Steel shell tower manufacturing method and steel shell tower

Abstract

The invention provides a steel shell tower manufacturing method and a steel shell tower. In use, blocks of all sections are manufactured in a manufacturing site of the steel shell tower; after each section is manufactured, carrying out pre-assembly inspection on included blocks of the section, judging whether the section is qualified or not after being assembled according to an inspection result through the pre-assembly inspection, and if the inspection result is qualified, marking an installation control point position and then continuing to carry out subsequent procedures; when the inspection result is unqualified, correction processing is carried out, and pre-assembly inspection is carried out again until the pre-assembly inspection is qualified; and after all the sections are manufactured, all the sections are transferred to an installation site of the steel shell tower to be installed. In the manufacturing process of the steel shell tower sections, the steel shell tower sections are subjected to pre-assembly inspection and correction, so that the technical problems that in the site construction process, due to the fact that the manufacturing precision is poor, site adjustment wastes time and labor, steel shell tower components are damaged, and the quality and the installation progress of the steel shell tower are seriously affected are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of the construction of steel shell towers, and particularly relates to a manufacturing method of a steel shell tower and a steel shell tower. Background Art

[0002] A steel shell tower is a special bridge or building structure, mainly used as a cable tower in large bridges such as cable-stayed bridges. By combining the steel shell with concrete, using the steel shell as the external structure, it provides good bearing capacity and stability, and fills the concrete inside the steel shell to enhance the overall stiffness and durability. The steel shell tower has been widely used due to its beautiful appearance and reliable performance.

[0003] In the existing construction of steel shell towers, generally, the components of the steel shell tower are produced and processed in a factory, and then directly transported to the construction site for group welding and installation to realize the fabrication of the steel shell tower.

[0004] However, in the process of on-site group welding and installation, it is often found that due to the lack of pre-inspection of the steel shell tower before fabrication, the manufacturing accuracy of the components of the steel shell tower is poor, and there are large accuracy errors between adjacent components. And the on-site inspection means are limited, it is time-consuming and laborious to adjust the components of the steel shell tower, which not only easily damages the components of the steel shell tower, but also has a long matching adjustment time, seriously affecting the quality and installation progress of the steel shell tower. Summary of the Invention

[0005] In order to solve the technical problems in the background art that after the components of the steel shell tower are produced and processed in a factory and directly transported to the construction site, due to the lack of pre-inspection of the steel shell tower before fabrication, during the on-site group welding and installation process, due to poor manufacturing accuracy, large errors between adjacent components, limited on-site inspection means, time-consuming and laborious adjustment, not only easily damages the components of the steel shell tower, but also has a long matching adjustment time, seriously affecting the quality and installation progress of the steel shell tower, the present invention provides a manufacturing method of a steel shell tower and a steel shell tower.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] In the first aspect, the present invention provides a manufacturing method of a steel shell tower, and the manufacturing method of the steel shell tower includes:

[0008] S1: Obtain the design model and three-dimensional space feature template of the steel shell tower, and based on the design model and three-dimensional space feature template of the steel shell tower, divide the steel shell tower into multiple segments, and divide each segment into multiple sub-blocks;

[0009] S2: Manufacture the sub-blocks of each segment, and conduct partial pre-assembly inspection during the manufacturing process, and perform corresponding correction processing according to the results of the partial pre-assembly inspection;

[0010] S3: After the segmented manufacturing of each segment is completed, perform pre-assembly inspection on the segments corresponding to each segment to obtain the inspection results for the misalignment amount and docking gap at the docking interface; if the inspection result is qualified, mark the installation control points; if the inspection result is unqualified, correct the segments of this segment and repeat step S3;

[0011] S4: After the segmented manufacturing and pre-assembly inspection of all segments are completed, perform group welding and installation on the segments of each segment in sequence to complete the fabrication of the steel shell tower.

[0012] Optionally, in step S1, when dividing the steel shell tower into multiple segments and further dividing each segment into multiple sub-blocks, it is determined based on the design model of the steel shell tower and the three-dimensional space feature template, considering the shape, weight of the steel shell tower, and the lifting height and lifting weight parameters of the construction equipment at the installation site.

[0013] Optionally, step S2 specifically includes:

[0014] S2.1: According to the design model of the steel shell tower and the three-dimensional space feature template, fabricate the wall plate units, rib plate units, diaphragm units, and web plate units corresponding to the sub-blocks of any two adjacent segments.

[0015] S2.2: According to the design model of the steel shell tower and the three-dimensional space feature template, fabricate the jigs corresponding to two adjacent segments.

