High-pile wharf superstructure prefabricated component installation device and installation method

Abstract

The application discloses a high-pile wharf superstructure prefabricated component mounting device, which comprises a longitudinal beam assembly, a longitudinal beam transverse moving walking assembly, a cross beam assembly, a cross beam longitudinal moving walking assembly and a crown block; the cross beam walking assembly is arranged on the top surface of a pile cap which has been constructed, the cross beam assembly is arranged on the cross beam longitudinal moving walking assembly through a supporting leg assembly, and the longitudinal movement of the cross beam assembly is realized; the longitudinal beam assembly is connected to the cross beam assembly through the longitudinal beam transverse moving walking assembly, and the transverse movement of the longitudinal beam assembly is realized; and the crown block is movably arranged on the longitudinal beam assembly. The cross beam assembly comprises two cross beams, the two ends of the two cross beams are connected through cross beam pull rods, and the lower end surfaces of each of the cross beams are respectively connected with a supporting leg assembly. The application aims at overcoming the defects of the prior art and providing a high-pile wharf superstructure prefabricated component mounting device and a mounting method, and the construction efficiency and safety are improved, and the comprehensive cost is reduced.

Description

Technical Field

[0001] This invention relates to an installation device and method for prefabricated components of the superstructure of a high-pile wharf. Background Technology

[0002] High-pile wharves, as a core form of modern port hydraulic structures, dominate the construction of large-scale port projects along my country's coast and inland waterways due to their excellent wave-permeability, adaptability to soft soil foundations, and ease of maintenance. Their superstructures generally employ a prefabrication and on-site assembly construction method. Major components include berthing components, crossbeams, longitudinal beams, track beams, and various panels, characterized by their complexity, large individual component weight, stringent installation precision requirements, and dynamically complex operating environment. Especially in nearshore areas with significant tidal ranges and frequent waves, construction not only needs to address the compressed window of opportunity caused by sea state changes but also requires high-precision positioning within a limited space densely populated with existing pile foundations and structures. This places extremely high demands on the stability, environmental adaptability, and operational continuity of construction equipment.

[0003] Traditional high-pile wharf prefabricated component installation relies heavily on general-purpose lifting equipment such as floating cranes, crawler cranes, or truck cranes, supplemented by auxiliary systems such as temporary trestle bridges, support frames, or water barges. This approach played a significant role in the early construction of small and medium-sized wharves. Its technical logic lies in providing vertical lifting capacity through external lifting machinery, combined with manual measurement and temporary supports to achieve component placement.

[0004] However, as wharves become larger and deeper, and as construction efficiency and safety standards continue to improve, the inherent limitations of this model are becoming increasingly apparent. On the one hand, floating crane operations are severely constrained by tidal cycles and weather conditions, resulting in a narrow effective operating window and making it difficult to ensure a continuous construction rhythm. On the other hand, large crawler cranes or truck cranes on land often face difficulties in positioning and insufficient turning radius at narrow wharf fronts, especially when operating near existing structures, posing a risk of collision and making it difficult to cover cantilevered areas. More importantly, for cantilevered components such as berthing components without permanent bottom support, conventional lifting methods cannot provide effective temporary support, necessitating the erection of complex full-span scaffolding or underwater platforms. This not only significantly increases material and labor costs and prolongs the construction period but also significantly increases safety risks due to the combined high-altitude and water-based operations.

[0005] Therefore, in response to the above problems, an installation device and method for prefabricated components of the superstructure of a high-pile wharf are proposed. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing methods by providing a prefabricated component installation equipment and method for the superstructure of high-pile wharves, which improves construction efficiency and safety and reduces overall costs.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an installation device for prefabricated components of a high-pile wharf superstructure, comprising a longitudinal beam assembly, a longitudinal beam transverse movement assembly, a crossbeam assembly, a crossbeam longitudinal movement assembly, and a crane; The crossbeam traveling assembly is set on the top surface of the completed pile cap. The crossbeam assembly is set on the crossbeam longitudinal traveling assembly through the support leg assembly to realize the longitudinal movement of the crossbeam assembly. The longitudinal beam assembly is connected to the transverse beam assembly via the longitudinal beam lateral movement assembly, thereby enabling the longitudinal beam assembly to move laterally. The overhead crane is movably mounted on the longitudinal beam assembly.

[0008] Preferably, the crossbeam assembly includes two crossbeams, the two ends of which are connected by a crossbeam tie rod; each of the lower ends of each crossbeam is connected to a support leg assembly.

[0009] Preferably, the outrigger assembly includes a fixed outrigger, and a hydraulic cylinder is disposed inside the fixed outrigger. The output end of the hydraulic cylinder is connected upward to the lower end face of the crossbeam; the lower end of the fixed outrigger is connected to the longitudinal movement assembly of the crossbeam.

