Frame repair method

Abstract

To provide a frame repair method that allows for easy repair.SOLUTION: The present invention pertains to a method for repairing a frame having a plurality of truss structures, each of which includes: an upper chord member or a lower chord member; vertical members that support the upper chord member and the lower chord member; and diagonal members that are angled relative to the vertical members and support the upper chord member and the lower chord member. The method for repairing a frame includes: a first installation step of providing a first mounting portion for providing a first repairing member provided in a direction along the disposing direction of the diagonal member on at least one of the upper chord member and the lower chord member; a second installation step of providing a second mounting portion for providing a second repairing member provided in a direction along the disposing direction of the vertical member on at least one of the upper chord member and the lower chord member; a first repairing member installation step of providing the first repairing member on the first mounting portion; and a second repairing member installation step of providing the second repairing member on the second mounting portion.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for repairing a frame having a plurality of truss structures. [Background technology]

[0002] One example of a frame with multiple truss structures is the frame of a belt conveyor. Belt conveyors are used outdoors, for example, in steel mills to transport raw materials. Belt conveyor frames are generally made of steel sections. When the raw materials piled up on the belt conveyor become wet with rainwater, the rainwater drips onto the belt conveyor frame, bringing it into contact with water. Furthermore, when the raw materials piled up on the belt conveyor are washed away with water, the belt conveyor frame comes into contact with the cleaning water.

[0003] Belt conveyor frames deteriorate due to corrosion caused by contact with water. When a belt conveyor frame corrodes, the thinned parts of the components are repaired with a contact plate using electric welding. Contact plate repair is economically rational as it can be performed only on the thinned parts. In addition, contact plate repair can be performed while maintaining the truss structure of the belt conveyor frame.

[0004] However, if corrosion progresses significantly, the heat from electric welding may melt the components, making it impossible to repair the backing plate. Therefore, the truss structure members are replaced while maintaining the independence of the truss structure.

[0005] For example, in Patent Document 1, a temporary chord is attached between the upper chord and the lower chord, and the temporary chord and the upper chord are connected with a plurality of temporary diagonal members to form a temporary truss. Also in Patent Document 1, the lower ends of the lower chord and the diagonal members connected to it are removed, and new lower chords and the lower ends of new diagonal members are attached. In other words, in Patent Document 1, the lower ends of the lower chord and the diagonal members are removed while the truss shape is maintained by the temporary truss. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2019-178607 Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the repair method described in Patent Document 1, the existing truss structure is significantly modified when the temporary truss is formed. The temporary truss is required to have the same strength as the existing truss structure. Therefore, it is necessary to calculate the strength of the temporary truss before carrying out the repair work, which results in the problem of taking time before the work can begin.

[0008] The present invention has been made in consideration of the above problems, and has an object to provide a frame repair method that allows repairs to be performed easily. [Means for solving the problem]

[0009] In order to solve the above problems, the present invention has the following features.

