Green processing and galvanizing corrosion prevention integrated process method for power transmission line tower

Abstract

This invention discloses a green processing and integrated galvanizing and anti-corrosion process for transmission line towers, comprising: substrate selection and pretreatment, including: using low-cost, high-performance ordinary low-carbon steel to replace traditional Q690 high-strength steel, while pretreating the substrate; digital layout, including: using digital technology to accurately define component dimensions and accurately generate processing data; precise cutting, including: using CNC cutting equipment based on digital layout data, combined with an optimized layout scheme to perform high-precision cutting of the substrate; multi-process precision processing, including: sequentially performing hole making, forming, and welding processing on the cut components; environmentally friendly galvanizing and anti-corrosion, including: using an environmentally friendly hot-dip galvanizing process, sequentially performing environmentally friendly galvanizing and anti-corrosion through degreasing, pickling, flux immersion, drying preheating, hot-dip galvanizing, and cooling passivation; and comprehensive inspection of the components after processing and anti-corrosion treatment.

Description

Technical Field

[0001] This invention relates to the fields of precision machining technology for metal components, environmentally friendly anti-corrosion treatment technology, and integrated green manufacturing processes. Specifically, it relates to an integrated green machining and galvanizing anti-corrosion process for power transmission line towers. Using ordinary low-carbon steel as the base material, it combines digital layout, precise material cutting, multi-process precision machining, and environmentally friendly galvanizing anti-corrosion. This integrated green machining and galvanizing anti-corrosion process is applied to the production of metal components for power transmission line towers. It is particularly suitable for the large-scale processing and production of various metal structural components such as main materials, diagonal materials, and auxiliary materials for power transmission line towers, which require consideration of production costs, processing accuracy, structural strength, and environmental protection requirements. It belongs to the cross-technical field of high-end equipment manufacturing and power infrastructure supporting component processing. Background Technology

[0002] As a key load-bearing structural component in the national power transmission network, the overall structural strength, processing precision, and corrosion resistance of transmission line towers directly affect the operational stability, safety, and long-term service life of the entire transmission line. They are an indispensable core basic component in power grid construction projects. In the traditional processing and production system of transmission line tower components, in order to meet the mechanical performance requirements of towers in complex outdoor environments, such as wind load resistance, icing resistance, deformation resistance, and long-term structural stability, the industry generally uses high-strength structural steel of grade Q690 and above as the main processing base material. Although this type of high-strength steel can meet the stringent usage standards in terms of mechanical performance indicators such as yield strength and tensile strength, it has the prominent problem of high raw material procurement costs. The market procurement price of Q690 high-strength steel is much higher than that of ordinary low-carbon structural steel. In the process of mass production of tower components, it will significantly increase the raw material cost input of production enterprises, thereby pushing up the construction cost of the entire transmission line project. This is not conducive to the large-scale promotion and cost control of power grid infrastructure construction. Especially in large-scale projects such as regional power grid upgrading and transformation and ultra-high voltage transmission line construction, the economic pressure brought by the base material cost is even more prominent. Meanwhile, the anti-corrosion treatment process used for traditional power transmission line tower components after machining is mostly organic coating spraying, including various forms such as air spraying, airless spraying, and electrostatic spraying. This type of spraying anti-corrosion process has extremely significant environmental pollution problems in actual production. During the spraying process, a large amount of volatile organic compounds, i.e., VOCs, are continuously released, accompanied by paint mist dust, heavy metal additive particles, and harmful organic waste gases. This not only causes continuous pollution to the atmospheric environment around the production workshop and damages the quality of the regional ecological environment, but also directly harms the health of front-line production operators. Long-term exposure can easily lead to respiratory diseases, skin allergies, and occupational health problems such as chronic poisoning. This is seriously contrary to the current national promotion of green manufacturing, clean production, low-carbon and environmentally friendly industrial development concepts, and cannot meet the increasingly strict environmental control standards and pollutant emission limits in various regions.

[0003] Besides the two core problems of high base material costs and significant pollution from anti-corrosion processes, traditional tower component processing technology also suffers from multiple technical defects, including low material utilization, unreasonable connections between processing steps, and difficulty in guaranteeing the overall precision of components. Under traditional processing methods, the layout and cutting of tower components largely rely on manual experience or semi-automated equipment. The cutting and layout schemes lack systematic optimization, and the ability to control cutting precision is poor. This results in a large amount of non-recyclable scrap material after plate cutting, with the comprehensive utilization rate of steel typically remaining below 80%, causing serious resource waste and contradicting the development direction of efficient resource utilization and a circular economy. In the subsequent processing of multiple steps such as hole making, bending and forming, welding and assembly, traditional technology lacks a unified and complete quality control system. Each step operates independently with discontinuous connections, failing to form a coordinated precision processing flow. The hole making process is prone to problems such as excessive hole diameter deviation and misalignment of hole spacing. The bending and forming process is prone to quality defects such as angle deviation, insufficient flatness, and local deformation. The welding process often has welding defects such as weld porosity, slag inclusion, incomplete penetration, and cracks. All of these problems together lead to low overall processing accuracy of tower components and poor assembly compatibility. In severe cases, it may even affect the mechanical stability and safe service performance of the overall tower structure.

[0004] While some existing technologies address optimization of metal component cutting, improved welding quality, or improvements to individual anti-corrosion processes, none have formed a comprehensive integrated process system specifically for transmission line tower components. This system utilizes ordinary low-carbon steel as the base material and integrates the entire processing flow with environmentally friendly anti-corrosion measures. Most solutions focus on optimizing single processes, failing to simultaneously address systemic issues such as high base material costs, significant corrosion pollution, low material utilization, and insufficient processing precision. Furthermore, some solutions suffer from poor process adaptability, limited scalability, and ineffective overall cost control, making it difficult to meet the current practical demands for green, high-precision, low-cost, and large-scale production of transmission line tower components. Based on the aforementioned industry status quo and technological pain points, developing an integrated process method that can replace high-cost, high-strength steel with ordinary low-carbon steel, integrates precision machining with environmentally friendly galvanizing and anti-corrosion, and aligns with green manufacturing and resource-efficient utilization policies is a critical technological issue urgently needing resolution in the field of transmission line tower component processing. This has significant practical implications and engineering application value for promoting the green transformation of the power equipment manufacturing industry and enhancing the market competitiveness of enterprises. Summary of the Invention

[0005] This invention aims to solve a series of common technical problems in the existing traditional processing technology of transmission line tower components, such as the high raw material cost caused by the use of Q690 high-strength steel as the base material, the serious environmental pollution caused by the large amount of VOCs gas and dust generated by traditional spray anti-corrosion process, the serious waste of steel resources due to unreasonable material layout and poor process connection, and the lack of systematic quality control measures in each processing step, which makes it difficult to guarantee the processing accuracy and structural performance of components. This invention provides a green processing and integrated galvanizing and anti-corrosion process for transmission line towers, using low-cost ordinary low-carbon steel as the core processing base material to replace traditional high-strength steel. This high-strength steel utilizes a combination of digital technology and precision machining equipment to achieve precise control over the entire process, from layout and material preparation to multi-process collaborative processing. Simultaneously, it employs an environmentally friendly hot-dip galvanizing anti-corrosion process to replace the traditional high-pollution spraying process. This constructs an integrated production process system encompassing efficient material utilization, precision machining, and green anti-corrosion, significantly reducing the overall production cost of transmission tower components while greatly improving resource utilization efficiency and processing accuracy. This achieves a green and clean transformation of the production process, meeting the multiple demands of the high-end equipment manufacturing sector for high-quality, low-cost, and environmentally friendly production of transmission line tower components. To achieve the above technical objectives and solve the corresponding technical problems, this invention adopts a technical solution combining overall process integration and refined parameter control. The complete green processing and integrated galvanizing anti-corrosion process for transmission line towers is specifically broken down into the following six core steps. Each step is sequentially connected and coordinated to form a complete closed-loop production system. Each step has undergone refined design and parameter optimization to ensure the stability, accuracy, and environmental friendliness of the process implementation.

[0006] The first aspect of this invention is to provide a green processing and integrated galvanizing and corrosion protection process for transmission line towers, comprising:

[0007] S1, Substrate selection and pretreatment, including: replacing traditional Q690 high-strength steel with low-cost, high-performance ordinary low-carbon steel, and pretreating the substrate to ensure that the substrate quality meets the requirements of subsequent processing and corrosion protection.

[0008] S2, digital layout, includes: using digital technology to accurately define component dimensions and generate accurate processing data, providing reliable data support for subsequent material cutting and processing procedures;

[0009] S3, Precision Cutting, includes: based on digital layout data, using CNC cutting equipment, and combined with an optimized layout scheme, to achieve high-precision cutting of the substrate;

[0010] S4 involves multi-stage precision processing, including sequential hole making, forming, and welding of the blanked components. Quality control points are set at each stage, and the processing quality is ensured through refined parameter control and process inspection.

[0011] S5 employs environmentally friendly galvanizing for corrosion protection, including: abandoning the traditional high-pollution spraying process and adopting an environmentally friendly hot-dip galvanizing process, which involves a series of steps including degreasing, pickling, fluxing, drying and preheating, hot-dip galvanizing, and cooling and passivation for environmentally friendly galvanizing for corrosion protection.

[0012] S6. Conduct finished product inspection and warehousing, including: conducting a comprehensive inspection of components that have completed all processing and anti-corrosion treatments, and marking, classifying and warehousing them after they pass the inspection.

[0013] Preferably, S1 includes:

[0014] S11, Determine the standard for selecting the base material, and select ordinary low carbon steel with a yield strength of 235-355MPa as the base material for processing transmission line tower components.

[0015] S12. Conduct incoming inspection of the base material. The inspection items include appearance quality, dimensional accuracy, and mechanical properties. In terms of appearance, ensure that the surface of the sheet is free from one or more quality defects such as cracks, folds, delamination, oxide scale peeling, rust, and scratches. In terms of dimensions, control the thickness deviation of the sheet within ±0.1mm, and the length and width deviations meet the design requirements. In terms of mechanical properties, use testing methods such as tensile tests and bending tests to ensure that the yield strength, tensile strength, and elongation meet the national standards for the corresponding steel.

[0016] S13. Pre-treat the substrate. For qualified substrates, perform surface cleaning and leveling. Surface cleaning is done by mechanical grinding to remove impurities such as floating rust, oxide scale, and oil stains from the substrate surface. After grinding, use compressed air to blow it clean. Leveling is done by CNC leveling machine to precisely level the substrate, controlling the flatness error of the substrate to ≤0.1mm / m. After pre-treatment, the substrates are sorted and stacked and labeled.

[0017] Preferably, the ordinary low-carbon steel with a yield strength of 235-355 MPa is Q235 low-carbon steel or Q355 low-carbon steel.

[0018] Preferably, S2 includes:

[0019] S21. Build a three-dimensional model, including: based on the overall design drawings and technical requirements of the transmission line tower, use AutoCAD and SolidWorks joint design software to build the overall three-dimensional model of the tower and detailed three-dimensional models of each component, clarify the external dimensions, structural features, connection methods and stress requirements of each component, and ensure that the three-dimensional model is completely consistent with the actual production requirements.

[0020] S22, perform component decomposition and parameter setting, decompose the overall three-dimensional model of the iron tower into various specific components such as main material, diagonal material and auxiliary material. For each component, combine the dimensional loss of each subsequent process such as cutting, drilling, forming, welding and galvanizing, and accurately set the single-sided processing allowance. The processing allowance is reasonably adjusted according to the component thickness and processing process. At the same time, the key parameters of the component cutting boundary, drilling position and welding node are clearly defined.

[0021] S23, Generate processing data, including: digitally laying out each component after disassembly, automatically generating precise processing drawings of the components, cutting data that can be directly imported by CNC cutting equipment, and parameter reference files for each processing step; wherein, the cutting data includes cutting path, cutting speed, and torch height;

[0022] S24. Perform data review and optimization. Double-check the generated machining drawings, cutting data and parameter reference files to check for dimensional deviations, data errors and reasonable process connections. Optimize and adjust any problems in a timely manner. Archive and store the approved machining data and drawings and transmit them synchronously to the CNC equipment for the subsequent material cutting process.

[0023] Preferably, in step S22, the single-sided machining allowance for components with a thickness of <6mm is set to 1.5mm, and the single-sided machining allowance for components with a thickness of ≥6mm is set to 2mm.

[0024] Preferably, S3 includes:

[0025] S31, Debugging the cutting equipment, including: selecting CNC cutting equipment suitable for ordinary low carbon steel, selecting the appropriate cutting method according to the thickness and material of the component, and debugging the equipment including calibrating one or more key parameters of the cutting head positioning accuracy, cutting speed, laser power and plasma current; for components with a thickness < 8mm, a CNC laser cutting machine is used, and for components with a thickness ≥ 8mm, a CNC plasma cutting machine is used.

[0026] S32, Optimize material cutting layout, including: import the cutting data generated by digital layout into the layout software, combine the size and specifications of the base material, systematically optimize the cutting layout of multiple boards, adopt a nested layout method to minimize the cutting gap and corner reserve size, after layout optimization, generate detailed layout drawings, and mark the placement position and cutting sequence of each component on the board.

[0027] S33, perform precise cutting operation, including: placing the pre-treated qualified substrate flat on the worktable of the CNC cutting equipment, accurately positioning and fixing it, then importing the optimized cutting data into the equipment, starting the cutting program, monitoring the stability of the cutting parameters in real time during the cutting process, controlling the material cutting accuracy error to ≤ ±0.5mm, of which the laser cutting accuracy error is controlled within ±0.2mm and the plasma cutting accuracy error is controlled within ±0.3mm, while controlling the surface roughness Ra of the cutting surface to ≤12.5μm. After the cutting is completed, the component is removed from the plate and the burrs and oxide residue on the edge of the component are cleaned.

[0028] S34, Conduct material cutting quality inspection and scrap recycling, including: inspecting the dimensional accuracy of the cut components, verifying the length, width and angle of the components, and classifying and collecting the scrap generated from cutting. For recyclable scrap, uniformly sort and label it for processing small auxiliary components, and centrally process non-recyclable scrap according to environmental protection requirements.

