WO2017177518A1

WO2017177518A1 - Method for manufacturing hot extruded polyethylene zinc-aluminium alloy-plated steel wire hauling cable

Info

Publication number: WO2017177518A1
Application number: PCT/CN2016/083894
Authority: WO
Inventors: 赵军; 宁世伟; 薛花娟; 周祝兵; 吴琼; 强强; 黄可彬; 朱晓雄; 束卫洪; 王进; 梁中梅; 翟鹏程
Original assignee: 江苏法尔胜缆索有限公司
Priority date: 2016-04-13
Filing date: 2016-05-30
Publication date: 2017-10-19
Also published as: US20180100269A1; EP3348712A4; CN105862592A; EP3348712A1; CN105862592B; EP3348712B1

Abstract

Provided is a method for manufacturing a hot extruded polyethylene zinc-aluminium alloy-plated steel wire hauling cable. The method involves: in accordance with arrangement rules for steel wires at the cross section of a hauling cable (4), the length of the hauling cable is controlled through a central standard wire, zinc-aluminium alloy-plated steel wires are bundled at a twisting angle of 2°-4°, a high-strength polyester belt is wound externally on the steel wire bundle, a double-layer high-density polyethylene protection layer is hot-extruded through a double-cavity co-extrusion one-time moulding process, anti-wind- and rain-induced vibration embossments are arranged on the outer layer of a polyethylene protection jacket according to design requirements of the hauling cable (4) regarding wind- and rain-induced vibration, and the hauling cable is coiled and stored after both ends of the hauling cable (4) are anchored. Finally, the hauling cable is transported to an erection site according to delivery requirements, and erected one by one. The process for manufacturing the hauling cable (4) is not limited by a construction site, is less affected by climate factors, is convenient to control due to industrialised production management, and can satisfy the service requirements of long length, high accuracy, and durability for stay cables in super -long-span bridges in a marine environment.

Description

Description: A method for manufacturing hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable

[0001] The present invention belongs to the field of bridge cable technology, and particularly relates to a method for manufacturing a hot extruded polyethylene-zinc-aluminum alloy coated steel wire cable.

Background technique

[0002] A cable-stayed bridge, also known as a diagonal bridge, is a bridge that directly suspends a main beam on a tower column with a stay cable. Its special feature is light structure and strong applicability. It can change the combination of beam, cable and tower into different systems, which are suitable for different geological and topographical conditions. The main beam has a significantly reduced bending moment due to the addition of the intermediate stay cable. Compared with other large-span bridges, the steel and concrete are saved. With the pre-tension of the cable-stayed bridge, the internal force of the main beam can be adjusted to make the distribution uniform and reasonable, and the economic effect can be obtained. The main beam can be made into an equal-section beam, which is easy to manufacture and install. The horizontal component of the inclined cable is equivalent. The pre-stress applied to the main beam, which in turn increases the crack resistance of the beam (especially concrete beams) and gives full play to the properties of the material.

[0003] The concept of cable-stayed bridges began to appear in the 17th century, but due to conditions, it has not been greatly developed. In 1984, German CJ. Loscher built a wooden cable-stayed bridge with a span of 32m in Fribourg. The bridge is supported by a wooden drawbar attached to a wooden pylon. This is the first true diagonal pull. bridge. After the Second World War, the reconstruction of Europe and the advancement of modern mechanics theory and various technologies, people began to realize that the cable-stayed bridge has great advantages in a certain span range in order to find a bridge that is both economical and convenient to construct. The bridge type has been re-emphasized. The world's first modern cable-stayed bridge is the Stro msimd bridge built in Sweden in 1955. It is a steel cable-stayed bridge spanning 182.6m across the Strom Strait, marking the end of the development of modern cable-stayed bridges. . In 1962, Venezuela built the world's first concrete cable-stayed bridge (135 m main span). At this point, the cable-stayed bridge has developed rapidly. By the end of the 20th century, France had built the Normandy Bridge with a main span of 856 meters, while Japan built the Dorado Bridge with a main span of 890 meters, and the cables of these bridges were all hot-dip galvanized steel strands or steel wires.

[0004] With the rapid development of modern bridges, a number of large-span cross-sea bridges will soon be built. These bridges have long cable lengths, high precision and long design life. Traditional galvanized steel wire ropes are used. The requirements for the durability of bridges in these extra-large span marine environments have not been met. technical problem

[0005] The technical problem to be solved by the present invention is to provide a method for manufacturing a hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable according to the above prior art, which adopts a central standard wire length control process according to the wire arrangement rule of the cable section. The zinc-aluminum alloy coated steel wire is bundled by a twist angle of 2° to 4°, the steel wire bundle is wrapped with a high-strength polyester wrapping tape, and then the double-layer high-density polyethylene sheath is hot-squeezed by a double-cavity co-extrusion molding process. And according to the cable wind and vibration design requirements, the outer layer of the polyethylene sheath is provided with anti-wind and vibration embossing. Both ends of the cable are anchored with packing, and finally coiled and stored. The cable is transported to the erection site and erected one by one.

