WO2015078186A1 - 齿轮齿条爬升式垂直升船机齿条安装方法及辅助调节装置 - Google Patents
齿轮齿条爬升式垂直升船机齿条安装方法及辅助调节装置 Download PDFInfo
- Publication number
- WO2015078186A1 WO2015078186A1 PCT/CN2014/081971 CN2014081971W WO2015078186A1 WO 2015078186 A1 WO2015078186 A1 WO 2015078186A1 CN 2014081971 W CN2014081971 W CN 2014081971W WO 2015078186 A1 WO2015078186 A1 WO 2015078186A1
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- WIPO (PCT)
- Prior art keywords
- rack
- mounting
- lateral
- adjustment
- shiplift
- Prior art date
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Classifications
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02C—SHIP-LIFTING DEVICES OR MECHANISMS
- E02C5/00—Mechanisms for lifting ships vertically
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63C—LAUNCHING, HAULING-OUT, OR DRY-DOCKING OF VESSELS; LIFE-SAVING IN WATER; EQUIPMENT FOR DWELLING OR WORKING UNDER WATER; MEANS FOR SALVAGING OR SEARCHING FOR UNDERWATER OBJECTS
- B63C3/00—Launching or hauling-out by landborne slipways; Slipways
- B63C3/06—Launching or hauling-out by landborne slipways; Slipways by vertical movement of vessel, i.e. by crane
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02B—HYDRAULIC ENGINEERING
- E02B17/00—Artificial islands mounted on piles or like supports, e.g. platforms on raisable legs or offshore constructions; Construction methods therefor
- E02B17/04—Equipment specially adapted for raising, lowering, or immobilising the working platform relative to the supporting construction
- E02B17/08—Equipment specially adapted for raising, lowering, or immobilising the working platform relative to the supporting construction for raising or lowering
- E02B17/0818—Equipment specially adapted for raising, lowering, or immobilising the working platform relative to the supporting construction for raising or lowering with racks actuated by pinions
Definitions
- the present invention relates to an efficient mounting method and apparatus for a rack, and more particularly to an efficient mounting method and an auxiliary adjusting device suitable for an ultra-high precision rack mounting project of various types of rack and pinion climbing vertical ship lifts.
- the technical problem to be solved by the present invention is to provide an efficient installation method for rack and pinion climbing vertical ship lift rack, and realize fast and high quality installation of the rack and pinion climbing vertical ship lift rack, and solve each
- the construction is difficult, economical and high-efficiency; the invention also provides an auxiliary adjusting device for the method, which has the advantages of simple structure, quick and convenient use, recyclability and meeting installation requirements.
- a method for efficiently mounting a rack of a rack and pinion climbing vertical shiplift comprising the following steps:
- Rack height adjustment of the rack Use the high-precision measuring instrument to measure the rack mounting elevation by the horizontal cutting height measurement method, then adjust the rack elevation by the jack arranged at the bottom of the rack; After the rack elevation adjustment is passed Two dial gauges are arranged at the top of the top of the rack for monitoring the rack elevation change;
- Rack positive adjustment of the rack Perform the quality adjustment and reinforcement of the forward mounting of the rack. After the positive adjustment of the rack is adjusted, four dial gauges are arranged at the four corners of the forward side of the rack for the positive mounting quality of the rack. Change monitoring
- a set of racks needs to have a lateral positioning reference point and two forward positioning reference points on the base plate.
- three positioning of a set of racks The reference point must be measured and positioned in the same measurement punctuation, the same measuring instrument, and the same measuring station.
- the bottom auxiliary device is a bottom steel structure tool used with a jack
- the auxiliary device is a lateral steel structure tool disposed on the second stage of the rack corresponding to the lateral four-corner position of the rack, and a plurality of sets of high-precision process screws, and a plurality of sets of high-precision process screws are passed through the panel.
- High-strength bolt holes, the rack is fixed in the second stage of the rack, and the lateral steel structure tool is used with the jack;
- the forward mounting quality of the rack is adjusted by using a plurality of high-precision process screws, and the lateral mounting quality adjustment and reinforcement of the rack is performed by the jack on the lateral steel structure tool, and the jack bottom elevation is performed by the jack on the bottom steel structure tooling. Installation quality adjustment and reinforcement.
- step 4 the wire frame is arranged at the top of the rack 400 ⁇ 600 to make the height (the optimal height is 500).
- the wire frame needs to be welded firmly, avoiding the change of the measuring tooling position caused by the wire frame swaying.
- the tooling position should be roughly aligned with the rack positioning reference point on the corresponding base plate to make the return point between the reference point and the tooling.
- step 5 the pitch point regulation measurement method is between the arranged bottom positioning reference point and the top point point regulation measuring tool, and the laser zenith instrument is used to reproduce the bottom positioning reference point accurate point return to the top of the pitch point regulation. Measuring the measurement method on the tooling can effectively eliminate the measurement error caused by the conventional shooting point.
- the horizontal cut height measurement method is to first design the rack height by measuring the punctuation using a high-precision total station. The value is placed on the vertical wall near the rack, and then the high-precision level is used to measure the rack mounting elevation by the horizontal measurement method, which can effectively avoid the measurement error caused by the total station's upward measurement;
- the initial values are recorded by two dial gauges arranged at the two ends of the top of the rack.
- the changes caused by the rack elevation can be monitored at any time and processed in time.
