Portal crane jacking method for assembling TBM in limited space of underground engineering cavern

Abstract

The application provides a gantry crane jacking method for assembling a TBM in a limited space of an underground engineering cavern, which realizes the step-by-step climbing of a main beam on a stand by driving the movement of a jacking beam through a hydraulic cylinder. The method first installs a hydraulic jacking mechanism on the stand, then installs the main beam on the hydraulic jacking mechanism, pulls out the bolt, starts the hydraulic cylinder, step-by-step lifts the first jacking beam, and fixes it. Then, the second jacking beam is moved and fixed by pulling out the bolt and starting the hydraulic cylinder. These steps are repeated until the main beam reaches the designed installation height under the driving of the hydraulic jacking mechanism. By using this jacking method, the mode of assembling the cavern by using drill and blast expansion is avoided, and the installation work of the jacking gantry crane device is realized.

Description

Technical Field

[0001] This invention belongs to the field of TBM installation technology, and particularly relates to a gantry crane lifting method for assembling TBMs in confined spaces within underground engineering caverns. Background Technology

[0002] TBM (Tunnel Boring Machine) is a tunnel boring machine that integrates mechanics, electronics, hydraulics, lasers, and control. It can realize mechanized and automated construction of tunnel excavation, muck removal, and support.

[0003] TBMs are among the most advanced tunnel construction equipment currently available, capable of cutting the required cross-section in a single operation. Under the same conditions, their tunneling speed is four times that of traditional drill-and-blast methods. Currently, pumped-storage power stations in China are developing rapidly, and TBM methods are being piloted in these stations, primarily using three types of TBMs: large-section horizontal tunnel TBMs for traffic tunnels and ventilation tunnels, TBMs for water intake shafts, and small-section TBMs for drainage systems. Currently, there are no successful cases for water intake shafts. This is because water intake shafts are characterized by their long length and steep slope, making them a significant challenge in pumped-storage power station construction. Raised shaft drilling combined with drill-and-blast excavation poses high safety risks and creates a poor construction environment. TBM construction of pumped-storage water intake shafts typically involves a three-stage horizontal tunnel + two-stage inclined shaft arrangement. A single water intake shaft gantry crane needs to be frequently installed and dismantled six times between the lower, middle, and upper horizontal tunnels for TBM installation, diameter changes, and dismantling during the process. However, compared with the drill and blast method, the TBM method has a high degree of mechanization, less disturbance to the surrounding rock, and is safe and environmentally friendly. It can significantly improve construction efficiency, shorten the construction time of the water diversion system, reduce construction safety risks, and protect the safety of workers.

[0004] The construction of the TBM for the water diversion inclined shaft requires digging a branch tunnel from the access tunnel to the tail end of the water diversion system, followed by drilling and blasting to enlarge the excavation and support of the tunnel chamber to form the TBM assembly tunnel. Then, the water diversion inclined shaft is constructed from bottom to top within the TBM tunnel. The TBM equipment is massive, with numerous and long supporting facilities. The excavation diameter is 6.53m, the total weight is approximately 700t, and the length is 75m (the diameter of the TBM cutterhead and shield body in the later middle-level tunnel is 8.03m). Transporting and assembling the large TBM equipment within the tunnel is challenging in pumped-storage underground engineering projects. One traditional method involves installing a conventional traveling gantry crane (gantry crane) on a track within the already excavated and lined assembly tunnel. However, installing a conventional gantry crane requires further enlargement of the TBM assembly tunnel to create space for the truck crane to freely extend and retract its boom during the gantry crane installation process. Another method is to set up a top-anchor hoisting system in favorable surrounding rock conditions at the top of the excavated tunnel arch. However, the installation of top-anchors is limited by the geological conditions of the top arch and is unsuitable for poor surrounding rock conditions. Furthermore, the installation of overhead anchors for large TBM components lacks flexibility and poses high construction safety risks. Chinese invention patent CN218579500U discloses a multi-functional self-deforming hoist, which includes a column with a vertical telescopic mechanism. The column comprises an outer column and an inner column. The top of the inner column is slidably disposed inside the bottom of the outer column, and a steering wheel is installed at the bottom of the inner column. An inner crossbeam is fixedly installed at the top of the outer column, and the other end of the inner crossbeam is slidably connected to the outer crossbeam. A horizontal telescopic mechanism is provided between the inner and outer crossbeams. A main slide rail lateral movement drive device is provided between the inner sides of the outer crossbeams, and an electric chain hoist is driven and connected to the main slide rail lateral movement drive device. An electric hoist is fixedly installed on one side of the outer column, and the electric hoist is connected to a pallet via a pull rope. However, because this multi-functional self-deforming hoist cannot adjust the horizontal height of the crossbeams, it increases the corresponding construction content and workload before installation, leading to extended construction time and increased costs. Summary of the Invention

[0005] The purpose of this invention is to provide a gantry crane lifting method for assembling TBMs in the limited space of underground engineering caverns, so as to solve the technical problem that the installation of existing gantry cranes requires further expansion and excavation of the TBM assembly cavern.

