Method for producing extra-large scale fluidic

Abstract

This application provides a method for manufacturing an extra-large guide body, comprising the following steps: S1. Dividing the extra-large guide body along its height into an upper guide body, multiple middle guide bodies, and a lower guide body, and manufacturing them separately; S2. Vertically connecting flanges to the bottom of the upper guide body, the top and bottom of the middle guide bodies, and the top of the lower guide body, and circumferentially connecting stiffening plates between the outer wall of each guide body and the flange, correspondingly forming a first segment, a second segment, and a third segment; S3. Adjusting each segment to a horizontal state, ensuring that the straightness tolerance of the skin generatrix meets the design requirements; machining the flanges to ensure a verticality tolerance ≤ 0.1mm and machining bolt holes; S4. Performing horizontal pre-assembly of each segment, connecting the mating flanges, and machining locating pin holes at both ends of the connected mating flanges; S5. Covering the outside of the mating flanges with a guide shroud; S6. Removing the guide shroud and disconnecting the flange connections. This application significantly improves the consistency of segment manufacturing accuracy through the "horizontal pre-assembly" process.

Description

Technical Field

[0001] This application relates to the field of industrial equipment manufacturing technology, and in particular to a method for manufacturing an extra-large fluid guide. Background Technology

[0002] Some recirculation piping systems with low airflow velocities are constructed using concrete to reduce construction costs due to lower impact loads. However, core components used for airflow testing and airflow redirection require higher precision and toughness, thus necessitating the use of steel structures. These recirculation piping systems contain four redirection sections to achieve airflow redirection. The exterior of each redirection section is a concrete structure serving as the airflow channel, while multiple guide tubes are installed internally to facilitate airflow redirection.

[0003] With the continuous improvement of my country's industrialization level, reflux pipeline equipment is gradually developing towards larger size and higher parameters. In particular, some reflux pipeline equipment with low airflow velocity can have cross-sectional dimensions (width and height) of 50×50m or more. The height of the duct installed in the turning section can reach 45m or more. These extra-large ducts together with the extra-large concrete pipes outside constitute extra-large turning sections.

[0004] like Figure 1 As shown, the extra-large air intake 1 is crescent-shaped and includes longitudinal steel sections 2, transverse partitions 3, convex skins 4, and end skins 5. The steel frame structure composed of the longitudinal steel sections 2 and the transverse partitions 3 is the main structure of the extra-large air intake 1. The convex surface and end of the steel frame are respectively covered with convex skins 4 and end skins 5. After the extra-large air intake 1 is manufactured, a noise reduction device is installed in the steel frame composed of the longitudinal steel sections 2 and the transverse partitions 3 for noise reduction. At the same time, the outer wall of the noise reduction device, together with the convex skins 4 and end skins 5, forms the outer skin of the extra-large air intake 1, serving as the airflow profile.

[0005] Because the spacing between adjacent manifolds after on-site installation is small, installing the noise reduction device is extremely difficult. Furthermore, it involves high-altitude work, resulting in very low installation efficiency and failing to meet project deadlines. Therefore, in existing technologies, the noise reduction device is installed horizontally after the manifold is fabricated, forming a whole before on-site installation. However, for extra-large manifolds, due to their excessive height, it is difficult to install them as a whole after fabrication. Extra-large manifolds need to be divided into several sections for fabrication and installation, but this presents two challenges: First, the heat input generated during on-site welding of the segmented extra-large manifolds can damage the noise reduction device. If other connection processes are used, there are issues with insufficient rigidity and poor sealing at the joints. Second, the segmented fabrication of extra-large manifolds results in low precision consistency, thus compromising on-site installation quality.

[0006] Therefore, it is necessary to develop a method for manufacturing ultra-large fluids to solve the aforementioned problems. Summary of the Invention

[0007] To improve the problems of low precision in the segmented connection process design and segmented fabrication of extra-large fluid guides, this application provides a method for fabricating extra-large fluid guides.