[0010] [1] A repair method for a frame having a plurality of truss structures each having an upper chord member formed to extend in one direction, or a lower chord member arranged opposite the upper chord member and formed to extend in the one direction, a vertical member that connects the upper chord member and the lower chord member in the opposite direction, and a diagonal member that is arranged at an angle to the vertical member and connects the upper chord member and the lower chord member, a first installation step of providing a first mounting portion on at least one of the upper chord member and the lower chord member for providing a first repair member that is provided in a direction along the arrangement direction of the diagonal member; a second installation step of providing a second mounting portion on at least one of the upper chord member and the lower chord member for providing a second repair member that is provided in a direction along the arrangement direction of the vertical member; a first repair member installation step of fixing the first repair member to the upper chord member and the lower chord member via at least one of the first mounting portions; a second repair member installation step of fixing the second repair member to the upper chord member and the lower chord member via at least one of the second mounting portions; A frame repair method comprising: [2] The frame repair method described in [1], wherein the first repair member installation step and the second repair member installation step are carried out while the truss structure is maintained by the upper chord, the lower chord, the vertical members, and the diagonal members. [3] In the first repair member installation step, the first repair member is provided adjacent to the diagonal member in the one direction, The frame repair method according to [1] or [2], wherein in the second repair member installation step, the second repair member is installed adjacent to the vertical member in the one direction. [4] The diagonal member is removed after the first repair member is provided, The frame repair method according to any one of [1] to [3], wherein the vertical member is removed after the second repair member is provided. [5] The first repair member faces the diagonal member and is attached to the first mounting portion by welding, The frame repair method according to any one of [1] to [4], wherein the distance between the first repair member and the diagonal member is set to be longer than the weld leg length of the first repair member. [6] [4] A frame repair method described in [4], wherein the second repair member is attached after the portion of the diagonal member facing the second mounting portion is removed. [7] the frame has a pair of supports provided at one end side and the other end side in the one direction, A frame repair method described in any of [1] to [6], wherein the first installation step, the second installation step, the first repair member installation step, and the second repair member installation step are performed while the frame is supported by the pair of supports. [8] the first mounting portion and the second mounting portion are formed of a single plate-shaped member, The frame repair method according to any one of [1] to [7], wherein the first installation step and the second installation step are carried out simultaneously. [Effects of the Invention]

[0011] According to the frame repair method of the present invention, a new truss structure similar to the existing truss structure can be formed using the first repair member and the second repair member while maintaining the truss structure with the existing members. Because the new truss structure has the same form as the existing truss structure, it can be considered to have the same strength as the existing truss structure. Therefore, the frame can be repaired without performing strength calculations for the new truss structure, making the repair work easy.

[0012] Furthermore, by forming a new truss structure using the first repair member and the second repair member, the strength of the frame can be guaranteed, so the existing truss structure members can be removed at any time. For example, if the frame is a conveyor frame installed in a factory, the equipment downtime required for repair work can be minimized, and a decrease in production volume at the factory can be prevented. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is an explanatory diagram showing the configuration of a belt conveyor frame, which is an example of a frame having multiple truss structures. [Figure 2] FIG. 2 is an explanatory diagram showing the configuration of the belt conveyor frame of FIG. 1. [Figure 3] FIG. 2 is a flow chart showing a method for repairing the belt conveyor frame of FIG. 1. [Figure 4] 4 is an explanatory diagram showing the first installation step and the second installation step of FIG. 3. FIG. [Figure 5] 5 is an explanatory view showing a state in which the first attachment portion and the second attachment portion in FIG. 4 are installed. FIG. [Figure 6] 4 is an explanatory view showing an aspect of the first repair member installation step of FIG. 3. FIG. [Figure 7] FIG. 7 is an explanatory view showing how the first repair member in FIG. 6 is installed. [Figure 8] 4 is an explanatory view showing an aspect of the second repair member installation step of FIG. 3. FIG. [Figure 9] 4 is an explanatory view showing an aspect of the second repair member installation step of FIG. 3. FIG. [Figure 10] FIG. 4 is an explanatory diagram showing an aspect of the removal step in FIG. 3. DETAILED DESCRIPTION OF THE INVENTION

[0014] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will now be described with reference to the accompanying drawings. Fig. 1 shows the configuration of a belt conveyor frame 100, which is an example of a frame having a plurality of truss structures.

[0015] 1, the belt conveyor frame 100 is formed to extend in one direction, namely, a conveying direction D1. Although not particularly limited, the belt conveyor frame 100 can have a height of 1.5 m when assembled with carrier rollers (not shown).

[0016] The belt conveyor frame 100 is provided with a pair of supports 21, 22 at one end and the other end in the conveying direction D1. The distance between the supports 21, 22 is not particularly limited, but may be, for example, 20 m. The belt conveyor frame 100 is supported by the supports 21, 22 and is installed at a height of, for example, 4 m above the ground.

[0017] The belt conveyor frame 100 has a gravity tensioning device 30 that applies tension to the belt. In other words, by adjusting the gravity tensioning device 30, the tension of the belt of the belt conveyor frame 100 can be adjusted.

