Lightweight straddle-type monorail cast steel tension support anchor rod replacement device and method

Abstract

The application discloses a light-type straddle-type monorail cast-steel tension support anchor rod replacement device, which comprises a track beam and a cast-steel tension support arranged at the end of the track beam. The light-type straddle-type monorail cast-steel tension support anchor rod replacement device comprises the following steps: S1, preliminary preparation and equipment inspection; S2, removing attachments and installing tooling; S3, synchronously jacking up the track beam and arranging temporary supports; S4, replacing the anchor rod; S5, falling back the track beam and three-dimensional fine adjustment; and S6, resuming the site and leaving the site. The application sets an anti-overturning baffle in the existing bolt hole, realizes the combination of temporary reinforcement and permanent structure, and can effectively resist the overturning risk; the modular small equipment is adopted, the operation can be conducted in a limited space, and large hoisting machinery is not needed; and the millimeter-level accurate jacking and locking are realized through the electric control synchronous hydraulic jack, and the three-dimensional fine adjustment device can realize rapid resetting.

Description

Technical Field

[0001] This invention mainly relates to the field of inspection and maintenance technology for lightweight straddle-type monorails, specifically a device and method for replacing cast steel tension support anchor bolts of lightweight straddle-type monorails. Background Technology

[0002] As a medium-capacity rail transit system, the light straddle-type monorail uses a PC track beam that integrates the beam and rail. The two ends of the track beam are connected to the piers or cap beams through cast steel tension supports. These supports form a core load-bearing system with the anchor boxes pre-embedded in the pier pad stone through high-strength anchor rods. The train load is mainly transmitted through mechanical interlocking and friction. Under long-term cyclic dynamic loads and environmental corrosion, the anchor rods of the supports may suffer from fatigue fracture, thread stripping, or rust damage, which seriously affects structural safety and must be replaced in time.

[0003] Currently, the mainstream method for replacing these types of anchor bolts in the industry is to use large lifting equipment (such as a large-tonnage truck crane) to lift the entire track beam as a whole, in order to create enough space for anchor bolt disassembly and assembly. However, this method has many drawbacks in practical applications: First, a single track beam can weigh over 80 tons, and the lifting operation requires the coordinated operation of two cranes with a capacity of 220 tons or more. The time required for large cranes to enter the site for assembly, positioning, trial lifting, and formal lifting is lengthy, often far exceeding the track maintenance window at night, which can easily lead to operational delays. At the same time, the rental of large equipment, the cost of operating shifts, and the large number of command, rigging, and safety personnel involved make the cost of a single construction item extremely high.

[0004] Secondly, large truck cranes have strict requirements on the load-bearing capacity, flatness and space of the site. The space under the bridge is often occupied by pipelines, greenery or roads. Many areas simply cannot meet the conditions for the deployment of large equipment, which makes it impossible to carry out the anchor bolt replacement operation and leaves safety hazards.

[0005] Furthermore, using flexible slings to suspend rigid track beams tens of meters long makes them prone to twisting and shifting during lifting and lowering. After the anchor bolts are replaced, the track beams often cannot return to their initial design positions, resulting in significant deviations in alignment and elevation. To meet the millimeter-level precision requirements for high-speed and stable train operation, a large amount of manpower and time must be spent on tedious post-processing adjustments, further extending the construction period.

[0006] In addition, once the track beam is suspended in the air, it is prone to swaying due to wind loads, and there is a high risk of collision with the existing structure in the narrow space under the bridge. At the same time, relying solely on slings for suspension, the beam lacks effective restraint in the horizontal direction. Under the construction disturbance of replacing anchor bolts, uncontrollable displacement or even overturning may occur, posing significant safety risks.

[0007] Therefore, in order to solve the problems existing in the above-mentioned prior art, it is urgent to develop an anchor bolt replacement device and method that is simple to operate, quick to deploy, and has a short construction time. This has become a technical problem that needs to be solved in this field. Summary of the Invention

[0008] This invention addresses the problem of overly simplistic solutions in existing technologies by providing a significantly different approach. It primarily offers a lightweight, straddle-type monorail cast steel tension support anchor replacement device and method. This addresses the technical problems of existing anchor replacement methods mentioned in the background section, such as high construction costs, low efficiency, significant site limitations, high safety risks, and difficulty in guaranteeing the accuracy of track beam repositioning after construction.

[0009] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: A lightweight straddle-type monorail cast steel tension support anchor replacement device includes a track beam and further includes: A cast steel tension support is installed at the end of the track beam to transfer the load of the track beam to the lower foundation structure. The cast steel tension support is connected to the pre-embedded anchor box through anchor rods. Anti-tipping baffle assembly, used to install finger-shaped plates on the side of the track beam to limit the displacement of the track beam during construction; A hydraulic jack device is used to lift the track beam to make room for anchor bolt replacement. The hydraulic jack device includes at least two jacks and an electric control terminal for controlling their synchronous movement. A temporary support assembly is used to provide temporary support for the track beam during the lifting process; The three-dimensional jack fine-tuning device is used to finely adjust the three-dimensional spatial position of the track beam after it has fallen back to its original position.

