Detailed Production Process ofTransmission/Telecommunication Towers
● Customized steel procurement :
○ Raw material selection : According to the design requirements, choose high-strength and weather-resistant steel, such as Q345 and Q420 steel, to ensure compliance with international standards, such as ASTM and EN standards. Pay special attention to the ductility and weldability of the material when purchasing.
○ Supplier Audit : Strictly audit supplier qualifications and select suppliers with international certifications (such as ISO 9001) to ensure the quality and traceability of materials.
● Warehouse inspection :
○ Chemical composition analysis : Use a spectrometer to detect the chemical composition of steel to ensure that the element content (such as carbon, manganese, silicon, etc.) meets the design specifications.
○ Physical property testing : Conduct tensile tests and impact tests to detect the tensile strength, yield strength and elongation of steel to ensure that the material meets the requirements.
○ Surface inspection : Perform visual inspection on the steel surface to ensure there are no defects such as cracks, delamination, rust, etc.
○ Raw material selection : According to the design requirements, choose high-strength and weather-resistant steel, such as Q345 and Q420 steel, to ensure compliance with international standards, such as ASTM and EN standards. Pay special attention to the ductility and weldability of the material when purchasing.
○ Supplier Audit : Strictly audit supplier qualifications and select suppliers with international certifications (such as ISO 9001) to ensure the quality and traceability of materials.
● Warehouse inspection :
○ Chemical composition analysis : Use a spectrometer to detect the chemical composition of steel to ensure that the element content (such as carbon, manganese, silicon, etc.) meets the design specifications.
○ Physical property testing : Conduct tensile tests and impact tests to detect the tensile strength, yield strength and elongation of steel to ensure that the material meets the requirements.
○ Surface inspection : Perform visual inspection on the steel surface to ensure there are no defects such as cracks, delamination, rust, etc.
● CNC cutting :
○ Equipment preparation : According to the design drawings, use CAD/CAM software to convert the cutting diagram of the steel plate into the program of the CNC cutting machine, and set the cutting path and parameters (such as cutting speed and nozzle diameter).
○ Precision cutting : Use plasma cutting or laser cutting equipment to accurately cut the steel plate to ensure smooth edges and accurate dimensions with a tolerance of ±0.5mm.
○ Inspection after cutting : After cutting, the size of each steel plate is checked and the cut edges are trimmed to remove burrs and scale.
○ Equipment preparation : According to the design drawings, use CAD/CAM software to convert the cutting diagram of the steel plate into the program of the CNC cutting machine, and set the cutting path and parameters (such as cutting speed and nozzle diameter).
○ Precision cutting : Use plasma cutting or laser cutting equipment to accurately cut the steel plate to ensure smooth edges and accurate dimensions with a tolerance of ±0.5mm.
○ Inspection after cutting : After cutting, the size of each steel plate is checked and the cut edges are trimmed to remove burrs and scale.
● Bending and rolling :
○ Bending process : According to the design requirements, use a CNC bending machine to bend the steel plate. Set the bending angle and pressure to ensure that the bending radius meets the design requirements and control the bending springback.
oRolling process : For the cylindrical components of the tower body, a plate rolling machine is used for rolling. The positions of the upper and lower rollers are adjusted to ensure that the diameter and roundness of the cylindrical structure meet the requirements.
● Quality Inspection :
○ Dimension measurement : Use measuring tools (such as vernier calipers, goniometers) to measure the dimensions and angles of the formed components to ensure that they meet the drawing requirements.
○ Shape inspection : For rolled components, use a dedicated roundness measuring instrument to check the roundness to ensure its uniformity and standard.
○ Bending process : According to the design requirements, use a CNC bending machine to bend the steel plate. Set the bending angle and pressure to ensure that the bending radius meets the design requirements and control the bending springback.
oRolling process : For the cylindrical components of the tower body, a plate rolling machine is used for rolling. The positions of the upper and lower rollers are adjusted to ensure that the diameter and roundness of the cylindrical structure meet the requirements.
● Quality Inspection :
○ Dimension measurement : Use measuring tools (such as vernier calipers, goniometers) to measure the dimensions and angles of the formed components to ensure that they meet the drawing requirements.
○ Shape inspection : For rolled components, use a dedicated roundness measuring instrument to check the roundness to ensure its uniformity and standard.
● CNC drilling :
○ Hole positioning : According to the drawing requirements, use a laser locator to mark the position of each drill hole to ensure the accuracy of the drilling position.
○ Drilling operation : Use CNC drilling machine to drill or punch holes in steel plates. Set the drilling depth and speed to ensure that the hole diameter and hole wall quality meet the standards.
○ Post-hole treatment : After drilling, use a deburring tool to clean the burrs around the hole and perform rust-proof treatment on the hole wall.
