Intelligent concrete column construction system and method

Abstract

The invention provides an intelligent concrete column building system and method.The intelligent concrete column building system comprises a stand column system, a plurality of vertical stand columns are arranged on the stand column system, a bearing platform and a construction platform which can move up and down are arranged on the stand columns, a formwork system is arranged above the bearing platform, and a formwork device is arranged on the formwork system; an automatic concrete vibrating system is arranged above the formwork system, and a hoisting device is further arranged on the top of the stand column system. And a main control center is further arranged and used for monitoring the working conditions of the stand columns, the formwork device and the hoisting device, and the main control center is further used for controlling climbing of the bearing platform and the construction platform and hoisting operation of the hoisting device. The automatic and intelligent level of pier column construction is greatly improved, an intelligent control technology is introduced in the links of formwork installation, steel bar component manufacturing, steel bar component hoisting, climbing formwork erecting construction, pouring construction, vibrating construction, maintenance construction and the like, the pier column construction quality and construction efficiency are improved, and safety accidents are reduced or even eradicated.

Description

Technical Field

[0001] The invention relates to the field of bridge construction, and in particular to an intelligent pier column construction system and a construction method. Background Art

[0002] In recent years, the rapid economic development has increased the demand for infrastructure. As traffic channel resources become increasingly scarce, the demand for bridge construction is increasing. For example, viaducts in cities can effectively improve urban traffic congestion and greatly improve traffic efficiency. The piers of urban viaducts are usually no more than 50 meters high, with a common height of about 5 to 30 meters. In addition, the number of piers is relatively dense, and the construction period takes a long time. At present, the construction of cast-in-place piers is mostly carried out by flipping, sliding or climbing forms. The automation and intelligence level of each process of pier construction is not high. The quality of cast-in-place pier body is not good, mainly reflected in: 1. The existing equipment construction is mainly supported by the main structure (pier body), and embedded parts or tie rod holes need to be set on the main structure. After the pier body is formed, the holes are repaired. The quality of cast-in-place pier body is not good, especially for piers in the sea or on the seaside, and piers under humid air conditions in the south. The embedded holes or tie rod holes in the pier body will have a very adverse effect on the durability of the main structure of the pier body. 2. The construction environment for workers is harsh and the protective platform is simple; for higher piers, they need to go up and down the ladder many times, which poses a high construction risk. 3. The efficiency and quality of loose steel bar binding are relatively low, and the labor intensity is very high; 4. Special lifting equipment needs to be configured next to the pier, which takes a long time to occupy the equipment, but the utilization rate is not high, which increases the construction cost. Patent document CN114603695A records a self-propelled opening and closing formwork system and a construction method for assembled railway bridge piers, which uses a self-propelled formwork, but the scheme is not suitable for piers with different heights, and the formwork system is similar to a full-house support structure, and the construction cost is relatively high. The on-site installation operation is relatively complicated. CN110396941A records a bridge pier construction system and construction method, which is equipped with a jacking device and a lifting device for climbing and turning the mold, but the use of the lifting device of the device is relatively limited, and it cannot assist in the lifting of the steel cage, and the lifting device will also interfere with the overall lifting of the steel cage. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide an intelligent pier construction system and construction method, which can greatly improve the automation and intelligence level of pier construction, greatly reduce the labor intensity of workers during the construction process, reduce the occupancy time of lifting equipment, and improve the efficiency and quality of pier construction.

[0004] In order to solve the above technical problems, the technical solution of the present invention is: an intelligent construction system for pier columns, including a column system, a plurality of vertical columns are arranged in the column system, a load-bearing platform and a construction platform that can move up and down are arranged on the columns, a formwork system is arranged above the load-bearing platform, the formwork system is provided with a template device, an automatic concrete vibrating system is arranged above the template system, and a hoisting device is also arranged on the top of the column system; There is also a main control center, which is used to monitor the working conditions of columns, formwork devices and lifting devices. The main control center is also used to control the climbing of the load-bearing platform and construction platform, and the lifting operation of the lifting device. In a preferred solution, the column system is provided with at least 4 columns, and at least one construction platform is sleeved on the columns and moves up and down along the columns; A column foundation is provided at the bottom of the column system, and the column is fixedly connected to the column foundation; Alternatively, a walking wheel set is provided at the bottom of the column, and the walking wheel set can be turned 90 degrees to facilitate walking.

[0005] In the preferred solution, each column is formed by splicing a plurality of sleeves; The end of the column is provided with a threaded section, and the sleeves of the column are fixedly connected through the threaded section. The end of the column is also provided with a pin section, and the other end of the column is provided with a pin hole. The pin section and the pin hole are used to control the verticality of the column.

[0006] In a preferred solution, each column is formed by splicing a plurality of I-beams, the ends of the I-beams are welded together, and stiffening plates are arranged at positions that do not interfere with the movement of the platform.

[0007] In the preferred solution, a plurality of vertical racks are fixedly provided on the outer wall of the column, a self-elevating motor is provided on the construction platform, the self-elevating motor is connected to the self-elevating gear, and the rack is meshedly connected to the self-elevating gear; Alternatively, a plurality of nuts are provided on the construction platform, and the rack is a rack with helical teeth. The nuts are threadedly connected to the rack with helical teeth on each column respectively, and a thrust bearing is provided between the nut and the construction platform. The outer wall of the nut is provided with teeth, which are meshed and connected with the self-lifting gear. The self-lifting motor is electrically connected to the main control center, and the climbing action is controlled by the main control center.

[0008] In the preferred solution, the mold frame system is located above the bearing platform, and a platform lifting cylinder is provided on the bearing platform near the column. Stop devices are provided at both ends of the platform lifting cylinder. The valve system of the platform lifting cylinder is electrically connected to the main control center, and the climbing action is controlled by the main control center.

[0009] In a preferred solution, inclination sensors are provided on the construction platform and the load-bearing platform. The inclination sensors are electrically connected to the main control center and are used to monitor the levelness of the construction platform and the load-bearing platform.

[0010] In a preferred solution, the construction platform includes a lower construction platform and an upper construction platform, which are respectively located above and below the bearing platform.

[0011] In the preferred solution, a plurality of adjustable struts are provided on the inner side of the construction platform. The adjustable struts are provided with threaded sleeves and bolts to adjust the length of the adjustable struts and fix them. One end of the adjustable struts is connected to the inner side of the construction platform, and the other end contacts the outer wall of the pier.

[0012] In the preferred solution, a laser collimator is provided on the base of the column, and a reflective target is provided on the top of the column or on the truss track of the hoisting device; An image acquisition device is provided near the reflective target to acquire images on the reflective target and send the images to the main control center. The main control center monitors the status of the column system according to the images on the reflective target.

[0013] In a preferred solution, a tuned mass damper is also provided on the column system, and the tuned mass damper is arranged on the truss track of the hoisting device or on a construction platform close to the top.

[0014] In a preferred solution, the truss track of the hoisting device is fixedly connected to the top of the column system, the truss track is a cantilever structure, one end of the truss track extends beyond the horizontal projection plane of the column system, and a counterweight is provided at the other end of the truss track; A gantry crane or an overhead crane is arranged on the truss track. The gantry crane or the overhead crane moves along the truss track. A lifting trolley is arranged on the gantry crane or the overhead crane.

[0015] In the preferred solution, the truss track is connected to the column through a truss track clamp, a truss track lifting cylinder is provided under the truss track, truss track stop devices are provided at both ends of the truss track lifting cylinder, the valve system of the truss track lifting cylinder is electrically connected to the main control center, and the climbing action of the lifting device is controlled by the main control center.

[0016] In the preferred scheme, a stroke sensor is provided on the traveling device of the gantry crane or the overhead crane, a torque sensor is provided on the motor of the lifting trolley, and a torque controller is also provided on the lifting trolley. The stroke sensor, the torque sensor and the torque controller are connected to the main control center. The main control center calculates the current maximum torque value based on the data of the stroke sensor and sends it to the torque controller. The current maximum torque value is compared with the real-time torque value of the torque sensor. If the real-time torque value exceeds the maximum torque value, the torque controller stops the lifting action of the lifting trolley and alarms.

[0017] In a preferred solution, one side of the construction platform and the load-bearing platform is a detachable structure, so that the column system can be transported from one construction site to another without at least disassembling the construction platform and the load-bearing platform.

[0018] In the preferred scheme, an intelligent pier column steel bar assembly system is also provided near the pier column, including a plurality of steel bar assembly columns, a steel bar truss track is fixedly provided at the top of the steel bar assembly column, at least one steel bar gantry crane is arranged on the steel bar truss track, a stirrup layered limiting device is provided on the steel bar assembly column, a plurality of limiting swing arms are provided on the stirrup layered limiting device from top to bottom, the height position of the limiting swing arm corresponds to the installation position of the stirrup, one end of the limiting swing arm is hinged to the stirrup layered limiting device, and the limiting swing arm is limited when it swings to the horizontal position.

[0019] In a preferred solution, a hanger limiting device is provided on the top of the stirrup layered limiting device, and the hanger limiting device adopts a retractable or swingable structure to limit the height position of the longitudinal reinforcement hanger.

[0020] In the preferred solution, a steel plate is provided below the stirrup layered limiting device, on which a plurality of longitudinal reinforcement auxiliary positioning seats are provided, in which permanent magnets are provided, and the longitudinal reinforcement auxiliary positioning seats correspond to the installation positions of the longitudinal reinforcements through moving positions.