[0016] S2.3: Using the jig as the outer mold and the diaphragm unit as the inner mold, on the jig, use the wall plate units, rib plate units, diaphragm units, and web plate units in the sub-blocks of two adjacent segments to assemble the sub-blocks of two adjacent segments in sequence, and during the assembly process, perform partial pre-assembly inspection on the wall plate units and rib plate units; if the partial pre-assembly inspection result is unqualified, correct the wall plate units and / or rib plate units of the sub-blocks of this segment.

[0017] Optionally, step S2.1 specifically includes:

[0018] S2.1.1: According to the design model of the steel shell tower and the three-dimensional space feature template, obtain the steel plate materials required for manufacturing.

[0019] S2.1.2: According to the design model of the steel shell tower and the three-dimensional space feature template, obtain the manufacturing parameters of the wall plate units, rib plate units, diaphragm units, and web plate units in the sub-blocks of each segment.

[0020] S2.1.3: According to the manufacturing parameters of the panel units, rib units, diaphragm units and web units in the blocks of any two adjacent segments, use the profiling die, numerical control cutting equipment and steel plate materials to prepare the panel units, rib units, diaphragm units and web units.

[0021] Optionally, the specific steps in step S2.3 include:

[0022] S2.3.1: Lay the panel units of one of the segments on the jig, make the panel units fit the jig, and spot-weld the panel units in place;

[0023] S2.3.2: Lay and spot-weld the panel units of its adjacent segment on the jig;

[0024] S2.3.3: Weld and install the rib units on the panel units of the two adjacent segments respectively;

[0025] S2.3.4: Conduct partial pre-assembly inspection on the error data at the butting joints between the panel units and rib units of the blocks of the two adjacent segments. If the error data meets the design requirements, the inspection result is qualified, and step S2.3.5 is executed; if the error data does not meet the design requirements, the inspection result is unqualified, correct the panel units and rib units of the blocks of the two adjacent segments, and re-execute this step;

[0026] S2.3.5: Based on the rib units, alternately install the diaphragm units and web units on the panel units of the two adjacent segments through the group welding process to obtain the blocks of the two adjacent segments.

[0027] Optionally, the specific steps in step S3 include:

[0028] S3.1: Prepare a pre-assembly inspection platform;

[0029] S3.2: Move the corresponding blocks in the segment to be inspected onto the pre-assembly inspection platform;

[0030] S3.3: Conduct pre-assembly on the corresponding blocks of this segment on the pre-assembly inspection platform;

[0031] S3.4: Inspect the misalignment and butting gap at the joints of the blocks after pre-assembly to obtain the inspection result;

[0032] S3.5: If the inspection result is qualified, mark the installation control points, and disassemble the pre-assembled segment into blocks;

[0033] If the inspection result is unqualified, correct the blocks of this segment, and repeat steps S3.2 to S3.5.

[0034] Optionally, the specific steps in step S3.4 include:

[0035] S3.4.1: Use a theodolite or total station to detect the overall linearity of the pre-assembled segment, as well as the misalignment and docking gap at the segment interface, and obtain error data;

[0036] S3.4.2: Determine whether the error data meets the design requirements. If the error data meets the design requirements, the inspection result is qualified; if the error data does not meet the design requirements, the inspection result is unqualified.

[0037] Optionally, the pre-assembly inspection platform in step S3.1 is obtained by ultra-leveling the jig.

[0038] Optionally, in step S3.5, if the inspection result is qualified, the marked installation control points are: mark the base points of the major axis and minor axis of this segment on the wall panel unit, and mark the control points of the web panel unit on the wall panel unit;

[0039] If the inspection result is unqualified, the correction process for the segmented block of this segment is: eliminate the error corresponding to the segmented block of this segment through mechanical correction or thermal adjustment correction.

[0040] In the second aspect, the present invention provides a steel shell tower, and the steel shell tower is obtained by manufacturing based on the steel shell tower manufacturing method provided above.

