Large-diameter steel corrugated pipe culvert construction positioning system

Abstract

The invention discloses a large-diameter steel corrugated pipe culvert construction positioning system which is characterized in that the system comprises a main lifting unit, an auxiliary lifting unit and a self-adaptive balance butt joint unit, the main lifting unit is used for lifting a to-be-installed pipe culvert to an installation station, and the auxiliary lifting unit is used for lifting the to-be-installed pipe culvert to an installation station; the butt joint end of the to-be-installed pipe culvert is opposite to the butt joint end of the installed pipe culvert, and a gap is reserved between the butt joint end and the butt joint end; the self-adaptive balance butt joint unit comprises a lifting rope module, the lifting rope module comprises at least one rope wheel assembly and a lifting rope, the lifting rope winds around the rope wheel assembly, and the two ends of the lifting rope are detachably connected with a first detachable connecting module and a second detachable connecting module respectively. The first detachable connecting module is used for being detachably connected to a flange plate at the butt joint end of a pipe culvert to be installed. The problems that leveling is difficult, efficiency is low and safety is poor during installation and butt joint of the large-diameter steel corrugated pipe culverts are effectively solved, rapid, accurate and self-adaptive synchronous alignment of the ends of the two pipe culverts is achieved, and the construction quality, efficiency and safety are effectively improved.

Description

Technical Field

[0001] This invention belongs to the field of corrugated steel pipe culvert construction technology, specifically relating to a large-diameter corrugated steel pipe culvert construction positioning system. Background Technology

[0002] Corrugated steel pipe culverts are circular or arched tubular structures made of corrugated metal plates rolled and spliced ​​together. They are widely used in culverts, passages and drainage projects in infrastructure such as highways, railways and water conservancy. Large-diameter (usually referring to diameters of 1 meter or more) corrugated steel pipe culverts are particularly suitable for high embankment sections and soft soil foundations because they have advantages such as light weight, strong resistance to deformation, quick construction and strong adaptability to foundation.

[0003] In existing technologies, the on-site installation of large-diameter corrugated steel pipe culverts typically relies on large lifting equipment to hoist the pipe sections to be installed to the vicinity of the ends of the already installed pipe sections. The installation then involves repeated lifting, lowering, and rotating of the lifting equipment, combined with manual fine-tuning using tools such as crowbars and jacks, to align the bolt holes of the flanges at both ends of the pipes. This method has significant shortcomings in actual construction: First, the response to fine-tuning of the heavy pipe sections at high altitudes is slow. The operation heavily relies on the experience and frequent coordination between the crane operator and ground workers, resulting in low efficiency. Furthermore, the parallelism and center height difference of the flanges are difficult to control precisely, easily leading to abnormal stress in the connecting bolts or poor sealing at the interfaces. Second, the entire leveling and alignment process is time-consuming, requiring large lifting equipment to be occupied for extended periods for precise micro-operations, resulting in poor construction economy. More importantly, workers perform high-intensity prying and correction under the suspended heavy load, while the crane needs to perform high-risk millimeter-level micro-movements, significantly increasing the safety risks of human-machine collaboration. Therefore, existing construction methods have bottlenecks that urgently need improvement in terms of efficiency, accuracy, and safety. Summary of the Invention

[0004] To address the shortcomings and problems in existing large-diameter corrugated steel pipe culvert construction, this invention provides a large-diameter corrugated steel pipe culvert construction positioning system. This system effectively solves the problems of difficult leveling, low efficiency, and poor safety during the installation and docking of large-diameter corrugated steel pipe culverts. It enables rapid, accurate, and adaptive synchronous alignment of the ends of the two culverts, effectively improving construction quality, efficiency, and safety.

