WO2022088053A1 - 运梁车、运梁***、钢箱梁装配***及钢箱梁装配方法 - Google Patents
运梁车、运梁***、钢箱梁装配***及钢箱梁装配方法 Download PDFInfo
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- WO2022088053A1 WO2022088053A1 PCT/CN2020/125303 CN2020125303W WO2022088053A1 WO 2022088053 A1 WO2022088053 A1 WO 2022088053A1 CN 2020125303 W CN2020125303 W CN 2020125303W WO 2022088053 A1 WO2022088053 A1 WO 2022088053A1
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- Prior art keywords
- steel box
- box girder
- frame
- assembly
- track
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 247
- 239000010959 steel Substances 0.000 title claims abstract description 247
- 238000000034 method Methods 0.000 title claims abstract description 35
- 230000007246 mechanism Effects 0.000 claims abstract description 43
- 238000009434 installation Methods 0.000 claims description 31
- 230000003014 reinforcing effect Effects 0.000 claims description 17
- 238000013461 design Methods 0.000 claims description 13
- 239000003638 chemical reducing agent Substances 0.000 claims description 9
- 230000008569 process Effects 0.000 claims description 9
- 210000001364 upper extremity Anatomy 0.000 claims description 6
- 230000001360 synchronised effect Effects 0.000 claims description 5
- 238000000926 separation method Methods 0.000 claims 1
- 230000007723 transport mechanism Effects 0.000 claims 1
- 230000032258 transport Effects 0.000 description 80
- 238000010586 diagram Methods 0.000 description 9
- 238000010276 construction Methods 0.000 description 8
- 230000010354 integration Effects 0.000 description 4
- 230000008602 contraction Effects 0.000 description 3
- 238000011065 in-situ storage Methods 0.000 description 3
- 238000003032 molecular docking Methods 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000007812 deficiency Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000011900 installation process Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009417 prefabrication Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C9/00—Travelling gear incorporated in or fitted to trolleys or cranes
- B66C9/10—Undercarriages or bogies, e.g. end carriages, end bogies
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D2/00—Bridges characterised by the cross-section of their bearing spanning structure
- E01D2/04—Bridges characterised by the cross-section of their bearing spanning structure of the box-girder type
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01D—CONSTRUCTION OF BRIDGES, ELEVATED ROADWAYS OR VIADUCTS; ASSEMBLY OF BRIDGES
- E01D21/00—Methods or apparatus specially adapted for erecting or assembling bridges
- E01D21/06—Methods or apparatus specially adapted for erecting or assembling bridges by translational movement of the bridge or bridge sections
Definitions
- the invention belongs to the technical field of steel box girder assembly, and in particular relates to a girder transport vehicle, a beam transport system, a steel box girder assembly system and a steel box girder assembly method.
- the steel box girder transportation and installation technology is to set up a prefabrication field behind the platform along the longitudinal axis of the bridge, prefabricate the girder body in stages, and transport the girder section by section to the designated position through the girder transporter, with the help of the original road, track and hydraulic beam transporter. Drop the beam after it is in place.
- various continuous steel box girder bridges have emerged in large numbers in the fields of highways, urban transportation, and railways. Due to the advantages of less land occupation, no impact on traffic under the bridge, no need for large lifting equipment, safety and reliability, and low cost, steel box girder transportation and installation trolleys are widely used in its construction.
- the existing tire flatbed beam transporter has the functions of leveling and leveling and automatic leveling when the platform is lifted, and has the functions of straight running, oblique running, lateral running, eight-character steering and in-situ steering.
- the steering adopts micro-electric control, which requires shockproof, anti-magnetic, moisture-proof and working stability under normal temperature (-200 ⁇ +500 °C).
- the platform is laid with non-slip grid steel plates, and multiple fault detection points are set up to fully consider the convenience of on-site repair and maintenance. It is equipped with a main and a pair of double cabs, and has an interlocking function.
- the suspension cylinder has the function of double-pipe safety protection for pipeline rupture.
- the number of tires is large, the size of the beam transporter is large, and the requirements for the construction environment are high, and the beam transport and installation cannot be realized on the high-altitude support.
- the existing rail-type beam transporter uses pre-installed rails to transport a beam at the same time through multiple rail-mounted beam transporters.
- rail transport beams are rarely used and can achieve synchronous three-dimensional and six-direction adjustment.
- the technical problem to be solved by the present invention is to provide a beam transporter, which has a novel and reasonable design, and can solve the transportation control and beam installation accuracy under complex linear conditions through three-dimensional and six-direction transportation and installation operations.
- the problem of difficult control improves the accuracy of each force value of the beam body during transportation and installation, prevents the beam body from being damaged by uneven force, and eliminates the horizontal load of the substructure, ensuring that the beam body is transported during transportation.
- the stability in the installation process, the use of rail transportation, the module car is small in size and large in bearing capacity, and can be used for beam transport on land and high-altitude supports, which solves the realization of the integration of high-altitude beam transport and installation, and is easy to promote and use.
- a beam transporting vehicle which is characterized in that: it includes two car boxes and a balance box beam connecting the two car boxes, and the front and rear ends of the bottom of the car box are provided with ledges.
- On the concrete base platform is the traveling wheel that moves the basic track of the transport beam.
- the car box is provided with a reducer that controls the rotation of the walking wheel and a drive motor that cooperates with the reducer.
- the middle of the balance box beam is provided with a beam transporter jack that protrudes from the top plate of the balance box beam.
- a beam carrier is fixedly installed on the jack of the owner of the beam carrier, and a top hat is placed on the top carrier.
- the top hat is provided with a plurality of pressure sensors and position sensors, and the bottom side of the top hat is provided with a horizontal push-pull top carrier.
- Auxiliary jack is provided.
- the above-mentioned beam transporter is characterized in that: the balance box beam is provided with a vehicle-mounted control box, the vehicle-mounted control box is provided with a vehicle-mounted control board, and the beam-transporting vehicle microcontroller is integrated on the vehicle-mounted control board, so the The signal output ends of the pressure sensor and the position sensor are connected with the input end of the micro-controller of the beam transporter. Controller control.
- the invention also discloses a beam transporting system, which is characterized by comprising the above beam transporting vehicle, and a slewing mechanism and a rail clamping mechanism both mounted on the beam transporting vehicle.
- the slewing mechanism includes a slewing bearing frame body installed on the outer side of the middle part of the balance box girder and a slewing bearing installed at the bottom of the slewing bearing frame body and abutting with the temporary support pier.
- the pier is set at the intersection of the beam transport foundation track and the beam transport steering track
- the beam transport steering track is pre-buried in the concrete turntable
- the beam transport foundation track and the beam transport steering track are set at the intersection with the beam transport foundation track or the transport beam steering track.
- the active track of the track mate.
- the rail clamping mechanism includes an upper ear plate and a lower ear plate installed at the front and rear ends of the car box, the lower ear plate is hinged with one end of the clamping frame, and the other end of the clamping frame is connected to the frame.
- the upper ear plate or the movable track is fixedly connected.
- the above-mentioned beam transporting system is characterized in that: the number of the beam transporting vehicles is multiple, and a first synchronization controller connected to a computer is integrated on the vehicle-mounted control board, and the first synchronization controller is connected with the computer. Corresponding to the connection of the beam transporter microcontroller on the vehicle control board.
- the invention also discloses a steel box girder assembling system, which is characterized by comprising the above-mentioned beam transporting system and a crane system matched with the beam transporting system, wherein the crane system includes a plurality of crane units.
- the crane unit includes a forward-moving base arranged on the assembly end of the steel box girder and a crane frame arranged on the forward-moving base and cantilevered out from the assembly end of the steel box girder, and the top of the overhanging end of the crane frame is A steel box girder two-dimensional adjustment mechanism and a balance pulley assembly located outside the steel box girder two-dimensional adjustment mechanism are installed, an upper pulley assembly is installed on the steel box girder two-dimensional adjustment mechanism, and a hoist is installed on the top of the crane frame away from the cantilevered end.
- the steel wire rope is connected with the lower pulley assembly through the upper pulley assembly and the balance pulley assembly, and the lower pulley assembly is connected with the
- An on-board control box is arranged on the crane frame, and an on-board control board is arranged in the on-board control box.
- the on-board control board is integrated with a hoist microcontroller and a second synchronization controller connected to a computer. , the second synchronization controller is connected with the hoist microcontroller on the corresponding onboard control board.
- the above-mentioned steel box girder assembly system is characterized in that: the crane frame is arranged on the forward base through the frame rear leg assembly and the frame front leg assembly, and the frame front supports
- the leg assembly is located at the assembly end of the steel box girder.
- the forward movement base includes a forward movement track and a bracket forward movement adjustment oil cylinder installed on the forward movement track.
- the front track is supported on the assembly end of the steel box girder through a plurality of frame temporary support blocks preset on the steel box girder.
- the above-mentioned steel box girder assembly system is characterized in that: the beam surface of the assembled steel box girder is provided with a plurality of reinforcing lugs, and the reinforcing lugs are fixedly connected with the forward track.
- the two-dimensional adjustment mechanism of the steel box girder includes a crane underframe that is slidingly matched with the top of the cantilever end of the crane frame, and a crane underframe arranged on the crane underframe and connected to the sky.
- the bottom frame of the crane is slidingly matched with the top frame of the crane.
- the crane frame is equipped with a bottom frame adjusting oil cylinder.
- the extension end of the bottom frame adjusting oil cylinder is connected with the bottom frame of the crane.
- the protruding end of the top frame adjusting oil cylinder is connected with the roof frame of the roof.
- guardrails are installed on both sides of the crane frame along the length direction.
- the above-mentioned steel box girder assembling system is characterized in that: a steel box girder fixing seat for connecting the steel box girder is arranged at the bottom of the sling, and a sling pitch adjusting oil cylinder is installed on the sling connecting seat, The protruding end of the pitch-adjusting oil cylinder is connected with the top plate of the spreader.
- the above-mentioned steel box girder assembly system is characterized in that: the upper pulley assembly includes N pulleys, and N is an even number not less than 4, and the number of pulleys in the lower pulley assembly is higher than that of the upper pulley assembly. There are two less pulleys in the balance pulley assembly, and one pulley is included in the balance pulley assembly.
- the above-mentioned steel box girder assembly system is characterized in that: the lower pulley assembly is located directly below the upper pulley assembly.
- the present invention also discloses a method for assembling a steel box girder, which is characterized in that: the method comprises the following steps:
- Step 1 The steel box girder is transported in place: use multiple beam transport vehicles to transport the steel box girder to the design position;
- Step 2 Lower the spreader to connect the steel box beam: the hoist is paid off, the steel wire rope is extended to lower the spreader, and the bottom of the spreader is provided with a steel box girder fixed catch seat for connecting the steel box beam, and a hanger is installed on the spreader connection seat. Equipped with a pitching adjusting oil cylinder, the extension end of the pitching adjusting oil cylinder of the spreader is connected with the top plate of the spreader;
- Step 3 Lift the steel box girder and adjust the position of the steel box girder three-dimensionally: the hoist takes up the line, the steel wire rope recovers the lifting sling, the sling lifts the steel box girder to the installation height, and then uses the two-dimensional adjustment mechanism of the steel box girder to move the steel box girder to the installation height.
