Manufacturing method of triangular gate of navigation channel ship lock

Abstract

The invention discloses a manufacturing method of a triangular gate of a navigation channel ship lock, and relates to the technical field of manufacturing processes, and the manufacturing method comprises the following steps: S1, selecting a material, and detecting the quality, appearance and size of the raw material; s2, blanking is conducted, specifically, construction drawings and technical specifications are familiar, the blanking size precision is controlled, blanking is conducted through a laser cutting method, programming is conducted based on a numerical control laser cutting machine and matched with CAD / CAM software, and the selected materials are put into the numerical control laser cutting machine to be cut; and S3, a jig frame is manufactured, and vertical supporting columns are welded through I-shaped steel and fixed through expansion bolts. In the manufacturing process, the precision is strictly controlled, reasonable welding deformation control measures are adopted, the good effect is achieved, in the aspect of precision control, the blanking size deviation is controlled within the extremely small range, the form and location tolerances of part machining all meet the design requirements, the symmetrical welding and segmented skip welding method is adopted, and the machining precision is greatly improved. And the welding deformation of the gate leaf is effectively controlled.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing processes, and particularly to a manufacturing method for a triangular gate of a navigation channel lock. Background Art

[0002] A triangular gate is a lock gate composed of two symmetrically arranged triangular or sector-shaped door leaves that rotate around a vertical end post axis. It mainly consists of door leaves, rigid frames, end posts, top (bottom) pivots, and waterstops. When blocking water, the resultant force of the water pressure acting on the door leaf passes through the center of the rotating shaft. When it does not pass through the center of the rotating shaft, only a small eccentricity is allowed, and its value is less than ±4 mm. Therefore, it can be opened and closed under water pressure, can withstand bidirectional water heads. When the lock head water head is not large, the sluice can be used for filling and draining water through the door gap, can close a high and wide orifice, and has the advantages of flexible opening and closing under dynamic water. However, the steel consumption of the door leaf structure is relatively large, the manufacturing, installation, and maintenance of the gate are relatively complex, the space occupied by the gate recess is relatively large, and the amount of work for the lock head is increased; When the gate is closed, the two doors are in close contact on the longitudinal axis of the lock, effectively blocking the water flow, forming a closed water-blocking barrier, preventing the upstream and downstream water bodies from flowing through; ensuring the stability of the water level in the lock chamber and providing a safe berthing and passage environment for ships; when the gate is opened, each door leaf smoothly rotates into the door chamber in its respective lock chamber, quickly opening the navigation channel, and ensuring the rapid and smooth entry and exit of ships from the lock. It is widely used in inland river locks with frequent water level changes and coastal locks undertaking flood control and tide protection tasks; In the existing manufacturing technology of triangular gates, many challenges are faced. Precision control is a key link in the manufacturing process. If the deviation of the cutting size cannot be strictly controlled, it will lead to inaccurate assembly of components, affecting the overall structural stability of the gate. In some manufacturing processes, the deviation of the cutting size is too large, resulting in gaps or interferences during the assembly of components, reducing the sealing performance and mechanical properties of the gate. If the geometric tolerances of component processing do not meet the design requirements, it will cause problems such as shaking and jamming of the gate during operation, affecting its normal use. During the welding process, due to the influence of welding heat input, the door leaf is prone to large deformation. For this reason, a manufacturing method for a triangular gate of a navigation channel lock is proposed. Summary of the Invention

[0003] To solve the above technical problems, a manufacturing method for a triangular gate of a navigation channel lock is provided, and this technical solution solves the above problems.

[0004] To achieve the above object, the technical solution adopted by the present invention is: a manufacturing method for a triangular gate of a navigation channel lock, and the manufacturing steps are as follows: S1. Select materials and detect the quality, appearance, and dimensions of the raw materials; S2. Material cutting: Familiarize with the construction drawings and technical specifications, control the dimensional accuracy of the cut materials, use the laser cutting method for cutting, program based on the CNC laser cutting machine and the matching CAD / CAM software, and place the selected materials into the CNC laser cutting machine for cutting. S3. Fabricate the jig: Weld vertical support columns using I-beams and fix them with expansion bolts, and add longitudinal horizontal support beams and transverse arc-shaped support plates. S4. Assemble and weld the main beam: Assemble and weld on the assembly platform, adjust the radius of curvature according to the main beam structure, consider the shrinkage amount during welding in the length direction, pre-bend the wing plate after welding, use ultrasonic inspection for the welds, and assemble and fix after passing the inspection. S5. Panel alignment: Align the panels on the jig, spread them from the bottom center to both sides, spot-weld the panels to the jig, and draw various centerlines as control and inspection lines. S6. Gate leaf assembly: Assemble the gate leaf components in sequence and control the gap between each beam and the panel. S7. Welding: Adjust the welding parameters based on different welding positions, clean the surface of the welded parts and check the gas protection system, and perform welding treatment. S8. Quality inspection: Conduct visual inspection and non-destructive testing on the welds, and inspect the dimensional quality.