[0010] Preferably, the longitudinal movement assembly of the crossbeam includes a longitudinal track and a longitudinal movement device; the longitudinal track is set on the top surface of the completed pile cap, the longitudinal movement device is movably connected to the longitudinal track, and the lower end of the fixed support leg is connected to the longitudinal movement device.

[0011] Preferably, the longitudinal beam assembly includes two longitudinal beams, and the two ends of the two longitudinal beams are connected by longitudinal beam tie rods.

[0012] Preferably, the longitudinal beam lateral movement assembly includes a lateral movement track and a lateral movement device; the lateral movement track is disposed at the upper end of the crossbeam, the lateral movement device is movably connected to the lateral movement track, and the upper end of the lateral movement device is connected to the longitudinal beam.

[0013] Preferably, the overhead crane includes a hoisting device for lifting, a special lifting tool for lifting, and a crane longitudinal movement device for its own movement; the longitudinal beam is provided with a crane longitudinal movement track for the crane longitudinal movement device to move.

[0014] Preferably, it also includes a PLC control unit, which is communicatively connected to the longitudinal beam transverse travel assembly, the transverse beam longitudinal travel assembly, and the overhead crane.

[0015] It also includes four temporary support legs, which are connected to the two ends of the lower face of the two crossbeams via quick-release components; The quick-release assembly includes a top plate, and each temporary support leg is connected to a top plate at its upper end. The top plate is connected to the lower end face of the crossbeam by fastening bolts.

[0016] An installation method for a precast component installation device for a high-pile wharf superstructure includes the following steps: Step S1, on-site equipment assembly: Lay longitudinal tracks on the top surface of the completed pile caps, install longitudinal moving devices on the tracks, connect a fixed support leg to the upper end of each longitudinal moving device, hoist the crossbeam to the top of the hydraulic cylinder inside the fixed support leg and connect it; install the transverse moving device on the longitudinal beam, hoist the longitudinal beam to install the transverse moving device onto the transverse track at the upper end of the crossbeam; install the overhead crane onto the overhead crane longitudinal moving track on the longitudinal beam; after installation, complete the wiring and debugging of the electrical and hydraulic systems. Step S2, transportation and acceptance of precast components: After the components are transported to the site, quality acceptance is carried out. When loading, a multi-point support method is used at the designed support position of the component. The component and the transport vehicle are locked together by a manual hoist and a steel wire rope. The contact part between the steel wire rope and the component is wrapped with a rubber pad. Step S3, Measurement and Layout and Grouting Treatment: Mark out the component installation control line on the top surface of the pile cap and check the elevation. Lay cement mortar on the component support surface. Step S4, Component Installation: Control the overall installation direction to advance from the far end frame to the near end frame. In each span, first install the two side berthing components and side beams, and then install other beam and slab components in sequence. In the berthing component installation step, install steel clamps made of two semi-circular steel plates fastened with high-strength bolts on the corresponding pile foundation. I-beams are erected on the top of the steel clamps as temporary longitudinal beams. The through holes reserved in the berthing component are inserted into the I-beams. Horizontal limiting steel bars are welded on the pile clamping steel to limit the inner displacement of the berthing component. The component elevation is adjusted by inserting steel plate spacers of different thicknesses. After the component is in place, the I-beams are temporarily welded to the steel clamps. In the conventional beam and slab installation step, the beam transport vehicle transports the prefabricated components to the area below the equipment. The overhead crane lifts them with a special lifting tool and moves them to the target position through three-way linkage for precise positioning. In the panel reverse installation mode step, the outriggers are retracted so that the top of the outriggers is higher than the top surface of the installed panel to avoid interference with movement, and then the panel components are installed. Step S5, Equipment dismantling: Dismantle each component of the equipment in reverse order.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: The installation equipment and method for prefabricated components of the superstructure of the high-pile wharf integrate hoisting, walking, and leveling functions into one unit. The equipment can walk directly on the existing pile caps without relying on tidal windows, enabling all-weather operation. The three-way walking system, combined with precision measurement and control, ensures that the component installation positioning accuracy is within ±3 mm. To address the problem of the lack of lower support for berthing components, a composite temporary support system consisting of steel clamps, perforated I40b I-beams, horizontal limiting steel bars, adjustable pads, and temporary welding is adopted to complete safe installation without the need for large-scale scaffolding. The main structure of the equipment adopts segmented manufacturing, pin hinges, and high-strength bolt connections, facilitating land transportation, rapid on-site assembly, and reuse. During component transportation, multi-point support, manual hoist locking, and rubber isolation measures effectively prevent transportation damage. Adjustable outrigger height and temporary outrigger configuration allow the equipment to adapt to special working conditions such as reverse panel installation, expanding its application range. The above technical solution can stably install prestressed track beams with a maximum weight of 49.56 tons, and is suitable for the installation of precast components in various high-pile wharves. It enables all-weather operation without tidal dependence, precise positioning and installation of unsupported components such as berthing components, and supports reverse panel installation, improving construction efficiency and safety. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is an isometric view of the prefabricated component installation equipment for the superstructure of the high-pile wharf of the present invention; Figure 2 This is an isometric view from another perspective of the installation equipment for the prefabricated components of the high-pile wharf superstructure of the present invention; Figure 3 This is a rear view of the prefabricated component installation equipment for the superstructure of the high-pile wharf according to the present invention. Figure 4 for Figure 3 Enlarged view of point A in the middle; Figure 5 This is a schematic diagram of the installation method of the prefabricated component installation equipment for the superstructure of the high-pile wharf according to the present invention.

