Gantry crane cart mechanism replacement method

Abstract

The invention relates to a gantry crane cart mechanism replacement method. The method comprises the following steps of pile foundation construction, jacking tool installation, jacking jig frame arrangement, gantry jacking, cart mechanism traction, cart mechanism disassembly and cart mechanism reset. Compared with a traditional replacement scheme, the gantry crane cart mechanism replacement method has the advantages that the safety, the reliability and the economical efficiency are remarkably improved, a large amount of high-altitude hoisting operation is reduced, the cart mechanism replacement period is shortened, the safety coefficient is increased, and the labor intensity is reduced.

Description

Technical Field

[0001] This invention relates to the field of cranes, and in particular to a method for replacing the trolley mechanism of a gantry crane. Background Technology

[0002] Cranes mainly refer to tower cranes, bridge cranes, gantry cranes, truck cranes, and other types of cranes. Gantry cranes primarily consist of a gantry structure, hoisting mechanism, trolley traveling mechanism, auxiliary trolley traveling mechanism, electrical system, and safety devices. The gantry is the main supporting structure of the crane, typically constructed from welded or bolted steel, and comes in two forms: rigid legs and flexible legs. Its main components include the main beam, legs, and lower crossbeam. The trolley traveling mechanism drives the entire crane to move longitudinally along the tracks, and its main components include the drive unit and wheel sets.

[0003] Because the trolley traveling mechanism is located at the bottom of the crane and bears a large load, its wheel sets experience severe wear, making replacement difficult. Currently, the most common approach is to disassemble the upper crossbeam and gantry structure before replacement, which involves extensive high-altitude work, poses significant safety risks, and has a long construction period, severely impacting the equipment's usability. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for replacing the gantry crane trolley mechanism that can reduce high-altitude operations, reduce the difficulty of operations and shorten the construction cycle.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a method for replacing the gantry crane trolley mechanism, the innovation of which is: including the following steps: pile foundation construction, installation of jacking fixtures, arrangement of jacking jigs, gantry crane jacking, trolley mechanism traction, trolley mechanism disassembly and trolley mechanism resetting.

[0006] Furthermore, the specific steps are as follows: S1: Pile foundation construction, anchoring position pre-measurement and layout → steel pipe pile inspection → pilot hole → pile driver positioning → pile extraction and hoisting → verticality adjustment → initial pressure application → check the verticality of the pile body → pile driving → pile splicing → entering the bearing layer → pile top elevation control → pile formation → pouring cap beam → foundation curing. S2: Install the lifting fixture. After the gantry crane trolley mechanism moves to the lifting position, the lifting fixture is installed. The lifting fixture includes an upper sealing plate, a lower bottom plate, a side sealing plate, and stiffening plates connecting the upper sealing plate and the lower bottom plate. The stiffening plates include inner stiffening plates and outer stiffening plates. The side sealing plates are located outside the inner stiffening plates and the outer stiffening plates. A triangular plate is also provided on the upper end face of the upper sealing plate. S3: Lifting frame arrangement. After installing the lifting fixture, once the gantry crane trolley mechanism has moved to the lifting position, tighten the windproof cables and install the windproof wedges. Move the upper and lower trolleys to the top limit position on the non-lifting side, cut off the power, and remove the accessories. Lay steel plates and install the road plate, bearing beam, lifting frame, jacks, lifting safety, and lifting beam in sequence. Remove the flange bolts of the trolley mechanism. Weld and fix temporary anti-tilting support frames on both sides of the gantry crane legs near the trolley mechanism. Steel plates need to be laid at the bottom of the support to expand the bearing surface and prevent foundation settlement. After installation, start lifting the gantry frame. S4: Mast lifting, trial lifting → formal lifting → lift the entire trolley mast by 10mm and then stop → maintain pressure and check settlement; S5: Traction of the trolley mechanism, arrangement of the winch → traction → arrangement of typhoon protection support; S6: Disassemble the trolley mechanism. After pulling out the trolley mechanism, add an anti-tipping A-frame to the three-level balance beam of the trolley mechanism. Disassemble each level of balance beam. Before removing each level of balance beam, prepare the anti-tipping support for the next level. Directly assemble the new trolley mechanism on the gantry crane's rail. Install the drive wheel set, driven wheel set, and lower balance beam of the trolley mechanism on the rail. When arranging each wheel set and lower balance beam, pay close attention to checking the straightness and perpendicularity data of the traveling wheels. If they are not up to standard, they need to be pre-adjusted in advance to ensure the margin for subsequent adjustments of the whole vehicle. S7: Reset the trolley mechanism. After the trolley mechanism is assembled, rearrange the winch in the opposite direction of the winch in step S5, and use a truck crane in conjunction with the winch to install the new trolley mechanism in place. Use the truck crane to support and stabilize the trolley mechanism, and then use a 10T winch to slowly drag the trolley mechanism to the original installation position, align it with the gantry crane frame, insert new high-strength bolts, tighten them and then release the hook. After installation, remeasure the dimensions of the traveling wheels and adjust them with a string line. Restore other removed accessories. After adjustment, test run to check the installation accuracy.

