Method for manufacturing an elliptic suspension bridge steel tower fish-belly section tower segment

Abstract

The application discloses a kind of production methods of elliptical suspension bridge steel tower fish belly type section tower section, it is related to bridge construction technical field, comprising the following steps: S1: making various parts, and the parts include outer top plate unit, inner top plate unit, outer bottom plate unit, inner bottom plate unit, outer web unit, inner web unit and baffle unit;S2: the parts in step S1 are assembled and welded, form lower block, middle block and upper block, and the lower block is box type structure, and the middle block, upper block is open channel type structure;S3: the lower block, middle block and upper block are assembled and welded, and the tower section section is made;The application solves the technical problems that fish belly type section tower section is difficult to make in the prior art.

Description

Technical Field

[0001] This invention relates to the field of bridge construction technology, and in particular to a method for manufacturing a fish-belly cross-section tower segment of an elliptical suspension bridge steel tower. Background Technology

[0002] As one of the main structural forms of long-span bridges, suspension bridges' towers are not only important load-bearing components but also key carriers embodying bridge aesthetics and regional cultural characteristics. In recent years, with the increasing demands for aesthetic appeal, cultural significance, and structural innovation in bridge construction, a number of bridge tower designs employing unique cross-sections and shapes have emerged.

[0003] Some existing bridge steel towers employ a fish-belly cross-section to create a unique spatial curved surface, achieving structural functionality while imbuing the bridge with distinct regional cultural connotations and visual recognizability. The following problems exist in the fabrication of these steel towers: (1) Difficulty in forming the spatial curved web: The outer web of the fish-belly cross section is a multi-directional spatial curved surface with large plate thickness and high material strength. It is difficult to achieve the precise forming of the designed curvature using traditional bending technology, and defects such as springback and local wrinkling are prone to occur. (2) Difficulty in controlling welding deformation: Due to the complex cross-sectional structure and dense and asymmetrical distribution of welds, the temperature stress and deformation generated during welding are difficult to effectively constrain through conventional processes. (3) High risk in the overall fabrication and hoisting of ultra-heavy and ultra-large segments: The fish-belly tower segment is huge in volume and extremely heavy. Large lifting equipment is required in the assembly, turning, and hoisting processes. The working space is limited, and stability control is difficult. Summary of the Invention

[0004] The purpose of this invention is to provide a method for manufacturing fish-belly cross-section tower segments of elliptical suspension bridge steel towers, which solves the technical problem of difficulty in manufacturing fish-belly cross-section tower segments in the prior art.

[0005] This application discloses a method for manufacturing a fish-belly cross-section tower segment of an elliptical suspension bridge steel tower, including the following steps: S1: Manufacturing various components, including an outer top plate unit, an inner top plate unit, an outer bottom plate unit, an inner bottom plate unit, an outer web plate unit, an inner web plate unit, and a partition plate unit; S2: Assemble and weld the components from step S1 to form a lower block, a middle block, and an upper block. The lower block is a box-shaped structure, and the middle block and the upper block are open slot-shaped structures. S3: Assemble and weld the lower block, middle block, and upper block to form a tower segment. The specific details of this step are as follows: S301: Arrange the segmental assembly frame according to the height of the outer web unit curved surface of the lower block, lay out the ground line, locate the lower block with the ground line as the reference, and inspect and adjust the lower block to make it horizontal. S302: Place the middle block on the lower block, and adjust the horizontal and vertical positions of the middle block so that the middle block is aligned with the lower block; S303: Adjust the distance between the middle block and the lower block, allow 2mm for welding shrinkage, conduct inspection, and secure the blocks after passing the inspection. S304: Place the upper block on the middle block, and adjust the horizontal and vertical positions of the upper block so that the upper block is aligned with the middle block; S305: Adjust the distance between the middle block and the upper block, allow 2mm for welding shrinkage, conduct inspection, and secure the blocks after passing the inspection. S306: Weld in sequence, after welding, adjust the box opening size, cut off the excess at the upper and lower ends, cut out the bevels at the upper and lower ends, and form the tower segment.

[0006] This application decomposes the fish-belly cross-section of the steel tower into multiple smaller, easier-to-manufacture sub-units (through longitudinal segmentation and further segmentation along the axial direction), and with precise positioning, reduces the manufacturing difficulty while ensuring the manufacturing accuracy of the complex curved web.

[0007] Based on the above technical solution, the present application can be further improved as follows: Furthermore, the specific steps for fabricating the outer web unit in step S1 are as follows: S101: Perform blanking to obtain multiple side outer web plates, multiple middle outer web plates and web plate ribs, and use laser scribing to scribing double-sided lines to draw all baselines and auxiliary lines; S102: A rolling machine is used to roll multiple intermediate outer web plates, and a bending machine is used to bend the web plate ribs. S103: Place the two side outer web plates on the horizontal jig and weld the plate ribs according to the baseline to form the side outer web plate unit; Multiple intermediate outer web plates are placed on a special curved surface jig and extended along the baseline. Plate ribs are then welded onto the special curved surface jig along the baseline. The curved surface height is adjusted by flame and checked using an inspection template. Once qualified, a curved web plate unit is formed. S104: Assemble and weld the curved web unit with the side outer web unit to form an outer web unit.

