CN115229436A - General splicing method for large double-width bolted steel box girder - Google Patents
General splicing method for large double-width bolted steel box girder Download PDFInfo
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- CN115229436A CN115229436A CN202210705892.XA CN202210705892A CN115229436A CN 115229436 A CN115229436 A CN 115229436A CN 202210705892 A CN202210705892 A CN 202210705892A CN 115229436 A CN115229436 A CN 115229436A
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 54
- 239000010959 steel Substances 0.000 title claims abstract description 54
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 claims abstract description 59
- 238000010276 construction Methods 0.000 claims abstract description 11
- 238000005520 cutting process Methods 0.000 claims abstract description 11
- 238000012545 processing Methods 0.000 claims abstract description 7
- 238000003466 welding Methods 0.000 claims description 232
- 238000007689 inspection Methods 0.000 claims description 31
- 238000012937 correction Methods 0.000 claims description 28
- 238000005192 partition Methods 0.000 claims description 28
- 238000005553 drilling Methods 0.000 claims description 22
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 18
- 238000001514 detection method Methods 0.000 claims description 18
- 238000003825 pressing Methods 0.000 claims description 10
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 9
- 239000001569 carbon dioxide Substances 0.000 claims description 9
- 230000003014 reinforcing effect Effects 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052782 aluminium Inorganic materials 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 8
- 230000002441 reversible effect Effects 0.000 claims description 8
- 238000007789 sealing Methods 0.000 claims description 8
- 238000010586 diagram Methods 0.000 claims description 7
- 238000003801 milling Methods 0.000 claims description 7
- 210000001503 joint Anatomy 0.000 claims description 6
- 238000005507 spraying Methods 0.000 claims description 6
- 238000005452 bending Methods 0.000 claims description 5
- 238000013461 design Methods 0.000 claims description 5
- 230000035515 penetration Effects 0.000 claims description 5
- 238000009659 non-destructive testing Methods 0.000 claims description 4
- 239000002390 adhesive tape Substances 0.000 claims description 3
- 238000005269 aluminizing Methods 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000009434 installation Methods 0.000 claims description 3
- 239000006247 magnetic powder Substances 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 claims description 3
- 238000004080 punching Methods 0.000 claims description 3
- 230000002093 peripheral effect Effects 0.000 claims description 2
- 238000005260 corrosion Methods 0.000 abstract 1
- 230000007797 corrosion Effects 0.000 abstract 1
- 101100334009 Caenorhabditis elegans rib-2 gene Proteins 0.000 description 13
- 238000001816 cooling Methods 0.000 description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 238000005498 polishing Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000007306 turnover Effects 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005536 corrosion prevention Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
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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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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D19/00—Structural or constructional details of bridges
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D2/00—Bridges characterised by the cross-section of their bearing spanning structure
- E01D2/04—Bridges characterised by the cross-section of their bearing spanning structure of the box-girder type
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D2101/00—Material constitution of bridges
- E01D2101/30—Metal
- E01D2101/34—Metal non-ferrous, e.g. aluminium
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Abstract
A general assembly method for large double-width bolted steel box girders comprises the following steps: step 1, blanking: adopting cutting equipment to perform blanking operation on the parts; step 2, checking: checking the overall dimension, the planeness, the straightness and the cut of the blanked parts; step 3, processing the U ribs of the bottom plate and the U ribs of the panel; and 4, manufacturing the base plate unit piece: step 5, manufacturing a diaphragm single element: step 6, manufacturing an inner web single element: step 7, manufacturing an anchor box unit piece; step 8, manufacturing a panel unit piece; step 9, manufacturing a middle cross beam unit piece; step 10, manufacturing a three-dimensional unit piece of the air nozzle; step 11, manufacturing a steel box girder total assembly jig frame; and step 12, manufacturing the steel box girder. The method is simple to operate, can improve the manufacturing precision of the steel box girder, and solves the problem of conflict between bolting of the middle cross beam and corrosion-resistant construction.
Description
Technical Field
The invention belongs to the technical field of steel box girders, and particularly relates to a total splicing method of a large double-width bolted steel box girder.
Background
With the rapid development of the steel bridge manufacturing industry in China, more and more large double-width bolted steel box girders are used, and the double-width bolted steel box girders are separated into double-width box type beams which are bolted and connected into a whole through a middle cross beam. The steel box girder has a large section, and the manufacturing precision is difficult to guarantee; the bolting surface of the middle cross beam is a friction surface, aluminum spraying treatment is required before bolting, and the bolting of the middle cross beam and the aluminum spraying operation conflict with each other. Therefore, it is necessary to improve the manufacturing method of the large double-width bolted steel box girder.
Disclosure of Invention
In view of the technical problems in the background art, the method for totally splicing the large double-width bolted steel box girder provided by the invention is simple to operate, can improve the manufacturing precision of the steel box girder, and solves the problem of conflict between bolting of the middle cross beam and corrosion prevention construction.
In order to solve the technical problems, the invention adopts the following technical scheme to realize:
a total splicing method for large double-amplitude bolted steel box girders comprises the following steps:
step 1, blanking: adopting cutting equipment to perform blanking operation on the parts;
and 4, manufacturing the base plate unit piece:
step 9, manufacturing a middle cross beam unit piece;
and step 12, manufacturing the steel box girder.
Preferably, in the step 1, a numerical control cutting machine is adopted to perform blanking and beveling on the bottom plate, the transverse partition plate longitudinal and transverse stiffening plates, the manhole, the pipeline hole reinforcing ring, the inner web plate rib, the anchor side plate, the anchor box anchor base plate, the n-shaped sealing plate, the anchor side plate vertical rib plate, the panel, the toothed plate, the middle cross beam upper flange plate, the middle cross beam lower flange plate, the middle cross beam web plate, the first longitudinal and transverse stiffening plate, the second longitudinal and transverse stiffening plate, the tuyere baffle plate, the middle cross beam connecting baffle plate and the baffle plate embedded compensation flange plate.
Preferably, the operation steps of step 3 are as follows:
3.1, selecting a steel plate from a stock dump according to a plate arrangement diagram, checking plate numbers, and then blanking by adopting a plasma numerical control gas cutting machine; the side bending of the plate after blanking is not more than 3mm, otherwise, the plate is adjusted before processing;
step 3.2, marking longitudinal center lines of the U ribs of the bottom plate and the U ribs of the panel, making sample punching marks at two ends of the longitudinal center lines, and marking numbers at two ends of the U ribs of the bottom plate and the U ribs of the panel;
step 3.3, drilling holes in the U ribs of the panel: drilling the U-shaped ribs of the panel by adopting a drilling jig, wherein after the U-shaped ribs of the panel are drilled, the periphery of the holes is not concave and convex, and the flatness of the holes must be ensured;
step 3.4, groove milling: milling grooves on groove machines workbench on the bottom plate U-shaped rib plate and the panel U-shaped rib plate;
and 3.5, pressing the U ribs of the bottom plate and the U ribs of the panel:
step 3.6, checking: cracks are not formed at the bent round corners of the U ribs of the bottom plate and the U ribs of the panel, field witness inspection is required when the first batch of U ribs of the bottom plate and the U ribs of the panel are processed, and at least 3 pieces are extracted to carry out magnetic powder inspection on the whole length of a bent area; and (4) checking the cross-sectional sizes of the U rib of the bottom plate and the U rib of the panel by using the U rib detection template.
