A method for measuring the full-size track linear control of a portal crane

Abstract

The application provides a gantry crane full-size track linear control measurement method, which comprises the following steps: lofting the center line of the gantry crane track on the basis of expansion and collecting the elevation, copying and compressing the gantry crane track according to the elevation, installing the track prism of the gantry crane, positioning the prism assembly in the track center by the limiting sheet, setting the station by the line orientation method and defining the assumed coordinate system of the gantry crane track, installing the track prism at the measured position of the gantry crane track, observing the three-dimensional coordinates of the track prism in the assumed coordinate system, and calculating and analyzing the span of the gantry crane, the height difference between the two tracks in the same section perpendicular to each other, the bending in the vertical plane along the length direction and the straightness. The method is simple and intuitive in observation data, and is beneficial to guide the track linear control of the gantry crane. The method can effectively solve the full-size track linear control measurement problem of the gantry crane track.

Description

Technical Field

[0001] This invention relates to the field of gantry crane track construction measurement technology, and in particular to a method for full-size track alignment control measurement of gantry cranes. Background Technology

[0002] The temporary construction works for the Yanji Yangtze River Bridge are diverse, including a steel bar processing yard, a steel structure processing yard, a material warehouse, a bridge deck prefabrication yard, and a small box girder prefabrication yard. To meet the construction schedule requirements, a total of 14 gantry cranes have been deployed, including 8 10t gantry cranes, 3 16t gantry cranes, 2 30t gantry cranes, and 1 60t gantry crane.

[0003] The track installation accuracy requirements for gantry cranes are high. When the span S ≤ 10m, the track gauge deviation △S = ±3mm; when the span S > 10m, the deviation △S = ±[3 + 0.25 × (S - 10)]mm, with a maximum of ±15mm. Traditionally, the track gauge of gantry cranes is measured using a calibrated steel tape measure to determine the distance between the center lines of the top surfaces of the two tracks. Since the top surfaces of the gantry crane tracks are rounded, the centering of the track top surfaces is subject to random errors due to human factors. The height difference △h between the two tracks on the same cross-section perpendicular to the track's running direction also requires high accuracy, with a maximum height difference of 10mm. Traditionally, the minimum distance between the two tracks on the same perpendicular cross-section is measured using a calibrated steel tape measure, but this method is significantly affected by the track's own linearity. Furthermore, the deviation of the track along its length in the vertical plane must not exceed 2mm at any point within a 2m measurement length. If the track gauge deviation of the gantry crane is too large, the gantry crane will not be parallel to the track during use, which will cause the track to bite, resulting in the gantry crane being subjected to eccentric load and affecting structural safety. Summary of the Invention

[0004] The purpose of this invention is to provide a full-size track alignment control measurement method for gantry cranes. This measurement method can effectively improve the accuracy of track gauge measurement and height difference measurement between two tracks on the same perpendicular cross section of the gantry crane, while also measuring the track straightness of the gantry crane.

[0005] The objective of this invention is achieved as follows:

[0006] A method for full-size track alignment control and measurement of a gantry crane, characterized by the following steps:

[0007] S1: The centerline of the gantry crane track is laid out on the strip enlargement basis using the polar coordinate method of the Leica TS60 total station, and the elevation of the centerline of the gantry crane track is collected using the geometric leveling method.

[0008] S2: Based on the elevation of the centerline of the gantry crane's track, steel plates are used to shim the bottom of the track. After the shims are leveled, the track of the gantry crane is pressed tightly by the track clamps of the gantry crane.

[0009] S3: Install the gantry crane track prism on the gantry crane track. Loosen the fastening knob above the fixed clamp of the gantry crane track prism, pull out the movable clamp, place the prism assembly above the point to be measured on the gantry crane track, connect the prism assembly to the round head nut, and keep the fixed baffle tightly against one side of the gantry crane track. Retract the movable baffle and keep it tightly against the other side of the gantry crane track. The installation of the gantry crane track prism is now complete.

[0010] S4: The track control measurement of the gantry crane is carried out using the line orientation method. The Leica TS60 total station is freely set up between the two gantry crane tracks. After leveling, it enters the line orientation station setting mode.

[0011] S5: Using the line orientation method, establish an assumed coordinate system. Slide the track prism of the gantry crane to the end of the track on either side of the gantry crane. Use a Leica TS60 total station to observe the three-dimensional coordinates of point A1. After observing A1, install the track prism at the other end of the track and observe the point as point An. After the observation, the line orientation is completed. Define a coordinate system with the direction of the track's movement as the X-axis, the direction perpendicular to the X-axis and passing through point A1 as the Y-axis, and the direction passing through point A1 and the vertical foot of the X-axis as the Z-axis.

