Tower climbing crane with rotary tower inner support and construction method thereof

Abstract

The application provides a rotary tower inner support tower climbing crane and a construction method thereof. The crane comprises a bearing system, the bearing system comprises two telescopic bearing beams, bearing plates are welded on the two bearing beams, a flat rotating system, a bearing system upper support, a truss beam and a hoisting system are sequentially arranged on the bearing system; during construction, the two bearing beams of the bearing system are supported on a bracket inside a cable tower, a cable tower prefabricated block is hoisted by the hoisting system, and the angle of the hoisting system is adjusted by the flat rotating system. After the installation of one segment of the cable tower is completed, brackets are installed on the inner wall, the crane is lifted by a jack by one segment height, and is then supported on the brackets inside the cable tower again, and the construction is circular. The crane has the advantages of small size, strong hoisting capacity, no need to set an attached wall structure, no occupation of ground space, high construction efficiency and low cost.

Description

Technical Field

[0001] This invention belongs to the field of bridge construction technology, and relates to the construction of suspension bridge or cable-stayed bridge towers. Specifically, it relates to a rotary tower internal support climbing crane and its construction method for the construction of prefabricated assembled towers. Background Technology

[0002] The pylons of suspension bridges or cable-stayed bridges are typically constructed using cast-in-place concrete, with tower cranes used to lift construction materials during the process. The height and size of the pylons present several challenges with cast-in-place construction, including: long construction periods due to the large volume of concrete being poured; the need for extensive on-site concrete transportation, mixing, and pumping equipment; the difficulty and complexity of formwork climbing, installation, and adjustment due to the variable cross-section of the tower; and high-risk construction due to the extensive hoisting and tying of reinforcing steel bars at height.

[0003] Given the aforementioned problems with cast-in-place construction of cable towers, and with the development of prefabrication technology, prefabrication methods are now being used for cable tower construction. This involves dividing the cable tower into multiple segments, each segment into multiple prefabricated blocks, and assembling the cable tower segment by segment using these prefabricated blocks. However, due to the large cross-section of the cable tower, each segment weighs over a thousand tons. Even if each segment is divided into four prefabricated blocks circumferentially, the lifting capacity of each prefabricated block still reaches several hundred tons. The lifting capacity of conventional tower cranes is far from sufficient, necessitating the design of ultra-large tonnage tower cranes. Ultra-large tonnage tower cranes are not only massive in size themselves, but also require the construction of large-volume tower crane foundations on the ground, resulting in high costs and a large footprint. Furthermore, as the construction height of the cable tower increases, the tower crane also needs to be continuously raised. To ensure the stability of the tower structure, wall-mounted supports are required between the tower and the cable tower. When using cast-in-place construction, wall-attached connectors can be pre-embedded in the tower body concrete. However, for precast assembled cable towers, wall-attached connectors need to be set on the precast blocks. During construction, the vibration of the tower crane may cause the installed precast block structure to loosen, which is not conducive to the overall stress and seismic resistance of the cable tower. Summary of the Invention

[0004] The purpose of this invention is to address the above-mentioned problems by providing a rotary tower internal support climbing crane and its construction method for the construction of prefabricated cable towers, which reduces the size and cost of the crane while meeting the requirements for large-tonnage lifting capacity.

[0005] The rotary tower crane with internal support provided by the present invention is characterized by comprising a load-bearing system, a horizontal rotation system, a support frame, a truss beam, and a lifting system;

[0006] The load-bearing system includes two telescopic load-bearing beams. Each load-bearing beam includes a fixed segment and two telescopic segments. The fixed segment is a sleeve with two hydraulic cylinders fixedly installed longitudinally inside. One end of each of the two telescopic segments is movably inserted into the two ends of the fixed segment and is fixedly connected to the telescopic rods of the two hydraulic cylinders inside the fixed segment. The two load-bearing beams are arranged in parallel with a certain distance between them, and a load-bearing plate is horizontally welded between the fixed segments of the two load-bearing beams.

