CN114268188B - Large corrugated pipe assembly method - Google Patents

Large corrugated pipe assembly method Download PDF

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CN114268188B
CN114268188B CN202111537551.8A CN202111537551A CN114268188B CN 114268188 B CN114268188 B CN 114268188B CN 202111537551 A CN202111537551 A CN 202111537551A CN 114268188 B CN114268188 B CN 114268188B
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corrugated pipe
face
support
horizontal
detection
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CN114268188A (en
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谢月
刘光
鲁明宣
宋云涛
盛亮
季玲玲
李正良
吴建伏
董桂萍
胡泊
刘素梅
陆坤
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Aerosun Tola Expansion Joint Co ltd
Hefei Institutes of Physical Science of CAS
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Aerosun Tola Expansion Joint Co ltd
Hefei Institutes of Physical Science of CAS
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Abstract

The assembly method of the large corrugated pipe comprises the steps of using a plurality of horizontal detection tools to assist assembly of the corrugated pipe, wherein the horizontal detection tools are provided with a support flat plate capable of changing positions in the vertical direction, the lower end face of the support flat plate is a detection end face, the upper end face of the support flat plate is a support end face, a laser distance sensor is arranged at a fixed position below the support flat plate, the gravity change of the corrugated pipe at the end A is recorded in the assembly process through the horizontal detection tools, the horizontal heights of the corrugated pipe at the middle connecting pipe and the corrugated pipe at the end B are assisted to be kept, and the assembly of the corrugated pipe is completed. The method has fine control on the height of each part of the corrugated pipe in the corrugated pipe assembly, and ensures the dimensional accuracy of the assembled large corrugated pipe.

