A cast-weld combined cable saddle and a manufacturing method thereof

Abstract

The present application relates to the technical field of suspension bridge cable saddle, and particularly discloses a cast-weld combined cable saddle and a manufacturing method thereof. The cast-weld combined cable saddle comprises a saddle head of a cast structure and a saddle body of a welded structure; the saddle body has a plurality of main steel plates welded with the saddle head; the bottom of the saddle head is used as a region for abutting the main steel plates of the saddle body, and a transition layer is formed by surfacing welding; in the overall structure of the cable saddle composed of the saddle head and the saddle body, the main steel plates of the saddle body are welded with the corresponding transition layers at the bottom of the saddle head. The present application effectively improves the mechanical properties of the welding combination region at the bottom of the saddle head of the cast structure, reduces (even eliminates) hidden defects, ensures the stability and reliability of the welding combination of the main steel plates of the saddle body, and is beneficial to improving the product qualification rate of the cable saddle, which is particularly suitable for the manufacturing of super-large cable saddles for large-span suspension bridges with a span of more than 2000 meters.

Description

Technical Field

[0001] This invention relates to the field of suspension bridge cable saddle technology, specifically a cast-welded composite cable saddle and its manufacturing method. Background Technology

[0002] In suspension bridge structures, cable saddles (including main cable saddles and auxiliary cable saddles) are permanent structural components used to support and steer the main cables. Common types of cable saddles include all-cast, all-welded, and cast-welded composite types. Among these, the cast-welded composite type combines the technical advantages of both all-cast and all-welded saddles. The complex saddle head is cast from steel, while the simpler saddle body is welded from steel plates. This effectively utilizes the structural strength and manufacturing advantages of all-cast and all-welded saddles, resolving the conflict between simplified manufacturing processes and efficient material utilization. It is currently the mainstream technology, particularly prominent in the construction of long-span suspension bridges.

[0003] Currently, there is a type of cast-welded composite cable saddle where the main steel plate of the saddle body (i.e., the steel plate that is combined with the saddle head) is directly welded to the bottom of the saddle head to form an integral cable saddle structure. For example, the Chinese patent document published under the title "Cast-Welded Main Cable Saddle Body Forming Method" with publication number CN 106181090 A and publication date of December 7, 2016, etc.

[0004] However, because the saddle head of a cast structure is typically solidified last in its thick bottom section during casting, and the large size of the saddle head results in slow cooling during the casting process, significant porosity and elemental segregation occur at the bottom. This creates a compositional gradient at the bottom of the saddle head, affecting its mechanical properties, especially prominent in ultra-large cable saddle structures used in long-span suspension bridges exceeding 2000 meters. Therefore, welding the main steel plate of the saddle body to the mechanically unstable bottom of the cast saddle head not only affects the product qualification rate of the finished cable saddle, increasing the overall manufacturing difficulty and cost, but also leads to instability in the overall mechanical properties of the finished cable saddle due to inherent defects in the casting. Summary of the Invention

[0005] The technical objective of this invention is to address the unique characteristics of the cast-welded composite cable saddle structure, where the main steel plate of the saddle body is welded together at the bottom of the saddle head, and to overcome the shortcomings of existing technologies. This invention provides a cast-welded composite cable saddle that effectively improves the mechanical properties of the welded area at the bottom of the cast saddle head, reduces (or even eliminates) potential defects, ensures the stability and reliability of the welded assembly with the main steel plate of the saddle body, and helps improve the pass rate of cable saddle products. It also includes a method for manufacturing this cast-welded composite cable saddle.

[0006] The technical objective of this invention is achieved through the following technical solution: a cast-welded composite cable saddle, comprising a saddle head with a cast structure and a saddle body with a welded structure; The saddle body has multiple main steel plates that are welded together with the saddle head; At the bottom of the saddle head, in the area used to connect with the main steel plates of the saddle body, a connecting transition layer is formed by overlay welding. In the overall cable saddle structure composed of the saddle head and the saddle body, each main steel plate of the saddle body and the corresponding butt joint transition layer at the bottom of the saddle head form a welded assembly.