[0019] In the diagram: 1. Overhead crane; 2. Crossbeam; 3. Crossbeam tie rod; 4. Fixed outrigger; 5. Longitudinal track; 6. Longitudinal traveling device; 7. Longitudinal beam; 8. Longitudinal beam tie rod; 9. Lateral track; 10. Lateral traveling device; 11. Overhead crane longitudinal track; 12. Temporary outrigger; 13. Top plate; 14. Fastening bolts. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] like Figures 1-4 As shown, a precast component installation device for the superstructure of a high-pile wharf includes a longitudinal beam assembly, a longitudinal beam lateral movement assembly, a crossbeam assembly, a crossbeam longitudinal movement assembly, and a crane 1. The crossbeam movement assembly is set on the top surface of the completed pile caps, and the crossbeam assembly is mounted on the crossbeam longitudinal movement assembly via support leg assemblies to achieve longitudinal movement of the crossbeam assembly. The longitudinal beam assembly is connected to the crossbeam assembly via the longitudinal beam lateral movement assembly to achieve lateral movement of the longitudinal beam assembly. The crane 1 is movably mounted on the longitudinal beam assembly.

[0022] The equipment for installing precast components of the superstructure of this high-pile wharf forms a specialized equipment system that can autonomously walk, precisely position, and efficiently install various precast components on the top surface of the completed pile caps.

[0023] Specifically, the crossbeam assembly includes two crossbeams 2, with the two ends of the two crossbeams 2 connected by crossbeam tie rods 3; each of the two ends of the lower end face of each crossbeam 2 is connected to a support leg assembly.

[0024] Specifically, the outrigger assembly includes a fixed outrigger 4, which has an outrigger hydraulic cylinder inside. The output end of the outrigger hydraulic cylinder is connected upward to the lower end face of the crossbeam 2. The lower end of the fixed outrigger 4 is connected to the longitudinal movement component of the crossbeam.

[0025] Specifically, the crossbeam longitudinal movement assembly includes a longitudinal track 5 and a longitudinal movement device 6; the longitudinal track 5 is set on the top surface of the completed pile cap, the longitudinal movement device 6 is movably connected to the longitudinal track 5, and the lower end of the fixed support leg 4 is connected to the longitudinal movement device 6.

[0026] Specifically, the center-to-center distance between the two crossbeams 2 is 27 meters. Each row of crossbeams 2 consists of five truss segments connected by pins, with lengths of 11.5 meters, 14.5 meters, 11.5 meters, 14.5 meters, and 11.5 meters respectively, for a total length of 63.5 meters. The main body of crossbeam 2 adopts a triangular truss structure welded from H-beams and square tubes, which has good longitudinal load-bearing capacity and torsional resistance. A walkway is integrated on the outside of the crossbeam for easy inspection and maintenance.

[0027] Specifically, the outrigger assembly includes two sets of fixed outriggers with a longitudinal center distance of 26 meters. Each set of fixed outriggers integrates an outrigger hydraulic cylinder with a stroke of ±300 mm, which is used to adjust the height of the entire machine and achieve horizontal leveling.

[0028] It also includes four temporary support legs 12, which are connected to the lower ends of the two crossbeams 2 via quick-release assemblies. Each quick-release assembly includes a top plate 13, with the upper end of each temporary support leg 12 connected to a top plate 13. The top plate 13 is connected to the lower end of the crossbeam 2 via fastening bolts 14. The temporary support legs 12 are installed to support the crossbeam 2 during operation. When the crossbeam 2 moves, the temporary support legs 12 are removed, and after movement, they are reinstalled to support the crossbeam 2.

[0029] Temporary outriggers 12 are symmetrically positioned 12 meters from the longitudinal centerline of the crossbeam 2, with one set on each side. These temporary outriggers also have built-in hydraulic cylinders to provide auxiliary support during reverse panel installation or large cantilever conditions. The crossbeam and outriggers are connected by M30 high-strength bolts, with shear keyways and locating pins at the connection points to prevent relative slippage.

