CN116575785A - Four-corner arc section ultra-thick plate bolting steel tower segment and manufacturing method - Google Patents

Abstract

The invention relates to a bolt-on steel tower segment of a super-thick plate with four-corner arc section manufactured by adopting a continuous matching manufacturing process of a block and segment multi-segment long line method and a manufacturing method thereof, comprising the bolt-on steel tower segment, wherein four corners of the bolt-on steel tower segment are designed by adopting an arc with the radius of more than or equal to 1m, the four-corner arc section of the super-thick plate is a bolt-on machine processing steel tower, the whole section is an annular closed structure, the bolt-on steel tower transfers force between an upper tower column and a lower tower column by metal contact, the flatness of the whole section is required to be within 0.25mm by end surface machining, the dislocation amount of the whole section wallboard is required to be less than or equal to 2mm, and the axis perpendicularity is required to be within 1/10000. The advantages are that: advanced and reliable technology, cost saving, obvious acceleration of construction progress, advanced technology and obvious economic benefit.

Description

Four-corner arc section ultra-thick plate bolting steel tower segment and manufacturing method

Technical Field

The invention relates to a bolt-on steel tower segment with four-corner arc section and super-thick plate manufactured by adopting a continuous matching manufacturing process of a block and segment multi-segment long line method and a manufacturing method thereof.

Background

Currently available bolted steel tower sections all adopt a polygonal design, wherein corners adopt an angular joint design, such as a saddle-hill steel tower and a Pu Yi steel tower, and particularly shown in fig. 12 and 13. The prior metal contact force transmission bolting steel tower has the advantages that the peripheral wall plates are of a mutual angle joint structure, the thickness of the wall plates is not more than 60mm, the welding stress and welding deformation are small in the welding process of the wall plates, and the control of the section size is relatively easy. And because of the corner joint design, the steel tower section wall plate also forms an opening design, and the tower column box opening can be adjusted through the free end of the wall plate edge. Based on the above conditions, when the prior steel tower is manufactured, independent total splicing of single sections is adopted, and staggered control of splicing plate bolting among the sections is ensured by means of section size precision control of the single sections. The defects are that: when the closed bolting steel tower is used for processing, as the ring opening is of a closed design, no space between adjacent plates can be used, so that the assembly process cannot be adjusted, and dislocation is easy to occur at the joint of adjacent sections.

Disclosure of Invention

The design purpose is as follows: the defects in the background technology are avoided, and a horizontal general assembly process adopting a block and segment multi-segment long line method for continuous matching manufacture is designed.

The design scheme is as follows: the invention aims at the development, research and design of factory manufacturing technology of bolted steel tower sections with arc sections at four corners. The bolting steel tower adopts a height-direction inclined constant-section design, and the whole structure consists of a peripheral ring wallboard, a middle web plate, a middle compartment plate, a horizontal partition plate and an anchor box. The wallboard is made of thick plates, the maximum thickness is 78mm, and the stiffening thickness is 38 mm-48 mm. According to different heights of the towers, 2-6 anchor boxes are arranged in a single tower section, the anchor boxes are arranged between two webs, and penetration welding is adopted between the anchor box webs and the tower webs. The four corners of the tower column adopt arc angle wall plates, the whole section wall plates form a closed loop design, the port size is 7 multiplied by 6m, the weight of the section is about 114 tons to 192 tons, and the manufacturing process of the section, the precision control of the section size and the matching precision of the box opening between the upper tower column and the lower tower column are manufacturing difficulties.

