CN116876341A - Ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and manufacturing method thereof - Google Patents
Ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and manufacturing method thereof Download PDFInfo
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- CN116876341A CN116876341A CN202310925808.XA CN202310925808A CN116876341A CN 116876341 A CN116876341 A CN 116876341A CN 202310925808 A CN202310925808 A CN 202310925808A CN 116876341 A CN116876341 A CN 116876341A
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- 239000002131 composite material Substances 0.000 title claims abstract description 22
- 239000004567 concrete Substances 0.000 title claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 238000003466 welding Methods 0.000 claims description 138
- 238000001514 detection method Methods 0.000 claims description 42
- 238000000034 method Methods 0.000 claims description 32
- 238000005452 bending Methods 0.000 claims description 25
- 229910000831 Steel Inorganic materials 0.000 claims description 24
- 238000007689 inspection Methods 0.000 claims description 24
- 239000010959 steel Substances 0.000 claims description 24
- 238000005520 cutting process Methods 0.000 claims description 22
- 238000007789 sealing Methods 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 10
- 239000007787 solid Substances 0.000 claims description 9
- 230000007704 transition Effects 0.000 claims description 8
- 230000008569 process Effects 0.000 claims description 7
- 238000012545 processing Methods 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 6
- 239000006247 magnetic powder Substances 0.000 claims description 5
- 239000003351 stiffener Substances 0.000 claims description 5
- 230000005674 electromagnetic induction Effects 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims 1
- 238000010276 construction Methods 0.000 abstract description 4
- 239000000523 sample Substances 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000012938 design process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 239000011150 reinforced concrete Substances 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000007142 ring opening reaction Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000005493 welding type Methods 0.000 description 1
Classifications
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- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D19/00—Structural or constructional details of bridges
- E01D19/12—Grating or flooring for bridges; Fastening railway sleepers or tracks to bridges
- E01D19/125—Grating or flooring for bridges
-
- 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
- B23K31/12—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 investigating the properties, e.g. the weldability, of materials
- B23K31/125—Weld quality monitoring
-
- 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
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
-
- 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
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Quality & Reliability (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
The application discloses an ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and a manufacturing method thereof, relating to the technical field of bridge construction, wherein the concrete structure comprises: the panel unit is a fold-line-shaped panel; a plurality of beam joint plates which are arranged at intervals on one side of the panel unit; the stiffening ribs are H-shaped, are installed on the panel unit at intervals and extend along the length direction of the panel unit. The application also discloses a manufacturing method of the ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit, and solves the technical problems that the bottom plate unit of the existing steel-concrete composite beam is difficult to weld and low in manufacturing precision.
Description
Technical Field
The application relates to the technical field of bridge construction, in particular to an ultra-wide fold-line-shaped steel-concrete composite beam H-shaped rib bottom plate unit and a manufacturing method thereof.
Background
In consideration of the stress characteristics of the steel girder of the reinforced concrete composite girder bridge and the economy of materials, the bearing requirement of the stiffening rib in the middle buttress area is usually increased while the section of the steel girder at the middle buttress part is enlarged in the design process. In order to adapt to the section change of the box mouth of the steel girder in the bridge length direction, the middle buttress part of the main girder bottom plate unit is required to be designed in a fold line shape, but is limited by the rolling capacity of a steel mill, the panel with the plate width of more than 4 meters is generally required to be subjected to material receiving and butt joint, and the construction method of bending first and then widening in the traditional process is difficult to ensure the manufacturing camber of the fold line-shaped bottom plate unit, so that the matching precision requirement of the site ring mouth of the steel-concrete composite girder bridge cannot be met.
Disclosure of Invention
The application aims to provide an ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and a manufacturing method thereof, which solve the technical problems of difficult welding and low manufacturing precision in the manufacturing of the bottom plate unit of the steel-concrete composite beam in the prior art.