[0010] More preferably, the anti-tipping baffle assembly includes multiple guide surface anti-tipping baffles and multiple stabilizing surface anti-tipping baffles, and both the guide surface anti-tipping baffles and the stabilizing surface anti-tipping baffles are provided with mounting holes that match the original finger plate bolt holes on the side of the track beam.

[0011] More preferably, the guide surface anti-overturning baffle and the stabilizing surface anti-overturning baffle include a fixed end and a movable end, and the steel plate of the movable end has an embedding hole for accommodating a bolt head on the outside of each of the mounting holes.

[0012] More preferably, the electric control end of the hydraulic jack device is an electric oil pump, which synchronously controls the lifting and lowering of the two jacks and enables the jacks to be locked and fixed at any height.

[0013] More preferably, the temporary support component is a layered stacked square timber temporary support.

[0014] More preferably, the three-dimensional jack fine-tuning device includes at least two three-dimensional jacks and an electric control terminal for controlling their movement. The three-dimensional jacks are used to achieve vertical and horizontal displacement adjustment. A method for replacing the anchor bolt of a lightweight straddle-type monorail cast steel tension bearing includes the following steps: S1: Install the anti-overturning baffle assembly at the finger plate installation position on the side of the track beam; S2: Use hydraulic jacks to lift the track beam to the preset height, and use temporary support components for temporary support during the lifting process; S3: Replace the anchor rod of the cast steel tension support within the operating space created by the jacking; S4: Control the hydraulic jack device to lower the track beam back to the initial support position; S5: Use a three-dimensional jack fine-tuning device to fine-tune the three-dimensional spatial position of the track beam after it has fallen back.

[0015] More preferably, before step S1, the method further includes removing the finger plate, contact rail, support anchor nut and wedge block from the track beam.

[0016] In a further preferred embodiment, in step S2, the lifting process is controlled by an electric oil pump to synchronously control two hydraulic jacks at both ends of the track beam, and to keep both sides lifting synchronously.

[0017] More preferably, after step S5, the method further includes the step of reinstalling the finger plate, contact rail, support anchor nut, and wedge block.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention creatively combines temporary reinforcement measures with the permanent structure of the beam by installing a special anti-overturning baffle at the original finger plate position on the side of the track beam. This provides reliable horizontal constraint for the track beam during the jacking process. The design makes full use of the original bolt holes and does not require any destructive drilling into the beam. Under the premise of ensuring structural safety, it effectively limits the lateral displacement and overturning risk of the beam under wind and construction disturbance, and overcomes the problem of beam suspension and swaying in the traditional hoisting method. Meanwhile, modularly transportable small jacks and support components eliminate the reliance on large cranes and open, high-load-bearing sites, making it possible to replace anchor bolts in various complex and confined spaces such as under bridges, curves, and junctions, thus improving environmental adaptability and construction safety.

[0019] 2. This invention uses a hydraulic jack system synchronously controlled by an electric control terminal for jacking operations, which realizes stable and synchronous millimeter-level micro-lifting and micro-lowering at both ends of the track beam, and can be locked at any height, providing a stable and controllable operating space for anchor bolt replacement; After the anchor bolts are replaced, the longitudinal, lateral, and vertical positions of the track beam can be precisely adjusted electrically using a three-dimensional jack fine-tuning device. This allows for rapid correction of minor deviations, ensuring that the beam is restored to its original design coordinates. This process of electric precision jacking combined with electric three-dimensional fine-tuning transforms the traditional large-scale hoisting and rough reset mode, which relies on manual experience and physical strength, into a controllable, measurable, and adjustable precision engineering operation. It not only controls the reset accuracy within the operational requirements but also integrates and accelerates the most time-consuming post-installation fine-tuning work in the traditional method, thereby improving overall construction efficiency.

[0020] 3. The device of this invention mainly consists of reusable standard chemical equipment, small hydraulic equipment and supporting materials. Once put into use, it can be used for similar operations on the entire line for a long time without the need to rent large cranes. Moreover, the entire process is compact and efficient, and can be quickly deployed to complete all operations, which can reduce interference with the normal operation of rail transit and avoid social impact and economic losses caused by construction delays.

[0021] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a partial structural diagram of the present invention; Figure 3 This is a schematic diagram of the anti-tipping baffle structure of the guide surface of the present invention; Figure 4 This is a schematic diagram of the anti-tipping baffle structure of the stabilizing surface of the present invention; Figure 5 This is a schematic diagram of the temporary timber support structure of the present invention.

