Method for processing bridge mega-tower pier

Abstract

This invention discloses a method for processing giant bridge tower piers, comprising the following steps: a pre-processing stage, establishing a three-dimensional solid BIM model, determining the dimensional parameters and assembly relationships of each component, and generating a visual processing flowchart and parameter table; a longitudinal rib segmentation stage, determining the segment length of the longitudinal ribs based on the spacing of the transverse diaphragms, ensuring that the length of a single longitudinal rib segment does not exceed four transverse diaphragm spacings and does not exceed 4m; a longitudinal rib curling stage, simulating the theoretical height loss of the longitudinal ribs after segmentation using the BIM model, and performing curling processing on longitudinal ribs with a height loss greater than 100mm after segmentation; a general assembly jig stage; an assembly stage, dividing the giant tower pier into multiple layers, assembling the giant tower pier symmetrically from the inside out; and a multi-segment pre-assembly and positioning matching stage. This invention enables high-precision, high-efficiency, and high-quality processing of tower pier components.

Description

Technical Field

[0001] This invention belongs to the field of bridge steel structure processing technology, and in particular relates to a processing method for giant bridge tower piers. Background Technology

[0002] As the core load-bearing component of long-span bridges, the giant tower pier is usually composed of multiple box-type steel structures spliced ​​together. It includes complex components such as outer wall panels, inner wall panels, transverse diaphragms, and longitudinal ribs. It is characterized by its huge volume (the weight of a single segment can reach hundreds of tons), irregular structure (mostly curved or inclined design), and high precision requirements (linear deviation must be controlled within millimeters). Its processing quality directly determines the overall load-bearing capacity and safety stability of the bridge, and is a key link in bridge engineering construction. Currently, the main method used is traditional segmented processing and on-site assembly. The applicant has found the following problems with this method: (1) Assembly accuracy is difficult to control: Traditional processing relies on manual layout and positioning. When the longitudinal ribs are assembled in sections and the transverse diaphragms are connected to the wall panels, the linear deviation is easily caused by the reference deviation. In particular, the height loss control after the arc components are segmented is difficult. The assembly accuracy can usually only reach ±2mm, which cannot meet the linear requirement of ±0.5mm for giant tower piers. (2) Poor control of welding deformation: The tower pier box body has a large amount of welding, and there is no unified standard for the traditional welding sequence. It is easy to cause deformation such as bulging of the wall panel and twisting of the segment, which requires multiple rework corrections. This not only prolongs the construction period, but may also reduce the mechanical properties of the component. (3) Poor overall assembly matching: Each segment is processed and shipped to the site independently. Due to the lack of pre-assembly matching process, it is difficult to control the interface gap on site, and misalignment often occurs. On-site cutting and adjustment are required, which increases construction risk and cost. As bridge engineering develops towards larger spans and lighter weights, the structures of giant tower piers are becoming increasingly complex, and traditional processing methods can no longer meet the demands for high-precision and high-efficiency processing. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a processing method for giant bridge tower piers, so as to achieve high-precision, high-efficiency and high-quality processing of tower pier components.

[0004] The objective of this invention is achieved through the following technical solution: A method for fabricating a giant bridge pier includes the following steps: In the pre-processing preparation stage, a three-dimensional solid BIM model is established to determine the dimensional parameters and assembly relationships of each component, and a visual processing flowchart and parameter table are generated. During the longitudinal rib segmentation process, the segment length of the longitudinal rib is determined according to the spacing of the transverse diaphragms, so that the length of a single longitudinal rib segment is no more than 4 times the spacing of the transverse diaphragms and does not exceed 4m. During the longitudinal rib rolling process, the theoretical height loss of the longitudinal rib after segmentation is simulated using a BIM model, and the longitudinal rib with a height loss of more than 100mm after segmentation is rolled. The final assembly jig stage; During the assembly phase, the giant tower piers are divided into multiple layers, and the giant tower piers are assembled symmetrically from the inside out. Multi-segment pre-assembly and positioning matching stage.

