Large thin-walled steel plate wall structure and welding deformation control method

Abstract

The application discloses a large thin-wall steel plate wall structure and a welding deformation control method. The steel plate wall is formed by interlaced splicing of bearing units and connecting units. The inner and outer plates of the bearing unit are provided with double ribs, and the end part is provided with an outer single V-shaped groove weld. An elliptical plug welding hole is arranged on the corresponding panel of the connecting middle rib to realize external welding of the inner weld. During manufacturing, a multi-directional shrinkage compensation is preset according to the length, width and rib spacing, and the units are independently welded. The units are symmetrically welded in sections and are subjected to deformation control by ballast. Then, the units are spliced into a wall surface. Finally, the units are assembled and folded in a specific order and are provided with temporary rigid supports. The application solves the problem of welding of internal welds by using the groove and plug welding structure. The overall deformation is decomposed into unit controllable deformation by using block manufacturing. The compensation blanking, symmetric welding and ordered folding process are combined to greatly reduce the wave and angle deformation of the thin-wall wall plate, improve the size precision and be suitable for industrialized batch welding production of long, narrow and dense stiffened thin-wall steel plate walls.

Description

Technical Field

[0001] This invention relates to the field of steel structure welding manufacturing technology, and in particular to a large thin-walled steel plate wall structure and a method for controlling welding deformation. Background Technology

[0002] Large thin-walled steel plate wall structures are widely used in industrialized construction and large-scale infrastructure projects due to their advantages such as light weight, high load-bearing capacity, and fast construction speed. These steel plate walls are typically formed by welding large areas of thin steel plates with densely arranged stiffening ribs. The overall dimensions can range from several meters to tens of meters. Concrete can be filled inside the steel plate wall, with the steel plate and concrete working together to bear the load, resulting in excellent mechanical properties. However, high manufacturing precision is required. Taking a rectangular steel plate wall structure as an example: it consists of four steel plate walls welded together to form a rectangular component, with a length of 20m × width of 4.8m × height of 4.8m. A single-sided steel plate wall is constructed by welding rectangular steel pipes, top and bottom panels, and stiffening ribs. Its length reaches 20 meters, its width is 4.8 meters, and its height is only 300mm. The internal stiffening rib spacing is ≤500mm, exhibiting typical structural characteristics of "narrow walls and dense ribs."

[0003] Due to the significant characteristics of steel plate wall structures—large area, thin wall thickness, and dense welds—the assembly and welding process faces the following technical challenges: First, controlling welding deformation is extremely difficult. Thin plates themselves have low stiffness and weak resistance to deformation, and the numerous dense stiffening rib welds will produce significant wavy deformation, angular deformation, and lateral bending. Existing technologies limit welding deformation by controlling the welding sequence of ribs or by setting fixed plates and limiting rods to form a rigid restraint structure. These are mostly "passive constraints" or localized controls. For steel plate wall structures with a large number of densely distributed stiffening rib welds, it is difficult to achieve systematic precision assurance during the manufacturing stage, and there is also a lack of an active control mechanism throughout the entire assembly and welding process.

[0004] Secondly, the accessibility of welding and deformation control of densely packed ribs has not been effectively resolved. The inner cavity of the steel plate wall is only 300mm high, and specialized welding equipment cannot enter the sealed cavity for welding. Existing technologies have not systematically solved this problem from the perspectives of bevel design and plug hole arrangement.

[0005] Third, large thin-walled steel plate wall structures are mostly assembled and welded on-site from scattered parts, making it difficult to guarantee the consistency of the dimensions of each unit. Existing segmented manufacturing methods are mainly for components such as box beams and towers, lacking unit division criteria and systematic assembly and welding processes for structures with "narrow, long, thin plates and dense ribs", and lacking effective control over the distribution and transmission of cumulative errors when splicing multiple units.