[0005] Preferably, the specific steps for material selection in step S1 are as follows: Select materials suitable for the manufacture of the triangular gate based on the design drawings and standard requirements; select steel materials with corresponding specifications and properties for different components. Verify the quality certification documents. Conduct chemical composition analysis on the materials, accurately measure the contents of carbon, silicon, manganese, sulfur, and phosphorus elements, and determine whether they meet the specified range. Carry out mechanical property tests, including tensile tests and impact tests, to check whether the yield strength, tensile strength, elongation rate, and impact toughness indexes of the materials meet the standards. Observe the surface of the raw materials to check for defects such as cracks, sand holes, air holes, and folds.

[0006] Preferably, the specific operating steps for material cutting in step S2 are as follows: Before cutting, organize technical personnel to familiarize with the construction drawings and relevant technical specifications. Program based on the CAD / CAM software. During the programming process, draw the contour graphics of each component according to the design drawings, and set the cutting path, cutting speed, and laser power parameters. Lift the qualified raw materials to the workbench of the CNC laser cutting machine for cutting, and monitor the cutting status in real time. After cutting, conduct random inspection on the dimensions of the cut parts, and re-cut the parts with dimensional deviations.

[0007] Preferably, the jig manufacturing steps in step S3 are as follows: Weld vertical support columns using I-beams, channel steels and angle steels, and firmly fix the support columns to the floor foundation using expansion bolts; Based on the support columns, add longitudinal horizontal support beams and transverse arc-shaped support plates, measure and determine the elevation of each node using a level, and weld them firmly to the support columns, and add diagonal braces; The longitudinal support beams and transverse support plates correspond to the positions of the partitions and main beams of the gate leaf, and the spacing distance is controlled within the range of 1000 - 1500 mm; After the jig is erected, use a theodolite to draw cross centerlines in the middle of the transverse and longitudinal directions of the jig.

[0008] Preferably, the specific steps of the main beam group welding in step S4 are as follows: Check the material and specifications of the flange plate and web plate, butt the flange plate and the web plate, grind the butt joint to remove the oxide layer and oil stain, and perform assembly welding on the assembly platform; When cutting the web plate of the main beam in the radian direction, adjust the radius of curvature. For the main beam with front and rear flange plates, according to the formula: r 主有 =r 主 - 0.7‰r 主 , calculate the radius of curvature; For the main beam equipped with only a rear flange plate and no front flange plate, according to the formula: r 主无 =r 主 + 2‰r 主 , calculate the radius of curvature; In the length direction, based on the length, height and plate thickness of the main beam, increase the welding shrinkage amount by 1.5‰ on the basis of the original design size; Butt and weld the web plate and flange plate of the main beam respectively. After welding, use a plate rolling machine to pre-bend the flange plate; Detect the weld seam, use ultrasonic waves for detection, and check whether there are defects such as pores, cracks and slag inclusions inside the weld seam; Among them, r 主有 represents the radius of curvature when the main beam has a front flange plate, r 主 represents the outer circle radius of the web plate of the main beam, r 主无 represents the radius of curvature when the main beam has no front flange plate.

[0009] Preferably, after the weld seam detection is completed, place the web plate of the main beam on the platform, assemble the pre-bent flange plate according to the designed position, and fix it with spot welding. The spot welding spacing is controlled within 200 - 300 mm; Use submerged arc automatic welding for welding. After welding is completed, lift the main beam to the specially drawn ground pattern, and use tools such as a square, a straight ruler and a tape measure to check whether the arc coincides with the ground pattern; If the overlap exceeds the range of ±2mm, adjust it by flame calibration.

