CN117697083A - Manufacturing method of novel large-span truss type box arch rib - Google Patents

Abstract

The invention relates to the technical field of steel structure manufacturing, and particularly discloses a manufacturing method of a novel large-span truss type box arch rib, which comprises the following steps of S1: dividing the arch rib into a plurality of arch rib segments according to the urban road transportation capacity and the member form of the arch rib; s2: mounting an arch rib sectional integral horizontal splicing jig frame and marking manufacturing control points; s3: manufacturing arch rib single elements and assembling arch ribs; s4: installing a limiting tool; s5: welding arch ribs; s6: installing an arch rib upper chord box top plate and an arch rib lower chord box bottom plate and welding; s7: correcting and pre-assembling; s8: hanging all the sections on the jig frame and conveying the sections to a sand blasting workshop for coating; s9: the hoisting sections are formed by on-site butt joint; the invention adopts the mode of in-factory manufacturing, pre-splicing and large-section transportation to field hoisting for construction, not only has higher efficiency, the manufacturing precision and the quality meet the design and specification requirements, but also the field hoisting is simpler and more convenient, and is more beneficial to the installation quality and safety.

Description

Manufacturing method of novel large-span truss type box arch rib

Technical Field

The invention relates to the technical field of steel structure manufacturing, in particular to a manufacturing method of a novel large-span truss type box arch rib.

Background

In the installation construction of the steel truss arch, because the steel truss arch supporting system is not allowed to be arranged or only a small amount of steel truss arch supporting system is allowed to be arranged on some roads and channels due to various factors such as safety, economy, social influence and the like, the span of the folding section of the steel truss arch has to be made large so as to reduce the occupation of the roads and channels.

The truss type box arch rib is designed in a novel bridge structural form, the structure is attractive, but the node structure is complex, the precision requirement is high, the manufacturing difficulty is high, the later correction of the large deformation of the components is difficult to manufacture by the traditional method, the matching and transferring times of the components are high, the novel deformation is easy to cause, and the matching workload is high.

The steel rib has large deformation caused by welding shrinkage and heat influence in the manufacturing process, the post-correction workload is large, and the steel rib is difficult to correct to an ideal state, so that an ideal manufacturing process is also very needed to reduce the deformation influence.

Disclosure of Invention

The invention aims to provide a rib manufacturing method with higher precision and better efficiency, which is constructed in a mode of in-factory manufacturing and pre-splicing and large-section transportation to on-site hoisting aiming at the adverse conditions of large structural size, complex structure, multiple components, large steel plate thickness, narrow construction site, large water construction difficulty and the like of a truss type box-type rib, and has the advantages that the efficiency is higher, the manufacturing precision and the quality meet the design and specification requirements, the on-site hoisting is simpler and more convenient, and the installation quality and safety are facilitated.

The invention relates to a manufacturing method of a novel large-span truss type box arch rib, which comprises the following steps,

s1: dividing the arch rib into a plurality of arch rib segments according to the urban road transportation capacity and the member form of the arch rib;

s2: mounting an arch rib sectional integral horizontal splicing jig frame and marking manufacturing control points;

s3: manufacturing arch rib single elements and assembling arch ribs;

s4: installing a limiting tool;

s5: welding arch ribs;

s6: installing an arch rib upper chord box top plate and an arch rib lower chord box bottom plate and welding;

s7: correcting and pre-assembling;

s8: hanging all the sections on the jig frame and conveying the sections to a sand blasting workshop for coating;

s9: and (5) butting the hoisting sections on site.

As a further improvement of the invention, the S1.1 long-span truss type box arch rib is a mid-span arch rib, the arc length is 187.36 meters, the large-span truss type box arch rib is divided into three hoisting sections GL1, GL2 and GL3 according to a site special construction scheme, and the GL1, GL2 and GL3 are divided into GL1A, GL1B, GL2A, GL2B, GL2C, GL2D, GL3 and A, GL B8 transportation sections in consideration of urban road transportation capacity and the structural form of the arch rib.

As a further development of the invention, S2.1: the arch rib GL1A, GL1B, GL2A, GL2B, GL C5 transportation sections are integrally matched and manufactured on one jig frame, and the arch rib GL2D, GL3A, GL B3 transportation sections are synchronously integrally matched and manufactured on the other jig frame;

s2.2: the jig frame consists of jig frame struts and an upper connecting plate and a lower connecting plate, the lower connecting plate is close to the ground, the top surface of the upper connecting plate is wholly horizontal and 60 cm away from the ground, the width of the jig frame is equal to the height of the arch rib, and 4 jig frame struts are distributed on the two outermost sides and the positions of the arch rib upper chord box web plate single element and the lower chord box web plate single element, which are close to the middle connecting arch rib web members; the longitudinal positions and the intervals of the jig frame struts are arranged according to the center line of the web member;

s2.3: the manufacturing control points are divided into an assembly control point and a forming control point, the assembly state and the final forming state of the component are greatly different under the influence of welding shrinkage and thermal effect, in order to reduce the difference, the deformation of each arch rib segment after welding is calculated by combining special welding simulation model software with a welding process, and then the assembly form is optimized according to the reserved deformation; extracting a plurality of points from the middle to two ends on the top contour line of the web plate of the arch rib upper chord box and the bottom contour line of the web plate of the arch rib lower chord box of each transportation section in an assembly form according to the interval of not more than 4 meters as assembly control points, wherein the forming control points are obtained by extracting a plurality of points from the positions of the two ends, the middle and the center points of the lifting lug holes of the top contour line of the web plate of the arch rib upper chord box and the bottom contour line of the web plate of the arch rib lower chord box of each transportation section of the final form model;

s3.4: the assembly control point and the forming control point are driven into the ground by steel nails, and are sprayed with different colors to distinguish and mark, and the steel nails are protected.

