Multifunctional prestressed prefabricated part production line and using method thereof

Abstract

According to the multifunctional prestressed prefabricated part production line and the using method thereof, end plates with the adjustable height are arranged on a tensioning machine and an anchoring plate, and the tensioning height of prestress can be adjusted so as to adapt to production of various prestressed parts such as prestressed laminated slabs and prestressed box girders; the application range of the prefabricated part production line is enlarged, and the application range is wider; and the integrated tensioning machine is capable of uniformly tensioning a plurality of prestressed tendons at the same time, so that the tensioning speed and the tensioning uniformity of the prestressed tendons are improved, and the tensioning precision is ensured.

Description

Technical Field

[0001] This invention relates to the field of building component manufacturing technology, and in particular to a multifunctional prestressed precast component production line and its usage method. Background Technology

[0002] Prestressed concrete components using the pre-tensioning method are widely used, including various types such as prestressed composite slabs, prestressed U-beams, and prestressed double-T slabs. Traditional prestressing tensioning production lines are customized for single components, such as box girder production lines and double-T slab production lines, which cannot meet the production needs of multiple components and lack versatility. Furthermore, the prestressing tensioning of traditional prestressed box girder production lines is done manually on a single beam, which is slow and has low precision.

[0003] Furthermore, the base plate of the traditional prestressed tensioning production line is a customized mold, which is not universal and cannot produce ordinary precast components. During the prestressed steel strand shearing stage, reaction forces are prone to occur, which can cause damage to the edges and corners of the precast components. Summary of the Invention

[0004] In view of this, the present invention provides a multifunctional prestressed precast component production line and its usage method to solve the problems existing in the background art.

[0005] A multifunctional prestressed precast component production line includes a tensioning machine, a mold table, and a prestressing protection device. The tensioning machine includes a tensioning table, an anchor plate, an end plate, and a drive mechanism. The tensioning table and the anchor plate are arranged opposite to each other. The end plate is respectively mounted on the tensioning table and the anchor plate and passes vertically through the tensioning table and the anchor plate so that its bottom is connected to the drive mechanism. The drive mechanism is used to drive the tensioning table to move in order to tension the prestressed tendons and to drive the end plates to move up and down to adapt to the production of different types of precast components. The formwork is positioned between the tensioning table and the anchor plate, and the prestressed protection device is fixed to the end of the formwork surface to prevent the tension retraction force generated after the prestressing tendons are sheared from damaging the ends of the precast components.

[0006] Preferably, the driving mechanism includes a horizontally arranged first driving element and a vertically arranged second driving element, the movable end of the first driving element being fixed to one end of the tensioning table, and the movable end of the second driving element being fixed to the bottom of the end plate.

[0007] Preferably, both the first driving element and the second driving element are hydraulic cylinders.

[0008] Preferably, the end plate is provided with a plurality of rib holes for the prestressing tendons to pass through, and the bottom of the end plate is fixed with a height-adjustable support rod.

[0009] Preferably, the height-adjustable strut is a scissor strut.

[0010] Preferably, a plurality of prestressed protection devices are fixed at one end or both ends of the mold table surface, and the arrangement positions of the prestressed protection devices in the transverse direction correspond to the arrangement positions of the hole groups on the end plates.

[0011] Preferably, the prestressed protection device comprises symmetrically arranged movable plates and fixed plates, a buffer spring arranged between the movable plates and the fixed plates, a pressure sensor fixed on the inner side of the movable plates, and a fixer arranged on the outer side of the movable plates, one end of the buffer spring is fixed with the pressure sensor, the other end is fixed with the fixed plate, the fixed plate is fixed on the mold table, and the fixer is locked on the prestressed tendon and in contact with the outer side of the movable plate.

[0012] Preferably, the movable plate and the fixed plate have the same structure, and each comprises a rectangular fixed plate and a sleeve vertically fixed on the rectangular fixed plate, a through hole is formed in the center of the rectangular fixed plate and communicates with the lumen of the sleeve, and the prestressed tendon passes through the sleeve and the through hole in the center of the rectangular fixed plate.

[0013] Preferably, the tensioning table is further provided with a tensioning locking device, the tensioning locking device comprises a locking screw, the locking screw passes through the tensioning table seat of the tensioning table and is fixed at both ends of the tensioning table seat, and a locking nut is fixed on the locking screw to lock the position of the tensioning table seat.

