Pier column capping beam construction device

Abstract

The invention discloses a pier stud and cover beam construction device which comprises a supporting system, a formwork system and a hoisting system, and through cooperation of the supporting system, the formwork system and the hoisting system, the pier stud and cover beam construction device can be converted into a digital intelligent construction device; according to the supporting system, stable lifting of the whole device on the square pier column can be achieved, two sets of supporting hoop mechanisms are locked on the square pier column in a hoop mode through friction force, and an opposite-pull screw does not need to be arranged in concrete; the pier column formwork and the cover beam formwork are converted for use by assembling the longitudinal formwork and the transverse formwork in the formwork system in different modes, on-site assembly and disassembly are facilitated through the modular combination design of formwork assemblies, the construction period is effectively shortened, and idling and waste of the formworks are reduced; by means of the hoisting system, hoisting and transferring of materials can be flexibly completed, dependence on a large-scale crane on the site is greatly reduced, the equipment cost can be reduced, the space occupation pressure of a construction site is relieved, and the site utilization efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of bridge engineering construction technology, and in particular to a pier-column cap beam construction device. Background Technology

[0002] In bridge construction, piers and cap beams are key load-bearing components of the bridge superstructure. The construction quality, safety, and efficiency of piers and cap beams directly determine the overall success of the bridge construction.

[0003] Traditional pier and cap beam construction techniques have long faced multiple technical bottlenecks, making it difficult to meet the requirements of intelligent construction. For example, traditional hydraulic climbing formwork mechanisms require manual installation of steel embedded parts before concrete pouring. These embedded parts bear the load and are securely connected to the pier, but manual operation is prone to problems such as positional displacement and insufficient anchorage, and their removal affects the appearance of the concrete. Traditional tie rod systems often use threaded solid steel rods as tie rods, requiring manual tightening of each rod individually, resulting in high labor intensity for workers. Furthermore, the pre-tightening force of the bolts relies entirely on worker experience, easily leading to uneven stress distribution. While traditional hydraulic systems can achieve overall climbing functionality, core operations such as pressure regulation and stroke control still rely on manual observation of the instrument panel and manual valve operation. The entire system lacks sensors and intelligent monitoring modules, making it impossible to collect key data in real time. Its early warning capabilities for structural deformation and equipment failure are poor, relying solely on periodic manual inspections, which is not only time-consuming and labor-intensive but also makes it difficult to detect potential risks. For example, traditional methods for constructing cap beams, such as the scaffolding method, clamping method, or through-steel bar support method, have significant limitations. The scaffolding method requires erecting a full-span scaffold around the pier, which not only consumes a large amount of materials and is time-consuming and labor-intensive to erect and dismantle, but also has strict requirements on the bearing capacity of the foundation. When constructing in special environments such as soft soil foundations, rivers, and lakes, complex foundation treatments such as replacement and grouting are required, which not only increases construction costs but may also cause deformation of the scaffolding due to foundation settlement, resulting in deviations in the cap beam alignment and even potential safety accidents. On the other hand, construction methods such as clamping and through-steel plate support rely on hoisting to transport and install materials such as scaffolding, formwork, and reinforcing bars, which have high costs and require a large amount of site space during operation. They are often difficult to implement in scenarios with narrow sites such as urban bridge reconstruction and mountain canyons, which seriously restricts the construction progress.

[0004] Chinese invention patent application CN118756584A discloses an integrated construction device and method for high pier columns and cap beams. The technical solution includes a support frame, a climbing frame, and a lifting frame. The support frame is detachably connected to the climbing frame and is located outside of it, with a movable template for pier column forming. The lifting frame is located on top of the support frame and has a lifting mechanism. The climbing frame is located outside the pier column and is used to drive the support frame and lifting frame upwards along the pier column. The climbing frame includes a lifting frame, a first fixing frame, and a second fixing frame arranged sequentially from top to bottom, with the lifting frame detachably connected to the support frame. Multiple clamping components for clamping the pier column are evenly distributed circumferentially on the lifting frame, the first fixing frame, and the second fixing frame. This patent's technical solution achieves the fixation of the climbing frame to the pier column by setting clamping components. Although it eliminates the need to pre-embed bolts inside the pier column during construction, it still requires tie rods to lock the fixing frames inside the concrete to achieve climbing. Therefore, it still suffers from the same drawbacks as traditional hydraulic climbing formwork mechanisms, failing to solve the problems of manual tightening, high labor intensity for workers, and uneven stress distribution. Furthermore, the templates used in this invention cannot simultaneously meet the casting requirements of both piers and cap beams. Two sets of template systems must be customized separately. Pier templates are often used after construction, while cap beam templates require long-term storage, which not only occupies space but also requires additional maintenance, easily leading to waste of material resources and reduced construction efficiency. Since workers need to be familiar with the operation of two sets of templates, there is a lot of repetitive work in the process connection, resulting in a significant waste of manpower and a high risk of delaying the construction period. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a pier and cap beam construction device that can achieve stable lifting of the overall formwork system, improve concrete pouring quality and construction efficiency, reduce construction costs and improve construction safety during the construction of piers and cap beams.