As a further development of the invention, S3.1: the arch rib unit includes: the upper chord box web single element, the lower chord box web single element, the upper chord box top bottom plate unit, the lower chord box top bottom plate unit, the web member single element and the partition plate unit, wherein the second layer of lower chord box web single element and the third layer of lower chord box web single element do not contain lifting lug plates;

s3.2: manufacturing an upper chord box web single element, a lower chord box web single element, an upper chord box top bottom plate unit and a lower chord box top bottom plate unit according to the length of each transport section, wherein butt welding seams adopt CO2 gas shielded welding and submerged arc welding cover surfaces, and web member single element welding seams adopt CO2 gas shielded automatic welding;

s3.3: in the arch rib assembling process, all the spliced weld joints are fixed by spot welding through the arc-guiding plates;

s3.4: and (3) placing the first-layer web plate single elements of the upper chord box and the first-layer web plate single elements of the lower chord box of all arch rib sections on the jig frame by referring to the assembly control points, and welding the bottoms of the first-layer web plate single elements of the upper chord box and the first-layer web plate single elements of the lower chord box on the upright post of the jig frame for a plurality of times in a discontinuous spot welding mode to be welded and fixed with the jig frame.

S3.5: drawing mounting lines of a first-layer upper chord box top bottom plate, a first-layer lower chord box top bottom plate and a first-layer box inner partition plate on the first-layer web plate single element of the upper chord box of the arch rib section and the first-layer web plate single element of the lower chord box, mounting according to the sequence of the partition plate and the top bottom plate, and fixing by spot welding;

s3.6: the first layer web member single element of the arch rib section is installed, and the bottom surface of the web member is fixed with the splicing welding seam of the first layer web plate of the upper chord box and the first layer web plate of the lower chord box of the arch rib section by spot welding;

s3.7: the second layer web plate of the upper chord box, the second layer web plate of the lower chord box and the first layer lifting lug plate of the arch rib section are installed by referring to the assembly control points, and spot welding is performed on the position of the splicing welding seam with the top surface of the first layer web member element;

s3.8: the mounting lines of the upper chord box partition plate, the lower chord box partition plate and the web member partition plate are drawn on the upper chord box second layer web plate and the lower chord box second layer web plate of the arch rib section, and are mounted and fixed by spot welding, and only one of the upper chord box partition plate, the lower chord box partition plate and the upper chord box partition plate can be mounted in consideration of later welding;

s3.9: installing a third layer web plate of an upper chord box, a third layer web plate of a lower chord box, a second layer lifting lug plate and a second layer web member single element of the arch rib section by referring to the assembly control points, and spot-welding and fixing at a splicing welding seam between the plates;

s3.10: drawing mounting lines of a second-layer upper chord box bottom plate, a second-layer lower chord box top plate and a second-layer box inner partition plate on a third-layer web plate of the upper chord box and a third-layer web plate of the lower chord box of the arch rib section, mounting according to the sequence of the partition plate and the top bottom plate, and fixing by spot welding;

s3.11: the fourth layer of web elements of the rib segments are installed with reference to the assembly control points, so that the overall assembly of all rib segments is completed, and the overall assembly of the rib GL1A, GL1B, GL2A, GL2B, GL C segments is consistent with the overall assembly of GL2D, GL3A, GL3B segments and will not be repeated.

As a further improvement of the invention, S4.1: welding and fixing the end face of the section and the jig frame in a discontinuous spot welding mode for multiple times by using X-shaped tools at two ends of the integral horizontal jig frame of the section, so that the end face of the section cannot be deformed in a torsion mode in the integral welding process of the section;

s4.2: a thick-wall steel pipe tool with the diameter slightly smaller than 2mm is pinned into the lifting lug holes of the upper layer and the lower layer of lifting lugs of all the sections, and the lifting lugs of the upper layer and the lower layer are fixed into a whole, so that the whole welding process of the sections cannot be deformed in a torsion mode;

s4.3: and a limiting tool is arranged at the outer side of the horizontal spliced jig frame near the position of the forming control point to limit the expansion and deformation of the segment to the outer side in the whole welding process. The sections can shrink and deform in the welding process, and a proper iron plate is inserted into a gap between the arch rib and the limiting tool in time by referring to the forming control point, so that the sections deform to a forming state;

s4.4: and the limiting plates are arranged on the first layer of web plate of the upper chord box, the first layer of web plate of the lower chord box, the third layer of web plate of the upper chord box and the third layer of web plate of the lower chord box according to the position lines of the top plate of the upper chord box and the bottom plate of the lower chord box at intervals of not more than 1 meter, and the top plate is limited to displace and deform towards the inner side of the arch rib in the installation and welding process.

As a further improvement of the present invention,

s5.1: all baffle units except lifting lug positions, vertical welding seams of the top and bottom plate units of the upper chord box and the top and bottom plate units of the lower chord box are welded layer by layer from the middle of the arch rib section to two ends;

s5.2: welding transverse welding seams of the upper chord box web single element, the lower chord box web single element, the upper chord box top and bottom plate unit and the lower chord box top and bottom plate unit layer by layer from the middle of the arch rib section to two ends;

s5.3: welding transverse welding seams between all baffle plate units, the upper chord box top and bottom plate units and the lower chord box top and bottom plate units at the positions of lifting lug plates from the middle of arch rib sections to two ends layer by layer from bottom to top;

s5.4: correcting the arch rib section by taking the central molding control point of the lifting lug as a reference;

s5.5: butt welding seams of the lifting lug plate and the lower chord box web plate single element in the step S3.1 are welded layer by layer from bottom to top,

s5.6: welding vertical welding seams of all partition plate units at the lifting lug plate positions in the step S5.1 and the top and bottom plate units of the lower chord box;

s5.7: welding transverse welding seams of all partition plate units at the lifting lug plate positions in the step S5.3 and the top and bottom plate units of the lower chord box;

s5.8: and carrying out nondestructive detection on all welding seams, and carrying out sand blasting and paint coating on hidden parts in the upper chord box and the lower chord box of the arch rib after the detection is qualified.