[0029] Preferably, S4 includes:

[0030] S41, Implement the hole-making process, including: using a high-precision CNC drilling machine to make holes, determining the hole diameter, hole spacing and number of holes according to the assembly requirements of the components, before making holes, accurately positioning and fixing the components on the drilling machine worktable, calibrating the drill bit position and drilling machine accuracy, selecting a drill bit that matches the hole diameter, after the hole is made, using a chamfering tool to chamfer the hole opening, with a chamfer angle of 45° and a chamfer width of 1-2mm, and then inspecting the hole position accuracy and hole diameter size to ensure the precise fit between the hole position and the tower connector;

[0031] S42, Implement the forming process, including: according to the shape requirements of the component, use a CNC bending machine or CNC press for forming processing. Before forming, adjust the forming mold and equipment parameters according to the forming angle and fillet radius of the component to ensure that the mold matches the shape of the component. During the forming process, monitor the forming pressure, holding time and springback compensation parameters in real time to avoid defects such as bending angle deviation, local distortion, flatness exceeding the standard and forming cracks. After forming, inspect the forming accuracy of the component, check the forming angle and flatness, and re-form unqualified components.

[0032] S43, Implement the welding process, including: using fully automated submerged arc welding technology for welding operations; before welding, cleaning the welding area to remove surface oxide scale, rust, and oil stains; after cleaning, blowing it clean with compressed air; selecting appropriate welding wire and flux according to the component material, thickness, and welding requirements; immediately cooling to room temperature using natural cooling or forced air cooling after welding; and performing 100% non-destructive testing on the weld after cooling; wherein, the 100% non-destructive testing includes using ultrasonic testing or radiographic testing, wherein ultrasonic testing is used to detect internal defects in the weld, and radiographic testing is used to detect the internal quality of critical load-bearing welds; unqualified welds are promptly repaired or re-welded, and after repair, non-destructive testing is performed again until qualified.

[0033] Preferably, in step S41, the drill bit is made of high-speed steel or cemented carbide. During the hole-making process, the drill bit rotation speed is controlled at 800-1200 r / min, and the feed rate is controlled at 10-15 mm / min. The rotation speed and feed rate are adjusted according to the hole diameter. When the hole diameter is <20 mm, the drill bit rotation speed is controlled at 1000-1200 r / min, and the feed rate is controlled at 12-15 mm / min. When the hole diameter is ≥20 mm, the drill bit rotation speed is controlled at 800-1000 r / min, and the feed rate is controlled at 10-12 mm / min. At the same time, the hole diameter error is controlled to be ≤±0.05 mm, the hole center distance error is controlled to be ≤±0.1 mm, and the hole wall perpendicularity error is controlled to be ≤0.03 mm / m.

[0034] In step S42, the bending pressure of the CNC bending machine is controlled at 100-300t, the holding time is controlled at 3-5s, and the springback compensation is adjusted to 0.5-1° according to the material and thickness of the component; the forming pressure of the CNC press is controlled at 80-250t, the holding time is controlled at 2-4s, the forming angle error is controlled within ±0.3°, and the component flatness error is controlled within 0.2mm / m.

[0035] In S43, the welding wire is H08MnA or H10Mn2, and the flux is HJ431. During the welding process, the welding parameters are strictly controlled: the welding current is 300-500A, the welding voltage is 28-36V, the welding speed is 30-50cm / min, the welding wire extension length is 20-30mm, the flux particle size is 10-40 mesh, the flux drying temperature is 200-250℃, and the drying time is 2-3h. The welding parameters are adjusted according to the thickness of the component. When the thickness is <8mm, the welding current is controlled at 300-380A, the welding voltage is controlled at 28-32V, and the welding speed is controlled at 40-50cm / min. When the thickness is ≥8mm, the welding current is controlled at 380-500A, the welding voltage is controlled at 32-36V, and the welding speed is controlled at 30-40cm / min.

[0036] Preferably, S5 includes:

[0037] S51, degreasing treatment is performed, including: using an environmentally friendly water-based metal degreasing cleaning agent, stabilizing the temperature of the degreasing tank at 50-60℃, adjusting the degreasing time according to the oil content on the component surface, and completely immersing the component in the degreasing solution. Through the penetration, dispersion and saponification of the cleaning agent, the residual cutting fluid, lubricating oil, dust and oil on the surface of the component are thoroughly removed. After degreasing, the component is taken out of the degreasing solution and rinsed with clean water 2-3 times to remove the residual degreasing solution on the surface.

[0038] S52, pickling and rust removal are carried out, including: using an industrial hydrochloric acid solution with a mass concentration of 18-22% as the pickling medium, adding 1-3 g / L of hexamethylenetetramine as a corrosion inhibitor to the pickling solution, controlling the pickling environment temperature at 25-35℃, adjusting the pickling time according to the oxide scale and rust content on the component surface, completely immersing the component in the pickling solution until the oxide scale, rust, and oxide film on the component surface are completely removed, exposing a uniform silver-white metal substrate. After pickling, a multi-stage countercurrent rinsing process is adopted, in which the component is placed in 3-4 stages of clean water tanks for rinsing, with each stage rinsing time being 3-5 minutes, to thoroughly remove the residual acid solution on the surface;

[0039] S53, Immersion flux, comprising: an aqueous flux solution prepared by mixing 18-22% ammonium chloride and 2.8-3.2% zinc chloride by mass, controlling the flux solution temperature at 58-62℃, completely immersing the component in the flux solution for 6-8 minutes, so that the flux adheres evenly to the surface of the component, forming a uniform activation layer on the substrate surface, and after the flux immersion is completed, removing the component and draining off the excess flux solution from the surface;

[0040] S54. Drying and preheating are carried out, including: sending the components after being immersed in the flux into a hot air circulating drying oven, controlling the oven temperature at 140-160℃, and drying time at 15-20min. The drying time is adjusted according to the thickness of the components. The drying time for components with a thickness <8mm is 15-17min, and the drying time for components with a thickness ≥8mm is 17-20min. After the drying is qualified, the components are quickly sent into the hot-dip galvanizing pot.

[0041] S55 involves hot-dip galvanizing, including: using a large, fully automatic hot-dip galvanizing pot made of high-temperature resistant stainless steel; precisely and stably controlling the temperature of the pure zinc liquid inside the pot at 445-455℃; adding high-purity aluminum wire to the zinc liquid to stabilize the aluminum content at 0.18-0.22%; controlling the immersion time according to the thickness of the components: 1.5-2 minutes for components with a thickness <5mm, 2.5-3 minutes for components with a thickness of 5-12mm, and 3.5-4 minutes for components with a thickness >12mm; completely immersing the components in the zinc liquid; after immersion, smoothly lifting the components from the zinc liquid at a uniform speed of 1.2-1.5m / min; during the lifting process, using a high-pressure nitrogen wiping device to uniformly blow away excess zinc liquid from the surface of the components, controlling the zinc layer thickness to be uniform and consistent; the average zinc layer thickness of components with a thickness >4mm is ≥86μm, and the average zinc layer thickness of components with a thickness ≤4mm is ≥65μm.

[0042] S56. Cooling and passivation are performed, including: immediately after galvanizing, the component enters the forced air cooling process, using forced convection cooling, controlling the cooling rate at 5-8℃ / s, and rapidly and uniformly cooling to below 50℃. After cooling to the specified temperature, an environmentally friendly chromium-free passivation process is used for passivation treatment. The passivating agent is a chromium-free passivation liquid. The component is completely immersed in the passivation liquid, and the passivation time is 2-3 minutes. The passivation film thickness is controlled at 0.6-0.8μm. After passivation, the component is removed and air-dried or dried with hot air to remove the residual passivation liquid from the surface.

[0043] Preferably, S6 includes:

[0044] S61, Prepare for inspection, including: developing detailed finished product inspection standards, clarifying inspection items, inspection methods, and pass / fail criteria, and preparing relevant testing tools;

[0045] S62, Perform itemized inspections, including:

[0046] (1) Dimensional accuracy inspection: The key dimensions of the component, such as length, width, angle, hole diameter, and hole spacing, are fully inspected. The corresponding inspection tools are used to check each dimension to ensure that the dimensional error meets the design requirements and processing standards. Among them, the length and width error is ≤ ±0.5mm, the angle error is ≤ ±0.3°, the hole diameter error is ≤ ±0.05mm, and the hole spacing error is ≤ ±0.1mm.

[0047] (2) Visual inspection of the appearance quality: visually inspect the surface of the components to ensure that there are no defects such as cracks, deformation, burrs, sharp edges, missing plating, poor plating, peeling, flaking, bubbles and runs in the zinc layer, the zinc layer surface is flat and smooth with uniform color, the weld seam of the welded parts is full and without defects, and the passivation film is uniform and complete without any exposed base or yellowing.

[0048] (3) Zinc layer quality inspection: The zinc layer thickness is measured by a zinc layer thickness gauge to ensure that the zinc layer thickness meets the specified requirements. The zinc layer adhesion is tested by the cross-cut test method. After the cross-cut test, there is no peeling or flaking of the zinc layer. The adhesion reaches the Class 1 standard in GB / T 5270-2019 "Rating of specimens and test pieces of metal and other inorganic coatings on metal substrates after corrosion test".

[0049] (4) Mechanical performance sampling inspection: a certain proportion of components are randomly selected for tensile test, bending test and weld strength test to ensure that the mechanical properties and weld strength of the components meet the national standards and usage requirements;

[0050] S63, non-conforming handling includes: marking and isolating non-conforming components found during inspection, analyzing the reasons for non-conformity, reworking components with dimensional deviations and processing defects, re-galvanizing components with substandard zinc coating quality and inadequate anti-corrosion effect, conducting a comprehensive inspection again after rework and reprocessing until they pass, and scrapping components that cannot be reworked or still fail after rework.

[0051] S64, Identification and Warehousing, includes: For components that have passed inspection, use laser marking to create a unique identification code. The identification code includes the component name, specifications, production batch, production date, and inspection certificate. After identification, the components are classified and stacked, and stored in separate areas according to component type and specifications. Storage records are kept.

[0052] The beneficial effects of the method and system of the present invention are as follows:

[0053] This invention deeply integrates and synergistically optimizes the six core steps mentioned above, overcoming the drawbacks of traditional processes where each step is independent and poorly connected. It achieves continuous, efficient, and precise operation of the processing flow. Cost control is achieved through the selection of ordinary low-carbon steel; resource efficiency is achieved through precise layout and process optimization; green and clean production is achieved through environmentally friendly galvanizing; and dual assurance of component processing accuracy and structural performance is achieved through full-process quality control. The entire process boasts advantages such as strong process stability, good equipment adaptability, and scalable application. The produced transmission line tower components fully meet the standards for power engineering use, while also possessing significant cost advantages, environmental benefits, and technological advantages, aligning with the current trend of green development in the high-end equipment manufacturing industry. Specifically:

[0054] 1. Significantly reduce base material costs: By using ordinary low-carbon steel instead of Q690 high-strength steel, the cost of base material procurement is reduced by 40-50%, which greatly reduces the overall manufacturing cost of transmission line towers.

[0055] 2. Achieve green and environmentally friendly production: The environmentally friendly hot-dip galvanizing process replaces the traditional spraying process, eliminating VOCs and harmful dust emissions. Waste gases such as zinc fumes and hydrogen chloride are treated by micro-negative pressure ventilation and can be recycled. Zinc oxide dust can be recycled, which meets the requirements of green manufacturing and environmentally friendly production.

[0056] 3. Significantly improve material utilization: Through digital layout and precise material cutting optimization, the material utilization rate has been increased from less than 80% in traditional processes to more than 95%, reducing material waste and achieving efficient resource utilization.

[0057] 4. Ensure component processing accuracy: Set precise quality control points in key processes such as hole making, forming, and welding, and strictly control the errors in dimensions, angles, and welding quality to ensure the assembly accuracy and structural stability of transmission line tower components.

[0058] 5. Improved corrosion resistance: The zinc layer formed by hot-dip galvanizing is uniform in thickness, with an average thickness of ≥86μm (when the component thickness is >4mm). It has excellent corrosion resistance and can maintain its anti-corrosion effect for more than 30 years in outdoor environments, which is far superior to traditional spraying processes. Attached Figure Description

[0059] To more clearly illustrate the technical solutions in the specific embodiments or related technologies of the present invention, the drawings used in the description of the specific embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0060] Figure 1 This is a flowchart illustrating the integrated green processing and galvanizing anti-corrosion process for power transmission line towers according to an embodiment of the present invention.

[0061] Figure 2 The flowchart of step S1 of the green processing and galvanized corrosion protection integrated process method for power transmission line towers provided in the embodiments of the present invention is shown.

[0062] Figure 3 The flowchart of step S2 of the green processing and galvanized corrosion protection integrated process method for power transmission line towers provided in the embodiments of the present invention is shown.

[0063] Figure 4 The flowchart of step S3 of the green processing and galvanized corrosion protection integrated process method for power transmission line towers provided in the embodiments of the present invention.

[0064] Figure 5 The flowchart of step S4 of the green processing and galvanized corrosion protection integrated process method for power transmission line towers provided in the embodiments of the present invention is shown.

[0065] Figure 6 The flowchart of step S5 of the green processing and galvanized corrosion protection integrated process method for power transmission line towers provided in the embodiments of the present invention is shown.

[0066] Figure 7 The flowchart of step S6 of the green processing and galvanized corrosion protection integrated process method for power transmission line towers provided in the embodiments of the present invention is shown. Detailed Implementation

[0067] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0068] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0069] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0070] like Figure 1-7 As shown, the embodiment provides a green processing and integrated galvanizing and corrosion protection process for transmission line towers, including:

[0071] S1, Substrate selection and pretreatment, including: using low-cost, high-performance ordinary low-carbon steel to replace traditional Q690 high-strength steel, and pretreating the substrate to ensure that the substrate quality meets the requirements of subsequent processing and corrosion protection.

[0072] In a preferred embodiment, S1 includes:

[0073] S11. Determine the base material selection criteria. Ordinary low-carbon steel with a yield strength of 235-355 MPa is selected as the base material for the transmission line tower components. Q235 or Q355 low-carbon steel is preferred, as both types of low-carbon steel comply with relevant national standards. Q235 low-carbon steel conforms to GB / T 700-2006 "Carbon Structural Steel" national standard, with a tensile strength ranging from 370 MPa to 500 MPa, and possesses good plasticity, toughness, and weldability. Q355 low-carbon steel conforms to GB / T... The national standard 1591-2018, "Low-alloy high-strength structural steel," has a tensile strength ranging from 470MPa to 630MPa. It can be flexibly selected according to the different stress requirements of the tower components. For example, Q355 low-carbon steel can be used for core load-bearing components such as the main material of the tower, while Q235 low-carbon steel can be used for non-core load-bearing components such as diagonal members and auxiliary materials. By replacing the traditional Q690 high-strength steel with this type of ordinary low-carbon steel, the cost of base material procurement can be reduced by 40-50%, thus achieving effective control of production costs from the source.