The embodiment of the application discloses an ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit, which comprises:
the panel unit is a fold-line-shaped panel;
a plurality of beam joint plates which are arranged at intervals on one side of the panel unit;
the stiffening ribs are H-shaped, are arranged on the panel unit at intervals and extend along the length direction of the panel unit;
the stiffener includes:
at least two vertical plates which are arranged on the panel unit at intervals;
the cover plate is arranged between the two vertical plates, and the bottom side of the cover plate, the inner wall of the vertical plate and the upper side of the panel unit are combined to form an assembly cavity;
the support plates are arranged on the inner wall of the assembly cavity at intervals and distributed along the length direction of the assembly cavity;
at least two steel gaskets are respectively arranged at two ends of the cover plate;
at least two shrouding set up respectively in the both ends of assembly chamber.
The structural design of the H-shaped stiffening rib is innovatively applied to the bottom plate unit, and the welding efficiency and the quality stability of the bottom plate unit are obviously improved.
Based on the technical scheme, the embodiment of the application can be further improved as follows:
further, each stiffening rib has at least eight steel pads and at least eight sealing plates;
the panel unit is formed by welding and widening a plurality of panels, and the stability of the structure is guaranteed through the plurality of connecting parts.
The application also discloses a manufacturing method of the ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit, which comprises the following steps:
s1: processing parts:
s101: flame cutting is carried out on the vertical plate, the cover plate, the supporting plate, the steel gasket and the sealing plate, a welding groove is cut, and meanwhile, the camber is arranged on the vertical plate;
s102: removing buckling deformation and wave deformation of the panel, so that the plane flatness allowable deviation of the panel is not more than 1mm/1m; performing top bending treatment on the vertical plate and the cover plate, wherein the rise of the rib of the plate needs to be subjected to multi-point jacking uniform and smooth fitting, and the allowable deviation of the rise is not more than 2mm;
s103: drawing bending lines of the vertical plate and the cover plate on the flat tire, and drawing a transverse datum line on the panel;
s104: welding the panel into the panel unit with the transverse reference line as a reference;
s105: correcting the transverse datum line by using the outline dimension of the panel unit in the width direction, drawing a longitudinal datum line by using a transverse datum line perpendicular to the transverse datum line, and drawing an assembly position line of the vertical plate and a bending line of the panel unit by using the longitudinal datum line and the transverse datum line as references;
s106: bending the vertical plate, the cover plate and the panel unit by taking the bending lines of the vertical plate, the cover plate and the panel unit as references;
s2: primary welding of the plate unit:
s201: a plurality of stays with different heights are arranged above the assembly jig, the panel unit is placed on the stays, and a weight block is arranged at the buttress position of the panel unit, so that the back side of the panel unit is closely attached to the stays and fixed by spot welding;
s202: welding the riser to on the panel unit, the riser with the welding seam of panel unit is in the central line both sides of buttress position 1.0m regional internal requirement sets up the groove welding, and the remaining region is the fillet weld requirement, when the welding groove region of riser is to non-groove district transition, 1 is seted up to the plate thickness direction of riser: 5, transitional slopes are used for ensuring uniform and smooth transition of welding seams;
s3: and (3) carrying out secondary splice welding on the plate units:
s301: dividing the vertical plates, dividing two adjacent vertical plates into one stiffening rib, and welding the stiffening rib, wherein the concrete steps of processing each stiffening rib are as follows: symmetrically welding a plurality of support plates on the inner sides of two vertical plates, wherein the interval between two adjacent support plates is not more than 1.5m, and welding the cover plate between the two vertical plates;
s302: carrying out nondestructive inspection on a bevel angle weld joint between the cover plate and the vertical plate by adopting ultrasonic detection, and carrying out the next step after the inspection is qualified;
s4: and (3) three times of splice welding of the plate units:
s401: sequentially assembling the sealing plate and the steel gasket, and assembling a joint plate by taking the longitudinal and transverse datum lines as references;
s402: and welding the joint plate, the sealing plate and the steel gasket to finish the processing.
Based on the technical scheme, the embodiment of the application can be further improved as follows:
further, the welding method in step S105 is as follows: before welding, heating two sides of a butt welding seam of the panel to a preheating temperature through a flexible electromagnetic induction heating belt, setting a pre-deformation amount, and selecting a solid welding wire CO 2 The welding is completed by the gas shielded welding backing and submerged-arc automatic welding filling cover surface composite welding process, the gas shielded welding material adopts a solid welding wire with the diameter of 1.2mm, the submerged-arc welding material adopts a welding wire with the diameter of 5.0mm, and the beneficial effect of the method is that the welding quality is improved by adopting a corresponding welding mode.