[0014] A method for using a multifunctional prestressed prefabricated component production line, specifically comprising the following steps: S1, adjusting the height of the left and right two end plates according to the height of the prefabricated component to be made; After the height position of the end plate is adjusted, the prestressed tendon is laid and fixed on the multifunctional prestressed prefabricated component production line, one end of the prestressed tendon passes through one of the end plates, the other end passes through the prestressed protection device and then passes through the other end plate; S2, controlling the driving mechanism to drive the tensioning table to move to tension the prestressed tendon, and when the prestressed tendon is tensioned to the design control stress, the fixer of the prestressed protection device is locked on the prestressed tendon and the outer side of the movable plate is in contact with the outer side of the movable plate; S3, arranging side molds on both sides of the mold table and binding non-prestressed ordinary steel bars; S4, pouring concrete to form a prefabricated component, cutting the prestressed tendon when the prefabricated component reaches the design tensioning strength, and observing the pressure value detected by the pressure sensor of the prestressed protection device, when the pressure value detected by the pressure sensor is less than 70%-80% of the theoretical compressive strength of the prefabricated component, removing the side mold and moving out the prefabricated component.

[0015] The beneficial effects of the present application are: 1、The present application can adjust the tensioning height of prestress by setting the height-adjustable end plate on the tensioning machine and the anchoring plate, so as to adapt to the production of various prestressed components such as prestressed composite slab and prestressed box girder, increase the application range of the prefabricated component production line, and make the application more widely; and the present application is an integrated tensioning machine, which can uniformly tension several prestressed tendons at the same time, improve the tensioning speed and uniformity of the prestressed tendon, and ensure the tensioning accuracy.

[0016] 2、The present application can effectively protect the prefabricated component by setting the prestress protection device on the mold table and using the prestress protection device to offset part of the tensioning force, so as to prevent the tensioning shrinkage force generated after the prestressed tendon is sheared from damaging the end of the prefabricated component; and the pressure sensor can detect the size of the prestressed tendon reaction force (tensioning shrinkage force), so as to avoid the damage of sheared prestressed tendon to the prefabricated component to the greatest extent. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiments will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0018] Figure 1 is a top view structural schematic diagram of the multifunctional prestressed prefabricated component production line of the present application.

[0019] Figure 2 is a three-dimensional structural schematic diagram of the multifunctional prestressed prefabricated component production line of the present application.

[0020] Figure 3 is a connection schematic diagram of the end plate and the second driving element.

[0021] Figure 4 is a structural schematic diagram of the prestress protection device.

[0022] The meanings of the reference numerals in the drawings are as follows: 1 is a tensioning machine, 2 is a mold table, 3 is an end plate, 31 is a tendon hole, and 32 is a height-adjustable supporting rod, 4 is a driving mechanism, 41 is a first driving element, and 42 is a second driving element, 5 is a tensioning and locking device, 6 is a tensioning table, 7 is a prestress protection device, 71 is a movable plate, 72 is a buffer spring, 73 is a pressure sensor, 74 is a fixator, and 75 is a fixed plate, 8 is an anchoring plate, 9 is a prestressed tendon. DETAILED DESCRIPTION

[0023] In order to make the objects, technical solutions and advantages of the present application clearer, the present application will be described below in detail with specific embodiments shown in the drawings. However, it should be understood that the description is only exemplary, but is not intended to limit the scope of the present application. In addition, in the following description, the description of the known structures and technologies is omitted to avoid unnecessary confusion of the concept of the present application.

[0024] The terms used in the present disclosure are merely for the purpose of describing specific embodiments, and are not intended to limit the present disclosure. The singular forms "a", "an" and "the" used in the present disclosure and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0025] It should be understood that although the terms first, second, third, etc. can be used in the present disclosure to describe various information, these information should not be limited to these terms, and should not be understood as indicating or implying relative importance. These terms are only used to distinguish one type of information from another. For example, without departing from the scope of the present disclosure, the first information can also be referred to as the second information, and similarly, the second information can also be referred to as the first information. Depending on the context, the word "if" as used herein can be interpreted as "when" or "upon" or "in response to determining".

[0026] In the description of the present application, it should be understood that the terms "longitudinal", "transverse", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0027] In the description of the present application, unless otherwise specified and limited, it should be noted that the terms "mounting", "connecting", "connection" should be understood broadly, for example, it can be a mechanical connection or an electrical connection, or a communication between two elements, or a direct connection, or an indirect connection through an intermediate medium, and the specific meaning of the above terms can be understood by those skilled in the art according to the specific circumstances.

