阅读说明：本技术 一种椭球形曲面网架钢模板的制作方法 (Method for manufacturing ellipsoidal curved surface net rack steel template ) 是由 张乐 宋其昌 魏金锁 耿秀伟 邱奕 于 2021-07-27 设计创作，主要内容包括：本发明公开了一种椭球形曲面网架钢模板的制作方法。钢模板整体分为共4层63块分块板进行制作；分块板包括型钢框、钢板壳、梁销子、加劲肋和栓钉,型钢框由若干径向梁和环向梁纵横交错固定连接而成,钢板壳底部与型钢框的上表面固定连接,梁销子穿过钢板壳与型钢框固定连接,加劲肋和栓钉固定连接在钢板壳上表面；分块板制作完成后由下向上依次拼接,每层的若干分块板按顺时针或逆时针顺序拼装完整后再拼装下一层。本发明通过对钢模板设计合理的分层分块,制定标准化的施工工艺流程,实现了钢模板的成功预制,为其现场拼装及吊装的实现提供了保障,同时也为核电建造工期的缩短提供了保证。(The invention discloses a method for manufacturing an ellipsoidal curved surface net rack steel template. The steel template is integrally divided into 4 layers of 63 block plates for manufacturing; the partitioning plate comprises a section steel frame, a steel plate shell, beam pins, stiffening ribs and studs, wherein the section steel frame is formed by fixedly connecting a plurality of radial beams and circumferential beams in a criss-cross manner; and after the manufacturing of the block plates is finished, the block plates are sequentially spliced from bottom to top, and a plurality of block plates on each layer are completely spliced according to the clockwise or anticlockwise sequence and then the next layer is spliced. According to the invention, the steel templates are divided into blocks in a layered mode reasonably designed, and a standardized construction process flow is formulated, so that the successful prefabrication of the steel templates is realized, the realization of on-site assembly and hoisting is guaranteed, and meanwhile, the shortening of the nuclear power construction period is guaranteed.)

1. The manufacturing method of the ellipsoidal curved surface net rack steel formwork is characterized in that the whole steel formwork is formed by assembling a plurality of partition plates (1), the partition plates (1) are divided into a plurality of layers and are sequentially spliced from bottom to top, the partition plates (1) on each layer are completely assembled in a clockwise or anticlockwise sequence and then assembled on the next layer, and the adjacent partition plates (1) are formed by welding and assembling;

the partitioning plate comprises a section steel frame (1-1), a steel plate shell (1-2) and a beam pin (1-3);

the section steel frame (1-1) is formed by fixedly connecting a plurality of radial beams (1-1-1) and circumferential beams (1-1-2) which are uniformly distributed in a criss-cross manner, each radial beam (1-1-1) is arranged along the radial direction, the length of each radial beam (1-1-1) is the same as that of each partition plate (1), a plurality of circumferential beams (1-1-2) arranged along the circumferential direction are arranged between every two adjacent radial beams (1-1-1), the radial beams (1-1-1) and the circumferential beams (1-1-2) are section steel, a steel plate shell (1-2) is formed by fixedly splicing a plurality of steel plates arranged along the radial direction, the steel plates are arranged along the direction of the radial beams (1-1-1), one steel plate is arranged between every two radial beams (1-1-1), the bottom of the steel plate shell (1-2) is fixedly connected with the upper surface of the section steel frame (1-1);

the steel plate shell structure is characterized in that a plurality of stiffening ribs (1-4) and studs (1-5) are fixedly connected to the upper surface of the steel plate shell (1-2), a plurality of holes are formed in the steel plate shell (1-2), the sizes of the holes are matched with those of beam pins (1-3), the beam pins (1-3) are the same in number and correspond to the holes one by one, the beam pins (1-3) penetrate through the corresponding holes and are fixedly connected to the section steel frame (1-1), and the beam pins (1-3) and the studs (1-5) are perpendicular to the surface of the steel plate shell (1-2).

2. The method for manufacturing the ellipsoidal curved net rack steel form according to claim 1, wherein the dividing plate (1) is divided into 4 layers, namely a first layer of dividing plate assembly (11), a second layer of dividing plate assembly (12), a third layer of dividing plate assembly (13) and a fourth layer of dividing plate assembly (14);

the first layer of block plate assemblies (11) comprises 22 block plates (1), wherein the angles of the 21 block plates (1) are 16.88 degrees, and the angles of the rest 1 block plates (1) are 5.52 degrees;

the second layer of block plate assembly (12) comprises 24 block plates (1), and the angle of each block plate (1) is 15 degrees;

the third layer of block plate assembly (13) comprises 16 block plates (1), and the angle of each block plate (1) is 22.5 degrees;

the fourth layer of block plate assemblies (14) comprises 1 block plate (1), and the angle of the block plate (1) is 360 degrees.

3. The method for manufacturing the ellipsoidal curved-surface net rack steel template according to claim 1, wherein the specific manufacturing process of the partition plate (1) comprises the following steps:

s1, construction preparation;

s2, lofting and blanking: according to the sizes of the section steel frame (1-1) and the steel plate shell (1-2), lofting to determine the sizes of the section steel and the steel plate, performing blanking cutting according to the sizes of the actual section steel and the actual steel plate to obtain the section steel and the steel plate, and reserving cutting allowance for the section steel;

s3, bending section steel: the radian of the upper surface of the profile steel is attached to the radian of the lower surface of the steel plate shell (1-2);

s4, secondary blanking of the section steel: performing secondary cutting on the allowance reserved at the two ends of the bent section steel;

s5, assembling the section steel frame: the circumferential beams (1-1-1) and the radial beams (1-1-2) are paired;

s6, welding the section steel frame: welding the assembled circumferential beam (1-1-1) and radial beam (1-1-2) to form a steel frame (1-1);

s7, nondestructive testing: detecting the quality of a connecting node and a welding seam between the section steels;

s8, assembling the steel plate shell, the beam pin and the stiffening rib: assembling a steel plate shell (1-2) on the upper surface of the section steel frame (1-1), and assembling a beam pin (1-3) and a stiffening rib (1-4) after the steel plate shell (1-2) is assembled;

s9, welding the steel plate shell, the beam pin and the stiffening rib: welding the steel plate shell (1-2) and the section steel frame (1-1), and welding the beam pin (1-3) and the stiffening rib (1-4) with the steel plate shell (1-2);

s10, stud welding: after the steel plate shell (1-2), the beam pin (1-3) and the stiffening rib (1-4) are welded, marking the position of each stud (1-5) on the upper surface of the steel plate shell (1-2), and welding the studs (1-5) on the corresponding positions of the steel plate shell (1-2);

s11, nondestructive testing;

s12, checking the overall size;

s13, cleaning and spraying paint, cleaning and removing rust, dust, moisture and oil stains in a welding seam area, and spraying paint after cleaning;

and S14, storing the serial number.