[0005] The solution adopted by this invention to solve its technical problem is: a construction positioning system for large-diameter corrugated steel pipe culverts, comprising a main lifting unit, a secondary lifting unit, and an adaptive balancing docking unit. The main lifting unit is used to lift the culvert to be installed to the installation position, so that the docking end of the culvert to be installed faces the docking end of the already installed culvert and leaves a gap. The adaptive balancing docking unit includes a lifting rope module, which includes at least one rope pulley assembly and a lifting rope. The lifting rope passes around the rope pulley assembly, and both ends of the lifting rope are detachably connected to a first detachable connection module and a second detachable connection module, respectively. Two detachable connection modules; the first detachable connection module is used to detachably connect to the flange of the culvert to be installed; the second detachable connection module is used to detachably connect to the flange of the installed culvert; the rope pulley assembly is connected to the auxiliary lifting unit and is used to lift the rope pulley assembly to tension the hoisting rope; when the hoisting rope is tensioned, the culvert to be installed and the installed culvert form a gravity balance system through the adaptive balance docking unit, so that the adjustment of the height of the docking end of any culvert can simultaneously cause the opposite adjustment of the height of the end of the other culvert.

[0006] The first detachable connection module includes a first connecting block and at least two first docking rods, and the second detachable connection module includes a second connecting block and at least two second docking rods; the first and second connecting blocks are respectively inserted into the back of the flanges at the ends of the two culverts through the corresponding docking rods, and the first connecting block and the second connecting block are respectively detachably connected to the two ends of the lifting rope.

[0007] The first and second docking rods have the same structure, both including an anti-detachment cap and a rod that are coaxially fixed together.

[0008] Both the first and second connecting blocks are arc-shaped blocks adapted to the curvature of the outer wall of the culvert, and the connecting blocks are inserted into the fan-shaped area at the top of the flange.

[0009] The docking rods in the first and second detachable connecting modules both extend outwards through the connecting block and the flange of the culvert in the direction of the other side of the pipe culvert. The positions of the first docking rod on the first connecting block and the second docking rod on the second connecting block are staggered. The flange of the culvert is provided with positioning holes that match the opposite docking rods, and the positioning holes penetrate the connecting block.

[0010] Both the first and second connecting blocks have at least four insertion holes evenly arranged along the circumference with the central axis of the flange as the center. The positions of the insertion holes overlap and align with the corresponding bolt holes on the flange, and are used to insert the mating rod to insert the connecting block and the flange together; and the insertion holes without mating rods are mated with the overlapping flange bolt holes to form positioning insertion holes.

[0011] The docking rods in the first and second detachable connecting modules both extend outwards through the flange of the connecting block and the culvert in the direction of the other culvert, and are coaxially fixed with a guide rod. The diameter of the guide rod is smaller than that of the docking rod, and the end of the docking rod is provided with a chamfer to dock with the guide rod.

[0012] The rope pulley assembly includes a bracket with a pulley rotatably mounted inside the bracket. The top of the bracket is connected to the auxiliary lifting unit. When the first and second detachable connecting units are respectively connected to the flanges at the docking ends of the two culverts, the auxiliary lifting unit raises the rope pulley assembly to tension the lifting rope.

[0013] The beneficial effects of this invention are as follows: The large-diameter corrugated steel pipe culvert construction positioning system provided by this invention adopts an adaptive gravity balance system based on pulleys and lifting ropes, coupling the ends of the two culvert sections to be installed and the already installed sections into a linked mechanical whole. This allows micro-adjustments to one side of the culvert to be synchronously and in reverse transmitted to the other side, thereby achieving rapid adaptive leveling of the height of the two flanges. This significantly reduces the reliance on the precise micro-operation of large hoisting equipment in traditional construction and effectively improves the efficiency of leveling operations. Furthermore, through the staggered arrangement of the docking rods and the design of the stepped shaft-shaped rod structure, the fault tolerance and first-time alignment success rate during horizontal advancement docking are significantly improved, effectively ensuring connection quality and sealing reliability.

[0014] The large-diameter corrugated steel pipe culvert construction positioning system provided by this invention not only greatly shortens the operation time of key processes and reduces equipment occupancy costs, but more importantly, it liberates construction personnel from high-risk, high-intensity precision prying and adjusting operations under suspended heavy objects, fundamentally improving the inherent safety level of high-altitude docking operations. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention.