[0007] As one of the preferred technical solutions, corresponding to the longitudinal and transverse arrangement of each main steel plate of the saddle body relative to the suspension bridge, the docking transition layer at the bottom of the saddle head has a longitudinal docking transition layer and a transverse docking transition layer that are adapted to the extension trajectory. The longitudinal butt transition layer is used to weld the corresponding longitudinal main steel plate of the saddle body; The transverse buttress transition layer serves as the corresponding transverse main steel plate for welding the saddle body.

[0008] Furthermore, the outline of each mating transition layer at the bottom of the saddle head is at least aligned with the mating outline of the corresponding main steel plate.

[0009] Furthermore, the length of the mating transition layer is at least 10mm longer than the length of the corresponding main steel plate mating surface; The width of the mating transition layer is at least 10mm greater than the width of the corresponding main steel plate mating surface. The coverage surface of the transition layer can completely cover the mating surface of the corresponding main steel plate.

[0010] As one of the preferred technical solutions, the mating transition layer is formed in the corresponding concave weld cavity at the bottom of the saddle head by a weld overlay structure; The concave welded cavity at the bottom of the saddle head forms a transition between adjacent surfaces with a rounded corner structure.

[0011] Furthermore, the thickness of the docking transition layer is 15–20 mm.

[0012] As one of the preferred technical solutions, the saddle head is a cast structure made of cast steel material with grade ZG300-500H; The main steel plate of the saddle body is a bridge steel plate structure of grade Q420qE; The transition layer is a welding structure using ER80S-G welding wire.

[0013] As one of the preferred technical solutions, the cable saddle is a loose cable saddle or a main cable saddle.

[0014] A method for manufacturing a cast-welded composite cable saddle, the method being based on the aforementioned cast-welded composite cable saddle; The manufacturing method includes the following process steps: Step A. Cast the saddle head using cast steel according to the design requirements of the saddle head; The obtained saddle head blank is subjected to rough machining. Step B. According to the arrangement of the main steel plates in the saddle body design requirements, perform corresponding groove processing on the bottom of the saddle head; The adjacent surfaces of each settling tank are transitioned by a rounded corner structure; Obtain the corresponding concave weld overlay cavity; Step C. Perform flaw detection on the concave weld overlay cavity of the saddle head from Step B; No defects exceeding the standard were confirmed; If defects exceed the standard, they must be removed first. Step D. Place the flaw-detected saddle head into the furnace for preheating treatment; Preheating temperature is 100-150℃, and the temperature should be maintained for at least 2 hours; Step E. Remove the preheated saddle head from the furnace and wrap it with asbestos cloth for insulation, leaving only the concave welding cavity area to be welded open. Step F. At the reserved current concave weld overlay cavity, perform the weld overlay process according to the weld overlay process requirements. During the weld overlay process, use a natural gas torch to heat the current concave weld overlay cavity to ensure that the temperature of the area to be welded during the weld overlay process is not lower than 150°C. The weld overlay area obtained after welding has sufficient machining allowance at the bottom of the saddle head; Step G. After the welding of all the concave cavities at the bottom of the saddle head is completed, immediately send the saddle head into the furnace for stress relief heat treatment; The stress relief heat treatment temperature is 520–560℃, and the holding time is at least 4 hours; Step H. After the saddle head has been removed from the furnace after stress relief heat treatment, perform air gouging on the weld overlay area and other processing on other parts; Step I. Perform a flaw detection inspection on the saddle head from Step H; After passing the inspection, the saddle head is transferred to the welding and assembly process with the saddle body, so that the main steel plates of the saddle body are welded together with the corresponding butt weld layers at the bottom of the saddle head. The process continues until the steel plates of the saddle body are welded and assembled at the saddle head to obtain the cable saddle blank. Step J. Perform corresponding heat treatment and finish machining on the cable saddle blank; Obtain the finished cable saddle.

