Integrated intelligent construction method for cast-in-place box girder, and system

Abstract

Provided in the present invention are an integrated intelligent construction method for a cast-in-place box girder, and a system. The method comprises the following steps: S1, designing a scheme on the basis of BIM; S2, forming and transporting a rebar part; S3, establishing a box girder formwork; S4, testing the precision of the formwork; S5, assembling the rebar part in the formwork; S6, testing the quality of the rebar part; S7, constructing a prestressed pipeline and performing alignment inspection; S7, casting concrete; S8, testing the quality of the concrete; S9, curing the concrete; S10, controlling the quality of curing; and S12, performing prestressed tensioning and grouting inspection. Intelligent integrated box girder construction is realized by means of the above steps. In the present invention, the above solution is used, and intelligent control technology is introduced into a construction method, so that the mechanization, automation and intelligence levels of cast-in-place box girder construction can be improved, thereby greatly improving the construction efficiency, reducing labor intensity, improving on-site management levels, and ensuring construction safety and construction quality.

Description

Integrated intelligent construction method and system for cast-in-situ box beams Technical Field

[0001] The present invention relates to the field of cast-in-situ box girder construction, and in particular to an integrated intelligent construction method and system for cast-in-situ box girders. Background Art

[0002] At present, the construction method of cast-in-place box girders uses a lot of manual labor, has many manual operation processes, high labor intensity for workers, many and messy on-site construction equipment, many cases of interference between materials and construction equipment, difficult on-site management, and difficult to form efficient construction. No better solution has been found in the existing technology. Technical issues

[0003] The technical problem to be solved by the present invention is to provide an integrated intelligent construction method and system for cast-in-place box girders, which can realize the mechanization, automation and intelligent construction of steel bar component production, formwork erection, steel bar component assembly, pouring, maintenance and prestressing, greatly improve construction efficiency, enhance construction quality, reduce labor intensity and ensure construction safety. Technical Solutions

[0004] To solve the above technical problems, the technical solution adopted by the present invention is: a method for integrated intelligent construction of cast-in-situ box beams, comprising the following steps:

[0005] S1. BIM-based design solution;

[0006] S2. Forming and transportation of steel bar components;

[0007] S3. Box girder formwork is set up;

[0008] S4, template accuracy detection;

[0009] S5. Assemble steel bar components in the formwork;

[0010] S6. Quality inspection of steel bar components;

[0011] S7. Prestressed pipe construction and linear detection;

[0012] S8, concrete pouring;

[0013] S9, concrete quality inspection;

[0014] S10, concrete curing;

[0015] S11, maintenance quality control;

[0016] S12, prestressed tensioning and grouting testing;

[0017] Through the above steps, intelligent integrated box girder construction can be realized.

[0018] Preferably, a main control center is provided, which includes a production scheduling center and a quality control center. The production scheduling center is used to control the intelligent integrated beam-building machine, the steel bar component forming factory, the formwork, the automatic material distribution device, the vibrator, the prestressed construction and testing device, and the concrete curing device according to the design plan and the data collected by the sensor;

[0019] The quality control center is used to collect the stress, shape and position parameters of steel bar components; it is also used to collect formwork positioning parameters; it is also used to collect concrete distribution parameters, concrete pouring quality parameters, prestressed pipe shape and position accuracy, tensioning force, grouting density, and concrete curing parameters, and feed back the collected parameters to the main control center, which then sends the control data to the production scheduling center.

[0020] Preferably, the box girder finite element simulation model is automatically updated based on the data collected and analyzed by the main control center, the real-time stress and linear state are mastered, and the optimal timing of formwork demoulding, prestressing and formwork spanning is determined;

[0021] Based on the commissioning time of the relevant equipment in each process, the actual time consumption and man-machine input of each process are determined. The main control center conducts data mining and statistical analysis, and establishes a mathematical model of man-machine and construction time consumption at the process level. According to the construction needs, the process-level construction optimization plan and resource allocation plan are determined to guide the construction.

