Segment welding jig and segment manufacturing method

Abstract

To provide a segment welding jig and a segment manufacturing method that can easily position and join outer main girders, joint plates, and skin plates even when the segments to be manufactured are large.SOLUTION: A segment welding jig which has a pair of outer main girders, joint plates attached to both longitudinal ends of the outer main girders, and a skin plate attached to an outer peripheral surface of the outer main girders comprises the outer main girders, the joint plates, a frame for positioning the skin plates, and pressing means for pressing the skin plates against the outer main girders and the joint plates. The pressing means is disposed along the longitudinal direction of the skin plates and comprises an expandable expansion member.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a segment assembly jig used in welding during segment assembly, and a method for manufacturing segments. [Background technology]

[0002] Conventional tunnel construction methods include the shield tunneling method and the tunnel boring machine (TBM) method. In these tunnel construction methods, the tunnel lining is formed by excavating the natural ground and installing cylindrical segment rings underground. The segment rings are formed by connecting joint plates located on the end faces of multiple segments.

[0003] The segments are formed in an arc-like or plate-like shape when viewed along the direction in which the tunnel extends. Each segment has a pair of main girders formed in an arc-like or linear shape in the longitudinal direction, joint plates attached to both longitudinal end faces of the pair of main girders, and a skin plate attached to the outer periphery of the arc-shaped main girders. The segment is a housing formed by joining two main girders and two joint plates to form a frame body, and then joining a skin plate to the frame body.

[0004] As described above, a segment is constructed by welding together a pair of main girders, joint plates, and skin plates, and therefore each component is fixed to an assembly jig for positioning and joining. Various structures of such assembly jigs are known.

[0005] For example, as described in Patent Document 1, a manufacturing method is known in which the jig holding frame is rotated 15°, the skin plate is set to fit the skin plate block, an air cylinder for holding the skin plate is then activated, and while holding the skin plate with the skin plate holding device, the skin plate is tensioned toward the free side while the skin plate holding device is still in the activated state, and then the skin plate is temporarily welded to the main girder and joint plate.

[0006] This method of manufacturing segments makes it possible to use a common temporary assembly jig for the temporary assembly of segments of various sizes, and also improves the uniformity of temporary assembly accuracy and rationalizes the number of workers required by allowing one person to perform the work, thereby significantly improving productivity and enabling the production of a wide variety of products in small quantities, thereby reducing manufacturing costs.

[0007] In addition to such segment manufacturing methods, an assembly jig is also known in which the main girder, joint plate, and skin plate are positioned and placed in a formwork, and welding is performed while the skin plate is pressed against the main girder and joint plate using a cam structure or the like.

[0008] With such an assembly jig, it is possible to prevent the device from becoming larger without having to rotate the jig holding frame, and it is possible to improve the uniformity of assembly precision and significantly improve productivity. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Japanese Patent Application Publication No. 8-60994 Summary of the Invention [Problem to be solved by the invention]

[0010] However, assembly jigs that use cam structures or the like to press the skin plate against the main girder and joint plate have the problem that as the segments being manufactured become larger, the skin plate also becomes larger and heavier, so when the skin plate is pressed using the cam structure, the pressing force becomes very large, placing a heavy burden on the worker.

[0011] Therefore, the present invention has been made in consideration of the above problems, and aims to provide a segment assembly jig and a segment manufacturing method that can easily position and join outer main girders, joint plates, and skin plates, even when the segments being manufactured are large. [Means for solving the problem]

[0012] The segment assembly jig of the present invention is a segment assembly jig having a pair of outer main girders, joint plates attached to both longitudinal ends of the outer main girders, and a skin plate attached to the outer peripheral surface of the outer main girders, and is characterized in that it comprises the outer main girders, the joint plates, a frame body that positions the skin plate, and a pressing means that presses the skin plate against the outer main girders and the joint plates, and the pressing means is arranged along the longitudinal direction of the skin plate and comprises an expandable expansion member.

[0013] In the segment assembly jig according to the present invention, it is preferable that the pressing means includes a backing plate member interposed between the expansion member and the skin plate.

[0014] In the segment assembly jig according to the present invention, it is preferable that the frame body includes a mount that houses the expansion member.

[0015] In the segment assembly jig according to the present invention, it is preferable that the expansion member is a fire hose.

[0016] In the segment assembly jig according to the present invention, it is preferable that the expansion member is expanded by air pressure.

[0017] In the segment assembly jig according to the present invention, it is preferable that a plurality of the pressing means are arranged along the short side direction of the skin plate.

