JPH1077609A - Steel member manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To ensure precision same as in the case where temporary assembly is executed and to eliminate a temporary assembly work by a method wherein verification of an assembly shape is performed without actual temporary assembly of manufactured steel bridge members and under the condition that the manufacture error of the member is managed within a specified value. SOLUTION: Manufacture of individual members, such as a main girder and a horizontal girder, includes a proceeding works and steps, such as assembly and a welding, and main constituting members necessary to an object steel bridge, in which a plurality of site joint bolt holes are formed, are manufactured with machining precision within an allowance preset at an NC full size system. The size of each part of an individual member is measured and a measuring result is inputted to a temporary assembly simulation system by a computer When the size and the shape of each part of each manufactured member are confirmed, virtual temporary assembly is effected by computer simulation displaying as 'member assembly', and a shape and a size at a manufacture completion stage and propriety of a joining state between members are confirmed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a main member such as a main girder, a cross girder and an inclined structure for forming a steel bridge, and an additional plate used for joining each main member at an erection site. The present invention relates to a method of manufacturing an assembly member such as a lower lateral groove member at a factory.

[0002]

2. Description of the Related Art Conventionally, a main girder for forming a steel bridge,
The main structural members such as the horizontal girder and the inclined structure and the assembling members such as the auxiliary plate and the lower horizontal groove member used for joining the main structural members at the erection site are manufactured in advance at the factory and then carried into the erection site. Erected by on-site assembly work. In the production of steel bridge members in factories, tentative labor savings have been achieved with advances in design technology using CAD / CAM and the spread of NC machine tools and welding robots. Prior to transporting the equipment to the construction site, temporary assembly work for temporarily assembling and inspecting and confirming each member in the factory yard is still performed, and this temporary assembly work requires many man-hours and personnel. I have.

[0003] The purpose of the temporary assembly is to confirm the joining state between the members, confirm the shape and dimensions at the stage of completing the production, confirm the attachment state of accessories, and confirm the erection procedure. The members are temporarily assembled and inspected and checked in the factory yard before the products are carried out to the construction site, and then disassembled and packed again, and shipped to the construction site.

[0004]

The existence of a temporary assembly process in the manufacture of steel bridge members requires special work costs in terms of man-hours, personnel, site, equipment, safety measures, etc., and is required to be carried out to the erection site. In addition to the need for a long-term process, members must be manufactured according to the process schedule that matches the temporary assembly, which is not suitable for split production with high manufacturing efficiency. Have been pointed out as inconvenient.

Therefore, in the present invention, the temporary assembly is performed by verifying the assembly shape under the condition that the manufacturing error of the member is controlled within a certain value without actually assembling the manufactured steel bridge member. An object of the present invention is to provide a method capable of guaranteeing the same accuracy as in the case, that is, a method of manufacturing a steel bridge member capable of omitting a conventional temporary assembly operation.

[0006]

According to a first aspect of the present invention, there is provided a method of manufacturing a steel bridge member, comprising: a main girder, a cross girder, and an inclined structure for forming a steel bridge; This is a method of manufacturing an assembly member such as an additional plate and a lower lateral groove member provided for joining members at a factory. In order to solve the above-described problem, a processing accuracy within an allowable error value based on member design data is used. A step of manufacturing each main component having a plurality of on-site joint bolt holes, a step of measuring the position dimensions of each part of each manufactured main component, and each main configuration using measurement data obtained by the measurement. A step of executing a tentative assembly simulation on a computer with a target of design data of a member to obtain a position of each part necessary for obtaining an appropriate assembling shape satisfying a predetermined tentative assembling accuracy and an adjustment amount for shape correction processing. A step of calculating processing information of each assembly member to give an appropriate assembly shape according to the obtained adjustment amount; and a step of performing post-processing such as drilling on each assembly member according to the calculated processing information. Have.

In the method for manufacturing a steel bridge member according to the second aspect of the present invention, in the step of manufacturing each main component in the above method, the partial positional dimension of each main component is measured, and the result of comparison with the design value is determined. Perform corrective finishing based on

In the present invention, based on member design data provided from a computer-aided design drafting system and a production information system (including a full-scale unfolding system and an automatic full-scale system), a plurality of sites are formed by NC machining work and assembly welding work. From the stage of manufacturing each main component having a joint bolt hole, it is basically to manage the production and assembly of the parts of each main component within the processing accuracy within a predetermined error tolerance. Set a target value for error tolerance, measure the partial position and dimensions of each major component, compare it with the design value, and determine if there is an error within the tolerance (for example, about ± 3 mm). It is determined whether or not it is within. If it is determined that the value is outside the allowable value (so-called error), correction or re-creation is performed at that location.

