Архив для категории: Новости

Industrial steel structure construction is a highly systematic process used to build facilities like factories, склады, электростанции, processing facilities, and large-scale workshops. Unlike traditional construction, it relies heavily on prefabrication, where major components are manufactured off-site in a controlled factory environment and then transported to the site for assembly.

Industrial Steel Building Construction Process

The construction process of an industrial steel structure is a complex and multi-stage endeavor that prioritizes precision, эффективность, and safety.

1. Дизайн и планирование:

Conceptual Design & Feasibility: This initial stage involves understanding the client’s needs, project requirements, and site conditions. Architects and engineers collaborate to develop conceptual designs.

Detailed Design & Engineering: Based on the conceptual design, detailed blueprints, specifications, and structural calculations are created. This includes determining the appropriate steel grades and types, considering load-bearing requirements, environmental factors, and regulatory standards. Компьютерное проектирование (ХАМ) software is extensively used for precise drawings.

Permits and Approvals: Obtaining all necessary permits and approvals from local authorities is a critical step before any physical work begins.

2. Procurement and Material Preparation:

Выбор материала & Acquisition: High-quality steel materials (листы, профили, coils) are selected and ordered based on the detailed design.

Quality Inspection of Raw Materials: Incoming raw materials undergo strict inspections to verify they meet quality and strength standards, including checks for size, specifications, surface quality, and certification documents.

Material Cutting: Steel is cut to the desired sizes and shapes using various methods such as shearing, распиловка, flame cutting, laser cutting, or plasma cutting, often employing CNC (Computer Numerical Control) machines for precision.

Bending and Shaping: Depending on the design, steel components like flanges and webs may be bent or pressed to achieve specific shapes and dimensions.

3. Fabrication (Off-site Manufacturing):

Sub-Assembly/Fitting: Individual steel components (балки, столбцы, trusses, п.) are meticulously fitted together and temporarily connected, often using tack welding to hold them in place at the correct angles.

Сварка и соединение: The primary method for joining steel components is welding (например, МНЕ, ТИГ, arc welding). Skilled welders ensure strong and durable connections. Bolting is also used, especially where disassembly or modification might be required. Reinforcing ribs and cleats are also welded.

Straightening: After welding, components may undergo straightening to remove any warping and ensure flatness and accurate edges.

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Steel structure factories are widely used in industrial settings due to their durability, cost-effectiveness, and quick construction. Однако, like any other structure, they require regular maintenance to ensure long-term performance, безопасность, and structural integrity. Proper maintenance prevents corrosion, structural failures, and operational disruptions, ultimately saving costs on major repairs or replacements.

Steel Structure Factory Maintenance

Maintaining a steel structure factory is crucial for ensuring its longevity, безопасность, and operational efficiency.

Why is Steel Structure Factory Maintenance Important?

Prevents Corrosion & Rust – Exposure to moisture, химикаты, and industrial pollutants can degrade steel over time.

Ensures Structural Stability – Loose bolts, cracked welds, or foundation issues can compromise safety.

Extends Lifespan – Regular upkeep can prolong the factory’s service life by decades.

Maintains Aesthetic & Functional Value – A well-maintained factory enhances operational efficiency and company image.

Complies with Safety Regulations – Many industries require periodic structural inspections to meet legal standards.

Steel Structure Factory Maintenance Steps

1. Регулярные проверки

Visual Inspections: Check for signs of corrosion, ржавчина, вмятины, трещины, or deformation.

Roof & Wall Cladding: Look for leaks, loose panels, or damaged insulation.

Foundation: Ensure no cracks or settling that could affect stability.

2. Защита от коррозии & Картина

Clean Surfaces: Remove dirt, жир, and rust before repainting.

Anti-Corrosion Coatings: Apply primer and paint suitable for industrial environments.

Galvanized Components: If the steel is galvanized, check for white rust or coating damage.

Touch-Up Repairs: Address small rust spots immediately to prevent spread.

3. Bolted & Welded Connections

Tighten Loose Bolts: Vibration and load changes can loosen bolts over time.

Check Welds: Look for cracks or fatigue, especially in high-stress areas.

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A slewing bearing (or slew ring) is a large-diameter rotational rolling-element bearing designed to carry heavy, slow-turning, or slow-oscillating loads. It’s the critical component that allows massive machinery like cranes, экскаваторы, and wind turbines to rotate smoothly and safely.

