阅读说明：本技术 一种悬索桥主缆用预制平行钢丝预成型索股的制作方法 (Manufacturing method of prefabricated parallel steel wire preformed strand for main cable of suspension bridge ) 是由 张罗美 魏杰 黄志标 于 2019-09-17 设计创作，主要内容包括：本发明公开了一种悬索桥主缆用预制平行钢丝预成型索股的制作方法,S1)标志钢丝的制作；S2)标准长度钢丝制作；S3)标记索鞍点；S4)放丝成型；S5)索鞍处的预成型；S6)预制平行钢丝预成型索股的盘卷；S7)预制平行钢丝预成型索股的灌锚；本发明公开的预制平行钢丝索股的制作方法相对于传统工艺更为简约,且整个加工过程采用黄铜合金制作标志钢丝和采用紫铜合金制作标准长度钢丝,使得整个标志钢丝和标准长度钢丝参考更为明确,更便于寻找,进一步提升整个加工的便利性；同时利用连接夹具连接索股和主索鞍以及散索鞍,无需对索股的局部进行二次整形加工,不仅简约加工工艺过程,且能最大限度的保护索股的整体性,保证索股的制作钢丝完整性。(The invention discloses a method for manufacturing a prefabricated parallel steel wire preformed strand for a main cable of a suspension bridge, and S1) manufacturing a mark steel wire; s2) manufacturing steel wires with standard lengths; s3) marking a saddle point; s4) wire releasing and forming; s5) preforming at the cable saddle; s6), coiling the preformed parallel steel wire rope strands; s7) prefabricating an anchor of the parallel steel wire preformed cable strand; compared with the traditional process, the manufacturing method of the prefabricated parallel steel wire rope strand is simpler, and the whole processing process adopts brass alloy to manufacture the marking steel wire and red copper alloy to manufacture the standard length steel wire, so that the whole marking steel wire and the standard length steel wire are more clearly referenced and are more convenient to find, and the convenience of the whole processing is further improved; meanwhile, the connecting clamp is utilized to connect the cable strand, the main cable saddle and the scattered cable saddle, secondary shaping processing is not needed to be carried out on the local part of the cable strand, the processing process is simplified, the integrity of the cable strand can be protected to the maximum extent, and the integrity of a manufactured steel wire of the cable strand is guaranteed.)

1. A manufacturing method of a prefabricated parallel steel wire preformed strand for a main cable of a suspension bridge is characterized by comprising the following steps:

s1) making of the steel wire: a brass alloy wire is manufactured by brass alloy and is used as a steel wire in the prefabricated parallel steel wire cable strand and participates in the manufacturing of the prefabricated parallel steel wire cable strand, and the brass alloy wire is the positioning mark steel wire;

s2) manufacturing steel wires with standard lengths: two or more red copper alloy wires with standard lengths are manufactured by using red copper alloy and are used as manufacturing steel wires in the prefabricated parallel steel wire cable strands, and the red copper alloy wires are used for controlling the length precision of the parallel steel wire bundles; the standard wires are used for controlling the overall length of the main cable strand of the suspension bridge, and preferably, all the red copper alloy wires are uniformly arranged at the corners of the cross section of the prefabricated parallel steel wire cable strand;

s3) marking the saddle point: making obvious position marks at characteristic positions corresponding to a scattered cable saddle control point, a main cable saddle center point, a side span middle, a mid-span middle and an anchor span anchor head starting point of 1 meter in the standard-length steel wire in the step S2 according to design requirements;

s4) wire releasing and forming: the prefabricated parallel steel wire rope strand consists of a plurality of steel wires, the tension of each circle of steel wire is adjusted after the looping steel wires with the same multiple length and the same rotation direction are placed into a pay-off rack during the forming, the section shape of the parallel steel wires is formed by a rolling die consisting of shaping wheels during the manufacturing of the prefabricated parallel steel wire rope strand, the rolling die has the section shape matched with the section shape of the rope strand, and then the formed parallel steel wire bundle is shaped and bound at equal intervals by a high-strength shaping wrapping belt;