[0006] The technical solution adopted by the present invention to solve the above-mentioned technical problems is: a pier column cap beam construction device, including a support system, a formwork system and a hoisting system; The support system includes two sets of support clamp mechanisms spaced apart along the height of the square pier column. Multiple support hydraulic jacks are connected between the upper and lower sets of support clamp mechanisms. The support clamp mechanism consists of two sets of support clamp components and multiple support clamp columns supported between the two sets of support clamp components. The support clamp component includes a longitudinal friction plate, a transverse friction plate, a support clamp longitudinal beam, and a support clamp transverse beam. The two longitudinal friction plates and the two transverse friction plates are connected together and abut against the square pier column. The two support clamp longitudinal beams are fixedly connected to the two longitudinal friction plates respectively. The two support clamp transverse beams are fixedly connected to the two transverse friction plates respectively. The support clamp transverse beams and the support clamp longitudinal beams are connected by support tie rods to form a square frame structure. A support tie rod locking device is provided at one end of one end of the support tie rod. The template system includes template components, template clamp components, and platform components. Each template component consists of two longitudinal templates and two transverse templates that are detachably connected. At least two sets of template clamp components are spaced apart along the height of the template component. Each template clamp component includes template clamp longitudinal beams, template clamp transverse beams, template hydraulic jacks, and template tie rods. Adjacent sets of template clamp components are fixedly connected by multiple template clamp columns. The two template clamp longitudinal beams are detachably connected to the two longitudinal templates, and the two template clamp transverse beams are detachably connected to the two transverse templates. The template hydraulic jacks... The top connection is between the template clamp horizontal beam and the template clamp longitudinal beam. The template clamp longitudinal beam and the template clamp horizontal beam are connected by template tie rods to form a square frame structure. One end of the template tie rod is equipped with a template tie locking device. The platform component includes an operating platform, a template assembly and disassembly platform, supporting truss columns and diagonal braces. The operating platform and the template assembly and disassembly platform are fixed to the top and bottom of the template component, respectively. Multiple supporting truss columns support the operating platform and the template assembly and disassembly platform. The template assembly and disassembly platform is fixedly connected to the supporting clamp mechanism located above in the supporting system through multiple diagonal braces. The hoisting system includes connecting truss columns, slide rails, and a tower crane; multiple connecting truss columns are fixedly connected to the operating platform, slide rails are fixed to the top of the connecting truss columns, and the tower crane slides in conjunction with the slide rails.

[0007] As an improvement to the above solution: both the longitudinal beam and the transverse beam of the support clamp are fixed with pre-tension rods extending along the length direction; the thickness of the longitudinal beam and the transverse beam of the support clamp gradually increases from the middle to both ends and forms two connecting seats that cooperate with the pre-tension rods. The two ends of the pre-tension rods pass through the two connecting seats respectively and are locked and fixed by nuts that abut against the outside of the connecting seats.

[0008] As an improvement to the above solution: the middle part of the supporting hoop longitudinal beam and the supporting hoop cross beam is a hollow structure, and both ends of the supporting hoop longitudinal beam and the supporting hoop cross beam are provided with a reinforcing structure.

[0009] As an improvement to the above solution: multiple buckles are fixedly installed on the outer surfaces of the longitudinal friction plate, the transverse friction plate, the longitudinal template, and the transverse template. The supporting clamp longitudinal beam, the supporting clamp horizontal beam, the template clamp longitudinal beam, and the template clamp horizontal beam are connected to the longitudinal friction plate, the transverse friction plate, the longitudinal template, and the transverse template respectively through corresponding buckles.

[0010] As an improvement to the above solution: the horizontal template is an integral template structure, and the vertical template is a split template structure composed of multiple template units that can be detachably connected; the multiple template units that make up the vertical template and the template units and the horizontal template are detachably connected through bolt holes and bolts.

[0011] As an improvement to the above solution: the output end of the template hydraulic jack is fixedly connected to a limiting block, and the back of the template clamp longitudinal beam and the template clamp transverse beam are provided with limiting grooves extending along their length direction; the limiting block connected to the output end of the template hydraulic jack is embedded in the corresponding limiting groove to form a sliding fit.

[0012] As an improvement to the above solution: both the supporting clamp beam and the template clamp beam are double-layered structures, with the supporting clamp longitudinal beam passing through the gap between the upper and lower layers of the supporting clamp beam, and the template clamp longitudinal beam passing through the gap between the upper and lower layers of the template clamp beam.

[0013] As an improvement to the above solution: multiple sliding grooves are fixedly provided on the bottom surface of the operating platform and the top surface of the template assembly, and the sliding grooves extend outward along the radial direction of the template assembly; the longitudinal template and the transverse template form a sliding fit with the sliding grooves through multiple sliders fixed at the top and bottom.

[0014] As an improvement to the above scheme, it also includes stress sensors installed on the pre-tension rod, support tie rod, and template tie rod. The support hydraulic jack, template hydraulic jack, stress sensors, support tie rod locking device, and template tie rod locking device are all electrically connected to the integrated control center located on the ground.

[0015] As an improvement to the above solution: the hoisting system further includes a horizontal truss, a tower trolley, a tower beam, and a tower crane base; two horizontal trusses are fixed in parallel to the top of the connecting truss columns, the tower beam is straddling between the two horizontal trusses and slides with the rails via the tower trolley, and the tower crane is fixedly mounted on the tower beam via the tower crane base.

[0016] The beneficial effects of this invention are as follows: By coordinating the support system, formwork system, and hoisting system, this invention transforms the construction device for piers and cap beams into a digital and intelligent construction device, thereby effectively ensuring construction safety, improving construction quality, reducing construction costs, and protecting the construction environment. The support system enables stable lifting and lowering of the entire device on square piers, and the upper and lower sets of support clamps utilize friction to lock the device onto the square piers, eliminating the need for tie rods inside the concrete. The formwork system achieves the conversion between pier and cap beam formwork by assembling the longitudinal and transverse formwork in different ways. The modular design of the formwork components facilitates on-site assembly and disassembly, effectively shortening the construction cycle and reducing formwork idleness and waste. The hoisting system allows for flexible material hoisting and transportation, significantly reducing reliance on large on-site cranes, lowering equipment costs, alleviating space occupation pressure on the construction site, and improving site utilization efficiency. Attached Figure Description

[0017] Figure 1A structural schematic diagram of the pier cap beam construction device; Figure 2 This is a schematic diagram of the support system. Figure 3 A schematic diagram of the supporting clamp mechanism; Figure 4 A schematic diagram of the structure supporting the clamp assembly; Figure 5 This is a schematic diagram of the template system. Figure 6 This is a schematic diagram of the mating structure between the template assembly and the template clamp assembly; Figure 7 This is a structural diagram of the template component; Figure 8 This is a structural schematic diagram of the template clamp assembly; Figure 9 This is a structural diagram of the hoisting system.