Further, the step S1 further includes a second flaw detection, where the first flaw detection is located between the step S104 and the step S105, that is, an ultrasonic detection method is adopted to perform nondestructive flaw detection on a longitudinal butt weld between the panels, and the step S105 is performed after the detection is qualified; otherwise, returning to step S104;
the second flaw detection is that after the step S106, the longitudinal butt welding lines within 150mm range on two sides of the bending position line of the panel are subjected to ray detection, and if the detection is qualified, the step S2 is performed, and the quality is ensured by the aid of the multiple flaw detection.
Further, the step S2 further includes a step S203: and carrying out nondestructive inspection on the foot-attached welding seam by adopting magnetic powder detection, carrying out nondestructive inspection on the bevel angle welding seam by adopting ultrasonic detection, and if the detection is qualified, entering the next step.
And carrying out nondestructive inspection on the fillet weld between the vertical plate and the panel by adopting a magnetic powder detection method, carrying out nondestructive inspection on the fillet weld of the groove by adopting an ultrasonic detection method, and carrying out the next step after the inspection is qualified.
Further, the step S2 further includes a step S204: and (3) thermally correcting, namely removing the weight blocks, thermally correcting the vertical plates in a flame baking mode, wherein the allowable deviation of the perpendicularity between the corrected vertical plates and the panel unit is not more than 0.5mm.
Further, the welding method in step S303 is to use a semi-automatic welding trolley matched with a flux-cored wire CO 2 The gas shielded welding method is used for finishing the welding of the bevel angle weld joint between the cover plate and the vertical plate.
Further, the step S3 further includes the following steps:
s303: and (3) clearing constraint welding seams between the panel and the tire frame stay, checking the line type of the panel unit in a free state, and thermally correcting the panel unit in a flame baking mode, wherein the transverse flatness of the corrected panel unit is not more than 1mm/1m, and the allowable deviation of the bridge-following camber value is 0 to +5mm.
S304: correcting the longitudinal and transverse datum lines of the base plate unit, and then marking two short-side cutting lines with the transverse datum lines according to the actual size of the base plate unit.
S305: and reserving the matched cutting amount for the two short sides of the panel unit, so as to ensure the overall outline size of the bottom plate unit.
Further, the step S4 further includes the following steps:
s403: and carrying out nondestructive inspection on butt welds between the beam joint plates and the panels by adopting ultrasonic detection, and scribing and flame cutting arc parts of the beam joint plates after the butt welds are detected to be qualified, wherein the radius of the arc is 200mm.
One or more technical solutions provided in the embodiments of the present application at least have the following technical effects or advantages:
1. according to the application, the bottom plate unit is improved, the U-shaped rib is changed into the H-shaped rib, and on the premise of ensuring the stress requirement of the steel beam at the middle buttress part, the technical problem of high welding and repairing difficulty in the welding line of the traditional closed U-shaped rib is effectively avoided, and the welding efficiency and the quality stability of the bottom plate unit are obviously improved.
2. The support plates are symmetrically and equidistantly welded on the inner sides of the vertical plates, so that the welding efficiency and the quality stability are improved, the overall rigidity of the H-shaped stiffening rib cover plate during assembly is improved, the distortion of the H-shaped stiffening rib cover plate during splice welding and hoisting is reduced, and the overall assembly welding precision of the H-shaped rib bottom plate unit is greatly improved.
3. The manufacturing method disclosed by the application comprises the steps of making an overall welding sequence of the H-shaped rib bottom plate unit, determining the rule of surrounding welding wrap angles of the end parts of the vertical plates, and providing a welding groove type of welding seams of all parts and a base metal transition principle, wherein the bottom plate unit has high welding efficiency, small post-welding deformation and a one-time test qualification rate of more than 98%.