If it is confirmed that the value is within the allowable range, the positional dimensions of each part of each of the main constituent members manufactured by the assembly are measured, and a temporary assembly simulation targeting design data is made using the measured data. Run on,
The shape and dimensions at the stage of completion of production and the quality of the joint between the main components are checked. At this time, if the provisional assembly accuracy is not satisfied, the assembly shape is adjusted by adjusting the distance between the bolt holes of the on-site joint portion in a simulation operation. Then, the result of adjustment of the assembly shape and post-processing information (such as the adjustment amount of the distance between the bolt holes) for post-processing of the assembly member such as the attachment plate and the lower lateral groove are calculated. Post-processing such as drilling is performed, and a printout of the adjustment information is attached as construction information as needed when being carried out (shipped) to the hypothetical site.

As described above, according to the present invention, it is possible to verify the assembled shape under the condition that the manufacturing error of the member is controlled within a certain value without actually assembling the manufactured steel bridge member. Accuracy equivalent to that in the case of temporary assembly can be guaranteed.

[0011]

FIG. 1 shows a basic flow of manufacturing a steel bridge member according to the present invention. As shown, the main girder, horizontal girder,
The manufacture of individual members such as a tilted structure includes the steps of drilling a hole, assembling and welding. In the pre-drilling, based on the member design data previously stored in the NC full-scale system by the computer, the main parts of the main girder, such as the NC marking of the flange and the web, the NC cutting, the NC drilling work, and the auxiliary parts of the main girder The stiffener, gusset, and cross-girder connections are manually marked, cut, and drilled, and the horizontal spar and inclined work are manually marked, cut, and drilled. The processing is performed with the processing accuracy within the error tolerance. The parts after the pre-hole processing are individually assembled in the following assembling / welding process. For example, as for the main girder, the processed flange and the web are assembled into an I-shape and welded, and the processed auxiliary parts such as stiffeners, gussets, and horizontal girder connections are assembled and welded. In each of these pre-drilling and assembling / welding processes, the position dimensions of each part of the member are measured and inspected with a steel tape measure, etc. at the break of each work process, and the result is compared with the above-mentioned member design data. Then, correction processing, corrective finishing of welding, or reworking is performed according to the determination result, and the member is finished as a member having a processing accuracy within a preset allowable error value. In this way, the main structural members having a plurality of bolts at the site joint, such as the main girder, the cross girder, and the inclined structure required for the target steel bridge, are manufactured with a processing accuracy within an allowable error value.

In the past, the accuracy of the dimensions and the shape of each part of each manufactured member was confirmed by actually temporarily assembling each member.
In the present invention, this temporary assembly is virtually performed by computer simulation shown as "member assembly" in FIG. Therefore, in the method according to the present invention, in order to confirm the accuracy of each manufactured member, the dimensions of each part of the individual member are measured, and the result is taken into a temporary assembly simulation system using a computer.

For the measurement of the members, two-dimensional measurement in which the partial dimensions (flange width, misalignment, etc.) in the above-mentioned manufacturing process are measured with a measuring instrument such as a steel tape measure or a caliper, and individual manufactured main components are measured. There is three-dimensional measurement in which the relative positions of the ends and bolt holes of the constituent members are measured by a three-dimensional measuring device. Calculate each position dimension from the measurement data obtained by these measurements, compare it with the design data, determine whether the error is within a certain tolerance (for example, ± 3 mm), and correct the member. In addition, the determination as to whether or not straightening and reworking is possible is performed, and the measurement data and calculation data are also used for virtual temporary assembly in a temporary assembly simulation.

For the three-dimensional measurement, for example, a three-dimensional measurement system including an optical remote observation system such as a three-dimensional measurement system “MONMOS” manufactured by Sokia Corporation and a measurement data processing system can be used. It should be noted that such a three-dimensional measurement system can provide a measurement result with sufficient accuracy compared to a steel tape measure used for measurement during the conventional temporary assembly work, and that the measurement accuracy is sufficiently reliable. I can say. In addition, there is almost no variation in measurement accuracy due to the difference of the measurers, and no special training is required.However, measurement is performed indoors because variations in the surface temperature distribution of members due to direct sunlight and temperature changes over time occur. It is desirable.

