A tilting dock door installation structure and installation method

Abstract

The present invention relates to the field of dock door installation equipment, and specifically discloses a tilting dock door installation structure and installation method, wherein a wall sealing structure is respectively set at the Wukan of the dock door, and a winch, a first pulley group and a hoist are set on the left and right shores, and the tilting dock door is pulled to adjust its posture on the sea surface. The ear shaft at the bottom of the tilting dock door is connected to the hinge bearing seat, so that the sealing performance of the dock door can be checked after the dock door is installed. The present invention installs and adjusts the horizontal prefabricated blocks and the vertical prefabricated blocks respectively, thereby improving the accuracy of the embedded parts; at the same time, the tilting dock door is transported from the sea surface, and the posture of the tilting dock door is adjusted by the winch, the first pulley group and the hoist, so that the dock door is smoothly installed on the hinge bearing seat, completing the overall installation; this device is not limited by the size of the tilting dock door, and has high installation accuracy, ensuring construction efficiency.

Description

Technical Field

[0001] The present invention relates to the field of marine engineering equipment installation, and in particular to a dumping type dock door installation structure and an installation method. Background Art

[0002] Dock gates, essential equipment in modern shipyards, fully guarantee the quality and progress of shipbuilding. They primarily serve as water barriers in dry docks, provide a land-like working environment for shipbuilding within the dock, and facilitate the launching of completed ships. Dock gates can be categorized by type, including pontoon-type, horizontally-pullable, flapper-type, and retractable types.

[0003] The installation of dock doors mainly includes two aspects: embedded parts installation and door body installation. According to the conventional method, it is difficult to achieve the embedded parts installation accuracy and door body transfer and placement method for super large dock doors. Now let's discuss the following items:

[0004] The installation of embedded components for dock doors is a prerequisite and fundamental condition for dock door installation, and their accuracy directly impacts the installation and operation of the dock door. In traditional installation of embedded components for tilting dock doors, installation and quality control are often performed based on the allowable tolerances of the design drawings. However, since dock doors are ultra-large steel structures, manufacturing errors are difficult to control, and measurements over large spans are also affected by thermal expansion and contraction caused by temperature fluctuations. This can result in poor or non-compliant sealing surfaces between the embedded components and the dock door after the dock door arrives for installation on site, leading to significant quality issues such as leakage or abnormal opening and closing of the dock door.

[0005] Furthermore, during the installation and construction of traditional tipping dock doors, due to their small size and light weight, traditional transportation and installation methods typically involve transporting them overland to the installation location and hoisting them into place using a crane or floating crane. While this traditional transportation and installation method is feasible for small and lightweight tipping dock doors, large tipping dock doors are enormous in size and often weigh thousands of tons, exceeding the lifting capacity of conventional cranes and floating cranes, as well as the load-bearing capacity of the dock. This makes traditional installation and construction methods difficult to implement and less economical. Summary of the Invention

[0006] The purpose of the present invention is to provide a tilting dock door installation structure and installation method to solve the problem that during the installation of large tilting dock doors, the installation accuracy of embedded parts is poor, resulting in dock door leakage or abnormal opening and closing, and the problem that the tilting dock door is too large and traditional lifting methods are difficult to apply.

[0007] In order to solve the above technical problems, the technical solution adopted by the present invention is: a tilting dock door installation structure, including a left installation structure and a right installation structure;

[0008] The left installation structure includes a wall sealing structure, a hinged bearing seat, a winch, a first pulley block, and multiple winches; the wall sealing structure is installed on the left side of the dock door; the hinged bearing seat is arranged at the bottom of the wall sealing structure, the first pulley block is arranged at the upper part of the wall sealing structure, the winch is arranged on the left side of the first pulley block, and drives the first pulley block to rotate; the winch is arranged on the side of the dock;

[0009] The right installation structure is the same as the left installation structure and is arranged on the right side of the dock door;

[0010] The top of the dumping dock door is connected to the first pulley set, the middle part is provided with a lifting lug matching the winch, and the bottom trunnion is hinged to the hinged bearing seat.

[0011] As a further technical solution of the above scheme, the wall sealing structure includes horizontal precast blocks, vertical precast blocks, first-phase concrete, horizontal embedded parts, and second-phase concrete; the first-phase concrete is L-shaped and is arranged on the left side of the dock door; the horizontal embedded parts include steel piers, wedge plates, shrinkage-free concrete piers and anchor bolts; the bottom of the steel pier is connected to the upper part of the first-phase concrete, and the top is supported by the wedge plate against the bottom of the horizontal precast block; the shrinkage-free concrete pier is arranged between the horizontal precast block and the first-phase concrete; the anchor bolts pass through the anchor bolt holes on the horizontal precast block and are anchored into the first-phase concrete; the second-phase concrete is L-shaped and is arranged on the inner side of the first-phase concrete; the horizontal precast block is arranged on the upper part of the horizontal edge of the second-phase concrete, and the vertical precast block is arranged on the right part of the vertical edge of the second-phase concrete.

[0012] As a further technical solution of the above scheme, the vertical prefabricated block includes multiple vertical prefabricated units, and expansion joint epoxy grouting material is provided between adjacent vertical prefabricated units; the expansion joint epoxy grouting material is arranged horizontally, and chemical anchor bars are provided on the left and right sides for fixing.