s5) preforming at the saddle: firstly, connecting clamp installation is carried out on cable strands at corresponding positions of a main cable saddle and a scattered cable saddle respectively, and then the main cable saddle and the scattered cable saddle are fixedly installed by utilizing the connecting clamp; the connecting clamp is used for connecting the cable strand, the main cable saddle and the scattered cable saddle, secondary shaping processing is not needed to be carried out on the local part of the cable strand, the processing process is simplified, the integrity of the cable strand can be protected to the maximum extent, and the integrity of a steel wire for manufacturing the cable strand is ensured;

s6) coiling of preformed parallel wire strands: pre-preparing parallel steel wire strands, and coiling the steel wire strands by using a demolding and disk rack, wherein the diameter of the coiled steel wire strands is not less than 30 times of the diameter of the cable strands;

s7) anchor pouring of the prefabricated parallel steel wire preformed cable strand: the anchorage device is a main structure which transfers the cable force of the prefabricated parallel steel wire preformed cable strand to an anchorage system and adopts alloy for casting; the anchor grouting process comprises the following steps: firstly, a pile locking disc (100) is sleeved at the end of a steel wire strand, then the pile locking disc (100) is fixedly arranged in the inner cavity of an anchor cup through bolts, the center of the wire strand is kept completely consistent with the center of the anchor cup, and any part of the steel wire is not contacted with the anchor cup; and finally, sealing the lower opening of the anchor cup and filling alloy liquid.

2. The method of claim 1, wherein the diameter of the brass alloy wire is one-fourth of the diameter of the preformed parallel wire strand.

3. The method of claim 2, wherein the diameter of the copper alloy wire is one third of the diameter of the preformed parallel steel wire strand.

4. The method of claim 1, wherein a steel wire hoop or a sizing fixture is further installed at the characteristic points of the formed parallel steel wire bundle, and the characteristic points include a front-back position of the saddle center point, a side span center, a side span anchor head start point and a mid span center on the strand.

5. The method of claim 1, wherein the cross-section of the installation cavity of the connecting clamp is identical to the cross-section of the cable strand.

6. The method for manufacturing a preformed strand of prefabricated parallel steel wires for a main cable of a suspension bridge according to any one of claims 1 to 5, wherein the vertical length of the steel wire strand under the anchor cup in the step S7 is not less than 20 times the diameter of the strand, and the bending radius is more than 30 times the diameter of the strand.

7. The method of claim 6, wherein the pre-heating of the anchor cup is required before the alloy liquid is poured into the anchor cup in step S7; and when the alloy liquid is injected into the anchor cup, the alloy liquid is poured in one step.

Technical Field

The invention relates to the technical field of prefabricated parallel steel wire preformed strands, in particular to a manufacturing method of a prefabricated parallel steel wire preformed strand for a main cable of a suspension bridge.

Background

Suspension bridges, also known as suspension bridges, are ancient bridge types, and people have long used rattans, bamboos and other materials to manufacture suspension bridges so as to solve traffic problems. The construction method of the main cable of the large-span suspension bridge comprises two construction methods, namely an Air Spinning method (AS) and a Prefabricated Parallel Wire Strand method (PPWS). The former is abbreviated AS AS method, and the latter is abbreviated AS PS method or PWS (parallel wire Strands) method. Each cable of the AS method contains a small number of total strands, about 30-90 strands, but each strand contains more than 400-500 filaments. Therefore, the single-strand anchoring tonnage is large, and the anchoring space is relatively concentrated. The main disadvantages of the AS method are poor wind resistance and much labor required for erecting (assembling) the main cable.

Chinese patent 201510906592.8 (grant No. CN 105421244B; grant No. 2017.07.28) is a method for pre-forming a plurality of galvanized steel wires into a regular hexagon cable strand in a factory, which mainly includes the steps of making and setting a sign steel wire and a standard steel wire and laying and forming the steel wires, and pre-forming the steel wires into a quadrilateral section at a position corresponding to a main cable saddle and a scattered cable saddle so as to facilitate saddle-entering operation, and anchoring two ends of the cable strand by hot-cast anchors, then coiling and transporting the cable strand to an erection site, and erecting the cable strand by strand. The method is not limited by construction site, has small influence of climate factor, is convenient for control of factory production management, relatively shortens construction time of site cable erection, improves cable erection efficiency and has stable quality.

