Inhaul cable fork lug with flange structure, anchor cable tensioning system and construction method

Abstract

The invention discloses an inhaul cable fork lug with a flange structure, an anchor cable tensioning system and a construction method, and relates to the technical field of bridge anchor cable tensioning, the inhaul cable fork lug is mainly composed of a fork lug inhaul cable, a hoop opposite-closing type tensioning tool, a tensioning rod kit, a hydraulic jack and an electric hydraulic subsystem. The flange structure is arranged on the fork lug body, precise limiting and stable stress are achieved in combination with the hoop type tool, and the structural reliability and construction safety in the tensioning process are remarkably improved. The invention further provides a complete construction method which comprises key procedures such as tool installation, system assembly, graded tensioning and locking dismantling and is suitable for lower end tensioning operation scenes of bridge inhaul cables and the like.

Description

Technical Field

[0001] This invention relates to the field of bridge anchor cable tensioning technology, specifically to a cable fork lug with a flange structure, an anchor cable tensioning system, and a construction method. Background Technology

[0002] With the rapid development of infrastructure construction in my country, anchor cables, as key load-bearing components in bridge cables and other engineering projects, face increasingly higher requirements for structural stability, tension reliability, and construction safety. Currently, anchor cable tensioning mostly adopts the top-end tensioning method, but it has the following shortcomings: ① The operating space at the top anchor head is narrow, making it difficult to tighten the nuts; ② High-altitude operations are required at the arch rib end, posing high safety risks; ③ Construction efficiency is low, failing to meet the needs of large-scale construction.

[0003] In comparison, bottom-tensioning offers advantages such as a larger working space, convenient construction, and no need for high-altitude operations. However, existing anchor cable structures adapted for bottom-tensioning have shortcomings, especially the bottom-tensioning fork lugs, which are mostly simple double-lug designs lacking positioning and limiting structures. This makes them prone to uneven stress, misalignment, and slippage during tensioning, potentially leading to structural damage in severe cases. Furthermore, existing tensioning systems are complex in structure, inconvenient to assemble, and lack standardized construction procedures, hindering the widespread application of bottom-tensioning technology.

[0004] Therefore, developing an anchor cable with flanged tensioning lugs that features precise positioning and stable stress, along with an efficient and safe lower tensioning system and standardized construction methods, has significant engineering application value. Summary of the Invention

[0005] The purpose of this invention is to provide a cable fork lug with a flange structure, an anchor cable tensioning system, and a construction method to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A cable fork lug with a flange structure includes a fork lug body, a tensioning flange is provided at one end of the fork lug body near the adjusting rod, the tensioning flange is located on the outside of the fork lug body, and a positioning shoulder is formed between the tensioning flange and the fork lug body.

[0007] An anchor cable tensioning system employing the aforementioned cable fork lugs, the system comprising a fork lug cable, a clamp-type tensioning fixture, a tensioning rod assembly, a hydraulic jack, and an electro-hydraulic subsystem.

[0008] As a further embodiment of the present invention: the fork-ear cable includes a fork-ear body, an adjusting rod, a connector, a tensioning end anchor cup, and a cable body. The cable body and the connector are both connected to the tensioning end anchor cup, the adjusting rod is connected to the connector, and the other end of the adjusting rod is threadedly connected to the fork-ear body.

[0009] As a further embodiment of the present invention: the clamp-type tensioning fixture includes a pressure plate, a crossbeam and a clamp plate that are fixedly connected to form clamp-type mating blocks. The two clamp-type mating blocks are connected by fastening screws and fastening nuts. The tensioning end anchor cup and the outer side of the positioning shoulder are both equipped with clamp-type tensioning fixtures. The tensioning rod kit is used to connect the two sets of clamp-type tensioning fixtures.

[0010] As a further embodiment of the present invention: the tension rod assembly is connected through a screw through hole on the pressure plate. The tension rod assembly includes a tension rod and a tension rod nut that is threadedly connected to the tension rod. When the tension rod nut contacts the pressure plate, it positions the tension rod.

[0011] As a further aspect of the present invention: the hydraulic jack has a through-hole structure, the tensioning rod passes through the hydraulic jack, and the tensioning of the clamp-type tensioning fixture is achieved under the hydraulic action of the hydraulic jack.

