.

[0177] 3. Requirements for positioning welding: (1) The welding material used for positioning welding shall be matched with the workpiece; (2) The positioning weld shall be uniform, the weld leg size and weld length shall be in accordance with the requirements of the process document, and the surface of the positioning weld shall not have cracks, incomplete fusion and other defects; (3) The distance between the positioning weld and the end of the workpiece shall be more than 30mm, the length shall be 50-100mm, the spacing shall be 400-600mm, and the weld leg size of the positioning weld shall not be greater than 1 / 2 of the design weld leg size.

[0178] 4. Requirements in the welding process: (1) Welders must strictly follow the requirements of the welding procedure specification for welding. When multi-layer and multi-pass welding is performed, the joint must be staggered, and the coating and spatter on the upper layer must be cleaned before the subsequent welding pass can be performed; (2) The end of the butt weld using submerged arc welding must be equipped with an arc guide plate and an arc extinguishing plate. After welding is completed, the arc guide and extinguishing plates must not be removed by hammering or other methods, but must be cut by a flame and left with a 1-3 mm margin, which is then ground to be flush with the base metal using a grinder; (3) When preheating is required, the weld must be performed after preheating according to the process requirements, and the preheating range must not be less than 100 mm on both sides of the weld. The temperature measurement point is on the back of the heated side, 50 mm away from the weld. The layer temperature must not be lower than the preheating temperature during welding, and each weld must be welded as much as possible at one time. When welding is interrupted, appropriate measures such as slow cooling must be taken. When welding is resumed, preheating must be performed according to the requirements before welding; (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 less than 99.5%; (5) For welds that require gas scarfing to clean the root, the root defects of the front welding pass must be completely removed, and the gas scarfing depth and width must be uniform, with at least an R≥6mm arc at the root; (6) When significant welding quality problems are found during welding, welding must be stopped immediately, and the welding engineer and the supervising engineer must be notified. After the causes of the problem are found and preventive measures and solutions are proposed, welding can continue.

[0179] 5. In-plant overhead weld welding control: (1) The in-plant segment overhead weld is the fillet weld between the wall plate and the ring plate, and the space between the two layers of wall plates and the web is large, so the welder can easily complete the overhead welding task; (2) The overhead weld must be welded strictly according to the welding parameters approved by the welding process evaluation to ensure welding quality; (3) The overhead welder must be given detailed technical briefing; (4) The overhead welder must hold a welder's certificate and pass the welder's examination before being allowed to work. According to the steel caisson design drawings and manufacturing process, the main types of welds in this project are butt welds and T-type fillet welds, mainly butt welds of bottom plates / wall plates, fillet welds of wall plates and ring plates, and fillet welds of angle steels and ring plates. The control of welding deformation mainly controls the deformation from the methods of setting pre-deformation, adjusting the welding sequence and welding direction, and rigid restraint, as shown in Fig. Figure 4

[0180] To ensure welding quality and ensure that the performance of the welded joint meets the design requirements, strict control will be exercised from the aspects of people, machines, materials, methods, and environment to ensure welding quality. Windproof measures such as windshields are added during welding, and when the environmental humidity is too high, preheating before welding and moisture-proof measures such as rain shelters are added.

[0181] Inspection and welding records:

[0182] ​(1) Welding appearance inspection, all welds shall be inspected after the weld metal cools and the inspection record shall be filled. All welds shall be free of cracks, incomplete fusion, weld reinforcement, slag inclusion, incomplete penetration, and lack of fusion. Welded components with unqualified appearance inspection shall not be allowed to proceed to the next process until the defects are treated and the requirements are met.(2) Non-destructive testing, the non-destructive testing personnel shall have a qualification of Level II and above, and the non-destructive testing supervisor engineer shall have a qualification of Level III. The non-destructive testing personnel shall be approved and recorded by the supervising engineer before they are allowed to work.(3) Welding record, all welds shall be registered by the welding personnel. The welding personnel can be traced, and the welding personnel who do not meet the standard shall be trained again and then be dismissed if they still do not meet the standard.

[0183] Steel caisson assembly welding protection measures, due to the welding environment requirements, when it rains, construction is generally stopped. If the progress requires rush work, in addition to local heating and wind protection, the entire weld needs to be placed under effective wind and rain protection before construction. When the wallboard vertical weld is welded, magnetic attraction type wind blocking strips are set up outside the hanging cage for protection.

[0184] Welding precautions

[0185] (1) The steel caisson welds shall be inspected by weld testing 24 hours after welding is completed;(2) The welding wire and flux shall be baked and stored in strict accordance with the provisions of the product specification before use. Inspection quantity: all inspection. Inspection method: check the quality certificate and baking record.(3) The welder must pass the examination and obtain a qualification certificate. The certified welder must weld within the scope of his examination and approval. Inspection quantity: all inspection. Inspection method: check the welder's qualification certificate and its approved scope and validity period.(4) The site welding environment shall meet the following requirements: wind speed < 5, temperature ≥ 5℃, humidity ≤ 80%, and outdoor welding is not allowed on rainy days. When the above environmental requirements are exceeded, measures shall be taken to ensure the quality of the welds before welding is performed.(5) When the steel caisson segment is welded by gas shielded welding, ventilation protection measures must be taken, and the operator must wear an oxygen mask.(6) All welds must be tested by non-destructive testing according to the design requirements.

