RU2805726C1 - Method for manufacturing block module - Google Patents

Abstract

FIELD: welding.

SUBSTANCE: manufacture of frame products by welding. The parts of the block module are assembled using a guide, which is made in the form of a rectangular beam structure. The stops are mounted in the corners of the guide on the outside, and on its beams on the inside. The clamps are located in the corners of the guide on the inside, and on its beams on the outside. First, the parts of the frame corners are secured using clamps on the inside of the guide corners. The parts of the long sides of the frame are secured with clamps to the corresponding stops of the guide. Weld the cross members. After securing the frame in the guide, 50 to 70 percent of the welds connecting the corner parts and the frame side parts are formed, and the frame is left in the guide for 15 to 45 minutes to cool. Remove the frame from the guide and weld the remaining seams. Then the frames are welded with racks and the internal space of the block module is formed using wall panels, windows and doors.

EFFECT: increasing the accuracy of the geometric parameters of the manufactured block module.

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Description

Field of technology to which the solution relates

The solution relates to the field of methods for manufacturing frame products by welding, in particular, to a method for manufacturing a block module.

State of the art

There is a known method for manufacturing a steel axisymmetric welded structure (RU2626116C1, publ. 2017.07.21). The known invention relates to the field of manufacturing welded steel vessels operating under high pressure. The welded structure contains an end base, a central tubular element in the form of a thin-walled glass and a thin-walled shell with a thickened bottom. A central tubular element is made from a circle of sheet steel by drawing in several steps with intermediate recrystallization annealing. Next, it is distributed to obtain the end thickening. Weldable edges are formed for welding the base and thin-walled shell. In this case, a thin-walled shell with a thickened bottom is obtained by extruding the bottom part from the circle and drawing with wall thinning in several transitions with intermediate recrystallization annealing, the end part of the shell is calibrated and a welded edge is formed by mechanical processing. The end base is made from a pipe blank, welded to the tubular element and pneumatic tests are carried out. The high dimensional accuracy and reliability of the welded vessel body increases.

However, in this solution a different design is made and a jig is not used, which impairs the manufacturing accuracy.

There is a known method for manufacturing a steel complex-combined axisymmetric welded structure operating under pressure (RU2449870C1, publ. 2012.05.10). The known invention relates to a method for manufacturing a steel complex-combined axisymmetric welded structure operating under pressure, containing a thin-walled shell, end bases, a central tubular element and a tubular jumper. A thin-walled tubular shell is produced by thermomechanical processing from a pipe blank. The welding edges of the tubular element elements are formed for the locking connection. They are assembled into subassemblies by means of a locking connection and the elements of the subassemblies and subassemblies are welded together using circumferential seams to form a tubular element. Pneumatic testing of the tightness of the resulting seams is carried out. The seams are made using a non-consumable electrode using automatic argon arc welding in several passes with the supply of filler material in the second pass at a current strength of 42...45 A per 1 mm of wall thickness and a welding speed of 12...15 m/h. One of the end bases is welded to the tubular element, after which the resulting subassembly is welded to the second end base. A thin-walled shell is welded to the bases. A tubular jumper is welded to the end bases using manual arc welding. Mechanical processing and pneumatic testing of the tightness of welds with internal pressure (0.3+0.5) MPa is carried out. The result is high-quality welded joints.

However, in this solution a different design is made and a jig is not used, which impairs the manufacturing accuracy.

A known method for manufacturing a block module, selected as a prototype, is known (SU1105370A1, publ. 1984.07.30), in which the elements of the block module body are assembled together, for example, in the form of two horizontal decks and four vertical bulkheads on hinges. Decks and bulkheads are folded on hinges into a three-dimensional structure, the joining edges of decks and bulkheads are adjusted, bases are coordinated and equipment installation locations are marked. Then the decks and bulkheads are laid out on a horizontal stand-bed, the equipment is installed on them and verified against the local bases of each element of the block-module hull, and the latter is secured to the decks and bulkheads. When installing, aligning and fastening equipment, mechanization tools are widely used. Next, the decks and bulkheads are hinged into a three-dimensional structure and fastened together, for example, by welding. The design of the block module consists of hull elements, for example, in the form of decks and bulkheads, connected to each other by means of hinges.

However, in this solution a different design is made, a different conductor is used, which makes it impossible to use the approach described in the prototype in the claimed solution.