4. The method for manufacturing the ellipsoidal curved net rack steel form according to claim 3, wherein in the step S2, when the width of the actual steel plate is smaller than the distance between two adjacent radial beams (1-1-1), the steel plates need to be spliced, and the width of each steel plate in the steel plate shell (1-2) is satisfied by secondary cutting after splicing a plurality of actual steel plates.

5. The method for manufacturing the ellipsoidal curved-surface net rack steel form according to claim 3, wherein in the step S2, when the radial length of the splitter plate (1) exceeds the length of the actual section steel, the section steel needs to be spliced, and the length of the section steel is satisfied by welding and connecting a plurality of actual section steels along the length direction.

6. The method for manufacturing an ellipsoidal curved grid steel form according to claim 3, wherein in step S2, a cutting margin is reserved in the radial direction at the lower part of each steel plate of the steel plate shells (1-2) on the block plates (1) of the first layer block plate assembly (11), the second layer block plate assembly (12) and the third layer block plate assembly (13).

7. The method for manufacturing the ellipsoidal curved-surface net rack steel form according to claim 3, wherein in the step S3, the section steel of the circumferential beam (1-1-1) and the radial beam (1-1-2) is formed by a bending process of cold bending and hot straightening.

8. The method for manufacturing the ellipsoidal curved-surface net rack steel template according to claim 3, wherein in the step S5, the radial beam (1-1-1) and the circumferential beam (1-1-2) are paired by using a special pairing tooling (2);

the special assembly fixture (2) comprises an assembly fixture base (2-1), a hyperboloid arc-shaped plate (2-2) and a plurality of inclined supports (2-3), wherein the base (2-1) is formed by vertically and horizontally fixedly connecting a plurality of steel sections, the bottoms of the inclined supports (2-3) are fixedly connected to the upper surface of the steel sections of the assembly fixture base (2-1), the hyperboloid arc-shaped plate (2-2) is fixedly connected to the top of the inclined supports (2-3), the radian of the top of each inclined support (2-3) is attached to the hyperboloid arc-shaped panel (2-2), and the lower surface of the hyperboloid arc-shaped plate (2-2) is fixedly connected with a plurality of reinforcing angle steels;

when the combined type double-curved-surface arc-shaped panel is combined, the annular beams (1-1-1) and the radial beams (1-1-2) are placed on the upper surface of the double-curved-surface arc-shaped panel (2-2), the positions of each radial beam (1-1-1) and each annular beam (1-1-2) placed on the surface of the double-curved-surface arc-shaped panel (2-2) are determined, each radial beam (1-1-1) is placed on the double-curved-surface arc-shaped panel (2-2) according to the corresponding position, two ends of each radial beam (1-1-1) are fixedly connected with the double-curved-surface arc-shaped panel (2-2) through a detachable first connecting piece, a plurality of limiting plates (2-4) are fixed on two sides of the bottom of each radial beam (1-1), and the limiting plates (2-4) are further fixed on the upper surface of the double-curved-surface arc-shaped panel (2-2);

each annular beam (1-1-2) is placed at a corresponding position on the hyperboloid arc-shaped plate (2-2), two ends of each annular beam (1-1-2) are respectively connected with two adjacent radial beams (1-1-1) in a spot welding mode, the annular beams (1-1-2) are sequentially assembled from one end of the hyperboloid arc-shaped plate (2-2) to the other end in the annular direction, and the assembly of the annular beams (1-1-1) and the radial beams (1-1-2) is completed;

after the circumferential beam (1-1-1) and the radial beam (1-1-2) are assembled, the limiting plates (2-4) on two sides of the bottom of the radial beam (1-1-1) and the first connecting piece, connected with the hyperboloid arc-shaped plate (2-2), at two ends of the radial beam (1-1-1) are removed.

9. The method for manufacturing the ellipsoidal curved-surface net rack steel template according to claim 3, wherein in the step S6, the radial beam (1-1-1) and the circumferential beam (1-1-2) are welded by a special welding tool (3) to obtain the section steel frame (1-1);

the special welding tool (3) comprises a welding tool base (3-1), a supporting upright post (3-2) and a plurality of arc-shaped supporting plates (3-3), the welding tool base (3-1) is formed by vertically and horizontally fixedly connecting a plurality of steel plates, the supporting upright post (3-2) is uniformly and fixedly connected to the welding tool base (3-1), the supporting upright posts (3-2) on two side edges of the welding tool base (3-1) along the length direction are fixedly connected with horizontal connecting rods (3-4), the bottoms of the arc-shaped supporting plates (3-3) are fixedly connected to the upper surface of the supporting upright posts (3-2), and the radian of the tops of the arc-shaped supporting plates (3-3) is matched with the arc-shaped panel (2-2) with the hyperboloid;

hoisting the annular beam (1-1-1) and the radial beam (1-1-2) to a special welding tool (3), attaching an arc-shaped support plate (3-3) to the bottoms of the annular beam (1-1-1) and the radial beam (1-1-2), fixedly connecting the arc-shaped support plate (3-3) with the radial beam (1-1-1) in contact with the arc-shaped support plate, welding from the center to the periphery of the section steel frame (1-1), bottoming the connecting nodes between all the radial beams (1-1-1) and the annular beam (1-1-2), uniformly filling and covering, keeping the welding speed of each position consistent in the welding process until the welding is finished, and finally obtaining the section steel frame (1-1).