[0005] In one embodiment, the longitudinal rib curling stage further includes: A CNC arc rolling machine is used to roll the longitudinal ribs to be processed. Based on the theoretical curvature of the segmented longitudinal ribs, the arc rolling parameters are set on the arc rolling machine. Then, the longitudinal ribs are fixed on the tooling table of the arc rolling machine. The actual height loss during the arc rolling process is monitored in real time by a laser rangefinder, so that the actual height loss after arc rolling is 50~100mm smaller than the theoretical height loss.

[0006] In one embodiment, the longitudinal rib curling stage further includes: After all the longitudinal ribs that need to be processed have been rolled, the longitudinal ribs with an absolute value of curvature deviation of less than 0.5mm are grouped into one category, and the rolling direction and number are marked.

[0007] In one embodiment, the stage of setting up the final assembly jig includes: During the foundation construction phase, longitudinal and transverse slats are laid on the ground according to the tooling points planned in the BIM model. The slats are fully welded to the pre-embedded steel plates in the ground to form a stable slat platform. In the stage of supporting the jig and setting the benchmark, the transverse side uses plate ribs and vertical steel pipes inserted and welded, and the longitudinal and transverse sides use angle steel to set horizontal and vertical supports to form a three-dimensional frame jig. During the frame alignment inspection and adjustment phase, the overall alignment elevation of the frame is measured and compared with the theoretical elevation of the BIM model. If the absolute value of the deviation exceeds 0.3mm, it is corrected by adjusting the adjusting bolts at the top of the uprights until the frame alignment matches the drawings.

[0008] In one embodiment, the assembly stage further includes: The giant tower pier was divided into six layers; First, lay the fourth layer of outer wall panels from the middle to both sides, then push the fourth layer of transverse partitions from the middle to both sides, and then assemble the fourth layer of outer wall panels, inner wall panel longitudinal ribs, and inner wall panels. Then, the upper outer wall panels are laid in sequence, and the corresponding horizontal diaphragms, longitudinal ribs and inner wall panels are assembled. After each process is completed, the elevation and alignment of the tooling are checked with a total station. Only after confirming that there are no deviations can the next process be carried out.

[0009] In one embodiment, the assembly stage further includes: If there are longitudinal ribs that affect the welding of the inner and outer wall panels during the assembly process, the longitudinal ribs should be added in the form of a single V-groove after the inner and outer wall panels have been welded together.

[0010] In one embodiment, the assembly stage further includes: First, weld the transverse diaphragm to the inner wall panel, then weld the longitudinal rib to the wall panel, and finally weld the outer wall panel splicing weld. During the welding process, carbon dioxide gas shielded welding is used, with the current controlled at 200~280A, the voltage controlled at 24~30V, and the welding speed controlled at 300~500mm / min.

[0011] In one implementation, the multi-segment pre-assembly and positioning matching stage includes: Pre-assembly jigs are set up according to the segment division of the tower piers, and multiple pre-assembly jigs are set up to ensure that the jig alignment is consistent with the final assembly jig. A total station is used to calibrate the jig elevation and baseline. Segment matching assembly: the core area of ​​the tower leg V-leg matches the adjacent standard V-leg segment, and the core area of ​​the tower leg V-leg matches the anchoring segment; After the pre-assembly is qualified, positioning and matching parts are set up on each box.

[0012] In one implementation, the core area of ​​the tower leg V-leg matches the standard segment of the adjacent V-leg, including: The tower leg V-leg is divided into three large jigs for assembly. Each jig must meet the requirement of assembling at least three segments as a whole. Before the core components of the tower leg V-leg are shipped, the adjacent components that have been processed on the jig are pre-assembled with the core area to ensure that the absolute value of the matching accuracy in all directions is less than 0.3mm.

[0013] In one implementation, the core area of ​​the tower leg V-shaped section is matched with the anchoring segment, including: The second layer of the core area of ​​the V-leg of the tower foot is processed with the anchoring segment in a straight-fitting manner. The components on both sides of the third layer are processed in two half-areas. After processing, the anchoring segment is shipped out, and the remaining half-area is matched with the core area components for a second time to ensure that the docking gap is ≤1mm.