[0008] The method for fabricating an extra-large fluid guide provided in this application adopts the following technical solution: A method for fabricating an extra-large drainage fluid includes the following steps: S1. Divide the extra-large drainage system along the height direction into an upper drainage system, multiple middle drainage systems, and a lower drainage system, and fabricate them separately; S2. Vertical flanges are connected to the bottom of the upper fluid guide, the top and bottom of the middle fluid guide, and the top of the lower fluid guide, and ribs are connected circumferentially between the outer wall of each fluid guide and the flange, forming the first segment, the second segment, and the third segment respectively. S3. Adjust each section to a horizontal position so that the straightness tolerance of the skin busbar meets the design requirements; process the flange to ensure the perpendicularity tolerance is ≤0.1mm and make bolt holes; S4. Perform horizontal pre-assembly of each section, connect the docking flanges, and make positioning pin holes at both ends of the connected docking flanges. S5. Cover the outside of the connecting flange with the flow guide and adjust the inner contour to fit the gap between it and the outer wall of each section ≤0.5mm; S6. Remove the fairing and disconnect the flange connection.

[0009] Furthermore, the flange is crescent-shaped, and the outer contour of the flange is formed by offsetting the cross-sectional contour of the extra-large fluid guide by 50-100mm.

[0010] Furthermore, the stiffener is a triangular stiffener, with its bottom connected to the flange and its sides connected to the longitudinal steel section of the extra-large fluid-guiding structure.

[0011] Furthermore, the bolt holes are arranged circumferentially on the flange; The bolt holes on the flange of the first section are located between the outer contour of the upper fluid guide and the outer contour of the flange. The bolt holes on the flange of the second section are located between the outer contour of the central fluid guide and the outer contour of the flange. The bolt holes on the flange of the third section are located between the outer contour of the lower fluid guide and the outer contour of the flange.

[0012] Furthermore, in step S4, after connecting the mating flange, the straightness tolerance of the skin busbar of the overall structure composed of each segment is first adjusted to meet the design requirements, and the misalignment between each segment of the skin is adjusted to meet the design requirements, and then the positioning pin holes are made.

[0013] Furthermore, the fairing has a crescent-shaped annular structure, which is a hemispherical steel cover plate with a spherical radius of 60-110mm, and the thickness of the fairing is the same as the thickness of the skin.

[0014] Furthermore, the flanges, stiffening plates, and corresponding fluid guides are all welded connections, and all are welded using tungsten inert gas welding.

[0015] Furthermore, the extra-large drain is crescent-shaped, and its main structure includes a steel frame structure composed of longitudinal steel sections and transverse partitions. The convex surface and ends of the steel frame are respectively covered with convex surface skin and end skin, and noise reduction devices are installed inside each section.

[0016] Furthermore, the method for adjusting the straightness tolerance of the skin busbar in steps S3 and S4 is as follows: A flexible support frame with hydraulic lifting function is laid on a horizontal platform to place each segment. A laser tracker is used to establish a three-dimensional coordinate system along the skin surface to scan the outline of the generatrix. Based on the deviation data, the corresponding flexible support frame is controlled to lift or push and pull to correct the deviation.

[0017] Furthermore, in the pre-assembly of step S4 and the on-site installation after completion, adjacent sections are connected only by flanges and bolt holes to avoid damage to the noise reduction device inside the fluid inlet by on-site heat input.