However, there are problems in the implementation of this method, such as the use of color-coated marker wires, which are difficult to be separated directly from the cross-section, and the color coating is easy to be removed during the processing, resulting in unclear marker wires; in addition, the cable saddle preforming process needs to reshape the partial cross section of the cable strand preforming part, so that the problem of partial steel wire breakage is easily caused, and the overall quality is affected. Therefore, the invention provides a method for manufacturing a prefabricated parallel steel wire preformed cable strand for a main cable of a suspension bridge, which is further improved.

Disclosure of Invention

The invention aims to provide a method for manufacturing a prefabricated parallel steel wire preformed cable strand for a main cable of a suspension bridge, which aims to solve the problems in the background technology.

In order to achieve the purpose, the invention provides the following technical scheme:

a manufacturing method of a prefabricated parallel steel wire preformed strand for a main cable of a suspension bridge comprises the following steps:

s1) making of the steel wire: a brass alloy wire is manufactured by brass alloy and is used as a steel wire in the prefabricated parallel steel wire cable strand and participates in the manufacturing of the prefabricated parallel steel wire cable strand, and the brass alloy wire is the positioning mark steel wire;

s2) manufacturing steel wires with standard lengths: two or more red copper alloy wires with standard lengths are manufactured by using red copper alloy and are used as manufacturing steel wires in the prefabricated parallel steel wire cable strands, and the red copper alloy wires are used for controlling the length precision of the parallel steel wire bundles; the standard wires are used for controlling the overall length of the main cable strand of the suspension bridge, and preferably, all the red copper alloy wires are uniformly arranged at the corners of the cross section of the prefabricated parallel steel wire cable strand;

s3) marking the saddle point: making obvious position marks at characteristic positions corresponding to a scattered cable saddle control point, a main cable saddle center point, a side span middle, a mid-span middle and an anchor span anchor head starting point of 1 meter in the standard-length steel wire in the step S2 according to design requirements;

s4) wire releasing and forming: the prefabricated parallel steel wire rope strand consists of a plurality of steel wires, the tension of each circle of steel wire is adjusted after the looping steel wires with the same multiple length and the same rotation direction are placed into a pay-off rack during the forming, the section shape of the parallel steel wires is formed by a rolling die consisting of shaping wheels during the manufacturing of the prefabricated parallel steel wire rope strand, the rolling die has the section shape matched with the section shape of the rope strand, and then the formed parallel steel wire bundle is shaped and bound at equal intervals by a high-strength shaping wrapping belt;

s5) preforming at the saddle: firstly, connecting clamp installation is carried out on cable strands at corresponding positions of a main cable saddle and a scattered cable saddle respectively, and then the main cable saddle and the scattered cable saddle are fixedly installed by utilizing the connecting clamp; the connecting clamp is used for connecting the cable strand, the main cable saddle and the scattered cable saddle, secondary shaping processing is not needed to be carried out on the local part of the cable strand, the processing process is simplified, the integrity of the cable strand can be protected to the maximum extent, and the integrity of a steel wire for manufacturing the cable strand is ensured;

s6) coiling of preformed parallel wire strands: pre-preparing parallel steel wire strands, and coiling the steel wire strands by using a demolding and disk rack, wherein the diameter of the coiled steel wire strands is not less than 30 times of the diameter of the cable strands;

s7) anchor pouring of the prefabricated parallel steel wire preformed cable strand: the anchorage device is a main structure which transfers the cable force of the prefabricated parallel steel wire preformed cable strand to an anchorage system and adopts alloy for casting; the anchor grouting process comprises the following steps: firstly, a pile locking disc is arranged at the end head of a steel wire rope strand, then the pile locking disc is fixedly arranged in the inner cavity of an anchor cup through a bolt, the center of the wire strand is kept completely consistent with the center of the anchor cup, and any part of a steel wire is not contacted with the anchor cup; and finally, sealing the lower opening of the anchor cup and filling alloy liquid.