Problem solution

Technical solution

[0006] The technical solution adopted by the present invention to solve the above problems is as follows: A method for manufacturing a hot extruded polyethylene-zinc-aluminum alloy coated steel wire cable, comprising the following implementation steps:

[0007] (1) Making zinc-aluminum alloy coated steel wire

[0008] The steel wire used in the invention adopts zinc-aluminum alloy coated steel wire, which has higher corrosion resistance than pure zinc coating. The anti-corrosion mechanism is as follows: 1) The chemical properties of aluminum are very active, and a layer of steel wire is formed after hot-plating. Dense alumina, which is easily passivated to form a protective layer in a corrosive environment. In the corrosive medium, the surface zinc-rich phase is first corroded as an anode, and its aluminum content is continuously increased to increase the alumina content, making the coating more resistant to harmful substances. The addition of the same bismuth aluminum also inhibits the formation of a loosely structured zinc-iron alloy transition layer with weak anti-corrosion properties, which is beneficial to improve the overall corrosion resistance of the coating. 2) The zinc-aluminum alloy coating is destroyed and exposed to iron. The coating is dissolved as the anode of the iron-zinc-aluminum battery, and the steel substrate is protected. The corrosion potential of zinc-aluminum alloy is slightly lower than that of pure zinc layer, which is about -0.87, but its corrosion current is only 1/5 of that of hot-dip pure zinc. In the protection of sacrificial anode, the same amount of zinc-aluminum alloy coating The consumption time is five times that of the hot-dip galvanized layer, which provides a longer sacrificial barrier to better durability. The zinc-aluminum alloy coating layer of the invention is divided into two kinds of Zn95A15 and Zn90A110, wherein the mass content of aluminum is 4.2<3⁄4~7.2<3⁄4 and 9.2%~12.2<3⁄4, respectively, and the coating weight is not less than 300g/m 2 , and the uniformity index of the coating is satisfied. The number of copper sulfates is not less than 4 times, 60 seconds each time.

[0009] (2) Making standard length steel wire

[0010] Since the wire of each layer of the stay cable has a certain twist angle, it is impossible to directly control the length of the cable body by using the outer wire. Only the center wire of the stay cable does not twist during the whole process, and it always keeps straight. Therefore, the center wire of the cable body is used as the standard wire to control the overall length of the cable.

[0011] The length of the standard wire is determined by the baseline length measurement method. The specific operation is to apply a certain tension to both ends of the wire to make the wire straight and perform stress and temperature correction. The correction formula is:

L=L ox [ (1+F/EA) +α (Τ-20) ]

[0013] wherein: L: the length under the stress of the steel wire, the unit m;

[0014] L ₀ : unstressed design length, unit m;

[0015] F: tension, unit N;

[0016] E: the elastic modulus of the steel wire, the standard wire is measured, the unit is MPa;

[0017] A: the cross-sectional area of the steel wire, the measured value of the standard wire is taken, the unit is m ² ;

[0018] α: steel wire linear expansion coefficient;

[0019] Τ: ambient temperature, unit °C.

[0020] A standard length wire is made, and a specific (cut) mark is made on the head and tail of the wire, and then the length of all the cables is determined by the transfer method based on the standard length wire. Through the above method, the length error of the stay cable can be greatly reduced, the precision of the standard wire is more than 1/30000, and the precision of the finished cable is increased from 1/5000 of the Chinese national standard to 1/20000.

[0021] (3) Wire bundle twisting

[0022] The cable is composed of several layers of steel wire. The standard wire is placed at the center of the cable section during the wire-drawing process. All the wires are twisted by left-handed twist, the twist angle is 2°~4°, and then the whole package is shaped. Wrap the belt, wrap the belt around the right to obtain the semi-finished cable body; due to the difference in the length of the steel wire after twisting, calculate the length L of the other layer of steel wire, calculate the relationship:

[0023] L ₀ = L 'xcosa+K

[0024] wherein: a - the twist angle, the range of values 2 ° ~ 4 °,

[0025] K—production margin, selected according to specific specifications and operations, unit m,

[0026] L '-the length of the wire of other layers of wire, in m,

[0027] L o - center standard wire length, unit m;

[0028] The outer diameter of the twisted wire bundle, that is, the bare wire diameter is measured. Since the wire bundle has a hexagonal or notched hexagonal cross section, the circumscribed circle of all the selected wire bundle sections is directly the bare wire diameter.

[0029] The wrapping tape is preferably a high-strength polyester fiber tape having a bandwidth (40-60) mm and a tensile strength of not less than 500 N/25 m. m ² °

[0030] (4) Extrusion

[0031] A double-layer high-density polyethylene (HDPE) protective layer is disposed outside the cable bare cable, and the polyethylene protective layer has a density of 0.942~0.978g/cm ³ , environmental stress cracking ≥5000 F ₀ /h, melting Index ≤ 0.45 g/10min, the specific operation: Before extrusion, set the die mouth and extrusion speed according to the outer diameter of the cable and the thickness of the two layers of polyethylene protective layer, using double cavity co-extrusion molding Technology, double-layer polyethylene plastic covers the bare wire during the extrusion process to achieve anti-corrosion requirements. According to the requirements of the cable to suppress the weatherproof vibration, after the extrusion, according to the design requirements, the spiral or embossing is arranged on the outer surface of the HDPE to meet the effect of effectively suppressing the wind and rain excitation, and the drag coefficient should be no more than 0.8.

[0032] (5) Fine cutting

[0033] The measurement determines the initial unloading position of each cable, and after partial stripping, finds the cutting mark points at both ends of the center standard wire, and cuts the cable body by using a non-liquid cutting machine, and the cutting boring should strictly ensure the cutting end face of the cable. The perpendicularity to the axis of the cable. Then, according to the set length, the strip is exposed to expose the steel wire, and the steel plating layer is not damaged during the stripping process.