[0022] Preferably, the main control center is also connected to an interactive digital twin system, which establishes an interactive digital twin system of the box girder construction progress based on data provided by the main control center;

[0023] The interactive digital twin system is equipped with an expert system that provides recommended solutions based on the construction rule library and warning library, and sends the recommended solutions to the main control center in a loosely coupled manner;

[0024] The expert database system includes expert members and artificial intelligence models, identifies technical problems based on large-scale artificial intelligence semantic recognition, analyzes and decomposes technical problems, and provides solutions based on the listing of constraints.

[0025] The solution includes one or more optional solutions, which are sent to the main control center in a non-mandatory manner. After selection and decision-making, the main control center sends the final execution plan with constraints to the interactive digital twin system to iterate the expert library system.

[0026] Preferably, in step S2, the BIM has multiple design schemes for steel bar components, which are compared and determined according to different box girder types and size parameters;

[0027] Design options for multiple reinforcement components include a core box solution, a sheet-block solution, and a mesh-block solution;

[0028] The core box solution is a design solution that first prepares the central box and then inserts the reinforcement components of the flange structure;

[0029] The sheet-block solution is a design solution where the transverse reinforcement is first welded into a sheet, then the main reinforcement is inserted into the sheet to form a block, and then the steel components are assembled.

[0030] The mesh-block solution is a design solution in which the transverse and longitudinal bars are first welded into a steel mesh, the steel mesh is then bent or welded into steel blocks, and then assembled into steel components.

[0031] Preferably, the sheet-block solution of the BIM design solution is to decompose the steel bar component into multiple top plate units, multiple web plate units, multiple oblique hook bar units and bottom plate units. The longitudinal bars and hook bars at the connection positions between the units are reserved but not installed when the units are manufactured. When the steel bar component is assembled, the longitudinal bars and hook bars at the connection positions between the units are installed.

[0032] The intelligent integrated beam-building machine assists in lifting and assembles the units except the top plate unit into steel bar components on the steel bar frame, and then lifts the entire unit into the outer formwork for assembly.

[0033] Preferably, the intelligent integrated beam-building machine includes a main beam and a lifting trolley arranged along the longitudinal direction of the bridge. There are multiple lifting trolleys, which are arranged on the top of the main beam. The multiple lifting trolleys move along the main beam. Front legs, middle legs and rear legs are provided at the bottom of the main beam. The bottoms of the front legs, middle legs and rear legs are all provided with running wheels. The front legs are of a liftable and foldable or detachable structure, the middle legs are of a detachable structure, and the rear legs are of a liftable structure.

[0034] The steps for the production scheduling center to control the intelligent integrated beam building machine include:

[0035] S101. Move the main beam to the top of the steel bar parts factory. Move the overhead crane to the lifting point to take the steel bar parts. Hang the steel bar parts under the overhead crane. Swing and fold the front legs to the sides.

[0036] S102: The main beam moves toward the span to be cast. The front outrigger passes over the rear hanger of the mobile formwork. The front outrigger is retracted. The front outrigger wheel assembly falls onto the track at the top of the mobile formwork flange. The middle outrigger connecting pin is removed to release the connection between the middle outrigger and the triangular truss.

[0037] S103: The middle outrigger is turned as a whole in-situ to leave space for the rear outrigger to pass through;

[0038] S104. The main beam continues to move forward, supported by the front and rear outriggers, until it reaches the top of the span to be poured. The overhead crane hoists the steel bar components to the top of the span to be poured and lowers them to the designed position.

[0039] S105. After the steel bar components are installed, the folding roof is opened to create factory-like working conditions. The overhead crane assists in the lifting, laying and vibrating processes until the box girder is cast.

[0040] S106. The main beam retreats under the support of the front and rear legs. When the installation position of the middle leg passes over the rear hanger of the mobile formwork, the middle leg connecting pin is reinstalled to connect the middle leg to the triangular truss and bear the force. At the same time, the front leg is swung and folded to the sides.

[0041] S107. The main beam returns to the top of the steel bar parts factory under the support of the front and rear legs.

