A subway shield tunnel artificial steel ring reinforcing and assembling device

Abstract

The utility model discloses a subway shield tunnel artificial steel ring reinforcing assembly device relates to shield tunnel reinforcing technical field, including base, the corner of the upper surface of base is connected with the lower end screw thread of stand, and the upper end of stand is installed with the swivel seat, the swivel seat is hinged with the jib, and the upper surface of jib is installed with motor, and the working end of motor is installed with the roller, and the roller is wound with the cable, and the lateral wall of cable is connected with the limiting steel ring piece. The utility model discloses a subway shield tunnel artificial steel ring reinforcing assembly device, through the modular design, the track adaptation, electromechanical control etc. core technology, realizes the remarkable breakthrough in the construction convenience, the efficiency, the cost, the skylight point utilization and the pipeline protection etc.

Description

Technical Field

[0001] This utility model relates to the field of shield tunnel reinforcement technology, and in particular to a manual steel ring reinforcement assembly device for subway shield tunnels. Background Technology

[0002] To ensure the long-term stability, safety, and durability of the tunnel structure, it is necessary to reinforce the tunnel segments to address various risks that may arise during the construction and operation phases.

[0003] Existing shield tunnel lining steel ring robotic arm reinforcement devices have the following shortcomings:

[0004] 1) Existing technologies mostly use large machinery (traction locomotives and steel ring reinforced flatbed trucks with robotic arms) to assemble steel rings in shield tunnels. Large machinery is bulky and requires traction locomotives to manage flatbed trucks to support robotic arms, and it also has high requirements for tunnel space.

[0005] 2) Existing large-scale mechanical assembly equipment has a complex structure and numerous parts. When it is moved or repaired, the disassembly and assembly process is cumbersome and time-consuming.

[0006] 3) The purchase cost of large machinery is high, and construction in the specific space of shield tunnels requires the tunnel to be adapted to meet the passage and operation requirements of large machinery, which further increases the construction cost;

[0007] 4) Large-scale mechanical assembly equipment requires flatbed trucks as carriers and is towed by tractor vehicles into the section for operation; it is greatly restricted by the operating route and cannot meet the needs of continuous operation.

[0008] 5) Assembling the robotic arm requires relocating all pipelines within the tunnel construction area, dismantling the evacuation platform, and restoring it to its original state after reinforcement. The pipeline relocation process is risky and can easily cause pipeline failures, affecting normal operations.

[0009] Developing a manual steel ring reinforcement assembly device for subway shield tunnels to achieve convenient, efficient, and low-cost steel ring reinforcement assembly within shield tunnels, while reducing reliance on tunnel windows and pipeline relocation, and improving construction safety and economy, has become a technical challenge that urgently needs to be solved by those skilled in the art. Utility Model Content

[0010] The purpose of this invention is to provide a manual steel ring reinforcement assembly device for subway shield tunnels, which solves the problems listed in the background art.

[0011] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0012] This utility model discloses an artificial steel ring reinforcement assembly device for subway shield tunnels, including a base, one corner of the upper surface of the base being threadedly connected to the lower end of a column, and a rotating seat being installed at the upper end of the column.

[0013] The rotating base is hinged to the boom, a motor is mounted on the upper surface of the boom, a roller is mounted on the working end of the motor, a sling is wound around the roller, and the sling is connected to the lifting lug of the steel ring plate;

[0014] It also includes a steel ring plate limiting rod, which is fixedly installed at equal angles on the inner side wall of the tunnel, and the steel ring plate limiting rod abuts against the inner arc surface of the steel ring plate.

[0015] Preferably, it also includes a mounting frame, which is fixed to the inner wall of the tunnel by expansion bolts, and an electric hoist is mounted on the mounting frame.

[0016] Preferably, the base is welded from high-strength aluminum alloy square tubing, and two sets of fixed wheels are installed on the lower surface of the base.

