jig

Abstract

To provide: a method for manufacturing asymmetrical members capable of efficiently manufacturing the asymmetrical members and improving safety and efficiency in transportation of the asymmetrical members; and jigs used for the method.SOLUTION: A method for manufacturing asymmetrical members comprises: arranging two base members side by side in a direction horizontally orthogonal to a predetermined horizontal direction with or without inverting one of the two base members relative to the other thereof in the predetermined horizontal direction, and in this state, integrally fixing the two base members; and joining joint members to the respective base members so that, with respect to one of two asymmetrical members to be completed, the other thereof is inverted in a predetermined horizontal direction, to manufacture the asymmetrical members.SELECTED DRAWING: Figure 13

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing an asymmetrical member and a jig used therefor. [Background technology]

[0002] Asymmetrical shaped components (hereinafter referred to as asymmetrical components), such as L-shaped components, in which another metal straight component is joined at an angle to the longitudinal end of a metal straight component, are used for girders and other components in civil engineering structures.

[0003] When a relatively large and heavy asymmetric component is to be moved to another location, a transport device such as a crane is used. If an attempt is made to lift such an asymmetric component 100 with a single crane, the asymmetric shape of the asymmetric component 100 will cause the component 100 to tilt relative to its position before lifting, as shown in Figure 15, making it impossible to transport (move) the asymmetric component safely. For this reason, in the past, multiple cranes were used to lift and transport the asymmetric component without tilting it.

[0004] Furthermore, when joining the components that make up an asymmetrical member by welding, downward welding is performed in which the torch is pointed downward to ensure safe and high-quality welding. When rotating the asymmetrical member to change its position for downward welding, the asymmetrical member is lifted and rotated using multiple cranes in the same manner as described above. Patent Document 1 discloses a rotation device for rotating pillar members. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 08-091759 Summary of the Invention [Problem to be solved by the invention]

[0006] As mentioned above, if an asymmetrical component is to be transported without tilting, multiple transport devices and the installation space required for each device are required. Furthermore, even for asymmetrical components used in structures other than civil engineering, if a single transport device is used to lift and transport the component, it is necessary to use a transport device with a large transport output or a transport device equipped with a special mechanism. As such, transporting asymmetrical components is costly.

[0007] An object of the present invention is to provide a method for manufacturing an asymmetrical member that can efficiently manufacture an asymmetrical member and can increase the safety and efficiency of transporting the asymmetrical member, and a jig used therefor. [Means for solving the problem]

[0008] The method for manufacturing an asymmetrical member involves arranging two base members in a direction horizontally perpendicular to the predetermined horizontal direction, with or without inverting one of the two base members relative to the other in a predetermined horizontal direction, fixing the two base members together, and joining a joining member to each base member so that one of the two asymmetrical members to be completed is inverted in the predetermined horizontal direction relative to the other.

[0009] In addition, the manufacturing method for an asymmetrical member may involve fixing two base members, one of which is offset relative to the other in a predetermined horizontal direction, and joining a joining member within the offset section of each of the two base members.

[0010] In addition, a method for manufacturing an asymmetric member may include attaching two fixed base members to a rotation device, which rotates the two base members around a predetermined horizontal direction, and joining members being joined to each of the base members by welding, and rotating the two base members by the rotation device according to the welding locations.

[0011] The jig is used to fix two lined-up base members, and comprises a pair of fixing parts that are placed opposite the two base members, and a clamping tool that clamps the pair of fixing parts, and also comprises a protruding part that protrudes from the fixing parts and is interposed between the two lined-up base members.

[0012] The jig may also be provided with a sling portion on the fixing portion or clamping tool to which a sling tool can be attached. [Effects of the Invention]

[0013] The method for manufacturing an asymmetrical member allows for efficient manufacturing of the asymmetrical member, and also allows for increased safety and efficiency in transporting the asymmetrical member. The jig has protrusions that allow the two base members to be fixed together without interference, making it possible to manufacture high-quality asymmetric members. [Brief explanation of the drawings]

