CN113653861A - 一种双壁螺旋焊管及其制造方法 - Google Patents

一种双壁螺旋焊管及其制造方法 Download PDF

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CN113653861A
CN113653861A CN202110902131.9A CN202110902131A CN113653861A CN 113653861 A CN113653861 A CN 113653861A CN 202110902131 A CN202110902131 A CN 202110902131A CN 113653861 A CN113653861 A CN 113653861A
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战福军
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Nanjing Dade Steel Pipe Co ltd
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Nanjing Lianzhong Engineering Technology Co ltd
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    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • B23K31/027—Making tubes with soldering or welding
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    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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    • B23K9/02—Seam welding; Backing means; Inserts
    • B23K9/032—Seam welding; Backing means; Inserts for three-dimensional seams
    • B23K9/0325—Seam welding; Backing means; Inserts for three-dimensional seams helicoidal seams
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    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
    • F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
    • F16L58/04—Coatings characterised by the materials used
    • F16L58/06—Coatings characterised by the materials used by cement, concrete, or the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/16—Rigid pipes wound from sheets or strips, with or without reinforcement
    • F16L9/165—Rigid pipes wound from sheets or strips, with or without reinforcement of metal
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/16—Rigid pipes wound from sheets or strips, with or without reinforcement

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Abstract

本发明公开了一种双壁螺旋焊管，由双层复合钢带螺旋状卷焊形成；所述双层复合钢带包括等宽平行对齐设置的第一钢带层和第二钢带层，所述第一钢带层和第二钢带层之间设有至少两条与之垂直的支撑钢条，所述支撑钢条在第一钢带层和第二钢带层的两侧端部设置并与之共同延伸排布，所述第一钢带层、第二钢带层以及两侧端部的支撑钢条相互焊接形成延伸方向截面为矩形的双层复合钢带。还公开了该双壁螺旋焊管的制造方法。本发明设计的双壁螺旋焊管结构强度高，在满足钢管现有国家标准的外压及内压强度的前提下，可极大的节省材料用量，降低成本；在焊接边设计焊接坡口，可使焊接处更为稳固，同时由于是坡口，焊缝焊接后，管壁更为平滑，利于顶管施工。