[0013] As a further technical solution of the above solution, the horizontal prefabricated block includes multiple horizontal prefabricated units, and expansion joint epoxy grouting material is provided between adjacent horizontal prefabricated units.

[0014] As a further technical solution of the above solution, a second pulley set is provided on the top of the dumping dock door, and the second pulley set is connected to the first pulley set through a steel wire rope.

[0015] A method for installing a dumping dock door, using the above dumping dock door installation structure, includes the following steps:

[0016] Step S1: Setting a wall sealing structure at the dock gate, and setting a winch, a first pulley block, and a hoist on the shore; filling the dock with water and excavating a cofferdam in front of the dock entrance so that the water level in the dock is consistent with the sea level;

[0017] Step S2, using a tugboat or other power traction equipment to tow and float the dumping dock door from the temporary berthing position to the ocean side in front of the dock entrance;

[0018] Step S3, adjusting the winches and the hauling ropes of the left and right mounting structures according to the position of the dumping dock door, wherein the winches are connected to the lifting lugs at the left and right ends of the dumping dock door, respectively, to assist in traction movement and position adjustment;

[0019] Step S4, starting different winches to adjust the position of the tilting dock door lying flat on the sea surface so that the trunnions at both ends of its bottom face the hinged bearing seats at the dock sill on the seabed;

[0020] Step S5: Arrange a water injection pump and a water injection pipe to fill the water tanks of each compartment of the dumping dock door with water to ballast the door so that its posture gradually changes from lying flat to tilted upright, and the trunnions on the left and right sides gradually sink and slide into the hinged bearing seat to connect;

[0021] Step S6, connect the first pulley block to the top of the dumping dock door through a wire rope, start the winch to drive the first pulley block to rotate the dumping dock door to complete the opening and closing, drain the water in the dock and check the sealing performance of the dumping dock door.

[0022] As a further technical solution of the above solution, it also includes horizontal prefabricated blocks, vertical prefabricated blocks, first-phase concrete, horizontal embedded parts, second-phase concrete, steel piers, wedge plates, and non-shrinkage concrete piers. In step S1, the wall sealing structure is provided, including the following steps:

[0023] Step S11, pre-embedding stainless steel anchor bolts in the first phase of concrete according to the anchor bolt holes reserved on the horizontal prefabricated blocks and the vertical prefabricated blocks;

[0024] Step S12, arranging the steel buttresses and wedge plates according to the length of a single prefabricated unit, and adjusting them so that one prefabricated unit supports two sets of steel buttresses and wedge plates;

[0025] Step S13: Based on the axis of the sealing surface, a reference bracket and a reference line for measurement and adjustment are arranged at a position offset from the sealing surface by a certain distance. The reference line is a piano wire with good toughness and strength.

[0026] Step S14, hoisting and placing the horizontal prefabricated unit on the wedge plate, adjusting the axis position of the sealing surface with the reference line, and adjusting the elevation of the horizontal prefabricated unit with the center point of the sealing surface;

[0027] Step S15: Fix the horizontal prefabricated units with the adjusted sealing surface axis and elevation using anchor bolts, adjusting and fixing each unit piece by piece until the sealing adjustment of all the horizontal prefabricated units is completed;

[0028] Step S16: Casting shrinkage-free concrete buttresses at the bottom of each horizontal precast unit. After arranging two buttresses for support in each horizontal precast unit, the steel buttresses and wedge plates are removed and then the precast block cushion concrete is cast. Then, epoxy grouting is performed horizontally for the expansion joints between the precast units, and finally the second phase of concrete is cast.

[0029] Step S17: After the horizontal prefabricated blocks are installed and concrete is poured, support steel bars of the vertical prefabricated blocks are supported at the connection positions of the horizontal prefabricated blocks and the vertical prefabricated blocks on both sides by using the rebar planting method;

[0030] Step S18: hoist the vertical prefabricated block onto the supporting steel bars, secure it with wire and tie bolts to prevent it from falling over, align the sealing surface of the vertical prefabricated block with the sealing surface of the horizontal prefabricated block, weld them with stainless steel plates, and then measure and adjust the verticality of the sealing surface using the plumb bob method.

[0031] Step S19, after adjusting the verticality of the vertical prefabricated block, first pour the expansion joint epoxy grouting material in the gap between the vertical prefabricated units, and then pour the second phase of concrete; after the pouring is completed, the same method is used to install, adjust and pour the next vertical prefabricated unit.

[0032] Compared with the prior art, the present invention has the following advantages and beneficial effects: the present invention installs and adjusts the horizontal prefabricated blocks and the vertical prefabricated blocks separately, thereby improving the accuracy of the embedded parts; at the same time, the tipping dock door is transported from the sea surface, and the posture of the tipping dock door is adjusted by the winch, the first pulley group and the hoist, so that the dock door can be smoothly installed on the hinged bearing seat to complete the overall installation; this device is not limited by the size of the tipping dock door, and has high installation accuracy, thereby ensuring construction efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the layout of the left installation structure and the right installation structure.

[0034] Figure 2 This is a schematic diagram of the installation of the winch and the first pulley assembly.

[0035] Figure 3 It is a schematic diagram of the connection relationship between the dock door and the hinged bearing seat.

[0036] Figure 4 Schematic diagram of the connection between the horizontal precast blocks and the first phase of concrete.