- step 7 the lateral mounting quality adjustment control of the rack is performed by four sets of jacks arranged at the four corners of the rack, and the measuring tool used for the adjustment is a self-made seated micrometer, and the rack side is measured by the micrometer with a seat. 001mm, to ensure the accuracy of the installation meets the high standard requirements;
- the initial values are recorded by two dial gauges on the upper and lower sides of the rack.
- the lateral changes of the rack can be monitored at any time and processed in time.
- step 8 the plurality of sets of high-precision process screws arranged in the forward direction of the rack are used for quality adjustment and reinforcement of the forward mounting of the rack.
- the measuring tool used for the adjustment is a self-made seated micrometer, and the rack is measured by the micrometer with a seat.
- the positive working surface is spaced from the reference perpendicular to adjust the positioning.
- the micrometer can effectively control the measurement accuracy to 0. 001mm, ensuring the installation quality accuracy meets the high standard requirements;
- the initial values are recorded by four dial gauges arranged at the four corners of the rack front panel.
- the forward changes of the rack can be monitored at any time and processed in time.
- step 9 the fixed support of the template shall not be placed on the rack, which eliminates the possibility of displacement of the rack due to the force applied by the template during the grouting process.
- the periphery of the template must be sealed with glass glue. The sealing property is tested by a water filling test after the template is installed.
- step 11 the rack mounting quality has been adjusted after step 8), and in the process of steps 9) and 10), the rack is affected by the external force, and there is a possibility of displacement being extremely small, so in the step 10) After the formal measurement and acceptance of the rack is required, the acceptance method is shown in steps 6), 7) and 8).
- step 12 when the cumulative displacement difference generated by the rack during the grouting process is greater than 0.2 mm, it indicates that the quality of the installation of the individual main control items may exceed the standard at this time, and the grouting needs to be suspended to analyze the monitoring data. Determine whether processing is required based on the results of the data analysis.
- An auxiliary adjusting device for efficiently mounting a rack and pinion climbing vertical shiplift rack is composed of an auxiliary device and a bottom auxiliary device arranged at the bottom of the second stage of the rack, the auxiliary device is arranged at the four corners of the rack Corresponding rack second stage embedded and rack forward.
- the lateral steel structure tooling is welded on the second stage embedded part of the rack corresponding to the four corners of the rack, and the jack is mounted on the lateral steel structure tool, and the plurality of high-precision process screws pass through the high-strength bolt holes on the panel, and the teeth are Strip is fixed in the tooth The second phase of the article is embedded.
- the number of high precision process screws is 12 sets.
- a jack is mounted on the bottom steel structure tooling.
- the invention provides an efficient installation method for rack and pinion climbing vertical shiplift rack, through the adjustment and reinforcement of the rack, adopts the original measuring process method to complete the measurement and control of the rack mounting quality precision, and finds the most efficient by experiment.
- the rack mounting process smoothly realizes the high-precision and high-efficiency installation of the ship rack rack, solves various construction difficulties, and is economical and high-efficiency.
- the invention also provides an auxiliary adjusting device for the method, which has a simple structure and uses. Quick and easy, able to recycle and meet installation needs.
- the invention is particularly suitable for the ultra-high-precision nut column installation engineering of various types of rack and pinion climbing vertical ship lifts, and can also provide useful reference for high-precision installation of similar metal structures and large equipment in other engineering fields.
- FIG. 1 is a schematic view showing the arrangement of a rack positioning reference point determined in step 1) of the method of the present invention
- Figure 2 is a plan view of the auxiliary adjusting device of the present invention.
- Figure 3 is a front elevational view of the steps of the method of the present invention.
- Figure 4 is a side view of the steps of the method of the present invention after completion
- FIG. 5 is a schematic diagram showing the arrangement of the dial gauge monitoring measurement points in the method of the present invention.
- a method for efficiently mounting a rack and pinion climbing vertical shiplift rack comprises the following steps:
- Rack 3 elevation adjustment of the rack 3 Using a high-precision measuring instrument, the rack height is measured by the horizontal cut height measurement method, and then the rack elevation is adjusted by the jack 12 arranged at the bottom of the rack; the rack elevation adjustment After passing the qualification Two dial gauges Hl and H2 are arranged at the top ends of the rack for monitoring the rack elevation change;
- Lateral adjustment and reinforcement of the rack 3 The lateral mounting quality adjustment and reinforcement of the rack are carried out at the four corners of the rack side. After the lateral mounting quality adjustment of the rack is passed, two percentages are arranged on the upper and lower corners of the rack side. Tables XI and X2 are used to monitor the quality change of the lateral mounting of the rack;
- Rack 3 forward adjustment and reinforcement Carry out the quality adjustment and reinforcement of the forward mounting of the rack. After the positive adjustment of the rack is passed, four dial gauges Yl, ⁇ 2, ⁇ 3, ⁇ 4 are arranged at the four corners of the forward plate of the rack. Used for monitoring the quality change of the rack forward installation;
- a set of racks 3 needs to have a lateral positioning reference point 2 and two forward positioning reference points 1 arranged on the base plate 11, and a set of racks is used for positioning the reference points with a high-precision measuring instrument.
- the three positioning reference points of 3 must complete the measurement positioning in the same measuring punctuation, the same measuring instrument, and the same measuring station to overcome the measurement error caused by multiple erection instruments.
- the bottom auxiliary device is a bottom steel structure tooling 7 used with the jack 12;
- the auxiliary device is a lateral steel structure tooling 6 disposed on the second stage embedded part 4 corresponding to the lateral four-corner position of the rack, and a plurality of sets of high-precision process screws 5, and a plurality of sets of high-precision process screws 5
- the rack 3 is fixed in the forward direction of the second stage embedded part 4 of the rack, and the lateral steel structure tooling 6 is matched with the jack 12; the rack is forwarded by using a plurality of sets of high-precision process screws 5
- the installation quality is adjusted, and the jack 12 on the lateral steel structure tooling 6 is used to adjust and reinforce the lateral mounting quality of the rack.
