Frame repair method
The method allows for efficient repair of truss structures by installing repair members on chord and vertical members, forming a new structure with equivalent strength, thereby minimizing downtime and production losses.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- JFE STEEL CORP
- Filing Date
- 2024-01-25
- Publication Date
- 2026-07-29
AI Technical Summary
Existing methods for repairing truss structures, such as those in belt conveyor frames, require significant alterations and time-consuming strength calculations, making them inefficient and disruptive to operations.
A method involving the installation of first and second repair members on chord and vertical members, respectively, while maintaining the existing truss structure, followed by removal of diagonal and vertical members, allowing for the formation of a new truss structure with equivalent strength without additional calculations.
Enables easy and efficient repair of truss structures by maintaining structural integrity and minimizing downtime, ensuring the new structure's strength matches the original, thus reducing production losses.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to a method for repairing a frame having a plurality of truss structures.
Background Art
[0002] As one of the frames having a plurality of truss structures, a frame of a belt conveyor can be cited. The belt conveyor is used, for example, for transporting raw materials or the like in a steel mill and is installed outdoors. Steel section steel is generally used for the frame of the belt conveyor. When the raw materials deposited on the belt conveyor retain rainwater and the rainwater drips, the frame of the belt conveyor comes into contact with water. In addition, since the raw materials deposited on the belt conveyor are washed away with water, the frame of the belt conveyor comes into contact with the washing water.
[0003] The frame of the belt conveyor undergoes corrosion deterioration due to contact with water. When the frame of the belt conveyor corrodes, patch repair is performed using electric welding at the thinned part of the member. Patch repair can be performed only on the thinned part and is economically reasonable. In addition, patch repair can be performed while maintaining the truss structure of the frame of the belt conveyor.
[0004] However, when the corrosion progresses significantly, there is a risk that the member may melt due to the heat of electric welding and patch repair cannot be performed. Therefore, while maintaining the self-supporting property of the truss structure, the members of the truss structure are replaced.
[0005] For example, in Patent Document 1, a temporary chord member is attached between the upper chord member and the lower chord member, and the temporary chord member and the upper chord member are connected by a plurality of temporary diagonal members to form a temporary truss. In addition, in Patent Document 1, the lower chord member and the lower end side of the diagonal member connected thereto are removed, and a new lower chord member and the lower end side of the new diagonal member are attached. That is, in Patent Document 1, the lower chord member and the lower end side of the diagonal member are removed while maintaining the truss shape by the temporary truss.
Prior Art Documents
[0006] [Patent Document 1] Japanese Patent Publication No. 2019-178607 [Overview of the Initiative] [Problems that the invention aims to solve]
[0007] However, in the repair method described in Patent Document 1, the existing truss structure is significantly altered 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 perform strength calculations for the temporary truss before carrying out the repair work, which presents a problem as it takes time before the work can begin.
[0008] This invention has been made in view of the above-mentioned problems, and aims to provide a method for repairing a frame that can be easily repaired. [Means for solving the problem]
[0009] To solve the above problems, the present invention has the following features.