[0012] S6: Use a Leica TS60 total station to check the track of the gantry crane using the three-dimensional coordinate method. Select the track of the gantry crane and start observation from the end. Observe point A1 again and record it. Slide the track prism of the gantry crane every 2m. After sliding, observe the point. Continue until the entire track is observed. Record A2, A3, ..., An in sequence. After the observation of the track of the gantry crane is completed, install the track prism of the gantry crane on the track of another gantry crane. Starting from the end, select the position corresponding to the other track to observe the three-dimensional coordinates and record B1. Calculate the difference between the X value of point B1 and the X value of point A1. If they are inconsistent, slide the track prism of the gantry crane in the direction of the track until the difference between the X value of point B1 and the X value of point A1 is less than 5cm. Record the three-dimensional coordinates of point B1 again. Observe and record the three-dimensional coordinates of the remaining points to be measured in sequence.

[0013] S7: Calculate the span of the gantry crane, the height difference between two rails on the same perpendicular cross section, and the curvature and straightness along the length direction in the vertical plane based on the observation data.

[0014] In step S1, during the construction of the strip enlarged foundation, it is necessary to lay out the centerline of the gantry crane track in advance and embed the pre-embedded steel plate. After the construction of the strip enlarged foundation is completed, the elevation of the track centerline is collected, and the installation height of the bottom of the gantry crane track is determined according to the maximum elevation value.

[0015] In step S3, the track prism of the gantry crane includes a prism assembly, a fixed clamping plate, a movable clamping plate, and a slide. The fixed clamping plate has a "┐" shaped right-angle structure, and the movable clamping plate has a "┌" shaped right-angle structure. A rectangular clamping slot is provided in the middle of the fixed clamping plate. A downward-rotating fastening knob is provided on the top surface of the fixed clamping plate, next to the clamping slot. The movable clamping plate is located below the fixed clamping plate. A round-headed nut is provided at the center of the cross on the movable clamping plate, below the clamping slot. The connecting screw at the bottom of the prism assembly passes downward through the clamping slot and is screwed into the round-headed nut, connecting the prism assembly, the fixed clamping plate, and the movable clamping plate into one unit. The prism assembly is installed on the movable clamping plate. At the center of the gantry, a fastening knob passes through the fixed clamping plate and abuts against the top surface of the movable clamping plate. Rotating the fastening knob controls the tightness between the fixed and movable clamping plates. A slide body is located below the movable clamping plate, with an upward-opening slide groove at the top. A ball bearing that can slide within the slide groove is installed at the bottom of the movable clamping plate. A movable baffle is located on the side of the movable clamping plate, and a fixed baffle is located on the side of the fixed clamping plate. The movable clamping plate moves laterally as the fastening knob on the top of the fixed clamping plate is tightened or loosened, so that the movable baffle is in close contact with the side of the gantry crane's rail. A limiting piece is located at the center of the slide groove, slightly off-center from the fixed clamping plate, so that the starting position of the prism assembly is the center of the fixed and movable baffles.

[0016] In step S3, the track prism uses a limiting plate to position the center of the prism assembly at the center of the fixed baffle and the movable baffle. The fixed baffle and the movable baffle are respectively in close contact with both sides of the track, and the center of the prism assembly is located at the center of the track.

[0017] In step S5, a hypothetical coordinate system is established by setting up the station using the line orientation method. The coordinate system takes the first measuring point of the station as the origin, the track direction as the X-axis, the direction that is horizontally perpendicular to the X-axis and passes through the origin of the coordinate system as the Y-axis, and the direction that is vertically perpendicular to the X-axis and passes through the origin of the coordinate system as the Z-axis.

[0018] In step S7, the straightness of the track can be obtained by analyzing the Y value of the observation data; the height difference between two tracks on the same perpendicular cross section can be obtained by analyzing the difference in the Z value of the corresponding observation points of the tracks of the two gantry cranes; the span of the gantry crane can be obtained by analyzing the difference in the Y value of the corresponding observation points of the tracks of the two gantry cranes; and the curvature in the vertical plane along the length direction can be obtained by analyzing the difference in the Z value of adjacent points of each gantry crane track.

