Permanent sling anchoring block body of suspension bridge steel box girder and manufacturing method of permanent sling anchoring block body

Abstract

The invention discloses a permanent sling anchoring block for a suspension bridge steel box girder. The permanent sling anchoring block comprises a lifting lug inserting plate and an anchoring top plate unit. The anchoring top plate unit comprises a top plate, a plurality of plate rib sets, a plurality of transverse partition plates and a plurality of longitudinal partition plates, each plate rib set is provided with a plurality of plate ribs, each plate rib, each transverse partition plate and each longitudinal partition plate are welded to the top plate, each plate rib and each transverse partition plate are perpendicular to the top plate, and each transverse partition plate and the plate rib sets are welded together. A longitudinal partition plate is arranged between any two adjacent transverse partition plates, and the longitudinal partition plate and the two adjacent transverse partition plates are welded together; a first inserting groove is formed in the top plate, a second inserting groove is formed in each transverse partition plate, a lifting lug inserting plate is inserted into the first inserting groove and the second inserting grooves, the lifting lug inserting plate and the top plate are welded together, and the lifting lug inserting plate and each transverse partition plate are welded together. The method is high in manufacturing precision, convenient to construct, high in manufacturing efficiency, low in cost, safe and reliable, and the quality is guaranteed.

Description

Technical Field

[0001] This invention belongs to the field of suspension bridges, and more specifically, relates to a permanent cable anchoring block for a steel box girder of a suspension bridge and its manufacturing method. Background Technology

[0002] With the rapid development of my country's economy and society, the construction of bridges spanning rivers and seas has entered a boom period. In recent years, suspension bridges have become the preferred option for long-span cross-sea bridges due to their ultra-long span capacity, unique structural form, reasonable stress system, and aesthetic design. At the same time, suspension bridges, with their unique technological advantages, are helping my country's cross-sea bridge technology to reach international leading levels.

[0003] Suspension bridges are mainly composed of main cables, bridge towers, anchorages, suspenders, and bridge deck box girders. The permanent suspender anchor blocks, as part of the bridge deck box girder, effectively connect the suspenders to the bridge deck and bear the enormous tensile force transmitted by the suspenders. Therefore, the manufacturing quality of the permanent suspender anchor blocks directly affects the overall stability and safety of the suspension bridge.

[0004] Traditional suspension bridge projects typically feature relatively simple cable anchorage blocks, primarily consisting of lugs and internal longitudinal and transverse stiffeners. Fabrication is relatively easy and the process is fairly conventional. However, for complex, long-span, split-type steel box girder suspension bridges, the stress system is more complex, and the lug design is also more intricate. The cable anchorage blocks are positioned on both sides of the steel box girder, anchored through a box-shaped structure formed by lug assemblies, diaphragms, and partial diaphragms on both sides. The cables are connected to the lugs via pins. Traditional anchorage structures often employ a simple "lug + stiffener" configuration. In this configuration, the connection between the lugs and the top plate and diaphragms relies mainly on simple butt welds or fillet welds. Due to the lack of deeply embedded physical structures, the enormous concentrated loads transmitted by the cables are almost entirely borne by the weld shear force. Under high-frequency vehicle live loads and wind loads, the welds are highly susceptible to fatigue cracking, leading to instability in the load transmission path.

[0005] The suspension bridge construction project used 60mm thick lug plates for the cable anchorage blocks, with the central diaphragm locally thickened to 36mm and the side diaphragms locally 30mm thick. The permanent cable anchorage blocks are characterized by complex structures, various plate thicknesses, dense welds (all full penetration fillet welds or bevel welds), and limited construction space. Their fabrication quality directly affects the overall linear control and geometric accuracy of the steel box girder segments. Traditional unit-component welding techniques suffer from difficulties in controlling cable anchorage block deformation and extreme difficulty in correction, failing to meet the demands of large-scale production, especially under tight deadlines where component precision and quality control are extremely challenging. Summary of the Invention

[0006] In view of the above-mentioned defects or improvement needs of the existing technology, the present invention provides a permanent cable anchorage block for a steel box girder of a suspension bridge and its manufacturing method. It has high manufacturing precision, guaranteed quality, convenient construction, high manufacturing efficiency, low cost and safety and reliability. It solves the technical problems of large welding deformation and weld quality that cannot meet higher requirements due to complex structure, and greatly improves the quality of cable anchorage blocks.

[0007] To achieve the above objectives, according to one aspect of the present invention, a permanent cable anchorage block for a steel box girder of a suspension bridge is provided, comprising a lug insert plate, an anchorage top plate unit, multiple transverse diaphragms, and multiple longitudinal diaphragms, wherein: The lifting lug insert plate is provided with insert plate holes; The anchored top plate unit includes a top plate and multiple sets of plate ribs. Each set of plate ribs has multiple plate ribs, each plate rib is parallel to the X-axis, and the multiple plate ribs of each set of plate ribs are arranged on the same straight line parallel to the X-axis. These plate rib sets are distributed on multiple straight lines. Each rib, each transverse diaphragm, and each longitudinal diaphragm are welded to the top plate. Each transverse diaphragm is parallel to the Y-axis and these transverse diaphragms are parallel to each other. The Y-axis is perpendicular to the X-axis. Each rib and each transverse diaphragm are perpendicular to the top plate. The angle between each longitudinal diaphragm and the top plate is greater than 0° and less than 90°. Each transverse diaphragm is welded together with multiple sets of ribs. A longitudinal partition is provided between any two adjacent transverse partitions, and the longitudinal partition is welded together with both adjacent transverse partitions. Two longitudinal partitions welded to the same transverse partition are symmetrically arranged on both sides of this transverse partition; The top plate is provided with a first slot, and each of the transverse partitions is provided with a second slot. The lifting lug plate is inserted into the first slot and each of the second slots. The lifting lug plate is welded to the top plate and to each of the transverse partitions.

