Fabricated truss structure horizontal tower crane adaptive to wind power installation

Abstract

The invention discloses a fabricated truss structure horizontal tower crane adaptive to wind power installation, and belongs to the technical field of building construction machinery. The tower crane is arranged on one side of a wind power center and comprises a tower frame formed by splicing a plurality of assembly type modules, four trusses are arranged in a rectangular mode and connected through transverse connecting rods, and the bottom of the tower frame is designed to be in a pressing rod stress mode; the horizontal truss is fixedly mounted at the top of the tower; the horizontal walking trolley is arranged on the horizontal truss and can move horizontally; the counterweight is arranged at one end of the horizontal truss; the steel strand hydraulic lifters are arranged on the periphery of the tower in a surrounding mode and used for lifting and detaching the tower; an assembly type structure is adopted, the modularization degree is high, transportation is convenient, and cost can be remarkably reduced; through a pressing rod stress mode and a tension-free design, the overturning risk is eliminated; the invention provides two structures with rotary support and without rotary support, respectively meets the requirements of flexible operation and accurate centering, and is adaptive to hoisting of wind turbine types with the height of more than 200 meters and the height of 10 MW to 25 MW and heavy components with the height of 50 t to 400 t, thereby being suitable for hoisting of wind turbine types with the height of more than 200 meters and heavy components with the height of 50 t to 400 t.

Description

Technical Field

[0001] This invention relates to a prefabricated truss structure horizontal tower crane adapted for wind power installation, belonging to the field of construction machinery technology. It covers both structures with slewing bearings (suitable for flexible operation in multiple sites and with multiple models) and structures without slewing bearings (suitable for precise centering operations in wind power centers). It is suitable for hoisting wind power towers of 200m and above and heavy components of 50t to 400t, and can achieve horizontal transport with a large span of 10m to 20m, meeting the safe and efficient installation requirements of different wind power sites and models. Background Technology

[0002] In the current wind power installation field, traditional luffing tower cranes have three major limitations: First, they have small spans (≤15m) and weak load-bearing capacity (≤250t), making them unsuitable for wind power components with spans of 15m or more and a load capacity of 300t (such as 16MW wind turbine nacelles); second, the towers are mostly integral steel structures, requiring specialized vehicles for transportation, and the cost of road construction at remote wind power sites is high (over 2 million yuan per project); third, the stress distribution mode is unreasonable, as traditional tower cranes rely on tension balance, making them prone to overturning risks due to wind speed changes (wind speeds at a height of 200m often reach 22m / s), with an accident rate exceeding 0.5%.

[0003] Although existing wind power tower cranes have been optimized, they still have shortcomings: prefabricated design is not widespread, and the modularity is low (single module weight ≥15t); there is no targeted dual-structure design, the centering accuracy of the slewing model is poor, and the site adaptability of the non-slewing model is weak; personnel operation requires working at height (≥30m), the fall risk rate exceeds 0.8%, and the overall cost (labor + materials + transportation) is only 10% lower than that of traditional equipment, failing to form a cost advantage.

[0004] Furthermore, the following technical defects exist: 1. Insufficient span and load-bearing capacity; Traditional luffing jib tower cranes have a span of ≤15m and a load capacity of ≤250t, making them unsuitable for wind power components with spans of 15m or more and a load capacity of 300t. When operating at a height of 200m, the deflection exceeds 8mm / m. 2. High transportation and deployment costs; The transportation of the integrated tower requires road construction (width ≥ 6m), and the transportation + road construction cost for a single project exceeds 3 million yuan, with a deployment cycle of more than 15 days for remote sites; 3. Significant risk of overturning; Relying on tensile force to balance the load, at a height of 200m and a wind speed of 20m / s, the lateral displacement exceeds 30mm, and the overturning risk rate exceeds 0.5%. 4. Poor compatibility between height and machine model; The maximum tower height is ≤150m, which cannot be used with wind turbine towers over 200m, and it only supports wind turbine models ≤10MW, with a compatibility rate of ≤70%. 5. Lack of dual-structure design; The machine features a differentiated design with and without slewing. The centering accuracy of the non-slewing model is ≤5mm, while the operating radius of the slewing model is strictly limited (≤100m). 6. Safety and cost disadvantages; Personnel need to work at heights (≥30m), which poses a high risk of falling; the overall cost reduction rate (labor + materials + transportation) is ≤10%, making it uneconomical. Summary of the Invention

