WO2024041336A1 - 一种复合结构壁大口径螺旋焊接钢管及其制造方法 - Google Patents

一种复合结构壁大口径螺旋焊接钢管及其制造方法 Download PDF

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WO2024041336A1
WO2024041336A1 PCT/CN2023/110713 CN2023110713W WO2024041336A1 WO 2024041336 A1 WO2024041336 A1 WO 2024041336A1 CN 2023110713 W CN2023110713 W CN 2023110713W WO 2024041336 A1 WO2024041336 A1 WO 2024041336A1
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Prior art keywords
steel
layer
steel strip
welded
composite
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PCT/CN2023/110713
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English (en)
French (fr)
Inventor
战福军
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南京大得钢管有限公司
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Priority claimed from CN202211023603.4A external-priority patent/CN115405767A/zh
Priority claimed from CN202222252797.7U external-priority patent/CN218510348U/zh
Application filed by 南京大得钢管有限公司 filed Critical 南京大得钢管有限公司
Publication of WO2024041336A1 publication Critical patent/WO2024041336A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/16—Rigid pipes wound from sheets or strips, with or without reinforcement

Definitions

  • the present invention relates to the technical field of steel pipe welding, and in particular to a composite structural wall large-diameter spiral welded steel pipe and a manufacturing method thereof.
  • P internal pressure
  • D pipe inner diameter
  • ⁇ S allowable stress
  • k weld coefficient (spiral welded pipe)
  • the allowable stress in the above calculation is taken as 2 times Safety factor.
  • the wall thickness of water supply pipes with a diameter of 3m and 0.6MPa is more than 25mm, which is a serious waste of material.
  • the method of increasing the moment of inertia of the pipe wall section can be used.
  • Increasing the wall thickness is also a way to increase the moment of inertia of the pipe wall section, but it is only a proportional multiple relationship, not a geometric multiple relationship.
  • the steel plate material of the steel mill cannot be formed into a steel coil. The state delivery can only be delivered in the state of a single flat steel plate.
  • the processing method of the steel pipe is to first roll a single steel plate into a round shape and then weld butt it into a straight seam to make a single section of steel pipe.
  • the length of a single section of steel pipe is generally 3m long, and then more Single-section steel pipes are butt-welded to make pipe sections of standard length.
  • This method has low production efficiency, and the stress effect of the straight weld is worse than that of the spiral weld.
  • the weld coefficient is lower, and the thickness of the steel plate required is larger than that of the spiral weld of the same specification.
  • the welded pipe is large and wastes material.
  • the double-walled composite structure spiral steel pipe has a very large cross-sectional moment of inertia during the rolling process, so the rolling force is required to be large, and the rolling force is all driven forward by the steel belt.
  • the propulsion force is formed by the driving roller acting on the upper and lower parts of the steel belt to compress the steel belt up and down, and the friction force formed by the roller pressing the steel belt up and down pushes the steel belt.
  • the propulsion force is required to be very large, the steel belt is pushed up and down.
  • the pressure required for the upper and lower rollers to clamp the steel strip is very large.
  • the first purpose of the present invention is to disclose a large-diameter spiral welded steel pipe with a composite structural wall;
  • the second purpose is to disclose a manufacturing method of the above-mentioned large-diameter spiral welded steel pipe with a composite structural wall.
  • the composite structural wall large-diameter spiral welded steel pipe disclosed by the present invention is formed by spiral welding of double-layer composite steel strips; the double-layer composite steel strips include equal-width, parallel, and staggered first steel strip layers. and a second steel belt layer. There are at least two perpendicular reinforcing bars between the first steel belt layer and the second steel belt layer. The reinforcing bars are respectively provided on the first steel belt layer and the second steel belt layer. The lateral ends of both sides of the vertically overlapping portion of the belt layer are arranged together with the steel belt layer. The other two sides of the first steel belt layer and the second steel belt layer are respectively directed toward the reinforcing ribs on both sides. The outside extends to the same length to form a welded edge, and the first steel strip layer, the second steel strip layer and the reinforcing bars at the ends of both sides are welded to each other to form a double-layer composite steel strip.
