WO2023226419A1 - 一种高塔筒类设备高效安装装置及方法 - Google Patents

一种高塔筒类设备高效安装装置及方法 Download PDF

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Publication number
WO2023226419A1
WO2023226419A1 PCT/CN2022/141264 CN2022141264W WO2023226419A1 WO 2023226419 A1 WO2023226419 A1 WO 2023226419A1 CN 2022141264 W CN2022141264 W CN 2022141264W WO 2023226419 A1 WO2023226419 A1 WO 2023226419A1
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Prior art keywords
lifting
tower
rope
section
efficient installation
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PCT/CN2022/141264
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English (en)
French (fr)
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谭志国
王毅
高鹏
杨天冉
吴国林
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中国长江三峡集团有限公司
中国三峡建工(集团)有限公司
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Publication of WO2023226419A1 publication Critical patent/WO2023226419A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/40—Arrangements or methods specially adapted for transporting wind motor components
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/728—Onshore wind turbines

Definitions

  • the invention relates to the technical field of engineering construction, and in particular to an efficient installation device and method for high tower equipment.
  • the present invention provides an efficient installation device for high tower equipment to solve the above problems.
  • an efficient installation device for high tower equipment which includes a lifting device for lifting the tower from a horizontal state to an inclined state, and a lifting device for lifting the tower from a horizontal state to an inclined state.
  • the push pin has a bottom surface and a lifting surface that is inclined relative to the bottom surface.
  • multiple sets of rolling bearings are installed on both the bottom surface and the lifting surface.
  • the lifting system includes four sets of lifting devices.
  • the four sets of lifting devices are located at four directions of the tower respectively.
  • the lifting device is a winch.
  • the lifting device includes a lifting trolley, which includes a frame, legs and an operating room.
  • a rotating platform is installed on the frame, and a support column is connected to the center of the rotating platform.
  • the support The top of the column is hinged with a continuous tension hydraulic jack, and a hydraulic station connected to the continuous tension hydraulic jack is installed on the frame; a lifting rope drum and an electric control box are also installed on the frame, and the hydraulic station, lifting The rope drum is electrically connected to the electric control box.
  • the invention also provides an efficient installation method for high tower equipment, which includes the following steps:
  • S1 tower assembly and debugging use small mobile lifting equipment to hoist the foundation section, hinge the first tower section and the foundation section through the rotating shaft, then use support pads to appropriately raise the first tower section, and install the jacking device. Push the support shoes that support the first tower section, and then install the subsequent tower sections section by section. After installing the lug tower section, install the lifting device in place, extend the lifting rope and connect it to the lifting ring on the lug tower section, and Install an angle meter on the tower and finally debug the functional components;
  • S2 tower jacking start the jacking cylinder, push the jacking shoes to jack up the tower from a horizontal state to an inclined state;
  • S3 tower lifting Observe the angle meter reading. When the tower reaches the predetermined angle, start the lifting system to lift the tilted tower to the vertical state. Then connect and fix the first tower section with the foundation section, and proceed confirmatory debugging;
  • mutually adapted positioning sleeves and positioning cards are respectively provided on the foundation section and the first tower section.
  • the positioning sleeve and positioning card can be quickly realized through the mutually adapted positioning sleeves and positioning cards.
  • the S4 winding lifting rope includes the following steps:
  • S41 installs a winch on the ground, passes the wire rope of the winch through the lifting eye, connects it to the lifting rope, and unties the connection between the lifting rope and the lifting eye;
  • the S42 winch releases the rope to lower the hoisting rope, and at the same time starts the lifting device to retract the rope.
  • the end of the hoisting rope drops to the ground, untie the connection between the hoisting rope and the winch wire rope;
  • the present invention has the following beneficial effects:
  • wind turbine towers Take the installation of wind turbine towers as an example.
  • the current wind turbine towers are installed using crawler cranes. Because super-large crawler cranes are expensive, the installation and disassembly process is cumbersome, and the workload is large. Generally, only one super-large crawler crane is used to install the wind turbine cluster. installation. After a super-large crawler crane has installed a fan, the crawler crane needs to be disassembled, transferred, and reassembled to the new fan to be installed before installing the subsequent fan.
  • the installation process involves lifting multiple tower sections and equipment in sequence. Installation, the installation efficiency of a single unit is very low, the installation period of the wind turbine group is very long, and the construction period of the wind farm is long.
  • the device and method of this patent decompose the installation into parallel horizontal assembly, and then carry out the installation method of lifting the top of each stage.
  • the fan units can be carried out at the same time, and only need to use multiple units, which are cheap, versatile and easy to rent.
  • the mobile small car cranes can be carried out separately, which greatly improves the installation efficiency; the top lifting stage is divided into two stages, because the wheeled lifting trolley is easy to move and can be quickly positioned, and its ground anchors can complete the construction, jacking and lifting in advance. This step only takes 1 day to complete, and then it can be transferred to the next fan for lifting.
