CN115365764B - Manufacturing method of four-corner arc-section variable-section steel shell tower section with ribs - Google Patents
Manufacturing method of four-corner arc-section variable-section steel shell tower section with ribs Download PDFInfo
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- CN115365764B CN115365764B CN202210907054.0A CN202210907054A CN115365764B CN 115365764 B CN115365764 B CN 115365764B CN 202210907054 A CN202210907054 A CN 202210907054A CN 115365764 B CN115365764 B CN 115365764B
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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Abstract
The invention discloses a manufacturing method of a four-corner arc section variable-section steel shell tower section with ribs, which comprises the following steps: (S1) manufacturing four arc wallboard units with ribs; (S2) manufacturing four straight-line segment blocks with ribs: firstly manufacturing an inner wall plate unit, an outer wall plate unit and a partition plate unit, then assembling and welding the plate units into blocks, penetrating outer wall plate circumferential reinforcing steel bars and inner wall plate horizontal reinforcing steel bars, and forming a reinforced straight-line block structure; and (S3) manufacturing the steel shell tower segment in a total splicing way: and adopting a vertical total splicing process to splice four arc wall plate units with ribs and four straight line segment blocks with ribs to finish segment manufacture. The manufacturing method adopts a vertical total splicing process combining the manufacture of the arc wall plate units with the ribs and the manufacture of the blocks with the straight line segments with the ribs, reduces the total splicing time, accelerates the construction progress, and is beneficial to improving the construction quality and controlling the precision.
Description
Technical Field
The invention relates to a manufacturing method of a steel shell tower segment, in particular to a manufacturing method of a steel shell tower segment with four corners, circular arc sections and variable cross sections.
Background
At present, the steel shell section of the existing reinforced concrete tower is not provided with a partition plate between the inner wall plate and the outer wall plate, and in addition, after the plate unit is manufactured, the existing technology is adopted, the existing technology directly participates in the vertical total splicing of the section, the total splicing construction amount and the construction difficulty are large, the installation precision is difficult to ensure, and the total splicing time is long.
Disclosure of Invention
The invention aims to: in order to solve the problems in the prior art, the invention provides a manufacturing method of a steel shell tower section with a variable cross section and four corners and arc sections, wherein the steel shell tower section is provided with a variable cross section reinforced concrete combined tower section with four corners adopting arc sections, and is manufactured by adopting a factory, and the reinforced concrete combined tower section is manufactured in the factory to finish the section manufacture comprising the installation of the reinforcing steel bars in the steel shell tower.
The technical scheme is as follows: the invention relates to a manufacturing method of a steel shell tower segment with four corners, arc sections and variable cross sections, which comprises the following steps:
(S1) manufacturing four arc wallboard units with ribs: controlling the external dimensions of the rib-attached arc wallboard units by adopting a process partition plate and an arc outer jig frame, assembling the reinforcing steel bars and the rib-attached arc wallboard units, and positioning by utilizing a positioning tool to form the rib-attached arc wallboard units;
(S2) manufacturing four straight-line segment blocks with ribs: firstly manufacturing an inner wall plate unit, an outer wall plate unit and a partition plate unit, then assembling and welding the plate units into blocks, penetrating outer wall plate circumferential reinforcing steel bars and inner wall plate horizontal reinforcing steel bars, and forming a reinforced straight-line block structure;
and (S3) manufacturing the steel shell tower segment in a total splicing way: and the four arc wall plate units with ribs and the four straight line segment blocks with ribs are spliced together by adopting a vertical total splicing process, and finally, the annular steel bar mechanical connecting joints at the outer wall plate side are connected to finish segment manufacture.
The invention aims at the industrial manufacturing of the steel shell tower section with the variable cross section of the four-corner arc section of the reinforcing steel bar, combines the difficult problem of the installation of the reinforcing steel bar, adopts the vertical total splicing process of the wall plate unit with the circular arc section of the reinforcing steel bar and the block body with the straight line section of the reinforcing steel bar through reasonable unit and block division, forms a whole set of original technology aiming at the steel shell tower with the reinforced concrete combined structure, and effectively ensures the installation of the reinforcing steel bar of the steel shell tower and the manufacturing precision of the section of the steel shell tower with the four-corner arc structure.
As a preferred embodiment of the invention, the steel shell tower segments are symmetrical along the bridge direction and have inward inclined structures with the same slope on two sides; the steel shell tower segment transverse bridge is of a structure with different slopes on two sides and inclined to one side.
As a preferred embodiment of the present invention, the steel shell tower segment comprises an outer wall plate, a compartment plate, an inner wall plate, vertical stiffening and horizontal stiffening arranged inside the steel shell tower segment, welding nails welded to the outer wall plate and the inner wall plate, outer wall plate circumferential steel bars and inner wall plate horizontal steel bars.
As a preferred embodiment of the invention, the horizontal stiffening angle control is realized by controlling the assembly angles of the horizontal stiffening and the outer wall plate, the partition plate and the inner wall plate, so that the accurate butt joint of the horizontal stiffening of different vertical faces of the steel shell tower segment is ensured.
As a preferred embodiment of the present invention, the steel shell tower segment inclination angle is controlled by the following method: the four rib-attached arc wallboard units and the four rib-attached straight-line section blocks are positioned through the positioning tool, the inclination angles of the rib-attached straight-line section blocks are adjusted, measuring points are arranged on each surface below the top surface of the steel shell tower segment, the measuring points are projected to the bottom plane of the jig frame, the theoretical value of the distance between the projection points and the inner wallboard or the outer wallboard edge of the block is calculated and determined through the height difference value between the measuring points and the projection points and the theoretical inclination angle, the deviation of the actual measured value is ensured to be less than or equal to 1.0mm, and the inclination angle of the steel shell tower segment is controlled.