As a further improvement of the invention, the top plate of the upper chord box of the mounting arch rib and the bottom plate of the lower chord box of the arch rib and the welding process are as follows:

s6.1: sand blasting and paint coating are carried out on the upper chord box top plate of the arch rib and the lower chord box bottom plate of the arch rib close to the inner box side;

s6.2: and installing and tightly supporting the limiting plates in S4.4 according to the position lines of the arch rib upper chord box top plate and the arch rib lower chord box bottom plate, and fixing. Note that the top and bottom plates cannot directly fall on the first layer of web plates, but the center lines of the top and bottom plates are aligned with the center lines after molding in the vertical direction by referring to the molding control points, and a certain distance is reserved between the first layer of web plates and the fourth layer of web plates;

s6.3: the welding of the arch rib upper chord box top plate and the arch rib lower chord box bottom plate with the upper chord box second layer web plate, the lower chord box second layer web plate, the upper chord box third layer web plate and the lower chord box third layer web plate is completed layer by layer according to the sequence from the center of the segment to the two ends, and the upper chord box top plate and the lower chord box bottom plate are required to be symmetrically welded;

s6.4: installing S3.8: the other one of the double-spliced partition plates between the upper chord boxes and the double-spliced partition plates between the lower chord boxes is welded;

s6.5: welding the arch rib upper chord box top plate and the arch rib lower chord box bottom plate with the upper chord box first layer web plate, the lower chord box first layer web plate and the fourth layer web plate single elements from bottom to top in sequence from the center of the segment to the two ends;

s6.6: correcting the arch rib segments with reference to the molding control points;

s6.7: welding seams between the arch rib lifting lug plate and the bottom plate of the lower chord box and connecting seams between the web member single element and the upper chord box and the lower chord box;

s6.8, carrying out nondestructive testing on all welding seams.

As a further improvement of the present invention,

s7.1: all limit tools are removed;

s7.2: taking the center forming control point of the lifting lug hole of each arch rib section as a reference, and performing flame heating correction on the arch ribs by referring to the forming control point;

s7.3: correction S2.1 with reference to the molding control point: the staggered edges among all the transportation sections on the two jig frames are punched with on-site butt-joint matching sample punching points, and control sample punching points are measured;

s7.4: hoisting GL2C to S2.1 by crane: and the other jig frame is matched with GL2D, the staggered edges and the spacing between the two transportation sections are corrected by referring to the molding control points, and then the on-site butt-joint matching sample punching points are punched.

As a further improvement of the invention, the sand blasting and coating process comprises the following steps:

s8.1: all sections on the jig frame are lifted and sent to a sand blasting workshop, and a new round of arch rib assembly and manufacture are started on the jig frame

S8.2: all sections of sand blasting are sent to a coating workshop for coating after being detected to be qualified;

s8.3: all the sections are sent to a storage area for storage after being detected to be qualified.

As a further improvement of the invention, S9.1 is close to a hoisting position on site, and GL1, GL3 and GL2 vertical splicing jig frames are erected according to different arch rib hoisting sections;

and S9.2, conveying GL1A, GL1B, GL3A, GL3B, GL2A, GL2B, GL2C, GL2D to the site according to the splicing sequence, and performing site butt joint matching sample punching points according to S7.3 and S7.4 to finish butt joint welding and paint coating of GL1, GL3 and GL2 hoisting sections on the vertical splicing jig frame.

Compared with the prior art, the invention has the following beneficial effects:

1. aiming at the adverse conditions of large truss type box arch rib structure size, complex structure, multiple components, large steel plate thickness, narrow construction site, large water construction difficulty and the like, the invention adopts the mode of in-factory manufacturing and pre-splicing, and large-section transportation to site hoisting for construction, thereby not only having higher efficiency, manufacturing precision and quality meeting the design and specification requirements, but also being simpler and more convenient for site hoisting and being more beneficial to installation quality and safety.

2. The invention utilizes the site conditions of factory production, adopts large-span integral horizontal splicing, reduces the workload of segment matching, better ensures the production quality, effectively utilizes the site space and fully improves the working efficiency of mechanical equipment and personnel.

3. The invention adopts the technology of splicing arch rib members by reserving deformation, optimizes the traditional manufacturing mode of passive deformation re-correction into active reserved deformation, and greatly reduces the work load of post correction.

4. The invention adopts the welding sequence of post-welding of the lifting lug, and solves the problems that the traditional lifting lug cannot be corrected or has low correction precision in the post-welding stage.

5. The invention adopts large-section manufacturing matching in factories, has small mutual influence on natural environment, is more beneficial to ensuring manufacturing quality, and can improve the influence of enterprises by large-scale arch rib manufacturing, thereby creating certain economic benefit, social benefit and environmental benefit.

6. The invention adopts the steps of manufacturing and matching large sections in a factory and then transporting the large sections to the site for butt joint installation, thereby reducing the site occupation of a construction site, the site welding quantity and the hoisting quantity, facilitating the site installation, reducing the installation risk and improving the installation quality and the installation precision.

Drawings

The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute an undue limitation to the application. In the drawings:

FIG. 1 is a sectional view of a mid-span arch rib of the present invention;

FIG. 2 is a schematic view of a cross rib overall horizontal jig;

FIG. 3 is the mid-span rib overall horizontal splice arrangement of FIG. 1;

FIG. 4 is the mid-span rib overall horizontal splice arrangement of FIG. 2;

FIG. 5 is a field jigsaw of a lifting section of a midspan arch rib CL 2;

FIG. 6 is a step 1 of overall horizontal splicing of mid-span ribs;

FIG. 7 is a step 2 of overall horizontal splicing of mid-span ribs;

FIG. 8 is a mid-span rib integral horizontal splicing step 3;

fig. 9 shows the overall horizontal splicing step 4 of the mid-span arch rib.