[0037] Figure 5 Schematic diagram of the baseline layout of horizontal precast blocks.

[0038] Figure 6 Schematic top view of the baseline layout of the horizontal precast blocks.

[0039] Figure 7 This is a schematic diagram of the front connection between the horizontal prefabricated blocks and the vertical prefabricated blocks.

[0040] Figure 8 Schematic diagram of the side connection relationship between the horizontal prefabricated blocks and the vertical prefabricated blocks.

[0041] Figure 9 This is an enlarged schematic diagram of the connection between the horizontal prefabricated blocks and the vertical prefabricated blocks.

[0042] Figure 10 Schematic diagram of the opening and closing of the dumping dock door.

[0043] Figure 11 It is in the floating state when the dock door is inverted and there is no water in each compartment.

[0044] Figure 12 Procedure 1 for installing the dumping dock door: Floating state when the S and T compartments are filled with water.

[0045] Figure 13 Procedure 2 for installing the dumping dock door: floating state when E1 and E2 compartments are filled with water.

[0046] Figure 14 Procedure 3 for installing the dumping dock door: Floating state when the K, L and R compartments are filled with water.

[0047] Figure 15 Procedure 4 for installing the dumping dock door: Floating state when the U compartment is filled with water.

[0048] Figure 16 Procedure 5 for installing the tilting dock door: Use cable traction to adjust the movement of the dock door.

[0049] Figure 17 Installation procedure 6 for the tilting dock door: U-compartment continues to fill with water and the trunnion is in place.

[0050] Figure 18 Procedure 7 for installation of the dumping dock door: Wire rope installation and dock door closed status diagram.

[0051] Figure 19 This is a schematic diagram of the overall layout of auxiliary equipment and site during the installation of the dumping dock door.

[0052] Figure 20 This is a side structural diagram of the installation process of the dumping dock door.

[0053] Figure 21 Schematic diagram of the height of the vertical pulley and inclined pulley base plate of the first pulley group.

[0054] Figure 22 This is a schematic diagram of the position of the inclined pulley base plate of the first pulley group using the projection method.

[0055] The meanings of the numbers in the figure are as follows: left installation structure-1; wall sealing structure-11; horizontal precast block-111; vertical precast block-112; first phase concrete-113; anchor bolt-114; second phase concrete-115; steel pier-116; wedge plate-117; non-shrinkage concrete pier-118; hinged bearing seat-12; winch-13; first pulley block-14; hoist-15; right installation structure-2; tilting dock door-3; lifting eye-31; trunnion-32; second pulley block-33; epoxy grouting material for expansion joint-4; chemical anchoring-5; reference bracket-6; reference line-7; tugboat-8; depth gauge-9; sealing plate-10; floating crane-101. DETAILED DESCRIPTION

[0056] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings in the embodiments of the present invention, so as to have a further understanding of the concept of the present invention, the technical problems solved, the technical features constituting the technical solutions and the technical effects brought about.

[0057] like Figures 1-20 As shown, a dumping type installation structure and installation method, the specific operation is as follows:

[0058] 1) At the prefabrication yard, prepare the prefabrication platform and tooling to ensure the flatness of the sealing surface. Prepare stainless steel rebar and bend it into shape. Prepare ashlars and cement that meets standard requirements. Prepare stainless steel plates and weld stainless steel rebar to the back of the sealing surface as anchor bars.

[0059] 2) Arrange stainless steel plates on the prefabricated platform, tie stainless steel bars to form a steel mesh, then support the formwork and pour ashlar concrete. After the prefabricated blocks reach the curing period, transport them to the dock installation site.

[0060] 3) After the horizontal and vertical prefabricated blocks are transported to the site, the horizontal prefabricated blocks are installed first. Before installation, two sets of steel piers are arranged for each section of the horizontal prefabricated blocks according to their length, and wedge plates for adjusting the elevation and level are arranged on the steel piers.

[0061] 4) Use a total station to measure and locate the axis of the horizontal prefabricated block sealing surface, and arrange the fixing brackets for the reference piano wire at a certain distance outside the axis of the horizontal prefabricated block sealing surface. After the fixing bracket is firmly fixed, use the total station to measure the distance from the axis of the prefabricated block sealing surface on the crossbeam of the fixing bracket, and mark the notch with a sample punch or saw blade. Then, tie the reference piano wire to the notch position of the crossbeam of the fixing bracket. The fixing bracket is fixed at both ends of the entire horizontal sealing surface arrangement position. If the span is too large, several fixing brackets can be added in the middle position, and the reference piano wire is taut between the two fixing brackets.

[0062] 5) Use lifting equipment to insert the horizontal prefabricated blocks into the anchor bolts and hoist them onto the wedge plate. Mark the center line of the width on the stainless steel plate. Align the bottom of the depth gauge with the center line and measure the height with a precision level. Use the wedge plate to adjust the height of the horizontal prefabricated blocks to be consistent, including the height of both ends of a single horizontal prefabricated block and the height of each horizontal prefabricated block.

[0063] 6) After the height of the horizontal prefabricated blocks is adjusted to be consistent and in line with the design elevation, adjust the gap between adjacent horizontal prefabricated blocks to meet the requirements.