[0028] In order to better understand the technical solutions of the present application, the present application will be described in detail below with reference to the drawings.

[0029] The application provides a multifunctional prestressed prefabricated component production line, which comprises a tensioning machine 1, a mold table 2 and a prestress protection device 7.

[0030] The tensioning machine 1 comprises a tensioning table 6, an anchoring plate 8, end plates 3 and a driving mechanism 4. The tensioning table 6 is oppositely arranged with the anchoring plate 8. The end plates 3 are arranged on the tensioning table 6 and the anchoring plate 8 respectively and vertically pass through the tensioning table 6 and the anchoring plate 8 so that the bottom of the end plates 3 is connected with the driving mechanism 4. The driving mechanism 4 is used to drive the tensioning table 6 to move to realize tensioning of the prestressed reinforcement and to drive the end plates 3 to move up and down to adapt to the production of different types of prefabricated components.

[0031] The tensioning table 6 is composed of a fixed pedestal and a tensioning pedestal. The fixed pedestal is in the shape of U. The tensioning pedestal is arranged in the fixed pedestal and the two end portions of the tensioning pedestal are sleeved with the two ends of the tensioning pedestal. The tensioning pedestal can move under the movement of the driving mechanism 4.

[0032] The driving mechanism 4 comprises a first driving element 41 arranged horizontally and a second driving element 42 arranged vertically. The active end of the first driving element 41 is fixed with one end portion of the tensioning table 6. The active end of the second driving element 42 is fixed with the bottom of the end plate 3. In the embodiment, the first driving element 41 and the second driving element 42 are hydraulic cylinders or air cylinders. Two first driving elements 41 are arranged. Four second driving elements 42 are arranged. The two first driving elements 41 are arranged horizontally on one side of the tensioning table 6 and the active end of the first driving element 41 is fixed with the tensioning pedestal of the tensioning table 6. The two first driving elements 41 drive the tensioning pedestal to move. Two second driving elements 42 are fixed on the bottom of one end plate 3. The other two second driving elements 42 are fixed on the bottom of the other end plate 3.

[0033] A plurality of reinforcement holes 31 for the prestressed reinforcement to pass through are arranged on the end plate 3 and the reinforcement holes 31 are distributed in a matrix. A through groove for the end plate 3 to pass through is arranged on the tensioning pedestal of the tensioning table 6 and the anchoring plate 8. The shape of the through groove matches the shape of the cross section of the end plate 3. The end plate 3 moves up and down under the driving of the second driving element 42 to adjust the position in the height direction.

[0034] In order to ensure the stability of the end plate 3, the bottom of the end plate 3 is fixed with a height-adjustable support rod 32. The overall height of the height-adjustable support rod 32 can be adaptively adjusted according to the height position of the end plate 3. In the embodiment, the height-adjustable support rod 32 is a scissor-type support rod, which is composed of two cross-arranged support rods fixed by a pin shaft. The intersection angle between the two support rods can be adjusted.

[0035] In the preferred embodiment, the tensioning platform 6 is further provided with a tensioning locking device 5, which comprises a locking screw penetrating the tensioning platform seat of the tensioning platform 6 and having its two ends fixed on the fixed platform seat of the tensioning platform 6, and a plurality of locking nuts fixed on the locking screw and used to lock the position of the tensioning platform seat. When the tensioning platform seat is driven by the first driving element 41 to tension the prestressed tendon to the design control stress, the locking nuts on the locking screw are screwed to tightly press the side surface of the tensioning platform seat from both sides of the tensioning platform seat, so as to limit the position of the tensioning platform seat to prevent it from moving in the subsequent concrete pouring process.

[0036] The mold platform 2 is arranged between the tensioning platform 6 and the anchoring plate 8, and the prestress protection device 7 is fixed on the surface end of the mold platform 2 to prevent the tensioning retraction force generated by the shearing of the prestressed tendon from damaging the end of the prefabricated component. The prestress protection device 7 can be arranged on one end or both ends of the surface of the mold platform 2. In the embodiment, the two end portions of the surface of the mold platform 2 are both provided with a plurality of prestress protection devices 7, and the plurality of prestress protection devices 7 on one side are arranged at equal intervals. The arrangement position of the prestress protection device 7 in the transverse direction corresponds to the arrangement position of the tendon hole on the end plate 3 one by one, so as to ensure that the prestressed tendon at each position of the two end plates 3 can pass through the prestress protection device 7 at the position.

