Pushing box culvert jacking safety device

Abstract

This utility model discloses a safety device for jacking box culverts, consisting of a positioning detection system and a hydraulic execution system. The device uses a steel cutting edge welded to the front shell and tail sleeve as a guide base, and its trapezoidal cross-section structure enhances jacking stability. A network of laser rangefinders symmetrically arranged at the front and rear of the box culvert acquires three-dimensional spatial deviation data in real time, and combines this with attitude monitoring by dual three-axis tilt sensors to construct a dynamic posture model. Eight 200-ton hydraulic jacks are embedded in the mounting slot in a four-quadrant symmetrical layout, achieving vector thrust output through multiple independent hydraulic lines. Adjustable flow valves can precisely control the jacking force value at each point. The integrated control box uses a signal fusion algorithm to convert deviation data into hydraulic control commands, achieving millimeter-level dynamic correction. This device has fully automatic closed-loop control capabilities, solving the problem of lag in response to traditional manual correction, and is particularly suitable for jacking large-section box culverts under complex geological conditions.

Description

Technical Field

[0001] This utility model relates to the field of civil engineering construction technology, and more specifically to a safety device for jacking up box culverts. Background Technology

[0002] In the construction of box culverts passing under highways, traditional methods require the demolition and excavation of the existing highway, resulting in long construction periods, high costs, and significant safety hazards. While existing jacking construction techniques reduce earthwork excavation, the box culvert's axis is susceptible to deviations from the design trajectory due to geological conditions and uneven jacking force, leading to decreased construction quality and even structural damage. Conventional correction methods rely heavily on manual measurement and adjustment of jacks, which are inefficient and lack precision. Therefore, a highly automated device capable of real-time and accurate correction is urgently needed to improve construction efficiency and safety. Utility Model Content

[0003] The purpose of this invention is to provide a safety device for jacking box culverts, in order to solve the aforementioned technical problems. By integrating automated measurement with the linkage control of multiple sets of correction jacks, real-time monitoring and dynamic adjustment are achieved during the jacking process, ensuring that the box culvert axis is highly consistent with the design trajectory, thereby improving construction accuracy and efficiency.

[0004] The technical solution adopted by this utility model is as follows: A safety device for jacking up a box culvert includes: The steel cutting edge is formed by welding the front shell and the tail sleeve with high-strength steel plates to form a rigid frame. The axial section of the front shell is a trapezoid with a larger upper section and a smaller lower section. An installation groove is formed between the front shell and the tail sleeve. The laser positioning component, including a laser rangefinder, is fixedly installed at the top and left and right symmetrical points of the front shell section and the top and left and right symmetrical points of the tail section of the box culvert. The attitude detection component includes two triaxial tilt sensors, which are fixed to the centerline of the front shell and the centerline of the rear of the box duct by bolts, respectively. The hydraulic alignment assembly includes hydraulic jacks, which are symmetrically arranged in the mounting groove between the front shell and the tail sleeve. Each set of hydraulic jacks is rigidly connected to the mounting groove through a welded base. The hydraulic control assembly includes multiple hydraulic lines that are independently connected to each hydraulic jack. Each line is equipped with an adjustable flow valve, and each line is connected to a central hydraulic pump station. The electrical connection assembly includes a control box with an integrated signal processor, which is electrically connected to the laser rangefinder, tilt sensor, and adjustable flow valve via waterproof cables.

[0005] The rigid steel blade frame provides structural stability; multiple laser rangefinders enable three-dimensional spatial positioning and monitoring; dual triaxial tilt sensors accurately detect the pitch / tilt attitude of the box culvert; symmetrically arranged large-tonnage hydraulic jacks provide balanced correction force; independent hydraulic pipelines and adjustable flow valves enable precise pressure control; and an integrated electrical system enhances the level of automation, comprehensively ensuring the real-time correction efficiency and accuracy of the jacking construction.

[0006] Preferably, the mounting groove between the front shell and the tail sleeve is filled with a cross-shaped reinforcing rib welded inside.

[0007] Preferably, the welding base includes a circular base plate and a cylindrical support, the base plate is fully welded to the bottom surface of the mounting groove, and the top of the support is provided with a hemispherical hinge seat.

[0008] Preferably, the adjustable flow valve is an electromagnetic proportional valve, and a displacement sensor is integrated on its valve body. The displacement sensor is connected to the control box via an RS485 interface.

[0009] Preferably, the laser rangefinder is mounted on an adjustable gimbal, and the bottom of the gimbal is provided with a rotating base with a scale. The rotating base is fixed to the front shell and the rear end surface by expansion bolts.