[0041] The beneficial effects of the present invention are:

[0042] The present invention provides a steel shell tower manufacturing method. According to the design model and three-dimensional space feature template of the steel shell tower, the steel shell tower is segmented and divided into blocks, and its parameters are obtained. In the segment manufacturing site of the steel shell tower, the segmented blocks of adjacent segments are manufactured simultaneously. During the process of manufacturing the segmented blocks, partial pre-assembly inspection is first carried out on the segmented blocks of two adjacent segments to improve the manufacturing accuracy; after each segment is manufactured, pre-assembly inspection is carried out on the segmented blocks it contains. Through the pre-assembly inspection, it is judged whether the segment is qualified after assembly according to the inspection result. When the inspection result is qualified, mark the installation control points and then continue with the subsequent processes; when the inspection result is unqualified, carry out correction treatment and conduct pre-assembly inspection again until it is qualified; after all segments are manufactured, transfer all segments to the installation site of the steel shell tower for group welding and installation. The steel shell tower manufacturing method provided by the present invention, because during the process of manufacturing the segments of the steel shell tower, pre-assembly inspection and correction are carried out, it avoids the technical problems that during the on-site construction process, due to poor manufacturing accuracy, the installation error is large, on-site adjustment is time-consuming and laborious, damage to the components of the steel shell tower, and seriously affecting the quality and installation progress of the steel shell tower. Description of the Drawings

[0043] Figure 1It is a schematic diagram of the manufacturing method of the steel shell tower in the present invention;

[0044] Figure 2 It is a schematic diagram of the block division of the anchoring section;

[0045] Figure 3 It is a schematic diagram of the block division of the non-anchoring section;

[0046] Figure 4 It is a schematic diagram of the section of the steel shell tower under construction in the example of the present invention;

[0047] Figure 5 It is a schematic diagram of manufacturing a wall panel unit using a profiled die in the example of the present invention;

[0048] Figure 6 It is a schematic diagram of installing the wall panel unit on the jig in the example of the present invention;

[0049] Figure 7 It is a schematic diagram of installing rib plates on the wall panel of the non-anchoring section in the example of the present invention;

[0050] Figure 8 It is a schematic diagram of installing a transverse diaphragm on the non-anchoring section in the example of the present invention;

[0051] Figure 9 It is a schematic diagram of installing transverse webs on both sides of the non-anchoring section in the example of the present invention;

[0052] Figure 10 It is a schematic diagram of installing transverse diaphragms on both sides of the non-anchoring section in the example of the present invention;

[0053] Figure 11 It is a schematic diagram of installing a longitudinal web on the non-anchoring section in the example of the present invention;

[0054] Figure 12 It is a schematic diagram of installing rib plates on the side-block wall panel of the anchoring section in the example of the present invention;

[0055] Figure 13 It is a schematic diagram of installing a longitudinal web on the side-block of the anchoring section in the example of the present invention;

[0056] Figure 14 It is a schematic diagram of installing a transverse diaphragm on the side-block of the anchoring section in the example of the present invention;

[0057] Figure 15 It is a schematic diagram of installing a transverse web on the middle-block of the anchoring section in the example of the present invention;

[0058] Figure 16 It is a schematic diagram of installing an anchor box on the middle-block of the anchoring section in the example of the present invention;

[0059] Figure 17It is a schematic diagram of installing a partition board in the middle block of the anchoring section in the example of the present invention;

[0060] Figure 18 It is a schematic diagram of installing the upper transverse web in the middle block of the anchoring section in the example of the present invention;

[0061] Figure 19 It is a schematic diagram of installing the upper side wall plate in the middle block of the anchoring section in the example of the present invention;

[0062] Figure 20 It is a schematic diagram after pre-assembling the non-anchoring section in the example of the present invention;

[0063] Figure 21 It is a schematic diagram after pre-assembling the anchoring section in the example of the present invention. Detailed implementation manners

[0064] In order to explain the steel shell tower manufacturing method and the steel shell tower provided in the present invention in detail, the following will explain it in detail through embodiments.

[0065] It should be noted that the following described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and in no way limits the present invention and its application or use. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0066] It should be noted that the terms used herein are only for describing specific implementation manners and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0067] Embodiment 1

[0068] Refer to Figure 1 , which shows a schematic diagram of a steel shell tower manufacturing method described in the present application, including:

[0069] S1: Obtain the design model and three-dimensional space feature template of the steel shell tower, and based on the design model and three-dimensional space feature template of the steel shell tower, divide the steel shell tower into multiple segments, and divide each segment into multiple blocks.

[0070] Optionally, in step S1, when the steel shell tower is divided into multiple segments and each segment is further divided into multiple sub-blocks, it is determined based on the design model of the steel shell tower and the three-dimensional space feature template, considering the shape, weight of the steel shell tower, as well as the lifting height and lifting weight parameters of the construction equipment at the installation site.

[0071] Specifically, at least an anchoring segment for connecting the steel cables and a non-anchoring segment not connecting the steel cables are included in the segments of the steel shell tower; among them, the anchoring segment is generally located in the upper half of the steel shell tower, while the non-anchoring segment is located in the lower half of the steel shell tower.