(6) anchoring

[0035] The anchoring device is the main connecting structure for transmitting the cable force to the tower and the beam. The anchoring structure used in the cable in the present application mainly comprises a nut screw type at both ends, a pad adjusting type and a fork pin connecting type. Kinds of anchorage anti-corrosion is hot-dip galvanized or painted, the thickness of hot-dip galvanizing is not less than 90μηι _; the thickness of paint coating is set according to steel structure specifications and design requirements. The structural performance of the specific anchor is as follows:

[0036] 1 nut screw-type anchor

[0037] The nut-rotating anchor is mainly composed of an anchor cup, a nut, an anchor plate, a connecting barrel sealing component and the like. The cable of the structure mainly transmits the load through the bearing end of the nut, and the nut and the anchor cup are screwed through the trapezoidal thread with good strength to realize the continuous adjustment of the length of the cable. The anchor cup has a tensioned internal thread and is installed at the construction site. The cable is applied to the cable by the traction anchor. The anchor plate mainly functions as a dividing wire. The steel plate holes are distributed on the anchor plate, and the wire in the cable is passed through the corresponding hole to perform the hammering. The outer frustum can fit snugly into the inner cone cavity of the anchor cup.

[0038] 2 end pressure anchors

[0039] The end pressure bearing anchor is mainly composed of an anchor cup, an anchor plate, a connecting barrel sealing component and the like, and the structural shape The cable is directly pressed against the end plate of the anchor pad, and the length of the cable is adjusted by using different gap adjusting plates. The lashing plates are available in a variety of thicknesses to meet the needs of the construction site. The anchor cup has a tensioned internal thread and is installed at the construction site. The cable is applied to the cable by the traction anchor. This type of anchor does not require a nut and the anchor cup does not have an external thread. The anchor plate acts as a dividing wire, and the steel wire eyelet is distributed on the anchor plate, and the wire in the cable is passed through the corresponding hole to perform the hammering. The outer frustum can fit snugly into the inner cone cavity of the anchor cup.

[0040] 3 one end fork pin and one end nut screw anchor

[0041] One end fork pin and one end nut screw-type anchor mainly consists of a fork ear, a pin shaft, an anchor cup, a nut, a connecting barrel sealing component and the like. One end of the cable of this structure is connected to the tower or beam end steel structure through the fork ear and the pin shaft, and the other end transmits pressure through the nut end face and realizes continuous adjustment of the cable length. The anchor cup has a tensioned internal thread and is installed at the construction site. The cable is applied to the cable by the traction anchor. The anchor plate mainly functions as a dividing wire, and the steel wire hole is distributed on the anchor plate, and the wire in the cable is passed through the corresponding hole to perform the hammering. The outer frustum can fit snugly into the inner cone cavity of the anchor cup.

[0042] The above three structures of the connecting barrel sealing assembly adopt a novel cable end sealing technology, and the first sealing is performed by using a sealing cover on the outside of the connecting barrel, and the elastic sealing ring and the sealing pressing ring are realized on the inner wall of the connecting barrel near the port. Two seals. Through the two seals, the sealing of the cable end, that is, the anchor and the PE cable body boundary is finally realized. The sealing assembly is more rigid, not easy to break, has a longer service life, and the sealing structure is more durable.

[0043] The sealing of the cable end provides a reliable mechanical sealing structure to solve the problem of corrosion caused by moisture entering the anchor along the PE cable body, and the steel structure is sealed as an alternative to the heat shrink sleeve structure, which can overcome the heat shrinkage. Set of easy to break puzzles.

[0044] The technical solution adopted by the present invention to solve the above problems is as follows: A novel cable end end type durable sealing structure is installed in cooperation with the connecting barrel of the anchoring device, including an elastic sealing ring, a sealing pressing ring and a sealing cover, the sealing The pressure ring is disposed in the connection barrel port and the outer end is exposed outside the connection tube. The inner wall of the connection tube is formed with an extrusion surface on the inner end surface of the sealing pressure ring, and the elastic sealing ring is disposed on the inner end surface of the sealing pressure ring and the Between the pressing faces, and under the action of the pressing face, it is pressed and deformed to fit the outer wall of the cable; the sealing cover is disposed at the front end of the connecting barrel, has a haval structure, and the front part is in contact with the outer wall of the cable A sealing ring is disposed on the corresponding contact surface, and the rear portion is in contact with the sealing pressure ring or the connecting cylinder and a sealing strip is disposed at the corresponding contact surface. [0045] The anchoring is carried out by using a cold-casting head anchor or a hot-casting anchor, and the specific operations are as follows:

[0046] 1 cold cast skull anchor

[0047] a wire end and anchor cup fixed on the anchoring platform, the oil wire of the anchor cup part is cleaned and rusted, and the inner wall of the anchor cup is cleaned at the same time;

[0048] b threading taro: the wire at both ends is evenly divided according to the hole position of the anchor plate, and each wire is subjected to steaming with a steamer. The size of the steamed head is required: the diameter of the steamed head is ≥ 1.40, and the height of the steamed bread is ≥ 1.0. D, D is the wire diameter;

[0049] The main components of the cold-filled filler in the anchor cup include steel balls, rock powder, epoxy resin, curing agent, dibutyl acrylate, and diluent. The uniformly filled cold filler is poured into the anchor cup, and the same enthalpy is combined with the vibration. The pump vibrates, so that the cold packing fully fills the gap between the anchor and the steel wire. After the completion of the pouring, the anchor is placed in the heating furnace to be cured and cured, the curing temperature is 180±10°C, and the curing time is not less than 6 hours, each of which is not less than 6 hours. The anchor cup is provided with a set of test patterns for detecting the strength of the cast body in the anchor cup, and the size of the test mold is a cube or a cylinder;

[0050] The compressive strength of the d cold filler casting satisfies the requirement of ≥ 147 MPa.