[0021] In a preferred solution, a stirrup bottom limiting device is further provided below the stirrup layered limiting device. The stirrup bottom limiting device adopts a retractable structure to limit the height position of the stirrups at the bottom layer.

[0022] In the preferred solution, a welding robot slide seat is also provided on the steel bar assembly column, which slides up and down along the steel bar assembly column. A welding robot is provided on the welding robot slide seat. The welding robot is an articulated robot, and the welding robot moves along the welding robot slide seat. The welding robot slide can climb by itself or be lifted and lowered by a steel gantry crane.

[0023] In the preferred solution, an upper construction platform is provided on the top of the formwork system, and a longitudinal reinforcement auxiliary positioning device is provided at the bottom of the upper construction platform. The longitudinal reinforcement auxiliary positioning device is a camera or a laser scanner. The longitudinal reinforcement auxiliary positioning device is connected to the main control center and is used to obtain the position of the end of the poured longitudinal reinforcement.

[0024] In the preferred solution, a sleeve tightening tool is further provided, and the sleeve tightening tool is used to tighten the threaded sleeve connected to the end of the longitudinal reinforcement; The sleeve tightening tool is provided with an openable and closable movable handle, which is hinged to the tightening handle. Multiple guide wheels are provided on the movable handle and the tightening handle. The friction belt passes around the multiple guide wheels, one of which is connected to the tightening motor. The friction belt passes through the opening between the movable handle and the tightening handle to drive the threaded sleeve to rotate through friction force.

[0025] In the preferred solution, a melting joint device is also provided, the end of the handle is provided with a fixed chuck, and the position of the handle near the end is also pivotally connected to the movable chuck; The shapes of the fixed clamp and the movable clamp are adapted to the shapes of the steel bar ends, and extend to both sides to cover the cast steel bar ends and the uncast steel bar ends. The fixed clamp and the movable clamp are provided with electromagnetic coils; The extended end of the movable chuck is hinged to one end of the chuck cylinder, and the other end of the chuck cylinder is hinged to the handle.

[0026] In the preferred scheme, an intelligent vibrating device is also provided on the top of the mold frame system, the x-axis trolley is routably mounted on the x-guide rail, the x-guide rail is fixedly connected to the mold frame system, a cantilever rail is provided at the bottom of the x-axis trolley, the y-axis trolley is routably mounted on the y-guide rail, a y-axis motor is fixedly provided on the cantilever rail, the y-axis motor is connected to the y-axis trolley through a screw nut mechanism to drive the y-axis trolley to move along the y-guide rail, a winding device is also provided on the y-guide rail, a guide wheel is provided on the y-axis trolley, and the hose of the vibrating rod passes around the guide wheel and is connected to the winding device.

[0027] In a preferred solution, a gravity sensor is provided at the position of the guide wheel, or a torque sensor is provided at the winding device, and the gravity sensor or the torque sensor is used to monitor whether the vibrating rod is blocked by the steel bar.

[0028] In a preferred solution, in the template device, a template truss is provided on the back of the template, and a sealing membrane cloth is coated outside the template truss; A steaming device and a negative pressure device are also provided, and the steaming device and the negative pressure device are connected with the sealing membrane cloth through pipelines.

[0029] In a preferred solution, a top cover is also provided, which covers the top of the cast pier column and forms a sealing structure.

[0030] A construction method of the above-mentioned pier column intelligent construction system comprises the following steps: S1. Obtain BIM design plan; S2, construction of the pier cap and the first section of the pier; S3, install the column foundation, install the columns, and install the lower construction platform; S4, steel bar parts assembly; S5. Quality inspection of steel bar components; S6. Hoisting of steel bar components of the second section of the pier column; S7. Install the construction platform and formwork system; S8, pouring the second section of the pier column; S9. Install the construction platform and lifting device; The above steps complete the first two stages of pouring of the pier and the installation of the column system.

[0031] The preferred solution also includes the following steps: S10, the hoisting device hoists the column and climbs to the top; S11. Hoisting of pier column steel bar parts; S12, the load-bearing platform and formwork system climb automatically or by lifting and climbing through the lifting device; S13, formwork device formwork; S14, mold standing accuracy detection; S15, pouring concrete and vibrating automatically; S16, automatic concrete curing; S17, after demoulding, repeat steps S10 to S16; The construction of the pier is completed through the above steps.

[0032] In the preferred solution, the main control center is equipped with a production scheduling center and a quality control center. The production scheduling center is used to control the lifting device, the bearing platform, the formwork system, the construction platform, the pier column steel bar intelligent assembly system, the intelligent vibrating device and the concrete curing device according to the design plan and the sensor collection data; The quality control center is used to collect parameters of the column system, including: shape and position parameters of the pier column reinforcement components; it is also used to collect template positioning parameters, intelligent vibration parameters and concrete curing parameters, the verticality and stress condition of the column, the posture and stress condition of the construction platform and the load-bearing platform, the position accuracy of the template device, the travel and lifting weight of the hoisting device; The collected parameters are fed back to the main control center, which generates control data and then sends it to the production scheduling center.

[0033] In a preferred solution, the climbing of the construction platform includes the following steps: S21. Obtain the total climbing height of the construction platform from the main control center; S22. Calculate the distance of each staged climb; S23, converting the climbing distance into a climbing angle of the self-elevating motor; S24, controlling each self-elevating motor to rotate synchronously; S25, construction platform inclination detection; S26, if the error exceeds the tolerance, the self-elevating motor is controlled to compensate for the inclination error; S27, loop steps S23 to S26 to complete the automatic climbing of the construction platform.

[0034] In a preferred embodiment, the assembly of the steel bar components includes the following steps: S31. Obtain the design plan of BIM steel bar components; S32, making longitudinal reinforcement hangers; S33, laying longitudinal reinforcement on the tire frame; S34, the longitudinal reinforcement is inserted into the longitudinal reinforcement hanger and fixed; S35. Arrange a stirrup bottom limiter at the bottom of the pier column steel bar intelligent assembly system according to the position of the longitudinal reinforcement; S36. The stirrups are hoisted into the pier column steel bar intelligent assembly system, the stirrup bottom limit device is extended, and the stirrups are hoisted on the stirrup bottom limit device; S37, hoist in the longitudinal reinforcement and adjust its position; S38, setting a limit swing rod of the stirrup layer limit device; S39, arrange stirrups in layers; S40. Check the shape and position of the longitudinal reinforcement and stirrups; S41, intelligently identify welding node positions and generate welding plans; S42, lifting or climbing the welding robot slide; S43. The welding robot automatically welds according to the welding plan.

[0035] In a preferred embodiment, the lifting of the steel bar components includes the following steps: S51, obtaining an image of the poured steel bar ends; S52, intelligent identification of poured steel bar ends; S53, obtaining the offset data of the poured steel bar ends by comparing with the design plan; S54, correcting the ends of the poured steel bars according to the offset data; S55, hoisting pier column steel bar parts; S56, preliminary alignment of steel bar ends; S57. First select some of the longitudinal reinforcements of the pier column reinforcement parts and fix them to the ends of the poured reinforcements, and then fix the other longitudinal reinforcements.

[0036] In a preferred solution, in step S55: S551. When hoisting the steel bar components of the pier column, first obtain the cross-sectional shape and position parameters of the pier column; S552, preliminarily calculating the travel parameters of the hoisting device; S553. Hoist the steel bar components of the pier column to align the ends of the steel bars preliminarily; S554. Select some longitudinal reinforcement ends and fix them first; The inner steel bar ends are connected by melting, and the outer steel bar ends are connected by threaded sleeves.

[0037] In a preferred embodiment, the automatic vibration comprises the following steps: S61, obtaining the cross-sectional shape and position parameters of the pier column, and obtaining the shape and position parameters of the steel bar components of the pier column; S62, initialization of intelligent vibrating device; S63, generating a vibration scheme according to the structural form and the working performance status of the concrete, the vibration scheme including vibration process parameters, and avoiding the position of the steel bars in the vibration scheme; S64, generating an x-direction trolley control program, generating a y-direction trolley control program, and generating a winding device control program; S65. Implement intelligent vibration operation.

[0038] The preferred solution also includes the following steps: S66, monitoring the obstruction of the vibrating rod, monitoring the value of the gravity sensor of the guide wheel, or monitoring the value of the torque sensor in the winding device, and sending it to the main control center, which analyzes the received value to determine whether the vibrating rod is blocked by the steel bar; If so, implement disposal measures; S67. If the problem is solved, continue to implement the intelligent vibration operation. If it is not solved, an alarm is issued and manual processing is transferred, or the current position is marked to notify subsequent manual processing. The intelligent vibration operation skips the current position and continues the operation at the next position.

[0039] In a preferred embodiment, the automatic maintenance comprises the following steps: S71, obtaining ambient temperature and humidity parameters; S72, generating a maintenance plan; S73, steam curing device: starting the steam curing device to deliver water vapor with a pressure higher than normal pressure into the closed template space; S74, monitoring the temperature and humidity in the template space, and adjusting the working state of the steaming device according to the feedback of the temperature and humidity in the template space.

[0040] In a preferred solution, the automatic maintenance further comprises the following steps: S75. After the curing device has worked for a preset time, the device is switched to the negative pressure device. The negative pressure device evacuates the template space to promote exhaust of the concrete surface, monitors the pressure in the template space, and controls the working time of the negative pressure device. After the negative pressure is maintained for a preset time, the device is switched to the curing device to continue curing.