[0008] Preferably, the lifting lug insert plate is provided with multiple reinforcing plates and multiple stiffening plates. Each reinforcing plate is parallel to the lifting lug insert plate and is welded to it. Each reinforcing plate is provided with a reinforcing plate hole. Each insert plate hole communicates with a reinforcing plate hole on at least one of the reinforcing plates. The insert plate hole and the corresponding reinforcing plate hole together form a lifting lug hole. Each stiffening plate is welded to the lifting lug insert plate and is perpendicular to the lifting lug insert plate.

[0009] Preferably, the stiffening plate and the transverse partition are located on two opposite surfaces of the top plate, and each stiffening plate is provided with a positioning plane, which is respectively attached to the surface of the top plate.

[0010] Preferably, there is a partition groove between any two adjacent plate ribs in each group of plate ribs, each of the transverse partitions passes through multiple partition grooves, and each of the transverse partitions is welded to the plate ribs on both sides of the partition groove.

[0011] According to another aspect of the present invention, a method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge is also provided, comprising the following steps: 1) Machining the lifting lug plate on a CNC machining center; 2) Weld the lifting lug plate and the reinforcing plate together to form the plate assembly; 3) The reinforcing plate is milled using a CNC machining center, and the insert plate assembly is bored to form lifting lug holes; 4) Weld multiple stiffening plates onto the lug plate of the insert plate assembly, and the insert plate assembly and all the stiffening plates together form the lug assembly; 5) Weld multiple rib plates onto one of the surfaces of the top plate, and the top plate and the multiple rib plates together form an anchored top plate unit; 6) Weld at least one transverse diaphragm to the top plate of the anchored top plate unit, the transverse diaphragm being welded together with multiple plate ribs; 7) Weld longitudinal diaphragms to opposite sides of the transverse diaphragm; 8) Weld other transverse diaphragms to the top plate of the anchoring top plate unit, and weld the transverse diaphragms welded in this step together with the longitudinal diaphragms. The anchoring top plate unit, all the transverse diaphragms and all the longitudinal diaphragms together form a groove-shaped component. 9) Fix the grooved component to the jig, with the side of the top plate away from the rib facing upwards. Insert the lifting lug plate of the lifting lug assembly into the slots of the top plate and each transverse partition from top to bottom. Then weld the lifting lug plate to the top plate and weld the lifting lug plate to each transverse partition.

[0012] Preferably, in step 2), the weld area of ​​the lug insert and the reinforcing plate of the insert assembly is subjected to ultrasonic hammering.

[0013] Preferably, in step 5), multiple plate ribs are welded to one of the plates on the top plate on the anti-deformation frame.

[0014] Preferably, in step 7), the thickness of the transverse partition is greater than the thickness of the longitudinal partition, and the transition slope pre-processed on the transverse partition forms a thickness gradient structure so as to weld the longitudinal partition on the transverse partition.

[0015] Preferably, step 9) further includes: A limiting plate is welded to the surface of the top plate near the ribs. The limiting plate is welded together with the lifting lug plate and also with multiple ribs.

[0016] Preferably, the lug inserts, reinforcing plates, stiffening plates, top plates, transverse diaphragms, and longitudinal diaphragms are all laid out using BIM 3D modeling and CNC precision cutting or laser cutting.

[0017] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects: 1) The present invention relates to a permanent cable anchorage block for a steel box girder of a suspension bridge. The lug insert plate is deeply embedded through a first slot in the top plate and second slots in each transverse diaphragm, and is welded to the top plate and multiple transverse diaphragms. This insert structure achieves a transformation from a single weld-seam force transmission mode to a dual mode of physical embedding + weld-seam force transmission in terms of mechanical effect. When the cable transmits a large concentrated tensile force, the load is no longer transmitted solely through the weld shear force on the side of the lug, but through the bearing stress between the lug insert plate and the slot contact surface, and the physical anchorage force penetrating multiple transverse diaphragms. As the main load-bearing component, the lug insert plate's force flow can smoothly enter the anchorage top plate unit and the internal transverse and longitudinal stiffening system through the slot interface, greatly expanding the structural range involved in the load-bearing and reducing severe stress concentration at the anchorage root.

[0018] 2) The present invention discloses a permanent cable anchoring block for a steel box girder of a suspension bridge. The anchoring top plate unit forms an internal stiffening system similar to a honeycomb lattice through a combination of a top plate, multiple sets of plate ribs, multiple transverse diaphragms, and multiple longitudinal diaphragms. Each plate rib is parallel to the X-axis, and the transverse diaphragms are parallel to the Y-axis and perpendicular to the top plate. This orthogonally distributed plate structure forms a multi-directional reinforced beam system. Under the impact of alternating cable loads, this system can provide extremely high in-plane and out-of-plane stiffness, effectively suppressing local buckling deformation of the top plate under heavy loads. The angle between each longitudinal diaphragm and the top plate is greater than 0° and less than 90°, a geometric feature that helps to improve the structure's extremely strong spatial torsional resistance. The obliquely arranged longitudinal diaphragms, together with the horizontal top plate and the vertical transverse diaphragms, form a spatial triangular stable configuration, which can effectively resist structural distortion caused by eccentric loads or wind-induced vibration loads.

[0019] 3) In a permanent cable anchorage block for a steel box girder of a suspension bridge according to the present invention, two longitudinal diaphragms welded to the same transverse diaphragm are symmetrically arranged on both sides. This design ensures that the internal stress field of the anchorage block is highly symmetrical when subjected to axial tensile force. The symmetrical structure can effectively eliminate the additional bending moment caused by stiffness eccentricity, ensuring the stress stability of the anchorage block during long-term service. Multiple sets of ribs are distributed on multiple straight lines and parallel to the X-axis. This equidistant or regular distribution pattern allows the surface load of the top plate to be uniformly transferred to the main beam frame. The vertical welding of each rib, transverse diaphragm, and top plate ensures the shortest force transmission path and maximizes efficiency.

