A large-tonnage, large-diameter integral rotating support installation device and installation method

Abstract

This invention belongs to the technical field of bridge slewing bearings, specifically relating to an installation device and method for a large-tonnage, large-diameter integral slewing bearing. It includes a lower slewing plate, an upper slewing plate, and a slewing bearing positioned between the lower and upper slewing plates. A rotation system is also provided between the lower end face of the upper slewing plate and the lower end face of the lower slewing plate. The lower and upper slewing plates are rotatably connected via the slewing bearing. The slewing bearing includes a lower ball joint fixed to the lower slewing plate and an upper ball joint fixed to the upper slewing plate, rotatably connected to each other. A limiting pin is provided at the center of the lower ball joint. This invention enables the rotation of large bridges, ensuring that traffic is not affected during construction. Furthermore, the support legs and annular steel plate slides of this invention ensure the force balance of the box girder during rotation, preventing tilting. The embedded plate serves as an emergency rotation mechanism; even if the upper and lower ball joints become stuck and cannot rotate, the embedded plate can be used to continue rotating into position.

Description

Technical Field

[0001] This invention belongs to the field of bridge slewing bearing technology, specifically relating to a large-tonnage, large-diameter integral slewing bearing installation device and installation method. Background Technology

[0002] Construction is significantly affected by railway conditions on sections of railway lines with frequent train traffic and high speeds. Ensuring both the safe and smooth progress of bridge construction and the normal operation of the railway line during construction presents considerable challenges and is a major hurdle in the project.

[0003] To address this challenge, the T-shaped bridge project employed a planar rotation construction technique. The beams for the overpass section were prefabricated along the existing railway line, then rotated into position using a rotating platform before the cast-in-place sections were connected. Strict control was maintained throughout the construction process, ensuring the installation accuracy of the rotation system, the quality of construction techniques at each stage, and monitoring during the rotation process to guarantee the quality of the bridge rotation and the safety of railway traffic.

[0004] Patent CN 214939282 U describes a rotating support for bridge pier top rotation construction, comprising an upper support and a lower support connected by a first sliding plate. The lower support is connected to a lower support plate at its lower end. The lower support has a lower protrusion, and the lower support plate has a groove along its longitudinal direction. The lower protrusion of the lower support and the groove of the lower support plate cooperate to form a sliding structure, allowing the lower support to move along the groove of the lower support plate. A movable locking mechanism is provided between the lower support and the lower support plate to lock the lower support and the lower support plate together. Although the above structure can realize bridge rotation, uneven force during the rotation process can cause tilting and safety accidents. In addition, if the upper and lower supports get stuck during the rotation and cannot rotate, there is no alternative rotation scheme, and the rotation structure must be re-established. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a large-tonnage, large-diameter integral rotating support installation device and installation method to solve the problems mentioned in the background technology.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a large-tonnage, large-diameter integral rotating support installation device, comprising a lower rotating plate, an upper rotating plate, and a rotating support disposed between the lower rotating plate and the upper rotating plate, wherein a rotating system is further provided between the lower end face of the upper rotating plate and the lower end face of the lower rotating plate.

[0007] The lower rotating plate and the upper rotating plate are rotatably connected by a rotating support; the rotating support includes a lower ball joint fixed to the lower rotating plate and an upper ball joint fixed to the upper rotating plate, the upper ball joint and the lower ball joint are rotatably connected, and a limiting pin is provided at the center of the lower ball joint.

[0008] Furthermore, the rotation system includes a traction system and a propulsion system.

[0009] Furthermore, the traction system is provided in two sets, which are centrally symmetrically distributed on both sides of the rotating support. Each set of traction system includes a traction reaction seat fixed to the lower plate of the rotating body, a continuous jack fixed to the traction reaction seat, and a traction steel bundle connected to the continuous jack. The other end of the traction steel bundle is fixedly connected to the upper plate of the rotating body.

[0010] Furthermore, the booster system includes an annular steel plate slide rail on the lower plate of the rotating body, and a plurality of support legs evenly distributed on the lower end face of the upper plate of the rotating body. The support legs are located inside the annular steel plate slide rail and are slidably connected to the annular steel plate slide rail.

[0011] Furthermore, multiple sets of boosting reaction seats are distributed on the inner and outer sides of the annular steel plate slide, and boosting jacks are provided between the boosting reaction seats and the support feet.

[0012] Furthermore, an embedded plate is provided between the lower ball joint and the lower rotating plate, and the embedded plate is fixedly connected to the lower ball joint and the lower rotating plate by bolts.

[0013] Furthermore, a modified polytetrafluoroethylene slider is provided between the upper ball joint and the lower ball joint.

[0014] An installation method for a large-tonnage, large-diameter integral rotating support installation device.

[0015] (1) After the bored pile construction is completed, the pile cap is excavated, the pile head is removed, and the first layer of concrete is poured for the rotating base.

[0016] (2) Install the annular steel plate slide frame and the lower ball joint frame.

[0017] (3) Tie the pre-reserved groove of the ball joint and the reinforcing bars of the lower slide, and install the annular slide steel plate and the lower ball joint.

[0018] (4) Pour the second layer of concrete for the lower plate of the rotating body, including the concrete for the booster reaction seat and the traction reaction seat.

[0019] (5) Install the polytetrafluoroethylene slider on the lower ball joint.

