A double-layered bidirectional anchoring unit and manufacturing method, anchoring system and manufacturing method

Abstract

This invention discloses a double-layer bidirectional anchoring unit and its manufacturing method, as well as an anchoring system and its manufacturing method, relating to the field of bridge engineering technology, to solve the problems of low overall construction efficiency, long construction time, and high safety risks of cable-stayed bridges. The double-layer bidirectional anchoring unit includes two brackets and two anchor beams. Each bracket includes two vertically arranged supports. The two vertically arranged anchor beams correspond one-to-one with the two supports, and both ends of each anchor beam are supported on the corresponding supports of the two brackets, with the anchor beams fixedly connected to the corresponding supports. Each anchor beam has two horizontally arranged anchor box units at both ends. The double-layer bidirectional anchoring unit and its manufacturing method, as well as the anchoring system and its manufacturing method provided by this invention, are used to improve the construction efficiency of cable-stayed bridge anchoring systems and shorten the time spent on high-altitude operations at bridge sites.

Description

Technical Field

[0001] This invention relates to the field of bridge engineering technology, and in particular to a double-layer bidirectional anchoring unit and its manufacturing method, as well as an anchoring system and its manufacturing method. Background Technology

[0002] With the continuous improvement of urbanization, the demand for cable-stayed bridges is increasing in span and architectural aesthetics. In cross-sea cable-stayed bridges, the steel anchor beams and corbels on the pylons serve as the anchoring system, transferring the tension of the stay cables to the main tower structure and foundation, ensuring the overall stress balance and stability of the bridge. Currently, the steel anchor beams and corbels of existing cable-stayed bridge pylons are mostly manufactured using a single-layer, unidirectional composite structure. That is, each manufacturing and transportation unit has only one layer of anchor beams and one layer of supporting corbels, and one anchoring unit can only anchor one pair of stay cables.

[0003] However, each segment of the aforementioned single-layer unidirectional anchoring unit contains only one anchor beam and one corbel, resulting in low overall construction efficiency of the pylon. This is especially problematic in the high-altitude, sea-enclosed environment at the bridge site, where construction time is long and safety risks are high. Therefore, there is an urgent need for an anchoring unit structure and its manufacturing method that can improve construction efficiency and reduce high-altitude work time. Summary of the Invention

[0004] The purpose of this invention is to provide a double-layer bidirectional anchoring unit and its manufacturing method, as well as an anchoring system and its manufacturing method, to improve the construction efficiency of the cable-stayed bridge anchoring system and shorten the time for high-altitude operations at the bridge site.

[0005] To achieve the above objectives, in a first aspect, the present invention provides a double-layer bidirectional anchoring unit, comprising: two brackets, each bracket including two brackets arranged vertically; two anchor beams arranged vertically, the two anchor beams corresponding one-to-one with the two brackets, each anchor beam having its two ends supported on the corresponding brackets of the two brackets, and the anchor beams being fixedly connected to the corresponding brackets; each anchor beam having two anchor box units arranged side by side in the transverse direction at its two ends.

[0006] Furthermore, the anchor beam includes a top plate, a bottom plate, three web plates, a partition plate, and a stiffening plate; the three web plates are arranged side by side in the transverse direction between the top plate and the bottom plate, and an anchor box unit is respectively provided at both ends between every two adjacent web plates; the partition plate is fixedly connected between the top plate and the bottom plate and is arranged intersecting with the web plates; the end of the bottom plate protrudes from the web plates, and the stiffening plate is provided on the outside of the web plates and is fixedly connected to the web plates and the bottom plate respectively.

[0007] Furthermore, the anchor box unit includes an anchor box anchor plate, an anchor box bearing plate, an anchor box force transmission plate, and an anchor box stiffening plate; the anchor box anchor plate is fixedly disposed on one side surface of the anchor box bearing plate; the anchor box force transmission plate is fixedly disposed on the other side of the anchor box bearing plate and is fixedly connected to the web plate; the anchor box stiffening plate is arranged crosswise with the anchor box force transmission plate, and the anchor box stiffening plate is fixedly connected to both the anchor box bearing plate and the anchor box force transmission plate.

[0008] Furthermore, each of the brackets includes a bracket wall panel, two brackets fixed to the bracket wall panel, and a plurality of anchor pipes disposed on the bracket wall panel; the bracket includes a bracket top plate and a bracket web plate, the bracket web plate is fixedly disposed at the bottom of the bracket top plate, and the anchor beam is fixedly disposed on the bracket top plate.

[0009] Furthermore, the bottom surface of the anchor beam is a plane that has been machined and milled across the entire cross section, and the top surface of the bracket is a plane that has been machined and milled as a whole.

[0010] Furthermore, the anchor beam and the bracket are connected by high-strength bolts.

[0011] As can be seen from the above, the double-layer bidirectional anchoring unit provided in this application has the following beneficial effects: 1. Significantly Improved Construction Efficiency and Reduced Safety Risks: This invention integrates two layers of anchor beams and two layers of brackets on a single anchoring unit. Each anchor beam has four anchor box units at both ends, capable of simultaneously anchoring four pairs of stay cables. In contrast, existing single-layer unidirectional schemes can only anchor one pair of stay cables per unit. At the same tower height, the required number of anchoring units is reduced by approximately 75%, thus significantly reducing the number of units requiring hoisting, positioning, bolting, and welding at the bridge site. Since the bridge site is located in a high-altitude sea environment with harsh working conditions, reducing the on-site installation of each unit significantly shortens the working time for workers in a cantilevered position, reducing safety risks such as falls and collisions. Simultaneously, more manufacturing and pre-assembly work can be completed in the factory. The factory environment is controllable, equipped with complete facilities, and offers precise measurements, enabling streamlined operations and significantly improving overall construction efficiency.