[0041] In a preferred solution, the template of the template device adopts a breathable template, a breathable layer is provided on the surface of the template, and the steel plate of the template is provided with breathable holes.

[0042] In a preferred solution, in the formwork device, a transparent formwork is provided at a portion of the position with an outward-cambered formwork, and an image acquisition device is provided outside the transparent formwork. The image acquisition device acquires an image of the concrete surface and sends it to the main control center. The main control center identifies concrete surface defects and adjusts the vibration plan.

[0043] The intelligent pier column construction system and construction method provided by the present invention have the following beneficial effects by adopting the above scheme: 1. The present invention greatly improves the automation and intelligence level of pier construction. It introduces intelligent control technology from the installation of formwork, the production of steel bar components, the hoisting of steel bar components, the climbing formwork construction, the pouring construction, the vibration construction and the maintenance construction, etc., which greatly improves the automation and intelligence level of pier construction, reduces the labor intensity of workers during the construction process, improves the quality and efficiency of pier construction, and reduces or even eliminates safety accidents.

[0044] 2. The structure of the system of the present invention eliminates the need to bury embedded parts in the outer wall of the pier, thereby improving the corrosion resistance of the pier, and is particularly suitable for pier construction at the seaside, in the sea, and in humid areas in the south.

[0045] 3. The hoisting device provided in the present invention can hoist construction components, including formwork, columns, steel bar components and inner mold formwork. In some construction conditions, it can also assist in lifting the construction platform in conjunction with special hoists, greatly reducing the time occupied by the hoisting equipment.

[0046] 4. The intelligent pier construction system of the present invention can move to the next pier in whole or in part after constructing one pier, which greatly reduces the assembly time of the system and the occupancy time of the lifting equipment. It is particularly suitable for sites with narrow construction locations that are difficult for lifting equipment to enter, and is also suitable for working conditions where piers are densely packed and not far apart.

[0047] 5. The construction method of the present invention can perform automated and intelligent control of various components, greatly improve construction efficiency, ensure construction safety, and reduce labor intensity. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The present invention will be further described below in conjunction with the accompanying drawings and embodiments: Figure 1 It is the front view of the intelligent construction system of pier column in the present invention.

[0049] Figure 2 It is a side view of the intelligent construction system of pier columns in the present invention.

[0050] Figure 3 It is a schematic diagram of the connection structure of the middle column of the present invention.

[0051] Figure 4 It is a front view of another preferred pier column intelligent construction system in the present invention.

[0052] Figure 5 It is a side view of another preferred pier column intelligent construction system in the present invention.

[0053] Figure 6 It is a schematic cross-sectional view of the template device of the present invention when closing or demoulding.

[0054] Figure 7 The entire column system in the present invention moves to the next Figure 8 It is a partial schematic diagram of the connection structure between the construction platform and the column in the present invention.

[0055] Fig. 9 It is a partial schematic diagram of the connection structure between the self-elevating motor and the column in the present invention.

[0056] Fig.10 It is a schematic diagram of a horizontal cross section of the construction platform in the present invention.

[0057] Fig.11 It is a horizontal cross-sectional schematic diagram of the template device in the present invention.

[0058] Fig.12 It is a schematic diagram of the intelligent construction system of the integrally movable pier column in the present invention.

[0059] Fig.13 It is a structural schematic diagram of the pier column reinforcement intelligent assembly system of the present invention.

[0060] Fig.14 It is a schematic diagram of the structure of the pier column steel bar component during hoisting in the present invention.

[0061] Fig.15 It is a top view schematic diagram of the fusion joint device in the present invention.

[0062] Fig.16 A schematic front view of a fusion joint device according to the present invention.

[0063] Fig.17 A schematic structural diagram of the sleeve fastening tool in the present invention.

[0064] Fig.18 Schematic diagram of the overall structure of the intelligent vibrating device in the present invention.

[0065] Fig.19 A schematic diagram of the partially enlarged structure of the intelligent vibrating device in the present invention.

[0066] Fig. 20 Construction flow chart of the first and second sections of the pier column in the invention.

[0067] Fig.21 Flow chart of pier construction in the present invention.

[0068] Fig. 22 Flow chart of automatic climbing of the construction platform in the present invention.

[0069] Fig.23 Flow chart of the intelligent assembly of steel bar components in the present invention.

[0070] Fig.24 Flow chart of steel bar component hoisting in the present invention.

[0071] Fig.25 Flow chart of the preferred solution for lifting steel bar components in the present invention.

[0072] Fig.26 Flow chart of intelligent vibration in the present invention.

[0073] Fig. 27 Flow chart of intelligent maintenance in the present invention.

[0074] Fig.28 Flow chart of intelligent construction of pier columns in the present invention.

[0075] In the figure: lifting device 1, gantry crane 101, truss rail 102, lifting trolley 103, truss rail clamp 104, truss rail backstop 105, truss rail lifting cylinder 106, overhead crane 107, intelligent vibrating device 2, x-guide rail 201, x-trolley 202, cantilever rail 203, winding device 204, y-motor 205, y-guide rail 206, y-trolley 207, vibrating rod 208, template device 3, template truss 31, template system 4, bearing platform 5, flat Platform top lifting cylinder 51, backstop device 52, locking hoop 53, column system 6, pin section 61, tapered thread section 62, column 63, lower construction platform 7, thrust bearing 71, nut 72, self-lifting motor 73, self-lifting gear 74, rack 75, quick-release truss 76, column foundation 8, upper construction platform 9, template fine-tuning cylinder 10, adjustable support rod 11, pier 12, pier first section 121, pier second section 122, column transfer vehicle 13, track 14, pier steel bar intelligent assembly system 15, Steel bar gantry crane 151, steel bar truss track 152, steel bar assembly column 153, welding robot slide 154, welding robot 155, longitudinal bar hanger 156, longitudinal bar 157, hanger limit device 158, stirrup layer limit device 159, limit swing rod 160, stirrup bottom limit device 161, longitudinal bar auxiliary positioning seat 162, stirrup 163, longitudinal bar auxiliary positioning device 16, pier column steel bar parts 17, cast steel bar end 171, uncast steel bar end 172, fusion joint device 1 8, handle 181, chuck cylinder 182, movable chuck 183, half sleeve 184, electromagnetic coil 185, fixed chuck 186, connecting hole 187, sleeve fastening tool 19, guide wheel 191, friction belt 192, movable handle 193, tightening motor 194, fastening handle 195, steel cone sleeve 20, top cover 21, steam curing device 22, negative pressure device 23, inner mold cover 24, sealing film cloth 25, laser collimator 26, reflective target 27, walking wheel group 28, mold clamping hydraulic cylinder 29 DETAILED DESCRIPTION

[0076] Embodiment 1: like Figures 1 to 4In the invention, an intelligent construction system for pier columns includes a column system 6, a plurality of vertical columns 63 are arranged on the column system 6, a load-bearing platform 5 and a construction platform that can move up and down are arranged on the columns 63, a formwork system 4 is arranged above the load-bearing platform 5, the formwork system 4 is provided with a template device 3, an automatic concrete vibrating system is arranged above the template system 4, and a hoisting device 1 is also arranged on the top of the column system 6; A main control center is also provided, which is used to monitor the working conditions of the columns 63, the formwork device 3 and the lifting device 1. The main control center is also used to control the climbing of the load-bearing platform 5 and the construction platform, and the lifting operation of the lifting device 1. The above structure combines the column system with the self-lifting platform system and the automatic control system, which greatly improves the automation level of the pier 12 construction, especially for urban elevated transportation, the construction efficiency of the pier group is significantly improved. Since there is no need to bury embedded parts, the piers constructed by the construction system of the present invention have better appearance and stronger overall durability. The main control center in this example preferably adopts a combination of PLC and industrial computer.

[0077] The preferred solution is Figures 1 to 6 In the figure, the column system 6 is provided with at least 4 columns 63, at least one construction platform is sleeved on the columns 63, and moves up and down along the columns 63; preferably, three construction platforms are used, namely the upper construction platform 9, the bearing platform 5 and the lower construction platform 7, wherein the upper construction platform 9 and the lower construction platform 7 are not only used for construction purposes, but also serve as the reinforcement structure of the column system 6.

[0078] A column foundation 8 is provided at the bottom of the column system 6, and the column 63 is fixedly connected to the column foundation 8; this solution is used for the construction of piers 12 with a relatively high height to ensure the structural strength.

[0079] Alternatively, a walking wheel set 28 is provided at the bottom of the column 63, and the walking wheel set 28 can be turned 90 degrees for easy walking. This solution is mainly used for the construction of piers 12 with low heights, so as to quickly move between different construction positions. This solution also needs to ensure that the ground height difference between the construction positions of each pier is within a preset range. For construction positions with excessive height differences, a jacking device needs to be provided to level the column system 6.

[0080] The preferred solution is Figures 5 to 7 In the embodiment, each column 63 is formed by splicing a plurality of sleeves; The end of the column 63 is provided with a threaded section 62, and each sleeve of the column 63 is fixedly sleeved by the threaded section 62. The end of the column 63 is also provided with a pin shaft section 61, and the other end of the column 63 is provided with a pin shaft hole. The pin shaft section 61 and the pin shaft hole are used to control the verticality of the column 63. With this structure, the column system 6 can be easily disassembled and assembled, and is convenient for recycling, especially suitable for the construction of piers with various heights. For example, the piers of urban elevated roads In another optional solution, each column 63 is formed by splicing a plurality of I-beams, the ends of the I-beams are welded, and stiffening plates are arranged at positions that do not interfere with the movement of the platform. This structure has a lower cost and is suitable for scenes where the heights of the pier groups are not much different, such as the piers of highways and railway bridges.