[0010] [1] A method for repairing a frame having a plurality of truss structures, each having an upper chord member formed extending in one direction, or a lower chord member positioned opposite the upper chord member and also extending in the same direction, vertical members that erect the upper chord member and the lower chord member in the opposing direction, and diagonal members that are provided at an angle to the vertical members and erect the upper chord member and the lower chord member, A first installation step involves 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 which is provided in a direction along the direction in which the diagonal member is arranged, A second installation step involves 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 which is provided in a direction along the arrangement direction of the vertical member, A first repair member installation step involves 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 involves 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 method for repairing a frame, comprising [the specified element]. [2] The frame repair method according to [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 in close proximity to the diagonal member in one direction. The method for repairing a frame according to [1] or [2], wherein in the second repair member installation step, the second repair member is provided in close proximity to the vertical member in one direction. [4] The diagonal member is removed after the first repair member is installed. The method for repairing a frame according to any one of [1] to [3], wherein the vertical member is removed after the second repair member is installed. [5] The first repair member is positioned opposite the diagonal member and is provided on 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 welding leg length of the first repair member. [6] The method for repairing a frame according to [4], wherein the second repair member is installed after the portion of the diagonal member facing the second mounting portion has been removed. [7] The frame has a pair of supports provided on one end and the other end in the aforementioned direction. The frame repair method according to any one 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 composed of a single plate-shaped member. The frame repair method described in any of [1] to [7], wherein the first installation step and the second installation step are performed simultaneously. [Effects of the Invention]
[0011] According to the frame repair method of the present invention, a new truss structure can be formed using the first and second repair members, while the truss structure is maintained with the existing members, similar to the existing truss structure. Since 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, since frame repair can be performed without performing strength calculations for the new truss structure, repair work can be easily carried out.
[0012] Furthermore, by forming a new truss structure using the first and second repair members, the strength of the frame can be guaranteed, allowing the removal of existing truss structure members at any time. For example, if the frame is a conveyor frame installed in a factory, the downtime of the equipment required for repair work can be minimized, thereby suppressing the reduction in production volume at the factory. [Brief explanation of the drawing]
[0013] [Figure 1] This 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] Figure 1 is an explanatory diagram showing the configuration of the belt conveyor frame. [Figure 3] This is a flowchart showing the repair method for the belt conveyor frame shown in Figure 1. [Figure 4] It is an explanatory drawing showing the aspects of the first installation step and the second installation step of FIG. 3. [Figure 5] It is an explanatory drawing showing the aspect in which the first attachment part and the second attachment part of FIG. 4 are installed. [Figure 6] It is an explanatory drawing showing the aspect of the first repair member installation step of FIG. 3. [Figure 7] It is an explanatory drawing showing the aspect in which the first repair member of FIG. 6 is installed. [Figure 8] It is an explanatory drawing showing the aspect of the second repair member installation step of FIG. 3. [Figure 9] It is an explanatory drawing showing the aspect of the second repair member installation step of FIG. 3. [Figure 10] It is an explanatory drawing showing the aspect of the removal step of FIG. 3.
Mode for Carrying Out the Invention
[0014] Hereinafter, embodiments of the present invention will be described based on the 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] As shown in FIG. 1, the belt conveyor frame 100 is formed to extend in the conveying direction D1, which is one direction. The belt conveyor frame 100 is not particularly limited, but the height dimension assembled with carrier rollers (not shown) can be 1.5 m.
[0016] The belt conveyor frame 100 is provided with a pair of supports 21 and 22 at one end side and the other end side in the conveying direction D1. The distance between the supports 21 and 22 is not particularly limited, but can be, for example, 20 m. The belt conveyor frame 100 is provided at a height of 4 m above the ground, for example, by being supported by the supports 21 and 22.
[0017] The belt conveyor frame 100 has a gravity tensioning device 30 that applies tension to the belt. In other words, the tension of the belt on the belt conveyor frame 100 can be adjusted by adjusting the gravity tensioning device 30.
[0018] Figure 2 shows the configuration of the belt conveyor frame 100. As shown in Figure 2, the belt conveyor frame 100 has an upper chord member 11 that extends in the conveying direction D1 and a lower chord member 12 that is positioned opposite the upper chord member 11 and also extends in the conveying direction D1. The belt conveyor frame 100 has vertical members 13 that span the upper chord member 11 and the lower chord member 12 in opposing directions. The belt conveyor frame 100 has diagonal members 14 that are provided at an angle to the vertical members 13 and span the upper chord member 11 and the lower chord member 12.
