Manufacturing method of ship-shaped variable-cross-section curved-edge supporting bracket structure

Abstract

The invention discloses a manufacturing method of a ship-shaped variable-cross-section curved-edge supporting bracket structure, and relates to the technical field of bridge construction, and the manufacturing method comprises the following steps: S1, pretreatment and blanking: rolling a steel plate to be flat, and then performing fine cutting and blanking; s2, unit manufacturing is conducted, specifically, all parts are assembled and welded, and a top plate unit, a bottom plate unit, a web plate unit and a partition plate unit are formed; s3, detection before assembly: detecting units participating in assembly, and entering the next step after the units are qualified; s4, step-by-step positioning, assembling and welding are conducted, specifically, the top plate unit and the partition plate unit are assembled and welded firstly, then the partition plate unit and the web plate unit are assembled and welded, finally, the bottom plate unit is assembled, welded and finished, and bracket sections are formed; s5, support related part assembling and port processing are carried out, specifically, support parts are manufactured and assembled, and then port processing and detection are carried out; the technical problem that in the prior art, a ship-shaped variable-cross-section curved-edge supporting bracket is difficult to manufacture under the requirements of complex geometry, narrow space and high precision is solved.

Description

Technical Field

[0001] This invention relates to the field of bridge construction technology, and in particular to a method for manufacturing a ship-shaped variable cross-section curved edge support bracket structure. Background Technology

[0002] As a primary structural form for long-span bridges, suspension bridges rely heavily on the corbel, a crucial supporting component, for load transfer between the main tower and the main girder. The corbel must withstand the immense vertical pressure, horizontal thrust, and resulting additional bending moments transmitted from the main girder; its load-bearing performance directly impacts the overall safety, stability, and durability of the bridge. With advancements in bridge engineering technology and continuous breakthroughs in span records, the loads borne by the main girder are becoming increasingly complex and varied, placing higher demands on the mechanical properties and structural form of the corbel. Simultaneously, modern bridge design increasingly emphasizes the synergy between structural function and aesthetic appeal, prompting corbel structures to evolve towards more streamlined and structurally sound complex forms.

[0003] In existing technologies, some suspension bridges employ ship-shaped variable cross-section curved support brackets. These bracket structures feature complex curved profiles, densely distributed reinforcing ribs on the inner side, forming a multi-partitioned box-like arrangement. Furthermore, the weld connecting the bracket's base plate and web plate is a curved weld, with the cross-sectional height gradually decreasing from the main tower connection point to the bracket end. This results in high precision requirements for curve machining, limited welding space for the irregularly shaped box body, strict dimensional control at the connection point with the main tower, and difficulty in ensuring the flatness of the support surface. These issues lead to significant manufacturing difficulties and challenges in improving the forming accuracy of the brackets, consequently impacting the efficient transmission of influence, structural coordinating of stress, and the overall stability and durability of the suspension bridge. Summary of the Invention

[0004] The purpose of this invention is to provide a method for manufacturing a ship-shaped variable cross-section curved edge support bracket structure, which solves the technical problem of the difficulty in manufacturing ship-shaped variable cross-section curved edge support brackets under complex geometry, narrow space and high precision requirements in the prior art.

[0005] This application discloses a method for manufacturing a ship-shaped variable cross-section curved support bracket structure, including the following steps: S1: Pre-treatment and blanking: Roll the steel plate flat, and then perform precision cutting to form various parts; S2: Unit fabrication: Assemble and weld the various components to form the top plate unit, bottom plate unit, web plate unit, and partition plate unit; S3: Pre-assembly inspection: Inspect the units to be assembled, and proceed to the next step if they pass the inspection; S4: Step-by-step positioning assembly and welding: First, assemble and weld the top plate unit and the partition plate unit, then assemble and weld the partition plate unit and the web plate unit, and finally assemble and weld the bottom plate unit to form the corbel segment. S5: Assembly and port processing of support-related components: Assemble the support components, and then process and test the ports.

[0006] This application divides the corbel structure into modular units such as top plate units, bottom plate units, web plate units, and partition plate units for modular fabrication. This allows welding operations inside the originally cramped box to be performed at the unit stage, expanding the operating space. During unit fabrication and assembly, standardized processes such as defining baselines, assembling ribs, welding, flaw detection, and finishing ensure the quality and precision of each unit.

[0007] Based on the above technical solution, the present application can be further improved as follows: Furthermore, in step S2, both the web plate unit and the bottom plate unit are curved irregular-shaped parts.

[0008] Furthermore, step S2 in the fabrication of the base plate unit also includes the following: the base plate is unfolded and cut according to the angular curved surface, and a dense multi-pass bending process is adopted to bend it with bending lines parallel to the end lines; the base plate ribs are simultaneously cut with laser cutting to create bevels. The beneficial effect of this step is that it can reduce the deformation of the base plate ribs and ensure the accuracy of the base plate unit.