The load capacity is the single most important parameter when selecting a slewing bearing. It defines the maximum forces the bearing can withstand without failure. В double-row ball slewing ring is a specific design engineered to handle exceptionally high loads, particularly tilting moments.

Load Capacity of Double Row Ball Slewing Bearings

Combined Load Handling: Unlike simpler bearings, double-row ball slewing bearings are specifically designed to simultaneously handle a combination of:

Axial Loads: Forces acting along the axis of rotation (например, vertical weight from a crane boom).

Radial Loads: Forces acting perpendicular to the axis of rotation (например, side forces from a robotic arm).

Overturning Moments (Tilting Moments): Torques caused by eccentric loads that try to tip or rotate the bearing (например, twisting forces on a wind turbine blade). This is where they particularly shine.

Enhanced Capacity vs. Single-Row: The presence of two rows of rolling elements significantly increases their load-bearing capabilities compared to single-row slewing bearings of the same size. This is because the load is distributed over more contact points, уменьшение стресса на отдельные компоненты.

Optimized Raceways: Many double-row designs feature two independent raceways, often with different ball diameters. The upper and lower raceways are typically designed with 90° bearing angles, which allows them to effectively bear large axial forces and tilting moments.

Suitable for High Static and Dynamic Loads: While the rotational speed of slewing bearings is generally slow, their load capacity primarily refers to their static load capacity. Double-row ball bearings are built to withstand considerable static loads and also perform well under dynamic operating conditions.

Stiffness and Stability: The double-row configuration inherently provides greater stiffness and stability, minimizing deformation and deflection even under extreme loads.

Factors Influencing Load Capacity:

Bearing Dimensions: The outer diameter, внутренний диаметр, and overall height of the bearing directly impact its load capacity. Larger bearings generally have higher capacities.

Ball Diameter: The size of the steel balls used plays a crucial role. Larger balls can carry more load.

Качество материала: High-strength steels and advanced manufacturing processes contribute to the overall durability and load resistance.

Дизайн гоночной трассы: The specific geometry and heat treatment of the raceways are critical for distributing stress and ensuring longevity.

Presence of Gearing: Bearings with integrated gear teeth (internal or external) will also have specifications related to the gear’s torque capacity.

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Non-standard Мы все знаем, что независимо от того, какой подшипник are crucial components in various heavy machinery and precision equipment, разработан для обработки значительных осевых, радиальный, и нагрузки момента в высокоспециализированных приложениях. В отличие от стандартных подшипников, their customization process is intricate, involving close collaboration between the client and the manufacturer to meet unique operational demands.

Non-standard slewing bearing customization process

1. Initial Consultation and Requirement Gathering

The process begins with a comprehensive understanding of the client’s needs. This involves:

Application Analysis: Understanding the specific machine or system where the slewing bearing will be used. This includes factors like the type of equipment (cranes, экскаваторы, ветряные турбины, медицинское оборудование, робототехника, п.), его операционная среда (морской пехотинец, высокая/низкая температура, пыльный, коррозийный), и общие требования к производительности.

Анализ нагрузки: Подробная информация о статических и динамических нагрузках, которые подшипник выдержит, в том числе осевые, радиальный, и переворачивание моментов нагрузки, а также ударные нагрузки и вибрация.

Размерные ограничения: Точные размеры монтажного пространства, в том числе внешний диаметр, размер отверстия, ширина, и любые конкретные конфигурации монтажного отверстия.

Спецификации производительности: Требуется скорость вращения, точность (допуски на развод), жесткость, Требования к крутящему моменту, and expected service life.

Environmental Factors: Воздействие влаги, saltwater, химикаты, пыль, extreme temperatures, and the need for specialized sealing or corrosion protection.

Особые возможности: Any unique requirements such as integrated gearing (internal, external, helical, worm gears), lubrication systems, control devices, or monitoring systems.

Material Preferences: While manufacturers often recommend materials, clients may have specific preferences or requirements for certain alloys (например, high-strength steel, нержавеющая сталь, specialized alloys like 42CrMo4, 50Mn, or even aluminum for lightweight applications).

Compliance and Certifications: Any industry-specific standards (например, ИСО, AGMA, DEF STAN) or certifications required for the bearing.