2 hot cast anchor

[0052] The hot casting anchor is cast by zinc alloy, and the two kinds are usually zinc-copper or zinc-copper-aluminum alloy, wherein the composition of the zinc-copper alloy is 98<3⁄4±0.2<3⁄4 zinc and 2<3⁄4±0.2<3⁄4 Copper; zinc-aluminum alloy has an aluminum content of 4%~7<3⁄4, copper content^. ~? ^, Zinc content 91<3⁄4~95<3⁄4.

[0053] The specific anchoring process is as follows:

[0054] a wire end and the anchor cup are vertically fixed on the anchoring platform, and the zinc-aluminum alloy coated steel wire of the anchor cup portion is concentrically scattered, and then the oil stain and rust on the surface of the steel wire are cleaned, and the inner wall of the anchor cup is cleaned at the same time;

[0055] b the wire in the anchor cup should keep the center of the cable body in line with the center of the anchor cup, and ensure that no part of the wire is in contact with the anchor cup;

[0056] The lower opening of the anchor cup should be sealed to prevent the injected alloy from leaking from the lower port, and the anchor cup should be preheated before casting the zinc-copper or zinc-copper-aluminum alloy;

[0057] d injection of the alloy into the anchor cup 吋, should avoid any vibration, casting should be completed at one time, without interruption.

(7) Tension / Top Pressure Detection

[0059] Tensioning/topping pressure is an important means to check the quality of the cable. According to the different filling and anchoring materials, the cold casting anchor cable is tested for tension before leaving the factory, and the hot casting anchor cable is used for top pressure detection. The specific operation is as follows: :

[0060] cold casting anchor cable, the tensile tension of the cable takes 1.1 to 1.5 times the design cable force, and the tension is completed in the anchor cup. Casting retraction value does not exceed 6mm,

[0061] After tensioning, the tension is unloaded to 20% of the tensile force or the bridge cable force. Under this condition, the cable length measurement is performed, and the length measurement should be performed under constant temperature and light protection conditions. The calculation of the unstressed length at temperature is as follows:

[0062]

[0063] L eo - the unstressed length at the reference temperature of the cable, in units of m;

[0064] L _C P - the cable is subjected to a tensile force P 2 . Length, in m;

[0065] P ₂₀ - 20% of the tensile tension, the unit is N;

[0066] A - the nominal cross-sectional area of the wire bundle, the unit is mm ² ;

[0067] E - modulus of elasticity, the unit is MPa;

[0068] —— cable-staying coefficient of the cable, taking 0.000012 / ° C;

[0069] t-cable length measuring 稳定 stable uniform temperature, the unit is °C;

[0070] t o - cable tie bridge design reference temperature, determined by design, the unit is ° C;

[0071] The stress-free length error at the cable reference temperature is as follows:

[0072] L _co ≤ 100m, the cable length error should not exceed 10mm;

[0073] L co > 100m, the cable length error should not exceed L _ra / 20000 + 5mm;

[0074] The top pressure of the hot-cast anchor cable is 1.25 times of the design cable force, and the top pressure is completed, and the retraction value of the casting body in the anchor cup is not more than 6 mm;

(8) Coil

[0076] The cable is wound in the form of a tire or a steel disk, and the outer surface of the cable is packaged before coiling, and then the coil is wound up layer by layer, and the inner diameter of the coil is required to be not less than 20 times the outer diameter of the cable, and the disk is The inner diameter of the roll is not less than 1.6 m.

(9) Storage

[0078] The finished cable is stored indoors or outdoors, and the outdoor storage should be covered with a tarpaulin. The storage site is ventilated and fire resistant to ensure the quality and safety of the cable storage period.

Advantageous effects of the invention

Beneficial effect

[0079] The hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable is prepared according to the rule of the wire section of the cable, the length of the cable is controlled by the central standard wire, and the zinc is twisted at a twist angle of 2°~4°. Aluminum alloy coated steel wire The bundle is bundled, the high-strength polyester tape is wrapped around the wire bundle, and the double-layer high-density polyethylene protective layer is hot-squeezed by a double-cavity co-extrusion molding process. According to the requirements of the cable wind and rain vibration design, the outer layer of the polyethylene protective cover is provided with weatherproof Vibrating lines, coiled and stored at both ends of the cable. Finally, according to the delivery requirements, transport to the erection site, erected one by one. The cable making process of the invention is not restricted by the construction site, the climate factor is small, the factory production management is easy to control, and the long cable length, high precision and durability requirement of the cable in the bridge of the large span marine environment can be met.

Brief description of the drawing

DRAWINGS

1 is a screw-on anchor of a two-end nut according to an embodiment of the present invention;

2 is an anchoring device for adjusting the gap between two end plates according to an embodiment of the present invention;

[0082] FIG. 3 is a perspective view of an embodiment of the present invention;

4 is a side view of the structure shown in FIG. 3.

[0084] 1 anchor plate, 2 anchor cup, 3 connecting barrel sealing assembly, 4 cable, 5 cable end sealing structure, 6 nut, 7 lashing plate, 8 pin shaft, 9 fork ears.