[0017] Preferably, the track gauge of the fixed wheel set is 1435mm ± 50mm.

[0018] Preferably, the boom is a three-section telescopic boom, and the telescopic range of the boom is 1.2 to 1.7m.

[0019] Preferably, the cross-section of each telescopic arm is box-shaped.

[0020] Compared with the prior art, the beneficial technical effects of this utility model are as follows:

[0021] I. Convenience of construction

[0022] 1) Lowered operating threshold: The mechanical device is simple and can be operated with a two-button remote control. Ordinary workers can start working after 2 hours of training. No professional mechanical operator is required, reducing labor costs by 30%.

[0023] 2) Improved access efficiency: The rail transport platform has a maximum travel speed of 5km / h and can complete the movement from the end gate of the section to the work area (500m interval) within 10 minutes, saving more than 1 hour compared with traditional mechanical assembly operations (which require waiting for the main line to be powered off and to be pulled from the depot to the work area by an engineering tractor).

[0024] II. Cost Control

[0025] 1) Reduced equipment costs: The manufacturing cost of this device is approximately RMB 50,000 per set, which is only 3.3% of the cost of a traditional large steel ring reinforcement vehicle (RMB 1.5 million per unit); the annual maintenance cost is approximately RMB 2,000, which is 98% lower than that of traditional machinery (RMB 100,000 per year);

[0026] 2) Reduced tunnel renovation costs: Only pipeline supports within the relocation area are required (approximately 20% of the traditional relocation amount), resulting in savings of over 80% in pipeline relocation costs per project;

[0027] 3) Reduced energy costs: Electric drive consumes approximately 3 kWh per shift, costing 3 yuan; mechanical assembly uses hydraulic drive, consuming approximately 30 kWh per shift, costing 30 yuan, resulting in a 90% reduction in energy costs.

[0028] 4) Reduced equipment rental costs: This device does not require the use of a traction locomotive. Compared with the mechanical assembly and rental of a traction locomotive at 10,000 yuan per unit, the cumulative annual equipment rental cost is 1 million yuan (100 train operations per year).

[0029] III. Restrictions on Skylight Points

[0030] 1) Optimized utilization of skylight window: The assembly / disassembly of the device takes only 15 minutes and the entire process of "entry-assembly-exit" can be completed within a 3-hour skylight window, which is 200% more efficient than traditional mechanical assembly (which requires more than 1 hour of preparation time, more than 1 hour of withdrawal time, and only 1 hour of actual usable time).

[0031] 2) Extended working time: Traditional machinery relies on engineering vehicles for towing (and can only work within the maintenance window), while this device can directly enter the section after the subway stops operating, and use the "non-maintenance window period when the section is out of power" for construction. The effective working time is extended from 8-10 maintenance windows for EMU operations per month (about 10 hours) to 16-20 maintenance windows per month (more than 60 hours), an increase of 83%.

[0032] 3) Enhanced emergency response capability: It can be quickly deployed to areas of sudden deformation, and the equipment can be brought in and assembled within 4 hours, which is 92% faster than traditional machinery (which requires more than 48 hours of preparation).

[0033] IV. Pipeline Protection

[0034] 1) Significantly reduced relocation volume: Only pipeline supports (such as cable supports and fire pipes) within a 1-meter area of ​​the assembly range need to be relocated, reducing the relocation volume by 80% compared to traditional mechanical methods (which require relocation of the entire tunnel pipeline), thus avoiding the risk of pipeline damage caused by large-scale relocation.

[0035] 2) Non-contact construction: The slide rail precisely limits the steel ring, avoiding the potential danger of traditional robotic arms colliding with pipelines;

[0036] V. Economic and Social Benefits

[0037] Throughout the project, operational efficiency was improved, investment in large equipment was reduced, and safety risks were mitigated.