[0014] The beneficial effects of this invention are as follows: (1) Significantly improved assembly accuracy: Through BIM modeling and planning, precise setting of the general assembly jig benchmark and layered assembly process, the assembly accuracy of the longitudinal rib segments reaches ±0.3mm, and the segment line deviation is controlled within ±0.5mm, which is much higher than the ±2mm of the traditional method, meeting the high precision requirements of the giant tower pier. (2) Effective control of welding deformation: By adopting a combination of symmetrical welding sequence, temporary support and fixation and flame straightening, the bulging deformation of the component after welding is ≤0.5mm and the twist is ≤0.3mm / m. Compared with the existing technology, the rework rate is reduced by more than 90%, ensuring the mechanical properties of the component; (3) Improved on-site installation efficiency: The multi-segment factory pre-assembly and positioning matching parts ensure that the gap between the interfaces on site is controlled within ≤1mm, avoiding on-site cutting and adjustment, shortening the installation period by 40% and reducing construction risks; (4) High versatility: It is suitable for processing giant tower piers of different specifications and irregular structures. By adjusting the BIM model parameters and the jig layout, it can quickly adapt to new types of tower piers and reduce process development costs. Attached Figure Description

[0015] The invention will now be described in more detail with reference to embodiments and the accompanying drawings. Figure 1 This shows a schematic diagram of the pier rib segmentation of the present invention; Figure 2 A schematic cross-sectional view of the tooling of the present invention is shown; Figure 3 This diagram shows a layered schematic of the V-leg of the tower foot of the present invention; Figure 4 A schematic diagram of the ground sample placement method of the present invention is shown; Figure 5 A schematic diagram of the fourth outer wall panel of the present invention is shown; Figure 6 A schematic diagram of the third outer wall panel of the present invention is shown; Figure 7 A schematic diagram of the third inner wall panel of the present invention is shown; Figure 8 A schematic diagram of the weld between the inner wall panel and the partition plate of the box is shown in the present invention. Figure 9 A schematic diagram of the sixth layer of outer wall panel of the present invention is shown; Figure 10 A schematic diagram of the installation of the middle box partition plate according to the present invention is shown; Figure 11 A schematic diagram of the matching and pre-assembly process of the present invention is shown; In the accompanying drawings, the same parts use the same reference numerals. The drawings are not to scale. Detailed Implementation

[0016] The invention will now be further described with reference to the accompanying drawings.