[0018] In summary, this application includes at least one of the following beneficial technical effects: 1. By using outwardly expanding flanges for bolted connections between extra-large fluid diversion sections, and by installing stiffening plates between the flanges and the perimeter of the sections (between the flanges and the longitudinal steel sections), the rigidity and integrity of the structure at the section connections are effectively enhanced. This structure avoids placing the connection structure inside the steel frame, not only providing space for the installation of internal noise reduction devices, but also completely preventing damage to the internal noise reduction devices from the heat input generated by on-site section welding; 2. To address the issue that gaps between two flange connection surfaces can lead to airflow acceleration and separation, this application innovatively incorporates a flow guide shroud around the flange to enclose it. This not only solves the problem of poor sealing between flanges but also designs the flow guide shroud as a spherical curved surface (hemispherical steel cover), enabling progressive and adherent airflow at the connection point and effectively preventing boundary layer separation and energy loss. 3. After segmented fabrication, the biggest risk is the straightness deviation of the overall assembly. This application utilizes a "horizontal pre-assembly" process. After machining the flange surface (perpendicularity ≤ 0.1mm), the segments are horizontally connected, and the overall straightness deviation and misalignment are adjusted to meet design requirements before uniformly fabricating "locating pin holes." During subsequent on-site installation, simply inserting the locating pins perfectly restores the qualified high-precision state of the pre-assembly, significantly improving the consistency of segmented fabrication accuracy and ensuring the quality of on-site installation. Attached Figure Description

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

[0020] Figure 1 It is an isometric view of the extra-large fluid in the background technology; Figure 2 This is a schematic diagram of the structure of the first segment in an embodiment of this application; Figure 3 This is a schematic diagram of the structure of the second segment in an embodiment of this application; Figure 4 This is a schematic diagram of the structure of the third segment in an embodiment of this application; Figure 5 This is a schematic diagram of the pre-assembly process during the fabrication of an extra-large fluid in an embodiment of this application; Figure 6 This is a schematic diagram of the structure of the air deflector according to an embodiment of this application.

[0021] Figure label: 1. Extra-large flow guide; 2. Longitudinal steel section; 3. Transverse partition; 4. Convex skin; 5. End skin; 6. First section; 7. Second section; 8. Third section; 9. Upper flow guide; 10. Middle flow guide; 11. Lower flow guide; 12. Flange; 13. Rib plate; 14. Bolt hole; 15. Flow guide. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0023] The subject targeted by the solution in this embodiment is as follows: Figure 1 As shown, the extra-large air intake 1 is crescent-shaped and includes longitudinal steel sections 2, transverse partitions 3, convex skins 4, and end skins 5. The steel frame structure composed of the longitudinal steel sections 2 and the transverse partitions 3 is the main structure of the extra-large air intake 1. The convex surface and end of the steel frame are respectively covered with convex skins 4 and end skins 5. After the extra-large air intake 1 is manufactured, a noise reduction device is installed in the steel frame composed of the longitudinal steel sections 2 and the transverse partitions 3 for noise reduction. At the same time, the outer wall of the noise reduction device, together with the convex skins 4 and end skins 5, forms the outer skin of the extra-large air intake 1, serving as the airflow profile.

[0024] Because the spacing between adjacent water inlets after on-site installation is small, installing the noise reduction device is extremely difficult. Furthermore, it involves high-altitude work, resulting in very low installation efficiency and failing to meet the project schedule. Therefore, in existing technology, the noise reduction device is installed in a horizontal position after the water inlet is fabricated, forming a whole before on-site installation. However, for the extra-large water inlet 1, due to its excessive height, it is difficult to install as a whole after fabrication. It is necessary to divide the extra-large water inlet 1 into several sections for fabrication and installation. However, two problems exist: First, the heat input generated during on-site welding of the segmented extra-large water inlet 1 after segmented fabrication will damage the noise reduction device. If other connection processes are used, there will be problems with insufficient rigidity and poor sealing at the joints. Second, the segmented fabrication of the extra-large water inlet 1 results in low precision consistency, thus failing to guarantee the quality of on-site installation.

[0025] Therefore, it is necessary to develop a method for manufacturing an ultra-large drainage fluid 1, firstly to solve the design problem of the connection process between the segments of the ultra-large drainage fluid 1; and secondly to solve the problem of low consistency in the manufacturing precision of the segments of the ultra-large drainage fluid 1.

[0026] In view of the above, this application is hereby made.

[0027] Reference Figures 2-6 This application discloses a method for manufacturing an extra-large fluid guide, which includes the following steps: S1. Divide the extra-large drainage fluid 1 into an upper drainage fluid 9, multiple middle drainage fluids 10, and a lower drainage fluid 11 along the height direction from top to bottom, and complete the fabrication of the upper drainage fluid 9, middle drainage fluid 10 and lower drainage fluid 11 respectively.