[0072] Further, referring to Figure 2 and Figure 3 , the anchoring segment can be divided into three sub-blocks, namely the middle sub-block with an anchoring box installed, and two side sub-blocks arranged on both sides of the middle sub-block; the non-anchoring segment can be divided into two symmetric sub-blocks.

[0073] S2: Manufacture the sub-blocks of each segment, and conduct partial pre-assembly inspection during the manufacturing process, and perform corresponding rectification processing according to the results of the partial pre-assembly inspection.

[0074] Optionally, step S2 specifically includes:

[0075] S2.1: According to the design model of the steel shell tower and the three-dimensional space feature template, manufacture the wall plate units, rib plate units, diaphragm plate units and web plate units corresponding to the sub-blocks of any two adjacent segments.

[0076] S2.2: According to the design model of the steel shell tower and the three-dimensional space feature template, manufacture the jigs corresponding to two adjacent segments.

[0077] S2.3: Using the jig as the outer mold and the diaphragm plate unit as the inner mold, on the jig, use the wall plate units, rib plate units, diaphragm plate units and web plate units in the sub-blocks of two adjacent segments to assemble the sub-blocks of two adjacent segments in sequence. During the assembly process, conduct partial pre-assembly inspection on the wall plate units and rib plate units; if the result of the partial pre-assembly inspection is unqualified, rectify the wall plate units and / or rib plate units of the sub-blocks of this segment.

[0078] Optionally, step S2.1 specifically includes:

[0079] S2.1.1: According to the design model of the steel shell tower and the three-dimensional space feature template, obtain the steel plate materials required for manufacturing.

[0080] S2.1.2: According to the design model of the steel shell tower and the three-dimensional space feature template, obtain the manufacturing parameters of the wall plate units, rib plate units, diaphragm plate units and web plate units in the sub-blocks of each segment.

[0081] S2.1.3: According to the manufacturing parameters of the panel units, rib units, diaphragm units, and web units in the segmentation of any two adjacent segments, use the profiling die, numerical control cutting equipment, and steel plate materials to prepare the panel units, rib units, diaphragm units, and web units.

[0082] Specifically, during use, place the steel plate material under the profiling die, and use the hydraulic press to bend the steel plate line by line. At the same time, during the profiling process, also use the inspection template to conduct inspections while profiling to ensure the profiling efficiency and quality of the panel units. And after the profiling of the panel units is completed, the panel units can be lifted and transported to the jig for comparison and fitting. If the fitting is not good, it means that the profiling process is unqualified, and the profiling operation needs to be carried out again.

[0083] Specifically, both the diaphragm units and the web units are manufactured by numerical control cutting equipment for blanking and are obtained by combining the group welding process.

[0084] Optionally, step S2.3 specifically includes:

[0085] S2.3.1: Lay the panel units of one of the segments on the jig, make the panel units fit with the jig, and spot-weld the panel units in place.

[0086] S2.3.2: Lay and spot-weld the panel units of its adjacent segment on the jig.

[0087] S2.3.3: Weld and install the rib units on the panel units of the two adjacent segments respectively.

[0088] S2.3.4: Conduct partial pre-assembly inspection on the error data at the butting joints between the panel units and rib units of the two adjacent segment segments. If the error data meets the design requirements, the inspection result is qualified, and step S2.3.5 is executed; if the error data does not meet the design requirements, the inspection result is unqualified, and the panel units and rib units of the two adjacent segment segments are corrected and this step is executed again.

[0089] S2.3.5: Based on the rib units, alternately install the diaphragm units and web units on the panel units of the two adjacent segments through the group welding process to obtain the segments of the two adjacent segments.

[0090] Specifically, when laying the panel units on the jig, align the short-axis center line on the panel with the center of the jig to ensure that the panel units are closely attached to the jig, and fix the panel units on the jig for installation.

[0091] Specifically, when installing the diaphragm units on the panel units, the group welding installation is carried out according to the preset diaphragm assembly line on the panel units, and during the installation process, ensure that the diaphragm is perpendicular to the horizontal plane.

[0092] Specifically, in step S2.3.4, the rectification process may include mechanical rectification or thermal adjustment rectification.

[0093] In this step, the blocks corresponding to two adjacent segments are fabricated synchronously. During the synchronous fabrication process, a preliminary pre-assembly inspection is carried out on the panel units and rib units of the blocks corresponding to the two adjacent segments, thereby improving the manufacturing accuracy of the panel units and rib units of the blocks and reducing the error degree during the block fabrication process.