[0081] There are multiple solutions for the climbing of the upper construction platform 9, the load-bearing platform 5 and the lower construction platform 7, which can be flexibly selected according to the on-site working conditions, including: 1. The lifting device 1 cooperates with a specific lifting device to achieve the climbing of the platform. 2. Self-climbing is achieved through a hydraulic or meshing transmission mechanical device installed on the platform. 3. Climbing is achieved through multiple electric hoists installed on the platform. All platform systems are equipped with attitude monitoring sensors and anti-fall safety mechanisms.

[0082] In the preferred solution, a plurality of vertical racks 75 are fixedly provided on the outer wall of the column 63, and a self-elevating motor 73 is provided on the construction platform, the self-elevating motor 73 is connected to the self-elevating gear 74, and the rack 75 is meshedly connected to the self-elevating gear 74; the self-elevating motor 73 drives the self-elevating gear 74 to realize the self-climbing of the construction platform. The advantage of this solution is that the structure is simple, and it is suitable for construction platforms with light weight. This solution is also suitable for the column 63 structure formed by splicing I-beams.

[0083] Or, if Figure 8 , 9 As shown in , a plurality of nuts 72 are also provided on the construction platform, and the rack 75 is a rack with helical teeth. The nuts 72 are respectively threadedly connected with the rack with helical teeth on each column 63. A thrust bearing 71 is provided between the nut 72 and the construction platform. The outer wall of the nut 72 is provided with teeth, which are meshed and connected with the self-elevating gear 74. The self-elevating motor 73 is electrically connected to the main control center, and the climbing action is controlled by the main control center. The advantage of this solution is that the climbing force is large, self-locking can be achieved, it is suitable for construction platforms with heavy deadweight, and it is safer. In this example, a plurality of threaded holes are provided on the outer wall of the column 63, and a horizontal oblong hole is provided on the rack 75. After the circular column 63 is vertically connected, the rack 75 is fixedly installed on the surface of the column 63 by screws. Preferably, a plurality of racks 75 are provided on each column 63, and the continuity of the thread is ensured during installation.

[0084] The preferred solution is Figure 1 , 3 In , 5, and 6, the mold frame system 4 is located above the bearing platform 5, and a platform lifting cylinder 51 is provided near the column on the bearing platform 5. Both ends of the platform lifting cylinder 51 are provided with a stop device 52. The valve system of the platform lifting cylinder 51 is electrically connected to the main control center, and the climbing action is controlled by the main control center. Preferably, as Figure 5 As shown in , the template device 3 is used for setting up and removing the mold by adjusting the position through multiple telescopic devices, such as cylinders or double-headed screws.

[0085] In the preferred solution, a tilt sensor is provided on the construction platform and the load-bearing platform 5, and the tilt sensor is electrically connected to the main control center to monitor the levelness of the construction platform and the load-bearing platform 5. This structure ensures safety during climbing and daily construction. A threshold is set for the output signal of the tilt sensor. When the tilt of the tilt sensor exceeds the threshold, the main control center alarms. If it is in the climbing process, the main control center controls the climbing device to stop for inspection.

[0086] The preferred solution is Figure 1 , 3 In the figure, the construction platform includes a lower construction platform 7 and an upper construction platform 9, which are respectively located above and below the bearing platform 5.

[0087] The preferred solution is Fig.10 , 11 In the embodiment, a plurality of adjustable struts 11 are provided on the inner side of the construction platform, and the adjustable struts 11 are provided with threaded sleeves and bolts to adjust the length of the adjustable struts 11 and fix them, and one end of the adjustable struts 11 is connected to the inner side of the construction platform, and the other end is in contact with the outer wall of the pier 12. With this structure, the cast pier 12 is used to provide auxiliary support for the column 63.

[0088] The preferred solution is Figure 1 In the figure, a laser collimator 26 is provided on the column base 8, and a reflective target 27 is provided on the top of the column 63 or on the truss track 102 of the hoisting device 1; An image acquisition device is provided near the reflective target 27, which is used to acquire images on the reflective target 27 and send them to the main control center, which monitors the state of the column system 6 according to the images on the reflective target 27. With this structure, deformation control of the column system 6 can be achieved at a relatively low cost.

[0089] In a preferred solution, a tuned mass damper is also provided on the column system 6, and the tuned mass damper is arranged on the truss track 102 of the hoisting device 1 or on a construction platform near the top. With this structure, the tuned mass damper can effectively block the swing of the high pier structure, and is suitable for construction sites with strong winds and high-rise and relatively weak pier columns 12, such as double-support high pier structures.

[0090] The preferred solution is Figure 3 , 4 In the figure, the truss rail 102 of the hoisting device 1 is fixedly connected to the top of the column system 6, the truss rail 102 is a cantilever structure, one end of the truss rail 102 extends beyond the horizontal projection plane of the column system 6, and a counterweight is provided at the other end of the truss rail 102; A gantry crane 101 or an overhead crane 107 is arranged on the truss track 102, and the gantry crane 101 or the overhead crane 107 moves along the truss track 102, and a lifting trolley is arranged on the gantry crane 101 or the overhead crane 107. With this structure, the occupation of the lifting crane is reduced. During the construction process, the lifting crane is basically not occupied, and the construction efficiency is improved. This structure is particularly suitable for working conditions where the height of the piers 12 is close. In some occasions, this structure is also suitable for sites where the ground height difference changes slowly. Because the ground slope is small, there is no need to dismantle the lifting device 1 during the transfer of the entire column system 6, further improving the construction efficiency.

[0091] Another preferred solution is Figure 1 , 2 In the embodiment, the truss rail 102 is connected to the column 63 through the truss rail clamp 104, and a truss rail lifting cylinder 106 is provided below the truss rail 102. Both ends of the truss rail lifting cylinder 106 are provided with truss rail stop devices 105. The valve system of the truss rail lifting cylinder 106 is electrically connected to the main control center, and the main control center controls the climbing action of the lifting device 1. With this structure, the self-climbing of the column system 6 can be achieved according to the construction progress, which is suitable for the construction of piers 12 with higher heights, such as the construction of piers 12 with a height of more than 20. This solution is also suitable for working conditions with a large ground slope. When transferring the column system 6 in this working condition, the lifting device 1 can be conveniently and temporarily dismantled to facilitate the overall movement of the column system 6 to the next workstation.

[0092] In the preferred solution, a travel sensor is provided on the traveling device of the gantry crane 101 or the overhead crane 107, a torque sensor is provided on the motor of the lifting trolley 103, and a torque controller is also provided on the lifting trolley 103. The travel sensor, the torque sensor and the torque controller are connected to the main control center. The main control center calculates the current maximum torque value according to the data of the travel sensor and sends it to the torque controller. The current maximum torque value is compared with the real-time torque value of the torque sensor. If the real-time torque value exceeds the maximum torque value, the torque controller stops the lifting action of the lifting trolley 103 and alarms. The travel sensor can monitor the position of the gantry crane 101 or the overhead crane 107 on the cantilever. After calibration, different bearing capacities are set at each position of the cantilever along the length direction to ensure safety. The cantilever position is matched with the output torque, that is, the closer the position is to the end of the cantilever, the smaller the current maximum torque value of the output torque is. Through this solution, the safety of the lifting construction is ensured.

[0093] The preferred solution is Figures 6 to 12As shown in , one side of the construction platform and the carrying platform 5 is a detachable structure, so that the column system 6 can be transported from one construction site to another without at least disassembling the construction platform and the carrying platform 5. With this structure, the time and workload of rebuilding and adjusting the column system 6 are greatly reduced, and the construction efficiency is improved. In particular, the accuracy error caused by frequent disassembly of the columns 63 is avoided, such as the influence on the installation accuracy of the spiral rack on the surface of the columns 63.

[0094] The preferred solution is Fig.13 In the embodiment, a pier column steel bar intelligent assembly system 15 is also provided near the pier column 12 to reduce the deformation of the pier column steel bar component 17 during transportation. The pier column steel bar intelligent assembly system 15 includes a plurality of steel bar assembly columns 153, a steel bar truss track 152 is fixedly provided at the top of the steel bar assembly columns 153, at least one steel bar gantry crane 151 is arranged on the steel bar truss track 152, a stirrup layering limiting device 159 is provided on the steel bar assembly columns 153, and a plurality of limiting swing rods 160 are provided on the stirrup layering limiting device 159 from top to bottom, and the height position of the limiting swing rod 160 corresponds to the installation position of the stirrup 163, one end of the limiting swing rod 160 is hinged to the stirrup layering limiting device 159, and the limiting swing rod 160 is limited when swinging to a horizontal position. The stirrup layering limiting device 159 is used to spread the stirrup 163 and position it at different height positions. Preferably, in this example, two groups of steel gantry cranes 151 are provided, one group is mainly used for hoisting longitudinal reinforcement 157, and the other group is used for hoisting stirrups 163 or welding robot slide 154. When in use, the steel gantry crane 151 is used to hoist the stirrups 163, and then the limiting rocker arms 160 are lowered in layers to limit the stirrups 163, that is, the stirrups 163 are arranged in layers according to the designed position.