[0037] The prestress protection device 7 comprises symmetrically arranged movable plates 71 and fixed plates 75, a buffer spring 72 arranged between the movable plate 71 and the fixed plate 75, a pressure sensor 73 fixed on the inner side of the movable plate 71, and a fixer 74 arranged on the outer side of the movable plate 71. One end of the buffer spring 72 is fixed with the pressure sensor 73, and the other end is fixed with the fixed plate 75. The fixed plate 75 is fixed on the mold platform 2, and the fixer 74 is locked on the prestressed tendon and in contact with the outer side of the movable plate 71.

[0038] The movable plate 71 and the fixed plate 75 have the same structure, which comprises a rectangular fixed plate and a sleeve vertically fixed on the rectangular fixed plate. A through hole is formed in the center of the rectangular fixed plate and communicates with the lumen of the sleeve. The prestressed tendon penetrates the sleeve and the through hole in the center of the rectangular fixed plate.

[0039] In the installation of the prestressed tendon 9, one end of the prestressed tendon 9 is passed through the tendon hole of the end plate 3 arranged on the tensioning platform 6, the other end is passed through the fixing plate 75, the buffer spring 72, the movable plate 71, the tendon hole of the end plate 3 arranged on the anchoring plate 8 in sequence, and then the fixer 74 is locked and fixed on the prestressed tendon and the fixer 74 is tightly attached to the outer side of the movable plate 71. When the prestressed tendon is cut after tensioning, the prestressed tendon 9 is retracted under the driving of the elastic recovery, so as to move the fixer 74 to the left, the fixer 74 extrudes the movable plate 71 on the right side to compress the spring, so as to offset a part of the prestress originally directly applied to the prefabricated component, so as to protect the prefabricated component and avoid damage to the prefabricated component due to excessive prestress.

[0040] The hydraulic oil cylinder and the pressure sensor are electrically connected with the controller.

[0041] The application also provides a use method of the multifunctional prestressed prefabricated component production line, and specifically includes the following steps: S1, adjusting the height of the left and right two end plates 3 according to the height of the prefabricated component to be made; After the height position of the end plate is adjusted in place, the required number of prestressed tendons is laid and fixed on the multifunctional prestressed prefabricated component production line, so that one end of the prestressed tendon is passed through the left end plate 3 and the other end is passed through the prestress protection device 7 and then passed through the right end plate 3.

[0042] S2, controlling the driving mechanism 4 to drive the tensioning platform 6 to move to tension the prestressed tendon, and locking the fixer 74 of the prestress protection device 7 on the prestressed tendon and making the fixer 74 contact the outer side of the movable plate 71 when the prestressed tendon is tensioned to the design control stress.

[0043] S3, arranging side molds on both sides of the mold platform 2 and binding non-prestressed ordinary steel bars.

[0044] S4, pouring concrete into the mold to form a prefabricated component, and cutting the prestressed tendon when the prefabricated component reaches the design tensioning strength, wherein when the prestressed tendon is cut after tensioning, the prestressed tendon is retracted under the driving of the elastic recovery, so as to move the fixer 74 to the left, and the fixer 74 extrudes the movable plate 71 on the right side to compress the spring; When the pressure value detected by the pressure sensor 73 of the prestress protection device 7 (the tensioning and retraction force generated after the prestressed tendon is cut is detected by the pressure sensor 73) is less than 70%-80% of the theoretical compressive strength of the prefabricated component, the side mold is removed and the prefabricated component is removed.

[0045] It should be noted that the described embodiments are merely some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.

Claims

1. A multi-functional pre-stressed precast component production line, characterized in that, The tensioning machine (1), the mold table (2) and the prestress protection device (7), The tensioning machine (1) comprises a tensioning table (6), an anchoring plate (8), an end plate (3) and a driving mechanism (4), the tensioning table (6) is arranged opposite to the anchoring plate (8), the end plate (3) is arranged on the tensioning table (6) and the anchoring plate (8) respectively and vertically penetrates the tensioning table (6) and the anchoring plate (8) so that the bottom thereof is connected with the driving mechanism (4), the driving mechanism (4) is used to drive the tensioning table (6) to move to realize tensioning of the prestressed reinforcement and to drive the end plate (3) to move up and down to adapt to production of different types of prefabricated components, The mold table (2) is arranged between the tensioning table (6) and the anchoring plate (8), and the prestress protection device (7) is fixed to the surface end of the mold table (2) to prevent the tensioning shrinkage force generated after the prestressed reinforcement is sheared from damaging the end of the prefabricated component.