[0042] Preferably, a first obstacle sensor is provided at both ends of the front leg, a second obstacle sensor is provided at both ends of the middle leg, and a third obstacle sensor is provided at the rear leg close to the direction of the span to be cast;

[0043] The main control center receives the approach signal from the first obstacle sensor and first determines the direction of movement of the intelligent integrated beam-building machine. If it is determined to be moving towards the span to be cast, it sends a control signal to swing and fold the front legs to both sides.

[0044] The intelligent integrated beam-building machine continues to move forward. When it receives the approach signal from the second obstacle sensor, the main control center first sends a control signal for the front outrigger to reset. After completion, it then sends a control signal for the middle outrigger to separate from the triangular truss and rotate.

[0045] The intelligent integrated beam-building machine continues to move forward until it receives a signal from the third obstacle sensor, at which point it stops.

[0046] When it is necessary to return, the intelligent integrated beam-building machine moves in the opposite direction until it receives a signal from the second obstacle sensor on the front outrigger near one end of the cast box beam. The main control center then sends a control signal for the middle outrigger to connect with the triangular truss and rotate and reset. After completion, the main control center sends a control signal for the front outrigger to swing and fold to both sides.

[0047] The above steps realize the automated operation of the hanger after the automated crossing of the mobile mold frame.

[0048] Preferably, before the steel bar components are hoisted, an image of the measured longitudinal reinforcement of the cast box girder is obtained;

[0049] The main control center compares the measured image of the box girder longitudinal reinforcement with the designed box girder longitudinal reinforcement position, finds the error value, and provides a longitudinal reinforcement correction plan;

[0050] The longitudinal reinforcement correction plan includes correction of the longitudinal reinforcement of the cast box beam and correction of the reinforcement parts in production;

[0051] In the longitudinal reinforcement correction scheme, correction is first performed within the correction range of the longitudinal reinforcement of the cast box girder;

[0052] If there are longitudinal reinforcements that exceed the correction range of the longitudinal reinforcements of the cast box girder, the longitudinal reinforcements of the assembled steel bar components shall be corrected in the design plan.

[0053] Preferably, the steel bar components are assembled according to the design plan, and the longitudinal bars at the non-connected positions between each steel bar unit in the top plate unit, web unit, oblique hook bar unit and web unit are first connected to the longitudinal bars of the cast box girder, and then the longitudinal bars at the connection parts between each steel bar unit are installed and connected to the longitudinal bars of the cast box girder.

[0054] Preferably, a transparent template is provided at a position where the template exhaust is unfavorable, and a template camera for collecting concrete images is provided at a position facing the transparent template. The images collected by the template camera are sent to the main control center, and after recognition, the main control center sends a control instruction to the vibrator to vibrate to eliminate bubbles and make the concrete dense.

[0055] The vibrator includes an attached vibrator, and the attached vibrator array is arranged on the outer wall of the template. According to the control instructions, the overall vibration is formed so that the array attached vibrators vibrate at different phases respectively, forming an overall vibration waveform based on the outer wall of the template, so that the vibration is transmitted in the form of waves on the surface of each template unit to assist exhaust according to the collected concrete image.

[0056] Preferably, the template is arranged on a movable template, a steam curing machine and a vacuum machine are provided at the position of the movable template, a template sealing layer is coated on the outer template, a top plate sealing layer is provided at the top open position, and an end surface sealing layer is provided on the end surface, so as to construct a sealed concrete curing space, and the steam curing machine and the vacuum machine are connected to the concrete curing space through valves and pipelines;

[0057] Based on the collected ambient temperature and humidity, the main control center generates a maintenance plan. The maintenance plan includes the time the steam curing machine provides steam exceeding normal pressure and the time the vacuum machine evacuates the concrete to a pressure below normal pressure in the curing space. Through time-based automatic control, intelligent maintenance of concrete box girders is achieved.

[0058] A system for the above-mentioned integrated intelligent construction method of cast-in-situ box girders includes a main control center, which is equipped with a production scheduling center and a quality control center;

[0059] The production scheduling center is used to generate design and control plans for controlling the steel component factory, intelligent integrated beam building machine, formwork, concrete distribution device, intelligent vibrating device and intelligent maintenance device;

[0060] The quality control center is used to test the production accuracy of steel components, the accuracy of formwork setting, the accuracy of steel component assembly, the smoothness of prestressed pipes, the quality of concrete vibration, concrete strength, elastic modulus and curing quality, and to modify the design and control plan of the production scheduling center based on the feedback of quality parameters.