Description

一种双壁螺旋焊管及其制造方法
技术领域
本发明涉及钢管焊接技术领域，尤其是涉及一种双壁螺旋焊管及其制造方法。
背景技术
目前的螺旋焊钢管绝大多数都是单层管壁，当要求钢管口径超过2米时，为满足钢管内水压的要求和钢管外部荷载的要求，管壁厚度在20毫米左右，钢材用量大；当要求管道直径在3米左右时，钢管的厚度需要在30毫米左右。这种情况下：钢材用量大，造价高；30毫米厚的钢板，钢厂的交货状态是矩形块状的平板，已经无法以钢卷或钢带状态交货，也就无法满足螺旋焊管的生产线式的连续卷制和连续焊接，只能将矩形的块状钢板单独预弯卷圆成筒状，焊接平直的焊缝，制成长度较短的单元节直缝焊管，然后各个单元节再对接焊接，生产的效率大大下降。另外，直缝焊管的焊缝承受内压的能力比螺旋焊管弱，壁厚通常比螺旋焊管厚度加厚10％～25％，导致造价提高。再有，当单层壁的螺旋焊管直径达到2.5米左右时，承受外部荷载的能力明显降低，甚至自由状态放置时，在钢管自重的情况下就会产生椭圆形的变形，需要在管内设置米字形临时支撑。
发明内容
发明目的：为了克服背景技术的不足，本发明第一目的是公开一种双壁螺旋焊管；第二目的是公开了该双壁螺旋焊管的制造方法。
技术方案：本发明所公开的双壁螺旋焊管，由双层复合钢带螺旋状卷焊形成；所述双层复合钢带包括等宽平行对齐设置的第一钢带层和第二钢带层，所述第一钢带层和第二钢带层之间设有至少两条与之垂直的支撑钢条，所述支撑钢条在第一钢带层和第二钢带层的两侧端部设置并与之共同延伸排布，所述第一钢带层、第二钢带层以及两侧端部的支撑钢条相互焊接形成延伸方向截面为矩形的双层复合钢带。
进一步的，所述支撑钢条设于第一钢带层和第二钢带层两侧端部后，支撑钢条的外侧边突出钢带层，在所述双层复合钢带卷焊时，两侧的支撑钢条突出的部分拼接，与钢带层形成焊接坡口。
通过此焊接坡口可以将相接触的支撑钢条以及相邻的钢带层焊接在一起，且能够做到焊后管壁平滑。
进一步的，钢带层两侧的支撑钢条之间同时间隔设有多条支撑钢条，对第一钢带层和第二钢带层内部进行支撑，所有支撑钢条相互平行共同延伸排布。
进一步的，所述第一钢带层由多条分体钢带并列排布焊接形成，相邻分体钢带的接缝处均对应一条支撑钢条。
对相邻分体钢带的接缝处进行焊接时，可同时与对应的支撑钢条进行焊接，实现三者的固定，使得结构更加稳固。
同时，由于分体钢带之间存在焊缝，卷焊成管道时即形成连续的螺旋状焊缝，该螺旋状焊缝并不利于水流快速通过，所以双层复合钢带卷焊时，所述第一钢带层位于管道外壁，使得螺旋状焊缝位于管外壁。
上述双壁螺旋焊管的制造方法，包括以下步骤：
S1、从钢卷上放出第二钢带，水平放置形成第二钢带层；
S2、从多个竖向钢卷上放出支撑钢条，垂直于第二钢带层放置，其中有两条置于第二钢带层的侧边端部，支撑钢条的底部与第二钢带层焊接；
S3、从钢卷上放出与第二钢带等宽的第一钢带，与第二钢带对应水平放置于支撑钢条上形成第一钢带层，并焊接固定形成双层复合钢带；
S4、将双层复合钢带用螺旋钢焊管加工设备螺旋状弯曲卷圆，对管内外两处焊缝持续焊接，钢管持续成型。
其中，S2中置于第二钢带层的侧边端部支撑钢条外侧边突出钢带层，S4在卷圆时，当钢带卷圆完成一圈轨迹，与未卷圆的钢带的边缘接触时，会形成管内外两处焊接坡口，通过焊接坡口将接触的支撑钢条与相邻的钢带层焊接固定。
进一步的，钢带由下往上进行持续卷圆，对于同一位置的内外两处焊接坡口，先对管内焊接坡口进行焊接，在管道上方再对管外焊接坡口进行焊接，持续焊接固定。
进一步的，S3中第一钢带层包括多条并列排布的分体钢带，分别由钢卷放出置于支撑钢条上，相邻分体钢带接缝均对应一条支撑钢条，形成焊缝，通过焊缝对三者进行焊接固定。
有益效果：与现有技术相比，本发明的优点为：
1、本发明设计的双壁螺旋焊管结构强度高，在满足钢管现有国家标准的外压及内压强度的前提下，可极大的节省材料用量，降低成本；
2、在焊接边设计焊接坡口，可使焊接处更为稳固，同时由于是坡口，焊缝焊接后，管壁更为平滑，利于顶管施工；
3、由于整体采用分体拼装焊接的方式，可以对其进行分装运输，解决了3米以上直径的钢管因为钢板材料太厚不能卷状交货只能板状交货，且不能连续生产螺旋焊管的难题；同时，内外层钢板可单独使用或全部使用不锈钢，或者使用不锈钢复合钢，钢管耐久性增加，极大延长钢管寿命，而造价不升或仅稍有上升；
4、通过支撑钢条支撑整体管壁，可以在内外层之间的空腔填充混凝土增加结构强度，同时防止内部腐蚀；
5、达到相同的结构强度前提下，本发明管道重量减轻，施工吊装成本减少，同时单节长度可以更长，减少工地的管节焊接接缝。
附图说明
图1为本发明双壁螺旋焊管结构示意图；
图2为本发明双层复合钢带延伸方向截面图；
图3为本发明焊接坡口结构图；
图4为本发明双层复合钢带内部支撑钢条截面图；
图5为本发明双层复合钢带分体钢带结构图；
图6为本发明制造流程图。
具体实施方式
下面结合附图和具体实施方式对本发明进一步详细描述。
如图1所示的双壁螺旋焊管，由双层复合钢带螺旋状卷焊形成。
如图2所示，所述双层复合钢带包括等宽平行对齐设置的第一钢带层1和第二钢带层2，共同延伸开。所述第一钢带层1和第二钢带层2之间设有两条与之垂直的支撑钢条3，所述支撑钢条3在第一钢带层1和第二钢带层2的两侧端部设置并与之共同延伸排布，排布时，支撑钢条3的外侧边突出钢带层，所述第一钢带层1、第二钢带层2以及两侧端部的支撑钢条3相互焊接形成延伸方向截面为矩形的双层复合钢带。
如图3所示，在所述双层复合钢带卷焊时，两侧的支撑钢条3突出的部分拼接，与钢带层形成焊接坡口4，对该焊接坡口4进行焊接时，可将相拼接的两个支撑钢条3以及相邻的两个钢带层四者同时焊接固定，且其焊缝相对管壁较为平整。
如图4所示，所述支撑钢条3设于第一钢带层1和第二钢带层2两侧端部后，两侧的支撑钢条3之间同时间隔设有两条支撑钢条3，对第一钢带层1和第二钢带层2内部进行支撑，所有支撑钢条3相互平行共同延伸排布，整体焊接固定。
如图5所示，考虑到内部多条支撑钢条3与钢带层不便焊接，将所述第一钢带层1设计为三条分体钢带101并列排布焊接形成，相邻分体钢带101的接缝处均对应一条支撑钢条3。每个相邻分体钢带101与对应的支撑钢条3形成一条焊缝，便于三者焊接固定。为了避免该连续的焊缝对排水产生不利影响，在上述双层复合钢带卷焊时，所述第一钢带层1位于管道外壁，使得焊缝产生于管道外壁。
如图6所示，上述双壁螺旋焊管的制造方法，包括以下步骤：
S1、从钢卷上放出第二钢带，水平放置形成第二钢带层2；
S2、从四个竖向钢卷上放出支撑钢条3，垂直于第二钢带层2放置，其中有两条置于第二钢带层2的侧边端部并突出钢带层，还有两条置于中部，支撑钢条3的底部与第二钢带层2焊接；
S3、从钢卷上放出与第二钢带等宽的第一钢带，与第二钢带对应水平放置于支撑钢条3上形成第一钢带层1，第一钢带层1包括三条并列排布的分体钢带101，分别由钢卷放出置于支撑钢条3上，相邻分体钢带101接缝均对应一条支撑钢条3，形成焊缝，通过焊缝对三者进行焊接固定，形成双层复合钢带；
S4、将双层复合钢带用螺旋钢焊管加工设备螺旋状弯曲卷圆，卷圆时，第一钢带层1为外圈，当钢带卷圆完成一圈轨迹，与未卷圆的钢带的边缘接触时，两边的支撑钢条3接触会形成管内外两处焊接坡口4，通过焊接坡口4将接触的支撑钢条3与相邻的钢带层焊接固定，钢带由下往上进行持续卷圆，对于同一位置的内外两处焊接坡口4，先对管内焊接坡口进行焊接，在管道上方再对管外焊接坡口进行焊接，持续焊接固定，钢管持续成型。