- the hoist takes up the line, the steel wire rope recovers the lifting sling, the sling lifts the steel box girder to the installation height, and then uses the two-dimensional adjustment mechanism of the steel box girder to move the steel box girder to the installation height.
- Step 4 Steel box girder slope adjustment: start the spreader pitch adjustment cylinder to adjust the steel box girder to the design slope;
- Step 5 Assemble the steel box girder: connect the steel box girder to the assembly end of the steel box girder to realize the extension of the steel box girder, and the assembly end of the steel box girder is updated at this time;
- Step 6 Move the base forward to the assembly end of the updated steel box girder.
- the process is as follows:
- Step 601. The rack jack is lifted to separate the rack rear outrigger assembly and the rack front outrigger assembly from the forward-moving track, remove the connection between the reinforcing ear plate and the forward-moving track, and the bracket forward-moving adjustment oil cylinder drives Move the forward track forward, and then fix the reinforcing ear plate with the forward track;
- Step 602 the rack jack is retracted, so that the rack rear outrigger assembly and the rack front outrigger assembly fall on the forward-moving track, and the bracket forward-moving adjustment oil cylinder pushes the rack front outrigger assembly to move forward on the forward-moving track move, and then realize the forward movement of the crane frame;
- Step 603 repeat steps 601 and 602 several times, until the advance track is moved forward to the end of the updated steel box girder assembly end, and the advance track is fixedly connected to the beam surface of the assembled steel box girder by using reinforcing lugs ;
- Step 7 Repeat steps 1 to 6 for several times until the steel box girder is assembled.
- step 1 the process of transporting the steel box girder into place is as follows:
- Step 101 laying out the beam transporting vehicle: laying the beam transporting steering track, the beam transporting steering track is pre-buried in the concrete turntable, the beam transporting steering track intersects with multiple beam transporting base rails, and laying a plurality of transporting beam shifting rails on the beam transporting steering track.
- a beam transporter is placed on each beam transport foundation track, the beam transporter on the beam transport foundation track is regarded as the base beam transporter, and the beam transporter on the beam transport steering track is regarded as a steering beam transporter;
- a movable track is arranged to cooperate with the beam-transporting foundation rail or the beam-transporting steering track;
- Step 102 the steel box girder is inserted into the rail: the steel box girder is jacked up synchronously by multiple basic beam transport vehicles, so that the steel box beam is separated from the steel box girder tire frame, and the multiple basic beam transport vehicles transport the steel box girder to the transport beam steering On the track, the foundation beam transporter is parked on the movable track at this time;
- Step 103 steel box girder replacement: utilize multiple steering girder transport vehicles to synchronously lift the steel box girder, so that the steel box girder is separated from a plurality of basic beam transport vehicles;
- Step 104 Steering of the foundation beam transporter: use the rail clamping mechanism to clamp the movable track, use the temporary support pier to lift the foundation beam transporter, the foundation beam transporter does not contact the steel box girder, and the bottom surface of the movable track is higher than the beam transporter steering The top surface of the track and the beam-carrying foundation track; use the slewing mechanism to steer the foundation beam-carrying vehicle;
- Step 105 steel box girder transportation: the temporary support pier lowers the foundation beam transportation vehicle, so that the movable track and the beam transportation steering track are connected, and the rail clamping mechanism is retracted. At this time, the foundation beam transportation vehicle and the steering beam transportation vehicle are in the same direction, and the use of more A basic beam transporter synchronously lifts the steel box girder, so that the basic beam transporter and the steering beam transporter can jointly transport the steel box beam.
- the present invention also discloses a method for assembling a steel box girder, which is characterized in that: the method comprises the following steps:
- Step A build a support frame: build a support frame at the bottom of the steel box girder design position;
- Step B laying the track: laying multiple groups of beam transport foundation rails on the support frame, and setting a beam transport vehicle on each group of beam transport foundation rails;
- Step C Lifting and moving of steel box girder: use multiple beam transport vehicles to synchronously lift the steel box beam to separate the steel box beam from the steel box girder tire frame, and multiple beam transport vehicles move the steel box beam to the steel box beam synchronously assembly end;
- Step D three-dimensional space position adjustment and assembly of the steel box girder: use the girder transport vehicle to move on the beam transport foundation track to determine the position of the steel box girder in the extension direction of the bridge, adjust the height position of the steel box girder with the beam transport vehicle owner jack, and use Auxiliary jacks for transporting beams are horizontally pushed and pulled to realize the position of the top hat and the steel box girder in the width direction of the bridge;
- the steel box girder is assembled to the end of the assembly end of the steel box girder, and the support of the steel box girder is unloaded by multiple beam transport vehicles and returned to the steel box girder to be installed in the next section. bottom;
- Step E repeat steps C and D for many times until the steel box girder is assembled.
- the present invention has the following advantages:
- the beam transporter of the present invention solves the problems of difficult transportation control and beam installation accuracy under complex linear conditions through three-dimensional and six-direction transportation and installation operations, and improves the accuracy of each force value of the beam body during transportation and installation.
- the module car is small in size and large in bearing capacity , can be used to transport beams above land and high-altitude supports, which solves the realization of the integration of high-altitude beam transport and installation, and is easy to popularize and use.
- the beam transport system of the present invention realizes the in-situ steering of the beam transport vehicle with the rail through the slewing mechanism and the rail clamping mechanism, the beam transport is stable and reliable, and the use effect is good. There is a broad market in the installation field, and it can better solve the linear control of the small-radius vertical curved beam body.
- the steel box girder assembly system of the present invention moves the girder in place through the girder transportation system, and the longitudinal movement of the bridge deck crane adopts the walking type, hydraulic drive, and completes the forward movement of the whole machine through the expansion and contraction of the longitudinal movement oil cylinder in coordination with the lifting and lowering of the whole machine. No manual movement is required, and the crane can move forward entirely by the ability of the equipment itself.
- the hoist is used to provide power, and the maximum lifting weight can be met through the conversion of the wire rope magnification. Synchronous or independent operation avoids the partial beam body caused by equipment coordination during the lifting process.
- the crane realizes three-dimensional displacement control, which better solves the linear control of small-radius vertical curved beams, and its control accuracy reaches the millimeter level, which reduces the number of back and forth beams and improves
- the efficiency of construction provides the overall accuracy and efficiency of steel box girder assembly.
- a steel box girder assembling method of the present invention has simple steps, stable girder transport, accurate docking, precise lifting and slope adjustment of the steel box girder, and the longitudinal movement of the bridge deck crane adopts the walking type, which is driven by hydraulic pressure.
- the whole machine can be moved forward by telescopic and coordinated with the rise and fall of the whole machine. It does not need manual movement.
- Another steel box girder assembly method of the present invention has simple steps, laying a high-altitude track, using a beam transport vehicle to move on the beam transport foundation track to determine the position of the steel box beam in the extension direction of the bridge, and using the beam transport vehicle owner jack to adjust the steel box
- the height position of the beam, the horizontal push-pull top support of the auxiliary jack of the beam transporter is used to realize the position of the top hat and the steel box beam in the width direction of the bridge, which solves the realization of the integration of high-altitude beam transport and installation.
- the present invention has novel and reasonable design, stable beam transport, accurate docking, precise lifting and slope adjustment of steel box girder, and the longitudinal movement of the bridge deck crane adopts walking walking, hydraulic drive, and is adjusted through the telescopic coordination of the longitudinal movement oil cylinder.
- the whole machine can be moved forward when the machine is up and down, without manual movement, and the crane can move forward completely by the equipment's own ability.
- FIG. 1 is a schematic structural diagram of the installation of a slewing mechanism and a rail clamping mechanism on a beam-carrying vehicle of the present invention.
- FIG. 2 is a right side view of FIG. 1 .
- FIG. 3 is a state diagram of the beam transporting vehicle of the present invention when it is used as a basic beam transporting vehicle.
- FIG. 4 is a schematic diagram of the cooperation relationship between the beam transporter and the temporary support pier according to the present invention.
- FIG. 5 is a schematic diagram of the connection relationship between the beam transporting vehicle and the movable track according to the present invention.
- FIG. 6 is a state diagram of the beam transporting vehicle of the present invention as a steering beam transporting vehicle.
- FIG. 7 is a schematic diagram of the placement position of the beam transporting vehicle on the beam transporting foundation track and the beam transporting diverting track according to the present invention.
- FIG. 8 is a schematic diagram of the position state of the basic beam transporting vehicle moving to the intersection of the beam transporting basic rail and the beam transporting diverting rail in FIG. 7 .
- FIG. 9 is a schematic diagram of the position state of the steering of the basic beam transport vehicle in FIG. 8 .
- Fig. 10 is a use state diagram of the hoist of the present invention.
- FIG. 11 is a top view of the unlifted steel box girder in FIG. 10 .
- Fig. 12 is a right side view of the wire rope in Fig. 10 not being recovered.
- Fig. 13 is a flow chart of a method for assembling a steel box girder according to the present invention.
- FIG. 14 is a flow chart of another steel box girder assembling method of the present invention.
- 1 concrete abutment
- 2 transport beam foundation track
- 3 movable track
- 7-1 basic beam carrier
- 7-2 steerering beam carrier
- 8 steel box girder tire frame
- 49 pitch adjustment cylinder
- 50 steerel box girder fixed grip
- a beam transporter includes two boxes 10 and a balance box beam 11 connecting the two boxes 10 .
- the concrete base 1 is provided with a traveling wheel 17 for moving the beam base rail 2
- the car box 10 is provided with a reducer 22 that controls the rotation of the traveling wheel 17 and a drive motor 23 that cooperates with the reducer 22, and the middle of the balance box beam 11 is provided with a protruding
- a beam-carrying car owner jack 12 for balancing the top plate of the box beam 11 is fixedly mounted on the beam-carrying car owner jack 12 with a jack 24 on which a top cap 15 is placed, and a plurality of pressure sensors and position sensors are arranged in the top hat 15
- the bottom side of the top cap 15 is provided with a beam-carrying auxiliary jack 21 that pushes and pulls the top support 24 horizontally.
- the beam transporter of the present invention defines the dimensional position of the beam along the extension direction through the track, and the dimensional position in the width direction of the beam is defined by the fulcrum position between the beam transporter and the beam, but the actual beam transporter and the beam. There is a certain deviation between the positions of the fulcrums.
- the auxiliary jack 21 for the beam transporter with the horizontal push-pull top bracket 24 is arranged on the bottom side of the top hat 15 to realize the precise adjustment of the dimensional position of the beam width direction.