[0064] 7) Measure the distance between the sealing surface of each horizontal sealing prefabricated block and the reference piano line based on the reference piano line, and adjust the distances between the two ends of each horizontal prefabricated block and the upper and lower measuring points to be consistent.

[0065] 8) Check again that the center height of the sealing surface of the horizontal prefabricated blocks is consistent, the gap between adjacent horizontal prefabricated blocks meets the requirements, and the distance from the reference piano line is consistent, then tighten the nuts of the anchor bolts to fix them.

[0066] 9) Pour non-shrinkage concrete buttresses at the bottom of the adjusted and fixed horizontal precast blocks. Place a non-shrinkage concrete buttress at each end of each horizontal precast block to firmly support it. Then remove the wedge plate and steel buttresses and pour non-shrinkage concrete all over the bottom of the horizontal precast block. After the non-shrinkage concrete reaches its curing period, fill the gaps between the horizontal precast blocks with expansion joint epoxy grouting material. Finally, pour concrete on the back of the horizontal precast blocks. The second phase of concrete forms an overall L-shape, but it should be poured in layers. First, pour the horizontal portion at the bottom of the sealing surface of the horizontal precast block, then pour the vertical portion on its side to integrate it with the first phase of concrete.

[0067] 10) After the second phase of concrete pouring of the horizontal prefabricated block sealing surface is completed, select an appropriate temperature value time period to use a total station to measure the overall flatness of the sealing surface, calculate the average horizontal coordinate of the measured value, and calculate and determine the distance L between the center of the embedded hinged bearing seat and the horizontal prefabricated block sealing surface based on the average value of the actual measured flatness of the dock door's trunnion from the sealing structure surface. Combined with the measured average value of the horizontal prefabricated block sealing surface, determine the horizontal coordinate position of the hinged bearing seat; determine the longitudinal coordinate position of the hinged bearing seat based on the measured value S2 of the center span of the trunnions at both ends of the dock door; determine the height difference between the dock door trunnion and the sealing structure surface. The height difference is calculated, and then the installation elevation of the hinged bearing seat is calculated according to the center elevation of the sealing surface of the horizontal prefabricated block that has been installed and poured on site; then the various parameters of the hinged bearing seat are measured and adjusted using a total station; after the span S2, the distance L from the horizontal prefabricated sealing surface and the elevation are adjusted and meet the deviation requirements of the calculated values, the vertical part of the second phase concrete pouring is started. The pouring sequence is: first, grouting the reserved holes for the anchor bolts, then tightening the nuts of the anchor bolts, and finally installing the guide plates on the sides of the hinged bearing seat and pouring the entire second phase; the casting bearing is monitored throughout the grouting and pouring process.

[0068] 11) After the hinged bearing seat is installed and the second phase of concrete pouring and fixing is completed, the installation of the vertical prefabricated sealing surface of the dock is started. First, according to the center span of the sealing surface of the vertical prefabricated blocks at both ends, the total station is used to locate the position of the sealing surface on the horizontal prefabricated block. Then, holes are drilled at this position to adjust the chemical anchoring for the vertical expansion joint support. The anchoring height is consistent with the expansion joint gap. Then, the vertical prefabricated block is hoisted onto the chemical anchoring for the vertical expansion joint support adjustment. During hoisting, the stainless steel sealing plate is aligned with the stainless steel sealing plate on the horizontal prefabricated block. After checking that there is no misalignment or offset with tools such as a ruler, prepare to adjust the verticality of the stainless steel sealing plate.

[0069] 12) Before adjusting the verticality, first use the scaffolding support rods and tension screws to fix the vertical prefabricated blocks, such as Figure 6 As shown, the scaffolding support rod thread is used to rotate and tighten the screw rod and cooperate with the sling to pull the vertical prefabricated block. The supporting and pulling are arranged at right angles, which can well fix the vertical prefabricated block.

[0070] 13) Start adjusting the verticality, hang a plumb line from the top of the vertical prefabricated block to the bottom, measure the distance b between the top stainless steel sealing plate and the plumb line, and the distance a between the bottom stainless steel sealing plate and the plumb line, check the deviation of the two measured distances, if the top distance is greater than the bottom distance, it means that the top of the vertical prefabricated block is leaning forward, then slowly loosen the scaffolding struts, and tighten the tensioning screws at the same time, until the distance between the stainless steel sealing plate and the plumb line is consistent, if the top distance is less than the bottom distance, it means that the top of the vertical prefabricated block is leaning back, then continue to tighten the scaffolding struts and loosen the tensioning screws at the same time, until the distance between the stainless steel sealing plate and the plumb line is consistent, thus completing the verticality adjustment of the front and rear directions of the sealing surface. Figure 7 shown.

[0071] 14) Next, adjust the lateral verticality of the sealing surface. At this time, use the side of the stainless steel sealing plate as the measuring point and adjust the lateral verticality of the sealing surface according to the measurement and adjustment method in the front and rear directions.

[0072] 15) After the front-to-back direction and lateral verticality are adjusted, check again the misalignment and offset of the stainless steel sealing plates of the horizontal and vertical prefabricated blocks. If misalignment or offset occurs, use a jack to make fine adjustments until there is no misalignment or offset, and then use stainless steel ribs to weld them together.