[0030] Specifically, the longitudinal traversing device 6 includes a drive motor, a reducer, a set of traveling wheels, and a braking device. The traveling wheels are in contact with the longitudinal track 5, which uses P43 type steel rails and is laid along the length of the wharf on the top surface of the completed pile caps. The track gauge is 27 meters, consistent with the center distance of the crossbeams. Track pads and supporting structures are installed under the track to distribute the load and ensure that the track maintains geometric stability during long-term use. The maximum running speed of the traveling wheels along the track is 12 meters per minute. It is also equipped with an encoder feedback device, forming a closed-loop control system with the PLC control unit to achieve precise positioning of the entire machine in the longitudinal direction.

[0031] The main body of the longitudinal traversing device 6 is the traveling frame, which is welded from structural steel and has an overall frame structure to balance structural strength and weight optimization. The top surface of the traveling frame is equipped with a connecting flange, which is detachably connected to the lower end of the fixed support leg 4 via high-strength bolts. Elastic gaskets are added at the connection points to buffer vibration loads during operation, and to facilitate installation, debugging, and subsequent maintenance and replacement. The bottom surface of the traveling frame has a pre-drilled guide groove adapted to the longitudinal track 5. Wear-resistant liners made of high-manganese steel are installed inside the guide grooves and fixed to the frame with countersunk bolts, effectively reducing wear when in contact with the track and extending the device's service life.

[0032] The longitudinal traversing device 6 is equipped with a double-sided guide positioning wheel mechanism. The guide positioning wheels are mounted on both sides of the traveling frame and elastically connected to the frame via brackets. The wheel surfaces of the positioning wheels are in close contact with the sides of the longitudinal traversing track 5, allowing for real-time correction of device offset and preventing deviation caused by uneven load or track errors. Simultaneously, the traveling frame is also equipped with travel limit switches, which are fixed to both ends of the frame via brackets. When the device moves to the extreme position at the end of the track, the limit switch contacts the stop block at the end of the track, triggering the motor to stop, thus achieving mechanical limit protection for the longitudinal traversal and preventing damage to the equipment due to overtraversal.

[0033] Specifically, the longitudinal beam assembly includes two longitudinal beams 7, and the two ends of the two longitudinal beams 7 are connected by longitudinal beam tie rods 8.

[0034] Specifically, the two longitudinal beams 7 are spaced 3.2 meters apart. Each longitudinal beam 7 consists of three truss segments connected by pins, with lengths of 16.625 meters, 14.75 meters, and 16.625 meters respectively, for a total length of 48 meters. The main body of the longitudinal beam 7 adopts a four-truss structure welded from H-beams and square tubes, possessing high bending stiffness and overall stability. The longitudinal beam tie rods 8 connect the two rows of longitudinal beams to enhance lateral stiffness and prevent lateral instability under eccentric lifting loads.

[0035] Specifically, it also includes a longitudinal beam platform, which is fixed to the top of the longitudinal beam 7 for operators to pass through and for equipment maintenance. The platform surface is covered with anti-slip steel plates and equipped with safety railings.

[0036] Specifically, the longitudinal beam transverse movement assembly includes a transverse track 9 and a transverse movement device 10; the transverse track 9 is located at the upper end of the transverse beam 2, the transverse movement device 10 is movably connected to the transverse track 9, and the upper end of the transverse movement device 10 is connected to the longitudinal beam 7.

[0037] Specifically, the lateral moving device 10 is installed below the end of the longitudinal beam and can move laterally on a pre-set track on the top surface of the crossbeam 2. The center distance between the tracks is 27 meters. The lateral moving device 10 cantileveres 10.5 meters on each side to cover the front area of ​​the wharf and meet the installation requirements of special locations such as berthing components. The longitudinal beam 7 and the lateral moving device 10 are connected by M30 high-strength bolts, and the connection surface is provided with positioning pin holes to ensure assembly accuracy.

[0038] Specifically, the lateral movement device 10 includes a lateral base, a lateral drive motor, a lateral reducer, a lateral wheel set, and a lateral track 9. The lateral track 9 is fixed to the crossbeam 2, and the lateral wheel set rolls in contact with the lateral track 9. The lateral drive motor is connected to the lateral reducer via a coupling, and the output shaft of the lateral reducer drives the lateral wheel set to rotate, thereby causing the longitudinal beam 7 to move laterally along the lateral track 9. The lateral base is fastened to the bottom of the longitudinal beam 7 with M30 high-strength bolts, and the connection interface has double locating pin holes to ensure the stability of the longitudinal beam's posture during lateral movement. The lateral movement speed of the lateral movement device 10 is 0 to 6 meters per minute. It is equipped with an encoder feedback device to transmit position information to the PLC control unit in real time, forming a closed-loop control circuit to ensure precise and controllable motion trajectory.