  • the reinforcing ribs are provided at the side ends of the first steel strip layer and the second steel strip layer, and the outer edges of the reinforcing ribs protrude from the steel strip layer.
  • the contacting reinforcing ribs and adjacent steel strip layers can be welded together, and the pipe wall can be smooth after welding.
  • a plurality of reinforcing bars are spaced between the reinforcing bars on both sides of the steel belt layer to support the interior of the first steel belt layer and the second steel belt layer, and all reinforcements are arranged parallel to each other and extend together.
  • the additional reinforcement bars inside the steel strip layer are integrated with the steel strip layer by penetration welding.
  • the first steel strip layer is formed by a plurality of split steel strips arranged and welded side by side, and the joints of adjacent split steel strips each correspond to a reinforcing rib.
  • the first steel strip layer is located on the outer wall of the pipeline.
  • scissor nails are provided inside the first steel belt layer and the second steel belt layer.
  • steel bars are provided between the first steel belt layer and the second steel belt layer.
  • the gaps between the first steel belt layer and the second steel belt layer are filled with concrete.
  • the reinforcing bars are shaped steel, such as: H-shaped steel or channel steel or angle steel rods or thin steel pipes or steel bars or corrugated steel.
  • the manufacturing method of the above-mentioned large-diameter spiral welded steel pipe with composite structural wall includes the following steps:
  • the two reinforcing bars mentioned in S2 are respectively corresponding to a distance from one end of the first steel strip layer and the other end of the first steel strip layer, and are welded and fixed to form a double-layer composite steel strip;
  • S4 when the steel strip is rolled to complete a circle, it is different from the unfinished steel strip.
  • the protruding part of the reinforcing rib on one side overlaps with the welding on the other side, forming a welding port with the steel strip layer, and the two welding ports inside and outside the pipe are welded and fixed.
  • the remaining reinforcing ribs in S3 except for the two side reinforcing ribs are welded through penetration welding to the second steel strip layer.
  • the first steel strip layer in S3 includes a plurality of split steel strips arranged side by side, which are respectively released from steel coils and placed on the reinforcing ribs.
  • the joints of adjacent split steel strips correspond to one reinforcing rib to form a weld.
  • the three are welded and fixed through welds.
  • the upper and lower pressure rollers entering the delivery propulsion device are pressed on the outside of the first steel belt layer and the second steel belt layer respectively.
  • the upper and lower pressure rollers correspond to the first steel belt layer.
  • a pressure strengthening wheel is provided at the welding edge of the second steel strip layer. The pressure strengthening wheel and the pressure roller are respectively pressed on the inner and outer surfaces of the welding edge to increase the contact surface between the propulsion device and the double-layer composite steel strip, thereby increasing the Propulsion force, and ensure that the steel strip section does not deform under pressure and propulsion force.
  • the spiral welded steel pipe designed in the present invention requires only one reinforcing rib at the welding joint during the manufacturing process, which reduces the amount of steel used.
  • penetration welding technology can be directly used to fix the reinforcing ribs to the steel strip layer, so that the entire steel strip can be used for both steel strip layers without the need for striping.
  • the structure of this patent has a much smaller cross-sectional moment of inertia than the original patented rectangular cross-section composite steel strip, which can greatly reduce the power of the production equipment and at the same time reduce the equipment cost. Structural strength requirements reduce equipment costs.
  • Figure 1 is the welding groove structure diagram of the previous application 202110902131.9;
  • Figure 2 is a structural diagram of the composite steel strip after transitional extrusion deformation of the previous application 202110902131.9;
  • Figure 3 is a structural diagram of a large-diameter spiral welded steel pipe with a composite structural wall according to the present invention
  • Figure 4 is a cross-sectional view of the extension direction of the double-layer composite steel strip of the present invention.
  • Figure 5 is a cross-sectional view of the internal reinforcement of the double-layer composite steel strip of the present invention.
  • Figure 6 is a structural diagram of the split steel strip of the double-layer composite steel strip of the present invention.
  • Figure 7 is a manufacturing flow chart using penetration welding according to the present invention.
  • Figure 8 is a flow chart for manufacturing split steel strips according to the present invention.