[0012] As a further aspect of the invention, it also includes an electro-hydraulic subsystem for powering the hydraulic jack.

[0013] A construction method for constructing any of the above-mentioned anchor cable tensioning systems, including construction preparation, tooling installation, system assembly, graded tensioning, locking and dismantling, and quality inspection.

[0014] As a further embodiment of the present invention: the construction preparation includes: checking and releasing stress by releasing the cable, hoisting the cable body to the arch rib and installing the anchor head, and installing the lower end fork lug; cleaning the surface of the tensioning end and checking the integrity of each component; The tooling installation includes: installing two sets of clamp-type tensioning tooling on the positioning shoulder surface below the tensioning flange and the cable body above the tensioning end anchor cup, respectively, and locking them with fastening screws and fastening nuts; The system assembly includes: sequentially inserting the tension rod and hydraulic jack, installing and pre-tensioning the tension rod nut, and completing the system assembly; The graded tensioning includes: connecting the electro-hydraulic subsystem, applying pressure in stages according to the design value after no-load trial operation, monitoring the pressure and cable elongation in real time, and adjusting the adjusting rod synchronously until the design value is reached; The locking and dismantling process includes: locking the adjusting rod after stabilizing the pressure, unloading the hydraulic system, and dismantling the tension rod, hydraulic jack, and tooling. The quality inspection includes: verifying cable tension and elongation, and recording and organizing construction data. Compared with the prior art, the beneficial effects of the present invention are: 1. Anchor cable structure innovation: A tensioning flange and a positioning shoulder are set on the tensioning fork lug to form a reliable limiting structure, which solves the problems of traditional fork lug lack of positioning, uneven force and slippage, and significantly improves the structural stability and safety during the tensioning process.

[0015] 2. Innovative tensioning fixture: The fixture adopts a clamp-type tensioning fixture, which achieves rapid clamping and disassembly through two sets of clamping blocks, fastening screws and nuts. The inner edge of the clamp plate is designed with an arc structure that matches the cable body and positioning shoulder surface to ensure a tight fit, avoid clamping damage, and improve the transmission efficiency of tension force.

[0016] 3. System Integration Innovation: The flanged anchor cable, clamp tooling, tension rod kit, through-hole jack and electro-hydraulic system are integrated into a complete lower tensioning system. All components work together to achieve standardization of the entire process from tooling installation and tensioning to locking and dismantling, which greatly reduces the risk of high-altitude operations and improves construction efficiency.

[0017] 4. Innovative construction methods: A complete set of lower end tensioning construction steps was proposed, including key technologies such as cable release stress, double tooling positioning and installation, rapid assembly of tension rods and jacks, coordinated control of staged tensioning and synchronous adjustment rod rotation, and dual control and locking of bridge deck elevation and cable force. These technologies ensured tensioning accuracy and long-term structural stability, filling the gap in standardized lower end tensioning construction. Attached Figure Description

[0018] Figure 1 System overall schematic diagram.

[0019] Figure 2 : Cross-sectional view of the anchor cable structure.

[0020] Figure 3 Top view of the clamping fixture.

[0021] Figure 4 Side view of the clamping fixture.

[0022] Figure 5 : Schematic diagram of clamping blocks.

[0023] Figure 6 Cross-sectional view of fastening screw and nut.

[0024] Figure 7 Cross-sectional view of tension rod and nut.

[0025] Figure 8 : Structure diagram of the pressure plate.

[0026] Figure 9 : Horizontal beam structure diagram.

[0027] Figure 10 : Structure diagram of the clamp plate.

[0028] Figure 11 Schematic diagram of an electro-hydraulic system.

