A prefabricated casting system for pier columns and a method for casting them off-site

Abstract

The present invention provides a prefabricated casting system for piers and a method for casting them off-site, including a bottom mold assembly, four side mold assemblies and four cleaning assemblies are arranged around the bottom mold assembly, the side mold assemblies include a first side mold assembly and three second side mold assemblies, and the cleaning assemblies include a first cleaning assembly and three second cleaning assemblies; the prefabricated casting system of the pier is used to make a casting body at the prefabrication site, and the casting body is transported to the road and bridge construction site through a transportation system. The present invention replaces on-site casting with factory standardized casting, and the casting is subject to fewer restrictions and is not affected by factors such as weather. The opening and closing of each template is achieved through mechanized drive, and the casting efficiency and casting accuracy are high, the safety hazard is small, and no manual command is required to achieve avoidance during the casting process. The opening and closing of each template is smooth and reliable, and the position of the bottom template can be adjusted, which can further improve the casting accuracy and the general performance of casting.

Description

Technical Field

[0001] The invention relates to the field of construction, and in particular discloses a prefabricated casting system of a pier column and a remote casting method thereof. Background Art

[0002] Pouring, also known as concrete pouring, is the construction process of pouring the mixed concrete materials into warehouses, leveling the warehouses, and compacting them. Road and bridge construction is the focus of infrastructure construction. General bridges include pier structures used as supports.

[0003] During the process of road and bridge construction, piers are cast on-site at the road and bridge construction site. Workers form a casting mold through steel or wooden formwork at the construction site, and then inject concrete into the casting mold to achieve casting. The casting and production of piers in the existing technology has problems such as complex construction conditions, cumbersome procedures, and high work intensity of workers, and the casting and production efficiency of piers is low. Summary of the invention

[0004] Based on this, it is necessary to provide a prefabricated casting system for piers and a remote casting method thereof to address the existing technical problems, which has high casting efficiency, high casting accuracy, few restrictions on casting, and few safety hazards.

[0005] In order to solve the problems of the prior art, the present invention discloses a prefabricated casting system for a pier column, comprising a bottom mold assembly, four side mold assemblies and four cleaning assemblies are alternately arranged around the bottom mold assembly, the side mold assembly comprises a first side mold assembly and three second side mold assemblies, and the cleaning assembly comprises a first cleaning assembly and three second cleaning assemblies;

[0006] The bottom mold assembly includes a rotating mechanism, a rotating bracket is fixed to the output end of the rotating mechanism, a lifting mechanism is provided on the rotating bracket, an adjustable lifting bracket is fixed to the output end of the lifting mechanism, and a bottom mold plate is fixed to the adjustable lifting bracket;

[0007] The first side mold assembly includes a side mold support beam, a side mold translation mechanism is provided on the side mold support beam, a first support platform is fixed to the output end of the side mold translation mechanism, and a first side mold plate is fixed to a side of the first support platform close to the bottom mold assembly;

[0008] The second side mold assembly includes a side mold yielding track, the side mold yielding track is located below one side of the adjustable lifting bracket, a second support platform is slidably connected to the side mold yielding track, a stripping translation mechanism is provided outside the side mold yielding track, an output end of the stripping translation mechanism is fixedly connected to the second support platform, a second side mold is fixed on one side of the second support platform close to the bottom mold assembly, a side mold bracket is fixed on the second support platform, and the bottom mold is located between each first side mold and the second side mold;

[0009] The first cleaning assembly includes a first cleaning bracket, the first cleaning bracket is provided with a cleaning translation mechanism, a first cleaning platform is fixed to the output end of the cleaning translation mechanism, and there is a distance between the first cleaning platform and the first side template or the second side template;

[0010] The second cleaning component includes a cleaning yield track, which is located at a lower side of the adjustable lifting bracket. A second cleaning bracket is slidably connected to the cleaning yield track, and a second cleaning platform is fixed on the second cleaning bracket. A yield translation mechanism is also provided outside the cleaning yield track, and an output end of the yield translation mechanism is fixedly connected to the second cleaning platform. There is a distance between the second cleaning platform and the first side template or the second side template.

[0011] Furthermore, the second side mold assembly and the second cleaning assembly are adjacent to each other.