[0018] Fig. 2 shows the configuration of the belt conveyor frame 100. As shown in Fig. 2, the belt conveyor frame 100 has an upper chord member 11 formed to extend in the conveying direction D1, and a lower chord member 12 arranged opposite the upper chord member 11 and formed to extend in the conveying direction D1. The belt conveyor frame 100 has vertical members 13 that support the upper chord member 11 and the lower chord member 12 in the opposing direction. The belt conveyor frame 100 has diagonal members 14 that are arranged at an angle to the vertical members 13 and support the upper chord member 11 and the lower chord member 12.

[0019] The belt conveyor frame 100 has a plurality of truss structures 15, each of which is made up of an upper chord member 11 or a lower chord member 12, a vertical member 13, and a diagonal member 14. The truss structures 15 are arranged adjacent to one another in the conveying direction. In other words, the belt conveyor frame 100 has a plurality of truss structures 15. The upper chord member 11, the lower chord member 12, the vertical member 13, and the diagonal member 14 are not particularly limited, but may be, for example, an L-shaped angle.

[0020] Fig. 3 is a flow diagram showing a method for repairing the belt conveyor frame 100. The method for repairing the belt conveyor frame 100 is performed according to the flow shown in Fig. 3. A first installation step is performed in which a first mounting portion is provided on at least one of the upper chord member 11 and the lower chord member 12 (step S01).

[0021] Subsequently, a second installation step is performed in which a second mounting portion is provided on at least one of the upper chord member 11 and the lower chord member 12 (step S02).

[0022] Subsequently, a first repair member installation step is performed in which a first repair member is fixed to the upper chord member 11 and the lower chord member 12 via at least one first attachment portion (step S03).

[0023] The first repair member installation step of step S03 may be performed by, but is not particularly limited to, welding or using a fastening member such as a bolt, as long as the first repair member can be installed on the first mounting portion.

[0024] Furthermore, a second repair member installation step is performed in which a second repair member is fixed to the upper chord member 11 and the lower chord member 12 via at least one second mounting portion (step S04).

[0025] The second repair member installation step of step S04 may be performed by, but is not limited to, welding or using a fastening member such as a bolt, as long as the second repair member can be installed on the second attachment portion.

[0026] It should be noted that either the first repair member installation step in step S03 or the second repair member installation step in step S04 may be performed first.

[0027] Finally, a removal step is performed in which the vertical members 13 and the diagonal members 14 are removed (step S05).

[0028] Fig. 4 shows the first installation step S01 and the second installation step S02 in Fig. 3. As shown in Fig. 4, the first mounting portion 41 is a member for mounting a first repair member (not shown) that is provided in a direction along the installation direction of the diagonal member 14. The first mounting portion 41 is formed, for example, in a plate shape.

[0029] The second mounting portion 42 is a member for mounting a second repair member (not shown) that is provided in a direction along the direction in which the vertical member 13 is disposed. The second mounting portion 42 is formed, for example, in a plate shape.

[0030] Here, the first mounting portion 41 and the second mounting portion 42 may be integrally formed, or may be formed as separate members. In this embodiment, the first mounting portion 41 and the second mounting portion 42 are described as being integrally formed. That is, when the first mounting portion 41 and the second mounting portion 42 are integrally formed, the first installation step of step S01 and the second installation step of step S02 in FIG. 3 are performed simultaneously.

[0031] In Figure 4, the first mounting portion 41 and the second mounting portion 42 are provided on the upper chord 11 so as to face one end side of the diagonal member 14. The first mounting portion 41 and the second mounting portion 42 are provided on the lower chord 12 so as to face the other end side of the diagonal member 14.

[0032] Figure 5 shows how the first mounting portion 41 and the second mounting portion 42 of Figure 4 are installed. As shown in Figure 5, the upper chord member 11 and the lower chord member 12 are formed in an L-shape. The first mounting portion 41 and the second mounting portion 42 are connected to the tip surface of the L-shape of the upper chord member 11 or the lower chord member 12, for example.