BEST MODE FOR CARRYING OUT THE INVENTION

[0085] The present invention will be further described in detail below with reference to the embodiments of the drawings.

[0086] The cable involved in the embodiment is that the zinc-aluminum alloy coated steel wire is twisted together to form a cable body, and then the polyethylene protective layer is hot extruded in the outer layer of the cable, anchored at both ends, and then coiled and transported to Erect the site and erect it one by one.

[0087] Specific implementation steps:

[0088] (1) Making a zinc-aluminum alloy coated steel wire

[0089] The steel wire used in the embodiment adopts a zinc-aluminum alloy coated steel wire, which has higher corrosion resistance than the pure zinc plating layer, and the zinc-aluminum alloy plating layer is divided into two kinds of Zn95A15 and Zn90A110, wherein the mass content of aluminum is 4.2% respectively~ 7.2<3⁄4 and 9.2<3⁄4~12.2<3⁄4, the plating weight is not less than 300g/m ² .

[0090] (2) Making a standard length wire

[0091] Since the wire of each layer of the stay cable has a certain twist angle, only the center wire does not twist during the whole manufacturing process, and always keeps straight, so the center wire of the cable body is used as the standard wire to control the cable. Overall length [0092] The length of the standard wire is determined by the baseline length measurement method. The specific operation is to apply a certain tension to both ends of the wire to make the wire straight, and perform stress and temperature correction. The correction formula is:

L=L ox [ (1+F/EA) +α (Τ-20) ]

Wherein: L: length under steel wire stress, m;

[0095] L ₀ : unstressed design length, m;

[0096] F: tension, N;

[0097] E: elastic modulus of the steel wire, MPa, the standard wire is measured value;

[0098] A: the cross-sectional area of the steel wire, m ² , the measured value of the standard wire is taken;

[0099] α: steel wire linear expansion coefficient;

[0100] Τ: ambient temperature.

[0101] A standard length wire is made, and a specific (cut) mark is made on the head and tail of the wire, and then the length of all the cables is determined by the transfer method based on the standard length wire.

(3) Wire bundle twist forming

[0103] The cable is composed of a multi-layer steel wire. The standard wire is placed at the center of the cable section during the wire-drawing process, and all the wires are twisted by a left-hand twist, the twist angle is 2°~4°, and then the whole package is shaped. Wrap-wrapped belt, wrap-around belt is twisted right-handed to obtain a semi-finished cable body; due to the difference in length of each layer of steel wire after twisting, the wire length L of other layers of steel wire, the calculation relationship:

L ₀ = L 'xcosa+K

[0105] wherein: a - the twist angle, the range of values is 2 ° ~ 4 °,

[0106] K—Making the margin, according to specific specifications and operations, etc., unit m,

[0107] L '—the length of the wire of the other layer of steel, in m,

[0108] L ₀ - Center Standard wire length in m;

[0109] After the cable body is shaped, the outer diameter of the cable body, that is, the diameter of the bare cable is measured. Since the cross section of the cable body is hexagonal, the circumscribed circle of the cable body section is generally selected as the diameter of the bare cable, and the measurement is not required at the circumscribed circle position. Measure multiple points and take the maximum value as the bare wire diameter.

(4) Extrusion

[0111] A double-layer high-density polyethylene (HDPE) protective layer is disposed outside the cable bare cable. Before extrusion, according to the outer diameter of the cable The thickness of the two-layer polyethylene protective layer is required to set the extrusion die extrusion speed and the extrusion speed. The double-cavity co-extrusion molding technology is adopted, that is, the two-layer discharge passage is set in the die, and the double-layer polyethylene plastic is extruded during the extrusion process. The same cover covers the bare cord.

[0112] According to the requirements of the cable to suppress the weathering resistance, after the extrusion, according to the design requirements, a spiral or embossing is arranged on the outer surface of the HDPE to satisfy the effect of effectively suppressing the wind and rain excitation, and the drag coefficient should be no more than 0.8. .

(5) Fine cutting

[0114] The measurement determines the initial unloading position of each cable, and after partial stripping, finds the cutting mark points at both ends of the center standard wire, and cuts the cable body by using a non-liquid cutting machine, and the cutting boring should strictly ensure the cutting end face of the cable. The perpendicularity to the axis of the cable. Then, according to the set length, the strip is exposed to expose the steel wire, and the steel plating layer is not damaged during the stripping process.

(6) Anchoring

[0116] The anchor is the main connection structure for transmitting the cable force to the tower and the beam. Generally, the anchor structure used for the cable mainly includes the screwing type of the two ends of the nut as shown in FIG. 1 , and the cushioning type of the pad is as shown in FIG. 2 . The one end of the fork pin and the one end of the nut are screwed as shown in Figures 3 and 4.

[0117] nut screw anchor

[0118] The nut-rotating anchor is mainly composed of an anchor cup, a nut, an anchor plate, a connecting barrel sealing component and the like. The cable of the structure mainly transmits the load through the bearing end of the nut, and the nut and the anchor cup are screwed through the trapezoidal thread with good strength to realize the continuous adjustment of the length of the cable. The anchor cup has a tensioned internal thread and is installed at the construction site. The cable is applied to the cable by the traction anchor. The anchor plate mainly functions as a dividing wire. The steel plate holes are distributed on the anchor plate, and the wire in the cable is passed through the corresponding hole to perform the hammering. The outer frustum can fit snugly into the inner cone cavity of the anchor cup.