[0007] The rotating system includes a turntable and a motor. The turntable is supported on the load-bearing plate by a rotating shaft. Gears are provided on the outer edge of the turntable. The motor is fixedly installed on one side of the load-bearing plate. The output end of the motor is provided with a drive gear that meshes with the gears of the turntable.

[0008] The support includes four columns arranged at the four vertices of a rectangle. Adjacent columns are connected by horizontal bracing and diagonal bracing. The lower end of each column is fixedly connected to the turntable.

[0009] The truss beam is supported on the top of the support frame, and the lower chord of the truss beam is fixedly connected to the upper end of the support column. The truss beam extends into cantilever arms of equal length on two opposite sides of the support frame.

[0010] The lifting system includes two overhead cranes, each equipped with two winches. The two cranes are respectively located at the top of the two cantilever arms of the truss beam and can travel longitudinally along the upper chord of the truss beam.

[0011] The construction method for the aforementioned rotary tower crane with internal support is characterized by including the following steps:

[0012] (1) The first three sections of the tower are constructed by cast-in-place. After the construction is completed, pads are placed at equal intervals around the top of the third section, and the precast sections of the tower are installed. First, two corbels of equal height are installed on the four sides of the inner wall of the third section. Then, the load-bearing system is lifted into the tower using a crawler crane or truck crane. The two telescopic rods of each load-bearing beam of the load-bearing system are supported on the two opposite corbels inside the tower. The horizontal rotation system is installed on the load-bearing beam. Then, the bracket, truss beam, and lifting system are installed in sequence. During installation, the distance between the bottom of the truss beam and the top of the third section should be greater than the height of one section. Anchor rods are connected between the truss beam and each corbel directly below it.

[0013] (2) Transport the precast blocks of the tower to the two cantilever beams of the tower base truss beam. The two cranes move outward to the appropriate position. The winch on one crane lowers the lifting device first and lifts one precast block to a height above the third segment. Then the crane carries the precast block inward to the top of the third segment and lowers the precast block to the designed installation position on the third segment. Then the other crane lifts the other precast block to the installation position in the same way.

[0014] (3) Release the anchor rod between the truss beam and the lower bracket, drive the turntable to rotate through the horizontal rotation system, so that the support and truss beam rotate 90°, and then reconnect the anchor rod between the truss beam and the lower bracket.

[0015] (4) The lifting system uses the same method as in step (2) to lift the other two precast blocks to the installation position at the top of the third segment and connect them with the two precast blocks that have been installed. The post-reinforcement bars are installed in the post-reinforcement through holes at the joint ends of the adjacent precast blocks to complete the splicing of the precast blocks of the fourth segment. The vertical main reinforcement bars between the fourth segment and the third segment are connected by threaded sleeves, and the wet joint concrete between the two segments is poured to complete the installation of the fourth segment of the tower.

[0016] (5) Install brackets on the four sides of the inner wall of the fourth section respectively; set two sets of vertical jacks on the two sides of the top of the fourth section opposite the truss beam to lift the truss beam upward, so that the load-bearing beam is raised to between the brackets of the inner wall of the third and fourth sections, and then simultaneously contract the oil cylinders in the two load-bearing beams to contract the telescopic rods at both ends of each load-bearing beam inward until the overall length of each load-bearing beam is less than the distance between the two opposite brackets on the fourth section.

[0017] (6) The vertical jack continues to lift the truss beam upwards, so that the load-bearing beam is higher than the height of the corbel on the fourth segment. Then, the hydraulic cylinder inside the load-bearing beam is started simultaneously, so that the telescopic segments at both ends of the load-bearing beam slide outwards until the length of the load-bearing beam is greater than the distance between the two opposite corbels on the fourth segment.

[0018] (7) Lower the truss beam with a vertical jack and support the two load-bearing beams on the two opposite sides of the inner wall of the fourth segment; connect the anchor rod between the truss beam and the lower bracket;

[0019] (8) Follow the steps (2) to (7) in a cyclical manner to complete the installation of all prefabricated segments of the tower; then disassemble the crane in the reverse order of crane installation and use a light tower crane to lift the crane components to the ground to complete the installation of the prefabricated segments of the tower.

