A manufacturing method for a composite lightweight bridge standard bridge joint

Abstract

The application discloses a manufacturing method of a composite lightweight bridge standard bridge joint, which comprises the following steps: firstly, machining connecting joints of upper chord bars and lower chord bars in the standard bridge joint according to drawing requirements; installing and positioning the connecting joints of the processed lower chord bars to an installation jig; spot welding and positioning the lower chord bar members and the connecting joints; assembling the connecting joints of the upper chord bar members with the upper chord bar members; assembling and positioning the upper chord bar members to the installation jig; calibrating coaxialities and sizes; synchronously welding the upper chord bar members and the connecting joints and the lower chord bar members and the connecting joints under temperature control; secondly, welding inclined vertical bars and inclined web bars in sequence from two ends to the middle, and welding transverse connecting bar lugs; and finally, taking the standard bridge joint from the installation jig after the welding is completed. The standard bridge joint is once installed and welded in place through the installation jig, so that the time and cost of secondary processing and transportation are saved, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of manufacturing processes for standard bridge sections, and more particularly to a method for manufacturing standard bridge sections for lightweight composite bridges. Background Technology

[0002] In the manufacturing of standard bridge sections for lightweight bridges, especially those using composite materials, the existing manufacturing technology involves creating openings at the joints of the bridge sections. After the overall manufacturing is completed on the tooling, secondary processing is performed to ensure that the joint openings meet the drawing requirements. The main reason for using this method is that the main material of the bridge is a combination of composite materials and metal materials. After welding, the thermal expansion coefficients of the different materials are inconsistent, and the shrinkage after welding cannot be precisely controlled, resulting in the hole positions not meeting the drawing requirements.

[0003] The above manufacturing process requires large-scale processing equipment. After the standard bridge section is manufactured as a whole, it needs to be processed again. The manufacturing cycle is long, and the manufacturer cannot equip itself with a variety of large-scale processing equipment, so it needs to outsource the processing, which extends the manufacturing cycle. The manufacturing cost is high, and the secondary processing requires a variety of operations such as transportation, hoisting and processing, which increases the cost. Summary of the Invention

[0004] Purpose of the invention: The purpose of this invention is to provide a manufacturing method for lightweight composite bridge standard bridge sections, which can improve the welding accuracy of standard bridge sections during the manufacturing process, and complete the manufacturing process of standard bridge sections in one go on the mounting jig, thereby improving manufacturing efficiency and reducing manufacturing costs.

[0005] Technical solution: The present invention provides a method for manufacturing a standard bridge section for lightweight composite bridges, specifically comprising the following steps:

[0006] S1: The connection joints of the upper chord members and lower chord members of the left and right triangular trusses in the standard bridge section shall be processed according to the drawing requirements;

[0007] S2: Installation jig for standard bridge sections, including tooling lugs;

[0008] S3: Position and install the connecting joint of the lower chord member of the standard bridge section onto the mounting frame;

[0009] S4: Spot weld the lower chord members of the standard bridge section to the connecting joint to complete the positioning of the lower chord;

[0010] S5: Insert the upper chord member of the standard bridge section and the connecting joint into the assembly;

[0011] S6: Position and install the upper chord members of the standard bridge section together with the connecting joints onto the mounting frame;

[0012] S7: After calibrating the coaxiality and dimensions, simultaneously weld the lower chord members and upper chord members of the standard bridge section to the connection joint under controlled temperature conditions;

[0013] S8: After the lower chord and upper chord of the standard bridge section are welded, weld the diagonal vertical members at both ends of the lower chord and upper chord, as well as the diagonal web members between the lower chord and upper chord. Finally, weld the diagonal vertical members in the middle of the lower chord and upper chord.

[0014] S9: Spot weld the transverse connecting rod lugs of the left and right triangular trusses;

[0015] S10: Trial assembly of the transverse connecting rod; after confirming the positioning is correct, weld the transverse connecting rod lug plate.

[0016] S11: After the left and right triangular trusses of the welded standard bridge section are removed from the mounting jig.

[0017] Preferably, the mounting frame includes an upper transverse frame, a lower transverse frame, and support legs. An upper chord and a lower chord are installed inside the upper and lower transverse frames, and the support legs are connected between the upper and lower transverse frames to position the relative positions of the upper and lower transverse frames.

[0018] Preferably, the upper transverse frame includes two sets of opposing upper transverse connectors, with connecting joints positioned at both ends of the upper transverse connectors, and upper chord members welded between the connecting joints.

[0019] Preferably, the two ends of the upper transverse connector are respectively provided with double ear plates and single ear plates or single ear plates and double ear plates. The double ear plates and single ear plates are matched with the single ear plates or double ear plates on the connecting joint. The double ear plates and single ear plates, as well as the single ear plates and double ear plates, are positioned by pins.

[0020] Preferably, the lower transverse frame includes two sets of opposing lower transverse connectors, with connecting joints positioned at both ends of the lower transverse connectors, and a lower chord member welded between the connecting joints.