- the jack 12 on the bottom steel structure tooling 7 is used for the height adjustment and reinforcement of the rack bottom elevation.
- step 4 the wire rack is arranged at a height of 400 ⁇ 600mm at the top of the rack 3 (the optimal height is 500mm), the wire frame needs to be welded firmly, and the position of the measuring tool is changed due to the sway of the wire frame, and the shooting point is arranged on the wire rack.
- the measuring tool 8 is adjusted, the tooling position should be roughly aligned with the rack positioning reference point on the corresponding base plate 11 to make the return point between the reference point and the tooling.
- step 5 the pitch control measurement method is between the arranged bottom positioning reference point and the top point-adjusting measuring tool 8, and the laser zenith is used to reproduce the bottom positioning reference point to the top point. The measurement method on the measuring tool 8 is adjusted to effectively eliminate the measurement error generated when the conventional shooting point is performed.
- the horizontal cut height measurement method is to first use the high-precision total station to measure the rack design elevation value to the vertical wall near the rack by measuring the punctuation, and then use the high-precision level to measure the rack mounting elevation by the horizontal measuring method.
- the measurement method can effectively avoid the measurement error caused by the total station's upward measurement when using the measurement method;
- the initial values are recorded by two dial gauges Hl and H2 arranged at the top ends of the rack 3, and the changes caused by the rack elevation can be monitored and processed in time during the subsequent construction.
- step 7 the lateral mounting quality adjustment control of the rack is carried out by four sets of jacks arranged at the four corners of the rack.
- the measuring tool used for the adjustment is a self-made seated micrometer, and the rack side is measured by the micrometer with a seat. 001mm, to ensure the accuracy of the installation meets the high standard requirements;
- the initial values are recorded by placing two dial gauges XI and X2 on the upper and lower corners of the rack. During the subsequent construction, the lateral changes of the rack can be monitored at any time and timely. deal with.
- step 8 the plurality of sets of high-precision process screws 5 arranged in the forward direction of the rack are used for quality adjustment and reinforcement of the forward mounting of the rack.
- the measuring tool used for the adjustment is a self-made seated micrometer, and the measuring tooth is measured by the micrometer with a seat.
- the positive working surface is spaced from the reference vertical line to adjust the positioning; the micrometer can effectively control the measurement accuracy to 0. 001mm, ensuring the installation quality accuracy meets the high standard requirements;
- the initial values are recorded by four dial gauges Yl, ⁇ 2, ⁇ 3, ⁇ 4 arranged at the four corners of the rack front panel.
- the forward movement of the rack can be monitored at any time during the subsequent construction. Handle in a timely manner.
- step 9 the fixed support of the template shall not be placed on the rack, which eliminates the possibility of displacement of the rack due to the force applied by the template during the grouting process.
- the periphery of the template must be sealed with glass glue. The sealing property is tested by a water filling test after the template is installed.
- step 11 the rack mounting quality has been adjusted after step 8).
- the rack is affected by the external force, and there is a small possibility of displacement, so in the step 10)
- the acceptance method is shown in steps 6), 7) and 8).
- step 12 when the cumulative displacement difference generated by the rack during the grouting process is greater than 0. 2mm, it indicates that the quality of the installation of the individual main control items may exceed the standard at this time, and the grouting needs to be suspended to analyze the monitoring data. Determine whether processing is required based on the results of the data analysis.
- an auxiliary adjusting device for efficient mounting of a rack and pinion climbing vertical shiplift rack the device is provided by an auxiliary device and arranged at the bottom of the second stage embedded rack 4
- the bottom auxiliary device is composed of auxiliary devices arranged in the forward direction of the second stage embedded part 4 and the rack 3 corresponding to the four corners of the rack 3.
- the lateral steel structure tooling 6 is welded on the second stage embedded part 4 corresponding to the four corners of the rack, and the jack 12 is mounted on the lateral steel structure tooling 6, and the plurality of high precision process screws 5 pass through the high strength on the panel.
- the bolt hole is fixed to the rack 2 in the second stage of the rack.
- the number of high-precision process screws 5 is 12 sets.
- a jack 12 is mounted on the bottom steel structure tooling 7.
- the invention provides an efficient installation method for rack and pinion climbing vertical shiplift rack, through the adjustment and reinforcement of the rack, adopts the original measuring process method to complete the measurement and control of the rack mounting quality precision, and finds the most efficient by experiment.
- the rack mounting process smoothly realizes the high-precision and high-efficiency installation of the ship rack rack, solves various construction difficulties, and is economical and high-efficiency.
- the invention also provides an auxiliary adjusting device for the method, which has a simple structure and uses. Quick and easy, able to recycle and meet installation needs.
- the invention is particularly suitable for the ultra-high-precision nut column installation engineering of various types of rack and pinion climbing vertical ship lifts, and can also provide useful reference for high-precision installation of similar metal structures and large equipment in other engineering fields.