  • Figure 9 is a structural diagram of the pressure strengthening wheel of the present invention.
  • Figure 10 is a cross-sectional view of the steel pipe after cutting according to the present invention.
  • Figure 11 is an enlarged structural view of the welding joint at position A in Figure 10 of the present invention.
  • the composite structural wall large-diameter spiral welded steel pipe shown in Figure 3 is formed by spiral coil welding of double-layer composite steel strips.
  • the double-layer composite steel strip includes a first steel strip layer 1 and a second steel strip layer 2 of equal width, parallel and staggered arrangement.
  • the first steel strip layer 1 and the second steel strip layer 2 are provided with two perpendicular reinforcing ribs 3.
  • the reinforcing ribs 3 are respectively arranged at the lateral ends of both sides of the vertically overlapping portion of the first steel strip layer 1 and the second steel strip layer 2, and are connected with
  • the steel belt layers are arranged in a common extension, and the other two sides of the first steel belt layer 1 and the second steel belt layer 2 respectively extend to the outside of the reinforcement bars 3 on both sides by the same length to form welding edges 4.
  • the steel strip layer 1, the second steel strip layer 2 and the reinforcing bars 3 at the ends of both sides are welded to each other to form a double-layer composite steel strip.
  • the reinforcing ribs 3 are provided behind the side ends of the first steel belt layer 1 and the second steel belt layer 2, and the outer edges of the reinforcing ribs 3 protrude from the steel belt layer.
  • the protruding part of the reinforcing bar on one side overlaps with the welding edge of the other side of the steel strip that reaches the joining position between the steel strips after being rolled in a circle, forming a layer with the steel strip.
  • Welding port 5 through which the steel strip can be coiled and welded.
  • reinforcing rib 3 in the middle of the reinforcing ribs 3 on both sides of the steel belt layer, which provides a strong connection between the first steel belt layer 1 and
  • the second steel strip layer 2 is internally supported, and all reinforcing bars 3 are arranged in parallel and coextensive arrangement.
  • penetration welding is used to weld the steel strip layer into one body.
  • the first steel strip layer 1 needs to be divided into multiple split steel strips 101 and arranged side by side. Welding, the joints of adjacent split steel strips 101 each correspond to a reinforcing rib 3. In order to prevent the continuous weld seam from adversely affecting drainage, during the coil welding of the above-mentioned double-layer composite steel strip, the first steel strip layer 1 is located on the outer wall of the pipeline, so that the weld seam is generated on the outer wall of the pipeline.
  • the reinforcing bars 3 are shaped steel, such as H-shaped steel, channel steel, angle steel rods, thin steel pipes, steel bars, corrugated steel, etc.
  • the manufacturing method of the above-mentioned large-diameter spiral welded steel pipe with composite structural wall includes the following steps:
  • the bars 3 respectively correspond to a distance from one end of the first steel belt layer 1 and the other end of the first steel belt layer 1, and are welded and fixed to form a double-layer composite steel belt, except for the reinforcing bars 3 on both sides.
  • the rest of the outer reinforcing bars 3 are welded to the second steel strip layer 2 by penetration welding. Among them, the outer edges of the reinforcing ribs 3 at the side ends of the first steel strip layer 1 and the second steel strip layer 2 protrude from the steel strip.
  • the first steel strip layer 1 is divided into two split steel strips 101 arranged side by side, each made of steel coils. It is released and placed on the reinforcing rib 3. The joints of the adjacent split steel strips 101 correspond to one reinforcing rib 3 to form a weld, and the three are welded and fixed through the weld.
  • the process is shown in Figure 8.
  • the upper and lower pressure rollers entering the delivery propulsion device are pressed on the outside of the first steel belt layer 1 and the second steel belt layer 2 respectively.
  • the upper and lower pressure rollers correspond to
  • the welding edges 4 of the first steel strip layer 1 and the second steel strip layer 2 are respectively provided with pressure intensifying wheels 6.
  • the pressure intensifying wheels 6 and the pressure rollers are respectively pressed on the inner and outer surfaces of the welding edges 4, and then are spirally processed by the processing equipment.