Disclosure of the Invention

In one aspect of the invention, a method for manufacturing a block module is disclosed, comprising the steps of:

- manufacture parts of the block module;

- assemble the block module using a conductor;

characterized by the fact that

block module parts are made through bending operations from metal sheets pre-cut to size,

the block module consists of an upper frame, a lower frame, racks, the upper frame and lower frame consist of corner parts and side parts,

the upper frame, which is a steel rectangle, is welded using a jig,

in this case, the parts of the corners of the upper frame are secured to the jig from below in the inner corners and from above on the corresponding protrusions of the jig on its sides using clamps,

in this case, the parts of the long sides of the frame are secured from below to the corresponding protrusions of the jig using clamps, and the required distance between the parts of the long sides is ensured from above using a spacer, after the parts of the sides are welded,

provide additional rigidity to the frame using a cross member, welding it in the middle of the frame along the long side,

in this case, after fixing the frame in the jig, from 50 to 70 percent of the welds connecting the parts of the corners and the parts of the sides of the frame are formed, the frame is left in the jig for a period of 15 to 45 minutes to cool, then the frame is removed from the jig and the remaining seams are welded,

the lower frame is made in a similar way,

then the frames and racks of the block module are cleaned and prepared for painting, they are painted, the frames are filled with fillers, the frames and racks are welded, and the internal space of the block module is formed using wall panels, windows and doors.

In additional aspects, it is disclosed that before welding, the diagonal size of the frame is 1-2 mm larger than specified in the technical documentation; strengthen the welded joint of the long sides by welding an additional reinforcing element on top of the weld.

A block module is a structure consisting of a metal frame and enclosing elements, having a closed internal space of a small area, suitable for use for domestic and industrial purposes. The developed jig is used to manufacture the upper and lower frames of block modules. These frames are a rectangular welded structure, which is subject to fairly high requirements in terms of geometric and strength parameters.

Block module parts are metal products manufactured through bending operations that must be welded to each other. To improve the accuracy of the geometric parameters of the block module, the claimed solution uses a conductor.

The main objective of the claimed solution is to produce a block module with precise dimensions.

The essence of the solution is that the frame parts of the block module are made through bending operations, these elements are welded using a jig according to the developed technology, then the internal space of the block module is formed, walls, doors and windows are mounted, thus obtaining a finished block module.

The technical result achieved by the solution is to increase the accuracy of the geometric parameters of the manufactured block module.

Brief description of drawings

Fig. 1 shows a top view of the conductor.

Fig. 2 shows a top view of the assembled frame.

Figure 3 shows exemplary profiles of frame parts.

FIG. 4 shows a block diagram framework.

FIG. 5 shows a block diagram of a manufacturing sequence of a block module.

Carrying out the invention

The proposed conductor is shown in figure 1, in which

101 – conductor,

102 – protrusions for securing parts of the block module frame in the conductor,

103 – clamps.

The jig 101 is a welded rectangular structure of two long and two short beams, on which projections 102 (essentially metal plates protruding from the beams) and clamps 103 are installed at predetermined locations.

The frame manufactured using a jig is shown in Fig. 2, in which

201 – details of frame corners,

202 – details of the short sides of the frame,

203 – details of the long sides of the frame,

204 – cross members.

The manufactured frame consists of corner parts 201, side parts 202, 203 and cross members 204, connected to each other by welding. Parts 201, 202, 203, 204 have a complex shape, which is determined by the requirements for the strength of the frame, the requirements for the further connection of the frame with other elements of the block module. The specific shape of the mentioned parts is not a limiting feature, since it can vary depending on the characteristics of the block module. It remains essential that the frame consists of corner parts 201, side parts 202, 203 and cross members 204, which are made of sheets of metal, sections of which are bent so as to have an L-shaped, U-shaped or other necessary shape. The number of bends and their geometric parameters are determined by the requirements for the block module, which does not relate to the essence of the claimed solution. An exemplary profile of parts 201, 202, 203, 204 is shown in FIG. 3. Number and locations of folds, geometric relationships, etc. may change, which does not relate to the essence of the stated solution.

Preferably, the frame consists of four corner pieces 201, two short side pieces 202, and six long side pieces 203. In this case, the frame dimensions are 244 by 615 cm. Parts 203 are made of the same length for unification. The number of parts 203 on the side - 3 is selected based on the possibilities of their production, taking into account the maximum length limitation.