[0010] Preferably, the specific steps of panel grouping in step S5 are: According to the design size, use CNC cutting machine to cut the steel plate and mix the materials according to the size of the incoming material; Set the transverse weld at the center of the main beam, using the "V"-shaped groove single-sided welding method, with the groove facing outward and leaving a 2-3mm gap; For double-sided welds, the groove is set on the inside of the gate, and the outside is cleaned. The width and height of the panel are increased by 1.2‰ welding shrinkage based on the actual size; The panel is rolled using a plate rolling machine. After rolling, the pre-sample is used for roundness calibration. Assemble the panels on the built frame, starting from the bottom center of the door leaf, and assemble them in the order of the center first and then the two sides; All panels are fixed to the frame by spot welding with connecting plates.

[0011] Preferably, the specific steps of door leaf assembly in step S6 are: After the panels are assembled, the door leaf components are assembled from the middle to the top and bottom of the door leaf, and the middle main beam, partition, secondary beam and pontoon are assembled in sequence and fixed by spot welding; After all beam systems are assembled, assemble the partitions and stiffening plate components at the horns; Part of the rigid frame is welded to the door leaf into a whole. The rigid frame is first assembled and welded into pieces on the ground, and then assembled and welded to the door leaf. After all components are assembled, they are inspected.

[0012] Preferably, in the welding of the pontoon, the surfaces are connected to each other by seam welding to form a whole. After welding, the welds are verified for air leakage and welding leaks by inflating the pontoon. If air leakage or welding leaks exist, they are repaired and the air tightness verification is continued after the repair until the air tightness standard is met. If air leakage or welding leaks do not exist, air is pumped into the pontoon and the pontoon is sealed.

[0013] Preferably, the specific steps of welding in step S7 are: During the welding process, based on different welding positions, flat welding, vertical welding, horizontal welding, overhead welding and panel climbing welding are adopted, and corresponding welding process parameters are formulated respectively; Before welding, use a grinding wheel to carefully grind the surface of the weldment to remove oil and rust impurities, and check the gas protection system of the welding equipment; For long welds and thick workpieces, submerged arc welding is used. When welding the combined weld of the main beam web and flange, a wire with a diameter of 4 mm is used, the welding current is 600 - 800 A, the voltage is 32 - 34 V, and the welding speed is 30 - 40 cm / min. When welding the panel of the gate leaf and the grillage, start from the center position of the gate leaf and carry out symmetric welding construction towards both sides simultaneously.

[0014] Preferably, in step S8, the quality inspection checks the formation of the weld, including whether the width and height of the weld are uniform, whether the surface of the weld is smooth and flat, and whether there are defects such as undercut, weld bead, porosity, and cracks.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: In the manufacturing process of the present invention, by strictly controlling the precision and taking reasonable welding deformation control measures, good results have been achieved. In terms of precision control, the deviation of the cutting size is controlled within a very small range, and the geometric tolerances of the parts processing meet the design requirements. In terms of welding deformation control, by optimizing the welding process parameters and using the methods of symmetric welding and segmented skip welding, the welding deformation of the gate leaf has been effectively controlled. Through the refinement and technological innovation of the above steps, the manufacturing efficiency and reliability of the triangular gate can be significantly improved, providing a benchmark case for similar projects and laying a solid foundation for the high-quality manufacturing of the triangular gate, enabling it to operate stably for a long time in a complex working environment and providing reliable infrastructure support for the development of water transportation. Description of the Drawings

[0016] Figure 1 It is a flowchart of the manufacturing steps of the triangular gate of the present invention; Figure 2 It is a schematic structural diagram of the triangular gate of the present invention. Detailed Embodiments

[0017] The following description is used to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments described below are only examples, and those skilled in the art can think of other obvious variations.