Preferably, the operation steps of step 4 are as follows:
step 4.1, positioning and scribing: lifting the bottom plate on a platform, marking a bottom plate reference line, and marking a bottom plate U rib positioning line and a diaphragm single-element positioning line;
step 4.2, assembling the U ribs of the bottom plate: pressing a U rib of a bottom plate and the bottom plate tightly through a U rib profiling module of the movable assembling machine, carrying out code-free assembly after alignment, and carrying out spot welding positioning by adopting carbon dioxide arc welding;
step 4.3, welding a U-shaped rib angle welding seam of the bottom plate: placing the base plate unit element on a reversible deformation jig frame, and clamping and fixing the base plate unit element and the reversible deformation jig frame by adopting a hydraulic device; welding the U rib of the bottom plate and the bottom plate by adopting a 6-head double-wire U rib gantry welding machine;
step 4.4, correcting the base plate single element: checking the flatness of the base plate unit element, and locally correcting by adopting flame;
step 4.5, checking and marking the base plate single element: hoisting the base plate unit piece to a detection platform, and detecting the length, the width, the diagonal difference, the welding quality and the flatness of the base plate unit piece; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
Preferably, the operation steps of step 5 are as follows:
step 5.1, positioning and scribing: hanging the transverse clapboard on a horizontal jig frame, and marking out a transverse clapboard longitudinal and transverse stiffening plate positioning line;
step 5.2, installing the longitudinal and transverse stiffening plates 4 of the transverse partition plate to a line, and measuring an assembly gap and perpendicularity; assembling a manhole and a pipeline hole reinforcing ring 5 in two sections, and tightly attaching the hole edges; welding seams of all parts by adopting carbon dioxide gas protection automatic welding; firstly welding an upper flange plate and a lower flange plate with flange plates;
step 5.3, correcting the diaphragm single element: checking the planeness of the diaphragm single element, and locally correcting by adopting flame;
step 5.4, hoisting the diaphragm plate unit piece to an inspection platform, and inspecting the length, the width, the diagonal difference, the welding quality and the flatness of the diaphragm plate unit piece; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
Preferably, the operation steps of step 6 are as follows:
step 6.1, positioning and scribing: hoisting an inner web plate on a platform, marking an inner web plate rib assembly line, and marking a transverse diaphragm unit element positioning line and an inspection line;
step 6.2, assembling the ribs of the inner web plate: installing inner web plate ribs along lines, and performing tack welding to control the verticality of the inner web plate ribs; the inner web plate unit element is arranged on the hydraulic reversible deformation jig frame for welding;
step 6.3, correcting the inner web single element: checking the flatness of the inner web single element, and locally correcting by adopting flame;
step 6.4, checking and marking the inner web single element: hoisting the inner web single element onto a detection platform, and checking the length, the width, the diagonal difference, the welding quality and the flatness of the single element; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
Preferably, the operation steps of step 7 are as follows:
step 7.1, manufacturing an outer web plate unit piece: the manufacturing method is consistent with the manufacturing method of the inner web single element;
7.2, drawing the center line of the anchor side plate and the assembling and positioning line of the n-shaped component on the non-structural side of the outer web single element, and reporting and checking;
7.3, assembling an anchor side plate on the anchor backing plate, and spot-welding the anchor side plate into an n-shaped component;
step 7.4, assembling an n-shaped component on the non-structural side of the edge web plate single element, welding structural welding seams of the n-shaped component and the web plate, wherein the welding seams are penetration welding seams, and performing nondestructive testing after welding;
step 7.5, installing a welding anchor seat plate on the anchor base plate of the n-shaped component, firstly welding the whole circle of fillet weld of the anchor seat plate and the anchor base plate on the inner ring, and then welding the three sides of the outer side for girth welding;
7.6, welding vertical welding seams of the anchor backing plate and the anchor side plates;
step 7.7, welding an n-shaped piece sealing plate on the n-shaped component;
and 7.8, installing and welding the vertical rib plates of the anchor side plates, and paying attention to sequential retreating and installing welding from the side close to the web plate.
Preferably, the operation steps of step 8 are as follows:
step 8.1, positioning and scribing: hanging the panel on a platform, marking a panel reference line, and marking a panel U rib positioning line and a toothed plate positioning line;
step 8.2, assembling the U ribs of the panel: pressing the panel U rib and the panel tightly through a U rib profiling module of the movable assembling machine, carrying out code-free assembly after alignment, and carrying out spot welding positioning by adopting carbon dioxide gas shielded welding;
step 8.3, welding the U rib corner weld of the panel: placing the panel unit element on an anti-deformation jig frame, and clamping and fixing the panel unit element with the jig frame by adopting a hydraulic device; welding the U ribs of the panel by adopting a 6-head double-wire U rib gantry welding machine;
step 8.4, single element correction: checking the planeness of the panel unit element, and locally correcting by adopting flame;
step 8.5, installing a welding tooth-shaped plate: assembling the toothed plate according to the marking line, measuring the perpendicularity and the assembling clearance of the toothed plate and the panel, welding the toothed plate, the panel and the U-shaped rib angle welding line of the panel, and performing secondary correction and inspection report after welding;
step 8.6, checking and marking the panel unit piece: hoisting the panel unit element to a detection platform, and checking the length, the width, the diagonal difference, the welding quality and the flatness of the unit element; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
Preferably, the operation steps of step 9 are as follows:
step 9.1, welding the upper flange plate of the middle cross beam and the lower flange plate of the middle cross beam: assembling an upper flange plate of a middle cross beam and a lower flange plate of the middle cross beam on a plane jig frame according to a drawing, measuring the assembling clearance and the verticality between a web plate of the middle cross beam and the upper flange plate of the middle cross beam and the lower flange plate of the middle cross beam, and performing cantilever submerged arc automatic welding;
step 9.2, correcting the cross beam: adopting flame straightening;
step 9.3, after the correction is finished, mounting the jig frame again, drawing a longitudinal and transverse stiffening rib assembly line and an inspection line on the web plate of the middle cross beam, mounting the longitudinal and transverse stiffening plates to the line, measuring the assembly gap and the perpendicularity between the longitudinal and transverse stiffening plates and the web plate of the middle cross beam, and fixing by tack welding;
step 9.4, assembling the longitudinal and transverse stiffening plates on the other side in a turnover manner, and completing welding; then turning over again and welding the welding seams of the front longitudinal and transverse stiffening plates;
step 9.5, single element secondary straightening: performing fire correction on the out-of-tolerance part;
step 9.6, drilling holes in the web plate of the middle cross beam and the lower flange plate of the middle cross beam: and a cover die is adopted for drilling holes to ensure the hole position precision.