2. The multi-functional pre-stressed precast component production line according to claim 1, characterized in that, The driving mechanism (4) comprises a horizontally arranged first driving element (41) and a vertically arranged second driving element (42), the movable end of the first driving element (41) is fixed to one end of the tensioning table (6), and the movable end of the second driving element (42) is fixed to the bottom of the end plate (3).

3. The multi-functional pre-stressed precast component production line according to claim 2, characterized in that, The first driving element (41) and the second driving element (42) are both hydraulic oil cylinders.

4. The multi-functional pre-stressed precast component production line according to claim 1 or 2, characterized in that, The end plate (3) is provided with a plurality of reinforcement holes (31) for the prestressed reinforcement to pass through, and the bottom of the end plate (3) is fixed with height-adjustable support rods (32).

5. The multi-functional pre-stressed precast component production line according to claim 4, characterized in that, The height-adjustable support rod (32) is a scissor-type support rod.

6. The multi-functional pre-stressed precast component production line according to claim 1, characterized in that, One end or both ends of the surface of the mold table (2) is fixed with a plurality of prestress protection devices (7) arranged at equal intervals, and the arrangement positions of the prestress protection devices (7) in the transverse direction correspond to the arrangement positions of the reinforcement holes in the end plate (3) one by one.

7. The multi-functional pre-stressed precast component production line according to claim 1 or 6, characterized in that, The prestress protection device (7) comprises symmetrically arranged movable plates (71) and fixed plates (75), buffer springs (72) arranged between the movable plates (71) and the fixed plates (75), pressure sensors (73) fixed to the inner side of the movable plates (71), and fixers (74) arranged on the outer side of the movable plates (71), one end of the buffer spring (72) is fixed to the pressure sensor (73), the other end is fixed to the fixed plate (75), the fixed plate (75) is fixed to the mold table (2), and the fixer (74) is locked on the prestressed reinforcement and the fixer (74) is in contact with the outer side of the movable plate (71).

8. The multi-functional pre-stressed precast component production line according to claim 7, characterized in that, The movable plate (71) and the fixed plate (75) have the same structure, both of which comprise a rectangular fixed plate and a sleeve vertically fixed on the rectangular fixed plate, a through hole communicating with the sleeve lumen is formed in the center of the rectangular fixed plate, and the prestressed reinforcement passes through the sleeve and the through hole in the center of the rectangular fixed plate.

9. The multi-functional pre-stressed precast component production line according to claim 1, characterized in that, The tensioning table (6) is further provided with a tensioning locking device (5), the tensioning locking device (5) comprises a locking screw, the locking screw penetrates the tensioning table seat of the tensioning table (6) and makes both ends thereof fixed on the fixed seat of the tensioning table (6), and a locking nut is fixed on the locking screw to lock the position of the tensioning table seat.

10. A method of using the multi-functional pre-stressed precast component production line according to any one of claims 1-9, characterized in that, Specifically comprising the following steps: S1, according to the height of the prefabricated component to be made, adjusting the height of the left and right two end plates (3); After the height position of the end plate is adjusted in place, laying and fixing the prestressed tendon on the multifunctional prestressed prefabricated component production line, so that one end of the prestressed tendon passes through one of the end plates (3), the other end passes through the prestressed protection device (7) and then passes through the other end plate (3); S2, controlling the driving mechanism (4) to drive the tensioning table (6) to move to tension the prestressed tendon, and when the prestressed tendon is tensioned to the design control stress, locking the fixer (74) of the prestressed protection device (7) on the prestressed tendon and making the fixer (74) contact the outer side of the movable plate (71); S3, setting side forms on both sides of the mold table (2) and binding non-prestressed ordinary steel bars; S4, pouring concrete to form a prefabricated component, cutting the prestressed tendon when the prefabricated component reaches the design tensioning strength, and observing the pressure value detected by the pressure sensor (73) of the prestressed protection device (7) at the same time, removing the side forms when the pressure value detected by the pressure sensor (73) is less than 70%-80% of the theoretical compressive strength of the prefabricated component.

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