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Abstract
一种齿轮齿条爬升式垂直升船机齿条安装方法,该方法包括以下步骤:1)齿条(3)基准点(1,2)布置;2)底部辅助装置安装;3)齿条(3)吊装及齿条(3)初步加固;4)齿条(3)顶部焊接线架及布置投点调控测量工装(8);5)向投点调控测量工装(8)上返点、挂垂线(9);6)齿条(3)高程方向调整加固;7)齿条(3)侧向调整加固;8)齿条(3)正向调整加固;9)立模板;10)预应力钢筋(10)安装;11)齿条(3)灌浆前验收;12)间隙灌浆;13)灌浆后张拉;14)预应力钢筋(10)张拉完成后,最终安装质量验收。还提供了一种齿轮齿条爬升式垂直升船机齿条安装的辅助调节装置。
Description
齿轮齿条爬升式垂直升船机齿条安装方法及辅助调节装置
技术领域
[0001] 本发明涉及一种齿条高效安装方法及装置, 尤其是一种适合应用于各类型齿轮齿条 爬升式垂直升船机超高精度齿条安装工程的高效安装方法及辅助调节装置。
背景技术
[0002] 三峡大型齿轮齿条爬升式垂直升船机工程, 作为国内外水电工程升船机领域内的首 创科研工程, 面临着许多技术难题。 在相关领域内没有任何可以借鉴的经验, 其具有单件尺 寸重量大、 结构复杂、 安装高度高、 技术难度大、 安装质量要求极高等突出施工难点, 必须 创新研发出适宜的安装技术来克服各种难点, 实现工程的顺利施工。
发明内容
[0003] 本发明所要解决的技术问题是提供一种齿轮齿条爬升式垂直升船机齿条高效安 装方法, 实现了齿轮齿条爬升式垂直升船机齿条的快速优质安装, 解决了各项施工难点、 经 济优质高效; 本发明还提供了用于该方法的辅助调节装置, 结构简单、 使用快捷方便、 能够 循环使用、 满足安装需求。
为解决上述技术问题, 本发明所采用的技术方案是: 一种齿轮齿条爬升式垂直升船机齿 条高效安装方法, 包括以下步骤:
1 ) 齿条基准点布置: 在齿条安装位置底部基础底板上, 通过高精度测量仪器测量投点 完成齿条定位基准点的测放;
2) 在齿条二期埋件的底部布置搭配千斤顶使用的底部辅助装置;
3 ) 将齿条吊装就位后, 安装辅助装置, 通过底部辅助装置及辅助装置进行齿条临时加 固;
4) 在齿条顶部合适位置焊接线架, 布置投点调控测量工装;
5 ) 通过投点调控测量法将齿条定位基准点返点到线架上的投点调控测量工装上, 然后 向下挂垂线;
6 ) 齿条高程方向调整加固: 利用高精度测量仪, 采用水平截高测量方法定位齿条安装 高程, 然后通过齿条底部布置好的千斤顶将齿条高程调整就位; 齿条高程调整合格后在齿条 顶部两端布置两台百分表用于齿条高程变化监控;
7 ) 齿条侧向调整加固: 在齿条侧向四角位置进行齿条侧向安装质量调整及加固, 齿条
侧向安装质量调整合格后在齿条一侧上下两角布置两台百分表用于齿条侧向安装质量变化监 控;
8 ) 齿条正向调整加固: 进行齿条正向安装质量调整及加固, 齿条正向安装质量调整合 格后在齿条正向面板四角布置四台百分表用于齿条正向安装质量变化监控;
9 ) 立模板: 进行齿条四周缝隙立模板, 模板固定体系布置在齿条二期埋件上, 模板四 周缝隙利用玻璃胶密封;
10) 按照操作手册完成齿条预应力钢筋的安装;
11 ) 进行齿条与二期埋件间隙灌浆, 灌浆全程通过百分表监测齿条在灌浆过程中产生的 位移差值;
13) 灌浆完成 14天后按照操作手册进行预应力钢筋张拉;
14) 预应力钢筋张拉完成后, 进行齿条最终安装质量验收;
从而完成齿轮齿条爬升式垂直升船机齿条的高效安装。
步骤 1 ) 中, 一组齿条需要在基础底板上布置一个侧向定位基准点以及两个正向定位基 准点, 在利用高精度测量仪器进行基准点定位时, 一组齿条的三个定位基准点必须在同一个 测量标点、 同一台测量仪器、 同一测量站内完成测量定位。
步骤 2) 中, 底部辅助装置为搭配千斤顶使用的底部型钢结构工装;
步骤 3 ) 中, 辅助装置为布置在与齿条侧向四角位置对应的齿条二期埋件上的侧向型钢 结构工装以及多组高精度工艺螺杆, 多组高精度工艺螺杆通过面板上的高强螺栓孔, 将齿条 正向固定在齿条二期埋件上, 侧向型钢结构工装搭配千斤顶使用;
利用多组高精度工艺螺杆对齿条进行正向安装质量调整, 利用侧向型钢结构工装上的千 斤顶进行齿条侧向安装质量调整及加固, 利用底部型钢结构工装上的千斤顶进行齿条底部高 程安装质量调整及加固。
步骤 4) 中, 线架布置适宜在齿条顶部 400〜600讓高处 (最佳高度为 500讓), 线架需 焊接牢固, 避免线架晃动引起测量工装位置发生变化, 在线架上布置投点调控测量工装时, 工装位置需与对应的基础底板上的齿条定位基准点大致对齐, 以便进行基准点与工装间的投 返点。
步骤 5 ) 中, 投点调控测量法为在布置好的底部定位基准点与顶部的投点调控测量工装 之间, 采用激光天顶仪将底部定位基准点精确返点重现到顶部的投点调控测量工装上的测量 方法, 能有效消除常规投点时产生的测量误差。