[0018] Refer to Figure 1 As shown, a manufacturing method of a triangular gate for a waterway lock, the manufacturing steps are as follows: S1. Select materials and detect the quality, appearance, and dimensions of the raw materials; S2. Cutting, familiarize with the construction drawings and technical specifications, control the cutting size accuracy, use the laser cutting method for cutting, program based on the CNC laser cutting machine and the matching CAD / CAM software, and put the selected materials into the CNC laser cutting machine for cutting; S3. Fabricate the jig, weld the vertical support columns using I-beams and fix them with expansion bolts, and add longitudinal horizontal support beams and transverse arc-shaped support plates. S4. Weld the main girders. Assemble and weld them on the assembly platform. Adjust the curvature radius according to the main girder structure, consider the welding shrinkage in the length direction, pre-bend the flange after welding, and use ultrasonic testing to inspect the welds. After passing the inspection, assemble and fix them. S5. Assemble the panels. Assemble the panels on the jig, spread them from the bottom center to both sides, spot-weld the panels to the jig, and draw various centerlines as control and inspection lines. S6. Assemble the gate leaf. Assemble the gate leaf components in sequence and control the gap between each beam and the panel. S7. Weld. Adjust the welding parameters based on different welding positions, clean the surface of the welded parts and check the gas protection system, and then carry out welding treatment. S8. Quality inspection. Inspect the appearance of the welds and conduct non-destructive testing, and also check the dimensional quality.

[0019] This application strictly screens materials and inspects their quality, appearance, and dimensions, which can ensure that the raw materials put into production meet the design requirements of high strength and high stability. Using steel with substandard quality may cause cracks in the gate under the action of water pressure, affecting its service life and safety. Through this step, the quality is controlled from the source, providing a reliable foundation for the subsequent manufacturing process. After being familiar with the construction drawings and technical specifications, use the laser cutting method and CNC laser cutting machine in combination with CAD / CAM software programming for blanking, which can control the dimensional deviation within an extremely small range. The precise blanking size makes the splicing of each component closer. For example, the tight splicing of the gate leaf can effectively improve the overall structural strength and water stop effect of the gate, reduce the risk of leakage, and improve the operation efficiency of the ship lock. Weld the vertical support columns using I-beams and fix them firmly, and set longitudinal horizontal support beams and transverse arc-shaped support plates, which can build a stable jig. A stable jig is the key to ensuring the accurate external dimensions of the gate leaf, providing a reliable reference for the subsequent panel assembly and gate leaf fabrication, and avoiding the influence of gate leaf dimensional deviation on the installation and use of the gate. Weld the main girders on the assembly platform, adjust the curvature radius according to the main girder structure and consider the welding shrinkage, pre-bend the flange and strictly inspect the welds, which can ensure the accurate radian of the main girder and high welding quality. As a key structural component, the performance of the main girder directly affects the load-bearing capacity of the gate. The fine welding process can enhance the overall structural strength of the gate, enabling it to withstand greater water pressure. Assemble the panels regularly on the jig, spread the panels from the bottom center to both sides and spot-weld them in place, and draw various centerlines, which helps to ensure the accurate installation position of the panels, reduce welding deformation, and the accurately installed panels can better cooperate with other components, improving the sealing performance and overall quality of the gate. Assemble the gate leaf components in sequence and control the gaps. Weld some of the rigid frames to the gate leaf in advance, which can enhance the rigidity and strength of the gate leaf, prevent deformation, and a stable gate leaf structure can ensure that the gate maintains good performance during frequent opening and closing, extending its service life; Adjust the parameters according to different welding positions, clean the surface of the welded parts and check the gas protection system, and adopt a reasonable welding sequence, which can effectively control welding deformation and residual stress, improve welding quality, and high-quality welding can make the weld firm and beautiful, enhancing the waterproof performance and overall performance of the gate; Conduct visual and non-destructive inspections on the welds, and conduct multi-link inspections and corrections on the dimensions, which can promptly detect and repair defects and deviations in the manufacturing process. Strict quality inspections can ensure that the delivered triangular gates meet high standards, guarantee the safe and stable operation of the ship lock, and reduce the later maintenance cost.

[0020] The specific steps for material selection in step S1 are as follows: Select materials suitable for the manufacture of triangular gates based on the design drawings and standard requirements; for different components, select steel with corresponding specifications and properties; Verify the quality certification documents; Conduct chemical composition analysis on the materials, accurately determine the content of carbon, silicon, manganese, sulfur, and phosphorus elements, and judge whether they meet the specified range; Carry out mechanical property tests, including tensile tests and impact tests, to check whether the yield strength, tensile strength, elongation, and impact toughness indexes of the materials meet the standards; Observe the surface of the raw materials to check for defects such as cracks, sand holes, air holes, and folds.