[0020] (6) Install the limit pin on the lower ball joint and hoist the upper ball joint.

[0021] (7) Tie the inner steel bars of the upper ball joint and pour the micro-expansion epoxy concrete inside the upper ball joint.

[0022] (8) Erect the upper plate formwork on the upper ball hinge, tie the upper foundation reinforcement, embed the traction steel bundles in the upper plate of the rotating body, and pour the upper foundation concrete.

[0023] (9) The support feet are located in the annular steel plate slide and fixed to the lower end face of the rotating body plate. The continuous jack is fixed to the traction reaction seat and connected to the traction steel bundle.

[0024] Furthermore,

[0025] The lower ball joint frame is installed as follows:

[0026] Before installing the ball joint frame, accurately calculate the bottom elevation and planar position of the lower ball joint frame. During the construction of the rotating lower plate, pay attention to controlling the concrete pouring position and pre-embed the lower ball joint frame in a timely manner. Before installation, the dimensions of the lower ball joint frame must be measured and verified in detail, and the installation position and elevation of the frame must be calculated. Based on the calculation, the installation position should be accurately measured and laid out, and the frame adjusting bolts should be adjusted to half of their adjustable range. During the frame installation, initially control its planar position and top elevation, requiring that the planar position deviation not exceed 5mm. After installation, the top surface of the frame must be flat and level, with a relative height difference of less than 5mm. After the frame position is determined, positioning and reinforcement should be carried out to ensure that the position of the ball joint frame does not move during the subsequent concrete pouring process.

[0027] Alternatively, the lower ball joint can be installed as follows:

[0028] Hoist the lower ball joint onto the frame, then center and level it. The centering error of the lower ball joint's center should not exceed 1mm longitudinally and 1.5mm transversely. The crosshair centering method is used. For horizontal adjustment, first use a standard level, then a precision level, ensuring the relative error at all points around the top surface of the ball joint is no more than 0.5mm. Then, fix the adjusting bolts. During the installation of the lower ball joint, ensure the ball cap is horizontal and the sleeve is vertical. After adjustment, promptly lock the lower ball joint onto the ball joint frame.

[0029] Alternatively, the second layer of concrete for the rotating lower plate may be poured as follows:

[0030] After the lower ball joint is installed, concrete is poured under the lower ball joint plate. During the pouring process, it is strictly forbidden for the vibrator to collide with the ball joint frame. At the same time, it is necessary to closely check whether the plane position, elevation and supporting structure of the ball joint have changed. Ensure that the plane position and elevation of the ball joint and the slide are accurate during the concrete pouring process. At the same time, pay attention to covering and protecting the surface of the ball joint and the lower ball joint sleeve during the concrete pouring process to prevent concrete debris from contaminating it. Strengthen the vibration of the concrete under the ball joint during the pouring process to ensure that the concrete under the lower ball joint is poured full and compacted. Eight large concrete vibration holes are reserved in advance on the rotating lower plate, and vent holes and grouting holes are set at certain intervals. When pouring concrete, vibration is carried out sequentially from the bottom of the rotating lower plate upwards. When the concrete is poured to the position of each vibration hole, while vibrating in the horizontal direction, an immersion vibrator is used to penetrate deep into the plate from the vibration hole to compact it. On-site observation shows that the concrete does not sink and that sufficient cement slurry emerges from the surrounding vent holes.

[0031] Alternatively, the installation of the limit pin and the upper ball joint is as follows:

[0032] Lift and place the limit pin into the lower ball joint sleeve. After installation, ensure that the center of the limit pin coincides with the center of the lower ball joint, and ensure the verticality of the limit pin. When lifting the limit pin, take effective protective measures for the spherical surface of the lower ball joint to prevent debris from falling into the sliding surface of the ball joint.

[0033] After the limit pin is installed, lift the upper ball joint. Before installing the upper ball joint, first clean the lower ball joint surface and the bottom surface of the upper ball joint to remove rust. Use a wire brush and a vacuum cleaner to clean the rust and debris from the lower ball joint surface and the bottom surface of the upper ball joint. Apply a layer of grease and PTFE powder evenly to the convex ball surface. Align the upper ball joint with the center pin and gently lower it onto the lower ball joint. Use a zipper pull to finely adjust the position of the upper ball joint so that it is horizontal and consistent with the gap of the outer ring of the lower ball joint. Remove any excess grease that has been squeezed out. Seal the gaps between the edges of the upper and lower ball joints with wide tape.

[0034] Alternatively, the installation of the traction steel bundle:

[0035] The traction steel strands are set with 37Φs15.2mm steel strands according to calculations. The traction cables are pre-embedded in the upper plate of the rotating body by pouring concrete. The pre-embedded ends are P-type anchors. The anchoring end of the traction cable is buried in the upper plate of the rotating body for no less than 4.0m and is smoothly wound on the turntable. Special attention should be paid to the direction of the traction cable during construction. The traction cable support steel bars are pre-embedded during construction. The pre-embedded depth of the support steel bars is 100mm. The height of the steel strands is consistent with the height of the reserved hole of the traction reaction seat.

[0036] Furthermore, the installation of the booster reaction seat:

[0037] The booster reaction seats provide starting force for the rotation traction and axis fine-tuning. Eight sets are evenly spaced on the lower plate of the rotating body. When constructing the lower plate, ensure the reinforcing steel bars of the booster reaction seats are pre-embedded. During construction, ensure each set of booster reaction seats is perpendicular to the support leg axis.