[0039] The lateral movement device 10 is used to drive the longitudinal beam 7 to move smoothly and accurately along the lateral movement track 9 at the upper end of the crossbeam 2. The main body of the lateral movement device 10 is an integrated load-bearing frame, welded from Q355B steel, which ensures both the connection rigidity with the longitudinal beam 7 and the ability to accommodate the nested installation of the lateral movement track 9. The top surface of the load-bearing frame is machined with a flat connecting surface, which is fastened to the lower flange of the longitudinal beam 7 by high-strength bolts. Cross-shaped reinforcing ribs are added at the connection, with a rib thickness of not less than 12mm, to effectively distribute the vertical load transmitted by the longitudinal beam and avoid structural deformation caused by local stress concentration. The inner side wall of the frame has a reserved track clearance groove, and the groove wall is pasted with polyurethane wear-resistant strips to prevent direct friction between the frame and the side of the track, while also playing a buffering and vibration reduction role, and adapting to the slight flatness error that may exist at the upper end of the crossbeam.

[0040] Specifically, the overhead crane 1 includes a hoisting device for lifting, a special lifting tool for lifting, and a crane longitudinal movement device for its own movement; the longitudinal beam 7 is provided with a crane longitudinal movement track 11 for the crane longitudinal movement device to move.

[0041] Specifically, the rated lifting capacity of the overhead crane 1 is 80 tons; the overhead crane 1 integrates a hoisting device, a crane longitudinal movement device and a special lifting tool, wherein the hoisting device adopts frequency conversion speed regulation control, and the hoisting speed can be steplessly adjusted within the range of 0 to 8 meters per minute; the maximum running speed of the crane longitudinal movement device along the longitudinal beam 7 is 15 meters per minute.

[0042] Specifically, it also includes a PLC control unit, which is connected to the longitudinal beam transverse travel assembly, the transverse beam longitudinal travel assembly, and the overhead crane 1 via communication.

[0043] Specifically, the PLC control unit integrates the electrical and hydraulic systems. It features both wireless remote control and local operation modes, supporting both remote operation and on-site manual intervention, enhancing operational flexibility and safety. The hydraulic system is driven by an electric hydraulic pump station, controlling the outrigger lifting, longitudinal beam lateral movement, and crane hoisting and running actions. The entire machine achieves precise positioning of precast components at any installation location in three-dimensional space through a three-way linkage mechanism of longitudinal movement, longitudinal beam lateral movement, and crane operation, with a positioning repeatability accuracy of no more than ±3 mm.

[0044] Specifically, the specialized lifting equipment includes a main lifting beam, an adjustable lifting point crossbeam, wire rope slings, and a rotary locking mechanism. The main lifting beam is connected to the overhead crane's lifting pulley system at both ends via pins. The adjustable lifting point crossbeam moves laterally along the main lifting beam via a sliding groove structure and is locked in a preset position by limit bolts to accommodate the lifting point arrangement requirements of precast components of different widths. One end of the wire rope sling is connected to the adjustable lifting point crossbeam, and the other end is connected to the pre-embedded lifting ring on the precast component. The rotary locking mechanism is located at the connection between the adjustable lifting point crossbeam and the main lifting beam, used to fine-tune the component's planar angle after it is positioned, ensuring axis alignment. This lifting equipment structure effectively prevents components from twisting or tilting during lifting, improving installation accuracy and safety.

[0045] like Figure 5 As shown, an installation method for a precast component installation device for a high-pile wharf superstructure includes the following steps: Step S1, on-site equipment assembly: Lay longitudinal track 5 on the top surface of the completed pile cap, set longitudinal travel device 6 on longitudinal track 5, connect a fixed support leg 4 to the upper end of each longitudinal travel device 6, hoist the crossbeam 2 to the upper part of the support leg hydraulic cylinder inside the fixed support leg 4 and connect it, install temporary support legs 12 at both ends of the crossbeam 2 to support the crossbeam 2; install the transverse travel device 10 on the longitudinal beam 7, hoist the longitudinal beam 7 to install the transverse travel device 10 onto the transverse track 9 at the upper end of the crossbeam 2; hoist the overhead crane 1 onto the overhead crane longitudinal travel track 11 on the longitudinal beam 7; after installation, complete the wiring and debugging of the electrical and hydraulic systems. Step S2, transportation and acceptance of precast components: After the components are transported to the site, quality acceptance is carried out. When loading, a multi-point support method is used at the designed support position of the component. The component and the transport vehicle are locked together by a manual hoist and a steel wire rope. The contact part between the steel wire rope and the component is wrapped with a rubber pad. In the transportation and acceptance of precast components, after the components are transported to the site by land, their concrete strength reports, dimensional deviations, embedded part positions, and appearance quality are verified. During loading, a multi-point support method is used, with the support points located at the designed support positions of the components. The support material is hardwood, and rubber or sheet metal insulation layers are added to the corners of the components. The components are locked to the flatbed of the transport vehicle using six 2-3 ton manual hoists with 28 mm diameter steel wire ropes. The contact points between the steel wire ropes and the components are wrapped with rubber pads at least 3 mm thick to prevent displacement or damage to the components due to vibration or sudden braking during transportation.

