3DAS series,Intelligent 3D adjustment system

3DAS series,Intelligent 3D adjustment system

High Pressure 3D hydraulic cylinder is a special equipment for heavy load movement, For railway, highway construction and shipbuilding field, it can be used for girder, beam or heavy structure moving in X/Y/Z direction, to achieve precise positioning and adjustment. The system uses PLC controlling module, can make several working point action in synchronous.

Features

Working Principle

Parameters

Components

Application

Video

  • Combine X/Y/Z direction pulling and pushing cylinders, Special for heavy object of 3 Dimensions and 6 directions short distance movement or position adjustment.
  • High load capacity with 700bar hydraulic power unit, provides 100~6000Tons of heavy object adjustment.
  • High integrated level, compact human- machine interaction interface, modularized design of hydraulic system, quick connector, compact, light weight, easy to operate and maintain.
  • High accuracy, PLC for precise synchronization and control, provides accuracy of 1.0mm across full stroke. number of lifting points: 4, 8, 12.
  • Good compatibility, hand pump, electrical pump, wired and wireless controller can be matched.
  • Safe and stable, 40Cr cylinder body, sensor monitoring, safe lock, self-locking cylinder, Siemens PLC, finite- element design.
  • Equipped with removable hardened steel saddles and Heel block, to deal with rough working surface and increase jacking range.
  • Widely used in structure and building moving, girder lifting and adjustment, shipbuilding, and assembly of heavy duty segment.

3DAS combines mechanical technology, electrical technology, computer control technology, hydraulic technology.
PLC collect the required state information of object and convert it to computer program, then send signal to pump station and controlling valve, to control velocity of flow, oil flow, displacement, pressure distribution to achieve hydraulic cylinder synchronous movement, while the multiple sensors give feedbacks to PLC controller then adjust computer program.

3ds02

Model

Load Capacity(T)

Stroke (mm)

Working Pressure (Mpa)

Cylinder Effective Area (cm2)

TZJ250

Vertical     (Z)

250

200

70

363

Horizontal  (X)

50

150

70

78.5

Longitudinal (Y)

50

500

70

78.5

TZJ400

Vertical     (Z)

400

200

70

572.3

Horizontal  (X)

60

150

70

95

Longitudinal (Y)

60

400

70

95

TZJ600

Vertical     (Z)

600

200

70

855

Horizontal  (X)

100

150

70

133

Longitudinal (Y)

100

400

70

133

TZJ1000

Vertical     (Z)

1000

200

70

1250

Horizontal  (X)

200

±60

70

283

Longitudinal (Y)

200

±60

70

283

Model name Picturev Product features Parameters Need Qty
3D adjustment hydraulic cylinder 3D adjustment hydraulic cylinder

  • 3D and 6 directions movement.
  • Double acting Self locking
  • Customization is available.
  • High load capacity
  • Good adaptability
  • Wide application.
Load capacity:100-1000TonMaximum Operating Pressure: 700bar Vertical stroke:0-300mm Horizontal stroke:0-200mm Accuracy@ full stroke: 1.0mm 2,4 pcs
Power and controlling system 02

Compact design,small size, light weight, overload, overheating and electric leakage protection.l Corrosion resistant coating. Base on PLC and windows system, human- machine interaction interface.l Communication bus control. Input voltage: 220V, 380V.Maximum Operating Pressure: 700barOil capacity: 300LWeight:1.5~2.0TonWorking point: 2~99Synchronous accuracy: 2mmPositioning accuracy: 1mm 1set
Sensor Sensor

High precision pressure and displacement sensor, Rated Pressure: 35~100MpaAccuracy: 0.25%.Output current 4~20mA 4,8 set
Cable Cable

LC, TLC series cable. Stable signal transmission. Fast plug connector, Length can be customized. Length: 5, 10m, or customized. 2,4 set
Hose Hose

PU coating for corrosion resistant. Including Fast connector and dust cap. Max. bearing pressure: 70MPa. Dia.: 6.4, 9.7mm Length: 18m 2,4 set

3das031

Project name: 3DAS series, Intelligent 3D adjustment system applied in Hongkong-zhuhai-macao Bridge