[0012] Furthermore, the rotating mechanism is a rotating cylinder, and the lifting mechanism includes three hydraulic cylinders.

[0013] Furthermore, the side mold translation mechanism is a hydraulic cylinder, a side mold opening and closing guide rail is fixed on the side mold support beam, a side mold opening and closing guide wheel is rotatably connected under the first support platform, and the side mold opening and closing guide wheel is rollingly connected to the side mold opening and closing guide rail.

[0014] Furthermore, the cleaning translation mechanism is a hydraulic cylinder, a cleaning opening and closing guide rail is fixed on the first cleaning bracket, a cleaning opening and closing guide wheel is rotatably connected under the first cleaning platform, and the cleaning opening and closing guide wheel is rollingly connected to the cleaning opening and closing guide rail.

[0015] Furthermore, the material removal and translation mechanism is a hydraulic cylinder, and a side mold yielding guide wheel is rotatably connected under the side mold bracket, and the side mold yielding guide wheel roller is connected to the side mold yielding track.

[0016] Furthermore, the yielding translation mechanism is a hydraulic cylinder, and a cleaning yielding guide wheel is rotatably connected under the second cleaning bracket, and the cleaning yielding guide wheel is rollingly connected to the cleaning yielding track.

[0017] Furthermore, the minimum distance between the first cleaning platform and the first side template or the second side template is 25 to 50 mm, and the minimum distance between the second cleaning platform and the first side template or the second side template is 25 to 50 mm.

[0018] Furthermore, a first side mold guardrail is fixed to the side of the first side mold away from the bottom mold assembly, a second side mold guardrail is fixed to the side of the second side mold away from the bottom mold assembly, a first cleaning guardrail is fixed to the first cleaning platform, and a second cleaning guardrail is fixed to the second cleaning platform; the first cleaning guardrail and the second cleaning guardrail are both safe and foldable guardrails.

[0019] The present invention also discloses a method for casting a pier column off-site, comprising a prefabricated casting system for any of the above-mentioned pier columns, wherein a casting body is manufactured at a prefabrication site using the prefabricated casting system for the pier column, and the casting body is transported to a road and bridge engineering construction site via a transportation system.

[0020] The beneficial effects of the present invention are as follows: the present invention discloses a prefabricated casting system for piers and a method for casting them off-site, wherein standardized factory casting replaces on-site casting, and casting is subject to fewer restrictions and is not affected by factors such as weather. The opening and closing of each template is achieved through mechanized drive, and the casting efficiency is high, the casting accuracy is high, and the safety hazard is small. Furthermore, no manual command is required to avoid during the casting process, and the opening and closing of each template is smooth and reliable, and the position of the bottom template can be adjusted, which can further improve the casting accuracy and the general performance of the casting. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the top structure of the present invention.

[0022] Figure 2 The present invention is in standby mode. Figure 1 Schematic diagram of the cross-sectional structure along the line A-A'.

[0023] Figure 3 The present invention is in standby mode. Figure 1 Schematic diagram of the cross-sectional structure of B-B'.

[0024] Figure 4 For the present invention, when pouring Figure 1 Schematic diagram of the cross-sectional structure of C-C'.

[0025] Figure 5 The present invention is in standby mode. Figure 1 Schematic diagram of the cross-sectional structure along D-D'.

[0026] The accompanying drawings are marked as follows: bottom mold assembly 10, rotating mechanism 11, rotating bracket 12, lifting mechanism 13, adjustable lifting bracket 14, bottom mold plate 15, first side mold assembly 20, side mold support beam 21, side mold opening and closing guide rail 211, side mold translation mechanism 22, first support platform 23, side mold opening and closing guide wheel 231, first side mold plate 24, first side mold guardrail 241, second side mold assembly 30, side mold giving way rail 31, stripping translation mechanism 311, second support platform 32, side mold giving way guide wheel 3 21. The second side formwork 33. The second side formwork guardrail 331. The side formwork bracket 34. The first cleaning component 40. The first cleaning bracket 41. The cleaning opening and closing guide rail 411. The cleaning translation mechanism 42. The first cleaning platform 43. The cleaning opening and closing guide wheel 431. The first cleaning guardrail 432. The second cleaning component 50. The cleaning yielding track 51. The yielding translation mechanism 511. The second cleaning bracket 52. The cleaning yielding guide wheel 521. The second cleaning platform 53. The second cleaning guardrail 531. The cast body 60. DETAILED DESCRIPTION

[0027] In order to further understand the features, technical means, specific objectives and functions of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0028] refer to Figures 1 to 5 .