Preferably, the operation steps of step 10 are as follows:
step 10.1, manufacturing a blast nozzle panel unit piece, a blast nozzle bottom plate unit piece and a blast nozzle side plate unit piece: the manufacturing method is consistent with the manufacturing method of the inner web single element;
step 10.2, positioning a horizontal jig frame on the blast nozzle bottom plate unit piece;
step 10.3, positioning a jig frame on the air nozzle partition plate, checking the verticality of the partition plate and the bottom plate, and temporarily supporting stably;
step 10.4, positioning a jig frame on a side plate of the tuyere;
step 10.5, positioning a jig frame on the air nozzle panel, after the assembly is completed, firmly performing spot welding on all welding seams, and then welding the welding seams of the air nozzle partition plate and the air nozzle bottom plate;
step 10.6, firstly welding a welding seam of the tuyere diaphragm and a tuyere base plate unit piece; turning over the nozzle panel unit downwards, welding the nozzle clapboard and the nozzle panel unit and the nozzle side plate unit, and finally welding the nozzle side plate unit and the nozzle panel unit and the nozzle bottom plate unit;
step 10.7, flaw detection, correction and inspection reporting are carried out to the next procedure;
the operation steps of step 11 are as follows:
step 11.1, calculating elevation values of the moulding bed templates of each moulding bed according to the design line type, the monitoring data value and the inverse deformation empirical value;
step 11.2, building a jig frame according to the total assembly jig frame diagram of the steel box girder;
step 11.3, setting a positioning identifier: marking a marking line, a steel box girder center positioning line, a girder segment center line, an angle positioning control line and the like for positioning each unit element on the ground of a jig area by using the cooperation of a total station;
the operation steps of step 12 are as follows:
step 12.1, the base plate unit piece comprises a base plate reference unit piece and an adjacent base plate unit piece, and the base plate reference unit piece D1 and the base plate reference unit piece D4 are positioned on a jig;
step 12.2, taking the center line of the bridge as a reference, matching the ground sample line, sequentially positioning an adjacent bottom plate unit element D2, an adjacent bottom plate unit element D3, an adjacent bottom plate unit element D5, an adjacent bottom plate unit element D6 and an adjacent bottom plate unit element D7, and welding longitudinal bottom plate seams in sequence;
step 12.3, after all the bottom plate unit pieces on the two sides are installed and tested, positioning and fixing a diaphragm unit piece HG1 and a diaphragm unit piece HG2 of a left box chamber and a right box chamber of the steel box girder, and assembling a diaphragm embedding flange plate;
step 12.4, positioning the inner web single element and the middle cross beam connecting partition plate upper jig;
step 12.5, positioning the anchor box unit piece: after the anchor box unit piece is assembled in place, sequentially welding a transverse diaphragm unit piece HG1 and a transverse diaphragm unit piece HG2 butt weld, and welding the transverse diaphragm unit piece HG1, the transverse diaphragm unit piece HG2 and an embedded compensation flange plate butt weld; then welding fillet welds of the inner web single element and the diaphragm single element HG2, welding fillet welds of the inner web single element and the diaphragm connecting diaphragm, welding welds of the anchor box single element and the diaphragm single element HG1, welding fillet welds of the anchor box single element and all the base plate single elements, welding fillet welds of the inner web single element and the adjacent base plate single element D7, and welding fillet welds of the diaphragm single element HG1, the diaphragm single element HG2 and all the base plate single elements;
step 12.6, positioning the panel reference unit piece on a jig: sequentially welding fillet welds of the inner web single element, the anchor box single element, the reference panel single element M1 and the reference panel single element M7, sequentially positioning the adjacent panel single element M2, the adjacent panel single element M3, the adjacent panel single element M4, the adjacent panel single element M5 and the adjacent panel single element M6, welding the butt longitudinal weld of the reference panel single element M1 and the adjacent panel single element M2, welding the butt longitudinal weld of the adjacent panel single element M2 and the adjacent panel single element M3, welding the butt longitudinal weld of the adjacent panel single element M3 and the adjacent panel single element M4, welding the butt longitudinal weld of the adjacent panel single element M4 and the adjacent panel single element M5, welding the butt longitudinal weld of the adjacent panel single element M5 and the adjacent panel single element M6, and welding the butt longitudinal weld of the adjacent panel single element M6 and the reference panel single element M7;
step 12.7, welding seams of the toothed plate and the inner web single element, the diaphragm single element HG1 and the diaphragm single element HG2 are welded in sequence, and the butt joint seam of the toothed plate is welded;
12.8, positioning and fixing the middle cross beam unit element, firstly welding a butt welding seam of the panel, then drilling ink holes of the middle cross beam web plate and the middle cross beam lower flange plate connecting plate, and mounting the high-strength bolt on the jig frame again after derusting and aluminizing the drilled connecting plate; the middle cross beam unit piece is positioned in the front bolt group for derusting, spraying aluminum and protecting;
step 12.9, the high-strength bolt holes of the web plate and the lower flange plate of the middle cross beam are matched as follows: connecting and fixing a web plate of the middle cross beam and a lower flange plate of the middle cross beam by adopting a connecting plate, a positioning pin and a common bolt, carrying out ink hole on a hole group on the side, which is not drilled, of the connecting plate by using an ink hole device, removing the connecting plate, drilling the connecting plate on a rocker drill, marking the connecting plate, resetting the connecting plate after drilling, initially screwing a torque wrench, and finally screwing the flange butt welding seam to the position;
step 12.10, installing a welding air nozzle three-dimensional unit piece;
step 12.11, beam section straightening: after the beam section main structure is assembled and welded, beam section constraint is removed;
step 12.12, correcting the part: the free plate edges of the two ports of the beam section are subjected to wave deformation and matched with the staggered edges of the port plates, and the longitudinal welding seam is subjected to angular deformation; the angular point of the beam section port is out of tolerance and the free edge is poor in height linear;
correction means: the baking gun and the matched tooling are adopted to carry out the fire correction on the places needing to be corrected,
step 12.11, installing accessory facilities of the matching parts according to the alignment of the drawing;
step 12.12, segment control point placement and protection: after all sections are constructed in each round and are qualified through inspection, positioning marks and identifications are made at the positions of the left compartment room, the right compartment room, the middle cross beam and the ports of the adjacent sections, and the positioning marks and the identifications are protected by adhesive tapes; then, the other segments except the lower wheel pre-spliced reserved segment enter coating and storing procedures;
step 12.13, retesting the jig: and adjusting the assembly jig frame template line shape according to the designed line shape, fixing the tail section in the previous round of assembly construction on the jig frame to be used as a reference section, and sequentially carrying out the assembly construction of adjacent subsequent sections according to the sequence.
This patent can reach following beneficial effect:
1. the reasonable welding sequence of the invention reduces the welding deformation and the correction workload;
2. the precision control of the steel box girder is facilitated;
3. the inspection tool for the U-shaped ribs is adopted for inspection, and the inspection efficiency is improved.
4. The matching precision of the steel box girder is improved and the installation period of the steel box girder is shortened by matching and manufacturing the steel box girder.
5. Construction is convenient, and the production progress, construction quality and construction safety of the large-scale steel box girder are guaranteed.
Drawings
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
FIG. 1 is a view of a base plate unit of the present invention;
FIG. 2 isbase:Sub>A sectional view taken along line A-A of FIG. 1;
FIG. 3 is a structural view of a diaphragm unit HG1 of the present invention;
FIG. 4 isbase:Sub>A cross-sectional view A-A of FIG. 3;
FIG. 5 is a structural view of a diaphragm single element HG2 of the present invention;
FIG. 6 isbase:Sub>A cross-sectional view A-A of FIG. 5;
FIG. 7 is a cross-sectional view taken along line B-B of FIG. 5;
FIG. 8 is a drawing of an inner web element of the present invention;
FIG. 9 isbase:Sub>A sectional view taken along line A-A of FIG. 8;
FIG. 10 is a drawing of an anchor box unit element of the present invention;
FIG. 11 is a view of a panel unit of the present invention;
FIG. 12 isbase:Sub>A sectional view taken along line A-A of FIG. 11;
FIG. 13 is a view of a cross beam unit piece according to the present invention;
FIG. 14 isbase:Sub>A sectional view taken along line A-A of FIG. 13;
FIG. 15 is a perspective view of a single element of a tuyere of the present invention;
FIG. 16 is a front view of the steel box girder of the present invention;
FIG. 17 is a left side view of the structure of FIG. 16;
FIG. 18 is a view of the right frame of FIG. 16;
FIG. 19 is a plan view of the bottom plate of the steel box girder according to the present invention;
FIG. 20 is a drawing (plan view) of the steel box girder assembly jig of the present invention;
FIG. 21 is a diagram of a steel box girder assembly jig frame (front view) according to the present invention;
FIG. 22 is a drawing of a U-rib test panel according to the present invention.
In the figure: the device comprises a base plate 1, a base plate U rib 2, a diaphragm plate 3, a diaphragm plate longitudinal and transverse stiffening plate 4, a pipeline hole stiffening ring 5, an inner web plate 6, an inner web plate rib 7, an anchor side plate 9, an anchor box anchor backing plate 10, an anchor seat plate 11, an n-shaped sealing plate 12, an anchor side plate vertical reinforcing plate 13, a panel 14, a panel U rib 15, a tooth-shaped plate 16, a middle cross beam upper flange plate 17.1, a middle cross beam lower flange plate 17.2, a middle cross beam web plate 18, a first longitudinal and transverse stiffening plate 19, a second longitudinal and transverse stiffening plate 20, a tuyere panel unit piece 21, a tuyere bottom plate unit piece 22, a tuyere side plate unit piece 23, a tuyere partition 24, a middle cross beam connecting partition 25, a partition plate embedding and compensating flange plate 26, an inner web unit piece 27, an anchor box unit piece 28, a middle cross beam unit piece 29, a tuyere three-dimensional unit piece 30 and a U rib detection template 31.