4. The application establishes the technological process of firstly widening and then bending the panel, determines the assembly process of taking the special assembly jig as the outer tire and taking the vertical plate with preset camber as the inner tire, and is matched with the constraint measure of arranging the weight block in the middle of the plate unit, thereby effectively ensuring the line shape of the finished product manufactured by the bottom plate unit, laying a solid foundation for the follow-up assembly and bridge site construction, and obviously improving the precision of ring opening matching and the line shape of the solid bridge.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present application, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view of an H-shaped rib base plate unit of an ultra-wide folded linear steel-concrete composite beam according to an embodiment of the application;
FIG. 2 is a partial schematic view of FIG. 1;
FIG. 3 is a left side view of FIG. 1;
FIG. 4 is an enlarged schematic view of portion A of FIG. 3;
FIG. 5 is a side view of the panel unit of FIG. 1;
FIG. 6 is a top view of the panel unit of FIG. 1;
FIG. 7 is a schematic diagram of a process flow product of a method for manufacturing an H-shaped rib base plate unit of an ultra-wide folded steel-concrete composite beam according to an embodiment of the application;
FIG. 8 is a schematic view of an assembled jig frame in a method for manufacturing an ultra-wide folded steel-concrete composite beam H-ribbed bottom plate unit according to an embodiment of the application;
1-a panel unit; 2-a beam joint plate; 3-stiffening ribs;
101-a panel;
301-risers; 302-cover plate; 303-assembly chamber; 304-a support plate; 305-steel gasket; 306-sealing plate.
Detailed Description
Embodiments of the technical scheme of the present application will be described in detail below with reference to the accompanying drawings. The following examples are only for more clearly illustrating the technical aspects of the present application, and thus are merely examples, and are not intended to limit the scope of the present application.
It is noted that unless otherwise indicated, technical or scientific terms used herein should be given the ordinary meaning as understood by one of ordinary skill in the art to which this application belongs.
In the present application, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art according to the specific circumstances.
In order to better understand the above technical solutions, the following detailed description will refer to the accompanying drawings and specific embodiments.
Examples:
as shown in fig. 1-6, the embodiment of the application discloses an ultra-wide folded linear steel-concrete composite beam H-shaped rib base plate unit, which comprises the following specific structures:
a panel unit 1, wherein the panel unit 1 is a fold line-shaped panel;
a plurality of beam joint plates 2 installed at intervals on one side of the panel unit 1;
the stiffening ribs 3 are H-shaped, the stiffening ribs 3 are arranged on the panel unit 1 at intervals, and the stiffening ribs 3 extend along the length direction of the panel unit;
the stiffener 3 includes:
at least two risers 301 mounted at intervals on the panel unit 1;
at least one cover plate 302 disposed between the two risers 301, wherein the bottom side of the cover plate 302, the inner wall of the risers 301, and the upper side of the panel unit 1 are combined to form an assembly cavity 303;
a plurality of support plates 304 installed on the inner wall of the assembly chamber 303 at intervals, wherein the support plates 304 are distributed along the length direction of the assembly chamber 303;
at least two steel gaskets 305 respectively disposed at two ends of the cover plate 302;
at least two sealing plates 306 are respectively disposed at two ends of the assembly cavity 303.
In one embodiment, each of the stiffeners 3 has at least eight steel liners 305 and sealing plates 306;
the panel unit 1 is formed by welding a plurality of panels 101.