[0095] The preferred solution is Fig.13 In the embodiment, a hanger limiting device 158 is provided on the top of the stirrup layer limiting device 159. The hanger limiting device 158 adopts a retractable or swingable structure to limit the height position of the longitudinal reinforcement hanger 156. Preferably, the hanger limiting device 158 adopts a threaded sleeve, the longitudinal reinforcement 157 is placed on the tire frame, the longitudinal reinforcement hanger 156 is installed, and then the hanger limiting device 158 is installed on the longitudinal reinforcement 157 respectively, and the longitudinal reinforcement hanger 156 is turned over 90° as a whole and then hoisted between the stirrups 163.

[0096] The preferred solution is Fig.13 In the embodiment, a steel plate is provided below the stirrup layered limiting device 159, on which a plurality of longitudinal reinforcement auxiliary positioning seats 162 are provided, and a permanent magnet is provided in the longitudinal reinforcement auxiliary positioning seat 162, and the longitudinal reinforcement auxiliary positioning seat 162 moves to correspond to the installation position of the longitudinal reinforcement 157. This structure is used to temporarily fix the end of the longitudinal reinforcement 157.

[0097] The preferred solution is Fig.13 In the embodiment, a stirrup bottom limiting device 161 is provided below the stirrup layer limiting device 159. The stirrup bottom limiting device 161 adopts a retractable structure and is used to limit the height position of the bottom stirrup 163. The stirrup bottom limiting device 161 has a certain height from the steel plate to facilitate the operator to adjust the position of the longitudinal reinforcement auxiliary positioning seat 162.

[0098] The preferred solution is Fig.13 In the figure, a welding robot slide 154 is also provided on the steel bar assembly column 153, which slides up and down along the steel bar assembly column 153. A welding robot 155 is provided on the welding robot slide 154. The welding robot 155 is an articulated robot, and the welding robot 155 moves along the welding robot slide 154. The welding robot slide 154 is lifted by itself or by the steel bar gantry crane 151. With this structure, the welding robot 155 moves back and forth on the welding robot slide 154 to weld the nodes of the longitudinal reinforcement 157 and the stirrup 163 together, thereby realizing the automated assembly of the pier column steel bar component 17.

[0099] The preferred solution is Figures 1 to 4 In the embodiment, an upper construction platform 9 is provided on the top of the formwork system 4, and a longitudinal reinforcement auxiliary positioning device 16 is provided on the bottom of the upper construction platform 9. The longitudinal reinforcement auxiliary positioning device 16 is a camera or a laser scanner. The longitudinal reinforcement auxiliary positioning device 16 is connected to the main control center and is used to obtain the position of the end of the poured longitudinal reinforcement. If there is a deviation in the position of the longitudinal reinforcement end, a sleeve is used to cover the longitudinal reinforcement end for adjustment. In the preferred scheme, an electromagnetic coil is provided at the end of the sleeve. When adjusting the deviation, the lower part of the longitudinal reinforcement end is first heated to red heat, and then the offset deformation of the longitudinal reinforcement end is adjusted. For thicker diameter steel bars, such as steel bars with a diameter exceeding 20 mm, the adjustment is more convenient.

[0100] The preferred solution is Fig.17 In the embodiment, a sleeve fastening tool 19 is also provided, and the sleeve fastening tool 19 is used to fasten the threaded sleeve connected to the end of the longitudinal reinforcement; The sleeve tightening tool 19 is provided with an openable and closable movable handle 193, which is hinged to the tightening handle 195. A plurality of guide wheels 191 are provided on the movable handle 193 and the tightening handle 195. The friction belt 192 passes through the plurality of guide wheels 191, one of which is connected to the tightening motor 194. The friction belt 192 passes through the opening between the movable handle 193 and the tightening handle 195 to drive the threaded sleeve to rotate by friction. Since the stirrups 163 and the longitudinal bars 157 of the pier steel bar component 17 are densely distributed, the labor intensity of docking the longitudinal bars 157 of the two groups of pier steel bar components 17 one by one is high and the efficiency is extremely low. The sleeve tightening tool 19 is provided to drive the threaded sleeve to rotate through the friction belt 192, which greatly improves the construction efficiency.

[0101] The preferred solution is Fig.15 , 16 In the invention, a melting joint device 18 is also provided, and a fixed clamp 186 is provided at the end of a handle 181. The fixed clamp 186 is used to align the ends of two steel bars, and the handle 181 is also pivotally connected to a movable clamp 183 near the end. The shapes of the fixed clamp 186 and the movable clamp 183 are adapted to the shapes of the steel bar ends, and extend to both sides to cover the cast steel bar ends 171 and the uncast steel bar ends 172. An electromagnetic coil 185 is provided on the fixed clamp 186 and the movable clamp 183; through the heating of the electromagnetic coil 185, the cast steel bar ends 171 and the uncast steel bar ends 172 are heated to a molten state, so that the two are welded together.

[0102] The extended end of the movable clamp 183 is hinged to one end of the clamp cylinder 182, and the other end of the clamp cylinder 182 is hinged to the handle 181. With this structure, the cast steel bar end 171 and the uncast steel bar end 172 can be quickly connected. It is particularly suitable for the connection of the longitudinal reinforcement end located in the inner circle. In a further preferred solution, two semicircular half sleeves 184 are also provided, which are used to be sleeved on the cast steel bar end 171 and the uncast steel bar end 172. The electromagnetic coil 185 is heated to melt the half sleeve 184, the cast steel bar end 171 and the uncast steel bar end 172 together.

[0103] The preferred solution is Figure 1 , 4 In , 18 and 19, an intelligent vibrating device 2 is further provided on the top of the mold frame system 4, an x-axis trolley 202 is rotatably mounted on the x-guide rail 201, and the x-guide rail 201 is fixedly connected to the mold frame system 4, a cantilever rail 203 is provided at the bottom of the x-axis trolley 202, a y-axis trolley 207 is rotatably mounted on the y-guide rail 206, a y-axis motor 205 is fixedly provided on the cantilever rail 203, and the y-axis motor 205 is connected to the y-axis trolley 207 through a screw nut mechanism to drive the y-axis trolley 207 to move along the y-guide rail 206, a winding device 204 is also provided on the y-guide rail 206, a guide wheel is provided on the y-axis trolley 207, and the hose of the vibrating rod 208 passes around the guide wheel and is connected to the winding device 204.

[0104] The preferred solution is Fig.19 In the embodiment, a gravity sensor is provided at the position of the guide wheel, or a torque sensor is provided at the winding device 204. The gravity sensor or torque sensor is used to monitor whether the vibrating rod 208 is blocked by the steel bar. That is, when the vibrating rod 208 is lowered or recovered, the torque or gravity usually increases or decreases linearly. If a sudden change occurs, it may be blocked by the steel bar. In order to ensure the vibrating effect, corresponding disposal measures need to be taken.

[0105] The preferred solution is Fig.18 In the template device 3, a template truss 31 is provided on the back of the template, and a sealing membrane cloth 25 is covered outside the template truss 31; A steaming device 22 and a negative pressure device 23 are also provided, and the steaming device 22 and the negative pressure device 23 are connected to the sealing membrane cloth 25 through pipelines.

[0106] The preferred solution is Fig.18 In the embodiment, a top cover 21 is also provided, which covers the top of the cast pier and forms a sealing structure. The above structure realizes the curing of cast concrete with formwork, and improves the curing quality of concrete. Further preferably, the negative pressure device 23 can also evacuate the sealed environment of the formwork device 3, so that steam can enter the interior of the concrete to further promote full hydration and reduce the occurrence of cracks.

[0107] Embodiment 2: On the basis of Example 1, Fig. 20 A construction method of the above-mentioned pier column intelligent construction system comprises the following steps: S1. Obtain the BIM design plan, including the construction process, the shape and size of the pier column steel bar component 17, the shape and size of the template, vibration requirements, etc.; S2, the cap of the construction pier and the first section of the pier 121; S3, install the column foundation 8, install the column 63, and install the lower construction platform 7; S4, steel bar parts assembly; S5. Steel bar component quality inspection, mainly inspecting the shape and position accuracy of steel bar components; S6. Hoisting of steel bar components of the second section of the pier column; S7. Install the construction platform and formwork system; S8, pouring the second section 122 of the pier column; S9. Install the construction platform and lifting device; The above steps complete the first two stages of pouring of the pier and the installation of the column system.

[0108] The preferred solution is Fig.21 The following steps are also included: S10, optionally, the hoisting device 1 hoists the column 63 and climbs to the top; in another optional solution, such as Figure 3 , 4 As shown, since the lifting device 1 is fixedly connected to the column 63, this step is not applicable.

[0109] S11, hoisting pier column steel bar parts 17; S12, the carrying platform 5 and the formwork system 4 climb automatically or are lifted and climbed by the lifting device 1; S13, adjusting the position of the template device 3 by adjusting the telescopic device, such as the mold clamping hydraulic cylinder 29, to complete the mold erection; S14, mold standing accuracy detection, through video acquisition, laser scanning and other solutions, the position of the template is detected, the fixed structure of the template device 3 is used as a positioning system, and the gap between the template and the design position is detected. If it is less than the threshold, it meets the mold standing accuracy requirements, and if it is greater than the threshold, the position of the template needs to be readjusted; S15, pouring concrete and vibrating automatically; S16, automatic concrete curing; S17, after demoulding, repeat steps S10 to S16; The construction of the pier is completed through the above steps.