  • the steel pipe is bent and rolled into a round shape, and the two welds inside and outside the pipe are continuously welded, and the steel pipe is continuously formed.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Rigid Pipes And Flexible Pipes (AREA)

Abstract

公开了一种复合结构壁大口径螺旋焊接钢管及其制造方法。其中钢管由双层复合钢带螺旋状卷圆焊接形成；双层复合钢带包括等宽、平行、错开设置的第一钢带层（1）和第二钢带层（2）；第一钢带层（1）和第二钢带层（2）之间设有至少两条与之垂直的加强筋（3），并与钢带层共同延伸排布；在第一钢带层（1）与第二钢带层（2）竖直方向重合的边沿各设有加强筋（3），螺旋卷圆后，钢管相邻的钢带层通过错边连接。这种螺旋焊接钢管的内管壁与外管壁焊缝不重合，避免了应力集中，增大了钢管的强度，制作时节省材料，卷圆动力要求低。

Description

一种复合结构壁大口径螺旋焊接钢管及其制造方法 技术领域
本发明涉及钢管焊接技术领域，尤其是涉及一种复合结构壁大口径螺旋焊接钢管及其制造方法。
背景技术
目前的大口径钢管用来作为供水管道的较多，且大部分是埋地的。所以钢管自身除了满足管道内部流通介质的内压，还要满足外部载荷的压力，以及防止自身重量引起的鸭蛋形变形，这就需要钢管的壁厚很厚，其实，钢管的主要目的是输送流体，满足内部压力，满足这项要求时钢管的壁厚不需要太厚，例如：3米直径的供水管满足内压时的壁厚＝PD/zk(σS)＝(0.6MPa*3000mm)/(2*0.85*177.5MPa)＝5.96mm，上式中，P：内压力，D：管道内径，σS：许用应力，k：焊缝系数(螺旋焊管)，上述计算中许用应力取2倍安全系数。从上述计算中可以得知，3000mm直径内部压力0.6MPa时钢管壁厚仅5.96mm即可，但实际应用中为了防止钢管的自重变形及埋地时外压引起的变形，往往都要增加壁厚，实际工程中，3m直径，0.6MPa的供水管壁厚都在25mm以上，严重浪费材料，其实防止钢管自重变形及埋地外压引起的变形，可以用增加管壁截面惯性矩的办法，虽然增加壁厚也是增加管壁截面惯性矩的方法，但只是呈正比倍数关系，而不是几何倍数关系，另外，超大口径的钢管，当壁厚大于25mm时，因钢厂的钢板材料无法呈钢卷状态交货，只能是单张平钢板状态交货，所以钢管的加工方式是先单块钢板卷圆，焊对接直缝，制成单节钢管，单节钢管长度一般是3m长，然后多个单节钢管对接焊，制成标准长度的管节，这种方法生产效率低，并且直焊缝受力效果比螺旋焊缝差，焊缝系数低，所需要的钢板厚度比同规格的螺旋焊管大，浪费材料。
本申请人在先申请了一件名称为：一种双壁螺旋焊管及其制造方法，申请号为：202110902131.9的专利，并于今年初开始投入产品试制，在试制过程中发现，钢管内外管壁的焊缝在一条直线上形成焊缝重合，易形成应力集中，另外在卷制试验过程中，螺旋焊缝处的竖向加强环是并排两条，如图1所述，强度太高，给卷圆加工带来困难，也增加了材料成本。