[0006] Therefore, developing a systematic and engineering-implementable method for controlling deformation during welding of thin-walled steel plate walls has significant engineering value and innovative implications. Summary of the Invention

[0007] The purpose of this invention is to provide a large thin-walled steel plate wall structure and a method for controlling welding deformation, so as to solve the technical problems in the prior art such as the difficulty in controlling welding deformation of large thin-walled steel plate walls, the poor accessibility of internal rib welds, and the overall instability during closure.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A large thin-walled steel plate wall structure includes a wall body, which is composed of load-bearing units and connecting units that are staggered and spliced ​​together in a horizontal direction. Furthermore, the load-bearing unit is formed by a first panel, a second panel, and box-shaped columns disposed at both ends of the first panel and the second panel, and a first rib and a second rib that are parallel to each other are provided between the first panel and the second panel. Furthermore, the connecting unit includes a third panel and a fourth panel, and a third rib, a fourth rib, and a fifth rib are arranged in parallel to each other and in a horizontal direction between the third panel and the fourth panel; the fourth panel has a plurality of plug welding holes spaced apart at positions corresponding to the fourth rib. Furthermore, in the load-bearing unit, the two ends of the first panel and the second panel are respectively connected to the box column through a single-sided V-groove weld facing the outside of the box column; one end of the first rib and the second rib is connected to the second panel through a double-sided fillet weld, and the other end of the first rib and the second rib is connected to the first panel through a single-sided fillet weld facing the port of the first panel. Furthermore, in the connecting unit, one end of the third rib, the fourth rib, and the fifth rib is connected to the third panel through a double-sided fillet weld; the other end of the third rib and the fifth rib is connected to the fourth panel through a single-sided fillet weld facing the port of the fourth panel; and the other end of the fourth rib is plug-welded to the fourth panel through the plug weld hole.

[0009] As a preferred embodiment, the bevel angle of the single-sided V-groove weld is 45° to 60°, the plug weld hole is elliptical with a minor axis of 8 to 15 mm and a major axis of 100 to 200 mm, the spacing between adjacent plug weld holes is 100 to 200 mm, and the first panel and the second panel are rectangular strip steel plates.

[0010] As a preferred embodiment, the lengths of the first rib, second rib, third rib, fourth rib, and fifth rib are less than or equal to 300 mm, and the spacing between adjacent ribs is less than or equal to 500 mm.

[0011] A welding method for a large thin-walled steel plate wall structure, using any of the above-mentioned load-bearing units and connecting units, specifically includes the following steps: S1. Raw material pre-preparation and multi-directional shrinkage compensation: The large thin-walled steel plate wall is divided into several load-bearing units and connecting units along the width direction. The load-bearing units and connecting units are staggered and spliced ​​in sequence along the horizontal direction. For each required load-bearing unit and connecting unit, the shrinkage compensation amount is preset along the longitudinal, transverse and rib spacing directions respectively. S2. Steel plate wall preparation: S201. The steel obtained in step S1 is independently assembled and welded to produce several load-bearing units. S202. The steel obtained in step S1 is independently welded to produce several connecting units; S203. Weld the load-bearing units and connecting units obtained in steps S201 and S202 in sequence according to requirements to obtain a steel plate wall. S3. Repeat step S2 to obtain several steel plate walls, the steel plate walls including a lower steel plate wall, a side steel plate wall and an upper steel plate wall; S4. Rectangular wall assembly: Assemble the several sets of steel plate walls obtained in step S3 into a rectangular wall. Specifically, using the lower steel plate wall as a reference, assemble the side steel plate walls on both sides in sequence, add rigid supports, and finally hoist the upper steel plate wall to complete the rectangular wall assembly. S5. Rectangular wall welding: Weld the rectangular wall obtained in step S4 according to the welding sequence of "first the horizontal weld, then the vertical welds on both sides, and finally the horizontal weld". The final product is obtained.

[0012] As a preferred embodiment, in step S1, the shrinkage compensation amount is specifically: the longitudinal shrinkage compensation amount is 2-3 mm / m, the transverse shrinkage compensation amount is 1-2 mm / m, and the rib spacing shrinkage compensation amount is 0.5-1 mm / spacing.