[0018] The diagram is labeled as follows: 100-Square pier column, 200-Support system, 210-Support clamp mechanism, 211-Longitudinal friction plate, 212-Transverse friction plate, 213-Support clamp longitudinal beam, 214-Support clamp transverse beam, 215-Support tie rod, 216-Support tie rod locking device, 217-Pre-tension rod, 220-Support hydraulic jack, 230-Support clamp column, 300-Formwork system, 310-Formwork assembly, 311-Longitudinal formwork, 312-Transverse formwork, 313-Bolt hole, 320-Formwork clamp assembly, 321-Formwork clamp longitudinal beam, 322 - Template clamp beam, 323- Template hydraulic jack, 324- Template tie rod, 325- Template tie locking device, 326- Limit block, 327- Limit groove, 331- Operating platform, 332- Template assembly / disassembly platform, 333- Support truss column, 334- Diagonal brace, 335- Slide groove, 340- Template clamp column, 400- Lifting system, 410- Connecting truss column, 420- Slide rail, 430- Tower crane, 440- Horizontal truss, 450- Tower support trolley, 460- Tower support beam, 470- Tower crane base, 500- Buckle, 600- Stress sensor. Detailed Implementation

[0019] To facilitate understanding of the present invention, the invention will be further described below with reference to the accompanying drawings.

[0020] In the description of this invention, it should be noted that the terms "front", "rear", "left", "right", "up", "down", "inner", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0021] like Figure 1 As shown, the pier-cap beam construction device disclosed in this invention consists of a support system 200, a formwork system 300, and a hoisting system 400. The support system 200 is used to fix the entire pier-cap beam construction device on the square pier 100 and to support the load of the formwork system 300 and the hoisting system 400 above. The formwork system 300 is used to install and fix the formwork components for pouring the pier and cap beam on the square pier 100, and to realize the pouring construction of the pier and cap beam through the formwork components. The hoisting system 400 is used to hoist the materials and equipment required for construction.

[0022] Specifically, such as Figures 2 to 4 As shown, the support system 200 used in this invention consists of a support clamp mechanism 210 and a support hydraulic jack 220. The support clamp mechanism 210 is used to fix the entire support system 200 onto the square pier 100, and the support hydraulic jack 220 is used to drive the entire support system 200 to climb on the square pier 100. This invention achieves stable locking on the square pier 100 through the clamping action of the support clamp mechanism 210 and the support hydraulic jack 220, which drives the support clamp mechanism 210 to rise and fall along the height direction of the square pier 100. Through their coordinated action, stable locking on the square pier 100 is achieved, and the load borne during construction can be transferred to the square pier 100, achieving adaptive lifting during the climbing process. Through the clamping locking characteristics of the support clamp mechanism 210, this invention can adapt to different sizes and loads of the square pier 100, providing flexible support for different square pier 100s.

[0023] like Figure 2As shown, this invention provides two sets of support clamp mechanisms 210 on a square pier 100. These two sets of support clamp mechanisms 210 are spaced vertically along the height of the square pier 100, and multiple support hydraulic jacks 220 are connected between the two sets of support clamp mechanisms 210. The support hydraulic jacks 220 are continuous hydraulic rod type jacks. During installation, the cylinder of the support hydraulic jack 220 is connected and fixed to the lower support clamp mechanism 210, and the top of the piston rod of the support hydraulic jack 220 is connected and fixed to the upper support clamp mechanism 210, forming an integral frame system with the upper and lower sets of support clamp mechanisms 210 and the support hydraulic jacks 220. This invention achieves the climbing of the entire support system 200 on the square pier 100 through the alternating locking action of the two sets of support clamp mechanisms 210 in conjunction with the driving action of the support hydraulic jacks 220. When the support system 200 is being lifted, the following procedure is followed: Initially, both the upper and lower support clamp mechanisms 210 are locked, ensuring stable load-bearing of the overall structure. Then, the lower support clamp mechanism 210 is lifted, while the upper support clamp mechanism 210 remains locked to bear the full load, and the support hydraulic jack 220 retracts. After the lower support clamp mechanism 210 is lifted to the preset height, it is re-locked. Finally, the entire support system 200 is lifted. After the lower support clamp mechanism 210 is locked, the upper support clamp mechanism 210 is released, and the support hydraulic jack 220 performs the lifting operation, driving the upper support clamp mechanism 210 upwards. After reaching the desired height, the upper support clamp mechanism 210 is re-locked, completing one lifting cycle.

[0024] like Figure 2 and Figure 3 As shown, the support clamp mechanism 210 used in this invention consists of a support clamp assembly and a support clamp column 230. Each support clamp mechanism 210 includes two sets of support clamp assemblies and multiple support clamp columns 230. The support clamp assembly is used to clamp and lock onto the square pier column 100 to fix the support system 200. The support clamp column 230 is used to connect the two sets of support clamp assemblies and play a supporting and connecting role in fixing the support clamp assembly.

[0025] like Figure 3 and Figure 4As shown, the support clamp assembly includes longitudinal friction plates 211, transverse friction plates 212, a support clamp longitudinal beam 213, and a support clamp transverse beam 214. Two longitudinal friction plates 211 are symmetrically arranged along the longitudinal direction of the square pier 100, and two transverse friction plates 212 are symmetrically arranged along the transverse direction of the square pier 100. Both the longitudinal and transverse friction plates 211 and 212 are tightly fitted to the surface of the square pier 100, so that the two longitudinal friction plates 211 and two transverse friction plates 212 together form a square friction system adapted to the transverse cross-section of the square pier 100, providing friction for the entire support system 200. To ensure the strength and service life of the friction plates, both the longitudinal friction plates 211 and the transverse friction plates 212 are made of lightweight, high-strength, wear-resistant steel.