[0061] Preferably, the steel bar parts factory is set up on the ground and / or on the cast box beam, and is equipped with one or more of an automatic reinforcement arranging machine, an automatic welding machine, an automatic single reinforcement bending machine, an automatic mesh bending machine and an automatic assembly welding machine;

[0062] The automatic reinforcement spreading and arranging machine is used to spread out the steel bars and arrange them at preset spacings, and the robot arranges the transverse bars on the longitudinal bars;

[0063] Automatic welding machine is used to weld steel bar nodes;

[0064] Automatic mesh bending machine is used to bend steel mesh;

[0065] Automatic single bar bending machine is used to produce stirrups;

[0066] Automatic welding machine is used to weld stirrups and longitudinal reinforcement;

[0067] A laser scanner or video acquisition device is also provided to locate the position of the steel bars, the position of the steel bar nodes and to detect the shape and position accuracy of the finished product.

[0068] Preferably, the intelligent integrated beam-building machine includes a main beam and a lifting trolley arranged along the longitudinal direction of the bridge. There are multiple lifting trolleys, which are arranged on the top of the main beam. The multiple lifting trolleys move along the main beam. Front legs, middle legs and rear legs are provided at the bottom of the main beam. The bottoms of the front legs, middle legs and rear legs are all provided with running wheels. The front legs are of a liftable and foldable or detachable structure, the middle legs are of a detachable structure, and the rear legs are of a liftable structure.

[0069] The main beam includes triangular trusses on both sides, and transverse connecting beams are provided at both ends of the main beam to connect the triangular trusses into a whole;

[0070] The bottom of the triangular truss is a side and the top is a corner. The top of the triangular truss is provided with a main beam track for the crane to travel.

[0071] The front outrigger and the rear outrigger are located near the two ends of the main beam, and the middle outrigger is located between the front outrigger and the rear outrigger, close to the front outrigger.

[0072] The structure of the front outrigger is as follows: the front outrigger wheel assembly seat is connected to the bottom of the lifting column, the top of the lifting column is hinged to the triangular truss through the front outrigger hinge seat, the front outrigger hinge seat swings in the horizontal direction, one end of the front outrigger transverse support is connected to the triangular truss, and the other end is connected to the bottom of the lifting column, one end of the front outrigger folding cylinder is connected to the triangular truss, and the other end is connected to the front outrigger transverse support, and the front outrigger folding cylinder is used to drive the front outrigger to fold to avoid obstacles;

[0073] The front legs rest on the flanges on both sides of the mobile formwork;

[0074] A hinged portion is provided in the middle of the front leg transverse support to form a foldable structure. The front leg transverse support, the lifting column and the bottom of the triangular truss form a triangular structure. The front leg folding cylinder is connected to the upper half of the front leg transverse support. The front leg folding cylinder pushes the front leg to fold.

[0075] In the lifting column, the front leg upper column is connected to the front leg hinge seat, the front leg upper column is connected to the front leg lower column through the front leg telescopic cylinder, and the front leg lower column is connected to the front leg wheel assembly seat;

[0076] A front outrigger longitudinal strut is also provided, one end of the front outrigger longitudinal strut is connected to the triangular truss, and the other end is connected to the front outrigger wheel assembly seat.

[0077] Preferably, the structure of the middle leg is as follows: the bottom of the middle leg crossbeam is connected to the middle leg wheel seat, and the top of the middle leg crossbeam is connected to the middle leg swing seat through the middle leg connecting pin. The middle leg can be disassembled by removing the middle leg connecting pin.