[0028] S2. A flange 12 is vertically connected to the bottom of the upper fluid guide 9, and a circumferential stiffening plate 13 is connected between the outer wall of the upper fluid guide 9 and the flange 12 to form a first segment 6; flanges 12 are vertically connected to the top and bottom of the middle fluid guide 10 respectively, and a circumferential stiffening plate 13 is connected between the outer wall of the middle fluid guide 10 and the flange 12 to form a second segment 7; a flange 12 is vertically connected to the top of the lower fluid guide 11, and a circumferential stiffening plate 13 is connected between the outer wall of the lower fluid guide 11 and the flange 12 to form a third segment 8.

[0029] S3. Adjust the first segment 6, the second segment 7, and the third segment 8 to a horizontal position, and ensure that the straightness tolerance of the generatrix of the skin of the first segment 6, the second segment 7, and the third segment 8 meets the design requirements; process the flange 12 of each segment, and ensure that the perpendicularity tolerance of the flange 12 face is ≤0.1mm; and make bolt holes 14 on the flange 12.

[0030] S4. Pre-assemble the first segment 6, the second segment 7, and the third segment 8 in a horizontal position, and connect the docking flanges 12 between the segments; make locating pin holes at both ends of the connected docking flanges 12.

[0031] S5. Cover the completed flow guide 15 with the connected mating flange 12 and adjust the inner contour of the flow guide 15 until the fitting gap between the flow guide 15 and the outer wall of the first segment 6, the second segment 7, and the third segment 8 is ≤0.5mm. S6. Remove the flow guide shroud 15, disconnect the connection between the flanges 12, and complete the fabrication of the extra-large flow guide 1.

[0032] Specifically, such as Figure 2 As shown, a flange 12 is vertically connected to the bottom of the upper fluid guide 9, and a circumferentially connected stiffening plate 13 forms the first segment 6 between the outer wall of the upper fluid guide 9 and the flange 12. Figure 3 As shown, a flange 12 is vertically connected to the top and bottom of the central fluid guide 10, respectively, and a circumferentially connected stiffening plate 13 forms the second segment 7 between the outer wall of the central fluid guide 10 and the flange 12. Figure 4 As shown, a flange 12 is vertically connected to the top of the lower fluid guide 11, and a circumferentially connected stiffening plate 13 forms the third segment 8 between the outer wall of the lower fluid guide 11 and the flange 12.

[0033] Furthermore, flange 12 is crescent-shaped, and the cross-sectional profile of the extra-large fluid 1 is offset outward by 80mm, which is the outer profile of flange 12.

[0034] Furthermore, the stiffening plate 13 is a triangular stiffening plate 13, with the bottom of the stiffening plate 13 connected to the flange 12 and the side of the stiffening plate 13 connected to the longitudinal steel section 2.

[0035] Furthermore, flange 12, stiffening plate 13, and upper drain 9 are welded together; flange 12, stiffening plate 13, and middle drain 10 are welded together; and flange 12, stiffening plate 13, and lower drain 11 are welded together.

[0036] Furthermore, the flange 12, stiffener 13, and upper drain 9 are welded by tungsten inert gas welding; the flange 12, stiffener 13, and middle drain 10 are welded by tungsten inert gas welding; and the flange 12, stiffener 13, and lower drain 11 are welded by tungsten inert gas welding.

[0037] Adjust the first segment 6, the second segment 7, and the third segment 8 to a horizontal position, and ensure that the straightness tolerance of the generatrix of the skin of the first segment 6, the second segment 7, and the third segment 8 meets the design requirements; process the flanges 12 of the first segment 6, the second segment 7, and the third segment 8, and ensure that the perpendicularity tolerance of the flange 12 face is ≤0.1mm; and make the bolt holes 14 on the flange 12.