Detailed Description
As shown in fig. 1 to 22, a method for assembling a large double-width bolted steel box girder,
step 1, blanking: adopting cutting equipment to perform blanking operation on the parts;
a bottom plate 1, a diaphragm plate 3, a diaphragm plate longitudinal and transverse stiffening plate 4, a manhole, a pipeline hole reinforcing ring 5, an inner web plate 6, an inner web plate rib 7, an anchor side plate 9, an anchor box anchor base plate 10, an anchor seat plate 11, an n-shaped piece sealing plate 12, an anchor side plate vertical rib plate 13, a panel 14, a toothed plate 16, a middle cross beam upper wing edge plate 17.1, a middle cross beam lower wing edge plate 17.2, a middle cross beam web plate 18, a first longitudinal and transverse stiffening plate 19, a second longitudinal and transverse stiffening plate 20, a tuyere baffle 24, a middle cross beam connecting baffle 25 and a baffle plate embedding stiffening wing plate 26 are blanked and beveled by a numerical control cutting machine.
The thickness of the anchor box anchor backing plate 10 and the anchor seat plate 11 is 80mm, the perforating difficulty is high, the boring precision requirement is high, multiple cutting tests are required before blanking, and the process is continuously adjusted to ensure that the blanking and boring precision of the anchor backing plate 10 and the anchor seat plate 11 meets the process requirement.
3.1, selecting a steel plate from a stock dump according to a plate arrangement diagram, checking plate numbers, and then adopting a plasma numerical control gas cutting machine for blanking; the side bending of the plate after blanking is not more than 3mm, otherwise, the plate is adjusted before processing;
step 3.2, marking longitudinal center lines of the bottom plate U rib 2 and the panel U rib 15, making sample punching marks at two ends of the longitudinal center lines, and marking numbers at two ends of the bottom plate U rib 2 and the panel U rib 15;
step 3.3, drilling holes in the U ribs 15 of the panel: drilling holes in the panel U ribs 15 are drilled by adopting a drill jig, and after the panel U ribs 15 are drilled, the concave-convex part around the holes is not formed, so that the flatness of the holes must be ensured;
polishing the protruding part of the outer edge of the drilled hole by using a polishing machine at the later stage;
step 3.4, groove milling: milling grooves on groove machines working tables on the bottom plate U rib 2 plate and the panel U rib 15 plate;
milling all bevel angles according to the requirements of a drawing, wherein the surface roughness Ra is lower than 25um;
step 3.5, pressing the bottom plate U rib 2 and the panel U rib 15:
the bottom plate U rib 2 and the panel U rib 15 are pressed by a numerical control plate bending machine, and the groove is ensured to face downwards; fixing the plate by using a positioning die, and finely adjusting by using a screw rod to accurately position the plate; during pressing, the middle of the press is pressed as far as possible without bias, so that the press is stressed uniformly.
Step 3.6, checking: cracks cannot be formed at the bent round corners of the U ribs 2 of the bottom plate and the U ribs 15 of the panel, field witness inspections are needed when the U ribs 2 of the bottom plate and the U ribs 15 of the panel are firstly processed, and at least 3 pieces of the U ribs are extracted to carry out magnetic powder flaw detection on the whole length of a bent area; the cross-sectional dimensions of the bottom plate U-rib 2 and the panel U-rib 15 are inspected using a U-rib inspection template 31.
Flaw detection standard GB/T26952-2011;
and 4, manufacturing the base plate unit pieces (D1-D7): the panel unit piece comprises a bottom plate 1 and a bottom plate U rib 2;
step 4.1, positioning and scribing: lifting a base plate 1 onto a platform, marking a base plate 1 reference line, and marking a base plate U rib 2 positioning line and a diaphragm single element positioning line;
step 4.2, assembling the U rib 2 of the bottom plate: pressing a bottom plate U rib 2 and a bottom plate 1 through a U rib profiling module of the movable assembling machine, carrying out code-free assembly after alignment, and carrying out spot welding positioning by adopting carbon dioxide arc welding;
step 4.3, fillet welding of the U rib 2 of the bottom plate: placing the base plate unit element on a reversible deformation jig frame, and clamping and fixing the base plate unit element and the reversible deformation jig frame by adopting a hydraulic device; welding the bottom plate U rib 2 and the bottom plate 1 by adopting a 6-head double-wire U rib gantry welding machine;
the welding seam area is strictly cleaned before welding, and a welding process is strictly executed to ensure that the weld penetration meets the requirements; the bottom plate U rib is one part of the bottom plate unit piece; the bottom plate unit piece consists of a bottom plate and a bottom plate U rib;
step 4.4, base plate single element straightening: checking the flatness of the base plate unit element, and locally correcting by adopting flame;
controlling the correction temperature to be 600-800 ℃, naturally cooling, and strictly prohibiting overburning, hammering and water cooling;
step 4.5, checking and marking the base plate single element: hoisting the base plate unit piece to a detection platform, and detecting the length, the width, the diagonal difference, the welding quality and the flatness of the base plate unit piece; and (5) marking the qualified unit and then transferring to storage.
step 5.1, positioning and scribing: hanging the transverse clapboard 3 on a horizontal jig frame, and marking out positioning lines of the transverse clapboard longitudinal and transverse stiffening plates 4;
step 5.2, installing the longitudinal and transverse stiffening plates 4 of the transverse partition plate to a line, and measuring an assembly gap and perpendicularity; assembling a manhole and a pipeline hole reinforcing ring 5 in two sections, and tightly attaching the hole edges; welding seams of all parts by adopting carbon dioxide gas protection automatic welding; firstly welding an upper flange plate and a lower flange plate with flange plates;
step 5.3, correcting the diaphragm single element: checking the planeness of the diaphragm single element, and locally correcting by adopting flame;
controlling the correction temperature to be 600-800 ℃, naturally cooling, and strictly prohibiting overburning, hammering and water cooling;
step 5.4, hoisting the diaphragm plate unit piece to an inspection platform, and inspecting the length, the width, the diagonal difference, the welding quality and the flatness of the diaphragm plate unit piece; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
step 6.1, positioning and scribing: hanging an inner web 6 on a platform, scribing an inner web plate rib 7 assembly line, and scribing a transverse diaphragm unit element positioning line and an inspection line;
step 6.2, assembling the inner web plate rib 7: installing the inner web plate rib 7 in a line and performing tack welding to control the verticality of the installation of the inner web plate rib 7; the inner web plate unit element is arranged on the hydraulic reversible deformation jig frame for welding;
step 6.3, correcting the inner web single element: checking the flatness of the inner web single element, and locally correcting by adopting flame;
controlling the correction temperature to be 600-800 ℃, naturally cooling, and strictly prohibiting overburning, hammering and water cooling;
step 6.4, checking and marking the inner web single element: hoisting the inner web single element onto a detection platform, and checking the length, the width, the diagonal difference, the welding quality and the flatness of the single element; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
step 7.1, manufacturing an outer web unit piece 8: the manufacturing method is consistent with the manufacturing method of the inner web single element;
step 7.2, drawing the center line of the anchor side plate 9 and an n-shaped component assembling and positioning line on the non-structural side of the outer web single element 8, and reporting the inspection;
7.3, assembling an anchor side plate 9 on the anchor backing plate 10, and spot-welding the anchor side plate into an n-shaped component;
ensuring that the verticality deviation between the anchor backing plate 10 and the anchor side plate 9 is not more than 1.5mm;
step 7.4, assembling n-shaped components on the non-structural side of the edge web plate single element 8, welding structural welding seams of the n-shaped components and the web plates, wherein the welding seams are penetration welding seams, and performing nondestructive testing after welding;
note that the two anchor side plates 9 are symmetrically welded at the same time, the corner points on the two sides of the anchor backing plate 10 are filled with welding seams and are uniformly polished, and after the flaw detection of the welding seams is qualified, the welding toes are hammered to eliminate stress.