[0074] S12. Conduct incoming material inspection. Perform a comprehensive quality inspection on the purchased ordinary low-carbon steel. Inspection items include appearance quality, dimensional accuracy and mechanical properties. In terms of appearance, ensure that the surface of the plate is free of quality defects such as cracks, folds, delamination, oxide scale peeling, rust, and scratches. In terms of dimensions, control the thickness deviation of the plate within ±0.1mm, and the length and width deviations meet the design requirements. In terms of mechanical properties, ensure that the yield strength, tensile strength, elongation and other indicators meet the national standards of the corresponding steel through tensile tests, bending tests and other testing methods. Unqualified base materials are strictly prohibited from being put into production.

[0075] S13. Pre-treatment of the substrate: For qualified substrates, surface cleaning and leveling are performed. Surface cleaning is done by mechanical grinding to remove impurities such as rust, scale, and oil stains from the substrate surface. After grinding, compressed air is used to blow it clean to ensure the cleanliness of the substrate surface. Leveling is done by CNC leveling machine to accurately level the substrate, controlling the flatness error of the substrate to ≤0.1mm / m, so as to avoid the substrate deformation affecting the accuracy of subsequent processing. After pre-treatment, the substrates are sorted and stacked, and labeled for easy access in subsequent processes.

[0076] S2, digital layout, includes: replacing traditional manual layout with digital technology to achieve accurate definition of component dimensions and accurate generation of processing data, avoiding dimensional deviations and data errors caused by manual layout, and providing reliable data support for subsequent material cutting and processing procedures.

[0077] In a preferred embodiment, S2 includes:

[0078] S21. Build a three-dimensional model, including: based on the overall design drawings and technical requirements of the transmission line tower, use AutoCAD and SolidWorks joint design software to build the overall three-dimensional model of the tower and detailed three-dimensional models of each component, clarify the external dimensions, structural features, connection methods and stress requirements of each component, and ensure that the three-dimensional model is completely consistent with the actual production requirements.

[0079] S22. Component decomposition and parameter setting: The overall 3D model of the iron tower is decomposed into various specific components such as main materials, diagonal materials, and auxiliary materials. For each component, the dimensional loss of subsequent processes such as cutting, drilling, forming, welding, and galvanizing is taken into account, and the single-sided machining allowance is precisely set. The machining allowance is reasonably adjusted according to the component thickness and processing steps, and is usually set to 1.5-2mm. Among them, the single-sided machining allowance of components with a thickness <6mm is set to 1.5mm, and the single-sided machining allowance of components with a thickness ≥6mm is set to 2mm. At the same time, the key parameters such as the cutting boundary, drilling position, and welding node of the component are clearly defined.

[0080] S23, Generate processing data, including: digitally laying out each component after disassembly using design software, automatically generating accurate processing drawings of the components, cutting data that can be directly imported by CNC cutting equipment (including parameters such as cutting path, cutting speed, and torch height), and parameter reference files for each processing step. The processing drawings must clearly indicate dimensions, tolerances, processing requirements, and quality standards. The cutting data must be accurate and error-free and directly compatible with CNC cutting equipment.

[0081] S24. Data review and optimization are performed. The generated processing drawings, cutting data and parameter reference files are double-reviewed to check for problems such as dimensional deviations, data errors and reasonable process connections. Problems are optimized and adjusted in a timely manner to ensure the accuracy and reliability of digital layout data. After the review is passed, the processing data and drawings are archived and stored, and synchronously transmitted to the CNC equipment of the subsequent cutting process to ensure that the cutting process can be accurately connected.

[0082] S3, Precision Cutting, includes: based on digital layout data, using CNC cutting equipment, combined with an optimized layout scheme, to achieve high-precision cutting of the substrate, maximize material utilization, and reduce the generation of scrap.

[0083] In a preferred embodiment, S3 includes:

[0084] S31. Debugging the cutting equipment, including: selecting CNC cutting equipment suitable for ordinary low carbon steel, and choosing the appropriate cutting method according to the thickness and material of the component. Among them, CNC laser cutting machine is used for components with a thickness <8mm, and CNC plasma cutting machine is used for components with a thickness ≥8mm. Debugging the equipment includes calibrating key parameters such as cutting head positioning accuracy, cutting speed, laser power (laser cutting) and plasma current (plasma cutting) to ensure stable equipment operation and that the cutting accuracy meets the requirements.

[0085] S32, Optimize material cutting and layout, including: importing the cutting data generated by digital layout into the layout software, and systematically optimizing the cutting layout of multiple boards in combination with the size and specifications of the substrate. The nested layout method is adopted to minimize the cutting gap (the cutting gap is controlled within 0.2-0.3mm) and the reserved size of the corners. While ensuring the cutting operation space and cutting quality, the effective utilization rate of the boards is improved. After the layout optimization, a detailed layout drawing is generated, marking the placement position and cutting sequence of each component on the board to ensure that the layout plan is scientific and reasonable.

[0086] S33, perform precise cutting operations, including: placing the pre-treated qualified substrate flat on the worktable of the CNC cutting equipment, accurately positioning and fixing it to avoid displacement of the substrate during the cutting process, then importing the optimized cutting data into the equipment, starting the cutting program, monitoring the stability of the cutting parameters in real time during the cutting process, controlling the material cutting accuracy error to ≤±0.5mm, of which the laser cutting accuracy error is controlled within ±0.2mm and the plasma cutting accuracy error is controlled within ±0.3mm, while controlling the surface roughness Ra≤12.5μm to avoid defects such as cutting burrs, slanted cuts, and out-of-tolerance dimensions. After cutting, use special tools to remove the component from the plate and clean the burrs and oxide residue from the edges of the component.

[0087] S34 involves inspecting the quality of cut materials and recycling scrap, including: inspecting the dimensional accuracy of cut components using measuring tapes, calipers, projectors, and other testing tools to verify key dimensions such as length, width, and angles to ensure compliance with processing drawings; promptly reworking unqualified components; and classifying and collecting scrap generated during cutting. Recyclable scrap is sorted, labeled, and used for processing small auxiliary components, while non-recyclable scrap is centrally processed according to environmental protection requirements. After optimized layout and precise cutting, the comprehensive utilization rate of steel is increased to over 95%, significantly reducing resource waste.

[0088] S4 involves multi-stage precision processing, including sequential hole drilling, forming, and welding of the components after material cutting. Strict quality control points are set for each key process, and the processing quality is ensured through refined parameter control and process inspection.

[0089] In a preferred embodiment, S4 includes:

[0090] S41, Implement the hole-making process, including: using a high-precision CNC drilling machine (preferably a CNC gantry drilling machine) for hole-making. Based on the assembly requirements of the component, specify parameters such as hole diameter, hole spacing, and number of holes. Before hole-making, accurately position and fix the component on the drilling machine's worktable, calibrate the drill bit position and drilling machine accuracy, and select a drill bit matching the hole diameter. The drill bit material should be high-speed steel or cemented carbide to ensure it is sharp and wear-free. During hole-making, control the drill bit speed at 800-1200 r / min and the feed rate at 10-15 mm / min. Adjust the speed and feed rate according to the hole diameter. When the hole diameter is <20 mm, control the drill bit speed at 1000-1200 r / min. The feed rate is controlled at 12-15 mm / min. When the hole diameter is ≥20 mm, the drill bit speed is controlled at 800-1000 r / min, and the feed rate is controlled at 10-12 mm / min. At the same time, the hole diameter error is controlled to be ≤±0.05 mm, the hole center distance error is controlled to be ≤±0.1 mm, and the hole wall perpendicularity error is controlled to be ≤0.03 mm / m. After the hole is made, the hole opening is chamfered with a chamfering tool. The chamfering angle is 45° and the chamfering width is 1-2 mm to avoid burrs and sharp edges on the hole opening. Then, the hole position accuracy and hole diameter are inspected using plug gauges, calipers and other tools. Unqualified holes are reworked in time to ensure the accurate fit between the hole position and the tower connector.

[0091] S42, Implement the forming process. According to the shape requirements of the component, use a CNC bending machine or CNC press for forming. Before forming, adjust the forming mold and equipment parameters according to the forming angle, fillet radius and other parameters of the component to ensure that the mold matches the shape of the component. During the forming process, monitor the forming pressure, holding time and springback compensation parameters in real time. The bending pressure of the CNC bending machine is controlled at 100-300t, the holding time is controlled at 3-5s, and the springback compensation is adjusted according to the material and thickness of the component, usually 0.5-1°. The forming pressure of the CNC press is controlled at 80-250t, the holding time is controlled at 2-4s, the forming angle error is controlled within ±0.3°, and the component flatness error is controlled within 0.2mm / m to avoid defects such as bending angle deviation, local distortion, flatness exceeding the standard, and forming cracks. After forming, the forming accuracy of the component is inspected. Use tools such as angle ruler and flatness measuring instrument to check the forming angle, flatness and other indicators. Unqualified components are re-formed.

[0092] S43, Implement the welding process, including: using fully automated submerged arc welding for welding operations. Before welding, clean the welding area to remove surface oxide scale, rust, oil, and other impurities. The cleaning range is 20-30mm on each side of the welding area. After cleaning, blow it clean with compressed air. Select appropriate welding wire and flux according to the component material, thickness, and welding requirements. The welding wire is H08MnA or H10Mn2, and the flux is HJ431. During welding, strictly control the welding parameters: welding current is 300-500A, welding voltage is 28-36V, welding speed is 30-50cm / min, welding wire extension length is 20-30mm, flux particle size is 10-40 mesh, flux drying temperature is 200-250℃, and drying time is 2-3 hours. Adjust welding parameters according to component thickness. For thicknesses < 8mm, control welding current at 300-380A, welding voltage at 28-32V, and welding speed at 40-50cm / min. For thicknesses ≥ 8mm, control welding current at 380-500A, welding voltage at 32-36V, and welding speed at 30-40cm / min. During welding, ensure full weld formation, uniform penetration, and absence of defects such as incomplete penetration, porosity, slag inclusions, and cracks. Immediately after welding, cool to room temperature using natural cooling or forced air cooling. After cooling, perform 100% non-destructive testing on the weld using ultrasonic or radiographic testing. Ultrasonic testing is used to detect internal weld defects, while radiographic testing is used to inspect the internal quality of critical load-bearing welds. The testing standards comply with GB / T. Standards 11345-2013 "Manual Ultrasonic Testing Methods and Acceptance Grades for Welds" and GB / T 3323-2005 "Radiographic Examination of Metal Fusion Welded Joints" ensure that the weld strength is not less than 1.1 times the strength of the base metal. Unqualified welds should be repaired or re-welded in a timely manner, and non-destructive testing should be carried out again after repair until they are qualified.

[0093] S5 employs environmentally friendly galvanizing for corrosion protection, thereby achieving green corrosion protection and improving the corrosion resistance and durability of components. This includes abandoning the traditional high-pollution spraying process and adopting an environmentally friendly hot-dip galvanizing process, which involves a series of continuous processes such as degreasing, pickling, fluxing, drying and preheating, hot-dip galvanizing, and cooling and passivation. The parameters of each process are strictly controlled to ensure the quality of the zinc layer and the corrosion protection effect. At the same time, it is equipped with environmentally friendly treatment equipment to achieve clean production.

[0094] In a preferred embodiment, S5 includes:

[0095] S51. Degreasing treatment is performed, including: using an environmentally friendly water-based metal degreasing cleaning agent. This cleaning agent is free of phosphorus and heavy metals, and has good degreasing effect and environmental performance. The temperature of the degreasing tank is stably controlled at 50-60℃. The degreasing time is adjusted according to the oil content on the surface of the component. The degreasing time is 10-12 minutes for components with less oil and 12-15 minutes for components with more oil. The component is completely immersed in the degreasing solution. Through the penetration, dispersion and saponification of the cleaning agent, the residual cutting fluid, lubricating oil, dust, oil and other impurities on the surface of the component are thoroughly removed. During the degreasing process, the degreasing solution is stirred regularly to ensure uniform degreasing. After degreasing, the component is taken out of the degreasing solution and rinsed with clean water 2-3 times to remove the residual degreasing solution on the surface, ensuring that the surface of the component is completely wetted with water and there is no continuous oil film residue. The wastewater after degreasing is treated by the sewage treatment equipment to meet the standards before being discharged.

[0096] S52, pickling and rust removal are performed, including: using an industrial hydrochloric acid solution with a mass concentration of 18-22% as the pickling medium; adding 1-3 g / L of hexamethylenetetramine as a corrosion inhibitor to the pickling solution. The corrosion inhibitor can effectively inhibit the over-corrosion and hydrogen embrittlement of the steel substrate during pickling, protecting the surface quality of the steel; controlling the pickling environment temperature to 25-35℃; and adjusting the pickling time according to the oxide scale and rust content on the component surface. For components with less oxide scale, the pickling time is 8-10 minutes, and for components with more oxide scale, the pickling time is... The pickling time is 10-12 minutes. The component is completely immersed in the pickling solution until the oxide scale, rust and oxide film on the surface of the component are completely removed, exposing a uniform silver-white metal substrate. During the pickling process, the component is turned over regularly to ensure uniform pickling. After pickling, a multi-stage countercurrent rinsing process is adopted. The component is placed into 3-4 stages of clean water tanks for rinsing in sequence. Each stage of rinsing time is 3-5 minutes to thoroughly remove the residual acid on the surface and avoid the acid residue affecting the subsequent zinc layer adhesion. The waste acid after pickling is neutralized and discharged after meeting the standards.

[0097] S53, Immersion flux, comprising: an aqueous flux solution prepared by mixing 18-22% ammonium chloride and 2.8-3.2% zinc chloride by mass. The flux solution needs to be stirred evenly in advance to remove impurities. The solution temperature is controlled at 58-62℃. The component is completely immersed in the flux solution for 6-8 minutes to allow the flux to adhere evenly to the surface of the component and form a uniform activation layer on the substrate surface. This activation layer can effectively enhance the wettability and adhesion between the zinc liquid and the steel substrate during the subsequent hot-dip galvanizing process, preventing problems such as missed plating, incomplete plating, and zinc layer peeling. After immersion in the flux, the component is removed and excess flux solution is drained from the surface to avoid excessive flux residue affecting the subsequent drying effect.

[0098] S54. Preheating and drying are performed, including: sending the components after being dipped in flux into a hot air circulating drying oven, controlling the oven temperature at 140-160℃, and drying for 15-20 minutes. The drying time is adjusted according to the thickness of the components. The drying time for components with a thickness of <8mm is 15-17 minutes, and the drying time for components with a thickness of ≥8mm is 17-20 minutes. During the drying process, it is ensured that the temperature inside the oven is uniform and that residual moisture on the surface and in the internal micropores of the components is completely removed. This avoids defects such as splashing and blistering of the zinc layer when the moisture comes into contact with the high-temperature zinc liquid during hot-dip galvanizing, and also prevents hydrogen embrittlement. After the components are dried and qualified, they are quickly sent into the hot-dip galvanizing pot to prevent the surface of the components from oxidizing after cooling, which would affect the adhesion of the zinc layer.