As a preferred embodiment of the present invention, in step (S1), the ribbed circular arc wall plate unit is prepared by:
(S1-1) drawing an arc starting line for bending an outer wall plate in the reinforced arc wall plate unit, stiffening an assembly position line, controlling the opening size of the bent arc outer wall plate according to positive tolerance, and controlling the welding deformation of the arc outer wall plate by utilizing an arc outer jig frame and a process baffle plate when assembling and welding the stiffening plate;
and (S1-2) penetrating the annular reinforcing steel bars of the outer wall plate into the vertically stiffened reinforcing steel bar holes of the circular arc-shaped outer wall plate, and simultaneously retracting the annular reinforcing steel bars of the outer wall plate in the circular arc-shaped wall plate units of the reinforcing steel bars into the outer wall opposite joints for a certain distance at the positions of the circular arc-shaped wall plate units of the reinforcing steel bars, so that the reinforcing steel bars and the wall plates are not interfered when the sections are assembled.
As a preferred embodiment of the invention, the two side ends of the annular reinforcing steel bars of the outer wall plate are positioned at the installation positions of the annular reinforcing steel bars of the outer wall plate by using the positioning tool, the positioning tool can be laterally inserted into the vertically stiffened reinforcing steel bar holes, the positioning tool is provided with an open notch, and the positioning tool is removed after the arc wall plate units with the reinforcing steel bars are mechanically connected with the reinforcing steel bar mechanical connection joints of the linear segment blocks with the reinforcing steel bars.
In the step (S2), the block body with the straight line segment with the rib is manufactured in a horizontal state, and the method comprises the following steps:
(S2-1) paving an outer wall plate on a jig frame of the longitudinal and transverse beam system, assembling a partition plate by taking a datum line of the outer wall plate as a datum line, assembling an inner wall plate by lines, checking the assembly size, welding a fillet weld at the intersection of the partition plate, the outer wall plate and the inner wall plate, and welding a butt weld with horizontal stiffening;
(S2-2) sequentially penetrating the outer wall plate circumferential reinforcing steel bars through the vertical stiffening steel bar holes of the outer wall plate of the straight-line section block body with the reinforcing steel bars, penetrating the steel bar holes of the partition plate, sequentially penetrating the inner wall plate horizontal reinforcing steel bars through the vertical stiffening steel bar holes of the inner wall plate of the straight-line section block body with the reinforcing steel bars, penetrating the steel bar holes of the partition plate, fixing and positioning the horizontal reinforcing steel bars on one side of the inner wall plate by using temporary positioning steel bars after the reinforcing steel bars penetrate, controlling the distance between the reinforcing steel bars, and facilitating mutual avoidance of staggered reinforcing steel bars of the straight-line section block body with the reinforcing steel bars when the sections are assembled.
As a preferred embodiment of the present invention, in step (S3), the steel shell tower segment is manufactured by:
(S3-1) bottom box port size positioning of steel shell tower segments: firstly marking a center line of the section size of the bottom of a steel shell tower section on a jig frame platform, positioning and assembling a straight line section supporting and positioning tool for positioning a straight line section block with ribs on a bottom beam of the jig frame platform according to the section size of the bottom of the steel shell tower section, controlling the distance between a positioning line and a transverse bridge center line and the distance between the positioning line and a forward bridge center line, and ensuring that the overall flatness of the top surface of the straight line section supporting and positioning tool is less than or equal to 1.0mm; the positioning assembly is used for positioning the arc-shaped support positioning tool for the arc-shaped wall plate unit with the ribs, so that the alignment of the arc edge and a positioning line of the straight line section support positioning tool is ensured, and the overall flatness of the top surface of the upper cover plate of the arc-shaped support positioning tool is ensured to be less than or equal to 1.0mm;
(S3-2) assembling and positioning four rib-attached straight-line segment blocks according to lines, ensuring alignment of outer wall plate skins and positioning lines of straight-line segment supporting and positioning tools, ensuring mutual staggered avoidance of horizontal steel bars of inner wall plates of the rib-attached straight-line segment blocks in the assembling process, adjusting the inclination angle of the rib-attached straight-line segment blocks and the section cross section size of a top opening of a segment, and after meeting the size requirement, temporarily fixing and stacking spot welding and stacking plates;
(S3-3) assembling a pair of diagonal rib-attached arc wallboard units by taking four rib-attached straight line segment blocks and an arc support positioning tool as references, ensuring that the arc edges of the rib-attached arc wallboard units are aligned with the arc edges of the arc positioning tool, controlling the deviation between the diagonal line spacing of the rib-attached arc wallboard units and a theoretical numerical value to be less than or equal to 3.0mm, ensuring the box opening size of the assembled arc position of the rib-attached arc wallboard units, and temporarily not assembling the other pair of rib-attached arc wallboard units;
(S3-4) welding butt welds between inner wall plates of four straight-line segment blocks with ribs, so as to ensure that the four straight-line segment blocks with ribs are welded into a whole;
(S3-5) taking four rib-attached straight-line segment blocks and an arc support positioning tool as references, assembling another pair of diagonal rib-attached arc wallboard units, ensuring that the arc edges of the rib-attached arc wallboard units are aligned with the arc edges of the arc support positioning tool, controlling the deviation between the diagonal distances of the rib-attached arc wallboard units and theoretical numerical values to be less than or equal to 3.0mm, and ensuring the size of a box opening at the arc position after the whole segment rib-attached arc wallboard units are assembled;
(S3-6) upper column upper box port size of steel shell column segment: controlling the local box opening size of the rib-attached arc wallboard unit, controlling the distance from the center line of the box opening on the section of the steel shell tower to the auxiliary positioning line of the arc supporting and positioning tool, controlling the box opening size of the longitudinal and transverse outer wallboard, controlling the deviation between the diagonal distance of the rib-attached arc wallboard unit and the theoretical value to be less than or equal to 3.0mm, and ensuring the box opening size of the arc position after the assembly of the rib-attached arc wallboard unit on the whole section of the upper box opening;
and (S3-7) presetting reverse deformation of butt welds between the four rib-attached arc wallboard units and the outer wall plates of the rib-attached straight-line segment blocks, welding the butt welds between the four rib-attached arc wallboard units and the outer wall plates of the adjacent blocks and the butt welds between the horizontal stiffening, performing flaw detection after welding, completing the welding operation of the sections, connecting the four rib-attached arc outer wall plate units and the outer wall plate side circumferential steel bar mechanical connectors of the rib-attached straight-line segment blocks, ensuring the connection quality of the mechanical connection joint threaded sleeves, and completing the manufacturing of the steel shell tower sections.