[0013] As a preferred option, step S201 specifically includes: The first step is to level the workbench surface to a flatness of ≤0.3mm / m, lay the second panel on the work platform, mark the position lines of the first and second ribs, assemble the first and second ribs and weld double-sided fillet welds, with at least two welders welding symmetrically, segmentally and alternately from the middle to both ends, with a weld height of 5mm; assemble the first panel, weld the first rib, the second rib and the single-sided fillet weld of the first panel, apply a weight on the upper surface during welding, and weld symmetrically, segmentally and alternately from the middle to both ends to obtain a semi-finished load-bearing unit; The second step involves securing the semi-finished load-bearing units obtained in the first step back-to-back with process clamps and adding temporary supports on both sides. Then, the box-shaped columns are placed at both ends of the semi-finished product, and the welds between the box-shaped columns and the panels of the semi-finished product are welded. At least two welders weld symmetrically from the middle to both ends. After one side of the weld is completed, the unit is disassembled, flipped, and the other side of the weld is welded. After welding, the flatness of the load-bearing unit is checked. If it does not meet the requirements, mechanical correction is used until the flatness is ≤1mm / m.

[0014] As a preferred embodiment, step S202 specifically involves: first, leveling the workbench surface to a flatness of ≤0.3mm / m, laying the third panel on the work platform, and marking the position lines of the third, fourth, and fifth ribs; second, assembling the third, fourth, and fifth ribs and welding double-sided fillet welds, with at least two welders performing symmetrical, segmented, and alternating welding from the middle to both ends, with a weld height of 5mm; then assembling the fourth panel, welding the single-sided fillet welds of the third and fifth ribs to the fourth panel, applying a weight to the upper end during welding, and welding in a symmetrical, segmented, and alternating manner from the middle to both ends; finally, completing the plug weld connection between the fourth rib and the fourth panel through the plug weld holes on the fourth panel.

[0015] As a preferred option, step S203 specifically involves: assembling the load-bearing unit and the connecting unit, controlling the flatness of the assembled unit to be no greater than 1 mm / m, and then welding the load-bearing unit and the connecting unit. The connection between the panel and the box column uses a single-sided V-groove weld, and the welding deformation is controlled by using a weight and welding symmetrically from the middle to both ends. After welding, the weld is inspected by ultrasonic testing. The interpass temperature during welding is ≤150℃, and the flatness of the outer surface of the welded steel plate wall unit is no greater than 1 mm / m.

[0016] As a preferred embodiment, in step S4, the rigid support includes an inclined support structure or a "well"-shaped support structure; during assembly, a total station is used to check and ensure that the perpendicularity between the side steel plate wall and the bottom steel plate wall is ≤5mm, and the parallelism between the side steel plate walls on both sides is ≤5mm.

[0017] As a preferred option, in step S5, after welding is completed, the rigid support is removed. After the weld has cooled to room temperature, the support is cut off by gas cutting at a distance of 3-5mm from the wall and then ground smooth before magnetic particle testing is performed. After welding, the single-sided V-groove weld is inspected by ultrasonic testing.

[0018] The beneficial effects of this invention are: To address the shortcomings of existing technologies, this invention provides a large-scale thin-walled steel plate wall structure and a method for controlling welding deformation. By optimizing the structural design and welding process, this invention achieves the following technical effects: Firstly, this invention solves the technical problems of limited internal cavity height and inability of specialized welding equipment to enter the interior for welding by setting single-sided V-groove welds facing the outside of the box column in the load-bearing unit and setting intermittent plug weld holes in the connecting unit, thereby transferring all inaccessible welds inside to the outside for welding and achieving welding heat input segmentation through regional plug welding. This achieves accessibility welding of all welds and controllable welding deformation, reducing the wave deformation of the steel plate wall by more than 50%.

[0019] Secondly, this invention breaks down the large thin-walled steel plate wall structure into load-bearing units and connecting units along the width direction. Each unit is independently assembled and welded before being spliced ​​together in sequence. This decomposes the overall welding deformation problem of the narrow and long structure into a local controllable problem of multiple units. This solves the technical problem of multiple degrees of freedom of deformation and difficulty in precise control during the overall assembly welding of the existing technology, and realizes the active deformation control of "breaking down the whole into parts and independently adjusting".

[0020] Thirdly, this invention solves the technical problem of poor welding operability and the need for repeated lifting and flipping of components caused by unreasonable welding sequence during the closure of rectangular walls by adopting the welding sequence of "first the horizontal weld, then the vertical welds on both sides, and finally the horizontal weld" and adding rigid support at the opening end. It ensures that all closure welds are completed in one go, effectively controls the welding deformation during closure, and guarantees the closure accuracy.