[0021] Preferably, the two ends of the lower transverse connector are respectively provided with two pairs of double-ear plates and single-ear plates, or single-ear plates and double-ear plates. The double-ear plates and single-ear plates are matched with the single-ear plates or double-ear plates on the connecting joint. The double-ear plates and single-ear plates, as well as the single-ear plates and double-ear plates, are positioned by pins.

[0022] Preferably, the lower transverse connectors in the lower transverse frame are parallel to each other and located at the same height.

[0023] Preferably, when the lower chord member is made of composite material, water injection holes are provided at the connection joints at both ends of the lower chord member away from the welding position, and cold water is injected into the water injection holes during welding.

[0024] As a preferred option, when cold water is injected into the water injection hole, the connection joints at both ends of the lower chord member where the water injection hole is located are wrapped with sponges that absorb cold water.

[0025] Preferably, the welding temperature controlled in S7 does not exceed 200°.

[0026] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:

[0027] (1) The present invention ensures the accuracy of welding by positioning and installing the connecting joint on the mounting frame and controlling the assembly sequence and welding temperature.

[0028] (2) The present invention installs and welds standard bridge sections into place in one go by installing a jig, saving time and cost of secondary processing and transportation, and improving production efficiency. Attached Figure Description

[0029] Figure 1 This is a side view of the mounting frame in this invention.

[0030] Figure 2 This is a top view of the upper transverse frame, lower transverse frame, and support leg on one side of the mounting frame in this invention.

[0031] Figure 3 This is a perspective view of the standard bridge section in this invention.

[0032] Figure 4 This is a front view of the standard bridge section in this invention.

[0033] The components include: 1. Connecting joint; 2. Support leg; 3. Upper chord member; 4. Lower chord member; 5. Upper transverse connector; 6. Lower transverse connector; 7. Double ear plate; 8. Single ear plate; 9. Left triangular truss; 10. Right triangular truss. Detailed Implementation

[0034] The technical solution of the present invention will be further described below with reference to the accompanying drawings.

[0035] See appendix Figures 1-4 Figure 1 illustrates the manufacturing method of the standard bridge section for lightweight composite bridges according to the present invention, which specifically includes the following steps:

[0036] S1: The connection joint 1 of the upper chord member 3 and the lower chord member 4 in the left triangular truss 9 and the right triangular truss 10 of the standard bridge section shall be processed according to the drawing requirements.

[0037] S2: The installation jig for the standard bridge section, including tooling lugs, specifically:

[0038] In this embodiment, the mounting frame includes an upper transverse frame, a lower transverse frame, and support legs 2. The upper and lower transverse frames are internally fitted with upper and lower chords, and the support legs 2 are connected between the upper and lower transverse frames to position the relative positions of the upper and lower transverse frames.

[0039] The upper transverse frame includes two sets of opposing upper transverse connectors 5. The right end of the upper transverse connector 5 is provided with a double ear plate 7, and the left end is provided with a single ear plate 8.

[0040] The lower transverse frame includes two sets of opposing lower transverse connectors 6. Two pairs of single-ear plates 8 are provided at the right end of the lower transverse connectors 6, and two pairs of double-ear plates 7 are provided at the left end.

[0041] The lower transverse connectors 6 in the lower transverse frame are parallel to each other and located at the same height.

[0042] S3: Position and install the connecting joint 1 of the lower chord member 4 of the standard bridge section onto the mounting frame, specifically:

[0043] A double-ear plate connecting joint 1 is provided at the single ear plate 8 on the right side of the lower transverse connector 6. The single ear plate 8 extends between the double ear plates, and the single ear plate 8 and the double ear plates are connected and positioned by a through pin. A single ear plate connecting joint 1 is provided at the double ear plate 7 on the left side of the lower transverse connector 6. The single ear plate of the connecting joint 1 extends between the double ear plates 7, and the double ear plates 7 and the single ear plate are connected and positioned by a through pin.

[0044] S4: Spot weld the lower chord member 4 of the standard bridge section to the connecting joint 1 to complete the positioning of the lower chord member.

[0045] S5: Insert the upper chord member 3 of the standard bridge section and the connecting joint 1 into the assembly.

[0046] S6: Position and install the upper chord member 3 of the standard bridge section together with the connecting joint 1 onto the mounting frame. Specifically:

[0047] A single-ear plate connector 1 is provided at the double-ear plate 7 on the right side of the upper transverse connector 5. The single-ear plate of the connector 1 extends between the double-ear plates 7, and the double-ear plate 7 and the single-ear plate are connected and positioned by a through pin. A double-ear plate connector 1 is provided at the single-ear plate 8 on the left side of the upper transverse connector 5. The single-ear plate 8 extends between the double-ear plates, and the single-ear plate 8 and the double-ear plate are positioned and connected by a through pin.