[0038] Alternatively, the installation of the traction reaction seat:

[0039] The traction reaction seat is a fixed structure for securing the continuous jacks during the rotation process. It is installed on the lower plate of the rotating body, symmetrically positioned about the center of the lower plate. During the construction of the lower plate, attention should be paid to pre-embedding the reinforcing steel bars of the traction reaction seat to ensure that the reserved traction holes are at the same height as the traction steel bundles.

[0040] Alternatively, the installation of the annular steel plate slide rail:

[0041] A 1.3m wide, 7.5m radius circular steel plate slide is constructed beneath the support legs. After the concrete for the rotating lower plate is poured to a certain height, the steel plate slide frame is installed. Once the frame is precisely leveled, positioned, and securely fixed, a second concrete pour is made for the rotating lower plate, outside the steel plate slide frame. The steel reinforcement of the steel plate slide frame is tied, and the slide steel plate is hoisted and placed on the frame. It is then centered and leveled, with the longitudinal and transverse errors not exceeding 1mm. The crosshair centering method is used. For horizontal adjustment, a standard level is first used, followed by a precision level. Coordinate control points are used to ensure that the relative error at each point on the top surface around the slide is no more than 2mm. The adjusting bolts are then fixed, and concrete is poured into the pre-reserved groove under the steel plate slide. The concrete must be vibrated to ensure compaction during pouring. If the concrete under the slide is not vibrated to a compacted state, grouting should be performed.

[0042] Alternatively, the installation of the support legs:

[0043] The upper rotating platform is equipped with eight sets of support legs. Each set consists of three 800mm diameter steel pipes welded to a 30mm thick fan-shaped steel track. The support legs are filled with micro-expansion concrete. The support legs are evenly distributed around the circumference of the rotating platform. A 30mm gap is reserved between the bottom of the support legs and the annular steel plate slide. The support legs are installed simultaneously with the construction of the upper rotating platform. Before construction, the surveying team uses a total station to mark the position lines of the support legs. During construction, a 26mm thick steel track is installed below the designed support leg positions. The board and 4mm wooden wedges are filled with quartz sand. The support legs are placed horizontally on the quartz sand, and their plane position and elevation are adjusted. Then, the support legs are fixed. The sand box is installed, its position and elevation are adjusted, and it is fixed. The upper rotating platform template is erected, and the upper ball joint and upper rotating platform reinforcement are tied. The upper ball joint and upper rotating platform concrete are poured. After the turntable concrete has solidified, the steel plates under the support legs are removed, the quartz sand is released, and the debris between the support legs and the steel plate slide is cleaned.

[0044] Alternatively, a sand box may be provided within the annular steel plate slide between every two adjacent support legs, and the sand box may be installed as follows:

[0045] A total of 12 sets of sand boxes are evenly distributed between the lower and upper rotating platforms. Eight sets are evenly distributed on the slide rail, and four sets are outside the slide rail. Each set contains three sand boxes, for a total of 36 sets. The sand boxes are 800mm in diameter and are used to support the weight of the upper rotating platform and its superstructure, while also stabilizing the upper rotating platform. Each sand box consists of two parts: the upper part is welded from 750mm diameter steel pipes and plates, and the lower part is welded from 800mm diameter steel pipes and plates. The upper part has reinforcing steel plates welded inside the steel pipes and is filled with C30 concrete, while the lower part is filled with... Add 30cm of quartz sand. After the steel plate slide is installed, install the sand box. The center line of the sand box should coincide with the center line of the steel plate slide. Set up 3 sets of sand boxes between every two adjacent support legs. Fill the lower part of the steel pipe of the sand box with sand. Combine the upper and lower parts together to pre-compress the sand box to ensure the compactness of the sand inside and minimize the settlement of the sand box during the beam construction. The sand boxes should be on the same circumference and the top surface elevation of the sand boxes should be equal. After the sand box is installed, set up the rotating upper plate formwork to ensure that the top surface elevation of the sand box is equal to the bottom surface elevation of the rotating upper plate.

[0046] The advantages of this invention, a large-tonnage, large-diameter integral rotating support installation device and method, are as follows: This invention enables the rotation of large bridges, ensuring that traffic is not affected during construction. In addition, the support feet and annular steel plate slides of this invention can ensure the force balance of the box girder during the rotation process and prevent tilting. The embedded plate serves as an emergency rotation mechanism, so that even if the upper and lower ball joints are stuck and cannot rotate, the embedded plate can still be used to continue to rotate into place. Attached Figure Description

[0047] Figure 1 This is a schematic diagram of the main structure of an embodiment of the present invention;

[0048] Figure 2 This is a top view of the structure according to an embodiment of the present invention;

[0049] Figure 3 This is a cross-sectional structural diagram of the rotating support according to an embodiment of the present invention;

[0050] Figure 4 This is a top view of the rotating lower plate structure according to an embodiment of the present invention;

[0051] In the picture:

[0052] 1. Rotating lower plate, 2. Rotating upper plate, 3. Lower ball joint, 4. Upper ball joint, 5. Limiting pin, 6. Traction reaction seat, 8. Traction steel bundle, 9. Annular steel plate slide, 10. Support foot, 11. Assist reaction seat, 12. Assist jack, 13. Embedded plate, 100. Rotating support. Detailed Implementation

[0053] The specific implementation method will be further described below with reference to the accompanying drawings.