[0019] This invention controls the centerline and elevation of the gantry crane's track strip foundation. After the track is clamped, a track prism is installed on the track to replace the traditional method of measuring the centerline distance between the top surfaces of the two tracks using a calibrated steel tape measure. This minimizes the impact of human factors on measurement accuracy. The line orientation method enables high-precision measurement of the gantry crane's track gauge and the height difference between two tracks on the same perpendicular cross section. It also measures the straightness of the gantry crane's track. The observation data is simple and intuitive, which is beneficial for guiding the track alignment control of the gantry crane. This invention provides a completely new method for full-size track alignment control measurement of gantry cranes. Attached Figure Description

[0020] Figure 1 An exploded view of the track prism of a gantry crane;

[0021] Figure 2 This is an elevation view of the track prism of a gantry crane. Detailed Implementation

[0022] The specific embodiments of the present invention are further described below with reference to specific examples and the accompanying drawings.

[0023] A method for full-size track alignment control and measurement of a gantry crane includes the following steps:

[0024] During the construction of the strip-shaped enlarged foundation, a pre-embedded steel plate is embedded in the top surface of the concrete. The pre-embedded steel plate is embedded according to the polar coordinate method of the Leica TS60 total station to lay out the centerline of the gantry crane track.

[0025] After the reinforcement of the strip spread foundation is tied, the center line of the gate crane track is laid out at both ends of the strip spread foundation and marked with a steel rod. The steel rod is marked with an ink line, and the ink line is adjusted to be 2cm higher than the top surface of the reinforcement. Every 2m at the position of the ink line on the top surface of the reinforcement, a 2cm thick embedded steel plate is welded. The top surface of the concrete pouring of the strip spread foundation is 1cm lower than the top surface of the embedded steel plate.

[0026] S1: The centerline of the gantry crane track is laid out on the strip enlargement basis using the polar coordinate method of the Leica TS60 total station, and the elevation of the centerline of the gantry crane track is collected using the geometric leveling method.

[0027] The installation height of the bottom of the gantry crane track is determined based on the maximum elevation of the centerline of the gantry crane track.

[0028] S2: Based on the difference between the elevation of the centerline of the gantry crane track and the elevation of the bottom of the gantry crane track, steel plates are used to shim the track below. After the shims are leveled, the track of the gantry crane is pressed tightly by the track clamping components.

[0029] according to Figure 1The diagram shows an exploded view of the track prism of a gantry crane. The track prism of the gantry crane includes a prism assembly 1, a fixed clamping plate 2, a movable clamping plate 3, and a slide 4. The fixed clamping plate 2 has a "┐" shaped right-angle structure, and the movable clamping plate 3 has a "┌" shaped right-angle structure. A rectangular clamping slot 11 is provided in the middle of the fixed clamping plate 2. A downward-rotating fastening knob 5 is provided on the top surface of the fixed clamping plate 2, next to the clamping slot 11. The movable clamping plate 3 is located below the fixed clamping plate 2. A round-headed nut 9 is provided at the center of the cross on the movable clamping plate 3, below the clamping slot 11. The connecting screw 12 at the bottom of the prism assembly 1 passes downward through the clamping slot 11 and is screwed into the round-headed nut 9, connecting the prism assembly 1, the fixed clamping plate 2, and the movable clamping plate 3 into one unit. The prism assembly 1 is installed on the movable clamping plate. At the center of the cross 3, the fastening knob 5 passes through the fixed clamping plate 2 and abuts against the top surface of the movable clamping plate 3. By rotating the fastening knob 5, the tightness between the fixed clamping plate 2 and the movable clamping plate 3 can be controlled. The slide body 4 is located below the movable clamping plate 3. The top of the slide body 4 is provided with an upward-opening slide groove 13. The bottom of the movable clamping plate 3 is equipped with a sliding ball 8 that can slide in the slide groove 13. The movable clamping plate 3 is provided with a movable baffle 7 on its side and the fixed clamping plate 2 is provided with a fixed baffle 6 on its side. The movable clamping plate 3 moves laterally as the fastening knob 5 on the top of the fixed clamping plate 2 is tightened or loosened, so that the movable baffle 7 is in close contact with the side of the gantry crane's rail 14. A limiting piece 10 is provided on the side of the slide groove 13 of the slide body 4, which is slightly off the fixed clamping plate 2, so that the starting position of the prism assembly 1 is the center of the fixed baffle 7 and the movable baffle 6.

[0030] S3: Install the gantry crane track prism on the gantry crane track 14, loosen the fastening knob 5 above the fixed clamp 2 of the track prism, pull out the movable clamp 3, place the prism assembly 1 above the point to be measured on the gantry crane track 14, connect the prism assembly 1 to the round head nut 9, the fixed baffle 7 is tightly attached to one side of the gantry crane track 14, and the movable baffle 6 is retracted and tightly attached to the other side of the gantry crane track 14. The installation of the gantry crane track prism is complete.

[0031] S4: The line orientation method is used to control and measure the track 14 of the gantry crane. The Leica TS60 total station is freely set up in the middle of the two gantry crane tracks. After leveling, it enters the line orientation station setting mode.