[0021] Fourth, this invention proposes for the first time a four-in-one systematic approach, filling the technological gap in deformation control of narrow and long thin plate densely ribbed structures. This technology provides a systematic solution for the segmented manufacturing and final assembly of large steel plate wall or composite steel plate wall structures with thin walls, narrow and long cavities, and small spacing of internal stiffening ribs, and provides a completely new technical path for welding deformation control of similar thin-walled densely ribbed structures. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is an overall schematic diagram of the rectangular steel plate wall structure of the present invention; Figure 2 This is a structural schematic diagram of the load-bearing unit; Figure 3 This is a structural schematic diagram of the connecting unit; Figure 4 Schematic diagram of panel plug solder hole design; Figure 5This is a schematic diagram of the back-to-back fixing structure during the welding process of the load-bearing unit; Figure 6 This is a schematic diagram of the structure after the load-bearing units and connecting units are welded together in an alternating manner. Figure 7 These are schematic diagrams of rigid support structures, where Figure a shows an inclined support structure and Figure b shows a "well" shaped support structure. In the diagram: 1. First panel, 2. Second panel, 3. Box column, 4. First rib, 5. Second rib, 6. Third panel, 7. Fourth panel, 8. Third rib, 9. Fourth rib, 10. Fifth rib, 11. Plug weld hole, 12. Single-sided V-groove weld, 13. Double-sided fillet weld, 14. Single-sided fillet weld, 15. Lower steel plate wall, 16. Side steel plate wall, 17. Upper steel plate wall, 18. Process plate, 19. Temporary support, 20. Diagonal support. Detailed Implementation

[0024] The present invention will now be described in detail through exemplary embodiments. However, it should be understood that, without further description, elements, structures, and features in one embodiment may be advantageously incorporated into other embodiments.

[0025] It should be noted that, unless otherwise defined, the technical or scientific terms used herein should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "a," "an," or "the," etc., used in the specification and claims of this patent application do not express a quantity limitation, but rather indicate the presence of at least one; terms such as "comprising" or "including" indicate that the elements or objects preceding "comprising" encompass the elements or objects listed following "comprising" or "including" and their equivalents, but do not exclude other elements or objects having the same function.

[0026] To more clearly describe the specific embodiments of the present invention, the accompanying drawings are provided. Figure 1 To be continued Figure 6 This embodiment is described as follows: This embodiment describes a large thin-walled steel plate wall component with the following structural parameters: total length 20m, total width 4.8m, and total height 4.8m. It is a rectangular steel plate wall component formed by welding four steel plate walls. Each single-sided steel plate wall is constructed by welding box-shaped columns 3, first panel 1, second panel 2 (or third panel 6 and fourth panel 7), and ribs. It is a narrow wall structure with densely packed stiffeners, reaching a length of 20 meters, a width of 4.8 meters, and a height of only 300mm. The spacing between the internal stiffening ribs is ≤500mm. The thickness of the first panel 1, second panel 2, third panel 6, and fourth panel 7 is 13mm. The box-shaped columns 3 have dimensions of 300×300×13mm, are made of Q355B material, and are welded using CO2 gas shielded welding with ER50-6 welding wire.

[0027] The large thin-walled steel plate wall structure in this embodiment includes a wall body, which is composed of load-bearing units and connecting units that are sequentially and alternately spliced ​​along the horizontal direction to form a rectangular steel plate wall structure system that is enclosed on all four sides.

[0028] In this embodiment, the steel plate wall is divided into several load-bearing units and connecting units along the width direction. The width of each load-bearing unit and connecting unit is ≤2500mm, and the number of ribs in each unit is ≤3, to ensure that all outer rib fillet welds can be welded using conventional CO2 gas shielded welding methods.

[0029] The specific steps are as follows: Step S1, Raw material pre-preparation and multi-directional shrinkage compensation: The large thin-walled steel plate wall is divided into several load-bearing units and connecting units along the width direction according to actual needs. By adopting the "scale reduction" strategy, each unit has the rigidity for independent welding and can be assembled and welded independently. The overall welding deformation problem of the narrow and long structure is decomposed into a local controllable problem of multiple units, realizing the active deformation control of "breaking down the whole into parts and independently adjusting".

