Manufacturing process of half-through concrete-filled steel tube combined arch bridge side girder

Abstract

The invention relates to a half-through concrete-filled steel tube combined arch bridge side girder manufacturing process, which comprises the following steps of: shortening the length of each side beam section forming a side girder according to the active tension closure requirement of the side girder, adjusting the position of a partition plate of each side beam section and the position of an anchor box, and processing according to a redesigned drawing, the manufacturing method comprises the following steps: preparing plate units, sequentially assembling a bottom plate unit, a partition plate unit, a web plate unit and a top plate unit to form a box-shaped edge beam section, assembling and welding a joint plate unit, assembling and welding an anchor box, assembling and welding the anchor box on an edge main beam, and finally drilling holes to complete the manufacturing of the edge beam section. According to the edge main beam manufacturing process, the length size of each edge beam section of the edge main beam is redesigned firstly, the positions of partition plates of the edge beam sections and the positions of anchor boxes are correspondingly adjusted, and then the bottom plate unit, the partition plate unit, the web plate unit, the top plate unit and the anchor boxes are sequentially assembled and welded, so that the edge main beam is manufactured. And a high-precision side girder meeting the requirement of active tension technology construction can be manufactured.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of steel tube concrete composite arch bridge manufacturing, in particular to a half-through steel tube concrete composite arch bridge side girder manufacturing process. BACKGROUND

[0002] The newly built Jianyang Tuojiang super major bridge of Chongqing-Yunnan middle line railway is a (72+320+72) m half-through non-thrust composite arch bridge. The side span is a steel concrete composite box arch, and the middle span is a steel tube concrete arch. The middle span is connected together by the side arch and the orthotropic steel bridge deck panel. In order to realize the non-horizontal thrust of the arch support, the side arch and the steel girder are used as the tie rod, and the force is transmitted out from the side arch by the tensioned steel girder to offset the horizontal force of the steel tube arch.

[0003] In order to realize the above design, after the tension calculation, the position of the steel girder partition plate and the anchor box need to be pre-offset. In order to realize the manufacturing precision and the variable girder manufacturing line shape of the structure, the construction process and the welding deformation shrinkage need to be considered in detail to achieve the design intention. However, this bridge structure is the first bridge in the world to use active tensioning technology to close, and there is no experience to learn from other bridges. At the same time, the side girder structure is complex, and the welding deformation amount is difficult to accurately control. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a half-through steel tube concrete composite arch bridge side girder manufacturing process with high manufacturing precision.

[0005] In order to solve the above technical problem, the technical scheme of the present application is as follows: a half-through steel tube concrete composite arch bridge side girder manufacturing process, which is characterized by the following steps: first, according to the active tensioning closure requirement of the side girder, the length of each side girder segment constituting the side girder is designed to be shortened, and the position of the side girder segment partition plate and the anchor box is adjusted. According to the redrawing of the drawing after the design, each plate unit required by different parts of the side girder is prepared, and then the bottom plate unit, the partition plate unit, the web plate unit and the top plate unit are assembled in turn to form the box-shaped side girder segment. The box body weld is welded, then the joint plate unit is assembled and welded, and then the anchor box is assembled and welded on the side girder. Finally, the hole is drilled to complete the manufacturing of the side girder segment.