[0012] 2. Reasonable structural design and reliable force transmission: The anchor beam of this invention employs three webs arranged side-by-side in the transverse direction, with an anchor box unit between every two adjacent webs, forming two parallel box chambers. Each anchor box unit is fixedly connected to the web through a force transmission plate, forming a clear force transmission path: cable tension → anchor box anchor plate → anchor box bearing plate → anchor box force transmission plate → web → entire anchor beam → corbel → tower. The three-web structure disperses concentrated loads into multiple force flow paths, avoiding stress concentration and significantly improving the tensile and fatigue resistance of the anchor beam. The corbel bracket uses a top plate and web plate structure, ensuring sufficient rigidity and bearing capacity; the anchor box stiffening plate prevents the bearing plate and force transmission plate from becoming unstable under pressure, extending fatigue life.

[0013] 3. Reliable connection and good maintainability: The anchor beam and bracket are connected by high-strength bolts, which is a detachable connection, avoiding the heat-affected zone and residual stress of welding. During factory pre-assembly, it can be disassembled and adjusted multiple times until the through hole rate is 100%; on-site installation at the bridge site does not require hot work; if replacement is needed during service, the detachable bolts can be used for local maintenance, reducing the total life cycle cost.

[0014] 4. Integrated design reduces the number of segments and on-site workload: This invention integrates two layers of anchor beams into a single anchoring unit. Each steel bracket has two vertically arranged brackets that support the upper and lower anchor beams respectively. A single double-layer, bidirectional anchoring unit can achieve the double-layer anchoring function that originally required four independent single-layer segments, reducing the number of segments required for the pylon by approximately 75%, halving the number of on-site circumferential welds, reducing cumulative installation errors, significantly shortening the time spent on high-altitude work at the bridge site, and improving construction efficiency and installation accuracy.

[0015] Secondly, the present invention also provides a method for manufacturing the above-mentioned double-layer bidirectional anchoring unit, comprising the following steps: S100. Separately manufacture anchor beams and corbels; among them, computer BIM 3D modeling and layout are used, the bottom surface of the anchor beam is machined and milled in its entirety, and the top surfaces of the two brackets of the corbel are machined and milled as a whole. S200, fixed assembly fixtures; mark the anchor beam and corbel assembly layout lines on the flat ground, and fix the assembly fixtures according to the layout lines; S300, Initially position the double-layer anchor beam; Position and install the lower and upper anchor beams respectively on the assembly fixture; S400, Positioning brackets; Position and install two brackets on both sides of the anchor beam respectively; S500, Precisely position the anchor beam; adjust the position and vertical elevation of the anchor beam, perform precise positioning, ensure that the bottom surface of the anchor beam is in close contact with the top surface of the bracket of the corbel, and use a through-hole tool to check the bolt hole pass rate to ensure 100% pass rate; S600, forming a double-layer bidirectional anchoring unit; the closely fitted anchor beam and the bracket of the corbel are connected and fixed with high-strength bolts, and the anchor pipe is installed to form a double-layer bidirectional anchoring unit.

[0016] Further, S100 includes: S101. Fabrication of the bracket: First, fabricate the box-shaped wall panel of the bracket. Use a laser scribing device to scribing the bracket assembly position lines on the wall panel of the bracket. Assemble the bracket of the bracket according to the position lines and use an angle template to control the assembly angle deviation between the bracket and the wall panel to ≤0.1°. Then, use a full-section machining equipment to mill the top surface of the two brackets as a whole, controlling the flatness of the bracket wall panel to ≤2mm, the flatness deviation of the bracket top surface to ≤0.2mm, the distance deviation between the two brackets to ≤0.5mm, and the parallelism deviation between the two brackets to ≤0.5mm. Finally, use CNC drilling to drill the high-strength bolt holes on the bracket. S102. Fabricate the anchor beam; use CNC blanking, laser scribing, and robotic welding to assemble the anchor box unit. Place the anchor box bearing plate on a leveled platform, and assemble the anchor box force transmission plate and anchor box stiffening plate by scribing lines with the circular hole of the anchor box bearing plate as a reference, ensuring the perpendicularity of each part to the anchor box bearing plate and the requirements for grinding and tightening; assemble the anchor box anchor plate with the cross line at the center of the circular hole of the anchor box bearing plate as a reference, ensuring the concentricity of the hole of the anchor plate and the hole of the anchor box bearing plate; assemble the anchor beam on a special assembly fixture, and perform cross-section milling on the bottom plate of the anchor beam, controlling the anchor beam length deviation ≤2mm, width deviation ≤1mm, bottom plate flatness deviation ≤0.2mm, and anchor box position angle deviation ≤0.1°, and use CNC drilling to drill high-strength bolt holes.

[0017] Furthermore, the assembly fixture includes a jig, supports, and a steel bracket, wherein the supports and the steel bracket are both fixed to the jig; S300 includes: S301. Install the lower anchor beam; Place the lower steel anchor beam on the support pier with the longitudinal and transverse ground lines as the reference and level it. Use the leveling shims on the top of the support pier to roughly adjust the elevation. S302. Install and position the steel support; mark the plane position line and ground line of the steel support as a reference, and install the steel support. The steel support includes a crossbeam and an adjustable steel pad. The theoretical height of the top surface of the crossbeam below the bottom surface of the upper anchor beam is 20mm. The adjustable steel pad is placed on the crossbeam. The adjustment range of the adjustable steel pad is 5mm-50mm. S303. Install the upper anchor beam; place the upper steel anchor beam on the crossbeam of the steel support with the ground line as the reference and level it, and use the leveling shims of the crossbeam to adjust the elevation.

[0018] Furthermore, S400 includes: aligning the lower edges of the wall panels of the two corbels with the corresponding outer skin ground pattern lines, aligning the vertical baseline with the horizontal baseline of the jig ground pattern, measuring the elevation using a level instrument to ensure that the horizontal baselines are at the same height when assembling the wall panels of the corbels; setting diagonal supports on both sides of the corbel wall panels to position the wall panel angle, and measuring the wall panel tilt angle using a laser plumb bob or total station. After passing the test, positioning baffles are used to position the bottom and secure it to the bottom jig platform.