[0030] In this embodiment, shrinkage compensation amounts are preset for each required load-bearing unit and connecting unit along the longitudinal, transverse, and stiffener spacing directions. The first panel 1, second panel 2, third panel 6, fourth panel 7, and ribs have a preset longitudinal shrinkage compensation amount of 2mm / m along the length of the steel plate wall, with a length of 20000mm and a cutting length of 20060mm; the transverse shrinkage compensation amount is preset at 1mm / m along the width direction, with a width of 900mm and a cutting length of 901mm; the stiffener spacing has a preset stiffener spacing compensation amount of 0.5mm / spacing, and the rib spacing of 300mm is implemented as 300.5mm.

[0031] Step S2, Steel Plate Wall Preparation: S201, Preparation of the load-bearing unit: The first step is to level the workbench surface to a flatness of ≤0.3mm / m, lay the second panel 2 on the work platform, mark the position lines of the first rib 4 and the second rib 5, assemble the first rib 4 and the second rib 5 and weld the double-sided fillet weld 13. At least two welders should weld symmetrically, segmentally and alternately from the middle to both ends, with a weld height of 5mm. Assemble the first panel 1 and weld the single-sided fillet weld 14 between the first rib 4, the second rib 5 and the first panel 1. Apply a weight to the upper end face during welding. The welding sequence is to weld symmetrically, segmentally and alternately from the middle to both ends to obtain a semi-finished load-bearing unit.

[0032] The second step involves securing the semi-finished load-bearing units obtained in the first step back-to-back with process clamps 18 and adding temporary supports 19 on both sides. Then, the box-shaped columns 3 are placed at both ends of the semi-finished product, and the welds between the box-shaped columns 3 and the panels of the semi-finished product are welded. At least two welders perform symmetrical welding from the middle to both ends. After the weld on one side is completed, the unit is disassembled, flipped, and the weld on the other side is welded. After welding, the flatness of the load-bearing unit is checked. If it does not meet the requirements, mechanical correction is used until the flatness is ≤1mm / m.

[0033] The load-bearing unit is formed by a first panel 1, a second panel 2, and box-shaped columns 3 located at both ends of the first panel 1 and the second panel 2. A first rib 4 and a second rib 5, parallel to each other, are provided between the first panel 1 and the second panel 2. In the load-bearing unit, both ends of the first panel 1 and the second panel 2 are connected to the box-shaped columns 3 via single-sided V-groove welds 12 facing outwards. The bevel angle of the single-sided V-groove is 45°-60°. One end of the first rib 4 and the second rib 5 is connected to the first panel 1 via double-sided fillet welds 13, and the other end of the first rib 4 and the second rib 5 is connected to the second panel 2 via single-sided fillet welds 14 facing the end of the second panel 2.

[0034] S202, Fabrication of the connecting unit: First, level the workbench surface to a flatness of ≤0.3mm / m. Lay the third panel 6 on the work platform and mark the position lines of the third rib 8, fourth rib 9, and fifth rib 10. Next, assemble the third rib 8, fourth rib 9, and fifth rib 10 and weld the double-sided fillet weld 13. At least two welders should weld symmetrically, segmentally, and alternately from the middle to both ends, with a weld height of 5mm. Then, assemble the fourth panel 7 and weld the single-sided fillet weld 14 between the third rib 8, fifth rib 10, and fourth panel 7. Apply a weight to the upper end face during welding. The welding sequence is symmetrical, segmentally, and alternately from the middle to both ends. Finally, complete the plug weld connection between the fourth rib 9 and the fourth panel 7 through the plug weld hole 11 on the fourth panel 7.

[0035] The connecting unit consists of a third panel 6, a fourth panel 7, and a third rib 8, a fourth rib 9, and a fifth rib 10 arranged parallel to each other and horizontally between the third panel 6 and the fourth panel 7. In the connecting unit, one end of the third rib 8, the fourth rib 9, and the fifth rib 10 is connected to the third panel 6 by a double-sided fillet weld 13; the other end of the third rib 8 and the fifth rib 10 is connected to the fourth panel 7 by a single-sided fillet weld 14 facing the port of the fourth panel 7; and the other end of the fourth rib 9 is plug-welded to the fourth panel 7 through a plug weld hole 11.