[0029] In the diagram: 1. Fork-shaped cable; 2. Clamping tensioning fixture; 3. Tensioning rod kit; 4. Hydraulic jack; 5. Electro-hydraulic subsystem; 1-1. Fork-shaped cable body; 1-2. Adjusting rod; 1-3. Connector; 1-4. Tensioning end anchor cup; 1-5. Cable body; 1-6. Tensioning flange; 1-7. Positioning shoulder; 2-1. Pressure plate; 2-2. Crossbeam; 2-3. Clamping plate; 2-4. Fastening screw; 2-5. Fastening nut; 2-6. Tensioning rod through hole; 2-7. Tensioning buckle; 2-8. Screw through hole; 3-1. Tensioning rod; 3-2. Tensioning rod nut; 5-1. Electro-hydraulic pump; 5-2. High-pressure oil pipe. Detailed Implementation

[0030] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0031] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0032] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0033] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0034] Please refer to the attached diagram. A cable fork lug with a flange structure includes a lug body 1-1. A tensioning flange 1-6 is specifically provided on the outer side of the lug body 1-1 near the adjusting rod 1-2. The function of this tensioning flange 1-6 is to cooperate with the subsequent tensioning fixture for positioning. Therefore, at the connection between it and the lug body 1-1, a positioning shoulder surface 1-7 is naturally formed. The positioning shoulder surface 1-7 allows for precise positioning and installation of the fixture, preventing displacement during tensioning. This structural design is simple and improves the stability of the tensioning process, making it suitable for mass production and practical engineering applications.

[0035] An anchor cable tensioning system employing the aforementioned cable fork lugs comprises a fork lug cable 1, a clamp-type tensioning fixture 2, a tensioning rod assembly 3, a hydraulic jack 4, and an electro-hydraulic subsystem 5. All components work together to ensure the smooth execution of the tensioning operation. The specific component composition and connection method are as follows: (a) Forked Ear Cable 1 The fork-ear cable 1 is the core load-bearing component of the system, mainly composed of the fork-ear body 1-1, adjusting rod 1-2, connector 1-3, tension end anchor cup 1-4, and cable body 1-5. Cable body 1-5 and connector 1-3 are both connected to tension end anchor cup 1-4. One end of adjusting rod 1-2 is connected to connector 1-3, and the other end is threaded to fork-ear body 1-1. All component connections use existing connection methods, facilitating production assembly and on-site installation.

[0036] (ii) Clamp-type tensioning fixture 2 The clamp-type tensioning fixture 2 is a supporting component for tensioning operations. Its clamp-type design facilitates on-site installation and disassembly, meeting the high-efficiency construction needs of practical engineering projects. It mainly consists of a bearing plate 2-1, a crossbeam 2-2, and a clamp plate 2-3. These three components are first welded or bonded to form clamp blocks, or they can be integrally molded. Then, two such clamp blocks are locked together using fastening screws 2-4 and fastening nuts 2-5. The clamp plate 2-3 has a tensioning buckle 2-7 with an arc-shaped inner edge that matches the outer diameter of the cable body 1-5 or the positioning shoulder surface 1-7, ensuring a tight fit. A screw through-hole 2-8 is opened on the crossbeam 2-2, through which the fastening screw 2-4 passes to connect the two crossbeams 2-2, thus forming a complete fixture.

[0037] During actual installation, the two sets of clamp-type tensioning fixtures 2 need to be installed separately: one set is installed on the positioning shoulder surface 1-7 below the tensioning flange 1-6, and the other set is installed on the cable body 1-5 above the tensioning end anchor cup 1-4. After installation, they are locked by fastening screws 2-4 and fastening nuts 2-5 to ensure that the fixtures fit tightly with the components.

[0038] (III) Tensioner assembly 3 The function of tension rod kit 3 is to connect two sets of clamp-type tensioning fixtures 2. It mainly includes tension rod 3-1 and tension rod nut 3-2. The tension rod nut 3-2 is threaded to the tension rod 3-1. During installation, the tension rod 3-1 is inserted through the tension rod through hole 2-6 on the pressure plate 2-1. When the tension rod nut 3-2 is in close contact with the pressure plate 2-1, the tension rod 3-1 can be accurately positioned, ensuring stable force transmission during tensioning. The threaded connection also facilitates on-site adjustment and disassembly.

[0039] (iv) Hydraulic jacks 4 and electro-hydraulic subsystems 5 The hydraulic jack 4 adopts a through-hole structure. The advantage of this structure is that it allows the tension rod 3-1 to pass directly through the jack, facilitating force transmission and making it suitable for on-site tensioning operations. During construction, under the hydraulic action of the hydraulic jack 4, the clamp-type tensioning fixture 2 can be tensioned, thereby driving the cable body 1-5 to reach the design cable force.