[0010] Preferably, the joint of the waterproof cable is fitted with a corrugated pipe protective sleeve, and the two ends of the protective sleeve are fastened with hose clamps.

[0011] Preferably, the steel cutting edge is made of Q460C steel plate, the front shell is welded with a wear-resistant alloy liner, and the whole body is coated with epoxy zinc-rich primer after being heat-treated.

[0012] Preferably, the triaxial tilt sensor integrates a temperature compensation module and communicates with the control box via a CAN bus.

[0013] Preferably, the hydraulic pump station's oil outlet pipeline is equipped with a temperature sensor to monitor the hydraulic oil temperature in real time and transmit the data to the control box. When the oil temperature exceeds 60°C, the circulating water cooling system is automatically activated.

[0014] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are: 1. High-precision correction: Combining automated measurement and control technologies, the correction accuracy can reach the millimeter level, avoiding human error; 2. Improved construction efficiency: Real-time dynamic adjustments reduce downtime, with a single correction response time of less than 30 seconds; 3. Enhanced safety: Rigid support structure and redundant design of multiple sets of jacks prevent structural damage caused by local stress concentration; 4. Wide range of applications: It can be adapted to box culverts of different sizes and complex geological conditions, and has strong versatility. Attached Figure Description

[0015] This utility model will be described by way of example and with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the steel cutting edge of this utility model; Figure 2 This is a front view structural diagram of the steel blade angle of this utility model; Figure 3 This is a rear view structural schematic diagram of the steel blade angle of this utility model; Figure 4 This is a schematic diagram of the left-side structure of the steel blade angle of this utility model; The markings in the diagram are: 1-front shell, 11-rigid frame, 12-laser rangefinder, 13-through hole, 14-mounting slot, 15-hydraulic jack, 16-three-axis tilt sensor, 2-tail sleeve. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can typically be arranged and designed in various different configurations.

[0017] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0018] In one embodiment of this utility model, such as Figure 1-4 As shown, this embodiment provides a safety device for jacking a box culvert, including: The steel cutting edge is formed by welding the front shell 1 and the tail sleeve 2 with high-strength steel plates to form a rigid frame 11. The axial section of the front shell 1 is a trapezoid with a larger upper section and a smaller lower section. An installation groove 14 is formed between the front shell 1 and the tail sleeve 2. The tail sleeve 2 is connected to the box culvert and is corrected by hydraulic jacks 15. The front shell 1 is inserted into the ground in front, providing a safe digging space for the excavator loader. The laser positioning assembly includes 2-6 laser rangefinders 12, of which 1-3 are fixedly installed on the top and left and right symmetrical points of the front shell section 1, and the other 1-3 are installed on the top and left and right symmetrical points of the box culvert tail section. The attitude detection component includes two triaxial tilt sensors 16, which are respectively fixed to the centerline of the front shell 1 and the centerline of the rear of the box culvert by bolts. The hydraulic correction assembly includes eight sets of 200-ton hydraulic jacks 15, which are symmetrically arranged in the mounting groove 14 between the front shell 1 and the tail sleeve 2. Each set of hydraulic jacks 15 is rigidly connected to the mounting groove 14 through a welded base. The hydraulic control assembly includes multiple hydraulic lines that are independently connected to each hydraulic jack 15. Each line is equipped with an adjustable flow valve, and each line is connected to the central hydraulic pump station. The electrical connection assembly includes a control box with an integrated signal processor, which is electrically connected to the laser rangefinder 12, the tilt sensor, and the adjustable flow valve via waterproof cables.

[0019] The rigid steel blade frame provides structural stability; multiple laser rangefinders 12 enable three-dimensional spatial positioning and monitoring; dual triaxial tilt sensors 16 accurately detect the pitch / tilt attitude of the box culvert; symmetrically arranged large-tonnage hydraulic jacks 15 provide balanced correction force; independent hydraulic pipelines and adjustable flow valves enable precise pressure control; and an integrated electrical system enhances the level of automation, comprehensively ensuring the real-time correction efficiency and accuracy of the jacking construction.

[0020] In another embodiment of this utility model, the mounting groove 14 between the front shell 1 and the tail sleeve 2 has a depth of 300mm, and a cross-shaped reinforcing rib with a thickness of 20mm is welded inside the groove. The 300mm depth of the mounting groove 14 provides sufficient space for jack installation, and the cross-shaped reinforcing rib (20mm thick) significantly improves the deformation resistance of the mounting groove 14, ensuring the structural stability of the hydraulic components under high pressure conditions.