Claims (9)

1.一种双壁螺旋焊管，其特征在于：由双层复合钢带螺旋状卷焊形成；所述双层复合钢带包括等宽平行对齐设置的第一钢带层(1)和第二钢带层(2)，所述第一钢带层(1)和第二钢带层(2)之间设有至少两条与之垂直的支撑钢条(3)，所述支撑钢条(3)在第一钢带层(1)和第二钢带层(2)的两侧端部设置并与之共同延伸排布，所述第一钢带层(1)、第二钢带层(2)以及两侧端部的支撑钢条(3)相互焊接形成延伸方向截面为矩形的双层复合钢带。
2.根据权利要求1所述的双壁螺旋焊管，其特征在于：所述支撑钢条(3)设于第一钢带层(1)和第二钢带层(2)两侧端部后，支撑钢条(3)的外侧边突出钢带层，在所述双层复合钢带卷焊时，两侧的支撑钢条(3)突出的部分拼接，与钢带层形成焊接坡口(4)。
3.根据权利要求1所述的双壁螺旋焊管，其特征在于：钢带层两侧的支撑钢条(3)之间同时间隔设有多条支撑钢条(3)，对第一钢带层(1)和第二钢带层(2)内部进行支撑，所有支撑钢条(3)相互平行共同延伸排布。
4.根据权利要求1所述的双壁螺旋焊管，其特征在于：所述第一钢带层(1)由多条分体钢带(101)并列排布焊接形成，相邻分体钢带(101)的接缝处均对应一条支撑钢条(3)。
5.根据权利要求4所述的双壁螺旋焊管，其特征在于：双层复合钢带卷焊时，所述第一钢带层(1)位于管道外壁。
6.权利要求1所述的双壁螺旋焊管的制造方法，其特征在于，包括以下步骤：
S1、从钢卷上放出第二钢带，水平放置形成第二钢带层(2)；
S2、从多个竖向钢卷上放出支撑钢条(3)，垂直于第二钢带层(2)放置，其中有两条置于第二钢带层(2)的侧边端部，支撑钢条(3)的底部与第二钢带层(2)焊接；
S3、从钢卷上放出与第二钢带等宽的第一钢带，与第二钢带对应水平放置于支撑钢条(3)上形成第一钢带层(1)，并焊接固定形成双层复合钢带；
S4、将双层复合钢带用螺旋钢焊管加工设备螺旋状弯曲卷圆，对管内外两处焊缝持续焊接，钢管持续成型。
7.根据权利要求6所述的双壁螺旋焊管的制造方法，其特征在于：S2中置于第二钢带层(2)的侧边端部支撑钢条(3)外侧边突出钢带层，S4在卷圆时，当钢带卷圆完成一圈轨迹，与未卷圆的钢带的边缘接触时，会形成管内外两处焊接坡口(4)，通过焊接坡口(4)将接触的支撑钢条(3)与相邻的钢带层焊接固定。
8.根据权利要求7所述的双壁螺旋焊管的制造方法，其特征在于：钢带由下往上进行持续卷圆，对于同一位置的内外两处焊接坡口(4)，先对管内焊接坡口进行焊接，在管道上方再对管外焊接坡口进行焊接，持续焊接固定。
9.根据权利要求6所述的双壁螺旋焊管的制造方法，其特征在于：S3中第一钢带层(1)包括多条并列排布的分体钢带(101)，分别由钢卷放出置于支撑钢条(3)上，相邻分体钢带(101)接缝均对应一条支撑钢条(3)，形成焊缝，通过焊缝对三者进行焊接固定。
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