Example 2:
based on embodiment 1, as shown in fig. 7-8, the application also discloses a manufacturing method of the ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit, which comprises the following steps:
s1: processing parts:
s101: flame cutting is carried out on the vertical plate, the cover plate, the supporting plate, the steel gasket and the sealing plate, a welding groove is cut, and meanwhile, the camber is arranged on the vertical plate; specifically, the method comprises the following steps:
wherein, the vertical plate, the cover plate and the panel adopt a numerical control cutting machine for flame cutting and blanking, and a flame cutting trolley is adopted for cutting a welding groove on the flat tire, wherein, the steel gasket, the supporting plate, the sealing plate and the cross beam joint plate adopt a gate cutting machine for flame cutting and blanking;
when the panel is precisely cut by a numerical control cutting machine, reserving a matched cutting process amount in the length direction, and cutting two short sides of the panel by using a semi-automatic trolley after the stiffening ribs are welded, so that the overall outline size is ensured;
presetting camber when the vertical plate of each H-shaped stiffening rib is precisely cut by a numerical control cutting machine, and when the bottom plate unit is assembled at one time, taking a special assembly jig as an outer tire and the vertical plate of each H-shaped stiffening rib as an inner tire, so as to ensure that the bottom plate unit is manufactured in a linear shape;
s102: removing buckling deformation and wave deformation of the panel, so that the plane flatness allowable deviation of the panel is not more than 1mm/1m; performing top bending treatment on the vertical plate and the cover plate, wherein the rise of the rib of the plate needs to be subjected to multi-point jacking uniform and smooth fitting, and the allowable deviation of the rise is not more than 2mm; the method comprises the following steps:
correcting buckling deformation and wave deformation of the panel by adopting a hydraulic straightener, wherein the allowable deviation of the planeness of the panel is not more than 1mm/1m, jacking and bending the vertical plate and the cover plate by adopting a hydraulic jacking and bending machine, and the rise of the plate rib needs to be uniformly and smoothly fitted by multi-point jacking, the allowable deviation of the rise is not more than 2mm, so that the planeness of the panel and the rise of the longitudinal rib are ensured to meet the manufacturing requirement;
s103: drawing bending lines of the vertical plate and the cover plate on the flat tire, and drawing a transverse datum line on the panel;
s104: welding the panel into the panel unit with the transverse reference line as a reference; the method comprises the following steps: the transverse datum line is taken as a reference, the panel is assembled into a whole, the straightness of the transverse datum line is ensured, a single-sided double-sided V-shaped welding groove is adopted for the butt welding seam of the panel in the width direction and the longitudinal direction, the allowable deviation of the assembly gap before welding of the panel is not more than 0.5mm, and the dislocation in the thickness direction is not more than 0.5mm; heating two sides of a butt welding seam to a preheating temperature requirement through a flexible electromagnetic induction heating belt before welding, setting a pre-deformation amount, adopting a solid welding wire CO2 gas shielded welding backing and a submerged arc automatic welding filling cover surface composite welding process to finish welding, adopting a solid welding wire G49A3C1S6 (phi 1.2 mm) as a gas shielded welding material, and adopting a welding wire S49A4UFB-SU35H5 (phi 5.0 mm) as a submerged arc welding material and combining welding fluxes;
s105: correcting the transverse datum line by using the outline dimension of the panel unit in the width direction, drawing a longitudinal datum line by using a line perpendicular to the transverse datum line, and drawing assembly position lines of two vertical plates and bending lines of the panel unit by using the longitudinal datum line and the transverse datum line as references; the dimension of the sample punch eyes at the two ends of the base line is required to be not less than 50mm from the edge of the plate;
s106: bending the vertical plates, the cover plates and the panel units by taking the bending lines of the two vertical plates, the bending lines of the cover plates and the bending lines of the panel units as references, wherein the bending radius deviation is required to be not more than 2mm;
in the step S1, the method further includes a second flaw detection, wherein the first flaw detection is located between the step S104 and the step S105, that is, the ultrasonic detection method is adopted to perform nondestructive flaw detection on the longitudinal butt weld seam between the panels, and the step S105 is performed after the detection is qualified; otherwise, returning to step S104;
the second flaw detection is that after the step S106, the longitudinal butt welding lines within 150mm range at two sides of the bending position line of the panel are subjected to ray detection, and if the detection is qualified, the step S2 is performed;
s2: primary welding of the plate unit:
s201: a plurality of stays with different heights are arranged above the assembly jig, the panel unit is placed on the stays, and a weight block is arranged at the buttress position of the panel unit, so that the back side of the panel unit is closely attached to the stays and fixed by spot welding; the method comprises the following steps:
the panel unit is subjected to splice welding on a special assembly jig, stays with different longitudinal heights are arranged above the special assembly jig, a weight block is arranged at a buttress position of the panel unit, the back side of the panel unit is closely adhered to the stay below the panel unit and is fixed by spot welding under the constraint action of the weight block, the allowable deviation of the camber elevation of the linear pad of the panel unit is +3 to +7mm, the vertical plate is assembled according to a longitudinal rib assembly position line, the requirement on the perpendicularity between the vertical plate and the panel is not more than 1.0mm, and the direction side, the road center line side and the arrow mark are marked by an oily pen;
s202: welding the riser to on the panel unit, the riser with the welding seam of panel unit is in the central line both sides of buttress position 1.0m regional internal requirement sets up the groove welding, and the remaining region is the fillet weld requirement, when the welding groove region of riser is to non-groove district transition, 1 is seted up to the plate thickness direction of riser: 5, transitional slopes are used for ensuring uniform and smooth transition of welding seams; the method comprises the following steps:
the welding of the corner joint between the vertical plate and the panel is completed by adopting a semi-automatic welding trolley and a flux-cored wire CO2 gas shielded welding method;
s203, performing nondestructive inspection on the fillet weld between the vertical plate and the panel by adopting a magnetic powder detection method, performing nondestructive inspection on the fillet weld of the groove by adopting an ultrasonic detection method, and performing the next step after the inspection is qualified;
s204: removing the weight block, thermally correcting the vertical plate in a flame baking mode, wherein the allowable deviation of the perpendicularity between the corrected vertical plate and the panel is not more than 0.5mm;
s3: and (3) carrying out secondary splice welding on the plate units:
s301: dividing the vertical plates, dividing two adjacent vertical plates into one stiffening rib, and welding the stiffening rib, wherein the concrete steps of processing each stiffening rib are as follows: symmetrically welding a plurality of support plates on the inner sides of two vertical plates, wherein the interval between two adjacent support plates is not more than 1.5m, and welding the cover plate between the two vertical plates;
s302: carrying out nondestructive inspection on a bevel angle weld joint between the cover plate and the vertical plate by adopting ultrasonic detection, and carrying out the next step after the inspection is qualified;
s303: and (3) clearing constraint welding seams between the panel and the tire frame stay, checking the line type of the panel unit in a free state, and thermally correcting the panel unit in a flame baking mode, wherein the transverse flatness of the corrected panel unit is not more than 1mm/1m, and the allowable deviation of the bridge-following camber value is 0 to +5mm.
S304: correcting the longitudinal and transverse datum lines of the panel unit, and then marking two short-side cutting lines with the transverse datum line according to the actual size of the panel unit.
S305: reserving a matched cutting amount for two short sides of the panel unit to ensure the overall outline size of the panel unit;
s4: and (3) three times of splice welding of the plate units:
s401: sequentially assembling the sealing plates and the steel gaskets in each stiffening rib, and assembling the joint plates by taking the longitudinal and transverse datum lines as references;
s402: welding the joint plate, the sealing plate and the steel gasket to finish machining, specifically adopting a solid welding wire CO2 gas shielded welding method to finish welding butt welding seams between the cross beam joint plate and the bottom plate;
s403: and carrying out nondestructive inspection on butt welds between the beam joint plates and the panels by adopting ultrasonic detection, and scribing the arc parts of the flame cutting joint plates to form the beam joint plates after the butt welds are detected to be qualified, wherein the radius of the arc is 200mm.
In step S202 of the application, in order to ensure the quality of butt welding seams of bridge-position block repair segments, the two ends of the welding seams between the vertical plate and the panel adopt 6mm welding angles in the range of 100mm in the length direction, the plate thickness direction adopts 4mm welding angles to carry out manual corner wrapping girth welding, and the formal welding seams and the corner wrapping welding seams adopt 1:5 slope uniform transition.
The nondestructive inspection is carried out in the application, and the qualified standard is required to meet the general standard of the industry.
In order to ensure that enough probe scanning distance is provided when the butt welding seam between the beam joint plate and the panel is detected in an ultrasonic way, the beam joint plate adopts rectangular blanking, and the arc of the beam joint plate is cut by scribing and flame after the butt welding seam is detected to be qualified, and the radius of the arc is 200mm.