- the beam is adjusted by the main beam transporter jack 12. The dimensional position in the height direction, and then realize the three-dimensional space adjustment of the beam transporter to the beam.
- a vehicle-mounted control box 16 is arranged on the balance box beam 11, and a vehicle-mounted control board is arranged in the vehicle-mounted control box 16.
- the signal output end of the position sensor is connected to the input end of the micro-controller of the beam transporter, and the reducer 22, the drive motor 23, the beam transporter main jack 12 and the beam transporter auxiliary jack 21 are all controlled by the beam transporter micro-controller. Controller control.
- the beam transporter solves the problems of transportation control under complex linear conditions and the difficulty in controlling the installation accuracy of beam sections through the three-dimensional and six-direction transportation and installation operations, and improves the accuracy of the force values of the beam body during transportation and installation. It prevents the beam body from being damaged by uneven force, and at the same time eliminates the horizontal load of the substructure, ensuring the stability of the beam body during transportation and installation. It adopts rail transportation, and the module car is small in size and has a high bearing capacity. It is large and can be used to transport beams above land and high-altitude supports, which solves the realization of the integration of high-altitude beam transport and installation.
- a beam transporting system as shown in Figures 2 to 5 includes the beam transporting vehicle of the present invention, and a slewing mechanism and a rail clamping mechanism both mounted on the beam transporting vehicle.
- the beam transport system of the present invention realizes the in-situ steering of the beam transport vehicle with the rail through the slewing mechanism and the rail clamping mechanism, the beam transport is stable and reliable, the use effect is good, and the land occupation and equipment investment are reduced under the complex construction environment.
- the slewing mechanism includes a slewing support frame 13 installed on the outer side of the middle of the balance box girder 11 and a slewing bearing 14 installed at the bottom of the slewing support frame 13 and abutting with the temporary support 6.
- the temporary support 6 It is arranged at the intersection of the beam transport foundation track 2 and the beam transport steering track 5, the beam transport steering track 5 is pre-buried in the concrete turntable 4, and the beam transport foundation track 2 and the beam transport steering track 5 are provided at the intersection position with the beam transport foundation.
- the track 2 or the moving beam steering track 5 is matched with the movable track 3.
- the temporary support pier 6 can be a concrete pier supported manually, or a jack can be used to realize the lifting and lowering of the beam-carrying vehicle.
- the rail clamping mechanism includes an upper lug plate 18 and a lower lug plate 19 installed on the front and rear ends of the car box 10 , the lower lug plate 19 is hinged with one end of the clamping frame 20 , and the other end of the clamping frame 20 is connected with the upper lug plate 19 .
- the lugs 18 or the movable rails 3 are fixedly connected.
- the number of the beam transporting vehicles is multiple, and the vehicle-mounted control board is integrated with a first synchronization controller connected to a computer. Beam car microcontroller connection.
- a steel box girder assembly system as shown in FIGS. 1 to 6 and 10 to 12 includes the beam transport system according to the present invention, and a crane system matched with the beam transport system.
- the crane The system includes a plurality of hoist units, the hoist units include a forward-moving base disposed on the assembly end of the steel box girder, and a crane frame 30 disposed on the forward-moving base and cantilevering out of the assembly end of the steel box girder , the top of the cantilevered end of the crane frame 30 is installed with a two-dimensional adjustment mechanism of steel box girder and a balance pulley assembly 38 located outside the two-dimensional adjustment mechanism of the steel box girder, and an upper pulley assembly 37 is installed on the two-dimensional adjustment mechanism of the steel box beam,
- a hoist 31 is installed on the top of the machine frame 30 away from the cantilevered end.
- the wire rope 39 of the hoist 31 is connected to the lower pulley assembly 48 through the upper pulley assembly 37 and
- the hoist frame 30 is provided with an on-board control box, and an on-board control board is arranged in the on-board control box, and the on-board control board is integrated with a hoist microcontroller and a second synchronous control device connected to a computer.
- the second synchronization controller is connected with the hoist microcontroller on the corresponding onboard control board.
- the steel box girder assembly system of the present invention transports the beams in place through the beam transport system, and the longitudinal movement of the bridge deck crane adopts walking walking, hydraulic drive, and the whole machine is completed by the expansion and contraction of the longitudinal movement oil cylinder in coordination with the lifting and lowering of the whole machine.
- Moving forward no manual movement is required, and the crane is completely moved forward by the ability of the equipment itself.
- the hoist is used to provide power, and the maximum lifting weight can be met through the conversion of the wire rope magnification. Synchronous or independent operation avoids equipment coordination during the lifting process.
- the crane realizes the three-dimensional displacement control, which better solves the linear control of the small-radius vertical curve beam body, and its control accuracy reaches the millimeter level, which reduces the return of the beam back and forth.
- the number of times improves the efficiency of construction, and provides the overall accuracy and efficiency of steel box girder assembly.
- the hoist frame 30 is arranged on the forward base through the frame rear support leg assembly 40 and the frame front support leg assembly 41, and the frame front support leg assembly 41 is located on the steel frame.
- the forward movement base includes a forward movement rail 42 and a bracket forward movement adjustment cylinder 45 installed on the forward movement rail 42.
- the extended end of the bracket forward movement adjustment cylinder 45 is assembled with the frame front leg assembly 41 is connected, the forward track 42 is supported on the assembly end of the steel box girder through a plurality of rack temporary supports 43 preset on the steel box girder 9, the rack rear support leg assembly 40 and the rack front support leg assembly
- the outer side of 41 is provided with a frame jack anchor plate 51 for installing the frame jack 52 .
- a plurality of reinforcing lugs 44 are provided on the beam surface of the assembled steel box girder, and the reinforcing lugs 44 are fixedly connected with the forward track 42 .
- a plurality of rack temporary support blocks 43 are temporarily fixed and assembled at the assembly end of the steel box girder.
- the used ones on the assembled bridge deck will be
- One rack temporary support block 43 is disassembled and installed on the new steel box girder 9, which can be used repeatedly.
- a plurality of reinforcing lugs 44 are fixedly connected to the advance rail 42 and the plurality of rack temporary support blocks 43, and the support moves forward.
- the adjusting oil cylinder 45 pulls the advancing rail 42 to slide on the plurality of frame temporary support blocks 43 to avoid friction between the advancing rail 42 and the bridge deck and damage the bridge deck.
- the extended end of the bracket advance adjustment cylinder 45 is connected with the frame front leg assembly 41, and the fixed end of the bracket advance adjustment cylinder 45 is connected with the advance track 42.
- the bracket advance adjustment cylinder 45 is in the extended state.
- the rear outrigger assembly 40 and the front outrigger assembly 41 of the frame are jacked up, and a plurality of reinforcements that fix the forward rail 42 are removed.
- the lug plate 44 makes the advance track 42 uncompressed.
- the support is retracted to advance the adjustment cylinder 45, and the fixed end of the bracket advance adjustment cylinder 45 moves forward, which drives the advance track 42 to move forward, and then uses a plurality of reinforcing lugs to move forward.
- the plate 44 fixedly connects the forward-moving rail 42 with a plurality of rack temporary support blocks 43, lowers the rack rear support leg assembly 40 and the rack front support leg assembly 41 to the forward-moving rail 42, and adjusts the forward movement of the extension bracket
- the oil cylinder 45 at this time, the fixed end of the bracket advance adjustment oil cylinder 45 is fixed at the connection position of the forward movement rail 42, and the frame rear leg assembly 40 and the frame front leg assembly 41 move forward on the forward movement rail 42. , the operation is simple, without the use of large mechanical equipment.
- the steel box girder two-dimensional adjustment mechanism includes a crane underframe 34 that is slidingly matched with the top of the cantilevered end of the crane frame 30 , and a crane underframe 34 that is disposed on the crane underframe 34 and slidably matched with the crane underframe 34 .
- the crane frame 35 is provided with a bottom frame adjusting oil cylinder 33, the extension end of the bottom frame adjusting oil cylinder 33 is connected with the top frame bottom frame 34, and a top frame adjusting oil cylinder is installed on the top frame adjusting oil cylinder 34. 36.
- the extension end of the top frame adjusting oil cylinder 36 is connected with the roof frame 35 of the roof.
- guardrails 32 are installed on both sides of the crane frame 30 along the length direction.
- the bottom of the spreader 46 is provided with a steel box girder fixing grip 50 for connecting the steel box beam 9
- the spreader connecting seat 47 is installed with a spreader pitch adjustment oil cylinder 49, and the spreader pitch adjustment oil cylinder
- the protruding end of 49 is connected with the top plate of the hanger 46 .
- the horizontal hoisting of the steel box girder 9 by the spreader 46 can be realized by a symmetrical structure, but the actual bridge deck often has a certain slope.
- the tilt and pitch of the spreader 46 is realized by the push and pull of the spreader pitch adjustment oil cylinder 49, which is close to the linear design of the bridge deck.
- the upper pulley assembly 37 includes N pulleys, and N is an even number not less than 4, and the number of pulleys in the lower pulley assembly 48 is two less than the number of pulleys in the upper pulley assembly 37 One, the balance pulley assembly 38 includes one pulley.
- the function of setting the balance pulley assembly 38 is to balance the force on the wire rope between the upper pulley assembly 37 and the lower pulley assembly 48. If the force on the wire rope 39 is uneven, there will be a side force in the upper pulley assembly 37. When the large side force is small, the balance of the force is maintained by the rotation of the pulley in the balance pulley assembly 38.
- the winding method of the wire rope 39 is that one end is fixed on the hoist, and the other end passes through the upper pulley assembly 37, the lower pulley assembly 48 and the balance pulley. The assembly 38 is then fixed on the hoist.
- the balance pulley assembly 38 includes a pulley, and this pulley is located beside the middle of the upper pulley assembly 37. Therefore, the upper pulley assembly 37 includes N pulleys, and N takes an even number, Taking N as 8 as an example, this pulley in the balance pulley assembly 38 is located beside the position between the fourth pulley and the fifth pulley in the upper pulley assembly 37, and the wire rope 39 passes through the upper pulley assembly 37.
- the upper part of the fourth pulley is wound to the bottom of the pulley in the balance pulley assembly 38, and then comes out from the top of the pulley in the balance pulley assembly 38 and is wound to the upper part of the fifth pulley in the upper pulley assembly 37, so that the upper pulley assembly 37
- the winding direction on the 1st pulley to the 4th pulley in the middle is opposite to the winding direction on the 5th pulley to the 8th pulley in the upper pulley assembly 37, so the wire rope 39 is wound on the upper pulley assembly 37.
- the wire rope 39 is also symmetrically wound on the lower pulley assembly 48, and the first pulley to the fourth pulley in the upper pulley assembly 37 cooperate with the first pulley to the third pulley on the lower pulley assembly 48.