[0005] This invention overcomes the shortcomings of existing technologies and provides a prefabricated truss structure horizontal tower crane suitable for wind power installation. Utilizing a prefabricated truss tower, it achieves a span ≥15m, a load capacity ≥400t, and a deflection ≤3mm / m at a height of 200m. Furthermore, the weight of a single module after modular disassembly is ≤8t, reducing transportation and road construction costs. The optimized tower stress pattern ensures all components are compression members, eliminating tension members and preventing overturning at a wind speed of 22m / s at a height of 200m. The four-truss structure achieves a tower height ≥200m, adapting to all wind turbine models from 10MW to 25MW. The dual-structure differentiated design (with / without slewing) meets the alignment and operational requirements of different sites. The personnel operating platform is separated from the wind turbine's internal operations, eliminating the risk of falls, while achieving an overall cost reduction rate ≥30%.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a prefabricated truss structure horizontal tower crane adapted for wind power installation, the tower crane being installed on one side of the wind power center, comprising: The tower is assembled from multiple prefabricated modules, and adopts a rectangular layout of four trusses connected by horizontal connecting rods. The bottom of the tower is designed as a compression member bearing mode. A horizontal truss is fixedly installed on the top of the tower; A horizontal traveling trolley is mounted on the horizontal truss and is used to move horizontally along it; A steel strand hydraulic lifter is installed around the perimeter of the tower; it is used for lifting and dismantling the tower.

[0007] Furthermore, the assembled module adopts a detachable structure in which the main chord and the web members are riveted together.

[0008] Furthermore, the tower also includes a slewing bearing structure, which is disposed between the top of the tower and the horizontal truss, for driving the horizontal truss and the horizontal traveling trolley to rotate 360°.

[0009] Furthermore, the tower does not have a slewing bearing structure, and the horizontal truss is fixedly connected to the top of the tower; in this case, the wind power center, the tower crane center, and the center of the short side of the tower must be kept on the same axis.

[0010] Furthermore, the tower is connected by flanges and bolts to form different numbers of tower segments, with a maximum assembly height of up to 250 meters; the span of the horizontal truss is adjusted between 10 meters and 20 meters by adding or removing modules.

[0011] Furthermore, it also includes a personnel operating platform, which is located at a height of no more than 10 meters on the tower and is equipped with guardrails and non-slip flooring.

[0012] Furthermore, the prefabricated module includes an upper chord, a lower chord, and a web member. The upper chord is parallel to the lower chord and coplanar with the web member. The web member is inclinedly connected between the upper chord and the lower chord to form a triangular stable structure. The connecting grooves pre-welded to the connection parts of the upper chord and lower chord and the connecting grooves at the ends of the web members can be movably and properly inserted together. At least two connecting holes are opened in the connecting grooves, and the connecting holes are symmetrically distributed along the central axis of the web members. Rivets are inserted into the connecting holes between the web members and the upper and lower chords, and the rivets connect the upper and lower chords to the web members.

[0013] Furthermore, the clearance between the connecting hole and the rivet rod is controlled at 0.1 to 0.3 mm, laying the foundation for the subsequent expansion process.

[0014] Furthermore, the connection between the upper and lower chords and the connecting groove at the end of the web members are subjected to vibration aging after welding to remove stress, so that the residual stress is ≤50MPa, thereby reducing the impact of internal stress on fatigue performance.

[0015] Furthermore, the positioning and guiding structure is provided with positioning pins and positioning holes at the docking ends of adjacent spatial truss structural units. The gap between the diameter of the positioning pin and the diameter of the positioning hole is ≤0.1mm. During on-site assembly, the positioning pins are used to quickly align the components and avoid docking deviations. In addition, guide grooves are provided on the docking flange plates of the upper chord and the lower chord to achieve "guidance first, then fastening" in conjunction with the positioning pins, thereby improving assembly efficiency.