Project location: Lingdingyang

3das041

3das051

Profile:
Hongkong-zhuhai-macao Bridge(HZMB) is part of G94 highway, being  situated at the waters of Lingdingyang of Pearl River Estuary, is a mega-size sea crossing linking Hong Kong, Zhuhai City and Macao. The functions of the Bridge can meet the demand of passenger and freight land transport among Hong Kong, Mainland and Macao, to establish a new land transport link between the east and west banks of the Pearl River, and to enhance the economic and sustainable development of the three places. The project includes a 29.6 km dual 3-lane carriageway and 6.7 km tunnel, this is the longest bridge-cum-tunnel structure in the world. designed speed is 100~120km per hour.

Challenge: Prefabricated pile caps 3D positioning in deep water. Underwater positioning device need to be pre-installed in the prefabricated Caps.
The collision issue between prefabricated pile cap and pre-installed cylinders in the process. Equipment reliability issues for use in deep water.

Solution: Kattor provided solution including: four points synchronous lifting of steel pile and bridge pier, used 1200 tons of double acting cylinders to synchronous lift large diameter steel pile and bridge pier.
Underwater precise adjustment for bridge piers, set PLC controlling system to control 4 3DAS cylinders to do horizontal and longitudinal movement, and use PLC to control 12 100tons self loading cylinders to do correction underwater.
3D precise positioning for concrete pre-casting girder and steel girder in offshore.

Kattor products: 1200 tons of double acting cylinders, 100ton of self locking cylinder, 3DAS cylinder

3das06Project name: Intelligent Synchronous Lifting System and Intelligent 3D adjustment system applied in Mau Bin Bridge repair work

Project location: Myanmar
Profile:

Mau Bin Bridge linking Rangoon and MauBin, which built in April 1994 and completed in February 1998. total length is 721.8m, consists of 8 spans of simple- supported T girder and 4 spans of continuous steel trussed girder. Bridge span 4*30m + 4*120 + 4*30m.
Challenge:
End expansion bearing of Main Bridge on P8 was damaged, result in big gap between truss beam and pre-stressed concrete girders, bridge bearing need to be replaced. Movement of Pier and bearing from approach bridge to Yangon side, result in no gap between two girders, need to horizontally move the whole bridge toward to designated position.

3das07Solution:
1. Set 3DAS cylinders.
2. P11, lift 10mm, check if it has any abnormal.
3. P11, lift 70mm, place cushion block.
4. P11, lower the beam on cushion block.
5. Replacement of old bearing by new one.
6. A2, lift up to 50% of total load.
7. P11, lift up 5 to 10mm, remove the cushion blocks.
8. Move toward Maubin for 10mm, check if there is any problem.
9. Move toward Maubin to designated position.
10. Adjust the position of bridge bearings on P11.

Kattor products: Intelligent Synchronous Lifting System, 3DAS cylinder(3D adjustment system)

3das0713das081Project name: 3DAS series, Intelligent 3D adjustment system applied in Jingyue Yangtze Bridge

Profile:
Jing-Yue Yangtze River (Highway) bridge, the north shore of bridge site locates in Jianli Hubei, and South bank is Yueyang Hunan, it’s the first bridge connects Hubei and Hunan provinces in the Yangtze River. It designed to  steel box girder and twin towers, total length of Bridge over 5400 meters, with a total investment of over 2.3 billion RMB, two-way six-lane, the main span of hole up to 816 meters, ranking sixth in the world in the same bridge.

Challenge:
Bridge site with complex geological structure, and have navigation, flood controlling important constraints. Main span is 816m pre-stressed concrete girder bridge, total weight 3,200 tons, how to push the beam in place? How to achieve synchronous lifting  under so harsh environment? How to complete beam precision position in small space?

Solution:
Kattor used PLC controlling system to control 3D cylinders, make it under full load conditions while achieving 1,500 tons of pushing force and 120 tons of longitudinal force, to complete beam precise position. Set tilt saddle with maximum tilt angles
up to 5°on each of cylinders, to ensure the safety of the construction process

Kattor products: 600tons of 3DAS cylinder