As a preferred embodiment of the present invention, the inclination angle of the straight-line segment block with ribs is controlled by the following method: and 3 measuring points are arranged on each surface 100mm below the top surface of the segment, the longitudinal bridge inclination angle measuring points are C1, the transverse bridge inclination angle measuring points are C2 and C3 respectively, the measuring points are projected to the bottom plane of the jig frame, the projection points are D1, D2 and D3 respectively, the height difference value between the measuring points C1, C2 and C3 and the projection points D1, D2 and D3 and the theoretical inclination angle can be calculated to determine the theoretical values S1, S2 and S3 of the distance between the projection points and the edges of the inner wall plate or the outer wall plate of the block, and the actual measurement value deviation is ensured to be less than or equal to 1.0mm in the construction process.
The beneficial effects are that: (1) The invention takes the reinforcing steel bar as a part of a steel structure and participates in the whole segment manufacturing process in a factory, overcomes the industrial manufacturing of the structural type reinforcing steel shell tower, ensures the construction quality, systematically develops a vertical general splicing process of combining the reinforcing steel arc wallboard unit and the reinforcing steel straight line segment block, and realizes the segment manufacturing and the precision control of the reinforcing steel shell tower: when the segments are assembled together, the segments are divided into four rib-attached arc outer wall plate units and four rib-attached block body straight line segment block body assembly welding, and when the rib-attached arc outer wall plate units are manufactured, the outline dimensions of the arc outer wall plate units are controlled by adopting a process partition plate and an arc outer tire frame, and the steel bars are assembled with the rib-attached arc wall plate units and positioned by utilizing a positioning tool to form the rib-attached arc wall plate units; when the block body with the straight line section of the rib is manufactured, firstly, an inner wall plate unit, an outer wall plate unit and a partition plate unit are manufactured, then the plate units are assembled and welded into a block body, and the annular reinforcing steel bars of the outer wall plate and the horizontal reinforcing steel bars of the inner wall plate are penetrated to form the block body structure with the straight line section of the rib; (2) The invention adopts the vertical total splicing process to splice four arc wall plate units with ribs and straight line segment blocks with ribs, has advanced and reliable technology, saves cost, can obviously accelerate construction progress, and has obvious economic benefit; (3) The manufacturing method of the invention adopts the vertical total splicing process combining the rib attaching unit and the rib attaching straight line segment block manufacturing, thereby reducing the total splicing time, accelerating the construction progress, being beneficial to improving the construction quality and the precision control, and most of the construction is completed in the block stage, reducing the overhead working time, being beneficial to reducing the safety risk of constructors.
Drawings
FIG. 1 is a top cross-sectional view of a steel shell tower;
FIG. 2 is a front elevational view of a steel shell tower;
FIG. 3 is a side elevation view of a steel shell tower;
FIG. 4 is a top view of a steel reinforcement section of a steel shell tower;
FIG. 5 is a schematic view of a steel shell segment block division structure;
FIG. 6 is a schematic diagram of a process for making a ribbed circular arc wall plate unit;
fig. 7 is a schematic structural view of installing an outer wall plate circumferential reinforcing steel bar through a positioning tool;
FIG. 8 is a schematic cross-sectional view of a positioning tool;
FIG. 9 is a side view of a positioning tool;
FIG. 10 is a schematic view of the plate unit manufacturing structure of blocks K1 and K2;
FIG. 11 is a schematic view of the plate unit manufacturing structure of blocks K1 and K2;
FIG. 12 is a schematic view of a process for manufacturing a straight segment block with ribs;
FIG. 13 is a schematic view of the process of manufacturing a straight segment block with ribs;
FIG. 14 is a schematic illustration of a bottom bin port positioning process for a steel shell tower segment assembly;
FIG. 15 is a schematic view of the tilt angle control process for four straight section blocks of the steel shell tower segment;
FIG. 16 is a schematic view of the tilt angle control process for four straight section blocks of the steel shell tower segment;
FIG. 17 is a schematic illustration of the upper box opening size control of the upper column of the steel shell column segment assembly;
FIG. 18 is a schematic diagram of control of preset reverse deformation of butt welds between a ribbed circular arc wall plate unit and a block outer wall plate;
fig. 19 is a schematic diagram of an assembly welding process of the arc wall plate unit A1 with the block K1 and the block K2;
fig. 20 is a schematic diagram of the assembly welding process of the arc wall plate unit A1 with the block K1 and the block K2.