步骤 6 ) 中, 水平截高测量方法为首先利用高精度全站仪通过测量标点将齿条设计高程
值投放到齿条附近垂直墙壁上, 然后利用高精度水平仪采用水平测量方法定位齿条安装高程 的测量方法, 能有效避免全站仪仰视测量时引起的测量误差;
高程调整合格后通过齿条顶部两端布置的两台百分表记录初始数值, 在后续施工过程中 可以随时监控齿条高程产生的变化并进行及时的处理。
步骤 7 ) 中, 利用布置在齿条侧向四角位置的安装在四套千斤顶进行齿条侧向安装质量 调整控制, 调整时采用的测量工具为自制带座千分尺, 通过带座千分尺测量齿条侧向工作面 与基准垂线间距来进行调整定位, 采用千分尺可以将测量精度有效控制在 0. 001mm, 保证安 装质量精度满足高标准要求;
齿条侧向安装质量调整合格后, 通过齿条一侧上下两角布置两台百分表记录初始数值, 在后续施工过程中可以随时监控齿条侧向产生的变化并进行及时的处理。
步骤 8 ) 中, 利用布置在齿条正向的多组高精度工艺螺杆, 进行齿条正向安装质量调整 及加固, 调整时采用的测量工具为自制带座千分尺, 通过带座千分尺测量齿条正向工作面与 基准垂线间距来进行调整定位, 采用千分尺可以将测量精度有效控制在 0. 001mm, 保证安装 质量精度满足高标准要求;
齿条正向安装质量调整合格后, 通过齿条正向面板四角布置四台百分表记录初始数值, 在后续施工过程中可以随时监控齿条正向产生的变化并进行及时的处理。
步骤 9 ) 中, 模板固定受力支撑不得布置在齿条上, 杜绝了灌浆过程中因模板受力而引 起齿条产生位移的可能性。 同时因浆液流动性较强, 模板四周必须利用玻璃胶进行密封, 密 封性在模板安装后通过一次充水试验进行检测。
步骤 11 ) 中, 齿条安装质量经过步骤 8)后已经调整合格, 在经过步骤 9)、 10 ) 的过程 中, 齿条会受到外力影响, 存在极小的产生位移的可能性, 所以在步骤 10 ) 后需对齿条进 行一次正式测量验收, 验收方法见步骤 6)、 7)、 8)。
步骤 12 ) 中, 当齿条在灌浆过程中产生的累积位移差值大于 0. 2mm 时, 说明齿条此时 个别主控项目安装质量精度有可能超标, 需要暂停灌浆, 对监控数据进行分析, 根据数据分 析结果确定是否需要进行处理。
一种用于齿轮齿条爬升式垂直升船机齿条高效安装的辅助调节装置, 该装置由辅助装置 以及布置于齿条二期埋件底部的底部辅助装置组成, 辅助装置布置于齿条四角对应的齿条二 期埋件及齿条正向。
辅助装置中, 侧向型钢结构工装焊接于齿条四角对应的齿条二期埋件上, 侧向型钢结构 工装上安装有千斤顶, 多组高精度工艺螺杆通过面板上的高强螺栓孔, 将齿条正向固定在齿
条二期埋件上。
高精度工艺螺杆的数量为 12组。
底部辅助装置中, 底部型钢结构工装上安装有千斤顶。
本发明提供的一种齿轮齿条爬升式垂直升船机齿条高效安装方法, 通过齿条的调整加 固, 采用独创测量工艺方法完成齿条安装质量精度的测量控制, 通过试验摸索出效率最高的 齿条安装工艺, 顺利实现了升船机齿条高精度、 高效率的安装, 解决了各项施工难点、 经济 优质高效; 本发明还提供了用于该方法的辅助调节装置, 结构简单、 使用快捷方便、 能够循 环使用、 满足安装需求。
本发明尤其适用适合应用于各类型齿轮齿条爬升式垂直升船机超高精度螺母柱安装工 程, 亦可为其他工程领域内相类似金属结构和大型设备高精度安装提供有益的借鉴。
附图说明
下面结合附图和实施例对本发明作进一步说明:
图 1为本发明方法步骤 1 ) 中确定的齿条定位基准点的布置示意图;
图 2为本发明的辅助调节装置的俯视图;
图 3为本发明方法各步骤完成后的主视图;
图 4为本发明方法各步骤完成后的侧视图;
图 5为本发明方法中的百分表监控测量点位的布置示意图。
具体实施方式
如图 1、 图 3、 图 4和图 5所示, 一种齿轮齿条爬升式垂直升船机齿条高效安装方法, 该方法包括以下步骤:
1 ) 齿条基准点布置: 在齿条安装位置底部基础底板 11 上, 通过高精度测量仪器测量 投点完成齿条定位基准点的测放;
2 ) 在齿条二期埋件 4的底部布置搭配千斤顶 12使用的底部辅助装置;
3 ) 将齿条 3 吊装就位后, 安装辅助装置, 通过底部辅助装置及辅助装置进行齿条临时 加固;
4) 在齿条 3顶部合适位置焊接线架, 布置投点调控测量工装 8;
5 ) 通过投点调控测量法将齿条定位基准点返点到线架上的投点调控测量工装 8上, 然 后向下挂垂线 9;
6 ) 齿条 3高程方向调整加固: 利用高精度测量仪, 采用水平截高测量方法定位齿条安 装高程, 然后通过齿条底部布置好的千斤顶 12 将齿条高程调整就位; 齿条高程调整合格后
在齿条顶部两端布置两台百分表 Hl、 H2用于齿条高程变化监控;
7 ) 齿条 3侧向调整加固: 在齿条侧向四角位置进行齿条侧向安装质量调整及加固, 齿 条侧向安装质量调整合格后在齿条一侧上下两角布置两台百分表 XI、 X2 用于齿条侧向安装 质量变化监控;