[0015] A method for manufacturing a cast-welded composite cable saddle, the method being based on the aforementioned cast-welded composite cable saddle; The manufacturing method includes the following process steps: Step 1. Cast the saddle head using cast steel according to the design requirements of the saddle head; The obtained saddle head blank is subjected to rough machining. Step 2. According to the arrangement of the main steel plates in the saddle body design requirements, perform corresponding groove processing on the bottom of the saddle head; The adjacent surfaces of each settling tank are transitioned by a rounded corner structure; Obtain the corresponding concave weld overlay cavity; Step 3. Perform flaw detection on the concave weld overlay cavity of the saddle head from Step 2; No defects exceeding the standard were confirmed; If defects exceed the standard, they must be removed first. Step 4. Place the flaw-detected saddle head into the furnace for preheating treatment; Preheating temperature is 100-150℃, and the temperature should be maintained for at least 2 hours; Step 5. Remove the preheated saddle head from the furnace and wrap it with asbestos cloth for insulation, leaving only the concave welding cavity area to be welded open. Step 6. At the reserved current concave welding cavity, perform the welding process according to the welding process requirements. During the welding process, use a natural gas torch to heat the current concave welding cavity to ensure that the temperature of the area to be welded is not lower than 150°C. The weld overlay area obtained after welding has sufficient machining allowance at the bottom of the saddle head; Step 7. After the welding of all the concave cavities at the bottom of the saddle head is completed, the weld and heat-affected zone are preheated to 300-350°C using a hydrogen removal method and kept at that temperature for at least 2 hours. Step 8. While the fabric is kept warm with asbestos cloth, allow it to cool slowly to room temperature; Grind the weld seams of the saddle head; Step 9. Perform a flaw detection inspection on the saddle head from Step 8; After passing the test, the saddle head is sent into the furnace for stress relief heat treatment; The stress relief heat treatment temperature is 520–560℃, and the holding time is at least 4 hours; Step 10. After the saddle head has been removed from the furnace after stress relief heat treatment, perform air gouging on the weld overlay area and other processing on other parts; Step 11. Transfer the saddle head from Step 10 to the welding assembly process with the saddle body, so that the main steel plates of the saddle body are welded together with the corresponding butt weld layers at the bottom of the saddle head, until the welding assembly of the various steel plates of the saddle body is completed on the saddle head, and the cable saddle blank is obtained. Step 12. Perform corresponding heat treatment and finishing on the cable saddle blank; Obtain the finished cable saddle.

[0016] The beneficial technical effects of this invention are as follows: Addressing the unique characteristics of the cast-welded composite cable saddle structure where the main steel plates of the saddle body are welded together at the bottom of the saddle head, the bottom of the saddle head is used as the area for welding the main steel plates of the composite saddle body. A weld overlay structure with dense microstructure, minimal elemental segregation, and superior mechanical properties compared to the saddle head is formed at the bottom of the saddle head, creating a weld overlay structure that serves as a butt joint transition layer for the corresponding main steel plates of the composite saddle body. This allows the main steel plates of the saddle body to form a welded assembly based on this transition layer at the bottom of the saddle head. This significantly improves the porosity and elemental segregation issues caused by thickness differences in the welded assembly area at the bottom of the saddle head. Furthermore, the strength of the weld overlay wire increases the mechanical properties of the transition layer in the welded assembly area at the bottom of the saddle head, reducing stress tension during the subsequent welding process between the cast saddle head and the main steel plates of the saddle body. This greatly enhances the stability and reliability of the welded assembly between the cast saddle head and the welded saddle body, thus improving the product qualification rate of the formed cast-welded composite cable saddle.

[0017] Therefore, the above-mentioned technical measures effectively improve the mechanical properties of the welded assembly area at the bottom of the saddle head of the casting structure, reduce (or even eliminate) hidden defects, so as to ensure the stability and reliability of the welded assembly with the main steel plate of the saddle body, which is conducive to improving the qualification rate of cable saddle products. This is particularly applicable to the manufacturing and forming of ultra-large cable saddles used in large-span suspension bridges of 2000 meters and above, and has positive technical significance and economic benefits for ensuring the overall mechanical properties of the cable saddle. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of one structure of the present invention (the saddle head and saddle body are in a disassembled state).

[0019] Figure 2 for Figure 1 A schematic diagram of the saddle head structure.

[0020] Figure 3 for Figure 2 A magnified view of part A in the image.

[0021] Figure 4 for Figure 2 A magnified view of section B in the image.

[0022] Figure 5 for Figure 1 A structural diagram of the combined state (the saddle is shown in perspective).