- the number of pulleys in the lower pulley assembly 48 is two less than the number of pulleys in the upper pulley assembly 37, that is, N is an even number not less than 4.
- the lower pulley assembly 48 is located directly below the upper pulley assembly 37 .
- a method for assembling a steel box girder as shown in Figure 13 includes the following steps:
- Step 1 The steel box girder is transported in place: use multiple beam transport vehicles to transport the steel box girder 9 to the design position;
- Step 2 lowering the spreader to connect the steel box beam: the hoist 31 pays off the wire, the wire rope 39 extends and lowers the spreader 46, and the bottom of the spreader 46 is provided with a steel box girder fixing grip 50 for connecting the steel box beam 9.
- the spreader A spreader pitch adjustment oil cylinder 49 is installed on the connecting base 47, and the extension end of the spreader pitch adjustment cylinder 49 is connected to the top plate of the spreader 46;
- Step 3 Lift the steel box girder and adjust the position of the steel box girder three-dimensionally: the hoist 31 takes up the wire, the wire rope 39 recovers the lifting sling 46, the sling 46 carries the steel box girder 9 and rises to the installation height, and then uses the steel box girder two-dimensional adjustment mechanism to lift the steel box girder.
- the box girder 9 is moved to the installation position;
- Step 4 steel box girder slope adjustment: start the spreader pitch adjustment oil cylinder 49, and adjust the steel box girder 9 to the design slope;
- Step 5 Assemble the steel box girder: connect the steel box girder 9 with the assembly end of the steel box girder to realize the extension of the steel box girder, and the assembly end of the steel box girder is updated at this time;
- Step 6 Move the base forward to the assembly end of the updated steel box girder.
- the process is as follows:
- Step 601 Lift the rack jack 52 to separate the rack rear outrigger assembly 40 and the rack front outrigger assembly 41 from the forward-moving rail 42, remove the connection between the reinforcing ear plate 44 and the forward-moving rail 42,
- the support advance adjustment oil cylinder 45 drives the advance track 42 to move forward, and then the reinforcing lug plate 44 is fixedly connected with the advance track 42;
- Step 602 the frame jack 52 is retracted, so that the frame rear outrigger assembly 40 and the frame front outrigger assembly 41 fall on the forward moving rail 42 , and the frame forward movement adjusting oil cylinder 45 pushes the frame front outrigger assembly 41 move forward on the forward movement track 42, thereby realizing the forward movement of the hoist frame 30;
- Step 603 repeat steps 601 and 602 several times, until the advancing rail 42 is moved forward to the end of the updated steel box girder assembly end, and the front rail 42 is connected to the beam of the assembled steel box girder by using the reinforcing lug plate 44. surface fixed connection;
- Step 7 Repeat steps 1 to 6 for several times until the steel box girder is assembled.
- step 1 the process of transporting the steel box girder into place in step 1 is as follows:
- Step 101 laying out the beam transporting vehicle: laying the beam transporting steering track 5, the beam transporting steering track 5 is pre-buried in the concrete turntable 4, the beam transporting steering track 5 intersects with a plurality of beam transporting base rails 2, and the beam transporting steering track 5 is A plurality of beam transport vehicles are arranged on the top of the beam, and one beam transport vehicle is placed on each beam transport foundation track 2.
- the beam transport vehicle on the beam transport base track 2 is regarded as the basic beam transport vehicle 7-1, and the beam transport is turned to the track 5.
- the beam-carrying vehicle above is regarded as a steering beam-carrying vehicle 7-2;
- a movable rail 3 that cooperates with the basic rail 2 for transporting beams or the steering rail for transporting beams 5 is arranged at the intersection of the beam transporting base rail 2 and the transporting beam steering rail 5;
- Step 102 the steel box girder is inserted into the rail: use a plurality of basic beam transport vehicles 7-1 to simultaneously lift the steel box beam 9, so that the steel box beam 9 is separated from the steel box beam tire frame 8, and a plurality of basic beam transport vehicles 7-1 1. Move the steel box girder 9 to the beam-transporting steering track 5, and the basic beam-transporting vehicle 7-1 stops on the movable track 3 at this time;
- Step 103 changing the support of the steel box beam: using a plurality of steering beam transport vehicles 7-2 to synchronously lift the steel box beam 9, so that the steel box beam 9 is separated from the multiple basic beam transport vehicles 7-1;
- Step 104 the basic beam transporting vehicle is turned: the movable rail 3 is clamped by the rail clamping mechanism, and the basic beam transporting vehicle 7-1 is lifted by the temporary support pier 6, and the basic beam transporting vehicle 7-1 is not in contact with the steel box girder 9, and The bottom surface of the movable track 3 is higher than the top surface of the beam transport steering track 5 and the beam transport foundation track 2; the basic beam transport vehicle 7-1 is turned by the slewing mechanism;
- Step 105 steel box girder transportation: the temporary support pier 6 lowers the basic beam transporting vehicle 7-1, so that the movable track 3 and the beam transporting steering track 5 are docked, and the rail clamping mechanism is retracted. At this time, the basic beam transporting vehicle 7-1 and The steering beam transporter 7-2 is in the same direction, and multiple basic beam transporters 7-1 are used to simultaneously lift the steel box girder 9, so that the basic beam transporter 7-1 and the steering beam transporter 7-2 can jointly move the steel box girder 9.
- the steel box girder assembly method has simple steps, stable girder transport, accurate docking, precise lifting and slope adjustment of the steel box girder, and the longitudinal movement of the bridge deck crane adopts walking walking, hydraulic drive, and the whole machine is coordinated through the expansion and contraction of the longitudinal movement cylinder. It can complete the forward movement of the whole machine after the rise and fall, without manual movement, and completely rely on the ability of the equipment itself to realize the forward movement of the crane, with a high degree of automation.
- a method for assembling a steel box girder as shown in Figure 14 includes the following steps:
- Step A build a support frame: build a support frame at the bottom of the steel box girder design position;
- Step B laying the track: laying multiple groups of beam transport foundation rails 2 on the support frame, and setting a beam transport vehicle on each group of beam transport foundation rails 2;
- Step C the lifting of steel box girder and the movement: utilize a plurality of beam transport vehicles to synchronously lift the steel box beam 9, so that the steel box beam 9 is separated from the steel box beam tire frame 8, and the multiple beam transport vehicles are transported synchronously Steel box girder 9 to the assembly end of the steel box girder;
- Step D steel box girder three-dimensional space position adjustment and assembly: utilize the beam transport vehicle to move on the beam transport foundation track 2 to determine the position of the steel box beam 9 on the bridge extension direction, and utilize the beam transport vehicle owner jack 12 to adjust the position of the steel box beam 9.
- the auxiliary jack 21 of the beam transporter is used to push and pull the top support 24 horizontally to realize the position of the top hat 15 with the steel box girder 9 in the width direction of the bridge;
- the steel box girder 9 is assembled to the end of the assembly end of the steel box girder, and the support for the steel box girder 9 is unloaded by a plurality of beam transport vehicles and returned to the next section to be installed. Bottom of steel box girder 9;
- Step E repeat steps C and D for many times until the steel box girder is assembled.
- the steel box girder assembly method has simple steps, laying a high-altitude track, using the girder transport vehicle to move on the beam transport foundation track to determine the position of the steel box girder in the extension direction of the bridge, and using the beam transport vehicle owner's jack to adjust the height position of the steel box girder,
- the position of the top hat and the steel box girder in the width direction of the bridge is realized by horizontally pushing and pulling the top support with the auxiliary jack of the beam transporter, which solves the problem of the integration of high-altitude transport beams and installation.
- the present invention has novel and reasonable design, stable beam transport, accurate docking, and precise lifting and slope adjustment of steel box beams.
- the whole machine is moved forward without manual movement, and the crane can be moved forward entirely by the ability of the equipment itself, with a high degree of automation.