[0019] As can be seen from the above, the manufacturing method of the double-layer bidirectional anchoring unit provided in this application, in addition to having the same beneficial effects as the aforementioned double-layer bidirectional anchoring unit, also has the following beneficial effects: 1. High Manufacturing Precision and Guaranteed Quality: This invention features full-section milling of the bottom surface of the anchor beam and integral milling of the top surfaces of the two brackets of the corbel, effectively ensuring the flatness (≤0.2mm) of the bottom surface of the anchor beam and the top surface of the brackets, guaranteeing a tight fit between them. Simultaneously, high-precision manufacturing methods such as computer-aided BIM 3D modeling and layout, CNC blanking, laser scribing, and robotic welding are employed, along with strict control over the deviations of each component (e.g., flatness of the anchor beam bottom plate ≤0.2mm, flatness of the bracket top surface ≤0.2mm, angle deviation between the bracket and the wall panel ≤0.1°, etc.), ensuring the manufacturing precision of the double-layer bidirectional anchoring unit from the source. High-precision planar contact ensures that the contact area of ​​the high-strength bolts exceeds 95%, effectively avoiding point contact or local indentation and preventing bolt loosening under cyclic loads.

[0020] 2. Economical and Reliable Assembly Scheme with Controllable Precision: This invention adopts a "vertical" assembly scheme, first positioning the lower anchor beam, then positioning the two corbels, and finally fine-tuning the upper anchor beam. This scheme requires less tooling and has lower costs (approximately 60% lower than horizontal assembly), eliminating the need for large-scale turning equipment. Through the combined use of various measurement methods such as ground survey lines, total stations, theodolites, levels, and laser plumb bobs, it ensures a tight fit between the bottom surface of the anchor beam and the top surface of the corbels, guaranteeing a 100% through-hole rate for high-strength bolts, effectively solving the problem of high spatial precision requirements in double-layer, two-way structures. The vertical assembly method also avoids deformation and measurement errors caused by turning over after horizontal assembly.

[0021] 3. High anchor installation accuracy: After the anchoring unit is assembled as a whole, the invention uses a theodolite and total station to spatially position and install the anchor pipe, controlling the spatial position deviation of the anchor pipe to ≤1mm and the angle deviation to ≤0.1°, ensuring the precise connection between the anchor pipe and the stay cable, avoiding the inability to install the stay cable or the sheath being scratched due to the anchor pipe deviation, and ensuring that the force direction of the stay cable is consistent with the design.

[0022] Thirdly, the present invention also provides an anchoring system comprising a plurality of the above-mentioned double-layer bidirectional anchoring units, wherein the plurality of double-layer bidirectional anchoring units are stacked vertically along the tower, and the brackets of two adjacent double-layer bidirectional anchoring units are fixedly connected by welding.

[0023] As can be seen from the above, the anchoring system provided in this application has the same beneficial effects as the aforementioned double-layer bidirectional anchoring unit, which will not be repeated here.

[0024] Fourthly, the present invention also provides a method for manufacturing an anchoring system, comprising the following steps: T100. Multiple double-layer bidirectional anchoring units are stacked vertically along the tower. Two adjacent double-layer bidirectional anchoring units are pre-assembled in a 1+1 vertical manner. The manufacturing accuracy is checked by matching the rings between the wall panels of the upper and lower corbels. The misalignment of the wall panels of the upper and lower corbels is controlled to be ≤0.5mm, the spacing deviation of the anchor beams between each layer is ≤1mm, and the spatial position deviation of the anchor pipe is ≤1mm. T200. Weld and fix the brackets of the two adjacent double-layer bidirectional anchoring units together.

[0025] As can be seen from the above, the anchoring system and manufacturing method provided in this application have the following beneficial effects: Factory pre-assembly verification avoids bridge site rework—This invention performs 1+1 vertical pre-assembly of two adjacent anchoring units in the factory, and verifies the manufacturing accuracy by matching the circumferential joints between the upper and lower corbel panels, controlling the misalignment between the upper and lower corbel panels to ≤0.5mm, the spacing deviation of anchor beams between layers to ≤1mm, and the spatial position deviation of anchor pipes to ≤1mm. This step simulates the actual installation state at the bridge site, identifying and resolving manufacturing deviations in advance, avoiding the discovery of problems only after transporting unqualified products to the bridge site, thus avoiding the high costs and safety risks of high-altitude rework at sea, and achieving "zero-repair" installation at the bridge site. Attached Figure Description

[0026] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the structure of a double-layer bidirectional anchoring unit provided in an embodiment of the present invention; Figure 2 An exploded view of an anchor beam provided in an embodiment of the present invention; Figure 3 This is a structural schematic diagram of an anchor box unit provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of a cow leg provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of a bracket provided in an embodiment of the present invention; Figure 6 A flowchart illustrating a manufacturing method for a double-layer bidirectional anchoring unit provided in an embodiment of the present invention; Figure 7A flowchart illustrating a method for manufacturing a double-layer bidirectional anchoring unit according to an embodiment of the present invention; Figure 8 This is a schematic diagram of the structure of an assembly tool provided in an embodiment of the present invention; Figure 9 This is a structural schematic diagram of the assembly tooling and the assembly process of the two anchor beams provided in the embodiment of the present invention; Figure 10 This is a structural schematic diagram of the assembly process of two anchor beams and two brackets provided in an embodiment of the present invention; Figure 11 This is a structural schematic diagram of the assembly process of the double-layer bidirectional anchoring unit provided in an embodiment of the present invention; Figure 12 This is a structural schematic diagram of the anchor tube assembly process of the double-layer bidirectional anchoring unit provided in an embodiment of the present invention. Figure 13 This is a schematic diagram of an anchoring system provided in an embodiment of the present invention; Figure 14 A flowchart illustrating a manufacturing method for an anchoring system provided in an embodiment of the present invention.