[0020] 4) The permanent cable anchorage block of a suspension bridge steel box girder according to the present invention, through the welding of the transverse diaphragm to multiple sets of plate ribs and the deep coupling of the lug insert plate to the transverse diaphragm, allows the load to undergo multiple interface diversions during transmission. This design makes the stress gradient in the anchorage area extremely gentle, reducing the initiation of microcracks caused by sudden changes in hard force. In this cable anchorage block structure, the welds are not isolated but distributed on multiple spatial planes (top plate plane, transverse diaphragm plane, plate rib plane). The multi-point, multi-faceted welding connection makes the entire anchorage block form an integral rigid box, significantly reducing the stress amplitude of individual welds, thereby significantly improving the fatigue life of the structure under complex load environments.

[0021] 5) In the permanent cable anchoring block of the steel box girder of the suspension bridge of the present invention, the design of the first slot and the second slot provides a positioning reference for the installation of the lug insert plate. During the assembly process, the insertion of the lug insert plate completes the precise definition of the spatial position, reduces the reliance on manual measurement and positioning, and ensures that the anchoring center line is highly coincident with the bridge design axis.

[0022] 6) This invention provides a method for manufacturing permanent cable anchorage blocks for steel box girders in suspension bridges. Through precision machining, modular assembly, slot positioning, and a controlled manufacturing logic, it solves the manufacturing challenge of having thick plates, dense welds, and high-precision holes coexisting within the same component. This method not only ensures the geometric accuracy of the anchorage blocks under static conditions but also optimizes their dynamic mechanical response and fatigue performance through technological means, providing a crucial technological guarantee for ensuring the long-term operational stability of long-span suspension bridges. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the lug insert plate in this invention; Figure 2 This is a schematic diagram of the insert assembly in this invention; Figure 3 This is a schematic diagram of the insert assembly after milling and boring in this invention; Figure 4 This is a schematic diagram of the lug assembly in this invention; Figure 5 This is a schematic diagram of the anchored top plate unit in this invention; Figure 6 This is a schematic diagram of a transverse diaphragm welded onto the anchored top plate unit in this invention; Figure 7 This is a schematic diagram of a transverse diaphragm and two longitudinal diaphragms welded onto the anchoring top plate unit in this invention. Figure 8 This is a schematic diagram of the groove-shaped component in this invention; Figure 9 This is a schematic diagram of inserting the lifting lug assembly into the grooved component on the jig frame; Figure 10 This is a process flow diagram of a method for manufacturing a permanent cable anchoring block for a steel box girder of a suspension bridge according to the present invention.

[0024] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 1. Lifting lug plate; 11. Plate hole; 2. Anchoring top plate unit; 21. Top plate; 22. Rib assembly; 221. Rib; 23. Horizontal diaphragm; 24. Longitudinal diaphragm; 3. Reinforcing plate; 31. Reinforcing plate hole; 4. Stiffening plate; 41. Positioning plane; 222. Dividing groove; 5. Limiting plate; 211. First slot; 231. Second slot; 6. Frame. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0026] Reference Figures 1-9 A permanent cable anchoring block for a steel box girder of a suspension bridge includes a lug plate 1, an anchoring top plate unit 2, multiple transverse diaphragms 23, and multiple longitudinal diaphragms 24, wherein: The lug insert plate 1 is provided with insert plate holes 11; The anchoring top plate unit 2 includes a top plate 21 and multiple sets of plate ribs 22 (see...). Figure 5 Five sets of plate ribs 22 are shown. Each set of plate ribs 22 has multiple plate ribs 221. Each plate rib 221 is parallel to the X-axis. The multiple plate ribs 221 of each set of plate ribs 22 are arranged on the same straight line parallel to the X-axis. These plate ribs 22 are distributed on multiple straight lines. Each rib 221, each transverse diaphragm 23, and each longitudinal diaphragm 24 are respectively welded to the top plate 21. Each transverse diaphragm 23 is parallel to the Y-axis and these transverse diaphragms 23 are parallel to each other. The Y-axis is perpendicular to the X-axis. Each rib 221 and each transverse diaphragm 23 are perpendicular to the top plate 21. The angle between each longitudinal diaphragm and the top plate 21 is greater than 0° and less than 90°. Each transverse diaphragm 23 is welded together with multiple sets of rib groups 22.

[0027] A longitudinal partition 24 is provided between any two adjacent transverse partitions 23, and the longitudinal partition 24 is welded together with both adjacent transverse partitions 23.

[0028] Two longitudinal partitions 24, welded to the same transverse partition 23, are symmetrically arranged on both sides of the transverse partition 23.

[0029] The top plate 21 is provided with a first slot 211, and each of the transverse partitions 23 is provided with a second slot 231. The lifting lug 1 is inserted into the first slot 211 and each of the second slots 231. The lifting lug 1 is welded to the top plate 21 and to each of the transverse partitions 23.

[0030] The lug insert 1 is not a simple surface connection, but rather deeply embedded through a first slot 211 on the top plate 21 and a second slot 231 on each transverse diaphragm 23, and connected by multi-point, multi-faceted welding. This design allows the load to be transferred to the internal stiffening system in a progressively decreasing manner along the depth direction of the lug insert 1, effectively reducing abrupt stress changes on the surface of the top plate 21. Through its ingenious slot-embedded connection structure, a spatial lattice stiffening system combining orthogonal and oblique angles, and a symmetrically distributed internal force smoothing mechanism, this invention not only achieves efficient and stable load transfer on a macroscopic level, but also effectively controls stress concentration and fatigue damage on a microscopic level. This technical solution produces significant synergistic gains in multiple dimensions, including mechanical performance, manufacturing precision, and safety redundancy, laying a solid structural foundation for the long-term stable service of suspension bridges in complex environments.