[0019] The belt conveyor frame 100 has multiple truss structures 15, each composed of an upper chord 11 or lower chord 12, vertical members 13, and diagonal members 14. The truss structures 15 are arranged adjacent to each other in the conveying direction. In other words, the belt conveyor frame 100 has multiple truss structures 15. The upper chord 11, lower chord 12, vertical members 13, and diagonal members 14 are not particularly limited, but for example, L-shaped angles can be used.
[0020] Figure 3 is a flowchart showing a repair method for the belt conveyor frame 100. The repair method for the belt conveyor frame 100 is carried out according to the flow shown in Figure 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] Next, 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] Next, a first repair member installation step is performed, in which the first repair member is fixed to the upper chord member 11 and the lower chord member 12 via at least one first mounting portion (step S03).
[0023] The first repair member installation step of step S03 can be performed by installing the first repair member on the first mounting portion, and is not particularly limited, but can be done using welding or fastening members such as bolts.
[0024] Furthermore, a second repair member installation step is performed in which the 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] Step S04, the step of installing the second repair member, is not particularly limited as long as the second repair member can be installed on the second mounting portion, but it can be carried out using welding or fastening members such as bolts.
[0026] Furthermore, the first repair member installation step in step S03 and the second repair member installation step in step S04 may be performed in either order.
[0027] Finally, a removal step is performed in which the vertical members 13 and diagonal members 14 are removed (step S05).
[0028] Figure 4 shows the configuration of the first installation step S01 and the second installation step S02 in Figure 3. As shown in Figure 4, the first mounting portion 41 is a member for providing a first repair member (not shown) which is provided in a direction along the arrangement direction of the diagonal member 14. The first mounting portion 41 is formed, for example, in the shape of a plate.
[0029] The second mounting portion 42 is a member for providing a second repair member (not shown) which is provided in a direction along the arrangement direction of the vertical member 13. The second mounting portion 42 is formed, for example, in the shape of a plate.
[0030] Here, the first mounting portion 41 and the second mounting portion 42 may be formed integrally or may be formed from separate components. In this embodiment, the first mounting portion 41 and the second mounting portion 42 will be described as being formed integrally. That is, when the first mounting portion 41 and the second mounting portion 42 are formed integrally, the first installation step in step S01 and the second installation step in step S02 in Figure 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 member 11 so as to face one end of the diagonal member 14. The first mounting portion 41 and the second mounting portion 42 are also provided on the lower chord member 12 so as to face the other end of the diagonal member 14.
[0032] Figure 5 shows the configuration in which 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, for example, to the L-shaped end faces of the upper chord member 11 or the lower chord member 12.
[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. This welding is performed, for example, by electric welding while the belt conveyor frame 100 is supported by a pair of supports 21 and 22.
[0034] Figure 6 shows the configuration of the first repair member installation step S03 in Figure 3. As shown in Figure 6, the first repair member 43 is provided in a direction along the arrangement direction of the diagonal member 14. In this embodiment, the first repair member 43 is provided parallel to the arrangement direction of the diagonal member 14.
[0035] In step S03, the first repair member installation step, the first repair member 43 should preferably have physical properties such as strength equivalent to that of the diagonal member 14. Furthermore, the first repair member 43 should preferably be installed in close proximity to the diagonal member 14 in the transport direction D1, which is one direction. By installing the first repair member 43 in this manner, the strength calculation can be simplified.
[0036] Figure 7 shows how the first repair member 43 of Figure 6 is installed. More specifically, it shows how the first repair member 43 is attached to the upper chord member 11 or the lower chord member 12 as viewed from the side of the frame 100. As shown in Figure 7, the first repair member 43 is provided on 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, for example, by electric welding.
[0037] The spacing W1 should be set to be longer than the welding leg length W2 of the first repair member 43. In other words, the first mounting portion 41 is formed to ensure a spacing W1 that is longer than the welding leg length W2.
[0038] Figure 8 shows the configuration of the second repair member installation step S03 in Figure 4. As shown in Figure 8, the second repair member 44 is provided in a direction along the arrangement direction of the vertical member 13. In this embodiment, the second repair member 44 is provided parallel to the arrangement direction of the vertical member 13. The second repair member 44 is fixed to the second mounting portion 42 by, for example, electric welding.