The four corners of the steel tower section are designed by adopting a 1m radius arc, and the full section is of an annular closed structure, as shown in figure 5. The bolting machine for the four-corner arc sections of the ultra-thick plates is adopted for the first time, the bolting machine is used for transferring force to upper and lower tower columns by metal contact, the full-section flatness required by end face machining is within 0.25mm, the dislocation amount required by the full-section wall plates is less than or equal to 2mm, the axis perpendicularity required by the full-section wall plates is within 1/10000, and the precision requirement is extremely high. Intersecting in the past steel tower, the outer wall plate is a quadrangle circular arc section, and the circular arc wall plate and the straight line section wall plate are welded into an integrally closed frame structure by adopting penetration butt welding seams. And the maximum plate thickness is 78mm, the forming of the arc wallboard units is controlled, after the sections are welded, due to welding shrinkage and self structural forms, the internal residual stress is larger than the stress of the traditional steel tower lap joint weld, the welding deformation is difficult to control, and the section size of the sections and the dislocation easily occur due to the influence of the welding deformation. In particular, the bending residual internal stress of the four-corner arc part is overlapped with the stress after butt welding, and the cross section size and the section dislocation control are extremely difficult. In order to overcome the industrial manufacturing of the structural steel tower, the manufacturing precision and the processing quality are ensured, the original manufacturing process combining continuous matching manufacturing of blocks and sections and horizontal general splicing is systematically developed, and the manufacturing and the precision control of the closed-type bolting steel tower sections are realized.

The manufacturing method adopts a continuous matching manufacturing process of the block and the segment by a multi-segment long line method for the first time, and in the total splicing manufacturing process of the block and the segment, the box openings of adjacent segments are mutually checked, so that the full-section staggered platform qualification rate of the box openings is improved, the total splicing time is reduced, the construction progress is accelerated, and the improvement of the construction quality and the precision control are facilitated. The invention has advanced and reliable technology, saves cost and has obvious economic and social benefits.

Compared with the background technology, the invention has the advantages that firstly, the technology is advanced and reliable, the continuous matching manufacturing technology is adopted, the matching operation of the interfaces is synchronously completed in the manufacturing process of the tower column blocks and the sections, the mutual fitting of the box openings can be realized under the condition that the closed-loop box opening design can not be adjusted in size, the size consistency of the interfaces among different tower columns is effectively ensured, the matching degree of the box openings is effectively improved, and the dislocation is reduced; secondly, the cost is saved; thirdly, the construction progress is obviously accelerated; ensuring the manufacturing precision; fourthly, the technology is advanced, and compared with the traditional technology, the continuous matching manufacturing technology is more beneficial to manufacturing the closed-type bolting steel tower, and is beneficial to precision control and box mouth matching; fifthly, the method has remarkable economic benefit.

Drawings

Fig. 1 is a schematic cross-sectional view of a steel tower.

Fig. 2 is a schematic elevation view of a steel tower segment.

Fig. 3 is a schematic diagram of a section of a steel tower in cross-section.

Fig. 4 is a schematic diagram of a section of a steel tower in cross section two.

Fig. 5 is a schematic perspective view of a steel tower segment.

Fig. 6 is a block division schematic of a steel tower segment.

FIG. 7 is a schematic cross-sectional view of a bolting tower.

Fig. 8 is a block assembly flow schematic.

Fig. 9 is a schematic diagram of a multiple block continuous matching fabrication.

FIG. 10 is a schematic view of a process splice plate installation.

Fig. 11 is a schematic diagram of a multiple block continuous matching fabrication.

Fig. 12 is a schematic cross-sectional view of a saddle-hill steel tower of the prior art.

Fig. 13 is a schematic diagram of a Pu Yi steel tower cross-section in the background art.

Description of the embodiments

Example 1: with reference to fig. 1-11. The structural scheme of the invention is as follows: the invention relates to a manufacturing method of a four-corner arc closed type ultra-thick plate bolting steel tower segment, and the structural form of the steel tower segment is shown in fig. 6, 7, 8 and 9. 1-a wallboard; 2-corner wall panels; 3-side wall panels; 4-a compartment plate; 5-web; 6-an intermediate separator; 7-side separators; 8-vertical stiffening; 9-corner panel connection plates; 10-anchor box.

The bolting steel tower is designed by four-corner thick plate circular arcs, and the full section forms a closed loop, so that compared with the prior bolting steel tower, the manufacturing difficulty and the section size control difficulty are improved. In order to realize high-quality processing of the bolted steel tower section, the steel tower section is manufactured by adopting a plate unit-block-section manufacturing process, and continuous matching manufacturing processes are adopted during assembly of the block and the section in order to improve the matching precision of the steel tower box opening.