[0016] Furthermore, the rivets are made of stainless steel or high-strength aluminum alloy, and their tensile and shear strengths are not lower than those of the truss unit material, avoiding local stress concentration caused by insufficient strength of the connecting parts; the rivet shank length is equal to the sum of the thicknesses of the two ends plus 1.4 times the rivet shank diameter, and the rivet head diameter is 2 to 2.5 times the shank diameter, increasing the bearing area and evenly distributing the load; the rivets are crimped using hydraulic riveting equipment, applying axial pressure and radial expansion force to the rivet shank after piercing, causing the shank to plastically deform and expand to fill the 0.1 to 0.3 mm gap until it is completely in contact with the inner wall of the hole; continued pressure is applied to press the shank end into a second rivet head with the same size as the fixed rivet head, forming a double rivet head + clearance-free fit structure, completely eliminating the risk of loosening, ensuring uniform load transfer, and protecting fatigue performance.

[0017] Furthermore, a 2-3mm thick rubber or polyurethane gasket is provided between the adjacent planes of the connecting groove of the upper chord and lower chord and the connecting groove of the end of the web member after they are inserted. The gap between the through hole of the gasket and the rivet rod is ≤0.1mm. After riveting, the gasket is pressed tightly, which not only fills the tiny gaps to prevent corrosion, but also buffers vibration and impact.

[0018] This invention discloses an operation method for a horizontal tower crane based on a prefabricated truss structure, including a precise centering operation process without a slewing bearing structure, the steps of which are as follows: a. Site preparation: Confirm that the wind turbine center, tower crane center, and short side center axis are aligned, and deploy fixed counterweights; b. Tower assembly: Transporting and assembling prefabricated modules to the target height; c. Component hoisting: The horizontal traveling trolley moves along the horizontal truss to lift the component, and a laser positioning instrument is used to ensure centering accuracy; d. Safe operation: The operator controls the hoisting from the middle platform of the tower crane, while the wind turbine installers enter the wind turbine to carry out the installation work.

[0019] Furthermore, an operation method for a horizontal tower crane based on a prefabricated truss structure includes a flexible operation process with a slewing bearing structure, the steps of which are as follows: a. Site deployment: Assemble the tower and install the slewing bearing in a site that meets the requirements of the operating radius and lifting weight; b. Tower assembly: Assemble the tower to the target height, fix the counterweight, and calibrate the levelness of the slewing bearing; c. Rotary transfer: Start the rotary motor, adjust the working direction 360°, and lift the component; d. Precise installation: Move the trolley to the target position, make fine adjustments and install the components, and the operator controls the entire process on the platform.

[0020] The advantages of this invention compared to existing technologies are as follows: Compared to traditional luffing jib tower cranes, this invention features a larger tower span, stronger load-bearing capacity, and better safety under various working conditions; the tower is a prefabricated truss that can be disassembled, making transportation more convenient and significantly reducing transportation and road construction costs; the larger tower span means the tower crane is not subjected to tension, only compression members, eliminating any risk of overturning; the tower height can reach over 200 meters, making it suitable for installing all wind turbine models on the market; this invention uses a fixed counterweight system, and the tower crane can be divided into those with and without slewing, which can be selected according to the site and turbine model; for models without slewing, the wind turbine center must be aligned with the tower crane center, and the short side centers must be on the same axis, while models with slewing are more flexible, only needing to meet the working radius and lifting weight requirements; in this invention, all personnel operate on the tower crane platform, while wind turbine installers are inside the wind turbine, eliminating the risk of falls; due to the use of prefabricated modules, the overall costs of labor, materials, transportation, and installation are significantly reduced; Attached Figure Description

[0021] The present invention will now be further described with reference to the accompanying drawings.

[0022] Figure 1 This is a positional diagram of the present invention without a rotary mechanism (they must be concentric).

[0023] Figure 2 This is a schematic diagram of the position of the present invention with a rotary mechanism (concentricity is not required).

[0024] Figure 3 This is a schematic diagram of the initial structure of the tower when it is erected according to the present invention.