[0036] For the structure with three rows of vertical ribs in the connecting unit, the middle row of ribs (i.e., the fourth rib 9) and the fourth panel 7 are designed to be plug-welded: elliptical plug-weld holes 11 are made on the fourth panel 7 (13mm thick) corresponding to the fourth rib 9 (6mm thick). The minor axis of the plug-weld hole 11 is 8mm, the major axis is 100mm, and the spacing between adjacent plug-weld holes 11 is 100mm. By dividing the plug-weld holes 11 into areas, arranging them in a staggered manner, and welding them independently and intermittently, the plug-weld holes 11 can simultaneously achieve the dual functions of internal weld accessibility and welding heat input segmentation, reducing the corrugation deformation of the steel plate wall by more than 50%.

[0037] In the load-bearing and connecting units, the panel and the box-type column 3 are connected by a single-sided V-groove weld 12 with a groove angle of 45°-60°. By setting the groove on the outside of the component, all penetration welds can be welded from the outside of the component, transferring all inaccessible welds from the inside to the outside, avoiding welding in confined spaces inside, and structurally ensuring weld accessibility and quality control.

[0038] S203, Steel plate wall splicing: The load-bearing units and connecting units obtained in steps S201 and S202 are welded sequentially according to requirements to obtain the steel plate wall surface. Specifically, the load-bearing units and connecting units are assembled, and the flatness of the assembled unit is controlled to be no more than 1 mm / m. Then, the load-bearing units and connecting units are welded. The connection between the panel and the box column 3 uses a single-sided V-groove weld 12. Welding deformation is controlled by using a weight and welding symmetrically from the middle to both ends. After welding, the weld is inspected by ultrasonic testing. The interpass temperature during welding is ≤150℃, and the flatness of the outer surface of the welded steel plate wall unit is no more than 1 mm / m.

[0039] Step S3: Repeat step S2 to obtain four steel plate walls, namely the lower steel plate wall 15, the two side steel plate walls 16 and the upper steel plate wall 17.

[0040] Step S4: Closing the rectangular wall: The four steel plate walls obtained in step S3 are assembled into a rectangular wall. Specifically, the upper steel plate wall 17, the side steel plate walls 16, and the lower steel plate wall 15 are assembled into a rectangular wall, following the assembly sequence of "lower horizontal first → both sides vertical → finally upper horizontal," and temporary rigid reinforcement is added to the open ends. The specific assembly sequence is as follows: using the lower steel plate wall 15 as a reference, the side steel plate walls 16 are assembled sequentially, and diagonal supports 20 are added for rigid fixation. The diagonal supports 20 are made of channel steel, and one is welded at a spacing of 1.5m. Finally, the upper steel plate wall 17 is hoisted. During assembly, a total station is used to check and ensure that the perpendicularity between the side steel plate wall 16 and the lower steel plate wall 15 is ≤5mm, and the parallelism between the two side walls is ≤5mm.

[0041] Before welding, two rows of channel steel supports are added every 1.5m between the side steel plate wall 16 and the lower steel plate wall 15 to increase rigidity; temporary "well" rigid supports are added at the openings at both ends of the wall, with the supports 500mm from the end face. The temporary "well" rigid supports are made of rectangular steel pipes. These rigid supports are welded to the wall and can be reused; after the supports are removed and the weld has cooled to room temperature, the weld is cut off 3-5mm from the wall surface by gas cutting and then ground smooth before magnetic particle testing to ensure that no defects are generated after cutting.

[0042] Step S5, Welding of the rectangular wall surface: First, weld the lower horizontal weld (symmetrically from the middle to both ends), then weld the upper horizontal weld; welding must be strictly performed according to the corresponding welding specifications. After welding, the bevel welds are inspected by ultrasonic testing. This sectional welding method ensures that all welding positions are horizontal, reducing construction difficulty and ensuring that all welds of the rectangular steel plate wall component are completed in one operation without secondary flipping, thus reducing manufacturing difficulty and shortening the production cycle.

[0043] After welding is completed, the temporary support is removed. After the weld has cooled to room temperature, the support is cut off by gas cutting 3-5mm away from the wall and then ground smooth before magnetic particle testing. After welding, the bevel weld is inspected by ultrasonic testing to ensure that the internal quality of the weld meets the design requirements.