[0008] Furthermore, during the material cutting process in step S101, a 10mm allowance is reserved on each of the two long sides of the intermediate outer web plate. The roller bending in step S102 is as follows: Roller bending is performed using the equivalent arc centerline of the broken line centerline. Each middle outer web plate is rolled into an arched surface in one direction. Multiple curved web plates are extended along the broken line centerline to form a curved web plate. The number of intermediate outer web plates in step S103 is 4-6. The beneficial effect of this step is that by approximating the complex arc as the central axis of the broken line and performing unidirectional roll bending on each intermediate outer web plate, the forming difficulty is greatly simplified, making it possible to realize complex curved surfaces that were originally difficult to manufacture.

[0009] Furthermore, step S1 also includes the following steps: S105: Use a door cutting and blanking equipment to cut out the parts of each plate unit, scribing them out and then using a rolling machine to bend them. Weld plate ribs on a special curved surface jig to produce the outer top plate unit, inner top plate unit, outer bottom plate unit, and inner bottom plate unit. S106: The plate unit parts are cut out using CNC blanking equipment, and the baseline and auxiliary lines are drawn using laser scribing equipment. Plate ribs are welded on a horizontal jig to produce the inner web plate unit and partition plate unit. The advantage of this step is that the baseline is accurately scribed using laser before bending, which avoids the problem of scribing difficulties after bending.

[0010] Furthermore, the specific details of creating the lower block in step S2 are as follows: S201: Assemble the middle partition unit based on the longitudinal and transverse baselines of the outer web unit, adjust the middle partition unit left and right to ensure that the partition does not exceed the position line of the inner top and bottom plate unit, and control the partition spacing and verticality. S202: Using the longitudinal and transverse baselines of the outer web plate unit as a reference, and the middle partition plate unit as the inner tube, assemble the inner top plate unit and the inner bottom plate unit, control the spacing and verticality of the inner top and bottom plate units, and fix the inner top and bottom plate units to the partition plate unit after passing the inspection. S203: Assemble the partition units on both sides based on the longitudinal and transverse baselines of the outer web plate unit, adjust the spacing between the partition units, control the verticality deviation of the partition units to ≤1mm, ensure that the installation position of the outer top and bottom plate units is reserved on the plate edge, and fix the partitions to the inner top and bottom plate units after the inspection is qualified. S204: Assemble the outer top plate unit and outer bottom plate unit using the two side partition units as inner tubes, control the spacing and verticality of the outer top and bottom plate units, and fix the outer top and bottom plate units to the partition units after passing the inspection. S205: Assemble the inner web unit based on the longitudinal and transverse baselines of the outer web unit, adjust the longitudinal position of the inner web unit to ensure that the transverse baselines of the inner web unit and the outer web unit are aligned, and control the deviation of the block box opening height and width dimensions to ≤2mm, and the deviation of the box opening diagonal difference to ≤1.5mm. S206: Welding the inner top and bottom plate units and the outer web plate units; welding the inner corner welds of the outer top and bottom plate units and the outer web plate units; welding the partition units and the outer web plate units and the inner and outer top and bottom plate units. After the flaw detection is qualified, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units are welded, the outer corner welds of the outer top and bottom plate units and the outer web plate units are welded, and the remaining corner welds of the partition units are welded. The welding deformation is repaired to obtain the lower block. The beneficial effect of this step is that the welding deformation and dimensional accuracy of the lower block are easier to control, thus laying the foundation for the final overall accuracy.

[0011] Furthermore, the specific details of creating the intermediate block in step S2 are as follows: Set up a horizontal jig, set up longitudinal and transverse ground lines, locate the inner web plate unit according to the lines, and after passing the inspection, secure the inner web plate unit to the jig to prevent displacement during assembly and welding. Assemble the partition unit, inner top and bottom plate unit, and outer top and bottom plate unit in sequence, controlling the verticality and spacing deviation of each plate unit. Control the height and width deviation of the block opening to ≤2mm, and the diagonal difference deviation of the opening to ≤1.5mm. Inspect and correct any lateral bending or twisting of the blocks. After passing the inspection, weld the fillet welds between the inner top and bottom plate units and the inner web plate units, the fillet welds between the outer top and bottom plate units and the inner web plate units, and the fillet welds between the partition plate units and the inner web plate units, as well as the inner and outer top and bottom plate units. After the flaw detection is qualified, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units, the corner welds of the outer top and bottom plate units and the inner web plate units, and the remaining corner welds of the partition units are made. The welding deformation is repaired to obtain the middle block.

[0012] Furthermore, the specific details of creating the upper block in step S2 are as follows: Assemble the middle partition unit based on the longitudinal and transverse baselines of the outer web unit, and adjust the middle partition unit left and right to ensure that the partition does not exceed the position line of the inner top and bottom plate unit, and control the partition spacing and verticality. Using the longitudinal and transverse baselines of the outer web plate unit as a reference, and the middle partition plate unit as the inner tube, assemble the inner top plate unit and the inner bottom plate unit, control the spacing and verticality of the inner top and bottom plate units, and after passing the inspection, fix the inner top and bottom plate units to the partition plate unit. Assemble the partition units on both sides based on the longitudinal and transverse baselines of the outer web plate unit, adjust the spacing between the partition units, control the verticality deviation of the partition units to ≤1mm, ensure that the installation position of the outer top and bottom plate units is reserved on the plate edge, and fix the partitions to the inner top and bottom plate units after passing the inspection. Assemble the outer top plate unit and outer bottom plate unit using the two side partition units as inner tubes, control the spacing and verticality of the outer top and bottom plate units, and fix the outer top and bottom plate units to the partition units after passing the inspection. Welding the inner top and bottom plate units and the outer web plate units; welding the inner corner welds of the outer top and bottom plate units and the outer web plate units; welding the partition plate units and the outer web plate units and the inner and outer top and bottom plate units. After the flaw detection is qualified, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units are welded, the outer corner welds of the outer top and bottom plate units and the outer web plate units are welded, and the remaining corner welds of the partition units are welded; the welding deformation is repaired to obtain the lower block.