[0027] Figure label: 100-Double-layer bidirectional anchoring unit; 1-Corner; 11-Bracket; 111-Corner bracket top plate; 112-Corner bracket web plate; 12-Corner wall plate; 13-Anchor pipe; 2-Anchor beam; 21-Top plate; 22-Bottom plate; 23-Partition plate; 24-Web plate; 25-Stiffening plate; 26-Anchor box unit; 261-Anchor box anchor plate; 262-Anchor box bearing plate; 263-Anchor box force transmission plate; 264-Anchor box stiffening plate; 200-Assembly tooling; 201-Support; 202-Steel support. Detailed Implementation

[0028] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0029] It should be noted that when a component is referred to as "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0030] Furthermore, the terms "first" and "second" 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 as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0031] In the description of this invention, it should be understood that the terms "upper" and "lower" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this 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. Therefore, they should not be construed as limiting this invention.

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

[0033] Currently, cable-stayed bridge tower anchoring systems mostly adopt a single-layer, unidirectional composite structure. That is, each manufacturing and transportation unit contains only one layer of anchor beam 2 and one layer of supporting brackets, and one anchoring unit 100 can only hold one pair of stay cables. This structure results in long construction time, high safety risks, and low overall construction efficiency in the high-altitude and sea-area environment of the bridge site.

[0034] To solve the above problems, such as Figures 1 to 5 As shown, this embodiment of the invention provides a double-layer bidirectional anchoring unit 100, including two brackets 1 and two anchor beams 2 arranged vertically. Each bracket 1 includes two brackets 11 arranged vertically; the two anchor beams 2 correspond one-to-one with the two brackets 11, and the two ends of each anchor beam 2 are respectively supported on the corresponding brackets 11 of the two brackets 1, and the anchor beam 2 is fixedly connected to the corresponding bracket 11; each end of each anchor beam 2 has two anchor box units 26 arranged side by side in the transverse direction.

[0035] During operation, the lower anchor beam 2 is first supported on the lower bracket 11 of the two corbels 1, and the upper anchor beam 2 is supported on the upper bracket 11 of the two corbels 1. The bottom plate 22 of the anchor beam 2 is then fixed to the top surface of the bracket 11 (i.e., the top plate 111 of the corbel bracket) through a fixed connection (e.g., welding or bolting). Each anchor beam 2 has four anchor box units 26 at both ends, which are used to anchor the stay cables. During bridge site installation, multiple anchoring units 100 are stacked vertically, and the corbels 1 of adjacent units are fixed by welding to form an anchoring system.

[0036] Through the above structure and working process, this embodiment integrates two layers of anchor beams 2 and two layers of brackets 11 on one anchoring unit 100. Each anchor beam 2 has four anchor box units 26 at both ends, which can simultaneously anchor four pairs of stay cables. In contrast, the existing single-layer unidirectional scheme can only anchor one pair of stay cables per unit. At the same tower height, the number of anchoring units 100 required is reduced by about 75%, thereby significantly reducing the number of units that need to be hoisted, positioned, and welded on-site at the bridge site. Since the bridge site is located in a high-altitude sea environment with harsh working conditions, reducing the on-site installation of each unit can significantly shorten the working time of workers in a high-altitude cantilevered state and reduce safety risks such as falls and collisions.

[0037] For example, bracket 1 is a steel bracket, and anchor beam 2 is a steel anchor beam.

[0038] Furthermore, such as Figure 2 As shown, the anchor beam 2 includes a top plate 21, a bottom plate 22, three web plates 24, a partition plate 23, and a stiffening plate 25. The three web plates 24 are arranged side by side in the transverse direction between the top plate 21 and the bottom plate 22, and an anchor box unit 26 is provided at each end between every two adjacent web plates 24. The partition plate 23 is fixedly connected between the top plate 21 and the bottom plate 22 and is arranged intersecting with the web plates 24. The end of the bottom plate 22 protrudes from the web plates 24, and the stiffening plate 25 is provided on the outside of the web plates 24 and is fixedly connected to the web plates 24 and the bottom plate 22 respectively. By setting up three web plates 24, two parallel boxes are formed, and an anchor box unit 26 is arranged at each end of each box, so that the tension of the inclined cable of each anchor box unit 26 can be directly transmitted to the two adjacent web plates 24, and then the force is diffused to the top plate 21 and the bottom plate 22 of the entire anchor beam 2 through the web plates 24. The three-web structure disperses concentrated loads into multiple force flow paths, avoiding stress concentration and significantly improving the tensile and fatigue resistance of the anchor beam 2. The end of the bottom plate 22 protrudes beyond the web 24, providing installation space for the stiffening plate 25. The stiffening plate 25 is fixed to the outer side of the outer web 24, further enhancing the lateral stiffness of the web 24 and preventing instability caused by lateral forces generated by the cables under heavy loads. The diaphragm 23 strengthens the stability between two adjacent webs 24.

[0039] Furthermore, such as Figure 3As shown, the anchor box unit 26 includes an anchor box anchor plate 261, an anchor box bearing plate 262, an anchor box force transmission plate 263, and an anchor box stiffening plate 264. The anchor box anchor plate 261 is fixedly disposed on one side surface of the anchor box bearing plate 262; the anchor box force transmission plate 263 is fixedly disposed on the other side of the anchor box bearing plate 262 and is fixedly connected to the web plate 24; the anchor box stiffening plate 264 is arranged crosswise with the anchor box force transmission plate 263, and the anchor box stiffening plate 264 is fixedly connected to both the anchor box bearing plate 262 and the anchor box force transmission plate 263. This structure forms a clear force transmission path: the tension of the stay cable first acts on the anchor plate 261 of the anchor box. Due to the large area of ​​the anchor plate, the concentrated force is converted into a uniformly distributed pressure and transmitted to the anchor box bearing plate 262; the anchor box bearing plate 262 then transmits the force to the anchor box force transmission plate 263 perpendicular to it; the anchor box force transmission plate 263 is welded to the web plate 24, and the force is finally input into the main structure of the anchor beam 2. The anchor box stiffening plate 264 is intersected with the anchor box force transmission plate 263 and fixed to the anchor box bearing plate 262 and the anchor box force transmission plate 263 to form a reinforcing rib, which effectively prevents the anchor box bearing plate 262 from bending and deforming under compression, and also avoids the anchor box force transmission plate 263 from out-of-plane instability under tension.