[0078] The structure of the rear leg is as follows: a vertical rear leg sleeve is provided on the triangular truss, a rear leg sliding column is slidably connected to the rear leg sleeve, a rear leg telescopic cylinder is provided between the rear leg sleeve and the rear leg sliding column, a rear leg inner folding seat is provided at the bottom of the rear leg sliding column, the bottom of the rear leg inner folding seat is connected to the rear leg wheel seat through the rear leg rocking seat, and the rear leg inner folding seat has an inward bending structure so that when the rear leg moves longitudinally, the running wheels of the rear leg wheel seat fall on the root of the flange of the cast box girder;

[0079] A plurality of running wheels are provided at the bottom of the rear outrigger wheel seat and the middle outrigger wheel seat, and the running wheels are connected to the wheel seat through a rotating seat so that the running wheels can rotate in different directions.

[0080] Preferably, a first obstacle sensor is provided at both ends of the front leg, a second obstacle sensor is provided at both ends of the middle leg, and a third obstacle sensor is provided at the rear leg close to the direction of the span to be cast;

[0081] The first obstacle sensor, the second obstacle sensor and the third obstacle sensor are laser radars or ultrasonic sensors.

[0082] Preferably, a fusion joint device is further provided, the end of the handle is provided with a fixed chuck, and the position of the handle near the end is also pivotally connected to the movable chuck;

[0083] The shapes of the fixed clamp and the movable clamp are adapted to the shapes of the steel bar ends, and extend to both sides to cover the cast steel bar ends and the uncast steel bar ends. The fixed clamp and the movable clamp are provided with electromagnetic coils;

[0084] The extended end of the movable chuck is hinged to one end of the chuck cylinder, and the other end of the chuck cylinder is hinged to the handle.

[0085] Preferably, an arch-eliminating vibration device is also provided, which includes an arch-eliminating head fixed to the end of the vibrating rod, an arch-eliminating side slider and an arch-eliminating head slider provided in the arch-eliminating head, a capsule provided in the arch-eliminating head, and the capsule is connected to the pressure interface seat of the vibrating rod through a pressure interface, so that the capsule is deformed by inputting a pressure medium, thereby causing the arch-eliminating side slider and the arch-eliminating head slider to extend beyond the outer wall of the arch-eliminating head, thereby eliminating the arch cavity of the concrete by volume change.

[0086] Preferably, an exhaust layer is provided on the inner surface of the template at the exhaust-unfavorable position of each template unit, and exhaust holes are provided on the template steel plate to assist the exhaust of concrete. Beneficial effects

[0087] The present invention provides an integrated intelligent cast-in-place box girder construction method and system. By adopting the above solution, it can enhance the mechanization, automation, and intelligence levels of cast-in-place box girder construction, significantly improving construction efficiency, reducing labor intensity, enhancing on-site management, and ensuring safe and high-quality construction. Further technical details and technical advantages are further described in the detailed implementation method. BRIEF DESCRIPTION OF THE DRAWINGS

[0088] The present invention will be further described below with reference to the accompanying drawings and examples:

[0089] FIG1 is a schematic flow diagram of the method of the present invention.

[0090] FIG2 is another preferred schematic flow chart of the method of the present invention.

[0091] FIG3 is a flow chart of the steel bar component quality monitoring method of the present invention.

[0092] FIG4 is a schematic flow chart of the concrete quality monitoring method of the present invention.

[0093] FIG5 is a front view schematic diagram of the overall structure of the intelligent integrated beam-building machine of the present invention.

[0094] FIG6 is a schematic cross-sectional view taken along line AA of FIG5 .

[0095] FIG7 is a schematic structural diagram of the movable mold frame of the present invention before the mold is erected.

[0096] FIG8 is a schematic structural diagram of the movable mold frame of the present invention after the mold is erected.

[0097] FIG9 is a schematic diagram of the cross section of the main beam of the intelligent integrated beam-building machine of the present invention.

[0098] FIG10 is a front view of the front legs of the intelligent integrated beam-building machine of the present invention.

[0099] FIG11 is a schematic diagram of a cross section of the front legs of the intelligent integrated beam-building machine of the present invention.

[0100] FIG12 is a schematic diagram of the support position of the front legs of the intelligent integrated beam-building machine of the present invention.

[0101] FIG13 is a schematic diagram of the folding structure of the front legs of the intelligent integrated beam-building machine of the present invention when passing an obstacle.