According to the bolted steel tower structure constitution, the steel tower section is divided into two blocks K1, two wallboard units A1, an anchor box M1 and other accessory components. The wallboard unit A1 consists of a wallboard 1 and a vertical stiffening member 8. The block K1 is composed of side wall plates 3, corner wall plates 2, webs 5, compartment plates 4, vertical stiffening 8 and side partition plates 7.

According to the structural form of the steel tower, the traditional manufacturing process of plate units, blocks and sections is adopted. In order to reduce the influence of welding shrinkage of the ultra-thick plate on the overall size and ensure the matching precision of the section size and the box opening of the steel tower, in the manufacturing process of the steel tower, a plate unit overall processing process, a multi-block continuous matching assembly process and a multi-section continuous matching assembly process are respectively provided for the first time.

The integral machining process of the plate unit comprises the following steps: the steel tower plate unit is manufactured by adopting a single element integral machining process, and after finishing the plate unit, straight edges and straight edge grooves on two sides are integrally machined. The advantages are that: firstly, the influence of shrinkage deformation on the whole size in the manufacturing process of the plate units is avoided, and the width is consistent in the whole height range of the plate units; secondly, after the plate units are manufactured, straight edges are machined, so that the straightness of the plate edges on two sides of the plate units is ensured, and the accuracy control of the subsequent section assembly box mouth is ensured; thirdly, the groove is machined integrally, the groove size is uniform, and welding shrinkage is uniform during segment assembly.

The multi-block continuous matching manufacturing process comprises the following steps: the section of the steel tower is rectangular, four corners are designed by adopting circular arcs, the longitudinal and transverse width dimensions of the whole port are strictly controlled, and the allowable deviation is 0-2 mm. As the block-segment assembling process is adopted, as can be seen from FIG. 11, the segments are composed of upper and lower blocks, an intermediate anchor box and wall plates, when the blocks are assembled, the straight section sizes of the wall plates at the two side corners are the cross section sizes of the tower column, and the two blocks K1 and the intermediate anchor box together form the width sizes of the section of the tower column, so that the control of the sizes of the tower column in the longitudinal and transverse directions is completed in the block and the segment assembling process.

The continuous multi-block matching process is mainly to assemble blocks on the same side of a plurality of tower columns in a simultaneous continuous posture, and adjacent interfaces are mutually matched, mutually inspected and corrected in the assembling process. The multi-block continuous matching manufacturing process ensures that the manufacturing of blocks can follow the standard, can control the dislocation amount of each plate within 1mm when the size of the control box opening meets the rule requirement, and effectively improves the manufacturing precision of the steel tower blocks and even the sections.

Continuous matching and manufacturing of multiple blocks: (1) firstly, arranging block jig frame supports according to the inclination rate of a tower column; (2) the continuous matching manufacturing requirement of the multiple blocks is strictly completed by arranging and welding blocks on the same side of adjacent tower columns one by one in sequence; (3) before matching, the first block is qualified by each size inspection, and then subsequent blocks are positioned and assembled one by taking the first block as a reference, and the size of a box opening and the board staggering amount at an interface are strictly controlled in the process; (4) the multi-block continuous matching assembly is used as one round together with at least three blocks, meanwhile, each round is required to be carried out one by one according to the sequence, and the last block is required to be left as a reference block of the next round after the previous round is completed, so as to participate in the matching production of the next round.

Assembling:

before the block K1 is manufactured, a side wall plate unit K11, a corner wall plate unit K12, a compartment plate unit K13, and a side wall plate unit K14 which constitute the block K1 are manufactured.

(1) In order to control welding deformation, improve assembly welding precision and improve matching degree of box openings among tower sections, tower column block bodies are manufactured and assembled on jig frame platforms of a longitudinal and transverse beam system, flatness of top surfaces of the jig frame platforms is guaranteed to be less than or equal to 2.0mm, and deformation in the manufacturing process is controlled.

(2) In order to improve the matching degree between the box openings and reduce the dislocation in the plate thickness direction, the manufacture of the tower column block adopts a continuous matching manufacture process.

(3) First, a longitudinal base line, i.e., a longitudinal center line, is laid on a platform, a first sidewall plate unit is laid on a jig frame, and the longitudinal base line of the sidewall plate unit is aligned with both ends of the longitudinal base line on the jig frame.