[0054] Example:

[0055] Figure 1-4 As shown, a large-tonnage, large-diameter integral rotating support 100 installation device includes a lower rotating plate 1, an upper rotating plate 2, and a rotating support 100 disposed between the lower rotating plate 1 and the upper rotating plate 2. A rotating system is also provided between the lower end face of the upper rotating plate 2 and the lower end face of the lower rotating plate 1.

[0056] The lower rotating plate 1 and the upper rotating plate 2 are rotatably connected by a rotating support 100; the rotating support 100 includes a lower ball joint 3 fixed to the lower rotating plate 1 and an upper ball joint 4 fixed to the upper rotating plate 2. The upper ball joint 4 and the lower ball joint 3 are rotatably connected, and a limiting pin 5 is provided at the center of the lower ball joint 3.

[0057] The rotation system includes a traction system and a propulsion system.

[0058] The traction system is provided in two sets, which are centrally symmetrically distributed on both sides of the rotating support 100. Each set of traction system includes a traction reaction seat 6 fixed to the lower rotating plate 1, a continuous jack fixed to the traction reaction seat 6, and a traction steel bundle 8 connected to the continuous jack. The other end of the traction steel bundle 8 is fixedly connected to the upper rotating plate 2.

[0059] The booster system includes an annular steel plate slide 9 on the lower rotating plate 1 and a plurality of support feet 10 evenly distributed on the lower end face of the upper rotating plate 2. The support feet 10 are located inside the annular steel plate slide 9 and are slidably connected to the annular steel plate slide 9.

[0060] Multiple sets of booster reaction seats 11 are distributed on the inner and outer sides of the annular steel plate slide 9, and booster jacks 12 are provided between the booster reaction seats 11 and the support legs 10. If the structure cannot rotate normally due to other factors, the two booster jacks 12 that have been installed in place can be used to apply force evenly to rotate the structure, or it can be used when the beam needs to be finely adjusted after it has been rotated into place.

[0061] An embedded plate 13 is also provided between the lower ball joint 3 and the rotating lower plate 1. The embedded plate 13 is fixedly connected to both the lower ball joint 3 and the rotating lower plate 1 by bolts. When the upper ball joint 4 and the lower ball joint 3 are stuck and cannot rotate, the bolts between the embedded plate 13 and the rotating lower plate 1 are loosened, and the rotating surface is changed from the contact surface between the upper ball joint 4 and the lower ball joint 3 to the contact surface between the embedded plate 13 and the rotating lower plate 1.

[0062] A modified polytetrafluoroethylene slider is provided between the upper ball joint 4 and the lower ball joint 3.

[0063] An installation method for a large-tonnage, large-diameter integral rotating support 100 installation device.

[0064] (1) After the bored pile construction is completed, the pile cap is excavated, the pile head is removed, and the first layer of concrete is poured for the rotating lower plate 1.

[0065] (2) Install the annular steel plate slide rail 9 frame and the lower ball joint 3 frame.

[0066] (3) Tie the pre-reserved groove of the ball joint and the reinforcing bars of the lower slide, and install the annular slide steel plate and the lower ball joint 3.

[0067] (4) Pour the second layer of concrete for the lower plate 1 of the rotating body, and pour concrete for the booster reaction seat 11 and the traction reaction seat 6.

[0068] (5) Install the polytetrafluoroethylene slider on the lower ball joint 3.

[0069] (6) Install the limiting pin 5 on the lower ball joint 3, and hoist the upper ball joint 4.

[0070] (7) Tie the inner steel bars of the upper ball joint 4, and pour the micro-expansion epoxy concrete inside the upper ball joint 4.

[0071] (8) Set up the formwork for the upper rotating plate 2 on the upper ball hinge 4, tie the upper bearing reinforcement, embed the traction steel bundle 8 in the upper rotating plate 2, and pour the upper bearing concrete.

[0072] (9) The support foot 10 is located in the annular steel plate slide 9 and fixed to the lower end face of the rotating upper plate 2. The continuous jack is fixed on the traction reaction seat 6 and connected to the traction steel bundle 8.

[0073] The installation of the lower ball joint 3 frame is as follows:

[0074] Before installing the ball joint frame, accurately calculate the bottom elevation and planar position of the lower ball joint 3 frame. During the construction of the rotating lower plate 1, pay attention to controlling the concrete pouring position and promptly pre-embed the lower ball joint 3 frame. Before installation, the dimensions of the lower ball joint 3 frame must be measured and verified in detail, and the installation position and elevation of the frame must be calculated. Based on the calculation, the installation position should be accurately measured and laid out, and the frame adjusting bolts should be adjusted to half of their adjustable range. During frame installation, initially control its planar position and top elevation, requiring a planar position deviation of no more than 5mm. After installation, the top surface of the frame must be flat and level, with a relative height difference of less than 5mm. After the frame position is determined, positioning and reinforcement should be carried out to ensure that the position of the ball joint frame does not move during subsequent concrete pouring.