[0014] [Figure 1] 1A, 1B, and 1C are diagrams showing an asymmetric member, in which (A) is a plan view, (B) is a rear view, and (C) is a side view. [Figure 2] FIG. 10 is a side view showing a state in which two base members are fixed by a jig. [Figure 3] FIG. 10 is a plan view showing a state in which two base members are fixed together with a jig. [Figure 4] FIG. 4 is an enlarged partial end view taken along line IV-IV in FIG. [Figure 5] FIG. 4 is a side view showing the first fixing part. [Figure 6] FIG. 6 is an enlarged partial end view taken along line VI-VI in FIG. 4. [Figure 7] FIG. 4 is a plan view showing a second fixing portion. [Figure 8] FIG. 2 is a side view showing a state in which two base members are attached to a rotation device. [Figure 9] FIG. 2 is a plan view showing a state in which two base members are attached to a rotation device. [Figure 10]FIG. 9 is an enlarged cross-sectional view taken along line XX in FIG. 8. [Figure 11] FIG. 1 is an exploded side view of two asymmetrical members. [Figure 12] FIG. 10 is a rear view showing the state in which two asymmetric members are rotated by a rotation device, with the jig omitted. [Figure 13] FIG. 10 is a side view showing the two asymmetrical members in their completed state. [Figure 14] FIG. 10 is a side view showing the lifting of two completed asymmetrical members. [Figure 15] FIG. 10 is a side view showing the lifting of an asymmetric member. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, an embodiment of a method for manufacturing an asymmetrical member and a jig used therein will be described with reference to the drawings. Here, the asymmetrical member 1 (2) refers to a member that is not symmetrical, such as an L-shaped member or an F-shaped member.

[0016] The method for manufacturing asymmetric members involves first arranging the two base members 10, 20 side by side in a direction horizontally perpendicular to the predetermined horizontal direction, with or without inverting one of the two base members 10, 20 relative to the other, and then fixing the two base members 10, 20 together. Regarding whether or not to invert the base members 20(10), if the base members 10, 20 are asymmetric, the other base member 20(10) is inverted, and if the base members 10, 20 are symmetric, the other base member 20(10) is not inverted.

[0017] Next, the asymmetrical members 1 and 2 are manufactured by joining the joining members 30 and 40 to the base members 10 and 20 so that one of the two asymmetrical members 1 and 2 to be completed is inverted in a predetermined horizontal direction relative to the other.

[0018] In this embodiment, the asymmetrical component 1 (2) is an L-shaped steel component used for girders of civil engineering structures, as shown in Fig. 1. The asymmetrical component 1 (2) is manufactured by joining a base component 10 (20) and a joining component 30 (40).

[0019] As shown in Figures 2 to 4, each base member 10 (20) is a linearly extending H-shaped steel beam equipped with a web 11 (21) and two flanges 13, 13 (23, 23) connected to both longitudinal ends of the web 11 (21). One longitudinal end of each base member 10, 20 is inclined upward from the lower end toward the outside in the longitudinal direction. Therefore, each base member 10, 20 is asymmetrical front to back. The inclined end of each base member 10, 20 becomes the joint portion to which the joining members 30, 40 (described later) are joined.

[0020] In this embodiment, the basic position of the base member 10 (20) is a position in which the surfaces of the flanges 13, 13 (23, 23) are horizontal. The longitudinal direction of the base member 10 (20) is defined as the front-rear direction, the horizontal direction perpendicular to this is defined as the left-right direction, and the direction perpendicular to these directions is defined as the up-down direction. The longitudinal direction (front-rear direction) of the base member 10 (20) corresponds to a predetermined horizontal direction. The left-right direction corresponds to a direction horizontally perpendicular to the predetermined horizontal direction.

[0021] 2 and 3, the two base members 10, 20 are fixed by a jig 50 so that one is inverted relative to the other in the longitudinal direction (front-to-back direction) of the base member 10 (20) and aligned horizontally in a direction (left-to-right direction) perpendicular to the longitudinal direction of the base member 10 (20). The two base members 10, 20 may also be fixed so that one is offset relative to the other in the longitudinal direction of the base member 10 (20).

[0022] The jig 50 is used to integrally fix the two aligned base members 10, 20. In this embodiment, the jig 50 includes a first jig 60 and a second jig 70, as shown in FIGS.