(4) The side wall panels are sequentially laid out with a distance of about 40mm apart, so that longitudinal base lines between the side wall panels are required to be in the same straight line, and the deviation of the thickness direction between the side wall panels is required to be strictly controlled to be less than or equal to 1mm. To ensure continuous matching, process splice plates are added between the side wall plates, temporary bolting is carried out on the side wall plates, the plate thickness direction dislocation between adjacent side wall plates is reduced, and the stiffening dislocation is reduced.

(5) The two side corner wall plate units are assembled in sequence, the distance from the upper longitudinal base line of the corner wall plate unit to the longitudinal base line of the side wall plate is controlled in an important way, the opening distance of the two side corner wall plates is controlled, and meanwhile, the board thickness direction staggering amount of the corner wall plates between adjacent blocks is controlled, including the stiffening staggering amount.

(6) A side partition plate unit is assembled by taking partition plate position lines on the side wall plates as reference positions, and the perpendicularity of the side partition plate and the side wall plates is controlled in an important way.

(7) The partition plate units are assembled according to the partition plate unit assembly position line, the perpendicularity between the partition plates and the side wall plates is guaranteed, the staggered amount of the adjacent block partition plate in the plate thickness direction is controlled, and the process splice plates or the spot welding connection plates can be bolted and fastened according to requirements, so that staggered positions between the adjacent blocks at the side wall plates are reduced.

(8) And assembling another side partition plate unit on the position line of the right side partition plate, wherein the verticality of the side partition plate and the side wall plate is controlled in a key way, and the plate thickness central line dislocation amount of the side partition plates at two sides is less than or equal to 1mm.

(9) The web plate units are paved, the width dimension of the tower column block body is detected, the opening dimension is trimmed to be within a required value range, and meanwhile, the web plate thickness direction dislocation between adjacent block bodies is strictly controlled, and the stiffening dislocation is included.

And finishing welding of the welding line in the box, and finishing welding of the welding line on the outer side of the wallboard by turning over.

After the first round of block assembly is completed, the remaining block participates in the next round of block manufacture, and the matching operation of blocks among rounds is completed.

In order to ensure the overall stability of the steel tower assembly, the steel tower column adopts a horizontal assembly process in consideration of the cheapness of welding. Meanwhile, considering the box opening matching of the bolting steel tower column, the plate thickness dislocation quantity in the full section range of the adjacent sections is controlled to meet the process requirement, and the continuous matching manufacturing process is still selected for the tower column assembly. Meanwhile, the tower column manufacturing is required to be completed on a special segment assembly platform.

Multi-segment continuous matching total spelling: (1) firstly, arranging block jig frame supports according to the inclination rate of a tower column; (2) the multi-section continuous matching total splicing requirement is strictly completed by sequentially arranging and welding adjacent tower columns on the same side one by one; (3) before matching, the first section is qualified by each dimension inspection, and then the subsequent sections are positioned and assembled one by taking the first section as a reference, and the dimension of a box opening and the staggering amount of the plate at the interface are strictly controlled in the process; (4) the multi-segment continuous matching assembly is used as one round together with at least three segments, each round is required to be carried out one by one according to the sequence, and the last segment is required to be left as the reference segment of the next round after the previous round is completed, so as to participate in the matching assembly of the next round.

Considering that the circular arc wallboard staggering is not easy to control, adopting a continuous matching mode to carry out total splicing, in order to improve the manufacturing precision, reduce the turning times, and when the blocks are continuously matched and manufactured, the welding seams at the two side end parts are all welded, the sections are properly pulled apart by a fixed interval of about 40mm, and the interval in the whole section of the box opening is controlled by a process splice plate to be about 40 mm.

The specific assembly process is as follows:

(1) and aligning the longitudinal base lines on the total jig frame, and positioning and assembling the lower block of the first section.

(2) And (3) pulling gaps of about 40mm to sequentially position blocks below other sections in the same round, and mainly controlling the staggered quantity among the blocks, wherein a process splice plate bolt is adopted and fixed when necessary.

(3) And positioning and assembling the anchor box unit according to the anchor box position line, and simultaneously assembling the tensioning platform.

(4) The base lines of the upper block body and the lower block body are aligned, the upper block body is assembled in a positioning mode, the size of the box opening is controlled in an important mode, and the thickness direction of the full section plate between the adjacent sections is staggered.