Description

Large corrugated pipe assembly method
Technical Field
The invention belongs to the technical field of machining, relates to assembly of large corrugated pipes, and discloses a method for assembling large corrugated pipes.
Background
For the overall assembly of large-caliber rectangular corrugated pipes, due to large size and heavy parts, the assembly errors cannot be adjusted conveniently like the assembly of small corrugated pipe parts, and when the assembly parts require the interface form and position tolerance and the overall size tolerance, special tools and special assembly process methods are needed to effectively control the assembly of all the parts, and meanwhile, the assembly process is ensured to meet the factory safety regulations.
At present, no existing special tool is used for assembling large-caliber compound square waves (caliber reaches about 4 meters by 4 meters, total height is about 1.5 meters, weight is close to 3 tons), the total parallelism is required to be 2mm, and the tolerance of the total assembly length is required to be +/-6 mm.
The existing general assembly process flow is as follows:
1. placing the section A corrugated pipe on the rubber ground, hoisting the section A connecting pipe flange onto the section A corrugated pipe by using a crane, directly laying down, and then welding;
2. turning over the section A, hoisting the middle connecting pipe to the other side of the section A corrugated pipe by using a crane, and if the middle connecting pipe is heavy, directly hoisting the middle connecting pipe by using the crane for welding;
3. lifting the corrugated pipe at the end B by using a crane and falling into the other side of the middle connecting pipe, and directly putting down for welding;
4. and lifting the B-end joint pipe flange to the other side of the B-end corrugated pipe by using a crane, and directly putting down for welding to complete the whole assembly process.
The whole process has no control on parallelism and total assembly size, the drawing requirement is difficult to achieve, the whole process only uses driving tools, no other special tools participate, the size control is more difficult to carry out, the driving is only hoisting and transferring tools, and the driving tools cannot be used as tools in the process of welding the total assembly according to the safety regulations, so that potential safety hazards exist.
Disclosure of Invention
The invention aims to solve the problems that: for the final assembly of the large-caliber corrugated pipe, the prior art has no process control, potential safety hazards exist in the final assembly process of the corrugated pipe, and the final assembly precision cannot be ensured.
The technical scheme of the invention is as follows: the utility model provides a large-scale bellows assembly method, large-scale bellows refers to the bore and exceeds 3.5 meters, perhaps total weight exceeds 3 tons' compound bellows structure, use the assembly of a plurality of horizontal detection instrument auxiliary bellows, horizontal detection instrument has a supporting plate that can change the position in the vertical direction, the lower terminal surface of supporting plate is the detection terminal surface, the up end is the supporting terminal surface, supporting plate below fixed position is equipped with laser distance sensor, the assembly of bellows includes the following steps:
1) Measuring the height dimension of the B-port flange, comparing with a design drawing, and recording the maximum deviation value as a machining dimension error E1;
2) Welding the end A interface flange and the end A corrugated pipe together on a horizontal platform;
3) Taking the A-port interface flange as a bottom, and placing the A-port interface flange on a horizontal plane;
4) Selecting a wave side end face of the uppermost wave of the corrugated pipe at the end A to be a gravity detection end face, enabling the detection end face of a horizontal detection tool to be aligned with the gravity detection end face, recording data of a laser distance sensor at the moment, and marking the data as a first gravity distance X;
5) Hoisting the middle connecting pipe on the corrugated pipe at the end A, freely placing, aligning the detection end surface of the horizontal detection tool with the gravity detection end surface again, and detecting the distance of the gravity detection end surface to be recorded as a second gravity distance Y;
6) Lifting the middle connecting pipe, using the supporting plates of the plurality of horizontal detection tools as supporting points, and placing the middle connecting pipe on a support formed by the supporting plates of the plurality of horizontal detection tools;
7) The position of a supporting plate of the horizontal detection tool is adjusted, the reading of the laser distance sensor is taken as a supporting distance, and the supporting distance is calculated according to the formula: support distance=m+e3=m+ (E-E1)/2, where M is a theoretical nominal design dimension, that is, a dimension from a horizontal plane to a lower end surface of the intermediate connection pipe in an ideal state, E is a tolerance satisfied by a bellows assembly requirement, and E3 is a tolerance equally distributed to an a-end bellows, so that a relative error of support distance displayed by a laser distance sensor of each horizontal detection tool is ensured to be within 1 mm;
8) Welding the middle connecting pipe and the corrugated pipe at the end A;
9) Hoisting the corrugated pipe at the end B to the middle connecting pipe, and directly welding;
