CN114012372B - Construction method of super-large-diameter single-pile composite cylinder - Google Patents
Construction method of super-large-diameter single-pile composite cylinder Download PDFInfo
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- CN114012372B CN114012372B CN202210002422.7A CN202210002422A CN114012372B CN 114012372 B CN114012372 B CN 114012372B CN 202210002422 A CN202210002422 A CN 202210002422A CN 114012372 B CN114012372 B CN 114012372B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D27/00—Foundations as substructures
- E02D27/32—Foundations for special purposes
- E02D27/42—Foundations for poles, masts or chimneys
- E02D27/425—Foundations for poles, masts or chimneys specially adapted for wind motors masts
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D5/00—Bulkheads, piles, or other structural elements specially adapted to foundation engineering
- E02D5/22—Piles
- E02D5/24—Prefabricated piles
- E02D5/28—Prefabricated piles made of steel or other metals
- E02D5/285—Prefabricated piles made of steel or other metals tubular, e.g. prefabricated from sheet pile elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D2300/00—Materials
- E02D2300/0026—Metals
- E02D2300/0029—Steel; Iron
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Abstract
The invention discloses a construction method of an oversized-diameter single-pile composite cylinder, which comprises the following steps: s1, manufacturing a shell ring; s2, arranging a roller frame and a welding frame; s3, longitudinal sewing; s4, pairing; s5, manufacturing a first platform; s6, folding the middle section B and the rear section C; s7, shift: s8, manufacturing a second platform; s9, arranging a roller frame; s10, folding greatly; s11, checking straightness; and S12, coating. The invention adopts a horizontal manufacturing method, can effectively save the assembly time of the pipe joint, can use submerged arc automation, improves the production efficiency and saves the production time.
Description
Technical Field
The invention belongs to the technical field of wind power equipment manufacturing, and particularly relates to a building method of an oversized-diameter single-pile composite cylinder for a floating wind power base.
Background
The traditional large-diameter section composite cylinder with the diameter smaller than phi 10000mm is generally constructed by the method that the large-diameter composite cylinder needs to be assembled and welded vertically, and then the section is turned over and folded. The method has low efficiency mainly because the vertical assembling shell ring has low efficiency and lower welding circular seam efficiency, and because the vertical assembling can not use submerged arc welding, only can use carbon dioxide gas shielded welding, the assembling and welding efficiency is low, and the processing period is long.
Disclosure of Invention
The invention aims to provide a construction method of an oversized-diameter single-pile composite cylinder, so as to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a construction method of an ultra-large diameter single-pile composite cylinder comprises the following steps:
s1, making a shell section: dividing the composite cylinder into a section A, a section B and a section C, blanking and cutting a steel plate according to the size of each section, rolling each steel plate, and welding the steel plates into cylinder sections after rolling;
s2, setting a roller frame and a welding frame: because the maximum diameter of the current assembly machine and the welding frame can be used within a range of 10m, and after the diameter exceeds 10m, the included angle of the roller is less than 45 degrees of a safety angle, in order to be suitable for the diameter larger than 10m, firstly, the roller frame and the welding frame need to be heightened and widened (as shown in figure 1), a support structure is welded on two side surfaces of the roller frame, holes are drilled on the support structure, and the roller structure moves more than 1 hole site outwards according to the size of a cylinder section;
s3, longitudinal seam: carrying out full penetration welding on the cylindrical sections after being rolled, and carrying out rounding after welding;