[0026] The supporting longitudinal beam 213 and the supporting transverse beam 214 are respectively connected and fixed to the longitudinal friction plate 211 and the transverse friction plate 212. The supporting longitudinal beam 213 and the supporting transverse beam 214 are connected by supporting tie rods 215 to form a square frame structure. One end of the supporting tie rod 215 is provided with a supporting tie locking device 216. Two supporting tie rods 215 are symmetrically arranged between the two supporting longitudinal beams 213 and the two supporting transverse beams 214. The diameter of the supporting tie rods 215 is determined according to the load calculation of the square pier column 100 to ensure that the maximum vertical bearing capacity requirement can be met. After the supporting clamp longitudinal beam 213 is fixedly connected to the longitudinal friction plate 211 and the supporting clamp transverse beam 214 is fixedly connected to the transverse friction plate 212, the two supporting clamp longitudinal beams 213 and the two supporting clamp transverse beams 214 are pulled and locked together by the supporting tie rods 215, thereby generating pressure on the longitudinal friction plate 211 and the transverse friction plate 212. Through the friction between the longitudinal friction plate 211 and the transverse friction plate 212 and the surface of the square pier column 100, the weight of the entire supporting system 200 and the formwork system 300 and the hoisting system 400 supported on the supporting system 200, as well as the formwork load and personnel load during the construction process, can be transferred to the square pier column 100, achieving the bearing effect of boltless anchoring and laying the foundation for subsequent lifting operations. The support tension locking device 216 in this invention adopts a mechanical self-locking structure. It is powered by a built-in hydraulic system to drive the support tension locking device 216 to rotate relative to the threaded support tension screw 215. The support tension screw 215 is tensioned, thereby applying prestress to the support clamp longitudinal beam 213 and the support clamp transverse beam 214. The support tension locking device 216 integrates a hydraulic drive module and a position sensor. It can drive the support clamp longitudinal beam 213 and the support clamp transverse beam 214 to be synchronously squeezed inward through synchronous hydraulic control, thereby pressing the longitudinal friction plate 211 and the transverse friction plate 212 to achieve uniform tightening of the square pier column 100.

[0027] Furthermore, such as Figure 3 and Figure 4 As shown, the present invention provides pre-tension rods 217 on both the longitudinal beam 213 and the transverse beam 214 of the supporting clamp. The pre-tension rods 217 extend along the length of the corresponding longitudinal beam 213 or transverse beam 214. The thickness of the longitudinal beam 213 and transverse beam 214 gradually increases from the middle to both ends, forming two connecting seats that mate with the pre-tension rods 217. The two ends of the pre-tension rods 217 pass through the two connecting seats and are locked in place by nuts abutting against the outside of the connecting seats. As the main load-bearing components of the supporting clamp assembly, the longitudinal beam 213 and transverse beam 214 are structurally defined to create variable cross-sections, with a smaller cross-section in the middle and larger cross-sections at both ends. During construction, when an external force is applied to the support tie rod 215 to tighten the support clamp assembly, the middle area of ​​the support clamp longitudinal beam 213 and the support clamp transverse beam 214 will undergo displacement deformation away from the surface of the square pier column 100, thereby weakening the friction of the support clamp assembly and reducing the vertical bearing capacity of the support clamp assembly. To eliminate the aforementioned adverse effects, this invention applies prestress to the supporting longitudinal beam 213 and supporting transverse beam 214 by setting pre-tension rods 217. The two ends of the pre-tension rods 217 are connected to two connecting seats, and a preset tension is applied to the pre-tension rods 217 via a hydraulic tensioning device. As the tension gradually increases, the pre-tension rods 217 pull the middle section of the beam to generate a pre-camber. The magnitude of the pre-camber is calculated and determined. When the entire support system 200 is installed and begins to bear load, the beam will undergo downward bending deformation under load. At this time, the pre-camber formed by the pre-tension rods 217 can precisely offset the bending deformation, keeping the supporting longitudinal beam 213 and supporting transverse beam 214 in a straight state. Therefore, by setting pre-tension rods 217, this invention ensures that the longitudinal friction plate 211 and transverse friction plate 212 maintain uniform contact with the surface of the square pier column 100, thereby ensuring that the entire support system 200 can stably withstand the expected vertical load.

[0028] Furthermore, such as Figure 4As shown, the present invention features a hollow structure in the middle region of the supporting clamp longitudinal beam 213 and the supporting clamp crossbeam 214, and reinforced structures at both ends of the supporting clamp longitudinal beam 213 and the supporting clamp crossbeam 214. The reinforced structures can be achieved by increasing the steel thickness and optimizing the cross-sectional shape, thereby increasing the bending stiffness of the end portions compared to the middle region. Furthermore, to facilitate the fit between the supporting clamp longitudinal beam 213 and the supporting clamp crossbeam 214, the present invention uses a double-layer structure for the supporting clamp crossbeam 214, allowing the supporting clamp longitudinal beam 213 to pass through the gap between the upper and lower layers of the supporting clamp crossbeam 214 during assembly. Multiple clips 500 are fixedly installed on both the longitudinal friction plate 211 and the transverse friction plate 212, and the supporting clamp longitudinal beam 213 and the supporting clamp crossbeam 214 are connected to the longitudinal friction plate 211 and the transverse friction plate 212 respectively via corresponding clips 500. The buckle 500 adopts a slot-type buckle. A row of buckles 500 is fixedly installed on the upper and lower parts of the outer side of the longitudinal friction plate 211 and the transverse friction plate 212, so that the upper and lower ends of the two friction plates are fixed with a layer of supporting hoop longitudinal beam 213 and supporting hoop transverse beam 214 through the buckles 500, forming a double-layer connection structure composed of friction plates and beams.

[0029] like Figure 2 and Figure 3 As shown, the present invention has four supporting hydraulic jacks 220 set between the two sets of supporting clamp mechanisms 210 and four supporting clamp columns 230 set between the two sets of supporting clamp assemblies, which are respectively fixed at the four corners of the supporting clamp mechanism 210 and the four corners of the supporting clamp assembly; the supporting hydraulic jacks 220 and the supporting clamp columns 230 correspond one-to-one and are aligned in the height direction of the square pier column 100.