[0009] Furthermore, the welding steps in step S4 are as follows: S401: The top plate unit, web plate unit, and bottom plate unit are welded together on the jig in two parts; S402: Lifting partition unit, welding ordinary partition, supporting partition and top plate unit with fillet weld or full penetration fillet weld; S403: Assemble the internal support stiffeners of the support partition. First, install the first support stiffener, weld the first support stiffener to the support partition with a full penetration fillet weld at the vertical position, and weld the first support stiffener to the top plate unit with a full penetration fillet weld at the horizontal angle. Then, assemble the third support stiffener, weld the third support stiffener to the first support stiffener with a full penetration fillet weld at the vertical position, and weld the third support stiffener to the top plate unit with a full penetration fillet weld at the horizontal angle. Next, assemble the second support stiffener, weld the second support stiffener to the support partition with a full penetration fillet weld at the vertical position, and weld the second support stiffener to the top plate unit with a full penetration fillet weld at the horizontal angle. Finally, weld the third support stiffener to the second support stiffener with a full penetration fillet weld at the vertical position. S404: Assemble the web plate unit and weld the full penetration fillet weld between the web plate unit and the top plate unit; S405: Weld the fillet weld between the ordinary diaphragm and the web unit, and weld the full penetration fillet weld between the supporting diaphragm and the web unit; S406: Assemble the base plate unit and weld the full penetration fillet weld between the web plate unit and the base plate unit; S407: Full penetration fillet weld between the web plate unit and the top plate unit; S408: Welding fillet welds between ordinary partition plates and base plate units, and welding full penetration fillet welds between supporting partition plates and base plate units; S409: Weld the full penetration fillet weld between the first support stiffener and the base plate unit to complete the assembly. The advantage of this step is that it can effectively control welding deformation through reasonable welding procedures.

[0010] Furthermore, in steps S406 and S407, when welding the web plate unit and the bottom and top plate units, the area with a gentle change in curvature is welded first, and then the process is gradually advanced to the part with a sudden change in curvature. Welding is performed in the order from the middle to both sides and from the inside to the outside. The heat distribution is balanced by symmetrical welding. For the web plate unit with a large thickness, multi-pass welding is used, and the thickness of each weld does not exceed 3-4 mm. The beneficial effect of this step is that the welding sequence can effectively control welding deformation and avoid warping caused by local stress concentration.

[0011] Furthermore, in steps S406 and S407, the welds between the web plate unit and the top and bottom plate units are double-sided welds. During welding, the inner 1 / 3 thickness is welded first, and after cooling, the workpiece is flipped over to weld the corresponding outer 1 / 3 thickness. This process is repeated until the bevel is filled. By alternating welding and gas gouging to clean the root, the root of the weld can be ensured to be fully penetrated. After each welding, it is necessary to let it cool naturally to the ambient temperature. The beneficial effect of this step is that it adopts layered multi-pass welding, controls the thickness of each weld, and avoids excessive heat from a single welding that could cause changes in material properties.

[0012] Furthermore, the support component in step S5 includes multiple stiffening ribs and a support pad, wherein the stiffening ribs are welded to the support pad; the stiffening ribs include a first stiffening rib, a second stiffening rib, a third stiffening rib, a fourth stiffening rib, and a fifth stiffening rib. The first stiffening rib is located in the middle of the support pad, and there are multiple second stiffening ribs, which are located on both sides of the first stiffening rib and are parallel to the first stiffening rib. There are multiple third stiffening ribs, and the third stiffening ribs are located between the first stiffening ribs and the second stiffening ribs, and the third stiffening ribs are parallel to each other; The fourth stiffening rib is multiple, and the fourth stiffening ribs are arranged in parallel and spaced between the first stiffening ribs and the second stiffening ribs, and the fourth stiffening ribs are located outside the third stiffening ribs; The fifth stiffening rib is multiple, and the fifth stiffening ribs are arranged in parallel at intervals on the outside of the second stiffening rib.