[0013] Furthermore, the welding sequence in step S306 is as follows: The block hoisting and positioning are completed, and the butt welds between the outer top and bottom plate units of the block and the lower block are being welded. Welding the butt welds between the outer top and bottom plate units of the upper block and the middle block; The fillet welds between the top and bottom plates and the inner web plate units of the block are welded together. Welding full-penetration fillet welds between the top and bottom plates and the inner web plate units of the upper block; Fillet welds are applied between the block partition unit and the inner web plate unit during welding; Fillet welds are applied between the upper block partition unit and the inner web plate unit; Fillet welds are applied between the block partition unit and the top and bottom plate units of the lower block during welding; Welding fillet welds between the upper block partition unit and the upper and lower block outer top and bottom plate units has the advantage of optimizing the assembly sequence, ensuring that the critical partition and web fillet welds are always located at the top, which facilitates welding operations, avoids high-difficulty and low-quality overhead welding, significantly improves welding quality and efficiency, and reduces construction safety risks.

[0014] Furthermore, the partition units of the upper, middle, and lower blocks all adopt R-shaped slots.

[0015] Furthermore, in the upper and lower blocks, the slots of the partition units are arranged in the forward direction, and the slots of the partition units connected to the outer web plate units are symmetrical about the center of the lower or upper block. The welding edge and the inclined edge of the slots in the partition units facing the curved edge of the outer web plate units are increased by 3~4mm.

[0016] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages: 1. This application provides a method for manufacturing elliptical suspension bridge steel tower segments with a fish-belly cross-section, which solves the manufacturing problem of the spatial curved web of the fish-belly cross-section, and solves the technical problems of difficult control of welding deformation of curved steel tower segments, high difficulty in controlling the manufacturing accuracy of segments, and high construction difficulty and safety risks in the overall assembly, turning over and hoisting of ultra-heavy and ultra-large segments, thus ensuring the manufacturing accuracy and construction efficiency of the fish-belly cross-section curved segments.

[0017] 2. This application addresses the complex spatial curved surface characteristics of the outer web unit by decomposing it into multiple smaller, more easily manufactured sub-units. By approximating the complex arc as the central axis of a broken line and performing unidirectional roll bending on each small segment, the forming difficulty is greatly simplified, enabling the realization of complex curved surfaces that were previously difficult to manufacture. Precise laser scribing before bending ensures the accuracy of the baseline, avoiding the difficulty of scribing after bending. Furthermore, the principle that the baseline's vertical projection after forming is a straight line provides a basis for subsequent quality control. These methods ensure the manufacturing precision of the complex curved outer web unit.

[0018] 3. This application decomposes the entire tower section into three relatively independent blocks—lower, middle, and upper—for step-by-step manufacturing and assembly. This makes it easier to control the welding deformation and dimensional accuracy of each block, thereby ensuring the final overall accuracy. Attached Figure Description

[0019] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of a steel tower segment in a method for manufacturing an elliptical suspension bridge steel tower with a fish-belly cross-section, as described in a specific embodiment of the present invention. Figure 2 This is a schematic diagram of the steel tower segment division in a method for manufacturing an elliptical suspension bridge steel tower fish-belly cross-section tower segment according to a specific embodiment of the present invention; Figure 3 for Figure 2 A schematic diagram of the lower block structure; Figure 4 for Figure 3 The main view; Figure 5 for Figure 3 A block diagram of the outer web unit; Figure 6 This is a diagram illustrating the welding sequence of steel tower segments in a method for fabricating an elliptical suspension bridge steel tower with a fish-belly cross-section, as described in a specific embodiment of the present invention.

[0021] Figure 7 This is a schematic flowchart illustrating a method for manufacturing an elliptical suspension bridge steel tower with a fish-belly cross-section, according to a specific embodiment of the present invention. The attached figures are labeled as follows: 1-Steel tower segment; 2-Upper block; 3-Middle block; 4-Lower block; 401 - Outer web plate unit; 402 - Lateral outer web plate; 403 - Intermediate outer web plate; 404 - Inner web plate unit; 405 - Outer top plate unit; 406 - Inner top plate unit; 407 - Partition plate unit; 408 - Inner bottom plate unit; 409 - Outer bottom plate unit; 410 - Partition plate unit slot. Detailed Implementation

[0022] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of the present invention and are therefore merely examples, and should not be construed as limiting the scope of protection of the present invention.

[0023] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application should have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0024] To better understand the above technical solutions, the following will provide a detailed description of the technical solutions in conjunction with the accompanying drawings and specific embodiments.