[0075] The lower ball joint 3 is installed as follows:

[0076] Hoist the lower ball joint 3 onto the frame, then center and level it. The centering requirement is that the longitudinal error of the lower ball joint 3's center should not exceed 1mm, and the transverse error should not exceed 1.5mm. The crosshair centering method is used during construction. For horizontal adjustment, first use a standard level, then a precision level, ensuring that the relative error at each point on the top surface around the ball joint does not exceed 0.5mm. Then, fix the adjusting bolts. During the installation of the lower ball joint 3, ensure the ball cap is horizontal and the sleeve is vertical. After the ball joint is adjusted, promptly lock the lower ball joint 3 onto the ball joint frame.

[0077] The second layer of concrete pouring for the lower plate 1 of the rotating structure is as follows:

[0078] After the lower ball joint 3 is installed, concrete is poured under the lower ball joint 3 plate. During the pouring process, it is strictly forbidden for the vibrator to collide with the ball joint frame. At the same time, it is necessary to closely check whether the plane position, elevation and supporting structure of the ball joint have changed. Ensure that the plane position and elevation of the ball joint and the slide are accurate during the concrete pouring process. At the same time, pay attention to covering and protecting the surface of the ball joint and the sleeve of the lower ball joint 3 during the concrete pouring process to prevent concrete debris from contaminating it. Strengthen the vibration when pouring concrete under the ball joint to ensure that the concrete under the lower ball joint 3 is poured full and compacted. Eight large concrete vibration holes are reserved in advance on the rotating lower plate 1, and vent holes and grouting holes are set at certain intervals. When pouring concrete, vibration is carried out from the bottom of the rotating lower plate 1 upwards. When the concrete is poured to the position of each vibration hole, while vibrating in the horizontal direction, an immersion vibrator is used to penetrate into the plate from the vibration hole to compact it. On-site observation shows that the concrete does not sink and that sufficient cement slurry emerges from the surrounding vent holes.

[0079] The installation of the limiting pin 5 and the upper ball joint 4 is as follows:

[0080] Hoist the limiting pin 5 and place it into the steel sleeve of the lower ball joint 3. After installation, ensure that the center of the limiting pin 5 coincides with the center of the lower ball joint 3, and ensure the perpendicularity of the limiting pin 5. When hoisting the limiting pin 5, take effective protective measures for the spherical surface of the lower ball joint 3 to prevent debris from falling into the sliding surface of the ball joint.

[0081] After the limit pin 5 is installed, lift the upper ball joint 4. Before installing the upper ball joint 4, first clean the rust from the lower ball joint 3 and the bottom surface of the upper ball joint 4. Use a wire brush and a vacuum cleaner to clean the rust and debris from the surface of the lower ball joint 3 and the bottom surface of the upper ball joint 4. Apply a layer of grease and PTFE powder evenly to the convex ball surface. Align the upper ball joint 4 with the center pin and gently lower it onto the lower ball joint 3. Use a zipper pull to finely adjust the position of the upper ball joint 4 so that it is horizontal and consistent with the gap of the outer ring of the lower ball joint 3. Remove any excess grease that has been squeezed out. Seal the gaps at the edges of the upper and lower ball joints 3 with wide tape.

[0082] Installation of the traction steel bundle 8:

[0083] According to calculations, the traction steel strand 8 is set with 37Φs15.2mm steel strands. The traction cable is pre-embedded in the upper plate 2 of the rotating body by pouring concrete. The pre-embedded end adopts P-type anchor. The anchoring end of the traction cable is buried in the upper plate 2 of the rotating body for not less than 4.0m and is smoothly wound on the turntable. Special attention should be paid to the direction of the traction cable during construction. During construction, the traction cable support steel bar is pre-embedded. The pre-embedded depth of the support steel bar is 100mm. The height of the steel strand is consistent with the height of the reserved hole of the traction reaction seat 6.

[0084] Installation of the booster reaction seat 11:

[0085] The booster reaction seat 11 provides starting power for the rotation traction start and axis fine adjustment. Eight sets are equally divided into circles on the lower plate of the rotating body 1. When constructing the lower plate of the rotating body 1, pay attention to pre-embedding the reinforcing steel of the booster reaction seat 11. During the construction process, ensure that each set of booster reaction seats 11 is perpendicular to the axis of the support leg 10.

[0086] Installation of the traction reaction seat 6:

[0087] The traction reaction seat 6 is a fixing structure for securing the continuous jack during the rotation process. The traction reaction seat 6 is installed on the lower plate 1 of the rotating body, symmetrically positioned about the center of the lower plate 1. During the construction of the lower plate 1, attention should be paid to pre-embedding the reinforcing steel bars of the traction reaction seat 6 to ensure that the traction pre-drilled holes are at the same height as the traction steel bundle 8.

[0088] Installation of the annular steel plate slide 9:

[0089] A 1.3m wide annular steel plate slide 9 with a centerline radius of 7.5m is installed below the support leg 10. After the concrete of the rotating lower plate 1 is poured to a certain height, the steel plate slide frame is installed. After the frame is precisely leveled, positioned, and firmly fixed, the second concrete pouring of the rotating lower plate 1 is carried out. The pouring part is the concrete outside the steel plate slide frame. The steel plate slide frame reinforcement is tied, and the slide steel plate is hoisted and placed on the frame. It is then centered and leveled. The centering requirement is that the longitudinal and transverse errors are no more than 1mm. The construction adopts the cross-line centering method. The horizontal adjustment is first leveled with an ordinary level, and then leveled with a precision level. The horizontal control points are fixed by coordinate control method, so that the relative error of each point on the top surface around the slide is no more than 2mm. The fixed adjustment bolts are fixed, and the concrete in the reserved groove under the steel plate slide is poured. It is required that the concrete be vibrated and compacted during pouring. If the concrete under the slide is not vibrated and compacted, grouting should be carried out.