[0020] The present invention has the following advantages:

[0021] 1. Taking advantage of the hollow interior of the tower, the crane is supported on the inner wall of the tower. As the construction height of the tower increases, the crane is continuously raised as a whole through jacking, without the need to pour a ground foundation and without occupying ground space.

[0022] 2. The crane does not need to be attached to the wall, which avoids the impact of setting wall-mounted embedded parts on the precast blocks on the appearance of the tower, and also avoids affecting the installation stability of the precast blocks;

[0023] 3. The low height of the crane support is conducive to the overall stability of the crane structure, allowing large-tonnage winches to be installed on the truss, ensuring that the lifting capacity required for construction is met;

[0024] 4. The crane has a simple structure, small size, low operating cost, and high construction efficiency;

[0025] 5. Wide range of applications; can be used for the prefabrication and installation of hollow single-column towers with various cross-sections such as rectangular, elliptical, and circular. Attached Figure Description

[0026] Figure 1 This is a three-dimensional structural schematic diagram of the crane of the present invention;

[0027] Figure 2 This is a side view of the crane structure.

[0028] Figure 3 It is a 3D view of the crane being installed and lifting inside the tower;

[0029] Figure 4 This is a side view of the crane being installed and lifted inside the tower;

[0030] Figure 5 This is a 3D view of the crane in its lifting state after rotating 90°;

[0031] Figure 6 This is a 3D view of the crane preparing to lift.

[0032] Figure 7 This is a side view of the crane in its lifting position;

[0033] Figure 8 This is a side view diagram of the crane lifting one section. Detailed Implementation

[0034] like Figure 1 , Figure 2 As shown, the crane of the present invention includes a load-bearing system, a horizontal rotation system, a support frame, a truss beam, and a lifting system;

[0035] The load-bearing system includes two telescopic load-bearing beams 1. Each load-bearing beam includes a fixed segment 11 and two telescopic segments 12. The fixed segment 11 is a sleeve with two hydraulic cylinders 13 fixedly installed longitudinally inside. One end of each of the two telescopic segments 12 is movably inserted into both ends of the fixed segment 11 and is fixedly connected to the telescopic rods of the two hydraulic cylinders 13 inside the fixed segment. The two load-bearing beams are arranged in parallel with a certain distance between them, and a load-bearing plate 2 is horizontally welded between the fixed segments 11 of the two load-bearing beams.

[0036] The rotating system includes a turntable 3 and a motor 4. The turntable 3 is supported on the load-bearing plate 2 by a rotating shaft 5. The outer edge of the turntable 3 is provided with a gear. The motor 4 is fixedly installed on one side of the load-bearing plate 2. The output end of the motor 4 is provided with a drive gear 41 that meshes with the turntable gear.

[0037] The support 6 includes four columns arranged at the four vertices of a rectangle. Adjacent columns are connected by horizontal bracing and diagonal bracing. The lower end of each column is fixedly connected to the turntable.

[0038] The truss beam 7 is supported on the top of the support 6. The lower chord of the truss beam is fixedly connected to the upper end of the support column. The truss beam extends cantilever arms of equal length on two opposite sides of the support.

[0039] The lifting system includes two overhead cranes 8, each equipped with two winches 9. The two cranes are respectively located at the top of the two cantilever arms of the truss beam and can travel longitudinally along the upper chord of the truss beam.

[0040] The above structure allows the telescopic segment to slide within a fixed segment via a hydraulic cylinder inside the load-bearing beam, thereby adjusting the length of the load-bearing beam; the horizontal rotation system drives a turntable to rotate via a motor, thereby rotating the support and the truss beam on the support.