[0029] The embodiment of the present invention discloses a prefabrication casting system for a pier column, including a bottom mold assembly 10. Four side mold assemblies and four cleaning assemblies are alternately arranged around the bottom mold assembly 10, that is, a cleaning assembly is provided between two adjacent side mold assemblies, and a side mold assembly is provided between two adjacent cleaning assemblies. The alternating arrangement can make full use of the space around the bottom mold assembly 10 to avoid mutual obstruction between the side mold assembly and the cleaning assembly during movement. The opening and closing of the molds is stable and reliable, and the prefabrication efficiency is high. Preferably, the four side mold assemblies and the four cleaning assemblies are evenly distributed, that is, the angle between the adjacent side mold assemblies and the cleaning assemblies is 45 degrees with the bottom mold assembly 10 as the center. The side mold assembly includes a first side mold assembly 20 and three second side mold assemblies 30. The cleaning assembly includes a first cleaning assembly 40 and three second cleaning assemblies 50.

[0030] The bottom mold assembly 10 includes a rotating mechanism 11, a rotating bracket 12 is fixed to the output end of the rotating mechanism 11, a lifting mechanism 13 is provided on the rotating bracket 12, an adjustable lifting bracket 14 is fixed to the output end of the lifting mechanism 13, a bottom mold plate 15 is fixed to the adjustable lifting bracket 14, the adjustable lifting bracket 14 is formed by stacking and clamping a plurality of segments, and different numbers of segments are used to form the adjustable lifting bracket 14 according to different application requirements. The adjustable lifting bracket 14 can also be other bracket structures with height adjustable function;

[0031] The first side mold assembly 20 includes a side mold support beam 21, on which a side mold translation mechanism 22 is provided, a first support platform 23 is fixed to the output end of the side mold translation mechanism 22, and a first side mold plate 24 is fixed to the side of the first support platform 23 close to the bottom mold assembly 10;

[0032] The second side mold assembly 30 includes a side mold yielding track 31, which is located below one side of the adjustable lifting bracket 14 to prevent the side mold yielding track 31 from hindering the stripping action of the cast body 60 obtained by casting, and can ensure that the second support platform 32 and the second side mold plate 33 can effectively and reliably yield to the stripping. The side mold yielding track 31 is slidably connected to the second support platform 32, and a stripping translation mechanism 311 is provided outside the side mold yielding track 31. The output end of the stripping translation mechanism 311 is fixed to the second support platform 32. The second supporting platform 32 is connected to the second side template 33 on one side close to the bottom template assembly 10. The first side template 24 and the second side template 33 are at the same height. A side template bracket 34 is fixed on the second supporting platform 32. Preferably, a landing gear is fixed on one side of the side template bracket 34. The landing gear can facilitate workers to enter each platform. The bottom template 15 is located between each first side template 24 and the second side template 33, that is, the height position of the bottom template 15 will not exceed the top and bottom ends of the first side template 24, which can ensure the reliability of casting.

[0033] The first cleaning assembly 40 includes a first cleaning bracket 41, on which a cleaning translation mechanism 42 is provided, and a first cleaning platform 43 is fixed at the output end of the cleaning translation mechanism 42. There is a distance between the first cleaning platform 43 and the first side template 24 or the second side template 33, which can effectively avoid obstruction;

[0034] The second cleaning component 50 includes a cleaning yielding track 51, which is located at the lower side of the adjustable lifting bracket 14 to prevent the cleaning yielding track 51 from obstructing the material removal action of the cast body 60 obtained by casting, and can ensure that the second cleaning platform 53 can reliably give way for material removal. The cleaning yielding track 51 is slidably connected to the second cleaning bracket 52, and the second cleaning platform 53 is fixed on the second cleaning bracket 52. A yielding translation mechanism 511 is also provided outside the cleaning yielding track 51, and the output end of the yielding translation mechanism 511 is fixedly connected to the second cleaning platform 53. There is a distance between the second cleaning platform 53 and the first side template 24 or the second side template 33, which can further avoid obstruction.