  • the installation process is decomposed and constructed in parallel, which effectively improves the installation efficiency. This method can still be used to remove the fan, just follow the reverse of the above method.
  • the device and method of this patent have more advantages in the installation and disassembly of taller and heavier wind turbines or tower equipment.
  • the device and method of this patent divide debugging into functional debugging and confirmatory debugging.
  • Functional debugging includes the installation of the electronic control system, cable wiring inspection, live experiments, etc., all of which can be done after the horizontal assembly of the fan is completed, and then in the horizontal state. It is carried out in a down-to-earth manner, which avoids the increased difficulty and risk of high-air conditioning commissioning and greatly improves the debugging efficiency; the confirmatory commissioning is after the fan is completed with top lifting, and only the final inspection and confirmation is carried out before the fan is put into operation. After it is correct, it can be put into normal operation. This greatly improved the quality of debugging, increased safety, and advanced the construction schedule.
  • the equipment has strong versatility.
  • the core equipment of this patent, the jacking device and the hoisting device are easy to transfer, highly versatile, and simple to maintain. They can not only be installed in wind turbines, but can also be used in the installation of other tower equipment. If the force is greater, multiple lifting trolleys can be used at one lifting point. For example, if the lifting force of the front lifting point is very large, a balanced lifting beam can be connected to the lifting ring, and multiple lifting trolleys can be used to provide lifting force for this lifting point, which is very convenient and flexible. It can also be widely used in other engineering fields, with high utilization rate and good economy.
  • the super-large crawler crane has poor versatility. If used in situations with small lifting capacity, it is often difficult to install, dismantle and transfer, and the gain often outweighs the loss. Therefore, the utilization rate of super-large crawler cranes is very low, maintenance costs are generally high, and economic efficiency is poor.
  • Figure 1 is a schematic diagram of the installation state of S1 in the method of the present invention.
  • Figure 2 is a schematic diagram of the installation state of S2 in the method of the present invention.
  • Figure 3 is a schematic diagram of an installation state of S3 in the method of the present invention.
  • Figure 4 is a schematic diagram of another installation state of S3 in the method of the present invention.
  • Figure 5 is a schematic diagram of another installation state of S3 in the method of the present invention.
  • Figure 6 is a schematic diagram of another installation state of S3 in the method of the present invention.
  • Figure 7 is a schematic structural diagram of the jacking device after installation in the present invention.
  • Figure 8 is a schematic structural diagram of the lifting trolley in the present invention.
  • Figure 9 is a schematic diagram of the state of the lifting device used for positioning adjustment in the present invention.
  • Figure 10 is a schematic diagram of the entire step state of the method of the present invention.
  • Figure 11 is a schematic diagram of the entire step state of the winding lifting rope in the present invention.
  • an efficient installation device for high tower equipment which includes: a jack for lifting the tower 100 from a horizontal state to an inclined state.
  • the lifting device 20 includes a lifting cylinder 21 and a pusher 22 connected to the piston rod 24 of the lifting cylinder.
  • the lifting system 30 includes four groups of lifting devices 200. When the tower 100 is installed, the four groups of the lifting devices 200 are respectively located at four directions of the tower 100.
  • the pusher 22 has a bottom surface 25 and a top inclined relative to the bottom surface 25. Rise to 26.
  • the lifting device 200 is a winch 50 .
  • multiple sets of rolling bearings 23 are installed on the bottom surface 25 and the lifting surface 26. Compared with other contact modes such as sliding bearings, the friction resistance is smaller and the required thrust is smaller. resistance during installation.
  • the core components of the jacking device 20 are the jacking cylinder 21 and the push pin 22 on its head, which are used to push the first tower section 120 to rotate around the rotation axis 130.
  • the push pin 22 slides on a fixed track, thereby gradually jacking up the fan. .
  • the lifting device 200 includes a lifting trolley 31.
  • the lifting trolley 31 includes a frame 32, legs 33 and an operating room 34.
  • a rotating platform 35 is installed on the frame 32. , the center of the rotating platform 35 is connected to a support column 36, the top of the support column 36 is hinged to a continuous tension hydraulic jack 37, and a hydraulic station 38 connected to the continuous tension hydraulic jack 37 is installed on the frame 32;
  • a lifting rope drum 39 and an electric control box 40 are also installed on the vehicle frame 32. The hydraulic station 38 and the lifting rope drum 39 are electrically connected to the electric control box 40.
  • the present invention takes the installation of the wind turbine tower 100 as an example to introduce the installation method of the present invention.
  • This patent follows the assembly and debugging of the wind turbine tower, the wind turbine The tower jacking, wind turbine tower lifting and adjustment steps have completed all the installation work.