[0025] Figure 4 This is a schematic diagram of the three-dimensional process structure of the tower of the present invention.

[0026] Figure 5 for Figure 4 A magnified structural diagram of region A in the middle.

[0027] Figure 6 This is a top view of the structure of the present invention.

[0028] Figure 7 for Figure 6 A magnified structural diagram of region B in the middle.

[0029] Figure 8 This is a schematic diagram of the structure of the present invention.

[0030] Figure 9 This is a schematic diagram of the tower assembly module in this invention.

[0031] In the diagram: 1 is the wind power center, 2 is the tower crane center, 3 is the short side center, 4 is the tower, 41 is the upper chord, 42 is the lower chord, 43 is the web member, 44 is the rivet, 45 is the connecting groove, 5 is the horizontal truss, 6 is the horizontal traveling trolley, 7 is the counterweight, and 8 is the steel strand hydraulic lifter. Detailed Implementation

[0032] The present invention will be further described below with reference to specific embodiments.

[0033] like Figures 1-9 As shown, this invention uses a prefabricated truss tower as its core, a dual-structure design as the key to adaptation, and safety and cost optimization as its goals to construct a horizontal tower crane with both slewing and non-slewing structures. Employing a prefabricated truss tower (single module ≤8t), it achieves a span of 10-20m, a load capacity of 400t, and a height of 200m+; it innovates the stress-bearing mode of the compression members, combined with fixed counterweights, to eliminate the risk of overturning; the slewing model allows for flexible operation, while the non-slewing model ensures precise centering (wind power center - tower center - short side center coaxial); personnel operations are concentrated on the tower crane platform, while wind turbine installation personnel work inside, resulting in an overall cost reduction of ≥30%.

[0034] The structure and function of the core components of this invention are as follows: I. Prefabricated Truss Tower Structure Design: 1. The tower adopts a detachable assembly design for the main chord and web members. The main chord is made of Q960 high-strength steel pipe (outer diameter 500mm, wall thickness 28mm), and the web members are made of Q690 angle steel (L120×12). After disassembly, the single module size is 3m×3m×8m, and the weight is ≤8t. It can be transported by ordinary trucks (width 2.5m) without the need for special road construction. 2. The tower span can be adjusted via add / remove modules. The four trusses are arranged in a rectangular layout (8m on each side), with a 4m spacing between transverse connecting rods and a torsional stiffness of 5×10. 5 kN・m / rad, deflection ≤3mm / m when bearing 400t at a height of 200m, and bearing ≥300t when span of 20m.

[0035] 3. Optimized stress distribution: The tower adopts a compression member stress distribution mode with no tension components. It is equipped with a fixed counterweight at the top (modular design, 10t per piece). The stress is monitored in real time by a pressure sensor (range 0~2000kN). At a height of 200m and a wind speed of 22m / s, the lateral displacement is ≤20mm, with no risk of overturning.

[0036] II. Dual-structure differentiated design (with / without rotation).

[0037] 1. Structure without slewing bearing (precise alignment): In this invention, the wind power center, tower crane center, and short side center must be aligned on the same axis with an alignment accuracy of ±2mm, calibrated using a laser alignment instrument (accuracy ±0.5mm). Suitable scenarios: open wind power sites, 10MW~25MW wind turbine models, operating radius 10m~20m, load 100t~400t, no need for multi-directional adjustment, stability is the priority.

[0038] 2. Structure with slewing bearing (for flexible operation): The invention features a central slewing bearing (2.5m in diameter, bearing capacity ≥2000kN, slewing accuracy ±0.05°), which, in conjunction with a 30kW drive motor, enables 360° continuous slewing. Suitable scenarios: complex sites (such as multiple wind turbine clusters), operating radius of 10m to 20m, no strict centering required, only the operating radius and lifting weight requirements (50t to 300t) need to be met, flexibility is the priority.

[0039] III. Height and Model Compatibility Design 1. Height adaptability: The tower segment height is 5m, and it can be spliced ​​with flange bolts to a maximum height of 250m, which is suitable for wind power towers of 200m to 250m. The verticality deviation of the tower body is ≤0.8 / 1000 (adjusted in real time through the attachment device). 2. Model compatibility: By adjusting the number of truss modules and the weight of the counterweight, it is compatible with all wind turbine models from 10MW to 25MW (nacelle weight 150t to 400t, rotor diameter 180m to 250m), with a compatibility rate of 100%.