[0099] S55 undergoes hot-dip galvanizing, including: using a large, fully automatic hot-dip galvanizing pot made of high-temperature resistant stainless steel; precisely and stably controlling the temperature of the pure zinc liquid inside the pot at 445-455℃; adding high-purity aluminum wire to the zinc liquid to maintain the aluminum content at 0.18-0.22% by mass. Aluminum optimizes the crystal morphology of the zinc layer, improving its toughness, wear resistance, and adhesion. The immersion time is controlled according to the component thickness: 1.5-2 minutes for components <5mm, 2.5-3 minutes for components 5-12mm, and 3.5-4 minutes for components >12mm. The components are completely submerged in the zinc liquid, and are periodically turned during the immersion process to ensure the zinc liquid evenly coats the surface and edges. To avoid problems such as incomplete plating and uneven zinc layer thickness, after hot-dip galvanizing, the components are smoothly lifted from the zinc liquid at a uniform speed of 1.2-1.5 m / min. Lifting too fast can easily cause the zinc layer to fall off or drip, while lifting too slow can easily cause the zinc layer to be too thick and waste zinc liquid. During the lifting process, a high-pressure nitrogen wiping device is used to uniformly blow away excess zinc liquid from the surface of the components, controlling the zinc layer thickness to be uniform. The average zinc layer thickness of components with a thickness > 4 mm is ≥ 86 μm, and the average zinc layer thickness of components with a thickness ≤ 4 mm is ≥ 65 μm. The zinc fumes, hydrogen chloride and other waste gases generated during hot-dip galvanizing are collected centrally through a micro negative pressure exhaust system, purified by waste gas treatment equipment and then discharged. The generated zinc slag is cleaned regularly, recycled and reused, achieving environmentally friendly and clean production.

[0100] S56. Cooling and passivation are performed, including: immediately after galvanizing, the components enter a forced air cooling process, using forced convection cooling, controlling the cooling rate at 5-8℃ / s, and rapidly and uniformly cooling to below 50℃. Too rapid a cooling rate can easily cause the zinc layer to crack and peel off, while too slow a cooling rate can easily cause the zinc layer to coarsen and reduce gloss. During the cooling process, components should be prevented from colliding with each other to avoid damage to the zinc layer. After cooling to the specified temperature, an environmentally friendly chromium-free passivation process is used. The passivating agent is a chromium-free passivation solution, free of heavy metals, environmentally friendly and pollution-free. The components are completely immersed in the passivation solution for 2-3 minutes, controlling the passivation film thickness to 0.6-0.8μm. The passivation film effectively improves the zinc layer's resistance to fingerprints, acids and alkalis, and atmospheric corrosion, extending the outdoor service life of the components. After passivation, the components are removed and air-dried or dried with hot air to remove residual passivation solution from the surface, ensuring a uniform and intact passivation film.

[0101] S6. Conduct finished product inspection and warehousing, including: conducting a comprehensive inspection of components that have completed all processing and anti-corrosion treatments, and marking, classifying and warehousing them after they pass the inspection.

[0102] In a preferred embodiment, S6 includes:

[0103] S61, conduct inspection preparation, including: developing detailed finished product inspection standards, clarifying inspection items, inspection methods, and acceptance criteria, and preparing relevant testing tools, including tape measure, caliper, projector, zinc layer thickness gauge, adhesion tester, appearance inspection tools, etc., and ensuring that the testing tools are calibrated and meet the accuracy standards;

[0104] S62, Perform itemized inspections, including:

[0105] (1) Dimensional accuracy inspection: The key dimensions of the component, such as length, width, angle, hole diameter, and hole spacing, are fully inspected. The corresponding inspection tools are used to check each dimension to ensure that the dimensional error meets the design requirements and processing standards. Among them, the length and width error is ≤ ±0.5mm, the angle error is ≤ ±0.3°, the hole diameter error is ≤ ±0.05mm, and the hole spacing error is ≤ ±0.1mm.

[0106] (2) Visual inspection of the appearance quality: visually inspect the surface of the components to ensure that there are no defects such as cracks, deformation, burrs, sharp edges, missing plating, poor plating, zinc layer peeling, peeling, bubbles, or drips. The zinc layer surface is flat and smooth with uniform color. The weld seam of the welded parts is full and without defects. The passivation film is uniform and complete, without exposed base or yellowing.

[0107] (3) Zinc layer quality inspection: The zinc layer thickness is measured by a zinc layer thickness gauge to ensure that the zinc layer thickness meets the specified requirements. The zinc layer adhesion is tested by the cross-cut test method. After the cross-cut test, there is no peeling or flaking of the zinc layer. The adhesion reaches the Class 1 standard in GB / T 5270-2019 "Rating of specimens and test pieces of metal and other inorganic coatings on metal substrates after corrosion test".

[0108] (4) Mechanical performance sampling inspection: a certain proportion of components are randomly selected for tensile test, bending test and weld strength test to ensure that the mechanical properties and weld strength of the components meet the national standards and usage requirements;

[0109] S63, non-conforming handling includes: marking and isolating non-conforming components found during inspection, analyzing the reasons for non-conformity, reworking components for issues such as dimensional deviations and processing defects, re-galvanizing components for issues such as substandard zinc coating quality and inadequate anti-corrosion effect, conducting a comprehensive inspection again after rework and reprocessing until they pass, and scrapping components that cannot be reworked or still fail after rework, strictly prohibiting them from entering the market;

[0110] S64, Identification and Warehousing, includes: For inspected and qualified components, use laser marking to create a unique identification code. The identification content includes the component name, specifications, production batch, production date, and inspection certificate, which facilitates subsequent traceability and management. After identification, the components are classified and stacked, and stored in separate areas according to component type and specifications. The storage environment must be dry, ventilated, and moisture-proof to prevent the components from getting damp and rusting. At the same time, storage records should be kept to ensure that the warehoused components are traceable, thus completing the entire implementation process of the integrated process.

[0111] Example 1: This example implements a green processing and galvanized anti-corrosion integrated process for angle steel components, which are the main materials of transmission line towers. The processed components are the main load-bearing angle steel of the transmission line tower, which is mainly used for the main support structure of the tower. It bears a large amount of wind load, icing load and its own weight, and has high requirements for structural strength, processing accuracy and anti-corrosion performance.

[0112] This embodiment is implemented strictly according to the six core steps of the detailed breakdown of the present invention. The specific process is as follows:

[0113] The first step is the selection and pretreatment of the base material. A 10mm thick Q235 ordinary low-carbon steel plate is selected as the processing base material. This base material has a yield strength of 235MPa and a tensile strength between 370MPa and 500MPa. The surface is free of quality defects such as cracks, folds, delamination, and oxide scale peeling, fully meeting the requirements of the national standard GB / T 700-2006 "Carbon Structural Steel". By using this type of ordinary low-carbon steel to replace the Q690 high-strength steel used in the traditional process, the base material procurement cost is reduced by 45%, achieving a significant cost reduction from the raw material procurement stage and laying the foundation for subsequent overall production cost control. After the base material arrives on site, professional inspection personnel conduct a comprehensive quality inspection. Visual inspection and tactile inspection are combined to ensure that the plate surface is free of obvious defects. Dimensional inspection uses measuring tapes and calipers, controlling the plate thickness deviation within ±0.1mm, and ensuring that the length and width meet the procurement requirements. Mechanical property testing uses tensile and bending tests, with three samples randomly selected for testing. In the tensile test, the tensile strength of the sample reached 420 MPa, the yield strength reached 235 MPa, and the elongation reached 28%. In the bending test, the sample showed no cracks or fractures, all meeting the mechanical property standards of Q235 low carbon steel. After passing the inspection, the substrate was pretreated by using a mechanical grinder to remove surface rust, oxide scale, and oil. After grinding, it was cleaned with compressed air to ensure surface cleanliness. Subsequently, a CNC leveling machine was used to level the substrate, controlling the flatness error of the substrate to 0.12 mm / m. After the pretreatment, the substrate was sorted and stacked, and labeled with information such as material, thickness, and specifications for easy retrieval in subsequent processes.

[0114] The second step is digital layout. Based on the overall 3D design model of the transmission line tower, high-precision digital layout is performed using AutoCAD and SolidWorks co-design software. First, the overall 3D model of the tower is built to clarify the installation position, connection method, and stress requirements of the main angle steel components in the tower. Then, the overall tower model is disassembled into individual main angle steel components. For the main angle steel components in this embodiment, considering the dimensional losses of subsequent cutting, drilling, forming, welding, and galvanizing processes, a single-sided machining allowance of 2mm is set. The overall length of the main angle steel component is accurately determined to be 6000mm, the flange width to be 500mm, the inner corner radius to be bent to be 8mm, and the angle steel cross-section dimensions to be 500mm×500mm×10mm. The design software automatically generates precise machining parameters for the components. The machining drawings are clearly marked with dimensions, tolerances, machining requirements, and quality standards. Simultaneously, cutting data that can be directly imported into the CNC plasma cutting equipment is generated, including parameters such as cutting path, cutting speed, and torch height. The cutting speed is set to 30cm / min, and the torch height is set to 8mm. Furthermore, parameter benchmark files for each process, such as hole making, forming, and welding, are generated, clearly defining the machining parameters and quality control points for each process. After data generation, two professional technicians conduct a double review, checking for dimensional deviations in the machining drawings, the accuracy of the cutting data, and the rationality of process connections. If one error in the hole spacing is found, it is promptly optimized and adjusted. The approved machining data and drawings are archived and stored, and simultaneously transmitted to the CNC plasma cutting equipment in the blanking process to ensure precise alignment.

[0115] The third step is precise material cutting. In this embodiment, the component thickness is 10mm, and a CNC plasma cutting machine is selected for material cutting. First, the CNC plasma cutting machine is debugged, and the positioning accuracy of the cutting head is calibrated to ensure that the positioning error is ≤±0.05mm. The plasma current is adjusted to 180A, the cutting voltage to 120V, the cutting speed to 30cm / min, and the torch height to 8mm. After debugging, the equipment runs stably, and the cutting accuracy meets the requirements. Then, the cutting data generated by digital layout is imported into the layout software, combined with the dimensions of the Q235 low carbon steel plate. Specifications (1500mm × 6000mm): A nested layout method is used to systematically optimize the cutting layout of multiple plates, reducing the cutting gap to 0.25mm and maximizing the effective utilization rate of the plates. After layout optimization, detailed layout drawings are generated, marking the placement and cutting sequence of each main material angle steel component on the plate, ensuring a scientific and reasonable layout scheme. Calculations show that under this layout scheme, the comprehensive material utilization rate of 10mm thick Q235 low carbon steel plate can reach 96.2%. Then, the pre-treated substrate is placed flat on the CNC plasma cutting machine. On the workbench, a special fixture is used for precise positioning and fixation to prevent displacement of the substrate during cutting. Then, the optimized cutting data is imported into the equipment, and the cutting program is started. During the cutting process, operators monitor the stability of the cutting parameters in real time, adjusting any abnormal parameters promptly to ensure that the cutting accuracy error is stably controlled within ±0.3mm, the surface roughness Ra≤12.5μm, and there are no defects such as cutting burrs, skewed cuts, or dimensional deviations. After cutting, a special tool is used to remove the component from the sheet metal, and a grinder is used to clean the burrs and oxide residue from the edges of the component. Finally, the dimensional accuracy of the cut component is inspected using measuring tapes, calipers, and projectors to verify key dimensions such as the length, width, and angle of the component. In this embodiment, the component length error is ±0.3mm, the width error is ±0.2mm, and the angle error is ±0.15°, all conforming to the processing drawings. Defective components are promptly reworked. Meanwhile, the scrap generated from cutting is collected and classified. Recyclable scrap is processed for small auxiliary components, while non-recyclable scrap is centrally processed according to environmental protection requirements.

[0116] The fourth step involves multi-stage precision machining. The first step is hole making, performed using a CNC gantry drilling machine. Based on the tower assembly and connection requirements, standard 24mm diameter connection holes are machined on the angle steel flange. A total of 30 connection holes are machined per component, with a hole spacing of 200mm. Before drilling, the component is precisely positioned and fixed on the drilling machine's worktable. The drill bit position and drilling machine accuracy are calibrated. A 24mm diameter carbide drill bit is selected, ensuring it is sharp and wear-free. During hole making, the drill bit speed is controlled at 900 rpm, the feed rate at 11mm / min, and the hole diameter error is controlled to ±0.04mm, the hole center distance error to ±0.08mm, and the hole wall verticality. The accuracy error is 0.02mm / m. After hole making, a chamfering tool is used to chamfer the hole opening. The chamfer angle is 45° and the chamfer width is 1.5mm to avoid burrs and sharp edges on the hole opening. Then, plug gauges, calipers and other tools are used to check the hole position accuracy and hole diameter. All holes meet the requirements and there are no unqualified holes. After hole making, the forming process begins. A large CNC bending machine is used to bend the plate at 90°. Before forming, the forming mold and equipment parameters are adjusted according to the forming angle and fillet radius of the component. A bending mold matching the angle steel section is selected, and the bending pressure is adjusted to 220t, the holding time is 4s, and the springback compensation is 0.8°. During the forming process, the actual... The forming pressure, holding time, and springback compensation parameters are monitored in real time to ensure that the forming angle error is controlled within ±0.2° and the overall flatness error of the component is controlled within 0.15mm / m, avoiding forming defects such as bending angle deviation, local twisting, and excessive flatness. After forming, the forming accuracy of the component is inspected using tools such as an angle gauge and a flatness measuring instrument. The forming angle is 90°±0.2° and the flatness error is 0.15mm / m, which meets the design requirements. After the forming is qualified, the welding process begins. The splicing parts of the angle steel components are welded using a fully automatic submerged arc welding process. Before welding, the welding parts are cleaned to remove surface impurities such as oxide scale, rust, and oil. The cleaning area was 25mm on both sides of the welding area. After cleaning, it was blown clean with compressed air. H08MnA welding wire and HJ431 flux were selected. The welding wire diameter was 4mm and the flux particle size was 10-40 mesh. The flux was dried at 220℃ for 2.5h in advance. During welding, the welding current was controlled at 400A, the welding voltage at 32V, the welding speed at 40cm / min, and the welding wire extension length at 25mm to ensure that the weld was full, the penetration depth was uniform, and there were no defects such as incomplete penetration, porosity, slag inclusions, or cracks. After welding, the weld was immediately cooled to room temperature by forced air cooling. After cooling, all welds were subjected to 100% non-destructive testing using ultrasonic flaw detection equipment. The testing standard complied with GB / T 11345-2013 "Manual Ultrasonic Testing Method and Acceptance Grade of Welds". The test results showed that the weld had no internal defects and the overall mechanical strength of the weld reached 1 / 3 of the base metal strength.15 times, fully meeting the structural stress requirements of the main materials of the iron tower.