[0013] Furthermore, the manufacturing and assembly steps of the support component are as follows: Step S501: Assemble the first stiffening rib and the third stiffening rib on the support plate, and weld the full penetration weld at the flat corner. Step S502: Weld the first stiffening rib to the support plate at the flat corner with a full penetration fillet weld; Step S503: Weld the third stiffening rib to the support plate at the flat corner with a full penetration fillet weld; Step S504: Assemble the second stiffening rib, and weld the third stiffening rib and the full penetration fillet weld of the upright part of the second stiffening rib; Step S505: Weld the second stiffening rib to the support plate at the flat angle of the joint with the weld seam. Step S506: Assemble the fifth stiffening rib and weld the fifth stiffening rib and the vertical part of the second stiffening rib with a full penetration fillet weld; Step S507: Weld the fifth stiffening rib and the support plate at the flat corner of the joint to complete the fabrication of the support component; Step S508: Turn the corbel segment 180° and adjust the pre-arch, assemble the support pad assembly in sequence with the thick side of the small plate facing the cantilever end; fasten the support component to the top plate unit of the corbel segment, and weld the first stiffening rib to the flat corner part of the top plate unit of the corbel segment with a full penetration weld. Step S509: Weld the outer third stiffening rib to the top plate unit of the corbel segment with a flat corner fillet weld; Step S510: Assemble the fourth stiffening rib, weld the vertical portion of the fourth stiffening rib to the first stiffening rib and the second stiffening rib with a full penetration fillet weld, weld the horizontal portion of the fourth stiffening rib to the top plate unit of the corbel segment with a full penetration fillet weld, and weld the vertical portion of the fourth stiffening rib to the support pad with a full penetration fillet weld. The advantage of this step is that it adopts a step-by-step and area-by-area welding sequence, that is, first weld the horizontal portion, then weld the vertical portion, and attach it to the top plate of the corbel in steps to control deformation.

[0014] Furthermore, in steps S4 and S5, the bevel is a gradually transitioning bevel, with the bevel angle gradually changing with the curvature of the surface, and the depth gradually increasing from 1 / 4 to 1 / 3 of the plate thickness. The beneficial effect of this step is that it increases the contact area compared with the traditional right-angle bevel. Tests have shown that the weld performance is improved compared with the conventional bevel, and the shear bearing capacity is enhanced.

[0015] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages: 1. This application ensures the dimensional accuracy and flatness of the basic components by performing refined pre-processing (rolling, straightening, and bending) and CNC precision cutting of the steel plates. For curved and irregular parts such as web plates and base plates, 3D modeling is used for precise layout, combined with dense multi-pass bending process and laser cutting for simultaneous beveling, which effectively controls the forming accuracy and rib deformation of complex curved surface components, laying the foundation for subsequent precise assembly.

[0016] 2. This application divides the corbel structure into modular units such as top plate units, bottom plate units, web plate units, and partition plate units for modular fabrication. This allows welding operations inside the originally cramped box to be performed at the unit stage, expanding the operating space. During unit fabrication and assembly, standardized processes such as defining baselines, assembling ribs, welding, flaw detection, and finishing ensure the quality and precision of each unit.

[0017] 3. This application solves the problems of welding deformation and stress concentration by optimizing the welding sequence, controlling heat transfer, and adopting multiple alternating welding on the inside and outside and natural cooling process, while ensuring the overall structural accuracy and stability.

[0018] 4. The manufacturing method disclosed in this application establishes an overall manufacturing and assembly scheme for the ship-shaped variable cross-section curved edge support bracket, from plate units to blocks, specifically addressing the welding challenges of complex curved surface structures (outer web plate and bottom plate), confined working spaces, and high-precision web plate planes. By optimizing the welding sequence, innovating the gradual transition bevel design, and employing multiple alternating inner and outer welding processes with natural cooling, welding deformation (flatness deviation ≤ 0.5 mm / m) is effectively controlled, weld quality is improved, and the dimensional accuracy and overall stability of the bracket structure are ensured. This method achieves efficient collaborative stress distribution between the bracket and the tower column, providing technical assurance for the safety and economy of suspension bridges and enhancing the safe service durability of the steel tower bracket structure. 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 flowchart illustrating a method for manufacturing a ship-shaped variable cross-section curved edge support bracket structure according to a specific embodiment of the present invention; Figure 2 This is a schematic diagram of the corbel structure in a method for manufacturing a ship-shaped variable cross-section curved edge support corbel structure according to a specific embodiment of the present invention; Figure 3 for Figure 2 A schematic diagram of the unfolded structure of the base plate unit; Figure 4 for Figure 2 A schematic diagram of the unfolded structure of the web unit in the diagram; Figure 5 for Figure 2 A schematic diagram of the support components in the diagram; The attached figures are labeled as follows: 1-Top plate unit; 2-Bottom plate unit; 3-Web plate unit; 4-Break plate unit; 5-Support component; 501 - Support plate; 502 - First stiffening rib; 503 - Second stiffening rib; 504 - Third stiffening rib; 505 - Fourth stiffening rib; 506 - Fifth stiffening rib. Detailed Implementation

[0021] 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 merely illustrative of the technical solution of the present invention and are therefore intended to limit the scope of protection of the present invention.

[0022] 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.

[0023] 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.