8 ) 齿条 3正向调整加固: 进行齿条正向安装质量调整及加固, 齿条正向安装质量调整 合格后在齿条正向面板四角布置四台百分表 Yl、 Υ2、 Υ3、 Υ4 用于齿条正向安装质量变化监 控;
9 ) 立模板: 进行齿条四周缝隙立模板, 模板固定体系布置在齿条二期埋件 4上, 模板 四周缝隙利用玻璃胶密封;
10 ) 按照操作手册完成齿条预应力钢筋 10的安装;
11 ) 进行齿条与二期埋件间隙灌浆, 灌浆全程通过百分表 Hl、 Η2、 XI、 Χ2、 Yl、 Υ2、 Υ3、 Υ4监测齿条 3在灌浆过程中产生的位移差值;
13 ) 灌浆完成 14天后按照操作手册进行预应力钢筋 10张拉;
14) 预应力钢筋 10张拉完成后, 进行齿条 3最终安装质量验收;
从而完成齿轮齿条爬升式垂直升船机齿条的高效安装。
步骤 1 ) 中, 一组齿条 3需要在基础底板 11上布置一个侧向定位基准点 2以及两个正 向定位基准点 1, 在利用高精度测量仪器进行基准点定位时, 一组齿条 3的三个定位基准点 必须在同一个测量标点、 同一台测量仪器、 同一测量站内完成测量定位, 以克服多次架设仪 器带来的测量误差。
步骤 2 ) 中, 底部辅助装置为搭配千斤顶 12使用的底部型钢结构工装 7;
步骤 3 ) 中, 辅助装置为布置在与齿条侧向四角位置对应的齿条二期埋件 4上的侧向型 钢结构工装 6 以及多组高精度工艺螺杆 5, 多组高精度工艺螺杆 5 通过面板上的高强螺栓 孔, 将齿条 3正向固定在齿条二期埋件 4上, 侧向型钢结构工装 6搭配千斤顶 12使用; 利用多组高精度工艺螺杆 5 对齿条进行正向安装质量调整, 利用侧向型钢结构工装 6 上的千斤顶 12进行齿条侧向安装质量调整及加固, 利用底部型钢结构工装 7上的千斤顶 12 进行齿条底部高程安装质量调整及加固。
步骤 4) 中, 线架布置适宜在齿条 3顶部 400〜600mm高处 (最佳高度为 500mm), 线架 需焊接牢固, 避免线架晃动引起测量工装位置发生变化, 在线架上布置投点调控测量工装 8 时, 工装位置需与对应的基础底板 11 上的齿条定位基准点大致对齐, 以便进行基准点与工 装间的投返点。
步骤 5) 中, 投点调控测量法为在布置好的底部定位基准点与顶部的投点调控测量工装 8之间, 采用激光天顶仪将底部定位基准点精确返点重现到顶部的投点调控测量工装 8上的 测量方法,, 有效消除常规投点时产生的测量误差。
步骤 6) 中, 水平截高测量方法为首先利用高精度全站仪通过测量标点将齿条设计高程 值投放到齿条附近垂直墙壁上, 然后利用高精度水平仪采用水平测量方法定位齿条安装高程 的测量方法, 采用此种测量方法可以有效避免全站仪仰视测量时引起的测量误差;
高程调整合格后通过齿条 3顶部两端布置的两台百分表 Hl、 H2记录初始数值, 在后续 施工过程中可以随时监控齿条高程产生的变化并进行及时的处理。
步骤 7) 中, 利用布置在齿条侧向四角位置的安装在四套千斤顶进行齿条侧向安装质量 调整控制, 调整时采用的测量工具为自制带座千分尺, 通过带座千分尺测量齿条侧向工作面 与基准垂线间距来进行调整定位, 采用千分尺可以将测量精度有效控制在 0. 001mm, 保证安 装质量精度满足高标准要求;
齿条侧向安装质量调整合格后, 通过齿条一侧上下两角布置两台百分表 XI、 X2记录初 始数值, 在后续施工过程中可以随时监控齿条侧向产生的变化并进行及时的处理。
步骤 8) 中, 利用布置在齿条正向的多组高精度工艺螺杆 5, 进行齿条正向安装质量调 整及加固, 调整时采用的测量工具为自制带座千分尺, 通过带座千分尺测量齿条正向工作面 与基准垂线间距来进行调整定位; 采用千分尺可以将测量精度有效控制在 0. 001mm, 保证安 装质量精度满足高标准要求;
齿条正向安装质量调整合格后, 通过齿条正向面板四角布置四台百分表 Yl、 Υ2、 Υ3、 Υ4 记录初始数值, 在后续施工过程中可以随时监控齿条正向产生的变化并进行及时的处 理。
步骤 9) 中, 模板固定受力支撑不得布置在齿条上, 杜绝了灌浆过程中因模板受力而引 起齿条产生位移的可能性。 同时因浆液流动性较强, 模板四周必须利用玻璃胶进行密封, 密 封性在模板安装后通过一次充水试验进行检测。
步骤 11 ) 中, 齿条安装质量经过步骤 8)后已经调整合格, 在经过步骤 9)、 10) 的过程 中, 齿条会受到外力影响, 存在极小的产生位移的可能性, 所以在步骤 10 ) 后需对齿条进 行一次正式测量验收, 验收方法见步骤 6)、 7)、 8)。
步骤 12) 中, 当齿条在灌浆过程中产生的累积位移差值大于 0. 2mm时, 说明齿条此时 个别主控项目安装质量精度有可能超标, 需要暂停灌浆, 对监控数据进行分析, 根据数据分 析结果确定是否需要进行处理。
如图 2、 图 3和图 4所示, 一种用于齿轮齿条爬升式垂直升船机齿条高效安装的辅助调 节装置, 该装置由辅助装置以及布置于齿条二期埋件 4底部的底部辅助装置组成, 辅助装置 布置于齿条 3四角对应的齿条二期埋件 4及齿条 3正向。