  • the installation is now carried out step by step:
  • Pad height On the one hand, padding can reserve space for jacking and reduce the difficulty of jacking. On the other hand, it can reserve height for the installation of fan motors and machine rooms to avoid installation difficulties due to insufficient clear height.
  • Support pad 140 can be made of sleepers or special Designed support pad tooling.
  • the jacking device 20 horizontally so that the push pin 22 supports the support shoe 121 on the first tower section 120, hinge the jacking cylinder 21 to the back support plate 123, and then install the subsequent tower sections section by section.
  • Install the lug tower section 150 Install the lifting trolleys 31 in place, install the four lifting trolleys 31 to the four orthogonal directions with the tower 100 as the center, extend the lifting rope 52 and connect it to the lifting rings 151 on the lifting lug tower section 150 , the installer can enter through the manhole opened on the first tower section 120, come out from the inlet hole on the lifting lug tower section 150, and operate on the operating platform 152 outside the tower section.
  • the lifting direction is 1 in front #Lifting trolley, there are 2# and 3# lifting trolleys on the left and right sides respectively, and the 4# lifting trolley is at the rear.
  • the wind turbine tower After the wind turbine tower is fully assembled, in order to reduce the difficulty of high-air conditioning testing and facilitate debugging and putting into operation, it should be debugged in a lying down state. After debugging is completed, lock the movable and rotating parts such as the fan room, generator, and fan blades securely, and you can start subsequent jacking and lifting related work. Pay special attention to the stop and lock position of the fan blades, which should not interfere with the lifting operation of the lifting rope 52
  • the lifting cylinder 21 is started, and the pusher 22 pushes up the support shoes 121 to lift the horizontal tower 100 to an inclined state; because the lifting device 20 cannot lift the fan device to a vertical state, the system 30 needs to be lifted Subsequent lifting is performed until the wind turbine tower is raised to a vertical state; however, the lifting system 30 cannot directly start lifting during the lying or jacking stage of the wind turbine. The reason is that at this stage, the horizontal angle of the wind turbine is small and the required lifting force is very large. , so the present invention designs the phased connection and cooperation between the jacking device 20 and the lifting system 30 .
  • the jacking cylinder 21 is started to push the pusher 22 to move along the track, and is in contact with the support shoes 121 on the first tower section 120 of the wind turbine tower.
  • Rolling bearings 23 are installed on the upper and lower sides of the pusher 22, which has greater friction resistance than other contact methods such as sliding bearings. Smaller, less thrust required.
  • the upper surface of the pusher 22 and the lower surface of the support shoe 121 of the first tower section 120 are both set as slopes or arcs at reasonable angles, which on the one hand increases the contact area and reduces the pressure, and on the other hand, the overall weight moment of the fan can be reduced.
  • Most of the resultant force generated on the pusher 22 is decomposed into a vertical component force, which is transmitted to the solid foundation surface through the track; a small part of the resultant force is decomposed into a horizontal force, which is overcome by the thrust of the jacking cylinder 21. This ingenious design effectively reduces the lifting force. Lift the working force required by the device 20 and the power capacity of the relevant supporting mechanisms.
  • the 2# lifting trolley or 3# lifting trolley can be fine-tuned to ensure that there is no excessive deflection or deviation between the fan and the installation axis.
  • the display of the angle gauge 122 on the first tower section 120 needs to be observed at any time. Once the predetermined angle is reached, the switch to the lifting mode begins.
  • the lifting trolley 31 when the fan is lifted to a predetermined angle, the lifting trolley 31, which is in place in four directions and connected to the ground anchor, performs lifting actions as needed.
  • the lifting rope 52 of the lifting trolley 31 is made of steel strands and the matching continuous tension hydraulic jack 37, which has strong tensioning capacity and good economy; the lower part of the continuous tension hydraulic jack 37 is connected with the hinge point through the hinge point.
  • the lifting trolley 31 is connected to automatically adjust the elevation angle of the continuous tension hydraulic jack as the angle of the lifting rope 52 changes during the lifting process to ensure the best stress state.
  • the 1# lifting trolley in front is an active trolley in the initial stage of lifting. It mainly provides the pulling force required for the fan lifting process.
  • the 2# and 3# platforms on the left and right sides provide auxiliary lifting force and also need to provide support for the fan lifting process at any time.
  • the 4# lifting trolley at the rear will only act as a following trolley and will not be responsible for the lifting action.
  • This patent designs the lifting ring 151 in such a way that the ring can rotate around the lifting ring rod, so as to facilitate the lifting of the lifting ring 151 and the lifting The rope 52 is well stressed throughout the process.
  • positioning ferrules 124 and positioning clips 125 are provided in front of the first tower section 120 and the foundation section 100 and on the left and right sides respectively.