[0024] Example: This application discloses a method for manufacturing a ship-shaped variable cross-section curved edge support bracket structure. The bracket support includes: a top plate unit, a bottom plate unit, a web plate unit, a diaphragm unit, and support-related components, such as... Figure 2-5 As shown; Its production method includes the following steps, such as Figure 1 As shown: S1: Pre-treatment and blanking: The steel plate is rolled flat and then precision cut to form various parts; the specific contents of this step are as follows: after the steel plate is rolled flat, the flatness in all directions is ≤1.0mm / m. Precision cutting or CNC precision cutting is used for blanking. Some parts are flame-cut and beveled and ground evenly; parts with a length >2m are straightened (flatness <1.0mm / m), and parts with a length >1.8m are bent (the bending of the straightened length edge is ≤3mm). S2: Unit Fabrication: Assemble and weld the various components to form the top plate unit, bottom plate unit, web plate unit, and partition plate unit; the specific details of this step are as follows: S201: Fabricate the top plate unit (including the top plate and top plate ribs): Draw longitudinal and transverse reference lines on the top plate with the short side reference end of the cantilever end and one long side reference end (ensure verticality), and draw the rib position lines and port lines according to the lines (make 3 center punches at both ends, >50mm from the plate edge); Assemble the top plate ribs with the lines as reference (gap ≤0.5mm, local ≤1.0mm, verticality ≤1mm / m), inspect for flaws after welding, and adjust the flatness (transverse ≤2mm, longitudinal ≤4mm, rib verticality ≤2mm). S202: Fabrication of the base plate unit (including the base plate and base plate ribs): The process is the same as the top plate unit, but the base plate needs to be additionally marked with bending lines and bent (control the bending radius and angle, twist ≤ 3.0mm, pay attention to the bevel direction), and inspect and repair after welding; Fabrication of the base plate rib assembly: butt joint with the edge of the repaired straight plate rib, inspect after welding, flame cut the arc extinguishing plate and grind, and repair welding deformation (ensure the flatness of the plate ribs). S203: Fabrication of web unit (including web and web ribs): On the platform, draw longitudinal and transverse reference lines with the short side reference end of the bridge centerline and the long side reference end of the tower top, draw the rib position lines and end lines (make sample punches); assemble the ribs (control the gap, verticality, and spacing), inspect for defects after welding, and adjust the flatness (transverse ≤2mm, longitudinal ≤4mm, rib verticality ≤2mm). S204: Partition Unit Fabrication: For frame-type / solid-web partitions, precision cutting and straightening are performed, followed by flame cutting and grinding of the bevel. Manhole reinforcing rings are assembled according to the lines, and after welding, flaw detection is conducted. Welds are then ground (flatness ≤ 1mm / m) to form individual partitions. For solid-web partitions, units must first be assembled according to the outline (with arc-starting and extinguishing plates installed at both ends of the butt weld). After welding flaw detection, the arc-starting and extinguishing plates are removed and trimmed, and then stiffening ribs are installed. Partition Unit Assembly Fabrication: On a platform, partition units are assembled according to the butt joint edges and outline dimensions (with arc-starting and extinguishing plates installed at both ends of the butt weld). After welding, flaw detection is conducted, and the arc-starting and extinguishing plates are flame-cut and ground, and deformation is corrected (ensuring flatness). S3: Pre-assembly inspection: Inspect the units to be assembled. If they pass the inspection, proceed to the next step. The specific contents of this step are as follows: Before the assembly of the blocks, conduct a comprehensive inspection of all the parts to be assembled, repair any deformation caused by transportation, hoisting, etc., and do not include unqualified products in the assembly. At the same time, inspect the jig to ensure that the overall flatness is ≤2mm, meets the preset slope requirements, and the verticality of the longitudinal and transverse baselines meets the regulations. S4: Step-by-step positioning assembly and welding: First, assemble and weld the top plate unit and the partition plate unit, then assemble and weld the partition plate unit and the web plate unit, and finally assemble and weld the bottom plate unit to form the corbel segment. S5: Assembly and Port Processing of Support Components: Assemble the support components, then process and test the ports. The specific steps are as follows: Assemble the bearing components: On the unmachined surface of the bearing pad, assemble the bearing stiffener according to the line positioning, ensuring that it is perpendicular to the surface, and weld the assembly; turn the bracket segment 180° and adjust the pre-camber, assemble the bearing pad assembly in sequence (with the thicker side of the smaller plate facing the cantilever end), ensure that the upper surface is horizontal, weld the relevant welds, and then inspect and repair them. Port processing and final inspection: Correct the longitudinal and transverse baselines of the segment based on the ground line, draw the port flame tangent, use a semi-automatic trolley to finely cut the bevel and grind away defects; inspect the bracket length L, box opening height H2, width B2 and diagonal difference, and repair local deformation; remove rust, paint, and make markings on the block.