[0023] Meaning of the codes in the image: 1—Saddle head; 11—Longitudinal docking transition layer; 12—Transverse docking transition layer; 2—Saddle body; 21—Longitudinal main steel plate; 22—Transverse main steel plate. Detailed Implementation

[0024] This invention relates to the field of suspension bridge cable saddle technology, specifically a cast-welded composite cable saddle and its manufacturing method. The main technical solution of this invention will be described in detail below with reference to several embodiments. Embodiment 1 is illustrated in conjunction with the accompanying drawings—that is… Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 The technical solution of the present invention is clearly and in detail explained; although other embodiments are not shown in separate drawings, their main structure can still be referred to the drawings of Embodiment 1.

[0025] It should be noted that the accompanying drawings of this invention are schematic, and unnecessary details have been simplified to clarify the technical objectives of this invention, so as to avoid obscuring the technical solutions contributed by this invention to the prior art. Furthermore, the terms "approximately" or "basically" used below to refer to quantities or fit relationships mean that reasonable assembly and processing errors are allowed in the industry, and do not literally describe absolute quantities or fit relationships.

[0026] Example 1 See Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, the present invention is a cast-welded composite cable saddle, which is aimed at the welded composite structure of the main steel plate of the welded saddle body at the bottom of the cast saddle head. Therefore, it includes a cast saddle head 1 and a welded saddle body 2, and they ultimately form a welded composite of the main steel plate of the saddle body 2 at the bottom of the saddle head 1.

[0027] Specifically, the cable saddle of this invention is a loose cable saddle. The saddle head 1 is cast from cast steel material of grade ZG300-500H. The saddle body 2 has multiple main steel plates welded together with the saddle head 1, including three longitudinal main steel plates 21 arranged along the longitudinal direction of the suspension bridge and three sets of transverse main steel plates 22 arranged along the transverse direction of the suspension bridge. Note that the transverse main steel plates 22 are defined as sets because each set of transverse main steel plates 22 corresponds to two of the three longitudinal main steel plates 21. The two transverse main steel plates 22 in the same set are arranged between the three longitudinal main steel plates 21 and are basically on the same plane. Whether it is the longitudinal main steel plates 21 or the transverse main steel plates 22, these main steel plates of the saddle body 1 are cut and formed from bridge steel plates of grade Q420qE. Of course, the above description of the main steel plates of the saddle body 2 is based on the direct connection relationship with the saddle head 1. The saddle body 2 also has other steel plates that are not directly connected to the saddle head 1. The arrangement of these other steel plates can be based on the conventional structure.

[0028] According to the molding structure of the saddle body 2, the main steel plates of the saddle body 2 form a cross arrangement structure in the longitudinal direction and the transverse direction of the suspension bridge. Correspondingly, at the bottom of the saddle head 1, three longitudinal butt transition layers for welding and assembling the corresponding longitudinal main steel plates 21 are formed, and three transverse butt transition layers for welding and assembling the corresponding transverse main steel plates 21 are formed. These longitudinal butt transition layers 11 and transverse butt transition layers 12 extend along a trajectory adapted to the arrangement direction of the corresponding main steel plates, so that butt transition layers arranged in an approximate "field" shape are formed at the bottom of the saddle head 1. That is to say, at the bottom of the saddle head 1, corresponding butt transition layers are formed in the areas for butting the main steel plates of the saddle body 2.

[0029] To ensure the mechanical properties of the welded assembly between the saddle head 1 and the main steel plates of the saddle body 2, the coverage outline of each butt transition layer at the bottom of the saddle head 1 is slightly larger than the outline of the joint surface (i.e., the top surface) of the corresponding main steel plate. Generally, the length of the butt transition layer is about 20mm slightly greater than the length of the joint surface of the corresponding main steel plate, and the width of the butt transition layer is about 20mm slightly greater than the width of the joint surface of the corresponding main steel plate, so that the coverage surface of the butt transition layer can completely cover the joint surface of the corresponding main steel plate.