When three-dimensionally measuring the main girder member, it is desirable to place the member vertically in consideration of workability and to use a restraint gantry in order to eliminate the influence of bending due to its own weight.
In addition, it is desirable to measure the bolt holes using a collimating target adapted as a measuring aid in order to correctly grasp the position. Figure 2 shows the flow of component measurement
Shown in Table 1 shows an example of the measurement items and the like in the measurement of each part with respect to the main girder, the horizontal girder, and the inclined structure.

[0016]

[Table 1]

The temporary assembly simulation shown as "member assembly" in FIG. 1 is performed according to the procedure shown in FIG. 3, and a three-dimensional CAD system can be used for this simulation system. That is, the three-dimensional measurement coordinate value and the design coordinate value (N
A temporary assembling simulation is performed based on the data created from the C full-scale system, which is the target of the assembling shape in the simulation), and the shape and dimensions at the stage of completion of production and the quality of the joint between the members are confirmed. Items to be checked are, for example, the total length of the steel bridge, span length, diagonal length of the plane,
As in the case of the main girder, the warp of the girder, the verticality of the main girder, the center-to-center distance of the main girder, the clearance of the joint at the site, the position of the sole plate, and the like. When the temporary assembly accuracy set in advance in the NC full-scale system is not satisfied at the time of this quality check, camber,
The assembling shape is adjusted by adjusting the distance between the bolt holes of the on-site joint until the tentative assembly accuracy is satisfied. Ultimately, the following information is provided for the actual assembly: Adjustment results of shape and dimensions at the stage of completion of production Amount of adjustment of distance between bolt holes in joints on site Attachment plate and lower horizontal groove machining accuracy (drilling) In order to make adjustments in the simulation effective,・ For the lower horizontal groove, secondary processing (drilling) is performed based on the distance between the bolt holes adjusted here. Of course, it goes without saying that the accuracy of the additional plate and the lower lateral groove processed in this way is measured with a steel tape measure or a vernier caliper, and the measurement data is attached to work materials on the site.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Table 2 shows a list of constructions to which a temporary assembly simulation was actually applied according to the present invention.

[0019]

[Table 2]

In the tentative assembly simulation, the assembly shape is determined with the aim of the assembly shape at the time of design so as not to cause a hole displacement in the bolt hole of the member connecting portion of the measurement data.
If the temporary assembly accuracy is not satisfied as described above, it is necessary to adjust the assembly shape. At this time, as shown in FIG. 4, Lu and Lb are given to the distance between the bolt holes of each joint at the site, and the camber, the span length, the gap at the joint at the site and the like are adjusted by adjusting Lu and Lb. In the first simulation before adjustment, design dimensions are given to Lu and Lb.

FIGS. 5 to 7 show the results of adjusting the assembling shape by the tentative assembling simulation on the bridge C in Table 1. FIG. From these, the following results were obtained as the assembled shape before adjustment. The span length error was almost positive, but some negative error occurred. (D in FIG. 5). The camber error showed a negative tendency as a whole, and in some cases exceeded the allowable value (indicated by a square in FIG. 6). The clearance of the joint at the site is within a tolerance of 5 mm for a design value of 10 mm (FIG. 7 (a)).

Therefore, the following adjustment was made for Bridge C. G1 to G3 with camber error increased to minus
For G6, the camber error was adjusted in the positive direction by setting the distance Lu between bolt holes (FIG. 4) to about 1 mm larger than the design dimension at some field joints. The bolt-to-bolt distances Lu and Lb (FIG. 4) were adjusted at each field joint so that the girder warping shapes of all the main girders matched. Simulation results in the case where the temporary assembly accuracy is ensured by performing the adjustment as described above are shown by the circles in FIGS. 5 and 6.