[0025] Example: like Figure 1-7 As shown in the embodiment, this application discloses a method for manufacturing an elliptical suspension bridge steel tower segment with a fish-belly cross-section. This fish-belly cross-section segment adopts a single-box, nine-cell structure with an arc-shaped quadrilateral equal cross-section. The outer web section is composed of a protruding circular arc and a straight line (tangent to the arc). The segment's central axis is circular, and the top and bottom plates are curved along the axial direction. The inner web of the segment is flat, while the remaining wall panels are curved plates. The stiffening ribs of the top and bottom plates are flat, while the stiffening ribs of the web plates are curved plates, and the cross-section uses plate-type stiffening ribs. The overall assembly, turning, and hoisting of such ultra-heavy and ultra-large segments are difficult to construct. Therefore, this application divides these segments into multiple pieces and units to facilitate subsequent processing.

[0026] Specifically, considering the structural characteristics of the single-box nine-chamber tower section with a fish-belly cross-section, and taking into account the influence of the sag of the outer top plate, outer bottom plate, and outer web plate on the arrangement of the support plates of the formwork, the web plate surface with the smaller sag is selected as the lower side of the formwork surface to reduce the height of the formwork arrangement. Considering the segment dimensions, the segment is divided into lower, middle, and upper blocks. Because the top and bottom plates of the fish-belly cross-section curved segment have a large bending sag, while the web plate has a small bending sag, selecting the web plate with the smaller sag for formwork fabrication reduces material waste and ensures construction safety.

[0027] The lower block is box-shaped and includes an outer web plate unit, an inner web plate unit, an outer top plate unit, an inner top plate unit, an outer bottom plate unit, an inner bottom plate unit, and a partition plate unit.

[0028] The middle block is an open slot type, which includes an inner web plate unit, an outer top plate unit, an inner top plate unit, an outer bottom plate unit, an inner bottom plate unit, and a partition plate unit.

[0029] The upper block is an open slot type, comprising an outer web plate unit, an outer top plate unit, an inner top plate unit, an outer bottom plate unit, an inner bottom plate unit, and a partition plate unit.

[0030] Specifically, the fish-belly-shaped cross-section curve segment is divided into three layers (upper, middle, and lower) according to the distribution of the partitions, considering that it is a single-box nine-chamber structure. To facilitate the assembly of the blocks, the upper and lower symmetrical blocks are not used. Instead, a box-shaped block on the lower side plus an inverted groove-shaped block on the upper side is used. This ensures that the corner welds of the partitions and webs are all on the upper side during the assembly of the segments. Personnel can perform partition positioning and welding work on the upper side of the webs, avoiding overhead welding in the assembly of segments, effectively reducing the welding difficulty and ensuring the welding quality.