[0110] The preferred solution is Fig.28 The main control center is equipped with a production scheduling center and a quality control center. The production scheduling center is used to control the lifting device 1, the bearing platform 5, the formwork system 4, the construction platform, the pier column steel bar intelligent assembly system 15, the intelligent vibrating device 2 and the concrete curing device according to the design plan and the sensor collection data; The quality control center is used to collect parameters of the column system 6, shape and position parameters of the pier column steel bar component 17; it is also used to collect template positioning parameters, intelligent vibration parameters and concrete curing parameters, the verticality and stress condition of the column 63, the posture and stress condition of the construction platform and the load-bearing platform 5, the position accuracy of the template device 3, the stroke and lifting weight of the hoisting device 1; the shape and position accuracy of the pier column steel bar component 17 is determined by video and picture collection, and the laser radar is used to realize the judgment of the accuracy error. The collection of template positioning parameters is the same as that of the pier column steel bar component 17. The intelligent vibration parameters and concrete curing parameters are mainly derived from the BIM design scheme. The verticality of the column 63 is determined by the laser collimator 26. The stress condition of the column 63 is obtained by collecting strain sensors set on the surface of the column 63, such as resistor sensors or piezoelectric sensors. The position accuracy of the template device 3 adopts the solution of video and picture positioning with laser radar. The stroke and lifting weight of the hoisting device 1 are acquired through data from a stroke sensor located on the hoisting device 1 and a torque sensor of the gantry crane 101 .

[0111] The collected parameters are fed back to the main control center, which generates control data and then sends it to the production scheduling center.

[0112] The preferred solution is Fig. 22 In the process of climbing the construction platform, the following steps are involved: S21. Obtain the total climbing height of the construction platform from the main control center; S22. Calculate the distance of each staged climb; S23, converting the climbing distance into a climbing angle of the self-elevating motor 73; S24, controlling each self-elevating motor 73 to rotate synchronously; S25, construction platform inclination detection; S26, if the inclination angle of the construction platform exceeds the tolerance, that is, exceeds the preset error value, the self-elevating motor 73 at the corresponding position is controlled to compensate for the inclination angle error by adjusting the rotation speed; S27, loop steps S23 to S26 to complete the automatic climbing of the construction platform.

[0113] The preferred solution is Fig.23 In the process, the assembly of steel bar parts includes the following steps: S31. Obtain the design plan of BIM steel bar components; S32, making longitudinal reinforcement hanger 156; S33, laying longitudinal reinforcement 157 on the tire frame; S34, longitudinal reinforcement 157 is inserted into longitudinal reinforcement hanger 156 and fixed with threaded sleeve; S35, arranging a stirrup bottom limiting device 161 at the bottom of the pier column steel bar intelligent assembly system 15 according to the position of the longitudinal reinforcement 157; S36, hoisting the stirrup 163 into the pier column steel bar intelligent assembly system 15, the stirrup bottom limiter 161 extends out, and the stirrup 163 is hoisted on the stirrup bottom limiter 161; S37, hoist in longitudinal reinforcement 157 and adjust the position; S38, setting the limiting swing rod 160 of the stirrup layer limiting device 159; S39, layered stirrups 163; S40, using a video acquisition device to detect the shape and position of the longitudinal reinforcement 157 and the stirrup 163; S41, intelligently identify the welding node position, generate welding coordinates, and then formulate a welding plan according to the construction plan; S42, lifting or climbing the welding robot slide 154; S43, the welding robot 155 automatically welds the node positions according to the welding plan.

[0114] The preferred solution is Fig.24 In the process of lifting steel bar parts, the lifting of steel bar parts includes the following steps: S51, obtaining an image of the poured steel bar end 171; S52, intelligently identifying the ends of cast steel bars 171; S53, obtaining the offset data of the poured steel bar end 171 by comparing with the design solution; S54, correcting the poured steel bar end 171 according to the offset data; S55, hoisting pier column steel bar parts 17; The preferred solution is Fig.25 In this step: S551, when hoisting the pier column steel bar component 17, first obtain the cross-sectional shape and position parameters of the pier column 12; S552, preliminarily calculating the travel parameters of the hoisting device 1; S553, hoist the pier column steel bar component 17 to align the steel bar ends preliminarily; S554. Select some longitudinal reinforcement ends and fix them first; The inner steel bar ends are connected by melting, and the outer steel bar ends are connected by threaded sleeves.

[0115] S56, preliminary alignment of steel bar ends; S57, first select some longitudinal reinforcements of the pier column reinforcement parts 17 and fix them to the cast reinforcement ends 171, and then fix the other longitudinal reinforcements.

[0116] In a preferred embodiment, the automatic vibration comprises the following steps: S61, obtaining the cross-sectional shape and position parameters of the pier 12, and obtaining the shape and position parameters of the pier steel bar component 17; S62, initialization of the intelligent vibrating device 2; S63, generating a vibration scheme according to the structural form and the working performance status of the concrete, the vibration scheme including vibration process parameters, and avoiding the position of the steel bars in the vibration scheme; S64, generating an x-direction trolley 202 control program, generating a y-direction trolley control program, and generating a winding device control program; S65. Implement intelligent vibration operation.

[0117] The preferred solution also includes the following steps: S66, monitoring of the obstacles of the vibrating rod, monitoring the value of the gravity sensor of the guide wheel position, or monitoring the value of the torque sensor in the winding device 204, and sending it to the main control center, the main control center analyzes the received value and determines whether the vibrating rod 208 is blocked by the steel bar; usually, during the lifting and vibrating process of the vibrating rod 208, the gravity value or torque value shows a linear change trend, and when the vibrating rod 208 is blocked by the steel bar, the gravity value or torque value shows a nonlinear change trend. In this way, it is determined whether the vibrating rod is blocked by an obstacle.

[0118] If so, implement treatment measures; the treatment includes moving a certain distance around to avoid the current steel bar interference.

[0119] S67. If the problem is solved, continue to implement the intelligent vibration operation. If it is not solved, an alarm is issued and manual processing is transferred, or the current position is marked to notify subsequent manual processing. The intelligent vibration operation skips the current position and continues the operation at the next position.

[0120] The preferred solution is Fig. 27 In the automatic maintenance, the following steps are included: S71, obtaining ambient temperature and humidity parameters; S72, generating a maintenance plan; S73, the steam curing device 22 starts the steam curing device to deliver water vapor with a pressure higher than normal pressure into the closed template space; S74, monitor the temperature and humidity in the template space, and adjust the working state of the steam curing device 22 according to the feedback of the temperature and humidity in the template space. With this structure, automated concrete curing is achieved, and the entire curing process adopts the most optimized curing parameters to further improve the quality of concrete.

[0121] In a preferred solution, the automatic maintenance further comprises the following steps: S75, after the steam curing device 22 works for a preset time, it switches to the negative pressure device 23, and the negative pressure device 23 evacuates the template space to promote the exhaust of the concrete surface, monitors the pressure in the template space, and controls the working time of the negative pressure device 23. After the negative pressure is maintained for a preset time, it switches to the steam curing device 22 to continue steam curing. According to this scheme, by evacuating and then switching to normal pressure, steam can enter the surface of the concrete, participate in the hydration process, and reduce the probability of surface cracks.

[0122] In a preferred solution, the template of the template device 3 is a breathable template, a breathable layer is provided on the surface of the template, and the steel plate of the template is provided with air holes. This structure facilitates the exhaust of the template and improves the apparent quality of the concrete.

[0123] In the preferred solution, in the template device 3, a transparent template is provided at a position where a part of the template has an outward camber, and an image acquisition device is provided outside the transparent template. The image acquisition device acquires the image of the concrete surface and sends it to the main control center, which identifies the surface defects of the concrete and adjusts the vibration scheme. With this structure, through an intelligent solution, the appearance defects such as honeycombs and pitting in the unfavorable positions of concrete exhaust are greatly reduced.

[0124] The above-mentioned embodiments are only preferred technical solutions of the present invention and should not be regarded as limitations of the present invention. The embodiments and features in the embodiments of the present application can be arbitrarily combined with each other without conflict. The protection scope of the present invention shall be the technical solutions recorded in the claims, including the equivalent replacement solutions of the technical features in the technical solutions recorded in the claims. That is, equivalent replacement improvements within this scope are also within the protection scope of the present invention.

Claims

1. An intelligent pier construction system, characterized by: The invention comprises a column system (6), wherein the column system (6) is provided with a plurality of vertical columns (63), a load-bearing platform (5) and a construction platform that can move up and down are provided on the columns (63), a formwork system (4) is provided above the load-bearing platform (5), the formwork system (4) is provided with a template device (3), an automatic concrete vibrating system is provided above the template system (4), and a lifting device (1) is also provided on the top of the column system (6); A main control center is also provided, and the main control center is used to monitor the working conditions of the columns (63), the formwork device (3) and the lifting device (1). The main control center is also used to control the climbing of the bearing platform (5) and the construction platform, and the lifting operation of the lifting device (1).

2. The intelligent construction system for pier columns according to claim 1 is characterized in that: The column system (6) is provided with at least four columns (63), and at least one construction platform is sleeved on the columns (63) and moves up and down along the columns (63); A column foundation (8) is provided at the bottom of the column system (6), and the column (63) is fixedly connected to the column foundation (8); Alternatively, a travel wheel set (28) is provided at the bottom of the column (63), and the travel wheel set (28) can be turned by 90° to facilitate walking.