Detailed Description
As shown in fig. 1-4, the steel shell tower section of the reinforced concrete combined steel shell tower is a four-corner arc section variable-section reinforced steel shell tower, the four corner horizontal directions are all arcs with the radius of 1m, and the section sizes of the transverse bridge direction and the longitudinal bridge direction are gradually reduced along with the increase of the section height. Fig. 1 is a top view cross section of a steel shell tower, wherein the forward bridge direction (A-A elevation view, fig. 2) is a symmetrical structure, the inward inclined structure with the same slope on two sides is adopted, the transverse bridge direction (B-B elevation view, fig. 3) is a uniform one-side inclined structure with different slopes on two sides, and the same inner wall plate 3 and the outer wall plate 1 on the same side have the same slope, namely the distance between the inner wall plate and the outer wall plate is kept unchanged. Specifically, the steel shell tower is inclined in the height direction and has a variable cross section, an inner wall plate and an outer wall plate are of a double-wall structure, the inner wall plate and the outer wall plate are provided with vertical stiffening and horizontal stiffening, the inner wall plate and the outer wall plate are connected through a partition plate, the inner wall plate and the outer wall plate are provided with reinforcing steel bar holes, horizontal reinforcing steel bars penetrate through the vertical stiffening and partition plate reinforcing steel bar holes, and the horizontal annular reinforcing steel bars of the outer wall plate are mechanically connected. In specific application, the section size of the reinforced concrete combined steel shell tower is 6.8-10.8 m, the width is 5.5-8 m, the height is 3.5-8 m, the section weight is about 62-135 tons, and the section manufacturing process, the section size precision control and the attached rib installation method and the installation precision are manufacturing difficulties.
In order to solve the difficulty in manufacturing the steel shell tower segment, the steel shell tower segment structurally comprises an outer wall plate 1, a partition plate 2, an inner wall plate 3, vertical stiffening 4, horizontal stiffening 5, welding nails 6 (cylindrical head welding nails), outer wall plate circumferential reinforcing steel bars 7 and inner wall plate horizontal reinforcing steel bars 8, wherein the partition plate 2 is distributed between the outer wall plate 1 and the inner wall plate 3.
In order to realize the manufacture of the steel shell tower segment with the rib structure, as shown in fig. 5, the steel shell tower segment is divided into four rib-attached arc wallboard units A1 and four rib-attached straight line segment blocks (comprising two blocks K1 and two blocks K2), wherein the rib-attached arc wallboard units A1 are composed of arc-shaped outer wallboards 1, vertical stiffening 4, horizontal stiffening 5, welding nails 6 and outer wallboards circumferential reinforcing bars 7. The block K1 and the block K2 are composed of an outer wall plate 1, a partition plate 2, an inner wall plate 3, vertical stiffening 4, horizontal stiffening 5, welding nails 6, outer wall plate circumferential reinforcing steel bars 7 and inner wall plate horizontal reinforcing steel bars 8. As shown in fig. 6, in order to facilitate the assembly of the blocks K1 and K2 and the rib-attached circular arc outer wall plate unit A1, the outer wall plate circumferential reinforcing steel bars 7 are retracted into the outer wall at the rib-attached circular arc wall plate unit A1 for a certain distance to the joint, so that the reinforcing steel bars and the wall plates do not interfere when the segments are assembled.
The manufacturing of the four-corner arc-section variable-section steel shell tower section with the ribs comprises the following steps:
[1] manufacturing a rib-attached arc wallboard unit A1:
and drawing out an arc starting line for bending the arc-shaped outer wall plate 1 by using a laser machine, and stiffening the assembly position line. In order to prevent the seam shrinkage of the outer wall plate to the seam from causing the sinking of the local seam when the segments are assembled together, the opening size of the bent arc wall plate is controlled according to positive tolerance, and the positive tolerance value is determined according to an empirical value or a test value. When the assembly welding is used for stiffening, the arc outer jig frame and the process partition plate are utilized to control the welding deformation of the arc outer wall plate. Finally, the outer wall plate circumferential steel bar 7 is penetrated into the vertical stiffening 4 steel bar holes of the circular arc-shaped outer wall plate 1, as shown in fig. 7, the end parts at two sides of the steel bar are positioned by special positioning tools 9, as shown in fig. 8 and 9, the positioning tools 9 are made of steel pipes or PVC pipes with the outer diameter smaller than the diameter of the vertical stiffening 4 steel bar holes and the inner diameter larger than the diameter of the steel bar by 2mm, one side is machined with an open notch, the positioning tools are ensured to be laterally inserted into the steel bar holes, and after the steel bar mechanical connection joint is connected with the block K1 and the block K2, the positioning tools 9 can be conveniently removed.