[0033] The first mounting portion 41 and the second mounting portion 42 are connected to, for example, the upper chord member 11 or the lower chord member 12 by welding. The welding is performed, for example, by electric welding while the belt conveyor frame 100 is supported by a pair of supports 21, 22.

[0034] Figure 6 shows the first repair member installation step of step S03 in Figure 3. As shown in Figure 6, the first repair member 43 is installed in a direction along the installation direction of the diagonal member 14. In this embodiment, the first repair member 43 is installed parallel to the installation direction of the diagonal member 14.

[0035] In the first repair member installation step of step S03, the first repair member 43 preferably has physical properties such as strength equivalent to those of the diagonal member 14. Furthermore, the first repair member 43 is preferably provided adjacent to the diagonal member 14 in the conveying direction D1, which is one direction. By providing the first repair member 43 in this manner, it is possible to simplify the strength calculation.

[0036] Figure 7 shows how the first repair member 43 in Figure 6 is installed. More specifically, it shows how the first repair member 43 is attached to the upper chord 11 or the lower chord 12 as viewed from the side of the frame 100. As shown in Figure 7, the first repair member 43 is provided at the first mounting portion 41 with a gap W1 between it and the diagonal member 14. The first repair member 43 is fixed to the first mounting portion 41 by, for example, electric welding.

[0037] The interval W1 is preferably set to be longer than the weld leg length W2 of the first repair member 43. In other words, the first mounting portion 41 is formed so as to ensure the interval W1 that is longer than the weld leg length W2.

[0038] Fig. 8 shows an aspect of the second repair member installation step of step S03 in Fig. 4. As shown in Fig. 8, the second repair member 44 is provided in a direction along the arrangement direction of the vertical members 13. In this embodiment, the second repair member 44 is provided parallel to the arrangement direction of the vertical members 13. The second repair member 44 is fixed to the second mounting portion 42 by, for example, electric welding.

[0039] Figure 9 shows the second repair member installation step in step S04 of Figure 4. As shown in Figure 9, by providing the first repair member 43 and the second repair member 44, multiple new truss structures 16 are formed, each consisting of the upper chord member 11 or the lower chord member 12, the first repair member 43, and the second repair member 44. By forming multiple new truss structures 16, the strength of the belt conveyor frame 100 is restored.

[0040] In the second repair member installation step S04, the second repair member 44 is preferably installed adjacent to the vertical member 13 in the conveyance direction D1, which is one direction. The second repair member 44 should also have physical properties such as strength equivalent to those of the vertical member 13. By installing the second repair member 44 in this manner, it is possible to simplify the strength calculation.

[0041] The shape of the first repair member 43 is not particularly limited as long as it can be attached to the upper chord 11 and the lower chord 12 via the first mounting portion 41. The first repair member 43 can be, for example, the same material as the diagonal member 14. It is also preferable that the first repair member 43 be formed to the same length as the diagonal member 14.

[0042] Furthermore, the shape of the second repair member 44 is not particularly limited as long as it can be attached to the upper chord 11 and the lower chord 12 via the second mounting portion 42. The second repair member 44 can be, for example, the same material as the vertical member 13. Furthermore, it is preferable that the second repair member 44 be formed to the same length as the diagonal member 14.

[0043] The first repair member 43 and the second repair member 44 are formed from the same members and of the same length as the vertical members 13 and diagonal members 14, thereby forming a new truss structure 16 equivalent to the truss structure 15. This simplifies the calculation of the strength of the new truss structure 16.

[0044] Figure 10 shows the removal step of step S05 in Figure 3. As shown in Figure 10, once the new truss structure 16 is formed, the vertical members 13 and the diagonal members 14 are removed.

[0045] In this way, the vertical members 13 may be removed after the first repair members 43 are installed. Also, the diagonal members 14 may be removed after the second repair members 44 are installed. By installing the first repair members 43 and the second repair members 44 in this way, repair work can be carried out while the truss structure 15 is maintained.

[0046] The second repair member 44 may be attached after removing the portion of the diagonal member 14 that faces the second mounting portion 42. By attaching the second repair member 44 to the second mounting portion 42 in this manner, the attachment work can be easily performed.