[0094] S3: After the blocks of each segment are fabricated, the blocks corresponding to the segment are subjected to pre-assembly inspection to obtain the inspection results of the offset amount and docking gap at the docking interface thereof; if the inspection result is qualified, the installation control points are marked; if the inspection result is unqualified, the blocks of the segment are subjected to rectification treatment, and step S3 is repeated.

[0095] Optionally, step S3 specifically includes:

[0096] S3.1: Prepare a pre-assembly inspection platform;

[0097] S3.2: Move the blocks corresponding to the segment to be inspected onto the pre-assembly inspection platform;

[0098] S3.3: On the pre-assembly inspection platform, pre-assemble the blocks corresponding to the segment;

[0099] S3.4: Inspect the offset amount and docking gap at the joints of the pre-assembled blocks to obtain the inspection results;

[0100] S3.5: If the inspection result is qualified, mark the installation control points and disassemble the pre-assembled segment into blocks;

[0101] If the inspection result is unqualified, rectify the blocks of the segment and repeat steps S3.2 to S3.5.

[0102] In this step, the blocks of the segment are pre-assembled on the pre-assembly inspection platform, thereby obtaining the manufacturing errors of the segment blocks and promptly carrying out rectification treatment, avoiding eliminating errors during the installation at the steel shell tower fabrication site and affecting the construction progress.

[0103] Furthermore, in this step, pre-assembly inspection can also be carried out on two adjacent segments in an extra-large factory building or a test scenario to obtain the installation errors between the segments and carry out corresponding rectification treatment to further improve the construction accuracy in the steel shell tower fabrication.

[0104] Optionally, the pre-assembly inspection platform in step S3.1 is obtained by super-leveling the jig.

[0105] Optionally, step S3.4 specifically includes:

[0106] S3.4.1: Use a theodolite or total station to detect the overall alignment of the pre-assembled segment, as well as the misalignment and butt gap at the segment interface, and obtain error data.

[0107] S3.4.2: Determine whether the error data meets the design requirements. If the error data meets the design requirements, the inspection result is qualified; if the error data does not meet the design requirements, the inspection result is unqualified.

[0108] Optionally, in step S3.5, if the inspection result is qualified, the marked installation control points are: mark the base points of the major axis and minor axis of this segment on the wall panel unit, and mark the control points of the web panel unit on the wall panel unit.

[0109] If the inspection result is unqualified, the correction treatment for the segments of this segment is: eliminate the errors corresponding to the segments of this segment through mechanical correction or thermal adjustment correction.

[0110] Specifically, during the inspection process, use a theodolite or total station to detect the longitudinal alignment of the pre-assembled segment. Based on the measurement control points for disconnecting the major and minor axes, measure the overall alignment in the height direction of the steel shell tower; detect the length of the steel arch of the pre-assembled segment. Based on the transverse baseline of the segment, measure the cumulative length of the segment; at the same time, detect the misalignment and gap of the wall panel.

[0111] Furthermore, the mechanical correction in the present invention can be achieved by press correction or jack correction method, and the thermal adjustment correction can be achieved by linear heating correction.

[0112] Specifically, the error data in the present invention can be determined according to the regulations on misalignment and butt gap in the "Code for the Fabrication and Installation of Highway Steel Structure Bridges".

[0113] At the same time, based on the parameters obtained from the detection, determine whether it is qualified. If the inspection result is unqualified, correction treatment can be carried out according to the parameters obtained from the detection.

[0114] S4: After the fabrication and pre-assembly inspection of all segments are completed, sequentially perform group welding and installation on the segments of each segment to complete the fabrication of the steel shell tower.

[0115] Specifically, after the fabrication of all segments is completed, transport the segments to the installation site of the steel shell tower, that is, the selected location of the steel shell tower, and perform installation and construction in sequence.

[0116] In this embodiment, a method for manufacturing a steel shell tower is provided. According to the design model and three-dimensional space feature template of the steel shell tower, the steel shell tower is segmented and divided into blocks, and its parameters are obtained. In the manufacturing site of the steel shell tower, the blocks of adjacent segments are successively manufactured. During the process of manufacturing the blocks, partial pre-assembly inspection is first carried out on the blocks of two adjacent segments to improve the manufacturing accuracy. After each segment is manufactured, pre-assembly inspection is carried out on the blocks it contains. Through the pre-assembly inspection, it is judged whether the segment is qualified after assembly according to the inspection results. When the inspection results are qualified, installation control points are marked and subsequent processes are continued. When the inspection results are unqualified, corrective treatment is carried out and pre-assembly inspection is carried out again until it is qualified. After all segments are manufactured, all segments are transferred to the installation site of the steel shell tower for group welding and installation. The method for manufacturing a steel shell tower provided by the present invention avoids the technical problems that in the on-site construction process, due to large precision errors, on-site adjustment is time-consuming and laborious, the components of the steel shell tower are damaged, and the quality and installation progress of the steel shell tower are seriously affected, because during the process of manufacturing the segments of the steel shell tower, pre-assembly inspection and correction are carried out on it.