[0038] 1) Economic benefits: Taking the 100-ring reinforcement project as an example, this device saves 250,000 yuan in equipment cost sharing, 1 million yuan in tractor rental fees, and 400,000 yuan in pipeline relocation fees compared with traditional machinery, resulting in a total cost reduction of 1.65 million yuan.

[0039] 2) Social benefits: Reduces disruption to subway operations; supports rapid on-site deployment for small-scale projects, providing a flexible solution for emergency reinforcement of urban rail transit.

[0040] In summary, this utility model discloses a manual steel ring reinforcement assembly device for subway shield tunnels. Utilizing a rail transport platform as its base, it is compact and flexible, enabling rapid movement and precise positioning on the track within the shield tunnel. This significantly improves the efficiency of the device's movement and placement within the tunnel. Furthermore, its compact size and flexibility allow for operation without large-scale tunnel modifications, reducing overall construction costs and offering significant economic advantages. Moreover, it allows for reinforcement work to be carried out immediately after subway operation ceases, meeting continuous operation requirements. The device can be assembled and disassembled quickly, greatly shortening preparation and equipment relocation time, thus improving construction continuity and overall efficiency. It also eliminates the need for extensive pipeline relocation or dismantling of evacuation platforms; only the supporting structures within the work area need to be moved outside the designated area, enhancing safety. This invention represents a significant breakthrough in terms of construction convenience, efficiency, cost, utilization of tunnel windows, and pipeline protection. Attached Figure Description

[0041] The present invention will be further described below with reference to the accompanying drawings.

[0042] Figure 1 This is a front view schematic diagram of an artificial steel ring reinforcement and assembly device for subway shield tunnels according to the present invention.

[0043] Explanation of reference numerals in the attached diagram: 1. Base; 2. Column; 3. Rotary seat; 4. Boom; 5. Motor; 6. Steel ring plate; 7. Sling; 8. Electric hoist; 9. Mounting bracket; 10. Steel ring plate limit rod. Detailed Implementation

[0044] To make the technical problem to be solved, the technical solution, and the beneficial effects of this utility model clearer, the present utility model 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 only used to explain this utility model and are not intended to limit this utility model.

[0045] like Figure 1 As shown, a manual steel ring reinforcement assembly device for subway shield tunnels includes a base 1, one corner of the upper surface of the base 1 is threadedly connected to the lower end of the column 2 for easy and quick installation and assembly, and a swivel 3 is installed on the upper end of the column 2.

[0046] The rotating seat 3 is hinged to the boom 4. A motor 5 is installed on the upper surface of the boom 4. A roller is installed on the working end of the motor 5. A sling 7 is wound around the roller. The sling 7 is connected to the lifting lug of the steel ring 6.

[0047] The boom can rotate 360° via the swivel and column with an accuracy of ±1°, and the boom and column can be adjusted in three stages of pitch.

[0048] It also includes a steel ring plate limiting rod 10, which is fixedly installed at equal angles on the inner wall of the tunnel. The steel ring plate limiting rod 10 abuts against the inner arc surface of the steel ring plate 6 to limit the movement of the steel ring plate.

[0049] Specifically, it also includes a mounting frame 9, which is fixed to the inner wall of the tunnel at position 3 or 9 by expansion bolts, and an electric hoist 8 is installed on the mounting frame 9;

[0050] During construction, the hook of the electric hoist is connected to the lifting lug of the steel ring plate to assist in lifting the steel ring plate.

[0051] Specifically, the base 1 is made of high-strength aluminum alloy square tube welding, which reduces weight by 40% compared with traditional steel structure, reducing transportation difficulty and energy consumption. Two sets of fixed wheel sets are installed on the lower surface of the base 1.

[0052] Specifically, the track gauge of the fixed wheel set is 1435mm±50mm. It can be adapted to different track gauges through the adjustment mechanism and is compatible with the existing subway track system. At the same time, the wheel set adopts a silent and anti-slip design to reduce construction noise and prevent track slippage.

[0053] Specifically, the boom 4 is a three-section telescopic boom, and the telescopic range of the boom 4 is 1.2 to 1.7m.