[0006] Further, the steps are specifically as follows: S1: first, the side girder is divided into several side girder segments. In order to realize the active tensioning closure, after the construction calculation, the length of each side girder segment is shortened, and the position of the side girder segment partition plate and the anchor box is adjusted. The position is resurveyed and the construction drawing is drawn according to the adjusted position. S2: according to the drawing of the construction drawing, the steel plate is cut, the wall plate unit and the partition plate unit are made, the wall plate unit is a horizontal steel plate, the partition plate unit is composed of a plurality of partition plates, the long axis direction of the partition plate is consistent with the long axis direction of the wall plate unit during assembly, and the partition plates are placed side by side along the width direction of the wall plate unit, and the longitudinal baseline and the transverse baseline are drawn on the wall plate unit; S3: the wall plate unit and the partition plate unit are assembled on the plate unit jig, the unevenness of the partition plate is trimmed by flame, the other three edges of the partition plate are processed based on the contact edge of the partition plate and the wall plate unit, and the size of the partition plate is ensured; S4: the assembled wall plate unit and partition plate unit are placed on the welding robot inverse deformation platform, the welding robot is used to weld the wall plate unit and the partition plate unit, and an integrated plate unit is formed, the plate unit is used as the bottom plate, the partition plate, the web plate and the top plate of the edge beam segment, and the welded plate unit is placed on the plate unit assembly jig to make the plate unit flat; S5: the bottom plate unit is assembled, the edge main beam ground pattern line is drawn on the ground according to the shape of the bottom plate of the edge beam segment, the bottom plate is placed on the jig until the bottom plate coincides with the ground pattern line, the bottom plate is fixed on the jig, and the partition plate line and the web plate line are drawn on the bottom plate according to the transverse baseline and the longitudinal baseline; S6: the partition plate unit is assembled, the partition plate is assembled on the bottom plate according to the partition plate line in step S5, and the perpendicularity of the partition plate and the spacing between the partition plates are ensured; S7: the web plate unit is assembled, the web plate is assembled on the bottom plate on both sides of the partition plate according to the web plate line in step S5, and the width and height of the edge beam segment are controlled by controlling the width and height of the partition plate and the baseline; S8: the top plate unit is assembled, the top plate is assembled at the top end of the partition plate and the web plate to form a box-shaped edge beam segment, one side of the bottom plate and the top plate has an extension segment extending out of one of the web plates, the top end of the web plate has an anchor plate extending out of the top plate, a through hole is formed in the top plate for the anchor plate to pass through, and an anchor box baseline is drawn on the anchor plate; S9: weld the box weld, weld the partition plate and the main longitudinal seam, and after flaw detection, proceed to step S10; S10: assemble and weld the joint plate unit, assemble the joint plate on the side wall of the web plate according to the transverse baseline, the upper and lower sides of the joint plate are located between the extension segments of the bottom plate and the top plate, the position accuracy of the joint plate is controlled, and the remaining welds are welded; S11: Assemble the anchor box. The anchor box consists of anchor plates, anchor pipes, pressure plates, and top sealing plates. There are two pressure plates, symmetrically distributed on both sides of the bottom surface of the top sealing plate. The bottom ends of the two pressure plates are fixed by a pair of anchor plates. An anchor pipe is also provided on the anchor plate, passing through the space between the two pressure plates and extending from the top sealing plate. The top sealing plate also has a through hole for the two anchor pipes to pass through. The contact surface between the anchor pipe and the anchor plate is ground flat, and the anchor pipe is welded to the anchor plate, ensuring that the anchor pipe is perpendicular to the anchor plate. The distance between the two pressure plates is controlled by several positioning rods. The pressure plates and anchor plates are symmetrically welded. After the welding flaw detection is completed, the top sealing plate is welded to seal it. The positioning line for subsequent assembly is reserved on the pressure plate between the two anchor plates, completing the preparation of the anchor box. S12: The anchor box and the side beam are assembled and welded in sections. The assembled anchor box and the two anchor plates on the side beam section are assembled according to the anchor box baseline position, and the remaining welds are welded. The side beam section is trimmed and cut at the non-reference head end according to the reference head. S13: Drilling. Drill holes in the template with the horizontal baseline as the reference to complete the fabrication of the side beam segments.

[0007] Furthermore, in step S2, when cutting the steel plate, due to the influence of welding shrinkage, if the construction is carried out according to the design dimensions of the construction drawing, it will cause the position deviation of the partition plate of the side beam segment and the length of the side beam segment to become shorter. Therefore, welding shrinkage allowance is set between the positions of each partition plate of the side beam segment before cutting.

[0008] Furthermore, in step S2, the longitudinal baseline is a center baseline of the wall panel unit drawn along the long axis of the wall panel unit, and the transverse baseline is a side baseline drawn along the width of the wall panel unit on one side of the wall panel unit, and one end of each partition plate is aligned with the transverse baseline.

[0009] The advantages of this invention are as follows: The manufacturing process of the side main beam in this invention involves redesigning the length dimensions of each side beam segment of the side main beam, adjusting the positions of the side beam segment partitions and anchor boxes accordingly, and then assembling and welding the bottom plate unit, partition unit, web plate unit, top plate unit and anchor box in sequence. By coordinating multiple reference lines at different positions, a high-precision side main beam that meets the requirements of active tensioning technology can be manufactured.

[0010] Welding of the plate unit is carried out with the assistance of a welding robot. The welding robot provides stable operation, effectively ensuring weld quality and controlling welding shrinkage. The anti-deformation jig can offset some of the welding deformation.