s4, pairing: respectively assembling the section A, the section B and the section C, and when the section A, the section B and the section C are assembled in a segmented mode, assembling the section A, the section B and the section C from one side with a large diameter to one side with a small diameter, adjusting the distance between roller frames at the lower end of each section of the cylinder section, enabling the support points of the cylinder section on the roller frames at the left side and the right side to form an included angle of 49 degrees with the circle center of the cylinder section, and because the reducing range is large, carrying out heightening treatment on the roller frame at the side with a small diameter of the composite cylinder, fixing a mounting block structure between the roller structure and a beam structure of the roller frame, keeping the axis of the segment in a horizontal state, and then carrying out girth welding on each group by using submerged arc automatic welding;
s5, manufacturing a first platform: manufacturing a roller frame platform by adopting H-shaped steel, and paving a track on the roller frame platform to enable the roller frame to move on the track;
s6, folding the sections B and C: placing the section C on two groups of roller frames, arranging the other two groups of roller frames on a track, then lifting the section B to the roller frames on the track by using two travelling crane double machines, wherein one group of the roller frames on the track is a driving roller frame, the other group of the roller frames on the track is a driven roller frame, the driving roller frame drives the driven roller frame and the section B to be close to the section C, and welding is carried out through automatic submerged arc welding after the section C is closed;
s7, shift: firstly, respectively shifting two roller carriers positioned in the middle of a BC section to the head end and the tail end of the BC section, then simultaneously moving four roller carriers to the tail end direction of the BC section, when the two roller carriers at the head end move to the edge of a roller carrier platform, stopping moving, moving a module vehicle with 20 axes to the bottom of the BC section at the moment, fixing the BC section on a shelf thereof, completely shifting the four roller carriers out of the bottom of the BC section, and finally shifting the folded BC section to a large folding station through the module vehicle;
s8, preparing a second platform: manufacturing a second platform for heightening, paving a track on the second platform, and connecting the track with the second platform through a clamping horse;
s9, setting a roller frame: three roller frames are arranged on the track of the second platform, and a driving roller frame is arranged on the track on the ground, wherein two roller frames close to the head end of the track of the second platform are paired roller frames with oil cylinders, and the other roller frame close to the tail end of the track of the second platform is a driven roller frame;
s10, large folding: placing the tail end of the folded BC section on a driving roller frame of a ground track through a module vehicle, placing the head end on an oil cylinder roller frame on the outer side of the tail end of a second platform, placing the head end of the A section on the driving roller frame on the second platform, and placing the tail end on the oil cylinder roller frame on the inner side of the tail end of the second platform; moving an oil cylinder roller carrier on the inner side to draw the section A to the section BC, and adopting submerged arc automatic welding to fold the section A and the section BC into a tubular pile;
s11, checking straightness: repeatedly checking the straightness by drawing a steel wire along the length of the tubular pile barrel at three radial points of 0 degree, 120 degrees and 240 degrees of the barrel, ensuring that the straightness meets the requirement of technical specifications, and welding a barrel circumferential weld by submerged arc welding according to welding process specifications after the straightness is checked to be qualified; performing flaw detection according to the requirements of a drawing after welding; rechecking the straightness after welding is finished until the straightness is qualified;
s12, coating: and after the welding is finished, transferring the whole composite cylinder to a coating workshop for coating.
The invention is further improved in that: the segment B in the step S1 is composed of segments B1 and B2.
The invention has the technical effects and advantages that:
by adopting the horizontal manufacturing method, the assembly time of the pipe joint can be effectively saved, the submerged arc automation can be used, the production efficiency is improved, the production time is saved, and the welding time is reduced from 15 days to about 10 days.