[0023] As shown in FIGS. 4 to 7, the first jig 60 and the second jig 70 each include a pair of fixing portions 61, 61, 71, 71 and clamping members 63, 73 that clamp the pair of fixing portions 61, 61, 71, 71 together.

[0024] Each fixing portion 61, 71 has a linearly extending contact portion 61a, 71a and rising portions 61b, 61b, 71b, 71b rising at approximately right angles from both ends of the contact portion 61a, 71a in the width direction, so that the cross section is approximately U-shaped. The bottom surface of the contact portion 61a, 71a is flat so as to be in surface contact with the flanges 13, 23 of the base members 10, 20.

[0025] The clamping devices 63, 73 include bolts 63a, 73a with female threads on both ends and two nuts 63b, 63b, 73b, 73b that can be fastened to the female threads of the bolts 63a, 73a. Two clamping devices 63, 73, each consisting of a set of bolts 63a, 73a and two nuts 63b, 63b, 73b, 73b, are provided on each of the first jig 60 and the second jig 70. All or part of the nut 73b of the second jig 70 is provided with a sling portion 75 to which a slinging device S, such as a wire, can be attached. The sling portion 75 may be of any shape as long as it can be used to attach the slinging device S, but in this embodiment, it has an annular portion. When the two base members 10, 20 and the two asymmetric members 1, 2 fixed by the jig 50 are transported by a transport device such as a crane, the sling S is attached to the sling portion 75 for transportation. Note that the sling portion 75 may be provided on the nut 63b of the clamping tool 63 of the first jig 60.

[0026] The contact portions 61a, 71a of the fixing portions 61, 71 are provided with two bolt holes 67, 77, which are holes through which the bolts 63a, 73a can be passed, spaced apart in the longitudinal direction of the contact portions 61a, 71a.

[0027] The pair of fixing portions 61, 61, 71, 71 of the first jig 60 or the second jig 70 includes a protruding portion 69 that protrudes from each fixing portion 61, 61, 71, 71 and is interposed between the two aligned base members 10, 20. In this embodiment, the protruding portion 69 is provided on each of the pair of fixing portions 61, 61 of the first jig 60. The protruding portion 69 is rectangular parallelepiped-shaped and protrudes from the bottom surface of the abutting portion 61 a in a direction perpendicular to the bottom surface. The length of the protruding portion 69 in the longitudinal direction of the abutting portion 61 a is referred to as the width of the protruding portion 69.

[0028] The following describes how the two base members 10, 20 are fixed using the jig 50. First, using a transport device such as a crane, one of the two base members 10, 20 is inverted relative to the other in the front-to-back direction of the base member 10 (20), and the two base members are arranged in the left-to-right direction with a gap approximately equal to the width of the protrusion 69 of the first jig 60 (see FIGS. 2 and 3, in which the jig is ignored). Furthermore, one of the two base members 10, 20 is offset relative to the other in the longitudinal direction of the base member 10 (20) so that the two base members 10, 20 are not lined up in the portions of each base member 10, 20 where the joining members 30, 40 are joined. The joining of the joining members 30, 40, which will be described later, is performed within the offset sections of the base members 10, 20, in other words, in the sections where the two base members 10, 20 do not overlap when viewed left-to-right.

[0029] 2 to 4, on one side in the longitudinal direction (front-rear direction) of the two aligned base members 10, 20, with the longitudinal directions of the pair of fixing portions 61, 61 of the first jig 60 parallel to the left-right direction, one fixing portion 61 has its protrusion 69 inserted into the gap between the upper flanges 13, 23 of the two base portions, and the bottom surface of its abutting portion 61 a is placed against the upper flanges 13, 23 of the two base portions. The other fixing portion 61 has its protrusion 69 inserted into the gap between the lower flanges 13, 23 of the two base portions, and the bottom surface of its abutting portion 61 a is placed against the lower flanges 13, 23 of the two base portions so as to face the one fixing portion 61. Next, a bolt 63a is passed through each of the two bolt holes 67, 67 provided in a pair of fixing portions 61, 61 of the first jig 60, and nuts 63b, 63b are tightened onto each end of the bolt 63a, thereby clamping the two base portions from above and below between the pair of fixing portions 61, 61 of the first jig 60 and fixing them.