[0073] 16) Measure the front, back and side verticality of the vertical precast blocks again. If there is a slight deviation, continue to make fine adjustments. If the verticality meets the requirements, do not turn the scaffolding support rods or tighten the screws. At this time, use the U-shaped clips to adjust the connection between the steel bars embedded in the first phase concrete and the stainless steel bars of the vertical precast blocks and tighten the U-shaped clip bolts. The number of U-shaped clips to be installed depends on the site conditions to ensure that there are steel bars connected at the top, middle and bottom.

[0074] 17) After ensuring that the vertical precast blocks are firmly fixed and will not move, start pouring epoxy grouting material into the gaps between the precast blocks. Make sure that the gaps are filled with epoxy grouting material for expansion joints.

[0075] 18) After the epoxy grouting material of the expansion joint reaches the curing period, start pouring concrete. At this time, be careful not to pour concrete to the top where the scaffolding struts and tensioning screws are arranged, and leave a small height to ensure the removal of the scaffolding struts and tensioning screws; wait for the concrete to reach the curing period, then remove the scaffolding struts and tensioning screws, and use a handheld cutting machine to cut off the stainless steel reinforcement plate. Be careful not to cut into the stainless steel sealing plate base material when cutting. After cutting, grind the welding points smooth and flat, and then prepare for the installation and adjustment of the next section of vertical prefabricated blocks.

[0076] 19) The installation and adjustment of the vertical precast blocks, concrete pouring methods and steps in the next section are the same as the previous section until all vertical precast blocks are installed and concrete poured.

[0077] 20) If Figure 21 and Figure 22 As shown, after the vertical prefabricated sealing surface is installed and poured, the vertical pulley and inclined pulley on the shore are installed. Before the installation begins, the height of the pulley groove where the wire rope passes is used as a reference. First, the distance L1 from the center of the vertical pulley to the center of the inclined pulley base plate is determined using the projection method on drawing software such as AutoCAD. The heights H1 and H2 of the top and bottom ends of the inclined surface of the inclined pulley base plate from the reference pulley groove are determined to ensure the accuracy of the inclination and height of the inclined pulley base plate during installation. The height H3 of the vertical pulley base plate from the reference pulley groove is determined. Then, according to the span of the pulleys at both ends of the dock door, the height of the vertical pulley base plate from the reference pulley groove is determined. Determine the span S3 of the pulleys on both sides of the shore based on the measured value S3; after all values ​​are determined, start installing the foundation plates of the vertical pulley and inclined pulley on the shore; use the total station to perform coordinate positioning and measurement and adjustment of the relative heights, adjust the height and position coordinate points of the top and bottom ends of the inclined pulley foundation plate from the elevation point of the reference pulley groove, and adjust the height and position coordinate points of the vertical pulley foundation plate from the elevation point of the reference pulley groove. After all measured values ​​meet the deviation requirements, install and fix the anchor bolts in the screw holes of the foundation plate and fix them firmly, then start pouring the second phase concrete, and carry out full monitoring during the pouring process.

[0078] 21) After the onshore vertical pulley and inclined pulley foundation plate and anchor bolts are installed and cast, the onshore vertical pulley and inclined pulley are fixed to the foundation plate with anchor bolts, thus completing the installation of all embedded parts of the dock door.

[0079] 22) Check and remove garbage and debris in the dry dock, check the flatness of the sealing surface of the dock door at the dock entrance, as well as the installation span, height and distance of the embedded hinge bearing seat relative to the sealing surface. After meeting the requirements for the installation of the dock door, start using a large water injection pump to inject water into the dock. The amount of water injected must ensure that its horizontal surface is consistent with the sea level outside the cofferdam.

[0080] 23) After the dry dock is filled with water and aligned with the sea level, the cofferdam excavation will begin. The excavation width and depth of the cofferdam will be determined based on the floating state of the dock gate when no water is added to the cabin, and must meet the conditions for floating entry of the dock gate. The cofferdam excavation will be carried out using a suction ditch vessel, which can suck sand and gravel into the cabin and transport them away during excavation, ensuring that no silt or impurities will accumulate at the cofferdam and dock sill, which would affect the installation of the dock gate.

[0081] 24) After the cofferdam is excavated, two tugboats, one in front and one behind, are used to lash the dock gate to the temporary berthing point. The tugboats' power is used to pull the dock gate through the cofferdam gap and transport it to the dry dock's installation location. The tugboats should be tied to the dock gate at the top of the dock gate to facilitate initial adjustment of the dock gate's bottom trunnion relative to the underwater hinge bearing seat after the dock gate enters the cofferdam.

[0082] 25) While the dock gate is being floated, winches and towing cables are deployed on both sides of the dry dock, with a minimum of four units deployed to enable precise, all-around positional adjustment of the dock gate, both at both ends and up and down. Once the dock gate enters the cofferdam, a floating crane equipped with a cable winder is deployed on the ocean side to serve as the brake and pull cable for dock gate adjustment, providing braking and adjustment during the towing process. The floating crane is secured via anchors and piles driven into the seabed, and a winch can also be deployed on the cofferdam to power the brake cable. Once the winches and floating crane are deployed, the towing and brake cables are attached to the upper and lower lifting lugs on either side of the dock gate.