[0041] The following embodiment illustrates the construction method of the crane of the present invention. In this embodiment, the cable tower being constructed is a variable cross-section single-column cable tower. The bottom three segments of the cable tower are constructed using a cast-in-place method, while the remaining stages utilize a prefabricated assembly structure. Each assembly segment is divided into four prefabricated blocks circumferentially, which are installed segment by segment. The prefabricated blocks are hoisted using the crane of the present invention, and the construction method is as follows:

[0042] (1) As Figure 3 , Figure 4 As shown, after the first three sections of the tower are constructed using the cast-in-place method, spacers are placed circumferentially at equal intervals on the top of the third section 200 to begin installing the precast tower sections. First, two corbels 100 of equal height are installed on each of the four sides of the inner wall of the third section. Then, the load-bearing system of the crane is lifted into the tower using a crawler crane or truck crane. The two telescopic rods of each load-bearing beam 1 of the load-bearing system are supported on two opposite corbels 100 inside the tower. The horizontal rotation system is installed on the load-bearing beam. Then, the bracket, truss beam, and lifting system are installed in sequence. During installation, the distance between the bottom of the truss beam and the top of the third section should be greater than the height of one section. Anchor rods 101 are connected between the truss beam 7 and each corbel 100 directly below it.

[0043] (2) Transport the precast blocks of the tower to the two cantilever beams of the tower base truss beam. The two cranes move outward to the appropriate position. The winch on one crane lowers the lifting device first and lifts a precast block 300 to a position higher than the third segment. Then the crane carries the precast block inward to the top of the third segment and lowers the precast block 300 to the designed installation position on the third segment. Then the other crane lifts another precast block to the installation position in the same way.

[0044] (3) Figure 5As shown, the anchor rods between the truss beam and the lower corbel are released, and the turntable is driven to rotate by the horizontal rotation system, so that the support and truss beam rotate 90°. Then, the anchor rods 101 are reconnected between the truss beam 7 and the lower corbel 100.

[0045] (4) The lifting system uses the same method as in step (2) to lift the other two precast blocks 300 to the installation position at the top of the third segment and connect them with the two precast blocks that have been installed. The post-reinforcement bars are installed in the post-reinforcement through holes at the joint ends of the adjacent precast blocks to complete the splicing of the precast blocks of the fourth segment. The vertical main reinforcement bars between the fourth segment and the third segment are connected by threaded sleeves, and the wet joint concrete between the two segments is poured to complete the installation of the fourth segment of the tower.

[0046] (5) Figure 6 As shown, brackets 100 are installed on the four sides of the inner wall of the fourth segment; two sets of vertical jacks 102 are set on the top two sides of the fourth segment, directly opposite the truss beam. The truss beam 7 is lifted upward by the jacks 102, which drives the load-bearing beam 1 to rise between the brackets 100 on the inner wall of the third and fourth segments. Then, the hydraulic cylinders 13 in the two load-bearing beams 1 are simultaneously contracted, so that the telescopic rods at both ends of each load-bearing beam retract inward until the overall length of each load-bearing beam 1 is less than the distance between the two opposite brackets 100 on the fourth segment.

[0047] (6) Figure 7 As shown, the vertical jack 102 continues to lift the truss beam upward, so that the load-bearing beam 1 is higher than the height of the corbel on the fourth segment. Then, the hydraulic cylinder inside the load-bearing beam is activated simultaneously, so that the telescopic segments at both ends of the load-bearing beam slide outward until the length of the load-bearing beam is greater than the distance between the two opposite corbels on the fourth segment.

[0048] (7) The vertical jack returns oil and lowers the truss beam, supporting the two load-bearing beams 1 on the two opposite sides of the inner wall of the fourth section; and connects the anchor rod 101 between the truss beam 7 and the lower bracket 100.

[0049] (8) Follow the steps (2) to (7) in a cyclical manner to complete the installation of all prefabricated segments of the tower; then disassemble the crane in the reverse order of crane installation and use a light tower crane to lift the crane components to the ground to complete the installation of the prefabricated segments of the tower.