[0032] When setting up a Leica TS60 total station, choose an open area where the tracks of two gantry cranes can be seen without obstruction.

[0033] S5: Using the line orientation method, establish an assumed coordinate system. Slide the track prism of the gantry crane to the end of track 14 on either side of the gantry crane. Use a Leica TS60 total station to observe the three-dimensional coordinates of point A1. After observing A1, install the track prism at the other end of track 14 and observe this point as point An. After the observation, the line orientation is completed. Define a coordinate system with the forward direction of track 14 as the X-axis, the horizontal direction perpendicular to the X-axis and passing through point A1 as the Y-axis, and the vertical direction passing through point A1 and perpendicular to the X-axis as the Z-axis.

[0034] S6: Use a Leica TS60 total station to check the three-dimensional coordinate method of the gantry crane track 14. Select the gantry crane track 14 and start observing from the end, recording A1. Slide the gantry crane track prism every 2m, and observe the point after sliding until the entire track 14 is observed, recording A2, A3, ..., An in sequence. After the observation of the gantry crane track 14 is completed, install the gantry crane track prism on another gantry crane track 14. Starting from the end, select the position corresponding to the other track 14 to observe the three-dimensional coordinates and record B1. Calculate the difference between the X value of point B1 and the X value of point A1. If they are inconsistent, slide the gantry crane track prism in the direction of the gantry crane track 14 until the difference between the X value of point B1 and the X value of point A1 is less than 5cm, and re-record the three-dimensional coordinates of point B1. Observe and record the three-dimensional coordinates of the remaining points to be measured in sequence.

[0035] S7: Calculate the span of the gantry crane, the height difference between two rails on the same perpendicular cross section, and the curvature and straightness along the length direction in the vertical plane based on the observation data.

[0036] Track straightness is determined by analyzing the convergence of the Y-values ​​of the same track. The station is set up using the line orientation method. If the Y-value of the track of one gantry crane is in the range of (-0.002, +0.002) and the Y-value of the track of another gantry crane is in the range of (S-0.002, S+0.002), the track straightness is considered to be good. S is the track span of the gantry crane.

[0037] The span of a gantry crane is determined by analyzing the difference in Y-values ​​at corresponding observation points on the tracks of two gantry cranes, and calculating ΔS = |YA|. n -YB n When the deviation △S ≤ ±[3+0.25×(S-10)] mm and △S≯15 mm, the span of the gantry crane meets the specification requirements.

[0038] The height difference between two tracks on the same perpendicular cross section is determined by analyzing the difference in Z-values ​​at corresponding observation points of the two gantry crane tracks. The height difference Δh = |ZA| is calculated. n -ZBn When the deviation △h≤10mm, the height difference between two tracks on the same perpendicular cross section meets the specification requirements.

[0039] The curvature along the length direction in the vertical plane is determined by analyzing the Z-value difference between adjacent points on the track of each gantry crane, and |ZA| is calculated. n -ZA n When -1|≤0.002, the bending along the length direction in the vertical plane meets the specification requirements.

[0040] The gantry crane tracks at observation points that do not meet the specifications need to be adjusted until they do.