Drawings
FIG. 1 is a schematic view of a roller frame;
FIGS. 2.1-2.3 are schematic diagrams of the subgroup in paragraph A;
FIGS. 3.1-3.4 are schematic diagrams of pairs of panels in section B;
FIGS. 4.1-4.4 are schematic diagrams of a small segment set-up;
FIG. 5.1 is a schematic diagram of the pairing of the sections B and C;
FIGS. 5.2-5.3 are schematic diagrams of displacement of segment BC;
FIG. 5.4 is a schematic diagram of an ABC segment folding group;
FIG. 6 is a flow chart of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Fig. 1 to 5.4 show a specific embodiment of the construction method of an ultra-large diameter single-pile composite cylinder of the present invention: the method comprises the following steps:
s1, making a shell section: dividing the composite cylinder into a section A, a section B and a section C, blanking and cutting a steel plate according to the size of each section, rolling each steel plate, and welding the steel plates into a cylinder section after rolling, wherein the section B consists of a section B1 and a section B2;
s2, setting a roller frame and a welding frame: because the maximum diameter of the current assembly machine and the welding frame can be used within a range of 10m, and after the diameter exceeds 10m, the included angle of the roller is less than 45 degrees of a safety angle, in order to be suitable for the diameter larger than 10m, firstly, the roller frame and the welding frame need to be heightened and widened (as shown in figure 1), a support structure is welded on two side surfaces of the roller frame, holes are drilled on the support structure, and the roller structure moves more than 1 hole site outwards according to the size of a cylinder section; when cylinder sections with the diameter of 12000mm are assembled on the roller frame, the included angle of the cylinder sections is 49 degrees, and the safety angle range requirement of the roller frame from 45 degrees to 110 degrees is met.
S3, longitudinal seam: carrying out full penetration welding on the cylindrical sections after being rolled, and carrying out rounding after welding;
s4, pairing: respectively assembling the section A, the section B and the section C, assembling the section A, the section B and the section C from the side with the larger diameter to the side with the smaller diameter in the sectional assembling process (the assembling sequence is shown in detail in figures 2.1-4.4), and assembling the section A, the section B and the section C from the side with the larger diameter to the side with the smaller diameter in the sectional assembling process to adjust the distance between the roller frames at the lower ends of the sections of the cylinder sections so that the support points of the cylinder sections on the roller frames at the left and right sides and the circle center of the cylinder section form an included angle of 49 degrees, because the diameter change range is larger, the height difference of the outer surface of the whole composite cylinder is larger because the diameter change section of the composite cylinder is larger, and during the assembling process, the sectional axis needs to be kept in a horizontal state, therefore, the height of the roller frames needs to be adjusted, the cushion height treatment needs to be carried out on the roller frame at the side with the smaller diameter of the composite cylinder, a mounting pad structure is fixed between the roller frame, and the sectional axis is kept in a horizontal state, then, carrying out girth welding on each group by using automatic submerged arc welding;
when the assembly is carried out to the section B, the front three roller frames need to use a heightening block with the height of 300mm, when the assembly is carried out to the section C, the front two roller frames need to use a beam raising block with the height of 200mm, the problem of large height difference caused by large diameter variation difference is effectively solved by using the method, the sectional welding method adopts submerged arc welding, the inner side adopts submerged arc automatic welding, the outer side of a cylinder section is welded, the submerged arc automatic welding is also used, the welding is needed to be carried out on the welding frame, only pipe sections with the diameter smaller than 10m can be met by the currently adopted welding frame, therefore, the original welding frame needs to be heightened and widened to adapt to the assembly of pipe sections with large diameter variation, and simultaneously, the girth welding frame is reformed (as shown in figure 5.1) when the circular seam is welded, and the height and the width need to be reformed to be 12000 mm;
s5, manufacturing a first platform: the roller frame platform is made of H-shaped steel, the height of the assembly platform is 700mm, the H-shaped steel with the height of 700mm is used for manufacturing, and a rail is laid on the roller frame platform, so that the roller frame can move on the rail;