[0040] IV. Safety and Cost Optimization Design 1. Safety Protection: Personnel operating platform: Located in the middle of the tower crane (height ≤ 10m), equipped with guardrails (height 1.2m) and non-slip flooring to prevent high-altitude operations; Wind turbine operation separation: Wind turbine installers enter the wind turbine through an internal ladder to work, completely separated from the tower crane operating platform, reducing the risk of fall to 0%.

[0041] 2. Cost optimization: Prefabricated modules: manual installation efficiency is increased by 50% (from 3 days / section to 1.5 days / section), and material loss rate is reduced from 5% to 2%; Transportation costs: With ordinary truck transportation, no road repairs are required. The cost of transportation plus road repair for a single project has been reduced from 3 million yuan to 800,000 yuan, resulting in an overall cost reduction of ≥30%.

[0042] The steps of the operation method of this invention are as follows: I. Operation process for structures without slewing bearings (precise alignment for wind power).

[0043] 1. Site preparation: Confirm that the wind turbine center, tower crane center, and short side center axis are aligned, the site flatness deviation is ≤3mm / m, and deploy fixed counterweights; 2. Tower assembly: Transport prefabricated modules (each ≤ 8t), assemble the tower to a height of 200m, and calibrate the verticality ≤ 0.8 / 1000; 3. Component hoisting: The horizontal traveling trolley moves along the 20m span truss to lift the 120t wind turbine tower section. The laser positioning instrument (accuracy ±0.5mm) ensures that the centering deviation is ≤2mm. 4. Safe operation: The tower crane operator controls the operation from the middle platform, while the fan installer enters the interior. When the wind speed is 20m / s, the pressure bar is stable and there is no risk of overturning. A single operation takes 22 minutes.

[0044] II. Operation process for structures with slewing bearings (flexible site).

[0045] 1. Site deployment: No strict alignment is required, only the working radius (e.g., 20m) and lifting weight (e.g., 80t) need to be met. Assemble a 7.2m wide diamond truss and install a slewing bearing. 2. Tower assembly: Assemble the tower to a height of 220m, fix the counterweight, and calibrate the slewing bearing levelness to ≤0.1mm / m; 3. Rotary transfer: Start the rotary motor (0.5r / min), adjust the working direction 360°, lift 80t nacelle components, and suppress the sway ≤45mm under a wind speed of 18m / s; 4. Precise installation: The trolley moves to the target position, and the laser positioning fine-tuning deviation is ≤2mm. The operator controls the operation from the platform, while the fan operator works inside. Each operation takes 20 minutes.

[0046] The following is a detailed explanation using a wind power operation without a slewing bearing (25MW wind turbine) as an example.

[0047] 1. Equipment parameters; The prefabricated tower is 250m high, with a span of 10-20m, consisting of 4 rectangular trusses (8m on each side) and a fixed counterweight of 0-100t. 2. Working conditions; The wind power center, tower crane center, and short side center are coaxial; the component is a 120t wind power tower section; the wind speed is 20m at a height of 20m. 3. Work results; With a centering accuracy of 1.8mm and a tower deflection of 2.8mm / m, there is no risk of overturning; the transportation cost is 800,000 yuan (compared to 3 million yuan for traditional methods), reducing the overall cost by 35%, and the time taken for a single operation is 22 minutes.

[0048] The following is a detailed explanation using a wind power operation with a slewing bearing structure (10MW wind turbine) as an example.

[0049] 1. Equipment parameters; The prefabricated tower is 200m high, with a span of 100m, consisting of 4 diamond trusses (7.2m wide) and a slewing bearing diameter of 2.5m. 2. Working conditions; Complex site (multiple wind turbine clusters), 80t nacelle components, 80m operating radius, 18m / s wind speed at 200m height; 3. Work results; The horizontal deviation of 360° rotation is 0.2mm / m, and the docking accuracy is 1.5mm; the deployment cycle is 7 days (traditional 15 days), the labor cost is reduced by 40%, and the time for a single operation is 20 minutes.