本申请人在试制及研究过程中发现双壁复合结构螺旋钢管，在卷圆过程中由于管壁的截面惯性矩非常大，卷圆力要求大，而卷圆力全部是靠钢带向前的推进力形成的，而推进力是靠作用在钢带上下的驱动辊轴上下压紧钢带，依靠辊轴上下压紧钢带，形成的摩擦力推进钢带，要求推进力非常大时，就要求上下辊轴夹紧钢带的压力非常大，通过计算及实际试验表明，对钢带的压紧力很大时，钢带内的竖向加强筋会产生失稳弯曲现象，复合钢带则会被压扁，如图2所示，这时如果增加竖向加强筋的厚度来解决该问题， 则卷圆力就会增加，钢带推进力就会增加，对钢带的压紧力就会增大，竖向加强筋就会承受更大的压力，还是会被压溃，致使生产加工无法实现。
发明内容
发明目的：为了克服背景技术的不足，本发明第一目的是公开一种复合结构壁大口径螺旋焊接钢管；第二目的是公开上述复合结构壁大口径螺旋焊接钢管的制造方法。
技术方案：本发明所公开的复合结构壁大口径螺旋焊接钢管，由双层复合钢带螺旋状卷焊形成；所述双层复合钢带包括等宽、平行、错开设置的第一钢带层和第二钢带层，所述第一钢带层和第二钢带层之间设有至少两条与之垂直的加强筋，所述加强筋分别设置于第一钢带层与第二钢带层竖直方向重合部分两侧侧向端部，并与钢带层共同延伸排布，所述第一钢带层与第二钢带层的另外两个侧边分别向两侧的加强筋外侧延伸相同长度形成焊边，所述第一钢带层、第二钢带层以及两侧边端部的加强筋相互焊接形成双层复合钢带。
进一步的，所述加强筋设于第一钢带层和第二钢带层侧边端部后，加强筋的外侧边突出钢带层，在所述双层复合钢带卷焊时，一侧加强筋的突出部分与一侧加强筋的突出部分与卷圆一圈后到达钢带间接合位置的另一侧钢带的焊边搭接，与钢带层形成焊接口。
通过此焊接坡口可以将相接触的加强筋以及相邻的钢带层焊接在一起，且能够做到焊后管壁平滑。
进一步的，钢带层两侧的加强筋之间同时间隔设有多条加强筋，对第一钢带层和第二钢带层内部进行支撑，所有加强相互平行共同延伸排布。
进一步的，钢带层内部增设的加强筋采用穿透焊与钢带层焊接为一体。
进一步的，在不采用穿透焊的情况下，所述第一钢带层由多条分体钢带并列排布焊接形成，相邻分体钢带的接缝处均对应一条加强筋，双层复合钢带卷焊时，所述第一钢带层位于管道外壁。
对相邻分体钢带的接缝处进行焊接时，可同时与对应的加强筋进行焊接，实现三者的固定，使得结构更加稳固。
同时，由于分体钢带之间存在焊缝，卷焊成管道时即形成连续的螺旋状焊缝，该螺旋状焊缝并不利于水流快速通过，所以双层复合钢带卷焊时，所述第一钢带层位于管道外壁，使得螺旋状焊缝位于管外壁。
进一步的，所述第一钢带层和第二钢带层内侧设置剪刀钉。
进一步的，所述第一钢带层和第二钢带层之间设置钢筋。
进一步的，所述第一钢带层和第二钢带层的空隙内填充有混凝土。
进一步的，所述加强筋为型钢，如：H型钢或槽钢或角钢钢棒或细钢管或钢筋或波形钢。
上述复合结构壁大口径螺旋焊接钢管的制造方法，包括以下步骤：
S1、从钢卷上放出第二钢带，水平放置形成第二钢带层；
S2、从多个竖向钢卷上放出加强筋，垂直于第二钢带层放置，其中最外侧的两条加强筋，一条置于第二钢带层侧边端部，另一条加强筋置于距离第二钢带层另一侧端部一段距离处，加强筋底部与第二钢带层焊接；
S3、从钢卷上放出与第二钢带等宽的第一钢带，与第二钢带对应水平错开放置于加强筋上形成第一钢带层，S2中提及的两条加强筋分别对应距离第一钢带层一侧端部一段距离处，及第一钢带层的另一侧边端部，并焊接固定形成双层复合钢带；
S4、将双层复合钢带用螺旋钢焊管加工设备螺旋状弯曲卷圆，对管内外两处焊缝持续焊接，钢管持续成型。