3. The intelligent construction system for pier columns according to claim 2 is characterized in that: Each column (63) is formed by splicing a plurality of sleeves; The end of the column (63) is provided with a threaded section (62), and each sleeve of the column (63) is fixedly sleeved by the threaded section (62). The end of the column (63) is also provided with a pin shaft section (61), and the other end of the column (63) is provided with a pin shaft hole. The pin shaft section (61) and the pin shaft hole are used to control the verticality of the column (63).

4. The intelligent construction system for pier columns according to claim 2 is characterized in that: Each column (63) is formed by splicing a plurality of I-beams, the ends of the I-beams are welded together, and a stiffening plate is arranged at a position that does not interfere with the movement of the platform.

5. The intelligent construction system for pier columns according to claim 3 is characterized in that: The outer wall of the column (63) is also fixedly provided with a plurality of vertical racks (75), and a self-elevating motor (73) is provided on the construction platform. The self-elevating motor (73) is connected to a self-elevating gear (74), and the racks (75) are meshingly connected to the self-elevating gear (74); Alternatively, a plurality of nuts (72) are further provided on the construction platform, the rack (75) is a rack with helical teeth, the nut (72) is respectively threadedly connected to the rack with helical teeth on each column (63), a thrust bearing (71) is provided between the nut (72) and the construction platform, the outer wall of the nut (72) is provided with teeth, the teeth are meshedly connected with the self-elevating gear (74), the self-elevating motor (73) is electrically connected to the main control center, and the climbing action is controlled by the main control center.

6. The intelligent construction system for pier columns according to claim 4 is characterized in that: The outer wall of the column (63) is also fixedly provided with a plurality of vertical racks (75), and a self-elevating motor (73) is provided on the construction platform. The self-elevating motor (73) is connected to the self-elevating gear (74), and the racks (75) are meshingly connected to the self-elevating gear (74).

7. The intelligent construction system for pier columns according to claim 1 is characterized in that: The mold frame system (4) is located above the bearing platform (5), and a platform lifting cylinder (51) is provided at a position close to the column on the bearing platform (5). Both ends of the platform lifting cylinder (51) are provided with a stop device (52). The valve system of the platform lifting cylinder (51) is electrically connected to the main control center, and the climbing action is controlled by the main control center.

8. The intelligent construction system for pier columns according to claim 5 or 6, characterized in that: Inclination sensors are provided on the construction platform and the bearing platform (5), and the inclination sensors are electrically connected to the main control center and are used to monitor the horizontality of the construction platform and the bearing platform (5).

9. The intelligent construction system for pier columns according to claim 1 is characterized in that: The construction platform comprises a lower construction platform (7) and an upper construction platform (9), which are respectively located above and below the bearing platform (5).

10. The intelligent construction system for pier columns according to claim 1 is characterized in that: A plurality of adjustable struts (11) are provided on the inner side of the construction platform. The adjustable struts (11) are provided with threaded sleeves and bolts to adjust the length of the adjustable struts (11) and fix them. One end of the adjustable struts (11) is connected to the inner side of the construction platform, and the other end is in contact with the outer wall of the pier column (12).

11. The intelligent construction system for pier columns according to claim 2 is characterized in that: A laser collimator (26) is provided on the column base (8), and a reflective target (27) is provided on the top of the column (63) or on the truss track (102) of the hanging device (1); An image acquisition device is provided near the reflective target (27) for acquiring an image on the reflective target (27) and sending the image to a main control center. The main control center monitors the status of the column system (6) based on the image on the reflective target (27).

12. The intelligent construction system for pier columns according to claim 1 is characterized in that: A tuned mass damper is also provided on the column system (6), and the tuned mass damper is arranged on the truss track (102) of the hoisting device (1) or on a construction platform close to the top.

13. The intelligent construction system for pier columns according to claim 1 is characterized in that: The truss track (102) of the hoisting device (1) is fixedly connected to the top of the column system (6); the truss track (102) is a cantilever structure; one end of the truss track (102) extends beyond the horizontal projection plane of the column system (6); and a counterweight is provided at the other end of the truss track (102); A gantry crane (101) or an overhead crane (107) is arranged on the truss track (102); the gantry crane (101) or the overhead crane (107) moves along the truss track (102); and a lifting trolley is arranged on the gantry crane (101) or the overhead crane (107).

14. The intelligent construction system for pier columns according to claim 13 is characterized in that: The truss track (102) is connected to the column (63) via a truss track clamp (104); a truss track lifting cylinder (106) is provided below the truss track (102); truss track stop devices (105) are provided at both ends of the truss track lifting cylinder (106); a valve system of the truss track lifting cylinder (106) is electrically connected to a main control center, and the main control center controls the climbing action of the hoisting device (1).

15. The intelligent construction system for pier columns according to claim 14 is characterized in that: A travel sensor is provided on the traveling device of the gantry crane (101) or the overhead crane (107), a torque sensor is provided on the motor of the lifting trolley (103), and a torque controller is also provided on the lifting trolley (103). The travel sensor, the torque sensor and the torque controller are connected to a main control center. The main control center calculates the current maximum torque value based on the data of the travel sensor and sends it to the torque controller. The current maximum torque value is compared with the real-time torque value of the torque sensor. If the real-time torque value exceeds the maximum torque value, the torque controller stops the lifting action of the lifting trolley (103) and issues an alarm.

16. The intelligent construction system for pier columns according to claim 1 is characterized in that: One side of the construction platform and the bearing platform (5) is a detachable structure, so that the column system (6) can be transported from one construction site to another without at least disassembling the construction platform and the bearing platform (5).

17. The intelligent construction system for pier columns according to claim 1 is characterized in that: A pier column steel bar intelligent assembly system (15) is also provided near the pier column (12), comprising a plurality of steel bar assembly columns (153), a steel bar truss track (152) fixedly provided at the top of the steel bar assembly column (153), at least one steel bar gantry crane (151) arranged on the steel bar truss track (152), a stirrup layered limiting device (159) provided on the steel bar assembly column (153), a plurality of limiting swing rods (160) provided on the stirrup layered limiting device (159) from top to bottom, the height position of the limiting swing rod (160) corresponding to the installation position of the stirrup (163), one end of the limiting swing rod (160) being hinged to the stirrup layered limiting device (159), and the limiting swing rod (160) being limited when swinging to a horizontal position.

18. The intelligent construction system for pier columns according to claim 17 is characterized in that: A hanger limiter (158) is provided on the top of the stirrup layer limiter (159). The hanger limiter (158) adopts a retractable or swingable structure and is used to limit the height position of the longitudinal reinforcement hanger (156).

19. The intelligent construction system for pier columns according to claim 18 is characterized in that: A steel plate is also provided below the stirrup layered limiting device (159), on which a plurality of longitudinal reinforcement auxiliary positioning seats (162) are provided. The longitudinal reinforcement auxiliary positioning seats (162) are provided with permanent magnets. The longitudinal reinforcement auxiliary positioning seats (162) correspond to the installation positions of the longitudinal reinforcements (157) by moving their positions.

20. The intelligent construction system for pier columns according to claim 18 is characterized in that: A stirrup bottom limiting device (161) is also provided below the stirrup layer limiting device (159). The stirrup bottom limiting device (161) adopts a retractable structure and is used to limit the height position of the stirrup (163) at the bottom layer.

21. The intelligent construction system for pier columns according to any one of claims 17 to 20, characterized in that: A welding robot slide seat (154) is also provided on the steel bar assembly column (153) and slides up and down along the steel bar assembly column (153); a welding robot (155) is provided on the welding robot slide seat (154); the welding robot (155) is an articulated robot, and the welding robot (155) moves along the welding robot slide seat (154); The welding robot slide (154) climbs by itself or is lifted and lowered by a steel bar gantry crane (151).

22. The intelligent construction system for pier columns according to claim 1 is characterized in that: An upper construction platform (9) is provided on the top of the formwork system (4), and a longitudinal reinforcement auxiliary positioning device (16) is provided on the bottom of the upper construction platform (9). The longitudinal reinforcement auxiliary positioning device (16) is a camera or a laser scanner. The longitudinal reinforcement auxiliary positioning device (16) is connected to the main control center and is used to obtain the position of the end of the poured longitudinal reinforcement.

23. The intelligent construction system for pier columns according to claim 21, characterized in that: A sleeve tightening tool (19) is also provided, and the sleeve tightening tool (19) is used to tighten the threaded sleeve connected to the end of the longitudinal reinforcement; The sleeve tightening tool (19) is provided with an openable and closable movable handle (193), the movable handle (193) being hinged to the tightening handle (195), a plurality of guide wheels (191) being provided on the movable handle (193) and the tightening handle (195), a friction belt (192) passing around the plurality of guide wheels (191), one of the guide wheels being connected to a tightening motor (194), and the friction belt (192) passing through an opening between the movable handle (193) and the tightening handle (195) so as to drive the threaded sleeve to rotate by means of friction.

24. The intelligent construction system for pier columns according to claim 23, characterized in that: A fusion joint device (18) is also provided, and a fixed clamp (186) is provided at the end of the handle (181), and a position of the handle (181) near the end is also pivotally connected to a movable clamp (183); The shapes of the fixed clamp (186) and the movable clamp (183) are adapted to the shapes of the steel bar ends, and extend to both sides to cover the cast steel bar ends (171) and the uncast steel bar ends (172). The fixed clamp (186) and the movable clamp (183) are provided with electromagnetic coils (185); An extended end of the movable chuck (183) is hinged to one end of the chuck cylinder (182), and the other end of the chuck cylinder (182) is hinged to the handle (181).