[0054] Specifically, the cross-section of each telescopic arm is box-shaped, which increases torsional stiffness by 20% while reducing weight.

[0055] Construction process of this utility model:

[0056] I. Equipment Assembly and Arrival

[0057] 1) Design and fabrication of the device

[0058] The base measures 1.5×1.7m and is made of 50×50×3mm high-strength aluminum alloy square tubing. Two sets of fixed wheels are installed at the bottom, which are compatible with a track gauge of 1435mm±50mm. Place the base on the tunnel track and adjust the adjustable track wheels at the bottom.

[0059] 2) Modular assembly

[0060] The boom is fixed to the column via the swivel, and the 1400W motor control line and wireless remote control receiver are connected. The electrical system connection is completed without special tools and takes 15 minutes.

[0061] 3) Quick entry

[0062] Power-driven: The base is equipped with a quick-release push rod and a braking system, which is manually pushed to the work area, with a maximum speed of 5km / h;

[0063] Access efficiency: It only takes 10 minutes to get from the end gate of the section to the work area 500m away, without waiting for the engineering towing vehicle, saving more than 1 hour of preparation time compared with traditional mechanical assembly;

[0064] II. Preparations before steel ring assembly

[0065] 1) Pipeline relocation

[0066] Only the cable supports and fire pipe supports within the assembly area are relocated, with the relocation amount being 20% ​​of that of the traditional process. Self-made steel slide rails (composed of supports, bearings, and stainless steel pipes, fixed by M16 expansion bolts, 10 rails per ring) are installed on the inner wall of the tunnel segments for limiting the displacement of the steel ring segments and assisting in sliding.

[0067] 2) Steel ring segmentation and layout

[0068] The steel ring is made of Q355 steel, 20mm thick, and each ring is divided into 12 pieces. The weight of each piece is ≤400kg. BIM layout is used to ensure that it fits the curvature of the tunnel.

[0069] 3) Track bed cutting and removal

[0070] For ordinary track beds, it is necessary to cut and remove the track beds on both sides, and then install steel brackets later. Vibration-damping track beds do not require this.

[0071] III. Steel Ring Assembly Operation

[0072] 1) Horizontal transport of steel rings

[0073] The device uses a base-mounted rail transport platform to carry a self-made hoisting flatbed truck to transport the segmented steel ring pieces to the work site at a speed of 3 km / h, with 6 pieces transported at a time.

[0074] 2) Lifting and positioning

[0075] boom operation

[0076] ① When the three-section telescopic boom extends to 1.7m, the hook of the sling is aligned with the steel ring lifting point via a 360° rotation mechanism and three-stage pitch adjustment (±15° angle):

[0077] ②Start the 1400W motor and lift the steel ring plate at a speed of 5m / min, accurately positioning it above the slide rail with an error of ≤2mm;

[0078] Taking the assembly sequence of the low-voltage side as an example

[0079] ① First, use a crane to place the two pieces of ox leg (segment 1 and segment 12) into the excavated track bed;

[0080] ② Hoist the steel ring pieces sequentially in the order of block 6 → block 2. Each steel ring piece is assisted in sliding into place by a slide rail and temporarily fixed with bolts (2 bolts per piece).

[0081] ③ After welding block 6 and block 5, lift them as a whole and install the remaining blocks in sequence (assemble the power side in the order of block 7 → block 10, and lay out block 11 separately).

[0082] 3) Welding and anchoring

[0083] Welding process: Carbon dioxide gas shielded welding is adopted, the weld fullness reaches the second level standard, and 3% of the welds are randomly inspected for flaw detection.