[0025] Further explanation of step S2 of this application: The web plate unit, the bottom plate unit and its ribs are all curved irregular parts. The web plate unit and the bottom plate unit are obliquely intersecting, and the angle between the web plate unit and the bottom plate unit changes abruptly at the end. The size of the web plate unit will become wider or narrower due to the oblique relationship. Moreover, the bottom plate unit is a spatial curved surface, and the actual blanking shape and size need to be laid out. Therefore, before blanking, three-dimensional modeling is used to simulate the positional relationship between the web plate and the bottom plate, and the shape and size of the web plate and the bottom plate are laid out.

[0026] Because the base plate unit in this application is fitted with a variable cross-section parallelogram partition, and after forming it is a curved surface structure with an off-angle, the base plate is cut according to the curved surface with an off-angle, and a dense multi-stage bending process is adopted, with bending lines parallel to the end lines for bending. The base plate ribs are arranged perpendicular to the plate surface. Due to the characteristics of the off-angle structure of the base plate, the base plate ribs are crescent-shaped spatial curved surfaces. When cutting, laser cutting is used to cut the bevel simultaneously to avoid the deformation of the ribs caused by secondary cutting of the bevel, which would affect the accuracy. During bending, multiple multi-angle bending lines are arranged for bending to control the assembly angle between the ribs and the base plate after bending.

[0027] Further explanation of step S4 of this application includes the following: S401: The top plate unit, web plate unit, and bottom plate unit are welded together on the jig in two parts; S402: Lifting partition unit, welding ordinary partition, supporting partition and top plate unit with fillet weld or full penetration fillet weld; S403: Assemble the internal support stiffeners of the support partition. First, install the first support stiffener, weld the first support stiffener to the support partition with a full penetration fillet weld at the vertical position, and weld the first support stiffener to the top plate unit with a full penetration fillet weld at the horizontal angle. Then, assemble the third support stiffener, weld the third support stiffener to the first support stiffener with a full penetration fillet weld at the vertical position, and weld the third support stiffener to the top plate unit with a full penetration fillet weld at the horizontal angle. Next, assemble the second support stiffener, weld the second support stiffener to the support partition with a full penetration fillet weld at the vertical position, and weld the second support stiffener to the top plate unit with a full penetration fillet weld at the horizontal angle. Finally, weld the third support stiffener to the second support stiffener with a full penetration fillet weld at the vertical position. S404: Assemble the web plate unit and weld the full penetration fillet weld between the web plate unit and the top plate unit; S405: Weld the fillet weld between the ordinary diaphragm and the web unit, and weld the full penetration fillet weld between the supporting diaphragm and the web unit; S406: Assemble the base plate unit and weld the full penetration fillet weld between the web plate unit and the base plate unit; S407: Full penetration fillet weld between the web plate unit and the top plate unit; S408: Welding fillet welds between ordinary partition plates and base plate units, and welding full penetration fillet welds between supporting partition plates and base plate units; S409: Weld the full penetration fillet weld between the first support stiffener and the base plate unit to complete the assembly.

[0028] Specifically, the complex curved surface structure formed by the web and bottom plate, coupled with the limited working space at their connection, significantly restricts welding operations. Furthermore, the web surface requires extremely high precision; heat input and stress release during welding can easily lead to planar deformation, directly affecting the structural dimensional accuracy. In addition, welding quality is closely related to the overall stability and safety of the bridge. Weld defects (such as incomplete fusion or cracks) can cause uneven structural stress, creating safety hazards. Therefore, stringent requirements are placed on the welding process. To address these complex conditions, the following welding sequence was established: In steps S406 and S407, when welding the web plate unit and the bottom and top plate units, the area with a gentle change in curvature is welded first, and then the curvature is gradually advanced to the part with a sudden change. Welding is performed in the order from the middle to both sides and from the inside to the outside. The heat distribution is balanced by symmetrical welding. For the web plate unit with a large thickness, multi-pass welding is used in layers, and the thickness of each weld does not exceed 3-4mm. The core logic is as follows: (1) Geometric feature adaptation: Combining the geometric parameters such as the curvature of the web plate unit and the oblique angle of the bottom plate unit, the area with a gentle change in curvature is welded first, and then the curvature is gradually advanced to the part with a sudden change, so as to avoid warping caused by local stress concentration; (2) Heat transfer control: Welding is performed in the order of "from the middle to both sides and from the inside to the outside", and the heat distribution is balanced by symmetrical welding. When welding the connection between the web unit and the top and bottom plate units, the middle section is welded first, and then the two sides are welded alternately to reduce the deformation caused by overheating on one side; (3) Matching steel properties: According to the thermal expansion coefficient of the steel, control the continuous welding time in the same area. For the web unit with a large thickness, use layered multi-pass welding. The thickness of each weld should not exceed 3-4mm to avoid excessive heat in a single welding process that could cause changes in material properties.