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Abstract
本发明公开了一种运梁车,包括两个车箱、平衡箱梁、运梁车主千斤顶和运梁车辅千斤顶。本发明还公开了一种运梁***,包括运梁车、回转机构和夹轨机构。本发明还公开了一种钢箱梁装配***,包括运梁***和吊机***。本发明还公开了一种钢箱梁装配方法,包括步骤:一、钢箱梁运梁到位;二、下放吊具连接钢箱梁;三、提升钢箱梁并三维调节钢箱梁位置;四、钢箱梁坡度调节;五、装配钢箱梁;六、前移基座移动至更新后的钢箱梁装配端;七、钢箱梁装配结束。本发明还公开了一种钢箱梁装配方法,包括步骤:A、搭建支撑架;B、铺设轨道;C、钢箱梁的顶升及运移;D、钢箱梁三维空间位置调节及装配;E、钢箱梁装配结束。本发明钢箱梁装配精度高。
Description
本发明属于钢箱梁装配技术领域,具体涉及一种运梁车、运梁***、钢箱梁装配***及钢箱梁装配方法。
钢箱梁运输安装技术是沿桥纵轴方向的台后设置预制场,分阶段预制梁体,通过运梁车,借助原有道路、轨道、液压运梁车,将逐段梁运输至指定位置就位后落梁。随着我国桥梁设计与施工技术水平的不断提高,在公路、城市交通、铁路等领域大量涌现出各种连续钢箱梁桥。因占地少、对桥下交通无影响、无需大型吊运机具、安全可靠、造价低等优点,钢箱梁运输安装小车在其施工中得到广泛应用。现有的轮胎平板式运梁车,轮胎平板车具有平升平降及平台升降时自动调平功能,具有直线行驶、斜行、横行、八字转向和原位转向功能。转向采用微电控制,要求防震、防磁、防潮和常温(-200~+500℃)下工作稳定性。设置前灯、示廓灯、警示灯和工作航灯。平台铺设防滑网格钢板,设置多个故障检测点,充分考虑现场维修和保养方便,配置一主一副双驾驶室,且具有互锁功能。悬挂油缸具有管路破裂双管路安全保护功能。轮胎数量较多,运梁车尺寸较大,对施工环境场地要求高,不能再高空支架上实现运梁和安装。
现有的轨道式运梁车,利用事先安装好的轨道,通过多台有轨运梁车同时对一片梁进行运输,轨道运输梁目前应用较少,能达到同步三维六方向调整的更少,应用在高空支架上运输安装的几乎没有。
现有机具普遍存在以下的缺点和不足:第一,现有运输设备技术同步精度不够,过程中配合指挥误差大;第二,现有运输车很难控制大坡度及钢箱梁跨径大、宽度宽、总吨位大、施工环境复杂、线性复杂情况下的合拢精度 且受力数值精度很难掌握;第三,需要操作人员较多,劳动力投入较大;第四,很少有高空支架上运输安装一体化的设备和施工技术。
发明内容
本发明所要解决的技术问题在于针对上述现有技术中的不足,提供一种运梁车,其设计新颖合理,通过三维六向的运输安装作业解决复杂线性情况下的运输控制以及梁段安装精度把控难的问题,提升了梁体在运输安装过程中各受力数值的精准度,防止了梁体不均匀受力而造成损伤,同时消除了下部结构的水平载荷,确保了梁体在运输和安装过程中的稳定性,采用有轨道运输,模块车体积较小,承载能力大,可用于陆地及高空支架上方运梁,解决了高空运梁及安装一体化的实现,便于推广使用。
为解决上述技术问题,本发明采用的技术方案是:一种运梁车,其特征在于:包括两个车箱和连接两个车箱的平衡箱梁,所述车箱底部的前后两端均设置有沿混凝土基台上运梁基础轨道移动的行走轮,车箱上设置有控制行走轮转动的减速机和与减速机配合的驱动电机,平衡箱梁中部设置有伸出平衡箱梁顶板的运梁车主千斤顶,运梁车主千斤顶上固定安装有顶托,顶托上放置有顶帽,所述顶帽内设置有多个压力传感器和位置传感器,顶帽底部一侧设置有水平推拉顶托的运梁车辅千斤顶。
上述的一种运梁车,其特征在于:所述平衡箱梁上设置有车载控制箱,车载控制箱内设置有车载控制板,所述车载控制板上集成有运梁车微控制器,所述压力传感器和所述位置传感器的信号输出端与所述运梁车微控制器的输入端连接,减速机、驱动电机、运梁车主千斤顶和运梁车辅千斤顶均由所述运梁车微控制器控制。
本发明还公开了一种运梁***,其特征在于:包括上述的运梁车,以及均安装在所述运梁车上的回转机构和夹轨机构。
上述的一种运梁***,其特征在于:所述回转机构包括安装在平衡箱梁中部外侧的回转支承架体和安装在回转支承架体底部且与临时支墩抵 接的回转支承,临时支墩设置在运梁基础轨道和运梁转向轨道交汇位置处,运梁转向轨道预埋在混凝土转台内,运梁基础轨道和运梁转向轨道交汇位置处设置有与运梁基础轨道或运梁转向轨道配合的活动轨道。
上述的一种运梁***,其特征在于:所述夹轨机构包括安装在车箱前后两端的上耳板和下耳板,下耳板与夹持架的一端铰接,夹持架的另一端与上耳板或活动轨道固定连接。
上述的一种运梁***,其特征在于:所述运梁车的数量为多个,所述车载控制板上均集成有与计算机连接的第一同步控制器,所述第一同步控制器与对应车载控制板上的运梁车微控制器连接。
本发明还公开了一种钢箱梁装配***,其特征在于:包括上述的运梁***,以及与所述运梁***配合的吊机***,所述吊机***包括多个吊机单元,所述吊机单元包括设置在钢箱梁装配端的前移基座和设置在所述前移基座上且悬挑伸出钢箱梁装配端的吊机机架,吊机机架的悬挑端顶部安装有钢箱梁二维调节机构和位于所述钢箱梁二维调节机构外侧的平衡滑轮总成,钢箱梁二维调节机构上安装有上滑轮总成,吊机机架远离悬挑端的顶部安装有卷扬机,卷扬机的钢丝绳通过上滑轮总成和平衡滑轮总成与下滑轮总成连接,下滑轮总成通过吊具连接座与吊具连接;
所述吊机机架上设置有机载控制箱,机载控制箱内设置有机载控制板,所述机载控制板上集成有吊机微控制器和与计算机连接的第二同步控制器,所述第二同步控制器与对应机载控制板上的吊机微控制器连接。
上述的一种钢箱梁装配***,其特征在于:所述吊机机架通过机架后支腿总成和机架前支腿总成设置在所述前移基座上,机架前支腿总成位于钢箱梁装配端,所述前移基座包括前移轨道和安装在前移轨道上的支架前移调节油缸,支架前移调节油缸的伸出端与机架前支腿总成连接,前移轨道通过预设在钢箱梁上的多个机架临时支块支设在钢箱梁装配端,机架后支腿总成和机架前支腿总成的外侧均设置有用于安装机架千斤顶的机架千斤顶锚板,机架千斤顶的伸出端通过机架千斤顶支块与已装配钢箱梁的 梁面配合。
上述的一种钢箱梁装配***,其特征在于:所述已装配钢箱梁的梁面上设置有多个补强耳板,补强耳板与前移轨道固定连接。
上述的一种钢箱梁装配***,其特征在于:所述钢箱梁二维调节机构包括与吊机机架的悬挑端顶部滑动配合的天车底架和设置在天车底架上且与天车底架滑动配合的天车顶架,吊机机架上安装有底架调节油缸,底架调节油缸的伸出端与天车底架连接,天车底架上安装有顶架调节油缸,顶架调节油缸的伸出端与天车顶架连接。
上述的一种钢箱梁装配***,其特征在于:所述吊机机架沿长度方向的两侧安装有护栏。
上述的一种钢箱梁装配***,其特征在于:所述吊具底部设置用于连接钢箱梁的钢箱梁固定抓座,所述吊具连接座上安装有吊具俯仰调节油缸,吊具俯仰调节油缸的伸出端与吊具顶板连接。
上述的一种钢箱梁装配***,其特征在于:所述上滑轮总成中包括N个滑轮,且N为不小于4的偶数,所述下滑轮总成中的滑轮数量比上滑轮总成中的滑轮数量少两个,所述平衡滑轮总成中包括一个滑轮。
上述的一种钢箱梁装配***,其特征在于:所述下滑轮总成位于上滑轮总成正下方。
同时,本发明还公开了一种钢箱梁装配的方法,其特征在于:该方法包括以下步骤:
步骤一、钢箱梁运梁到位:利用多个运梁车将钢箱梁运输至设计位置;
步骤二、下放吊具连接钢箱梁:卷扬机放线,钢丝绳伸长下放吊具,吊具底部设置用于连接钢箱梁的钢箱梁固定抓座,所述吊具连接座上安装有吊具俯仰调节油缸,吊具俯仰调节油缸的伸出端与吊具顶板连接;
将钢箱梁与钢箱梁固定抓座连接;
步骤三、提升钢箱梁并三维调节钢箱梁位置:卷扬机收线,钢丝绳回收提升吊具,吊具携带钢箱梁上升至安装高度,再利用钢箱梁二维调节机 构将钢箱梁移动至安装位置;
步骤四、钢箱梁坡度调节:启动吊具俯仰调节油缸,将钢箱梁的调节至设计坡度;
步骤五、装配钢箱梁:将钢箱梁与钢箱梁装配端连接,实现钢箱梁的延长,此时钢箱梁装配端更新;
步骤六、前移基座移动至更新后的钢箱梁装配端,过程如下:
步骤601、机架千斤顶顶升,使机架后支腿总成和机架前支腿总成从前移轨道上分离,拆卸补强耳板与前移轨道的连接,支架前移调节油缸带动前移轨道前移,再将补强耳板与前移轨道固定连接;
步骤602、机架千斤顶收回,使机架后支腿总成和机架前支腿总成落在前移轨道上,支架前移调节油缸推动机架前支腿总成在前移轨道上前移,进而实现吊机机架的前移;
步骤603、多次循环步骤601和步骤602,直至前移轨道前移至更新后的钢箱梁装配端的端头,利用补强耳板将前移轨道与已装配钢箱梁的梁面固定连接;
步骤七、多次循环步骤一至步骤六,直至钢箱梁装配结束。
上述的方法,其特征在于:步骤一中钢箱梁运梁到位过程如下:
步骤101、布放运梁车:铺设运梁转向轨道,运梁转向轨道预埋在混凝土转台内,运梁转向轨道与多个运梁基础轨道交汇,在运梁转向轨道上布放多个运梁车,在每个运梁基础轨道上布放一个运梁车,运梁基础轨道上的运梁车视为基础运梁车,运梁转向轨道上的运梁车视为转向运梁车;
运梁基础轨道和运梁转向轨道交汇位置处设置有与运梁基础轨道或运梁转向轨道配合的活动轨道;
步骤102、钢箱梁入轨:利用多个基础运梁车同步顶升钢箱梁,使钢箱梁从钢箱梁胎架上分离,多个基础运梁车将钢箱梁运移至运梁转向轨道上,此时基础运梁车停在活动轨道上;
步骤103、钢箱梁换撑:利用多个转向运梁车同步顶升钢箱梁,使钢 箱梁从多个基础运梁车上分离;
步骤104、基础运梁车转向:利用夹轨机构夹持活动轨道,利用临时支墩顶升基础运梁车,基础运梁车与钢箱梁不接触,且活动轨道的底面高于运梁转向轨道和运梁基础轨道的顶面;利用回转机构对基础运梁车转向;