2. Проектирование и проектирование

Once the requirements are thoroughly understood, the engineering team commences the design phase:

Conceptual Design: Engineers develop initial concepts based on the gathered data, considering different slewing bearing types (например, four-point contact ball bearings, crossed cylindrical roller bearings, triple-row roller bearings, combined roller/ball bearings) that best suit the application.

Detailed CAD Modeling: Using advanced 3D modeling software, a detailed design of the non-standard bearing is created. This includes precise geometries of the inner and outer rings, raceways, тела качения, cages/spacers, gearing, and sealing systems.

Выбор материала: Based on load, environment, and performance requirements, appropriate materials are selected for the rings, тела качения, и другие компоненты. This often involves specialized heat treatments to achieve desired hardness, износостойкость, and fatigue strength.

Structural Analysis (FEA): Finite Element Analysis (FEA) simulations are performed to validate the design’s integrity under various load conditions, predict stress distribution, deflection, and stiffness, and optimize the design for maximum performance and lifespan.

Lubrication System Design: Designing or recommending a suitable lubrication system (смазка или масло) и указание смазков на основе рабочих условий. Это включает в себя определение интервалов смазки и потенциал для передовых систем смазки.

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Wind tower fabrication is a highly specialized and welding-intensive industry that relies heavily on automation due to the massive size and thick steel components involved. Сварочные вращатели play a crucial role in this process by enabling precise and efficient welding of cylindrical wind tower sections.

Wind Tower Welding Rotator Welding Process

Here’s a breakdown of the welding process for wind tower welding rotators:

1. Wind Tower Fabrication Process (where rotators fit in):

Plate Rolling: Large steel plates (often exceeding 80mm thick) are rolled into cylindrical “cans.”

Longitudinal Welding: Individual cans are seam-welded along their length. This often involves manipulators and column-and-boom systems.

Circumferential Welding (where rotators are key): Once individual cans are formed, they are aligned and joined to each other with circumferential welds to form tower sections. This is the primary application for welding rotators. Rotators hold and rotate the heavy, cylindrical sections, allowing a stationary welding head (typically on a column and boom manipulator) to perform the circular weld.

Flange Welding: Flanges are attached to the ends of sections, also by circumferential welds, for on-site assembly.

Door Frame Welding: Door frames are welded, typically using mechanized flux-cored or metal-cored arc welding.

2. Key Welding Process for Wind Towers:

Сварка под флюсом (ПИЛА): This is the dominant welding process for both longitudinal and circumferential seams in wind tower fabrication.

High Deposition Rate: SAW can deliver extremely high weld metal deposition rates and the necessary heat for the thick steel used in wind towers.

Automation: SAW is highly adaptable to automation, which is critical for consistent quality and productivity on large, repetitive welds.

Multi-wire SAW: To further increase productivity, multi-wire SAW systems (например, twin arc, tandem arc, tandem twin arc) are commonly used, where multiple welding torches feed the same weld pool.

Flux Shielding: The arc is submerged under a blanket of granular flux, protecting the weld pool from atmospheric contamination. This also makes it less susceptible to environmental factors like wind.

Ориентация: SAW typically requires gravity to hold the weld metal and flux in place, meaning the parts must be reoriented (например, rotated by rotators) to maintain a flat or horizontal welding position.

Other Processes (for specific applications):

Газовая металлическая сварка (GMAW or MIG) and Flux Cored Arc Welding (Fcaw): Used for various applications, including door frame welding or in conjunction with SAW for certain passes.

Electrogas Arc Welding (EGW): A high-efficiency vertical automatic welding process used for thick plates, especially in offshore wind power generation facilities. A newer variant, SESLA, offers advantages like minimal spatter and fumes and excellent wind resistance.

Narrow Gap Welding: Applied to reduce weld volume, utilizing special flat welding heads and single or tandem wire heads.

3. The Role of Welding Rotators:

Точное вращение: Сварочные вращатели (also known as turning rolls) use wheels to align and rotate cylindrical workpieces, such as the “cans” of a wind tower, at a uniform and controlled speed.

Types of Rotators:

Обычные ротаторы: Simple, твердый, and widely used for internal welding, long seam welding, обработка поверхности, and internal equipment installation.

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