[0030] The above-mentioned butt transition layers, namely the longitudinal butt transition layers 11 and the transverse butt transition layers 12, are surfacing structures formed by a welding wire with grade ER80S-G at the bottom of the saddle head 1, that is, the corresponding butt transition layers are formed at the bottom of the saddle head 1 by a surfacing structure. To adapt to the surfacing molding of the butt transition layers, concave surfacing cavities are formed as concave structures at the bottom of the cast saddle head 1 at the designed positions of each butt transition layer, so that the surfacing molding structure of the welding wire with grade ER80S-G in the corresponding concave surfacing cavity constitutes the butt transition layer. Usually, the thickness of each butt transition layer at the bottom of the saddle head 1 is selected within the range of 15 to 20mm, such as 15mm, 17mm or 20mm.

[0031] In addition, when the butt transition layers are formed, in order to reduce the tendency of welding cracks, the concave surfacing cavity at the bottom of the saddle head 1 adopts a rounded corner transition between adjacent surfaces forming the cavity, that is, the edges and corners inside the concave surfacing cavity are rounded with R transition.

[0032] Based on the aforementioned casting structure, the saddle head 1 with a bottom transition layer, and the saddle body 2 with a main steel plate and a welded structure, the two are welded together to form an integral cable saddle structure. In the integral cable saddle structure composed of the saddle head 1 and the saddle body 2, each main steel plate of the saddle body 2 is welded to the corresponding bottom transition layer of the saddle head 1. The covering surface of the bottom transition layer of the saddle head 1 completely covers the joint surface of the corresponding main steel plate. That is to say, each main steel plate of the saddle body 2 is only welded to the corresponding bottom transition layer of the saddle head 1, and not to the casting structure of the saddle head 1 body.

[0033] The aforementioned cast-welded composite cable saddle, based on the butt transition layer of the welded structure at the bottom of the saddle head 1, greatly improves the potential defects such as porosity and element segregation caused by thickness difference in the welded assembly area at the bottom of the saddle head 1. The strength of the weld wire also increases the mechanical properties of the transition layer in the welded assembly area at the bottom of the saddle head 1, which reduces stress tension during the subsequent welding process between the cast steel saddle head and the saddle body steel plate, greatly improving the mechanical properties of the welded assembly between the cast steel saddle head and the saddle body steel plate, as well as the pass rate of the welded joint.

[0034] The manufacturing method of the above-mentioned cast-welded composite cable saddle includes the following process steps: Step A. Cast the saddle head using cast steel material of grade ZG300-500H according to the design requirements of saddle head 1; The obtained saddle head blank is subjected to rough machining, especially the bottom part; Step B. According to the arrangement of the main steel plates in the design requirements of saddle body 2, perform corresponding groove processing on the bottom of saddle head 1; The adjacent surfaces of each settling tank are transitioned by a rounded corner structure; Obtain the corresponding concave weld overlay cavity; Step C. Perform flaw detection on the concave weld overlay cavity of the saddle head from Step B using either MT or UT flaw detection methods. Confirm that there are no defects exceeding the standard (defects exceeding the standard are determined according to ultrasonic testing standards). If defects exceed the standard, they must be removed first. Step D. Place the flaw-detected saddle head 1 into the furnace for preheating treatment; The preheating temperature can be selected within the range of 100 to 150°C, such as 100°C, 120°C or 150°C, and the temperature should be maintained at the set preheating temperature for at least 2 hours, such as 2 hours, 2.5 hours or 3 hours. Step E. Remove the preheated saddle head 1 from the furnace and wrap it with asbestos cloth for insulation, leaving only the concave welding cavity area to be welded open. Step F. At the reserved current concave weld overlay cavity, use welding wire of grade ER80S-G (welding wire diameter 1.2mm) to perform the weld overlay process according to the weld overlay process requirements. During the weld overlay process, use a natural gas torch to heat the current concave weld overlay cavity to ensure that the temperature of the area to be welded during the weld overlay process is not lower than 150℃. The weld overlay area obtained after welding has sufficient machining allowance at the bottom of the saddle head 1, usually with a machining allowance of 2mm or 3mm. Step G. After the welding of all the concave cavities at the bottom of the saddle head 1 is completed, the saddle head 1 is immediately sent into the furnace for stress relief heat treatment. The temperature for stress relief heat treatment is selected within the range of 520 to 560°C, such as 520°C, 540°C or 560°C. The temperature is maintained at the set stress relief heat treatment temperature for at least 4 hours, such as 4 hours, 4.5 hours or 5 hours. Step H. After the saddle head 1 is removed from the furnace after stress relief heat treatment, perform air gouging on the weld overlay area and other processing on other parts; Step I. Perform flaw detection inspection on the saddle head 1 from step H using either MT or UT flaw detection methods; After passing the test, the saddle head 1 is transferred to the welding and assembly process with the saddle body 2, so that the main steel plates of the saddle body 2 are welded together with the corresponding butt weld layers at the bottom of the saddle head 1. Until the steel plates of the saddle body 2 are welded and assembled on the saddle head 1, the cable saddle blank is obtained; Step J. Perform corresponding heat treatment and finish machining on the cable saddle blank; Obtain the finished cable saddle.