[0035] The four side molds are opened and closed mechanically, with high opening and closing efficiency and stable action. The opening and closing action is stable and smooth, and there is no need for workers to give online instructions to avoid, and the side mold components and the cleaning components will not hinder each other. After the four side molds are molded on the four sides of the bottom mold 15, a casting mold cavity can be formed, and the casting device can pour cement and other materials into the casting mold cavity to cast and produce, thereby obtaining a casting body 60. When opening the mold, the side mold translation mechanism 22 and the cleaning translation mechanism 42 respectively drive the first side mold 24 and the first cleaning platform 43 to move away from the bottom mold 15, and the stripping translation mechanism 311 drives the second side mold 33 and the side mold bracket 34 away from the bottom The template 15 moves, and the second cleaning bracket 52 and the second cleaning platform 53 are driven by the drive structure to move away from the bottom template 15, ensuring that there is enough space on one side of the cast body 60 to realize material removal, and the material removal is convenient; during maintenance, workers or corresponding cleaning devices can clean each template based on the cleaning platform to ensure the subsequent production quality; according to actual applications, the bottom template 15 can be driven to rotate by the rotating mechanism 11 to match the surrounding side templates, which can effectively reduce the casting error, and the height of the bottom template 15 can be adjusted by the lifting mechanism 13, so that the cast body 60 with different heights can be obtained, and the casting prefabrication has strong versatility. The cast body 60 is generally a cylinder or a prism.

[0036] In this embodiment, the second side mold assembly 30 and the second cleaning assembly 50 are arranged adjacent to each other. When the mold is opened, the second side mold assembly 30 and the second cleaning assembly 50 can jointly provide a sufficiently large space for removing the cast body 60.

[0037] In this embodiment, the rotating mechanism 11 is a rotating oil cylinder, and the lifting mechanism 13 includes three hydraulic oil cylinders.

[0038] In this embodiment, the side mold translation mechanism 22 is a hydraulic cylinder, and the side mold translation mechanism 22 can also be a screw drive mechanism, which includes a slide seat, a screw, a slider and a motor, the motor output end is coaxially fixed with the screw, the slider is slidably connected in the slide seat, the screw is threadedly connected to the slider, and the slider is the output end of the screw drive mechanism, the side mold opening and closing guide rail 211 is fixed on the side mold support beam 21, and the side mold opening and closing guide wheel 231 is rotatably connected under the first support platform 23, and the side mold opening and closing guide wheel 231 is rollingly connected to the side mold opening and closing guide rail 211, which can effectively improve the reliability of the opening and closing action. Or the side mold support beam 21 is rotatably connected to the side mold opening and closing guide wheel 231, and the side mold opening and closing guide rail 211 is fixed under the first support platform 23, and the side mold opening and closing guide rail 211 is slidably connected to the side mold opening and closing guide wheel 231. Preferably, the side mold opening and closing guide wheel 231 can be a wheel group composed of multiple rollers.

[0039] In this embodiment, the cleaning translation mechanism 42 is a hydraulic cylinder, and the cleaning translation mechanism 42 can also be a screw drive mechanism, which includes a slide seat, a screw, a slider and a motor, the motor output end is coaxially fixed with the screw, the slider is slidably connected in the slide seat, the screw and the slider are threadedly connected, and the slider is the output end of the screw drive mechanism. A cleaning opening and closing guide rail 411 is fixed on the first cleaning bracket 41, and a cleaning opening and closing guide wheel 431 is rotatably connected under the first cleaning platform 43. The cleaning opening and closing guide wheel 431 is rollingly connected to the cleaning opening and closing guide rail 411, which can effectively improve the reliability of the opening and closing mold action. Or a cleaning opening and closing guide rail 411 is fixed under the first cleaning platform 43, and a cleaning opening and closing guide wheel 431 is rotatably connected to the first cleaning bracket 41, and the cleaning opening and closing guide rail 411 is slidably connected to the cleaning opening and closing guide wheel 431. Preferably, the cleaning opening and closing guide wheel 431 can be a wheel group composed of multiple rollers.