[0046] Step S3, Measurement and Layout and Grouting Treatment: Mark out the component installation control line on the top surface of the pile cap and check the elevation. Lay cement mortar on the component support surface. In the measurement and layout process, a total station is used to mark the component installation axis, end line and elevation control points on the top surface of the pile cap. A level is used to verify the elevation of the support surface, and the error is controlled within ±2 mm. Installation ink lines are then marked on the pile cap as the reference for component placement.

[0047] In the grouting process, M20 cement mortar is laid on the surface where the component rests. The mortar thickness is 10 to 20 mm, and the laying area is slightly larger than the bottom surface of the component. The mortar surface has an outer slope that is higher than the inner slope, with a height difference of 2 to 3 mm, in order to facilitate the removal of air and ensure that the grouting is dense.

[0048] Step S4, Component Installation: Control the overall installation direction to advance from the far end frame to the near end frame. In each span, first install the two side berthing components and side beams, and then install other beam and slab components in sequence. In the berthing component installation step, install steel clamps made of two semi-circular steel plates fastened with high-strength bolts on the corresponding pile foundation. I-beams are erected on the top of the steel clamps as temporary longitudinal beams. The through holes reserved in the berthing component are inserted into the I-beams. Horizontal limiting steel bars are welded on the clamping steel to limit the inner displacement of the berthing component. The component elevation is adjusted by inserting steel plate spacers of different thicknesses. After the component is in place, the I-beams are temporarily welded to the steel clamps. In the conventional beam and slab installation step, the beam transport vehicle transports the precast components to the area below the equipment. The overhead crane 1 lifts them with a special lifting tool and moves them to the target position through three-way linkage for precise positioning. In the panel reverse installation mode step, the outriggers are retracted so that the top of the outriggers is higher than the top surface of the installed panel to avoid interference with movement, and then the panel components are installed. In the component installation sequence control step, the overall installation direction is to advance from 80 rows of frames to 1 row of frames. In each span, the two side berth components and side beams are installed first, and then the cross beams, longitudinal beams and panels are installed in sequence towards the middle trestle bridge to ensure that the overall stability of the structure is gradually established and to avoid safety hazards caused by excessive local cantilever.

[0049] In the unsupported installation of the berthing components, steel clamps are installed on the corresponding pile foundations. The clamps consist of two semi-circular steel plates secured to the pile body with high-strength bolts. I40b I-beams are erected on top of the clamps as temporary longitudinal beams. Four through holes are pre-drilled in each berthing component, and one I40b I-beam is inserted into each hole, for a total of four beams. Horizontal restraint bars with a diameter of 16 mm are welded to the clamping steel to limit the inward displacement of the berthing components. The component elevation is adjusted by inserting Q235 steel plate spacers with a thickness of 2 mm, 3 mm, or 5 mm to compensate for settlement caused by the deflection of the I-beams. After the components are in place, the I40b I-beams and steel clamps are temporarily welded together using E43 welding rods, with a weld length of not less than 100 mm, forming a reliable temporary support system to ensure the safe installation of the berthing components without permanent lower support.

[0050] In the standard beam installation process, a beam transport vehicle carries precast crossbeams, longitudinal beams, or track beams to the area beneath the equipment via an intermediate steel trestle. A crane then lifts the components using specialized lifting equipment, moves them along the longitudinal beam direction to the target span, and achieves precise positioning through trolley operation and fine-tuning. After positioning, the four corner elevations and axis deviations are checked; once they meet the requirements, the hooks are released. The entire process relies on a three-way linkage control system, combined with real-time feedback position data, to ensure a high success rate of first-time component placement and reduce efficiency losses caused by repeated adjustments.

[0051] In the panel reverse installation mode, retract all four sets of support legs to their maximum height, ensuring the top of the support legs is at least 200 mm above the top surface of the installed panel to avoid interference with movement. The remaining installation steps are the same as the conventional beam and slab installation, suitable for special working conditions where subsequent panels need to be installed from above the completed panel.

[0052] Step S5, Equipment dismantling: Dismantle each component of the equipment in reverse order.

[0053] During the equipment dismantling process, the overhead crane 1, longitudinal beam tie rod 8, longitudinal beam 7, cross beam tie rod 3, cross beam 2, temporary support legs, fixed support legs 4, and longitudinal track 5 are dismantled in reverse order. The dismantling and hoisting are completed with the assistance of a truck crane, and each component is transported away from the site by road, realizing the rapid dismantling and reuse of the equipment.