The tentative assembly accuracy (simulated predicted value) in the tentatively assembled ready-made form of the simulation result obtained in this way was compared with the actually measured value obtained by actually performing the tentative assembly for the C bridge in Table 1. However, the following results were obtained. (1) Strut length Fig. 8 shows the comparison result of span length error. As a result, the simulation prediction value and the temporary assembly actual measurement value have a good error tendency as a whole, and all the errors are less than ± 2.6 mm, which sufficiently satisfies the allowable error (± 13 mm). Also,
When the errors were compared with each other, the maximum relative difference was 1.6 mm (G1). (2) Camber Fig. 9 shows the comparison result of camber error. Here also, the error between the simulation predicted value and the tentatively-assembled actually measured value is in good agreement with each other in the range of -3.0 mm to +4.0 mm.
The maximum relative difference was 4.8 mm (for G1), averaging -0.9 mm.

From the above, there is no significant difference between the simulation predicted value and the temporary assembly actual measured value. In addition, as a result of examining inspection items for provisional assembly accuracy, such as entry and exit at the end of the girder, all items were in good agreement.

Tables 3 and 4 show the results of a comparison of the completed shapes of the single-girder bridges A to I shown in Table 2 between the simulated assembly simulation and the actual tentative assembly and erection for the span length and camber. . As can be seen from the relative differences between the simulation prediction values shown in these tables and the actual measured values during temporary assembly or installation, the results obtained by simulation are faithfully reflected even during temporary assembly or installation. I have.

[0026]

[Table 3]

[0027]

[Table 4]

In the embodiment described above, the standard I
Although the case where the present invention is applied to a girder bridge is illustrated, it is needless to say that the present invention is applicable to steel bridges having various girder structures such as a box girder bridge.

[0029]

As described above, according to the present invention,
The actual work of temporary assembly in steel bridge production can be omitted, and therefore the actual work of temporary assembly (man-hours, site, equipment,
Safety measures, etc.), as well as shortening the manufacturing process and split production, improving production capacity and enabling just-in-time production in line with the transport process.
Since an efficient production plan can be achieved, remarkable effects can be obtained, such as production can be performed on a minimum site (temporary placement, painting, etc.).

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing a basic flow of manufacturing a steel bridge member according to the present invention.

FIG. 2 is an explanatory diagram illustrating a flow of member measurement.

FIG. 3 is a flowchart showing a procedure of a temporary assembly simulation.

FIG. 4 is a side view of an I-girder joint illustrating an adjustment position of a temporary assembly shape.

FIG. 5 is a diagram showing measurement results of span length errors before and after adjustment of the assembly shape, in which the horizontal axis represents the digit number and the vertical axis represents the error (mm).

FIG. 6 is a diagram showing a measurement result of a camber error before and after adjustment of an assembling shape of each girder, in which a horizontal axis represents a measurement position and a vertical axis represents an error (mm).

FIG. 7 is an explanatory diagram showing measurement results of field joint errors before and after assembly shape adjustment at two joint portions J1 and J2 in the girder G3.

FIG. 8 is a diagram showing a comparison of a span length error between the temporary assembly simulation result and the actual temporary assembly actual measurement value, wherein the horizontal axis represents the digit number and the vertical axis represents the error (mm).

FIG. 9 is a diagram showing a comparison of the camber error between the tentative assembly simulation result of each digit and the actual tentative assembly actual measurement value. The horizontal axis represents the measurement position, and the vertical axis represents the error (mm).

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hiroshi Kudo 17 Nishiminato-cho, Tadotsu-cho, Tadotsu-gun, Nakatado-gun, Kagawa Pref.

Claims (2)

[Claims] 1. Assembly of main structural members such as a main girder, a cross girder, and an inclined structure for forming a steel bridge, and an additional plate and a lower horizontal groove member used for joining each main structural member at an erection site. A method of manufacturing a member at a factory, comprising: a step of manufacturing each main component having a plurality of on-site joint bolt holes with a processing accuracy within an error tolerance based on member design data; and a process of manufacturing each main component. The step of measuring the positional dimensions of each part and the provisional assembly simulation which targets the design data of each main component using the measurement data obtained by the measurement are executed on the computer, and the predetermined temporary assembly accuracy is satisfied. A step of calculating an adjustment amount for the position and shape correction processing of each part necessary to obtain an assembly shape; and a step of calculating processing information of each assembly member to give an appropriate assembly shape according to the obtained adjustment amount. , Arithmetic Subjecting each assembly member to post-processing such as drilling in accordance with the processing information output. 2. The method according to claim 1, wherein in the step of manufacturing each main component, a partial positional dimension of each main component is measured, and a corrective finish is performed based on a result of comparison with a design value. 2. The method for manufacturing a steel bridge member according to 1.