[0017] This invention provides a method for processing giant bridge piers, such as... Figures 1 to 11 As shown, it includes the following steps: Step S1, Pre-processing preparation stage: Based on the design drawings of the giant tower pier, a three-dimensional solid model was established to clarify the dimensional parameters (such as the arc radius of the outer wall panel, the spacing of the transverse diaphragm, and the cross-sectional specifications of the longitudinal rib) and their assembly relationships of each component (outer wall panel, inner wall panel, transverse diaphragm, and longitudinal rib). The processing units were broken down according to the model to determine the segmentation scheme of the longitudinal rib, the layout points of the assembly jig, and the welding sequence. A visual processing flowchart and parameter table (including key parameters such as the segment length of the longitudinal rib, the arc height loss, and the spacing of the jig uprights) were generated. After shot blasting to remove rust (Sa2.5 grade), the raw steel plates are cut using a CNC plasma cutting machine with a cutting accuracy of ±0.3mm and a UT flaw detection pass rate of 100%. Step S2, longitudinal rib segmentation processing stage: like Figure 1 As shown, the length of the longitudinal rib segments is determined according to the spacing of the transverse diaphragms, so that the length of a single longitudinal rib segment is no more than 4 times the spacing of the transverse diaphragms and does not exceed 4m, so as to avoid deformation during transportation and assembly due to excessively long segments. Step S3, Longitudinal Rib Rolling Processing Stage: By simulating the theoretical height loss of the longitudinal ribs after segmentation using a BIM model, the longitudinal ribs with a height loss greater than 100mm after segmentation are processed by arc rolling. A CNC arc rolling machine can be used to perform the arc rolling operation on the longitudinal ribs to be processed. First, based on the theoretical curvature of the longitudinal rib after segmentation, the arc rolling parameters (arc rolling pressure, feed speed) are set on the arc rolling machine. Then, the longitudinal ribs are fixed on the tooling table of the arc rolling machine. The actual height loss during the arc rolling process is monitored in real time using a laser rangefinder to ensure that the actual height loss after arc rolling is 50-100mm smaller than the theoretical height loss (to allow for welding deformation compensation). After the arc rolling is completed, the longitudinal ribs with curvature deviation within ±0.5mm are grouped together and marked with the arc rolling direction (clockwise / counterclockwise) and a unique number to avoid confusion during assembly. Step S4, setting up the final assembly jig stage, includes the following steps: Step S401, Construction of the frame foundation: Lay longitudinal and transverse slats (30mm×300mm) on the ground according to the tooling points planned in the BIM model. The slats are fully welded to the pre-embedded steel plates in the ground (the weld height is not less than 8mm) to form a stable slat platform. After the platform passes the acceptance test, install the tooling uprights (using Φ160mm×6mm steel pipes). The spacing of the uprights is determined according to the weight and size of the tower pier segment (generally, the transverse spacing is 1.5-2m and the longitudinal spacing is 2-3m). Step S402, Carrier Support and Reference Setting: The transverse (bend line direction) uses 20mm×200mm plate ribs and vertical steel pipes for insertion and welding (welding depth not less than 50mm). Both the longitudinal and transverse directions use L80mm×8mm angle steel to set horizontal and vertical supports to form a three-dimensional frame-type jig, ensuring the overall rigidity of the jig (bearing capacity not less than 500kN / m²). Set longitudinal and transverse baselines 200mm outside the longitudinal and transverse edges of the tooling uprights. The intersection of the baselines is the reference point. The reference point is fixed on a steel plate with a thickness of not less than 20mm (to prevent displacement). The accuracy of the baselines and reference points is calibrated by a total station (linear deviation ≤ 0.1mm / m), and marked accordingly. Step S403, Tire frame alignment inspection and adjustment: like Figure 2 As shown, after the formwork is erected, the elevation of the entire line of the formwork is measured (the distance between measurement points is no more than 1m). The elevation is compared with the theoretical elevation of the BIM model. If the deviation exceeds ±0.3mm, it is corrected by adjusting the adjusting bolts at the top of the uprights until the formwork line is completely consistent with the drawings. Step S5, assembly stage, includes: The giant tower pier (taking the core area of ​​the V-leg at the tower foot + anchoring segment as an example) is divided into six layers, such as... Figure 3 As shown, the giant tower piers are assembled symmetrically in layers from the inside out, in the following order: 1. First layer assembly: Lay the fourth layer of outer wall panels from the middle to both sides (no allowance in the longitudinal direction in the middle, leave 30mm allowance on each side, and allowable deviation of 0-2mm in the transverse width), assemble the TJB-5A transverse partition (push from the middle to both sides, ensuring that the partition end coincides with the ground line), and then assemble the TJB-5A outer wall panels and inner wall panel longitudinal ribs (curved longitudinal ribs are installed according to the corresponding numbers), and inner wall panels; 2. Assembly of layers 2-6: Lay the upper outer wall panels in sequence, and assemble the corresponding transverse diaphragms, longitudinal ribs and inner wall panels. During the assembly process, after each process is completed, use a total station to check the elevation and alignment of the tooling. Only proceed to the next process after confirming that there are no deviations. Among them, the longitudinal ribs that affect the welding of the inner wall panels and the outer wall panels are not assembled for the time being. They are added in the form of a single V bevel after the wall panels are welded and the flaw detection is qualified. Specifically, taking the core area (floors 4, 5, and 6) as an example, the assembly process is as follows: (1) such as Figure 4 As shown, first lay out the ground sample, and set up tooling frames 1 and 2. During this process, check the ground sample line and tooling coordinates. The positioning lines of the outer contour, segment openings, inner and outer wall panels, and transverse partitions