[0090] Installation of the support leg 10:

[0091] The upper rotating platform 2 is equipped with 8 sets of support legs 10. Each set of support legs 10 consists of three 800mm diameter steel pipes welded to a 30mm thick fan-shaped steel track plate. The support legs 10 are filled with micro-expansion concrete. The support legs 10 are evenly distributed around the circumference of the rotating platform. A 30mm gap is reserved between the bottom of the support legs 10 and the annular steel plate slide 9. The installation of the support legs 10 is carried out simultaneously with the construction of the upper rotating platform 2. Before construction, the surveying team uses a total station to mark the position lines of the support legs 10. During construction, a 26mm thick support is installed below the designed position of the support legs 10. A steel plate and 4mm wooden wedges were used, filled with quartz sand. Support legs 10 were placed horizontally on the quartz sand. The plane position and elevation of support legs 10 were adjusted, and then support legs 10 were fixed. A sand box was installed, its position and elevation adjusted, and then fixed. The template for the upper rotating platform 2 was erected, and the reinforcing bars for the upper ball joint 4 and the upper rotating platform 2 were tied. Concrete was poured for the upper ball joint 4 and the upper rotating platform 2. After the turntable concrete solidified, the steel plate under support legs 10 was removed, the quartz sand was released, and debris between support legs 10 and the steel plate slide was cleaned.

[0092] Each of the two adjacent support legs 10 is provided with a sand box in the annular steel plate slide 9. The sand box is installed as follows:

[0093] A total of 12 sets of sand boxes are evenly distributed between the lower rotating plate 1 and the upper rotating plate 2. Eight sets are evenly distributed on the slide rail, and four sets are outside the slide rail. Each set contains three sand boxes, for a total of 36 sets. The sand boxes are 800mm in diameter and are used to support the weight of the upper rotating plate 2 and the superstructure, while also stabilizing the upper rotating plate 2. Each sand box consists of two parts: the upper part is welded from 750mm diameter steel pipes and plates, and the lower part is welded from 800mm diameter steel pipes and plates. The upper part has reinforcing steel plates welded inside the steel pipes and is filled with C30 concrete, while the lower part is filled with... Add 30cm of quartz sand. After the steel plate slide is installed, install the sand box. The center line of the sand box should coincide with the center line of the steel plate slide. Set up 3 sets of sand boxes between every two adjacent support legs with a gap of 10cm. Fill the lower part of the steel pipe of the sand box with sand. Combine the upper and lower parts together and pre-compress the sand box to ensure the compactness of the sand inside the sand box and minimize the settlement of the sand box during the beam construction process. The sand boxes should be on the same circumference and the top surface elevation of the sand boxes should be equal. After the sand box is installed, support the upper plate 2 template of the rotating body to ensure that the top surface elevation of the sand box is equal to the bottom surface elevation of the upper plate 2 of the rotating body.

[0094] The principle of the rotation system is as follows: the weight of the box girder is transferred to the upper ball joint 4 through the pier column, and the upper ball joint 4 transfers the weight to the lower ball joint 3 and the pier cap through the PTFE plate between the ball joints. After the main body of the box girder is completed, the sand box is emptied, and the entire weight of the girder is transferred to the ball joints. Then, weighing and counterweighting are carried out. Using the traction cable and continuous jacks embedded in the upper rotating plate 2, the dynamic friction torque between the upper and lower ball joints 3 and between the support leg 10 and the annular steel plate slide 9 is overcome, so that the bridge body rotates into place.

[0095] The above embodiments are merely illustrative of the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made based on the essence of the content of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A large-tonnage, large-diameter integral rotating support installation device, characterized in that: It includes a lower rotating plate, an upper rotating plate, and a rotating support disposed between the lower rotating plate and the upper rotating plate. A rotating system is also provided between the lower end face of the upper rotating plate and the lower end face of the lower rotating plate. The lower rotating plate and the upper rotating plate are rotatably connected by a rotating support; the rotating support includes a lower ball joint fixed to the lower rotating plate and an upper ball joint fixed to the upper rotating plate, the upper ball joint and the lower ball joint are rotatably connected, and a limiting pin is provided at the center of the lower ball joint. An embedded plate is also provided between the lower ball joint and the lower rotating plate, and the embedded plate is fixedly connected to the lower ball joint and the lower rotating plate by bolts; When the upper and lower ball joints are stuck and cannot rotate, loosen the bolts between the embedded plate and the lower rotating plate, and change the rotating surface from the contact surface between the upper and lower ball joints to the contact surface between the embedded plate and the lower rotating plate.

2. The large-tonnage, large-diameter integral rotating support installation device according to claim 1, characterized in that: The rotation system includes a traction system and a propulsion system.

3. The large-tonnage, large-diameter integral rotating support installation device according to claim 2, characterized in that: The traction system is provided in two sets, which are symmetrically distributed on both sides of the rotating support. Each set of traction system includes a traction reaction seat fixed to the lower plate of the rotating body, a continuous jack fixed to the traction reaction seat, and a traction steel bundle connected to the continuous jack. The other end of the traction steel bundle is fixedly connected to the upper plate of the rotating body.