[0035] In step F above, the welding process is GMAW welding, and the appropriate parameter can be selected within the following parameter range: The gas type is 100% CO2, the interpass temperature is ≤200℃, and the gas flow rate is 15~20L / min. The process is carried out in the form of root pass, fill pass, and cover pass. The welding current for the root pass is 260–280A, the welding voltage is 30–32V, the current type / polarity is DC+, and the welding speed is 240–320mm / min. The welding current for filler welds is 280–300A, the welding voltage is 32–34V, the current type / polarity is DC+, and the welding speed is 350–500 mm / min. The welding current for the cover pass is 280–300A, the welding voltage is 32–34V, the current type / polarity is DC+, and the welding speed is 250–500mm / min.

[0036] If the above flaw detection inspection adopts the MT method, then GB / T26952-2011 shall be implemented, with a detection degree of 100% and a detection requirement of level 1; if the UT method is adopted, then GB / T11345-2023 shall be implemented, with an inspection level of B, a detection degree of 100%, and a detection requirement of GB / T29712-2023 and an acceptance level of level 2.

[0037] Example 2 The rest of the contents of this embodiment are the same as those of Embodiment 1, except for the manufacturing method.

[0038] In this embodiment, the manufacturing method includes the following process steps: Step 1. Cast the saddle head using cast steel according to the design requirements of the saddle head; The obtained saddle head blank is subjected to rough machining. Step 2. According to the arrangement of the main steel plates in the saddle body design requirements, perform corresponding groove processing on the bottom of the saddle head; The adjacent surfaces of each settling tank are transitioned by a rounded corner structure; Obtain the corresponding concave weld overlay cavity; Step 3. Perform flaw detection on the concave weld overlay cavity of the saddle head from Step 2; No defects exceeding the standard were confirmed; If defects exceed the standard, they must be removed first. Step 4. Place the flaw-detected saddle head into the furnace for preheating treatment; The preheating temperature can be selected within the range of 100 to 150°C, such as 100°C, 130°C or 150°C, and the temperature should be maintained at the set preheating temperature for at least 2 hours, such as 2 hours, 2.5 hours or 3 hours. Step 5. Remove the preheated saddle head from the furnace and wrap it with asbestos cloth for insulation, leaving only the concave welding cavity area to be welded open. Step 6. At the reserved current concave welding cavity, perform the welding process according to the welding process requirements. During the welding process, use a natural gas torch to heat the current concave welding cavity to ensure that the temperature of the area to be welded is not lower than 150°C. The weld overlay area obtained after welding has sufficient machining allowance at the bottom of the saddle head; Step 7. After the welding of all the concave cavities at the bottom of the saddle head is completed, the weld and heat-affected zone are preheated to 330°C (or 300°C, or 350°C) using the hydrogen removal method, and kept at that temperature for 2.5 hours (or 3 hours, or 2 hours). Step 8. While the fabric is kept warm with asbestos cloth, allow it to cool slowly to room temperature; Grind the weld seams of the saddle head; Step 9. Perform a flaw detection inspection on the saddle head from Step 8; After passing the test, the saddle head is sent into the furnace for stress relief heat treatment; The temperature for stress relief heat treatment is selected within the range of 520 to 560°C, such as 520°C, 540°C or 560°C. The temperature is maintained at the set stress relief heat treatment temperature for at least 4 hours, such as 4 hours, 4.5 hours or 5 hours. Step 10. After the saddle head has been removed from the furnace after stress relief heat treatment, perform air gouging on the weld overlay area and other processing on other parts; Step 11. Transfer the saddle head from Step 10 to the welding assembly process with the saddle body, so that the main steel plates of the saddle body are welded together with the corresponding butt weld layers at the bottom of the saddle head, until the welding assembly of the various steel plates of the saddle body is completed on the saddle head, and the cable saddle blank is obtained. Step 12. Perform corresponding heat treatment and finishing on the cable saddle blank; Obtain the finished cable saddle.