must be fixed and cannot be moved. The positioning axis is based on the coordinate origin. (2) The outer wall panel of the first section, such as Figure 5As shown, the outer wall panels are laid from the middle to both sides. During construction, there is no allowance in the longitudinal middle of the outer wall panels and negative deviation is not allowed. There is a 30mm allowance in the longitudinal direction of each outer wall panel. The transverse width of a single outer wall panel is allowed to be 0~2mm and negative deviation is not allowed. (3) Assemble the TJB-5A partition. During this process, all partitions, longitudinal ribs and stiffening positioning lines on the inner and outer wall panels are drawn before the wall panels are bent. The numbers can be marked with a paint pen. The assembly sequence of the horizontal partition is from the middle to both sides. The ends of the horizontal partition must coincide with the ground line. (4) Assemble the TJB-5A outer wall panel and inner wall panel longitudinal ribs. During this process, the positioning of the longitudinal ribs at the interface must be accurate on site. The longitudinal ribs that affect the welding of the inner wall panel and the outer wall panel will not be assembled for the time being. They will be assembled after the inner wall panel and the outer wall panel are welded and the flaw detection is qualified (open single V bevel). The outer wall panel longitudinal ribs are assembled in sections. The arc is rolled according to the sag of the longitudinal rib section length. The arc sag is 50~100mm smaller. (5) Assemble the TJB-5A inner wall panel. During this process, the longitudinal and transverse positioning of the inner wall panel must be accurate, and the end point must coincide with the ground line. (6) Assemble the longitudinal ribs of the outer wall panel of the adjacent segment of TJB-5A. During this process, assemble the longitudinal ribs of the outer wall panel according to the positioning line of the outer wall panel. Do not weld after completion. (7) Lay the third layer of outer wall panels and assemble the fourth layer of partitions, such as Figure 6 As shown, during this process, the outer wall panels are laid from the middle to both sides; there is no allowance in the longitudinal direction of the outer wall panels, and negative deviation is not allowed; there is a 30mm allowance in the longitudinal direction of each outer wall panel; the transverse width of a single outer wall panel is allowed to be 0~2mm, and negative deviation is not allowed; all partitions, longitudinal ribs and reinforcement positioning lines on the inner and outer wall panels are drawn before the wall panels are bent, and are marked with numbers using a paint pen; the assembly sequence of the horizontal partitions is from the middle to both sides, and the ends of the horizontal partitions must coincide with the ground line; (8) Assemble the fourth layer of inner wall panel and its longitudinal ribs. During this process, the positioning of the longitudinal ribs at the interface must be accurate on site. The longitudinal ribs that affect the welding of the inner wall panel and the outer wall panel shall not be assembled for the time being. They shall be assembled after the inner wall panel and the outer wall panel are welded and the flaw detection is qualified (open single V bevel). The longitudinal ribs of the outer wall panel shall be assembled in sections. The arc shall be rolled according to the sag of the segment length of the longitudinal rib. The arc sag shall be 50~100mm smaller. (9) Lay the fifth layer of outer wall panels, assemble the lower partition of the third layer and its corresponding inner and outer wall panel longitudinal ribs. During this process, the positioning of the longitudinal ribs at the interface must be accurate on site. The longitudinal ribs that affect the welding of the inner and outer wall panels will not be assembled for the time being. They will be assembled after the inner and outer wall panels are welded and the flaw detection is qualified (open single V bevel). The longitudinal ribs of the outer wall panels are assembled in sections. The arc is rolled according to the sag of the segment length of the longitudinal rib. The arc sag is 50~100mm smaller. The assembly sequence of the transverse partitions is from the middle to both sides. The ends of the transverse partitions must coincide with the ground line. (10) Assemble the fifth layer partition and the longitudinal ribs of the outer wall panel. During this process, the positioning of the longitudinal ribs at the interface must be accurate on site. The longitudinal ribs that affect the welding of the inner wall panel and the outer wall panel shall not be assembled for the time being. They shall be assembled after the inner wall panel and the outer wall panel are welded and the flaw detection is qualified (open single V bevel). The longitudinal ribs of the outer wall panel shall be assembled in sections. The arc shall be rolled according to the sag of the longitudinal rib section length. The arc sag shall be 50~100mm smaller. The assembly sequence of the transverse partition shall be from the middle to both sides. The ends of the transverse partitions shall coincide with the ground line. (11) Assemble the third layer of longitudinal inner wall panels, such as Figure 7 As shown, during this process, the longitudinal and transverse positioning of the inner wall panel must be accurate, and the port must coincide with the ground line; (12) Assemble the upper partition of the third layer and its corresponding inner and outer wall longitudinal ribs; (13) Assemble the third layer of lateral outer wall panels; (14) Assemble the third layer of lateral inner wall panels; (15) such as Figure 8 As shown, during the third layer of the overturning welding, the inner wall panel and the partition of the box are welded together. During this process, the box is overturned and welded on the tooling platform. The box is arc-shaped and requires the construction of arc-shaped tooling points. After the welding is completed, it is returned to the original jig position for matching and pre-assembly. (16) such as Figure 9 As shown, the sixth layer of outer wall panels is laid, and the outer elbow plate of the third layer of lateral outer wall panels is assembled. (17) The lower components of TJB-6A and TJB-7A and the second-layer components are matched with the third-layer components, and the sixth-layer partition and the longitudinal ribs of the outer wall panel are assembled. (18) Lay the inner wall panel of the fourth layer component (only the jig 1), and assemble the side wall panel of the sixth layer component; (19) Assemble the