  • the positioning ferrules 124 have a lower opening and an upper closing structure. The open opening is convenient for guiding and closing. In this way, the positioning can basically be completed. If there is still a small deviation during installation, refer to Figure 9. You can use the pusher 22 of the jacking cylinder 21 to slightly push the first tower section 120, thereby further ensuring that the first tower section 120 Combined with the accurate alignment of the basic section 110.
  • the subsequent second simple confirmatory debugging can be carried out.
  • the simple confirmatory debugging After the simple confirmatory debugging is completed, it can be put into formal use. Before being put into operation, personnel should also go up to the operating platform 152 outside the lug tower section 150 through the passage in the tower 100, and use the auxiliary winch 50 arranged on the ground to slowly lower the lifting rope 52 to the ground.
  • S4 winding up the lifting rope 52 includes the following steps:
  • the S42 winch 50 releases the rope to lower the lifting rope 52, and at the same time starts the lifting device 200 to retract the rope.
  • the end of the lifting rope 52 drops to the ground, untie the connection between the lifting rope 52 and the steel wire rope 51;
  • the continuous tension hydraulic jack 37 is the equipment cited in the standard DL/T 5400-2007 Technical specifications for the construction of sliding formwork for hydraulic buildings, and is also the current invention disclosed in the Chinese patent application document with the publication number CN100424003C. There is equipment, so the specific structure of the existing equipment is not described in detail in the description of this patent. Those skilled in the art should know that it does not affect the implementation of this patent.

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  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
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  • Chemical & Material Sciences (AREA)
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Abstract