其中，S3中置于第一钢带层和第二钢带层侧边端部的加强筋外侧边突出钢带层，S4在卷圆时，当钢带卷圆完成一圈轨迹，与未卷圆的钢带的边缘接触时，一侧加强筋的突出部分与另一侧的焊搭接，与钢带层形成焊接口，对管内外两处焊接口焊接固定。
进一步的，S3中除两侧加强筋外的其余加强筋采用穿透焊与第二钢带层焊接为一体。
进一步的，S3中第一钢带层包括多条并列排布的分体钢带，分别由钢卷放出置于加强筋上，相邻分体钢带接缝均对应一条加强筋，形成焊缝，通过焊缝对三者进行焊接固定。
进一步的，S4中在双层复合钢带制成后，进入递送推进装置的上下压辊，分别压于第一钢带层和第二钢带层外侧，该上下压辊对应第一钢带层和第二钢带层的焊边处分别设有压力加强轮，所述压力加强轮与压辊分别压于焊边的内外面，以增加推进装置与双层复合钢带的接触面，增大推进力，并保证钢带截面在压力和推进力下不变形。
有益效果：与现有技术相比，本发明的优点为：
1、本发明设计的螺旋焊接钢管的内管壁与外管壁焊缝不重合，避免了应力集中，增大了钢管的强度。
2、本发明设计的螺旋焊接钢管在制造过程中焊接口处只需要一个加强筋，使得钢材用量减少。
3、本发明螺旋焊接钢管在推进过程中，得益于复合钢带结构左右两侧单层钢板焊边的设计，以及与之对应的推进结构中，压力加强轮的加入，因为压力加强轮的压力施加在单层钢板上，不必担心复合钢带被压变形，使得推进力增大，并保证钢带截面在压 力和推进力下不变形。
4、本发明双层复合钢带内增加多条加强筋时，可以直接采用穿透焊技术将加强筋与钢带层固定，使得两个钢带层均可以采用整条钢带，无需分条。
5、同样宽度的双层结构的复合钢带，本专利的结构，比原来已申请专利的矩形截面的复合钢带，截面惯性矩大大减小，可以大大减小生产设备的动力，同时减少设备结构方面的强度要求，降低设备造价。
附图说明
图1为在先申请202110902131.9的焊接坡口结构图；
图2为在先申请202110902131.9的复合钢带过渡挤压变形后结构图；
图3为本发明复合结构壁大口径螺旋焊接钢管结构图；
图4为本发明双层复合钢带延伸方向截面图；
图5为本发明双层复合钢带内部加强筋截面图；
图6为本发明双层复合钢带分体钢带结构图；
图7为本发明采用穿透焊制造流程图；
图8为本发明采用分体钢带制造流程图；
图9为本发明压力加强轮结构图；
图10为本发明钢管切断后的剖面图
图11为本发明图10中A处焊接口放大结构图。
具体实施方式
下面结合附图和具体实施方式对本发明进一步详细描述。
如图3所示的复合结构壁大口径螺旋焊接钢管，由双层复合钢带螺旋状卷焊形成。
如图4所示，所述双层复合钢带包括等宽、平行、错开设置的第一钢带层1和第二钢带层2，所述第一钢带层1和第二钢带层2之间设有两条与之垂直的加强筋3，所述加强筋3分别设置于第一钢带层1与第二钢带层2竖直方向重合部分两侧侧向端部，并与钢带层共同延伸排布，所述第一钢带层1与第二钢带层2的另外两个侧边分别向两侧的加强筋3外侧延伸相同长度形成焊边4，所述第一钢带层1、第二钢带层2以及两侧边端部的加强筋3相互焊接形成双层复合钢带。
如图11所示，所述加强筋3设于第一钢带层1和第二钢带层2侧边端部后，加强筋3的外侧边突出钢带层，在所述双层复合钢带卷焊时，一侧加强筋的突出部分与一侧加强筋的突出部分与卷圆一圈后到达钢带间接合位置的另一侧钢带的焊边搭接，与钢带层形成焊接口5，通过焊接口5即可对钢带卷焊成型。
如图5所示，钢带层两侧的加强筋3中间还设有一个加强筋3，对第一钢带层1和 第二钢带层2内部进行支撑，所有加强筋3相互平行共同延伸排布。考虑到钢带层内部增设的加强筋3不便与第一钢带层1进行固定，本实施例采用穿透焊与钢带层焊接为一体。