[0031] The specific steps for creating this application are as follows: S1: Manufacturing various components, including an outer top plate unit, an inner top plate unit, an outer bottom plate unit, an inner bottom plate unit, an outer web plate unit, an inner web plate unit, and a partition plate unit; the specific details are as follows: S101: Perform blanking to obtain multiple side outer web plates, multiple middle outer web plates and web plate ribs, and use laser scribing to scribing on both sides to draw all baselines and auxiliary lines. A 10mm allowance is reserved on each of the two long sides of the middle outer web plate. S102: A rolling machine is used to roll-bend multiple intermediate outer web plates, and a bending machine is used to bend the web plate ribs. During the roll bending, the equivalent arch arc centerline of the broken line centerline is used for roll bending. Each intermediate outer web plate is rolled into an arch surface in one direction, and multiple curved web plates are extended along the broken line centerline to form a curved web plate. S103: Place the two side outer web plates on the horizontal jig and weld the plate ribs according to the baseline to form the side outer web plate unit; Multiple intermediate outer web plates are placed on a special curved surface jig and extended along the baseline. Plate ribs are then welded onto the special curved surface jig along the baseline. The curved surface height is adjusted by flame and checked using an inspection template. Once qualified, a curved web plate unit is formed. S104: Assemble and weld the curved web plate unit and the side outer web plate unit to form an outer web plate unit; S105: Use a door cutting and blanking equipment to cut out the parts of each plate unit, scribing them out and then using a rolling machine to bend them. Weld plate ribs on a special curved surface jig to produce the outer top plate unit, inner top plate unit, outer bottom plate unit, and inner bottom plate unit. S106: Use CNC cutting equipment to cut out plate unit parts, use laser scribing equipment to scribing baselines and auxiliary lines, and weld plate ribs on a horizontal jig to produce inner web plate unit and partition plate unit. S2: Assemble and weld the components from step S1 to form a lower block, a middle block, and an upper block. The lower block is a box-shaped structure, and the middle block and the upper block are open slot-shaped structures. The specific steps for creating the lower block are as follows: S201: Assemble the middle partition unit based on the longitudinal and transverse baselines of the outer web unit, adjust the middle partition unit left and right to ensure that the partition does not exceed the position line of the inner top and bottom plate unit, and control the partition spacing and verticality. S202: Using the longitudinal and transverse baselines of the outer web plate unit as a reference, and the middle partition plate unit as the inner tube, assemble the inner top plate unit and the inner bottom plate unit, control the spacing and verticality of the inner top and bottom plate units, and fix the inner top and bottom plate units to the partition plate unit after passing the inspection. S203: Assemble the partition units on both sides based on the longitudinal and transverse baselines of the outer web plate unit, adjust the spacing between the partition units, control the verticality deviation of the partition units to ≤1mm, ensure that the installation position of the outer top and bottom plate units is reserved on the plate edge, and fix the partitions to the inner top and bottom plate units after the inspection is qualified. S204: Assemble the outer top plate unit and outer bottom plate unit using the two side partition units as inner tubes, control the spacing and verticality of the outer top and bottom plate units, and fix the outer top and bottom plate units to the partition units after passing the inspection. S205: Assemble the inner web unit based on the longitudinal and transverse baselines of the outer web unit, adjust the longitudinal position of the inner web unit to ensure that the transverse baselines of the inner web unit and the outer web unit are aligned, and control the deviation of the block box opening height and width dimensions to ≤2mm, and the deviation of the box opening diagonal difference to ≤1.5mm. S206: Welding the inner top and bottom plate units and the outer web plate units; welding the inner corner welds of the outer top and bottom plate units and the outer web plate units; welding the partition units and the outer web plate units and the inner and outer top and bottom plate units. After passing the flaw detection, the block is turned over, and the corner welds of the top and bottom plate units and the inner web plate units are welded together, as are the outer corner welds of the top and bottom plate units and the outer web plate units, and the remaining corner welds of the partition units. The welding deformation is repaired to obtain the lower block. The specific details of the blocks being created are as follows: Set up a horizontal jig, set up longitudinal and transverse ground lines, locate the inner web plate unit according to the lines, and after passing the inspection, secure the inner web plate unit to the jig to prevent displacement during assembly and welding. Assemble the partition unit, inner top and bottom plate unit, and outer top and bottom plate unit in sequence, controlling the verticality and spacing deviation of each plate unit. Control the height and width deviation of the block opening to ≤2mm, and the diagonal difference deviation of the opening to ≤1.5mm. Inspect and correct any lateral bending or twisting of the blocks. After passing the inspection, weld the fillet welds between the inner top and bottom plate units and the inner web plate units, the fillet welds between the outer top and bottom plate units and the inner web plate units, and the fillet welds between the partition plate units and the inner web plate units, as well as the inner and outer top and bottom plate units. After passing the flaw detection, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units, the corner welds of the outer top and bottom plate units and the inner web plate units, and the remaining corner welds of the partition units are made. The welding deformation is repaired to obtain the middle block. The method for constructing the upper block is similar to that for the lower block, except that the assembly of the inner web plate unit is omitted. The specific details are as follows: Assemble the middle partition unit based on the longitudinal and transverse baselines of the outer web unit, and adjust the middle partition unit left and right to ensure that the partition does not exceed the position line of the inner top and bottom plate unit, and control the partition spacing and verticality. Using the longitudinal and transverse baselines of the outer web plate unit as a reference, and the middle partition plate unit as the inner tube, assemble the inner top plate unit and the inner bottom plate unit, control the spacing and verticality of the inner top and bottom plate units, and after passing the inspection, fix the inner top and bottom plate units to the partition plate unit. Assemble the partition units on both sides based on the longitudinal and transverse baselines of the outer web plate unit, adjust the spacing between the partition units, control the verticality deviation of the partition units to ≤1mm, ensure that the installation position of the outer top and bottom plate units is reserved on the plate edge, and fix the partitions to the inner top and bottom plate units after passing the inspection. Assemble the outer top plate unit and outer bottom plate unit using the two side partition units as inner tubes, control the spacing and verticality of the outer top and bottom plate units, and fix the outer top and bottom plate units to the partition units after passing the inspection. Welding the inner top and bottom plate units and the outer web plate units; welding the inner corner welds of the outer top and bottom plate units and the outer web plate units; welding the partition plate units and the outer web plate units and the inner and outer top and bottom plate units. After passing the flaw detection, the block is turned over, and the corner welds of the top and bottom plate units and the inner web plate units are welded together, as are the outer corner welds of the top and bottom plate units and the outer web plate units, and the remaining corner welds of the partition units. The welding deformation is repaired to obtain the lower block. S3: Assemble and weld the lower block, middle block, and upper block to form a tower segment. The specific details of this step are as follows: S301: Arrange the segmental assembly frame according to the height of the outer web unit curved surface of the lower block, lay out the ground line, locate the lower block with the ground line as the reference, and inspect and adjust the lower block to make it horizontal. S302: Place the middle block on the lower block, and adjust the horizontal and vertical positions of the middle block so that the middle block is aligned with the lower block; S303: Adjust the distance between the middle block and the lower block, allow 2mm for welding shrinkage, conduct inspection, and secure the blocks after passing the inspection. S304: Place the upper block on the middle block, and adjust the horizontal and vertical positions of the upper block so that the upper block is aligned with the middle block; S305: Adjust the distance between the middle block and the upper block, allow 2mm for welding shrinkage, conduct inspection, and secure the blocks after passing the inspection. S306: Weld in sequence, after welding, adjust the box opening size, cut off the excess at the upper and lower ends, cut out the bevels at the upper and lower ends, and form the tower segment.