本发明涉及工程施工技术领域，具体涉及一种高塔筒类设备高效安装装置，它包括用于将塔筒从平卧状态顶升至倾斜状态的顶升装置，和用于将塔筒从倾斜状态提升至竖直状态的提升系统；所述顶升装置包括顶升油缸和连接在顶升油缸活塞杆上的推销。本发明还还提供了高塔筒类设备高效安装方法，包括塔筒拼装和调试、塔筒顶升、塔筒提升和收卷提升绳等步骤。本发明的结构和方法改变了高塔筒类设备的安装方式，实现了高塔筒类设备的批量化快速安装和拆除；降低了调试难度、提高了调试效率，提高了安装过程中的抗风险能力。

Description

一种高塔筒类设备高效安装装置及方法 技术领域
本发明涉及工程施工技术领域，尤其涉及一种高塔筒类设备高效安装装置及方法。
背景技术
发电风机等高塔筒式设备安装一直是设备安装中的难题，以往采用大型履带吊安装的方式，这就需要大型履带吊及其他中小型吊装设备配合，并且只能安装完成一台再安装另一台，安装效率和经济性很差。
随着风机技术的不断发展，风机塔筒越来越高，一味提高履带吊的起吊高度和起重量将越来越困难，经济性也会越来越差，需要一种效率更高、经济性更好、通用性更强的安装装置和方法，基于此，本专利采用创新性的装置和方法很好解决了此问题。
发明内容
针对现有技术中所存在的不足，本发明提供了一种高塔筒类设备高效安装装置，以解决上述问题。
为了解决上述技术问题，本发明采用的技术方案是：一种高塔筒类设备高效安装装置，它包括用于将塔筒从平卧状态顶升至倾斜状态的顶升装置，和用于将塔筒从倾斜状态提升至竖直状态的提升系统；所述顶升装置包括顶升油缸和连接在顶升油缸活塞杆上的推销，所述推销具有一底面和相对底面倾斜的顶升面。
优选的方案中，所述底面和顶升面上均安装多组滚动轴承。
优选的方案中，所述提升系统包括四组提升装置，安装塔筒时，四组所述提升装置分别位于塔筒的四个方位上。
优选的方案中，所述提升装置为卷扬机。
优选的方案中，所述提升装置包括提升台车，所述提升台车包括车架、支腿和操作室，所述车架上安装旋转平台，所述旋转平台中央连接支撑柱，所述支撑柱顶端铰接连续拉伸式液压千斤顶，车架上安装与所述连续拉伸式液压千斤顶连接的液压站；所述车架上还安装提升绳卷筒和电控箱，所述液压站、提升绳卷筒与所述电控箱电连接。
本发明还提供了高塔筒类设备高效安装方法，包括以下步骤：
S1塔筒拼装和调试：用小型移动式起重设备吊装基础节，将第一塔节与基础节通过旋转轴铰接，再用支垫对第一塔节进行适当垫高，安装顶升装置使推销支撑第一塔节上的撑靴，再逐节安装后续塔节，安装完吊耳塔节后将提升装置安装就位，伸出提升绳与吊耳塔节上的提 升吊环连接，并在塔筒上安装角度仪，最后对功能部件进行调试；
S2塔筒顶升：启动顶升油缸，推销顶起撑靴将水平状态的塔筒顶升至倾斜状态；
S3塔筒提升：观测角度仪读数，当塔筒顶升达到预定角度后，启动提升系统，将倾斜状态的塔筒提升至竖直状态，然后将第一塔节与基础节连接固定，并进行确认性调试；
S4收卷提升绳。
优选的方案中，在基础节和第一塔节上分别设置相互适配的定位卡套和定位卡，S3塔筒提升至竖直状态时，通过互相适配的定位卡套和定位卡快速实现定位
优选的方案中，S1中，塔节拼装和调试完成后，对连接或安装在塔筒上的可移动或可转动部件进行锁定。
优选的方案中，S1中，将四组提升装置分别安装到以塔筒为中心的四个正交方位上。
优选的方案中，S4收卷提升绳包括如下步骤：
S41在地面安装卷扬机，并将卷扬机的钢丝绳穿过提升吊环，并与提升绳连接，解开提升绳与提升吊环的连接；
S42卷扬机放绳，使提升绳下降，同时启动提升装置进行收绳，当提升绳的端部降到地面后，解开提升绳与卷扬机钢丝绳的连接；
S43卷扬机收绳。
相比于现有技术，本发明具有如下有益效果：
1.实现了高塔筒类设备的批量化快速安装和拆除。
以风力发电机塔筒安装为例，现行风机塔筒采用履带吊安装方式，因为超大型履带吊价格昂贵，安拆工序繁琐、工作量大，一般均仅采用1台超大型履带吊进行风机群的安装。超大型履带吊安装好一台风机后，需要将履带吊拆解、转移、复装至新的待安装风机处再进行后续风机的安装，且安装过程为将多个塔节和设备依次起吊并安装，单台机组安装功效很低，风机群安装周期很长，风电场建设周期长。
本专利的装置和方法把安装分解为并行卧式拼装，再进行分台顶提升的安装方式，卧式拼装过程，风机组可以同时进行，仅需借助多台价格便宜、通用性强、便于租借的移动式小型汽车吊分别进行即可，这样大幅度提高了安装效率；分台顶提升阶段，因为轮式提升台车行走方便，就位迅速，其地锚可以提前完成施工，顶升和提升环节仅需1天即可完成，随即可转至下台风机进行顶提升。通过本方法将安装过程分解和并行施工，有效提高了安装效率。拆除风机仍可以使用此方法，仅按照上述方法的逆方法实施即可。本专利的装置和方 法在越是高、越是重的风机或塔筒类设备的安拆方面越有优势。
2、降低调试难度、提高调试效率。本专利的装置和方法将调试分为功能性调试和确认性调试，功能性调试包括电控系统就位、电缆接线检查、带电实验等，均可在风机卧拼完成后，随即在卧平状态下进行，避免了高空调试增加的难度和风险，大幅提高了调试效率；确认性调试在风机完成顶提升后，风机投运前仅进行最后的检查、确认，无误后即可投入正常运行，大幅度提高了调试质量、增加了安全性、提前了工期。