In the figure: 1. an upper suspension box; 2. a lower suspension box; 3. a web member; 4. a lower chord box bottom plate; 5. a fourth layer of web elements; 6. a top plate of the upper chord box;

a. a top chord box web element; a1, a first layer of web plate of the upper chord box; a2, a second layer of web plate of the upper chord box; a3, a third layer web plate of the upper chord box;

b. a lower chordal box web element; b1, a first layer of web plate of the lower chord box; b2, a second layer of web plate of the lower chord box; b3, a third layer web plate of the lower chord box;

c. a top and bottom plate unit of the upper chord box; c1, a first layer of upper chord box bottom plate; c2, a second layer of upper chord box bottom plate;

d. a lower chordbox top plate unit; d1, a first layer of lower chord box top plate; d2, a second layer of lower chord box top plate;

e. a web member unit; e1, a first layer web member element; e2, a second layer web member unit element;

f. lifting lugs; f1, a first layer of lifting lug plate; f2, a second layer of lifting lug plate;

g. a partition plate unit; g1, a top chord box partition board; g2, a lower chord box division plate; g3, web member spacing plates; g4, a first layer of in-box partition board; and g5, a second layer of in-box partition board.

Detailed Description

Various embodiments of the present invention are disclosed in the following drawings, in which details are set forth in the following description for the sake of clarity. However, it should be understood that these physical details should not be used to limit the invention. That is, in some embodiments of the present invention, these physical details are not necessary. Moreover, for the purpose of simplifying the drawings, some conventional structures and components are shown in the drawings in a simplified schematic manner.

In addition, the descriptions of the "first," "second," and the like, herein are for descriptive purposes only and are not intended to be specifically construed as order or sequence, nor are they intended to limit the invention solely for distinguishing between components or operations described in the same technical term, but are not to be construed as indicating or implying any relative importance or order of such features. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In addition, the technical solutions of the embodiments may be combined with each other, but it is necessary to base that the technical solutions can be realized by those skilled in the art, and when the technical solutions are contradictory or cannot be realized, the combination of the technical solutions should be considered to be absent and not within the scope of protection claimed in the present invention.

Referring to fig. 1-9, the method for manufacturing the novel large-span truss type box arch rib of the invention comprises the following steps,

s1: dividing the arch rib into a plurality of arch rib segments according to the urban road transportation capacity and the member form of the arch rib;

s2: mounting an arch rib sectional integral horizontal splicing jig frame and marking manufacturing control points;

s3: manufacturing arch rib single elements and assembling arch ribs;

s4: installing a limiting tool;

s5: welding arch ribs;

s6: installing an arch rib upper chord box top plate 6 and an arch rib lower chord box bottom plate 4 and welding;

s7: correcting and pre-assembling;

s8: hanging all the sections on the jig frame and conveying the sections to a sand blasting workshop for coating;

s9: and (5) butting the hoisting sections on site.

As a further improvement of the invention, the S1.1 long-span truss type box arch rib is a mid-span arch rib, the arc length is 187.36 meters, the large-span truss type box arch rib is divided into three hoisting sections GL1, GL2 and GL3 according to a site special construction scheme, and the GL1, GL2 and GL3 are divided into GL1A, GL1B, GL2A, GL2B, GL2C, GL2D, GL3 and A, GL B8 transportation sections in consideration of urban road transportation capacity and the structural form of the arch rib.

As a further development of the invention, S2.1: the arch rib GL1A, GL1B, GL2A, GL2B, GL C5 transportation sections are integrally matched and manufactured on one jig frame, and the arch rib GL2D, GL3A, GL B3 transportation sections are synchronously integrally matched and manufactured on the other jig frame;

s2.2: the jig frame consists of jig frame struts and an upper connecting plate and a lower connecting plate, the lower connecting plate is close to the ground, the top surface of the upper connecting plate is wholly horizontal and 60 cm away from the ground, the width of the jig frame is equal to the height of the arch rib, and 4 jig frame struts are distributed on the two outermost sides and at the positions of the arch rib upper chord box web plate single element a and the lower chord box web plate single element b, which are close to the middle connecting arch rib web members; the longitudinal positions and the intervals of the jig frame struts are arranged according to the center line of the web member;

s2.3: the manufacturing control points are divided into an assembly control point and a forming control point, the assembly state and the final forming state of the component are greatly different under the influence of welding shrinkage and thermal effect, in order to reduce the difference, the deformation of each arch rib segment after welding is calculated by combining special welding simulation model software with a welding process, and then the assembly form is optimized according to the reserved deformation; extracting a plurality of points from the middle to two ends on the top contour line of the upper chord box web plate of the arch rib and the bottom contour line of the lower chord box web plate of the arch rib of each transportation section in an assembly form according to the interval of not more than 4 meters to serve as assembly control points, wherein the forming control points are obtained by extracting a plurality of points from the positions of the two ends of the top contour line of the upper chord box web plate of the arch rib and the bottom contour line of the lower chord box web plate of the arch rib of each transportation section of the final form model, the middle and the center point of the f holes of the lifting lug to serve as forming control points;

s3.4: the assembly control point and the forming control point are driven into the ground by steel nails, and are sprayed with different colors to distinguish and mark, and the steel nails are protected.

As a further development of the invention, S3.1: the arch rib unit includes: the upper chord box web single element a and the lower chord box web single element b, the upper chord box top bottom plate unit c and the lower chord box top bottom plate unit d, the web member single element e and the partition plate unit g, wherein the second layer lower chord box web single element b2 and the third layer lower chord box web single element b3 do not comprise lifting lug f plates;

s3.2: the upper chord box web single element a, the lower chord box web single element b, the upper chord box top bottom plate unit c and the lower chord box top bottom plate unit d are manufactured according to the length of each transportation section, butt welding seams adopt CO2 gas shielded welding and submerged arc welding covers, and web member single element e welding seams adopt CO2 gas shielded automatic welding;

s3.3: in the arch rib assembling process, all the spliced weld joints are fixed by spot welding through the arc-guiding plates;

s3.4: the first-layer web plate single element a1 of the upper chord box and the first-layer web plate single element b1 of the lower chord box of all arch rib sections are placed on the jig frame by referring to the assembly control points, and the bottoms of the first-layer web plate single elements are welded and fixed with the jig frame in a discontinuous spot welding mode at the upright post of the jig frame.