[0083] 26) After the preparatory work is completed, check the working conditions of the multiple water injection pumps arranged on the floating crane, connect the pumps to the water injection ports of each compartment on the tilting dock door using water injection pipes, and prepare for water injection and ballasting work; valves should be installed at the water injection ports of each compartment to facilitate closing the water injection ports at any time; the sealing plates of the exhaust pipes of each compartment should be removed so that the air in each compartment can be discharged in time during water injection. The exhaust pipe outlet is set at the top of the tilting dock door to prevent seawater from submerging the exhaust pipe outlet during water injection and ballasting.

[0084] 27) A gravity angle indicator is installed and fixed on the top of the dock side panel of the dock gate. The base of the gravity angle indicator is close to or parallel to the panel surface, so as to accurately determine the inclination angle of the dock gate during water filling and ballasting, and determine and adjust the water filling conditions of each compartment according to the inclination angle.

[0085] 28) After everything is ready, you can start the water filling and installation process of the dock door; Figure 11 As shown, at this point, the dock door compartments are empty, the top of the dock door is sunken, and the bottom trunnion end is tilted upward, with an included angle of approximately 11°. The tidal openings on the ocean side of compartments E1 and E2 are sealed with plugging plates.

[0086] 29) Installation procedure 1: Figure 12 As shown in FIG, 100% seawater is injected into the compartments S and T of the dumping dock door using a water injection pump. Figure 14 As shown, since the compartments S and T are located at the two ends of the bottom of the dock door, after being filled with water, the weight of the bottom of the dumping dock door becomes heavier, and the dock door is affected by gravity, causing the bottom ear shaft end to sink and the top to rise; the angle is about 5°.

[0087] 30) Installation procedure 2: Figure 13As shown in Figure 2, 40% of seawater needs to be injected into compartments E1 and E2. Figure 14 As shown, since compartments E1 and E2 are at the top end of the tilting dock gate, after injecting 40% of seawater, the top and bottom of the dock gate remain level, creating a gravity balance point for the subsequent continued water injection of the middle section compartment and the bottom compartment.

[0088] 31) Installation procedure 3: Figure 14 As shown, 100% seawater is then injected into compartments K, L, and R. Figure 4 The K, L, and R cabins shown are in the middle section of the tilting dock door. Affected by gravity, the top of the dock door sinks slightly, and the bottom tilts slightly, with an angle of about 3°. At this time, the water ballasting and gravity balance of the upper and middle cabins are completed, and the posture of the dock door can be adjusted at a large angle from lying flat to an upright state with an angle.

[0089] 32) Installation procedure 4: Figure 15 As shown, inject 91% of seawater into compartment U. At this time, closely observe the pointer position of the gravity angle indicator and stop injecting water immediately when its inclination angle reaches about 50°. At this time, the dock gate is in a balanced state at this inclination angle. If water is continued to be injected, the dock gate will begin to sink.

[0090] 33) Installation procedure 5: Figure 16 As shown, the winch is started and the position of the ear shafts at both ends of the lower part of the dock door is accurately adjusted by pulling the cable; the ear shafts are slowly pulled to the top of the hinge bearing seat, and the two ear shafts are aligned with the hinge bearing seat, and the ear shafts slightly contact the positive guide plate on the hinge bearing; this step requires a diver to go into the water to observe and direct the operation of the winch and cable reel for adjustment.

[0091] 34) Installation Procedure 6: Figure 17 As shown in the figure, after the relative position of the ear shaft and the hinge bearing seat is accurately adjusted, water is immediately poured into the compartment number U to make the dock door sink slowly. The ear shaft passes through the limit of the positive and transverse guide plates of the hinge bearing seat and falls accurately into the groove of the hinge bearing seat for hinged connection. Then the water injection is stopped and the water injection volume is about 94%.

[0092] After the dock door trunnions are installed in place, all the blocking plates on the tidal openings on the E1 and E2 compartments are removed, and seawater continues to be poured into the E1 and E2 compartments until it reaches the same level as the sea level, so that the dock door can swing up and down with the tide of the sea; the valves of the water inlets on each compartment are closed, and each water inlet and exhaust port is tightly sealed with a blind flange.

[0093] 35) Install the program 7: Figure 18As shown, after the ear shaft is hinged into the hinged bearing seat, the wire rope is installed. There is one wire rope for the dock door, which is led out from the drum of the left winch and passes through the left pulley on the shore, the left pulley on the tipping dock door, the right pulley on the tipping dock door, and the right pulley on the shore, and then connected to the drum of the right winch; the wire rope has a large diameter and is heavy, and it cannot be passed between the pulleys by manpower, so it needs to be pulled by the traction cable to pass through each pulley group separately; before passing through, one end of the traction cable is overlapped and tied firmly with the lead-out end of the wire rope to ensure that it will not loosen or detach during dragging, and then the traction cable is passed through the pulley on the shore and the pulley on the dock door one by one, and finally connected to the winch drum on the other side. , start the winches on both sides to rotate the drum at the same time, the left winch releases the wire rope, and the right winch receives the wound traction cable on the drum, and at the same time drags the wire rope through the pulley on the shore and the pulley on the dock door one by one along the path of the traction cable. Finally, the wire rope is pulled to the drum position of the right winch. At this time, the binding connection between the traction cable and the wire rope is removed, the traction cable wrapped on the drum is removed, and the wire rope is fixed to the drum of the right winch. Then start the left and right winches at the same time to continue the operation of releasing the wire rope with the left winch and receiving the wire rope with the right winch. When the number of wire rope winding circles and layers on the winch drums on both sides is the same, the installation of the wire rope is completed.