[0102] FIG14 is a schematic front view of the rear legs of the intelligent integrated beam-building machine of the present invention.

[0103] FIG15 is a schematic cross-sectional view of the rear support legs of the intelligent integrated beam-building machine of the present invention.

[0104] FIG16 is a schematic front view of the support legs of the intelligent integrated beam-building machine of the present invention.

[0105] FIG17 is a schematic diagram of the cross section of the middle leg of the intelligent integrated beam-building machine of the present invention.

[0106] FIG18 is an exploded schematic diagram of the connection structure of the steel bar component of the present invention.

[0107] FIG19 is a schematic diagram of the assembly structure of the steel bar component of the present invention.

[0108] FIG20 is a schematic structural diagram of a transparent template of the present invention.

[0109] FIG21 is a schematic diagram of the vibrating operation performed by the attached vibrator array of the present invention.

[0110] FIG22 is a schematic diagram of the intelligent monitoring of the longitudinal reinforcement ends of the present invention.

[0111] FIG23 is a schematic structural diagram of the top plate sealing layer of the present invention.

[0112] FIG24 is a schematic structural diagram of the end face sealing layer of the present invention.

[0113] FIG25 is a schematic structural diagram of the sealing pressure rod of the present invention.

[0114] FIG26 is a schematic structural diagram of the ear sealing plate of the present invention.

[0115] FIG27 is a schematic diagram of the top view of the fusion joint device of the present invention.

[0116] FIG28 is a side view schematic diagram of the fusion joint device of the present invention.

[0117] FIG29 is a schematic structural diagram of the sleeve fastening tool of the present invention.

[0118] Figure 30 is a schematic structural diagram of the arch-eliminating vibration device of the present invention. Modes for Carrying Out the Invention

[0119] Example 1:

[0120] As shown in Figures 1 to 4, a method for integrated intelligent construction of cast-in-situ box girders includes the following steps:

[0121] S1. Based on the BIM design scheme; that is, on the basis of the BIM design scheme, the intelligent construction method is introduced, including the intelligent control of construction equipment, the big data collection of construction progress and quality, the intelligent management of personnel, and the optimization of the BIM design scheme based on the above data feedback.

[0122] The preferred solution is shown in FIG2 , and a main control center is further provided. The main control center includes a production scheduling center and a quality control center. The production scheduling center is used to control the intelligent integrated beam-building machine, the steel bar component forming factory, the formwork, the automatic material distribution device 24, the vibrator 18, the prestressed construction and testing device, and the concrete curing device according to the design plan and the data collected by the sensors.

[0123] The quality control center collects stress, shape, and position parameters of the rebar component 10; also collects formwork positioning parameters; and collects concrete distribution parameters, concrete pouring quality parameters, prestressed pipe geometry and position accuracy, tensioning force, grouting density, and concrete curing parameters. These collected parameters are fed back to the main control center, which then transmits the control data to the production scheduling center. The main control center achieves the following technical advantages: First, it enables intelligent BIM-based construction, namely, intelligent plan planning and intelligent data analysis, leading to intelligent solution optimization. This allows for precise control of equipment, personnel, construction progress, and quality, and generates interactive graphical data to facilitate decision-making and oversight by management and supervisory personnel. Second, it collects relevant construction data and implements intelligent sensing to facilitate data analysis and generate further construction data, facilitating optimization or iteration of pre-planned solutions based on this data. Third, it facilitates automated control of relevant equipment, ensuring construction quality and accuracy, reducing human error, and reducing safety risks and labor intensity. Fourth, artificial intelligence-based construction management can greatly improve construction efficiency, reduce conflicts in work processes and equipment construction, and improve the level of on-site personnel and equipment management by seeking the optimal solution.

[0124] The preferred solution, shown in Figure 2, automatically updates the box girder finite element simulation model based on data collected and analyzed by the main control center, monitoring real-time stress and linear state, and determining the optimal timing for formwork demolding, prestressing, and formwork span transitions. During the construction process, the main control center collects a large amount of data, from which construction-related derivative data can be derived. For example, based on the detection of formwork shape and position data, the deviation between the formwork position and posture and the design can be determined, thus guiding the formwork erection.