[0032] Further explanation of the outer web plate unit in this application: Based on the steel mill's supply capacity, the outer web plate unit is divided into three sections along a dividing line parallel to the tower axis. The two outer web plates on both sides are tangent sections of a fish-belly cross-section, and the middle outer web plate is an arc section with a tangent section of a fish-belly cross-section. The middle outer web plate is divided into multiple middle outer web plates of equal length along the tower axis. Various types of web plates are cut out using CNC cutting equipment, and double-sided marking is performed using laser scribing equipment. A 1000-ton rolling mill is used to roll-bend the smaller middle fish-belly web plates, and a bending machine is used to bend the web plate ribs. The rib height is checked using an adjustable curved surface sag inspection template. The two outer web plates on both sides are placed on a horizontal jig and the ribs are welded according to the baseline. The middle outer web plate is placed on a special curved surface jig and extended according to the baseline. The curved surface sag is checked using an inspection template, and any deviations are adjusted using flame. Ribs are then welded according to the baseline on the special curved surface jig, the curved surface sag is adjusted using flame, and the inspection template is used for further checks.

[0033] The outer web unit is a complex spatial curved surface. The central axis of the tower column is circular, and the long side of the outer web unit is an arc. The cross-section consists of a protruding circular arc and a straight line (tangent to the arc). Therefore, the middle part of the outer web forms a protruding arch surface with a circular central axis, and the two sides are conical surfaces tangent to the middle. Ordinary pressing and bending processes cannot achieve the forming of this type of arc-shaped bending surface, and due to its thickness and high material content, the pressing and molding effect is not ideal. Therefore, the middle arc area and the two side sectional areas of the outer web unit are longitudinally divided into three plate units for fabrication. The middle arc area plate unit is divided into 4 to 6 pieces along the tower column axis. Roll bending is performed using the equivalent arc central axis of the broken line. Each middle outer web only needs to be rolled into an arch surface in one direction. Multiple curved webs are extended according to the broken line central axis to complete the fabrication of this spatial curved web. The relationship between the sag d of the arc with radius R and the arc length L is calculated as follows: (Angle system), therefore, with a central axis radius of 36250mm and an arc length of 2000mm, the arc sag is 13.8mm. According to 3D software modeling and experimental analysis, when using a broken line equivalent arc to make the curved web, the appearance is better when the arc sag is controlled to be less than 15mm, and the broken line change is not easily visible. Therefore, each outer web is divided into blocks of about 2 meters in length. In practice, the block length can be adjusted according to the size of the axis radius.

[0034] Specifically, the middle outer web of the central arc region needs to be extended using the longitudinal baseline, with a 10mm allowance reserved on each of the two long sides. This extension is performed after the web extension and rib welding are completed. This process eliminates misalignment of the plate edges after multiple extensions and resolves the issue of plate unit width shrinkage caused by rib welding and curved surface correction. During plate unit docking, reinforcement measures are applied to areas with local deviations, supplemented by flame straightening.

[0035] The outer web unit is a spatial curved surface, making it difficult to scribing after bending, and also challenging to verify and adjust the baseline. Therefore, after the part is cut and before bending, all baselines and auxiliary lines are scribed using a laser scribing device, and double-sided scribing is used to simultaneously meet the requirements of plate unit and segment fabrication. Considering that the baseline will change after the web is rolled, the baseline layout principle is to ensure that the vertical projection of the baseline on the web surface is a straight line after the web unit is formed. When modeling with 3D software, the baseline is modeled synchronously with the tower segment structure, and the baseline is simultaneously unfolded when the plate unit is unfolded and laid out. After cutting, the unfolded baseline and auxiliary lines are scribed using a laser scribing device. At this time, the baseline on the part is a curve, and after roll bending, the baseline is a straight line projected vertically onto the surface.

[0036] The welding sequence in step S306 of this application will be further explained as follows: Figure 5 As shown, the numbers ① to ⑧ represent the welding sequence, and the arrows indicate the welding direction; the specific details are as follows: The block hoisting and positioning are completed, and the butt welds between the outer top and bottom plate units of the block and the lower block are being welded. Welding the butt welds between the outer top and bottom plate units of the upper block and the middle block; The fillet welds between the top and bottom plates and the inner web plate units of the block are welded together. Welding full-penetration fillet welds between the top and bottom plates and the inner web plate units of the upper block; Fillet welds are applied between the block partition unit and the inner web plate unit during welding; Fillet welds are applied between the upper block partition unit and the inner web plate unit; Fillet welds are applied between the block partition unit and the top and bottom plate units of the lower block during welding; Fillet welds are applied between the upper block partition unit and the upper and lower block outer top and bottom plate units.

[0037] Specifically, when fabricating the upper, middle, and lower blocks, a 15mm allowance should be reserved at each of the two ends. After the segment welding is completed, the allowance will be removed according to the design value. This can eliminate misalignment at the ends caused by longitudinal misalignment of the blocks during segment assembly, and also avoid the impact of lateral bending and welding shrinkage on segment dimensions, thereby improving the segment manufacturing accuracy. During the block assembly process, misalignment between different block wall panels can be adjusted and eliminated by using bracing, or by reserving partial welds between partitions and wall panels, or reserving partial corner welds between wall panels to increase the adjustability.

[0038] Further explanation is given regarding the partition unit of this application, wherein the partition units of the upper, middle and lower blocks all adopt R-shaped slots.