[0038] Furthermore, bolt holes 14 are arranged circumferentially on flange 12; bolt holes 14 are located between the outer contour of the upper guide fluid 9 and the outer contour of flange 12, bolt holes 14 are located between the outer contour of the middle guide fluid 10 and the outer contour of flange 12, and bolt holes 14 are located between the outer contour of the lower guide fluid 11 and the outer contour of flange 12.

[0039] like Figure 5 As shown, the first segment 6, the second segment 7, and the third segment 8 are pre-assembled in a horizontal position, and the flanges 12 connecting the first segment 6, the second segment 7, and the third segment 8 are connected. The straightness tolerance of the generatrix of the skin of the integral structure composed of the first segment 6, the second segment 7, and the third segment 8 is adjusted to meet the design requirements, and the misalignment between the skins of the first segment 6, the second segment 7, and the third segment 8 is adjusted to meet the design requirements. Locating pin holes are made at both ends of the connecting flanges 12.

[0040] The completed flow guide 15 is wrapped around the outside of the connected mating flange 12, and the inner contour of the flow guide 15 is fitted until the fitting gap between the flow guide 15 and the outer wall of the first segment 6, the second segment 7, and the third segment 8 is ≤0.5mm. Furthermore, the fairing 15 has a crescent-shaped annular structure, and the fairing 15 is a hemispherical steel cover plate with a spherical radius of 60-110mm. The thickness of the fairing 15 is the same as the thickness of the skin.

[0041] Remove the flow guide shroud 15 and disconnect the connection between the flanges 12 to complete the fabrication of the extra-large flow guide 1. The fabricated extra-large flow guide 1 includes the first section 6, the second section 7, the third section 8, the flange 12, the stiffening plate 13, and the flow guide shroud 15.

[0042] After the extra-large diversion section 1 was installed on site, it was impossible to connect the sections by welding or riveting; therefore, bolting was the only viable method. There are two bolting methods: one is to install connecting plates on both sides of the longitudinal steel section 2 of adjacent extra-large diversion sections 1 for bolting; the other is to install flanges 12 on the end faces of the longitudinal steel section 2 of adjacent extra-large diversion sections 1 for bolting. Compared to connecting plate bolting, flange bolting provides better structural rigidity, strength, integrity, and stability at the connection point; therefore, flange bolting was chosen.

[0043] However, there are still two problems with using flange 12 bolt connection: First, the flange 12 plate is too large and has insufficient rigidity. If the thickness of the flange 12 plate is increased too much, it will increase the overall structural weight of the extra-large diverter 1, resulting in excessive self-weight load, thus requiring an increase in the size of the longitudinal steel 2 of the extra-large diverter 1; Second, there is a gap between the two flange 12 connection surfaces. When the airflow passes through the gap, it will generate airflow acceleration, separation, and vortex.

[0044] Therefore, it was considered to enlarge the outer dimensions of flange 12, making it larger than the cross-sectional dimensions of the extra-large guide fluid 1, and to install stiffening plates 13 around the periphery of flange 12. The stiffening plates 13 are welded to flange 12 and longitudinal steel 2, thereby increasing the overall rigidity of flange 12. At the same time, it avoids placing the stiffening plates 13 inside the steel frame composed of longitudinal steel 2 and transverse partition 3, as this would prevent the subsequent noise reduction device from being installed. To solve the problem that the two flange faces cannot be completely sealed, a flow guide shroud 15 is wrapped around flange 12. To avoid flow separation and boundary layer separation when the airflow passes through the flow guide shroud 15, the flow guide shroud 15 is designed as a spherical curved surface to achieve progressive and adhering airflow and avoid energy loss.

[0045] After the extra-large diverter section 1 is manufactured, the biggest quality risk during its transportation to the site for assembly and installation is the large deviation in the overall straightness of the extra-large diverter section 1. This is caused by the poor consistency in the manufacturing precision of the extra-large diverter section 1, as each section is manufactured individually. To solve this problem, each section is converted to a horizontal position after completion, and the straightness deviation is adjusted to meet the requirements. If the perpendicularity deviation of the flange 12 face meets the requirements at this time, then the connection of adjacent sections can ensure the smooth connection of the flange 12, and also ensure that the overall straightness deviation of the structure meets the requirements. Therefore, after adjusting the straightness deviation of each section to meet the requirements, the flange 12 face is machined immediately.