[0041] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A method for full-size track alignment control and measurement of a gantry crane, characterized in that: Includes the following steps: S1: The centerline of the gantry crane track is laid out on the strip enlargement basis using the polar coordinate method of the Leica TS60 total station, and the elevation of the centerline of the gantry crane track is collected using the geometric leveling method. S2: Based on the elevation of the centerline of the gantry crane's track, steel plates are used to shim the bottom of the track. After the shims are leveled, the track of the gantry crane is pressed tightly by the track clamps of the gantry crane. S3: Install the gantry crane track prism on the gantry crane track. Loosen the fastening knob above the fixed clamp of the gantry crane track prism, pull out the movable clamp, place the prism assembly above the point to be measured on the gantry crane track, connect the prism assembly to the round-head nut, and ensure the fixed baffle is flush against one side of the gantry crane track. Then, retract the movable baffle to flush against the other side of the gantry crane track. The installation of the gantry crane track prism is now complete. (Note:) The track prism of a gantry crane includes a prism assembly, a fixed clamping plate, a movable clamping plate, and a slide rail. The fixed clamping plate has a "┐" shaped right-angle structure, and the movable clamping plate has a "┌" shaped right-angle structure. The fixed clamping plate has a rectangular clamping slot in the middle. A downward-rotating fastening knob is located on the top surface of the fixed clamping plate, next to the clamping slot. The movable clamping plate is located below the fixed clamping plate. A round-headed nut is located at the center of the movable clamping plate, below the clamping slot. The connecting screw at the bottom of the prism assembly passes downward through the clamping slot and screws into the round-headed nut, connecting the prism assembly, fixed clamping plate, and movable clamping plate into one unit. The prism assembly is installed at the center of the movable clamping plate. At this location, a fastening knob passes through the fixed clamping plate and abuts against the top surface of the movable clamping plate. Rotating the fastening knob controls the tightness between the fixed and movable clamping plates. A slide body is located below the movable clamping plate, with an upward-opening slide groove at the top. A ball bearing that can slide within the slide groove is installed at the bottom of the movable clamping plate. A movable baffle is located on the side of the movable clamping plate, and a fixed baffle is located on the side of the fixed clamping plate. The movable clamping plate moves laterally as the fastening knob on the top of the fixed clamping plate is tightened or loosened, so that the movable baffle is in close contact with the side of the gantry crane's rail. A limiting piece is located at the center of the slide groove of the slide body, offset from the fixed clamping plate, so that the starting position of the prism assembly is the center of the fixed baffle and the movable baffle. S4: The track control measurement of the gantry crane is carried out using the line orientation method. The Leica TS60 total station is freely set up between the two gantry crane tracks. After leveling, it enters the line orientation station setting mode. S5: Using the line orientation method, establish an assumed coordinate system. Slide the track prism of the gantry crane to the end of the track on either side of the gantry crane. Use a Leica TS60 total station to observe the three-dimensional coordinates of point A1. After observing A1, install the track prism at the other end of the track and observe the point as point An. After the observation, the line orientation is completed. Define a coordinate system with the direction of the track's movement as the X-axis, the direction perpendicular to the X-axis and passing through point A1 as the Y-axis, and the direction passing through point A1 and the vertical foot of the X-axis as the Z-axis. S6: Use a Leica TS60 total station to check the track of the gantry crane using the three-dimensional coordinate method. Select the track of the gantry crane and start observation from the end. Observe point A1 again and record it. Slide the track prism of the gantry crane every 2m. After sliding, observe the point. Continue until the entire track is observed. Record A2, A3, ..., An in sequence. After the observation of the track of the gantry crane is completed, install the track prism of the gantry crane on the track of another gantry crane. Starting from the end, select the position corresponding to the other track to observe the three-dimensional coordinates and record B1. Calculate the difference between the X value of point B1 and the X value of point A1. If they are inconsistent, slide the track prism of the gantry crane in the direction of the track until the difference between the X value of point B1 and the X value of point A1 is less than 5cm. Record the three-dimensional coordinates of point B1 again. Observe and record the three-dimensional coordinates of the remaining points to be measured in sequence. S7: Calculate the span of the gantry crane, the height difference between two rails on the same perpendicular cross section, and the curvature and straightness along the length direction in the vertical plane based on the observation data.

2. The method for full-size track alignment control and measurement of a gantry crane according to claim 1, characterized in that: In step S1, when constructing the strip enlarged foundation, it is necessary to lay out the centerline of the gantry crane track in advance and embed the pre-embedded steel plate. After the construction of the strip enlarged foundation is completed, the elevation of the track centerline is collected, and the installation height of the bottom of the gantry crane track is determined according to the maximum elevation value.

3. The method for full-size track alignment control and measurement of a gantry crane according to claim 1, characterized in that: In step S3, the track prism uses a limiting plate to ensure that the center of the prism assembly is located between the fixed baffle and the movable baffle. The fixed baffle and the movable baffle are respectively in close contact with both sides of the track, and the center of the prism assembly is located at the center of the track.

4. The method for full-size track alignment control and measurement of a gantry crane according to claim 1, characterized in that: In step S5, a hypothetical coordinate system is established using the line orientation method. The first measuring point of the station is the origin of the coordinate system, the track direction is the X-axis, the direction perpendicular to the X-axis and passing through the origin of the coordinate system is the Y-axis, and the direction perpendicular to the X-axis and passing through the origin of the coordinate system is the Z-axis.

5. The method for full-size track alignment control and measurement of a gantry crane according to claim 1, characterized in that: In step S7, the straightness of the track can be obtained by analyzing the Y value of the observation data; the height difference between two tracks on the same perpendicular cross section can be obtained by analyzing the difference in the Z value of the corresponding observation points of the tracks of the two gantry cranes; the span of the gantry crane can be obtained by analyzing the difference in the Y value of the corresponding observation points of the tracks of the two gantry cranes; and the curvature in the vertical plane along the length direction can be obtained by analyzing the difference in the Z value of adjacent points of each gantry crane track.

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