Character business card
Just past 2021, the world's first 1,000-ton high-speed rail bridge-building integrated machine "Kunlun", in only 218 days, successfully completed the paving task of 10 kilometers of bridges. In 2016, China Academy of Railway Science Group Co., Ltd. established a research group on "Research on Key Technologies for the Construction of High-speed Railway Long-span Simple Support Box Girders". As an important member, China Railway Fifth Survey and Design Institute Group mainly focuses on the research and development of carrier integrated machines; the scientific research team works day and night to overcome difficulties, and through continuous innovation and exploration, a series of surprising breakthroughs have been made. The team carried out patent excavation and layout around the high-speed rail box girder erection technology, forming a patent portfolio of 56 pieces, and directly creating economic benefits of about 200 million yuan for the equipment manufacturing unit.
"Great, reluctant, but more important task - Hangzhou-Quzhou high-speed rail project department, still looking forward to the 'Kunlun' grin!" Not long ago, looking at the "old guy" who has been working together for nearly a year, Wang Bo, project manager of the Meizhou Bay Bridge of the Fuzhou-Xiamen High-speed Railway of China Railway Eleventh Bureau Group, showed reluctance in his eyes; recalling the past scenes with the "Kunlun", Wang Bo not only lamented the hardships along the way, but also full of pride and expectations...
"The 'Kunlun' has opened up the key technical links of laying frames to speed up the construction of special geomorphological railways in the western region and the new level of China's high-speed railway speed, and is also an attempt by scientific researchers to break through themselves and work hard to tackle key problems." Tang Youfu, secretary of the party committee and chairman of the board of directors of China Railway Fifth Survey and Design Institute Group Co., Ltd., said.
"'Never done' but also 'dare to challenge', to turn cutting-edge innovative big projects into a good platform for refining talents"
Where is the Kunlun powerful? "This 'big guy' 35 meters above the ground and 116 meters long carries a huge simple box girder weighing 1,000 tons and 40 meters long, which is equivalent to the weight of 200 adult Asian elephants. This weight, ordinary transport vehicles can not be loaded, the locomotive can not be dragged, the crane can not be pulled, but we 'Kunlun' in the air to carry it, steady. Wan Peng, executive deputy director of the R&D Center of Laying Technology and Equipment of the Tiewu Academy and the main person in charge of the technology of the "Kunlun" R&D and design project, said proudly.
Since 2006, the construction of high-speed rail bridges on the mainland has generally used simple box girders weighing 900 tons and 32 meters long. These 900-ton "big men" are "big heroes": it is thanks to the box girders and complete sets of construction technology that China's high-speed rail operating mileage can quickly jump and rank first in the world.
However, under the goal of being faster, more low-carbon and more economical, the box girder standard must achieve a span from 32 meters to 40 meters and larger. For scientific researchers, it is necessary to solve the erection problems such as frequent conversion of road, bridge, tunnel, and large slope and small curve.
In 2016, the research group of China Academy of Railway Science Group Co., Ltd. "Research on Key Technologies for the Construction of High-speed Railway Long-span Simple Support Box Girders" was established. The Iron Fifth Academy focuses on the research and development of the carrier integrated machine.
The news spread back to the TiewuYuan, and everyone was excited and nervous... A retired old expert said in a serious tone: "Now that there are not many people in our hospital who understand structure, can we bear this burden?" Don't look at the length to increase by 8 meters, the structural difficulty can be increased geometrically! ”
"The box girder is 8 meters long and 100 tons is not innovation for the sake of innovation, which is a problem that Must be broken through in China's high-speed rail construction." Chen Qi, chief engineer of the Tiewu Academy, director of the Laying Technology and Equipment R&D Center, and head of the "Kunlun" R&D and design project, said.