[0044] Steel plate wall components manufactured using the above method passed acceptance on the first attempt. Using a total station for assisted testing, the flatness (wave deformation) was found to be a maximum of 1 mm / m (far superior to the standard 1.5 mm / m); dimensional accuracy was: length deviation ±5 mm (after compensation), width deviation ±1 mm; the overall deformation was reduced by 70% compared to traditional processes, and the unit welding could be carried out in parallel, shortening the overall assembly time by about 40%; no large-area correction or repeated repairs were required, and the manufacturing cycle for a single piece was shortened from 45 days in traditional processes to 30 days, reducing the overall manufacturing cost by about 30%.

[0045] It should be noted that although the present invention has been described through the above embodiments, the present invention may have many other embodiments. Without departing from the spirit and scope of the present invention, those skilled in the art can obviously make various corresponding changes and modifications to the present invention, but all such changes and modifications should fall within the scope of protection of the appended claims and their equivalents.

Claims

1. A large thin-walled steel plate wall structure, comprising a wall body, characterized in that, The wall body is composed of load-bearing units and connecting units that are sequentially and alternately spliced ​​together in a horizontal direction. The load-bearing unit is formed by a first panel (1), a second panel (2) and box-shaped columns (3) located at both ends of the first panel (1) and the second panel (2). A first rib (4) and a second rib (5) are provided between the first panel (1) and the second panel (2) and are parallel to each other. The connecting unit includes a third panel (6) and a fourth panel (7). A third rib (8), a fourth rib (9) and a fifth rib (10) are arranged in parallel and horizontally between the third panel (6) and the fourth panel (7). A number of plug welding holes (11) are provided on the fourth panel (7) at intervals corresponding to the fourth rib (9). In the load-bearing unit, the two ends of the first panel (1) and the second panel (2) are respectively connected to the box column (3) through a single-sided V-groove weld (12) facing the outside of the box column (3); one end of the first rib (4) and the second rib (5) are connected to the first panel (1) through a double-sided fillet weld (13), and the other end of the first rib (4) and the second rib (5) are connected to the second panel (2) through a single-sided fillet weld (14) facing the port of the second panel (2); In the connecting unit, one end of the third rib (8), the fourth rib (9), and the fifth rib (10) is connected to the third panel (6) through a double-sided fillet weld (13); the other end of the third rib (8) and the fifth rib (10) is connected to the fourth panel (7) through a single-sided fillet weld (14) facing the port of the fourth panel (7), and the other end of the fourth rib (9) is plug-welded to the fourth panel (7) through the plug weld hole (11).

2. The large thin-walled steel plate wall structure according to claim 1, characterized in that, The bevel angle of the single-sided V-groove weld (12) is 45° to 60°. The plug weld hole (11) is elliptical with a minor axis of 8 to 15 mm and a major axis of 100 to 200 mm. The distance between adjacent plug weld holes (11) is 100 to 200 mm. The first panel (1) and the second panel (2) are rectangular strip steel plates.

3. The large thin-walled steel plate wall structure according to claim 1, characterized in that, The lengths of the first rib (4), the second rib (5), the third rib (8), the fourth rib (9), and the fifth rib (10) are less than or equal to 300 mm, and the spacing between adjacent ribs is less than or equal to 500 mm.

4. A method for controlling welding deformation of a large thin-walled steel plate wall structure, used for welding the large thin-walled steel plate wall structure according to any one of claims 1 to 3, characterized in that, Specifically, the following steps are included: S1. Raw material pre-preparation and multi-directional shrinkage compensation: The large thin-walled steel plate wall is divided into several load-bearing units and connecting units along the width direction. The load-bearing units and connecting units are staggered and spliced ​​in sequence along the horizontal direction. For each required load-bearing unit and connecting unit, the shrinkage compensation amount is preset along the longitudinal, transverse and stiffener spacing directions respectively. S2. Steel plate wall preparation: S201. The steel obtained in step S1 is independently assembled and welded to produce several load-bearing units. S202. The steel obtained in step S1 is independently welded to produce several connecting units; S203. Weld the load-bearing units and connecting units obtained in steps S201 and S202 in sequence according to requirements to obtain a steel plate wall. S3. Repeat step S2 to obtain several steel plate walls, including a lower steel plate wall (15), a side steel plate wall (16) and an upper steel plate wall (17). S4. Rectangular wall assembly: Assemble the several sets of steel plate walls obtained in step S3 into a rectangular wall. Specifically, take the lower steel plate wall (15) as the reference, assemble the side steel plate walls (16) on both sides in sequence, add rigid support, and finally hoist the upper steel plate wall (17) to complete the rectangular wall assembly. S5. Rectangular wall welding: Weld the rectangular wall obtained in step S4 according to the welding sequence of "first the horizontal weld, then the vertical welds on both sides, and finally the horizontal weld". The final product is obtained.