步骤105、钢箱梁运移:临时支墩下放基础运梁车,使活动轨道和运梁转向轨道对接,收起夹轨机构,此时基础运梁车和转向运梁车同向,利用多个基础运梁车同步顶升钢箱梁,实现基础运梁车和转向运梁车共同运移钢箱梁。
同时,本发明还公开了一种钢箱梁装配的方法,其特征在于:该方法包括以下步骤:
步骤A、搭建支撑架:在钢箱梁设计位置底部搭建支撑架;
步骤B、铺设轨道:在支撑架上铺设多组运梁基础轨道,并在每组运梁基础轨道上设置一个运梁车;
步骤C、钢箱梁的顶升及运移:利用多个运梁车同步顶升钢箱梁,使钢箱梁从钢箱梁胎架上分离,多个运梁车同步运移钢箱梁至钢箱梁装配端;
步骤D、钢箱梁三维空间位置调节及装配:利用运梁车在运梁基础轨道上移动确定钢箱梁在桥梁延伸方向上的位置,利用运梁车主千斤顶调节钢箱梁的高度位置,利用运梁车辅千斤顶水平推拉顶托实现顶帽连带钢箱梁在桥梁宽度方向上的位置;
待钢箱梁的三维空间位置调节完成后,将钢箱梁装配至钢箱梁装配端的端头,多个运梁车卸载对钢箱梁的支撑并退回至下一节待安装的钢箱梁底部;
步骤E、多次循环步骤C和步骤D,直至钢箱梁装配结束。
本发明与现有技术相比具有以下优点:
1、本发明运梁车通过三维六向的运输安装作业解决复杂线性情况下的运 输控制以及梁段安装精度把控难的问题,提升了梁体在运输安装过程中各受力数值的精准度,防止了梁体不均匀受力而造成损伤,同时消除了下部结构的水平载荷,确保了梁体在运输和安装过程中的稳定性,采用有轨道运输,模块车体积较小,承载能力大,可用于陆地及高空支架上方运梁,解决了高空运梁及安装一体化的实现,便于推广使用。
2、本发明运梁***通过回转机构和夹轨机构,实现运梁车带轨原位转向,运梁稳定可靠,使用效果好,在施工复杂环境下,减少占地及设备投入,在桥梁运输安装领域有广阔的市场,较好地解决了小半径竖曲线梁体的线性控制,其控制精度达到了毫米级,减少了来回调梁的次数,提高了施工的效率。
3、本发明钢箱梁装配***通过运梁***运梁到位,桥面吊机的纵移采用步履式行走,液压驱动,通过纵移油缸的伸缩配合整机的起落来完成整机前移,不需人工移动,完全依靠设备自身的能力实现起重机前移,采用有卷扬机提供动力,通过钢丝绳倍率的转换满足最大起升重量;同步或单独作业,避免了提升过程中因设备协调造成梁体局部应力集中而带来的损伤,吊机实现了三维立体的位移控制,较好地解决了小半径竖曲线梁体的线性控制,其控制精度达到了毫米级,减少了来回调梁的次数提高了施工的效率,整体提供钢箱梁装配精度和效率。
4、本发明一钢箱梁装配方法,步骤简单,运梁稳定、停靠精准,钢箱梁提吊调坡精准,桥面吊机的纵移采用步履式行走,液压驱动,通过纵移油缸的伸缩配合整机的起落来完成整机前移,不需人工移动,完全依靠设备自身的能力实现起重机前移,自动化程度高。
5、本发明另一钢箱梁装配方法,步骤简单,铺设高空轨道,利用运梁车在运梁基础轨道上移动确定钢箱梁在桥梁延伸方向上的位置,利用运梁车主千斤顶调节钢箱梁的高度位置,利用运梁车辅千斤顶水平推拉顶托实现顶帽连带钢箱梁在桥梁宽度方向上的位置,解决了高空运梁及安装一体化的实现问题。
综上所述,本发明设计新颖合理,运梁稳定、停靠精准,钢箱梁提吊 调坡精准,桥面吊机的纵移采用步履式行走,液压驱动,通过纵移油缸的伸缩配合整机的起落来完成整机前移,不需人工移动,完全依靠设备自身的能力实现起重机前移,自动化程度高,便于推广使用。
下面通过附图和实施例,对本发明的技术方案做进一步的详细描述。
图1为本发明运梁车安装回转机构和夹轨机构的结构示意图。
图2为图1的右视图。
图3为本发明运梁车作为基础运梁车的使用状态图。
图4为本发明运梁车与临时支墩的配合关系示意图。
图5为本发明运梁车与活动轨道的连接关系示意图。
图6为本发明运梁车作为转向运梁车的使用状态图。
图7为本发明运梁车在运梁基础轨道和运梁转向轨道上的布放位置示意图。
图8为图7中基础运梁车移动至运梁基础轨道和运梁转向轨道交汇位置处的位置状态示意图。
图9为图8中基础运梁车转向的位置状态示意图。
图10为本发明吊机的使用状态图。
图11为图10中未提吊钢箱梁的俯视图。
图12为图10中钢丝绳未回收的右视图。
图13为本发明一钢箱梁装配方法的流程框图。
图14为本发明另一钢箱梁装配方法的流程框图。
附图标记说明:
1—混凝土基台; 2—运梁基础轨道; 3—活动轨道;
4—混凝土转台; 5—运梁转向轨道; 6—临时支墩;
7-1—基础运梁车; 7-2—转向运梁车; 8—钢箱梁胎架;
9—钢箱梁; 10—车箱; 11—平衡箱梁;
12—运梁车主千斤顶; 13—回转支承架体; 14—回转支承;
15—顶帽; 16—车载控制箱; 17—行走轮;
18—上耳板; 19—下耳板; 20—夹持架;
21—运梁车辅千斤顶; 22—减速机; 23—驱动电机;
24—顶托; 30—吊机机架; 31—卷扬机;
32—护栏; 33—底架调节油缸; 34—天车底架;
35—天车顶架; 36—顶架调节油缸; 37—上滑轮总成;
38—平衡滑轮总成; 39—钢丝绳; 40—机架后支腿总成;
41—机架前支腿总成; 42—前移轨道; 43—机架临时支块;
44—补强耳板; 45—支架前移调节油缸;
46—吊具; 47—吊具连接座; 48—下滑轮总成;
49—吊具俯仰调节油缸; 50—钢箱梁固定抓座;
51—机架千斤顶锚板; 52—机架千斤顶; 53—机架千斤顶支块。
如图1和图3所示,本发明所述的一种运梁车,包括两个车箱10和连接两个车箱10的平衡箱梁11,所述车箱10底部的前后两端均设置有沿混凝土基台1上运梁基础轨道2移动的行走轮17,车箱10上设置有控制行走轮17转动的减速机22和与减速机22配合的驱动电机23,平衡箱梁11中部设置有伸出平衡箱梁11顶板的运梁车主千斤顶12,运梁车主千斤顶12上固定安装有顶托24,顶托24上放置有顶帽15,所述顶帽15内设置有多个压力传感器和位置传感器,顶帽15底部一侧设置有水平推拉顶托24的运梁车辅千斤顶21。
需要说明的是,本发明运梁车通过轨道限定梁沿延伸方向的维度位置,通过运梁车与梁之间的支点位置限定梁宽度方向的维度位置,但是实际运梁车与梁之间的支点位置之间存在一定的偏差,通过顶帽15底部一 侧设置是水平推拉顶托24的运梁车辅千斤顶21实现梁宽度方向的维度位置的精确调整,最后通过运梁车主千斤顶12调节梁高度方向的维度位置,进而实现运梁车对梁的三维空间调节。
实际安装使用中,
本实施例中,所述平衡箱梁11上设置有车载控制箱16,车载控制箱16内设置有车载控制板,所述车载控制板上集成有运梁车微控制器,所述压力传感器和所述位置传感器的信号输出端与所述运梁车微控制器的输入端连接,减速机22、驱动电机23、运梁车主千斤顶12和运梁车辅千斤顶21均由所述运梁车微控制器控制。
需要说明的是,运梁车通过三维六向的运输安装作业解决复杂线性情况下的运输控制以及梁段安装精度把控难的问题,提升了梁体在运输安装过程中各受力数值的精准度,防止了梁体不均匀受力而造成损伤,同时消除了下部结构的水平载荷,确保了梁体在运输和安装过程中的稳定性,采用有轨道运输,模块车体积较小,承载能力大,可用于陆地及高空支架上方运梁,解决了高空运梁及安装一体化的实现。
如图2至图5所示的一种运梁***,包括本发明所述的运梁车,以及均安装在所述运梁车上的回转机构和夹轨机构。
需要说明的是,本发明运梁***通过回转机构和夹轨机构,实现运梁车带轨原位转向,运梁稳定可靠,使用效果好,在施工复杂环境下,减少占地及设备投入,在桥梁运输安装领域有广阔的市场,较好地解决了小半径竖曲线梁体的线性控制,其控制精度达到了毫米级,减少了来回调梁的次数,提高了施工的效率。
本实施例中,所述回转机构包括安装在平衡箱梁11中部外侧的回转支承架体13和安装在回转支承架体13底部且与临时支墩6抵接的回转支承14,临时支墩6设置在运梁基础轨道2和运梁转向轨道5交汇位置处,运梁转向轨道5预埋在混凝土转台4内,运梁基础轨道2和运梁转向轨道5交汇位置处设置有与运梁基础轨道2或运梁转向轨道5配合的活动轨道 3。
需要说明的是,临时支墩6可采用人工支撑的混凝土墩,也可以采用千斤顶实现对运梁车的升降。
本实施例中,所述夹轨机构包括安装在车箱10前后两端的上耳板18和下耳板19,下耳板19与夹持架20的一端铰接,夹持架20的另一端与上耳板18或活动轨道3固定连接。
本实施例中,所述运梁车的数量为多个,所述车载控制板上均集成有与计算机连接的第一同步控制器,所述第一同步控制器与对应车载控制板上的运梁车微控制器连接。
如图1至图6、图10至图12所示的一种钢箱梁装配***,包括本发明所述的运梁***,以及与所述运梁***配合的吊机***,所述吊机***包括多个吊机单元,所述吊机单元包括设置在钢箱梁装配端的前移基座和设置在所述前移基座上且悬挑伸出钢箱梁装配端的吊机机架30,吊机机架30的悬挑端顶部安装有钢箱梁二维调节机构和位于所述钢箱梁二维调节机构外侧的平衡滑轮总成38,钢箱梁二维调节机构上安装有上滑轮总成37,吊机机架30远离悬挑端的顶部安装有卷扬机31,卷扬机31的钢丝绳39通过上滑轮总成37和平衡滑轮总成38与下滑轮总成48连接,下滑轮总成48通过吊具连接座47与吊具46连接;
所述吊机机架30上设置有机载控制箱,机载控制箱内设置有机载控制板,所述机载控制板上集成有吊机微控制器和与计算机连接的第二同步控制器,所述第二同步控制器与对应机载控制板上的吊机微控制器连接。
需要说明的是,本发明钢箱梁装配***通过运梁***运梁到位,桥面吊机的纵移采用步履式行走,液压驱动,通过纵移油缸的伸缩配合整机的起落来完成整机前移,不需人工移动,完全依靠设备自身的能力实现起重机前移,采用有卷扬机提供动力,通过钢丝绳倍率的转换满足最大起升重量;同步或单独作业,避免了提升过程中因设备协调造成梁体局部应力集中而带来的损伤,吊机实现了三维立体的位移控制,较好地解决了小半径竖曲线梁体的线 性控制,其控制精度达到了毫米级,减少了来回调梁的次数提高了施工的效率,整体提供钢箱梁装配精度和效率。