[2] Manufacturing other plate units of the steel shell with the ribs:
as shown in fig. 10 and 11, before the blocks K1 and K2 are manufactured, an outer wall plate unit K11, an inner wall plate unit K13, and a compartment plate unit K12 that constitute the block K1 are manufactured, and an outer wall plate unit K21, an inner wall plate unit K23, and a compartment plate unit K22 that constitute the block K2 are manufactured. The outer wall plate unit K11 and the outer wall plate unit K21 consist of an outer wall plate 1, a vertical stiffening 4, a horizontal stiffening 5 and welding nails 6; the inner wall plate unit K13 and the inner wall plate unit K23 consist of an inner wall plate 3, a vertical stiffening plate 4, a horizontal stiffening plate 5 and welding nails 6; the partition plate unit K12 and the partition plate unit K22 are composed of partition plates 3, horizontal stiffening 5 and welding nails 6. In order to control welding deformation and improve assembly welding precision, the plate units are assembled on jig frame platforms of the longitudinal and transverse beam system.
1) In order to control welding deformation and improve assembly welding precision, the plate units are manufactured on a jig frame platform of a longitudinal and transverse beam system, the flatness of the top surface of the jig frame platform is guaranteed to be less than or equal to 1.0mm, the overall flatness of the outer wall plate 1, the partition plate 2 and the inner wall plate 3 of a material piece is controlled, and deformation in the manufacturing process is controlled.
2) In the plate unit assembling process, the vertical stiffening 4 and the horizontal stiffening 5 are marked on the outer wall plate 1, the inner wall plate 3 and the partition plate 2, and the vertical stiffening 4 and the horizontal stiffening 5 are assembled according to lines.
3) Because the section is special-shaped variable cross-section structure, the steel shell tower section has inclination angles along the bridge direction and the transverse bridge direction, and for this purpose, an angle ruler or an angle template is adopted to control the assembly angles of the horizontal stiffening 5 and the outer wall plate 1, the partition plate 2 and the inner wall plate 3, so that the accurate butt joint of the horizontal stiffening in different vertical faces of the steel shell tower section is ensured.
4) For controlling welding deformation, the vertical stiffening 4 and the horizontal stiffening 5 are assembled simultaneously to form a self longitudinal and transverse stiffening constraint deformation system, and after the assembly, the self longitudinal and transverse stiffening constraint deformation system is synchronously and symmetrically welded from the middle to the outer side on the anti-deformation jig frame, namely, the welding deformation of the plate units of the thin-wall structure is controlled in a mode of combining the self constraint system of the self structure with the outer constraint of the anti-deformation jig frame.
6) And finally, scribing and welding shear nails, and trimming the welding deformation of the whole plate unit to ensure that the flatness is less than or equal to 1.0mm/m.
[3] Manufacturing a steel shell tower block with the ribs:
as shown in fig. 12 and 13, in order to accelerate the total splicing speed of the segments, improve the total splicing precision of the segments, facilitate the installation of the reinforcing steel bars, ensure the construction safety of personnel, and make the block K1 and the block K2 in a horizontal state, the assembly process and the control method are as follows:
1) an outer wall plate unit K11 (outer wall plate unit K21) is laid on a jig frame of a longitudinal and transverse beam system, then a partition plate unit K12 (partition plate unit K22) is assembled by taking a datum line of the outer wall plate unit K11 (outer wall plate unit K21) as a datum line, and an inner wall plate unit K13 (inner wall plate unit K23) is assembled in a matched line.
2) After the assembly size is checked and the requirements are met, 10mm fillet welds of the partition plate unit K12 (partition plate unit K22), the outer wall plate unit K11 (outer wall plate unit K21) and the inner wall plate unit K13 (inner wall plate unit K23) panels are welded, butt welds which are horizontally stiffened are welded, ultrasonic flaw detection is carried out, and the quality of the welds is ensured.
3) And checking the external dimensions after welding, trimming welding deformation in a flame correcting mode and the like, and ensuring the overall dimensional accuracy of the block K1 and the block K2.
4) The annular steel bars 7 of the outer wall plate sequentially pass through the vertical stiffening steel bar holes of the outer wall plates of the block K1 and the block K2 and pass through the steel bar holes of the partition plate 2; the inner wall plate steel bars 8 sequentially penetrate through the vertical stiffening steel bar holes of the inner wall plates of the block K1 and the block K2 and penetrate through the steel bar holes of the partition plate 2. After the steel bar penetrates, the horizontal steel bar on one side of the inner wall plate 3 is fixed and positioned by utilizing the temporary positioning steel bar 8a, the distance between the steel bars is controlled, and when the segments are assembled conveniently, the staggered steel bars of the block K1 and the block K2 are mutually avoided.
