摘要
针对大跨度桥梁钢-混组合桥塔钢壳因薄壁特性、复杂曲面造型及密集加劲肋引发的焊接变形失控、节段匹配精度不足等行业难题,创新性提出一种“分阶段精准管控+多工艺协同优化”的一体化焊接拼装技术。该技术涵盖壁板单元精细化制造、节段块体高效匹配组装、整体节段立体拼装及桥位精准连接4大核心环节,通过栓接孔差异化加工、结构适配型焊接工艺、智能拼装定位系统及焊接变形主动控制等关键技术,构建全流程质量保障体系。安罗黄河桥、狮子洋桥等重大工程应用结果表明:钢壳壁板单元平面度误差≤2mm,节段拼装垂直度≤1.5mm/m,焊缝一次合格率达99.7%以上,显著提升了组合桥塔制造效率与结构可靠性,为同类工程提供了可复制的技术范式。
Aiming at the industry problems such as uncontrolled welding deformation and insufficient segment matching accuracy of the steel shell of steel-concrete composite bridge towers in long-span bridges,which are caused by thin-wall characteristics,complex surface modeling and dense stiffeners,an integrated welding machine assembly technology of"phased precise control+multi-process collaborative optimization"is innovatively proposed.The technology covers four core links:refined manufacturing of wall plate units,efficient matching and assembly of segment blocks,three-dimensional assembly of integral segments and precise connection at the bridge site.Through key technologies such as differentiated processing of bolt holes,structure-adaptive welding processes,intelligent assembly positioning systems and active control of welding deformation,a full-process quality assurance system is constructed.Application results of major projects such as the Anlu Yellow River Bridge and the Shiziyang Bridge show that the flatness error of the steel shell wall plate unit is≤2mm,verticality of segmental assembly≤1.5mm/m,and the one-time qualification rate of welds reaches more than 99.7%,which significantly improves the manufacturing efficiency and structural reliability of composite bridge towers,and provides a replicable technical paradigm for similar projects.
作者
白玉明
高建忠
宋红飞
李小松
BAI Yuming;GAO Jianzhong;SONG Hongfei;LI Xiaosong(China Railway Shanhaiguan Bridge Group Co.,Ltd.,Qinhuangdao 066205,Hebei,China)
基金
河北省中央引导地方科技发展资金项目(254Z1004G)。
关键词
大跨度桥梁
钢-混组合桥塔
高效焊接
精度控制
变形控制
long-span bridges
steel-concrete composite bridge tower
efficient welding
precision control
deformation control