[0023] Numbering on the map: 1. Track beam; 2. Cast steel tension support; 3. Guide surface anti-overturning baffle; 4. Stabilizing surface anti-overturning baffle; 5. Hydraulic jack device; 6. Temporary timber support. Detailed Implementation

[0024] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the present invention. However, the present invention can be implemented in different forms and is not limited to the embodiments described in the text. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0025] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0026] Please refer to the appendix carefully. Figures 1-5 A lightweight straddle-type monorail cast steel tension support anchor replacement device includes an anti-overturning baffle assembly, a hydraulic jack device 5, a temporary square timber support 6, and a three-dimensional jack fine adjustment device.

[0027] The anti-overturning baffle assembly includes six sets each of guide surface anti-overturning baffles 3 and stabilizing surface anti-overturning baffles 4. The baffles are manufactured according to the dimensions and bolt hole positions of the original finger plates on the side of the track beam 1. They can be installed directly using the original bolt holes without the need to add new holes to the beam. The baffles include a fixed end and a movable end. The fixed end is a structure of two steel plates welded together. The diameter of the bolt holes in the baffles is 18mm. Each bolt hole (diameter 18mm) on the movable end steel plate is provided with an M16 bolt cap embedding hole (diameter 45mm, depth 15mm) on the outside, which facilitates bolt installation and ensures a tight fit.

[0028] The hydraulic jack device 5 includes two hydraulic jacks with a lifting stroke of 30cm and an electric control end (such as an electric oil pump). The electric control end can realize the synchronous lifting and synchronous lowering of the two jacks, and has the function of locking and fixing at any height to ensure that the construction process is stable and controllable.

[0029] The temporary square timber support 6 serves as a safety support during the lifting and lowering process. It uses square timber with a cross-sectional size of 100mm×100mm and is supported in layers (in a grid shape) according to the required lifting height.

[0030] The three-dimensional jack fine-tuning device includes two three-dimensional jacks and their electric control end. The electric control end can make precise electric fine-tuning of the position of the track beam 1 in three dimensions: vertical, horizontal and longitudinal, and correct the position deviation of the track beam 1 after reset.

[0031] A method for replacing the anchor bolt of a lightweight straddle-type monorail cast steel tension bearing includes the following steps: S1: Preliminary Preparations and Equipment Inspection Before construction, all tooling and equipment must be strictly inspected, and the weld quality of the guide surface anti-overturning baffle 3 and the stabilizing surface anti-overturning baffle 4 must be checked to ensure that there are no defects such as cracks or incomplete welds. Check the oil pipes, hydraulic oil status, and locking function of hydraulic jack device 5 and three-dimensional jack fine adjustment device to ensure they are working properly. Inspect the appearance and flatness of the temporary timber support 6.

[0032] S2: Removal of attachments and installation of tools First, the finger plates, contact rails, support anchor nuts, and wedge blocks on the track beam 1 section where the anchor bolts to be replaced are located are removed in sequence, and the working surface is cleaned. Then, the guide surface anti-overturning baffle 3 and the stabilizing surface anti-overturning baffle 4 are installed to the original finger plate bolt hole positions on the side of the track beam 1, and the bolts are tightened. Next, the hydraulic jack device 5 is transported to the predetermined working point below the cast steel tension support 2, ensuring that the jack's extended end is accurately aligned and fixed with the preset force point at the bottom of the track beam 1.

[0033] S3: Simultaneously lift the track beam and install temporary supports. Start the electric control end of the hydraulic jack device 5 to synchronously control the jacks at both ends of the track beam 1, and smoothly lift the track beam 1 and the cast steel tension support 2 at its ends. During the lifting process, the height of both ends of the beam needs to be monitored in real time to ensure synchronous lifting. At the same time, as the beam is lifted, temporary square timber supports 6 are added under the supports or other stress points as a safety guarantee. After lifting to the preset height (sufficient for anchor bolt operation), the locking function of the jack is used to stabilize the beam in this position.

[0034] S4: Replace anchor bolts Within the operating space created after the jacking, the construction workers removed the damaged old anchor rods from the cast steel tension support 2, cleaned the anchor box connection area, removed rust and impurities, and then installed and tightened the new anchor rods to the predetermined position.

[0035] S5: Drop Track Beam and Three-Dimensional Fine Adjustment After the anchor bolts are replaced and inspected and found to be qualified, the hydraulic jack device 5 is slowly and synchronously lowered through the electric control terminal, so that the track beam 1 and the cast steel tension support 2 are smoothly lowered to the initial support position.

[0036] After removing the jacks and most of the temporary supports, measuring instruments were used to check the alignment and positional deviations of track beam 1.

[0037] Subsequently, the three-dimensional jack fine-tuning device is installed at the preset fine-tuning stress point on the beam. Through its electric control end, the three-dimensional jack is precisely operated to finely adjust the slight deviations of the track beam 1 in three directions until its spatial position fully meets the operational technical requirements of the light straddle monorail.