[4] And (3) segment assembly manufacturing:
the segments are formed by welding two blocks K1, two blocks K2 and four arc wall plate units A1 with ribs in a splicing way into a whole, so that welding space is ensured for convenient construction, the total splicing progress is accelerated, a vertical total splicing process is adopted, and the concrete manufacturing process is as follows:
1) The bottom box opening size positioning process comprises the following steps: the support positioning tool Y1, the support positioning tool Z1 and the support positioning tool Z2 for manufacturing the bottom box opening, wherein the support positioning tool Y1 is an arc support positioning tool, the support positioning tool Z1 and the support positioning tool Z2 are straight line section support positioning tools, the support positioning tool Y1, the support positioning tool Z1 and the support positioning tool Z2 are T-shaped components, the support positioning tool Y1 is formed by a web plate and an upper cover plate, the web plate is welded on a support beam of a bottom platform of a vertical assembly jig frame in a positioning mode, and the upper cover plate is used for supporting and positioning a section. The supporting and positioning tool Y1 of the arc part is manufactured by adopting wire cutting finish machining, the overall dimensions of an arc with R=1000 mm and straight line sections with 200mm at the two ends are ensured, and an auxiliary positioning line Y12 is marked at a position 100mm away from a starting line and a stopping line (Y11) of the arc. The upper cover plates of the straight line section supporting and positioning tool Z1 and the supporting and positioning tool Z2 mark an outer wall plate assembling and positioning line Z11 and a positioning line Z21. When the positioning tool is used, a center line J1 and a center line J2 of the section bottom section size are marked on the jig frame platform, then a support positioning tool Z1 and a support positioning tool Z2 which are assembled are positioned on a bottom beam of the jig frame platform according to the section bottom section size, the distance (Lb+δ2) between a positioning line Z11 and a transverse bridge and a center line J2 is controlled, the distance (La+δ1) between a positioning line Z21 and a transverse and longitudinal bridge and the center line J1 is controlled, wherein La and Lb are theoretical distances between the section bottom section center line and the outer side of an outer wall plate, δ1 and δ2 are welding shrinkage technological quantities considered during assembly, and the integral flatness of the top surfaces of the support positioning tool Z1 and the support positioning tool Z2 is ensured to be less than or equal to 1.0mm. And the positioning lines Z11 and Z21 of the support positioning tool Z1 and the support positioning tool Z2 and the section dimension center lines J1 and J2 are used as references to position, assemble and support the positioning tool Y1, the distance between the auxiliary positioning line Y12 of the arc positioning tool and the center lines J1 and J2 is ensured, the alignment of the arc edge R=1000 mm and the positioning lines Z11 and Z21 of the straight line section support positioning tool is ensured, and the overall flatness of the top surface of the upper cover plate of the support positioning tool Y1 is less than or equal to 1.0mm.
2) As shown in fig. 15 and 16, the positioning blocks K1 and K2 are assembled by lines to ensure that the outer skin of the outer wall plate is aligned with the positioning lines Z11 and Z21 of the support positioning tool Z1 and the support positioning tool Z2. In the assembly process, the horizontal steel bars 8 of the inner wall plates of the block K1 and the block K2 are ensured to be staggered and avoided. And after the inclination angle of the block body and the section cross section size of the top opening of the section are adjusted to meet the size requirement, spot welding and temporary stacking and fixing of the stacking plates are realized. In order to control the inclination angles of four blocks, 3 measuring points are arranged on each surface at the position 100mm below the top surface of the segment, the measuring points of the longitudinal inclination angles are C1, the measuring points of the transverse inclination angles are C2 and C3 respectively, the measuring points are projected to the bottom plane of the jig frame, the projection points are D1, D2 and D3 respectively, the height difference values of the measuring points C1, C2 and C3 from the projection points D1, D2 and D3 and the theoretical inclination angles can be calculated to determine the theoretical values S1, S2 and S3 of the distances of the projection points from the edges of the inner wall plate or the outer wall plate of the block, and in the construction process, the actual measured value deviation is ensured to be less than or equal to 1.0mm, so that the inclination angle control purpose is achieved.
3) And assembling a pair of diagonal arc wall plate units A1 with the ribs and the arc wall plate units A1 with the support positioning tool Y1 as references, ensuring that the arc edges of the arc wall plate units A1 with the ribs and the arc edges of the support positioning tool Y1 are aligned, controlling the deviation between the diagonal spacing of the arc wall plate units with the ribs and the theoretical numerical value to be less than or equal to 3.0mm, and ensuring the size of the box opening at the assembled arc position of the arc wall plate units. The other pair of the arc wall plate units with ribs is not assembled temporarily (shown in fig. 19) so as to facilitate the personnel to enter the interior of the segment for welding.
4) And butt welding seams among the four block inner wall plates 3 are welded, so that the four blocks are welded into a whole.
5) And taking the block K1, the block K2 and the supporting and positioning tool Y1 of the straight line segment as references, assembling another pair of diagonal rib-attached arc wallboard units A1, ensuring that the arc edges of the rib-attached arc wallboard units A1 are aligned with the arc edges of the supporting and positioning tool Y1, controlling the deviation between the diagonal line spacing of the arc wallboard units and theoretical numerical values to be less than or equal to 3.0mm, and ensuring the size of a box opening at the arc position after the assembly of the whole segment arc wallboard units.
6) As shown in fig. 17, the upper box opening of the upper tower column controls the local box opening size of the arc wallboard by using an arc assembly positioning template Y2, marks an auxiliary positioning line Y22 at a position 100mm away from an arc starting and stopping line, controls the distance size from the central line J1 and the central line J2 of the upper box opening of the section to the auxiliary positioning line Y22 of the arc assembly positioning template Y2, controls the box opening sizes (la '+δ1) and (lb' +δ2) of the longitudinal and transverse outer wallboard, wherein δ1 and δ2 are welding shrinkage process allowance, controls the deviation between the diagonal distance and a theoretical value of the rib-attached arc wallboard unit to be less than or equal to 3.0mm, and ensures the box opening size of the arc position after the assembly of the rib-attached arc wallboard unit of the whole section of the upper box opening.
7) As shown in fig. 18, in order to control welding deformation, butt welds between the four ribbed circular arc wall plate units A1 and the block K1 and block K2 outer wall plates 1 are preset with a reverse deformation Δ.