[0040] Furthermore, such as Figure 4 and Figure 5 As shown, each corbel 1 includes a corbel wall panel 12, two brackets 11 fixed to the corbel wall panel 12, and multiple anchor pipes 13 disposed on the corbel wall panel 12. The bracket 11 includes a corbel bracket top plate 111 and a corbel bracket web plate 112. The corbel bracket web plate 112 is fixedly disposed at the bottom of the corbel bracket top plate 111, and the anchor beam 2 is fixedly disposed on the corbel bracket top plate 111. The corbel wall panel 12 adopts a box-shaped cross-section, possessing extremely high bending and torsional stiffness, capable of withstanding the enormous vertical and horizontal forces transmitted by the anchor beam 2 and dispersing them to the tower concrete. The bracket 11 adopts a T-shaped cross-section with a top plate and a web plate. The corbel bracket top plate 111 provides a flat support surface for the anchor beam 2, while the corbel bracket web plate 112 serves as the main shear-bearing component, transmitting the pressure on the top plate to the corbel wall panel 12 in the form of shear flow. Anchor pipe 13 is pre-positioned and welded on corbel wall panel 12, and its spatial angle is completely consistent with the design direction of the cable, ensuring the smooth passage of the cable and the accuracy of the force direction.

[0041] Furthermore, the bottom surface of the anchor beam 2 (i.e., the lower surface of the base plate 22) is a flat surface machined and milled from the entire cross section, and the top surface of the bracket 11 (i.e., the upper surface of the bracket top plate 111) is a flat surface machined and milled from the entire surface. Since welding deformation is unavoidable, the flatness of the bottom surface of the anchor beam 2 and the top surface of the bracket 11 after direct welding usually exceeds 1mm, failing to meet the requirement of tight fit. This invention, through full-section machined milling, precisely controls the flatness of the anchor beam 2 base plate 22 to ≤0.2mm and the flatness of the bracket top plate 111 to ≤0.2mm, while simultaneously maintaining a spacing deviation of ≤0.5mm and a parallelism deviation of ≤0.5mm between the two brackets 11. When the anchor beam 2 and the bracket 11 are fixedly connected, the two precision-machined surfaces can achieve almost complete fit, with a fit area exceeding 95%, thereby generating uniform contact pressure at the connection point.

[0042] Furthermore, the anchor beam 2 and the bracket 11 are connected by high-strength bolts. High-strength bolt connections are detachable connections, offering significant advantages over welding: firstly, during factory pre-assembly, they can be disassembled and adjusted multiple times until the through-hole rate reaches 100%; secondly, on-site installation at the bridge site requires no open flame, avoiding the adverse effects of welding heat input on the steel's metallographic structure and residual stress; and thirdly, during the bridge's service life, if it is necessary to replace the anchor beam 2 or the bracket 1, the bolts can be disassembled for localized maintenance, reducing the overall life-cycle cost.

[0043] It should be noted that some solutions employ a method of stacking multiple single-layer segments, where each segment is manufactured independently and then connected into a whole by circumferential welding of the steel bracket wall panels. This method involves only one anchor beam per segment, resulting in a large number of segments, a significant amount of on-site welding work, and difficulty in controlling cumulative errors. In contrast, this invention integrates two layers of anchor beams 2 within a single double-layer bidirectional anchoring unit 100. Each bracket 1 has two vertically arranged brackets 11, corresponding one-to-one with the two layers of anchor beams 2. This integrated design allows a single anchoring unit to achieve the double-layer anchoring that originally required two independent segments. This not only reduces the total number of segments in the tower but also avoids the cumulative deviation at the circumferential joint caused by stacking multiple segments, improving the overall accuracy and reliability of the anchoring system. Simultaneously, due to the reduced number of segments, the workload of on-site hoisting, positioning, and welding at the bridge site is significantly reduced, the time spent working at heights is shortened, and safety risks are also lowered.

[0044] This embodiment also provides a method for manufacturing the above-mentioned double-layer bidirectional anchoring unit 100, such as... Figure 6 and Figure 7 As shown, it includes the following steps: S100. Anchor beam 2 and bracket 1 are fabricated separately. Computer-aided BIM 3D modeling and layout are used. The bottom surface of anchor beam 2 is machined and milled across its entire cross-section, and the top surfaces of the two brackets 11 of bracket 1 are machined and milled as a whole. The use of computer-aided BIM 3D modeling and layout ensures design accuracy. The machined and milled surfaces of the anchor beam bottom and bracket top are controlled to a flatness of ≤0.2mm, ensuring a tight fit and providing a reliable foundation for high-strength bolt connections.

[0045] Specifically, S100 includes: S101. Fabrication of Bracket 1: First, fabricate the box-shaped wall panel of Bracket 1 (i.e., Bracket wall panel 12). Use a laser scribing device to mark the assembly position lines of the bracket 11 on the wall panel of Bracket 1. Assemble the bracket 11 of Bracket 1 according to the position lines and use an angle template to control the assembly angle deviation between the bracket 11 and the wall panel to be ≤0.1°. Then, use a full-section machining equipment to mill the top surfaces of the two brackets 11 as a whole, controlling the flatness of Bracket wall panel 12 to be ≤2mm, the flatness deviation of the top surface of bracket 11 to be ≤0.2mm, the distance deviation between the two brackets 11 to be ≤0.5mm, and the parallelism deviation between the two brackets 11 to be ≤0.5mm. Finally, use CNC drilling to drill high-strength bolt holes on the bracket 11.