[0094] After the wire rope is installed, the dumping dock door is closed. At the same time, the winches on both sides are activated to tighten the wire ropes, thereby pulling the dumping dock door's sealing structure up and slowly approaching the dock opening's sealing surface. When the sealing structure contacts the dock opening's sealing surface, the winches are stopped, the dumping dock door is raised, and the dry dock is then drained. It should be noted that before closing the dock door, the inspection gates and balancing filling valves on both sides of the dock must be opened simultaneously to ensure the sea level inside and outside the dock.

[0095] Start the drainage pumps in the buildings on both sides of the dry dock to drain the seawater in the dry dock. Before draining, close the gates, balancing filling valves and other equipment in the buildings on both sides of the dry dock that lead to the water filling corridor of the dry dock to prevent seawater from continuing to flow into the dry dock through the water filling corridor. During the drainage process, check the leakage of the dock door one by one as the water level drops, and use the inching function of the winch to continue to tighten the contact and pressure between the sealing structure of the dock door and the sealing surface of the dock mouth until the sealing leakage of the dock door meets the requirements.

[0096] 36) After the dock door is installed and the sealing and leakage conditions meet the requirements, set the stop limit of the dock door winch, set the manual and automatic ranges, check the tightness of the wire rope, and conduct comprehensive tests and adjustments on all functions and control systems of the winch; before starting the dock door commissioning, open the gate and balance filling valve of the water filling gallery, and fill water into the dock through the water filling gallery until the water level in the dock is consistent with the sea level, and then start the opening and closing commissioning of the dock door.

[0097] First, debug the dock door opening and adjust the dock door opening speed as follows: when the dock door is closed, start the winch to release the wire rope, select a shorter wire rope release distance (such as 1.5m), and operate manually to open the dock door slowly. When the wire rope is released 1.5m, set the automatic fast wire rope release program in the winch control cabinet, and the dock door will start to automatically and quickly dump. When it is 1.5m away from the pier, stop the automatic program setting, and continue to manually operate the dock door to slowly dump until the wooden block on the dock door contacts the pier. After the dock door stops on the pier, stop manual operation and check the tension of the wire rope. If the wire rope is too tight, continue to manually release the wire rope until the wire rope is no longer in a tight state, then start setting the limit switch.

[0098] Then debug the closing of the dock door, and adjust the opening speed of the dock door as follows: when the dock door is fully open, start the winch to retract the wire rope, select a shorter wire rope release distance (such as 1.5m), and operate manually to make the dock door close slowly. When the wire rope is retracted 1.5m, set the automatic and rapid wire rope retraction program in the winch control cabinet, and the dock door begins to automatically and rapidly pull up. When it is 1.5m away from the dock sill sealing surface, stop the automatic program setting, and continue to manually operate the dock door to slowly continue to lift and close until the sealing structure on the dock door contacts the dock sill sealing surface and presses the sealing strip, then start setting the limit switch.

[0099] The terms "connection" and "fixation" appearing in the description of the present invention may refer to fixed connection, processing and forming, welding, or mechanical connection. The specific meanings of the above terms in the present invention shall be understood according to the specific circumstances.

[0100] In the description of the present invention, the terms "center", "upper", "lower", "horizontal", "inner", "outer", etc., which indicate the orientation or position relationship, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation. Therefore, they should not be understood as limiting the present invention.

[0101] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some or all of the technical features therein can be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A dumping dock door installation structure, characterized by: Comprises a left installation structure and a right installation structure; The left installation structure (1) includes a wall sealing structure (11), a hinged bearing seat (12), a winch (13), a first pulley block (14) and a plurality of winches (15); the wall sealing structure (11) is installed on the left side of the dock door; the hinged bearing seat (12) is arranged at the bottom of the wall sealing structure (11), the first pulley block (14) is arranged on the upper part of the wall sealing structure (11), the winch (13) is arranged on the left side of the first pulley block (14), and drives the first pulley block (14) to rotate; the winch (15) is arranged on the side of the dock; The right mounting structure (2), which is the same as the left mounting structure (1), is arranged on the right side of the dock door; The top of the dumping dock door (3) is connected to the first pulley block (14), the middle portion is provided with a lifting lug (31) matching the winch (15), and the bottom trunnion (32) is hinged to the hinged bearing seat (12); The wall sealing structure (11) includes a horizontal prefabricated block (111), a vertical prefabricated block (112), a first-stage concrete (113), a horizontal embedded part, and a second-stage concrete (115); the first-stage concrete (113) is L-shaped and is arranged on the left side of the dock door; the horizontal embedded part includes a steel pier (116), a wedge plate (117), a non-shrinkage concrete pier (118) and an anchor bolt (114); the bottom of the steel pier (116) is connected to the upper part of the first-stage concrete (113), and the top supports the horizontal prefabricated block (115) through the wedge plate (117). 111); the non-shrinkage concrete pier (118) is arranged between the horizontal prefabricated block (111) and the first-stage concrete (113); the anchor bolt (114) passes through the anchor bolt hole on the horizontal prefabricated block (111) and is anchored in the first-stage concrete (113); the second-stage concrete (115) is L-shaped and arranged on the inner side of the first-stage concrete (113); the horizontal prefabricated block (111) is arranged on the upper part of the horizontal side of the second-stage concrete (115), and the vertical prefabricated block (112) is arranged on the right part of the vertical side of the second-stage concrete (115).