[0031] Furthermore, the lifting lug plate 1 is provided with multiple reinforcing plates 3 and multiple stiffening plates 4. Each reinforcing plate 3 is parallel to the lifting lug plate 1 and is welded to the lifting lug plate 1. Each reinforcing plate 3 is provided with a reinforcing plate hole 31. Each insertion plate hole 11 is connected to the reinforcing plate hole 31 on at least one of the reinforcing plates 3. The insertion plate hole 11 and the corresponding reinforcing plate hole 31 together form a lifting lug hole. Each stiffening plate 4 is welded to the lifting lug plate 1 and is perpendicular to the lifting lug plate 1.

[0032] By stacking multiple reinforcing plates 3, the effective pressure-bearing area of ​​the lifting lug hole wall is substantially increased. When the lifting cable pin transmits a huge concentrated tensile force through the lifting lug hole, this structure can significantly reduce the compressive stress on the hole wall, effectively preventing the metal material from yielding under high pressure. The parallel welding of multiple reinforcing plates 3 to the lifting lug insert plate 1 allows the load to be transmitted not only within the plane of the insert plate, but also guided to the reinforcing plates 3 through the weld and contact surface. This three-dimensional superposition effect makes the stress flow more uniformly distributed in the thickness direction, improving the overall stress strength of the hole opening.

[0033] The stiffening plate 4, perpendicular to the lug plate 1, forms a combined section similar to a T-shape or I-shape with the lug plate 1. This configuration significantly improves the out-of-plane bending stiffness of the lug plate 1 under asymmetric loads or lateral forces, effectively suppressing potential instability or warping under extreme tensile forces. The stiffening plate 4 divides the large continuous plane of the lug plate 1 into multiple smaller rigid elements. Under high-frequency vibration environments caused by wind loads or dynamic vehicle loads, this division effectively increases the fundamental frequency of the structure, prevents local resonant buckling, and ensures the dynamic stability of the anchorage node.

[0034] The reinforcing plate 3 and stiffening plate 4 are connected to the lug insert plate 1 via their respective welds, forming a complex weld group system. This design guides the stress originally concentrated around the insert plate hole 11 to the far ends of the stiffening plate 4 and reinforcing plate 3 through multiple paths, thus smoothing the stress gradient and significantly reducing the stress concentration factor. Through the stress dispersion around the hole by the reinforcing plate 3 and the constraint of plate surface deformation by the stiffening plate 4, this scheme effectively reduces the strain amplitude under alternating loads. During long-term service, this low-strain state is crucial for preventing fatigue cracks in the weld heat-affected zone, thereby significantly extending the service life of the permanent sling anchor block.

[0035] Due to the constraint of multiple reinforcing plates 3, the elastic and plastic deformation of the lifting lug hole can be strictly controlled when subjected to huge tensile forces. This ensures that the pin and the hole wall always maintain a good fit, reducing the loosening of the connection or the effect of dynamic impact caused by hole elongation.

[0036] Furthermore, the stiffening plate 4 and the transverse partition 23 are located on two opposite surfaces of the top plate 21, and each stiffening plate 4 is provided with a positioning plane 41, which is in contact with the surface of the top plate 21.

[0037] The enormous tensile force generated by the slings is transmitted to the stiffening plate 4 through the lug plate 1. Since the stiffening plate 4 and the transverse diaphragm 23 below the top plate 21 form a substantial correspondence or continuity in spatial position, the load can smoothly diffuse across the top plate 21 to the lower transverse diaphragm 23. This arrangement reduces the abrupt turning or deflection of force flow when passing through the top plate 21, significantly improving the overall force transmission efficiency of the structure. By symmetrically or relatively arranging reinforcing members on both sides of the top plate 21, the top plate 21 is placed in a balanced constrained state under localized stress, reducing the risk of shear deformation in the thickness direction.

[0038] Traditional connections rely primarily on the linear load-bearing capacity of the weld seam. However, this invention establishes a stable pressure-bearing contact surface by tightly fitting the positioning plane 41 on the stiffening plate 4 with the top plate 21. When subjected to alternating loads from the sling, some of the pressure can be directly transmitted through this physical contact surface, greatly alleviating fatigue pressure on the weld seam and improving the structural redundancy of the anchoring block under extreme conditions. This close fit between the stiffening plate 4 and the top plate 21 allows the stiffening plate 4 to more effectively support the top plate 21, suppressing local buckling or micro-flutter of the top plate 21 under heavy loads, and ensuring the stability of the anchoring system under high-frequency dynamic loads.

[0039] The presence of the positioning plane 41 provides precise physical positioning for the assembly of the lifting lug assembly and the anchored top plate unit 2. When the positioning plane 41 is fully aligned with the surface of the top plate 21, it indicates that the insertion depth and verticality of the lifting lug insert 1 have reached the predetermined design position. This hard interlocking mechanism significantly reduces the reliance on manual measurement and positioning, ensuring the absolute accuracy of the spatial position of the lifting lug hole relative to the bridge axis.

[0040] The stiffening plates 4 and the transverse diaphragms 23 located on opposite sides of the top plate 21 work together to form a localized reinforcing unit on the vertical plane, similar to an I-beam or truss. This configuration greatly enhances the torsional stiffness of the anchorage area. When the suspenders are subjected to lateral wind force or eccentric load, generating torque, the structure can quickly decompose the torque into in-plane stress of the plates, preventing local torsional instability of the structure.

[0041] Furthermore, there is a partition groove 222 between any two adjacent plate ribs 221 in each group of plate ribs 22, and each of the transverse partitions 23 passes through multiple partition grooves 222, and each of the transverse partitions 23 is welded to the plate ribs 221 on both sides of the partition groove 222.