[0186] Painting process

[0187] 1. Primer in the pre-painting workshop, before cutting, the plates and steel sections are subjected to shot blasting, primer spraying, and drying treatment in the pre-treatment production line. 2. Segment painting, surface treatment and spraying operations are carried out in a dedicated painting workshop, and the temperature and humidity in the painting room shall meet the corresponding specification requirements. The painting operation procedure shall follow the sequence of "edge polishing → oil and dirt removal → sand blasting → cleaning → spraying". 3. Supplementary painting, the reserved parts and damaged parts of the segment assembly welds are polished to meet the specification requirements for rust removal and surface roughness, and are painted layer by layer using the brushing method according to the painting system.

[0188] Segment transportation and storage: according to the construction technology and construction plan of the east anchorage steel caisson of Xiamen Third Passage A1, the steel caisson is temporarily stored after being completed in the manufacturing and processing base, and the steel caisson is transported according to the construction progress arrangement, and the whole assembly process is carried out in Quanzhou processing base. The second section cross section segment is 4.8m high and cannot be transported by land, so the second section cross section segment needs to be made into a segment with the two sides of the section made into a segment, and the cross joint is made into a plate unit for transportation. After transportation to the dock, it is assembled into a segment in the dock. The caisson segment is transported by car and road, and the company will choose a transport unit with sufficient transport capacity, good reputation and long-term cooperation with the company to undertake the transportation of the steel structure.

[0189] The above is only the preferred embodiment of the present application, and it should be noted that for ordinary skilled persons in the art, without departing from the principles of the present application, a number of improvements and refinements can be made, and these improvements and refinements should be considered as the protection scope of the present application.

Claims

1. A method for the intelligent construction and installation of an anchorage steel caisson, characterized in that: The method includes the following steps: Step 1: Steel pretreatment. Before cutting the steel plate, it is pretreated by shot blasting and rust removal on the pretreatment production line. After the surface treatment reaches Sa3.0 grade, 25~30μm of inorganic zinc silicate shop 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 shop primer spraying ensures that the steel plate will not be corroded during factory construction. Step 2: Material cutting. All sheet metal parts are cut using a CNC plasma or CNC laser cutting machine. The length and width of the wall panel unit are reserved for 0-8mm welding shrinkage based on the size of the sheet metal, the number of stiffeners, and the bevel type. A 20mm secondary cutting allowance is reserved in the length direction of the wall panel, and a 50mm secondary cutting allowance is reserved in the closure section. Step 3: Unit component fabrication, including processing of ordinary parts, processing of arc-shaped wall panel parts, fabrication of truss unit 1, fabrication of truss unit 2, fabrication of ordinary wall panel units, fabrication of the second widened segment wall panel unit, fabrication of the third arc-shaped right-angle unit, and fabrication of the cofferdam temporary internal support unit. Step 4: Steel caisson segment fabrication. Steel caisson segments include cross-shaped segments, L-shaped segments, straight segments, and arc-shaped segments. The process involves sequentially welding the segment assembly jig, continuously matching and fabricating the segments, manufacturing the cross-shaped segments, straight segments, L-shaped segments, and arc-shaped segments, then manufacturing the second cross-shaped segment, the second circular segment, the third L-shaped segment, and the third circular segment. Step 5: Steel caisson assembly construction. When assembling the steel caisson as a whole, the assembly is carried out from the middle to the surrounding area to form a stable structure. Finally, the four corners are joined together. After the assembly is completed, the next layer of construction will be carried out. Step 6: Perform welding and painting to complete the construction.