[0029] Furthermore, in actual welding operations, a process of "multiple alternating welding on the inner and outer sides + natural cooling" is adopted. Specifically, in steps S406 and S407, the welds between the web unit and the top and bottom plate units are double-sided welds. During welding, the inner 1 / 3 thickness is welded first, and after cooling, the workpiece is flipped over to weld the corresponding outer 1 / 3 thickness. This process is repeated until the bevel is filled. Multiple alternating welding and gas gouging ensure root penetration of the weld. After each welding, the workpiece must be allowed to cool naturally to ambient temperature. The temperature is monitored in real time to avoid stress concentration caused by rapid cooling. This process effectively releases stress, controlling the welding deformation to ≤1mm / m, far below the design allowable value. The flatness deviation of the web is controlled within 0.5mm / m, meeting high precision requirements and reducing the workload of subsequent correction processes.

[0030] Specifically, step S4 in this application also includes the following: positioning the top plate unit and assembling the partition unit: using an inverted assembly process, a ground survey line is laid out on the ground, the top plate unit is positioned and assembled according to the line and secured to the jig with a support plate; the partition unit is assembled with the longitudinal baseline of the top plate and the position line of the partition as a reference, ensuring that its verticality is ≤1mm, and each partition is supported by at least 3 angle steels of specification L50×5 or above on each side, and welded to the top plate unit after passing the inspection; Assemble the diaphragm longitudinal ribs, stiffeners, and web plate units: Using the top plate transverse baseline as a reference, install the diaphragm longitudinal ribs and stiffeners sequentially from the tower centerline side outwards, controlling the verticality to ≤1mm. Install the next longitudinal rib only after the previous one has passed the welding flaw detection. Assemble the web plate units using the top plate transverse baseline as a reference, controlling the spacing and inclination angle to ensure that the web plate plane is parallel to the top plate transverse baseline. After passing the inspection, use angle steel for temporary support and tack fixation. Assemble the base plate unit and weld and finish: Assemble the base plate unit based on the horizontal and vertical baselines of the top plate, ensuring that the cantilever end is aligned with the web and top plate. Check the length L, box opening height H1, width B1 and diagonal difference. After passing the inspection, tack fix it. Weld the base plate to the partition and web. After completion, turn the corbel over and weld the web to the top plate. Control the deformation and finish after flaw detection.

[0031] In this application, the support component connecting the main beam to the top plate unit of the corbel segment is a densely grid-type stiffening structure. The dense welding makes it difficult to control the flatness of the support pad. To ensure the flatness requirement for connection with the main beam, symmetrical stiffening welding, simultaneous welding and adjustment, and low-current welding are used for control. After welding, the support pad surface is machined to level it. When positioning on the corbel, the corbel angle is adjusted, and the top plate surface is adjusted to form a bridge arch to ensure the support pad surface is horizontal during installation.

[0032] The structure of the support component is as follows: it includes multiple stiffening ribs and a support plate, wherein the stiffening ribs are welded to the support plate; the stiffening ribs include a first stiffening rib, a second stiffening rib, a third stiffening rib, a fourth stiffening rib, and a fifth stiffening rib; The first stiffening rib is located in the middle of the support pad, and there are multiple second stiffening ribs, which are located on both sides of the first stiffening rib and are parallel to the first stiffening rib. There are multiple third stiffening ribs, and the third stiffening ribs are located between the first stiffening ribs and the second stiffening ribs, and the third stiffening ribs are parallel to each other; The fourth stiffening rib is multiple, and the fourth stiffening ribs are arranged in parallel and spaced between the first stiffening ribs and the second stiffening ribs, and the fourth stiffening ribs are located outside the third stiffening ribs; The fifth stiffening rib is multiple, and the fifth stiffening ribs are arranged in parallel at intervals on the outside of the second stiffening rib.

[0033] The specific steps for assembling the support components are as follows: Step S501: Assemble the first stiffening rib and the third stiffening rib on the support plate, and weld the full penetration weld at the flat corner. Step S502: Weld the first stiffening rib to the support plate at the flat corner with a full penetration fillet weld; Step S503: Weld the third stiffening rib to the support plate at the flat corner with a full penetration fillet weld; Step S504: Assemble the second stiffening rib, and weld the third stiffening rib and the full penetration fillet weld of the upright part of the second stiffening rib; Step S505: Weld the second stiffening rib to the support plate at the flat angle of the joint with the weld seam. Step S506: Assemble the fifth stiffening rib and weld the fifth stiffening rib and the vertical part of the second stiffening rib with a full penetration fillet weld; Step S507: Weld the fifth stiffening rib and the support plate at the flat corner of the joint to complete the fabrication of the support component; Step S508: Turn the corbel segment 180° and adjust the pre-arch, assemble the support pad assembly in sequence with the thick side of the small plate facing the cantilever end; fasten the support component to the top plate unit of the corbel segment, and weld the first stiffening rib to the flat corner part of the top plate unit of the corbel segment with a full penetration weld. Step S509: Weld the outer third stiffening rib to the top plate unit of the corbel segment with a flat corner fillet weld; Step S510: Assemble the fourth stiffening rib, weld the vertical part of the fillet weld between it and the first stiffening rib and the second stiffening rib, weld the horizontal part of the fillet weld between it and the top plate unit of the corbel segment, and weld the vertical part of the fillet weld between it and the support pad plate.