10. The method for manufacturing the ellipsoidal curved net rack steel form according to claim 3, wherein in the step S8, each two adjacent radial beams (1-1-1) correspond to a steel plate, the steel plate is placed between the two corresponding radial beams (1-1-1), two sides of the steel plate are respectively located on the two corresponding radial beams (1-1-1), two sides of the steel plate are fixedly connected to the upper surfaces of the two corresponding radial beams (1-1-1) through detachable second connecting pieces, the steel plate is formed by pressing on the upper surface of the steel frame (1-1), and the steel plates are sequentially assembled from the radial beam (1-1-1) on one side to the other side to complete the assembly of the steel plate shell (1-2).

Technical Field

The invention belongs to the technical field of construction of civil construction steel structures of nuclear islands, and particularly relates to a manufacturing method of an ellipsoidal curved surface net rack steel template.

Background

The Hualong I reactor type nuclear power technology is a third-generation nuclear power technology with complete independent intellectual property rights in China, and in order to improve the safety performance of the reactor, a double-layer containment design is adopted, wherein the thickness of a shell is 1.8m, and the reactor mainly plays a role in preventing aircraft collision. The 'Hualong I' extra-sea first pile applies a permanent steel template system in the outer shell dome for the first time, and the steel template is used as a dome bottom die and becomes a part of the outer dome. The permanent steel template system design is adopted, a large number of scaffolds required to be erected by adopting the wood template construction is avoided, the construction period is shortened, and the construction safety risk is reduced. The 'Hualong I' outer dome steel template is semi-ellipsoidal, the diameter of a lower opening is 53m, the total weight is about 366 tons, H-shaped steel is connected in a crisscross mode to serve as a support net rack, a 5mm steel plate is laid above the net rack, and meanwhile, an anchoring nail, a beam pin and the like are welded above the steel plate to serve as connecting accessories.

The 'Hualong I' outer shell dome steel template is adopted for the first time in the world, and compared with an inner shell dome, the steel template is more complex in structural form, completely different in construction process and capable of being adopted without mature construction experience. The manufacturing method is formed by summarizing prefabrication construction of a steel template of a shell dome of 'Hualong I', and is a complete set of complete manufacturing method of the ellipsoidal curved surface net rack steel template.

Disclosure of Invention

Aiming at the defects in the prior art, the invention provides an ellipsoidal curved surface net rack steel template.

In order to realize the purpose, the invention adopts the following technical scheme to manufacture the ellipsoidal curved surface net rack steel template:

the manufacturing method of the ellipsoidal curved surface net rack steel template is characterized in that the steel template is integrally formed by assembling a plurality of partition plates, the partition plates are divided into a plurality of layers and are sequentially spliced from bottom to top, the partition plates on each layer are completely spliced according to a clockwise or anticlockwise sequence and then spliced on the next layer, and the adjacent partition plates are spliced by welding; the partitioning plate comprises a steel section frame, a steel plate shell and a beam pin; the steel framework is formed by fixedly connecting a plurality of radial beams and annular beams which are uniformly distributed in a criss-cross mode, each radial beam is arranged along the radial direction, the length of each radial beam is the same as that of each partition plate, namely the radial size of each partition plate along the radial direction of the steel framework is the same as that of each partition plate, a plurality of annular beams are arranged between every two adjacent radial beams along the annular direction, the length of each annular beam is the arc length between every two adjacent radial beams, and the annular beams arranged between every two adjacent radial beams are arranged along the radial direction; the radial beams and the circumferential beams are all profile steels, the steel plate shell is formed by fixedly splicing a plurality of steel plates arranged along the radial direction, the steel plates are arranged along the radial beam direction, one steel plate is arranged between every two radial beams, and the bottom of the steel plate shell is fixedly connected with the upper surface of the profile steel frame; the upper surface fixed connection of steel sheet shell has a plurality of stiffening rib and toggle pin, it has the trompil of a plurality of quantity to open on the steel sheet shell, trompil size and roof beam pin phase-match, the roof beam pin is the same with trompil quantity and one-to-one, the roof beam pin passes the trompil that corresponds, fixed connection is on shaped steel frame, the steel sheet shell is the hyperboloid arc, roof beam pin and toggle pin are perpendicular with the tangent plane of the steel sheet shell that it locates, the beam pin can improve the joint strength between steel sheet shell and the shaped steel frame, stiffening rib and toggle pin can improve the intensity of steel sheet shell.

In order to optimize the technical scheme, the specific measures adopted further comprise:

furthermore, the block plates are divided into 4 layers which are respectively a first layer block plate assembly, a second layer block plate assembly, a third layer block plate assembly and a fourth layer block plate assembly; the first layer of block plate assemblies comprise 22 block plates, wherein the angles of 21 block plates are 16.88 degrees, and the angles of the rest 1 block plate are 5.52 degrees; the second layer of block plate assembly comprises 24 block plates, and the angle of each block plate is 15 degrees; the third layer of the block plate assembly comprises 16 block plates, and the angle of each block plate is 22.5 degrees; the fourth layer of block plate assembly comprises 1 block plate, and the angle of the block plate is 360 degrees; after all the partition plates are manufactured, the partition plates are sequentially assembled from the first layer to the fourth layer, and the partition plates of each layer are completely assembled according to the clockwise or anticlockwise sequence and then assembled on the next layer.