3、抗风险能力强。原超大型履带吊吊装方式因高空作业，履带吊司机视线受限，不便观察，在突遇大风等恶劣天气情况下容易失稳发生安全事故和风险。本专利装置和方法，一方面，通过前后左右全方位提升台车配合提升的方式，如遇大风，因为液压提升装置的提升能力富裕度大、纠偏和调整能力强，各安装维度均处于可调、在控状态，安全性大大提高；另一方面，本专利安装阶段，高空作业时间较原方案大大缩短，更进一步提高了抗风险能力，以及减少了出现风险的概率。
4、装备通用性强。本专利的核心设备，顶升装置和提升装置，转移方便、通用性很强、维保简单，不仅可以在风力发电机安装适用，还可以用于其他塔筒类设备的安装，在所需提升力更大的情况还可以一个提升点使用多台提升台车。例如：前提升点如提升力很大，可以在提升吊环处连接一个平衡吊梁，使用多台提升台车为此吊点提供提升力，非常方便灵活。还可以在其他工程领域广泛使用，使用率高和经济性好。不像原安装方法，超大型履带吊通用性很差，如用在小起重量的场合，因为其安拆转移困难，往往得不偿失。所以超大型履带吊使用率很低，维保成本一般高，经济性差。
附图说明
图1为本发明方法中S1的安装状态示意图。
图2为本发明方法中S2的安装状态示意图。
图3为本发明方法中S3的一种安装状态示意图。
图4为本发明方法中S3的另一种安装状态示意图。
图5为本发明方法中S3的另一种安装状态示意图。
图6为本发明方法中S3的另一种安装状态示意图。
图7为本发明中顶升装置安装后的结构示意图。
图8为本发明中提升台车的结构示意图。
图9为本发明中顶升装置用于调整定位的状态示意图。
图10为本发明方法的全步骤状态示意图。
图11为本发明中收卷提升绳全步骤状态示意图。
上述附图中：20、顶升装置；21、顶升油缸；22、推销；23、滚动轴承；24、顶升油缸活塞杆；25、底面；26、顶升面；30、提升系统；31、提升台车；32、车架；33、支腿；34、操作室；35、旋转平台；36、支撑柱；37、连续拉伸式液压千斤顶；38、液压站；39、提升绳卷筒；40、电控箱；50、卷扬机；51、钢丝绳；52、提升绳；100、塔筒；110、基础节；120、第一塔节；121、撑靴；122、角度仪；123、后撑板；124、定位卡套；125、定位卡；130、旋转轴；140、支垫；150、吊耳塔节；151、提升吊环；152、操作平台；200、提升装置。
具体实施方式
为了使本领域的技术人员更好地理解本发明的技术方案，下面结合具体实施例对本发明的优选实施方案进行描述，但是应当理解，附图仅用于示例性说明，不能理解为对本专利的限制；为了更好说明本实施例，附图某些部件会有省略、放大或缩小，并不代表实际产品的尺寸；对于本领域技术人员来说，附图中某些公知结构及其说明可能省略是可以理解的；附图中描述位置关系仅用于示例性说明，不能理解为对本专利的限制。
作为本发明的一种实施例，参阅附图7和附图8，提供一种高塔筒类设备高效安装装置，它包括：用于将塔筒100从平卧状态顶升至倾斜状态的顶升装置20，和用于将塔筒100从倾斜状态提升至竖直状态的提升系统30；所述顶升装置20包括顶升油缸21和连接在顶升油缸活塞杆24上的推销22,所述提升系统30包括四组提升装置200，安装塔筒100时，四组所述提升装置200分别位于塔筒100的四个方位上，所述推销22具有一底面25和相对底面25倾斜的顶升面26。
本实施例中，所述提升装置200为卷扬机50。
作为本发明的一种优选实施例，所述底面25和顶升面26上均安装多组滚动轴承23，较滑动轴承等其他接触方式摩擦阻力更小，所需的推力更小，用于减小安装过程中的阻力。
顶升装置20的核心部件为顶升油缸21和其头部的推销22，用于推动第一塔节120围绕旋转轴130进行转动，推销22在固定的轨道上滑动，从而将风机逐步顶起。
作为本发明的一种优选实施例，所述提升装置200包括提升台车31，所述提升台车31包括车架32、支腿33和操作室34，所述车架32上安装旋转平台35，所述旋转平台35中央连接支撑柱36，所述支撑柱36顶端铰接连续拉伸式液压千斤顶37，车架32上安装与所述连续拉伸式液压千斤顶37连接的液压站38；所述车架32上还安装提升绳卷筒39和电 控箱40，所述液压站38、提升绳卷筒39与所述电控箱40电连接。
本发明以风力发电机塔筒100的安装为例，介绍本发明的安装方法，参阅附图1-附图6，和附图10、附图11，本专利按照风机塔筒拼装和调试、风机塔筒顶升、风机塔筒提升及调整等步骤完成全部安装工作，现分步骤进行安装：
S1塔筒100拼装和调试
参阅附图1，先用小型移动式起重设备吊装和安装基础节110，在地面上浇筑或者铺设轨道，将第一塔节120与基础节110通过旋转轴130连接，用支垫140进行适当垫高，垫高一方面可以为顶升预留空间，减小顶升难度，另一方面为风机电机和机房安装预留高度，避免因净高不足安装困难；支垫140可以采用枕木或专门设计的支垫工装。