[0039] Example 3 The rest of the content of this embodiment is the same as that of embodiment 1 or embodiment 2, except that: The cast-welded composite cable saddle of the present invention is the main cable saddle of a suspension bridge.

[0040] The above embodiments are only used to illustrate the present invention and are not intended to limit it.

[0041] Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions of the above embodiments, or equivalent substitutions can be made to some of the technical features, such as the number of main steel plates arranged in the saddle body; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the present invention.

Claims

1. A cast-welded composite cable saddle, comprising a saddle head (1) of cast structure and a saddle body (2) of welded structure. The saddle body (2) has multiple main steel plates that are welded together with the saddle head (1); Its features are: At the bottom of the saddle head (1), the area used to connect with each main steel plate of the saddle body (2) is formed with a weld overlay structure to form a connecting transition layer; In the cable saddle integral structure composed of the saddle head (1) and the saddle body (2), each main steel plate of the saddle body (2) and the corresponding butt transition layer at the bottom of the saddle head (1) form a welded combination.

2. The cast-welded composite cable saddle according to claim 1, characterized in that: Corresponding to the longitudinal and transverse arrangement of each main steel plate of the saddle body (2) relative to the suspension bridge, the bottom of the saddle head (1) has a longitudinal docking transition layer (11) and a transverse docking transition layer (12) adapted to the extension trajectory. The longitudinal butt transition layer (11) is used as the corresponding longitudinal main steel plate (21) for welding the saddle body (2). The transverse butt transition layer (12) is used as the corresponding transverse main steel plate (21) for welding the saddle body (2).

3. The cast-welded composite cable saddle according to claim 2, characterized in that: Each mating transition layer at the bottom of the saddle head (1) has a coverage surface profile that is at least aligned with the mating surface profile of the corresponding main steel plate.

4. The cast-welded composite cable saddle according to claim 3, characterized in that: The length of the transition layer is at least 10mm longer than the length of the corresponding main steel plate mating surface. The width of the mating transition layer is at least 10mm greater than the width of the corresponding main steel plate mating surface. The coverage surface of the transition layer can completely cover the mating surface of the corresponding main steel plate.

5. The cast-welded composite cable saddle according to claim 1, 2, 3 or 4, characterized in that: The mating transition layer is formed in the corresponding concave weld cavity at the bottom of the saddle head (1) by a weld overlay structure; The concave welded cavity at the bottom of the saddle head (1) forms a transition between adjacent surfaces of the cavity with a rounded corner structure.

6. The cast-welded composite cable saddle according to claim 5, characterized in that: The thickness of the docking transition layer is 15-20 mm.

7. The cast-welded composite cable saddle according to claim 1, characterized in that: The saddle head (1) is a cast structure made of cast steel material with grade ZG300-500H; The main steel plate of the saddle body (1) is a bridge steel plate structure of grade Q420qE; The transition layer is a welding structure using ER80S-G welding wire.

8. The cast-welded composite cable saddle according to claim 1 or 7, characterized in that: The cable saddle is either a loose cable saddle or a main cable saddle.