[0006] To solve the above-mentioned technical problems, the specific technical solution of the present invention is as follows: A gantry crane lifting method for assembling a TBM in a confined space within an underground engineering cavern. The gantry crane includes columns on both sides and a main beam connecting the columns. Each column includes two legs connected by a hydraulic lifting mechanism. The hydraulic lifting mechanism includes two sleeves, a first lifting beam, a second lifting beam, and a hydraulic cylinder. Each sleeve has a first pin hole, and the two sleeves are connected by the first lifting beam. A second lifting beam is located below the first lifting beam, and the first and second lifting beams are connected by a hydraulic cylinder. Both ends of the second lifting beam have second pin holes. Each leg has multiple third pin holes along its height. The lifting method includes the following steps: Step 1: Install the outriggers. Place the sleeve onto the corresponding outrigger and connect the first pin hole and the second pin hole to the third pin hole on the outrigger respectively. Step 2: Detachably fix both ends of the main beam to the corresponding first lifting beam or sleeve; Step 3: Pull out the pin in the first pin hole, start the hydraulic cylinder to raise the first lifting beam, and then insert the pin into the first pin hole and the corresponding third pin hole to complete the fixing of the first lifting beam. Step 4: Pull out the pin in the second pin hole, start the hydraulic cylinder to move the second lifting beam closer to the first lifting beam, and then insert the pin into the second pin hole and the corresponding third pin hole to complete the fixing of the second lifting beam. Step 5: Repeat steps 3 and 4 until the main beam is raised to the designed installation height under the drive of the hydraulic jacking mechanism.

[0007] Therefore, this invention uses a hydraulic cylinder to drive the first lifting beam closer to or further away from the second lifting beam, while employing a sleeve to ensure that the movement trajectory of the first lifting beam does not deviate. This design, combined with a pin shaft, enables the lifting of both the first and second lifting beams. By using the hydraulic lifting mechanism designed in this application, the main beam can be gradually moved upwards from the lower end of the upper support leg during the installation of the gantry crane device until the designed height is reached. This avoids the need to complete the installation work by drilling and blasting to enlarge the TBM assembly chamber.

[0008] Furthermore, in step one, the support leg includes an upper support leg and a lower support leg that are connected to each other. The upper support leg and the lower support leg are detachably connected. The upper support leg has multiple third pin holes along its length, and the lower support leg has a walking mechanism at its lower end.

[0009] Furthermore, before step one, the walking mechanism needs to be installed first, and then the lower support leg needs to be installed on the walking mechanism.

[0010] Furthermore, in step one, the hydraulic lifting mechanism is installed on the corresponding upper support leg, and the upper support leg is installed on the corresponding lower support leg.

[0011] In addition, after step two, the overhead crane is installed on the main beam.

[0012] The gantry crane lifting method for assembling a TBM in a confined space within an underground engineering cavern, as described in this invention, has the following advantages: The hydraulic lifting mechanism and lifting gantry crane device of this invention significantly reduce the hoisting height of the gantry crane's main beam and trolley within the confined space of the underground engineering cavern. Through the hydraulic lifting mechanism of this gantry crane device, the main beam and trolley, installed at the lowest point of the upper support leg, are installed step by step to the designed height via hydraulic lifting. This avoids the need to complete the installation work by drilling and blasting to enlarge the TBM assembly chamber. This device can improve installation and dismantling efficiency inside the cavern, fully utilize its own lifting mechanism to complete the installation work, and reduce the usage time and operating costs of the mobile crane. In a pumped-storage power station, a single-shaft TBM (Tunnel Boring Machine) typically begins excavation into the lower inclined shaft after assembly in the lower horizontal tunnel. Then, in the middle horizontal tunnel, the TBM cutterhead is disassembled, its diameter reduced, and reassembled before excavation into the upper inclined shaft. Finally, the TBM is dismantled in the upper horizontal tunnel. All these processes require the use of a gantry crane as the primary lifting equipment and method for TBM installation and dismantling. The gantry crane needs to be installed and dismantled six times, all within the confined space inside the tunnel. This hydraulic jacking mechanism and gantry crane device offer significant advantages in terms of rapid installation and dismantling, saving time and costs within the limited space of the tunnel. Furthermore, auxiliary beams are installed to directly address the issue of narrow chambers lacking the conditions for installing guy ropes to secure the outriggers, allowing for quick and convenient securing of the outriggers and facilitating the installation of subsequent components. The hydraulic jacking mechanism and jacking gantry crane device of this invention have a simple overall structure, are easy to operate, facilitate installation, and are highly adaptable to different spaces. They reduce the volume of excavation work in tunnels, lower construction safety risks, reduce environmental pollution, and save on post-excavation support materials. Most importantly, they can shorten the construction period for TBM assembly in tunnels, thus reducing construction costs. This device can be widely used as a gantry crane for assembling various TBMs or tunnel boring machines in underground engineering tunnels. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the lifting gantry crane device of the present invention; Figure 2 This is a side view of the lifting gantry crane device of the present invention; Figure 3 This is a schematic diagram of the hydraulic lifting mechanism of the present invention; Figure 4 This is a side view of the hydraulic lifting mechanism of the present invention; Figure 5 This is a flowchart of the lifting method of the present invention.