8) As shown in fig. 20, butt welds between the four arc wall plate units A1 with ribs and the block K1 and the block K2 outer wall plate 1 and butt welds between the horizontal stiffeners 5 are welded, and flaw detection is performed after welding, thereby completing the welding operation of the segments.
9) And the four circular arc outer wall plate units A1, the block K1 and the block K2 are connected, and the annular steel bar mechanical connectors 7a are arranged on the outer wall plate sides, so that the connection quality of the threaded sleeves of the mechanical connectors is ensured to meet the quality requirement of the primary connection connector.
Claims (6)
1. A manufacturing method of a steel shell tower section with a four-corner arc section and a variable cross section is characterized in that the steel shell tower section is of a symmetrical structure along the bridge direction and is of an inward inclined structure with the same slope on two sides; the transverse bridge of the steel shell tower section is of a structure inclined to one side with different slopes on two sides; the steel shell tower section comprises an outer wall plate (1), a partition plate (2), an inner wall plate (3), vertical stiffening (4) and horizontal stiffening (5) which are arranged in the steel shell tower section, welding nails (6) welded on the outer wall plate and the inner wall plate, outer wall plate circumferential steel bars (7) and inner wall plate horizontal steel bars (8); the angle control of the horizontal stiffening (5) is realized by controlling the assembly angles of the horizontal stiffening (5) and the outer wall plate (1), the partition plate (2) and the inner wall plate (3), so that the accurate butt joint of the horizontal stiffening in different vertical faces of the steel shell tower segment is ensured;
the method comprises the following steps:
(S1) manufacturing four arc wallboard units with ribs: controlling the external dimensions of the rib-attached arc wallboard units by adopting a process partition plate and an arc outer jig frame, assembling the reinforcing steel bars and the rib-attached arc wallboard units, and positioning by utilizing a positioning tool to form the rib-attached arc wallboard units;
(S2) manufacturing four straight-line segment blocks with ribs: firstly manufacturing an inner wall plate unit, an outer wall plate unit and a partition plate unit, then assembling and welding the plate units into blocks, penetrating outer wall plate circumferential reinforcing steel bars and inner wall plate horizontal reinforcing steel bars, and forming a reinforced straight-line block structure;
(S3) total splicing and manufacturing of steel tower sections: adopting a vertical total splicing process to splice four arc wall plate units with ribs and four straight line segment blocks with ribs, and finally connecting annular steel bar mechanical connection joints at the outer wall plate side to finish segment manufacture;
the inclination angle of the steel shell tower segment is controlled by the following method: the four rib-attached arc wallboard units and the four rib-attached straight-line section blocks are positioned through the positioning tool, the inclination angles of the rib-attached straight-line section blocks are adjusted, measuring points are arranged on each surface below the top surface of the steel shell tower segment, the measuring points are projected to the bottom plane of the jig frame, the theoretical value of the distance between the projection points and the inner wallboard or the outer wallboard edge of the block is calculated and determined through the height difference value between the measuring points and the projection points and the theoretical inclination angle, the deviation of the actual measured value is ensured to be less than or equal to 1.0mm, and the inclination angle of the steel shell tower segment is controlled.
2. The method for manufacturing a four-corner arc-section variable-section steel shell tower segment according to claim 1, wherein in the step (S1), the reinforced arc wall plate unit is prepared by the following method:
(S1-1) drawing an arc starting line for bending an outer wall plate in the reinforced arc wall plate unit, stiffening an assembly position line, controlling the opening size of the bent arc outer wall plate according to positive tolerance, and controlling the welding deformation of the arc outer wall plate by utilizing an arc outer jig frame and a process baffle plate when assembling and welding the stiffening plate;
and (S1-2) penetrating the outer wall plate circumferential steel bars (7) into steel bar holes of the vertical stiffening bars (4) of the circular arc-shaped outer wall plates, and simultaneously retracting the outer wall plate circumferential steel bars (7) in the circular arc-shaped wall plate units with the ribs into the outer wall opposite joints for a certain distance at the positions of the circular arc-shaped wall plate units with the ribs, so that the steel bars and the wall plates are not interfered when the sections are assembled.
3. The manufacturing method of the four-corner arc-section variable-section steel-reinforced steel shell tower segment according to claim 2, wherein the two side ends of the outer wall plate circumferential steel bar (7) are used for positioning the installation position of the outer wall plate circumferential steel bar (7), the positioning tool can be laterally inserted into a steel bar hole of the vertical stiffening (4), the positioning tool is provided with an open notch, and the positioning tool is removed after the steel bar mechanical connection joint of the steel bar-reinforced arc wall plate unit and the steel bar-reinforced straight line segment block is connected.
4. The manufacturing method of the four-corner arc-section variable-section steel shell tower segment with ribs according to claim 3, wherein in the step (S2), the straight segment block with ribs is manufactured in a horizontal state, and the manufacturing method comprises the following steps:
(S2-1) paving an outer wall plate on a jig frame of the longitudinal and transverse beam system, assembling a partition plate by taking a datum line of the outer wall plate as a datum, assembling an inner wall plate by lines, checking the assembly size, welding fillet welds of the partition plate, the outer wall plate and an inner wall plate panel after meeting the requirement, and welding butt welds with horizontal stiffening;
(S2-2) sequentially penetrating the outer wall plate circumferential reinforcing steel bars through the vertical stiffening steel bar holes of the outer wall plate of the straight-line section block body with the reinforcing steel bars, penetrating the steel bar holes of the partition plate, sequentially penetrating the inner wall plate horizontal reinforcing steel bars through the vertical stiffening steel bar holes of the inner wall plate of the straight-line section block body with the reinforcing steel bars, penetrating the steel bar holes of the partition plate, fixing and positioning the horizontal reinforcing steel bars on one side of the inner wall plate by using temporary positioning steel bars after the reinforcing steel bars penetrate, controlling the distance between the reinforcing steel bars, and facilitating mutual avoidance of staggered reinforcing steel bars of the straight-line section block body with the reinforcing steel bars when the sections are assembled.