[0047] The removal step of step S05 is a step that is optionally executed depending on the embodiment. That is, when the new truss structure 16 is formed, the strength recovery of the belt conveyor frame 100 is completed. Therefore, it is possible to suppress the occurrence of an event that should be avoided due to corrosion of the belt conveyor frame 100. Therefore, the removal step of step S05 can be optionally executed depending on the necessity, thereby shortening the work period. As a result, for example, the period during which the equipment is stopped for repair work can be set depending on the work, and the reduction in the conveyance amount can be minimized.

[0048] The repair work of the belt conveyor frame 100, including the first installation step of step S01 to the removal step of step S05, can be performed in a state where the belt conveyor frame 100 is supported by the pair of supports 21, 22. In this case, the repair work of the belt conveyor frame 100 is performed, for example, by a worker on board an aerial work vehicle. Also, when the installation height of the belt conveyor frame 100 is high, the repair work may be performed using a mobile crane or the like after securing a work floor with scaffolding or the like.

[0049] As described above, it has conventionally been difficult to ensure sufficient space in the upper chord member 11 and the lower chord member 12 to install the first repair member 43 and the second repair member 44. In the frame repair method of the present invention, the first repair member 43 is attached to the upper chord member 11 and the lower chord member 12 via the first attachment portion 41. Furthermore, the second repair member 44 is attached to the upper chord member 11 and the lower chord member 12 via the second attachment portion 42. This makes it possible to ensure sufficient space in the upper chord member 11 and the lower chord member 12 to install the first repair member 43 and the second repair member 44.

[0050] Furthermore, according to the frame repair method of the present invention, the new truss structure 16 has the same form as the existing truss structure 15, and therefore can be considered to have the same strength as the existing truss structure 15. Therefore, there is no need to calculate the strength of the new truss structure 16, and repair work can be carried out immediately, making repair work easy.

[0051] It is also preferable to form the new truss structure 16 while the truss structure 15 is supported by a pair of supports 21, 22. That is, it is preferable to form the new truss structure 16 in the same manner as the existing truss structure 15 using the first repair member 43 and the second repair member 44, while maintaining the truss structure 15 with the existing members. By forming the new truss structure 16 in this manner, it is possible to reduce changes to the shape, etc. of the new truss structure 16 from the truss structure 15.

[0052] Furthermore, conventionally, there is a problem that repair work must be carried out for each predetermined area in order to ensure the strength of the frame 100. By forming the new truss structure 16 while maintaining the truss structure 15, the strength of the frame 100 is guaranteed, so repair work can be carried out for any area, including the entire area of the frame 100. This makes it possible to improve the efficiency of the work.

[0053] Furthermore, by forming the new truss structure 16 using the first repair member 43 and the second repair member 44, the strength of the frame 100 can be guaranteed, so that the members of the existing truss structure 15 can be removed at any time. For example, if the frame 100 is a conveyor frame installed in a factory, the downtime of equipment required for repair work can be minimized, and a decrease in production volume at the factory can be prevented.

[0054] Furthermore, when removing the members of the truss structure 15, it is preferable to remove the vertical members 13 and the diagonal members 14 after forming the new truss structure 16. By removing the vertical members 13 and the diagonal members 14 in this way, the load applied to the belt conveyor frame 100 can be reduced.

[0055] Furthermore, if there is sufficient space available in the upper chord 11 or the lower chord 12 to connect the first repair member 43, it is preferable to provide the first mounting portion 41 on at least one of the upper chord 11 and the lower chord 12.

[0056] Similarly, if there is sufficient space available in the upper chord 11 or the lower chord 12 to connect the second repair member 44, it is preferable to provide the second mounting portion 42 on at least one of the upper chord 11 and the lower chord 12.

[0057] Furthermore, as long as the frame has a plurality of truss structures 15, its use is not limited to belt conveyors, but may also be, for example, a frame supporting a bridge or a pipe for transporting raw materials or the like.