[0030] like Figure 4As shown, this invention incorporates stress sensors 600 on both the pre-tension rod 217 and the support tie rod 215. These stress sensors 600 collect stress and strain data in real time. An integrated control center is installed on the ground. The support hydraulic jack 220, stress sensors 600, and support tie rod locking device 216 are all electrically connected to the integrated control center via a wireless transmission module, enabling real-time data transmission. Through this approach, the invention ensures the safety performance of the support system 200 in complex construction environments and achieves monitoring and adaptive adjustment functions. After receiving the data transmitted by the stress sensors 600, the integrated control center compares it with preset safety thresholds using a built-in algorithm, thereby achieving precise control of the tension in the pre-tension rod 217 and the support tie rod 215. When the data monitored by the stress sensor 600 exceeds the upper limit threshold, the integrated control center transmits a pressurization command to the corresponding support tension locking device 216. The hydraulic system of the support tension locking device 216 is activated, and the mechanical lock assembly is unlocked through the hydraulic unloading mechanism, causing the tension of the support tension screw 215 to decrease slowly until the stress returns to the safe range. Then, the hydraulic system of the support tension locking device 216 stops working, and the support tension locking device 216 re-locks, maintaining the current tension state. When the data monitored by the stress sensor 600 is below the lower limit threshold, the integrated control center transmits a pressure replenishment command to the corresponding support tension locking device 216. The hydraulic system of the support tension locking device 216 is activated, and the support tension screw 215 is slightly tensioned through the hydraulic drive assembly to replenish the tension to the design range. Then, the hydraulic system of the support tension locking device 216 stops working, and the support tension locking device 216 enters an automatic locking pressureless working state.

[0031] Specifically, such as Figures 5 to 7 As shown, the template system 300 used in this invention includes a template component 310 and a template clamp component 320; the template component 310 serves as the template for casting and shaping piers and cap beams, and the template clamp component 320 is used to reinforce the template component 310 and to remove the template component 310 after the casting of piers and cap beams is completed.

[0032] like Figure 6 and Figure 7 As shown, the template assembly 310 used in this invention consists of a longitudinal template 311 and a transverse template 312. Two longitudinal templates 311 and two transverse templates 312 are connected to form a template assembly 310 adapted to the square pier 100. The template assembly 310 surrounds the outside of the square pier 100, forming a complete wrapping structure of the square pier 100 from four directions. This allows for the preliminary determination of the overall position of the template and ensures that the coverage area matches the size of the square pier 100. To achieve rapid assembly of the template assembly 310, this invention... Figure 7 As shown, the transverse template 312 adopts an integrated template structure, while the longitudinal template 311 adopts a split template structure, with the longitudinal template 311 composed of multiple template units. Pre-reserved bolt holes 313 are fixedly provided on the sides of both the template units and the transverse template 312, forming a universal connection interface. Multiple template units can be connected and assembled into the longitudinal template 311 by the cooperation of bolts with the bolt holes 313, thus enabling the rapid connection of the longitudinal template 311 and the transverse template 312 to form the template assembly 310. This invention, by setting the longitudinal template 311 as a split, combined template structure, lays the foundation for the flexible combination and disassembly of the template assembly 310 at different construction stages. During the pier construction stage, construction personnel only need to fasten the template units together with bolts to quickly assemble the complete longitudinal template 311, meeting the dimensional and sealing requirements of the template during pier casting construction. After the overall construction of the pier columns is completed, when entering the cap beam construction stage, there is no need to replace the formwork with new ones. Simply remove the connecting bolts to disassemble the longitudinal formwork 311 into independent formwork units. Then, the disassembled formwork units are connected and secured to the transverse formwork 312 according to the new arrangement, quickly forming the cap beam side formwork system. This invention, through the modular design of the formwork component 310, effectively reduces the transfer and replacement of formwork during construction, avoiding time and manpower waste caused by formwork replacement, and significantly improving construction efficiency. Furthermore, the formwork units that make up the longitudinal formwork 311 can achieve "one formwork, two uses," forming two different formwork structures through different arrangements, reducing construction costs and eliminating the need to purchase separate formwork for different construction stages, bringing good economic benefits to bridge construction projects. In addition, the formwork component 310 of this invention is easy to assemble and firmly connected, effectively ensuring that there is no leakage of concrete during pouring, ensuring the quality of the cast-in-place pier columns and cap beams.

[0033] like Figure 6 and Figure 8As shown, the template clamp assembly 320 used in this invention includes a template clamp longitudinal beam 321, a template clamp transverse beam 322, a template hydraulic jack 323, and a template tie rod 324. At least two sets of template clamp assemblies 320 are spaced apart along the height direction of the template assembly 310. The template clamp assemblies 320 form a frame structure around the template assembly 310. During the construction of the square pier column 100, the template clamp assemblies 320 can reinforce the template assembly 310. After the pouring is completed, the template clamp assemblies 320 can be used to quickly dismantle the template assembly 310. Template clamp columns 340 are set between adjacent template clamp assemblies 320. The template clamp columns 340 are vertically set, and their upper and lower ends are connected and fixed to the two sets of template clamp assemblies 320 respectively by bolts, thereby connecting the entire template assembly 310 and the template clamp assemblies 320 together, effectively improving the overall structural rigidity of the template system 300. The template clamp longitudinal beam 321 and template clamp transverse beam 322 are sequentially connected to form a square frame structure surrounding the template assembly 310. The template clamp longitudinal beam 321 is connected to the longitudinal template 311, and the template clamp transverse beam 322 is connected to the transverse template 320. The template clamp longitudinal beam 321 and template clamp transverse beam 322 are fixed by the buckles 500 fixed on the template assembly. Multiple buckles 500 are arranged at intervals along the circumference of the template assembly 310. The template clamp longitudinal beam 321 and template clamp transverse beam 322 are connected to the template assembly 310 by the corresponding buckles 500. The buckles 500 adopt two bent buckle structures that are fixed on the template assembly 310. The template clamp longitudinal beam 321 and template clamp transverse beam 322 are inserted laterally to form a buckle engagement with the buckles 500. The buckles 500 engage and fix the corresponding template clamp longitudinal beam 321 or template clamp transverse beam 322. The template tie rods 324 used in this invention are used to fasten the template clamp assembly 320. The template tie rods 324 do not need to penetrate the template assembly 310 and be inserted into the concrete; that is, there is no connection between the template tie rods 324 and the template assembly 310. Through holes adapted to the template tie rods 324 are pre-set at both ends of the template clamp longitudinal beam 321 and the template clamp transverse beam 322. Each template clamp assembly 320 is equipped with four template tie rods 324, meaning that two template clamp longitudinal beams 321 are connected by two template tie rods 324, and two template clamp transverse beams 322 are connected by two template tie rods 324.A template tension locking device 325 is configured at one end of the template tensioning screw 324. The template tension locking device 325 adopts a mechanical self-locking structure. It is powered by a built-in hydraulic system to drive the template tension locking device 325 to rotate relative to the threaded template tensioning screw 324. The template tensioning screw 324 is tensioned, thereby applying prestress to the template clamping longitudinal beam 321 and the template clamping cross beam 322. The template tension locking device 325 monitors the elongation of the template tensioning screw 324 in real time through a built-in displacement sensor. When the preset value is reached, it automatically stops rotating to avoid deformation of the template assembly 310 and the template clamping assembly 320 due to over-tensioning of the template tensioning screw 324.