[0014] The markings in the diagram are as follows: 1. Sleeve; 2. First pin hole; 3. First lifting beam; 4. Second lifting beam; 5. Hydraulic cylinder; 6. Second pin hole; 10. TBM assembly chamber; 11. Column; 12. Main beam; 13. Overhead crane; 14. Outrigger; 141. Upper outrigger; 142. Lower outrigger; 15. Third pin hole; 16. Traveling mechanism; 17. Auxiliary beam. Detailed Implementation

[0015] To better understand the purpose, structure, and function of this invention, the invention will be described in further detail below with reference to the accompanying drawings.

[0016] like Figure 1 and Figure 2 As shown, a jacking gantry crane device in this embodiment includes two columns 11 on both sides and a main beam 12 connecting the two columns 11. A crane 13 is mounted on the main beam 12. Each column 11 includes two legs 14, which are connected by a hydraulic jacking mechanism. Figure 3 and Figure 4 As shown, the hydraulic lifting mechanism includes two sleeves 1, a first lifting beam 3, a second lifting beam 4, and a hydraulic cylinder 5. Each of the two sleeves 1 has a first pin hole 2. The two sleeves 1 are connected by the first lifting beam 3. A second lifting beam 4 is located below the first lifting beam 3, and the first lifting beam 3 and the second lifting beam 4 are connected by the hydraulic cylinder 5. Both ends of the second lifting beam 4 have second pin holes 6. Specifically, the axes of the first pin holes 2 and the second pin holes 6 are parallel. The plane containing the axes of the first pin holes 2 and the second pin holes 6 is perpendicular to the horizontal plane. The axes of the two sleeves 1 are parallel to each other and perpendicular to the horizontal plane. The first lifting beam 3 and the second lifting beam 4 are parallel to each other. The fixed end of the hydraulic cylinder 5 is mounted on the second lifting beam 4, and the telescopic end of the hydraulic cylinder 5 is mounted on the first lifting beam 3. The hydraulic cylinder 5 provides a reaction force by lifting upwards, which pushes the first lifting beam 3, the main beam 12 and the gantry crane 13 to be lifted up step by step along the columns 11 on both sides from bottom to top, climbing to the installation design height.

[0017] The support legs 14 include upper support legs 141 and lower support legs 142 connected to each other. The upper support legs 141 are parallel to each other and have multiple third pin holes 15 along their length. Preferably, the distance between the multiple third pin holes 15 is 50cm. The 50cm spacing is used to facilitate reducing the installation height of the main beam and the overhead crane. Since the installation space in the TBM assembly chamber 10 is limited, expanding the assembly chamber by drilling and blasting would be costly and pose a significant safety risk. The sleeve 1 is fitted onto the upper support leg 141, and both the sleeve 1 and the second lifting beam 4 are engaged with the upper support leg 141 by pins. Each end of the main beam 12 is connected to a first lifting beam 3. The lower support legs 142 are connected by auxiliary beams 17, and each lower support leg 142 has a traveling mechanism 16 at its lower end, preferably a roller. The upper support leg 141 and the lower support leg 142 are detachably connected, and the main beam 12 is detachably connected to the first lifting beam 3. Preferably, the detachable connections in this embodiment are all bolted flange connections.