[0046] In this step, the laser scribing equipment achieves an accuracy of ±0.1mm, far exceeding that of manual scribing, ensuring the accuracy of the positioning reference for bracket 11. The angle template, a specialized measuring tool made to a 1:1 scale according to the design drawings, is placed against the bracket wall panel 12 and bracket 11, allowing for a direct assessment of whether the assembly angles are acceptable, which is more efficient than using general measuring tools. The overall milling process completes the machining of both bracket top plates 111 in one operation, ensuring the parallelism and spacing between the two bracket top plates 111 and avoiding cumulative errors from separate machining. Through systematic deviation control of height deviation (≤2mm), wall panel flatness (≤2mm), bracket top surface flatness (≤0.2mm), spacing and parallelism (≤0.5mm), and refined processes such as laser scribing, angle templates, and overall milling, the manufacturing accuracy of the brackets is guaranteed from the outset, laying the foundation for the overall accuracy of the subsequent anchoring system.

[0047] S102. Fabrication of Anchor Beam 2: Using CNC blanking, laser scribing, and robotic welding, the anchor box unit 26 is assembled. The anchor box bearing plate 262 is placed on a leveled platform. Using the circular hole of the anchor box bearing plate 262 as a reference, the anchor box force transmission plate 263 and the anchor box stiffening plate 264 are scribed and assembled to ensure the perpendicularity of each part to the anchor box bearing plate 262 and the requirements for grinding and tightening. Using the cross line at the center of the circular hole of the anchor box bearing plate 262 as a reference, the anchor box anchor pad plate 261 is assembled to ensure the concentricity of the hole of the anchor pad plate 261 and the hole of the anchor box bearing plate 262. The anchor beam 2 is assembled on a special assembly fixture. The bottom plate 22 of the anchor beam 2 is machined and milled to control the length deviation of the anchor beam 2 to ≤2mm, the width deviation to ≤1mm, the flatness deviation of the bottom plate 22 to ≤0.2mm, and the position angle deviation of the anchor box unit 26 to ≤0.1°. High-strength bolt holes are drilled using CNC.

[0048] In this step, the anchor box bearing plate hole is the most precise positioning reference in the anchor box unit 26. Using it as a reference for scribe lines ensures that the spatial positions of all anchor box force transmission plates 263 and anchor box stiffening plates 264 are strictly aligned with the center line of the anchor box bearing plate hole. Grinding and tightening require a seamless contact surface between the anchor box force transmission plate 263 and the anchor box bearing plate 262, ensuring uniform pressure transmission. The concentricity of the anchor box anchor pad hole and the anchor box bearing plate hole is controlled within 0.5mm, avoiding the additional bending moment caused by eccentric compression of the anchor box anchor pad plate 261 during cable anchoring, effectively preventing cracking of the anchor box anchor pad plate 261. High-precision manufacturing methods such as CNC blanking, laser scribing, and robotic welding are adopted to strictly control deviations in anchor beam length, width, base plate flatness, and anchor box position angle, ensuring the manufacturing accuracy of anchor beam 2. The assembly method based on the anchor box bearing plate hole ensures accurate force transmission path and high concentricity of anchor box unit 26, improving the stress reliability of the anchoring system.

[0049] S200, fixed assembly tooling 200 (such as...) Figure 8 As shown): Mark the anchor beam 2 and corbel assembly layout lines on the flat ground, and fix the assembly fixture 200 according to the layout lines. The assembly fixture 200 includes a jig, a support 201, and a steel bracket 202, with the support 201 and steel bracket 202 fixed on the jig. The layout lines provide a precise spatial positioning reference for assembly. The dedicated assembly fixture 200 has a simple structure and low cost, laying the foundation for subsequent "positioning method" assembly.

[0050] S300, Preliminary positioning of double-layer anchor beam 2 (as shown) Figure 9 (As shown): Position and install the lower anchor beam 2 and the upper anchor beam 2 on the assembly fixture 200 respectively. Specifically, this includes: S301, Install the lower anchor beam 2: Place the lower steel anchor beam on the support 201 with the longitudinal and transverse ground lines as the reference and level it. Use the leveling shims on the top of the support 201 to adjust the elevation. S302. Install and position the steel support 202: Mark the plane position line and ground line of the steel support 202 as a reference, and install the steel support 202. The steel support 202 includes a crossbeam and an adjustable steel pad. The theoretical height of the top surface of the crossbeam below the bottom surface of the upper anchor beam 2 is 20mm. The adjustable steel pad is placed on the crossbeam. The adjustment range of the adjustable steel pad is 5mm-50mm. S303, Install the upper anchor beam 2: Place the upper steel anchor beam on the crossbeam of the steel support 202 with the ground line as the reference and level it. Use the leveling shims on the crossbeam to adjust the elevation.

[0051] First, the lower anchor beam is positioned, and then the upper anchor beam is positioned using a steel bracket, thus achieving the initial spatial positioning of the double-layer anchor beam. The adjustment range of the height steel pad (5mm-50mm) provides sufficient margin for fine-tuning, facilitating subsequent precise alignment.

[0052] S400, Positioning Cow Leg 1 (e.g.) Figure 10 As shown): Two brackets 1 are positioned and installed on both sides of the anchor beam 2. Specifically, the lower edges of the wall panels of the two brackets 1 are aligned with the corresponding outer skin ground line, the vertical baseline is aligned with the horizontal baseline of the ground line of the jig, the elevation is measured using a level instrument to ensure that the horizontal baselines are at the same height, and the wall panels of the brackets 1 are assembled; diagonal supports are set on both sides of the wall panels of the brackets 1 to position the wall panel angle, and the tilt angle of the wall panel is measured using a laser plumb bob or total station. After passing the test, the bottom is positioned with a positioning baffle and secured to the bottom jig platform.

[0053] By combining various measurement methods such as ground survey lines, level instruments, laser plumb bobs, or total stations, the spatial position and tilt angle of the corbel wall panels are precisely controlled; the diagonal supports and positioning baffles reliably fix the corbels to prevent displacement in subsequent processes.

[0054] S500, Precisely Position Anchor Beam 2: Adjust the position and vertical elevation of anchor beam 2 for precise positioning, ensuring that the bottom surface of anchor beam 2 is in close contact with the top surface of bracket 11 of corbel 1. Use a through-hole tool to check the bolt hole pass rate and ensure 100% pass rate.