[0007] Furthermore, in step S2, when installing the lifting fixture, first hoist the bottom plate and adjust it into position before locating and welding it. Then, hoist the inner and outer stiffening plates in sequence, align them, and fix them. Hoist the top sealing plate above the inner and outer stiffening plates, adjust it, and fix it. Hoist the triangular plate above the top sealing plate, align it, and fix it. After welding in sequence, hoist the side sealing plates and weld them to complete the installation of the lifting fixture.

[0008] Furthermore, in step S4, when lifting the gantry, a trial lifting is first performed to apply preload pressure and check the overall stability of the lifting system. The lifting work is directed by the commanding personnel. During the process, the lifting height is checked and the lifting pressure is tested. Then, the formal lifting is performed, and the gantry is lifted by 10mm and then stopped. After maintaining the pressure for 12 hours, the tire frame and road plate are checked for any obvious settlement.

[0009] Furthermore, in step S5, when traction of the trolley mechanism, firstly, winches are arranged on both sides of the trolley mechanism, then the entire trolley mechanism is pulled under the gate frame using the winches on both sides, and then the trolley mechanism is supported and stabilized by a truck crane, and then the trolley mechanism is pulled to the dismantling position.

[0010] The advantages of this invention are as follows: Compared with traditional replacement methods, the gantry crane trolley mechanism replacement method of this invention significantly improves safety, reliability, and economy, reduces a large amount of high-altitude hoisting work, speeds up the replacement cycle of the trolley mechanism, improves the safety factor, and reduces labor intensity. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the gantry crane trolley mechanism in this invention.

[0012] Figure 2 This is a side view of the gantry crane trolley mechanism in this invention.

[0013] Figure 3 for Figure 2 Enlarged schematic diagram of part A.

[0014] Figure 4 This is a schematic diagram of the lateral stress on the flexible leg lifting side of the trolley mechanism in this invention.

[0015] Figure 5 This is a schematic diagram illustrating the calculation of the flexible leg lifting displacement of the trolley mechanism in this invention.

[0016] Figure 6 This is a schematic diagram of the rigid leg lifting side stress of the trolley mechanism in this invention.

[0017] Figure 7 This is a schematic diagram illustrating the calculation of the rigid leg lifting displacement of the trolley mechanism in this invention. Detailed Implementation

[0018] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0019] The method for replacing the gantry crane trolley mechanism of the present invention is achieved through the following steps: pile foundation construction, installation of jacking fixtures, arrangement of jacking jigs, gantry crane jacking, trolley mechanism traction, trolley mechanism disassembly and trolley mechanism resetting.

[0020] The following is in conjunction with the appendix Figure 1-7Taking a 500T gantry crane with a span of 138m, a trolley travel speed of 32m / min, a minimum centerline distance of 12.5m when two cranes are hoisted together, an upper trolley equipped with two 170T hooks, a lower trolley with a 250T hook, a hoisting height of 70m above the dock, 60m above the rails, and 10m below the rails, and a self-weight of approximately 2486T as an example, the method for replacing the gantry crane trolley mechanism of the present invention will be specifically explained: S1: For pile foundation construction, firstly, review the geological survey report to clarify the soil layer distribution and bearing capacity requirements. Then, measure and lay out the anchoring position in advance to determine the pile foundation location. Next, inspect the steel pipe piles, including checking the straightness of the pile body, the flatness of the end, and the integrity of the anti-corrosion layer. After the steel pipe piles pass the inspection, pile foundation construction will proceed.

[0021] The pile foundation construction includes: drilling the pilot hole → positioning the pile driver → removing and hoisting the pile → adjusting the verticality → initial pressure application → checking the verticality of the pile body → driving the pile → splicing the pile → entering the bearing layer → controlling the pile top elevation → completing the pile.

[0022] Next, the foundation is poured: reinforcement bars are arranged according to the drawings, the cap beam is poured, and finally the foundation is cured to complete the construction of the pile foundation.