[0046] Furthermore, to ensure efficient and precise assembly of the extra-large drainage fluid segment 1 during installation, the segment is pre-assembled. After adjusting the overall straightness deviation and misalignment to meet requirements, positioning pin holes are installed. During subsequent installation, by inserting positioning pins between adjacent extra-large drainage fluid segment 1 sections, the pre-assembled, qualified state of the segment can be restored.

[0047] The above measures can significantly improve the consistency of the manufacturing precision of the extra-large diversion fluid segment 1, ensuring the quality of on-site installation.

[0048] 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 should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing an extra-large fluid guide, characterized in that, Includes the following steps: S1. Divide the extra-large drainage system along the height direction into an upper drainage system, multiple middle drainage systems, and a lower drainage system, and fabricate them separately; S2. Vertical flanges are connected to the bottom of the upper fluid guide, the top and bottom of the middle fluid guide, and the top of the lower fluid guide, and ribs are connected circumferentially between the outer wall of each fluid guide and the flange, forming the first segment, the second segment, and the third segment respectively. S3. Adjust each section to a horizontal position so that the straightness tolerance of the skin busbar meets the design requirements; process the flange to ensure the perpendicularity tolerance is ≤0.1mm and make bolt holes; S4. Perform horizontal pre-assembly of each section, connect the docking flanges, and make positioning pin holes at both ends of the connected docking flanges. S5. Cover the outside of the connecting flange with the flow guide and adjust the inner contour to fit the gap between it and the outer wall of each section ≤0.5mm; S6. Remove the fairing and disconnect the flange connection.

2. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The flange is crescent-shaped, and its outer contour is formed by offsetting the cross-sectional contour of the extra-large fluid guide by 50-100mm.

3. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The stiffener is a triangular stiffener, with its bottom connected to the flange and its sides connected to the longitudinal steel section of the extra-large fluid diverter.

4. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The bolt holes are arranged circumferentially on the flange; The bolt holes on the flange of the first section are located between the outer contour of the upper fluid guide and the outer contour of the flange. The bolt holes on the flange of the second section are located between the outer contour of the central fluid guide and the outer contour of the flange. The bolt holes on the flange of the third section are located between the outer contour of the lower fluid guide and the outer contour of the flange.

5. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, In step S4, after connecting the flange, the straightness tolerance of the skin busbar of the overall structure composed of each segment is first adjusted to meet the design requirements, and the misalignment between each segment skin is adjusted to meet the design requirements, and then the positioning pin holes are made.

6. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The fairing has a crescent-shaped annular structure and is a hemispherical steel cover plate with a spherical radius of 60-110mm. The thickness of the fairing is the same as the thickness of the skin.

7. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The flanges, stiffening plates, and corresponding fluid guides are all welded connections, and all are welded using tungsten inert gas welding.

8. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The extra-large drain is crescent-shaped, and its main structure includes a steel frame structure composed of longitudinal steel sections and transverse partitions. The convex surface and ends of the steel frame are respectively covered with convex surface skin and end skin, and noise reduction devices are installed inside each section.

9. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, The method for adjusting the straightness tolerance of the skin generatrix in steps S3 and S4 is as follows: A flexible support frame with hydraulic lifting function is laid on a horizontal platform to place each segment. A laser tracker is used to establish a three-dimensional coordinate system along the skin surface to scan the outline of the generatrix. Based on the deviation data, the corresponding flexible support frame is controlled to lift or push and pull to correct the deviation.

10. The method for manufacturing an extra-large fluid according to claim 1, characterized in that, In the pre-assembly of step S4 and the on-site installation after completion, adjacent sections are connected only by flanges and bolt holes to avoid damage to the noise reduction device inside the fluid inlet by on-site heat input.

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