[0039] Figure 9 shows the configuration of the second repair member installation step S04 in 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. With the formation of multiple new truss structures 16, the strength of the belt conveyor frame 100 is restored.
[0040] In step S04, the second repair member installation step, the second repair member 44 is preferably installed in close proximity to the vertical member 13 in the transport direction D1, which is one direction. Furthermore, the second repair member 44 is preferably made of a material that has physical properties such as strength equivalent to that of the vertical member 13. By installing the second repair member 44 in this way, the strength calculation can be simplified.
[0041] Furthermore, the shape of the first repair member 43 is not particularly limited as long as it can be attached to the upper chord member 11 and the lower chord member 12 via the first mounting portion 41. For example, the first repair member 43 can be made from the same material as the diagonal member 14. In addition, it is 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 member 11 and the lower chord member 12 via the second mounting portion 42. For example, the second repair member 44 can be made from the same material as the vertical member 13. Also, it is preferable that the second repair member 44 be formed to the same length as the diagonal member 14.
[0043] By forming the first repair member 43 and the second repair member 44 with the same material and length as the vertical members 13 and diagonal members 14, a new truss structure 16 equivalent to the truss structure 15 can be formed. This simplifies the strength calculation 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 diagonal members 14 are removed.
[0045] Thus, the vertical members 13 are preferably removed after the first repair member 43 has been installed. Similarly, the diagonal members 14 are preferably removed after the second repair member 44 has been installed. By installing the first repair member 43 and the second repair member 44 in this way, repair work can be carried out while the truss structure 15 is maintained.
[0046] Furthermore, the second repair member 44 is preferably installed after the portion of the diagonal member 14 facing the second mounting portion 42 has been removed. By attaching the second repair member 44 to the second mounting portion 42 in this way, the installation work can be made easier.
[0047] Furthermore, the removal step S05 is a step that can be performed at will depending on the implementation method. That is, when the new truss structure 16 is formed, the strength of the belt conveyor frame 100 has been restored. Therefore, the occurrence of undesirable events due to corrosion of the belt conveyor frame 100 can be suppressed. Accordingly, the removal step S05 can be performed at will depending on the need, thereby shortening the work period. This allows, for example, the period during which the equipment is shut down for repair work to be set according to the work, and thus the reduction in conveying volume can be minimized.
[0048] Furthermore, the repair work on the belt conveyor frame 100, including the first installation step S01 to the removal step S05 described above, can be carried out while the belt conveyor frame 100 is supported by a pair of bearings 21 and 22. In this case, the repair work on the belt conveyor frame 100 can be carried out, for example, with a worker riding in an aerial work platform. Also, if the installation height of the belt conveyor frame 100 is high, the repair work may be carried out using a mobile crane or the like after securing a work platform with scaffolding or the like.
[0049] As described above, conventionally, it is difficult to secure space in the upper chord member 11 and the lower chord member 12 for installing 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 mounting 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 mounting portion 42. This makes it possible to secure space in the upper chord member 11 and the lower chord member 12 for installing 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 can therefore be considered to have the same strength as the existing truss structure 15. Consequently, strength calculations for the new truss structure 16 become unnecessary, and repair work can be carried out immediately, making the repair work easy.
[0051] Furthermore, it is preferable to form the new truss structure 16 while the truss structure 15 is supported by a pair of bearings 21 and 22. That is, it is preferable to form the new truss structure 16 in the same way as the existing truss structure 15, using the first repair member 43 and the second repair member 44, while the truss structure 15 is maintained with the existing members. By forming the new truss structure 16 in this way, it is possible to minimize changes to the shape of the new truss structure 16 from the truss structure 15.
[0052] Furthermore, conventionally, there is a problem in that repair work must be carried out in predetermined areas in order to guarantee 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 in any area, including the entire area of the frame 100. This makes the work more efficient.