Essential in the stated solution is the use not of pipes with a rectangular profile, but of parts made of steel sheets bent in a certain way. Parts made in this way, as a rule, have more precise geometric parameters (they are manufactured more accurately initially and do not deform during transportation and storage), while certain conditions must be met so that long parts do not deform when they are secured in the jig or during welding.

For accurate assembly of the frame, parts 201-204 must be securely fixed in place in the jig. To secure the parts 201, vertical projections 102 are made on the outer corners of the conductor 101. These vertical projections 102 can be made in the form of rectangular pipes welded to the conductor 101, or an angle welded to the conductor 101.

On the long and optionally on the short sides of the jig 101 there are horizontal projections 102, which can be made in the form of a rectangular pipe or an angle welded to the jig 101.

To accurately and reliably fix frame parts, it is necessary to use vertical protrusions in the corners, and horizontal protrusions on the sides.

To increase reliability, the protrusions of the short and long sides can be connected to each other by an angle welded to them and to the jig 101.

At the inner corners of the jig 101, clamps are installed that clamp the lower part of the part 201, exerting pressure on the inner corner of the part 201. Preferably, these clamps are screw clamps, since they are the most reliable in operation, however, options with other clamps known from the prior art are also possible . In order for the clamp to clamp the part 201 more accurately and reliably, a rectangular adapter is provided, which ensures uniform pressing of the entire inner corner of the part 201 to the outer protrusion of the jig 101.

The top of the parts 201 is pressed against the projections using two external clamps (screw clamps, mechanical clamps, pneumatic clamps). That is, part 201 is pressed at three points: at the bottom corner and at the top edges.

In order to increase the reliability of clamping by the external clamp, at the point of contact with the external clamp, the protrusions contain anti-friction sections, these can be notches, points, anti-friction linings attached to the protrusion.

An option is possible with upper clamps attached to the protrusions; in this option, they are placed on part 201 after its installation; this option complicates the design of the jig, but increases the speed of manufacturing the frame. Above and further, when we talk about one element, it is assumed that the same element is used in other identical sections of the conductor.

It is possible to fix part 201 only with the lower clamp, but it is preferable to use the upper clamps as well.

The block module contains an upper and lower frame, which are identical in design, therefore, unless specifically indicated, “frame” should be understood as any frame (upper or lower).

To secure the parts 203, the jig 101 on the inner sides of the long beams contains protrusions 102, which limit the movement of the parts 203 inside the jig 101, and on the outer sides of the long beams, the jig 101 contains clamps 103. Preferably, the clamps 103 are made in the form of screw clamps, but an option in the form pneumatic clamps. The clamps 103 are located opposite the projections 102 and at the same vertical level with them, which is necessary in order not to tilt the part 203 and to accurately fix it.

It is preferable to place the clamps 103 on the outside, since access to the screw clamps located on the inside is difficult. If the screw clamps were located internally, the worker would not be able to securely fix the part as if they were located externally.

Part 202, as a rule, does not require clamping, however, for greater reliability of fastening, protrusions 102 can be installed on the inner sides of the short beams, and clamps 103 can be installed on the outer sides.

After parts 201-204 are installed, clamped in the required positions and welded, a spacer is installed on top in the middle of the long side of the frame, which increases the accuracy of the block module assembly. Next, the main seams are welded (between parts 201, 202, 203, 204), welding is carried out at 50-70% of the length of the seams. The frame is kept in the conductor 101 for 15-45 minutes to cool the metal. This is necessary to relieve residual stresses and deformations that may occur in parts made from sheets 201-203. After the metal has cooled, the frame is released from the jig 101 and moved to a free place for final welding. Next, the remaining 30-50% of the seams are welded.

The crossmembers 204 are welded after the spacer is installed to ensure high precision assembly, then a longitudinal brace is welded on top of the crossmembers, which runs parallel to the long sides of the frame in the middle and provides additional rigidity and, as a result, dimensional accuracy of the frame.

Specific geometric parameters of the frame elements and steel grade are not disclosed in this description, since this does not relate to the essence of the solution. The length, width, thickness, profile shape and steel grade of all frame components are selected at the block module design stage, based on the requirements placed on it.