[0018] In addition, the segment manufacturing method of the present invention is a method for manufacturing a segment having a pair of outer main girders, joint plates attached to both longitudinal ends of the outer main girders, and a skin plate attached to the outer peripheral surface of the outer main girders, and is characterized by having a pre-assembly process in which the outer main girders, the joint plate, and the skin plate are assembled to a frame body, a pressing process in which the skin plate is pressed against the outer main girders and the joint plate by expanding expansion means attached to the frame body, and a welding process in which the outer main girders, the joint plate, and the skin plate are welded together.

[0019] In the segment manufacturing method according to the present invention, it is preferable that the pressing step presses the skin plate against the outer main girder and the joint plate using the segment assembly jig described above.

[0020] The above summary of the invention does not list all of the necessary features of the present invention, and subcombinations of these features may also constitute inventions. [Effects of the Invention]

[0021] According to the segment assembly jig and segment manufacturing method of the present invention, when manufacturing segments, welding of the outer main girder, joint plate and skin plate can be performed while pressing them with an expandable pressing means, making it possible to easily perform segment assembly work. [Brief explanation of the drawings]

[0022] [Figure 1] FIG. 2 is a perspective view of a segment assembled using the segment assembly jig according to the embodiment. [Figure 2] FIG. 4 is a plan view of an assembly jig for the segments according to the embodiment. [Figure 3] FIG. 3 is a perspective view of an assembly jig for the segments according to the embodiment. [Figure 4] FIG. 4 is a perspective view of a pressing means of the segment assembly jig according to the embodiment. [Figure 5] FIG. 4 is an exploded view of a pressing means of the segment assembly jig according to the embodiment. [Figure 6] 10A to 10C are diagrams for explaining the operation of the segment assembly jig according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0023] Preferred embodiments for carrying out the present invention will be described below with reference to the drawings. Note that the following embodiments do not limit the inventions according to the claims, and not all of the combinations of features described in the embodiments are necessarily essential to the solution of the invention.

[0024] FIG. 1 is an oblique view of a segment assembled using the segment assembly jig of this embodiment, FIG. 2 is a plan view of the segment assembly jig of this embodiment, FIG. 3 is an oblique view of the segment assembly jig of this embodiment, FIG. 4 is an oblique view of the pressing means of the segment assembly jig of this embodiment, FIG. 5 is an exploded view of the pressing means of the segment assembly jig of this embodiment, and FIG. 6 is a diagram for explaining the operation of the segment assembly jig of this embodiment.

[0025] As shown in Figure 1, segment 1 is a box-shaped structure made up of multiple steel members, with the bottom of the box curved in an arc. Segment 1 is used, for example, as a tunnel lining and is installed on the wall of a borehole formed by excavating the natural ground. Multiple segments 1 are connected circumferentially along the wall of the borehole to form a cylindrical segment ring. These segment rings are joined sequentially in the axial direction to form the tunnel lining. The inside of the box-shaped structure of segment 1 is filled with, for example, concrete, to form the wall surface inside the tunnel.

[0026] The segment 1 comprises a pair of outer main girders 4, a central main girder 7 as an intermediate member arranged between the pair of outer main girders 4, a pair of joint plates 5, a skin plate 6, and a plurality of longitudinal ribs 9.

[0027] The pair of outer main girders 4 are located at both ends of the segment 1 in the tunnel axis direction. The outer main girders 4 and the middle main girders 7 are formed in an arc shape according to the cross-sectional shape of the tunnel. The outer main girders 4 and the middle main girders 7 are members made of plate-shaped steel plates.

[0028] A pair of joint plates 5 are components attached to both ends of the segment 1 in the tunnel circumferential direction. The joint plates 5 are made of rectangular steel plates and are fixed between both longitudinal ends of a pair of outer main girders 4 and a middle main girder 7. A joint may be attached to the end of the segment 1 where the joint plates 5 are located to connect it to the segments 1 that form one segment ring. In addition, a seal groove (not shown) is formed on the outer peripheral surface of the segment 1 into which a seal material is attached.

[0029] The skin plate 6 is a plate-shaped member facing the natural ground side of the segment 1, and is formed by bending a rectangular steel plate into an arc in the surface direction. As shown in Figure 1, it is joined so as to close the opening on the natural ground side end face of the frame body obtained by joining a pair of exterior main girders 4, intermediate main girders 7, and joint plates 5. In other words, the skin plate 6 is attached to the outer periphery of the exterior main girders 4, intermediate main girders 7, and joint plates 5 that make up the segment 1.