Step 7.5, installing and welding an anchor seat plate 11 on the anchor backing plate 10 of the n-shaped component, firstly welding a full-circle fillet weld of the anchor seat plate 11 and the anchor backing plate 10 on an inner ring, and then welding three-side peripheral welding on the outer side;
7.6, welding vertical welding seams of the anchor backing plate 10 and the anchor side plates 9;
and (4) symmetrical welding is noticed, and nondestructive testing is carried out after welding.
Step 7.7, welding a n-shaped piece sealing plate 12 on the n-shaped component;
and 7.8, installing and welding the anchor side plate vertical rib plate 13, and paying attention to the sequential retreating and installing welding from the side close to the web plate.
step 8.1, positioning and scribing: hanging the panel 14 on a platform, scribing a reference line of the panel 14, and scribing a positioning line of a U rib 15 of the panel and a positioning line of a toothed plate 16;
step 8.2, assembling the panel U rib 15: pressing the panel U rib 15 and the panel 14 through a U rib profiling module of the movable assembly machine, carrying out code-free assembly after alignment, and carrying out spot welding positioning by adopting carbon dioxide gas shielded welding;
step 8.3, welding the corner welds of the U ribs 15 of the panel: placing the panel unit element on an anti-deformation jig frame, and clamping and fixing the panel unit element with the jig frame by adopting a hydraulic device; welding the panel U rib 15 by adopting a 6-head double-wire U rib gantry welding machine;
the welding seam area is strictly cleaned before welding, and a welding process is strictly executed to ensure that the weld penetration meets the requirements;
step 8.4, single element correction: checking the planeness of the panel unit element, and locally correcting by adopting flame;
controlling the correction temperature to be 600-800 ℃, naturally cooling, and strictly prohibiting overburning, hammering and water cooling;
step 8.5, installing the welding tooth-shaped plate 16: assembling a toothed plate 16 according to a marking line, measuring perpendicularity and an assembling gap between the toothed plate 16 and a panel 14, welding fillet welds of the toothed plate 16, the panel 14 and a U rib 15 of the panel, and performing secondary correction and report inspection after welding;
step 8.6, checking and marking the panel unit piece: hoisting the panel unit element to a detection platform, and checking the length, the width, the diagonal difference, the welding quality and the flatness of the unit element; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
Step 9, manufacturing a middle cross beam unit piece; the middle cross beam unit piece comprises a middle cross beam upper flange plate 17.1, a middle cross beam lower flange plate 17.2, a middle cross beam web plate 18, a first vertical and horizontal stiffening plate 19 and a second vertical and horizontal stiffening plate 20;
step 9.1, welding the upper flange plate 17.1 of the middle cross beam and the lower flange plate 17.2 of the middle cross beam: assembling an upper flange plate 17.1 of the middle cross beam and a lower flange plate 17.2 of the middle cross beam on a plane jig according to a drawing, measuring the assembling clearance and the perpendicularity of a web plate 18 of the middle cross beam and the upper flange plate 17.1 of the middle cross beam and the lower flange plate 17.2 of the middle cross beam, and performing submerged arc automatic welding on a cantilever;
step 9.2, correcting the cross beam: adopting flame straightening;
controlling the correction temperature to be 600-800 ℃, naturally cooling, and strictly prohibiting overburning, hammering and water cooling; observation and measurement should be carried out at any time and can be carried out properly so as to avoid correcting the head;
step 9.3, after the correction is finished, the jig frame is mounted again, a longitudinal and transverse stiffening rib 19 assembly line and an inspection line are drawn on the middle cross beam web plate 18, the longitudinal and transverse stiffening plates 19 are mounted to the line, the assembly gap and the perpendicularity between the longitudinal and transverse stiffening plates 19 and the middle cross beam web plate 18 are measured, and the positioning welding and the fixing are carried out;
step 9.4, assembling the longitudinal and transverse stiffening plates 20 on the other side in a turnover manner, and completing welding; then turning over and welding the weld joints of the front longitudinal and transverse stiffening plates 19 again;
step 9.5, single element secondary straightening: performing fire correction on the out-of-tolerance part;
and checking the flatness of the middle cross beam unit element, locally correcting by adopting flame, controlling the correction temperature to be 600-800 ℃, naturally cooling, and strictly prohibiting overburning, hammering and water cooling.
Step 9.6, drilling holes in the middle cross beam web plate 18 and the middle cross beam lower flange plate 17.2: and (4) drilling by using a die sleeve to ensure the hole position precision (all templates adopt numerical control holes to ensure the hole position precision).
step 10.1, manufacturing a blast nozzle panel unit piece 21, a blast nozzle bottom plate unit piece 22 and a blast nozzle side plate unit piece 23;
step 10.2, positioning a horizontal jig frame on the blast nozzle bottom plate unit piece 22;
step 10.3, positioning a jig on the air nozzle partition plate 24, checking the perpendicularity of the partition plate 24 and the bottom plate 22, and temporarily supporting stably;
step 10.4, positioning a jig frame on the tuyere side plate 23;
step 10.5, positioning a jig frame on the air nozzle panel 21, after the assembly is completed, firmly performing spot welding on all welding seams, and then welding the welding seams of the air nozzle partition plate 24 and the air nozzle bottom plate 22;
step 10.6, welding a welding seam between the air nozzle partition plate 24 and the air nozzle bottom plate unit piece 22; turning over the nozzle panel unit piece 21 downwards, welding the nozzle clapboard 24 and the nozzle panel unit piece 21 and the nozzle side plate unit piece 23, and finally welding the nozzle side plate unit piece 23 and the nozzle panel unit piece 21 and the nozzle bottom plate unit piece 22;
step 10.7, transferring the flaw detection, correction and inspection report to the next working procedure;
step 11.1, calculating elevation values of the moulding bed templates of each moulding bed according to the design line type, the monitoring data value and the inverse deformation empirical value;
step 11.2, building a jig frame according to the total assembling jig frame diagram of the steel box girder;
the error of the elevation value of the jig template is not more than 2mm.
Step 11.3, setting a positioning identifier: marking out longitudinal and transverse marking lines for positioning each unit element, a steel box girder center positioning line, a girder segment center line, an angle positioning control line and the like on the ground of a jig area by using the cooperation of a total station;
and step 12, manufacturing the steel box girder.