[0016] Figure 2 This is the adaptive balance docking unit of the present invention. Figure 3 This invention relates to a suspension rope module. Figure 4 This is the first detachable connection module of the present invention. Figure 5 This is the second detachable connection module of the present invention. Figure 6 This is a schematic diagram of the self-adjusting principle of the gravity balance system of the present invention.

[0017] Figure 7 This invention is a guide rod. The diagram labels are as follows: 1 for culvert a, 11 for flange a, 2 for hanger, 21 for lifting ring, 22 for lifting rope, 3 for four-legged chain hoist, 4 for adaptive balance docking unit, 5 for culvert b, 51 for flange b, 6 for rope module, 61 for rope pulley assembly, 611 for bracket, 612 for fixed pulley, 62 for lifting rope, 7 for first detachable connection module, 71 for first connecting block, 711 for socket a0, and 712 for socket a1. 713 is socket a2, 714 is socket a-1, 715 is socket a-2, 72 is the first docking rod, 8 is the second detachable connecting module, 81 is the second connecting block, 811 is socket b0, 812 is socket b1, 813 is socket b2, 814 is socket b-1, 815 is socket b-2, 82 is the second docking rod, 9 is the double-leg suspension chain, and 101 is the guide rod. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments. Example

[0019] like Figure 1-6 As shown, this embodiment provides a construction positioning system for large-diameter corrugated steel pipe culverts, mainly including a main lifting unit, an auxiliary lifting unit, and an adaptive balancing docking unit. In this embodiment, the main lifting unit adopts a large truck crane or crawler crane, whose function is to provide the main lifting capacity for lifting the culvert to be installed (culvert a is a corrugated steel pipe culvert) from the stacking area to the installation position. Specifically, the hook of the main lifting unit is matched with a culvert lifting tool for lifting the culvert to be installed (culvert a) from the stacking area to the installation position. The culvert lifting tool includes a lifting frame 2 and a four-legged chain 3. The width of the lifting frame 2 is larger than that of the culvert to be installed. The diameter of the culvert a is specified. Lifting rings 21 are installed at each of the four top corners of the hanger 2. These four lifting rings 21 are connected to the hook of the main lifting unit via a four-legged chain 3. Lifting rope assemblies are detachably installed at each of the four bottom corners of the hanger 2. Each rope assembly includes a lifting rope 22. The top of the lifting rope 22 is detachably connected to the hanger via a lifting ring and shackle. The bottom of the lifting rope is detachably connected to the flange of the adjacent corrugated steel culvert a via a lifting ring and shackle. For example, the flange has threaded bolt holes in the middle on both sides for installing lifting rings.

[0020] Therefore, during use, the main lifting unit can use the culvert lifting device to lift the corrugated steel culvert a to be installed from the stacking area to the installation position, so that the end flange a of the corrugated steel culvert a to be installed faces the end flange b of the corrugated steel culvert b that has been installed in place, with a certain distance reserved in both the horizontal and vertical directions. In this embodiment, a gap of about 10-30 cm is reserved in the horizontal direction and a gap of 10-30 cm is reserved in the vertical direction between the corrugated steel culvert a and the corrugated steel culvert b.

[0021] The adaptive balancing docking unit 4 is used to establish a dynamic, height-transferable mechanical connection between the installed culvert b5 and the culvert a1 to be installed, such as... Figure 2 As shown, the adaptive balance docking unit 4 mainly includes a rope module 6, a first detachable connection module 7, and a second detachable connection module 8. The rope module 6 includes a rope wheel assembly 61 and a rope 62. The rope wheel assembly includes a bracket 611 and a fixed pulley 612 rotatably mounted on the bracket 611. The bracket 611 can be directly hung on the hook of the auxiliary lifting unit.

[0022] In this embodiment, the suspension rope 611 is a steel wire rope. The suspension rope 611 passes around the fixed pulley 612, with both ends pointing downwards, and is detachably connected to the first detachable connection module and the second detachable connection module respectively. The fixed pulley 612 serves to guide and reduce friction.