Further, the specific manufacturing process of the partition plate comprises the following steps:

s1, construction preparation;

s2, lofting and blanking: according to the sizes of the section steel frame and the steel plate shell, setting out to determine the sizes of the section steel and the steel plate, performing blanking cutting according to the sizes of the actual section steel and the actual steel plate to obtain the section steel and the steel plate, and reserving cutting allowance for the section steel;

s3, bending section steel: the radian of the upper surface of the profile steel is attached to the radian of the lower surface of the steel plate shell;

s4, secondary blanking of the section steel: performing secondary cutting on the allowance reserved at the two ends of the bent section steel;

s5, assembling the section steel frame: assembling the circumferential beam and the radial beam;

s6, welding the section steel frame: welding the assembled annular beam and radial beam to form a steel frame;

s7, nondestructive testing: detecting the quality of a connecting node and a welding seam between the section steels;

s8, assembling the steel plate shell, the beam pin and the stiffening rib: assembling a steel plate shell on the upper surface of the steel frame, and in order to avoid deformation during welding of the steel plate, assembling a beam pin and a stiffening rib after the steel plate shell assembly is completed;

s9, welding the steel plate shell, the beam pin and the stiffening rib: after the steel plate shell is welded with the steel frame, the beam pins and the stiffening ribs are welded with the steel plate shell;

s10, stud welding: after the welding of the steel plate shell, the beam pins and the stiffening ribs is finished, marking the position of each stud on the upper surface of the steel plate shell, welding the studs on the corresponding positions of the steel plate shell, and ensuring that the positions of the studs fixed on the steel plate shell have no requirement;

s11, nondestructive testing;

s12, checking the overall size;

s13, cleaning and spraying paint, cleaning and removing rust, dust, moisture and oil stains in a welding seam area, and spraying paint after cleaning;

and S14, storing the serial number.

Further, in step S2, when the width of the actual steel plate is smaller than the distance between two adjacent radial beams, the steel plates need to be spliced, and the width of each steel plate in the steel plate shell is satisfied by secondary cutting after splicing a plurality of actual steel plates.

Further, in the step S2, when the radial length of the plate exceeds the length of the actual section steel, the section steel needs to be spliced, and the length of the section steel is satisfied by welding and connecting a plurality of actual section steels along the length direction.

Further, in step S2, a cutting margin is reserved in the radial direction at the lower portion of each steel plate of the steel plate shell on the split plates of the first layer split plate assembly, the second layer split plate assembly and the third layer split plate assembly.

Further, in step S3, the section steel of the circumferential beam and the radial beam is bent by a bending process of cold bending and hot straightening, and the size of the section steel after cold bending still has a deviation, so that the section steel needs to be finely adjusted by the hot straightening process.

Further, in the step S5, the radial beam and the circumferential beam are paired by using a dedicated pairing tool; the special assembly tool comprises an assembly tool base, a hyperboloid arc plate and a plurality of inclined supports, wherein the base is formed by vertically and horizontally fixedly connecting a plurality of section steels, the bottoms of the inclined supports are fixedly connected to the upper surface of the assembly tool base section steel, the hyperboloid arc plate is fixedly connected to the tops of the inclined supports, the radian of the tops of the inclined supports is fitted with the hyperboloid arc plate, and the lower surface of the hyperboloid arc plate is fixedly connected with a plurality of reinforcing angle steels;

when the combined type radial curved surface plate is combined, the annular beams and the radial beams are placed on the upper surface of the double curved surface plate, the positions of the radial beams and the annular beams on the surface of the double curved surface plate are determined firstly, each radial beam is placed on the double curved surface plate according to the corresponding position, two ends of each radial beam are fixedly connected with the double curved surface plate through a detachable first connecting piece, a plurality of limiting plates are fixed on two sides of the bottom of each radial beam, the limiting plates are also fixed on the upper surface of the double curved surface plate, the first connecting pieces at two ends of the section steel limit the radial movement of the radial beams, and the limiting plates on two sides of the section steel limit the annular movement of the radial beams;

each circumferential beam is placed at a corresponding position on the double-curved-surface arc plate, two ends of each circumferential beam are respectively connected with two adjacent radial beams in a spot welding mode, the circumferential beams are sequentially assembled from one end of the double-curved-surface arc plate to the other end along the circumferential direction, the assembly of the circumferential beams and the radial beams is completed, and after the section steels of each connecting node are spot-welded, the section steel frame has certain strength, so that the structural stability can be kept when the section steels are hoisted to a welding tool; after the circumferential beam and the radial beam are assembled, the limiting plates on two sides of the bottom of the radial beam and the first connecting pieces connected with the hyperboloid arc-shaped plate at two ends of the radial beam are disassembled, and the assembly of the rear separated steel frame and the assembly of the assembly tool are completed, so that the subsequent steel frame can be hoisted conveniently.

Further, in the step S6, the radial beam and the circumferential beam are welded by using a special welding tool to obtain a steel frame; the special welding tool comprises a welding tool base, a supporting upright post and a plurality of arc-shaped supporting plates, wherein the welding tool base is formed by vertically and horizontally fixedly connecting a plurality of steel plates, the supporting upright post is uniformly and fixedly connected to the welding tool base, horizontal connecting rods are fixedly connected to the supporting upright post at two side edges of the welding tool base along the length direction, the bottom of each arc-shaped supporting plate is fixedly connected to the upper surface of the corresponding supporting upright post, and the radian of the top of each arc-shaped supporting plate is matched with the arc-shaped panel of the hyperboloid;

hoisting the annular beam and the radial beam to a special welding tool, fitting the bottom of the annular beam and the bottom of the radial beam with an arc supporting plate, fixedly connecting the arc supporting plate with the radial beam in contact, welding all around from the center of the section steel frame, bottoming connecting nodes between all the radial beams and the annular beam, uniformly filling and capping, keeping the welding speed of each position consistent in the welding process until the welding is finished, and finally obtaining the section steel frame.

Further, in step S8, every two adjacent radial beams correspond to a steel plate, the steel plate is placed between the two corresponding radial beams, two sides of the steel plate are respectively located on the two corresponding radial beams, two sides of the steel plate are fixedly connected to the upper surfaces of the two corresponding radial beams through detachable second connecting pieces, the steel plate is pressed on the upper surface of the profile steel frame to be shaped, and the steel plate is sequentially assembled from the radial beam group on one side to the other side to complete the assembly of the steel plate shell.