S3.5: the method comprises the steps of drawing mounting lines of a first-layer upper chord box top bottom plate c1, a first-layer lower chord box top bottom plate d1 and a first-layer box inner partition plate g4 on a first-layer web plate single element a1 of an arch rib section upper chord box and a first-layer web plate single element b1 of a lower chord box, mounting according to the sequence of firstly dividing the partition plate and then the top bottom plate, and fixing by spot welding;

s3.6: the first layer web member unit element e1 of the arch rib section is installed, and spot welding is performed on the bottom surface of the web member 3 and the splicing welding seams of the upper chord box first layer web plate a1 and the lower chord box first layer web plate b1 of the arch rib section;

s3.7: the second layer web a2 of the upper chord box, the second layer web b2 of the lower chord box and the first layer lifting lug plate f1 of the arch rib section are installed by referring to the assembly control points, and spot welding is carried out on the splicing welding seam between the second layer web b2 and the top surface of the first layer web member element e 1;

s3.8: mounting lines of an upper chord box spacing plate g1, a lower chord box spacing plate g2 and a web member spacing plate g3 are drawn on an upper chord box second layer web plate a2 and a lower chord box second layer web plate b2 of the arch rib section, and are mounted and fixed by spot welding, and only one of the upper chord box spacing plate, the lower chord box spacing plate and the upper chord box double-spliced partition plate can be mounted in consideration of later welding;

s3.9: the third layer web a3 of the upper chord box, the third layer web b3 of the lower chord box, the second layer lifting lug plate f2 and the second layer web member unit element e2 of the arch rib section are installed by referring to the assembly control points, and spot welding is performed at the joint welding seam between the plates;

s3.10: the third layer web a3 of the upper chord box and the third layer web b3 of the lower chord box of the arch rib section are provided with a second layer of upper chord box bottom plate c2, a second layer of lower chord box top plate d2 and a second layer of inner baffle g5, and are arranged according to the sequence of firstly baffle and then top bottom plate and fixed by spot welding;

s3.11: with reference to the fourth layer of web elements 5 of the assembled control point installation rib segments, the overall assembly of all rib segments is completed, and the overall assembly of the rib GL1A, GL1B, GL2A, GL2B, GL C segments is consistent with the overall assembly of GL2D, GL3A, GL3B segments and will not be repeated.

As a further improvement of the invention, S4.1: welding and fixing the end face of the section and the jig frame in a discontinuous spot welding mode for multiple times by using X-shaped tools at two ends of the integral horizontal jig frame of the section, so that the end face of the section cannot be deformed in a torsion mode in the integral welding process of the section;

s4.2: a thick-wall steel pipe tool with the aperture slightly smaller than that of the hole is pinned into holes of upper and lower layers of lifting lugs f of all the sections, and the upper and lower layers of lifting lugs f are fixed into a whole, so that the whole welding process of the sections cannot be deformed in a torsion mode;

s4.3: and a limiting tool is arranged at the outer side of the horizontal spliced jig frame near the position of the forming control point to limit the expansion and deformation of the segment to the outer side in the whole welding process. The sections can shrink and deform in the welding process, and a proper iron plate is inserted into a gap between the arch rib and the limiting tool in time by referring to the forming control point, so that the sections deform to a forming state;

s4.4: and the limiting plates are arranged on the upper chord box first layer web plate a1, the lower chord box first layer web plate b1, the upper chord box third layer web plate a3 and the lower chord box third layer web plate b3 according to the position lines of the upper chord box top plate 6 and the lower chord box bottom plate 4 at intervals of not more than 1 meter, so that the displacement and deformation of the top bottom plate towards the inner side of the arch rib in the installation and welding process are limited.

As a further improvement of the present invention,

s5.1: welding vertical welding seams of all partition plate units g, the upper chord box top and bottom plate units c and the lower chord box top and bottom plate units d at the positions of lifting lugs f from the middle of arch rib sections to two ends layer by layer from bottom to top;

s5.2: welding transverse welding seams of an upper chord box web single element a, a lower chord box web single element b, an upper chord box top bottom plate unit c and a lower chord box top bottom plate unit d layer by layer from the middle of the arch rib section to two ends;

s5.3: welding transverse welding seams of all partition plate units g, the upper chord box top and bottom plate units c and the lower chord box top and bottom plate units d at the positions of lifting lug f plates from the middle of the arch rib sections to two ends layer by layer from bottom to top;

s5.4: correcting the arch rib section by taking the center forming control point of the lifting lug f as a reference;

s5.5: welding butt welding seams of the lifting lug f plate and the lower chord box web plate single element b in the step S3.1 from bottom to top,

s5.6: welding vertical welding seams of all partition plate units g at the positions of the lifting lug f plates in the S5.1 and a lower chord box top and bottom plate unit d;

s5.7: welding transverse welding seams of all partition plate units g at the positions of the lifting lug f plates in the S5.3 and a lower chord box top and bottom plate unit d;

s5.8: and carrying out nondestructive detection on all welding seams, and carrying out sand blasting and paint coating on hidden parts in the upper chord box 1 and the lower chord box 2 of the arch rib after the detection is qualified.

As a further improvement of the invention, the top plate 6 of the upper chord box of the arch rib and the bottom plate 4 of the lower chord box of the arch rib are installed and the welding process is as follows:

s6.1: sand blasting and paint coating are carried out on the arch rib upper chord box top plate 6 and the arch rib lower chord box bottom plate 4 close to the inner box side;

s6.2: the arch rib upper chord box top plate 6 and the arch rib lower chord box bottom plate 4 are installed according to the position lines and tightly support the limiting plate in the S4.4 and are fixed. Note that the top and bottom plates cannot directly fall on the first layer of web plates, but the center lines of the top and bottom plates are aligned with the center lines after molding in the vertical direction by referring to the molding control points, and a certain distance is reserved between the first layer of web plates and the fourth layer of web plates;

s6.3: welding the arch rib upper chord box top plate 6 and the arch rib lower chord box bottom plate 4 with the upper chord box second layer web a2, the lower chord box second layer web b2, the upper chord box third layer web a3 and the lower chord box third layer web b3 is completed layer by layer in the sequence from the center of the segment to the two ends, and the upper chord box top plate 6 and the lower chord box bottom plate 4 are required to be symmetrically welded;

s6.4: installing S3.8: the other one of the double-spliced partition plates between the upper chord boxes and the double-spliced partition plates between the lower chord boxes is welded;

s6.5: welding the arch rib upper chord box top plate 6, the arch rib lower chord box bottom plate 4, the upper chord box first layer web a1, the lower chord box first layer web b1 and the fourth layer web single element 5 from bottom to top in sequence from the center of the segment to the two ends;

s6.6: correcting the arch rib segments with reference to the molding control points;

s6.7: welding seams between the arch rib lifting lug f plate and the bottom plate 4 of the lower chord box and connecting seams between the web member element e and the upper chord box 1 and the lower chord box 2;

s6.8, carrying out nondestructive testing on all welding seams.