[0023] S2: Install the jacking fixture. After the gantry crane 11's trolley mechanism 12 travels to the jacking position, install the jacking fixture, such as... Figure 3 As shown in the schematic diagram, the lifting fixture includes an upper sealing plate 2, a lower bottom plate 5, a side sealing plate 3, and a stiffening plate 4 connecting the upper sealing plate 2 and the lower bottom plate 5. The stiffening plate 4 includes an inner stiffening plate and an outer stiffening plate. The side sealing plate 3 is located outside the inner stiffening plate and the outer stiffening plate. A triangular plate 1 is also provided on the upper end face of the upper sealing plate 2.

[0024] When installing the jacking fixture, first hoist the bottom plate 5, adjust it into position, and then perform tack welding. Next, hoist the inner and outer stiffening plates in sequence, and fix them in place. Hoist the top sealing plate 2 above the inner and outer stiffening plates, adjust it, and then fix it. Hoist the triangular plate 1 above the top sealing plate 2, adjust it, and then fix it in place. After welding in sequence, hoist the side sealing plates 3 and weld them. Inspect the welds according to the drawing requirements to complete the installation of the jacking fixture.

[0025] S3: Lifting frame arrangement. After installing the lifting fixture, once the trolley mechanism 12 has moved to the lifting position, pull the windproof cable and install the windproof wedge. Move the upper and lower trolleys to the top limit position on the non-lifting side, cut off the power, and remove the accessories.

[0026] Lay steel plates, then install the roadbed plate, load-bearing beam, lifting frame, jacks, lifting safety devices, and lifting beam in sequence. Remove the flange bolts of the trolley mechanism 12. Weld and fix temporary anti-tilting support frames on both sides of the legs of the gantry crane 11 near the trolley mechanism 12. Steel plates need to be laid at the bottom of the supports to expand the bearing surface and prevent foundation settlement. After installation, begin gantry crane lifting. The lateral force analysis of the flexible and rigid legs during gantry crane lifting is as follows: Figures 4-7 As shown.

[0027] S4: Mast lifting, trial lifting → formal lifting → lift the entire trolley mast by 10mm and then stop → maintain pressure and check settlement.

[0028] Specifically, a trial lifting is first conducted to apply preload pressure and check the overall stability of the lifting system. The lifting work is directed by the commanding personnel. During the process, the lifting height is checked and the lifting pressure is tested. Then, the formal lifting is carried out, and the entire gantry frame is lifted by 10mm before stopping. After maintaining the pressure for 12 hours, the tire frame and roadbed plate are checked for any obvious settlement.

[0029] S5: Traction by the trolley mechanism, arrangement of the winch → traction → arrangement of typhoon protection supports.

[0030] Specifically, when towing the trolley mechanism, firstly, winches are placed on both sides of the trolley mechanism. Then, the winches on both sides are used to pull the entire trolley mechanism directly under the gate frame. After that, a truck crane is used to hold and stabilize the trolley mechanism and tow it to the dismantling position.

[0031] S6: Disassemble the trolley mechanism. After pulling out the trolley mechanism 12, add an anti-tipping A-frame to the three-stage balance beam of the trolley mechanism 12. Disassemble each level of balance beam. Before removing each level of balance beam, prepare the anti-tipping support for the next level. Directly assemble the new trolley mechanism on the rail of the gantry crane 11. Install the drive wheel set, driven wheel set, and lower balance beam of the trolley mechanism 12 on the rail. When arranging each wheel set and lower balance beam, pay close attention to checking the straightness and perpendicularity data of the traveling wheels. If they are not up to standard, they need to be pre-adjusted in advance to ensure the margin for subsequent adjustments of the whole vehicle.

[0032] The trolley mechanism 12 is assembled in reverse order of the disassembly steps, and the straightness of the wheel set is initially adjusted during the assembly process.

[0033] S7: Reset the trolley mechanism. After the trolley mechanism is assembled, rearrange the winch in the opposite direction of the winch in step S5, and use a truck crane in conjunction with the winch to install the new trolley mechanism in place. Use the truck crane to support and stabilize the trolley mechanism, and then use a 10T winch to slowly drag the trolley mechanism to the original installation position, align it with the gantry crane frame, insert new high-strength bolts, tighten them and then release the hook. After installation, remeasure the dimensions of the traveling wheels and adjust them with a string line. Restore other removed accessories. After adjustment, test run to check the installation accuracy.

[0034] Compared with traditional replacement methods, the gantry crane trolley mechanism replacement method of the present invention adopts a partial jacking scheme. Based on this scheme, safety, reliability and economy are significantly improved, a large amount of high-altitude hoisting work is reduced, the replacement cycle of the trolley mechanism is accelerated, the safety factor is improved and the labor intensity is reduced.

[0035] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for replacing the gantry crane trolley mechanism, characterized in that: The process includes the following steps: pile foundation construction, installation of jacking equipment, arrangement of jacking jigs, gantry jacking, trolley mechanism traction, trolley mechanism disassembly and trolley mechanism resetting.