[0117] Embodiment 2

[0118] Secondly, the present invention also provides a steel shell tower, which is built based on any one of the steel shell tower manufacturing methods provided in Embodiment 1.

[0119] In this embodiment, the manufacturing method of the provided steel shell tower corresponds to the steel shell tower manufacturing method provided in Embodiment 1. The specific implementation manner can refer to the content in Embodiment 1. For the sake of brevity, it will not be elaborated in this embodiment.

[0120] Embodiment 3

[0121] In order to explain in detail the steel shell tower manufacturing method provided in Embodiment 1, it will be illustrated by examples in this embodiment.

[0122] For example, referring to Figure 4 , a single-pylon single-column spatial twisted cable plane floating system cable-stayed bridge with a pylon height of 140 meters is built, and the pylon is selected as a steel shell tower structure with a spiral upward shape.

[0123] The process of building it by using the steel shell tower manufacturing method provided in Embodiment 1 of the present invention is as follows:

[0124] S1: Obtain the design model and three-dimensional space feature template of the steel shell tower, and based on the design model and three-dimensional space feature template of the steel shell tower, segment the steel shell tower, divide the steel shell tower into multiple segments, and divide each segment into multiple blocks.

[0125] Referring to Figure 4, the steel shell tower is divided into 34 segments from top to bottom. Among them, the upper 16 segments are anchoring segments, which are divided into three sub-blocks along the major axis direction of the axial cross-section, namely two side sub-blocks and one middle sub-block; the lower 18 segments are non-anchoring segments, which are divided into two sub-blocks along the minor axis direction of the axial cross-section.

[0126] S2: Manufacture the sub-blocks of each segment, and conduct partial pre-assembly inspection during the manufacturing process, and perform corresponding correction processing according to the results of the partial pre-assembly inspection.

[0127] By analyzing the design model and three-dimensional space feature template of the steel shell tower, the steel plate materials required for the steel shell tower are obtained. Wall plate units, rib plate units, diaphragm plate units and web plate units are manufactured using the steel plate materials.

[0128] Refer to Figure 4 , the cross-section of the steel shell tower transitions from an ellipse to a circle, the major and minor axes of the ellipse gradually change, and the diameter of the circle also gradually changes. Therefore, after the outer wall plate is divided into wall plate units, all wall plate units are curved surfaces, and the upper and lower cross-section dimensions of the curved surfaces are inconsistent. Therefore, the outer wall plate units are irregular curved surfaces.

[0129] Refer to Figure 5 , place the steel plate material under the profiled die. Here, a strip-shaped profiled die is selected. Use a hydraulic press to bend the steel plate line by line. According to the size of the curvature radius of the steel plate, select the forward distance of the steel plate material each time and the density of the pressing points; at the same time, during the profiling process, an inspection template is also used to conduct inspections while profiling to ensure the profiling efficiency and quality of the wall plate units; and after the wall plate profiling is completed, the wall plate can be hoisted to the jig for comparison and fitting. If the fitting is not good, it means that the profiling process is unqualified and the profiling operation needs to be carried out again.

[0130] The diaphragm plate units and web plate units are all cut and manufactured using numerical control cutting equipment, and the diaphragm plate units and web plate units are obtained by combining the welding process.

[0131] The specific manufacturing process of each sub-block is as follows:

[0132] Refer to Figures 6 to 11 , for the non-anchoring segments, fix the wall plate units of two adjacent segments to the corresponding jigs, and sequentially assemble and weld the rib plates. As Figure 6 and Figure 7 shown, after installing the rib plates, check the error data between the wall plates and the rib plates and perform corresponding correction operations; according to the diaphragm assembly line on the wall plate unit, assemble and weld the diaphragm plates and ensure that the diaphragm plates are perpendicular to the horizontal plane, as Figure 8 shown; install the two-side transverse webs one by one, as Figure 9 shown; install the two-side diaphragm plates, as Figure 10As shown; install the longitudinal web plate piece by piece, aligning the center line of the longitudinal web plate with the center line of the jig, as Figure 11 shown; after completing the group welding, mark the lines and perform the secondary cutting operation to obtain the blocks of the non-anchoring section.