[0042] By setting partition grooves 222 between the plate ribs 221 parallel to the X-axis, the transverse diaphragm 23 parallel to the Y-axis can be physically passed through them. This interlocking structure establishes a physical interlocking relationship similar to the tenon joint in traditional mechanical structures in both the X and Y axes. When the anchor block is subjected to a huge concentrated tensile force transmitted by the sling, the load is no longer transmitted only through the lap welds on the plate surfaces, but is distributed more directly in three-dimensional space through this physical nesting structure.

[0043] The diaphragm 23 passes through the partition groove 222 and is welded to both sides of the side ribs 221, so that the stress of the ribs 221 along the X-axis can be smoothly converted into the shear stress of the diaphragm 23 through this intersection. This path shortens the force transmission distance, significantly improves the force transmission efficiency inside the structure, and ensures the consistency of the structural response of the anchor block under extreme load conditions.

[0044] By welding the diaphragm 23 to the side ribs 221 of the partition groove 222, a highly stable rigid core is formed at each intersection. Four independent vertical welding areas are formed at the intersection of the diaphragm 23 and the side ribs 221 of the partition groove 222. This multi-interface welding method significantly increases the effective weld length of a single node, effectively dispersing the stress that might have been concentrated at the weld root of the top plate 21 into these vertically distributed weld groups. Since the diaphragm 23 passes through the rib group 22, it provides extremely strong lateral restraint to the ribs 221, effectively suppressing any potential instability of the ribs 221 under compression or shear. This mutual restraint mechanism makes the entire anchored top plate unit 2 a high-rigidity lattice frame, greatly enhancing the anchored area's resistance to local deformation and spatial distortion.

[0045] The presence of the partition groove 222 provides a natural positioning guide for the installation of the diaphragm 23. During assembly, the diaphragm 23 only needs to be inserted along the partition groove 222 to automatically calibrate its relative position and perpendicularity to the rib assembly 22. This structurally constrained positioning design significantly reduces the reliance on the complex external jig 6 for positioning and reduces the cumulative tolerances caused by human measurement errors. Since the diaphragm 23 and the rib 221 have already formed a preliminary fixation through physical interlocking before welding, this physical interlocking structure acts as a strong internal support during the subsequent welding heat input process, restricting the free deformation of the plate due to thermal expansion and contraction. This not only ensures the geometrical accuracy of the finished anchor block but also guarantees the coaxiality and installation accuracy of the subsequent sling pin holes.

[0046] Reference Figure 10 According to another aspect of the present invention, a method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge is also provided, comprising the following steps: 1) Machining the lifting lug plate 1 on a CNC machining center; 2) Weld the lifting lug plate 1 and the reinforcing plate 3 together to form the plate assembly; 3) The reinforcing plate 3 is milled using a CNC machining center to bore holes in the insert assembly, forming lifting lug holes; 4) Weld multiple stiffening plates 4 onto the lug insert plate 1 of the insert plate assembly, and the insert plate assembly and all the stiffening plates 4 together form the lug assembly; 5) Weld multiple plate ribs 221 onto one of the plate surfaces of the top plate 21, and the top plate 21 and the multiple plate ribs 221 together form the anchored top plate unit 2; 6) At least one transverse diaphragm 23 is welded to the top plate 21 of the anchored top plate unit 2, and the transverse diaphragm 23 is welded together with multiple plate ribs 221; 7) Weld longitudinal partitions 24 to opposite sides of the transverse partition 23; 8) Weld other transverse diaphragms 23 onto the top plate 21 of the anchoring top plate unit 2, and weld the transverse diaphragms 23 welded in this step together with the longitudinal diaphragms 24. The anchoring top plate unit 2, all the transverse diaphragms 23 and all the longitudinal diaphragms 24 together form a groove-shaped component. 9) Fix the grooved component onto the jig 6, with the side of the top plate 21 facing away from the rib 221 upwards. Insert the lifting lug plate 1 of the lifting lug assembly into the slots of the top plate 21 and each transverse partition 23 from top to bottom. Then weld the lifting lug plate 1 to the top plate 21 and to each transverse partition 23. Each longitudinal partition 24 has a window to facilitate the welding of the lifting lug plate 1 to the transverse partition 23.

[0047] Steps 1) to 3) above employ a sequence of welding the reinforcing plate 3 first, followed by overall boring. By boring the reinforcing plate 3 using a CNC machining center after the insert assembly is formed, any misalignment that might occur when machining the reinforcing plate 3 and the lifting lug insert 1 separately can be completely eliminated. This process ensures that the final lifting lug hole has extremely high coaxiality and dimensional accuracy, guaranteeing smooth fit of the lifting pin during installation. The CNC milling of the reinforcing plate 3 and the boring process remove any microscopic unevenness that might occur in the weld heat-affected zone, resulting in a higher surface finish on the hole wall, thereby reducing the induction of micro-cracks under stress.

[0048] By welding multiple stiffening plates 4 onto the insert assembly in step 4), the lifting lugs acquire extremely high spatial rigidity before final assembly. This not only protects the geometry of the lifting lug holes but also provides a stable physical reference for subsequent insertion into the top plate 21 slot.

[0049] Steps 5) through 8) involve the orderly welding of the ribs 221, transverse diaphragms 23, and longitudinal diaphragms 24, gradually constructing a complex spatial groove-shaped component from a planar surface. This progressive forming process ensures that the shrinkage force generated by each welding step is offset by the already formed frame, significantly improving the forming quality of the component.