[0023] like Figure 4 As shown, the first detachable connection module 7 specifically includes a first connecting block 71 and two first docking rods 72. The second detachable connection module 8 includes a second connecting block 81 and two second docking rods 82. The first connecting block 71 and the second connecting block 81 have the same structure, both being arc-shaped blocks adapted to the curvature of the outer wall of the culvert. The connecting blocks are inserted into the middle of the fan-shaped area on the top of the flange of the corresponding culvert through the corresponding docking rods. In this embodiment, the first docking rods and the second docking rods also have the same structure, both including anti-detachment caps and rods fixed together on the same axis.

[0024] Specifically: the first connecting block 71 is inserted into the back of the flange a11 on the side of the culvert a1 to be connected by two first docking rods 72, and the first connecting block 71 is detachably connected to the end of the lifting rope 62; the first connecting block 71 is provided with a plurality of insertion holes evenly spaced along the circumferential direction, and the positions of the insertion holes overlap and align with the bolt holes in the fan-shaped area on the top of the flange a11; the insertion rods of the first docking rods 72 pass through the corresponding insertion holes on the first connecting block 71 and are inserted into the corresponding bolt holes of the flange of the corrugated steel culvert a to be installed, thereby inserting the first connecting block 71 and the flange on the side of the corrugated steel culvert a to be installed together, so that the first connecting block 71 fits against the side of the flange a facing away from the other culvert b.

[0025] There are several ways to detachably connect the first connecting block 71 to the end of the suspension rope. For example, in this embodiment, two suspension rings are symmetrically installed on the outer ring of the first connecting block 71, and the two suspension rings are connected to the end of the suspension rope through the double-leg suspension chain 9.

[0026] Similarly, the second connecting block 81 is also provided with multiple insertion holes evenly spaced along the circumference, and the positions of the insertion holes overlap and align with the bolt holes in the top fan-shaped area of ​​the flange b51 on the mating end side of the installed culvert b. The insertion rod of the second mating insertion rod 82 passes through the corresponding insertion hole on the second connecting block 81 and is inserted into the corresponding bolt hole of the flange b51 on the mating end side of the installed culvert b, thereby inserting the second connecting block 81 and the flange b on the mating end side of the installed corrugated steel culvert b together, so that the second connecting block 81 fits against the side of the flange b51 facing away from the other culvert a.

[0027] There are several ways to detachably connect the second connecting block 81 to the end of the suspension rope. For example, in this embodiment, two suspension rings are symmetrically installed on the outer ring of the second connecting block 81, and the two suspension rings are connected to the end of the suspension rope through the double-leg suspension chain 9.

[0028] In this embodiment, the auxiliary lifting unit 3 can be a small crane, a hand-operated hoist, or an electric hoist. Its function is not to lift the weight of the culvert itself, but rather, after the adaptive balance docking mechanism 2 is connected to the two culverts, it lifts the entire unit upward through the hook connection bracket 611 at an appropriate point until both ends of the lifting rope 62 are tensioned. At this time, the culvert to be installed a and the installed culvert b form a gravity balance system based on the balance of gravity and rope tension, with the pulley as the fulcrum. The ends of the two culvert sections are like two suspended weights connected by a rope that passes over the pulley.

[0029] like Figure 6 As shown, when construction workers need to adjust the height alignment of the two pipe ends, they only need to use a crowbar or jack to provide a slight upward pushing force F on the rear side of the pipe a joint, or a practical tool to provide a slight downward pushing force F on the side of the pipe a joint. Since the pipe a joint is linked to the pipe b5 joint via the suspension rope 62, the downward trend of the pipe a1 joint will be converted into an upward pulling force on the pipe b5 joint through the suspension rope 62. Thus, only a very small force F is needed to break the gravitational balance and start the movement. As the pipe a1 joint descends, the pipe b5 joint will also rise synchronously and passively. The lifting and lowering mechanisms move in opposite directions. Once the bolt holes on the flanges at the docking ends of the two corrugated steel pipe culverts are aligned, long bolts are passed through the aligned flange bolt holes in sequence and pre-tightened to initially fix the two flanges together. Then, all connecting bolts are installed and tightened according to the design requirements to complete the precise docking of the two pipe culvert sections. After confirming that the connection is secure, the auxiliary lifting unit is operated to slowly unload the load and disconnect the adaptive balance docking mechanism from the two pipe culverts. Subsequently, the main lifting unit is operated to gradually lower the pipe culvert, which has been connected as a whole, to the final design elevation position. The hoisting and docking operation of a single pipe culvert section is then completed. Example