[0038] S6: Site restoration and evacuation After the track beam 1 is finely adjusted and passes inspection, all attachment devices such as finger plates, contact rails, support anchor nuts, and wedge blocks are reinstalled in sequence.

[0039] Subsequently, the three-dimensional jack fine-tuning device, the remaining temporary square timber support 6, the guide surface anti-overturning baffle 3, and the stabilizing surface anti-overturning baffle 4 were dismantled and recovered in sequence. Finally, the construction site was cleaned up to ensure that the site was cleaned up after the work was completed and the normal environment of the work area was restored.

[0040] The present invention has been described by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvement made by adopting the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, shall be within the protection scope of the present invention.

Claims

1. A lightweight straddle-type monorail cast steel tension support anchor replacement device, comprising a track beam (1), characterized in that, Also includes: A cast steel tension support (2) is provided at the end of the track beam (1) to transfer the load of the track beam (1) to the lower foundation structure. The cast steel tension support (2) is connected to the pre-embedded anchor box through anchor rods. Anti-overturning baffle assembly, used to install finger-shaped plates on the side of the track beam (1) to limit the displacement of the track beam (1) during construction; A hydraulic jack device (5) is used to lift the track beam (1) to make room for the anchor rod replacement operation. The hydraulic jack device (5) includes at least two jacks and an electric control terminal for controlling their synchronous operation. A temporary support assembly is provided to provide temporary support for the track beam (1) during the jacking process; The three-dimensional jack fine adjustment device is used to finely adjust the three-dimensional spatial position of the track beam (1) after it has fallen back to its original position.

2. The lightweight straddle-type monorail cast steel tension support anchor replacement device according to claim 1, characterized in that: The anti-overturning baffle assembly includes multiple guide surface anti-overturning baffles (3) and multiple stabilizing surface anti-overturning baffles (4). The guide surface anti-overturning baffles (3) and the stabilizing surface anti-overturning baffles (4) are provided with mounting holes that match the original finger plate bolt holes on the side of the track beam (1).

3. The lightweight straddle-type monorail cast steel tension support anchor replacement device according to claim 2, characterized in that: The guide surface anti-overturning baffle (3) and the stabilizing surface anti-overturning baffle (4) include a fixed end and a movable end. On the steel plate of the movable end, an embedding hole for accommodating a bolt cap is provided on the outside of each of the mounting holes.

4. The lightweight straddle-type monorail cast steel tension support anchor bolt replacement device according to claim 1, characterized in that: The electric control end of the hydraulic jack device (5) is an electric oil pump. The electric oil pump synchronously controls the lifting and lowering of the two jacks and realizes the locking and fixing of the jacks at any height.

5. The lightweight straddle-type monorail cast steel tension support anchor replacement device according to claim 1, characterized in that: The temporary support assembly is a layered stacked temporary support of square timber (6).

6. The lightweight straddle-type monorail cast steel tension support anchor bolt replacement device according to claim 1, characterized in that: The three-dimensional jack fine-tuning device includes at least two three-dimensional jacks and an electric control terminal for controlling their movement. The three-dimensional jacks are used to achieve vertical and horizontal displacement adjustment.

7. A method for replacing anchor bolts of a lightweight straddle-type monorail cast steel tension bearing, comprising a device for replacing anchor bolts of a lightweight straddle-type monorail cast steel tension bearing according to any one of claims 1-6, characterized in that... Includes the following steps: S1: Install the anti-overturning baffle assembly at the finger plate installation position on the side of the track beam (1); S2: Use hydraulic jacks (5) to lift the track beam (1) to the preset height, and use temporary support components for temporary support during the lifting process; S3: Replace the anchor rod of the cast steel tension support (2) within the operating space created by the jacking; S4: Control the hydraulic jack device (5) to lower the track beam (1) back to the initial support position; S5: Use a three-dimensional jack fine-tuning device to fine-tune the three-dimensional spatial position of the track beam (1) after it has fallen back.

8. The method for replacing the anchor bolt of a lightweight straddle-type monorail cast steel tension support according to claim 7, characterized in that: Before step S1, the process also includes removing the finger plate, contact rail, support anchor nut and wedge block from the track beam (1).

9. The method for replacing the anchor bolt of a lightweight straddle-type monorail cast steel tension support according to claim 7, characterized in that: In step S2, the lifting process is controlled by an electric oil pump to synchronously control the two hydraulic jacks at both ends of the track beam (1) and keep both sides lifting synchronously.

10. The method for replacing the anchor bolt of a lightweight straddle-type monorail cast steel tension support according to claim 7, characterized in that: After step S5, the process also includes reinstalling the finger plate, contact rail, support anchor nut, and wedge block.

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