[0040] In this embodiment, the stripping translation mechanism 311 is a hydraulic cylinder, and the side mold bracket 34 is rotatably connected to a side mold yielding guide wheel 321, and the side mold yielding guide wheel 321 roller is connected to the side mold yielding track 31, which can effectively improve the reliability of the opening and closing mold stripping action. Preferably, the side mold opening and closing guide wheel 231 can be a wheel group composed of multiple rollers.

[0041] In this embodiment, the clearance translation mechanism 511 is a hydraulic cylinder, and a cleaning clearance guide wheel 521 is rotatably connected to the second cleaning bracket 52. The cleaning clearance guide wheel 521 is rollingly connected to the cleaning clearance track 51, which can effectively improve the reliability of the mold opening and closing stripping action. Preferably, the cleaning clearance guide wheel 521 can be a wheel group composed of multiple rollers.

[0042] In this embodiment, when the mold is closed, the minimum distance between the first cleaning platform 43 and the first side template 24 or the second side template 33 is 25-50 mm, and the minimum distance between the second cleaning platform 53 and the first side template 24 or the second side template 33 is 25-50 mm.

[0043] In this embodiment, a first side mold guardrail 241 is fixed to the side of the first side mold 24 away from the bottom mold assembly 10, and a second side mold guardrail 331 is fixed to the side of the second side mold 33 away from the bottom mold assembly 10, which can facilitate operators to perform maintenance, monitoring and other operations. A first cleaning guardrail 432 is fixed to the first cleaning platform 43, and a second cleaning guardrail 531 is fixed to the second cleaning platform 53, which can facilitate operators to perform maintenance, monitoring and other operations; the first cleaning guardrail 432 and the second cleaning guardrail 531 are both safe foldable guardrails. During cleaning, the cleaning platform enters the center of the bottom mold, and the first cleaning guardrail 432 and the second cleaning guardrail 531 are adjusted to facilitate cleaning of the mold structure.

[0044] The embodiment of the present invention also discloses a method for casting a pier column off-site, including a prefabricated casting system of any of the above-mentioned pier columns, using the prefabricated casting system of the pier column to manufacture a casting body 60 in a prefabricated place such as a factory building, and transporting the casting body 60 to a road and bridge engineering construction site through a transportation system. In an environment with small restrictions such as indoor space, the prefabricated casting system of the pier column is used to realize the manufacture of the casting body 60, and then the casting body 60 is transported to the road and bridge engineering construction site through a transportation system such as water transportation, railway, and highway, which can effectively improve the construction efficiency and effectively ensure the quality of the casting body 60. Preferably, when applied, two sets of prefabricated casting systems of the pier column can be used, one set for solving the standard height and the other set for casting the non-standard height, which can ensure that the foundations of each prefabricated casting body 60 are accurately combined.

[0045] The above embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the present invention. It should be pointed out that, for a person of ordinary skill in the art, several modifications and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention patent shall be subject to the attached claims.