辅助装置中, 侧向型钢结构工装 6焊接于齿条四角对应的齿条二期埋件 4上, 侧向型 钢结构工装 6上安装有千斤顶 12, 多组高精度工艺螺杆 5通过面板上的高强螺栓孔, 将齿 条 3正向固定在齿条二期埋件 4上。
高精度工艺螺杆 5的数量为 12组。
底部辅助装置中, 底部型钢结构工装 7上安装有千斤顶 12。
上述装置的使用过程如下:
1 ) 在齿条底部二期埋件 4上焊底部型钢结构工装 7;
2 ) 在底部型钢结构工装 7上布置好千斤顶 12;
3 ) 将齿条 3吊装下放到底部型钢结构工装 7上的千斤顶 12上;
4) 在齿条 3四角对应的齿条底部二期埋件 4上焊接四套侧向型钢结构工装 6;
5 ) 在侧向型钢结构工装 6与齿条 3间布置好千斤顶 12;
6 ) 将 12组高精度工艺螺杆 5通过齿条 3及二期埋件面板上的高强螺栓孔布置好;
7 ) 利用布置在齿条 3底部的千斤顶 12进行齿条高程调整及固定;
8 ) 利用布置在齿条 3侧向的千斤顶 12进行齿条侧向调整及固定;
9 ) 利用布置在齿条 3正向的 12组高精度工艺螺杆 5进行齿条正向调整及固定; 通过上述步骤实现齿条 3的高效安装。 工业实用性
本发明提供的一种齿轮齿条爬升式垂直升船机齿条高效安装方法, 通过齿条的调整加 固, 采用独创测量工艺方法完成齿条安装质量精度的测量控制, 通过试验摸索出效率最高的 齿条安装工艺, 顺利实现了升船机齿条高精度、 高效率的安装, 解决了各项施工难点、 经济 优质高效; 本发明还提供了用于该方法的辅助调节装置, 结构简单、 使用快捷方便、 能够循 环使用、 满足安装需求。
本发明尤其适用适合应用于各类型齿轮齿条爬升式垂直升船机超高精度螺母柱安装工 程, 亦可为其他工程领域内相类似金属结构和大型设备高精度安装提供有益的借鉴。
Claims
1. 一种齿轮齿条爬升式垂直升船机齿条高效安装方法, 其特征在于该方法包括 以下步骤:
1 ) 齿条基准点布置: 在齿条安装位置底部基础底板 (11 ) 上, 通过高精度测量 仪器测量投点完成齿条定位基准点的测放;
2) 在齿条二期埋件 (4) 的底部布置搭配千斤顶 (12) 使用的底部辅助装置;
3)将齿条(3) 吊装就位后, 安装辅助装置, 通过底部辅助装置及辅助装置进行 齿条临时加固;
4) 在齿条 (3) 顶部合适位置焊接线架, 布置投点调控测量工装 (8) ;
5)通过投点调控测量法将齿条定位基准点返点到线架上的投点调控测量工装(8) 上, 然后向下挂垂线 (9) ;
6)齿条(3)高程方向调整加固: 利用高精度测量仪, 采用水平截高测量方法定 位齿条安装高程,然后通过齿条底部布置好的千斤顶(12)将齿条高程调整就位; 齿条高程调整合格后在齿条顶部两端布置两台百分表 (Hl、 H2)用于齿条高程变 化监控;
7)齿条(3)侧向调整加固: 在齿条侧向四角位置进行齿条侧向安装质量调整及 加固, 齿条侧向安装质量调整合格后在齿条一侧上下两角布置两台百分表 (Xl、 X2) 用于齿条侧向安装质量变化监控;
8)齿条(3)正向调整加固: 进行齿条正向安装质量调整及加固, 齿条正向安装 质量调整合格后在齿条正向面板四角布置四台百分表 (Yl、 Υ2、 Υ3、 Υ4)用于齿 条正向安装质量变化监控;
9) 立模板: 进行齿条四周缝隙立模板, 模板固定体系布置在齿条二期埋件 (4) 上, 模板四周缝隙利用玻璃胶密封;
10) 按照操作手册完成齿条预应力钢筋 (10) 的安装;
11 )进行齿条与二期埋件间隙灌浆, 灌浆全程通过百分表(Hl、 Η2、 XI、 Χ2、 Yl、 Υ2、 Υ3、 Υ4)监测齿条 (3) 在灌浆过程中产生的位移差值;
13) 灌浆完成 14天后按照操作手册进行预应力钢筋 (10) 张拉;
14) 预应力钢筋 (10) 张拉完成后, 进行齿条 (3) 最终安装质量验收; 从而完成齿轮齿条爬升式垂直升船机齿条的高效安装。
2.根据权利要求 1或 2所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其
特征在于:
步骤 1) 中, 一组齿条 (3) 需要在基础底板 (11) 上布置一个侧向定位基准点 (2)以及两个正向定位基准点(1),在利用高精度测量仪器进行基准点定位时, 一组齿条 (3) 的三个定位基准点必须在同一个测量标点、 同一台测量仪器、 同 一测量站内完成测量定位。
3.根据权利要求 1或 2所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其 特征在于:
步骤 2) 中, 底部辅助装置为搭配千斤顶 (12) 使用的底部型钢结构工装 (7) ; 步骤 3) 中, 辅助装置为布置在与齿条侧向四角位置对应的齿条二期埋件 (4) 上的侧向型钢结构工装(6) 以及多组高精度工艺螺杆(5) , 多组高精度工艺螺 杆 (5) 通过面板上的高强螺栓孔, 将齿条 (3) 正向固定在齿条二期埋件 (4) 上, 侧向型钢结构工装 (6) 搭配千斤顶 (12) 使用;