s6, folding the sections B and C: placing the section C on two groups of roller frames, arranging the other two groups of roller frames on a track, then lifting the section B to the roller frames on the track by using two travelling crane double machines, wherein one group of the roller frames on the track is a driving roller frame, the other group of the roller frames on the track is a driven roller frame, the driving roller frame drives the driven roller frame and the section B to be close to the section C, and welding is carried out through automatic submerged arc welding after the section C is closed; the roller frame on the first platform rail is 350T, and the roller frame on the ground rail is 650T;
s7, shift: after the BC section is folded, the weight reaches 485 tons, and the two traveling cranes cannot be used for shifting, so that a module vehicle is needed to shift the folded section, firstly, two roller frames positioned in the middle of the BC section are respectively shifted to the head end and the tail end of the BC section, then, four roller frames simultaneously move towards the tail end of the BC section, when the two roller frames at the head end move to the position 700mm away from the edge of a roller frame platform, the movement is stopped, at the moment, the module vehicle with 20 axes is moved to the bottom of the BC section, the BC section is fixed on a shelf thereof, the four roller frames are all moved out of the bottom of the BC section, and finally, the folded BC section is shifted to a large folding station through the module vehicle (as shown in figures 5.2 and 5.3);
s8, preparing a second platform: manufacturing a second platform for padding, paving a track on the second platform, and connecting the track and the second platform through a clamping horse, wherein the height of the second platform is 1600 mm;
s9, setting a roller frame: three roller frames are arranged on the track of the second platform, and a driving roller frame is arranged on the track on the ground, wherein two roller frames close to the head end of the track of the second platform are paired roller frames with oil cylinders, and the other roller frame close to the tail end of the track of the second platform is a driven roller frame (as shown in figure 5.4), so that the problem of large radius difference can be effectively solved;
s10, large folding: placing the tail end of the folded BC section on a driving roller frame of a ground track through a module vehicle, placing the head end on an oil cylinder roller frame on the outer side of the tail end of a second platform, placing the head end of the A section on the driving roller frame on the second platform, and placing the tail end on the oil cylinder roller frame on the inner side of the tail end of the second platform; moving an oil cylinder roller carrier on the inner side to draw the section A to the section BC, and adopting submerged arc automatic welding to fold the section A and the section BC into a composite cylinder;
s11, checking straightness: repeatedly checking the straightness by drawing a steel wire along the length of the tubular pile barrel at three radial points of 0 degree, 120 degrees and 240 degrees of the barrel, ensuring that the straightness meets the requirement of technical specifications, and welding a barrel circumferential weld by submerged arc welding according to welding process specifications after the straightness is checked to be qualified; performing flaw detection according to the requirements of a drawing after welding; rechecking the straightness after welding is finished until the straightness is qualified;
s12, coating: after the welding is finished, the composite barrel is integrally transferred to a coating workshop, the two middle roller carriers are moved to one side of the head part, then the 24-axis module vehicle is used for entering the bottom position of the composite barrel, the center position of the module vehicle is required to be aligned with the gravity center position of the composite barrel, the roller carriers are withdrawn from the bottom of the composite barrel, then the module vehicle is used for transferring the composite barrel to the coating workshop, and the transferring process is required to be stable.
The invention adopts a horizontal manufacturing method, can effectively save the assembly time of the pipe joint, can use submerged arc automation, improves the production efficiency, saves the production time, and reduces the welding time from 15 days to about 10 days.
The applicant further states that the present invention is described in the above embodiments to explain the implementation method and device structure of the present invention, but the present invention is not limited to the above embodiments, i.e. it is not meant to imply that the present invention must rely on the above methods and structures to implement the present invention. It should be understood by those skilled in the art that any modifications to the present invention, the implementation of alternative equivalent substitutions and additions of steps, the selection of specific modes, etc., are within the scope and disclosure of the present invention.
The present invention is not limited to the above embodiments, and all the ways of achieving the objects of the present invention by using the structure and the method similar to the present invention are within the protection scope of the present invention.