[0048] S7: After calibrating the coaxiality and dimensions, simultaneously weld the lower chord member 4 and upper chord member 3 of the standard bridge section to the connecting joint 1 under controlled temperature conditions;

[0049] When the lower chord member 4 is made of composite material, water injection holes are provided at the connection joints 1 at both ends of the lower chord member 4 and away from the welding position. During welding, cold water is injected into the water injection holes. At the same time, when the water injection holes are injected with cold water, the connection joints 1 at both ends of the lower chord member 4 where the water injection holes are located are wrapped with sponges that absorb cold water. The two work together to control the welding temperature below 200°.

[0050] S8: After the lower chord and upper chord of the standard bridge section are welded, weld the diagonal vertical members at both ends of the lower chord and upper chord, as well as the diagonal web members between the lower chord and upper chord. Finally, weld the diagonal vertical members in the middle of the lower chord and upper chord.

[0051] S9: The transverse connecting rod lugs of the left triangular truss 9 and the right triangular truss 10 in the spot-welded standard bridge section;

[0052] S10: Trial assembly of the transverse connecting rod; after confirming the positioning is correct, weld the transverse connecting rod lug plate.

[0053] S11: Remove the left triangular truss 9 and right triangular truss 10 from the installation jig after welding the standard bridge section, thereby saving placement space and finally completing the overall installation and welding process of a standard bridge section.

[0054] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A method for manufacturing a standard bridge section for lightweight composite bridges, characterized in that: Specifically, the following steps are included: S1: The connection joints of the upper chord members and lower chord members of the left and right triangular trusses in the standard bridge section shall be processed according to the drawing requirements; S2: Installation jig for standard bridge sections, including tooling lugs; S3: Position and install the connecting joint of the lower chord member of the standard bridge section onto the mounting frame; S4: Spot weld the lower chord members of the standard bridge section to the connecting joint to complete the positioning of the lower chord; S5: Insert the upper chord member of the standard bridge section and the connecting joint into the assembly; S6: Position and install the upper chord members of the standard bridge section together with the connecting joints onto the mounting frame; S7: After calibrating the coaxiality and dimensions, simultaneously weld the lower chord members and upper chord members of the standard bridge section to the connection joint under controlled temperature conditions; The lower chord member is made of composite material. Water injection holes are provided at the connection joints at both ends of the lower chord member away from the welding position. Cold water is injected into the water injection holes during welding. When cold water is poured into the water injection hole, the connection joints at both ends of the lower chord member where the water injection hole is located are wrapped with sponges to absorb the cold water. The controlled temperature shall not exceed 200℃; S8: After the lower chord and upper chord of the standard bridge section are welded, weld the diagonal vertical members at both ends of the lower chord and upper chord, as well as the diagonal web members between the lower chord and upper chord. Finally, weld the diagonal vertical members in the middle of the lower chord and upper chord. S9: Spot weld the transverse connecting rod lugs of the left and right triangular trusses; S10: Trial assembly of the transverse connecting rod; after confirming the positioning is correct, weld the transverse connecting rod lug plate. S11: After the left and right triangular trusses of the welded standard bridge section are removed from the mounting jig.

2. The manufacturing method of a standard bridge section for lightweight composite bridges according to claim 1, characterized in that: The mounting frame includes an upper transverse frame, a lower transverse frame, and support legs. An upper chord and a lower chord are installed inside the upper and lower transverse frames. The support legs connect the upper and lower transverse frames and position them relative to each other.

3. The manufacturing method of a standard bridge section for lightweight composite bridges according to claim 2, characterized in that: The upper transverse frame includes two sets of opposing upper transverse connectors, with connecting joints positioned at both ends of the upper transverse connectors, and upper chord members welded between the connecting joints.

4. A method for manufacturing a standard bridge section for lightweight composite bridges according to claim 3, characterized in that: The two ends of the upper transverse connector are respectively provided with double ear plates and single ear plates or single ear plates and double ear plates. The double ear plates and single ear plates are matched with the single ear plates or double ear plates on the connector. The double ear plates and single ear plates, as well as the single ear plates and double ear plates, are positioned by pins.

5. A method for manufacturing a standard bridge section for lightweight composite bridges according to claim 2, characterized in that: The lower transverse frame includes two sets of opposing lower transverse connectors, with connecting joints positioned at both ends of the lower transverse connectors, and a lower chord member welded between the connecting joints.

6. A method for manufacturing a standard bridge section for lightweight composite bridges according to claim 5, characterized in that: The lower transverse connector is provided with two pairs of double-ear plates and single-ear plates or single-ear plates and double-ear plates at both ends. The double-ear plates and single-ear plates are matched with the single-ear plates or double-ear plates on the connector. The double-ear plates and single-ear plates, as well as the single-ear plates and double-ear plates, are positioned by pins.

7. A method for manufacturing a standard bridge section for lightweight composite bridges according to claim 5, characterized in that: The lower transverse connectors in the lower transverse frame are parallel to each other and located at the same height.

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