partition, longitudinal ribs of the wall panel and the pedestrian passage of the fourth layer of the middle box. Match and pre-assemble the third layer with the adjacent sections on both sides. In this process, the manhole passage is first made into a plate unit as a whole. The manhole passage and the partition manhole ring are butt welded with a single-sided bevel weld, which is not fully fused. The lower section of the manhole passage is spot welded to the inner wall panel of the manhole passage. The manhole passage is first painted. The whole box is reinforced (especially the vertical welding). Then, the longitudinal ribs and inner wall panels and the horizontal partitions and inner wall panels that are covered by the manhole passage are welded first. (20) Assemble the fourth layer of side wall panels (only frame 1), and pre-assemble TJB-6B / 7B on frame 2 with TJB-6A / 7A on frame 1; (21) As Figure 10 As shown, the 5th and 6th layers of inner wall panels are laid. (22) Lay the 5th and 6th layer middle box partitions and wall panel longitudinal ribs; (23) Assemble the outer wall panel of the 6th layer, the side wall panel of the middle box of the 5th layer, and assemble the longitudinal ribs of the inner wall panel of the middle box of the 4th and 5th layers. (24) Assemble the inner wall panels of the fourth and fifth layers of the box; (25) Welds between the inner wall panels and partitions of the middle box of the 4th and 5th layers; (26) For example Figure 11 As shown, the fourth layer is pre-assembled with the adjacent segments on both sides. After the fourth layer is matched and corrected, it is installed at the shipping site. (27) The fifth layer is pre-assembled with adjacent segments on both sides; (28) After the matching and calibration of the 5th layer is completed, the installation will be carried out at the shipping site; (29) TJB-13B / 14B on frame 2 is matched and pre-assembled with TJB-13A / 14A on frame 1. The 6th layer is matched and pre-assembled with the adjacent segments on both sides. After the matching and correction of the 6th layer is completed, it is installed at the shipping site. It should be noted that in this invention, the principle of "symmetrical welding, inside before outside, horizontal before vertical" is adopted. Welding of the horizontal diaphragm and the inner wall panel is prioritized, followed by welding of the longitudinal rib and the wall panel, and finally welding of the outer wall panel splicing weld, thereby reducing welding stress concentration. CO2 gas shielded welding (80% Ar + 20% CO2 mixed gas) is used. The welding current is controlled at 200-280A, the voltage at 24-30V, and the welding speed at 300-500mm / min. The interpass temperature is adjusted according to the thickness of the component (not exceeding 250℃). The outer wall panel and tooling plate ribs are spot welded at the longitudinal diaphragm, the transverse inner wall panel, and every other longitudinal rib (spot weld length 50-80mm, spacing 200-300mm). Temporary supports of φ150mm×6mm round pipes are set on site for the interface accessories. The box is fixed before welding to avoid welding deformation. After welding, the arc-shaped components are flame straightened (heating temperature 700-800℃). The straightening deviation is ≤0.5mm. Step S6: Multi-segment pre-assembly and positioning matching: To ensure on-site installation accuracy, pre-assembly and matching are performed after the segments are fabricated in the factory. The specific steps are as follows: Step S601, Pre-assembly jig setting: According to the tower pier segment division, set up multiple pre-assembly jigs (e.g., set up 3 jigs for the tower base segment). The jig alignment is consistent with the final assembly jig. Use a total station to calibrate the jig elevation and baseline. Step S602, Segment matching and assembly: (1) The V-leg is divided into 3 large jigs for assembly. Each jig is required to complete the assembly of 3 segments. Before the core area components are shipped, the adjacent components that have been processed on the jigs are pre-assembled with the core area to ensure that the matching accuracy in each direction is ±0.3mm. (2) Matching the core area with the anchoring segment: The second layer of the core area and the anchoring segment are matched and processed in a straight assembly. The components on both sides of the third layer are processed in two half-areas (the upper half-area is assembled with the core area as a whole, and the lower half-area is assembled with the anchoring segment and the second layer in the same jig). After processing, the anchoring segment is shipped out, and the half-area is reserved for secondary matching with the core area components to ensure that the docking gap is ≤1mm. Step S603, Positioning and Matching Part Settings, including: After the pre-assembly is qualified, positioning and matching parts are added to each box. The positioning ear plate can be made of 16mm×135mm×230mm steel plate, and the connecting plate can be made of 16mm×90mm×580mm steel plate, both of which are made of Q355B. The distance from the on-site interface is 60mm. There are 3 points in the height direction of the single outer wall panel (100mm from the top and bottom of the interface and 1 in the middle), 3 points in the length direction according to the arc length (the spacing is about 2m, and the two ends are 100mm from the interface), and 3 points in the width direction (100mm from the interface on the left and right and 1 in the middle) to ensure that the assembly gap between the boxes can be controlled during on-site installation. In this invention, through BIM modeling and planning, precise setting of the assembly jig benchmark, and layered assembly process, the segmented assembly accuracy of the longitudinal ribs reaches ±0.3mm, and the segmental line deviation is controlled within ±0.5mm, far exceeding the ±2mm of the traditional method, meeting the high-precision requirements of giant tower piers and significantly improving assembly accuracy. After welding, the component's bulging deformation is ≤0.5mm, and the twist is ≤0.3mm / m, reducing the rework rate by more than 90% and ensuring the mechanical properties of the components. The multi-segment factory pre-assembly and positioning matching parts ensure that the gap between on-site interfaces is controlled within ≤1mm, avoiding on-site cutting and adjustment, shortening the installation period by 40%, and reducing construction risks. Moreover, it is applicable to the processing of giant tower piers of different specifications and irregular structures. By adjusting the BIM model parameters and jig layout, new types of tower piers can be quickly adapted, reducing process development costs.