[0011] This process mainly consists of a ground line, a plate unit welding robot, a plate unit straightening jig, and a side beam segment assembly jig. After assembling the plate units according to the design drawings, the plate unit welding robot is used for welding. After welding, the plate unit straightening jig is used to straighten the plate units. Then, the straightened plate units are placed on the side beam segment assembly jig for assembly and welding to form side beam segments. Finally, the completed side beam segments are straightened and drilled. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the side beam of the mid-span steel-concrete composite arch bridge of the present invention.

[0013] Figure 2 This is a schematic diagram of the longitudinal and transverse baselines in this invention.

[0014] Figures 3-9 This is a schematic diagram of the assembly process in this invention. Detailed Implementation

[0015] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0016] like Figure 1 The diagram shows a side beam of a mid-span steel-concrete composite arch bridge. The side beam includes a main side beam 1 and two side box arches 2, which are respectively located on both sides of the main side beam 1. The diagram shows only half of the entire side beam structure; the other half is connected to... Figure 1 The structure shown is the same, with the side beam divided into several segments, which are defined as A1, A2, A3, B1, C1, D1, C2, D2, E1, E2, F1, F2, F3, F4, F5, F6, F7, F8, F9 and F10 in sequence. Among them, A1, A2 and A3 are the arch-beam combination area, B1 is the widening area, C1 and C2 are the column area, D1 and D2 are the regular area, E1 and E2 are the arch-beam intersection area, and F1, F2, F3, F4, F5, F6, F7, F8, F9 and F10 are the hanger area.

[0017] The fabrication process of the side main beams of the mid-span steel-concrete composite arch bridge of the present invention is the fabrication process of F1, F2, F3, F4, F5, F6, F7, F8, F9 and F10, which is specifically achieved through the following steps: S1: First, the main beam 1 is divided into several side beam segments. In order to achieve active tensioning and closure, after construction calculation, the length of each side beam segment is shortened and the position of the side beam segment partition and anchor box is adjusted. The cross-section of the side beam segment has an outer height of 2.5m and an inner width of 1.6m. At the beam end, in order to adapt to the connection with the side arch, the width gradually changes to 3.0m (i.e., B1). The center distance is 17.2m and the bridge deck width is 18.8~20.2m. The layout is redone according to the adjusted position, and the construction drawings are drawn.

[0018] S2: Cut steel plates according to the drawn construction drawings, and make wall panel units and partition units. During the cutting process, due to the influence of welding shrinkage, if the construction is carried out according to the design dimensions of the construction drawings, it will cause the position deviation of the partition of the side beam segment and the length of the side beam segment will be shortened. Therefore, welding shrinkage allowance is set between the positions of each partition of the side beam segment before cutting.

[0019] The wall panel unit is a horizontal steel plate, and the partition unit is composed of several partitions. During assembly, the long axis of the partitions is aligned with the long axis of the wall panel unit. The partitions are placed side by side along the width of the wall panel unit. The longitudinal and transverse baselines are drawn on the wall panel unit.

[0020] Specifically, such as Figure 2 As shown, the longitudinal baseline is a center baseline of the wall panel unit drawn along the long axis of the wall panel unit, and the transverse baseline is a side baseline drawn along the width of the wall panel unit on one side of the wall panel unit, and one end of each partition plate is aligned with the transverse baseline.

[0021] S3: Assemble the wall panel unit and partition unit on the panel unit jig, and use flame to trim the unevenness of the partition plate. Using the contact edge between the partition plate and the wall panel unit as a reference, process the other three sides of the partition plate to ensure the size of the partition plate.

[0022] S4: The assembled wall panel units and partition units are placed on the anti-deformation platform of the welding robot. The welding robot welds the wall panel units and partition units to form a single plate unit. This plate unit serves as the bottom plate, partition, web plate, and top plate of the side beam segment. The welded plate unit is then placed on the plate unit assembly jig and heat-straightened to a flat surface. Welding of the plate units is achieved with the assistance of the welding robot. The welding robot provides stable operation, effectively ensuring weld quality and controlling welding shrinkage. The anti-deformation jig can offset some of the welding deformation.

[0023] S5: Assemble the base plate unit, such as Figure 3 As shown, the bottom plate of the segmented edge beam is used as the shape of the bottom surface of the jig. The ground pattern line of the edge main beam is drawn on the ground. The jig is placed on the jig until the bottom plate coincides with the ground pattern line. The bottom plate is then fixed to the jig. Based on the horizontal and vertical baselines, the partition line and web line are drawn on the bottom plate.

[0024] S6: Assemble the partition unit, such as Figure 4 As shown, according to the partition line in step S5, the partitions are assembled on the base plate to ensure the verticality of the partitions and the spacing between them. As the inner core of the side beam segment, the manufacturing accuracy of the partitions directly affects the geometric dimensions of the side beam segment. Therefore, controlling the assembly accuracy of the partitions provides a good foundation for the high precision of the geometric dimensions of the subsequent side beam segment.