4. The large-tonnage, large-diameter integral rotating support installation device according to claim 2, characterized in that: The booster system includes an annular steel plate slide rail on the lower plate of the rotating body, and several supporting feet evenly distributed on the lower end face of the upper plate of the rotating body. The supporting feet are located inside the annular steel plate slide rail and are slidably connected to the annular steel plate slide rail.

5. The large-tonnage, large-diameter integral rotating support installation device according to claim 4, characterized in that: Multiple sets of boosting reaction seats are distributed on the inner and outer sides of the annular steel plate slide, and boosting jacks are provided between the boosting reaction seats and the support feet.

6. The large-tonnage, large-diameter integral rotating support installation device according to claim 1, characterized in that: A modified polytetrafluoroethylene slider is provided between the upper ball joint and the lower ball joint.

7. An installation method for a large-tonnage, large-diameter integral rotating support installation device as described in any one of claims 1-6, characterized in that: (1) After the bored pile construction is completed, the pile cap is excavated, the pile head is removed, and the first layer of concrete is poured for the rotating lower plate. (2) Install the annular steel plate slide frame and the lower ball joint frame. (3) Tie the pre-reserved groove and lower slide rail reinforcement of the ball joint, and install the annular slide rail steel plate and lower ball joint. (4) Pour the second layer of concrete for the lower plate of the rotating body, including the concrete for the boosting reaction seat and the traction reaction seat. (5) Install the PTFE slider on the lower ball joint. (6) Install the limit pin on the lower ball joint and hoist the upper ball joint. (7) Tie the inner steel bars of the upper ball joint and pour the micro-expansion epoxy concrete inside the upper ball joint. (8) Set up the upper plate formwork on the upper ball joint, tie the upper foundation reinforcement, embed the traction steel bundle in the upper plate of the rotating body, and pour the upper foundation concrete. (9) The support feet are located in the annular steel plate slide and fixed to the lower end face of the rotating body plate. The continuous jack is fixed to the traction reaction seat and connected to the traction steel bundle.

8. The installation method of the large-tonnage, large-diameter integral rotating support installation device according to claim 7, characterized in that: The lower ball joint frame is installed as follows: Before installing the ball joint frame, accurately calculate the bottom elevation and planar position of the lower ball joint frame. During the construction of the rotating lower plate, pay attention to controlling the concrete pouring position and pre-embed the lower ball joint frame in a timely manner. Before installation, the dimensions of the lower ball joint frame must be measured and verified in detail, and the installation position and elevation of the frame must be calculated. Based on the calculation, the installation position should be accurately measured and laid out, and the frame adjusting bolts should be adjusted to half of their adjustable range. During the frame installation, initially control its planar position and top elevation, requiring that the planar position deviation not exceed 5mm. After installation, the top surface of the frame must be flat and level, with a relative height difference of less than 5mm. After the frame position is determined, positioning and reinforcement should be carried out to ensure that the position of the ball joint frame does not move during the subsequent concrete pouring process. The lower ball joint is installed as follows: Hoist the lower ball joint onto the frame, then center and level it. The centering error of the lower ball joint's center should not exceed 1mm longitudinally and 1.5mm transversely. The crosshair centering method is used. For horizontal adjustment, first use a standard level, then a precision level, ensuring the relative error at all points around the top surface of the ball joint is no more than 0.5mm. Then, fix the adjusting bolts. During the installation of the lower ball joint, ensure the ball cap is horizontal and the sleeve is vertical. After adjustment, promptly lock the lower ball joint onto the ball joint frame. The second layer of concrete pouring for the rotating lower plate is as follows: After the lower ball joint is installed, concrete is poured under the lower ball joint plate. During the pouring process, it is strictly forbidden for the vibrator to collide with the ball joint frame. At the same time, it is necessary to closely check whether the plane position, elevation and supporting structure of the ball joint have changed. Ensure that the plane position and elevation of the ball joint and the slide are accurate during the concrete pouring process. At the same time, pay attention to covering and protecting the surface of the ball joint and the lower ball joint sleeve during the concrete pouring process to prevent concrete debris from contaminating it. Strengthen the vibration of the concrete under the ball joint during the pouring process to ensure that the concrete under the lower ball joint is poured full and compacted. Eight large concrete vibration holes are reserved in advance on the rotating lower plate, and vent holes and grouting holes are set at certain intervals. When pouring concrete, vibration is carried out sequentially from the bottom of the rotating lower plate upwards. When the concrete is poured to the position of each vibration hole, while vibrating in the horizontal direction, an immersion vibrator is used to penetrate deep into the plate from the vibration hole to compact it. On-site observation shows that the concrete does not sink and that sufficient cement slurry emerges from the surrounding vent holes. The installation of the limit pin and the upper ball joint is as follows: Lift and place the limit pin into the lower ball joint sleeve. After installation, ensure that the center of the limit pin coincides with the center of the lower ball joint, and ensure the verticality of the limit pin. When lifting the limit pin, take effective protective measures for the spherical surface of the lower ball joint to prevent debris from falling into the sliding surface of the ball joint. After the limit pin is installed, lift the upper ball joint. Before installing the upper ball joint, first clean the lower ball joint surface and the bottom surface of the upper ball joint to remove rust. Use a wire brush and a vacuum cleaner to clean the rust and debris from the lower ball joint surface and the bottom surface of the upper ball joint. Apply a layer of grease and PTFE powder evenly to the convex ball surface. Align the upper ball joint with the center pin and gently lower it onto the lower ball joint. Use a zipper pull to finely adjust the position of the upper ball joint so that it is horizontal and consistent with the gap of the outer ring of the lower ball joint. Remove any excess grease that has been squeezed out. Seal the gaps between the edges of the upper and lower ball joints with wide tape. Installation of the traction steel bundle: The traction steel strands are set with 37Φs15.2mm steel strands according to calculations. The traction cables are pre-embedded in the upper plate of the rotating body by pouring concrete. The pre-embedded ends are P-type anchors. The anchoring end of the traction cable is buried in the upper plate of the rotating body for no less than 4.0m and is smoothly wound on the turntable. Special attention should be paid to the direction of the traction cable during construction. The traction cable support steel bars are pre-embedded during construction. The pre-embedded depth of the support steel bars is 100mm. The height of the steel strands is consistent with the height of the reserved hole of the traction reaction seat.