Claims

1. A rotary tower crane with internal support, characterized in that: This includes the load-bearing system, the horizontal rotation system, the support frame, the truss beams, and the lifting system; The load-bearing system includes two telescopic load-bearing beams. Each load-bearing beam includes a fixed segment and two telescopic segments. The fixed segment is a sleeve with two hydraulic cylinders fixedly installed longitudinally inside. One end of each of the two telescopic segments is movably inserted into the two ends of the fixed segment and is fixedly connected to the telescopic rods of the two hydraulic cylinders inside the fixed segment. The two load-bearing beams are arranged in parallel with a certain distance between them, and a load-bearing plate is horizontally welded between the fixed segments of the two load-bearing beams. The rotating system includes a turntable and a motor. The turntable is supported on the load-bearing plate by a rotating shaft. Gears are provided on the outer edge of the turntable. The motor is fixedly installed on one side of the load-bearing plate. The output end of the motor is provided with a drive gear that meshes with the gears of the turntable. The support includes four columns arranged at the four vertices of a rectangle. Adjacent columns are connected by horizontal bracing and diagonal bracing. The lower end of each column is fixedly connected to the turntable. The truss beam is supported on the top of the support frame, and the lower chord of the truss beam is fixedly connected to the upper end of the support column. The truss beam extends into cantilever arms of equal length on two opposite sides of the support frame. The lifting system includes two overhead cranes, each equipped with two winches. The two cranes are respectively located at the top of the two cantilever arms of the truss beam and can travel longitudinally along the upper chord of the truss beam.

2. A construction method for a rotary tower crane with internal support as described in claim 1, characterized in that, Includes the following steps: (1) The first three sections of the tower are constructed by cast-in-place. After the construction is completed, pads are placed at equal intervals around the top of the third section, and the precast sections of the tower are installed. First, two corbels of equal height are installed on the four sides of the inner wall of the third section. Then, the load-bearing system is lifted into the tower using a crawler crane or truck crane. The two telescopic rods of each load-bearing beam of the load-bearing system are supported on the two opposite corbels inside the tower. The horizontal rotation system is installed on the load-bearing beam. Then, the bracket, truss beam, and lifting system are installed in sequence. During installation, the distance between the bottom of the truss beam and the top of the third section should be greater than the height of one section. Anchor rods are connected between the truss beam and each corbel directly below it. (2) Transport the precast blocks of the tower to the two cantilever beams of the tower base truss beam. The two cranes move outward to the appropriate position. The winch on one crane lowers the lifting device first and lifts one precast block to a height above the third segment. Then the crane carries the precast block inward to the top of the third segment and lowers the precast block to the designed installation position on the third segment. Then the other crane lifts the other precast block to the installation position in the same way. (3) Release the anchor rod between the truss beam and the lower bracket, drive the turntable to rotate through the horizontal rotation system, so that the support and truss beam rotate 90°, and then reconnect the anchor rod between the truss beam and the lower bracket. (4) The lifting system uses the same method as in step (2) to lift the other two precast blocks to the installation position at the top of the third segment and connect them with the two precast blocks that have been installed. The post-reinforcement bars are installed in the post-reinforcement through holes at the joint ends of the adjacent precast blocks to complete the splicing of the precast blocks of the fourth segment. The vertical main reinforcement bars between the fourth segment and the third segment are connected by threaded sleeves, and the wet joint concrete between the two segments is poured to complete the installation of the fourth segment of the tower. (5) Install brackets on the four sides of the inner wall of the fourth section respectively; set two sets of vertical jacks on the two sides of the top of the fourth section opposite the truss beam to lift the truss beam upward, so that the load-bearing beam is raised to between the brackets of the inner wall of the third and fourth sections, and then simultaneously contract the oil cylinders in the two load-bearing beams to contract the telescopic rods at both ends of each load-bearing beam inward until the overall length of each load-bearing beam is less than the distance between the two opposite brackets on the fourth section. (6) The vertical jack continues to lift the truss beam upwards, so that the load-bearing beam is higher than the height of the corbel on the fourth segment. Then, the hydraulic cylinder inside the load-bearing beam is started simultaneously, so that the telescopic segments at both ends of the load-bearing beam slide outwards until the length of the load-bearing beam is greater than the distance between the two opposite corbels on the fourth segment. (7) Lower the truss beam with a vertical jack and support the two load-bearing beams on the two opposite sides of the inner wall of the fourth segment; connect the anchor rod between the truss beam and the lower bracket; (8) Follow the steps (2) to (7) in a cyclical manner to complete the installation of all prefabricated segments of the tower; then disassemble the crane in the reverse order of crane installation and use a light tower crane to lift the crane components to the ground to complete the installation of the prefabricated segments of the tower.

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