[0040] The electro-hydraulic subsystem 5 is the power source for the hydraulic jack 4, specifically providing stable hydraulic power to ensure that the jack can output cable force smoothly and accurately, avoiding errors caused by manual operation, improving construction efficiency and safety, and making it suitable for large-scale engineering construction. The electro-hydraulic subsystem 5 consists of an electro-hydraulic pump 5-1 and a high-pressure oil pipe 5-2, with a specific structure consistent with existing structures. Precise adjustment and feedback of tensioning pressure are achieved through an electronic control system.

[0041] A construction method for an anchor cable tensioning system, specifically designed for the aforementioned anchor cable tensioning system, is clearly defined and practical, balancing construction safety and quality. The method comprises six steps: construction preparation, tooling installation, system assembly, staged tensioning, locking and dismantling, and quality inspection. The specific operations for each step are as follows: (I) Construction Preparation Preparatory work before construction is fundamental to ensuring the smooth progress of tensioning operations. The following three points are crucial: First, conduct a cable release inspection of cable body 1-5, simultaneously releasing internal stress to prevent residual stress from affecting tensioning accuracy. Second, use hoisting equipment to lift cable body 1-5 to the designated position on the arch rib, install the upper anchor head, and then install the lower fork lugs, ensuring all components fit tightly without looseness. Third, clean the surfaces of all components at the tensioning end, removing dust, oil, and other debris. Simultaneously, check the integrity of all components, including fork lugs, tooling, and jacks, replacing any damaged or deformed parts promptly to prevent malfunctions during construction.

[0042] (ii) Tooling installation The installation of the fixtures must be strictly carried out in accordance with the positioning requirements to ensure that the fixtures are accurately positioned and firmly fixed. The specific operation is as follows: install the two sets of clamp-type tensioning fixtures 2 into place. One set is clamped on the positioning shoulder surface 1-7 below the tensioning flange 1-6, and the other set is installed on the cable body 1-5 above the tensioning end anchor cup 1-4. After installation, use the fastening screws 2-4 and fastening nuts 2-5 to completely lock the fixtures. After locking, it is necessary to check again to ensure that the fixtures will not shift, in order to prepare for subsequent tensioning operations.

[0043] (III) System Assembly The system assembly follows the "put in first, then install" procedure, which is simple and easy to operate. Specifically, the steps are as follows: First, thread the tension rod 3-1 through the through holes of the bearing plates 2-1 of the two sets of clamp-type tensioning fixtures 2. Then, thread the hydraulic jack 4 onto the tension rod 3-1. Finally, install the tension rod nut 3-2 and pre-tighten it. After pre-tightening, check the connection of each component. Once confirmed to be correct, the assembly of the entire system is complete.

[0044] (iv) Graded tensioning Staged tensioning is a crucial step to ensure that the cable tension of cables 1-5 reaches the design value, requiring smooth operation and real-time monitoring. Specific operation: First, connect the electro-hydraulic subsystem 5 to the hydraulic jack 4. After connection, conduct a no-load test run to check if the hydraulic system is normal and if there are any leaks in any components. After the test run is normal, apply pressure in stages according to the designed cable tension value. During the pressure application process, monitor the pressure value of the hydraulic jack 4 and the elongation of cables 1-5 in real time, and simultaneously adjust the adjusting rods 1-2 until both the pressure value and the cable elongation reach the design requirements, then stop applying pressure.

[0045] (v) Locking and Removal After the tension reaches the design value, pressure stabilization treatment is required. After stabilization for a period of time, lock the adjusting rod 1-2 in time to ensure that the cable force of the cable body 1-5 remains stable and there will be no rebound. After locking, unload the pressure of the hydraulic system, and then remove the tensioning rod 3-1, hydraulic jack 4 and clamp-type tensioning fixture 2 in sequence. During the removal process, pay attention to protect each component to avoid damage, so as to facilitate subsequent reuse and reduce construction costs.

[0046] (vi) Quality Inspection Quality inspection is the final step in construction and a crucial step in ensuring project quality. Specific procedures include: verifying the actual cable force and elongation of cables 1-5 to confirm compliance with design requirements; making timely adjustments if deviations are found; and compiling and recording all data from the construction process, including pressure values, elongation, and adjustment records, to create complete construction documentation for future project acceptance and traceability.