[0030] 2, 3, and 6, a second jig 70 is placed next to the first jig 60 to which the two base members 10 and 20 are fixed, and with the longitudinal directions of the pair of fixing portions 71 and 71 of the second jig 70 parallel to the vertical direction, the bottom surface of the abutting portion 71a of one fixing portion 71 is placed against the outer side edges of the upper and lower flanges 13 and 23 of one base member 10. The bottom surface of the abutting portion 71a of the other fixing portion 71 is placed against the outer side edges of the upper and lower flanges 13 and 23 of the other base member 20 so as to face the one fixing portion 71. Next, a bolt 73a is passed through two bolt holes 77 and 77 provided in the pair of fixing portions 71 and 71 of the second jig 70, and nuts 73b and 73b are tightened onto both ends of the bolt 73a. As a result, the two base portions are sandwiched and fixed from the left and right between the pair of fixing portions 71, 71 of the second jig 70. On the other side of the longitudinal direction (front-rear direction of the base members 10, 20) of the two aligned base members 10, 20, the two base members 10, 20 are fixed by the first jig 60 and the second jig 70 in the same manner as on the one side.

[0031] The two base members 10, 20 fixed by the jig 50 are fixed together without interfering with each other, with a gap of the width of the protrusion 69 provided on the first jig 60. Furthermore, by providing the protrusion 69, the two base members 10, 20 can be fixed together by the jig 50 without interfering with each other, even if the base members 10, 20 are provided with stud dowels D or the like that protrude further outward from the base members 10, 20 in the direction in which the two base members 10, 20 are aligned, as shown by the dotted lines in Fig. 4. The width of the protrusion 69 is set appropriately depending on the shape of the base members.

[0032] When joining the joining members 30, 40 by welding, the two base members 10, 20 fixed by the jig 50 are attached to a rotation device 80. The rotation device 80 is used to rotate the two base members 10, 20 fixed by the jig 50 and change the position of the two base members 10, 20 so that welding can be performed facing downward. The joining members 30, 40 can be joined by any means that can be joined, such as bolts, but in this embodiment, they are joined by welding.

[0033] 8 and 9, this embodiment is provided with two rotation devices 80. As shown in FIG. 10, each rotation device 80 includes a base 81, a rotation unit 83, and a drive unit (not shown).

[0034] The base 81 is equipped with the components of the rotation device 80. The rotation unit 83 is mounted on the base 81 and is rotatable around a predetermined horizontal axis, in this case, the axis in the front-to-rear direction. The rotation unit 83 is configured in a substantially annular shape by a rotation unit main body 83a and an opening / closing unit 83b. One circumferential end of the opening / closing unit 83b is attached to one circumferential end of the rotation unit main body 83a so as to be rotatable around an axis in the up-down direction, and the other circumferential end is detachable from the other circumferential end of the rotation unit main body 83a. As shown in FIG. 10 , the basic position of the rotation unit 83 is when the opening / closing unit 83b is positioned approximately directly above. The interior of the rotation unit 83 is a fixed space 83c that penetrates the rotation unit 83 in the front-to-rear direction and is a space to which the two base members 10 and 20 are fixed. The bottom of the fixed space 83c is flat. When the rotating part 83 is in the basic position, by rotating the opening / closing part 83b relative to the rotating part main body 83a, the top of the fixed space 83c opens, and the rotated body (two base members 10, 20 fixed to the jig 50) can be transported into the fixed space 83c from above the rotating part 83.

[0035] As shown in FIG. 10 , when the rotating unit 83 is in the basic position, the rotating unit 83 includes a vertical fixing portion 85 that fixes the rotated body to the rotating unit 83 in the vertical direction and a horizontal fixing portion 87 that fixes the rotated body to the rotating unit 83 in the left-right direction. When the first operating portion 85b is rotated with a tool, the vertical fixing portion 85 moves a holding portion 85a up and down depending on the direction of rotation. The vertical fixing portion 85 moves up and down depending on the direction of rotation. The vertical fixing portion 85 moves up and down depending on the direction of rotation. The rotating body is fixed to the rotating unit 83 by being sandwiched between the holding portion 85a and the bottom of the fixing space 83c. When the second operating portion 87b is rotated with a tool, the horizontal fixing portion 87 moves two claws 87a closer to or farther away from each other depending on the direction of rotation. The rotational body is fixed to the rotating unit 83 in the left-right direction depending on the direction of rotation. The movement of the two claws 87a moves the two claws 87a. The rotated body is fixed to the rotating part 83 by being sandwiched between the two claws 87a, 87a from the left and right directions.