○ Hole positioning : According to the drawing requirements, use a laser locator to mark the position of each drill hole to ensure the accuracy of the drilling position.
○ Drilling operation : Use CNC drilling machine to drill or punch holes in steel plates. Set the drilling depth and speed to ensure that the hole diameter and hole wall quality meet the standards.
○ Post-hole treatment : After drilling, use a deburring tool to clean the burrs around the hole and perform rust-proof treatment on the hole wall.
● Pre-assembly inspection :
○ Trial assembly : According to the design drawings, the steel components are trial assembled. Use connecting bolts and clamps to temporarily fix the components and check the fit between the components.
○ Adjustment and correction : If it is found that the connection between parts is not tight or there is a dimensional deviation, adjust and correct it immediately to ensure smooth final assembly.
● Manual Soldering :
○ Welding process formulation : According to the requirements of different parts, select the appropriate welding process, such as gas shielded welding (MIG/TIG), submerged arc welding or manual arc welding, and set the welding current, voltage and welding speed.
○ Weld seam treatment : During welding, ensure that the weld is uniform, free of pores and slag inclusions. After welding, use an ultrasonic flaw detector to perform nondestructive testing of the weld to ensure welding quality.
○ Weld grinding : Use a grinder to grind the weld to ensure that the weld is smooth, has no protrusions, and has a beautiful appearance.
○ Trial assembly : According to the design drawings, the steel components are trial assembled. Use connecting bolts and clamps to temporarily fix the components and check the fit between the components.
○ Adjustment and correction : If it is found that the connection between parts is not tight or there is a dimensional deviation, adjust and correct it immediately to ensure smooth final assembly.
● Manual Soldering :
○ Welding process formulation : According to the requirements of different parts, select the appropriate welding process, such as gas shielded welding (MIG/TIG), submerged arc welding or manual arc welding, and set the welding current, voltage and welding speed.
○ Weld seam treatment : During welding, ensure that the weld is uniform, free of pores and slag inclusions. After welding, use an ultrasonic flaw detector to perform nondestructive testing of the weld to ensure welding quality.
○ Weld grinding : Use a grinder to grind the weld to ensure that the weld is smooth, has no protrusions, and has a beautiful appearance.
● Galvanizing process control :
○ Surface pretreatment : Before galvanizing, pickling, immersion and drying are carried out to ensure that the steel surface is clean and free of oil and rust. The pickling time and temperature must be strictly controlled to avoid excessive corrosion.
○ Hot-dip galvanizing : Immerse the treated components in molten zinc at 450°C-460°C, control the immersion time, and ensure that the zinc layer is uniform and the thickness meets the standard (such as 80-120μm).
○ Cooling and passivation : After galvanizing, the components are quickly cooled and passivated to improve the corrosion resistance and service life of the zinc layer.
● Zinc layer quality inspection :
○ Thickness detection : Use a coating thickness gauge to detect the thickness of the zinc layer to ensure that it meets standard requirements.
○ Adhesion test : Conduct zinc layer adhesion test to ensure that the zinc layer will not peel off and has a long-term anti-corrosion effect.
○ Surface pretreatment : Before galvanizing, pickling, immersion and drying are carried out to ensure that the steel surface is clean and free of oil and rust. The pickling time and temperature must be strictly controlled to avoid excessive corrosion.
○ Hot-dip galvanizing : Immerse the treated components in molten zinc at 450°C-460°C, control the immersion time, and ensure that the zinc layer is uniform and the thickness meets the standard (such as 80-120μm).
○ Cooling and passivation : After galvanizing, the components are quickly cooled and passivated to improve the corrosion resistance and service life of the zinc layer.
● Zinc layer quality inspection :
○ Thickness detection : Use a coating thickness gauge to detect the thickness of the zinc layer to ensure that it meets standard requirements.
○ Adhesion test : Conduct zinc layer adhesion test to ensure that the zinc layer will not peel off and has a long-term anti-corrosion effect.
● Pre-assembly and inspection :
○ Trial installation steps : Carry out trial installation in the factory, assemble all components according to the design sequence, simulate the on-site installation process, and ensure that all parts can be assembled accurately and correctly.
○ Structural inspection : Check the verticality of the overall structure, the tightness of the joints, and the matching between components to ensure there are no problems during on-site installation.
○ Trial installation adjustment : If any problems are found during the trial installation, timely adjustments or rework will be made to ensure that all problems are resolved in the factory.
○ Trial installation steps : Carry out trial installation in the factory, assemble all components according to the design sequence, simulate the on-site installation process, and ensure that all parts can be assembled accurately and correctly.