[0047] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0048] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A cable fork lug with a flange structure, comprising a lug body (1-1), characterized in that, A tensioning flange (1-6) is provided at one end of the fork ear body (1-1) near the adjusting rod (1-2). The tensioning flange (1-6) is located outside the fork ear body (1-1), and a positioning shoulder surface (1-7) is formed between the tensioning flange (1-6) and the fork ear body (1-1).

2. An anchor cable tensioning system employing the cable fork lug as described in claim 1, characterized in that, The system includes a fork-ear cable (1), a clamp-type tensioning fixture (2), a tensioning rod kit (3), a hydraulic jack (4), and an electro-hydraulic subsystem (5).

3. The anchor cable tensioning system according to claim 2, characterized in that, The fork-ear cable (1) includes a fork-ear body (1-1), an adjusting rod (1-2), a connector (1-3), a tensioning end anchor cup (1-4), and a cable body (1-5). The cable body (1-5) and the connector (1-3) are both connected to the tensioning end anchor cup (1-4). The adjusting rod (1-2) is connected to the connector (1-3). The other end of the adjusting rod (1-2) is threadedly connected to the fork-ear body (1-1).

4. The anchor cable tensioning system according to claim 3, characterized in that, The clamp-type tensioning fixture (2) includes a pressure plate (2-1), a crossbeam (2-2), and a clamp plate (2-3) that are fixedly connected to form clamp-type blocks. The two clamp-type blocks are connected by a fastening screw (2-4) and a fastening nut (2-5). The tensioning end anchor cup (1-4) and the outer side of the positioning shoulder surface (1-7) are both equipped with clamp-type tensioning fixtures (2). The tensioning rod kit (3) is used to connect the two sets of clamp-type tensioning fixtures (2).

5. The anchor cable tensioning system according to claim 4, characterized in that, The tension rod assembly (3) is connected through the tension rod through hole (2-6) on the pressure plate (2-1). The tension rod assembly (3) includes a tension rod (3-1) and a tension rod nut (3-2) threadedly connected to the tension rod (3-1). When the tension rod nut (3-2) contacts the pressure plate (2-1), it positions the tension rod (3-1).

6. The anchor cable tensioning system according to claim 5, characterized in that, The hydraulic jack (4) has a through-hole structure. The tensioning rod (3-1) passes through the hydraulic jack (4) and the tensioning of the clamp-type tensioning fixture (2) is achieved under the hydraulic action of the hydraulic jack (4).

7. The anchor cable tensioning system according to claim 6, characterized in that, It also includes an electro-hydraulic subsystem (5) that powers the hydraulic jack (4).

8. A construction method for constructing the anchor cable tensioning system according to any one of claims 2-7, characterized in that, This includes construction preparation, tooling installation, system assembly, graded tensioning, locking and dismantling, and quality inspection.

9. The construction method according to claim 8, characterized in that, The construction preparation includes: checking and releasing stress by laying cables, hoisting the cable body (1-5) to the arch rib and installing the anchor head, and installing the lower end fork lug; cleaning the surface of the tensioning end and checking the integrity of each component; The tooling installation includes: installing two sets of clamp-type tensioning tooling (2) on the positioning shoulder (1-7) below the tensioning flange (1-6) and the cable body (1-5) above the tensioning end anchor cup (1-4) respectively, and locking them with fastening screws (2-4) and fastening nuts (2-5); The system assembly includes: sequentially inserting the tension rod (3-1) and the hydraulic jack (4), installing and pre-tensioning the tension rod nut (3-2), and completing the system assembly; The graded tensioning includes: connecting the electric hydraulic subsystem (5), applying pressure in stages according to the design value after no-load trial operation, monitoring the pressure and the elongation of the cable (1-5) in real time, and adjusting the adjusting rod (1-2) synchronously until the design value is reached; The locking and dismantling include: locking the adjusting rod (1-2) after stabilizing the pressure, unloading the hydraulic system, and dismantling the tension rod (3-1), hydraulic jack (4), and tooling; The quality inspection includes: verifying cable tension and elongation, and recording and organizing construction data.

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