10 The support flat plates of the plurality of horizontal detection tools are used as support points to support the B-end joint flange, and the position height of the support flat plates of the plurality of horizontal detection tools is the nominal design height Z of the B-end joint flange, namely the ideal design dimension height from the water plane to the lower end face of the B-end joint pipe flange in the design drawing;
11 Adjusting the position of the supporting plate of each horizontal detection tool so that the numerical value of the laser distance sensor is M ' +E2=M ' + (E-E1), M ' =Z- |X-Y|, and the relative deviation of the laser distance sensor of each horizontal detection tool does not exceed the parallelism requirement specified by the drawing;
12 Welding the B-end interface flange to the B-end corrugated pipe to finish final assembly.
The invention provides a process control technological scheme for the large-caliber rectangular corrugated pipe assembly, designs a special tool, manually/automatically adjusts the assembly, and improves the process safety on the premise that the size and form and position tolerance requirements of the product drawing are met for the product after the assembly.
The invention has the following beneficial effects:
1. the method fully considers the gravity influence of large parts in the whole assembly process of the corrugated pipe, designs the height adjustment of different parts by combining the process and the drawing design, M is an ideal design size, E2 and E3 are numerical values controlled when the total tolerance requirement is distributed to each part for assembly according to a tolerance distribution scheme, and when E2 and E3 can be controlled within the calculated numerical value range, the E tolerance required by the total drawing can be met;
2. the compression influence of the gravity of the heavy connecting pipe on the corrugated pipe is fully considered, and the phase error is conveniently compensated through pre-calculation;
3. controlling the relative parallelism error of the end interface plane with high precision;
4. the height dimension error of the final product is effectively controlled.
Drawings
Fig. 1 is a schematic view of the structure of each part of a double rectangular corrugated pipe.
FIG. 2 is a schematic diagram of the pre-calculation error of the present invention.
FIG. 3 is a schematic view of the horizontal detecting tool according to the present invention.
Fig. 4 is a schematic diagram of the horizontal detecting tool for detecting the gravity distance X of the corrugated pipe at the end a.
FIG. 5 is a schematic view of the level detection tool of the present invention adjusting the position of the B-port interface flange.
Fig. 6 is a schematic diagram of the general assembly of the present invention.
Detailed Description
The present invention is directed to a compound bellows structure having a caliber exceeding 3.5 meters, or a total weight exceeding 3 tons, which cannot be visually observed for a distance or a part that must be moved by means of a lifting tool such as a crane.
The method for assembling a large corrugated pipe provided by the invention is described below by an embodiment, in which the caliber of a rectangular compound corrugated pipe reaches about 4 m by 4 m, the total height is about 1.5 m, the weight is close to 3 tons, the total parallelism is required to be 2mm, and the tolerance of the total assembly length is required to be +/-6 mm.
For the accurate control of the assembly of the corrugated pipe, the invention designs a special tool, as shown in fig. 3, wherein the flat detection tool comprises a transmission screw, a telescopic nut, a vertical guide post, a support flat plate, a laser distance sensor, a three-phase alternating current motor, a worm reducer and a worm transmission box, wherein the telescopic nut is sleeved on the transmission screw and the vertical guide post, the support flat plate is fixed on the telescopic nut, the lower end face of the support flat plate is a detection end face, the upper end face is a support end face, the laser distance sensor is arranged at a fixed position below the support flat plate, the three-phase alternating current motor drives the transmission screw through the worm reducer and the worm transmission box, and the telescopic nut moves up and down along with the rotation of the transmission screw to drive the support flat plate to change positions in the vertical direction.
This embodiment uses 4 level detection tools to assist in the assembly of the bellows, a single tool is responsible for fine control of the height values, and 4 are combined to control the level of the plane. As shown in fig. 1, the compound corrugated pipe comprises an a-end interface flange, an a-end corrugated pipe, an intermediate connection pipe, a B-end corrugated pipe and a B-end interface flange, and the final assembly comprises the following steps.
1) And measuring the height dimension of the B-port flange, and comparing with a design drawing, and recording the maximum deviation value as a machining dimension error E1.
2) And welding the end A interface flange and the end A corrugated pipe together on a horizontal platform.
3) Taking the A-port interface flange as a bottom, and placing the A-port interface flange on a horizontal plane; the a-port flange is preferably placed on a set of auxiliary support tables, which are of uniform height, forming a horizontal plane supporting the a-port flange. The laser distance sensor of the horizontal detection tool is the same as the horizontal plane where the A-port flange is located.
4) The wave side end face of the uppermost wave of the corrugated pipe at the end A is selected as a gravity detection end face, as shown in fig. 1 and 4, the detection end face of a horizontal detection tool is aligned with the gravity detection end face, and the data of a laser distance sensor at the moment is recorded and marked as a first gravity distance X.