[0119] end pressure bearing anchor

[0120] The end pressure bearing anchor is mainly composed of an anchor cup, an anchor plate, a connecting barrel sealing component and the like. The cable of the structural form directly presses the end surface thereof on the anchor plate, by using different gaps. Adjust the plate to adjust the length of the cable. The lashing plates are available in a variety of thicknesses to meet the needs of the construction site. The anchor cup has a tensioned internal thread and is installed at the construction site. The cable is applied to the cable by the traction anchor. This type of anchor does not require a nut and the anchor cup does not have an external thread. The anchor plate acts as a dividing wire, and the steel wire eyelet is distributed on the anchor plate, and the wire in the cable is passed through the corresponding hole to perform the hammering. The outer frustum can be tight with the cone inside the anchor cup Close fit.

[0121] One end fork pin pin and one end nut screw type anchor

[0122] One end fork pin and one end nut screw type anchor is mainly composed of fork ears, pin shafts, anchor cups, nuts, connecting barrel sealing components and the like. One end of the cable of this structure is connected to the tower or beam end steel structure through the fork ear and the pin shaft, and the other end transmits pressure through the nut end face and realizes continuous adjustment of the cable length. The anchor cup has a tensioned internal thread and is installed at the construction site. The cable is applied to the cable by the traction anchor. The anchor plate mainly functions as a dividing wire, and the steel wire hole is distributed on the anchor plate, and the wire in the cable is passed through the corresponding hole to perform the hammering. The outer frustum can fit snugly into the inner cone cavity of the anchor cup.

[0123] The above three types of connecting barrel sealing assemblies adopt a novel cable end sealing technology, and the first sealing is adopted by using a sealing cover on the outside of the connecting barrel, and the elastic sealing ring and the sealing pressing ring are realized on the inner wall of the connecting barrel near the port. Two seals. Through the two seals, the sealing of the cable end, that is, the anchor and the PE cable body boundary is finally realized. The sealing assembly is more rigid, not easy to break, has a longer service life, and the sealing structure is more durable.

[0124] Further, the sealing of the cable end provides a reliable mechanical sealing structure to solve the problem of corrosion caused by moisture entering the anchor along the PE cable body, and the steel structure sealing is used as an alternative to the heat shrink sleeve structure, which can overcome The heat shrink sleeve is easy to break.

[0125] The technical solution adopted by the present invention to solve the above problems is as follows: A novel cable end end type durable sealing structure is installed in cooperation with a connecting barrel of an anchoring device, including an elastic sealing ring, a sealing pressing ring and a sealing cover, the sealing The pressure ring is disposed in the connection barrel port and the outer end is exposed outside the connection tube. The inner wall of the connection tube is formed with an extrusion surface on the inner end surface of the sealing pressure ring, and the elastic sealing ring is disposed on the inner end surface of the sealing pressure ring and the Between the pressing faces, and under the action of the pressing face, it is pressed and deformed to fit the outer wall of the cable; the sealing cover is disposed at the front end of the connecting barrel, has a haval structure, and the front part is in contact with the outer wall of the cable A sealing ring is disposed on the corresponding contact surface, and the rear portion is in contact with the sealing pressure ring or the connecting cylinder and a sealing strip is disposed at the corresponding contact surface.

[0126] The anti-corrosion of anchors is hot-dip galvanized or painted. The thickness of hot-dip galvanizing is not less than 90μηι, and the thickness of paint coating is set according to steel structure specifications and design requirements.

[0127] The anchoring is performed by using a cold-casting head anchor or a hot-casting anchor, and the specific operations are respectively

[0128] 1 cold cast skull anchor

[0129] a fixing the wire end and the anchor cup on the anchoring platform, cleaning the steel wire of the anchor cup portion, rusting , cleaning the inner wall of the anchor cup;

[0130] b threading taro: The wire at both ends is evenly divided according to the hole position of the anchor plate, and each wire is subjected to steaming with a steamer. The size of the steamed head is required: the diameter of the steamed head is ≥ 1.40, and the height of the steamed bread is ≥ 1.0. D, D is the wire diameter;

[0131] The main components of the cold-filled filler in the anchor cup include steel balls, rock powder, epoxy resin, curing agent, dibutyl acrylate, and diluent. The uniformly filled cold filler is poured into the anchor cup, and the perfusion is combined with vibration. The pump vibrates, allowing the cold packing to fully fill the gap between the anchor and the wire;

2 hot cast anchor

[0133] Casting is performed using zinc-copper or zinc-copper-aluminum alloy, wherein the composition of the zinc-copper alloy is 98%±0.2<3⁄4 of zinc and 2^iO^^ of copper; the aluminum content of the zinc-copper-aluminum alloy is 4<3⁄4~ 7<3⁄4, copper content 1<3⁄4~2<3⁄4, zinc content 91<3⁄4~ 95%, the anchoring process is as follows:

[0134] a wire end and the anchor cup are vertically fixed on the anchoring platform, and the zinc-aluminum alloy coated steel wire of the anchor cup portion is concentrically dispersed, and then the oil stain and rust on the surface of the steel wire are cleaned, and the inner wall of the anchor cup is cleaned at the same time;

[0135] b The wire in the anchor cup should keep the center of the cable body in line with the center of the anchor cup and ensure that no part of the wire is in contact with the anchor cup;

[0136] The lower opening of the anchor cup should be sealed to prevent the injected alloy from leaking from the lower port, and the anchor cup should be preheated before casting the zinc-copper or zinc-copper-aluminum alloy;

[0137] d Inject the alloy into the anchor cup, and any vibration should be avoided. The casting should be completed once and must not be interrupted.