[0018] Due to cost and environmental considerations in cavern design, the distance between the top arch of the expanded underground cavern and the highest point of the gantry crane installation is approximately 1 meter. Given this condition, the installation of the gantry crane and main beam cannot be completed using a crane due to insufficient hoisting space. This embodiment of the jacking gantry crane is suitable for installation inside the cavern, avoiding the need for drilling and blasting to create a larger assembly chamber to expand the installation space inside the underground cavern, thus saving costs and reducing safety risks. Within a limited space, the gantry crane's own hydraulic jacking mechanism is fully utilized to lift the main beam to the designed installation height, resulting in rapid and convenient installation and dismantling with high overall construction efficiency. This significantly reduces the time spent using cranes inside the cavern and avoids problems such as limited crane use and low installation / dismantling efficiency due to space constraints.

[0019] like Figure 5 As shown, the lifting method in this embodiment includes the following steps: Step 1: After installing the walking mechanism 16, install the outriggers 14. The lower outrigger 142 is installed on the walking mechanism 16, the hydraulic lifting mechanism is installed on the corresponding upper outrigger 141, the upper outrigger 141 is installed on the corresponding lower outrigger 142, and the first pin hole 2 and the second pin hole 6 are respectively connected to the third pin hole 15 on the outrigger 14 for pin insertion.

[0020] Step 2: Detachably fix both ends of the main beam 12 to the corresponding first lifting beam 3 or sleeve 1, and install the overhead crane 13 on the main beam 12.

[0021] Step 3: Pull out the pin in the first pin hole 2, start the hydraulic cylinder 5 to raise the first lifting beam 3, and then insert the pin into the first pin hole 2 and the corresponding third pin hole 15 to complete the fixing of the first lifting beam 3.

[0022] Step 4: Pull out the pin in the second pin hole 6, start the hydraulic cylinder 5 to move the second lifting beam 4 closer to the first lifting beam 3, and then insert the pin into the second pin hole 6 and the corresponding third pin hole 15 to complete the fixing of the second lifting beam 4.

[0023] Step 5: Repeat steps 3 and 4 until the main beam 12 is raised to the designed installation height under the drive of the hydraulic jacking mechanism.

[0024] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A gantry crane lifting method for assembling a TBM in a confined space within an underground engineering cavern, wherein the gantry crane includes two columns (11) on both sides and a main beam (12) connecting the two columns (11), and each column (11) includes two legs (14), characterized in that, The two outriggers (14) are connected by a hydraulic lifting mechanism, which includes two sleeves (1), a first lifting beam (3), a second lifting beam (4), and a hydraulic cylinder (5). Each of the two sleeves (1) has a first pin hole (2), and the two sleeves (1) are connected by a first lifting beam (3). The two ends of the main beam (12) are respectively connected to a first lifting beam (3). A second lifting beam (4) is provided below the first lifting beam (3), and the first lifting beam (3) and the second lifting beam (4) are connected by a hydraulic cylinder (5). Both ends of the second lifting beam (4) have a second pin hole (6). The outriggers (14) have multiple third pin holes (15) along the height direction. The lifting method includes the following steps: Step 1: The outrigger (14) includes an upper outrigger (141) and a lower outrigger (142) connected to each other. The upper outrigger (141) and the lower outrigger (142) are detachably connected. The upper outrigger (141) has multiple third pin holes (15) along its length. The lower end of each lower outrigger (142) is provided with a walking mechanism (16). Install the outrigger (14), put the sleeve (1) on the corresponding outrigger (14), and connect the first pin hole (2) and the second pin hole (6) to the third pin hole (15) on the outrigger (14) respectively. Install the hydraulic lifting mechanism on the corresponding upper outrigger (141) and install the upper outrigger (141) on the corresponding lower outrigger (142). Step 2: Detachably fix both ends of the main beam (12) to the corresponding first lifting beam (3); then, install the overhead crane (13) on the main beam (12); Step 3: Pull out the pin in the first pin hole (2), start the hydraulic cylinder (5) to raise the first lifting beam (3), and then insert the pin into the first pin hole (2) and the corresponding third pin hole (15) to complete the fixing of the first lifting beam (3); Step 4: Pull out the pin in the second pin hole (6), start the hydraulic cylinder (5) to move the second lifting beam (4) closer to the first lifting beam (3), and then insert the pin into the second pin hole (6) and the corresponding third pin hole (15) to complete the fixing of the second lifting beam (4); Step 5: Repeat steps 3 and 4 until the main beam (12) is raised to the designed installation height under the drive of the hydraulic jacking mechanism.

2. The gantry crane lifting method for assembling a TBM in a confined space within an underground engineering cavern according to claim 1, characterized in that, Before step one, the walking mechanism (16) needs to be installed first, and then the lower support leg (142) is installed on the walking mechanism (16).

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