Claims

1. A prefabricated casting system for piers, characterized in that: The invention comprises a bottom mold assembly (10), wherein four side mold assemblies and four cleaning assemblies are arranged alternately around the bottom mold assembly (10), wherein the side mold assembly comprises a first side mold assembly (20) and three second side mold assemblies (30), and the cleaning assembly comprises a first cleaning assembly (40) and three second cleaning assemblies (50); The bottom mold assembly (10) comprises a rotating mechanism (11), a rotating bracket (12) is fixed to the output end of the rotating mechanism (11), a lifting mechanism (13) is provided on the rotating bracket (12), an adjustable lifting bracket (14) is fixed to the output end of the lifting mechanism (13), and a bottom mold plate (15) is fixed to the adjustable lifting bracket (14); The first side mold assembly (20) comprises a side mold support beam (21), a side mold translation mechanism (22) is provided on the side mold support beam (21), a first support platform (23) is fixed to the output end of the side mold translation mechanism (22), and a first side mold plate (24) is fixed to a side of the first support platform (23) close to the bottom mold assembly (10); The second side mold assembly (30) comprises a side mold yielding track (31), the side mold yielding track (31) is located below one side of the adjustable lifting bracket (14), a second supporting platform (32) is slidably connected to the side mold yielding track (31), a material stripping translation mechanism (311) is provided outside the side mold yielding track (31), an output end of the material stripping translation mechanism (311) is fixedly connected to the second supporting platform (32), a second side mold plate (33) is fixed on the side of the second supporting platform (32) close to the bottom mold assembly (10), a side mold bracket (34) is fixed on the second supporting platform (32), and the bottom mold plate (15) is located between each of the first side mold plates (24) and the second side mold plates (33); The first cleaning component (40) comprises a first cleaning support (41), the first cleaning support (41) is provided with a cleaning translation mechanism (42), a first cleaning platform (43) is fixed at the output end of the cleaning translation mechanism (42), and there is a distance between the first cleaning platform (43) and the first side template (24) or the second side template (33); The second cleaning component (50) comprises a cleaning yielding track (51), the cleaning yielding track (51) being located below one side of the adjustable lifting bracket (14), a second cleaning bracket (52) being slidably connected to the cleaning yielding track (51), a second cleaning platform (53) being fixed to the second cleaning bracket (52), a yielding translation mechanism (511) being further provided outside the cleaning yielding track (51), an output end of the yielding translation mechanism (511) being fixedly connected to the second cleaning platform (53), and a spacing being present between the second cleaning platform (53) and the first side template (24) or the second side template (33).

2. A prefabricated casting system for piers according to claim 1, characterized in that: The second side mold assembly (30) and the second cleaning assembly (50) are adjacent to each other.

3. A prefabricated casting system for piers according to claim 1, characterized in that: The rotating mechanism (11) is a rotating oil cylinder, and the lifting mechanism (13) comprises three hydraulic oil cylinders.

4. A prefabricated casting system for piers according to claim 1, characterized in that: The side mold translation mechanism (22) is a hydraulic cylinder, a side mold opening and closing guide rail (211) is fixed on the side mold support beam (21), a side mold opening and closing guide wheel (231) is rotatably connected under the first support platform (23), and the side mold opening and closing guide wheel (231) is rollingly connected to the side mold opening and closing guide rail (211).

5. A prefabricated casting system for piers according to claim 1, characterized in that: The cleaning translation mechanism (42) is a hydraulic cylinder. A cleaning opening and closing guide rail (411) is fixed on the first cleaning bracket (41). A cleaning opening and closing guide wheel (431) is rotatably connected under the first cleaning platform (43). The cleaning opening and closing guide wheel (431) is rollingly connected to the cleaning opening and closing guide rail (411).

6. A prefabricated casting system for piers according to claim 1, characterized in that: The stripping translation mechanism (311) is a hydraulic cylinder, and a side mold yielding guide wheel (321) is rotatably connected below the side mold support (34), and the roller of the side mold yielding guide wheel (321) is connected to the side mold yielding track (31).

7. A prefabricated casting system for piers according to claim 1, characterized in that: The yielding translation mechanism (511) is a hydraulic oil cylinder, and a cleaning yielding guide wheel (521) is rotatably connected below the second cleaning bracket (52), and the cleaning yielding guide wheel (521) is rollingly connected to the cleaning yielding track (51).

8. A prefabricated casting system for piers according to claim 1, characterized in that: The minimum distance between the first cleaning platform (43) and the first side template (24) or the second side template (33) is 25 to 50 mm, and the minimum distance between the second cleaning platform (53) and the first side template (24) or the second side template (33) is 25 to 50 mm.

9. A prefabricated casting system for piers according to claim 1, characterized in that: A first side mold guardrail (241) is fixed to a side of the first side mold (24) away from the bottom mold assembly (10), a second side mold guardrail (331) is fixed to a side of the second side mold (33) away from the bottom mold assembly (10), a first cleaning guardrail (432) is fixed to the first cleaning platform (43), and a second cleaning guardrail (531) is fixed to the second cleaning platform (53); the first cleaning guardrail (432) and the second cleaning guardrail (531) are both foldable guardrails.

10. A method for pouring pier columns off-site, characterized in that: The prefabricated casting system of the pier column comprises any one of claims 1 to 9, wherein the prefabricated casting system of the pier column is used to manufacture a casting body (60) at a prefabrication site, and the casting body (60) is transported to a road and bridge construction site via a transportation system.

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