The invention has the beneficial effects that:

according to the invention, the steel template is reasonably designed to be divided into the layers, a standardized construction process flow is formulated, and special assembling and welding tools are designed and manufactured, so that the successful prefabrication of the steel template is realized, wherein the cold bending is mainly adopted in the profile steel bending process, and the rapid bending forming of the profile steel can be realized by the process of taking thermal straightening as an auxiliary, so that the hot forming efficiency is higher compared with that of the traditional profile steel; the split plate is directly pressed and formed, the traditional rolling process is omitted, and the manufacturing efficiency of the split plate is greatly improved; in addition, the steel template block design provided by the invention is matched with the manufacturing capability of a workshop, so that the highest production efficiency is ensured, the assembly amount of the existing field partition plates is reduced, the realization of on-site assembly and hoisting is guaranteed, and meanwhile, the construction period of a nuclear power station is also ensured.

Drawings

FIG. 1 is a schematic view of the steel form of the present invention in layered blocks.

FIG. 2 is a schematic diagram of a block plate structure of the present invention.

Fig. 3 is a schematic diagram of the splicing of steel plates according to the present invention.

FIG. 4 is a schematic illustration of the splicing of the section steel of the present invention.

FIG. 5 is a schematic view of a process for bending a section steel (section steel stretch bender) according to the present invention.

FIG. 6 is a schematic view of a process for bending a section steel (section steel bending machine) according to the present invention.

FIG. 7 is a schematic diagram of the structure of the dedicated assembly tooling of the present invention.

FIG. 8 is a schematic view of the forming of the steel frame assembly of the present invention.

FIG. 9 is a schematic view showing the fixing of the pair of steel frames according to the present invention.

Fig. 10 is a schematic structural view of the special welding tool of the present invention.

FIG. 11 is a schematic diagram of the application of the special welding tool of the present invention.

Fig. 12 is a schematic view of the structure of the radial beam and circumferential beam connection node of the present invention.

Detailed Description

The present invention will now be described in further detail with reference to the accompanying drawings.

EXAMPLE 1 Steel form layering partitioning

The embodiment provides an ellipsoid curved surface rack steel form, and the steel form adopts sectional type structural design, as shown in fig. 1, and the steel form is whole to comprise 63 blocks of block board 1, and block board 1 divide into 4 layers altogether, is first layer block board subassembly 11, second layer block board subassembly 12, third layer block board subassembly 13, fourth layer block board subassembly 14 respectively.

The first layer of segmented plate assemblies 11 comprises 22 segmented plates 1, wherein the angles of the 21 segmented plates 1 are all 16.88 degrees, and the angles of the remaining 1 segmented plates 1 are 5.52 degrees.

The second layer of segmented plate assemblies 12 comprises 24 segmented plates 1, each segmented plate 1 having an angle of 15 °.

The third layer of segmented plate assemblies 13 comprises 16 segmented plates 1, and each segmented plate 1 has an angle of 22.5 degrees.

The fourth layer of segmented plate assemblies 14 comprises 1 segmented plate 1, the angle of the segmented plate 1 being 360 °.

EXAMPLE 2 Structure of the Split plate

As shown in FIG. 2, each block plate 1 comprises a steel section frame 1-1, a steel plate shell 1-2 and a beam pin 1-3.

The section steel frame is formed by fixedly connecting a plurality of uniformly distributed radial beams 1-1-1 and circumferential beams 1-1-2 in a criss-cross manner.

The radial beams 1-1-1 are all arranged along the radial direction (the radial direction of the steel template), the length of the radial beams 1-1-1 is the same as the radial length of the block plate (the radial size of the block plate 1 along the radial direction of the steel template), and the radial beams 1-1-1 are sequentially distributed in the circumferential direction (the circumferential direction of the steel template).

The circumferential beams 1-1-2 are all arranged along the circumferential direction (the circumferential direction of the steel template); a plurality of annular beams 1-1-2 are arranged between every two adjacent radial beams 1-1-1 in the annular direction, the length of each annular beam 1-1-2 is the annular distance (arc length) between every two adjacent radial beams 1-1-1, and the annular beams 1-1-2 are sequentially distributed in the radial direction. A plurality of annular beams 1-1-2 among a plurality of groups of adjacent radial beams 1-1-1 are in one-to-one correspondence, and the corresponding annular beams 1-1-2 integrally form an annular beam assembly located on the same annular line.

A plurality of circumferential beam components of the left and right adjacent partition plates 1 are in one-to-one correspondence and are positioned on the same circumferential line.

The radial beam 1-1-1 and the circumferential beam 1-1-2 are both section steel.

The radial beams 1-1-1 are divided into radial main beams and radial secondary beams, the radial main beams are uniformly distributed on the partition plate 1, and the radial secondary beams are uniformly distributed between every two adjacent radial main beams; the types of the section steels forming the radial main beam and the radial secondary beam are different. A plurality of radial main beams between the adjacent upper and lower layers of the partition plates 1 are in one-to-one correspondence, namely, are positioned on the same radial line.

The plurality of circumferential beams 1-1-2 are divided into circumferential main beams and circumferential secondary beams, the circumferential main beams are uniformly distributed on the partition plate 1, the circumferential secondary beams are uniformly distributed between every two adjacent circumferential main beams, and the section steel models forming the circumferential main beams and the circumferential secondary beams are different.

The steel plate shell 1-2 is formed by fixedly splicing a plurality of steel plates arranged along the radial direction, the steel plates are arranged along the direction of the radial beams 1-1-1, one steel plate is arranged between every two radial beams 1-1-1, and the bottom of the steel plate shell 1-2 is fixedly connected with the upper surface of the section steel frame 1-1.