2. The tilting dock door installation structure according to claim 1, characterized in that: The vertical prefabricated block (112) comprises a plurality of vertical prefabricated units, and expansion joint epoxy grouting materials (4) are provided between adjacent vertical prefabricated units; the expansion joint epoxy grouting materials (4) are arranged horizontally, and chemical planting bars (5) are provided on the left and right sides for fixing.

3. The tilting dock door installation structure according to claim 2, characterized in that: The horizontal prefabricated block (111) comprises a plurality of horizontal prefabricated units, and expansion joint epoxy grouting material (4) is provided between adjacent horizontal prefabricated units.

4. The tilting dock door installation structure according to claim 1, characterized in that: A second pulley set (33) is provided on the top of the dumping dock door (3), and the second pulley set (33) is connected to the first pulley set (14) via a steel wire rope.

5. A method for installing a dumping dock door, characterized in that: Using the dumping dock door installation structure according to claim 1 includes the following steps: Step S1, setting a wall sealing structure (11) at the dock sill of the dock gate, and setting a winch (13), a first pulley block (14) and a hoist (15) on the shore; filling the dock with water and excavating a cofferdam in front of the dock entrance so that the water level in the dock is consistent with the sea level; Step S2, using a tugboat or other power traction equipment to tow and float the dumping dock door (3) from the temporary berthing position to the ocean front of the dock entrance; Step S3, adjusting the winches (15) and the ropes of the left mounting structure (1) and the right mounting structure (2) according to the position of the dumping dock door (3), the winches (15) being connected to the lifting ears at the left and right ends of the dumping dock door (3) respectively, to perform auxiliary traction movement and position adjustment; Step S4, starting different winches (15) to adjust the position of the dumping dock door (3) lying flat and floating on the sea surface so that the trunnions (32) at both ends of the bottom face the hinged bearing seat (12) at the dock sill position on the seabed; Step S5, arranging a water injection pump and a water injection pipe to inject water into the water tanks of each compartment of the dumping dock door (3) to gradually change its posture from lying flat to tilted upright, and the ear shafts (32) on the left and right sides gradually sink and slide into the hinge bearing seat (12) for connection; Step S6, connecting the first pulley block (14) to the top of the dumping dock door (3) through a steel wire rope, starting the winch (13) to drive the first pulley block (14) to rotate the dumping dock door (3) to complete the opening and closing, and draining the water in the dock to check the sealing performance of the dumping dock door (3).

6. The method for installing a dumping dock door according to claim 5, characterized in that: It also includes horizontal prefabricated blocks (111), vertical prefabricated blocks (112), first-phase concrete (113), horizontal embedded parts, second-phase concrete (115), steel buttresses (116), wedge plates (117), and non-shrinkage concrete buttresses (118). In step S1, setting the wall sealing structure includes the following steps: Step S11, pre-embedding stainless steel anchor bolts (114) in the first phase of concrete according to the anchor bolt holes reserved on the horizontal prefabricated block (111) and the vertical prefabricated block (112); Step S12, arranging the steel buttresses (116) and the wedge plates (117) according to the length of a single prefabricated unit, and adjusting them so that one prefabricated unit supports two sets of steel buttresses (116) and wedge plates (117); Step S13, based on the axis of the sealing surface, a reference bracket (6) and a reference line (7) for measurement and adjustment are arranged at a position offset from the sealing surface by a certain distance, and the reference line (7) is made of a piano wire with good toughness and strength; Step S14, hoisting and placing the horizontal prefabricated unit on the wedge plate (117), adjusting the axis position of the sealing surface with the reference line (7), and adjusting the elevation of the horizontal prefabricated unit with the center point of the sealing surface; Step S15, fixing the horizontal prefabricated units with the adjusted sealing surface axis and elevation using anchor bolts (114), adjusting and fixing each block until the sealing adjustment of all horizontal prefabricated blocks (111) is completed; Step S16, pouring non-shrinkage concrete buttresses (118) at the bottom of each horizontal precast unit, arranging two buttresses for each horizontal precast unit for support, removing the steel buttresses (116) and the wedge plate (117), and then pouring the precast block cushion concrete, and then grouting the expansion joint epoxy grouting material (4) between the precast units horizontally, and finally pouring the second phase of concrete (115); Step S17, after the horizontal prefabricated block (111) is installed and concrete is poured, the supporting steel bars of the vertical prefabricated block (112) are supported at the connection positions of the horizontal prefabricated block (111) and the vertical prefabricated block (112) on both sides by using the planting steel bar method; Step S18, hoisting the vertical prefabricated block (112) onto the supporting steel bars, binding them with wire and tie bolts to prevent them from falling over, first aligning the sealing surface of the vertical prefabricated block (112) with the sealing surface of the horizontal prefabricated block (111), and welding them with stainless steel plates, and then measuring and adjusting the verticality of the sealing surface using the plumb bob method; In step S19, after the verticality of the vertical prefabricated block (112) is adjusted, the gaps between the vertical prefabricated units are first filled with epoxy grouting material (4), and then the second phase of concrete (115) is poured. After the pouring is completed, the next vertical prefabricated unit is installed, adjusted, and poured using the same method.

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