[0050] Step 9) is the core of the process flow of this invention. It involves fixing the grooved component to the jig 6 and inserting the lifting lug plate 1 into the slot from top to bottom. Gravity assists the insertion, allowing the lifting lug assembly to smoothly enter the narrow slots of the top plate 21 and the transverse partition 23. Combined with the fixing effect of the jig 6, a height spatial match is achieved between the lifting lug assembly and the grooved component, ensuring the linearity of the anchor block in three dimensions. Because there are multiple slots between the lifting lug plate 1 and the top plate 21 and transverse partition 23, this physical constraint greatly reduces the amount of tack welding work before welding. During the formal welding, each plate is physically constrained in a predetermined position, effectively suppressing angular deformation and instability during the welding process.

[0051] The present invention, by welding the internal stiffeners (ribs 221 and longitudinal and transverse partitions 23) first and then performing the overall assembly welding, allows the welding stress of the smaller internal plates to be released and corrected in advance, reducing the huge composite residual stress generated in the final assembly stage and improving the long-term fatigue performance of the structure.

[0052] Because the lifting lug plate 1 and the cross diaphragm plate 23 are precisely fitted together via slots before welding, the contact surfaces fit extremely well. Under actual stress, this precision manufacturing quality ensures that the load is evenly distributed across all connected plates, eliminating impact dynamic loads caused by excessive machining clearances.

[0053] The aforementioned manufacturing method, through precision machining, modular assembly, slot positioning, and a controlled manufacturing logic, solves the manufacturing challenge of coexisting ultra-thick plates, dense welds, and high-precision holes within the same component. This method not only ensures the geometric accuracy of the anchor block under static conditions but also optimizes its dynamic mechanical response and fatigue performance through technological means, providing a crucial technological guarantee for ensuring the long-term operational stability of long-span suspension bridges.

[0054] During manufacturing, the insert plate assembly employs integral machining milling and boring processes to ensure a machined flatness ≤0.2mm / full cross-section; pin hole perpendicularity ≤0.2mm; and hole diameter tolerances meet the requirements. .

[0055] The flatness of the top surface of the anchor block frame 6 is ≤0.5mm / full cross section. When the transverse diaphragm 23, longitudinal diaphragm 24, etc. are assembled with the anchor top plate unit 2, the baseline alignment deviation is not greater than 0.5mm. When the lifting lug assembly insert plate is assembled, the positioning accuracy deviation of the angle positioning tool is ±0.3mm.

[0056] Further, in step 2), the weld area of ​​the lug insert plate 1 and the reinforcing plate 3 of the insert plate assembly is subjected to ultrasonic hammering. Ultrasonic hammering applies high-frequency impact energy to the weld and its heat-affected zone, causing severe plastic deformation of the metal surface. This deformation effectively counteracts the residual tensile stress generated during welding cooling, significantly reducing the stress level inside the weld. Ultrasonic hammering introduces uniformly distributed residual compressive stress on the weld surface and within a certain depth of the surface layer. Since the sling anchor block mainly bears high-frequency tensile cyclic loads during service, this pre-set compressive stress can partially offset the tensile stress during service, thereby greatly optimizing the stress environment of the component. Ultrasonic hammering makes the geometric transition at the weld toe smoother, eliminating possible micro-geometric abrupt changes during welding. This geometric optimization directly leads to a reduction in the stress concentration factor, delaying the initiation of fatigue cracks. After eliminating welding stress through ultrasonic hammering, the insert plate assembly is in a low-energy equilibrium state. This effectively prevents component warping or hole out-of-roundness caused by the redistribution of internal stress due to the removal of some metal during boring in step 3).

[0057] Further, in step 5), multiple plate ribs 221 are welded onto one of the plates of the top plate 21 on the anti-deformation frame 6.

[0058] In step 5), welding multiple ribs 221 to the top plate 21 introduces a significant amount of localized heat input. By using the anti-deformation jig 6, a prestress or geometric displacement opposite to the expected deformation direction is applied to the top plate 21 before welding begins. When the welding thermal cycle causes the weld metal to shrink and generate bending moments, this pre-set reverse deformation precisely counteracts the thermo-elastic-plastic deformation generated during welding. After the component cools and detaches from the jig 6, the balance between the material's internal springback and the welding shrinkage force allows the top plate 21 to achieve the desired flatness. This is a core technological guarantee for ensuring the overall geometrical accuracy of structures like suspension bridge steel box girders, which have extremely high requirements for linear control.

[0059] Welding performed under the constraint of the jig 6 allows for the planned guidance of weld and heat-affected zone shrinkage during cooling. This process helps reduce the peak value of local residual tensile stress at the connection between the top plate 21 and the rib 221, resulting in a more uniform and smooth stress distribution within the anchored top plate unit 2. Because internal residual stress is effectively managed, the risk of secondary deformation of the component in subsequent processes (such as grooving, boring, or long-term service) is significantly reduced. This is crucial for ensuring the consistency of the mechanical response of the anchor block under the enormous tensile force of the sling.

[0060] The anti-deformation bracket 6 ensures the flatness of the top plate 21, thereby preventing the slot from twisting or closing during welding and ensuring that the geometry of the first slot 211 meets design requirements. The flat anchoring top plate unit 2 ensures that the lug assembly can be smoothly inserted from top to bottom in step 9). This high-precision physical matching reduces the need for strong alignment during final assembly, thereby reducing the introduction of additional assembly stress and ensuring the structural integrity of the entire permanent sling anchor block.

[0061] Furthermore, in step 7), the thickness of the transverse partition 23 is greater than the thickness of the longitudinal partition 24, and the transition slope on the transverse partition 23 is pre-processed by machining to form a thickness gradient structure so as to weld the longitudinal partition 24 onto the transverse partition 23.