[0050] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A prefabricated truss structure horizontal tower crane adapted for wind power installation, characterized in that, The tower crane is located on one side of the wind power center and includes: The tower is assembled from multiple prefabricated modules, and adopts a rectangular layout of four trusses connected by horizontal connecting rods. The bottom of the tower is designed as a compression member bearing mode. A horizontal truss is fixedly installed on the top of the tower; A horizontal traveling trolley is mounted on the horizontal truss and is used to move horizontally along it; The counterweight is located on a horizontal truss away from the end of the horizontal traveling trolley. A steel strand hydraulic lifter is installed around the perimeter of the tower; it is used for lifting and dismantling the tower.

2. The prefabricated truss structure horizontal tower crane adapted for wind power installation according to claim 1, characterized in that, The assembled module adopts a detachable structure in which the main chord and web members are riveted together.

3. The prefabricated truss structure horizontal tower crane adapted for wind power installation according to claim 1, characterized in that, The tower also includes a slewing bearing structure, which is disposed between the top of the tower and the horizontal truss, and is used to drive the horizontal truss and the horizontal traveling trolley to rotate 360°.

4. The prefabricated truss structure horizontal tower crane adapted for wind power installation according to claim 1, characterized in that, The tower does not have a slewing bearing structure, and the horizontal truss is fixedly connected to the top of the tower; at this time, the wind power center, the tower crane center, and the center of the short side of the tower must be kept on the same axis.

5. The prefabricated truss structure horizontal tower crane adapted for wind power installation according to claim 1, characterized in that, The tower is connected by flanges and bolts to form different numbers of tower segments, with a maximum assembly height of 250 meters; the span of the horizontal truss is adjusted between 10 meters and 20 meters by adding or removing modules.

6. The prefabricated truss structure horizontal tower crane adapted for wind power installation according to claim 1, characterized in that, It also includes a personnel operating platform, which is located at a height of no more than 10 meters on the tower and is equipped with guardrails and non-slip flooring.

7. The prefabricated truss structure horizontal tower crane adapted for wind power installation according to claim 2, characterized in that, The prefabricated module includes an upper chord, a lower chord, and a web member. The upper chord is parallel to the lower chord and coplanar with the web member. The web member is inclinedly connected between the upper chord and the lower chord to form a triangular stable structure. The connecting grooves pre-welded to the connection parts of the upper chord and lower chord and the connecting grooves at the ends of the web members can be movably and properly inserted together. At least two connecting holes are opened in the connecting grooves, and the connecting holes are symmetrically distributed along the central axis of the web members. Rivets are inserted into the connecting holes between the web members and the upper and lower chords, and the rivets connect the upper and lower chords to the web members.

8. A method for operating a horizontal tower crane with a prefabricated truss structure as described in any one of claims 1 to 7, characterized in that, The process for precise alignment without a slewing bearing includes the following steps: a. Site preparation: Confirm that the wind turbine center, tower crane center, and short side center axis are aligned, and deploy fixed counterweights; b. Tower assembly: Transporting and assembling prefabricated modules to the target height; c. Component hoisting: The horizontal traveling trolley moves along the horizontal truss to lift the component, and a laser positioning instrument is used to ensure centering accuracy; d. Safe operation: The operator controls the hoisting from the middle platform of the tower crane, while the wind turbine installers enter the wind turbine to carry out the installation work.

9. A method for operating a horizontal tower crane based on the prefabricated truss structure as described in claim 3, characterized in that, This includes a flexible operating procedure with a slewing bearing structure, the steps of which are as follows: a. Site deployment: Assemble the tower and install the slewing bearing in a site that meets the requirements of the operating radius and lifting weight; b. Tower assembly: Assemble the tower to the target height, fix the counterweight, and calibrate the levelness of the slewing bearing; c. Rotary transfer: Start the rotary motor, adjust the working direction 360°, and lift the component; d. Precise installation: Move the trolley to the target position, make fine adjustments and install the components, and the operator controls the entire process on the platform.

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