[0054] To verify the actual effect of the technical solution of the present invention, the following embodiments and comparative experiments were conducted.

[0055] In one specific embodiment, the equipment and method described in this invention were used to install prestressed track beams in a coastal high-pile wharf project. Each track beam weighs 49.56 tons, is 28.5 meters long, and has a cross-sectional dimension of 1.2 meters × 1.8 meters. During installation, the tidal water level fluctuated by 3.2 meters, and the traditional floating crane operating window was less than 4 hours per day. Using the equipment of this invention, the entire machine moves autonomously on the existing pile caps, unaffected by tides, allowing for continuous operation around the clock. The component installation and positioning were verified using a PLC closed-loop control system and a total station. The final measured axis deviation was ±2.1 mm, and the maximum elevation difference at the four corners was 2.8 mm, meeting the design requirements (allowable deviation ±5 mm). The berthing components were installed using a supportless installation process; the temporary support system was stable and reliable, and no displacement or overturning accidents occurred. The overall installation cycle was shortened by 37% compared to traditional methods.

[0056] As a comparison, similar components were installed using a traditional crane vessel to lift prefabricated parts. Because the crane vessel needs to adjust its height according to the tides, the average effective working time per day is only 8 hours. During the component lifting process, the positioning is repeatedly adjusted due to the influence of wind and waves, resulting in a significant increase in the average installation time per component and substantial deviations in installation accuracy.

[0057] The table below compares the key performance indicators of the embodiments and comparative examples: The above data demonstrates that this invention, through its integrated hoisting, traveling, and leveling functions via a double-layer modular truss structure, achieves all-weather operation capability, high-precision positioning control, and safe installation of unsupported components for the installation of precast components at high-pile wharves. The main structure of the equipment utilizes segmented manufacturing, pin-hinge connections, and high-strength bolt connections, facilitating land transportation, rapid on-site assembly, and reuse, significantly improving construction efficiency and safety while reducing overall costs. This technical solution can stably install prestressed track beams with a maximum weight of 49.56 tons and is applicable to various high-pile wharf precast component installation projects, possessing broad engineering application value.

[0058] The equipment and method for installing precast components of the superstructure of this high-pile wharf integrate hoisting, walking, and leveling functions into one unit. The equipment can walk directly on the existing pile caps without relying on tidal windows, enabling all-weather operation. The three-way walking system, combined with precision measurement and control, ensures that the positioning accuracy of the components is within ±3 mm. To address the problem of the lack of lower support for the berthing components, a composite temporary support system consisting of steel clamps, perforated I40b I-beams, horizontal limiting steel bars, adjustable pads, and temporary welding is adopted to complete the safe installation without erecting large scaffolding. The main structure of the equipment adopts segmented manufacturing, pin hinges, and high-strength bolt connections, facilitating land transportation, rapid on-site assembly, and reuse. During component transportation, multi-point support, manual hoist locking, and rubber isolation measures effectively prevent transportation damage. Adjustable outrigger height and temporary outrigger configuration allow the equipment to adapt to special working conditions such as reverse panel installation, expanding its application range. The above technical solution can stably install prestressed track beams with a maximum weight of 49.56 tons, and is suitable for the installation of precast components in various high-pile wharves. It enables all-weather operation without tidal dependence, precise positioning and installation of unsupported components such as berthing components, and supports reverse panel installation, improving construction efficiency and safety.

[0059] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An installation device for prefabricated components of a high-pile wharf superstructure, characterized in that, Includes longitudinal beam assembly, longitudinal beam transverse travel assembly, crossbeam assembly, crossbeam longitudinal travel assembly and overhead crane (1); The crossbeam traveling assembly is set on the top surface of the completed pile cap. The crossbeam assembly is set on the crossbeam longitudinal traveling assembly through the support leg assembly to realize the longitudinal movement of the crossbeam assembly. The longitudinal beam assembly is connected to the transverse beam assembly via the longitudinal beam lateral movement assembly, thereby enabling the longitudinal beam assembly to move laterally. The overhead crane (1) is movably mounted on the longitudinal beam assembly.

2. The installation equipment for prefabricated components of the high-pile wharf superstructure according to claim 1, characterized in that, The crossbeam assembly includes two crossbeams (2), and the two ends of the two crossbeams (2) are connected by a crossbeam tie rod (3); each of the two ends of the lower end face of each crossbeam (2) is connected to a support leg assembly.

3. The installation equipment for prefabricated components of the high-pile wharf superstructure according to claim 2, characterized in that, The outrigger assembly includes a fixed outrigger (4), which is equipped with an outrigger hydraulic cylinder. The output end of the outrigger hydraulic cylinder is connected upward to the lower end face of the crossbeam (2). The lower end of the fixed outrigger (4) is connected to the crossbeam longitudinal movement assembly.