5. The method of manufacturing a square arc section variable cross section steel shell tower segment according to claim 4, wherein in step (S3), the steel shell tower segment is manufactured by:
(S3-1) bottom box port size positioning of steel shell tower segments: firstly marking a center line of the section size of the bottom of a steel shell tower section on a jig frame platform, positioning and assembling a straight line section supporting and positioning tool for positioning a straight line section block with ribs on a bottom beam of the jig frame platform according to the section size of the bottom of the steel shell tower section, controlling the distance between a positioning line and a transverse bridge center line and the distance between the positioning line and a forward bridge center line, and ensuring that the overall flatness of the top surface of the straight line section supporting and positioning tool is less than or equal to 1.0mm; the positioning assembly is used for positioning the arc-shaped support positioning tool for the arc-shaped wall plate unit with the ribs, so that the alignment of the arc edge and a positioning line of the straight line section support positioning tool is ensured, and the overall flatness of the top surface of the upper cover plate of the arc-shaped support positioning tool is ensured to be less than or equal to 1.0mm;
(S3-2) assembling and positioning four rib-attached straight-line segment blocks according to lines, ensuring alignment of outer wall plate skins and positioning lines of straight-line segment supporting and positioning tools, ensuring mutual staggered avoidance of horizontal steel bars of inner wall plates of the rib-attached straight-line segment blocks in the assembling process, adjusting the inclination angle of the rib-attached straight-line segment blocks and the section cross section size of a top opening of a segment, and after meeting the size requirement, temporarily fixing and stacking spot welding and stacking plates;
(S3-3) assembling a pair of diagonal rib-attached arc wallboard units by taking four rib-attached straight line segment blocks and an arc support positioning tool as references, ensuring that the arc edges of the rib-attached arc wallboard units are aligned with the arc edges of the arc positioning tool, controlling the deviation between the diagonal line spacing of the rib-attached arc wallboard units and a theoretical numerical value to be less than or equal to 3.0mm, ensuring the box opening size of the assembled arc position of the rib-attached arc wallboard units, and temporarily not assembling the other pair of rib-attached arc wallboard units;
(S3-4) welding butt welds between inner wall plates of four straight-line segment blocks with ribs, so as to ensure that the four straight-line segment blocks with ribs are welded into a whole;
(S3-5) taking four rib-attached straight-line segment blocks and an arc support positioning tool as references, assembling another pair of diagonal rib-attached arc wallboard units, ensuring that the arc edges of the rib-attached arc wallboard units are aligned with the arc edges of the arc support positioning tool, controlling the deviation between the diagonal distances of the rib-attached arc wallboard units and theoretical numerical values to be less than or equal to 3.0mm, and ensuring the size of a box opening at the arc position after the whole segment rib-attached arc wallboard units are assembled;
(S3-6) upper column upper box port size of steel shell column segment: controlling the local box opening size of the rib-attached arc wallboard unit, controlling the distance from the center line of the box opening on the section of the steel shell tower to the auxiliary positioning line of the arc supporting and positioning tool, controlling the box opening size of the longitudinal and transverse outer wallboard, controlling the deviation between the diagonal distance of the rib-attached arc wallboard unit and the theoretical value to be less than or equal to 3.0mm, and ensuring the box opening size of the arc position after the assembly of the rib-attached arc wallboard unit on the whole section of the upper box opening;
and (S3-7) presetting reverse deformation of butt welds between the four rib-attached arc wallboard units and the outer wall plates of the rib-attached straight-line segment blocks, welding the butt welds between the four rib-attached arc wallboard units and the outer wall plates of the adjacent blocks and the butt welds between the horizontal stiffening, performing flaw detection after welding, completing the welding operation of the sections, connecting the four rib-attached arc outer wall plate units and the outer wall plate side circumferential steel bar mechanical connectors of the rib-attached straight-line segment blocks, ensuring the connection quality of the mechanical connection joint threaded sleeves, and completing the manufacturing of the steel shell tower sections.
6. The manufacturing method of the four-corner arc-section variable-section steel shell tower segment with ribs, according to claim 1, is characterized in that the inclination angle of the straight segment block with ribs is controlled by the following method: and 3 measuring points are arranged on each surface 100mm below the top surface of the segment, the longitudinal bridge inclination angle measuring points are C1, the transverse bridge inclination angle measuring points are C2 and C3 respectively, the measuring points are projected to the bottom plane of the jig frame, the projection points are D1, D2 and D3 respectively, the height difference value between the measuring points C1, C2 and C3 and the projection points D1, D2 and D3 and the theoretical inclination angle can be calculated to determine the theoretical values S1, S2 and S3 of the distance between the projection points and the edges of the inner wall plate or the outer wall plate of the block, and the actual measurement value deviation is ensured to be less than or equal to 1.0mm in the construction process.
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