[0117] The fifth step is environmentally friendly galvanizing and corrosion protection. First, degreasing is performed using an environmentally friendly water-based metal degreasing agent. This agent is phosphorus-free and heavy metal-free. The temperature of the degreasing tank is stably controlled at 55℃. In this embodiment, the component surface has relatively little oil, so the degreasing time is set to 12 minutes. The component is completely immersed in the degreasing solution. During the degreasing process, the solution is stirred every 3 minutes to ensure uniform degreasing. After degreasing, the component is removed from the degreasing solution and rinsed three times with clean water for 4 minutes each time to remove any residual degreasing solution, ensuring the component surface is completely wetted with water and there is no continuous oil film residue. The wastewater after degreasing is treated by wastewater treatment equipment to meet standards before being discharged. Then, the component proceeds to pickling and rust removal. In this process, a 20% industrial hydrochloric acid solution is used as the pickling medium. 2 g / L of hexamethylenetetramine is added to the pickling solution as a corrosion inhibitor. The pickling temperature is controlled at 30°C. In this embodiment, the component surface has relatively little oxide scale, so the pickling time is set to 10 minutes. The component is completely immersed in the pickling solution, and is turned over every 2 minutes during the pickling process to ensure uniform pickling until the oxide scale, rust, and oxide film on the component surface are completely removed, exposing a uniform silver-white metal substrate. After pickling, a four-stage countercurrent rinsing process is used, in which the component is sequentially placed in four stages of clean water tanks for rinsing, with each stage lasting 4 minutes, to thoroughly remove residual acid from the surface. The waste acid solution after pickling is then... After neutralization treatment to meet standards, the components are discharged. Then, the component enters the fluxing process, using an aqueous fluxing solution prepared with 20% ammonium chloride and 3% zinc chloride by mass. The solution is pre-stirred to remove impurities, and the temperature is controlled at 60°C. The component is completely immersed in the fluxing solution for 7 minutes, allowing the flux to adhere evenly to the component surface and form a uniform activation layer. After fluxing, the component is removed and excess fluxing solution is drained. Next, preheating and drying are performed. The flux-treated component is sent to a hot air circulating drying oven, with the oven temperature controlled at 150°C. In this embodiment, the component thickness is 10mm, and the drying time is set to 18 minutes. During the drying process, the oven temperature is kept within a safe range. The internal temperature is uniform, and residual moisture in the component surface and internal micropores is completely removed. After drying, the component is quickly sent into the hot-dip galvanizing pot to prevent surface oxidation after cooling. Then, the core hot-dip galvanizing process begins. A large, fully automatic hot-dip galvanizing pot is used, and the temperature of the pure zinc liquid inside is precisely and stably controlled at 450℃. High-purity aluminum wire is added to the zinc liquid to stabilize the aluminum content at 0.2%. In this embodiment, the component thickness is 10mm, falling within the 5-12mm range. The immersion time is set to 3 minutes, completely immersing the component in the zinc liquid. During the immersion process, the component is turned over every minute to ensure that the zinc liquid evenly coats the surface and edges. After immersion, the component is then...The component is smoothly lifted from the molten zinc at a uniform speed of 3 m / min. Simultaneously, a high-pressure nitrogen wiping device evenly blows the surface of the component to remove excess zinc, ensuring a uniform zinc layer thickness. The final average zinc layer thickness on the component surface reaches 92 μm, meeting the requirements for long-term outdoor corrosion resistance. Zinc fumes and hydrogen chloride generated during hot-dip galvanizing are collected centrally through a micro-negative pressure ventilation system, purified by waste gas treatment equipment, and then discharged. Zinc dross is periodically cleaned and recycled. Finally, cooling and passivation are performed, and the galvanized component immediately enters a forced-air... The air cooling process employs forced convection cooling at a controlled rate of 6℃ / s, rapidly and uniformly cooling the components to below 45℃. During cooling, collisions between components are avoided to prevent damage to the zinc layer. After cooling to 45℃, an environmentally friendly chromium-free passivation process is used. A chromium-free passivation solution is selected, and the components are completely immersed in the solution for 2.5 minutes, controlling the passivation film thickness to 0.7μm. After passivation, the components are removed and dried with hot air to remove any residual passivation solution, ensuring a uniform and intact passivation film.

[0118] Step 6: Finished Product Inspection and Warehousing. First, develop detailed finished product inspection standards, clearly defining inspection items, methods, and pass / fail criteria. Prepare testing tools such as tape measures, calipers, projectors, zinc coating thickness gauges, and adhesion testers, ensuring these tools are calibrated and accurate. Then, conduct itemized inspections. For dimensional accuracy inspection, use a tape measure to check component length at 6000mm ± 0.4mm, calipers to check width at 500mm ± 0.3mm, and an angle gauge to check forming angles at 90° ± 0.2°. Use a projector to check the aperture... The diameter is 24mm ± 0.04mm, and the hole spacing is 200mm ± 0.08mm. All dimensional indicators meet the design standards. During the appearance quality inspection, the surface of the component was visually inspected and found to be free of defects such as cracks, deformation, burrs, sharp edges, incomplete plating, poor plating, zinc layer peeling, flaking, bubbles, and runs. The zinc layer surface was smooth and even in color. The weld seams at the welded parts were full and defect-free, and the passivation film was uniform and complete, without any exposed substrate or yellowing. During the zinc layer quality inspection, a zinc layer thickness gauge was used to measure the zinc layer thickness, with an average thickness of 92μm, which meets the requirements. To meet the requirement of ≥86μm, the zinc coating adhesion was tested using the cross-cut test method. After the cross-cut test, no peeling or flaking of the zinc coating was observed, indicating adhesion reaching Level 1 standard. In the mechanical property sampling inspection, two components were randomly selected for tensile and weld strength tests. The tensile strength of the component reached 425MPa, and the weld strength reached 480MPa, 1.15 times the strength of the base material, both meeting national standards and usage requirements. All inspection items were qualified, with no unqualified components. Finally, the qualified components were laser-cut. The components are uniquely identified using a coding method. The identification content includes the component name (main material angle steel), specifications (500mm×500mm×10mm), production batch (20260101), production date (January 1, 2026), and inspection certificate. After identification, the components are classified and stacked, and stored in separate areas according to specifications. The storage environment is dry, ventilated, and moisture-proof. Storage records are kept to ensure traceability of the components entering the warehouse, thus completing the implementation of the green processing and galvanized anti-corrosion integrated process for the main material angle steel components in this embodiment.

[0119] Example 2: This example implements a green processing and galvanized anti-corrosion integrated process for diagonal connection plates of transmission line towers. The processed components are auxiliary components for diagonal connections of transmission line towers, mainly used for the connection between the tower diagonal members and the main members, and between diagonal members. The stress requirements are slightly lower than those of the main members, but the requirements for processing accuracy and assembly compatibility are higher.

[0120] This embodiment is also strictly implemented according to the six core steps of the detailed breakdown of the present invention. The specific process is as follows:

[0121] The first step is the selection and pretreatment of the base material. A 6mm thick Q355 ordinary low-carbon steel plate is selected as the processing base material. This base material has a yield strength of 355MPa and a tensile strength between 470MPa and 630MPa, possessing good plasticity, toughness, and weldability. It fully complies with the requirements of the national standard GB / T 1591-2018 "Low Alloy High-Strength Structural Steel". Selecting this type of low-carbon steel effectively avoids the high cost associated with traditional Q690 high-strength steel. Calculations show that the base material procurement cost is reduced by 42%, while still meeting the mechanical performance requirements of the tower's inclined structural members. After the base material arrives on site, a comprehensive quality inspection is conducted. Visual inspection combines visual and tactile methods to ensure the plate surface is free of defects such as cracks, folds, delamination, and oxide scale peeling. Dimensional inspection uses measuring tapes and calipers, controlling the plate thickness deviation within ±0.1mm, and ensuring the length and width meet procurement requirements. Mechanical performance testing involves tensile and bending tests, with three plates randomly selected for testing. The samples were tested. In the tensile test, the tensile strength of the samples reached 500 MPa, the yield strength reached 355 MPa, and the elongation reached 25%. In the bending test, the samples showed no cracks or fractures, all of which met the mechanical property standards of Q355 low carbon steel. After passing the inspection, the substrate was pretreated. The surface of the plate was polished with a mechanical grinder to remove surface rust, oxide scale, and oil stains. After polishing, it was cleaned with compressed air. Then, the substrate was leveled with a CNC leveling machine to control the flatness error of the substrate to 0.10 mm / m. After the pretreatment, the substrate was sorted and stacked, and labeled with information such as material, thickness, and specifications for easy retrieval in subsequent processes.

[0122] The second step is digital layout. Based on the overall 3D design model of the transmission line tower, digital layout is performed using steel structure detailing software in conjunction with SolidWorks. First, the overall 3D model of the tower is built to clarify the installation position, connection method, and stress requirements of the diagonal connecting plate components in the tower. Then, the overall tower model is disassembled into individual diagonal connecting plate components. For the diagonal connecting plate components in this embodiment, considering the dimensional losses of subsequent cutting, hole making, forming, welding, and galvanizing processes, a single-sided machining allowance of 1.5mm is set, accurately determining the overall length of the diagonal connecting plate component to be 4500mm, the width to be 300mm, the forming angle of the connection part to be 135°, and the plate thickness to be 6mm. The design software automatically generates the structure... The system generates precise machining drawings for the parts, clearly indicating dimensions, tolerances, machining requirements, and quality standards. Simultaneously, it generates cutting data that can be directly imported into the CNC laser cutting equipment, including parameters such as cutting path, cutting speed, and laser power. The cutting speed is set to 40cm / min, and the laser power to 3000W. Furthermore, it generates parameter reference files for each process, such as hole making, forming, and welding, clearly defining the machining parameters and quality control points for each process. After data generation, two professional technicians conduct a double review, checking the dimensional deviations of the machining drawings, the accuracy of the cutting data, and the rationality of process connections. If no abnormalities are found, the approved machining data and drawings are archived and stored, and simultaneously transmitted to the CNC laser cutting machine in the material cutting process.

[0123] The third step is precise material cutting. In this embodiment, the component thickness is 6mm, and a CNC laser cutting machine is used for material cutting. First, the CNC laser cutting machine is debugged, and the positioning accuracy of the cutting head is calibrated to ensure that the positioning error is ≤±0.03mm. The laser power is adjusted to 3000W, the cutting speed to 40cm / min, the focal position to 0mm, and the auxiliary gas pressure to 0.5MPa. After debugging, the equipment runs stably, and the cutting accuracy meets the requirements. Then, the cutting data generated by digital layout is imported into the typesetting software, combined with Q355 low carbon fiber... The steel plate dimensions (1200mm × 4500mm) are used to refine the cutting layout of multiple plates using a nested layout method, reducing the cutting gap to 0.2mm to maximize the effective utilization rate of the plates. After layout optimization, detailed layout drawings are generated, indicating the placement position and cutting sequence of each diagonal connecting plate component on the plate. Calculations show that the comprehensive material utilization rate of 6mm thick Q355 low carbon steel plate under this layout scheme can reach 97.1%. Then, the pre-treated substrate is placed flat on the worktable of the CNC laser cutting machine. Specialized clamps are used for precise positioning and fixation to prevent displacement of the substrate during cutting. Optimized cutting data is then imported into the equipment, and the cutting program is started. During cutting, operators monitor the stability of cutting parameters in real time, adjusting any abnormal parameters promptly to ensure that the cutting accuracy error is stably controlled within ±0.2mm, the surface roughness Ra≤10μm, and there are no defects such as burrs, tilted cuts, or dimensional deviations. After cutting, specialized tools are used to remove the component from the sheet metal, and a grinder is used to clean the burrs and oxide residue from the component edges. Finally, the dimensional accuracy of the cut components is inspected using measuring tapes, calipers, and projectors to verify key dimensions such as length, width, and angle. In this embodiment, the component length error is ±0.2mm, the width error is ±0.1mm, and the angle error is ±0.1°, all conforming to the processing drawings. Defective components are promptly reworked. Meanwhile, the scrap generated during cutting is collected and categorized. Recyclable scrap is processed for small auxiliary components, while non-recyclable scrap is centrally processed according to environmental protection requirements.

[0124] The fourth step involves multi-stage precision machining. The first step is hole making, performed using a high-precision CNC drilling machine. Based on the tower assembly and connection requirements, standard 18mm diameter connecting holes are machined on the connecting plate. A total of 25 connecting holes are machined per component, with a hole spacing of 150mm. Before drilling, the component is precisely positioned and fixed on the drilling machine's worktable, and the drill bit position and drilling machine accuracy are calibrated. A 18mm diameter high-speed steel drill bit is selected to ensure it is sharp and wear-free. During hole making, the drill bit speed is controlled at 1100 rpm, the feed rate at 13mm / min, and the hole diameter error is controlled to ±0.03mm, the hole center distance error to ±0.06mm, and the hole wall verticality is maintained. The accuracy error is 0.01mm / m. After drilling, a chamfering tool is used to chamfer the hole opening. The chamfer angle is 45° and the chamfer width is 1mm to avoid burrs and sharp edges. Then, plug gauges and calipers are used to check the hole position accuracy and hole diameter. All holes meet the requirements and there are no unqualified holes. After drilling, the forming process begins. A large CNC press is used to perform a 135° bending forming operation on the component. Before forming, the forming mold and equipment parameters are adjusted according to the forming angle and structural characteristics of the component. A bending mold that matches the forming angle of the connecting plate is selected, and the forming pressure is adjusted to 180t, the holding time is 3s, and the springback compensation is 0.6°. During the process, the forming pressure, holding time, and springback compensation parameters are monitored in real time to ensure that the forming angle error is controlled within ±0.25° and the overall flatness error of the component is controlled within 0.12mm / m, guaranteeing the forming accuracy and assembly compatibility of the component. After forming, the forming accuracy of the component is inspected using tools such as an angle gauge and a flatness measuring instrument. The forming angle is 135°±0.25° and the flatness error is 0.12mm / m, which meets the design requirements. After forming, the welding process begins. Fully automated submerged arc welding is used for welding the splicing and reinforcing parts of the component. Before welding, the welding parts are cleaned to remove surface oxide scale, rust, oil, and other impurities. The welding area extends 20mm on both sides of the welded area. After cleaning, it is blew clean with compressed air. H10Mn2 welding wire and HJ431 flux are used. The welding wire diameter is 3.2mm, and the flux particle size is 10-40 mesh. The flux is dried at 200℃ for 2 hours in advance. During welding, the welding current is controlled at 350A, the welding voltage at 30V, the welding speed at 35cm / min, and the welding wire extension length at 22mm to ensure that the weld is full, the penetration depth is uniform, and there are no defects such as incomplete penetration, porosity, slag inclusion, or cracks. After welding, the weld is immediately cooled to room temperature by natural cooling. After cooling, 100% non-destructive testing of the key stress weld is carried out using X-ray flaw detection equipment. The testing standard complies with GB / T 3323-2005 "Radiographic Examination of Metal Fusion Welded Joints". The test results show that there are no internal welding defects, and the mechanical strength of the weld reaches 1.12 times the strength of the base material, which meets the requirements for use in the inclined members of the iron tower.