In a further embodiment, the diameter of the brass alloy wire is one quarter of the diameter of the wire of the preformed parallel strand wire.

In a further embodiment the diameter of the copper alloy wires is one third of the diameter of the wires of the preformed parallel wire strand.

In a further embodiment, a steel wire hoop or a shaping fixture is further arranged at the characteristic point of the formed parallel steel wire bundle, wherein the characteristic point comprises a front-back position corresponding to the central point of the scattered cable saddle, a front-back position corresponding to the central point of the main cable saddle, a side span midspan, a side span anchor head starting point and a mid span midspan on the cable strand.

In a further embodiment, the cross-section of the mounting cavity of the attachment clip is substantially the same shape as the cross-section of the strand.

In a further embodiment, the vertical length of the wire strand under the anchor cup in step S7 is not less than 20 times the strand diameter, and the bend radius should be greater than 30 times the strand diameter.

In a further embodiment, the anchor cup needs to be preheated before the alloy liquid is poured into the anchor cup in the step S7; and when the alloy liquid is injected into the anchor cup, the alloy liquid is poured in one step.

Compared with the prior art, the invention has the beneficial effects that:

1. compared with the traditional process, the manufacturing method of the prefabricated parallel steel wire rope strand disclosed by the invention is simpler, and the whole processing process adopts brass alloy to manufacture the marking steel wire and red copper alloy to manufacture the standard-length steel wire, so that the whole marking steel wire and the standard-length steel wire are more clearly referenced, the searching is more convenient, and the convenience of the whole processing is further improved.

2. The steel wire made of the brass alloy material is used as the marking steel wire, the color of the cross section of the marking steel wire is yellow, the marking steel wire can be easily found in the steel wire of the cross section of the cable strand, and later-stage installation and maintenance are facilitated; the phenomenon that the painting is removed in the processing process is avoided, and the marking function is ensured;

3. according to the invention, the red copper alloy is adopted to manufacture the steel wire with the standard length, so that the color of the steel wire with the standard length is reddish purple, the steel wire with the standard length is convenient to search in a strand steel wire, and the steel wire is convenient to search and compare by workers in the processing process, so that the length precision of a parallel steel wire bundle is ensured;

4. the connecting clamp is used for connecting the cable strand, the main cable saddle and the scattered cable saddle, secondary shaping processing is not needed to be carried out on the local part of the cable strand, the processing process is simplified, the integrity of the cable strand can be protected to the maximum extent, and the integrity of the manufactured steel wires of the cable strand is ensured.

Drawings

FIG. 1 is a schematic view of a work flow diagram of a method of making a preformed strand of pre-fabricated parallel wires for a main cable of a suspension bridge;

fig. 2 is a schematic structural diagram of a pile locking disc in the manufacturing method of the prefabricated parallel steel wire preformed strand for the main cable of the suspension bridge.

In the figure: 100-pile locking disk.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Referring to fig. 1-2, a method for manufacturing a prefabricated parallel steel wire preformed strand for a main cable of a suspension bridge includes the following steps:

s1) making of the steel wire: a brass alloy wire is manufactured by brass alloy and is used as a 'steel wire' in the prefabricated parallel steel wire cable strand and participates in the manufacturing of the prefabricated parallel steel wire cable strand, the brass alloy wire is a positioning mark steel wire, and the diameter of the brass alloy steel wire is one fourth of that of the prefabricated parallel steel wire cable strand;