[0018] In the description of this invention, it should be understood that the terms "upper", "lower", "bottom", "top", "front", "rear", "inner", "outer", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0019] While the invention has been described herein with reference to specific embodiments, it should be understood that these embodiments are merely examples of the principles and applications of the invention. Therefore, it should be understood that many modifications can be made to the exemplary embodiments, and other arrangements can be designed without departing from the spirit and scope of the invention as defined by the appended claims. It should be understood that different dependent claims and features described herein can be combined in ways different from those described in the original claims. It is also understood that features described in conjunction with individual embodiments can be used in other described embodiments.

Claims

1. A method for processing giant bridge piers, characterized in that, Includes the following steps: In the pre-processing preparation stage, a three-dimensional solid BIM model is established to determine the dimensional parameters and assembly relationships of each component, and a visual processing flowchart and parameter table are generated. During the longitudinal rib segmentation process, the segment length of the longitudinal rib is determined according to the spacing of the transverse diaphragms, so that the length of a single longitudinal rib segment is no more than 4 times the spacing of the transverse diaphragms and does not exceed 4m. During the longitudinal rib rolling process, the theoretical height loss of the longitudinal rib after segmentation is simulated using a BIM model, and the longitudinal rib with a height loss of more than 100mm after segmentation is rolled. The final assembly jig stage; During the assembly phase, the giant tower piers are divided into multiple layers, and the giant tower piers are assembled symmetrically from the inside out. Multi-segment pre-assembly and positioning matching stage.

2. The method for processing a giant bridge pier according to claim 1, characterized in that, The longitudinal rib curling process also includes: A CNC arc rolling machine is used to roll the longitudinal ribs to be processed. Based on the theoretical curvature of the segmented longitudinal ribs, the arc rolling parameters are set on the arc rolling machine. Then, the longitudinal ribs are fixed on the tooling table of the arc rolling machine. The actual height loss during the arc rolling process is monitored in real time by a laser rangefinder, so that the actual height loss after arc rolling is 50~100mm smaller than the theoretical height loss.