[0138] (7) Tensile/top pressure detection

[0139] Tensile/topping pressure is an important means to check the quality of the cable. According to the different filling and anchoring materials, the cold casting anchor cable is tested for tension before leaving the factory, and the hot casting anchor cable is used for top pressure detection. The specific operation is as follows: :

[0140] The cold-casting anchor cable, the tensile tension of the cable takes 1.1 to 1.5 times of the design cable force, and the tensioning of the casting body requires that the retraction value of the casting body does not exceed 6 mm.

[0141] After tensioning, the tension is unloaded to 20% of the tension or the bridge force. Under this condition, the cable length measurement is performed, and the length measurement should be performed under constant temperature and dark conditions. The calculation of the unstressed length at temperature is as follows:

[0142]

\* MERGEFORMAT

[0143] L eo - cable unstressed length at the reference temperature, in m;

[0144] L _C p—the cable is subjected to the tensile force P ₂ . Length, in m;

[0145] P ₂₀ - 20% of the tensile tension, the unit is N;

[0146] A—the nominal cross-sectional area of the wire bundle, in mm 2;

[0147] E - modulus of elasticity, the unit is MPa;

[0148] - the cable expansion coefficient of the cable, taking 0.000012 / ° C;

[0149] t—the length of the stay cable measures the stable uniform temperature of the crucible, in units of °C;

[0150] t o—the design temperature of the cable-stayed bridge, determined by design, in °C;

[0151] The stress-free length error at the cable reference temperature is as follows:

[0152] L co ≤ 100m, the cable length error should not exceed 10mm;

[0153] L co > 100 m, the cable length error should not exceed L _c . /20000+5mm;

[0154] The top pressure of the hot-cast anchor cable is 1.25 times of the design cable force, and the top pressure is required to complete the retraction value of the caster in the anchor cup not exceeding 6 mm.

[0155] (8) Coil

[0156] The cable is wound in the form of a tire or a steel disk. The outer surface of the cable is packaged before coiling, and then the coil is wound up layer by layer, and the inner diameter of the coil is required to be no less than 20 times the outer diameter of the cable, and the disk is The inner diameter of the roll is not less than 1.6 m.

[0157] (9) Storage

[0158] The finished cable is stored indoors or outdoors, and the outdoor storage should be covered with a tarpaulin. The storage site is ventilated and fire resistant to ensure the quality and safety of the cable storage period.

Embodiments of the invention

[0159] The description paragraphs of the embodiments of the present invention are entered here.

Industrial applicability [0160] Enter the paragraph of industrial applicability description here. Sequence table free content

[0161] Type a sequence listing free content description paragraph here.

Claims

Claim

[Claim 1] A method for fabricating a hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable, comprising: the following steps:

(1) Making zinc-aluminum alloy coated steel wire

A zinc-aluminum alloy coating is arranged on the surface of the steel wire, and the zinc-aluminum alloy coating layer is divided into two types, Zn95A15 and Zn90A110, wherein the mass content of aluminum is 4.2<3⁄4 7.2<3⁄4 and 9.2<3⁄4 12.2<3⁄4, and the coating weight is not less than 300g/m ² ;

(2) Making standard length wire

The cable uses the center wire as the standard wire to control the overall length of the cable. The length of the standard wire is determined by the baseline length measurement method. The specific operation is to apply a certain tension to the ends of the wire to make the wire straight, and Perform stress and temperature corrections, make a standard length wire, make a specific (cut) mark on the head and tail of the wire, and then use this standard length wire as a reference to control the length of all cables by transfer method;

(3) Wire bundle twisting

The cable is composed of several layers of steel wire. The standard wire is placed at the center of the cable section during the wire-drawing process. All the wires are twisted by left-handed twist, the twist angle is 2° 4°, and then the whole package is wrapped with a wrap. The wrapping tape is wound in the right direction to obtain the semi-finished cable body; according to the central standard wire length, considering the twisting rate, the length of the other wire is calculated.

L o= L ⁷ xcos +K

Where: _a _twist angle, value range 2° 4°

K—Making the allowance, according to the specific specifications and operation factors, the unit m L '—the length of the wire of other layers, unit m

L center standard wire length, in m;

(4) Extrusion

A double-layer polyethylene protective layer is arranged outside the cable bare cable. The density of the polyethylene protective layer satisfies 0.94 2 0.978g/cm ³ , the environmental stress cracking ≥5000 F o/h, and the melt index ≤0.45 g/10min

, Specific operation: Before extrusion, set the extruder die and extrusion speed according to the outer diameter of the cable and the thickness of the two protective layers of polyethylene. The die is provided with two layers of discharge channels, and the double layer during extrusion. Polyethylene plastic covers the bare wire at the same time;

(5) Cutting

Determine the position of the initial feeding position of the cable, and after partial stripping, find the cutting mark points at both ends of the standard wire at the center of the cable body, and cut the cable body with a non-liquid cutting machine to ensure the cutting end face of the cable and the axis of the cable Verticality, then stripping the wire according to the set length;

(6) Anchoring

The anchor is the main connection structure for transmitting the cable force to the tower and the beam. The anchor is protected by hot-dip galvanizing or paint coating. The thickness of the hot-dip galvanizing is not less than 90μηι. The thickness of the paint coating is according to the steel structure specification and design. Request for confirmation;