"'I haven't done it' and we must 'dare to challenge' and turn the large projects of cutting-edge innovation into a good platform for refining talents." Tang Youfu said that for more than 60 years, the Tiewuyuan has accompanied the iterative upgrading of China's railways, "Winning this project can help us seize the opportunity of a new round of high-speed rail innovation!" ”
"For researchers, drawings should not lie in the file bag, our goal is to paint into the mountains and rivers, transform the mountains and rivers"
The rallying cry sounds! The three subsidiaries and two professional institutes of the whole group immediately selected more than 20 professional experts to form a multidisciplinary research group; Liang Zhixin, deputy chief engineer of the Tiewu Academy, served as the chief engineer of the project design, and Wang Zhibin and Wan Peng served as the main technical leaders of the project. The conference room on the 6th floor of the main building of the Tiewu Academy has become the permanent base camp of the research group.
At the beginning of 2018, the lower guide girder after-pumping bridge erection machine scheme submitted by the Tie fifth hospital successfully passed the review, but Liang Zhixin lost sleep for several nights: using the lower guide girder design, although the erection capacity was increased by 100 tons, the self-weight of the bridge erector was more than 400 tons more than expected, and the application scenarios were limited. "The technical parameters are fine, but the economy is flawed and it is likely to be left out in the cold by the market." Liang Zhixin expressed his concern to Chen Qi.
"Good design" does not mean "market seat". R&D is about to enter the prototype production stage, and the delivery time of the bridge bridge machine is only a few months away, is it too late to rework now? Will the owner unit allow it? If the plan is overturned and restarted, what is the research group's long-term work for more than a year?
At the critical moment, Tang Youfu clapped the board: "If the new plan is more ideal, of course, we must be bold, and I will fight for it from the higher unit." Please change the thinking of the research group, we have applied for patents for both designs! In July 2018, after receiving the approval of the superior company, the Tiewu Academy held a research group meeting to start the technical design of the upper guide beam carrier integrated machine.
Liang Zhixin, who was under the pressure of technical decision-making, choked up, and sighed infinitely in his heart: "The pursuit of perfection is a challenge, but also a responsibility." The "guide beam" changes from "down" to "up", which seems to change from "lifting" to "lifting", but it means tens of thousands of recalculations.
Jiang Zhongming, the youngest member of the research group, was stunned for a moment, and he looked at his desk: the more than 400-page scheme calculation book has been perfected more than 10 times, and more than 150 versions of the main beam diagram alone have been stored; all the A3 drawings are stacked at least 10 meters high... This time, it's all over again.
Wang Zhibin, who once again served as the project leader, secretly resolved: "If we only pursue the successful conclusion of the project, we will always be followers." For researchers, the drawings should not lie in the file bag, our goal is to draw into the mountains and rivers, transform the mountains and rivers! ”
"All efforts, just to leave no regrets." Chen Qi is the project leader and the thought guide, he comforted everyone: "The biggest reluctance of R & D personnel is not that they do not have the opportunity and ability to design good products; but that they obviously have the opportunity, but because of the 'almost' mentality and the best solution!" ”
In the conference room, many people's eyes were red; no one left the table, no one spoke, everyone thought about it, and then opened the computer in unison... There was only the sound of mouse clicks in the conference room.
"The strength cannot be reduced, and the self-weight continues to decrease", such a goal forced Luo Jiulin, who was responsible for the design of the main beam, to no way back. Luo Jiulin led the team to improve the design 8 times, and the weight of the main beam alone was 60 tons less than the original, which can be called the pursuit of perfection in the challenge limit...
In only 3 months, the research team reduced the total weight of the "Kunlun" from 1450 tons to 975 tons, which made the experts sigh "accident" and "surprise"!
"It embodies the painstaking efforts of hundreds of developers in the industrial chain." This is not only a bridge machine, but also a 'spokesperson machine' for the heavy equipment of a big country."
Difficulties to be solved such as rolling peaks, one after the other!
"The GT785 steel used in the main girder structure of the Kunlun is very strong, and it is difficult for conventional welding processes to solve problems such as weld cracking." The design team not only invited industry experts such as the Iron and Steel Research Institute to give advice, but also directly "stationed in the factory". On April 8, 2020, Wuhan officially lifted the control of the passage from Han, and Duo Juntai, a post-90s designer, took the first high-speed train to go directly to Hanjiang Heavy Industry of the Eleventh Bureau of China Railway, staying for half a year, and found a set of process methods to ensure "seamless steel clothes".