[0084] Chemical anchor installation: Drill holes (depth ≥ 160mm) using an electric hammer, clean the dust in the holes with a blower, inject anchoring adhesive, insert M16 chemical anchors and cure them to achieve permanent connection between the steel ring and the segment;

[0085] IV. Key Technical Details and Effects

[0086] 1) Modular design

[0087] Advantages: The base and boom can be quickly disassembled and assembled. When moving to another site, they can be disassembled and manually carried to the adjacent work area without the need for large transportation equipment;

[0088] Cost comparison: The manufacturing cost of the device is 50,000 yuan per set, which is only 3.3% of that of traditional machinery (1.5 million yuan per unit), and the annual maintenance cost is only 2,000 yuan (100,000 yuan per year for traditional machinery);

[0089] 2) Telescopic boom system

[0090] Technical parameters

[0091] ① The telescopic range is 1.2 to 1.7 meters, and the torsional stiffness is increased by 20% compared with traditional steel structures;

[0092] ② Wireless remote control accuracy ±1°, which can accurately position the steel ring to the lifting operation area;

[0093] ③ Efficiency improvement: The assembly time for a single ring is 120 minutes (60 minutes for traditional machinery), but due to the increased utilization rate of the skylight (60 hours of effective working time per month vs. 10 hours for traditional machinery), the overall efficiency surpasses that of traditional processes by 83%.

[0094] 3) Rail transport and non-contact construction

[0095] ① Silent anti-slip wheel set: Reduces construction noise to below 70dB and avoids the risk of track slippage;

[0096] ② Slide rail limit: The steel ring is installed by slide rail guidance, which avoids the collision of traditional robotic arms with pipelines, reduces the amount of relocation by 80%, and eliminates the safety hazards of robotic arm operation;

[0097] V. Economic Benefits and Emergency Response

[0098] 1) Cost savings: Taking the 100-ring reinforcement project as an example, compared with the traditional process, it saves 250,000 yuan in equipment cost sharing, 1 million yuan in tractor rental, and 400,000 yuan in pipeline relocation, resulting in a total cost reduction of 1.65 million yuan.

[0099] 2) Emergency response capability: The device can be deployed and assembled within 4 hours (traditional machinery requires more than 48 hours), and is suitable for emergency reinforcement of tunnels in the event of sudden deformation.

[0100] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0101] The embodiments described above are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made to the technical solutions of the present utility model by those skilled in the art without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

Claims

1. A manual steel ring reinforcement assembly device for subway shield tunnels, comprising a base (1), characterized in that: One corner of the upper surface of the base (1) is threaded to the lower end of the column (2), and a swivel (3) is installed on the upper end of the column (2); The rotating seat (3) is hinged to the boom (4). A motor (5) is installed on the upper surface of the boom (4). A roller is installed on the working end of the motor (5). A sling (7) is wound around the roller. The sling (7) is connected to the lug of the steel ring (6). It also includes a steel ring plate limiting rod (10), which is fixedly installed at equal angles on the inner wall of the tunnel, and the steel ring plate limiting rod (10) abuts against the inner arc surface of the steel ring plate (6).

2. The artificial steel ring reinforcement assembly device for subway shield tunnels according to claim 1, characterized in that: It also includes a mounting frame (9), which is fixedly installed on the inner wall of the tunnel, and an electric hoist (8) is installed on the mounting frame (9).

3. The artificial steel ring reinforcement assembly device for subway shield tunnels according to claim 2, characterized in that: The base (1) is welded from high-strength aluminum alloy square tubes, and two sets of fixed wheels are installed on the lower surface of the base (1).

4. The artificial steel ring reinforcement assembly device for subway shield tunnels according to claim 3, characterized in that: The track gauge of the fixed wheel assembly is 1435mm ± 50mm.

5. The artificial steel ring reinforcement assembly device for subway shield tunnels according to claim 1, characterized in that: The boom (4) is a three-section telescopic boom, and the telescopic range of the boom (4) is 1.2 to 1.7 m.

6. The artificial steel ring reinforcement assembly device for subway shield tunnels according to claim 5, characterized in that: The cross-section of each telescopic arm is box-shaped.

Images