[0034] like Figure 6 and Figure 8 As shown, based on the template clamp assembly 320 which uses template clamp longitudinal beam 321 and template clamp cross beam 322, the present invention provides a template hydraulic jack 323 between the template clamp longitudinal beam 321 and template clamp cross beam 322. The template hydraulic jack 323 is used to provide demolding power when disassembling the template assembly 310. A hydraulic jack 323 is installed at each end of each template clamp longitudinal beam 321 and each template clamp cross beam 322, meaning two hydraulic jacks 323 are installed on each template clamp longitudinal beam 321 and each clamp cross beam 32. The cylinder of the hydraulic jack 323 is fixed to the corresponding template clamp longitudinal beam 321 or template clamp cross beam 322. The output end of the hydraulic jack 323, i.e., the piston rod, abuts against the adjacent template clamp cross beam 322 or template clamp longitudinal beam 321, thereby transmitting the power of the hydraulic jack 323 to the adjacent template clamp cross beam 322 or template clamp longitudinal beam 321. The hydraulic jack 323 can push the template clamp cross beam 322 or template clamp longitudinal beam 321 that cooperates with its piston rod outward. Meanwhile, to ensure the smooth movement of the template clamp longitudinal beam 321 and template clamp transverse beam 322 under the thrust of the template hydraulic jack 323, this invention also uses a limiting block 326 and a limiting groove 327 to guide and limit the movement of the template clamp transverse beam 322 and template clamp longitudinal beam 321 under the drive of the template hydraulic jack 323. Figure 8As shown, a limiting block 326 is fixedly connected to the output end of the template hydraulic jack 323. Limiting grooves 327 extending along their length are provided on the back of both the template clamp longitudinal beam 321 and the template clamp cross beam 322. The limiting block 326 connected to the piston rod of the template hydraulic jack 323 is embedded in the corresponding limiting groove 327 to form a sliding fit. The sliding of the limiting block 326 along the limiting groove 327 ensures that the moving path of the template clamp cross beam 322 and the template clamp longitudinal beam 321 remains horizontal. The present invention, through the limiting groove 327 limiting the limiting block 326, can ensure that the piston rod of the hydraulic jack 323 of the template extends and retracts in a fixed direction, avoiding deviation that would affect the power transmission efficiency. At the same time, it can also constrain the stroke of the piston rod to prevent excessive extension and retraction that could lead to damage. Through the lifting action of the hydraulic jack 323 of the template, when dismantling the template assembly 310, it can ensure that the two template clamp longitudinal beams 321 or the two template clamp cross beams 322 move outward synchronously along the radial direction of the template assembly 310, avoiding damage to the template assembly 310 or the cast-in-place pier due to uneven force.

[0035] like Figures 5 to 7As shown, the platform components used in this invention include an operating platform 331, a template assembly / disassembly platform 332, supporting truss columns 333, and diagonal braces 334. The operating platform 331 and the template assembly / disassembly platform 332 are respectively fixed to the top and bottom of the template assembly 310. Multiple supporting truss columns 333 support the operating platform 331 and the template assembly / disassembly platform 332. The template assembly / disassembly platform 332 is fixedly connected to the upper supporting clamp mechanism 210 in the supporting system 200 through multiple diagonal braces 334. This invention connects and fixes the operating platform 331 and the template assembly / disassembly platform 332 through the supporting truss columns 333, and provides support for the operating platform 331. This invention also fixes the entire template system 300 to the supporting system 200 through the diagonal braces 334. The lifting and lowering movement of the supporting system 200 will drive the entire template system 300 to lift and lower synchronously. The operating platform 331 is equipped with a pouring port that communicates with the interior of the formwork assembly 310. Concrete grout can be poured into the interior space of the formwork assembly 310 through the pouring port to form the pier and cap beam. A square hole adapted to the square pier 100 is provided at the center of the formwork assembly / disassembly platform 332. The top of the previously constructed square pier 100 extends into the square hole of the formwork assembly / disassembly platform 332, fixing the formwork assembly / disassembly platform 332 to the periphery of the square pier 100. Multiple sliding grooves 335 are fixedly installed on the bottom surface of the operating platform 331 and the top surface of the formwork assembly / disassembly platform 332. The sliding grooves 335 extend radially outward along the formwork assembly 310. The longitudinal formwork 311 and the transverse formwork 312 form a sliding engagement with the sliding grooves 335 through sliders fixed at the top and bottom. The sliding contact between the slider and the slide groove 335 guides and limits the translation of the longitudinal template 311 and the transverse template 312 during demolding, thereby further ensuring the stability of the translation of the longitudinal template 311 and the transverse template 312 during demolding.