[0062] When the longitudinal diaphragm 24 and the transverse diaphragm 23 are welded together, the force flow is prone to abrupt changes when crossing the thickness step due to their unequal thickness. The transition slope formed by machining provides a continuous and gentle geometric channel for stress flow in physical space, allowing the load to be smoothly diffused from the thinner longitudinal diaphragm 24 to the thicker transverse diaphragm 23 along the slope. The gradually changing plate thickness structure effectively eliminates the geometric discontinuities at the plate joints. This geometric smoothing treatment significantly reduces the stress concentration at the weld root under stress, thereby improving the structural safety of the entire anchor block when subjected to the periodic tension of the sling.

[0063] The transition slope design ensures that the thickness of the transverse diaphragm 23 at the weld edge is consistent with that of the longitudinal diaphragm 24, or forms a reasonable step. This design facilitates heat input balance between the metals on both sides during welding, avoiding uneven penetration or incomplete fusion defects caused by excessive thickness differences, thus ensuring the internal quality of the weld. The smooth transition slope also makes the stress distribution more uniform in fatigue-prone areas of the weld joint (such as the weld toe). For suspension bridges, which are subjected to dynamic loads for extended periods, this gradual connection effectively delays the initiation of fatigue cracks and significantly extends the service life of the anchorage joint.

[0064] The transverse diaphragm 23, as the main transverse frame supporting the lifting lug plate 1, bears the main load distribution task; its greater thickness provides higher bending stiffness. The longitudinal diaphragm 24, as an auxiliary stiffening member, employs a thinner design to ensure spatial stability while achieving efficient material utilization. This gradient thickness design creates a balanced layout of rigidity and flexibility within the anchoring block. The thicker transverse diaphragm 23 forms a robust load-bearing skeleton, while the longitudinal diaphragm 24, connected by transition slopes, provides better coordination and constraint in complex spatial stress fields.

[0065] Furthermore, step 9) also includes: A limiting plate 5 is welded to the surface of the top plate 21 near the plate rib 221. The limiting plate 5 is welded together with the lifting lug plate 1, and the limiting plate 5 is welded together with multiple plate ribs 221.

[0066] By directly connecting the lifting lug plate 1 to multiple plate ribs 221 through the limiting plate 5, a highly efficient load distribution system is mechanically constructed: the huge concentrated tensile force originally transmitted directly to the top plate 21 and the transverse diaphragm 23 by the lifting lug plate 1 is effectively distributed laterally and longitudinally through the limiting plate 5. As a force transfer station, the limiting plate 5 guides part of the load through the weld to the multiple plate ribs 221 connected to it, greatly expanding the structural volume involved in bearing the load. By adding the physical connection of the limiting plate 5 in the root region of the lifting lug plate 1, the shear stress borne by the main weld between the lifting lug plate 1 and the top plate 21 is significantly distributed, making the stress distribution in the anchorage core area more uniform and smooth.

[0067] The limiting plate 5 is located on the side of the top plate 21 near the ribs 221 and is welded to multiple ribs 221, forming a rigid plane with multi-point support in space. This structure greatly enhances the torsional stiffness at the root of the lifting lug plate 1, effectively resisting structural distortion caused by eccentric loads or dynamic wind loads. Since the limiting plate 5 connects the lifting lug plate 1 with the originally dispersed multiple ribs 221 into a whole, it significantly improves the overall stability of the ribs 221 under complex stresses, preventing local buckling of individual ribs 221 under extreme conditions.

[0068] Furthermore, the limiting plate 5 provides crucial structural redundancy. The simultaneous welding of the limiting plate 5 with the lifting lug plate 1 and multiple ribs 221 creates multiple parallel force transmission paths. Even if occasional microscopic damage occurs at a weld during long-term service, the auxiliary paths constructed by the limiting plate 5 can still maintain stable load transmission, reducing the risk of cascading structural failures. By distributing stress across multiple ribs 221, the stress amplitude borne by each component is correspondingly reduced. According to material fatigue laws, the reduction in stress amplitude can exponentially extend the fatigue life of the structure under cyclic dynamic loading.

[0069] The connection between the limiting plate 5 and the multiple plate ribs 221 forms a local high-rigidity zone in the welding area, which helps to offset the thermal deformation generated during the shrinkage of the final assembly weld and ensures that the geometric dimensional accuracy of the final finished anchor block meets the high-precision linear requirements of the suspension bridge.

[0070] Furthermore, the lifting lug plate 1, reinforcing plate 3, stiffening plate 4, top plate 21, transverse diaphragm 23 and longitudinal diaphragm 24 are all laid out using BIM three-dimensional modeling, and are cut by CNC precision cutting or laser cutting.

[0071] By introducing BIM (Building Information Modeling) 3D modeling and layout, the geometric parameters of each component are elevated from planar design to a 3D digital level.

[0072] The anchor block contains multiple sets of ribs 221, transverse diaphragms 23, and diagonally intersecting longitudinal diaphragms 24, resulting in an extremely precise structure. The BIM model can ensure, through computer simulation, that the positional accuracy of each component (such as the lug insert 1 and the slots of each transverse diaphragm 23) in three-dimensional space reaches the millimeter level, effectively reducing assembly difficulties caused by spatial positioning deviations.

[0073] Using BIM technology for digital lofting of complex irregular-shaped panels can accurately convert spatial curved surfaces or complex intersections into cutting dimensions. This digital lofting technology ensures the absolute accuracy of component cutting dimensions, providing a reliable digital foundation for subsequent slot-type physical mating.

[0074] CNC precision cutting or laser cutting offers extremely high heat concentration and cutting stability. Its cut edges are smooth and even, significantly reducing microcracks or excessive burrs in the heat-affected zone. This is crucial for core load-bearing components such as the lifting lug insert plate 1, as excellent edge quality significantly reduces the risk of fatigue crack initiation. Laser cutting enables extremely high dimensional tolerance control, resulting in excellent edge linearity. This ensures consistent weld gap height during beveling welding, thereby guaranteeing uniform weld penetration and improving the overall weld joint quality of the permanent sling anchor block.