3. The method for processing a giant bridge pier according to claim 2, characterized in that, The longitudinal rib curling process also includes: After all the longitudinal ribs that need to be processed have been rolled, the longitudinal ribs with an absolute value of curvature deviation of less than 0.5mm are grouped into one category, and the rolling direction and number are marked.

4. The method for processing a giant bridge pier according to claim 3, characterized in that, The final assembly jig setup stage includes: During the foundation construction phase, longitudinal and transverse slats are laid on the ground according to the tooling points planned in the BIM model. The slats are fully welded to the pre-embedded steel plates in the ground to form a stable slat platform. In the stage of supporting the jig and setting the benchmark, the transverse side uses plate ribs and vertical steel pipes inserted and welded, and the longitudinal and transverse sides use angle steel to set horizontal and vertical supports to form a three-dimensional frame jig. During the frame alignment inspection and adjustment phase, the overall alignment elevation of the frame is measured and compared with the theoretical elevation of the BIM model. If the absolute value of the deviation exceeds 0.3mm, it is corrected by adjusting the adjusting bolts at the top of the uprights until the frame alignment matches the drawings.

5. The method for processing a giant bridge pier according to claim 4, characterized in that, The assembly stage also includes: The giant tower pier was divided into six layers; First, lay the fourth layer of outer wall panels from the middle to both sides, then push the fourth layer of transverse partitions from the middle to both sides, and then assemble the fourth layer of outer wall panels, inner wall panel longitudinal ribs, and inner wall panels. Then, the upper outer wall panels are laid in sequence, and the corresponding horizontal diaphragms, longitudinal ribs and inner wall panels are assembled. After each process is completed, the elevation and alignment of the tooling are checked with a total station. Only after confirming that there are no deviations can the next process be carried out.

6. The method for processing a giant bridge pier according to claim 5, characterized in that, The assembly stage also includes: If there are longitudinal ribs that affect the welding of the inner and outer wall panels during the assembly process, the longitudinal ribs should be added in the form of a single V-groove after the inner and outer wall panels have been welded together.

7. The method for processing a giant bridge pier according to claim 6, characterized in that, The assembly stage also includes: First, weld the transverse diaphragm to the inner wall panel, then weld the longitudinal rib to the wall panel, and finally weld the outer wall panel splicing weld. During the welding process, carbon dioxide gas shielded welding is used, with the current controlled at 200~280A, the voltage controlled at 24~30V, and the welding speed controlled at 300~500mm / min.

8. A method for processing a giant bridge pier according to claim 7, characterized in that, The multi-segment pre-assembly and positioning matching stage includes: Pre-assembly jigs are set up according to the segment division of the tower piers, and multiple pre-assembly jigs are set up to ensure that the jig alignment is consistent with the final assembly jig. A total station is used to calibrate the jig elevation and baseline. Segment matching assembly: the core area of ​​the tower leg V-leg matches the adjacent standard V-leg segment, and the core area of ​​the tower leg V-leg matches the anchoring segment; After the pre-assembly is qualified, positioning and matching parts are set up on each box.

9. A method for processing a giant bridge pier according to claim 8, characterized in that, The core area of ​​the V-leg at the tower foot matches the standard segment of the adjacent V-leg, including: The tower leg V-leg is divided into three large jigs for assembly. Each jig must meet the requirement of assembling at least three segments as a whole. Before the core area components of the tower leg V-leg are shipped, the adjacent components that have been processed on the jig are pre-assembled with the core area to ensure that the absolute value of the matching accuracy in all directions is less than 0.3mm.

10. A method for processing a giant bridge pier according to claim 9, characterized in that, The core area of ​​the V-leg of the tower foot matches the anchoring segment, including: The second layer of the core area of ​​the V-leg of the tower foot is processed with the anchoring segment in a straight-fitting manner. The components on both sides of the third layer are processed in two half-areas. After processing, the anchoring segment is shipped out, and the remaining half-area is matched with the core area components for a second time to ensure that the docking gap is ≤1mm.

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