[0036] like Figure 8As shown, the present invention also installs a stress sensor 600 on the template tie rod 324 to monitor the stress state of the template tie rod 324 in real time. Similarly, stress sensors 600 can also be installed on the template assembly 310, the template clamp longitudinal beam 321, and the template clamp cross beam 322 to monitor the stress state of each component in real time. Simultaneously, the present invention electrically connects the stress sensor 600, the template tie rod locking device 325, and the template hydraulic jack 323 to the integrated control center for transmitting monitoring signal commands. The stress sensor 600 on the template tie rod 324 transmits the monitored real-time stress data to the integrated control center. After receiving the stress data, the integrated control center performs real-time comparison with a preset safety threshold using a set algorithm, thereby precisely controlling the tension of the template tie rod 324. This invention remotely controls the operation of the template hydraulic jack 323 through an integrated control center. When dismantling the template assembly 310, the integrated control center first controls the template tension locking device 325 to rotate in the opposite direction so that the template tension screw 324 is completely unloaded, releasing the active constraint on the template assembly 310. Then, the integrated control center sends a start command to the template hydraulic jack 323. The template hydraulic jack 323, fixed on the template clamp beam 322, starts according to a preset program. The piston rod of the template hydraulic jack 323 extends and pushes the corresponding template clamp longitudinal beam 321 to move outward. Under the action of the latch 500, the longitudinal beam 310 drives the connected longitudinal template 311 to move outward synchronously, completing the dismantling of the longitudinal template 311. Similarly, under the push of the template hydraulic jack 323 fixed on the template clamp longitudinal beam 321, the translation of the template clamp beam 322 drives the corresponding transverse template 312 to move outward, completing the dismantling of the transverse template 312. Throughout the entire demolding process, parameters such as the moving speed and position of the formwork can be displayed in real time on the screen of the integrated control center, facilitating real-time monitoring by operators. This invention enables intelligent demolding operations through an integrated control center, allowing for dynamic monitoring and precise control of the stress state of the formwork component 310. Compared to traditional manual demolding methods, this invention can increase the efficiency of demolding operations by over 90%, effectively preventing hard collisions between the formwork component 310 and the poured concrete surface, reducing damage to the formwork, significantly extending the service life of the formwork component 310, and ensuring construction safety.

[0037] When the operation of the template tensioning and locking device 325 is controlled by the integrated control center, the present invention can lock the template clamping longitudinal beam 321 and template clamping cross beam 322 in the template clamping assembly 320 after the template assembly 310 is installed. In normal operation, the template tensioning and locking device 325 is in an automatic locking state. At this time, the hydraulic system inside the template tensioning and locking device 325 is not activated, and no continuous hydraulic power is required. The tension on the template tensioning screw 324 is maintained solely by the self-locking characteristics of the mechanical structure, thus ensuring structural stability while saving energy. When the stress data monitored by the stress sensor 600 exceeds the set upper limit threshold, the integrated control center issues a pressure reduction command to the corresponding template tensioning device 325. At this time, the hydraulic system of the template tensioning device 325 is activated, and the mechanical locking component is unlocked through the hydraulic unloading mechanism, causing the tension of the template tension screw 324 to decrease slowly until the stress data returns to the safe range. Then, the hydraulic system of the template tensioning device 325 immediately stops working, and the template tensioning device 325 re-locks, maintaining the current tension state. When the stress sensor 600 detects that the stress data is lower than the set lower limit threshold, the integrated control center issues a pressure replenishment command to the template tensioning device 325. The hydraulic system of the template tensioning device 325 is activated, and the screw is slightly tensioned through the hydraulic drive component to replenish the tension to the preset range. Subsequently, the hydraulic system is shut down, and the template tensioning device 325 enters the automatic locking pressureless working state again. This invention, through the design of the template tensioning device 325, which is normally self-locking and pressure-free, and dynamically adjustable for pressure adjustment, minimizes the working time of the hydraulic system of the template tensioning device 325, reduces energy consumption and equipment wear, and can significantly improve the structural safety, reliability and economy of the entire template clamp assembly 320.

[0038] The integrated control center in this invention is deployed in a ground-based operating room. Through remote control commands, it enables intelligent operation of the entire pier and cap beam construction device, thereby reducing the amount of work required at heights, lowering the risks associated with such work, and significantly improving construction efficiency and quality. The integrated control center possesses functions including data collection, data processing, command execution, real-time calibration, coordinated control, full-process monitoring, and intelligent safety early warning. The data collection function receives real-time status information from various sensors and actuators. The data processing function analyzes, stores, and visualizes the collected data. The command execution function translates coordinated control commands into actual equipment actions and tracks their status. The real-time calibration function verifies and adjusts data accuracy, equipment performance, and control logic to ensure reliable system operation. The coordinated control function uniformly schedules the action sequence of various devices. The comprehensive monitoring function displays the structural status in real-time through a 3D simulation interface. The intelligent safety early warning function alerts operators through audible and visual alarms when abnormalities such as excessive stress or equipment malfunctions occur.

[0039] Specifically, such as Figure 1 and Figure 9 As shown, the hoisting system 400 used in this invention consists of a connecting truss column 410, a slide rail 420, a tower crane 430, a cross truss 440, a tower support trolley 450, a tower support beam 460, and a tower crane base 470.

[0040] Multiple sets of connecting truss columns 410 are fixedly installed on the operating platform 331. The number of connecting truss columns 410 is preferably four sets, so that the four sets of connecting truss columns 410 can be fixedly connected to the four corners of the operating platform 331 to provide stable support. The four sets of connecting truss columns 410 are aligned with the four sets of supporting truss columns 333 below to ensure that the load can be directly and stably transferred through the connecting truss columns 410 and the supporting truss columns 333, thus ensuring the rationality and safety of the structural stress.

[0041] The tops of the connecting truss columns 410 are laterally connected by two sets of transverse trusses 440 to integrate the two connecting truss columns 410 into a whole, enhancing the overall stability of the structure. Two parallel slide rails 420 are installed at the top of each set of transverse trusses 440. The tower crane trolley 450 slides with the slide rails 420, and limit devices are installed at both ends of the slide rails 420 to limit the operating range of the tower crane trolley 450 and ensure the safe operation of the equipment. The operation of the tower crane trolley 450 is controlled by the integrated control center. The two tower crane trolleys 450 are connected into a whole by a tower crane beam 460 to ensure that the two tower crane trolleys 450 can operate synchronously, ensuring operational coordination and accuracy. A tower crane base 470 is installed and fixed on the tower crane beam 460. After the tower crane base 470 is securely installed, the tower crane 430 is installed and fixed on the tower crane base 470.