2. The anchorage steel caisson intelligent construction and construction method according to claim 1, characterized in that: The specific process in step 5 is as follows: (1) Complete the surveying and setting out, and the piers are laid out as required. Use a total station to re-measure the positioning line of the steel caisson and the plane position and elevation of the wooden blocks below. (2) After the segment is transferred to the hoisting area, the segment is flipped and erected. A 95t crawler crane with a main hook and a secondary hook is used to flip the segment. The four wire ropes of the main hook are hung on the hoisting lugs on the upper side of the segment, and the two wire ropes of the secondary hook are hung on the turning lugs. The main hook is slowly lifted while the secondary hook remains stationary to complete the segment erection. (3) After the segment is flipped and erected, it is hoisted into place. The segment is roughly positioned by the ground line. The verticality of the segment is checked by the magnetic plumb line. After the spatial position of the positioning point on the segment is verified by the total station and meets the requirements, the segment is fixed by the inclined support to prevent it from overturning. (4) The surrounding segments are hoisted in sequence to form a stable grid-shaped structure. After hoisting and accurately positioning the adjacent segments, the vertical welds between the segments are welded using an all-round welding trolley. The welds of the two side wall panels are welded from bottom to top at the same time. After the welding is completed, the ring plate butt joint and other internal welds are welded using carbon dioxide gas shielding. After the vertical welds are completed, the bottom plate butt joint is welded using carbon dioxide gas shielding. After the overall welding of the segments is completed, the segment axis deviation is checked to see if it exceeds the allowable value. Correction is made according to the check results. Then the next segment is hoisted until all the segments of the first layer are hoisted. (5) After the first layer segment is hoisted, welded and completed and passes the inspection, the concrete is poured at the cutting edge, and after the concrete pouring is completed, the second layer segment is hoisted, the wall plate vertical weld and the ring plate weld are welded according to the welding sequence in step four, the first segment and the second segment steel caisson ring plate horizontal weld are welded after the wall plate vertical weld is completed, the two side ring plate horizontal welds are simultaneously welded by two trackless full-position crawling welding robots according to the segment hoisting direction, after the segment-to-segment weld is welded, it is checked whether the segment axis exceeds the allowable value, and the next segment is hoisted after the correction is made according to the checking result, until the second layer segment is completely hoisted; (6) Repeat step (5) until the third segment of all steel caisson segments is assembled and constructed; (7) After the first segment of the fourth layer is hoisted and precisely positioned, the positioning welding is performed, the inclined support is added inside the segment to prevent the segment from overturning, and the two trackless full-position crawling welding robots are simultaneously used to perform the girth welding according to the segment hoisting direction; after the adjacent segment is hoisted and precisely positioned and is reinforced by the inclined support, the two full-position welding trolleys are used to perform the segment-to-segment vertical weld, the two side wall plate welds are simultaneously welded from bottom to top, the carbon dioxide gas shielded welding is used to weld the ring plate butt joint and other internal welds, the girth welding is performed by the two trackless full-position crawling welding robots after the vertical weld is completed, and the subsequent segments are sequentially installed until the fourth segment of the steel caisson segment is completely hoisted; (8) The inclined rods are removed, the temporary support positioning bracket is hoisted, welded and fixed, and the inner support middle unit is hoisted; (9) The remaining steel pipes of the fourth segment of the inner support are hoisted and welded; (10) The fifth segment of the steel caisson is hoisted, the segment positioning is completed, the segment is loosened but not removed, the segment-to-segment vertical plate is increased from 500mm per row to 300mm per row, the steel shell outside horizontal joint is intermittently welded to more than 50%, the next segment is hoisted, and the fifth segment of the steel caisson is completely hoisted, the inner support steel pipe is installed after the fifth segment of the steel caisson is hoisted and welded; (11) Repeat step (10) to complete the hoisting of the sixth to seventh segments of the steel caisson; (12) The segmented hoisting truss type inner support is hoisted, the long side inner support of the steel caisson is hoisted first, and then the short side truss type inner support is hoisted.

3. The anchorage steel caisson intelligent construction and construction method according to claim 1, characterized in that: The unit part manufacturing in step 3 adopts an ERP management system for intelligent management, the ERP management system is composed of a warehouse management system, a project management system, a model visual management, a cloud material nesting and a cloud cutting system, covers the entire production process from the raw material into the factory to the steel caisson manufacturing, makes different departments and posts work collaboratively on the same platform, reduces the intermediate transmission links, shares the department achievements in real time, and masters the material inventory, production status, shipping progress and project dynamics in real time.

4. The anchorage steel caisson intelligent construction and construction method according to claim 1, characterized in that: In step 5, before assembling, virtual pre-assembly is carried out by three-dimensional laser scanning. The steel caisson segment is scanned in three dimensions. By comparing the point cloud model generated by scanning with the theoretical model, the construction error can be obtained and corrected. By virtually pre-assembling the point cloud models of adjacent segments, the matching between segments can be known in advance, guiding the assembly of steel caisson segments.

5. The anchorage steel caisson intelligent construction and construction method according to claim 1, characterized in that: In step 6, automatic tracking welding is carried out by using a guideless full-position crawling welding robot. In step 3, when the steel plate is assembled and stiffened, by using the code-free assembly equipment, adjusting the foot cup, top head and magnetic force controller, the work of steel plate leveling butt joint and stiffening rib assembly can be completed.

6. The anchorage steel caisson intelligent construction and construction method according to claim 1, characterized in that: In step 5, the internal stiffening structure of the cross-shaped and T-shaped segments is relatively complex, and the problem of part collision is easy to occur. Tekla software is used for modeling to check the collision, to determine whether there is a collision problem, and a three-dimensional diagram is used at the node position to indicate the direction, position and part number, and to clarify the assembly sequence.

7. The anchorage steel caisson intelligent construction and construction method according to claim 1, characterized in that: In step 6, if the butt joint of the steel caisson wall plate is greater than the set value, causing the size to decrease, the welding shrinkage should be considered in advance. According to the plate thickness, the number of stiffeners and the form of the groove, the corresponding welding shrinkage is added when the parts are cut, and the secondary cutting amount is set to ensure the overall size after welding.

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