[0021] This application selects materials based on the design drawings and standards, and selects corresponding steels for different components, which can ensure that each component obtains the most suitable materials. Verifying the quality certification documents can quickly understand information such as the manufacturer and batch of the materials, trace the production process and quality control situation of the materials, and accurately determine the content of elements such as carbon, silicon, manganese, sulfur, and phosphorus, which can deeply understand the chemical composition of the materials.

[0022] The specific operation steps for cutting in step S2 are as follows: Before cutting, organize technical personnel to familiarize themselves with the construction drawings and relevant technical specifications; Based on CAD / CAM software for programming, during the programming process, draw the contour graphics of each component according to the design drawings, and set the cutting path, cutting speed, and laser power parameters; Lift the qualified raw materials to the workbench of the numerical control laser cutting machine for cutting, and monitor the cutting status in real time; After cutting, conduct random inspections on the dimensions of the cut parts, and re-cut the parts with dimensional deviations.

[0023] This application organizes technical personnel to be familiar with construction drawings and relevant technical specifications, enabling them to comprehensively understand the design requirements of each component of the triangular gate, such as shape, size, and precision. Using CAD / CAM software, the contour graphics of the components are drawn according to the design drawings, and the cutting path, speed, and laser power parameters are set, which can achieve precise control of the cutting process.

[0024] In step S3, the steps for fabricating the jig are as follows: Weld vertical support columns using I-beams, channel steels, and angle steels, and firmly fix the support columns to the floor foundation using expansion bolts; Based on the support columns, add longitudinal horizontal support beams and transverse arc-shaped support plates. Use a level to measure and determine the elevation of each node, and weld them firmly to the support columns, and add diagonal braces; The longitudinal support beams and transverse support plates correspond to the positions of the diaphragms and main beams of the gate leaf, and the spacing distance is controlled within the range of 1000 - 1500 mm; After the jig is erected, use a theodolite to draw a cross center line in the middle of the transverse and longitudinal directions of the jig.

[0025] This application uses I-beams, channel steels, and angle steels to weld vertical support columns, and firmly fixes them to the floor foundation with the help of expansion bolts, which can provide a stable foundation for the entire jig. Based on the support columns, add longitudinal horizontal support beams and transverse arc-shaped support plates, use a level to measure and determine the elevation of each node and weld them firmly, and also add diagonal braces.

[0026] In step S4, the specific steps for welding the main beam are as follows: Check the material and specification of the flange and web, butt the flange and web, grind the butt joint to remove the oxide layer and oil stain, and perform assembly welding on the assembly platform; When cutting the main beam web in the radian direction, adjust the radius of curvature. For the main beam with front and rear flanges, according to the formula: r 主有 =r 主 -0.7‰r 主 calculate the radius of curvature, r 主有 represents the radius of curvature when the main beam has a front flange, and r 主 represents the outer circle radius of the main beam web; For the main beam equipped with only a rear flange and no front flange, according to the formula: r 主无 =r 主 +2‰r 主 , calculate the radius of curvature, r 主无 represents the radius of curvature when the main beam has no front flange; In the length direction, based on the length, height, and plate thickness of the main beam, increase the welding shrinkage by 1.5‰ on the basis of the original design size; Butt joint and weld the main girder web and flange respectively. After welding, use a plate rolling machine to pre-bend the flange. Detect the weld seams. Use ultrasonic waves for detection to check whether there are porosity, cracks and slag inclusions inside the weld seams.

[0027] This application checks the materials and specifications of the flange and web, which can ensure that the materials used meet the design requirements and avoid affecting the performance of the main girder due to material problems. Grind the butt joint to remove the oxide layer and oil stain, which can effectively improve the quality of the welded joint. According to the setting of the main girder flange, adjust the curvature radius according to different formulas respectively. For the main girder with front and rear flanges and the main girder only equipped with rear flanges, the heat deformation conditions during welding are different. By accurately calculating and adjusting the curvature radius, the arc of the main girder after welding can better meet the design requirements.