本实施例中,所述吊机机架30通过机架后支腿总成40和机架前支腿总成41设置在所述前移基座上,机架前支腿总成41位于钢箱梁装配端,所述前移基座包括前移轨道42和安装在前移轨道42上的支架前移调节油缸45,支架前移调节油缸45的伸出端与机架前支腿总成41连接,前移轨道42通过预设在钢箱梁9上的多个机架临时支块43支设在钢箱梁装配端,机架后支腿总成40和机架前支腿总成41的外侧均设置有用于安装机架千斤顶52的机架千斤顶锚板51,机架千斤顶52的伸出端通过机架千斤顶支块53与已装配钢箱梁的梁面配合。
本实施例中,所述已装配钢箱梁的梁面上设置有多个补强耳板44,补强耳板44与前移轨道42固定连接。
需要说明的是,多个机架临时支块43临时固定装配支设在钢箱梁装配端,当有新的钢箱梁9装配好之后,将已装配好的桥面上的使用过的多个机架临时支块43拆卸安装在新的钢箱梁9上,可重复周转使用,多个补强耳板44将前移轨道42与多个机架临时支块43固定连接,支架前移调节油缸45拉动前移轨道42在多个机架临时支块43上滑动,避免前移轨道42与桥面之间的摩擦,损伤桥面。
实时操作中,支架前移调节油缸45的伸出端与机架前支腿总成41连接,支架前移调节油缸45的固定端与前移轨道42连接,初始状态下,支架前移调节油缸45为伸长状态,当有新的钢箱梁9装配好之后,顶升机架后支腿总成40和机架前支腿总成41,拆卸掉固定前移轨道42的多个补强耳板44,使前移轨道42不受压,此时收缩支架前移调节油缸45,支架前移调节油缸45的固定端前移,带动前移轨道42前移,然后利用多个补强耳板44将前移轨道42与多个机架临时支块43固定连接,下放机架后支腿总成40和机架前支腿总成41至前移轨道42上,伸长支架前移调节油缸45,此时支架前移调节油缸45的固定端与前移轨道42连接位置固定 不动,机架后支腿总成40和机架前支腿总成41在前移轨道42上前移,操作简单,无需大型机械设备的使用。
本实施例中,所述钢箱梁二维调节机构包括与吊机机架30的悬挑端顶部滑动配合的天车底架34和设置在天车底架34上且与天车底架34滑动配合的天车顶架35,吊机机架30上安装有底架调节油缸33,底架调节油缸33的伸出端与天车底架34连接,天车底架34上安装有顶架调节油缸36,顶架调节油缸36的伸出端与天车顶架35连接。
本实施例中,所述吊机机架30沿长度方向的两侧安装有护栏32。
本实施例中,所述吊具46底部设置用于连接钢箱梁9的钢箱梁固定抓座50,所述吊具连接座47上安装有吊具俯仰调节油缸49,吊具俯仰调节油缸49的伸出端与吊具46顶板连接。
需要说明的是,吊具46对钢箱梁9平吊可通过对称结构实现,但是实际桥面往往带有一定的坡度,利用钢箱梁二维调节机构和钢丝绳39将钢箱梁9运移至钢箱梁装配端后,利用吊具俯仰调节油缸49的推拉实现吊具46的倾斜俯仰,逼近桥面线形的设计。
本实施例中,所述上滑轮总成37中包括N个滑轮,且N为不小于4的偶数,所述下滑轮总成48中的滑轮数量比上滑轮总成37中的滑轮数量少两个,所述平衡滑轮总成38中包括一个滑轮。
需要说明的是,设置平衡滑轮总成38的作用是平衡上滑轮总成37和下滑轮总成48之间钢丝绳受力的,如果钢丝绳39受力不均匀,出现上滑轮总成37中一边力大一边力小时,通过平衡滑轮总成38中滑轮转动维持力的平衡,其中,钢丝绳39的缠绕方式是一头固定在卷扬机上,另一头通过上滑轮总成37、下滑轮总成48和平衡滑轮总成38后又固定在卷扬机上,平衡滑轮总成38中包括一个滑轮,这一个滑轮位于上滑轮总成37中部旁侧,因此上滑轮总成37中包括N个滑轮,且N取偶数,以N取8为例,平衡滑轮总成38中的这一个滑轮位于上滑轮总成37中第4个滑轮和第5个滑轮之间位置的旁侧,钢丝绳39穿过上滑轮总成37中第4个滑轮 上部后绕到平衡滑轮总成38中的滑轮底部,再从平衡滑轮总成38中的滑轮顶部出来绕到上滑轮总成37中第5个滑轮上部,这样上滑轮总成37中第1个滑轮至第4个滑轮上的绕线方向与上滑轮总成37中第5个滑轮至第8个滑轮上的绕线方向相反,因此钢丝绳39在上滑轮总成37上绕线对称,同理钢丝绳39在下滑轮总成48上绕线也是对称,且上滑轮总成37中第1个滑轮至第4个滑轮与下滑轮总成48上第1个滑轮至第3个滑轮配合,由于对称结构,因此下滑轮总成48中的滑轮数量比上滑轮总成37中的滑轮数量少两个,即N为不小于4的偶数。
本实施例中,所述下滑轮总成48位于上滑轮总成37正下方。
如图13所示的一种钢箱梁装配的方法,该方法包括以下步骤:
步骤一、钢箱梁运梁到位:利用多个运梁车将钢箱梁9运输至设计位置;
步骤二、下放吊具连接钢箱梁:卷扬机31放线,钢丝绳39伸长下放吊具46,吊具46底部设置用于连接钢箱梁9的钢箱梁固定抓座50,所述吊具连接座47上安装有吊具俯仰调节油缸49,吊具俯仰调节油缸49的伸出端与吊具46顶板连接;
将钢箱梁9与钢箱梁固定抓座50连接;
步骤三、提升钢箱梁并三维调节钢箱梁位置:卷扬机31收线,钢丝绳39回收提升吊具46,吊具46携带钢箱梁9上升至安装高度,再利用钢箱梁二维调节机构将钢箱梁9移动至安装位置;
步骤四、钢箱梁坡度调节:启动吊具俯仰调节油缸49,将钢箱梁9的调节至设计坡度;
步骤五、装配钢箱梁:将钢箱梁9与钢箱梁装配端连接,实现钢箱梁的延长,此时钢箱梁装配端更新;
步骤六、前移基座移动至更新后的钢箱梁装配端,过程如下:
步骤601、机架千斤顶52顶升,使机架后支腿总成40和机架前支腿总成41从前移轨道42上分离,拆卸补强耳板44与前移轨道42的连接, 支架前移调节油缸45带动前移轨道42前移,再将补强耳板44与前移轨道42固定连接;
步骤602、机架千斤顶52收回,使机架后支腿总成40和机架前支腿总成41落在前移轨道42上,支架前移调节油缸45推动机架前支腿总成41在前移轨道42上前移,进而实现吊机机架30的前移;
步骤603、多次循环步骤601和步骤602,直至前移轨道42前移至更新后的钢箱梁装配端的端头,利用补强耳板44将前移轨道42与已装配钢箱梁的梁面固定连接;
步骤七、多次循环步骤一至步骤六,直至钢箱梁装配结束。
如图7至图9所示,本实施例中,步骤一中钢箱梁运梁到位过程如下:
步骤101、布放运梁车:铺设运梁转向轨道5,运梁转向轨道5预埋在混凝土转台4内,运梁转向轨道5与多个运梁基础轨道2交汇,在运梁转向轨道5上布放多个运梁车,在每个运梁基础轨道2上布放一个运梁车,运梁基础轨道2上的运梁车视为基础运梁车7-1,运梁转向轨道5上的运梁车视为转向运梁车7-2;
运梁基础轨道2和运梁转向轨道5交汇位置处设置有与运梁基础轨道2或运梁转向轨道5配合的活动轨道3;
步骤102、钢箱梁入轨:利用多个基础运梁车7-1同步顶升钢箱梁9,使钢箱梁9从钢箱梁胎架8上分离,多个基础运梁车7-1将钢箱梁9运移至运梁转向轨道5上,此时基础运梁车7-1停在活动轨道3上;
步骤103、钢箱梁换撑:利用多个转向运梁车7-2同步顶升钢箱梁9,使钢箱梁9从多个基础运梁车7-1上分离;
步骤104、基础运梁车转向:利用夹轨机构夹持活动轨道3,利用临时支墩6顶升基础运梁车7-1,基础运梁车7-1与钢箱梁9不接触,且活动轨道3的底面高于运梁转向轨道5和运梁基础轨道2的顶面;利用回转机构对基础运梁车7-1转向;
步骤105、钢箱梁运移:临时支墩6下放基础运梁车7-1,使活动轨 道3和运梁转向轨道5对接,收起夹轨机构,此时基础运梁车7-1和转向运梁车7-2同向,利用多个基础运梁车7-1同步顶升钢箱梁9,实现基础运梁车7-1和转向运梁车7-2共同运移钢箱梁9。
该钢箱梁装配方法,步骤简单,运梁稳定、停靠精准,钢箱梁提吊调坡精准,桥面吊机的纵移采用步履式行走,液压驱动,通过纵移油缸的伸缩配合整机的起落来完成整机前移,不需人工移动,完全依靠设备自身的能力实现起重机前移,自动化程度高。
如图14所示的一种钢箱梁装配的方法,该方法包括以下步骤:
步骤A、搭建支撑架:在钢箱梁设计位置底部搭建支撑架;
步骤B、铺设轨道:在支撑架上铺设多组运梁基础轨道2,并在每组运梁基础轨道2上设置一个运梁车;
步骤C、钢箱梁的顶升及运移:利用多个运梁车同步顶升钢箱梁9,使钢箱梁9从钢箱梁胎架8上分离,多个运梁车同步运移钢箱梁9至钢箱梁装配端;
步骤D、钢箱梁三维空间位置调节及装配:利用运梁车在运梁基础轨道2上移动确定钢箱梁9在桥梁延伸方向上的位置,利用运梁车主千斤顶12调节钢箱梁9的高度位置,利用运梁车辅千斤顶21水平推拉顶托24实现顶帽15连带钢箱梁9在桥梁宽度方向上的位置;
待钢箱梁9的三维空间位置调节完成后,将钢箱梁9装配至钢箱梁装配端的端头,多个运梁车卸载对钢箱梁9的支撑并退回至下一节待安装的钢箱梁9底部;
步骤E、多次循环步骤C和步骤D,直至钢箱梁装配结束。
该钢箱梁装配方法,步骤简单,铺设高空轨道,利用运梁车在运梁基础轨道上移动确定钢箱梁在桥梁延伸方向上的位置,利用运梁车主千斤顶调节钢箱梁的高度位置,利用运梁车辅千斤顶水平推拉顶托实现顶帽连带钢箱梁在桥梁宽度方向上的位置,解决了高空运梁及安装一体化的实现问题。
本发明设计新颖合理,运梁稳定、停靠精准,钢箱梁提吊调坡精准, 桥面吊机的纵移采用步履式行走,液压驱动,通过纵移油缸的伸缩配合整机的起落来完成整机前移,不需人工移动,完全依靠设备自身的能力实现起重机前移,自动化程度高。
以上所述,仅是本发明的较佳实施例,并非对本发明作任何限制,凡是根据本发明技术实质对以上实施例所作的任何简单修改、变更以及等效结构变化,均仍属于本发明技术方案的保护范围内。
Claims (17)