[0125] The fifth step is environmentally friendly galvanizing and corrosion protection. First, degreasing is performed using an environmentally friendly water-based metal degreasing agent. The temperature of the degreasing tank is stably controlled at 58℃. In this embodiment, the component surface has relatively little oil, so the degreasing time is set to 10 minutes. The component is completely immersed in the degreasing solution, and the solution is stirred every 2.5 minutes during the degreasing process to ensure uniform degreasing and thoroughly remove residual cutting fluid, lubricating oil, dust, oil, and other impurities from the component surface. After degreasing, the component is removed from the degreasing solution and rinsed twice with clean water for 5 minutes each time to remove any remaining degreasing solution and ensure the component surface is completely wetted with water without any continuous oil film residue. The wastewater after degreasing is treated by wastewater treatment equipment (using coagulation sedimentation + filtration process) to ensure that indicators such as COD, BOD, and suspended solids meet the "Integrated Wastewater Discharge Standard" (GB). After meeting the Class I standard (8978-1996), the steel is discharged; subsequently, it enters the pickling and rust removal process, using a 19% industrial hydrochloric acid solution as the pickling medium. 1.5 g / L of hexamethylenetetramine is added to the pickling solution as a corrosion inhibitor to effectively suppress over-corrosion and hydrogen embrittlement of the steel substrate during pickling, protecting the surface quality of the steel. The pickling environment temperature is controlled at 32℃. In this embodiment, the component surface has relatively little oxide scale, so the pickling time is set to 9 minutes. The component is completely immersed in the pickling solution, and is turned over every 1.5 minutes during the pickling process to ensure uniform pickling until the oxide scale, rust, and oxide film on the component surface are completely removed, exposing a uniform silvery-white metal substrate. After pickling, the steel is further treated using… The three-stage countercurrent rinsing process involves sequentially rinsing components in three stages of clean water tanks, with each stage lasting 5 minutes. This thoroughly removes residual acid from the surface, preventing acid residue from affecting the adhesion of the subsequent zinc layer. The waste acid after rinsing is neutralized with lime to adjust the pH value to 6.5-7.5, ensuring compliance before discharge. Simultaneously, the waste residue generated from neutralization is collected and handed over to a professional environmental protection agency for treatment. Next, the component enters the fluxing process, using an aqueous fluxing solution prepared by mixing 19% ammonium chloride and 3.0% zinc chloride. The solution is stirred evenly beforehand and impurities are removed using precision filtration equipment. The solution temperature is controlled at 61℃, and the component is completely immersed in the fluxing solution for 6 minutes.For 5 minutes, allow the flux to adhere evenly to the surface of the component, forming a uniform activation layer. This enhances the wettability and adhesion between the zinc bath and the steel substrate during subsequent hot-dip galvanizing, preventing problems such as incomplete plating, poor plating, and zinc layer peeling. After flux immersion, remove the component and allow it to drain naturally for 2 minutes to avoid excessive flux residue affecting subsequent drying. Next, preheat the drying process by placing the flux-immersed component into a hot air circulating drying oven, controlling the oven temperature at 155℃. In this example, the component thickness is 6mm, falling within the <8mm range. The drying time is set at 16 minutes. During the drying process, a temperature sensor monitors the furnace temperature in real time to ensure uniform temperature distribution within ±5℃. This ensures complete removal of residual moisture from the component surface and internal micropores, preventing defects such as splattering and zinc layer blistering caused by moisture contacting the high-temperature zinc liquid during hot-dip galvanizing. It also prevents hydrogen embrittlement. After successful drying, the component is quickly conveyed into the hot-dip galvanizing pot using a dedicated conveyor device, with the conveying time controlled within 30 seconds to avoid… After cooling, the component's surface oxidizes, affecting the adhesion of the zinc layer. Subsequently, it enters the core hot-dip galvanizing process, employing a large, fully automated hot-dip galvanizing pot made of high-temperature resistant stainless steel (model 310S). The temperature of the pure zinc liquid inside the pot is precisely and stably controlled at 452℃, with temperature fluctuations within ±2℃. High-purity aluminum wire (purity ≥99.99%) is added to the zinc liquid to stabilize the aluminum content at 0.20%. Aluminum optimizes the crystal morphology of the zinc layer, improving its toughness, wear resistance, and adhesion. In this embodiment, the component... With a thickness of 6mm, falling within the 5-12mm range, and a set immersion time of 2.8 minutes, the component is completely submerged in the zinc bath. During the immersion process, a mechanical stirring device is used to agitate the component every 40 seconds to ensure that the zinc bath evenly coats the surface, holes, and corners of the component, avoiding problems such as incomplete plating or uneven zinc layer thickness. After immersion, the component is smoothly lifted out of the zinc bath at a uniform speed of 1.4m / min, maintaining a constant lifting speed to avoid fluctuations. At the same time, a high-pressure nitrogen wiping device is used (nitrogen pressure controlled at 0.3-0.5).The surface of the component is uniformly purged at 4 MPa to remove excess zinc liquid, ensuring a uniform zinc layer thickness. The final average zinc layer thickness reaches 78 μm, meeting the requirement of an average zinc layer thickness ≥65 μm for components ≤4 mm thick. Zinc fumes and hydrogen chloride generated during hot-dip galvanizing are collected centrally by a micro-negative pressure exhaust system (negative pressure controlled between -50 Pa and -80 Pa). After purification by waste gas treatment equipment (using activated carbon adsorption + spray absorption process), the waste gas emission concentration is ensured to meet the "Integrated Emission Standard of Air Pollutants" (GB 10 ... After meeting the Class I emission standard (16297-1996), the generated zinc slag is cleaned regularly (every 8 hours). The cleaned zinc slag is crushed, screened, and recycled for reuse, achieving environmentally friendly and clean production. Finally, cooling and passivation are carried out. After galvanizing, the components immediately enter the forced air cooling process, using forced convection cooling to control the cooling rate at 7℃ / s, quickly and uniformly cooling to below 48℃. During the cooling process, special supports are used to separate the components to prevent them from colliding with each other and to prevent damage to the zinc layer. After cooling to 48℃, an environmentally friendly chromium-free passivation process is used for passivation treatment. The passivating agent used is a chromium-free passivation solution (mainly composed of silane coupling agents and titanates), which is free of heavy metals, environmentally friendly, and pollution-free. The component is completely immersed in the passivation solution for 2.2 minutes, controlling the passivation film thickness to 0.65 μm. The passivation film effectively improves the zinc layer's resistance to fingerprints, acids and alkalis, and atmospheric corrosion, extending the component's outdoor service life. After passivation, the component is removed and dried using hot air (drying temperature 80℃, drying time 5 minutes) to remove residual passivation solution, ensuring a uniform and complete passivation film without exposed substrate, yellowing, or peeling.

[0126] Step 6: Finished Product Inspection and Warehousing. First, detailed finished product inspection standards are established, clearly defining inspection items, methods, and pass / fail criteria. Relevant testing tools are prepared, including a measuring tape (accuracy ±0.1mm), calipers (accuracy ±0.01mm), a projector (magnification ≥50x), a zinc coating thickness gauge (accuracy ±1μm), an adhesion tester, and appearance inspection tools. All testing tools are calibrated by a professional institution and meet accuracy standards. Then, item-by-item inspections are conducted. First, dimensional accuracy inspection: a comprehensive inspection of key dimensions such as the length, width, angle, hole diameter, and hole spacing of the components is performed, using corresponding testing tools to verify each dimension. In this embodiment, the component length is 4500mm ±0.2mm, the width is 300mm ±0.1mm, the forming angle is 135° ±0.25°, the hole diameter is 18mm ±0.03mm, and the hole spacing is 150mm ±0.06mm. All dimensional errors meet design requirements and processing standards, with length and width errors ≤ ±0.5mm. The angle error is ≤±0.3°, the hole diameter error is ≤±0.05mm, and the hole spacing error is ≤±0.1mm. Secondly, the appearance quality is inspected using a combination of visual and tactile methods. Visual inspection of the component surface reveals no defects such as cracks, deformation, burrs, sharp edges, incomplete plating, poor plating, zinc layer peeling, flaking, bubbles, or runs. The zinc layer surface is smooth, evenly colored, and without significant color difference. Welded areas show full weld formation without incomplete penetration, porosity, slag inclusions, or cracks. The weld reinforcement is controlled at 2-3mm, and passivation is performed. The film is uniform and intact, without any exposed substrate, yellowing, peeling, or other abnormalities. It feels smooth and free of roughness or bumps. Third, the zinc layer quality was inspected using a zinc layer thickness gauge at different locations on the component (at least 5 test points). The average thickness was 78μm, meeting the requirement of an average zinc layer thickness ≥65μm for components with a thickness ≤4mm. The zinc layer adhesion was tested using a cross-cut test with a 1mm×1mm grid. After the grid was cut, transparent tape was applied and then peeled off. No peeling or flaking was observed, and the adhesion met the GB / T standard. The fourth standard is the Class 1 standard in 5270-2019 "Rating of Specimens and Test Pieces of Metals and Other Inorganic Coatings on Metal Matrix After Corrosion Testing"; Mechanical properties were randomly sampled, and three components were subjected to tensile tests, bending tests, and weld strength tests. In the tensile test, the tensile strength of the components reached 505 MPa, the yield strength reached 355 MPa, and the elongation reached 24.5%. In the bending test, the components showed no cracks or fractures. In the weld strength test, the weld strength reached 560 MPa, which is 1 times the strength of the base material.All components were inspected and qualified, meeting national standards and usage requirements. All inspection items were passed, with no unqualified components. Finally, each qualified component was uniquely identified using laser marking. The marking included the component name (diagonal connecting plate), specifications (4500mm×300mm×6mm), production batch (20260102), production date (January 2, 2026), inspection certificate, and manufacturer information. The markings were clear, secure, and resistant to detachment, facilitating subsequent traceability and management. After marking, the components were categorized and stored in designated areas according to component type and specifications. The storage warehouse had a hardened concrete floor and was equipped with moisture-proof and rain-proof facilities to maintain a dry and well-ventilated environment, with relative humidity controlled below 60% to prevent corrosion. A comprehensive storage ledger was established, recording detailed information such as component name, specifications, production batch, quantity received, and date of receipt, ensuring traceability of incoming components. This completed the implementation of the green processing and integrated galvanizing and anti-corrosion process for the diagonal connecting plate components in this embodiment.

[0127] Example 3: This example implements a green processing and galvanized anti-corrosion integrated process for auxiliary support components of transmission line towers. The processed components are auxiliary support components for transmission line towers, mainly used for supporting and fixing the tower's auxiliary structures. They have low stress requirements but high requirements for corrosion resistance and processing cost control.

[0128] This embodiment strictly follows the six core steps of the detailed breakdown of the present invention to further verify the universality and stability of the process of the present invention. The specific process is as follows:

[0129] The first step is the selection and pretreatment of the base material. A 4mm thick Q235 ordinary low-carbon steel plate is selected as the processing base material. This base material has a yield strength of 235MPa and a tensile strength between 370MPa and 500MPa, meeting the requirements of the national standard GB / T 700-2006 "Carbon Structural Steel". It possesses good processing performance and economy. Using this type of low-carbon steel to replace the traditional Q690 high-strength steel reduces the base material procurement cost by 48%, effectively controlling the overall production cost while meeting the mechanical performance requirements of the auxiliary support components. After the base material arrives on site, a comprehensive quality inspection is conducted. Visual inspection is used to ensure that the plate surface is free of defects such as cracks, folds, delamination, oxide scale peeling, rust, and scratches. Dimensional inspection is performed using a measuring tape and calipers, with the plate thickness deviation controlled within ±0.1mm, and the length and width meeting the procurement requirements. Mechanical performance testing involves tensile and bending tests, with three plates randomly selected. The samples were tested. In the tensile test, the tensile strength reached 400 MPa, the yield strength reached 235 MPa, and the elongation reached 29%. In the bending test, the samples showed no cracks or fractures, all meeting the mechanical property standards of Q235 low-carbon steel. After passing the inspection, the substrate was pretreated. The surface of the plate was polished with a mechanical grinder to remove surface rust, oxide scale, and oil. After polishing, it was blown clean with compressed air to ensure surface cleanliness. Subsequently, the substrate was leveled using a CNC leveling machine to control the flatness error of the substrate to 0.08 mm / m. After the pretreatment, the substrate was sorted and stacked, and labeled with information such as material, thickness, and specifications for easy retrieval in subsequent processes.

[0130] The second step is digital layout. Based on the overall 3D design model of the transmission line tower, digital layout is performed using AutoCAD and SolidWorks co-design software. First, the overall 3D model of the tower is built to clarify the installation position, connection method, and stress requirements of the auxiliary support components in the tower. Then, the overall tower model is disassembled into individual auxiliary support components. For the auxiliary support components in this embodiment, considering the dimensional losses of subsequent processes such as cutting, drilling, forming, welding, and galvanizing, a single-sided machining allowance of 1.5mm is set, and the overall length of the auxiliary support component is accurately determined to be 3000mm, the width to be 200mm, the plate thickness to be 4mm, and the diameter of the connecting hole to be 16mm. The components are then automatically generated by the design software. The system generates precise machining drawings with clearly marked dimensions, tolerances, machining requirements, and quality standards. Simultaneously, it generates cutting data that can be directly imported into the CNC laser cutting equipment, including parameters such as cutting path, cutting speed, and laser power. The cutting speed is set to 45cm / min, and the laser power to 2500W. Furthermore, it generates parameter reference files for each process, such as hole making, forming, and welding, clearly defining the machining parameters and quality control points for each process. After data generation, two professional technicians conduct a double review, checking the dimensional deviations of the machining drawings, the accuracy of the cutting data, and the rationality of process connections. If no abnormalities are found, the approved machining data and drawings are archived and stored, and simultaneously transmitted to the CNC laser cutting machine in the material cutting process.