[0021] In another embodiment of this utility model, the welding base includes a circular base plate with a diameter of 300 mm and a cylindrical support with a height of 150 mm. The base plate is fully welded to the bottom surface of the mounting groove 14, and a hemispherical hinge seat is provided on the top of the support. The full welding of the circular base plate enhances the load-bearing capacity of the base, while the cylindrical support and hemispherical hinge seat disperse stress concentration, adapting to the complex stress state during the jacking process and reducing the risk of local fatigue cracking.

[0022] In another embodiment of this invention, the adjustable flow valve is an electromagnetic proportional valve, with a displacement sensor integrated on its valve body. The displacement sensor is connected to the control box via an RS485 interface. The electromagnetic proportional valve achieves stepless flow regulation, and the integrated displacement sensor provides feedback on the valve position via RS485, forming a closed-loop control and improving the dynamic response accuracy of hydraulic correction.

[0023] In another embodiment of this utility model, the laser rangefinder 12 is mounted on an adjustable gimbal. The bottom of the gimbal has a rotating base with a scale, which is fixed to the front shell 1 and the rear end surface by expansion bolts. The adjustable gimbal, together with the scale rotating base, supports multi-angle calibration of the laser rangefinder 12, adapts to the measurement needs of different construction scenarios, and reduces installation errors.

[0024] In another embodiment of this utility model, a corrugated pipe protective sleeve is fitted at the joint of the waterproof cable, and the two ends of the protective sleeve are fastened with hose clamps. The double seal of the corrugated pipe protective sleeve and the hose clamps effectively prevents mud and water from seeping into the cable joint, reduces the short-circuit failure rate, and extends the service life of the equipment in humid environments.

[0025] In another embodiment of this utility model, the steel cutting edge is made of Q460C steel plate, and a 30mm thick wear-resistant alloy liner is welded to the soil-facing surface of the front shell 1. The entire surface is then coated with epoxy zinc-rich primer after heat treatment. The combination of Q460C steel plate and 30mm wear-resistant liner enhances the cutting edge's impact resistance and wear resistance; the heat treatment and epoxy zinc-rich coating synergistically improve corrosion resistance, adapting to high-friction, gravel-laden pushing environments.

[0026] In another embodiment of this utility model, the triaxial tilt sensor 16 achieves a measurement accuracy of ±0.001°, integrates a temperature compensation module, and communicates with the control box via a CAN bus. The ±0.001° high-precision measurement combined with temperature compensation eliminates the influence of environmental temperature drift; the IP67 protection rating and CAN bus communication ensure stable data transmission by the sensor under harsh operating conditions.

[0027] In another embodiment of this utility model, a temperature sensor is installed in the oil outlet pipeline of the hydraulic pump station to monitor the hydraulic oil temperature in real time and transmit the data to the control box. When the oil temperature exceeds 60°C, the circulating water cooling system is automatically activated. The temperature sensor monitors the oil temperature in real time, and the 60°C threshold triggers the water cooling system to prevent high-temperature deterioration of the hydraulic oil, maintain system pressure stability, and prevent correction failure due to excessively high oil temperature.

[0028] In another embodiment of this invention, the control box incorporates a built-in PID control algorithm module. This module receives real-time data from the laser rangefinder 12 and the tilt sensor, calculates the compensation pressure value of each hydraulic jack 15 using a fuzzy control algorithm, and outputs adjustment commands to the electromagnetic proportional valve. The fusion of the PID algorithm and fuzzy control dynamically optimizes the jack pressure distribution, achieving adaptive correction under multi-sensor data linkage. This significantly reduces the intensity of manual intervention and improves the reliability of correction under complex geological conditions.

[0029] The working principle of this utility model is as follows: During the jacking process, the measurement and positioning system monitors the position of the box culvert axis in real time; if a deviation is detected, the control system automatically starts the corresponding correction jack according to the direction and magnitude of the deviation, and adjusts the attitude of the box culvert through jacking or retraction actions; the correction process is carried out continuously until the error between the box culvert axis and the design trajectory is less than the allowable threshold (±10mm).

[0030] This invention relates to a fully automated hydraulic jacking method for box culvert construction, an advanced underground engineering construction technology. This method utilizes eight 500-ton jacks, equipped with a fully automated hydraulic system working in tandem. Through the intelligent control of this system, the jacking force parameters for each jacking operation can be precisely optimized, ensuring that the jacking process is always under optimal conditions, thereby effectively improving construction efficiency and quality.