[0030] Inside the box-shaped segment 1, vertical ribs 9 are erected, extending in a direction intersecting the outer main girder 4. The vertical ribs 9 are erected in the normal direction to the surfaces of the outer main girder 4, the middle main girder 7, and the skin plate 6, and the ends of the vertical ribs 9 in the tunnel axis direction are joined to the surface of the outer main girder 4.

[0031] 2 and 3, the segment assembly jig 10 according to this embodiment is used to position and assemble the above-mentioned component parts of the segment, namely, the outer main girder 4, the middle main girder 7, the joint plate 5, and the skin plate 6. The segment assembly jig 10 according to this embodiment is equipped with a frame 14 made up of outer main girder side wall portions 11 that abut against the pair of outer main girders 4, joint plate side wall portions 12 that abut against the joint plate 5, and reinforcing members 13 that connect the pair of outer main girder side wall portions 11 in the short direction (the extension direction of the joint plate side wall portions 12). The bottom of the frame 14 is equipped with a pressing means 20 on which the skin plate 6 is placed and which is arranged along the longitudinal direction of the skin plate 6.

[0032] The pressing means 20 are disposed at both ends and approximately the center in the short-side direction of the frame body 14. The number of pressing means 20 can be increased or decreased as appropriate depending on the size of the segment 1 to be manufactured (the weight of the skin plate 6).

[0033] As shown in Figures 4 and 5, the pressing means 20 comprises a base 22 arranged along the longitudinal direction of the skin plate 6 (the extension direction of the outer main girder side wall portion 11), an expansion member 23 accommodated in a groove portion (not shown) formed in the base 22, and a backing plate member 21 placed on the base 22 so as to be interposed between the expansion member 23 and the skin plate 6.

[0034] The base 22 is a long member having a groove formed therein as described above, and is preferably made of an H-shaped steel beam or the like. The base 22 is also formed with a pair of locking projections 25 that project toward the reinforcing member 13 so as to straddle the reinforcing member 13. This positions the pressing means 20 in the longitudinal direction.

[0035] The expansion member 23 is a member that can be expanded by filling it with gas or liquid, and a fire hose, for example, is preferably used. It is preferable to use air pressure to inflate the expansion member 23. By using air for expansion, it is possible to reduce costs by introducing outside air without placing an environmental burden on the environment when air is discharged as the expansion and contraction of the expansion member 23 occurs.

[0036] The valve member 26 for introducing or discharging the aforementioned outside air is attached to the end of the expansion member 23. To introduce outside air, air pressure that has been increased to a predetermined pressure by a compressor (not shown) can be introduced into the expansion member 23. It is preferable that the valve member 26 be a check valve so that air pressure can be appropriately charged and discharged.

[0037] The backing plate member 21 is a plate-like member disposed along the longitudinal direction of the frame 22, and is provided with a positioning portion 24 that engages with the side surface of the frame 22. The backing plate member 21 is disposed so as to come into face contact with the skin plate 6. Therefore, when the skin plate 6 is pressed against the outer main girder 4 and the joint plate 5 as the expansion member 23 described below expands, the pressing force caused by the expansion can be transmitted to the skin plate 6 evenly and without waste, and the skin plate 6 can be pressed so as to be bent appropriately along the curvature of the outer main girder 4, thereby improving the assembly accuracy of the segment 1.

[0038] Next, the manufacturing method of the segment according to this embodiment will be described with reference to Figure 6. The manufacturing method of the segment according to this embodiment includes a pre-assembly process of assembling the outer main girder 4, joint plates 5, and skin plates 6 to the frame body 14, a pressing process of pressing the skin plates 6 against the outer main girder 4 and joint plates 5 by expanding the expansion members 23 attached to the frame body 14, and a welding process of welding the outer main girder 3, joint plates 5, and skin plates 6 together.

[0039] In the temporary assembly process, the outer main girder 4, joint plate 5, and skin plate 6 are assembled to the frame body 14. The outer main girder 4 is positioned so as to abut against the outer main girder side wall portion 11 of the frame body 14, the joint plate 5 is positioned so as to abut against the joint plate side wall portion 12 of the frame body 14, and the skin plate 6 is positioned so as to abut against the backing plate member 21 of the pressing means 20 attached to the frame body 14.

[0040] In the pressing process, outside air is introduced into the expansion member 23 of the pressing means 20, and the expansion member 23 is expanded by the air pressure. At this time, since the expansion member 23 is housed in the groove of the frame 22, it expands in the vertical direction of the frame body 14 (the direction in which the skin plate 6 moves toward the outer main girder 4 and the joint plate 5). Due to this expansion of the expansion member 23, the backing plate member 21 moves in the vertical direction of the frame body 14, pressing the skin plate 6 against the outer main girder 4 and the joint plate 5, as shown in Figure 6.