[0055] Precise positioning ensures that the bottom surface of the anchor beam is in close contact with the top surface of the corbel, and the through-hole tool ensures that the high-strength bolts have a 100% through-hole rate, avoiding on-site hole enlargement or repair at the bridge site and significantly improving installation efficiency.

[0056] S600, forming a double-layer bidirectional anchoring unit 100: the closely fitting anchor beam 2 and the bracket 11 of the corbel 1 are connected and fixed by high-strength bolts (e.g., Figure 11 As shown), and install anchor pipe 13 (as shown). Figure 12 As shown in the figure, a double-layer bidirectional anchoring unit 100 is formed. The high-strength bolt connection is detachable and free from welding heat-affected zone, facilitating factory pre-assembly and adjustment and rapid installation at the bridge site.

[0057] Furthermore, during the installation of anchor pipe 13, a theodolite and total station were used for spatial positioning and installation, controlling the spatial position deviation of anchor pipe 13 to be ≤1mm and the angle deviation to be ≤0.1°. Anchor pipe 13 is the channel for the stay cable, and its spatial orientation directly determines whether the cable can pass through smoothly and be properly anchored. Using both theodolite and total station for cross-checking eliminates systematic errors of a single instrument. During installation, anchor pipe 13 was initially positioned, and then the three-dimensional coordinates of its two end center points were measured to calculate the actual inclination angle and azimuth angle. After comparing with the design values, fine adjustments were made until all deviations met the stringent requirements of ≤1mm and ≤0.1°. This high-precision installation ensured that the cable was not scratched inside anchor pipe 13, avoiding damage to the cable sheath and eccentric stress.

[0058] This invention employs a "vertical assembly method," first positioning the lower anchor beam, then preliminarily positioning the upper anchor beam, followed by positioning the two brackets, and finally fine-tuning the upper anchor beam. This method requires less tooling and is lower in cost (approximately 60% less than horizontal assembly), eliminating the need for large-scale turning equipment. By utilizing various measurement methods such as ground survey lines, total stations, theodolites, levels, and laser plumb bobs, it ensures a tight fit between the bottom surface of the anchor beam and the top surface of the bracket, guaranteeing 100% through-hole rate for high-strength bolts, effectively solving the challenge of high spatial accuracy requirements in double-layer, two-way structures. The vertical assembly method also avoids deformation and measurement errors caused by turning the structure after horizontal assembly.

[0059] This embodiment also provides an anchoring system, such as Figure 13 As shown, it includes multiple double-layer bidirectional anchoring units 100 as described in the above embodiments. The multiple double-layer bidirectional anchoring units 100 are stacked vertically along the tower, and the brackets 1 of two adjacent double-layer bidirectional anchoring units 100 are fixedly connected by welding.

[0060] This embodiment also provides a method for manufacturing the above-mentioned anchoring system, such as... Figure 14 As shown, it includes the following steps: T100. Multiple double-layer bidirectional anchoring units 100 are stacked vertically along the tower. Two adjacent double-layer bidirectional anchoring units 100 are pre-assembled in a 1+1 vertical manner. The manufacturing accuracy is checked by matching the rings between the wall panels of the upper and lower corbels 1. The misalignment of the wall panels of the upper and lower corbels 1 is controlled to be ≤0.5mm, the spacing deviation of the anchor beams 2 between each layer is ≤1mm, and the spatial position deviation of the anchor pipes 13 is ≤1mm.

[0061] In this step, the 1+1 pre-assembly refers to temporarily assembling two adjacent anchoring units 100 together in the factory according to the stacking sequence at the bridge site, simulating the actual installation state. By measuring the alignment of the upper and lower corbel wall panels 12, the spacing between the two layers of anchor beams 2, and the relative positions of the upper and lower anchor pipes 13, manufacturing deviations can be detected in advance. If misalignment or spacing exceeds the tolerance, it can be corrected in the factory, avoiding the discovery of problems only after transporting unqualified products to the bridge site, thus avoiding the high costs and safety risks of rework at high altitudes at sea. Factory pre-assembly verification avoids rework at the bridge site. The 1+1 vertical pre-assembly of two adjacent anchoring units in the factory simulates the actual installation state on site, allowing manufacturing deviations to be detected and resolved in advance, achieving "zero-repair" installation at the bridge site, and avoiding the high costs and safety risks of rework at high altitudes at sea.

[0062] T200, the brackets 1 of two adjacent double-layer bidirectional anchoring units 100 are welded and fixed together. The welding and fixing form a continuous integral anchoring system, ensuring that the cumulative error across the entire height is controllable, and making the force on the anchoring zone of the tower continuous and reliable.

[0063] In the description of the above embodiments, specific features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments or examples.

[0064] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A double-layer bidirectional anchoring unit, characterized in that, include: Two cow legs, each cow leg comprising two brackets arranged vertically; Two anchor beams are arranged vertically, and the two anchor beams correspond one-to-one with the two brackets. The two ends of each anchor beam are supported on the corresponding brackets of the two corbels, and the anchor beams are fixedly connected to the corresponding brackets. Each anchor beam has two anchor box units arranged side by side in the transverse direction at its two ends.

2. The double-layer bidirectional anchoring unit according to claim 1, characterized in that, The anchor beam includes a top plate, a bottom plate, three web plates, a diaphragm, and a stiffening plate; The three webs are arranged side by side in the transverse direction between the top plate and the bottom plate, and an anchor box unit is provided at each end between two adjacent webs. The partition is fixedly connected between the top plate and the bottom plate and is arranged to cross the web plate; The end of the bottom plate protrudes from the web plate, and the stiffening plate is disposed on the outside of the web plate and is fixedly connected to the web plate and the bottom plate respectively.

3. The double-layer bidirectional anchoring unit according to claim 2, characterized in that, The anchor box unit includes an anchor box anchor plate, an anchor box bearing plate, an anchor box force transmission plate, and an anchor box stiffening plate; The anchor box anchor plate is fixedly installed on one side surface of the anchor box bearing plate; The anchor box force transmission plate is fixedly installed on the other side of the anchor box pressure plate and is fixedly connected to the web plate. The anchor box stiffening plate and the anchor box force transmission plate are arranged crosswise, and the anchor box stiffening plate is fixedly connected to the anchor box bearing plate and the anchor box force transmission plate respectively.