Claims

1. A pier-column cap beam construction device, characterized in that: It includes a support system (200), a formwork system (300), and a hoisting system (400). The support system (200) includes two sets of support clamp mechanisms (210) spaced apart along the height direction of the square pier column (100), with multiple support hydraulic jacks (220) connected between the upper and lower sets of support clamp mechanisms (210); the support clamp mechanism (210) consists of two sets of support clamp assemblies and multiple support clamp columns (230) supported between the two sets of support clamp assemblies. The support clamp assembly includes a longitudinal friction plate (211), a transverse friction plate (212), a support clamp longitudinal beam (213), and a support clamp transverse beam (214). The longitudinal friction plate (211) and two transverse friction plates (212) are connected together and abut against the square pier (100). Two supporting clamp longitudinal beams (213) are fixedly connected to the two longitudinal friction plates (211) respectively. Two supporting clamp transverse beams (214) are fixedly connected to the two transverse friction plates (212) respectively. The supporting clamp transverse beams (214) and the supporting clamp longitudinal beams (213) are connected by supporting tie rods (215) to form a square frame structure. One end of the supporting tie rods (215) is provided with a supporting tie locking device (216). The template system (300) includes a template assembly (310), a template clamp assembly (320), and a platform assembly. The template assembly (310) is composed of two longitudinal templates (311) and two transverse templates (312) that are detachably connected. At least two sets of template clamp assemblies (320) are spaced apart along the height direction of the template assembly (310). The template clamp assembly (320) includes a template clamp longitudinal beam (321), a template clamp transverse beam (322), a template hydraulic jack (323), and a template tie rod (324). Adjacent sets of template clamp assemblies (320) are fixedly connected to each other through multiple template clamp columns (340). The two template clamp longitudinal beams (321) are detachably connected to the two longitudinal templates (311), and the two template clamp transverse beams (322) are detachably connected to the two transverse templates (312). The template hydraulic jack (323) is connected to the template clamp. The template clamp beam (322) is connected to the template clamp beam (321). The template clamp beam (321) and the template clamp beam (322) are connected by template tie rods (324) to form a square frame structure. One end of the template tie rod (324) is provided with a template tie locking device (325). The platform component includes an operating platform (331), a template assembly and disassembly platform (332), a support truss column (333) and a diagonal brace (334). The operating platform (331) and the template assembly and disassembly platform (332) are fixed to the top and bottom of the template component (310) respectively. Multiple support truss columns (333) are supported between the operating platform (331) and the template assembly and disassembly platform (332). The template assembly and disassembly platform (332) is fixedly connected to the support clamp mechanism (210) located above in the support system (200) through multiple diagonal braces (334). The hoisting system (400) includes connecting truss columns (410), slide rails (420) and tower cranes (430); multiple connecting truss columns (410) are fixedly connected to the operating platform (331), slide rails (420) are fixed to the top of the connecting truss columns (410), and tower cranes (430) slide in cooperation with slide rails (420).

2. The pier-column cap beam construction device as described in claim 1, characterized in that: Both the longitudinal beam (213) and the transverse beam (214) of the support clamp are fixed with pre-tension rods (217) extending along the length direction; the thickness of the longitudinal beam (213) and the transverse beam (214) of the support clamp gradually increases from the middle to both ends and forms two connecting seats that cooperate with the pre-tension rods (217). The two ends of the pre-tension rods (217) pass through the two connecting seats respectively and are locked and fixed by nuts that abut against the outside of the connecting seats.

3. The pier-column cap beam construction device as described in claim 2, characterized in that: The middle part of the supporting hoop longitudinal beam (213) and the supporting hoop horizontal beam (214) is a hollow structure, and both ends of the supporting hoop longitudinal beam (213) and the supporting hoop horizontal beam (214) are provided with reinforcing structures.

4. The pier-column cap beam construction device as described in claim 1, characterized in that: Multiple buckles (500) are fixedly provided on the outer surfaces of the longitudinal friction plate (211), the transverse friction plate (212), the longitudinal template (311), and the transverse template (312). The supporting clamp longitudinal beam (213), the supporting clamp horizontal beam (214), the template clamp longitudinal beam (321), and the template clamp horizontal beam (322) are connected to the longitudinal friction plate (211), the transverse friction plate (212), the longitudinal template (311), and the transverse template (312) respectively through the corresponding buckles (500).

5. The pier-column cap beam construction device as described in claim 1, characterized in that: The horizontal template (312) is an integral template structure, and the vertical template (311) is a split template structure composed of multiple template units that can be detachably connected. The multiple template units that make up the longitudinal template (311) are detachably connected to each other and to the transverse template (312) through bolt holes (313) and bolts.

6. The pier-column cap beam construction device as described in claim 1, characterized in that: The output end of the template hydraulic jack (323) is fixedly connected to a limiting block (326), and the back of the template clamp longitudinal beam (321) and the template clamp cross beam (322) are provided with limiting grooves (327) extending along their length direction; the limiting block (326) connected to the output end of the template hydraulic jack (323) is embedded in the corresponding limiting groove (327) to form a sliding fit.

7. The pier-column cap beam construction device as described in claim 1, characterized in that: Both the support clamp beam (214) and the template clamp beam (322) are double-layer structures. The support clamp longitudinal beam (213) passes through the gap between the upper and lower layers of the support clamp beam (214), and the template clamp longitudinal beam (321) passes through the gap between the upper and lower layers of the template clamp beam (322).

8. The pier-column cap beam construction device as described in claim 1, characterized in that: The bottom surface of the operating platform (331) and the top surface of the template assembly / disassembly platform (332) are both fixedly provided with multiple sliding grooves (335). The sliding grooves (335) extend outward along the radial direction of the template assembly (200). The longitudinal template (311) and the transverse template (312) form a sliding fit with the sliding grooves (335) through multiple sliders fixed at the top and bottom.

9. The pier-column cap beam construction device as described in claim 1, characterized in that: It also includes stress sensors (600) installed on the pre-tension rod (217), support tie rod (215) and template tie rod (324). The support hydraulic jack (220), template hydraulic jack (323), stress sensors (600), support tie rod locking device (216) and template tie rod locking device (325) are all electrically connected to the integrated control center installed on the ground.

10. The pier-column cap beam construction device as described in claim 1, characterized in that: The hoisting system (400) also includes a cross truss (440), a tower trolley (450), a tower beam (460), and a tower crane base (470); the two cross trusses (440) are fixed in parallel to the top of the connecting truss column (410), the tower beam (460) is arranged across the two cross trusses (440) and slides with the slide rail (420) through the tower trolley (450), and the tower crane (430) is fixed on the tower beam (460) through the tower crane base (470).

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