[0034] To further optimize weld quality, an innovative gradient transition bevel design was adopted, specifically as follows: In steps S4 and S5, the bevel is a gradient transition bevel, with the bevel angle gradually changing with the curvature of the surface, and the depth gradually increasing from 1 / 4 to 1 / 3 of the plate thickness. This ensures that the welding material fills the curved surface evenly, especially at the oblique intersection of the web and base plate, effectively avoiding the "dead corner" incomplete fusion problem caused by a fixed bevel angle. This design creates a smooth transition "sloping" connection between the weld and the base material, increasing the contact area compared to traditional right-angle bevels. Tests show that the weld performance is improved compared to conventional bevels, with enhanced shear capacity. Simultaneously, the bevel surface is smoothed by grinding (roughness ≥25μm), and combined with a semi-automatic flame cutting process, the straightness of the bevel edge is guaranteed to be ≤2mm, reducing the risk of impurity residue during welding and laying a solid foundation for subsequent welding quality.

[0035] This application discloses a method for fabricating a ship-shaped variable cross-section curved edge support bracket structure. It establishes an overall fabrication and assembly scheme for the ship-shaped variable cross-section curved edge support bracket, from plate units to blocks, and specifically addresses the welding challenges of complex curved surface structures (outer web plate and bottom plate), confined working spaces, and high-precision web plate planes. By optimizing the welding sequence, innovating a gradual transition bevel design, and employing multiple alternating inner and outer welding processes with natural cooling, welding deformation is effectively controlled (flatness deviation ≤ 0.5 mm / m), weld quality is improved, and the dimensional accuracy and overall stability of the bracket structure are ensured. This method achieves efficient collaborative stress distribution between the bracket and the tower column, providing technical assurance for the safety and economy of suspension bridges and enhancing the safe service durability of steel tower bracket structures.

[0036] 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.

[0037] 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.

[0038] 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 a boat-shaped variable cross-section curved edge support bracket structure, characterized by, It comprises the following steps: S1: pretreatment and blanking: the steel plate is rolled flat, and then is precisely cut and blanked to form various parts; S2: unit manufacturing: the various parts are assembled and welded to form a top plate unit, a bottom plate unit, a web plate unit and a partition plate unit; S3: pre-assembly detection: the units participating in assembly are detected, and after passing the detection, the next step is entered; S4: step-by-step positioning, assembly and welding: the top plate unit and the partition plate unit are assembled and welded first, then the partition plate unit and the web plate unit are assembled and welded, and finally the bottom plate unit is assembled and welded and trimmed to form a bracket segment; S5: assembly of support related parts and port processing: support parts are manufactured and assembled, and then port processing and detection are performed.

2. The production method according to claim 1, characterized by, In the step S2, the web plate unit and the bottom plate unit are both curve-shaped special-shaped parts.

3. The method of manufacturing according to claim 2, wherein, In the step S2, the following contents are further included when the bottom plate unit is manufactured: The bottom plate is unfolded and blanked according to an angle deviation surface, and is bent by using a dense multi-channel bending process with a bending line parallel to the port line; the bottom plate ribs are cut and beveled simultaneously by using laser cutting.

4. The method of manufacturing of claim 1, wherein, The welding step of the step S4 is as follows: S401: the top plate unit, the web plate unit and the bottom plate unit are two-ply welded on a jig; S402: the partition plate unit is hoisted, and the ordinary partition plate and the support partition plate are welded with the top plate unit at a corner weld or full penetration angle weld; S403: the internal support stiffeners of the support partition plate are assembled, the first support stiffener is installed first, full penetration angle welds between the first support stiffener and the support partition plate in a vertical position and between the first support stiffener and the top plate unit in a horizontal position are welded, the third support stiffener is then assembled, full penetration angle welds between the third support stiffener and the first support stiffener in a vertical position and between the third support stiffener and the top plate unit in a horizontal position are welded, the second support stiffener is then assembled, full penetration angle welds between the second support stiffener and the support partition plate in a vertical position and between the second support stiffener and the top plate unit in a horizontal position are welded, and finally full penetration angle welds between the third support stiffener and the second support stiffener in a vertical position are welded; S404: the web plate unit is assembled, and full penetration angle welds between the web plate unit and the top plate unit are welded; S405: the ordinary partition plate is welded with the web plate unit at an angle weld, and the support partition plate is welded with the web plate unit at a full penetration angle weld; S406: the bottom plate unit is assembled, and full penetration angle welds between the web plate unit and the bottom plate unit are welded; S407: full penetration angle welds between the web plate unit and the top plate unit are welded; S408: the ordinary partition plate is welded with the bottom plate unit at an angle weld, and the support partition plate is welded with the bottom plate unit at a full penetration angle weld; S409: full penetration angle welds between the first support stiffener and the bottom plate unit are welded, and the assembly is completed.