The application prefers the H-shaped stiffening rib, thus the plate thickness selection range is large, compared with the existing U-shaped rib (the plate thickness is only 6-12 mm), the stiffening rib can use medium-thickness steel plates, and the requirement of providing high bearing capacity for the plate units is met. Meanwhile, compared with the U-shaped rib, the H-shaped rib has strong applicability, can be used for steel beams with smaller plane curve radius, and overcomes the defect that the U-shaped rib cannot be manufactured in a curve mode.
In the description of the present application, numerous specific details are set forth. However, it is understood that embodiments of the application may be practiced without these specific details. In some instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms are not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present application, and not for limiting the same; although the application has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the application, and are intended to be included within the scope of the appended claims and description.
Claims (10)
1. An ultra-wide folded linear steel-concrete composite beam H-ribbed floor unit comprising:
the panel unit is a fold-line-shaped panel;
a plurality of beam joint plates which are arranged at intervals on one side of the panel unit;
the stiffening ribs are H-shaped, are arranged on the panel unit at intervals and extend along the length direction of the panel unit;
the stiffener includes:
at least two vertical plates which are arranged on the panel unit at intervals;
the cover plate is arranged between the two vertical plates, and the bottom side of the cover plate, the inner wall of the vertical plate and the upper side of the panel unit are combined to form an assembly cavity;
the support plates are arranged on the inner wall of the assembly cavity at intervals and distributed along the length direction of the assembly cavity;
at least two steel gaskets are respectively arranged at two ends of the cover plate;
at least two shrouding set up respectively in the both ends of assembly chamber.
2. The floor unit of claim 1, wherein said steel liner and said closure plate in each of said stiffeners are at least eight;
the panel unit is formed by welding a plurality of panels.
3. The manufacturing method of the ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit is characterized by comprising the following steps of:
s1: processing parts:
s101: flame cutting is carried out on the vertical plate, the cover plate, the supporting plate, the steel gasket and the sealing plate, a welding groove is cut, and meanwhile, the camber is arranged on the vertical plate;
s102: removing buckling deformation and wave deformation of the panel, so that the plane flatness allowable deviation of the panel is not more than 1mm/1m; performing top bending treatment on the vertical plate and the cover plate, wherein the rise of the rib of the plate needs to be subjected to multi-point jacking uniform and smooth fitting, and the allowable deviation of the rise is not more than 2mm;
s103: drawing bending lines of the vertical plate and the cover plate on the flat tire, and drawing a transverse datum line on the panel;
s104: welding the panel into the panel unit with the transverse reference line as a reference;
s105: correcting the transverse datum line by using the outline dimension of the panel unit in the width direction, drawing a longitudinal datum line by using a transverse datum line perpendicular to the transverse datum line, and drawing an assembly position line of the vertical plate and a bending line of the panel unit by using the longitudinal datum line and the transverse datum line as references;
s106: bending the vertical plate, the cover plate and the panel unit by taking the bending lines of the vertical plate, the cover plate and the panel unit as references;
s2: primary welding of the plate unit:
s201: a plurality of stays with different heights are arranged above the assembly jig, the panel unit is placed on the stays, and a weight block is arranged at the buttress position of the panel unit, so that the back side of the panel unit is closely attached to the stays and fixed by spot welding;
s202: welding the riser to on the panel unit, the riser with the welding seam of panel unit is in the central line both sides of buttress position 1.0m regional internal requirement sets up the groove welding, and the remaining region is the fillet weld requirement, when the welding groove region of riser is to non-groove district transition, 1 is seted up to the plate thickness direction of riser: 5, transitional slopes are used for ensuring uniform and smooth transition of welding seams;
s3: and (3) carrying out secondary splice welding on the plate units:
s301: dividing the vertical plates, dividing two adjacent vertical plates into one stiffening rib, and welding the stiffening rib, wherein the concrete steps of processing each stiffening rib are as follows: symmetrically welding a plurality of support plates on the inner sides of two vertical plates, wherein the interval between two adjacent support plates is not more than 1.5m, and welding the cover plate between the two vertical plates;
s302: carrying out nondestructive inspection on a bevel angle weld joint between the cover plate and the vertical plate by adopting ultrasonic detection, and carrying out the next step after the inspection is qualified;
s4: and (3) three times of splice welding of the plate units:
s401: sequentially assembling the sealing plate and the steel gasket, and assembling a joint plate by taking the longitudinal and transverse datum lines as references;
s402: and welding the joint plate, the sealing plate and the steel gasket.