水平安装顶升装置20使推销22支撑第一塔节120上的撑靴121，将顶升油缸21铰接到后撑板123上，然后逐节安装后续塔节，安装完吊耳塔节150后将提升台车31安装就位，将四台提升台车31分别安装到以塔筒100为中心的四个正交方位上，伸出提升绳52与吊耳塔节150上的提升吊环151连接，安装人员可以从第一塔节120上开设的进人孔进入，从吊耳塔节150上的进入孔出来到塔节外侧的操作平台152上进行操作,为了方便描述，提升方向前方为1#提升台车，左右两侧分别为2#、3#提升台车，后方为4#提升台车。
当风机塔筒全部拼装完成后，为减少高空调试难度，方便调试和投入运行，应进行卧倒状态调试。调试完成后将可风机机房、发电机、扇叶等可移动和转动部件锁定牢靠，即可开始后续的顶升、提升相关工作。特别注意风机扇叶的停止锁定位置，不应干扰提升绳52的提升作业
S2塔筒100顶升
参阅附图2，启动顶升油缸21，推销22顶起撑靴121将水平状态的塔筒100顶升至倾斜状态；因为顶升装置20无法将风机装置顶升至垂直状态，需要提升系统30进行后续的提升直至将风机塔筒提升至垂直状态；但提升系统30在风机平卧或顶升阶段又无法直接开始提升，原因在于这个阶段因为风机水平夹角小，所需的提升拉力非常大，所以本发明设计顶升装置20和提升系统30的分阶段衔接和配合。
启动顶升油缸21推动推销22延轨道移动，与风机塔筒的第一塔节120上的撑靴121接触受力，推销22上下面均安装了滚动轴承23，较滑动轴承等其他接触方式摩擦阻力更小，所需的推力更小。推销22上表面和第一塔节120的撑靴121下表面均设置为合理角度的斜面或弧面，这样一方面增大接触面积，减小压强，另一方面，可以将风机整体的重量力矩产生的对推销22的合力大部分分解为垂直方向的分力，通过轨道传递到坚实的基础面； 少部分合力分解为水平力，由顶升油缸21推力克服，这样巧妙的设计有效减少了顶升装置20所需的工作力和相关配套机构的功率容量。顶升过程中如发现风机向左或向右偏斜，可以微调牵拉2#提升台车或3#提升台车，以保证风机与安装轴线不出现过大偏斜和超差。顶升过程中还需随时观察第一塔节120上角度仪122的显示，达到预定角度后，即开始向提升方式转换。
S3塔筒100提升
参阅附图3-附图6，当风机顶升至预定角度以后，将4个方向提前就位且与地锚连接好的提升台车31按需进行提升动作。本实施例中，提升台车31提升绳52选用钢绞线和配套的连续拉伸式液压千斤顶37，张拉能力较强，经济性较好；连续拉伸式液压千斤顶37下部通过铰点与提升台车31连接，可以随着提升过程提升绳52角度的变化，自动调整连续拉伸式液压千斤顶仰角，确保处于最好的受力状态。
前方的1#提升台车在提升的初步阶段为主动台车，主要提供风机提升过程所需的拉力，左右两侧的2#、3#台提供辅助提升力，也需要随时为风机提升过程提供调偏拉力，后方的4#提升台车开始仅作为跟随台车，不承担提升动作。随着提升过程塔筒100的倾斜角度发生变化，提升绳52相对塔筒100的角度也会发生变化，本专利将提升吊环151设计为吊环可围绕吊环杆转动的方式，以便提升吊环151和提升绳52在整个过程中均受力良好。
当风机在提升阶段的后期，风机整体重心从第一节塔节120和基础节110接触转动点的后方越过到其前方时，这时由于风机整体巨大重力的作用，如果没有后方的反向拉力，风机整体会快速旋转下坠砸在基础节110上，这也是设置4#提升台车的主要作用。当风机提升至快接近临界点时，后方4#提升台车钢丝绳51应提前适当受力，在前方1#提升台车向前牵拉收绳的过程中，后方4#提升台车缓慢同步放绳，但也应保持受力状态，两侧的2#、3#仍承担左右向调整的作用。当风机越过第一塔节120和基础节110的接触转动点后，前方1#提升台车钢丝绳51送绳，不受力，主要靠后方4#提升台车受力进行缓慢放绳，结合两侧2#、3#提升台车钢丝绳51绷紧的跟随调整，慢慢将风机落到基础节100上，避免落得太快而导致上部机构产生剧烈晃动和损坏。
为了避免第一塔节120及上部结构与基础节110对位出现细微偏差，两节连接面间的螺栓无法准确对位。本专利在第一塔节120和基础节100前方和左、右两侧分别设置了定位卡套124和定位卡125，定位卡套124为下敞口上收口的结构，敞口方便导向，收口用于定位，这样基本就能完成定位了，安装时如果还有少量偏差，参阅附图9，可以利用顶升油缸21的推销22，略微推动第一塔节120，从而进一步确保第一塔节120和基础节110的准确 对位结合。
安装及拧紧第一塔节120和基础节110间的连接螺栓，即可进行后续的二次简单确认性调试，简单确认性调试完成后，即可投入正式使用。在投运前，人员还应通过塔筒100内的通道上到吊耳塔节150外的操作平台152，利用地面布置的辅助卷扬机50将提升绳52慢慢落放到地面。
S4收卷提升绳52。
作为本发明的一种优选实施例，参阅附图11，在上述实施例的基础上，S4收卷提升绳52包括如下步骤：
S41在地面安装卷扬机50，并将卷扬机50的钢丝绳51穿过提升吊环151，并与提升绳52连接，解开提升绳52与提升吊环151的连接；