利用多组高精度工艺螺杆 (5) 对齿条进行正向安装质量调整, 利用侧向型钢结 构工装 (6) 上的千斤顶 (12) 进行齿条侧向安装质量调整及加固, 利用底部型 钢结构工装 (7) 上的千斤顶 (12) 进行齿条底部高程安装质量调整及加固。
4.根据权利要求 1或 2所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其 特征在于:
步骤 4) 中, 线架布置适宜在齿条(3)顶部 400〜600mm高处, 线架需焊接牢固, 避免线架晃动引起测量工装位置发生变化,在线架上布置投点调控测量工装(8) 时, 工装位置需与对应的基础底板(11)上的齿条定位基准点大致对齐, 以便进 行基准点与工装间的投返点。
5.根据权利要求 1或 2所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其 特征在于:
步骤 5) 中, 投点调控测量法为在布置好的底部定位基准点与顶部的投点调控测 量工装 (8) 之间, 采用激光天顶仪将底部定位基准点精确返点重现到顶部的投 点调控测量工装 (8) 上的测量方法。
6.根据权利要求 1或 2所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其 特征在于:
步骤 6) 中, 水平截高测量方法为首先利用高精度全站仪通过测量标点将齿条设
计高程值投放到齿条附近垂直墙壁上,然后利用高精度水平仪采用水平测量方法 定位齿条安装高程的测量方法;
高程调整合格后通过齿条(3 )顶部两端布置的两台百分表(Hl、 H2)记录初始数 值, 在后续施工过程中可以随时监控齿条高程产生的变化并进行及时的处理。
7.根据权利要求 3所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其特征 在于- 步骤 7 ) 中, 利用布置在齿条侧向四角位置的安装在四套千斤顶进行齿条侧向安 装质量调整控制, 调整时采用的测量工具为自制带座千分尺,通过带座千分尺测 量齿条侧向工作面与基准垂线间距来进行调整定位;
齿条侧向安装质量调整合格后,通过齿条一侧上下两角布置两台百分表(Xl、 X2 ) 记录初始数值,在后续施工过程中可以随时监控齿条侧向产生的变化并进行及时 的处理。
8.根据权利要求 3所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其特征 在于- 步骤 8 ) 中, 利用布置在齿条正向的多组高精度工艺螺杆 (5 ) , 进行齿条正向 安装质量调整及加固, 调整时采用的测量工具为自制带座千分尺,通过带座千分 尺测量齿条正向工作面与基准垂线间距来进行调整定位;
齿条正向安装质量调整合格后,通过齿条正向面板四角布置四台百分表(Y1、Y2、 Υ3、 Υ4)记录初始数值, 在后续施工过程中可以随时监控齿条正向产生的变化并 进行及时的处理。
9.根据权利要求 1或 2所述的齿轮齿条爬升式垂直升船机齿条高效安装方法,其 特征在于:
步骤 12 ) 中, 当齿条在灌浆过程中产生的累积位移差值大于 0. 2mm时, 说明齿 条此时个别主控项目安装质量精度有可能超标, 需要暂停灌浆,对监控数据进行 分析, 根据数据分析结果确定是否需要进行处理。
10.一种用于齿轮齿条爬升式垂直升船机齿条高效安装的辅助调节装置, 其特征 在于: 该装置由辅助装置以及布置于齿条二期埋件 (4) 底部的底部辅助装置组 成, 辅助装置布置于齿条(3 ) 四角对应的齿条二期埋件 (4)及齿条(3 )正向。
11.根据权利要求 10所述的用于齿轮齿条爬升式垂直升船机齿条高效安装的辅
助调节装置, 其特征在于: 辅助装置中, 侧向型钢结构工装 (6) 焊接于齿条四 角对应的齿条二期埋件(4)上, 侧向型钢结构工装(6)上安装有千斤顶(12), 多组高精度工艺螺杆(5)通过面板上的高强螺栓孔, 将齿条(3)正向固定在齿 条二期埋件 (4) 上。
12.根据权利要求 11所述的用于齿轮齿条爬升式垂直升船机齿条高效安装的辅 助调节装置, 其特征在于: 高精度工艺螺杆 (5) 的数量为 12组。
13.根据权利要求 10所述的用于齿轮齿条爬升式垂直升船机齿条高效安装的辅 助调节装置, 其特征在于: 底部辅助装置中, 底部型钢结构工装 (7) 上安装有 千斤顶 ( 12) 。
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CN105735227B (zh) * | 2016-03-08 | 2017-07-14 | 中国长江三峡集团公司 | 高扬程齿爬式升船机螺母柱***施工方法及安装精度控制方法 |
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