5. The method of manufacturing according to claim 4, wherein, In the steps S406 and S407, when the web plate unit and the bottom plate unit and the top plate unit are welded, the curved surface curvature change gentle area is welded first, and then the curvature mutation position is gradually pushed forward, and the welding is performed according to the sequence from the middle to the two sides and from the inside to the outside, the heat distribution is balanced through symmetrical welding, the web plate unit with large thickness is welded by using layered multi-channel welding, and the thickness of each weld is not more than 3-4 mm.

6. The method of manufacturing according to claim 4, wherein, The welding seam between the web unit and the top plate unit and the bottom plate unit in the steps S406 and S407 is a double-sided welding seam, and when welding, the inner 1 / 3 thickness is welded first, and after cooling, the workpiece is turned over to weld the outer 1 / 3 thickness at the corresponding position, and this is repeated until the groove is filled, and the welding seam root penetration can be ensured by multiple alternating welding and air gouging; after each welding, it needs to be naturally cooled to ambient temperature.

7. The method of making of claim 1, wherein, The support part in the step S5 comprises a plurality of stiffening ribs and a support pad plate, the stiffening ribs are welded on the support pad plate; the stiffening ribs comprise a first stiffening rib, a second stiffening rib, a third stiffening rib, a fourth stiffening rib and a fifth stiffening rib; The first stiffening rib is located in the middle of the support pad plate, the second stiffening rib is a plurality of stiffening ribs, and the second stiffening rib is located on both sides of the first stiffening rib, and the second stiffening rib is parallel to the first stiffening rib; The third stiffening rib is a plurality of stiffening ribs, and the third stiffening rib is located between the first stiffening rib and the second stiffening rib, and the third stiffening rib is parallel to each other; The fourth stiffening rib is a plurality of stiffening ribs, and the fourth stiffening rib is arranged in parallel and spaced between the first stiffening rib and the second stiffening rib, and the fourth stiffening rib is located outside the third stiffening rib; The fifth stiffening rib is a plurality of stiffening ribs, and the fifth stiffening rib is arranged in parallel and spaced outside the second stiffening rib.

8. The method of manufacturing according to claim 7, wherein, The manufacturing and assembling steps of the support part are as follows: Step S501: assembling the first stiffening rib and the third stiffening rib on the support pad plate, and welding the flat angle position part of the first stiffening rib and the third stiffening rib to form a fusion welding seam; Step S502: welding the first stiffening rib and the support pad plate flat angle position part to form a fusion angle welding seam; Step S503: welding the third stiffening rib and the support pad plate flat angle position part to form a fusion angle welding seam; Step S504: assembling the second stiffening rib, and welding the third stiffening rib and the second stiffening rib vertical position part to form a fusion angle welding seam; Step S505: welding the second stiffening rib and the support pad plate flat angle position part to form a fusion welding seam; Step S506: assembling the fifth stiffening rib, and welding the fifth stiffening rib and the second stiffening rib vertical position part to form a fusion angle welding seam; Step S507: welding the fifth stiffening rib and the support pad plate flat angle position part to form a fusion welding seam, and completing the manufacturing of the support part; Step S508: turning the bracket segment over by 180° and adjusting the pre-camber, assembling the support pad plate assembly small plate thick side towards the cantilever end in sequence; the support part is buckled to the top plate unit of the bracket segment, and the first stiffening rib and the top plate unit of the bracket segment are welded to form a fusion welding seam at the flat angle position part; Step S509: welding the outer third stiffening rib and the top plate unit of the bracket segment to form a flat angle position angle welding seam; Step S510: assembling the fourth stiffening rib, welding the first stiffening rib and the second stiffening rib between the vertical position part to form a fusion angle welding seam, welding the top plate unit of the bracket segment at the flat angle position part to form a fusion angle welding seam, and welding the support pad plate at the upward angle position part to form a fusion angle welding seam.

9. The method of making of claim 1, wherein, The groove in the steps S4 and S5 is a gradually changing transition groove, the groove angle gradually changes with the curvature of the curved surface, and the depth gradually increases from 1 / 4 of the plate thickness to 1 / 3.

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