9. A method for manufacturing a cast-welded composite cable saddle, characterized in that: The manufacturing method is based on the cast-welded combined cable saddle as described in any one of claims 1 to 8; The manufacturing method includes the following process steps: Step A. Cast the saddle head using cast steel according to the design requirements of the saddle head; The obtained saddle head blank is subjected to rough machining. Step B. According to the arrangement of the main steel plates in the saddle body design requirements, perform corresponding groove processing on the bottom of the saddle head; The adjacent surfaces of each settling tank are transitioned by a rounded corner structure; Obtain the corresponding concave weld overlay cavity; Step C. Perform flaw detection on the concave weld overlay cavity of the saddle head from Step B; No defects exceeding the standard were confirmed; If defects exceed the standard, they must be removed first. Step D. Place the flaw-detected saddle head into the furnace for preheating treatment; Preheating temperature is 100-150℃, and the temperature should be maintained for at least 2 hours; Step E. Remove the preheated saddle head from the furnace and wrap it with asbestos cloth for insulation, leaving only the concave welding cavity area to be welded open. Step F. At the reserved current concave weld overlay cavity, perform the weld overlay process according to the weld overlay process requirements. During the weld overlay process, use a natural gas torch to heat the current concave weld overlay cavity to ensure that the temperature of the area to be welded during the weld overlay process is not lower than 150°C. The weld overlay area obtained after welding has sufficient machining allowance at the bottom of the saddle head; Step G. After the welding of all the concave cavities at the bottom of the saddle head is completed, immediately send the saddle head into the furnace for stress relief heat treatment; The stress relief heat treatment temperature is 520–560℃, and the holding time is at least 4 hours; Step H. After the saddle head has been removed from the furnace after stress relief heat treatment, perform air gouging on the weld overlay area and other processing on other parts; Step I. Perform a flaw detection inspection on the saddle head from Step H; After passing the inspection, the saddle head is transferred to the welding and assembly process with the saddle body, so that the main steel plates of the saddle body are welded together with the corresponding butt weld layers at the bottom of the saddle head. The process continues until the steel plates of the saddle body are welded and assembled at the saddle head to obtain the cable saddle blank. Step J. Perform corresponding heat treatment and finish machining on the cable saddle blank; Obtain the finished cable saddle.

10. A method for manufacturing a cast-welded composite cable saddle, characterized in that: The manufacturing method is based on the cast-welded combined cable saddle as described in any one of claims 1 to 8; The manufacturing method includes the following process steps: Step 1. Cast the saddle head using cast steel according to the design requirements of the saddle head; The obtained saddle head blank is subjected to rough machining. Step 2. According to the arrangement of the main steel plates in the saddle body design requirements, perform corresponding groove processing on the bottom of the saddle head; The adjacent surfaces of each settling tank are transitioned by a rounded corner structure; Obtain the corresponding concave weld overlay cavity; Step 3. Perform flaw detection on the concave weld overlay cavity of the saddle head from Step 2; No defects exceeding the standard were confirmed; If defects exceed the standard, they must be removed first. Step 4. Place the flaw-detected saddle head into the furnace for preheating treatment; Preheating temperature is 100-150℃, and the temperature should be maintained for at least 2 hours; Step 5. Remove the preheated saddle head from the furnace and wrap it with asbestos cloth for insulation, leaving only the concave welding cavity area to be welded open. Step 6. At the reserved current concave welding cavity, perform the welding process according to the welding process requirements. During the welding process, use a natural gas torch to heat the current concave welding cavity to ensure that the temperature of the area to be welded is not lower than 150°C. The weld overlay area obtained after welding has sufficient machining allowance at the bottom of the saddle head; Step 7. After the welding of all the concave cavities at the bottom of the saddle head is completed, the weld and heat-affected zone are preheated to 300-350°C using a hydrogen removal method and kept at that temperature for at least 2 hours. Step 8. While the fabric is kept warm with asbestos cloth, allow it to cool slowly to room temperature; Grind the weld seams of the saddle head; Step 9. Perform a flaw detection inspection on the saddle head from Step 8; After passing the test, the saddle head is sent into the furnace for stress relief heat treatment; The stress relief heat treatment temperature is 520–560℃, and the holding time is at least 4 hours; Step 10. After the saddle head has been removed from the furnace after stress relief heat treatment, perform air gouging on the weld overlay area and other processing on other parts; Step 11. Transfer the saddle head from Step 10 to the welding assembly process with the saddle body, so that the main steel plates of the saddle body are welded together with the corresponding butt weld layers at the bottom of the saddle head, until the welding assembly of the various steel plates of the saddle body is completed on the saddle head, and the cable saddle blank is obtained. Step 12. Perform corresponding heat treatment and finishing on the cable saddle blank; Obtain the finished cable saddle.

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