When the segments are manufactured, the segments are manufactured according to the ideas of 6+1, 6+1 and 4+1, the segments of each wheel are sequentially and simultaneously manufactured on the moulding bed in a matching manner, the segments on the moulding bed are taken as an integral object, the space linear shape inspection and the inter-segment port matching precision inspection are carried out, and the linear shape is adjusted according to the design requirements until the design requirements are met;
step 12.1, the base plate unit piece comprises a base plate reference unit piece and an adjacent base plate unit piece, and the base plate reference unit piece D1 and the base plate reference unit piece D4 are positioned on a jig;
the base plate reference unit piece D1 and the base plate reference unit piece D4 need to be sprayed with aluminum and protected before being positioned in a bolt hole group;
step 12.2, taking the center line of the bridge as a reference, matching the ground sample line, sequentially positioning an adjacent bottom plate unit element D2, an adjacent bottom plate unit element D3, an adjacent bottom plate unit element D5, an adjacent bottom plate unit element D6 and an adjacent bottom plate unit element D7, and welding longitudinal bottom plate seams in sequence;
before positioning, the bolt hole group needs to be subjected to aluminum spraying and protection by the adjacent bottom plate unit element D2, the adjacent bottom plate unit element D3, the adjacent bottom plate unit element D5, the adjacent bottom plate unit element D6 and the adjacent bottom plate unit element D7;
step 12.3, after all the bottom plate unit pieces on the two sides are installed and tested, positioning and fixing a diaphragm unit piece HG1 and a diaphragm unit piece HG2 of a left box chamber and a right box chamber of the steel box girder, and assembling a diaphragm embedding flange plate 26;
step 12.4, positioning the inner web single element 27 and the middle cross beam connecting partition plate 25 on a jig;
the middle cross beam connecting partition plate 25 positions the front bolt group and needs to be derusted, sprayed with aluminum and protected;
step 12.5, positioning the anchor box unit piece 28: the positioning accuracy requirement of the anchor box unit part 28 is high, and the coincidence degree of the front and back positions, four corners and a landmark point and the positioning line of the center of the anchor box are strictly controlled; after the anchor box unit piece 28 is assembled in place, the transverse diaphragm unit piece HG1 and the transverse diaphragm unit piece HG2 are welded in sequence to form a butt weld, and the transverse diaphragm unit piece HG1, the transverse diaphragm unit piece HG2 and the embedded flange plate 26 are welded to form a butt weld; then welding fillet welds of the inner web single element 27 and the diaphragm single element HG2, welding fillet welds of the inner web single element 27 and the middle cross beam connecting diaphragm 25, welding welds of the anchor box single element 28 and the diaphragm single element HG1, welding fillet welds of the anchor box single element 28 and all the base plate single elements, welding fillet welds of the inner web single element 27 and the adjacent base plate single element D7, and welding fillet welds of the diaphragm single element HG1, the diaphragm single element HG2 and all the base plate single elements;
step 12.6, positioning the panel reference unit part on a jig: sequentially welding fillet welds of the inner web unit piece 27, the anchor box unit piece 28, the reference panel unit piece M1 and the reference panel unit piece M7, sequentially positioning the adjacent panel unit piece M2, the adjacent panel unit piece M3, the adjacent panel unit piece M4, the adjacent panel unit piece M5 and the adjacent panel unit piece M6, sequentially welding the butt longitudinal seams of the reference panel unit piece M1 and the adjacent panel unit piece M2, welding the butt longitudinal seams of the adjacent panel unit piece M2 and the adjacent panel unit piece M3, welding the butt longitudinal seams of the adjacent panel unit piece M3 and the adjacent panel unit piece M4, welding the butt longitudinal seams of the adjacent panel unit piece M4 and the adjacent panel unit piece M5, welding the butt longitudinal seams of the adjacent panel unit piece M5 and the adjacent panel unit piece M6, and welding the butt longitudinal seams of the adjacent panel unit piece M6 and the reference panel unit piece M7;
step 12.7, welding seams of the toothed plate 16 and the inner web single element 28, the diaphragm single element HG1 and the diaphragm single element HG2 are sequentially welded, and a butt joint of the toothed plate 16 is welded;
12.8, positioning and fixing the middle cross beam unit element 29, firstly welding a butt-joint welding seam of the panels, then drilling ink holes of a connecting plate of the middle cross beam web 18 and the middle cross beam lower flange plate 17.2, and mounting high-strength bolts on the jig frame after derusting and aluminizing the drilled connecting plate; the middle cross beam unit piece 29 positions the front bolt group for derusting, aluminum spraying and protecting;
step 12.9, assembling high-strength bolt holes in a middle cross beam web plate 18 and a middle cross beam lower flange plate 17.2: connecting and fixing a web plate 18 of the middle cross beam and a lower flange plate 17.2 of the middle cross beam by adopting a connecting plate, a positioning pin and a common bolt, carrying out ink hole on a hole group on the side, which is not drilled, of the connecting plate by using an ink hole device, removing the connecting plate, drilling the connecting plate on a rocker drill, marking the connecting plate, resetting the connecting plate after drilling, initially screwing a torque wrench, and finally screwing the flange butt welding line to the position;
step 12.10, installing a welding air nozzle three-dimensional unit piece 30;
step 12.11, beam section straightening: after the beam section main structure is assembled and welded, removing beam section constraint (bottom plate and jig frame, temporary reinforcing support and the like);
step 12.12, correcting the part: the free plate edges of the two ports of the beam section are subjected to wave deformation and matched with the staggered edges of the port plates, and the longitudinal welding seam is subjected to angular deformation; the angular point of the beam section port is out of tolerance and the free edge is poor in height linear;
correction means: the baking gun and the matched tooling are adopted to carry out the fire correction on the places needing to be corrected,
auxiliary tools and tools such as a weight, a jack and the like can be adopted as matched tools;
step 12.11, installing accessory facilities of the matching parts according to the figure alignment;
step 12.12, segment control point placement and protection: after all sections are constructed in each round and are qualified through inspection, positioning marks and marks are made at the positions of the left compartment room, the right compartment room, the middle cross beam and the ports of the adjacent sections, and are protected by adhesive tapes; then, the other segments except the lower wheel pre-spliced reserved segment enter coating and storing procedures;
step 12.13, retesting the jig: and adjusting the form line of the assembly jig frame template according to the designed line shape, fixing the tail section in the previous round of assembly construction on the jig frame to be used as a reference section, and sequentially carrying out assembly construction on adjacent subsequent sections.
The above-described embodiments are merely preferred embodiments of the present invention, and should not be construed as limiting the present invention, and the scope of the present invention is defined by the claims, and equivalents including technical features described in the claims. I.e., equivalent alterations and modifications within the scope hereof, are also intended to be within the scope of the invention.
Claims (10)
1. A total assembly method for large double-width bolted steel box girders is characterized by comprising the following steps:
step 1, blanking: adopting cutting equipment to perform blanking operation on the parts;
step 2, checking: checking the overall dimension, flatness, straightness and split of the blanked parts;
step 3, processing the U ribs (2) of the bottom plate and the U ribs (15) of the panel;
and 4, manufacturing the base plate unit piece:
step 5, manufacturing a diaphragm single element:
step 6, manufacturing an inner web single element:
step 7, manufacturing an anchor box unit element;
step 8, manufacturing a panel unit piece;
step 9, manufacturing a middle cross beam unit piece;
step 10, manufacturing a tuyere three-dimensional unit piece;
step 11, manufacturing a steel box girder total assembly jig frame;
and step 12, manufacturing the steel box girder.
2. The method for assembling the large double-width bolted steel box girder according to claim 1, wherein the method comprises the following steps: in the step 1, a numerical control cutting machine is adopted to perform blanking and beveling on a bottom plate (1), a transverse partition plate (3), a transverse partition plate longitudinal and transverse stiffening plate (4), a manhole, a pipeline hole reinforcing ring (5), an inner web plate (6), an inner web plate rib (7), an anchor side plate (9), an anchor box anchor base plate (10), an anchor base plate (11), a n-shaped piece sealing plate (12), an anchor side plate vertical rib plate (13), a panel (14), a tooth-shaped plate (16), a middle cross beam upper flange plate (17.1), a middle cross beam lower flange plate (17.2), a middle cross beam web plate (18), a first longitudinal and transverse stiffening plate (19), a second longitudinal and transverse stiffening plate (20), a tuyere partition plate (24), a middle cross beam connecting partition plate (25) and a partition plate embedding and repairing flange plate (26).