When manufacturing the frame, ensure its diagonal size is 1-2 mm larger than specified in the technical documentation, since during welding the manufactured frame is reduced.

To ensure increased strength of the seams of parts 203, their joints are strengthened by welding an additional element in the form of a sheet of metal over the weld; this element also prevents deformation and, therefore, helps maintain the geometric parameters of the frame.

All elements of the claimed solution are connected to each other through assembly operations so as to ensure structural and functional unity. Welding is preferably used to connect the elements to each other. Unless specifically stated, the specific type of connection is not essential to the stated solution.

The conductor is produced at the manufacturing plant and delivered to the place of use, taking into account the specifics of its application; the manufacturing plant and the place of use can be one object.

Description of the block module production process

The conductor is manufactured as follows (Fig. 5):

1. Prepare the parts of the block module (parts 201-204, racks). Parts are made from steel sheets using bending machines.

2. Weld the lower frame 401 from parts 201-204 using a jig.

3. Weld the upper frame 402 from parts 201-204 using a jig.

4. Clean the lower and upper frames 401, 402. Cleaning the upper frame 401, lower frame 402 and racks 403 is done with drill machines in hard-to-reach places, also with corner cable machines (splashes, seams)

5. Shot blasting of frames 401, 402 is carried out. Shot blasting of the upper frame, lower frame and racks is carried out to a cleaning degree of Sa 2½.

6. Frames 401, 402 and racks 403 are painted. Painting is done with an airless paint sprayer. The dry film thickness of painted frames and uprights is 100 microns.

7. Fill frames 401 and 402 with insulation, protect the insulation with vapor barrier, plasterboard, galvanized sheets.

8. Assemble the block module. Frames 401, 402 and racks 403 are welded, walls, windows, and doors are mounted.

The embodiments are not limited to the designs described above, but other embodiments of the solution will become apparent to one skilled in the art based on the information set forth in the description and knowledge of the prior art, without departing from the spirit and scope of this solution.

Elements referred to in the singular do not exclude the plurality of elements unless specifically stated otherwise.

The stages of the method can be combined, the sequence of stages can change within the framework of the essence of the solution.

While exemplary embodiments have been described in detail and shown in the accompanying drawings, it is to be understood that such embodiments are illustrative only and are not intended to be limiting to a broader solution, and that the solution should not be limited to the specific arrangements and structures shown and described. since various other modifications may be apparent to those skilled in the art.

The features mentioned in the various dependent claims, as well as the implementations disclosed in various parts of the description, can be combined to achieve beneficial effects, even if the possibility of such combination is not explicitly disclosed.

Claims (10)

1. A method for manufacturing a block module based on a frame steel welded structure containing a rectangular upper frame, a lower frame and racks connecting them, including the manufacture of block module parts and their assembly using a jig, characterized in that the block module parts are made through bending operations from metal sheets pre-cut to size, while the upper frame and lower frame consist of corner parts and side parts, the upper frame is fixed in the jig, which has a rectangular beam structure and is equipped with stops mounted in the corners of the jig on its outer side, and on its beams - on the inner side to limit the movement of frame parts inside the jig, and clamps located in the corners of the jig on the inside , and on its beams - from the outside, while First, the parts of the frame corners are secured using clamps on the inside of the jig corners, then the parts of the long sides of the frame are secured using clamps on the corresponding stops of the jig, and from the outside the required distance is provided between the parts of the long sides of the frame using a spacer, after tack welding, after which the cross members are welded, and after fixing the frame in the jig, from 50 to 70 percent are formed weld seams connecting the corner parts and the frame side parts, and leave the frame in the jig for 15 to 45 minutes to cool, then remove the frame from the jig and weld the remaining seams, the lower frame is made in a similar way, then the frames and racks of the block module are cleaned and prepared for painting, they are painted, the frames are filled with fillers, the frames are welded with racks and the internal space of the block module is formed using wall panels, windows and doors. 2. The method according to claim 1, in which, before welding, the diagonal size of the frame is 1-2 mm larger than specified in the technical documentation. 3. The method according to claim 1, in which the welded joint of the long sides is strengthened by welding an additional reinforcing element on top of the weld. 4. The method according to claim 1, in which a longitudinal link is welded on top of the crossbars in the middle of the frame along the long side, providing additional rigidity to the frame.