[0025] S7: Assemble the web plate unit, such as Figure 5 As shown, according to the web line in step S5, the webs are assembled on both sides of the diaphragm on the bottom plate, and the width and height of the side beam segments are controlled by controlling the width and height of the diaphragm and the baseline.

[0026] S8: Assemble the top plate unit, such as Figure 6 As shown, a top plate is assembled at the top of the partition and the web to form a box-shaped side beam segment. One side of the bottom plate and the top plate has an extension that extends out of one of the webs. The top of the web has an anchor plate that extends out of the top plate. A through hole is opened on the top plate to allow the anchor plate to pass through. An anchor box baseline is drawn on the anchor plate.

[0027] S9: Weld the box body welds, weld the partitions and main longitudinal seams. After flaw detection, proceed to step S10.

[0028] S10: Assemble the connector plate unit and weld it, such as Figure 7 As shown, the joint plate is assembled on the side wall of the web with the transverse baseline as the reference. The upper and lower sides of the joint plate are located between the extensions of the bottom plate and the top plate, respectively. The positional accuracy of the joint plate is controlled, and the remaining welds are welded.

[0029] S11: Assemble the anchor box, such as Figure 8 As shown, the anchor box consists of anchor plates, anchor pipes, pressure plates, and a top sealing plate. There are two pressure plates, symmetrically distributed on both sides of the bottom surface of the top sealing plate. The bottom ends of the two pressure plates are fixed by a pair of anchor plates. An anchor pipe, passing between the two pressure plates and extending from the top sealing plate, is also provided on the anchor plates. A through hole for the two anchor pipes to pass through is also provided on the top sealing plate. The contact surfaces of the anchor pipe and the anchor plates are ground smooth, and the anchor pipe is welded to the anchor plates, ensuring the perpendicularity of the anchor pipe to the anchor plates. Several positioning rods control the distance between the two pressure plates to better control welding and hoisting deformation during subsequent welding of the pressure plates and anchor plates. The pressure plates and anchor plates are welded symmetrically. After welding flaw detection, the top sealing plate is welded to seal the structure. A positioning line for subsequent assembly is reserved on the pressure plates between the two anchor plates, completing the anchor box preparation. By controlling the precision during the anchor box preparation process, the verticality of the lifting rod area can be better controlled.

[0030] S12: The anchor box and the side beam are welded in sections, such as... Figure 9As shown, the assembled anchor box and the two anchor plates on the side beam segment are assembled according to the anchor box baseline position, and the remaining welds are welded. The side beam segment is trimmed and cut at the non-reference head end according to the reference head.

[0031] S13: Drilling. Drill holes in the template with the horizontal baseline as the reference to complete the fabrication of the side beam segments.

[0032] The manufacturing process of the side main beam in this invention involves first redesigning the length dimensions of each side beam segment of the side main beam, and correspondingly adjusting the positions of the side beam segment partitions and anchor boxes. Then, the bottom plate unit, partition unit, web plate unit, top plate unit, and anchor boxes are assembled and welded in sequence. By coordinating multiple reference lines at different positions, a high-precision side main beam that meets the requirements of active tensioning technology can be manufactured.

[0033] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A manufacturing process for the side main beam of a mid-span steel-concrete composite arch bridge, characterized in that: The process includes the following steps: First, based on the active tensioning and closure requirements of the main girder, the length of each side beam segment constituting the main girder is shortened and the positions of the side beam segment partitions and anchor boxes are adjusted. According to the redesigned drawings, the various plate units required for different parts of the main girder are first prepared, and then the bottom plate unit, partition unit, web plate unit and top plate unit are assembled in sequence to form a box-shaped side beam segment. The box welds are then welded, the joint plate units are assembled and welded, the anchor boxes are assembled and welded, and the anchor boxes are assembled and welded onto the main girder. Finally, holes are drilled to complete the fabrication of the side beam segment.