4. The installation equipment for prefabricated components of the high-pile wharf superstructure according to claim 3, characterized in that, The longitudinal moving component of the crossbeam includes a longitudinal moving track (5) and a longitudinal moving device (6); the longitudinal moving track (5) is set on the top surface of the completed pile cap, the longitudinal moving device (6) is movably connected to the longitudinal moving track (5), and the lower end of the fixed support leg (4) is connected to the longitudinal moving device (6).

5. The installation equipment for prefabricated components of the superstructure of a high-pile wharf according to claim 2, characterized in that, The longitudinal beam assembly includes two longitudinal beams (7), and the two ends of the two longitudinal beams (7) are connected by longitudinal beam tie rods (8).

6. The installation equipment for prefabricated components of the high-pile wharf superstructure according to claim 5, characterized in that, The longitudinal beam transverse movement assembly includes a transverse track (9) and a transverse movement device (10); the transverse track (9) is located at the upper end of the transverse beam (2), the transverse movement device (10) is movably connected to the transverse track (9), and the upper end of the transverse movement device (10) is connected to the longitudinal beam (7).

7. The installation equipment for prefabricated components of the superstructure of a high-pile wharf according to claim 5, characterized in that, The overhead crane (1) includes a hoisting device for lifting, a special lifting tool for lifting, and a crane longitudinal movement device for its own movement; the longitudinal beam (7) is provided with a crane longitudinal movement track (11) for the crane longitudinal movement device to move.

8. The installation equipment for prefabricated components of the superstructure of a high-pile wharf according to claim 5, characterized in that, It also includes a PLC control unit, which is communicatively connected to the longitudinal beam transverse movement assembly, the transverse beam longitudinal movement assembly and the overhead crane (1).

9. The installation equipment for prefabricated components of the superstructure of a high-pile wharf according to claim 2, characterized in that, It also includes four temporary support legs (12), which are connected to the two ends of the lower face of the two crossbeams (2) by quick-release assembly; The quick-release assembly includes a top plate (13), and the upper end of each temporary support leg (12) is connected to a top plate (13). The top plate (13) is connected to the lower end face of the crossbeam (2) by fastening bolts (14).

10. An installation method for the prefabricated component installation equipment for the superstructure of a high-pile wharf as described in claim 1, characterized in that, Includes the following steps: Step S1, on-site equipment assembly: Lay a longitudinal track (5) on the top surface of the completed pile cap, set a longitudinal moving device (6) on the longitudinal track (5), connect a fixed support leg (4) to the upper end of each longitudinal moving device (6), hoist the crossbeam (2) to the upper part of the support leg hydraulic cylinder inside the fixed support leg (4) and connect it; install the transverse moving device (10) on the longitudinal beam (7), hoist the longitudinal beam (7) to install the transverse moving device (10) on the transverse track (9) at the upper end of the crossbeam (2); hoist the overhead crane (1) to the overhead crane longitudinal moving track (11) on the longitudinal beam (7); after the installation is completed, complete the wiring and debugging of the electrical and hydraulic systems; Step S2, transportation and acceptance of precast components: After the components are transported to the site, quality acceptance is carried out. When loading, a multi-point support method is used at the designed support position of the component. The component and the transport vehicle are locked together by a manual hoist and a steel wire rope. The contact part between the steel wire rope and the component is wrapped with a rubber pad. Step S3, Measurement and Layout and Grouting Treatment: Mark out the component installation control line on the top surface of the pile cap and check the elevation. Lay cement mortar on the component support surface. Step S4, component installation: control the overall installation direction to advance from the far end frame to the near end frame, first install the two sides of the berthing components and the side beams in each span, and then install other beam and slab components in sequence; in the berthing component installation step, install steel clamps with two semi-circular steel plates fastened by high-strength bolts on the corresponding pile foundation, erect I-beams as temporary longitudinal beams on the top of the steel clamps, insert the through holes reserved in the berthing component into the I-beams, weld horizontal limiting steel bars on the clamping steel to limit the inner displacement of the berthing component, adjust the component elevation by inserting steel plate pads of different thicknesses, and temporarily weld the I-beams and the steel clamps after the component is in place; in the conventional beam and slab installation step, the beam transport vehicle transports the precast components to the bottom of the equipment, and the overhead crane (1) lifts them with special lifting tools, moves them to the target position through three-way linkage and then accurately positions them; in the panel reverse installation mode step, retract the legs so that the top of the legs is higher than the top surface of the installed panel by a certain height to avoid walking interference, and then install the panel components; Step S5, Equipment dismantling: Dismantle each component of the equipment in reverse order.

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