如图6所示，若不采用穿透焊工艺，考虑到内部加强筋3与钢带层不便焊接，则需要将所述第一钢带层1分为多条分体钢带101并列排布焊接，相邻分体钢带101的接缝处均对应一条加强筋3。为了避免该连续的焊缝对排水产生不利影响，在上述双层复合钢带卷焊时，所述第一钢带层1位于管道外壁，使得焊缝产生于管道外壁。
所述第一钢带层1和第二钢带层2内侧设置剪刀钉，并设置钢筋，在空隙内填充有混凝土。所述加强筋3为型钢，如H型钢或槽钢或角钢钢棒或细钢管或钢筋或波形钢等。
如图7所示，上述复合结构壁大口径螺旋焊接钢管的制造方法，包括以下步骤：
S1、从钢卷上放出第二钢带，水平放置形成第二钢带层2。
S2、从多个竖向钢卷上放出加强筋3，垂直于第二钢带层2放置，其中最外侧的两条加强筋3，一条置于第二钢带层2侧边端部，另一条加强筋3置于距离第二钢带层2另一侧端部一段距离处，在两侧的加强筋3中间还增设一个加强筋，共同延伸排布，加强筋3底部与第二钢带层2焊接。
S3、从钢卷上放出与第二钢带等宽的第一钢带，与第二钢带对应水平错开放置于加强筋3上形成第一钢带层1，S2中提及的两条加强筋3分别对应距离第一钢带层1一侧端部一段距离处，及第一钢带层1的另一侧边端部，并焊接固定形成双层复合钢带，除两侧加强筋3外的其余加强筋3采用穿透焊与第二钢带层2焊接为一体，其中，第一钢带层1和第二钢带层2侧边端部的加强筋3外侧边突出钢带层；若此步骤不用穿透焊工艺，考虑到内部加强筋3与钢带层不便焊接，则将第一钢带层1分为采用两条分体钢带101并列排布，分别由钢卷放出置于加强筋3上，相邻分体钢带101接缝均对应一条加强筋3，形成焊缝，通过焊缝对三者进行焊接固定，流程如图8所示。
S4、在双层复合钢带制成后，进入递送推进装置的上下压辊，分别压于第一钢带层1和第二钢带层2外侧，如图9所示，该上下压辊对应第一钢带层1和第二钢带层2的焊边4处分别设有压力加强轮6，所述压力加强轮6与压辊分别压于焊边4的内外面，再通过加工设备螺旋状弯曲卷圆，对管内外两处焊缝持续焊接，钢管持续成型。在卷圆时，当钢带卷圆完成一圈轨迹，与未卷圆的钢带的边缘接触时，一侧加强筋的突出部分与另一侧的焊边搭接，与钢带层形成焊接口5，对管内外两处焊接口5焊接固定，如图10和11所示。

Claims (14)

  1. 一种复合结构壁大口径螺旋焊接钢管，其特征在于：由双层复合钢带螺旋状卷焊形成；所述双层复合钢带包括等宽、平行、错开设置的第一钢带层(1)和第二钢带层(2)，所述第一钢带层(1)和第二钢带层(2)之间设有至少两条与之垂直的加强筋(3)，所述加强筋(3)分别设置于第一钢带层(1)与第二钢带层(2)竖直方向重合部分两侧侧向端部，并与钢带层共同延伸排布，所述第一钢带层(1)与第二钢带层(2)的另外两个侧边分别向两侧的加强筋(3)外侧延伸相同长度形成焊边(4)，所述第一钢带层(1)、第二钢带层(2)以及两侧边端部的加强筋(3)相互焊接形成双层复合钢带。
  2. 根据权利要求1所述的复合结构壁大口径螺旋焊接钢管，其特征在于：所述加强筋(3)设于第一钢带层(1)和第二钢带层(2)侧边端部后，加强筋(3)的外侧边突出钢带层，在所述双层复合钢带卷焊时，一侧加强筋的突出部分与卷圆一圈后到达钢带间接合位置的另一侧钢带的焊边搭接，与钢带层形成焊接口(5)。
  3. 根据权利要求1所述的复合结构壁大口径螺旋焊接钢管，其特征在于：钢带层两侧的加强筋(3)之间同时间隔设有多条加强筋(3)，对第一钢带层(1)和第二钢带层(2)内部进行支撑，所有加强筋(3)相互平行共同延伸排布。