2. The fabrication process of the side main beam of the mid-span steel-concrete composite arch bridge according to claim 1, characterized in that: The specific steps are as follows: S1: First, the main beam is divided into several side beam segments. In order to achieve active tensioning and closure, after construction calculation, the length of each side beam segment is shortened and the position of the side beam segment partition and anchor box is adjusted. The layout is redone according to the adjusted position and the construction drawing is drawn. S2: Cut steel plates according to the drawn construction drawings, and make wall panel units and partition units. The wall panel unit is a horizontal steel plate, and the partition unit is composed of several partitions. When assembling, the long axis of the partition is consistent with the long axis of the wall panel unit. Each partition is placed side by side along the width of the wall panel unit. Draw the longitudinal baseline and the transverse baseline on the wall panel unit. S3: Assemble the wall panel unit and partition unit on the panel unit jig, and use flame to trim the unevenness of the partition plate. Using the contact edge between the partition plate and the wall panel unit as a reference, process the other three sides of the partition plate to ensure the size of the partition plate. S4: Place the assembled wall panel unit and partition unit on the welding robot's anti-deformation platform, and use the welding robot to weld the wall panel unit and partition unit to form an integrated plate unit. The plate unit is used as the bottom plate, partition, web plate and top plate of the side beam segment. The welded plate unit is then placed on the plate unit assembly jig and the plate unit is heat-straightened to be flat. S5: Assemble the base plate unit. Using the base plate of the side beam segment as the shape of the bottom surface of the jig, draw the ground pattern line of the side main beam on the ground. Place it on the jig until the base plate coincides with the ground pattern line, and fix the base plate to the jig. Draw the partition line and web line on the base plate according to the horizontal and vertical baselines. S6: Assemble the partition unit. According to the partition line in step S5, assemble the partition on the base plate to ensure the verticality of the partition and the spacing between the partitions. S7: Assemble the web plate unit. According to the web plate line in step S5, assemble the web plates on both sides of the diaphragm on the bottom plate respectively. Control the width and height of the side beam segments by controlling the width and height of the diaphragm and the baseline. S8: Assemble the top plate unit, assemble the top plate at the top of the partition and the web to form a box-shaped side beam segment, and each side of the bottom plate and the top plate has an extension section extending out of one of the web plates. The top of the web plate has an anchor plate extending out of the top plate. A through hole is opened on the top plate to allow the anchor plate to pass through, and the anchor box baseline is drawn on the anchor plate. S9: Weld the box body welds, weld the partitions and main longitudinal seams, and proceed to step S10 after flaw detection is completed; S10: Assemble and weld the joint plate unit. Assemble the joint plate on the side wall of the web with the transverse baseline as the reference. The upper and lower sides of the joint plate are located between the extensions of the bottom plate and the top plate, respectively. Control the positional accuracy of the joint plate and weld the remaining welds. S11: Assemble the anchor box. The anchor box consists of anchor plates, anchor pipes, pressure plates, and top sealing plates. There are two pressure plates, symmetrically distributed on both sides of the bottom surface of the top sealing plate. The bottom ends of the two pressure plates are fixed by a pair of anchor plates. An anchor pipe is also provided on the anchor plate, passing through the space between the two pressure plates and extending from the top sealing plate. The top sealing plate also has a through hole for the two anchor pipes to pass through. The contact surface between the anchor pipe and the anchor plate is ground flat, and the anchor pipe is welded to the anchor plate, ensuring that the anchor pipe is perpendicular to the anchor plate. The distance between the two pressure plates is controlled by several positioning rods. The pressure plates and anchor plates are symmetrically welded. After the welding flaw detection is completed, the top sealing plate is welded to seal it. The positioning line for subsequent assembly is reserved on the pressure plate between the two anchor plates, completing the preparation of the anchor box. S12: The anchor box and the side beam are assembled and welded in sections. The assembled anchor box and the two anchor plates on the side beam section are assembled according to the anchor box baseline position, and the remaining welds are welded. The side beam section is trimmed and cut at the non-reference head end according to the reference head. S13: Drilling. Drill holes in the template with the horizontal baseline as the reference to complete the fabrication of the side beam segments.

3. The fabrication process of the side main beam of the mid-span steel-concrete composite arch bridge according to claim 2, characterized in that: In step S2, when cutting steel plates, welding shrinkage affects the construction. If the construction is carried out according to the design dimensions in the construction drawings, it will cause the position deviation of the partition plate of the side beam segment and the length of the side beam segment will be shortened. Therefore, welding shrinkage allowance is set between the positions of each partition plate of the side beam segment before cutting.

4. The fabrication process of the side main beam of the mid-span steel-concrete composite arch bridge according to claim 2, characterized in that: In step S2, the longitudinal baseline is a center baseline of the wall panel unit drawn along the long axis of the wall panel unit, and the transverse baseline is a side baseline drawn along the width of the wall panel unit on one side of the wall panel unit, and one end of each partition plate is aligned with the transverse baseline.

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