The upper surface of the steel plate shell 1-2 is fixedly connected with a plurality of stiffening ribs 1-4 and studs 1-5; the stiffening ribs 1-4 are arranged along the radial direction of the steel plate, the number of the stiffening ribs 1-4 is the same as that of the steel plate, and one stiffening rib 1-4 is fixed on the upper surface of each steel plate; the steel plate shell 1-2 is provided with a plurality of openings, the sizes of the openings are matched with the beam pins 1-3, the beam pins 1-3 are the same in number and correspond to the openings one by one, and the beam pins 1-3 penetrate through the corresponding openings and are fixedly connected to the section steel frame 1-1, so that the connection strength between the steel plate shell 1-2 and the section steel frame 1-1 is improved; the steel plate shell 1-2 is in a hyperboloid arc shape, and the beam pins 1-3 and the studs 1-5 are vertical to the surface of the steel plate shell 1-2; the stiffening ribs 1-4 and the studs 1-5 can improve the strength of the steel plate shell 1-2, so that the structure of the block plate 1 is more stable, and the strength requirement of steel formwork construction can be met.

Preferably, the radial main beam is made of profile steel with the size of HW200 × 8 × 12; the section steel size of the radial secondary beam is HN 200X 100X 5.5X 8 and HM 194X 150X 6X 9; the sizes of the section steels selected for the circumferential main beams are HW 200X 8X 12 and HN 200X 100X 5.5X 8; the size of the section steel selected for the annular secondary beam is HN 125X 60X 6X 8.

EXAMPLE 3 Process for producing Split plate

The specific manufacturing process of each block board 1 described in example 2 includes the following steps:

and S1, construction preparation.

S2, lofting and blanking: blanking the steel plate and the section steel by adopting a flame cutting method; adopting an expansion method for lofting to determine the sizes of the steel plate and the section steel for blanking and cutting, and carrying out blanking and cutting according to the lofted sizes; in order to facilitate on-site assembly and adjustment, the lower parts of the steel plate shells 1-2 on each of the second, third and fourth layered plates 1 are respectively reserved with allowance.

In the embodiment, the reserved allowance of the lower parts of the steel plate shells 1-2 on the second, third and fourth layered plates 1 is respectively 70mm, 70mm and 60mm, and when the layered plates 1 are assembled on site, the size of the lower parts of the steel plate shells 1-2 is adjusted according to the actual situation on site and then secondary cutting is carried out.

For the first layer of the divided plate 11, the steel plate shell 1-2 on the divided plate 1 is composed of 9 steel plates arranged along the radial direction, the width of each steel plate is 867mm, the width of the purchased actual steel plate is 1500mm, and the width of the residual steel plate after the purchased actual steel plate is cut is smaller than that of each steel plate in the steel plate shell 1-2. Therefore, in order to save steel plate materials and improve the utilization rate of the steel plates, as shown in fig. 3, 2 purchased actual steel plates are welded and spliced together through a butt joint seam 3-1, and are cut into 3 steel plates for the second time, and the secondary cutting lines 3-2 are positioned at two sides of the butt joint seam 3-1. The steel plates are spliced by adopting flux-cored wire gas shielded welding for welding in a full penetration groove mode, and the weld joint is subjected to 100% VT + 20% UT detection after welding.

For the third layer of the block plates 13, as the radial length of the block plates 1 is greater than the length of the purchased actual section steel, the radial beams 1-1-1 of the third layer of the block plates 13 need to be spliced and lengthened, and the two actual section steels are welded and spliced along the length direction of the actual section steel, so that the requirement of the radial length of the block plates 1 is met. As the section steel is pulled along the length direction of the section steel in the subsequent bending process, in order to reduce the transverse stress of the splicing welding line between the section steels, the section steel adopts a diagonal connection mode, and the schematic diagram of the section steel splicing and the groove is shown in figure 4. And welding the splicing part by adopting flux-cored wire gas shielded welding, fully penetrating the groove, and detecting a welding seam by 100% VT + 100% UT after welding.

S3, bending the section steel to enable the radian of the upper surface of the section steel to be attached to the radian of the lower surface of the steel plate shell, and adopting a bending process of cold bending firstly and then hot correcting for the section steel of the circumferential beam 1-1-1 and the radial beam 1-1-2 (the size of the section steel after cold bending still has deviation from the actual size, so that the section steel needs to be finely adjusted through the hot correcting process). Different cold bending processes are needed for different types of section steel (namely, a radial main beam, a radial secondary beam, a circumferential main beam and a circumferential secondary beam).

And bending and forming the radial main beam, the radial secondary beam and the annular main beam by using a section steel stretch bender 5, wherein the forming process schematic diagram of the section steel stretch bender is shown in fig. 5. The specific stretch bending steps are as follows: firstly, adjusting the radian of a molding fetal membrane 5-1 of a section steel stretch bender according to the radian of section steel to be molded, and considering the elastic deformation of the section steel, the radian radius of the molding fetal membrane 5-1 is slightly smaller than that of the section steel. Secondly, filling a dense wood board 5-2 on the inner side of the profile steel to be bent to prevent the profile steel from being distorted and deformed in the stretch bending process; thirdly, placing two ends of the section steel in the clamps 5-3 near two ends of the formed tire membrane 5-1; starting the section steel stretch bender 5, slowly stretching the section steel to the outer side radian surface of the forming die by the stretching arms 5-4, enabling the inner side of the section steel to be attached to the outer side radian surface of the forming tire membrane 5-1, and then completing the cold roll forming of the section steel. And after the stretch bending forming process is finished, unloading the bent section steel and hoisting the section steel to the ground.

For the circumferential secondary beam, the sectional size of the circumferential secondary beam is smaller, so the bending forming is performed by the section steel cold bending machine, and the schematic diagram of the bending forming process of the section steel cold bending machine is shown in fig. 6. The specific cold roll forming steps are as follows: firstly, pushing the section steel to be cold-bent between two driving rollers 6-1 by a door type bracket of an auxiliary system; secondly, starting a hydraulic system to enable a hydraulic cylinder to push the dovetail groove and the cold bending roller 6-2 to cold press the section steel; thirdly, when the radian required by the design is reached, the hydraulic system is closed, and the mechanical transmission system is started, so that the driving roller 6-1 rotates and drives the section steel to stably and slowly move forward by means of friction force, and continuous cold bending operation is realized; and fourthly, when the cold bending is finished, closing the mechanical transmission system, starting the hydraulic system, and withdrawing the hydraulic system, thereby completing the cold bending forming of the section steel. And after the cold bending forming process is finished, placing the cold-bent section steel on a door type bracket of the auxiliary system for later use.