○ Structural inspection : Check the verticality of the overall structure, the tightness of the joints, and the matching between components to ensure there are no problems during on-site installation.
○ Trial installation adjustment : If any problems are found during the trial installation, timely adjustments or rework will be made to ensure that all problems are resolved in the factory.
● Comprehensive inspection :
○ Size and shape inspection : Use professional measuring tools (such as laser rangefinder, level) to check the key size and shape of each component to ensure that it meets the design requirements.
○ Mechanical properties testing : Conduct tensile tests and impact tests to ensure that the mechanical properties of the components (such as tensile strength and toughness) meet the requirements.
○ Surface quality inspection : Carefully inspect the galvanized layer and coating on the surface of the component to ensure there are no defects such as cracks, peeling, bubbles, etc.
○ Size and shape inspection : Use professional measuring tools (such as laser rangefinder, level) to check the key size and shape of each component to ensure that it meets the design requirements.
○ Mechanical properties testing : Conduct tensile tests and impact tests to ensure that the mechanical properties of the components (such as tensile strength and toughness) meet the requirements.
○ Surface quality inspection : Carefully inspect the galvanized layer and coating on the surface of the component to ensure there are no defects such as cracks, peeling, bubbles, etc.
● Painting process :
○ Primer spraying : According to customer requirements, select a highly corrosion-resistant primer (such as epoxy zinc-rich primer) and spray it in multiple layers. Dry each layer thoroughly to ensure coating thickness and adhesion.
○ Topcoat spraying : Choose a topcoat with excellent weather resistance and UV resistance (such as polyurethane paint), spray two to three layers, and ensure that the gloss and uniformity of the coating meet customer requirements.
● Coating inspection :
○ Coating thickness detection : Use a coating thickness gauge to detect the thickness of each layer of coating to ensure that it meets the design standards.
○ Coating adhesion test : Conduct coating adhesion test to ensure that the coating will not fall off during long-term use.
○ Primer spraying : According to customer requirements, select a highly corrosion-resistant primer (such as epoxy zinc-rich primer) and spray it in multiple layers. Dry each layer thoroughly to ensure coating thickness and adhesion.
○ Topcoat spraying : Choose a topcoat with excellent weather resistance and UV resistance (such as polyurethane paint), spray two to three layers, and ensure that the gloss and uniformity of the coating meet customer requirements.
● Coating inspection :
○ Coating thickness detection : Use a coating thickness gauge to detect the thickness of each layer of coating to ensure that it meets the design standards.
○ Coating adhesion test : Conduct coating adhesion test to ensure that the coating will not fall off during long-term use.
● Export Packing :
○ Protective packaging : According to the shape of the components and transportation conditions, use anti-rust paper, plastic film, foam pads and other materials to package the components to prevent damage during transportation.
○ Classification and packing : Classify and pack the components according to the installation order, and use wooden boxes or iron frames to reinforce them to ensure that they will not shift or be damaged during transportation.
○ Protective packaging : According to the shape of the components and transportation conditions, use anti-rust paper, plastic film, foam pads and other materials to package the components to prevent damage during transportation.
○ Classification and packing : Classify and pack the components according to the installation order, and use wooden boxes or iron frames to reinforce them to ensure that they will not shift or be damaged during transportation.
● Container loading :
○ Packing plan : According to the customer's unloading order and site conditions, the packing sequence is reasonably arranged to ensure that the components can be easily unloaded and assembled in sequence after transportation.
○ Packing operation : Use lifting equipment to safely load the packaged components into the container, and use reinforcement straps and fixing brackets to ensure that the components will not move during transportation.
● Shipping and logistics management :
○ Shipping arrangement : According to the contract requirements, select the appropriate logistics method (sea transportation, land transportation, etc.) and arrange the loading time to ensure on-time delivery.
○ Logistics tracking : Track the logistics status throughout the entire process, report the transportation progress to customers in a timely manner, and provide all necessary documents (such as bill of lading, packing list, certificate of origin, etc.) to ensure smooth customs clearance.
○ Packing plan : According to the customer's unloading order and site conditions, the packing sequence is reasonably arranged to ensure that the components can be easily unloaded and assembled in sequence after transportation.
○ Packing operation : Use lifting equipment to safely load the packaged components into the container, and use reinforcement straps and fixing brackets to ensure that the components will not move during transportation.
● Shipping and logistics management :
○ Shipping arrangement : According to the contract requirements, select the appropriate logistics method (sea transportation, land transportation, etc.) and arrange the loading time to ensure on-time delivery.
○ Logistics tracking : Track the logistics status throughout the entire process, report the transportation progress to customers in a timely manner, and provide all necessary documents (such as bill of lading, packing list, certificate of origin, etc.) to ensure smooth customs clearance.
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