- 一种运梁车,其特征在于:包括两个车箱(10)和连接两个车箱(10)的平衡箱梁(11),所述车箱(10)底部的前后两端均设置有沿混凝土基台(1)上运梁基础轨道(2)移动的行走轮(17),车箱(10)上设置有控制行走轮(17)转动的减速机(22)和与减速机(22)配合的驱动电机(23),平衡箱梁(11)中部设置有伸出平衡箱梁(11)顶板的运梁车主千斤顶(12),运梁车主千斤顶(12)上固定安装有顶托(24),顶托(24)上放置有顶帽(15),所述顶帽(15)内设置有多个压力传感器和位置传感器,顶帽(15)底部一侧设置有水平推拉顶托(24)的运梁车辅千斤顶(21)。
- 按照权利要求1所述的一种运梁车,其特征在于:所述平衡箱梁(11)上设置有车载控制箱(16),车载控制箱(16)内设置有车载控制板,所述车载控制板上集成有运梁车微控制器,所述压力传感器和所述位置传感器的信号输出端与所述运梁车微控制器的输入端连接,减速机(22)、驱动电机(23)、运梁车主千斤顶(12)和运梁车辅千斤顶(21)均由所述运梁车微控制器控制。
- 一种运梁***,其特征在于:包括如权利要求2中所述的运梁车,以及均安装在所述运梁车上的回转机构和夹轨机构。
- 按照权利要求3所述的一种运梁***,其特征在于:所述回转机构包括安装在平衡箱梁(11)中部外侧的回转支承架体(13)和安装在回转支承架体(13)底部且与临时支墩(6)抵接的回转支承(14),临时支墩(6)设置在运梁基础轨道(2)和运梁转向轨道(5)交汇位置处,运梁转向轨道(5)预埋在混凝土转台(4)内,运梁基础轨道(2)和运梁转向轨道(5)交汇位置处设置有与运梁基础轨道(2)或运梁转向轨道(5)配合 的活动轨道(3)。
- 按照权利要求4所述的一种运梁***,其特征在于:所述夹轨机构包括安装在车箱(10)前后两端的上耳板(18)和下耳板(19),下耳板(19)与夹持架(20)的一端铰接,夹持架(20)的另一端与上耳板(18)或活动轨道(3)固定连接。
- 按照权利要求3所述的一种运梁***,其特征在于:所述运梁车的数量为多个,所述车载控制板上均集成有与计算机连接的第一同步控制器,所述第一同步控制器与对应车载控制板上的运梁车微控制器连接。
- 一种钢箱梁装配***,其特征在于:包括如权利要求6中所述的运梁***,以及与所述运梁***配合的吊机***,所述吊机***包括多个吊机单元,所述吊机单元包括设置在钢箱梁装配端的前移基座和设置在所述前移基座上且悬挑伸出钢箱梁装配端的吊机机架(30),吊机机架(30)的悬挑端顶部安装有钢箱梁二维调节机构和位于所述钢箱梁二维调节机构外侧的平衡滑轮总成(38),钢箱梁二维调节机构上安装有上滑轮总成(37),吊机机架(30)远离悬挑端的顶部安装有卷扬机(31),卷扬机(31)的钢丝绳(39)通过上滑轮总成(37)和平衡滑轮总成(38)与下滑轮总成(48)连接,下滑轮总成(48)通过吊具连接座(47)与吊具(46)连接;所述吊机机架(30)上设置有机载控制箱,机载控制箱内设置有机载控制板,所述机载控制板上集成有吊机微控制器和与计算机连接的第二同步控制器,所述第二同步控制器与对应机载控制板上的吊机微控制器连接。
- 按照权利要求7所述的一种钢箱梁装配***,其特征在于:所述吊 机机架(30)通过机架后支腿总成(40)和机架前支腿总成(41)设置在所述前移基座上,机架前支腿总成(41)位于钢箱梁装配端,所述前移基座包括前移轨道(42)和安装在前移轨道(42)上的支架前移调节油缸(45),支架前移调节油缸(45)的伸出端与机架前支腿总成(41)连接,前移轨道(42)通过预设在钢箱梁(9)上的多个机架临时支块(43)支设在钢箱梁装配端,机架后支腿总成(40)和机架前支腿总成(41)的外侧均设置有用于安装机架千斤顶(52)的机架千斤顶锚板(51),机架千斤顶(52)的伸出端通过机架千斤顶支块(53)与已装配钢箱梁的梁面配合。
- 按照权利要求8所述的一种钢箱梁装配***,其特征在于:所述已装配钢箱梁的梁面上设置有多个补强耳板(44),补强耳板(44)与前移轨道(42)固定连接。
- 按照权利要求7所述的一种钢箱梁装配***,其特征在于:所述钢箱梁二维调节机构包括与吊机机架(30)的悬挑端顶部滑动配合的天车底架(34)和设置在天车底架(34)上且与天车底架(34)滑动配合的天车顶架(35),吊机机架(30)上安装有底架调节油缸(33),底架调节油缸(33)的伸出端与天车底架(34)连接,天车底架(34)上安装有顶架调节油缸(36),顶架调节油缸(36)的伸出端与天车顶架(35)连接。
- 按照权利要求7所述的一种钢箱梁装配***,其特征在于:所述吊机机架(30)沿长度方向的两侧安装有护栏(32)。
- 按照权利要求7所述的一种钢箱梁装配***,其特征在于:所述吊具(46)底部设置用于连接钢箱梁(9)的钢箱梁固定抓座(50),所述吊具连接座(47)上安装有吊具俯仰调节油缸(49),吊具俯仰调节油缸(49)的伸出端与吊具(46)顶板连接。
- 按照权利要求7所述的一种钢箱梁装配***,其特征在于:所述上滑轮总成(37)中包括N个滑轮,且N为不小于4的偶数,所述下滑轮总成(48)中的滑轮数量比上滑轮总成(37)中的滑轮数量少两个,所述平衡滑轮总成(38)中包括一个滑轮。
- 按照权利要求7所述的一种钢箱梁装配***,其特征在于:所述下滑轮总成(48)位于上滑轮总成(37)正下方。
- 一种利用如权利要求9所述***进行钢箱梁装配的方法,其特征在于:该方法包括以下步骤:步骤一、钢箱梁运梁到位:利用多个运梁车将钢箱梁(9)运输至设计位置;步骤二、下放吊具连接钢箱梁:卷扬机(31)放线,钢丝绳(39)伸长下放吊具(46),吊具(46)底部设置用于连接钢箱梁(9)的钢箱梁固定抓座(50),所述吊具连接座(47)上安装有吊具俯仰调节油缸(49),吊具俯仰调节油缸(49)的伸出端与吊具(46)顶板连接;将钢箱梁(9)与钢箱梁固定抓座(50)连接;步骤三、提升钢箱梁并三维调节钢箱梁位置:卷扬机(31)收线,钢丝绳(39)回收提升吊具(46),吊具(46)携带钢箱梁(9)上升至安装高度,再利用钢箱梁二维调节机构将钢箱梁(9)移动至安装位置;步骤四、钢箱梁坡度调节:启动吊具俯仰调节油缸(49),将钢箱梁(9)的调节至设计坡度;步骤五、装配钢箱梁:将钢箱梁(9)与钢箱梁装配端连接,实现钢箱梁的延长,此时钢箱梁装配端更新;步骤六、前移基座移动至更新后的钢箱梁装配端,过程如下:步骤601、机架千斤顶(52)顶升,使机架后支腿总成(40)和机架前 支腿总成(41)从前移轨道(42)上分离,拆卸补强耳板(44)与前移轨道(42)的连接,支架前移调节油缸(45)带动前移轨道(42)前移,再将补强耳板(44)与前移轨道(42)固定连接;步骤602、机架千斤顶(52)收回,使机架后支腿总成(40)和机架前支腿总成(41)落在前移轨道(42)上,支架前移调节油缸(45)推动机架前支腿总成(41)在前移轨道(42)上前移,进而实现吊机机架(30)的前移;步骤603、多次循环步骤601和步骤602,直至前移轨道(42)前移至更新后的钢箱梁装配端的端头,利用补强耳板(44)将前移轨道(42)与已装配钢箱梁的梁面固定连接;步骤七、多次循环步骤一至步骤六,直至钢箱梁装配结束。
- 按照权利要求15所述的方法,其特征在于:步骤一中钢箱梁运梁到位过程如下:步骤101、布放运梁车:铺设运梁转向轨道(5),运梁转向轨道(5)预埋在混凝土转台(4)内,运梁转向轨道(5)与多个运梁基础轨道(2)交汇,在运梁转向轨道(5)上布放多个运梁车,在每个运梁基础轨道(2)上布放一个运梁车,运梁基础轨道(2)上的运梁车视为基础运梁车(7-1),运梁转向轨道(5)上的运梁车视为转向运梁车(7-2);运梁基础轨道(2)和运梁转向轨道(5)交汇位置处设置有与运梁基础轨道(2)或运梁转向轨道(5)配合的活动轨道(3);步骤102、钢箱梁入轨:利用多个基础运梁车(7-1)同步顶升钢箱梁(9),使钢箱梁(9)从钢箱梁胎架(8)上分离,多个基础运梁车(7-1)将钢箱梁(9)运移至运梁转向轨道(5)上,此时基础运梁车(7-1)停在活动轨道(3)上;步骤103、钢箱梁换撑:利用多个转向运梁车(7-2)同步顶升钢箱梁(9),使钢箱梁(9)从多个基础运梁车(7-1)上分离;步骤104、基础运梁车转向:利用夹轨机构夹持活动轨道(3),利用临时支墩(6)顶升基础运梁车(7-1),基础运梁车(7-1)与钢箱梁(9)不接触,且活动轨道(3)的底面高于运梁转向轨道(5)和运梁基础轨道(2)的顶面;利用回转机构对基础运梁车(7-1)转向;步骤105、钢箱梁运移:临时支墩(6)下放基础运梁车(7-1),使活动轨道(3)和运梁转向轨道(5)对接,收起夹轨机构,此时基础运梁车(7-1)和转向运梁车(7-2)同向,利用多个基础运梁车(7-1)同步顶升钢箱梁(9),实现基础运梁车(7-1)和转向运梁车(7-2)共同运移钢箱梁(9)。
- 一种利用如权利要求2所述运梁车进行钢箱梁装配的方法,其特征在于:该方法包括以下步骤:步骤A、搭建支撑架:在钢箱梁设计位置底部搭建支撑架;步骤B、铺设轨道:在支撑架上铺设多组运梁基础轨道(2),并在每组运梁基础轨道(2)上设置一个运梁车;步骤C、钢箱梁的顶升及运移:利用多个运梁车同步顶升钢箱梁(9),使钢箱梁(9)从钢箱梁胎架(8)上分离,多个运梁车同步运移钢箱梁(9)至钢箱梁装配端;步骤D、钢箱梁三维空间位置调节及装配:利用运梁车在运梁基础轨道(2)上移动确定钢箱梁(9)在桥梁延伸方向上的位置,利用运梁车主千斤顶(12)调节钢箱梁(9)的高度位置,利用运梁车辅千斤顶(21)水平推拉顶托(24)实现顶帽(15)连带钢箱梁(9)在桥梁宽度方向上的位置;待钢箱梁(9)的三维空间位置调节完成后,将钢箱梁(9)装配至钢箱梁装配端的端头,多个运梁车卸载对钢箱梁(9)的支撑并退回至下一节待安装的钢箱梁(9)底部;步骤E、多次循环步骤C和步骤D,直至钢箱梁装配结束。
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