S4, secondary blanking of the section steel: and performing secondary cutting on the allowance reserved at the two ends of the bent section steel.

S5, assembling the section steel frame: and adopting a special assembly tool 2 to assemble the radial beam 1-1-1 and the annular beam 1-1-2.

As shown in fig. 7, the special pairing fixture 2 comprises a pairing fixture base 2-1, a hyperboloid arc-shaped plate 2-2 and a plurality of inclined supports 2-3, the base 2-1 is formed by vertically and horizontally fixedly connecting a plurality of steel sections, the bottom of each inclined support 2-3 is fixedly connected to the upper surface of the corresponding pairing fixture base 2-1 steel section, the hyperboloid arc-shaped plate 2-2 is fixedly connected to the top of each inclined support 2-3, the radian of the top of each inclined support 2-3 is fitted with the hyperboloid arc-shaped plate 2-2, and a plurality of reinforcing angle steels are fixedly connected to the lower surface of the hyperboloid arc-shaped plate 2-2.

In this embodiment, the assembly fixture base 2-1 adopts section steel with the specification of HN200 × 100 × 5.5 × 8; the hyperboloid arc-shaped plate 2-2 is made of Q235B steel plate with the thickness of 6 mm; the oblique supports 2-3 are made of Q235B steel plates with the thickness of 10 mm; the angle steel of the specification of < 125 x 80 x 10 is adopted as the reinforcing angle steel.

As shown in fig. 8, when in pairing, the circumferential beams 1-1-1 and the radial beams 1-1-2 are placed on the upper surface of the hyperboloid arc panel 2-2, the positions of each radial beam 1-1-1 and each circumferential beam 1-1-2 on the surface of the hyperboloid arc panel 2-2 are determined, each radial beam 1-1-1 is placed on the hyperboloid arc panel 2-2 according to the corresponding position, two groups of detachable first connecting pieces are respectively arranged at two ends of each radial beam 1-1-1, as shown in fig. 9, two groups of first connecting pieces at the end part of each radial beam 1-1-1 are respectively positioned at two sides of the section steel, two ends of each radial beam 1-1-1 are fixedly connected with the hyperboloid arc panel 2-2 through the first connecting pieces, one limiting plate 2-4 is spot-welded at every 1m on two sides of the bottom of each radial beam 1-1-1, the limiting plate 2-4 is also fixed on the upper surface of the hyperboloid arc-shaped plate 2-2; the first connecting pieces at two ends of the section steel limit radial movement of the radial beams 1-1-1, the limiting plates 2-4 positioned at two sides of the section steel limit circumferential movement of the radial beams 1-1-1, and after the position of each radial beam 1-1-1 is determined, movement of each radial beam 1-1-1 is limited through the first connecting pieces and the limiting plates 2-4, so that all radial beam 1-1-1 assembly is completed.

And after all the radial beams 1-1-1 are assembled, assembling the annular beams 1-1-2. Each annular beam 1-1-2 is placed at a corresponding position on the hyperboloid arc-shaped plate 2-2, two ends of each annular beam 1-1-2 are respectively connected with two adjacent radial beams 1-1-1 in a spot welding mode, the annular beams 1-1-2 are sequentially assembled from one end of the hyperboloid arc-shaped plate 2-2 to the other end along the annular direction, the annular beams 1-1-1 and the radial beams 1-1-2 are assembled, after the two adjacent section steels at each connection node are connected in a spot welding mode, the section steel frame 1-1 has certain strength, and the section steel frame 1-1 can still keep stable in structure in the process of being hoisted to a welding tool.

After the annular beam 1-1-1 and the radial beam 1-1-2 are assembled, the limiting plates 2-4 on two sides of the bottom of the radial beam 1-1-1 and the first connecting pieces, connected with the hyperboloid arc-shaped plates 2-2, of two ends of the radial beam 1-1-1 are disassembled, and the assembly of the rear separated steel frame and the assembly tool is completed, so that the subsequent steel frame is conveniently hoisted.

In the embodiment, each group of first connecting pieces comprises a U-shaped clamp 2-4 and a wedge 2-5, as shown in fig. 9, the section steel and the hyperboloid arc-shaped plate 2-2 are clamped and fixed through the U-shaped clamp 2-4, and the wedge 2-5 is wedged between the section steel and the U-shaped clamp 2-4, so that the clamping stability of the U-shaped clamp 2-4 is improved.

S6, welding the section steel frame: welding the assembled circumferential beam 1-1-1 and radial beam 1-1-2 to form a steel frame 1-1, and welding the radial beam 1-1-1 and the circumferential beam 1-1-2 by using a special welding tool 3;

as shown in fig. 10, the special welding fixture 3 includes a welding fixture base 3-1, a support column 3-2 and a plurality of arc support plates 3-3, the welding fixture base 3-1 is formed by vertically and horizontally fixedly connecting a plurality of steel plates, the support column 3-2 is uniformly and fixedly connected to the welding fixture base 3-1, horizontal connecting rods 3-4 are fixedly connected to the support column 3-2 at two side edges of the welding fixture base 3-1 along the length direction, the bottom of the arc support plate 3-3 is fixedly connected to the upper surface of the support column 3-2, and the radian of the top of the arc support plate 3-3 is matched with the hyperboloid arc panel 2-2.

In the embodiment, a Q235 steel plate with the thickness of 25mm and the width of 300mm is selected as a steel plate for welding the tool base 3-1; the supporting upright post 3-2 adopts section steel with the model of HM 340X 250X 9X 14 and the height of 1000 mm; the arc-shaped support plate 3-3 is a Q235B steel plate with the thickness of 30 mm; the horizontal connecting rods 3-4 adopt section steel with the specification of HN200 × 150 × 5.5 × 8.