[0133] Refer to Figures 12 to 19 , for the anchoring section, it is divided into side blocks and middle blocks. Among them, the manufacturing process of the side blocks is as follows: fix the wall plate units of adjacent sections on their corresponding jigs, aligning the long axis center of the wall plate units with the center line of the jig, as Figure 12 shown; weld the rib plates separately. After installing the rib plates, inspect the error data between the wall plates and the rib plates and perform corresponding correction operations; install the longitudinal web plate and ensure that the longitudinal web plate is perpendicular to the horizontal plane, as Figure 13 shown; install the transverse diaphragms according to the transverse diaphragm assembly lines on the wall plate units, as Figure 14 shown. After completing the group welding, mark the lines and perform the secondary cutting to obtain the side blocks. Since the wall plates are on both sides of the middle block, its manufacturing process is as follows: fix and install its transverse web plate on the corresponding jig, as Figure 15 shown; install the anchor boxes according to the anchor box assembly lines on the transverse web plate, as Figure 16 shown; install the diaphragms between and on both sides of the anchor boxes, as Figure 17 shown; lay the transverse web plate on the upper side of the anchor boxes and the diaphragms, as Figure 18 shown; install the wall plate units, as Figure 19 shown. After completing the group welding, perform the secondary cutting to obtain the middle block.

[0134] S3: After the blocks of each section are manufactured, perform pre-assembly inspection on the blocks corresponding to the section to obtain the inspection results of the offset and butt gap at the butt joint; if the inspection results are qualified, mark the installation control points; if the inspection results are unqualified, correct the blocks of the section and repeat step S3.

[0135] The process of pre-assembly inspection for the non-anchoring section and the anchoring section is as follows: level the jig as the pre-assembly inspection platform, transfer the blocks of a section to the pre-assembly inspection platform and perform pre-assembly on it, as Figure 20 and Figure 21 shown; use a theodolite or total station to detect the overall alignment of the pre-assembled section, as well as the offset and butt gap at the butt joint of the section, and obtain the error data; determine whether the error data meets the design requirements. If the error data meets the design requirements, the inspection results are qualified. After marking the lines, disassemble the section into blocks; if the error data does not meet the design requirements, the inspection results are unqualified, and correct the section.

[0136] Specifically, mechanical correction or thermal adjustment correction can be used during the correction process to make the error within an acceptable range.

[0137] S4: After the segmented manufacturing and pre-assembly inspection of all segments are completed, the segments are successively assembled by welding to complete the fabrication of the steel shell tower.

[0138] Specifically, after the segmented manufacturing and pre-assembly inspection of all segments are completed, the pre-assembled segments are disassembled and transferred to the construction site of the steel shell tower for assembly by welding to complete the fabrication work of the steel shell tower.

[0139] In the method for fabricating the steel shell tower provided in the present invention, since the pre-assembly inspection and correction are carried out during the process of manufacturing the segments of the steel shell tower, the technical problems that during the on-site construction process, due to large precision errors, on-site adjustment is time-consuming and laborious, damaging the components of the steel shell tower, and seriously affecting the quality and installation progress of the steel shell tower are avoided.

Claims

1. A method for manufacturing a steel shell tower, characterized in that: The steel shell tower manufacturing method comprises: S1: obtaining a design model and a three-dimensional space feature template of a steel shell tower, and based on the design model and the three-dimensional space feature template of the steel shell tower, dividing the steel shell tower into a plurality of segments, and dividing each segment into a plurality of blocks; S2: The blocks of each segment are manufactured, and a partial pre-assembly inspection is performed during the manufacturing process, and corresponding correction processing is performed according to the partial pre-assembly inspection results; S3: After the manufacturing of the blocks of each segment is completed, the blocks corresponding to the segment are pre-assembled and inspected to obtain the inspection results of the misalignment amount and the butt gap at the interface; if the inspection result is qualified, the installation control point is marked; if the inspection result is unqualified, the blocks of the segment are corrected and step S3 is repeated; S4: After the block manufacturing and pre-assembly inspection of all segments are completed, the blocks of each segment are welded and installed in turn to realize the production of the steel shell tower.

2. The method for manufacturing a steel shell tower according to claim 1, characterized in that: In step S1, the steel shell tower is divided into a plurality of sections, and each section is divided into a plurality of blocks, which is determined based on the design model of the steel shell tower and the three-dimensional space feature template, the shape and weight of the steel shell tower, and the lifting height and lifting weight parameters of the construction equipment at the installation site.