[0058] In the above embodiment, it has been described that repair work on the belt conveyor frame 100 is performed in a state where the truss structure 15 is maintained by the upper chord member 11 or the lower chord member 12, the vertical members 13, and the diagonal members 14. However, repair work may be performed in a state where the truss structure is maintained by members other than these. For example, the diagonal members 14 may be removed after the first repair member 43 is installed, and then the second repair member 44 may be installed, and then the vertical members 13 may be removed. [Explanation of symbols]

[0059] 100 Belt conveyor frame 11 Top chord 12 Lower chord 13 Vertical members 14 Diagonals 15 Truss structure 41 First mounting part 42 Second mounting part 43 First repair member 44 Second repair member

Claims

1. A repair method for a frame having a plurality of truss structures each having an upper chord member formed to extend in one direction, or a lower chord member arranged opposite the upper chord member and formed to extend in the one direction, a vertical member that connects the upper chord member and the lower chord member in the opposite direction, and a diagonal member that is arranged at an angle to the vertical member and connects the upper chord member and the lower chord member, a first installation step of providing a first mounting portion on at least one of the upper chord member and the lower chord member for providing a first repair member that is provided in a direction along the arrangement direction of the diagonal member; a second installation step of providing a second mounting portion on at least one of the upper chord member and the lower chord member for providing a second repair member that is provided in a direction along the arrangement direction of the vertical member; a first repair member installation step of fixing the first repair member to the upper chord member and the lower chord member via at least one of the first mounting portions; a second repair member installation step of fixing the second repair member to the upper chord member and the lower chord member via at least one of the second mounting portions; A frame repair method comprising:

2. 2. A frame repair method as described in claim 1, wherein the first repair member installation step and the second repair member installation step are performed while the truss structure is maintained by the upper chord member, the lower chord member, the vertical member, and the diagonal member.

3. In the first repair member installation step, the first repair member is provided adjacent to the diagonal member in the one direction, The frame repair method according to claim 1 , wherein in the second repair member installing step, the second repair member is installed adjacent to the vertical member in the one direction.

4. In the first repair member installation step, the first repair member is provided adjacent to the diagonal member in the one direction, The frame repair method according to claim 2 , wherein in the second repair member installing step, the second repair member is installed adjacent to the vertical member in the one direction.

5. The diagonal member is removed after the first repair member is provided, The frame repair method according to claim 2 , wherein the vertical member is removed after the second repair member is provided.

6. The diagonal member is removed after the first repair member is provided, The frame repair method according to claim 3 , wherein the vertical member is removed after the second repair member is provided.

7. The diagonal member is removed after the first repair member is provided, The frame repair method according to claim 4 , wherein the vertical member is removed after the second repair member is provided.

8. The first repair member faces the diagonal member and is attached to the first mounting portion by welding, A frame repair method according to any one of claims 1 to 7, wherein the distance between the first repair member and the diagonal member is set to be longer than the weld leg length of the first repair member.

9. The frame repair method according to any one of claims 5 to 7, wherein the second repair member is attached after the portion of the diagonal member that faces the second mounting portion has been removed.

10. the frame has a pair of supports provided at one end side and the other end side in the one direction, A frame repair method according to any one of claims 1 to 7, wherein the first installation step, the second installation step, the first repair member installation step, and the second repair member installation step are performed while the frame is supported by the pair of supports.

11. the frame has a pair of supports provided at one end side and the other end side in the one direction, 9. The frame repair method according to claim 8, wherein the first installation step, the second installation step, the first repair member installation step, and the second repair member installation step are performed while the frame is supported by the pair of supports.

12. the frame has a pair of supports provided at one end side and the other end side in the one direction, 10. The frame repair method according to claim 9, wherein the first installation step, the second installation step, the first repair member installation step, and the second repair member installation step are performed while the frame is supported by the pair of supports.

13. the first mounting portion and the second mounting portion are formed of a single plate-shaped member, The frame repair method according to any one of claims 1 to 7, wherein the first and second installation steps are performed simultaneously.

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