9. The installation method of the large-tonnage, large-diameter integral rotating support installation device according to claim 7, characterized in that: Installation of the booster reaction seat: The booster reaction seats provide starting force for the rotation traction and axis fine-tuning. Eight sets are evenly spaced on the lower plate of the rotating body. When constructing the lower plate, ensure the reinforcing steel bars of the booster reaction seats are pre-embedded. During construction, ensure each set of booster reaction seats is perpendicular to the support leg axis. Installation of the traction reaction seat: The traction reaction seat is a fixed structure for securing the continuous jacks during the rotation process. It is installed on the lower plate of the rotating body, symmetrically positioned about the center of the lower plate. During the construction of the lower plate, attention should be paid to pre-embedding the reinforcing steel bars of the traction reaction seat to ensure that the reserved traction holes are at the same height as the traction steel bundles. Installation of the annular steel plate slide rail: A 1.3m wide, 7.5m radius circular steel plate slide is constructed beneath the support legs. After the concrete for the rotating lower plate is poured to a certain height, the steel plate slide frame is installed. Once the frame is precisely leveled, positioned, and securely fixed, a second concrete pour is made for the rotating lower plate, outside the steel plate slide frame. The steel reinforcement of the steel plate slide frame is tied, and the slide steel plate is hoisted and placed on the frame. It is then centered and leveled, with the longitudinal and transverse errors not exceeding 1mm. The crosshair centering method is used. For horizontal adjustment, a standard level is first used, followed by a precision level. Coordinate control points are used to ensure that the relative error at each point on the top surface around the slide is no more than 2mm. The adjusting bolts are then fixed, and concrete is poured into the pre-reserved groove under the steel plate slide. The concrete must be vibrated to ensure compaction during pouring. If the concrete under the slide is not vibrated to a compacted state, grouting should be performed. Installation of the support legs: The upper rotating platform is equipped with eight sets of support legs. Each set consists of three 800mm diameter steel pipes welded to a 30mm thick fan-shaped steel track. The support legs are filled with micro-expansion concrete. The support legs are evenly distributed around the circumference of the rotating platform. A 30mm gap is reserved between the bottom of the support legs and the annular steel plate slide. The support legs are installed simultaneously with the construction of the upper rotating platform. Before construction, the surveying team uses a total station to mark the position lines of the support legs. During construction, a 26mm thick steel track is installed below the designed support leg positions. The board and 4mm wooden wedges are filled with quartz sand. The support legs are placed horizontally on the quartz sand, and their plane position and elevation are adjusted. Then, the support legs are fixed. The sand box is installed, its position and elevation are adjusted, and it is fixed. The upper rotating platform template is erected, and the upper ball joint and upper rotating platform reinforcement are tied. The upper ball joint and upper rotating platform concrete are poured. After the turntable concrete has solidified, the steel plates under the support legs are removed, the quartz sand is released, and the debris between the support legs and the steel plate slide is cleaned. Each of the two adjacent support legs is equipped with a sand box in the annular steel plate slide. The sand box is installed as follows: A total of 12 sets of sand boxes are evenly distributed between the lower and upper rotating platforms. Eight sets are evenly distributed on the slide rail, and four sets are outside the slide rail. Each set contains three sand boxes, for a total of 36 sets. The sand boxes are 800mm in diameter and are used to support the weight of the upper rotating platform and its superstructure, while also stabilizing the upper rotating platform. Each sand box consists of two parts: the upper part is welded from 750mm diameter steel pipes and plates, and the lower part is welded from 800mm diameter steel pipes and plates. The upper part has reinforcing steel plates welded inside the steel pipes and is filled with C30 concrete, while the lower part is filled with... Add 30cm of quartz sand. After the steel plate slide is installed, install the sand box. The center line of the sand box should coincide with the center line of the steel plate slide. Set up 3 sets of sand boxes between every two adjacent support legs. Fill the lower part of the steel pipe of the sand box with sand. Combine the upper and lower parts together to pre-compress the sand box to ensure the compactness of the sand inside and minimize the settlement of the sand box during the beam construction. The sand boxes should be on the same circumference and the top surface elevation of the sand boxes should be equal. After the sand box is installed, set up the rotating upper plate formwork to ensure that the top surface elevation of the sand box is equal to the bottom surface elevation of the rotating upper plate.

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