Since the key components are all non-standard customization, the design team turned to all over the world: in coordination with Fujian Zhangzhou Longxi Bearing Factory to complete the manufacture of spherical bearings, on the basis of a 25% reduction in height, the bearings can carry 1200 tons of pressure and 200 tons of tensile force, to achieve 3 dimensions of rotation, to ensure that the "Kunlun" flexible walking; to recruit Guizhou forward cooperation in the development of small diameter, large bearing tires, the maximum axle load from 23 tons to 30 tons, to meet the heavy load needs of the "Kunlun"; united Baowu Steel to develop a new material GT785 steel The thickness of the main structural stressed parts of the plate is maintained at 50 mm, and the strength and impact power are increased to 785 MPa and 120 joules, making the main girder of the "Kunlun" strong and tough.
At the last moment of delivery of the technical solution, the research group worked overtime to rotate. Jiang Zhongming, who had just fallen in love, couldn't care about spending the previous month, soaking in the office all day, when he was really sleepy, he took two chairs to fight in the corner of the wall, and took a nap with clothes; Wan Peng once got up early in the morning to catch up with the drawings, nausea and dizziness were directly sent to the hospital by 120, filmed and rushed back to the office area...
The last collective overtime work until two o'clock in the morning, everyone found that Liang Zhixin suddenly disappeared; the young man just felt sad that "Liang Zong also has a day that he can't hold up", so he saw him holding a stack of instant noodles and appeared at the door of the conference room... While giving everyone noodles, Liang Zhixin said in a serious tone, "The drawings in our hands are not only the 'treasures' of the five hospitals, it condenses the painstaking efforts of hundreds of developers in the industrial chain." This is not only a bridge machine, but also a 'spokesperson machine' for a big country heavy weapon! ”
However, good things are more grinding. On June 20, 2020, at the construction site of the Meizhou Bay Bridge of the Fuzhou-Xiamen High-speed Railway, the "Kunlun" encountered a bad luck when starting the first beam erection.
The main beam was obviously pushing forward, but the sensor of the main leg on the main console suddenly turned red alarm, and the "Kunlun" stopped instantly! Is there a deviation in the angle calculation, or is the design of the stress system wrong? Standing under the bridge machine, Wan Peng was impatient, checked again and again against the calculation model, never found a breakthrough point, and watched the "Kunlun" fall into the dead cycle of "start-alarm-stop-start again"... The complaining receded, the workers withdrew, Wan Peng was left alone under the bridge machine, the back shadow was Xiao Suo, the work clothes were soaked, the shadow grew longer and longer as the sunset went down, and the past scenes in his mind kept flashing...
We must not abandon our previous achievements! At 10 o'clock that night, Wan Peng climbed up the 40-meter bridge deck and went through the drawings again and again with the control equipment until 3 a.m. "There is no problem with the structural design, only the hydraulic balance valve in the cylinder is too conservative, resulting in poor lateral movement of the lifting beam trolley." Wan Peng cut through the iron.
On the morning of June 22, the balance valve was replaced by the "Kunlun" of the hydraulic lock and officially resumed work. Wan Peng drilled into the "belly" of the bridge erector and issued an instruction to the driver, "Start!" ”
The Kunlun moved forward steadily, and the first beam was successfully erected after 40 minutes! The scene boiled over...
Figure (1): Luo Jiulin (front) conducts measurement work at the site. Figure (2): Wan Peng (right) guides the assembly work on site. Figure (3): At the construction site of the Meizhou Bay Cross-Sea Bridge of the Fuzhou-Xiamen Railway, the "Kunlun" is erecting a 40-meter box girder in the last hole of the line. Photo by Xinhua News Agency reporter Song Weiwei
"This is a new Chinese power and Chinese speed." Wan Peng, who had not closed his eyes for almost three nights, had sour eyes, "The 'Kunlun' was born in the hands of Chinese, and he will certainly be able to take Chinese wisdom and read the spring colors of the world." (Lu Yanan)
Source: People's Daily