[0031] During construction, the position and attitude of the box culvert were monitored through precise measurement and layout before each jacking operation to determine in real time whether any deviation had occurred. When deviation occurred, the eight sets of 200-ton correction jacks set between the front shell 1 and the tail sleeve 2 could respond quickly and achieve rapid correction through precise pressure control, ensuring that the box culvert advanced accurately along the designed route.

[0032] The precast box culvert of this process adopts a design combining a rectangular steel cutting edge with an excavator loader. The rectangular steel cutting edge is rigidly connected to the first three box culvert sections, forming a stable load-bearing structure that effectively distributes the load from the superstructure. During the excavation and jacking process, the steel cutting edge is maintained in a "soil-eating and pushing" operation mode, allowing the excavator loader to perform full-section mechanical excavation within the protection range of the steel cutting edge. This design not only significantly reduces over-excavation and greatly improves construction speed, but also provides reliable safety guarantees for construction personnel and equipment.

[0033] The fully automated hydraulic jacking box culvert construction technology, with its advantages of automation and intelligence, achieves efficient and continuous operation during the construction process. Through the automated operation of mechanical equipment, this technology greatly reduces manpower requirements, significantly accelerates construction progress, and effectively saves construction costs, demonstrating excellent practicality and significant economic benefits. It has broad application prospects and promotional value in the field of underground engineering construction.

[0034] Taking a box culvert project under the Guiliu Expressway as an example, after adopting this device, the maximum deviation of the axis during the entire construction process was only 8mm, and the average correction response time was 25 seconds. The efficiency was improved compared with the traditional manual correction, and no rework or structural damage caused by deviation occurred.

Claims

1. A safety device for jacking up a box culvert, characterized in that, include: The steel cutting edge is formed by welding the front shell and the tail sleeve with high-strength steel plates to form a rigid frame. The axial section of the front shell is a trapezoid with a larger upper section and a smaller lower section. An installation groove is formed between the front shell and the tail sleeve. The laser positioning component, including a laser rangefinder, is fixedly installed at the top and left and right symmetrical points of the front shell section and the top and left and right symmetrical points of the tail section of the box culvert. The attitude detection component includes two triaxial tilt sensors, which are fixed to the centerline of the front shell and the centerline of the rear of the box duct by bolts, respectively. The hydraulic alignment assembly includes hydraulic jacks, which are symmetrically arranged in the mounting groove between the front shell and the tail sleeve. Each set of hydraulic jacks is rigidly connected to the mounting groove through a welded base. The hydraulic control assembly includes multiple hydraulic lines that are independently connected to each hydraulic jack. Each line is equipped with an adjustable flow valve, and each line is connected to a central hydraulic pump station. The electrical connection assembly includes a control box with an integrated signal processor, which is electrically connected to the laser rangefinder, tilt sensor, and adjustable flow valve via waterproof cables.

2. The jacking safety device for box culverts according to claim 1, characterized in that: The mounting groove between the front shell and the tail sleeve has a cross-shaped reinforcing rib welded inside.

3. The jacking safety device for box culverts according to claim 1, characterized in that: The welding base includes a circular base plate and a cylindrical support. The base plate is fully welded to the bottom surface of the mounting groove, and the top of the support is provided with a hemispherical hinge seat.

4. The jacking safety device of claim 1, wherein: The adjustable flow valve is an electromagnetic proportional valve, and its valve body integrates a displacement sensor, which is connected to the control box via an RS485 interface.

5. The jacking safety device of claim 1, wherein: The laser rangefinder is mounted on an adjustable gimbal. The bottom of the gimbal has a rotating base with a scale, which is fixed to the front shell and the rear end surface by expansion bolts.

6. The jacking safety device for box culverts according to claim 1, characterized in that: The joint of the waterproof cable is fitted with a corrugated pipe protective sleeve, and the two ends of the protective sleeve are fastened with hose clamps.

7. The jacking safety device for box culverts according to claim 1, characterized in that: The steel cutting edge is made of steel plate, and the front shell has a wear-resistant alloy liner welded to the soil-facing surface. The entire surface is coated with epoxy zinc-rich primer after being heat-treated.

8. The jacking safety device for box culverts according to claim 1, characterized in that: The triaxial tilt sensor integrates a temperature compensation module and communicates with the control box via a CAN bus.

9. The jacking safety device for box culverts according to claim 4, characterized in that: The hydraulic pump station's oil outlet pipeline is equipped with a temperature sensor.

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