S42卷扬机50放绳，使提升绳52下降，同时启动提升装置200进行收绳，当提升绳52的端部降到地面后，解开提升绳52与钢丝绳51的连接；
S43卷扬机50收绳。
在本发明的描述中，连续拉伸式液压千斤顶37为标准DL/T 5400—2007水工建筑物滑动模板施工技术规范中引用的设备，也是公开号为CN100424003C的中国专利申请文件中公开的现有设备，故本专利的描述中对该现有设备未赘述其具体结构，本领域技术人员应当知晓其不影响本专利的实现。
最后说明的是，以上实施例仅用以说明本发明的技术方案而非限制，尽管参照较佳实施例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的宗旨和范围，其均应涵盖在本发明的权利要求范围当中。

Claims (10)

  1. 一种高塔筒类设备高效安装装置，其特征是，包括：
    用于将塔筒(100)从平卧状态顶升至倾斜状态的顶升装置(20)，和
    用于将塔筒(100)从倾斜状态提升至竖直状态的提升系统(30)；
    所述顶升装置(20)包括顶升油缸(21)和连接在顶升油缸活塞杆(24)上的推销(22)，
    所述推销(22)具有一底面(25)和相对底面(25)倾斜的顶升面(26)。
  2. 根据权利要求1所述的一种高塔筒类设备高效安装装置，其特征是：所述底面(25)和顶升面(26)上均安装多组滚动轴承(23)。
  3. 根据权利要求1所述的一种高塔筒类设备高效安装装置，其特征是：所述提升系统(30)包括四组提升装置(200)，安装塔筒(100)时，四组所述提升装置(200)分别位于塔筒(100)的四个方位上。
  4. 根据权利要求3所述的一种高塔筒类设备高效安装装置，其特征是：所述提升装置(200)为卷扬机(50)。
  5. 根据权利要求3所述的一种高塔筒类设备高效安装装置，其特征是：所述提升装置(200)包括提升台车(31)，所述提升台车(31)包括车架(32)、支腿(33)和操作室(34)，所述车架(32)上安装旋转平台(35)，所述旋转平台(35)中央连接支撑柱(36)，所述支撑柱(36)顶端铰接连续拉伸式液压千斤顶(37)，车架(32)上安装与所述连续拉伸式液压千斤顶(37)连接的液压站(38)；所述车架(32)上还安装提升绳卷筒(39)和电控箱(40)，所述液压站(38)、提升绳卷筒(39)与所述电控箱(40)电连接。
  6. 高塔筒类设备高效安装方法，其特征是，包括以下步骤：
    S1塔筒(100)拼装和调试：用小型移动式起重设备吊装基础节(110)，将第一塔节(120)与基础节(110)通过旋转轴(130)铰接，再用支垫(140)对第一塔节(120)进行适当垫高，安装顶升装置(20)使推销(22)支撑第一塔节(120)上的撑靴，再逐节安装后续塔节，安装完吊耳塔节(150)后将提升装置(200)安装就位，伸出提升绳(52)与吊耳塔节(150)上的提升吊环(151)连接，并在塔筒(100)上安装角度仪(122)，最后对功能部件进行调试；
    S2塔筒(100)顶升：启动顶升油缸(21)，推销(22)顶起撑靴(121)将水平状态的塔筒(100)顶升至倾斜状态；
    S3塔筒(100)提升：观测角度仪(122)读数，当塔筒(100)顶升达到预定角度后，启动提升系统(30)，将倾斜状态的塔筒(100)提升至竖直状态，然后将第一塔节(120)与基础节(110)连接固定，并进行确认性调试；
    S4收卷提升绳(52)。
  7. 根据权利要求6所述的高塔筒类设备高效安装方法，其特征是，在基础节(110)和第一塔节(120)上分别设置相互适配的定位卡套(124)和定位卡(125)，S3塔筒(100)提升至竖直状态时，通过互相适配的定位卡套(124)和定位卡(125)快速实现定位。
  8. 根据权利要求6所述的高塔筒类设备高效安装方法，其特征是，S1中，塔节拼装和调试完成后，对塔筒(100)进行锁定。
  9. 根据权利要求6所述的高塔筒类设备高效安装方法，其特征是，S1中，将四组提升装置(200)分别安装到以塔筒(100)为中心的四个正交方位上。
  10. 根据权利要求6所述的高塔筒类设备高效安装方法，其特征是，S4收卷提升绳(52)包括如下步骤：
    S41在地面安装卷扬机(50)，并将卷扬机(50)的钢丝绳(51)穿过提升吊环(151)，并与提升绳(52)连接，解开提升绳(52)与提升吊环(151)的连接；
    S42卷扬机(50)放绳，使提升绳(52)下降，同时启动提升装置(200)进行收绳，当提升绳(52)的端部降到地面后，解开提升绳(52)与钢丝绳(51)的连接；
    S43卷扬机(50)收绳。
PCT/CN2022/141264 2022-05-24 2022-12-23 一种高塔筒类设备高效安装装置及方法 WO2023226419A1 (zh)

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