[0028] Butt joint and weld the main girder web and flange respectively. After welding, use a high-precision plate rolling machine to pre-bend the flange. Through multiple debuggings and measurements, make the flange arc precisely coincide with the web arc. The butt weld is a type I weld with high quality requirements. Ultrasonic waves should be used for detection to ensure that there are no porosity, cracks, slag inclusions and other defects inside the weld seam. After the weld seam is detected to be qualified, place the web stably on a platform that has been horizontally calibrated, and then assemble the pre-bent flange according to the design position and fix it by spot welding. The spot welding spacing is controlled at 200 - 300 mm to ensure the stability of the assembled structure. Use submerged arc automatic welding for welding. During the welding process, strictly control the welding current, voltage and welding speed to ensure that the weld seam has a beautiful shape and reliable quality.

[0029] The specific steps of panel assembly in step S5 are as follows: According to the design dimensions, use a CNC cutting machine to cut the steel plate. Before cutting, batching should be carried out according to the incoming material dimensions. Pay special attention to the arrangement of the butt joints and joints of the panel. Try to set the transverse welds at the center of the main beam, with the groove facing outwards. Adopt the method of single-sided welding with a "V" groove. The groove should not be too large, leaving a gap of 2-3 mm. This can reduce the welding deformation and shrinkage of the panel. For double-sided welding, set the groove on the inner side of the gate and root the outside to facilitate carbon arc air gouging operation and reduce the labor intensity of workers. The width and height of the panel are increased by 1.2‰ welding shrinkage on the basis of the actual dimensions to ensure the accuracy of the panel cutting dimensions. Use a rolling machine for rolling. The radian of the horn part is small, and a CNC press can be used for pressing, with relatively guaranteed accuracy. After rolling, use a pre-template for roundness correction to control the rolling radius and radian to meet the design requirements. After all the panels are prepared, carry out panel assembly on the jig. Starting from the bottom center of the gate leaf, spread out to the left and right along the center line on the jig. The assembly of the first row of panels is very crucial. The bottom edge of the panel must be perpendicular to the longitudinal center line, and then lay other panels. To reduce welding deformation, all panels should be spot-welded to the jig with connecting plates. Finally, draw the assembly position lines of each beam (plate) on the panel, and also draw the longitudinal center line of the gate, the center lines of the top (bottom) main beams, and the water stop center line and extend them to make marks. These center lines are both control lines and final inspection lines.

[0030] The specific steps of the gate leaf assembly in step S6 are as follows: After the panel assembly is completed, assemble the gate leaf components in the order from the middle to the top and bottom of the gate leaf. Assemble the middle main beam, partition plate, secondary cross beam and floating box in turn, and fix them with spot welding; After all the beam systems are assembled, assemble the partition plate and stiffening plate components at the horn position; Weld part of the rigid frame and the gate leaf into a whole. First, draw lines, assemble and weld the rigid frame into a sheet on the ground, and then assemble and weld it with the gate leaf. After all the components are assembled, conduct inspections.

[0031] During the welding of the floating box after the floating box is assembled, after splicing each surface of the floating box, first use spot welding technology to carry out dot welding on the spliced floating box for the overall forming of the floating box. After the floating box is shaped, weld the joints between each surface by seam welding technology. After welding all the surface welds, conduct an airtightness test on the floating box by inflating the floating box to check whether there is air leakage or lack of welding. If there is air leakage or lack of welding, repair weld it and continue to perform the airtightness verification until it meets the airtightness standard. If there is no air leakage or lack of welding, fill the floating box with air and conduct a sealing treatment on the floating box.

[0032] The present application assembles the main beam, partition, secondary cross beam and pontoon in sequence from the middle to the top and bottom of the door leaf, and fixes them by spot welding, so as to build a stable basic structure for the door leaf. After all the beam systems are assembled, the partition and stiffening plate components at the horn position are assembled. This assembly sequence fully considers the particularity of the structure of the horn position.

[0033] The specific steps of welding in step S7 are: During the welding process, based on different welding positions, flat welding, vertical welding, horizontal welding, overhead welding and panel climbing welding are adopted, and corresponding welding process parameters are formulated respectively; Before welding, use a grinding wheel to carefully grind the surface of the weldment to remove oil and rust impurities, and check the gas protection system of the welding equipment; For long welds and thick welds, submerged arc welding is used. When welding the combined welds of the web and wing plates of the main beam, a 4mm diameter welding wire is used, the welding current is 600-800A, the voltage is 32-34V, and the welding speed is 30-40cm / min; When welding the door leaf panel and the beam grid, start from the center of the door leaf and weld symmetrically to both sides at the same time.