[0075] By directly importing BIM layout data into the CNC machining system, the generation of machining instructions is automated. This process eliminates random errors that may be introduced by traditional manual marking and measurement, ensuring that the manufactured physical entity is highly consistent with the design model in terms of geometric and topological relationships. For suspension bridges, which require a large number of anchorage blocks, digital control ensures that the quality specifications of each group of components and each plate (such as reinforcing plate 3 and stiffening plate 4) are completely uniform. This high degree of repeatability has profound engineering significance for the linear control and stress balance of the bridge as a whole. Based on BIM digital layout data, combined with the optimized algorithm of the CNC cutting system, the most scientific nesting and layout can be achieved on the raw material steel plates. This not only greatly improves the utilization rate of steel and reduces manufacturing costs, but also embodies the concept of green manufacturing by reducing waste output.

[0076] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A permanent cable anchoring block for a steel box girder of a suspension bridge, characterized in that, It includes lifting lugs, anchoring top plate units, multiple transverse diaphragms, and multiple longitudinal diaphragms, among which: The lifting lug insert plate is provided with insert plate holes; The anchored top plate unit includes a top plate and multiple sets of plate ribs. Each set of plate ribs has multiple plate ribs, each plate rib is parallel to the X-axis, and the multiple plate ribs of each set of plate ribs are arranged on the same straight line parallel to the X-axis. These plate rib sets are distributed on multiple straight lines. Each rib, each transverse diaphragm, and each longitudinal diaphragm are welded to the top plate. Each transverse diaphragm is parallel to the Y-axis and these transverse diaphragms are parallel to each other. The Y-axis is perpendicular to the X-axis. Each rib and each transverse diaphragm are perpendicular to the top plate. The angle between each longitudinal diaphragm and the top plate is greater than 0° and less than 90°. Each transverse diaphragm is welded together with multiple sets of ribs. A longitudinal partition is provided between any two adjacent transverse partitions, and the longitudinal partition is welded together with both adjacent transverse partitions. Two longitudinal partitions welded to the same transverse partition are symmetrically arranged on both sides of this transverse partition; The top plate is provided with a first slot, and each of the transverse partitions is provided with a second slot. The lifting lug plate is inserted into the first slot and each of the second slots. The lifting lug plate is welded to the top plate and to each of the transverse partitions.

2. The permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 1, characterized in that, The lifting lug insert plate is provided with multiple reinforcing plates and multiple stiffening plates. Each reinforcing plate is parallel to the lifting lug insert plate and is welded to it. Each reinforcing plate is provided with a reinforcing plate hole. Each insert plate hole communicates with a reinforcing plate hole on at least one of the reinforcing plates. The insert plate hole and the corresponding reinforcing plate hole together form a lifting lug hole. Each stiffening plate is welded to the lifting lug insert plate and is perpendicular to the lifting lug insert plate.

3. The permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 2, characterized in that, The stiffening plate and the transverse partition are located on two opposite surfaces of the top plate, and each stiffening plate is provided with a positioning plane, which is respectively attached to the surface of the top plate.

4. The permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 1, characterized in that, There is a partition groove between any two adjacent plate ribs in each group of plate ribs. Each of the transverse partitions passes through multiple partition grooves, and each of the transverse partitions is welded to the plate ribs on both sides of the partition groove.

5. A method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge as described in any one of claims 1 to 4, characterized in that, Includes the following steps: 1) Machining the lifting lug plate on a CNC machining center; 2) Weld the lifting lug plate and the reinforcing plate together to form the plate assembly; 3) The reinforcing plate is milled using a CNC machining center, and the insert plate assembly is bored to form lifting lug holes; 4) Weld multiple stiffening plates onto the lug plate of the insert plate assembly, and the insert plate assembly and all the stiffening plates together form the lug assembly; 5) Weld multiple rib plates onto one of the surfaces of the top plate, and the top plate and the multiple rib plates together form an anchored top plate unit; 6) Weld at least one transverse diaphragm to the top plate of the anchored top plate unit, the transverse diaphragm being welded together with multiple plate ribs; 7) Weld longitudinal diaphragms to opposite sides of the transverse diaphragm; 8) Weld other transverse diaphragms to the top plate of the anchoring top plate unit, and weld the transverse diaphragms welded in this step together with the longitudinal diaphragms. The anchoring top plate unit, all the transverse diaphragms and all the longitudinal diaphragms together form a groove-shaped component. 9) Fix the grooved component to the jig, with the side of the top plate away from the rib facing upwards. Insert the lifting lug plate of the lifting lug assembly into the slots of the top plate and each transverse partition from top to bottom. Then weld the lifting lug plate to the top plate and weld the lifting lug plate to each transverse partition.

6. The method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 5, characterized in that, In step 2), the weld area of ​​the lug insert and the reinforcing plate of the insert assembly is subjected to ultrasonic hammering.

7. The method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 5, characterized in that, In step 5), multiple plate ribs are welded onto one of the plates of the top plate on the anti-deformation frame.

8. The method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 5, characterized in that, In step 7), the thickness of the transverse partition is greater than the thickness of the longitudinal partition. The transition slope on the transverse partition is pre-machined to form a gradually changing plate thickness structure so that the longitudinal partition can be welded onto the transverse partition.

9. A method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 5, characterized in that, Step 9) also includes: A limiting plate is welded to the surface of the top plate near the ribs. The limiting plate is welded together with the lifting lug plate and also with multiple ribs.

10. A method for manufacturing a permanent cable anchorage block for a steel box girder of a suspension bridge according to claim 5, characterized in that, The lifting lugs, reinforcing plates, stiffening plates, top plates, transverse diaphragms, and longitudinal diaphragms are all laid out using BIM 3D modeling and are cut using CNC precision cutting or laser cutting.

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