As a further improvement of the present invention,

s7.1: all limit tools are removed;

s7.2: taking the center forming control point of the lifting lug f hole of each arch rib section as a reference, and performing flame heating correction on the arch ribs by referring to the forming control point;

s7.3: correction S2.1 with reference to the molding control point: the staggered edges among all the transportation sections on the two jig frames are punched with on-site butt-joint matching sample punching points, and control sample punching points are measured;

s7.4: hoisting GL2C to S2.1 by crane: and the other jig frame is matched with GL2D, the staggered edges and the spacing between the two transportation sections are corrected by referring to the molding control points, and then the on-site butt-joint matching sample punching points are punched.

As a further improvement of the invention, the sand blasting and coating process comprises the following steps:

s8.1: all sections on the jig frame are lifted and sent to a sand blasting workshop, and a new round of arch rib assembly and manufacture are started on the jig frame

S8.2: all sections of sand blasting are sent to a coating workshop for coating after being detected to be qualified;

s8.3: all the sections are sent to a storage area for storage after being detected to be qualified.

As a further improvement of the invention, S9.1 is close to a hoisting position on site, and GL1, GL3 and GL2 vertical splicing jig frames are erected according to different arch rib hoisting sections;

and S9.2, conveying GL1A, GL1B, GL3A, GL3B, GL2A, GL2B, GL2C, GL2D to the site according to the splicing sequence, and performing site butt joint matching sample punching points according to S7.3 and S7.4 to finish butt joint welding and paint coating of GL1, GL3 and GL2 hoisting sections on the vertical splicing jig frame.

The rib needs to be deeply designed before being divided:

the deepened design basis comprises an original bridge design construction drawing, related specifications, monitoring data pre-arch data provided by third party monitoring, on-site special construction schemes, factory processing technology files, steel structure welding technology assessment files and the like;

the large-span truss type box-shaped arch rib is a mid-span arch rib, the arc length is 187.36 meters, the large-span truss type box-shaped arch rib is deeply designed to be divided into three hoisting sections GL1, GL2 and GL3 according to a site special construction scheme, and GL1, GL2 and GL3 are further divided into GL1A, GL1B, GL2A, GL2B, GL2C, GL2D, GL3A, GL B8 transportation sections in consideration of the urban road transportation capacity and the structural form of the arch rib;

under the condition of meeting the requirements of transportation, hoisting, adjustment of installation deviation and the like, the deepened design controls the number of the field welding joints as much as possible, and is designed according to the principle that the number of the field welding joints is minimum;

the deepened design utilizes professional model software to assist in design, a three-dimensional model is established, each component is accurately lofted, detailed diagrams of each component part are drawn, and the detailed diagrams are used as the basis for drawing blanking nesting diagrams and numerical control programming;

obtaining the accurate theoretical size of part blanking through deepening design, and determining the blanking process size=theoretical size, welding shrinkage and machining allowance according to the processing requirement of the component and the welding shrinkage;

the deep design installation layout comprises a series of information which is necessary for installation, such as a plane layout, a vertical layout, field splicing, welding positions, component numbers, installation directions, elevations, installation instructions and the like,

raw materials need to be fed and pretreated before rib manufacture:

all the components should be fed according to the maximum length as far as possible, the plates with the same plate thickness must be uniformly sleeved and typeset, and meanwhile, the utilization rate of the materials is paid attention to;

all the spliced welding seams should avoid the mounting position lines of the diaphragm plates, the reinforcing ribs and the like, the avoiding distance is not less than 200mm, and all the adjacent welding seams should be staggered by a distance not less than 200 mm;

the blanking cutting of the raw materials should preferably adopt numerical control, plasma, photoelectricity, automatic or semi-automatic gas cutting, so that manual cutting is reduced, all parts with curves and abnormal shapes must adopt numerical control automatic cutting, and bending is not replaced, so that manufacturing precision is ensured;

before the raw material is fed and cut, the surface of the base material should be cleaned of greasy dirt, rust and moisture; the gas cutting surface after cutting should be smooth and free of cracks, slag and splashes;

the raw materials are subjected to pretreatment after being fed and cut, shot blasting and rust removal reach the sa2.5 level, and the pretreatment is completed by spraying workshop primer.

When the present invention is used.

The foregoing description is only illustrative of the invention and is not to be construed as limiting the invention. Various modifications and variations of the present invention will be apparent to those skilled in the art. Any modification, equivalent replacement, improvement, or the like, which is within the spirit and principles of the present invention, should be included in the scope of the claims of the present invention.

Claims (10)

1. A manufacturing method of a novel large-span truss type box arch rib is characterized by comprising the following steps: comprises the following steps of the method,

s1: dividing the arch rib into a plurality of arch rib segments according to the urban road transportation capacity and the member form of the arch rib;

s2: mounting an arch rib sectional integral horizontal splicing jig frame and marking manufacturing control points;

s3: manufacturing arch rib single elements and assembling arch ribs;

s4: installing a limiting tool;

s5: welding arch ribs;

s6: installing an arch rib upper chord box top plate (6) and an arch rib lower chord box bottom plate (4) and welding;

s7: correcting and pre-assembling;

s8: hanging all the sections on the jig frame and conveying the sections to a sand blasting workshop for coating;

s9: and (5) butting the hoisting sections on site.

2. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that: s1.1, the large-span truss type box-type arch rib is a mid-span arch rib, the arc length is 187.36 meters, the large-span truss type box-type arch rib is divided into three hoisting sections GL1, GL2 and GL3 according to a site special construction scheme, and the GL1, the GL2 and the GL3 are divided into GL1A, GL1B, GL2A, GL2B, GL2C, GL2D, GL3A, GL B8 transportation sections in consideration of the urban road transportation capacity and the structural form of the arch rib.

3. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that:

s2.1: the arch rib GL1A, GL1B, GL2A, GL2B, GL C5 transportation sections are integrally matched and manufactured on one jig frame, and the arch rib GL2D, GL3A, GL B3 transportation sections are synchronously integrally matched and manufactured on the other jig frame;

s2.2: the jig frame consists of jig frame struts and an upper connecting plate and a lower connecting plate, the lower connecting plate is close to the ground, the top surface of the upper connecting plate is wholly horizontal and 60 cm away from the ground, the width of the jig frame is equal to the height of the arch rib, and 4 jig frame struts are distributed on the two outermost sides and at the positions of the arch rib upper chord box web plate single element (a) and the lower chord box web plate single element (b) which are close to the middle connecting arch rib web members; the longitudinal positions and the intervals of the jig frame struts are arranged according to the center line of the web member;

s2.3: the manufacturing control points are divided into an assembly control point and a forming control point, the assembly state and the final forming state of the component are greatly different under the influence of welding shrinkage and thermal effect, in order to reduce the difference, the deformation of each arch rib segment after welding is calculated by combining special welding simulation model software with a welding process, and then the assembly form is optimized according to the reserved deformation; extracting a plurality of points from the middle to two ends on the top contour line of the upper chord box web plate of the arch rib and the bottom contour line of the lower chord box web plate of the arch rib of each transport section in an assembly form according to the interval of not more than 4 meters as assembly control points, wherein the forming control points are formed by extracting a plurality of points from the positions of the center points of the two ends, the middle and the lifting lug (f) holes of the top contour line of the upper chord box web plate of the arch rib and the bottom contour line of the lower chord box web plate of each transport section of the final form model;

s3.4: the assembly control point and the forming control point are driven into the ground by steel nails, and are sprayed with different colors to distinguish and mark, and the steel nails are protected.

4. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that:

s3.1: the arch rib unit includes: an upper chord box web unit (a) and a lower chord box web unit (b), an upper chord box top and bottom plate unit (c) and a lower chord box top and bottom plate unit (d), a web member unit (e) and a partition plate unit (g).

S3.2: the upper chord box web single element (a), the lower chord box web single element (b), the upper chord box top and bottom plate unit (c) and the lower chord box top and bottom plate unit (d) are manufactured according to the length of each transportation section, butt welding seams adopt CO2 gas shielded welding and submerged arc welding covers, and web member single element (e) welding seams adopt CO2 gas shielded automatic welding;

s3.3: in the arch rib assembling process, all the spliced weld joints are fixed by spot welding through the arc-guiding plates;

s3.4: the first-layer web plate single element (a 1) of the upper chord box and the first-layer web plate single element (b 1) of the lower chord box of all arch rib sections are placed on the jig frame by referring to the assembly control points, and the bottoms of the arch rib sections are welded and fixed with the jig frame in a discontinuous spot welding mode at the upright post of the jig frame in a multiple-time welding mode.

S3.5: drawing mounting lines of a first-layer upper chord box top bottom plate (c 1), a first-layer lower chord box top bottom plate (d 1) and a first-layer box inner partition plate (g 4) on a first-layer web plate single element (a 1) of an arch rib section upper chord box and a first-layer web plate single element (b 1) of a lower chord box, mounting according to the sequence of the first partition plate and the top bottom plate, and fixing by spot welding;

s3.6: a first layer web member unit element (e 1) of the arch rib section is installed, and spot welding is performed on the bottom surface of the web member (3) and the splice welding seams of the upper chord box first layer web plate (a 1) and the lower chord box first layer web plate (b 1) of the arch rib section;

s3.7: installing an upper chord box second layer web plate (a 2), a lower chord box second layer web plate (b 2) and a first layer lifting lug plate (f 1) of the arch rib section by referring to the assembly control points, and spot-welding and fixing the upper chord box second layer web plate (a 2), the lower chord box second layer web plate and the first layer lifting lug plate at a splicing welding seam with the top surface of the first layer web member element (e 1);

s3.8: the method comprises the steps that mounting lines of an upper chord box partition plate (g 1), a lower chord box partition plate (g 2) and a web member partition plate (g 3) are drawn on an upper chord box second layer web plate (a 2) and a lower chord box second layer web plate (b 2) of an arch rib section, and are mounted, so that spot welding is used for fixation, and only one of the upper chord box partition plates and the lower chord box partition plates can be mounted in consideration of later welding;

s3.9: installing an upper chord box third layer web plate (a 3), a lower chord box third layer web plate (b 3), a second layer lifting lug plate (f 2) and a second layer web member single element (e 2) of the arch rib section by referring to the assembly control points, and spot-welding and fixing at a splicing welding seam between the plates;

s3.10: drawing mounting lines of a second-layer upper chord box bottom plate (c 2), a second-layer lower chord box top plate (d 2) and a second-layer box inner partition plate (g 5) on a third-layer web plate (a 3) of the upper chord box of the arch rib section and a third-layer web plate (b 3) of the lower chord box, mounting according to the sequence of firstly the partition plates and then the top bottom plate, and fixing by spot welding;

s3.11: with reference to the fourth layer of web elements (5) of the assembled control point mounting rib segments, the overall assembly of all rib segments is completed, and the overall assembly of the rib GL1A, GL1B, GL2A, GL2B, GL C segments is consistent with the overall assembly of GL2D, GL3A, GL3B segments and will not be repeated.

5. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that:

s4.1: welding and fixing the end face of the section and the jig frame in a discontinuous spot welding mode for multiple times by using X-shaped tools at two ends of the integral horizontal jig frame of the section, so that the end face of the section cannot be deformed in a torsion mode in the integral welding process of the section;

s4.2: a thick-wall steel pipe tool with the aperture slightly smaller than 2mm is pinned into holes of upper and lower layer lifting lugs (f) of all the section lifting lugs (f), and the upper and lower layer lifting lugs (f) are fixed into a whole, so that the whole welding process of the sections cannot be deformed in a torsion mode;

s4.3: and a limiting tool is arranged at the outer side of the horizontal spliced jig frame near the position of the forming control point to limit the expansion and deformation of the segment to the outer side in the whole welding process. The sections can shrink and deform in the welding process, and a proper iron plate is inserted into a gap between the arch rib and the limiting tool in time by referring to the forming control point, so that the sections deform to a forming state;

s4.4: and (3) referring to position lines of an upper chord box top plate (6) and a lower chord box bottom plate (4) on the upper chord box first layer web (a 1), the lower chord box first layer web (b 1), the upper chord box third layer web (a 3) and the lower chord box third layer web (b 3), installing limiting plates according to a distance of not more than 1 meter, and limiting the displacement and deformation of the top bottom plate towards the inner side of the arch rib in the installation and welding process.

6. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that:

s5.1: all baffle units (g) except for the lifting lug (f) are welded with vertical welding seams of the upper chord box top bottom plate unit (c) and the lower chord box top bottom plate unit (d) layer by layer from the middle of the arch rib section to two ends;

s5.2: welding transverse welding seams of the upper chord box web single element (a), the lower chord box web single element (b), the upper chord box top and bottom plate unit (c) and the lower chord box top and bottom plate unit (d) layer by layer from the middle of the arch rib section to two ends;

s5.3: welding transverse welding seams between all baffle units (g) at the positions of lifting lug (f) plates, an upper chord box top bottom plate unit (c) and a lower chord box top bottom plate unit (d) from the middle of the arch rib section to two ends layer by layer from bottom to top;

s5.4: correcting the arch rib section by taking the central forming control point of the lifting lug (f) as a reference;

s5.5: butt welding seams of the lifting lug (f) plate and the lower chord box web plate single element (b) in the S3.1 are welded layer by layer from bottom to top,

s5.6: welding vertical welding seams of all baffle units (g) at the positions of the lifting lugs (f) and the lower chord box top and bottom plate units (d) in the S5.1;

s5.7: welding transverse welding seams of all baffle plate units (g) at the positions of the lifting lugs (f) and the lower chord box top and bottom plate units (d) in the S5.3;

s5.8: and carrying out nondestructive detection on all welding seams, and carrying out sand blasting and paint coating on hidden parts in the upper chord box (1) and the lower chord box (2) of the arch rib after the detection is qualified.

7. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that: the top plate (6) of the upper chord box of the installation arch rib and the bottom plate (4) of the lower chord box of the arch rib and the welding process are as follows:

s6.1: sand blasting and paint coating are carried out on the arch rib upper chord box top plate (6) and the arch rib lower chord box bottom plate (4) close to the inner box side;

s6.2: installing and tightly jacking the limiting plate in S4.4 according to the position lines of the arch rib upper chord box top plate (6) and the arch rib lower chord box bottom plate (4);

s6.3: welding the arch rib upper chord box top plate (6) and the arch rib lower chord box bottom plate (4) with the upper chord box second layer web plate (a 2), the lower chord box second layer web plate (b 2), the upper chord box third layer web plate (a 3) and the lower chord box third layer web plate (b 3) layer by layer in the sequence from the center of the segment to the two ends, and paying attention that the upper chord box top plate (6) and the lower chord box bottom plate (4) must be symmetrically welded;

s6.4: installing S3.8: the other one of the double-spliced partition plates between the upper chord boxes and the double-spliced partition plates between the lower chord boxes is welded;

s6.5: welding the arch rib upper chord box top plate (6) and the arch rib lower chord box bottom plate (4) with the upper chord box first layer web (a 1), the lower chord box first layer web (b 1) and the fourth layer web single element (5) is finished layer by layer from the center of the segment to the two ends;

s6.6: correcting the arch rib segments with reference to the molding control points;

s6.7: welding seams between the arch rib lifting lug (f) plate and the bottom plate (4) of the lower chord box and connecting seams between the web member single element (e) and the upper chord box (1) and the lower chord box (2);

s6.8, carrying out nondestructive testing on all welding seams.

8. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that:

s7.1: all limit tools are removed;

s7.2: taking the center forming control point of the lifting lug (f) hole of each arch rib section as a reference, and performing flame heating correction on the arch ribs by referring to the forming control point;

s7.3: correction S2.1 with reference to the molding control point: the staggered edges among all the transportation sections on the two jig frames are punched with on-site butt-joint matching sample punching points, and control sample punching points are measured;

s7.4: hoisting GL2C to S2.1 by crane: and the other jig frame is matched with GL2D, the staggered edges and the spacing between the two transportation sections are corrected by referring to the molding control points, and then the on-site butt-joint matching sample punching points are punched.

9. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that: the sand blasting and coating process comprises the following steps:

s8.1: all sections on the jig frame are lifted and sent to a sand blasting workshop, and a new round of arch rib assembly and manufacture are started on the jig frame

S8.2: all sections of sand blasting are sent to a coating workshop for coating after being detected to be qualified;

s8.3: all the sections are sent to a storage area for storage after being detected to be qualified.

10. The method for manufacturing the novel large-span truss type box arch rib according to claim 1, which is characterized in that:

s9.1, approaching to the hoisting position on site, and erecting GL1, GL3 and GL2 vertical splicing jig frames according to different arch rib hoisting sections;

and S9.2, conveying GL1A, GL1B, GL3A, GL3B, GL2A, GL2B, GL2C, GL2D to the site according to the splicing sequence, and performing site butt joint matching sample punching points according to S7.3 and S7.4 to finish butt joint welding and paint coating of GL1, GL3 and GL2 hoisting sections on the vertical splicing jig frame.