[0036] To attach the two base members 10, 20 secured by the jig 50 to the rotation device 80, the two rotation devices 80 are placed with a gap between them in the front-to-rear direction. Next, with the rotating portions 83 of the two rotation devices 80 in their basic positions, the opening / closing portions 83b of each rotating portion 83 are rotated to open the upper portion of the fixing space 83c. Next, a sling S is attached to the sling portion 75, and the two base members 10, 20 secured together by the jig 50 are lifted by a transport device such as a crane. The two base members 10, 20 are then carried into the fixing space 83c from above the rotating portions 83 of each rotation device 80 so that the longitudinal direction of the base members 10 (20) is approximately parallel to the front-to-rear direction of the rotation device 80, and installed on the rotating portions 83. Next, the two base members 10, 20 are secured to the rotating portions 83 of each rotation device 80 by the upper and lower fixing portions 85 and the left and right fixing portions 87 of each rotation device 80. Finally, the opening and closing portions 83b of each of the rotation devices 80 are closed, thereby completing the attachment of the two base members 10 and 20 to the rotation devices 80.

[0037] It should be noted that if the joining members 30, 40 are joined to the two base members 10, 20 fixed by the jig 50 by a method other than welding, such as bolts, the rotation device 80 is not necessary.

[0038] Next, connecting members 30, 40 are joined to the two base members 10, 20, respectively. In this embodiment, as shown in FIG. 11 , each connecting member 30, 40 is composed of a main connecting member 31, 41, a rib 33, 43, and a connecting flange 35, 45. The main connecting member 31, 41 is an H-beam similar to the base members 10, 20. The main connecting member 31, 41 has a web and flange notched at an angle at one corner of one longitudinal end of the main connecting member 31, 41. The angle of this inclination is approximately the same as the angle of inclination of one end of the base members 10, 20. The ribs 33, 43 are intended to reinforce the connection between the base members 10, 20 and the main connecting member 31, 41. The ribs 33, 43 are made of steel and are composed of a member shaped like a roughly right-angled triangle when viewed from the side and a flange joined to the inclined surface of this member. The joining flanges 35, 45 are steel plate-like members that are to be joined to the inclined portions of the joined base members 10, 20 and main joining members 31, 41, which will be described later. Each joining member 30, 40 is joined within the offset sections of the two base members 10, 20.

[0039] To join the joining members 30, 40 to the base members 10, 20, each main joining member 31, 41 is placed on the upper flanges 13, 23 of the base members 10, 20 with the end with the notched, inclined portion facing downward, its longitudinal direction parallel to the vertical direction, and the notched, inclined portion aligned approximately in a straight line with the inclination of one end of the base members 10, 20. The main joining members 31, 41 are then joined to the base members 10, 20 by welding. Next, ribs 33, 43 are welded to the corners where the main joining members 31, 41 are perpendicular to the base members 10, 20. Furthermore, joining flanges 35, 45 are welded to the inclined portions of the base members 10, 20 and the main joining members 31, 41. When joining the joining members 30, 40, the joining members 30, 40 are transported by a transport device such as a crane. Depending on the welding locations, the base members 10, 20 and the joining members 30, 40 joined thereto are rotated and welded by rotation devices 80, 80. Here, for the welded portions between the joining flanges 35, 45 and the base members 10, 20, which cannot be welded with a welding torch or the like facing downward, the base members 10, 20 and the joining members 30, 40 joined thereto are rotated and welded by rotation devices 80, 80 so that the welded portions are positioned so that they can be welded facing downward, as shown in FIG.