4. The method according to claim 3, wherein the welding method of step S105 is as follows: heating the two sides of the butt welding seam of the panel to a preset state by a flexible electromagnetic induction heating belt before weldingThe heat temperature is required and the pre-deformation is set, solid welding wire CO is selected 2 The welding is completed by the composite welding process of gas shielded welding backing and submerged-arc automatic welding filling cover surface, wherein the gas shielded welding material adopts a solid welding wire with the diameter of 1.2mm, and the submerged-arc welding material adopts a welding wire with the diameter of 5.0 mm.
5. The method according to claim 4, wherein the step S1 further comprises a second flaw detection, wherein the first flaw detection is located between the step S104 and the step S105, that is, the longitudinal butt weld between the panels is subjected to a nondestructive flaw detection by using an ultrasonic detection method, and the step S105 is performed after the inspection is qualified; otherwise, returning to step S104;
and the second flaw detection is that after the step S106, the longitudinal butt welding lines within 150mm range at the two sides of the bending position line of the panel are subjected to ray detection, and if the detection is qualified, the step S2 is performed.
6. The method according to claim 5, wherein the step S2 further comprises step S203: and carrying out nondestructive inspection on the foot-attached welding seam by adopting magnetic powder detection, carrying out nondestructive inspection on the bevel angle welding seam by adopting ultrasonic detection, and if the detection is qualified, entering the next step.
And carrying out nondestructive inspection on the fillet weld between the vertical plate and the panel by adopting a magnetic powder detection method, carrying out nondestructive inspection on the fillet weld of the groove by adopting an ultrasonic detection method, and carrying out the next step after the inspection is qualified.
7. The method according to claim 6, wherein the step S2 further comprises a step S204: and (3) thermally correcting, namely removing the weight blocks, thermally correcting the vertical plates in a flame baking mode, wherein the allowable deviation of the perpendicularity between the corrected vertical plates and the panel unit is not more than 0.5mm.
8. The method according to claim 7, wherein the welding in step S303 is performed by using a semi-automatic welding carriage in combination with a flux-cored wire CO 2 Gas and its preparation methodThe welding method is used for finishing the welding of the bevel angle weld joint between the cover plate and the vertical plate.
9. The method according to claim 8, wherein the step S3 further comprises the steps of:
s303: and (3) clearing constraint welding seams between the panel and the tire frame stay, checking the line type of the panel unit in a free state, and thermally correcting the panel unit in a flame baking mode, wherein the transverse flatness of the corrected panel unit is not more than 1mm/1m, and the allowable deviation of the bridge-following camber value is 0 to +5mm.
S304: correcting the longitudinal and transverse datum lines of the base plate unit, and then marking two short-side cutting lines with the transverse datum lines according to the actual size of the base plate unit.
S305: and reserving the matched cutting amount for the two short sides of the panel unit, so as to ensure the overall outline size of the bottom plate unit.
10. The method according to claim 9, wherein the step S4 further comprises the steps of:
s403: and carrying out nondestructive inspection on butt welds between the beam joint plates and the panels by adopting ultrasonic detection, and scribing the arc parts of the flame cutting joint plates to form the beam joint plates after the butt welds are detected to be qualified, wherein the radius of the arc is 200mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310925808.XA CN116876341A (en) | 2023-07-26 | 2023-07-26 | Ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310925808.XA CN116876341A (en) | 2023-07-26 | 2023-07-26 | Ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and manufacturing method thereof |
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| CN116876341A true CN116876341A (en) | 2023-10-13 |
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| CN202310925808.XA Pending CN116876341A (en) | 2023-07-26 | 2023-07-26 | Ultra-wide folded linear steel-concrete composite beam H-shaped rib bottom plate unit and manufacturing method thereof |
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| Country | Link |
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| CN (1) | CN116876341A (en) |
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- 2023-07-26 CN CN202310925808.XA patent/CN116876341A/en active Pending
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