[0041] Furthermore, since air pressure is used to expand the expansion member 23, a uniform pressing force can be applied along the longitudinal direction of the skin plate 6, and an appropriate bend can be imparted to the skin plate 6 along the arc shape of the outer main girder 4.

[0042] In the welding process, the outer main girder 4, the joint plate 5, and the skin plate 6 are welded together after the skin plate 6 has been pressed against the outer main girder 4 and the joint plate 5 in the pressing process and positioned. When manufacturing a segment equipped with an intermediate main girder 7 and a longitudinal rib 9, such as the segment 1 shown in Figure 1, these components may be assembled in the temporary assembly process or pressing process and then welded simultaneously.

[0043] In the welding process, the parts of the segments 1 where the components are close to each other are welded. In addition, in the welding process, the entire area where the components are close to each other is welded to ensure the joint strength between the components. To increase assembly efficiency, it is desirable that the welding process be performed automatically by a robot. In addition, parts that are difficult to weld by a robot may be welded manually as appropriate.

[0044] The segment 1 manufactured in this manner is positioned by pressing the skin plate 6 against the outer main girder 4 and the joint plate 5 using air pressure, so even if the segment 1 becomes larger and the weight of the skin plate 6 increases, the skin plate 6 can be easily positioned. In addition, the burden on workers in assembling the segments is reduced.

[0045] In the above embodiment, we have described a case where a central girder having approximately the same shape as the outer main girder is used as the intermediate member. However, the intermediate member may be a reinforcing rib that is not continuous in the longitudinal direction and is arranged only at the position where it is welded to the joint plate. Furthermore, we have described a case where three sets of pressing means 20 are arranged along the extension direction of the joint plate side wall portion 12. However, the number of pressing means 20 can be increased or decreased as appropriate depending on the size of the segment 1. Furthermore, in the above embodiment, we have described a case where the segment 1 has an arc-shaped curved shape. However, the outer main girder and the central main girder may be formed as rectangular plates. Furthermore, we have described a case where the frame 22 is made of H-shaped steel, but it may also be made of a combination of steel plates. It is clear from the claims that such modified or improved embodiments are also within the technical scope of the present invention. [Explanation of symbols]

[0046] 1 segment, 4 outer main girder, 5 joint plate, 6 skin plate, 7 middle main girder, 9 longitudinal rib, 10 assembly jig, 11 outer main girder side wall portion, 12 joint plate side wall portion, 13 reinforcing member, 14 frame body, 20 pressing means, 21 backing plate member, 22 frame, 23 expansion member, 24 positioning portion, 25 locking protrusion.

Claims

1. A segment assembly jig having a pair of outer main girders, joint plates attached to both ends of the outer main girders in the longitudinal direction, and skin plates attached to the outer peripheral surfaces of the outer main girders, a frame body that positions the outer main girder, the joint plate, and the skin plate; a pressing means for pressing the skin plate against the outer main girder and the joint plate, 10. A segment assembly jig, comprising: a pressing means disposed along the longitudinal direction of the skin plate and including an expandable expansion member;

2. The segment assembly jig according to claim 1, 10. A segment assembly jig, wherein the pressing means comprises a backing plate member interposed between the expansion member and the skin plate.

3. The segment assembly jig according to claim 1, A segment assembly jig characterized in that the frame body is provided with a stand that houses the expansion member.

4. The segment assembly jig according to claim 1, A segment assembly jig characterized in that the expansion member is a fire hose.

5. The segment assembly jig according to claim 1, A segment assembly jig, wherein the expansion member is expanded by air pressure.

6. The segment assembly jig according to claim 1, A segment assembly jig characterized in that a plurality of the pressing means are arranged along the short side direction of the skin plate.

7. A method for manufacturing a segment having a pair of outer main girders, joint plates attached to both ends of the outer main girders in the longitudinal direction, and a skin plate attached to an outer peripheral surface of the outer main girders, a temporary assembly process in which the outer main girder, the joint plate, and the skin plate are assembled to a frame body; a pressing step of pressing the skin plate against the outer main girder and the joint plate by expanding expansion means attached to the frame body; and a welding step of welding the outer main girder, the joint plate, and the skin plate together.

8. The segment manufacturing method according to claim 7, 7. A method for manufacturing a segment, wherein the pressing step presses the skin plate against the outer main girder and the joint plate using a segment assembly jig according to claim 1.

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