[0040] As a result of the above, two asymmetrical members 1 and 2 are completed, as shown in Figure 13. The two completed asymmetrical members 1 and 2 are in a state in which one is inverted relative to the other in a predetermined horizontal direction (front-to-back direction). The two completed asymmetrical members 1 and 2 are released from the upper and lower fixing parts 85 and the left and right fixing parts 87 of the rotation devices 80 and 80, and the opening / closing part 83b is rotated to open the top of the fixed space 83c. A sling S such as a wire is attached to the sling part 75, and the members are lifted and transported (carried out) by a single transport device such as a crane. The two asymmetrical members 1 and 2 fixed by the jig 50 have their centers of gravity located in the center in the front-to-back direction, so they can be lifted by a single transport device in the posture before lifting with almost no tilting, as shown in Figure 14.

[0041] The manufacturing method for an asymmetrical member is not limited to an asymmetrical member 1 (2) having an L-shaped shape. The manufacturing method for an asymmetrical member may also be used to manufacture two or more asymmetrical members 1, 2. The manufacturing method for an asymmetrical member is suitable for manufacturing relatively large and heavy members in which the asymmetrical member 1 (2) and its constituent members need to be lifted and rotated by a transport device such as a crane, but is not particularly limited to such members. The transport device may also be something other than a crane.

[0042] The manufacturing method for an asymmetrical member manufactures two asymmetrical members 1, 2 at a time, and therefore can efficiently manufacture the asymmetrical members 1, 2. Furthermore, in the manufacturing method for an asymmetrical member, the two completed asymmetrical members 1, 2 are fixed together in a state in which one of the two asymmetrical members 1, 2 is inverted relative to the other in a predetermined horizontal direction, and therefore the asymmetrical members 1, 2 can be lifted by a single transport device in the same position as before lifting with almost no tilting, and the asymmetrical members 1, 2 can be transported efficiently and safely.

[0043] Furthermore, in the manufacturing method for asymmetrical members, one of two base members 10, 20 is fixed to the other with a predetermined horizontal offset, and joining members 30, 40 are joined within the offset sections of each of the two base members 10, 20. This makes it easier to perform the joining work and reduces the time required for the joining work, as the other base member 20(10) does not get in the way when joining the joining member 30(40) to one base member 10(20).

[0044] In the manufacturing method for asymmetrical members, two fixed base members 10, 20 are attached to a rotation device 80, and when joining members 30, 40 to the base members 10, 20 by welding, the two asymmetrical members 1, 2 can be rotated to change their position, allowing welding to be performed always facing downward. Furthermore, the two asymmetrical members 1, 2 can be rotated more efficiently than when they are rotated by a crane.

[0045] The jig 50 used in the manufacturing method of the asymmetrical member has a protrusion 69 that protrudes from the fixing portion 61 (71) and is interposed between the two aligned base members 10, 20, thereby enabling the two aligned base members 10, 20 to be fixed together without interference, resulting in good quality of the asymmetrical members 1, 2.

[0046] Furthermore, by providing the jig 50 with the sling portion 75, the slinging tool S can be attached to the sling portion 75 easily and in a short time.

[0047] The present invention is not particularly limited to the above-described embodiment, and can be modified as appropriate within the scope of the gist of the present invention. [Explanation of symbols]

[0048] 1,2,100 Asymmetrical members 10,20 Base member 11,21 Web 13,23 flange 30,40 Joint members 31,41 Main joint members 33,43 Ribs 35,45 Joint flange 50 Jig 60 First jig 61 Fixed part 61a Contact part 61b Rising part 63 Clamping tool 63a Bolt 63b Nut 67 Bolt holes 69 Protrusion 70 Second jig 71 Fixed part 71a Contact part 71b Rising part 73 Clamping Tool 73a Bolt 73b Nut 75 Sling section 77 Bolt holes 80 Rotating Device 81 Mounting stand 83 Rotating part 83a Rotating body 83b Opening / closing part 83c fixed space 85 Upper and lower fixed part 85a Presser foot 85b 1st operation section 87 Left and right fixed parts 87a Claw 87b 2nd operation section D Stud dowel S Sling hook S

Claims

1. A jig for fixing two aligned base members, a pair of fixing portions that are applied to the two base members so as to face each other; and a clamping tool that clamps the pair of fixing portions; The jig includes a protruding portion that protrudes from the fixed portion and is interposed between the two aligned base members.

2. The jig according to claim 1 , wherein the fixing portion or the clamping device is provided with a sling portion to which a sling tool can be attached.

Images