s2) manufacturing steel wires with standard lengths: two or more red copper alloy wires with standard lengths are manufactured by using red copper alloy and are used as manufacturing steel wires in the prefabricated parallel steel wire cable strands, and the red copper alloy wires are used for controlling the length precision of the parallel steel wire bundles; the diameter of the red copper alloy wire is one third of that of the prefabricated parallel steel wire rope strand; the standard wires are used for controlling the overall length of the main cable strand of the suspension bridge, and preferably, all the red copper alloy wires are uniformly arranged at the corners of the cross section of the prefabricated parallel steel wire cable strand; the purple red copper alloy is obviously shown in all the steel wire bundles, so that the purple red copper alloy is convenient for workers to observe at any time, and the accuracy of the manufactured length is ensured;

s3) marking the saddle point: making obvious position marks at characteristic positions corresponding to a scattered cable saddle control point, a main cable saddle center point, a side span middle, a mid-span middle and an anchor span anchor head starting point of 1 meter in the standard-length steel wire in the step S2 according to design requirements;

s4) wire releasing and forming: the prefabricated parallel steel wire rope strand consists of a plurality of steel wires, the tension of each circle of steel wire is adjusted after the looping steel wires with the same multiple length and the same rotation direction are placed into a pay-off rack during the forming, the section shape of the parallel steel wires is formed by a rolling die consisting of shaping wheels during the manufacturing of the prefabricated parallel steel wire rope strand, the rolling die has the section shape matched with the section shape of the rope strand, and then the formed parallel steel wire bundle is shaped and bound at equal intervals by a high-strength shaping wrapping belt; further, a steel wire hoop or a shaping clamp is arranged at a characteristic point of the formed parallel steel wire bundle, and the characteristic point comprises a front position and a rear position of a cable strand corresponding to the central point of the scattered cable saddle, a front position and a rear position of the central point of the main cable saddle, a side span middle, a side span anchor head starting point and a middle span middle; when the prefabricated parallel steel wire rope strand is manufactured, the section shape of the parallel steel wire is molded through a rolling die consisting of a molding wheel, the rolling die has a section shape matched with the section shape of the rope strand, then the molded parallel steel wire bundle is molded and bound at equal intervals by using a high-strength molding wrapping belt so as to ensure that no loose wires, no messy wires and the like are generated in the traction process, and the molding wrapping belt is wound on the surface of the rope strand in the factory prefabrication process so as to well fix the shape of the steel wire bundle;

s5) preforming at the saddle: firstly, connecting clamp installation is carried out on cable strands at corresponding positions of a main cable saddle and a scattered cable saddle respectively, and then the main cable saddle and the scattered cable saddle are fixedly installed by utilizing the connecting clamp; the cross section of the mounting inner cavity of the connecting clamp is completely the same as the cross section of the cable strand, the main cable saddle and the scattered cable saddle are connected by the connecting clamp, secondary shaping processing on the local part of the cable strand is not needed, the processing process is simplified, the integrity of the cable strand can be protected to the maximum extent, and the integrity of the manufactured steel wires of the cable strand is ensured;

s6) coiling of preformed parallel wire strands: pre-preparing parallel steel wire strands, and coiling the steel wire strands by using a demolding and disk rack, wherein the diameter of the coiled steel wire strands is not less than 30 times of the diameter of the cable strands;

s7) anchor pouring of the prefabricated parallel steel wire preformed cable strand: the anchorage device is a main structure which transfers the cable force of the prefabricated parallel steel wire preformed cable strand to an anchorage system and adopts alloy for casting; the anchor grouting process comprises the following steps: firstly, a pile locking disc 100 is arranged at an end head sleeve of a steel wire strand, then the pile locking disc 100 is fixedly arranged in an inner cavity of an anchor cup through bolts, the center of the wire strand is kept completely consistent with the center of the anchor cup, and any part of a steel wire is not contacted with the anchor cup, wherein the vertical length of the steel wire strand under the anchor cup is not less than 20 times of the diameter of the strand, and the bending radius of the steel wire strand is more than 30 times of the diameter of the strand; finally, sealing the lower opening of the anchor cup and pouring alloy liquid, wherein the anchor cup needs to be preheated before the alloy liquid is poured into the anchor cup; and when the alloy liquid is injected into the anchor cup, the alloy liquid is poured in one step.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.