3. The method for manufacturing a steel shell tower according to claim 2, characterized in that: The step S2 specifically includes: S2.1: According to the design model of the steel shell tower and the three-dimensional space feature template, make the wall plate elements, rib plate elements, diaphragm plate elements and web plate elements corresponding to the blocks of any two adjacent segments; S2.2: According to the design model of the steel shell tower and the three-dimensional space feature template, make the tire frame corresponding to the two adjacent segments; S2.3: With the tire frame as the outer mold and the transverse partition unit as the inner mold, the blocks of two adjacent segments are assembled in sequence on the tire frame using the wall panel units, rib panel units, transverse partition units and web panel units in the blocks of two adjacent segments, and during the assembly process, a partial pre-assembly inspection is performed on the wall panel units and the rib panel units; if the partial pre-assembly inspection result is unqualified, the wall panel units and / or rib panel units of the blocks of the segment are corrected.

4. The method for manufacturing a steel shell tower according to claim 3, characterized in that: The step S2.1 specifically includes: S2.1.1: Obtain the steel plate materials required for manufacturing based on the design model of the steel shell tower and the three-dimensional space feature template; S2.1.2: According to the design model of the steel shell tower and the three-dimensional space feature template, obtain the manufacturing parameters of the wall plate unit, rib plate unit, diaphragm plate unit and web plate unit in each segment block; S2.1.3: According to the manufacturing parameters of the wall plate units, rib plate units, diaphragm plate units and web plate units in the blocks of any two adjacent segments, the wall plate units, rib plate units, diaphragm plate units and web plate units are prepared by using a press mold, CNC blanking equipment and steel plate materials.

5. The method for manufacturing a steel shell tower according to claim 4, characterized in that: The step S2.3 specifically includes: S2.3.1: Lay the wall panel unit of one segment on the tire frame, make the wall panel unit fit the tire frame, and fix the wall panel unit by spot welding; S2.3.2: Lay out and spot weld the adjacent wall panel units on the frame; S2.3.3: On the wall plate units of two adjacent segments, rib plate units are welded and installed respectively; S2.3.4: Perform partial pre-assembly inspection on the error data at the interface between the wall plate units and rib plate units of two adjacent segments. If the error data meets the design requirements, the inspection result is qualified and step S2.3.5 is executed; if the error data does not meet the design requirements, the inspection result is unqualified, and the wall plate units and rib plate units of the two adjacent segments are corrected and this step is executed again; S2.3.5: Based on the rib plate units, the diaphragm plate units and the web plate units are alternately installed on the wall plate units of two adjacent segments through the welding process to obtain the blocks of two adjacent segments.

6. The method for manufacturing a steel shell tower according to claim 1, characterized in that: The step S3 specifically includes: S3.1: Prepare the pre-assembly inspection platform; S3.2: Move the corresponding blocks in the segment to be inspected to the pre-assembly inspection platform; S3.3: Pre-assemble the corresponding blocks in the segment on the pre-assembly inspection platform; S3.4: Inspect the misalignment and butt clearance at the joints of the pre-assembled blocks and obtain the inspection results; S3.5: If the inspection result is qualified, the installation control points are marked and the pre-assembled segments are divided into blocks; If the inspection result is unqualified, the blocks of the segment are corrected and steps S3.2 to S3.5 are repeated.

7. The method for manufacturing a steel shell tower according to claim 6, characterized in that: The step S3.4 specifically includes: S3.4.1: Use a theodolite or total station to detect the overall alignment of the pre-assembled segments, as well as the misalignment and butt clearance at the segment interfaces, and obtain error data; S3.4.2: Determine whether the error data meets the design requirements. If the error data meets the design requirements, the test result is qualified; if the error data does not meet the design requirements, the test result is unqualified.

8. The steel shell tower method according to claim 7, characterized in that: The pre-assembly inspection platform in step S3.1 is obtained by super-flattening the tire frame.

9. The method for manufacturing a steel shell tower according to claim 8, characterized in that: In the step S3.5, if the inspection result is qualified, the marked installation control points are: the base points of the major axis and minor axis of the segment are marked on the wall plate unit, and the control points of the web plate unit are marked on the wall plate unit; If the inspection result is unqualified, the blocks of the segment are corrected by eliminating the errors corresponding to the blocks of the segment through mechanical correction or thermal correction.

10. A steel shell tower, characterized in that: The steel shell tower is manufactured based on the steel shell tower manufacturing method according to any one of claims 1 to 9.

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