2. The method for replacing the gantry crane trolley mechanism according to claim 1, characterized in that: The specific steps are as follows: S1: Pile foundation construction, anchoring position pre-measurement and layout → steel pipe pile inspection → pilot hole → pile driver positioning → pile extraction and hoisting → verticality adjustment → initial pressure application → check the verticality of the pile body → pile driving → pile splicing → entering the bearing layer → pile top elevation control → pile formation → pouring cap beam → foundation curing. S2: Install the lifting fixture. After the gantry crane trolley mechanism moves to the lifting position, the lifting fixture is installed. The lifting fixture includes an upper sealing plate, a lower bottom plate, a side sealing plate, and stiffening plates connecting the upper sealing plate and the lower bottom plate. The stiffening plates include inner stiffening plates and outer stiffening plates. The side sealing plates are located outside the inner stiffening plates and the outer stiffening plates. A triangular plate is also provided on the upper end face of the upper sealing plate. S3: Lifting frame arrangement. After installing the lifting fixture, wait for the gantry crane trolley mechanism to move to the lifting position, pull the windproof cable and install the windproof iron wedge. Move the upper and lower trolleys to the top limit position on the non-lifting side, cut off the power, and remove the accessories. Lay steel plates, and install the road plate, load-bearing beam, lifting frame, jacks, lifting safety device, and lifting beam in sequence. Remove the flange bolts of the trolley mechanism. Weld and fix temporary anti-tilting support frames on both sides of the gantry crane legs near the trolley mechanism. Steel plates need to be laid at the bottom of the support to expand the bearing surface and prevent foundation settlement. After the installation is completed, start lifting the gantry. S4: Mast lifting, trial lifting → formal lifting → lift the entire trolley mast by 10mm and then stop → maintain pressure and check settlement; S5: Traction of the trolley mechanism, arrangement of the winch → traction → arrangement of typhoon protection support; S6: Disassemble the trolley mechanism. After pulling out the trolley mechanism, add an anti-tipping A-frame to the three-level balance beam of the trolley mechanism. Disassemble each level of balance beam. Before removing each level of balance beam, prepare the anti-tipping support for the next level. Directly assemble the new trolley mechanism on the gantry crane's rail. Install the drive wheel set, driven wheel set, and lower balance beam of the trolley mechanism on the rail. When arranging each wheel set and lower balance beam, pay close attention to checking the straightness and perpendicularity data of the traveling wheels. If they are not up to standard, they need to be pre-adjusted in advance to ensure the margin for subsequent adjustments of the whole vehicle. S7: Reset the trolley mechanism. After the trolley mechanism is assembled, rearrange the winch in the opposite direction of the winch in step S5, and use a truck crane in conjunction with the winch to install the new trolley mechanism in place. Use the truck crane to support and stabilize the trolley mechanism, and then use a 10T winch to slowly drag the trolley mechanism to the original installation position, align it with the gantry crane frame, insert new high-strength bolts, tighten them and then release the hook. After installation, remeasure the dimensions of the traveling wheels and adjust them with a string line. Restore other removed accessories. After adjustment, test run to check the installation accuracy.

3. The method for replacing the gantry crane trolley mechanism according to claim 2, characterized in that: In step S2, when installing the lifting fixture, first hoist the bottom plate, adjust it into position, and then perform locating welding. Then, hoist the inner and outer stiffening plates in sequence, align them, and fix them. Hoist the top sealing plate above the inner and outer stiffening plates, adjust it, and then fix it. Hoist the triangular plate above the top sealing plate, align it, and then fix it. After welding in sequence, hoist the side sealing plates and weld them to complete the installation of the lifting fixture.

4. The method for replacing the gantry crane trolley mechanism according to claim 2, characterized in that: In step S4, when lifting the gantry, a trial lifting is first performed to apply preload pressure and check the overall stability of the lifting system. The lifting work is directed by the commanding personnel. During the process, the lifting height is checked and the lifting pressure is tested. Then, the formal lifting is performed, and the gantry is lifted by 10mm and then stopped. After maintaining the pressure for 12 hours, the tire frame and road plate are checked for any obvious settlement.

5. The method for replacing the gantry crane trolley mechanism according to claim 2, characterized in that: In step S5, when traction of the trolley mechanism, firstly, winches are arranged on both sides of the trolley mechanism. Then, the winches on both sides are used to pull the entire trolley mechanism directly under the gate frame. After that, a truck crane is used to hold and stabilize the trolley mechanism and then traction the trolley mechanism to the dismantling position.

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