5) And then hoisting the middle connecting pipe on the corrugated pipe at the end A, after the middle connecting pipe is freely placed, aligning the detection end surface of the horizontal detection tool with the gravity detection end surface again, and detecting the distance of the gravity detection end surface, namely a second gravity distance Y, as shown in fig. 4.
Step 4) 5) aligning the detection end face of the level detection tool with the gravity detection end face, comprising two ways: and (3) moving the support flat plate to enable the detection end face to be attached to the gravity detection end face, or moving the support flat plate to the wave side of the uppermost wave of the A-end corrugated pipe, and detecting whether the end face is level with the gravity detection end face or not by using a leveling rod.
6) And lifting the middle connecting pipe, using the supporting plates of the plurality of horizontal detection tools as supporting points, and placing the middle connecting pipe on a support formed by the supporting plates of the plurality of horizontal detection tools.
7) The position of a supporting plate of the horizontal detection tool is adjusted, the reading of the laser distance sensor is taken as a supporting distance, and the supporting distance is calculated according to the formula: support distance=m+e3=m+ (E-E1)/2, where M is the theoretical nominal design dimension, i.e. the dimension from the horizontal plane to the lower end face of the intermediate connection pipe in an ideal state, E is the tolerance that the bellows assembly requirement meets, and E3 is the tolerance that is equally distributed to the bellows at the a end, so that the relative error of the support distance displayed by the laser distance sensor of each horizontal detection tool is ensured to be within 1 mm.
8) And welding the middle connecting pipe and the A-end corrugated pipe.
9) And hoisting the corrugated pipe at the end B to the middle connecting pipe, and directly welding.
10 The support plates of the plurality of horizontal detection tools are used as support points to support the B-end joint flange, as shown in fig. 5, and the position height of the support plates of the plurality of horizontal detection tools is the nominal design height Z of the B-end joint flange, namely the ideal design dimension height from the water plane to the lower end face of the B-end joint pipe flange in the design drawing.
11 The positions of the supporting plates of the horizontal detection tools are adjusted, so that the values of the laser distance sensors are M ' +E2=M ' + (E-E1), M ' =Z- |X-Y|, and the relative deviation of the laser distance sensors of the horizontal detection tools does not exceed the parallelism requirement specified by the drawing.
12 Welding the B-port flange to the B-port bellows to complete the assembly, as shown in fig. 6.
In the method, besides the level of the welding, the level detection tool is more important to determine the tolerance distribution of the corrugated pipe at the end A and the corrugated pipe at the end B through preliminary calculation so as to achieve the final height deviation meeting the requirement of the product. The main purpose of performing both steps 4) and 5) is that, due to the high weight of the intermediate nipple, the direct placement on the a-end bellows will cause the a-end bellows to be compressed, resulting in uneven distribution of the final total assembly height over the tolerances, and therefore in step 4), 5) this compression is detected first and then the theoretical tolerances are distributed evenly for adjustment, which is why the division by 2 is the operation in the formula, when the weight of the intermediate nipple is borne by the support plate of the level detection tool at the time of adjustment, and not directly on the a-bellows. In theory, the value of X will be greater than the value of Y, and the difference between the two values is the influence of the gravity of the middle connecting pipe, when the step 11) is carried out, the difference is calculated that M 'and M' are equal to the ideal distance from the lower end surface of the B-end connecting pipe flange to the horizontal plane on the drawing, namely, the influence of the gravity on the precision of the assembly is considered, the height is readjusted through a horizontal detection tool in the process, and the error caused by the gravity in the assembly is reduced. In the tolerance analysis, when the total height tolerance is defined, how the tolerance is distributed between the fitting parts is generally the mean, in the invention, the total tolerance requirement is E, then what the tolerance is for the a-end bellows and the B-end bellows needs to be calculated earlier, since the intermediate pipe is heavy, the a-end bellows is already compressed when the assembly of the B-end bellows is started, so the data of the a-end bellows due to the gravity influence of the intermediate pipe need to be obtained earlier, and the data is changed when the assembly position of the final B-end pipe flange is controlled, only so that the total height of the final product actually = the design height of drawing-gravity compression amount when the final product is placed horizontally, but once the product is erected, gravity compression disappears, and the final height of the product (which should be called length at this time) meets the real product design requirement. This is the pre-calculation according to the invention, the schematic diagram of which is shown in fig. 2.
The invention is not only suitable for large-caliber rectangular corrugated pipes, but also has guiding significance for large-caliber circular corrugated pipes and non-compound corrugated pipes.