[0034] This application formulates corresponding process parameters according to different welding positions such as flat welding, vertical welding, horizontal welding, overhead welding and slope welding, which can adapt to the welding characteristics of each position. Before welding, the surface of the weldment is polished with a grinding wheel to remove oil and rust impurities, which can make the metal at the weld joint better fused and avoid pores and slag inclusion defects. Submerged arc welding is used for long welds and thick weldments. It has a large welding current and a fast deposition speed, which can reduce the number of welding layers and improve efficiency.

[0035] The quality inspection in step S8 is carried out by checking the formation of the weld, including whether the width and height of the weld are uniform, whether the weld surface is smooth and flat, and whether there are undercuts, weld bumps, pores and cracks.

[0036] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions only describe the principles of the present invention. The present invention may be subject to various changes and improvements without departing from the spirit and scope of the present invention, and these changes and improvements fall within the scope of the present invention claimed.

Claims

1. A manufacturing method of a triangular gate for a waterway lock, characterized in that, The manufacturing steps are: S1. Select materials and test the quality, appearance and size of raw materials; S2. Cutting materials: Be familiar with construction drawings and technical specifications, control the size accuracy of cutting materials, use laser cutting method for cutting materials, program based on CNC laser cutting machine, and use CAD / CAM software to place the selected materials into the CNC laser cutting machine for cutting; S3, making a tire frame, using I-beams to weld vertical support columns and fix them with expansion bolts, and adding longitudinal horizontal support beams and transverse arc support plates; S4, main beam assembly welding, assembly and welding on the assembly platform, adjust the curvature radius according to the main beam structure, consider the welding shrinkage in the length direction, pre-bend the wing plate after welding, use ultrasonic testing of the weld, and assemble and fix after passing the test; S5. Assemble the panels on the frame, spread them out from the bottom center to both sides, spot weld the panels and the frame, and draw various center lines as control and detection lines; S6, door leaf assembly, assemble the door leaf components in sequence and control the gap between each beam and the panel; S7, welding, adjusting welding parameters based on different welding positions, cleaning the weldment surface and checking the gas protection system, and performing welding processing; S8. Quality inspection, visual inspection and non-destructive testing of welds, and dimensional quality inspection.

2. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that The specific steps for door leaf assembly in step S6 are: After the panels are assembled, the door leaf components are assembled from the middle to the top and bottom of the door leaf, and the middle main beam, partition, secondary beam and pontoon are assembled in sequence and fixed by spot welding; After all beam systems are assembled, assemble the partitions and stiffening plate components at the horns; Part of the rigid frame is welded to the door leaf into a whole. The rigid frame is first assembled and welded into pieces on the ground, and then assembled and welded to the door leaf. After all components are assembled, they are inspected.

3. The manufacturing method of a triangular lock gate for a waterway lock according to claim 2, characterized in that, In the welding of the pontoon, the various surfaces are connected to each other by seam welding to form a whole. After welding, the pontoon is inflated to perform an airtightness test to verify whether there is any leakage or weld leakage. If there is any leakage or weld leakage, it will be repaired and the airtightness verification will be continued after the repair welding until it meets the airtightness standard. If there is no leakage or weld leakage, air will be flushed into the pontoon and the pontoon will be sealed.

4. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that, The specific steps for selecting materials in step S1 are: Select materials suitable for triangular gate manufacturing based on design drawings and standard requirements; select steel materials with corresponding specifications and performance for different components; Verify quality certification documents; Analyze the chemical composition of the material, accurately determine the content of carbon, silicon, manganese, sulfur and phosphorus, and determine whether it meets the specified range; Conduct mechanical property tests, including tensile tests and impact tests, to check whether the yield strength, tensile strength, elongation and impact toughness of the material meet the standards; Observe the surface of the raw materials to check for cracks, sand holes, pores and folding defects.

5. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that The specific operation steps of material unloading in step S2 are as follows: Before cutting, organize technical personnel to be familiar with construction drawings and relevant technical specifications; Programming is based on CAD / CAM software. During the programming process, the outline of each component is drawn according to the design drawings, and the cutting path, cutting speed and laser power parameters are set; Lift the qualified raw materials to the working table of the CNC laser cutting machine for cutting, and monitor the cutting status in real time. After cutting, conduct spot checks on the dimensions of the cut parts. For parts with dimensional deviations, re-cut them.

6. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that The steps for making the jig in step S3 are as follows: Weld vertical support columns using I-beams, channel steels and angle steels, and firmly fix the support columns to the floor foundation using expansion bolts. Based on the support columns, add longitudinal horizontal support beams and transverse arc-shaped support plates. Use a level to measure and determine the elevations of each node, and weld them firmly to the support columns. Add diagonal braces. The longitudinal support beams and transverse support plates correspond to the positions of the diaphragms and main beams of the gate leaf, and the spacing distance is controlled within the range of 1000 - 1500 mm. After the jig is erected, use a theodolite to draw cross centerlines in the middle of the transverse and longitudinal directions of the jig.

7. A manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that, The specific steps for the group welding of the main beam in step S4 are as follows: Check the materials and specifications of the flange plates and webs. Butt the flange plates and webs, grind the butt joints to remove the oxide layer and oil stains, and perform assembly welding on the assembly platform. When cutting the main beam web in the radian direction, adjust the radius of curvature. For the main beam with front and rear wing plates, according to the formula: r 主有 =r 主 - 0.7‰r 主 , calculate the radius of curvature; For the main beam equipped with only rear wing plates and no front wing plates, according to the formula: r 主无 = r 主 + 2‰r 主 , calculate the radius of curvature; In the length direction, based on the length, height and plate thickness of the main beam, increase the welding shrinkage amount by 1.5‰ on the basis of the original design dimensions. Butt and weld the web and flange plates of the main beam respectively. After welding, use a plate rolling machine to pre-bend the flange plates. Detect the welds. Use ultrasonic waves for detection to check whether there are defects such as pores, cracks and slag inclusions inside the welds. After the weld detection is completed, place the web of the main beam on the platform, assemble the pre-bent flange plates according to the designed positions, and fix them with spot welding. The spot welding spacing is controlled within 200 - 300 mm. Use submerged arc automatic welding for welding. After welding is completed, lift the main beam to the specially drawn ground pattern, and use tools such as angle rulers, straight rulers and tape measures to check whether the arc coincides with the ground pattern. If the coincidence degree exceeds the range of ±2 mm, adjust it by means of flame calibration. Among them, r 主有 represents the radius of curvature when the main beam has a front wing plate, and r 主 represents the outer circle radius of the main beam web, and r 主无 represents the radius of curvature when the main beam has no front wing plate.

8. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that, The specific steps for the panel assembly in step S5 are as follows: According to the design dimensions, use a CNC cutting machine to cut the steel plate and allocate materials based on the incoming material dimensions. Set the transverse weld at the center of the main beam, and use the "V" - shaped groove single - side welding method with the groove facing outwards, leaving a gap of 2 - 3 mm. For the welds of double - side welding, set the groove on the inner side of the gate, root - clean the outside, and increase the welding shrinkage amount by 1.2‰ for the width and height of the panel on the basis of the actual dimensions. Use a plate rolling machine to roll the cut panel. After rolling is completed, use a pre - template for circularity calibration. Conduct panel assembly on the erected jig. Start from the bottom center of the gate leaf and assemble it to both sides in the order of first in the middle and then on both sides. All panels are fixed to the jig with spot welding using connecting plates.

9. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that, The specific steps for welding in step S7 are as follows: During the welding process, based on different welding positions, adopt flat welding, vertical welding, horizontal welding, overhead welding and uphill welding of the panel, and formulate corresponding welding process parameters respectively. Before welding, carefully grind the surface of the welded parts with a grinding wheel to remove oil stains and rust impurities, and check the gas protection system of the welding equipment. For long welds and thick workpieces, submerged arc welding is adopted. When welding the combined weld of the main beam web and flange, a wire with a diameter of 4 mm is used, the welding current is 600 - 800 A, the voltage is 32 - 34 V, and the welding speed is 30 - 40 cm / min. When welding the panel of the gate leaf and the grillage, start from the central position of the gate leaf and carry out symmetric welding construction towards both sides simultaneously.

10. The manufacturing method of a triangular lock gate for a waterway lock according to claim 1, characterized in that, In step S8, the quality inspection is carried out by checking the formation of the weld, including whether the width and height of the weld are uniform, whether the surface of the weld is smooth and flat, and whether there are defects such as undercut, weld bead, porosity and crack.

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