[0039] Regarding the slot orientation of the partition unit, the slots of the partition unit are arranged in the same direction in the upper and lower blocks. The slots of the partition unit connected to the outer web plate unit are symmetrical about the center of the lower or upper block. The welding edge and bevel of the slot facing the curved edge of the outer web plate unit are increased by 3-4mm. The outer web plate ribs are perpendicular to the outer web plate surface. Due to the fish-belly cross-section structure of the outer web plate, the outer web plate ribs all point to the center of the arc surface. If the R-shaped slots are arranged in the same direction during partition assembly, they will be unable to be assembled due to interference from the ribs. By adopting a symmetrical slot arrangement and reserving an appropriate amount of allowance, the partition can be smoothly placed onto the web plate surface.

[0040] This application provides a manufacturing method that solves the problem of difficult manufacturing of this type of segment, and addresses the technical challenges of controlling welding deformation of curved steel tower segments, controlling the precision of segment manufacturing, and the high construction difficulty and safety risks in the overall assembly, turning over, and hoisting of ultra-heavy and ultra-large segments. It ensures the manufacturing precision and construction efficiency of fish-belly cross-section curved segments.

[0041] Numerous specific details are set forth in this specification. However, it will be understood that embodiments of the invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0042] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art will understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

Claims

1. A method for manufacturing an elliptic suspension bridge steel tower fish-belly section tower segment, characterized in that, Includes the following steps: S1: Fabricate various components, including an outer top plate unit, an inner top plate unit, an outer bottom plate unit, an inner bottom plate unit, an outer web plate unit, an inner web plate unit, and a partition unit; the specific steps for fabricating the outer web plate unit are as follows: S101: Perform blanking to obtain multiple side outer web plates, multiple middle outer web plates and web plate ribs, and use laser scribing to scribing double-sided lines to draw all baselines and auxiliary lines; S102: A rolling machine is used to roll multiple intermediate outer web plates, and a bending machine is used to bend the web plate ribs. S103: Place the two side outer web plates on the horizontal jig and weld the plate ribs according to the baseline to form the side outer web plate unit; Multiple intermediate outer web plates are placed on a special curved surface jig and extended along the baseline. Plate ribs are then welded onto the special curved surface jig along the baseline. The curved surface height is adjusted by flame and checked using an inspection template. Once qualified, a curved web plate unit is formed. S104: Assemble and weld the curved web plate unit and the side outer web plate unit to form an outer web plate unit; S2: Assemble and weld the components from step S1 to form a lower block, a middle block, and an upper block. The lower block is a box-shaped structure, and the middle block and the upper block are open slot-shaped structures. S3: Assemble and weld the lower block, middle block, and upper block to form a tower segment. The specific details of this step are as follows: S301: Arrange the segmental assembly frame according to the curved surface line of the outer web unit of the lower block, lay out the ground line, locate the lower block with the ground line as the reference, and inspect and adjust the lower block to make it horizontal. S302: Place the middle block on the lower block, and adjust the horizontal and vertical positions of the middle block so that the middle block is aligned with the lower block; S303: Adjust the distance between the middle block and the lower block, allow 2mm for welding shrinkage, conduct inspection, and secure the blocks after passing the inspection. S304: Place the upper block on the middle block, and adjust the horizontal and vertical positions of the upper block so that the upper block is aligned with the middle block; S305: Adjust the distance between the middle block and the upper block, allow 2mm for welding shrinkage, conduct inspection, and secure the blocks after passing the inspection. S306: Weld in sequence, after welding, adjust the box opening size, cut off the excess at the upper and lower ends, cut out the bevels at the upper and lower ends, and form the tower segment.

2. The production method according to claim 1, wherein When cutting material in step S101, a 10mm allowance is reserved on each of the two long sides of the middle outer web plate. The roller bending in step S102 is as follows: Roller bending is performed using the equivalent arc centerline of the broken line centerline. Each middle outer web plate is rolled into an arched surface in one direction. Multiple curved web plates are extended along the broken line centerline to form a curved web plate. The number of intermediate outer web plates in step S103 is 4-6.

3. The method of manufacturing according to claim 2, wherein, Step S1 further includes the following steps: S105: Use a door cutting and blanking equipment to cut out the parts of each plate unit, scribing them out and then using a rolling machine to bend them. Weld plate ribs on a special curved surface jig to produce the outer top plate unit, inner top plate unit, outer bottom plate unit, and inner bottom plate unit. S106: The plate unit parts are cut out using CNC cutting equipment, the baseline and auxiliary lines are drawn using laser scribing equipment, and the plate ribs are welded on the horizontal jig to obtain the inner web plate unit and partition plate unit.