(5) And installing side wall plate units at two sides to finish the welding operation of the tower column.

It should be understood that: although the above embodiments describe the design concept of the present invention in more detail, these descriptions are merely descriptions of the design concept of the present invention, and not limitations on the design concept of the present invention, and any combination, addition or modification not exceeding the design concept of the present invention falls within the scope of the present invention.

Claims (6)

1. The utility model provides a four corners circular arc section super thick plate bolting steel tower section, includes bolting steel tower section, characterized by: the four corners of the bolting steel tower section are designed by adopting arc with radius of more than or equal to 1m, the arc sections of the four corners of the ultra-thick plate are bolting machine-processed steel towers, the whole section is of an annular closed structure, the bolting steel towers transfer force between an upper tower column and a lower tower column by metal contact, the flatness of the whole section is required to be within 0.25mm by end face machining, the dislocation amount of the whole section wallboard is required to be less than or equal to 2mm, and the verticality of an axis is required to be within 1/10000.

2. The four corner arc section ultra thick plate bolting steel tower segment according to claim 1, wherein: the outer wall plate of the bolted steel tower section is a quadrangle arc section, and the arc wall plate and the straight line section wall plate are welded into an integrally closed frame structure by adopting penetration butt welding seams.

3. The four corner arc section ultra thick plate bolting steel tower segment according to claim 1, wherein: the maximum plate thickness of the bolted steel tower segment outer wall plate is 78mm.

4. A manufacturing method of a four-corner arc section ultra-thick plate bolting steel tower segment comprises a steel tower plate unit manufacturing process, a block manufacturing process and a segment manufacturing process, and is characterized in that:

the whole machining process of the plate unit comprises the following steps: the steel tower plate unit is manufactured by adopting a single element integral machining process, and after the plate unit is manufactured, straight edges are machined, so that straightness (the whole length is 1 mm) of the plate edges at two sides of the plate unit is ensured, the accuracy of box openings of subsequent section assembly is controlled (the length and the width of the box openings are controlled within +/-2 mm), and grooves are integrally machined on the straight edges and the straight edges at two sides, and the grooves are uniform in size and uniform, so that welding shrinkage is uniform during the section assembly;

the block manufacturing process is a multi-block continuous matching manufacturing process: the section of the steel tower is rectangular, four corners are designed by adopting circular arcs, the longitudinal and transverse width dimensions of the whole port are strictly controlled, the allowable deviation is 0-2 mm, the sections are composed of upper and lower blocks, an anchor box in the middle and wall plates, when the blocks are assembled, the straight section dimensions of the corner wall plates at two sides of the sections are the cross section dimension of the tower column, and the two blocks K1 and the middle anchor box are high to jointly form the width dimension of the section of the tower column, so that the dimension control of the tower column in the longitudinal and transverse directions is completed in the block and the section assembly section respectively.

5. The continuous matching process of the multi-block body is to assemble blocks on the same side of a plurality of tower columns in a continuous posture at the same time, and adjacent interfaces are matched with each other, inspected and corrected with each other in the assembling process. The multi-block continuous matching manufacturing process ensures that the manufacturing of blocks can follow the standard, and can control the dislocation amount of each plate within 1mm while controlling the size of the box opening to meet the rule requirement.

6. The method for manufacturing the four-corner arc section ultra-thick plate bolting steel tower segment according to claim 4, wherein the method is characterized in that a plurality of blocks are manufactured by continuous matching: (1) firstly, arranging block jig frame supports according to the inclination rate of a tower column; (2) the continuous matching manufacturing requirement of the multiple blocks is strictly completed by arranging and welding blocks on the same side of adjacent tower columns one by one in sequence; (3) before matching, the first block is qualified by each size inspection, and then subsequent blocks are positioned and assembled one by taking the first block as a reference, and the size of a box opening and the board staggering amount at an interface are strictly controlled in the process; (4) the multi-block continuous matching assembly is used as one round together with at least three blocks, meanwhile, each round is required to be carried out one by one according to the sequence, and the last block is required to be left as a reference block of the next round after the previous round is completed, so as to participate in the matching production of the next round.