[0053] Furthermore, by forming a 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, allowing the removal of existing truss structure 15 members at any time. For example, if the frame 100 is a conveyor frame installed in a factory, the downtime of the equipment required for repair work can be minimized, thereby suppressing a decrease in production volume at the factory.
[0054] Furthermore, when removing members of the truss structure 15, it is preferable to remove the vertical members 13 and diagonal members 14 after forming the new truss structure 16. By removing the vertical members 13 and diagonal members 14 in this way, the load on the belt conveyor frame 100 can be reduced.
[0055] Furthermore, if sufficient space can be secured in the upper chord member 11 or the lower chord member 12 for connecting the first repair member 43, it is preferable that the first mounting portion 41 be provided in at least one of the upper chord member 11 and the lower chord member 12.
[0056] Similarly, if there is sufficient space to connect the second repair member 44 in the upper chord member 11 or the lower chord member 12, the second mounting portion 42 should be provided in at least one of the upper chord member 11 and the lower chord member 12.
[0057] Furthermore, if the frame has multiple truss structures 15, its use is not limited to belt conveyors, but may also be used for other purposes, such as bridges or frames supporting piping for transporting raw materials, etc.
[0058] In the above-described embodiment, repair work on the belt conveyor frame 100 was explained in which 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 which 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 vertical members 13 may be removed after the second repair member 44 is installed. [Explanation of Symbols]
[0059] 100 Belt Conveyor Frames 11 Top chord 12 Lower string 13 vertical members 14 Diagonals 15 Truss structure 41 First mounting section 42 Second mounting section 43. First repair component 44. Second repair component
Claims
1. A method for repairing a frame having a plurality of truss structures, each having an upper chord member formed extending in one direction, or a lower chord member positioned opposite the upper chord member and also extending in the same direction, vertical members that erect the upper chord member and the lower chord member in the opposing direction, and diagonal members that are provided at an angle to the vertical members and erect the upper chord member and the lower chord member, A first installation step involves 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 which is provided in a direction along the direction in which the diagonal member is arranged, A second installation step involves 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 which is provided in a direction along the arrangement direction of the vertical member, A first repair member installation step involves 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 involves 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 method for repairing a frame, comprising [a specific feature / feature].
2. The method for repairing a frame according to 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 in close proximity to the diagonal member in one direction. The method for repairing a frame according to claim 1, wherein in the second repair member installation step, the second repair member is provided in close proximity to the vertical member in the one direction.
4. In the first repair member installation step, the first repair member is provided in close proximity to the diagonal member in one direction. The method for repairing a frame according to claim 2, wherein in the second repair member installation step, the second repair member is provided in close proximity to the vertical member in the one direction.
5. The diagonal member is removed after the first repair member is installed. The method for repairing a frame according to claim 2, wherein the vertical member is removed after the second repair member is installed.
6. The diagonal member is removed after the first repair member is installed. The method for repairing a frame according to claim 3, wherein the vertical member is removed after the second repair member is installed.
7. The diagonal member is removed after the first repair member is installed. The method for repairing a frame according to claim 4, wherein the vertical member is removed after the second repair member is provided.
8. The first repair member is positioned opposite the diagonal member and is provided on the first mounting portion by welding. The 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 welding leg length of the first repair member.
9. The method for repairing a frame according to any one of claims 5 to 7, wherein the second repair member is installed after the portion of the diagonal member facing the second mounting portion has been removed.
10. The frame has a pair of supports provided on one end and the other end in the aforementioned direction. The method for repairing a frame 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 on one end and the other end in the aforementioned direction. The method for repairing a frame 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 on one end and the other end in the aforementioned direction. The method for repairing a frame 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 composed of a single plate-shaped member. The frame repair method according to any one of claims 1 to 7, wherein the first installation step and the second installation step are performed simultaneously.