[0030] The difference between Example 2 and Example 1 is that, as Figure 4 , Figure 5 and Figure 7 As shown, the mating rods in the first detachable connecting module 7 and the second detachable connecting module 8 both extend outwards through the connecting block and the flange at the pipe culvert mating end in the direction of the other pipe culvert. The positions of the first mating rod 72 on the first connecting block 71 and the second mating rod 82 on the second connecting block 81 are staggered. Both the flange b on the installed pipe culvert mating end side and the flange a on the pipe culvert mating end side are provided with positioning holes matching the opposing mating rods. These positioning holes penetrate the connecting block. Specifically: In this embodiment, there are three first mating rods 72 and two second mating rods 82. The distribution positions of the first mating rods 72 on the first connecting block 71 and the distribution positions of the second mating rods 82 on the second connecting block 81 are staggered. The number of insertion holes on the connecting block is at least twice the number of mating rods. In this embodiment, both the first and second connecting blocks have five insertion holes. The insertion hole located in the middle matches the bolt hole at the center of the top of the corresponding flange. The insertion hole located in the middle of the first connecting block is numbered a0 insertion hole 711. The remaining insertion holes on both sides are numbered a1 insertion hole 712, a2 ​​insertion hole 713, a-1 insertion hole 714, and a-2 insertion hole 715 from the direction closest to the middle insertion hole outwards. The insertion rods of the three first mating insertion rods 72 are inserted into the bolt holes of the corresponding flanges through the insertion holes a2, a0, and a-2 on the first connecting block 71, respectively, and protrude from the bolt holes. The remaining insertion holes a1 and a-1 on the first connecting block 71 that are not used for inserting the first mating insertion rods are used as positioning insertion holes.

[0031] Similarly, the central insertion hole in the second connecting block is numbered as insertion hole 811 (b0), and the remaining two side insertion holes are numbered sequentially from the direction closest to the central insertion hole outwards as insertion hole 812 (b1), insertion hole 813 (b2), insertion hole 814 (b-1), and insertion hole 815 (b-2). The insertion rods of the two second mating rods 82 are inserted into the bolt holes of the corresponding flanges through insertion holes 81 (b1) and (b-1) on the second connecting block 81, respectively, and protrude from the bolt holes. The remaining insertion holes 80 (b0), 81-1 (b-1), and 81 (b1) on the second connecting block 81, which are not used for inserting the second mating rods, are used as positioning insertion holes. After the bolt holes of the flanges on the two corrugated steel pipe culverts are aligned, the construction workers push and pull the culvert to be installed (a) horizontally, so that it moves smoothly toward the installed culvert (b). During this process, the docking rods extending from the back of the two flanges will be inserted into the corresponding bolt holes on the opposite flange under the guidance of the progressive guide structure, and enter the positioning holes to achieve mechanical pre-positioning and forced alignment of the holes before docking. Then, long bolts are used to pass through the aligned flange bolt holes in sequence and pre-tighten them, thereby initially fixing the two flanges together and completing the precise docking of the two culvert sections.

[0032] Furthermore, in this embodiment, the ends of the first and second docking rods extending out of the flange in the direction of the culvert on the other side are coaxially fixed with a guide rod 101. The diameter of the guide rod is smaller than that of the docking rod, and the end of the docking rod is provided with a chamfer that mates with the guide rod, so as to facilitate insertion into the corresponding bolt hole on the opposite flange under guidance.