Claims (2)
1. A construction method of an oversized-diameter single-pile composite cylinder is characterized by comprising the following steps: the method comprises the following steps:
s1, making a shell section: dividing the composite cylinder into a section A, a section B and a section C, blanking and cutting a steel plate according to the size of each section, rolling each steel plate, and welding the steel plates into cylinder sections after rolling;
s2, setting a roller frame and a welding frame: heightening and widening a roller frame and a welding frame, welding support structures on two side surfaces of the roller frame, drilling holes on the support structures, and moving the roller structure outwards for more than 1 hole site according to the size of a barrel section;
s3, longitudinal seam: carrying out full penetration welding on the cylindrical sections after being rolled, and carrying out rounding after welding;
s4, pairing: respectively assembling the section A, the section B and the section C, wherein when the section A, the section B and the section C are assembled in a segmented mode, the section A, the section B and the section C are assembled from one side with a large diameter to one side with a small diameter, the distance between roller frames at the lower end of each section of the cylinder section is adjusted, so that the supporting points of the cylinder section on the roller frames at the left side and the right side and the circle center of the cylinder section form an included angle of 49 degrees, because the diameter change range is large, the roller frame at the side with a small diameter of the composite cylinder needs to be subjected to heightening treatment, a mounting pad structure is fixed between the roller structure and a beam structure of the roller frame, the axis of the segment is kept in a horizontal state, and then, submerged arc automatic welding is used for respectively carrying out girth welding on each group;
s5, manufacturing a first platform: manufacturing a roller frame platform by adopting H-shaped steel, and paving a track on the roller frame platform to enable the roller frame to move on the track;
s6, folding the sections B and C: placing the section C on two groups of roller frames, arranging the other two groups of roller frames on a track, then lifting the section B to the roller frames on the track by using two travelling crane double machines, wherein one group of the roller frames on the track is a driving roller frame, the other group of the roller frames on the track is a driven roller frame, the driving roller frame drives the driven roller frame and the section B to be close to the section C, and welding is carried out through automatic submerged arc welding after the section C is closed;
s7, shift: firstly, respectively shifting two roller carriers positioned in the middle of a BC section to the head end and the tail end of the BC section, then simultaneously moving four roller carriers to the tail end direction of the BC section, when the two roller carriers at the head end move to the edge of a roller carrier platform, stopping moving, moving a module vehicle with 20 axes to the bottom of the BC section at the moment, fixing the BC section on a shelf thereof, completely shifting the four roller carriers out of the bottom of the BC section, and finally shifting the folded BC section to a large folding station through the module vehicle;
s8, preparing a second platform: manufacturing a second platform for heightening, paving a track on the second platform, and connecting the track with the second platform through a clamping horse;
s9, setting a roller frame: three roller frames are arranged on the track of the second platform, and a driving roller frame is arranged on the track on the ground, wherein two roller frames close to the head end of the track of the second platform are paired roller frames with oil cylinders, and the other roller frame close to the tail end of the track of the second platform is a driven roller frame;
s10, large folding: placing the tail end of the folded BC section on a driving roller frame of a ground track through a module vehicle, placing the head end on an oil cylinder roller frame on the outer side of the tail end of a second platform, placing the head end of the A section on the driving roller frame on the second platform, and placing the tail end on the oil cylinder roller frame on the inner side of the tail end of the second platform; moving an oil cylinder roller carrier on the inner side to draw the section A to the section BC, and adopting submerged arc automatic welding to fold the section A and the section BC into a tubular pile;
s11, checking straightness: repeatedly checking the straightness by drawing a steel wire along the length of the tubular pile barrel at three radial points of 0 degree, 120 degrees and 240 degrees of the barrel, ensuring that the straightness meets the requirement of technical specifications, and welding a barrel circumferential weld by submerged arc welding according to welding process specifications after the straightness is checked to be qualified; performing flaw detection according to the requirements of a drawing after welding; rechecking the straightness after welding is finished until the straightness is qualified;
s12, coating: and after the welding is finished, transferring the whole composite cylinder to a coating workshop for coating.
2. The method for constructing an oversized-diameter single-pile composite barrel according to claim 1, wherein the method comprises the following steps: the segment B in the step S1 is composed of segments B1 and B2.
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| CN116944681B (en) * | 2023-09-19 | 2023-11-21 | 迪森(常州)能源装备有限公司 | Automatic pressure-resistant welding device and method for circumferential seams of pressure containers |
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