3. The large double-width bolted steel box girder total splicing method according to claim 2, characterized in that: the operation steps of step 3 are as follows:
3.1, selecting a steel plate from a stock dump according to a plate arrangement diagram, checking plate numbers, and then blanking by adopting a plasma numerical control gas cutting machine; the side bending of the plate after blanking is not more than 3mm, otherwise, the plate is adjusted before processing;
step 3.2, marking longitudinal center lines of the U ribs (2) of the bottom plate and the U ribs (15) of the panel, making sample punching marks at two ends of the longitudinal center lines, and marking numbers at two ends of the U ribs (2) of the bottom plate and two ends of the U ribs (15) of the panel;
step 3.3, drilling holes in the U ribs (15) of the panel: drilling holes in the panel U ribs (15) are drilled by adopting a drill jig, and after the panel U ribs (15) are drilled, the concave-convex parts around the holes cannot appear, so that the flatness of the holes must be ensured;
step 3.4, groove milling: milling grooves on groove machines working tables on the bottom plate U rib (2) plate and the panel U rib (15) plate;
and 3.5, pressing the U rib (2) of the bottom plate and the U rib (15) of the panel:
step 3.6, checking: cracks cannot be formed at the bent round corners of the U ribs (2) of the bottom plate and the U ribs (15) of the panel, field witness inspection is needed when the U ribs (2) of the bottom plate and the U ribs (15) of the panel are firstly processed, and at least 3 pieces of the U ribs are extracted to carry out magnetic powder inspection on the whole length of a bending area; the cross-sectional dimensions of the U rib (2) of the bottom plate and the U rib (15) of the panel are checked by using a U rib detection template (31).
4. The large double-width bolted steel box girder total splicing method according to claim 3, characterized in that: the operation steps of the step 4 are as follows:
step 4.1, positioning and scribing: lifting a bottom plate (1) on a platform, marking a reference line of the bottom plate (1), and marking a positioning line of a U rib (2) of the bottom plate and a positioning line of a single element of a diaphragm plate;
step 4.2, assembling the U rib (2) of the bottom plate: pressing a bottom plate U rib (2) and a bottom plate (1) tightly through a U rib profiling module of the movable assembling machine, carrying out code-free assembly after alignment, and carrying out spot welding positioning by adopting carbon dioxide gas shielded welding;
step 4.3, fillet welding of the U rib (2) of the bottom plate: placing the base plate unit element on an anti-deformation jig frame, and clamping and fixing the base plate unit element with the anti-deformation jig frame by adopting a hydraulic device; welding the U rib (2) of the bottom plate and the bottom plate (1) by adopting a 6-head double-wire U rib gantry welding machine;
step 4.4, base plate single element straightening: checking the flatness of the base plate unit element, and locally correcting by adopting flame;
step 4.5, checking and marking the base plate single element: hoisting the base plate unit piece to a detection platform, and detecting the length, the width, the diagonal difference, the welding quality and the flatness of the base plate unit piece; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
5. The method for assembling the large double-width bolted steel box girder according to claim 4, wherein the method comprises the following steps: the operation steps of the step 5 are as follows:
step 5.1, positioning and scribing: hanging the transverse clapboard (3) on a horizontal jig frame, and marking out a positioning line of the transverse clapboard longitudinal and transverse stiffening plates (4);
step 5.2, installing the transverse partition plate longitudinal and transverse stiffening plates (4) in a pair line mode, and measuring an assembling gap and perpendicularity; assembling a manhole and a pipeline hole reinforcing ring (5) in two sections, and tightly attaching the manhole and the pipeline hole reinforcing ring to the hole edge; welding the welding seams of all parts by adopting carbon dioxide gas protection automatic welding; firstly welding an upper flange plate and a lower flange plate with flange plates;
step 5.3, straightening the diaphragm single element: checking the planeness of the diaphragm single element, and locally correcting by adopting flame;
step 5.4, hoisting the diaphragm unit piece to a detection platform, and checking the length, the width, the diagonal difference, the welding quality and the flatness of the diaphragm unit piece; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
6. The large double-width bolted steel box girder total splicing method according to claim 5, characterized in that: the operation steps of step 6 are as follows:
step 6.1, positioning and scribing: hoisting an inner web (6) onto a platform, scribing an inner web plate rib (7) assembly line, and scribing a transverse diaphragm single element positioning line and an inspection line;
step 6.2, assembling the inner web plate rib (7): installing the inner web plate rib (7) in a line and performing tack welding to control the verticality of the installation of the inner web plate rib (7); the inner web plate unit element is arranged on the hydraulic reversible deformation jig frame for welding;
step 6.3, correcting the inner web single element: checking the flatness of the inner web single element, and locally correcting by adopting flame;
step 6.4, checking and marking the inner web single element: hoisting the inner web single element onto a detection platform, and checking the length, the width, the diagonal difference, the welding quality and the flatness of the single element; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
7. The method for assembling the large double-width bolted steel box girder according to claim 6, wherein the method comprises the following steps: the operation steps of step 7 are as follows:
step 7.1, manufacturing an outer web single element (8): the manufacturing method is consistent with the manufacturing method of the inner web single element;
step 7.2, drawing a central line of an anchor side plate (9) and an n-shaped component assembly positioning line on the non-structural side of the outer web plate single element (8), and reporting for inspection;
step 7.3, assembling an anchor side plate (9) on the anchor backing plate (10), and performing spot welding to form an n-shaped component;
step 7.4, assembling an n-shaped component on the non-structure side of the edge web plate single element (8) by wire, welding structural welding seams of the n-shaped component and the web plate, wherein the welding seams are penetration welding seams, and performing nondestructive testing after welding;
step 7.5, installing and welding an anchor seat plate (11) on the anchor backing plate (10) of the n-shaped component, firstly welding the whole circle of fillet weld of the anchor seat plate (11) and the anchor backing plate (10) on the inner ring, and then welding three-side peripheral welding on the outer side;
7.6, welding vertical welding seams of the anchor backing plate (10) and the anchor side plates (9);
step 7.7, welding a n-shaped piece sealing plate (12) on the n-shaped component;
and 7.8, installing and welding the anchor side plate vertical rib plate (13), and paying attention to the sequential retreating and installing welding from the side close to the web plate.
8. The method for assembling the large double-width bolted steel box girder according to claim 7, wherein the method comprises the following steps: the operation steps of step 8 are as follows:
step 8.1, positioning and scribing: hanging a panel (14) on a platform, scribing a reference line of the panel (14), and scribing a positioning line of a U-shaped rib (15) and a positioning line of a toothed plate (16) of the panel;
step 8.2, assembling the panel U rib (15): pressing a panel U rib (15) and a panel (14) tightly through a U rib profiling module of the movable assembly machine, carrying out code-free assembly after alignment, and carrying out spot welding positioning by adopting carbon dioxide arc welding;
step 8.3, fillet weld welding of a panel U rib (15): placing the panel unit element on a reversible deformation jig frame, and clamping and fixing the panel unit element with the jig frame by adopting a hydraulic device; welding the panel U rib (15) by adopting a 6-head double-wire U rib gantry welding machine;
step 8.4, single element correction: checking the flatness of the panel single element, and locally correcting by adopting flame;
and 8.5, installing a welding tooth-shaped plate (16): assembling the toothed plate (16) according to a marking line, measuring the perpendicularity and the assembling clearance of the toothed plate (16) and the panel (14), welding fillet welds of the toothed plate (16), the panel (14) and the panel U rib (15), and performing secondary correction and report inspection after welding;
step 8.6, checking and marking the panel unit piece: hoisting the panel unit piece to an inspection platform, and inspecting the length, the width, the diagonal difference, the welding quality and the flatness of the unit piece; and (5) marking the qualified unit pieces and then storing the qualified unit pieces.