Claims (7)

1. The assembly method of the large corrugated pipe, the said large corrugated pipe refers to the caliber exceeds 3.5 meters, or total weight exceeds 3 tons of compound corrugated pipe structure, its characteristic is to use the assembly of a plurality of horizontal detection tools to assist the corrugated pipe, the horizontal detection tool has a supporting flat plate that can change the position in the vertical direction, the lower end surface of the supporting flat plate is the detection end surface, the upper end surface is the supporting end surface, the fixed position below the supporting flat plate has laser distance sensors, the assembly of the corrugated pipe includes the following steps:
1) Measuring the height dimension of the B-port flange, comparing with a design drawing, and recording the maximum deviation value as a machining dimension error E1;
2) Welding the end A interface flange and the end A corrugated pipe together on a horizontal platform;
3) Taking the A-port interface flange as a bottom, and placing the A-port interface flange on a horizontal plane;
4) Selecting a wave side end face of the uppermost wave of the corrugated pipe at the end A to be a gravity detection end face, enabling the detection end face of a horizontal detection tool to be aligned with the gravity detection end face, recording data of a laser distance sensor at the moment, and marking the data as a first gravity distance X;
5) Hoisting the middle connecting pipe on the corrugated pipe at the end A, freely placing, aligning the detection end surface of the horizontal detection tool with the gravity detection end surface again, and detecting the distance of the gravity detection end surface to be recorded as a second gravity distance Y;
6) Lifting the middle connecting pipe, using the supporting plates of the plurality of horizontal detection tools as supporting points, and placing the middle connecting pipe on a support formed by the supporting plates of the plurality of horizontal detection tools;
7) The position of a supporting plate of the horizontal detection tool is adjusted, the reading of the laser distance sensor is taken as a supporting distance, and the supporting distance is calculated according to the formula: support distance=m+e3=m+ (E-E1)/2, where M is a theoretical nominal design dimension, that is, a dimension from a horizontal plane to a lower end surface of the intermediate connection pipe in an ideal state, E is a tolerance satisfied by a bellows assembly requirement, and E3 is a tolerance equally distributed to an a-end bellows, so that a relative error of support distance displayed by a laser distance sensor of each horizontal detection tool is ensured to be within 1 mm;
8) Welding the middle connecting pipe and the corrugated pipe at the end A;
9) Hoisting the corrugated pipe at the end B to the middle connecting pipe, and directly welding;
10 The support flat plates of the plurality of horizontal detection tools are used as support points to support the B-end joint flange, and the position height of the support flat plates of the plurality of horizontal detection tools is the nominal design height Z of the B-end joint flange, namely the ideal design dimension height from the water plane to the lower end face of the B-end joint pipe flange in the design drawing;
11 Adjusting the position of the supporting plate of each horizontal detection tool so that the numerical value of the laser distance sensor is M ' +E2=M ' + (E-E1), M ' =Z- |X-Y|, and the relative deviation of the laser distance sensor of each horizontal detection tool does not exceed the parallelism requirement specified by the drawing;
12 Welding the B-end interface flange to the B-end corrugated pipe to finish final assembly.
2. The method of assembling a large bellows according to claim 1, wherein the laser distance sensor of the level detection tool is at the same level as the a-port flange during the assembly process.
3. The method of assembling a large bellows according to claim 2, wherein in step 3), the a-port flanges are placed on a set of auxiliary support tables, which are uniform in height, forming a horizontal plane supporting the a-port flanges.
4. The large corrugated pipe assembly method according to claim 1, wherein the horizontal detection tool comprises a transmission screw, a telescopic nut, a vertical guide post, a support flat plate, a laser distance sensor, a three-phase alternating current motor, a worm reducer and a worm transmission box, wherein the telescopic nut is sleeved on the transmission screw and the vertical guide post, the support flat plate is fixed on the telescopic nut, the lower end face of the support flat plate is a detection end face, the upper end face is a support end face, the laser distance sensor is arranged at a fixed position below the support flat plate, the three-phase alternating current motor drives the transmission screw through the worm reducer and the worm transmission box, and the telescopic nut moves up and down along with the rotation of the transmission screw to drive the support flat plate to change positions in the vertical direction.
5. The method of assembling a large bellows according to claim 4, wherein the position of the support plate of the level detecting tool is controlled automatically by a three-phase ac motor when coarse adjustment is performed, and manually by a human hand when fine adjustment is required.
6. The method of assembling a large bellows according to claim 1, wherein step 4) 5) aligns the detection end face of the level detection tool with the gravity detection end face, includes two ways: and (3) moving the support flat plate to enable the detection end face to be attached to the gravity detection end face, or moving the support flat plate to the wave side of the uppermost wave of the A-end corrugated pipe, and detecting whether the end face is level with the gravity detection end face or not by using a leveling rod.
7. The large bellows assembly method of claim 1, wherein 4 horizontal inspection tools are used for distance inspection and support around the bellows part.
CN202111537551.8A 2021-12-15 2021-12-15 Large corrugated pipe assembly method Active CN114268188B (en)

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CN116290768A (en) * 2023-03-13 2023-06-23 深圳中广核工程设计有限公司 Leveling installation method and measuring device for embedded parts of nuclear plant

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