The anchoring is carried out by using cold-casting head anchors or hot-casting anchors. The specific operations are as follows:

1 cold cast skull anchor

a Fix the wire end and the anchor cup on the anchoring table, clean the steel wire of the anchor cup part, clean and rust, and clean the inner wall of the anchor cup;

b threading the hoe: The steel wire at both ends is evenly divided according to the hole position of the anchor plate. The hoe is used for each wire by the boring head. The size of the hoe is as follows: the diameter of the hoe is ≥1.40, the height of the hoe is ≥1.00, D is Wire diameter

c The main components of the cold-filled filler in the anchor cup include steel balls, rock powder, epoxy resin, curing agent, dibutyl grease, and thinner. The evenly mixed cold filler is poured into the anchor cup, and the same pumping is combined with the vibration pump to vibrate. Allowing the cold packing to adequately fill the gap between the anchor and the wire;

2 hot cast anchor

Casting with zinc-copper or zinc-copper-aluminum alloy, the composition of zinc-copper alloy is 98%±0.2 <3⁄4 zinc and 2<3⁄4±0.

2 <¾ copper; zinc and copper content of the aluminum alloy is 4% ~7 <¾, a copper content of 1% ~2 <¾, zinc content 91 ^{^<¾~95 <¾,}

The anchoring process is as follows:

a wire end and anchor cup are vertically fixed on the anchoring platform, and the zinc-aluminum alloy coated steel wire of the anchor cup portion is concentrically scattered, and then the oil stain and rust on the surface of the steel wire are cleaned, and the inner wall of the anchor cup is cleaned at the same time;

b The wire in the anchor cup should keep the center of the cable body in line with the center of the anchor cup and guarantee any wire The part is not in contact with the anchor cup;

The lower part of the C anchor cup should be sealed to prevent the injected alloy from leaking out from the lower port. The anchor cup should be preheated before casting zinc-copper or zinc-copper-aluminum alloy;

dInject the alloy into the anchor cup, and avoid any vibration. The casting should be completed once and must not be interrupted.

(7) Tension / top pressure detection

According to the different filling and anchoring materials, the cold-casting anchor cable is tested for tension before leaving the factory, and the hot-cast anchor cable is used for top pressure detection. The specific operations are as follows:

Cold casting anchor cable, the tensile tension of the cable takes 1.1~1.5 times of the design cable force, and the tension of the casting body in the anchor cup is not more than 6mm.

After tensioning, the tension is unloaded to 20% of the tension or the bridge cable force. Under this condition, the cable length measurement is performed. The length measurement should be carried out under constant temperature and light protection conditions. The calculation of the unstressed length is as follows:

L eo—the unstressed length at the reference temperature of the cable, in m;

L _CP — The cable is subjected to tension P ₂ . Length, in m;

P 20 - 20% over tension, in N;

A—the nominal cross-sectional area of the wire bundle, in mm 2 ;

E—elastic modulus, in MPa;

——The cable expansion coefficient of the cable stayed at 0.000012/°C;

T—the length of the stay cable measures the stable uniform temperature of the crucible, in °C;

t o—the design temperature of the cable-stayed bridge, determined by the design, in °C;

The top pressure of the hot-cast anchor cable is 1.25 times of the designed cable force. The completion of the top pressure requires that the retraction value of the cast body in the anchor cup does not exceed 6 mm;

(8) Coil

The cable is coiled in the form of a tire or steel disc. The outer surface of the cable is packaged before coiling, and then the coil is wound up layer by layer. The inner diameter of the coil is required to be no less than 20 times the outer diameter of the cable, and the inner diameter of the coil is not Less than 1.6m. [Claim 2] The hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable according to claim 1

, characterized by: The length of the standard wire in step (2) determines the stress and temperature correction formula of 吋:

L=L ox [ (1+F/EA) +α (Τ-20) ]

Where: L: length under steel wire stress, m;

L ₀ : unstressed design length, m;

F: tension, N;

E: the elastic modulus of the steel wire, MPa, the standard wire is the measured value;

A: the cross-sectional area of the steel wire, m ² , the measured value of the standard wire is taken;

α: steel wire expansion coefficient;

Τ: Ambient temperature.

[Claim 3] The hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable according to claim 1

It is characterized by: Step (4) During the extrusion process, a magnetic field is placed above the cable body to allow the cable body to be in a suspended state, and the polyethylene protective layer and the bare wire are arranged concentrically after extrusion.

[Claim 4] The hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable according to claim 1

The method is characterized in that: in the step (4), a spiral or an embossing is arranged on the outer surface of the polyethylene protective layer, and the drag coefficient is not more than 0.8.

[Claim 5] The hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable according to claim 1

The feature is as follows: The anchor structure in the step (6) is a nut-rotating type of both ends, a pad-type gap type or a fork-pin type.

[Claim 6] The method for manufacturing a hot extruded polyethylene zinc aluminum alloy coated steel wire cable according to claim 1

, characterized in that: the stress-free length error requirement of the cable at the reference temperature in step (7) is:

LC0≤100m, the cable length error should not exceed 10mm;

LC0>100m, cable length error should not exceed LC0/20000+5mm.

[Claim 7] The hot-extruded polyethylene-zinc-aluminum alloy coated steel wire cable according to claim 1

The wrap tape is a high-strength polyester fiber tape having a bandwidth of 40 to 60 mm and a tensile strength of not less than 500 N/25 mm ² .