9. The method for assembling the large double-width bolted steel box girder according to claim 3, wherein the method comprises the following steps: the operation steps of step 9 are as follows:
step 9.1, welding an upper flange plate (17.1) of the middle cross beam and a lower flange plate (17.2) of the middle cross beam: assembling an upper flange plate (17.1) of a middle cross beam and a lower flange plate (17.2) of the middle cross beam on a plane jig according to a drawing, measuring the assembly gap and the perpendicularity of a web plate (18) of the middle cross beam and the upper flange plate (17.1) of the middle cross beam and the lower flange plate (17.2) of the middle cross beam, and performing submerged automatic arc welding on a cantilever;
step 9.2, correcting the cross beam: adopting flame straightening;
step 9.3, after the correction is finished, the jig frame is mounted again, longitudinal and transverse stiffening rib (19) assembly lines and inspection lines are drawn on the middle cross beam web plate (18), the longitudinal and transverse stiffening plates (19) are mounted to the lines, the assembly gaps and the perpendicularity between the longitudinal and transverse stiffening plates (19) and the middle cross beam web plate (18) are measured, and the positioning welding is fixed;
step 9.4, turning over and assembling the longitudinal and transverse stiffening plates (20) on the other side, and completing welding; then welding the welding seam of the front longitudinal and transverse stiffening plate (19) by turning over again;
step 9.5, single element secondary rectification: performing fire correction on the out-of-tolerance part;
and 9.6, drilling holes in the middle cross beam web plate (18) and the middle cross beam lower flange plate (17.2): and drilling by using a cover die to ensure the hole position precision.
10. The method for assembling the large double-width bolted steel box girder according to claim 3, wherein the method comprises the following steps: the operation steps of step 10 are as follows:
step 10.1, manufacturing a blast nozzle panel unit piece (21), a blast nozzle bottom plate unit piece (22) and a blast nozzle side plate unit piece (23): the manufacturing method is consistent with the manufacturing method of the inner web single element;
step 10.2, positioning a horizontal jig frame on the blast nozzle bottom plate unit piece (22);
step 10.3, positioning a jig on the air nozzle partition plate (24), checking the verticality of the partition plate (24) and the bottom plate (22), and temporarily supporting stably;
step 10.4, positioning a jig frame on the tuyere side plate (23);
step 10.5, positioning a jig frame on the tuyere panel (21), after the assembly is finished, firmly performing spot welding on all welding seams, and then welding the welding seams of the tuyere partition plate (24) and the tuyere bottom plate (22);
step 10.6, welding a welding seam of the air nozzle partition plate (24) and the air nozzle bottom plate unit piece (22); turning over the nozzle panel unit piece (21) downwards, welding the nozzle clapboard (24) and the nozzle panel unit piece (21) and the nozzle side plate unit piece (23) and finally welding the nozzle side plate unit piece (23) and the nozzle panel unit piece (21) and the nozzle bottom plate unit piece (22);
step 10.7, transferring the flaw detection, correction and inspection report to the next working procedure;
the operation steps of step 11 are as follows:
step 11.1, calculating elevation values of the moulding bed templates of each moulding bed according to the design line type, the monitoring data value and the inverse deformation empirical value;
step 11.2, building a jig frame according to the total assembly jig frame diagram of the steel box girder;
step 11.3, setting a positioning identifier: marking a marking line, a steel box girder center positioning line, a girder segment center line, an angle positioning control line and the like for positioning each unit element on the ground of a jig area by using the cooperation of a total station;
the operation steps of step 12 are as follows:
step 12.1, the base plate unit piece comprises a base plate reference unit piece and an adjacent base plate unit piece, and the base plate reference unit piece D1 and the base plate reference unit piece D4 are positioned on a jig;
step 12.2, taking the center line of the bridge as a reference, matching the ground sample line, sequentially positioning an adjacent bottom plate unit element D2, an adjacent bottom plate unit element D3, an adjacent bottom plate unit element D5, an adjacent bottom plate unit element D6 and an adjacent bottom plate unit element D7, and welding longitudinal bottom plate seams in sequence;
step 12.3, after all the bottom plate unit pieces on the two sides are installed and tested, positioning and fixing a diaphragm unit piece HG1 and a diaphragm unit piece HG2 of a left box chamber and a right box chamber of the steel box girder, and assembling a diaphragm embedding flange plate (26);
step 12.4, positioning the inner web single element (27) and the middle cross beam connecting partition plate (25) on a jig;
step 12.5, positioning an anchor box unit piece (28): after the anchor box unit piece (28) is assembled in place, sequentially welding a transverse diaphragm unit piece HG1 and a transverse diaphragm unit piece HG2 in a butt joint manner, and welding the transverse diaphragm unit piece HG1, the transverse diaphragm unit piece HG2 and an embedded flange plate (26) in a butt joint manner; then welding fillet welds of the inner web single element (27) and the diaphragm single element HG2, welding fillet welds of the inner web single element (27) and the middle cross beam connecting diaphragm (25), welding welds of the anchor box single element (28) and the diaphragm single element HG1, welding fillet welds of the anchor box single element (28) and all the base plate single elements, welding fillet welds of the inner web single element (27) and the adjacent base plate single element D7, and welding fillet welds of the diaphragm single element HG1, the diaphragm single element HG2 and all the base plate single elements;
step 12.6, positioning the panel reference unit piece on a jig: sequentially welding fillet welds of an inner web single element (27), an anchor box single element (28), a reference panel single element M1 and a reference panel single element M7, sequentially positioning an adjacent panel single element M2, an adjacent panel single element M3, an adjacent panel single element M4, an adjacent panel single element M5 and an adjacent panel single element M6, welding a butt longitudinal seam of the reference panel single element M1 and the adjacent panel single element M2, welding a butt longitudinal seam of the adjacent panel single element M2 and the adjacent panel single element M3, welding a butt longitudinal seam of the adjacent panel single element M3 and the adjacent panel single element M4, welding a butt longitudinal seam of the adjacent panel single element M4 and the adjacent panel single element M5, welding a butt weld seam of the adjacent panel single element M5 and the adjacent panel single element M6, and welding a butt longitudinal seam of the adjacent panel single element M6 and the reference panel single element M7;
step 12.7, welding seams of the toothed plate (16) and the inner web single element (28), the diaphragm single element HG1 and the diaphragm single element HG2 are sequentially welded, and the butt joint of the toothed plate (16) is welded;
step 12.8, positioning and fixing the middle cross beam unit element (29), firstly welding a butt welding seam of a panel, then drilling ink holes of a connecting plate of a middle cross beam web plate (18) and a middle cross beam lower flange plate (17.2), and mounting the high-strength bolts on the jig again after derusting and aluminizing the drilled connecting plate; the middle cross beam unit piece (29) positions the front bolt group for derusting, spraying aluminum and protecting;
step 12.9, high-strength bolt holes of a middle cross beam web plate (18) and a middle cross beam lower flange plate (17.2) are matched: connecting and fixing a central beam web plate (18) and a central beam lower flange plate (17.2) by adopting a connecting plate, a positioning pin and a common bolt, carrying out ink hole on a hole group on the side, which is not drilled, of the connecting plate by using an ink hole machine, removing the connecting plate, drilling the connecting plate on a rocker drill, marking the connecting plate, resetting the connecting plate after drilling, initially screwing a torque wrench, and finally screwing the flange butt-joint welding line to the position;
step 12.10, installing a welding air nozzle three-dimensional unit piece (30);
step 12.11, beam section straightening: after the beam section main structure is assembled and welded, removing beam section constraint;
step 12.12, correcting the part: the free plate edges of the two ports of the beam section are subjected to wave deformation and matched with the staggered edges of the port plates, and the longitudinal welding seam is subjected to angular deformation; the angular point of the beam section port is out of tolerance and the free edge is poor in height linear;
a correction means: the baking gun and the matched tooling are adopted to carry out the fire correction on the places needing to be corrected,
step 12.11, installing accessory facilities of the matching parts according to the figure alignment;
step 12.12, segment control point placement and protection: after all sections are constructed in each round and are qualified through inspection, positioning marks and identifications are made at the positions of the left compartment room, the right compartment room, the middle cross beam and the ports of the adjacent sections, and the positioning marks and the identifications are protected by adhesive tapes; then, the other segments except the lower wheel pre-spliced reserved segment enter coating and storing procedures;
step 12.13, retesting the jig: and adjusting the assembly jig frame template line shape according to the designed line shape, fixing the tail section in the previous round of assembly construction on the jig frame to be used as a reference section, and sequentially carrying out the assembly construction of adjacent subsequent sections according to the sequence.
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