25. The intelligent construction system for pier columns according to claim 1 is characterized in that: An intelligent vibrating device (2) is also provided on the top of the mold frame system (4); an x-direction trolley (202) is rollably mounted on the x-direction guide rail (201); the x-direction guide rail (201) is fixedly connected to the mold frame system (4); a cantilever rail (203) is provided at the bottom of the x-direction trolley (202); a y-direction trolley (207) is rollably mounted on the y-direction guide rail (206); a y-direction motor (205) is fixedly provided on the cantilever rail (203); the y-direction motor (205) is connected to the y-direction trolley (207) via a screw nut mechanism to drive the y-direction trolley (207) to move along the y-direction guide rail (206); a winding device (204) is also provided on the y-direction guide rail (206); a guide wheel is provided on the y-direction trolley (207); and a hose of a vibrating rod (208) bypasses the guide wheel and is connected to the winding device (204).

26. The intelligent construction system for pier columns according to claim 25, characterized in that: A gravity sensor is provided at the position of the guide wheel, or a torque sensor is provided at the winding device (204), and the gravity sensor or the torque sensor is used to monitor whether the vibrating rod (208) is blocked by the steel bar.

27. The intelligent pier construction system according to claim 1 is characterized by: In the template device (3), a template truss (31) is provided on the back of the template, and a sealing membrane cloth (25) is coated outside the template truss (31); A steaming device (22) and a negative pressure device (23) are also provided, and the steaming device (22) and the negative pressure device (23) are connected to the sealing membrane cloth (25) through a pipeline.

28. The intelligent construction system for pier columns according to claim 27, characterized in that: A top cover (21) is also provided, and the top cover (21) covers the top of the poured pier column and forms a sealing structure.

29. A construction method of a pier column intelligent construction system according to any one of claims 1 to 28, characterized in that The following steps are involved: S1. Obtain BIM design plan; S2, construction of the pier cap and the first section of the pier (121); S3, installing the column foundation (8), installing the column (63), and installing the lower construction platform (7); S4, steel bar parts assembly; S5. Quality inspection of steel bar components; S6. Hoisting of steel bar components of the second section of the pier column; S7. Install the construction platform and formwork system; S8, pouring the second section of the pier column (122); S9. Install the construction platform and lifting device; The above steps complete the first two stages of pouring of the pier and the installation of the column system.

30. The construction method of the pier column intelligent construction system according to claim 29, characterized in that The following steps are involved: S10, the hoisting device (1) hoists the column (63) and climbs to the top; S11, hoisting pier column steel bar parts (17); S12, the carrying platform (5) and the formwork system (4) climb automatically or are lifted and climbed by the lifting device (1); S13, the template device (3) sets up the template; S14, mold standing accuracy detection; S15, pouring concrete and vibrating automatically; S16, automatic concrete curing; S17, after demoulding, repeat steps S10 to S16; The construction of the pier is completed through the above steps.

31. The construction method of the pier column intelligent construction system according to claim 30, characterized in that: The main control center is provided with a production dispatching center and a quality control center. The production dispatching center is used to control the hoisting device (1), the bearing platform (5), the formwork system (4), the construction platform, the pier column steel bar intelligent assembly system (15), the intelligent vibrating device (2) and the concrete curing device according to the design plan and the sensor collection data; The quality control center is used to collect parameters of the column system (6), including: shape and position parameters of the pier column steel bar component (17); it is also used to collect template positioning parameters, intelligent vibration parameters and concrete curing parameters, the verticality and stress condition of the column (63), the posture and stress condition of the construction platform and the bearing platform (5), the position accuracy of the template device (3), the travel and lifting weight of the lifting device (1); The collected parameters are fed back to the main control center, which generates control data and then sends it to the production scheduling center.

32. The construction method of the pier column intelligent construction system according to claim 30, characterized in that The climbing of the construction platform includes the following steps: S21. Obtain the total climbing height of the construction platform from the main control center; S22. Calculate the distance of each staged climb; S23, converting the climbing distance into a climbing angle of the self-elevating motor (73); S24, controlling each self-elevating motor (73) to rotate synchronously; S25, construction platform inclination detection; S26, if the error exceeds the tolerance, controlling the self-elevating motor (73) to compensate for the inclination error; S27, loop steps S23 to S26 to complete the automatic climbing of the construction platform.

33. The construction method of the pier column intelligent construction system according to claim 29, characterized in that the steel bar The assembly of the parts includes the following steps: S31. Obtain the design plan of BIM steel bar components; S32, making longitudinal reinforcement hangers (156); S33, laying longitudinal reinforcement (157) on the tire frame; S34, the longitudinal reinforcement (157) is inserted into the longitudinal reinforcement hanger (156) and fixed; S35, arranging a stirrup bottom limiting device (161) at the bottom of the pier column steel bar intelligent assembly system (15) according to the position of the longitudinal reinforcement (157); S36, hoisting stirrups (163) into the pier column steel bar intelligent assembly system (15), extending the stirrup bottom limiter (161), and hoisting the stirrups (163) onto the stirrup bottom limiter (161); S37, hoist in the longitudinal reinforcement (157) and adjust the position; S38, setting a limit swing rod (160) of the stirrup layer limit device (159); S39, layered stirrups (163); S40, inspecting the shape and position of the longitudinal reinforcement (157) and the stirrups (163); S41, intelligently identify welding node positions and generate welding plans; S42, lifting or climbing the welding robot slide (154); S43, the welding robot (155) automatically welds according to the welding plan.

34. The construction method of the pier column intelligent construction system according to claim 30, characterized in that The lifting of steel bar parts includes the following steps: S51, obtaining an image of the poured steel bar end (171); S52, intelligent identification of cast steel bar ends (171); S53, comparing with the design solution to obtain the offset data of the poured steel bar end (171); S54, correcting the cast steel bar end according to the offset data (171); S55, hoisting pier column steel bar parts (17); S56, preliminary alignment of steel bar ends; S57. First, select some longitudinal reinforcements of the pier column reinforcement parts (17) and fix them to the cast reinforcement ends (171), and then fix the other longitudinal reinforcements to connect them.

35. The construction method of the pier column intelligent construction system according to claim 34, characterized in that in step S55: S551, when hoisting the pier column steel bar component (17), first obtain the cross-sectional shape and position parameters of the pier column (12); S552, preliminarily calculating the travel parameters of the hoisting device (1); S553, hoist the pier column steel bar component (17) to align the steel bar ends preliminarily; S554. Select some longitudinal reinforcement ends and fix them first; The inner steel bar ends are connected by melting, and the outer steel bar ends are connected by threaded sleeves.

36. The construction method of the pier column intelligent construction system according to claim 29, characterized in that Automatic vibration includes the following steps: S61, obtaining the cross-sectional shape and position parameters of the pier column (12), and obtaining the shape and position parameters of the pier column steel bar component (17); S62, initializing the intelligent vibrating device (2); S63, generating a vibration scheme according to the structural form and the working performance status of the concrete, the vibration scheme including vibration process parameters, and avoiding the position of the steel bars in the vibration scheme; S64, generating an x-direction trolley (202) control program, generating a y-direction trolley control program, and generating a winding device control program; S65. Implement intelligent vibration operation.

37. The construction method of the pier column intelligent construction system according to claim 36 is characterized by further The following steps are involved: S66, monitoring the obstruction of the vibrating rod, monitoring the value of the gravity sensor of the guide wheel position, or monitoring the value of the torque sensor in the winding device (204), and sending it to the main control center, the main control center analyzes the received value and determines whether the vibrating rod (208) is blocked by the steel bar; If so, implement disposal measures; S67. If the problem is solved, continue to implement the intelligent vibration operation. If it is not solved, an alarm is issued and manual processing is transferred, or the current position is marked to notify subsequent manual processing. The intelligent vibration operation skips the current position and continues the operation at the next position.

38. The construction method of the pier column intelligent construction system according to claim 30, characterized in that Automatic maintenance includes the following steps: S71, obtaining ambient temperature and humidity parameters; S72, generating a maintenance plan; S73, the steam curing device (22) starts the steam curing device to deliver water vapor with a pressure higher than normal pressure into the closed template space; S74, monitoring the temperature and humidity in the template space, and adjusting the working state of the steam curing device (22) according to the feedback of the temperature and humidity in the template space.

39. The construction method of the pier column intelligent construction system according to claim 38, characterized in that Automatic maintenance also includes the following steps: S75. After the curing device (22) has worked for a preset time, the device is switched to the negative pressure device (23). The negative pressure device (23) evacuates the template space to promote exhaust of the concrete surface, monitors the pressure in the template space, and controls the working time of the negative pressure device (23). After the negative pressure is maintained for a preset time, the device is switched to the curing device (22) to continue curing.

40. The construction method of the pier column intelligent construction system according to claim 29, characterized in that: The template of the template device (3) is a breathable template, a breathable layer is provided on the surface of the template, and a steel plate of the template is provided with breathable holes.

41. The construction method of the pier column intelligent construction system according to claim 29, characterized in that: In the template device (3), a transparent template is provided at a portion of the position with the template having an outward camber angle, and an image acquisition device is provided outside the transparent template. The image acquisition device acquires an image of the concrete surface and sends it to the main control center. The main control center identifies defects on the concrete surface and adjusts the vibration scheme.

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