4. The method of making of claim 1, wherein, The specific steps for creating the lower block in step S2 are as follows: S201: Assemble the middle partition unit based on the longitudinal and transverse baselines of the outer web unit, adjust the middle partition unit left and right to ensure that the partition does not exceed the position line of the inner top and bottom plate unit, and control the partition spacing and verticality. S202: Using the longitudinal and transverse baselines of the outer web plate unit as a reference, and the middle partition plate unit as the inner tube, assemble the inner top plate unit and the inner bottom plate unit, control the spacing and verticality of the inner top and bottom plate units, and fix the inner top and bottom plate units to the partition plate unit after passing the inspection. S203: Assemble the partition units on both sides based on the longitudinal and transverse baselines of the outer web plate unit, adjust the spacing between the partition units, control the verticality deviation of the partition units to ≤1mm, ensure that the installation position of the outer top and bottom plate units is reserved on the plate edge, and fix the partitions to the inner top and bottom plate units after the inspection is qualified. S204: Assemble the outer top plate unit and outer bottom plate unit using the two side partition units as inner tubes, control the spacing and verticality of the outer top and bottom plate units, and fix the outer top and bottom plate units to the partition units after passing the inspection. S205: Assemble the inner web unit based on the longitudinal and transverse baselines of the outer web unit, adjust the longitudinal position of the inner web unit to ensure that the transverse baselines of the inner web unit and the outer web unit are aligned, and control the deviation of the block box opening height and width dimensions to ≤2mm, and the deviation of the box opening diagonal difference to ≤1.5mm. S206: Welding the inner top and bottom plate units and the outer web plate units; welding the inner corner welds of the outer top and bottom plate units and the outer web plate units; welding the partition units and the outer web plate units and the inner and outer top and bottom plate units. After the flaw detection is qualified, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units are welded, the outer corner welds of the outer top and bottom plate units and the outer web plate units are welded, and the remaining corner welds of the partition units are welded; the welding deformation is repaired to obtain the lower block.

5. The method of manufacturing according to claim 4, wherein, The specific details of creating the intermediate block in step S2 are as follows: Set up a horizontal jig, set up longitudinal and transverse ground lines, locate the inner web plate unit according to the lines, and after passing the inspection, secure the inner web plate unit to the jig to prevent displacement during assembly and welding. Assemble the partition unit, inner top and bottom plate unit, and outer top and bottom plate unit in sequence, and control the verticality and spacing deviation of each plate unit; control the height and width deviation of the block opening to ≤2mm, and the diagonal difference deviation of the opening to ≤1.5mm; check the side bending and twisting of the block and make corrections. After passing the inspection, weld the fillet welds between the inner top and bottom plate units and the inner web plate units, the fillet welds between the outer top and bottom plate units and the inner web plate units, and the fillet welds between the partition plate units and the inner web plate units, as well as the inner and outer top and bottom plate units. After the flaw detection is qualified, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units, the corner welds of the outer top and bottom plate units and the inner web plate units, and the remaining corner welds of the partition units are made. The welding deformation is repaired to obtain the middle block.

6. The method of manufacturing according to claim 5, wherein, The specific steps for creating the upper block in step S2 are as follows: Assemble the middle partition unit based on the longitudinal and transverse baselines of the outer web unit, and adjust the middle partition unit left and right to ensure that the partition does not exceed the position line of the inner top and bottom plate unit, and control the partition spacing and verticality. Using the longitudinal and transverse baselines of the outer web plate unit as a reference, and the middle partition plate unit as the inner tube, assemble the inner top plate unit and the inner bottom plate unit, control the spacing and verticality of the inner top and bottom plate units, and after passing the inspection, fix the inner top and bottom plate units to the partition plate unit. Assemble the partition units on both sides based on the longitudinal and transverse baselines of the outer web plate unit, adjust the spacing between the partition units, control the verticality deviation of the partition units to ≤1mm, ensure that the installation position of the outer top and bottom plate units is reserved on the plate edge, and fix the partitions to the inner top and bottom plate units after passing the inspection. Assemble the outer top plate unit and outer bottom plate unit using the two side partition units as inner tubes, control the spacing and verticality of the outer top and bottom plate units, and fix the outer top and bottom plate units to the partition units after passing the inspection. Welding the inner top and bottom plate units and the outer web plate units; welding the inner corner welds of the outer top and bottom plate units and the outer web plate units; welding the partition plate units and the outer web plate units and the inner and outer top and bottom plate units. After the flaw detection is qualified, the block is turned over, and the corner welds of the inner top and bottom plate units and the inner web plate units are welded, the outer corner welds of the outer top and bottom plate units and the outer web plate units are welded, and the remaining corner welds of the partition units are welded; the welding deformation is repaired to obtain the lower block.

7. The method of manufacturing according to claim 6, wherein, The welding sequence in step S306 is as follows: The block hoisting and positioning are completed, and the butt welds between the outer top and bottom plate units of the block and the lower block are being welded. Welding the butt welds between the outer top and bottom plate units of the upper block and the middle block; The fillet welds between the top and bottom plates and the inner web plate units of the block are welded together. Welding full penetration fillet welds between the top and bottom plates and the inner web plate units of the upper block; Fillet welds are applied between the block partition unit and the inner web plate unit during welding; Fillet welds are applied between the upper block partition unit and the inner web plate unit. Fillet welds are applied between the block partition unit and the top and bottom plate units of the lower block during welding; Fillet welds are applied between the upper block partition unit and the upper and lower block outer top and bottom plate units.

8. The manufacturing method according to claim 7, characterized in that, The partition units of the upper, middle and lower blocks all adopt R-shaped slots.

9. The manufacturing method according to claim 8, characterized in that, In the upper and lower blocks, the slots of the partition units are arranged in the same direction. The slots of the partition units connected to the outer web plate units are symmetrical about the center of the lower or upper block. The welding edge and the bevel of the slots of the partition units facing the curved edge of the outer web plate units are increased by 3-4mm.

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