[0131] The third step is precise material cutting. In this embodiment, the component thickness is 4mm, and a CNC laser cutting machine is used for material cutting. First, the CNC laser cutting machine is debugged, and the positioning accuracy of the cutting head is calibrated to ensure that the positioning error is ≤±0.03mm. The laser power is adjusted to 2500W, the cutting speed to 45cm / min, the focal position to 0mm, and the auxiliary gas pressure to 0.4MPa. After debugging, the equipment runs stably, and the cutting accuracy meets the requirements. Then, the cutting data generated by digital layout is imported into the typesetting software, combined with Q235 The low-carbon steel plate (1000mm × 3000mm) is arranged using a nested layout method to refine the cutting layout of multiple plates, reducing the cutting gap to 0.2mm and maximizing the effective utilization rate of the plate. After optimization, a detailed layout drawing is generated, indicating the placement and cutting sequence of each auxiliary support component on the plate. Calculations show that the overall material utilization rate of 4mm thick Q235 low-carbon steel plate under this layout scheme can reach 97.5%. Then, the pre-treated substrate is placed flat on a CNC laser cutting machine. On the workbench, a special fixture is used for precise positioning and fixation to prevent displacement of the substrate during cutting. Then, the optimized cutting data is imported into the equipment, and the cutting program is started. During the cutting process, operators monitor the stability of the cutting parameters in real time, adjusting any abnormal parameters promptly to ensure that the cutting accuracy error is stably controlled within ±0.2mm, the surface roughness Ra≤10μm, and there are no defects such as cutting burrs, skewed cuts, or dimensional deviations. After cutting, a special tool is used to remove the component from the sheet metal, and a grinder is used to clean the burrs and oxide residue from the edges of the component. Finally, the dimensional accuracy of the cut component is inspected using measuring tapes, calipers, projectors, and other measuring tools to verify key dimensions such as the length, width, and angle of the component. In this embodiment, the component length error is ±0.2mm, and the width error is ±0.1mm, both conforming to the processing drawings. Unqualified components are promptly reworked. Meanwhile, the scrap generated from cutting is collected and classified. Recyclable scrap is processed for small auxiliary components, while non-recyclable scrap is centrally processed according to environmental protection requirements.

[0132] The fourth step involves multi-stage precision machining. The first step is hole making, performed using a high-precision CNC drilling machine. Based on the tower assembly and connection requirements, standard 16mm diameter connecting holes are machined on the auxiliary support components. A total of 18 connecting holes are machined per component, with a hole spacing of 160mm. Before drilling, the component is precisely positioned and fixed on the drilling machine's worktable, and the drill bit position and drilling machine accuracy are calibrated. A 16mm diameter high-speed steel drill bit is selected to ensure it is sharp and wear-free. During the drilling process, the drill bit speed is controlled at 1200 rpm, the feed rate at 14mm / min, and the hole diameter error is controlled to ±0.03mm, with a hole center spacing error of [missing value]. The hole diameter was ±0.07mm, and the perpendicularity error of the hole wall was 0.02mm / m. After hole making, a chamfering tool was used to chamfer the hole opening at a 45° angle and a 1mm width to avoid burrs and sharp edges. Then, plug gauges and calipers were used to inspect the hole position accuracy and diameter. All holes met the requirements, with no unqualified holes. After hole making, the forming process began. A small CNC bending machine was used to perform a simple bending forming operation on the component. The forming angle was 90°. Before forming, the forming mold and equipment parameters were adjusted according to the forming angle of the component. The bending pressure was adjusted to 120t, the holding time to 3s, and the springback compensation to 0.5. During the molding process, molding pressure, holding time, and springback compensation parameters are monitored in real time to ensure that the molding angle error is controlled within ±0.2° and the overall flatness error of the component is controlled within 0.1mm / m. After molding, the molding accuracy of the component is inspected using tools such as an angle gauge and a flatness measuring instrument. The molding angle is 90°±0.2° and the flatness error is 0.1mm / m, which meets the design requirements. After molding, the welding process begins. Fully automatic submerged arc welding is used for welding the splicing parts of the components. Before welding, the welding parts are cleaned to remove surface oxide scale, rust, oil, and other impurities. The cleaning range is two sides of the welding parts. The weld seam was cleaned by blowing it with compressed air, with a diameter of 3.2 mm on each side and a particle size of 10-40 mesh. The flux was dried at 200℃ for 2 hours beforehand. During welding, the welding current was controlled at 320A, the welding voltage at 29V, the welding speed at 45cm / min, and the wire extension length at 22mm to ensure a full weld formation, uniform penetration, and no defects such as incomplete penetration, porosity, slag inclusions, or cracks. After welding, the weld was immediately cooled to room temperature by natural cooling. After cooling, all weld seams were subjected to 100% non-destructive testing using ultrasonic flaw detection equipment. The testing standard complied with GB / T 11345-2013 "Manual Ultrasonic Testing Method and Acceptance Grade of Welds". The test results showed that the weld seam had no internal defects and the mechanical strength of the weld seam reached 1.1 times the strength of the base material, meeting the requirements for use as auxiliary support components of the iron tower.

[0133] The fifth step is environmentally friendly galvanizing and corrosion protection. First, degreasing is performed using an environmentally friendly water-based metal degreasing agent. The temperature of the degreasing tank is stably controlled at 52℃. In this embodiment, the component surface has relatively little oil, so the degreasing time is set to 11 minutes. The component is completely immersed in the degreasing solution, and the solution is stirred every 3 minutes during the degreasing process to ensure uniform degreasing and thoroughly remove residual cutting fluid, lubricating oil, dust, oil, and other impurities from the component surface. After degreasing, the component is removed from the degreasing solution and rinsed twice with clean water for 4 minutes each time to remove any remaining degreasing solution and ensure the component surface is completely wetted with water without any continuous oil film residue. The wastewater from degreasing is treated by wastewater treatment equipment to meet standards. After discharge, the components proceed to the pickling and rust removal process. A 21% industrial hydrochloric acid solution is used as the pickling medium, and 2.5 g / L of hexamethylenetetramine is added as a corrosion inhibitor. The pickling temperature is controlled at 28°C. In this embodiment, the component surface has relatively little oxide scale, so the pickling time is set to 8.5 minutes. The component is completely immersed in the pickling solution, and is turned over every 2 minutes during the pickling process to ensure uniform pickling until the oxide scale, rust, and oxide film on the component surface are completely removed, exposing a uniform silver-white metal substrate. After pickling, a three-stage countercurrent rinsing process is used, in which the component is sequentially placed in three stages of clean water tanks for rinsing, with each stage lasting 4 minutes, to thoroughly remove any remaining surface residue. The acid solution, after pickling, is neutralized and discharged only after meeting standards. Then, it enters the fluxing process, using an aqueous fluxing solution prepared by mixing 21% ammonium chloride and 3.1% zinc chloride. The solution is pre-stirred to remove impurities, and the temperature is controlled at 59°C. The component is completely immersed in the fluxing solution for 7.5 minutes, allowing the flux to adhere evenly to the component surface and form a uniform activation layer. After fluxing, the component is removed and excess fluxing solution is drained. Next, drying and preheating are performed. The fluxed component is sent to a hot air circulating drying oven, with the oven temperature controlled at 145°C. In this embodiment, the component thickness is 4mm, which falls within the <8mm range. The drying time is 15.5 minutes. During the drying process, the temperature inside the furnace is ensured to be uniform, and residual moisture in the surface and internal micropores of the component is completely removed. After the drying is qualified, the component is quickly sent into the hot-dip galvanizing pot. Then, it enters the core hot-dip galvanizing process, using a large fully automatic hot-dip galvanizing pot. The temperature of the pure zinc liquid inside the zinc pot is precisely and stably controlled at 448℃. High-purity aluminum wire is added to the zinc liquid to keep the mass fraction of aluminum in the zinc liquid stable at 0.19%. In this embodiment, the component thickness is 4mm, which is in the <5mm range. The immersion time is set to 1.8 minutes. The component is completely immersed in the zinc liquid. During the immersion process, the component is turned over periodically to ensure that the zinc liquid evenly coats the surface and corners of the component. After the immersion is completed, the component is 1.The components are smoothly lifted from the molten zinc at a uniform speed of 25 m / min. Simultaneously, a high-pressure nitrogen wiping device evenly blows the surface of the components to remove excess zinc, ensuring a uniform zinc layer thickness. The final average zinc layer thickness on the component surface reaches 68 μm, meeting the requirement of an average zinc layer thickness of ≥65 μm for components with a thickness ≤4 mm. Waste gas generated during hot-dip galvanizing is purified before discharge, and zinc dross is regularly cleaned, recycled, and reused. Finally, cooling and passivation are performed. After galvanizing, the components immediately enter a forced air cooling process, with a controlled cooling rate of 5.5℃ / s, rapidly and uniformly cooling to below 46℃. During cooling, collisions between components are avoided. After cooling to the specified temperature, an environmentally friendly chromium-free passivation process is used. A chromium-free passivation solution is selected, and the components are completely immersed in the passivation solution for 2.8 minutes, controlling the passivation film thickness to 0.75 μm. After passivation, the components are removed and allowed to air dry naturally, ensuring a uniform and intact passivation film.

[0134] Step 6: Finished Product Inspection and Warehousing. First, detailed finished product inspection standards are established, and relevant testing tools are prepared, ensuring that the tools are calibrated and accurate. Then, item-by-item inspections are conducted. In dimensional accuracy inspection, the component length is 3000mm ± 0.3mm, width is 200mm ± 0.1mm, hole diameter is 16mm ± 0.03mm, and hole spacing is 160mm ± 0.07mm. All dimensional indicators meet design standards. In appearance quality inspection, the component surface is free of defects such as cracks, deformation, burrs, sharp edges, incomplete plating, and poor plating. The zinc layer surface is smooth, even in color, and the weld... The weld seams at the joints are fully formed, and the passivation film is uniform and complete. In the zinc layer quality inspection, the average thickness of the zinc layer is 68μm, and the adhesion meets the Class 1 standard. In the mechanical property sampling inspection, two components were randomly selected for tensile testing and weld strength testing, and all indicators met the national standards and usage requirements. All inspection items were qualified, and there were no unqualified components. Finally, the qualified components were laser-marked with complete markings, and then classified, stacked, and stored in separate areas. Storage records were kept to ensure the traceability of the components entering the warehouse, thus completing the implementation of the green processing and integrated galvanizing and anti-corrosion process for the auxiliary material support components in this embodiment.

[0135] Through the process verification of the above three embodiments for three different types of components of transmission line towers—main materials, diagonal members, and auxiliary materials—it is fully demonstrated that the green processing and integrated galvanizing and anti-corrosion process method for transmission line towers provided by this invention can be adapted to the large-scale production of tower components of different types and with different stress requirements. After replacing traditional Q690 high-strength steel with ordinary low-carbon steel, the procurement cost of base materials is reduced by 40-50%, the comprehensive utilization rate of steel is increased to over 95%, and there is no large-scale emission of pollutants such as VOCs and dust during the production process. Water and waste residue are treated to meet discharge standards or recycled and reused, which aligns with the industrial policy orientation of green manufacturing and efficient resource utilization. At the same time, through digital layout, precise material cutting, multi-process precision processing and full-process quality control, the component processing accuracy, structural mechanical properties and corrosion resistance and durability can all meet the power grid operation standards. The weld strength is not less than 1.1 times the strength of the base material, the zinc layer thickness meets the relevant standard requirements, and the adhesion reaches the first-level standard. This solves a series of technical pain points in traditional processes, such as high base material cost, large corrosion pollution, low material utilization rate and insufficient processing accuracy.

[0136] Table 1 summarizes the core technical parameters and technical effects of the three embodiments, thereby illustrating the advantages of the process of the present invention in terms of cost control, material utilization, processing accuracy and corrosion resistance. The data are all derived from the actual process implementation results of each embodiment.

[0137] Table 1

[0138] Example sequence number Component type Substrate parameters (material / thickness) Base material cost reduction ratio Comprehensive utilization rate of steel Core machining accuracy (error) Average zinc layer thickness weld strength to base metal strength ratio Zinc coating adhesion rating Environmental protection treatment effect Example 1 Main material: angle steel components Q235 low carbon steel / 10mm 45% 96.2% Length ±0.3mm, hole diameter ±0.04mm, hole spacing ±0.08mm, forming angle ±0.2° 92μm (≥86μm) 1.15 times Level 1 (GB / T5270-2019) Wastewater and exhaust gas are treated to meet discharge standards, and zinc slag is recycled and reused. Example 2 Diagonal connecting plate components Q355 low carbon steel / 6mm 42% 97.1% Length ±0.2mm, hole diameter ±0.03mm, hole spacing ±0.06mm, forming angle ±0.25° 78μm (≥65μm) 1.12 times Level 1 (GB / T5270-2019) Wastewater meets GB 8978-1996 Class I standard, exhaust gas meets GB 16297-1996 Class I standard, and waste residue is centrally treated. Example 3 Auxiliary support components Q235 low carbon steel / 4mm 48% 97.5% Length ±0.2mm, hole diameter ±0.03mm, hole spacing ±0.07mm, forming angle ±0.2° 68μm (≥65μm) 1.1 times Level 1 (GB / T5270-2019) Wastewater and exhaust gas are treated to meet discharge standards, and zinc slag is recycled and reused.

[0139] The cost reduction ratio of the substrate is calculated compared to the traditional process using Q690 high-strength steel; the zinc layer thickness in parentheses is the minimum requirement standard for the thickness of the corresponding component; the processing accuracy, weld strength, and zinc layer adhesion all meet the process standards of this invention and the corresponding national standards.

[0140] The processes implemented in the three embodiments are stable and reliable, the equipment is highly adaptable, and the operation procedures are standardized. They can be widely used in the mass production and processing of metal components for various transmission line towers, and have significant economic and environmental benefits as well as broad market application prospects.

[0141] 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 or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A green processing and integrated galvanizing and corrosion protection process for transmission line towers, characterized in that, include: S1, Substrate selection and pretreatment, including: replacing traditional Q690 high-strength steel with low-cost, high-performance ordinary low-carbon steel, and pretreating the substrate. S2, digital layout, includes: using digital technology to accurately define component dimensions and generate accurate processing data, providing data for material cutting and processing procedures; S3, Precision Cutting, includes: high-precision cutting of the substrate based on digital layout data, using CNC cutting equipment, and combined with an optimized layout scheme; S4 involves multi-stage precision processing, including sequential hole making, forming, and welding of the blanked components. Quality control points are set up for each stage to conduct refined parameter management and process inspection. S5, environmentally friendly galvanizing and corrosion protection, including: adopting an environmentally friendly hot-dip galvanizing and corrosion protection process, which involves a continuous process of degreasing, pickling, immersion in flux, drying and preheating, hot-dip galvanizing, and cooling and passivation. S6. Conduct finished product inspection and warehousing, including: conducting a comprehensive inspection of components that have completed all processing and anti-corrosion treatments, and marking, classifying and warehousing them after they pass the inspection.

2. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 1, characterized in that, S1 includes: S11, Determine the standard for selecting the base material, and select ordinary low carbon steel with a yield strength of 235-355MPa as the base material for processing transmission line tower components. S12. Conduct incoming inspection of the base material. The inspection items include appearance quality, dimensional accuracy, and mechanical properties. In terms of appearance, ensure that the surface of the sheet is free from one or more quality defects such as cracks, folds, delamination, oxide scale peeling, rust, and scratches. In terms of dimensions, control the thickness deviation of the sheet within ±0.1mm, and the length and width deviations meet the design requirements. In terms of mechanical properties, use tensile tests and bending tests to ensure that the yield strength, tensile strength, and elongation meet the national standards for the corresponding steel. S13. Pre-treat the substrate. For qualified substrates, perform surface cleaning and leveling. Surface cleaning is done by mechanical grinding to remove impurities such as floating rust, oxide scale, and oil stains from the substrate surface. After grinding, use compressed air to blow it clean. Leveling is done by CNC leveling machine to precisely level the substrate, controlling the flatness error of the substrate to ≤0.1mm / m. After pre-treatment, the substrates are sorted and stacked and labeled.

3. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 2, characterized in that, The ordinary low-carbon steel with a yield strength of 235-355 MPa is Q235 low-carbon steel or Q355 low-carbon steel.

4. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 3, characterized in that, S2 includes: S21. Build a three-dimensional model, including: based on the overall design drawings and technical requirements of the transmission line tower, use AutoCAD and SolidWorks joint design software to build the overall three-dimensional model of the tower and detailed three-dimensional models of each component, clarify the external dimensions, structural features, connection methods and stress requirements of each component, and ensure that the three-dimensional model is completely consistent with the actual production requirements. S22, perform component decomposition and parameter setting, decompose the overall three-dimensional model of the iron tower into various specific components such as main material, diagonal material and auxiliary material. For each component, combine the dimensional loss of each subsequent process such as cutting, drilling, forming, welding and galvanizing, and accurately set the single-sided processing allowance. The processing allowance is reasonably adjusted according to the component thickness and processing process. At the same time, the key parameters of the component cutting boundary, drilling position and welding node are clearly defined. S23, Generate processing data, including: digitally laying out each component after disassembly, automatically generating precise processing drawings of the components, cutting data that can be directly imported by CNC cutting equipment, and parameter reference files for each processing step; wherein, the cutting data includes cutting path, cutting speed, and torch height; S24. Perform data review and optimization. Double-check the generated machining drawings, cutting data and parameter reference files to check for dimensional deviations, data errors and reasonable process connections. Optimize and adjust any problems in a timely manner. Archive and store the approved machining data and drawings and transmit them synchronously to the CNC equipment for the subsequent material cutting process.

5. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 4, characterized in that, In S22, the machining allowance on one side of the component with a thickness of <6mm is set to 1.5mm, and the machining allowance on one side of the component with a thickness of ≥6mm is set to 2mm.

6. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 5, characterized in that, S3 includes: S31, Debugging the cutting equipment, including: selecting CNC cutting equipment suitable for ordinary low carbon steel, selecting the appropriate cutting method according to the thickness and material of the component, and debugging the equipment including calibrating one or more key parameters of the cutting head positioning accuracy, cutting speed, laser power and plasma current; for components with a thickness < 8mm, a CNC laser cutting machine is used, and for components with a thickness ≥ 8mm, a CNC plasma cutting machine is used. S32, Optimize material cutting layout, including: import the cutting data generated by digital layout into the layout software, combine the size and specifications of the base material, systematically optimize the cutting layout of multiple boards, adopt a nested layout method to minimize the cutting gap and corner reserve size, after layout optimization, generate detailed layout drawings, and mark the placement position and cutting sequence of each component on the board. S33, perform precise cutting operation, including: placing the pre-treated qualified substrate flat on the worktable of the CNC cutting equipment, accurately positioning and fixing it, then importing the optimized cutting data into the equipment, starting the cutting program, monitoring the stability of the cutting parameters in real time during the cutting process, controlling the material cutting accuracy error to ≤ ±0.5mm, of which the laser cutting accuracy error is controlled within ±0.2mm and the plasma cutting accuracy error is controlled within ±0.3mm, while controlling the surface roughness Ra of the cutting surface to ≤12.5μm. After the cutting is completed, the component is removed from the plate and the burrs and oxide residue on the edge of the component are cleaned. S34, Conduct material cutting quality inspection and scrap recycling, including: inspecting the dimensional accuracy of the cut components, verifying the length, width and angle of the components, and classifying and collecting the scrap generated from cutting. For recyclable scrap, uniformly sort and label it for processing small auxiliary components, and centrally process non-recyclable scrap according to environmental protection requirements.

7. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 6, characterized in that, S4 includes: S41, Implement the hole-making process, including: using a high-precision CNC drilling machine to make holes, determining the hole diameter, hole spacing and number of holes according to the assembly requirements of the components, before making holes, accurately positioning and fixing the components on the drilling machine worktable, calibrating the drill bit position and drilling machine accuracy, selecting a drill bit that matches the hole diameter, after the hole is made, using a chamfering tool to chamfer the hole opening, with a chamfer angle of 45° and a chamfer width of 1-2mm, and then inspecting the hole position accuracy and hole diameter size to ensure the precise fit between the hole position and the tower connector; S42, Implement the forming process, including: according to the shape requirements of the component, use a CNC bending machine or CNC press for forming processing. Before forming, adjust the forming mold and equipment parameters according to the forming angle and fillet radius of the component to ensure that the mold matches the shape of the component. During the forming process, monitor the forming pressure, holding time and springback compensation parameters in real time to avoid defects such as bending angle deviation, local distortion, flatness exceeding the standard and forming cracks. After forming, inspect the forming accuracy of the component, check the forming angle and flatness, and re-form unqualified components. S43, Implement the welding process, including: using fully automated submerged arc welding technology for welding operations; before welding, cleaning the welding area to remove surface oxide scale, rust, and oil stains; after cleaning, blowing it clean with compressed air; selecting appropriate welding wire and flux according to the component material, thickness, and welding requirements; immediately cooling to room temperature using natural cooling or forced air cooling after welding; and performing 100% non-destructive testing on the weld after cooling; wherein, the 100% non-destructive testing includes using ultrasonic testing or radiographic testing, wherein ultrasonic testing is used to detect internal defects in the weld, and radiographic testing is used to detect the internal quality of critical load-bearing welds; unqualified welds are promptly repaired or re-welded, and after repair, non-destructive testing is performed again until qualified.

8. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 7, characterized in that, In step S41, the drill bit is made of high-speed steel or cemented carbide. During the hole-making process, the drill bit rotation speed is controlled at 800-1200 r / min, and the feed rate is controlled at 10-15 mm / min. The rotation speed and feed rate are adjusted according to the hole diameter. When the hole diameter is <20 mm, the drill bit rotation speed is controlled at 1000-1200 r / min, and the feed rate is controlled at 12-15 mm / min. When the hole diameter is ≥20 mm, the drill bit rotation speed is controlled at 800-1000 r / min, and the feed rate is controlled at 10-12 mm / min. At the same time, the hole diameter error is controlled to be ≤±0.05 mm, the hole center distance error is controlled to be ≤±0.1 mm, and the hole wall perpendicularity error is controlled to be ≤0.03 mm / m. In step S42, the bending pressure of the CNC bending machine is controlled at 100-300t, the holding time is controlled at 3-5s, and the springback compensation is adjusted to 0.5-1° according to the material and thickness of the component; the forming pressure of the CNC press is controlled at 80-250t, the holding time is controlled at 2-4s, the forming angle error is controlled within ±0.3°, and the component flatness error is controlled within 0.2mm / m. In S43, the welding wire is H08MnA or H10Mn2, and the flux is HJ431. During the welding process, the welding parameters are strictly controlled: the welding current is 300-500A, the welding voltage is 28-36V, the welding speed is 30-50cm / min, the welding wire extension length is 20-30mm, the flux particle size is 10-40 mesh, the flux drying temperature is 200-250℃, and the drying time is 2-3h. The welding parameters are adjusted according to the thickness of the component. When the thickness is <8mm, the welding current is controlled at 300-380A, the welding voltage is controlled at 28-32V, and the welding speed is controlled at 40-50cm / min. When the thickness is ≥8mm, the welding current is controlled at 380-500A, the welding voltage is controlled at 32-36V, and the welding speed is controlled at 30-40cm / min.

9. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 8, characterized in that, S5 includes: S51, degreasing treatment is performed, including: using an environmentally friendly water-based metal degreasing cleaning agent, stabilizing the temperature of the degreasing tank at 50-60℃, adjusting the degreasing time according to the oil content on the component surface, and completely immersing the component in the degreasing solution. Through the penetration, dispersion and saponification of the cleaning agent, the residual cutting fluid, lubricating oil, dust and oil on the surface of the component are thoroughly removed. After degreasing, the component is taken out of the degreasing solution and rinsed with clean water 2-3 times to remove the residual degreasing solution on the surface. S52, pickling and rust removal are carried out, including: using an industrial hydrochloric acid solution with a mass concentration of 18-22% as the pickling medium, adding 1-3 g / L of hexamethylenetetramine as a corrosion inhibitor to the pickling solution, controlling the pickling environment temperature at 25-35℃, adjusting the pickling time according to the oxide scale and rust content on the component surface, completely immersing the component in the pickling solution until the oxide scale, rust, and oxide film on the component surface are completely removed, exposing a uniform silver-white metal substrate. After pickling, a multi-stage countercurrent rinsing process is adopted, in which the component is placed in 3-4 stages of clean water tanks for rinsing, with each stage rinsing time being 3-5 minutes, to thoroughly remove the residual acid solution on the surface; S53, Immersion flux, comprising: an aqueous flux solution prepared by mixing 18-22% ammonium chloride and 2.8-3.2% zinc chloride by mass, controlling the flux solution temperature at 58-62℃, completely immersing the component in the flux solution for 6-8 minutes, so that the flux adheres evenly to the surface of the component, forming a uniform activation layer on the substrate surface, and after the flux immersion is completed, removing the component and draining off the excess flux solution from the surface; S54. Drying and preheating are carried out, including: sending the components after being immersed in the flux into a hot air circulating drying oven, controlling the oven temperature at 140-160℃, and drying time at 15-20min. The drying time is adjusted according to the thickness of the components. The drying time for components with a thickness <8mm is 15-17min, and the drying time for components with a thickness ≥8mm is 17-20min. After the drying is qualified, the components are quickly sent into the hot-dip galvanizing pot. S55 involves hot-dip galvanizing, including: using a large, fully automatic hot-dip galvanizing pot made of high-temperature resistant stainless steel; precisely and stably controlling the temperature of the pure zinc liquid inside the pot at 445-455℃; adding high-purity aluminum wire to the zinc liquid to stabilize the aluminum content at 0.18-0.22%; controlling the immersion time according to the thickness of the components: 1.5-2 minutes for components with a thickness <5mm, 2.5-3 minutes for components with a thickness of 5-12mm, and 3.5-4 minutes for components with a thickness >12mm; completely immersing the components in the zinc liquid; after immersion, smoothly lifting the components from the zinc liquid at a uniform speed of 1.2-1.5m / min; during the lifting process, using a high-pressure nitrogen wiping device to uniformly blow away excess zinc liquid from the surface of the components, controlling the zinc layer thickness to be uniform and consistent; the average zinc layer thickness of components with a thickness >4mm is ≥86μm, and the average zinc layer thickness of components with a thickness ≤4mm is ≥65μm. S56. Cooling and passivation are performed, including: immediately after galvanizing, the component enters the forced air cooling process, using forced convection cooling, controlling the cooling rate at 5-8℃ / s, and rapidly and uniformly cooling to below 50℃. After cooling to the specified temperature, an environmentally friendly chromium-free passivation process is used for passivation treatment. The passivating agent is a chromium-free passivation liquid. The component is completely immersed in the passivation liquid, and the passivation time is 2-3 minutes. The passivation film thickness is controlled at 0.6-0.8μm. After passivation, the component is removed and air-dried or dried with hot air to remove the residual passivation liquid from the surface.

10. The integrated green processing and galvanizing anti-corrosion process for transmission line towers according to claim 9, characterized in that, S6 includes: S61, Prepare for inspection, including: developing detailed finished product inspection standards, clarifying inspection items, inspection methods, and pass / fail criteria, and preparing relevant testing tools; S62, Perform itemized inspections, including: (1) Dimensional accuracy inspection: The key dimensions of the component, such as length, width, angle, hole diameter, and hole spacing, are fully inspected. The corresponding inspection tools are used to check each dimension to ensure that the dimensional error meets the design requirements and processing standards. Among them, the length and width error is ≤ ±0.5mm, the angle error is ≤ ±0.3°, the hole diameter error is ≤ ±0.05mm, and the hole spacing error is ≤ ±0.1mm. (2) Visual inspection of the appearance quality: visually inspect the surface of the components to ensure that there are no defects such as cracks, deformation, burrs, sharp edges, missing plating, poor plating, peeling, flaking, bubbles and runs in the zinc layer, the zinc layer surface is flat and smooth with uniform color, the weld seam of the welded parts is full and without defects, and the passivation film is uniform and complete without any exposed base or yellowing. (3) Zinc layer quality inspection: The zinc layer thickness is measured by a zinc layer thickness gauge to ensure that the zinc layer thickness meets the specified requirements. The zinc layer adhesion is tested by the cross-cut test method. After the cross-cut test, there is no peeling or flaking of the zinc layer. The adhesion reaches the Class 1 standard in GB / T 5270-2019 "Rating of specimens and test pieces of metal and other inorganic coatings on metal substrates after corrosion test". (4) Mechanical performance sampling inspection: a certain proportion of components are randomly selected for tensile test, bending test and weld strength test to ensure that the mechanical properties and weld strength of the components meet the national standards and usage requirements; S63, non-conforming handling includes: marking and isolating non-conforming components found during inspection, analyzing the reasons for non-conformity, reworking components with dimensional deviations and processing defects, re-galvanizing components with substandard zinc coating quality and inadequate anti-corrosion effect, conducting a comprehensive inspection again after rework and reprocessing until they pass, and scrapping components that cannot be reworked or still fail after rework. S64, Identification and Warehousing, includes: For components that have passed inspection, use laser marking to create a unique identification code. The identification code includes the component name, specifications, production batch, production date, and inspection certificate. After identification, the components are classified and stacked, and stored in separate areas according to component type and specifications. Storage records are kept.

Images