[0033] It should be noted that the above embodiments and accompanying drawings are merely illustrative examples of the core principles and key structures of the "Construction Positioning System for Large-Diameter Corrugated Steel Pipe Culvert" of this invention. The accompanying drawings are simplified schematic diagrams, intended to clearly illustrate the structural, process, or mechanical relationships related to the innovative points of the technical solution, and are not intended to limit the complete form of the actual product. This specification focuses on the innovative technical means necessary to achieve the invention's objectives and solve the technical problems. While auxiliary or common-sense details that can be implemented without creative effort by those skilled in the art, such as "hook anti-detachment design," "wire rope end pressure plate fixing," "connecting block reinforcing rib arrangement," "hand-operated hoist hook and limit position," and "conventional steel structure welding and corrosion protection," are not elaborated upon, they should all be understood as naturally encompassed in the specific implementation of this invention and fall within the protection and implementation scope of this technical solution.

Claims

1. A construction positioning system for large-diameter corrugated steel culverts, characterized in that, The system includes a main lifting unit, a secondary lifting unit, and an adaptive balancing docking unit. The main lifting unit is used to lift the culvert to be installed to the installation position, ensuring that the docking end of the culvert to be installed faces the docking end of the already installed culvert with a gap. The adaptive balancing docking unit includes a lifting rope module, which includes at least one rope pulley assembly and a lifting rope. The lifting rope passes around the rope pulley assembly, and its two ends are detachably connected to a first detachable connection module and a second detachable connection module, respectively. The first detachable connection module is detachably connected to the flange of the docking end of the culvert to be installed; the second detachable connection module is detachably connected to the flange of the docking end of the already installed culvert. The rope pulley assembly is connected to the secondary lifting unit and is used to lift the rope pulley assembly to tension the lifting rope. When the lifting rope is tensioned, the culvert to be installed and the already installed culvert form a gravity balance system through the adaptive balancing docking unit, so that adjusting the height of the docking end of any culvert can simultaneously cause a reverse adjustment of the height of the other culvert end.

2. The balanced docking construction system according to claim 1, characterized in that, The first detachable connection assembly includes a first connecting block and at least two first docking rods, and the second detachable connection assembly includes a second connecting block and at least two second docking rods; the first and second connecting blocks are respectively inserted into the back of the flanges at the ends of the two culverts through the corresponding docking rods, and the first connecting block and the second connecting block are respectively detachably connected to the two ends of the lifting rope.

3. The large-diameter pipe culvert construction positioning system according to claim 2, characterized in that, The first and second docking rods have the same structure, both including an anti-detachment cap and a rod that are coaxially fixed together.

4. The balanced docking construction system according to claim 2, characterized in that, Both the first and second connecting blocks are arc-shaped blocks adapted to the curvature of the outer wall of the culvert, and the connecting blocks are inserted into the middle of the fan-shaped area at the top of the flange.

5. The large-diameter pipe culvert construction positioning system according to claim 2, characterized in that, The mating rods in the first and second detachable connecting assemblies both extend outwards through the connecting block and the flange of the culvert towards the other side of the pipe culvert. The positions of the first mating rod on the first connecting block and the second mating rod on the second connecting block are staggered. The flange of the culvert is provided with positioning holes that match the mating rods facing each other, and the positioning holes penetrate the connecting block.

6. The large-diameter pipe culvert construction positioning system according to claim 5, characterized in that, Both the first and second connecting blocks have at least four insertion holes evenly arranged along the circumference with the central axis of the flange as the center. The positions of the insertion holes overlap and align with the corresponding bolt holes on the flange, and are used to insert the mating rod to insert the connecting block and the flange together; and the insertion holes without mating rods are mated with the overlapping flange bolt holes to form positioning insertion holes.

7. The large-diameter pipe culvert construction positioning system according to claim 5, characterized in that, The mating rods in the first and second detachable connecting assemblies both extend outwards through the flange of the connecting block and the culvert in the direction of the other culvert, and are coaxially fixed with a guide rod. The diameter of the guide rod is smaller than that of the mating rod, and the end of the mating rod is provided with a chamfer to mate with the guide rod.

8. The large-diameter pipe culvert construction positioning system according to claim 1, characterized in that, The rope pulley assembly includes a bracket with a pulley rotatably mounted inside the bracket. The top of the bracket is connected to the auxiliary lifting unit. When the first and second detachable connecting units are respectively connected to the flanges at the docking ends of the two culverts, the auxiliary lifting unit raises the rope pulley assembly to tension the lifting rope.

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