Hoisting the circumferential beam 1-1-1 and the radial beam 1-1-2 with the spot-welded connection nodes in the step S5 to a special welding tool 3, as shown in figure 11, attaching an arc-shaped support plate 3-3 to the bottoms of the circumferential beam 1-1-1 and the radial beam 1-1-2, fixedly connecting the arc-shaped support plate 3-3 with the radial beam 1-1-1 in contact with the arc-shaped support plate, welding from the center to the periphery of the section steel frame 1-1, bottoming the connection nodes between all the radial beams 1-1-1 and the circumferential beam 1-1-2, uniformly filling and capping, keeping the welding speed of each position consistent in the welding process until the welding is finished, and finally obtaining the section steel frame 1-1.

In this embodiment, as shown in fig. 12, when the section steel frames 1-1 of the segment plate 1 are connected by two section steels with different heights to form a connection node, for example, a radial main beam (HW 200 × 8 × 12 section steel is selected) and a circumferential secondary beam (HN 125 × 60 × 6 × 8 section steel is selected), a reinforcing plate is fixed between bottom flanges of the radial main beam and the circumferential secondary beam, and a side edge of the reinforcing plate is fixed on a web of the radial main beam, so that stability at the connection node is improved.

S7, nondestructive testing: and detecting the quality of the connecting joints and the welding seams between the section steels. And after the welding of the nodes is finished, carrying out nondestructive testing, carrying out visual and ultrasonic testing on the full penetration welds of the upper flange and the lower flange of the circumferential beam 1-1-2, and carrying out visual testing on the fillet welds of the profile steel web.

S8, assembling the steel plate shell, the beam pin and the stiffening rib: and after the nondestructive testing of the connecting node between the annular beam 1-1-2 and the radial beam 1-1-1 is finished, assembling the steel plate shell 1-2. Assembling the steel plate shell 1-2 on the upper surface of the section steel frame 1-1, and assembling the beam pin 1-3 and the stiffening rib 1-4 after the steel plate shell 1-2 is finished. In order to prevent deformation during welding of the steel plate shells 1-2, the beam pins 1-3 and the stiffening ribs 1-4 need to be assembled before welding the steel plate shells 1-2.

Every two adjacent radial beams 1-1-1 correspond to a steel plate, the steel plate is placed between the two corresponding radial beams 1-1-1, two sides of the steel plate are respectively positioned on the two corresponding radial beams 1-1-1, two sides of the steel plate are fixedly connected to the upper surfaces of the two corresponding radial beams 1-1-1 through detachable second connecting pieces, the steel plate is pressed into a profile on the upper surface of the profile steel frame 1-1, and the steel plate is sequentially assembled from the radial beam 1-1-1 on one side to the other side to complete the assembly of the steel plate shell 1-2.

The second connecting piece includes U type card and drift in this embodiment, and steel sheet and shaped steel pass through U type card and hold fixedly, and the drift wedges between steel sheet and the U type card, improves the stability of U type card centre gripping.

S9, welding the steel plate shell, the beam pin and the stiffening rib: when the steel plate shells 1-2 are welded, firstly, single fillet welds on the inner sides of the steel plate shells 1-2 are welded, the whole welding sequence is that welding is carried out from the middle to the two sides, after the welding of the inner fillet welds is finished, fillet welds between adjacent steel plates on the outer sides of the steel plate shells 1-2 are welded, the welding passes are divided into two layers, the single fillet welds are welded from the middle to the two ends in a segmented mode, the whole welding is skip welding from the middle to the two ends, and meanwhile, the welding of the beam pins 1-3 and the welding of the stiffening ribs 1-4 is finished.

S10, stud welding, marking the position of each stud 1-5 on the upper surface of the steel plate shell 1-2 after the steel plate shell 1-2, the beam pin 1-3 and the stiffening rib 1-4 are welded, and welding the studs 1-5 on the corresponding positions of the steel plate shell 1-2; the fixing position of the studs 1-5 on the steel plate shell 1-2 has no requirement, and only a certain number of studs 1-5 per square meter on the steel plate shell 1-2 is required.

And (4) welding the studs 1-5 by adopting a special stud welding machine, placing the component obtained in the step S9 on the ground, and arranging sleepers on the lower part of the component. Before welding, a welding point of the stud 1-5 is marked on the steel plate shell, the marked part is polished by a polishing machine to expose the metallic luster, the stud 1-5 close to the on-site assembling and installing part is not welded in a workshop, and after the on-site installation is finished, repair welding is carried out.

And S11, nondestructive testing.

And S12, checking the overall size.

S13, cleaning and painting: and rust, dust, moisture, oil stain and the like in a welding line area are removed by adopting a sand blasting derusting process, and the roughness reaches Sa2.5 grade in a design file. And painting after the sand blasting is finished, wherein the thickness of the paint needs to meet the design requirement.

S14, storing serial numbers: after the partition plates 1 are manufactured, marks are numbered on the partition plates 1 of each layer, the marks are clear in writing and are obvious in position; the partition plates 1 are horizontally stored on a special bracket, and the number of each pile is not more than 5.

EXAMPLE 4 Split Panel Assembly

After all the block plates 1 are manufactured according to the process described in embodiment 3, the block plates 1 are sequentially assembled from the first layer to the fourth layer, two adjacent block plates 1 are connected by welding, and the block plates 1 in each layer are completely assembled according to the clockwise or counterclockwise sequence and then assembled into the next layer. And after all the partition plates 1 are assembled, the whole steel formwork is finally obtained.

It should be noted that the terms "upper", "lower", "left", "right", "front", "back", etc. used in the present invention are for clarity of description only, and are not intended to limit the scope of the present invention, and the relative relationship between the terms and the terms is not limited by the technical contents of the essential changes.

The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may be made by those skilled in the art without departing from the principle of the invention.