  4. 根据权利要求3所述的复合结构壁大口径螺旋焊接钢管，其特征在于：钢带层内部增设的加强筋(3)采用穿透焊与钢带层焊接为一体。
  5. 根据权利要求3所述的复合结构壁大口径螺旋焊接钢管，其特征在于：所述第一钢带层(1)由多条分体钢带(101)并列排布焊接形成，相邻分体钢带(101)的接缝处均对应一条加强筋(3)，双层复合钢带卷焊时，所述第一钢带层(1)位于管道外壁。
  6. 根据权利要求1所述的复合结构壁大口径螺旋焊接钢管，其特征在于：所述第一钢带层(1)和第二钢带层(2)内侧设置剪刀钉。
  7. 根据权利要求1所述的复合结构壁大口径螺旋焊接钢管，其特征在于：所述第一钢带层(1)和第二钢带层(2)之间设置钢筋。
  8. 根据权利要求1所述的复合结构壁大口径螺旋焊接钢管，其特征在于：所述第一钢带层(1)和第二钢带层(2)的空隙内填充有混凝土。
  9. 根据权利要求1所述的复合结构壁大口径螺旋焊接钢管，其特征在于：所述加强筋(3)为型钢，如：H型钢或槽钢或角钢钢棒或细钢管或钢筋或波形钢。
  10. 权利要求1所述的复合结构壁大口径螺旋焊接钢管的制造方法，其特征在于，包括以下步骤：
    S1、从钢卷上放出第二钢带，水平放置形成第二钢带层(2)；
    S2、从多个竖向钢卷上放出加强筋(3)，垂直于第二钢带层(2)放置，其中最外 侧的两条加强筋(3)，一条置于第二钢带层(2)侧边端部，另一条加强筋(3)置于距离第二钢带层(2)另一侧端部一段距离处，加强筋(3)底部与第二钢带层(2)焊接；
    S3、从钢卷上放出与第二钢带等宽的第一钢带，与第二钢带对应水平错开放置于加强筋(3)上形成第一钢带层(1)，S2中提及的两条加强筋(3)分别对应距离第一钢带层(1)一侧端部一段距离处，及第一钢带层(1)的另一侧边端部，并焊接固定形成双层复合钢带；
    S4、将双层复合钢带用螺旋钢焊管加工设备螺旋状弯曲卷圆，对管内外两处焊缝持续焊接，钢管持续成型。
  11. 根据权利要求10所述的复合结构壁大口径螺旋焊接钢管的制造方法，其特征在于：S3中置于第一钢带层(1)和第二钢带层(2)侧边端部的加强筋(3)外侧边突出钢带层，S4在卷圆时，当钢带卷圆完成一圈轨迹，与未卷圆的钢带的边缘接触时，一侧加强筋的突出部分与另一侧的焊边搭接，与钢带层形成焊接口(5)，对管内外两处焊接口(5)焊接固定。
  12. 根据权利要求10所述的复合结构壁大口径螺旋焊接钢管的制造方法，其特征在于：S3中除两侧加强筋(3)外的其余加强筋(3)采用穿透焊与第二钢带层(2)焊接为一体。
  13. 根据权利要求10所述的复合结构壁大口径螺旋焊接钢管的制造方法，其特征在于：S3中第一钢带层(1)包括多条并列排布的分体钢带(101)，分别由钢卷放出置于加强筋(3)上，相邻分体钢带(101)接缝均对应一条加强筋(3)，形成焊缝，通过焊缝对三者进行焊接固定。
  14. 根据权利要求10所述的复合结构壁大口径螺旋焊接钢管的制造方法，其特征在于：S4中在双层复合钢带制成后，进入递送推进装置的上下压辊，分别压于第一钢带层(1)和第二钢带层(2)外侧，该上下压辊对应第一钢带层(1)和第二钢带层(2)的焊边(4)处分别设有压力加强轮(6)，所述压力加强轮(6)与压辊分别压于焊边(4)的内外面。
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