5. The method for controlling welding deformation of a large thin-walled steel plate wall structure according to claim 4, characterized in that, In step S1, the shrinkage compensation amount is specifically as follows: the longitudinal shrinkage compensation amount is 2-3 mm / m, the transverse shrinkage compensation amount is 1-2 mm / m, and the rib spacing shrinkage compensation amount is 0.5-1 mm / spacing.

6. The method for controlling welding deformation of a large thin-walled steel plate wall structure according to claim 4, characterized in that, Step S201 is as follows: First step, level the workbench surface to a flatness of ≤0.3mm / m, lay the second panel (2) on the work platform, mark the position lines of the first rib (4) and the second rib (5), assemble the first rib (4) and the second rib (5) and weld the double-sided fillet weld (13), with at least 2 welders welding symmetrically, segmentally and alternately from the middle to both ends, with a weld height of 5mm; assemble the first panel (1), weld the single-sided fillet weld (14) of the first rib (4), the second rib (5) and the first panel (1), apply a weight to the upper end face during welding, and weld. The sequence is to weld symmetrically from the middle to both ends, segmented and alternately, to obtain a semi-finished load-bearing unit; the second step is to fix the semi-finished load-bearing units obtained in the first step back to back with process clamps (18) and install temporary supports (19) on both sides. Then, place the box column (3) at both ends of the semi-finished product and weld the weld between the box column (3) and the panel of the semi-finished product. At least two welders weld symmetrically from the middle to both ends. After the weld on one side is completed, disassemble and flip it to weld the weld on the other side. After welding, check the flatness of the load-bearing unit. If it does not meet the requirements, use mechanical correction to make the flatness ≤1mm / m. Step S202 is as follows: First, level the workbench surface to a flatness of ≤0.3mm / m, lay the third panel (6) on the work platform, and mark the position lines of the third rib (8), the fourth rib (9) and the fifth rib (10); second, assemble the third rib (8), the fourth rib (9) and the fifth rib (10) and weld the double-sided fillet weld (13). At least two welders will weld symmetrically, segmentally and alternately from the middle to both ends, and the weld height is 5mm; then assemble the fourth panel (7), and weld the single-sided fillet weld (14) of the third rib (8), the fifth rib (10) and the fourth panel (7). When welding, apply a weight to the upper end face. The welding sequence is to weld symmetrically, segmentally and alternately from the middle to both ends. Finally, complete the plug weld connection between the fourth rib (9) and the fourth panel (7) through the plug weld hole (11) on the fourth panel (7).

7. The method for controlling welding deformation of a large thin-walled steel plate wall structure according to claim 6, characterized in that, Step S203 is as follows: Assemble the load-bearing unit and the connecting unit, control the flatness of the assembled unit to be no more than 1 mm / m, and then weld them into a load-bearing unit and a connecting unit. Use a single-sided V-groove weld (12) at the connection between the panel and the box column (3). Use a weighted object and a symmetrical welding method from the middle to both ends to control the welding deformation. Perform ultrasonic testing on the weld after welding. The interlayer temperature during welding is ≤150℃. The flatness of the outer surface of the welded steel plate wall unit is no more than 1 mm / m.

8. The method for controlling welding deformation of a large thin-walled steel plate wall structure according to claim 4, characterized in that, In step S4, the rigid support includes a diagonal support (20) structure or a "well" type support structure; during assembly, a total station is used to check to ensure that the perpendicularity between the side steel plate wall (16) and the lower steel plate wall (15) is ≤5mm, and the parallelism between the side steel plate walls (16) on both sides is ≤5mm.

9. The method for controlling welding deformation of large thin-walled steel plate wall structures according to claim 4, characterized in that, In step S5, after welding is completed, the rigid support is removed. After the weld cools to room temperature, the support is cut off by gas cutting at a distance of 3-5 mm from the wall and then polished smooth before magnetic particle testing is performed. After welding, the single-sided V-groove weld (12) is subjected to ultrasonic testing.

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