4. The double-layer bidirectional anchoring unit according to claim 1, characterized in that, Each of the brackets includes a bracket wall panel, two brackets fixed to the bracket wall panel, and a plurality of anchor pipes disposed on the bracket wall panel; The bracket includes a top plate and a web plate. The web plate is fixedly installed at the bottom of the top plate, and the anchor beam is fixedly installed on the top plate.

5. A method for manufacturing a double-layer bidirectional anchoring unit as described in any one of claims 1 to 4, characterized in that, Includes the following steps: S100. Separately manufacture anchor beams and corbels; among them, computer BIM 3D modeling and layout are used, the bottom surface of the anchor beam is machined and milled in its entirety, and the top surfaces of the two brackets of the corbel are machined and milled as a whole. S200, fixed assembly fixtures; mark the anchor beam and corbel assembly layout lines on the flat ground, and fix the assembly fixtures according to the layout lines; S300, Initially position the double-layer anchor beam; Position and install the lower and upper anchor beams respectively on the assembly fixture; S400, Positioning brackets; Position and install two brackets on both sides of the anchor beam respectively; S500, Precisely position the anchor beam; adjust the position and vertical elevation of the anchor beam, perform precise positioning, ensure that the bottom surface of the anchor beam is in close contact with the top surface of the bracket of the corbel, and use a through-hole tool to check the bolt hole pass rate to ensure 100% pass rate; S600, forming a double-layer bidirectional anchoring unit; the closely fitted anchor beam and the bracket of the corbel are connected and fixed with high-strength bolts, and the anchor pipe is installed to form a double-layer bidirectional anchoring unit.

6. The manufacturing method according to claim 5, characterized in that, S100 includes: S101. Fabrication of the bracket: First, fabricate the box-shaped wall panel of the bracket. Use a laser scribing device to scribing the bracket assembly position lines on the wall panel of the bracket. Assemble the bracket of the bracket according to the position lines and use an angle template to control the assembly angle deviation between the bracket and the wall panel to ≤0.1°. Then, use a full-section machining equipment to mill the top surface of the two brackets as a whole, controlling the flatness of the bracket wall panel to ≤2mm, the flatness deviation of the bracket top surface to ≤0.2mm, the distance deviation between the two brackets to ≤0.5mm, and the parallelism deviation between the two brackets to ≤0.5mm. Finally, use CNC drilling to drill the high-strength bolt holes on the bracket. S102. Fabricate the anchor beam; use CNC blanking, laser scribing, and robotic welding to assemble the anchor box unit. Place the anchor box bearing plate on a leveled platform, and assemble the anchor box force transmission plate and anchor box stiffening plate by scribing lines with the circular hole of the anchor box bearing plate as a reference, ensuring the perpendicularity of each part to the anchor box bearing plate and the requirements for grinding and tightening; assemble the anchor box anchor plate with the cross line at the center of the circular hole of the anchor box bearing plate as a reference, ensuring the concentricity of the hole of the anchor plate and the hole of the anchor box bearing plate; assemble the anchor beam on a special assembly fixture, and perform cross-section milling on the bottom plate of the anchor beam, controlling the anchor beam length deviation ≤2mm, width deviation ≤1mm, bottom plate flatness deviation ≤0.2mm, and anchor box position angle deviation ≤0.1°, and use CNC drilling to drill high-strength bolt holes.

7. The manufacturing method according to claim 5, characterized in that, The assembly tooling includes a jig, supports, and steel brackets, with the supports and steel brackets both fixed to the jig. The S300 includes: S301. Install the lower anchor beam; Place the lower steel anchor beam on the support pier with the longitudinal and transverse ground lines as the reference and level it. Use the leveling shims on the top of the support pier to roughly adjust the elevation. S302. Install and position the steel support; mark the plane position line and ground line of the steel support as a reference, and install the steel support. The steel support includes a crossbeam and an adjustable steel pad. The theoretical height of the top surface of the crossbeam below the bottom surface of the upper anchor beam is 20mm. The adjustable steel pad is placed on the crossbeam. The adjustment range of the adjustable steel pad is 5mm-50mm. S303. Install the upper anchor beam; place the upper steel anchor beam on the crossbeam of the steel support with the ground line as the reference and level it, and use the leveling shims of the crossbeam to adjust the elevation.

8. The manufacturing method according to claim 7, characterized in that, The S400 includes: Align the lower edges of the two corbel panels with the corresponding outer skin ground line, align the vertical baseline with the horizontal baseline of the frame ground line, and use a level to measure the elevation to ensure that the horizontal baselines are at the same height when assembling the corbel panels. Set diagonal supports on both sides of the corbel panels to position the panel angle, and use a laser plumb bob or total station to measure the panel tilt angle. After passing the test, position the bottom with a positioning baffle and secure it to the bottom frame platform.

9. An anchoring system, characterized in that, It includes multiple double-layer bidirectional anchoring units as described in any one of claims 1 to 4, wherein the multiple double-layer bidirectional anchoring units are stacked vertically along the tower, and the brackets of two adjacent double-layer bidirectional anchoring units are fixedly connected by welding.

10. A method for manufacturing the anchoring system as described in claim 9, characterized in that, Includes the following steps: T100. Multiple double-layer bidirectional anchoring units are stacked vertically along the tower. Two adjacent double-layer bidirectional anchoring units are pre-assembled in a 1+1 vertical manner. The manufacturing accuracy is checked by matching the rings between the wall panels of the upper and lower corbels. The misalignment of the wall panels of the upper and lower corbels is controlled to be ≤0.5mm, the spacing deviation of the anchor beams between each layer is ≤1mm, and the spatial position deviation of the anchor pipe is ≤1mm. T200. Weld and fix the brackets of the two adjacent double-layer bidirectional anchoring units together.

Images