[0125] The preferred solution, shown in Figure 2, determines the actual time consumption and human-machine input for each process based on the commissioning time of the relevant equipment. The main control center conducts data mining and statistical analysis to establish a mathematical model of process-level personnel, materials, machinery, and construction time consumption. Based on construction requirements, a process-level construction optimization plan and resource allocation strategy are determined to guide construction. This solution can significantly improve construction efficiency and reduce construction schedule conflicts. The preferred algorithm uses a genetic algorithm for analysis. The advantage of using a genetic algorithm is that it can quickly analyze multiple parameters to obtain the optimal solution. It is also suitable for analysis under multiple constraints.

[0126] The preferred solution, as shown in Figure 2, connects the main control center to an interactive digital twin system. This system creates an interactive digital twin of the box girder construction progress based on data provided by the main control center. This interactive digital twin system generates a visual model consistent with the construction progress based on the data. By also connecting some control systems to the interactive digital twin system, remote management and technical personnel can directly access construction data from the interactive digital twin system and issue control instructions based on the data, significantly improving management and construction efficiency and quality. The control system includes control of some cameras, formwork accuracy, and vibrating devices.

[0127] The interactive digital twin system incorporates an expert system that provides recommendations based on a library of construction rules and warnings, and transmits these recommendations to the main control center in a loosely coupled manner. While expert system assistance can significantly improve construction efficiency and quality, expert systems are still not reliable enough. Therefore, a loosely coupled control approach is employed, providing only recommendations and requiring human input in decision-making to achieve a balance between efficiency and reliability.

[0128] In a preferred solution, the expert database system includes expert members and artificial intelligence models, identifies technical problems based on large-scale artificial intelligence semantic recognition, analyzes and decomposes technical problems, and provides solutions based on the listing of constraints.

[0129] The solution includes one or more optional solutions, which are sent to the main control center in a non-mandatory manner. After selection and decision-making, the main control center sends the final execution plan with constraints to the interactive digital twin system to iterate the expert library system.

[0130] S2. Forming and transportation of steel bar components;

[0131] S3. Box girder formwork is set up;

[0132] S4, template accuracy detection;

[0133] S5. Assemble steel bar components in the formwork;

[0134] S6. Quality inspection of steel bar components;

[0135] S7. Prestressed pipe construction and linear detection;

[0136] S8, concrete pouring;

[0137] S9, concrete quality inspection;

[0138] S10, concrete curing;

[0139] S11, maintenance quality control;

[0140] S12, prestressed tensioning and grouting testing;

[0141] Through the above steps, intelligent integrated box girder construction can be realized.

[0142] In a preferred solution, in step S2, the BIM has multiple design schemes for steel bar components, which are compared and determined based on different box girder types and size parameters;

[0143] Design options for multiple reinforcement components include a core box solution, a sheet-block solution, and a mesh-block solution;

[0144] The core box solution is a design solution that first prepares the central box body and then inserts the reinforcement components of the flange structure; it is mainly used for small box girders.

[0145] As shown in Figure 18, the sheet-block solution involves first welding the transverse reinforcement into steel sheets. For example, the stirrups are first bent, and then the ends are welded together to form sheets. The sheets are then stacked and arranged at a certain distance. The main reinforcement is then inserted and welded to the sheets to form a grid, forming a steel block. The steel block is then assembled into a design for the steel component.

[0146] The mesh-block design involves first welding transverse and longitudinal reinforcement into a mesh, then bending or welding the mesh into blocks, and then assembling the resulting steel components. This design approach can be selected based on the type and size of the box girder. Steel components are the most time-consuming step in cast-in-place box girders. Mechanized and intelligent construction of steel components can significantly improve construction efficiency and reduce labor intensity.

[0147] The preferred solution is shown in Figures 18 and 19. The sheet-block solution of the BIM design solution is to decompose the steel bar component 10 into multiple top plate units 1001, multiple web plate units 1002, multiple oblique hook bar units 1003, and bottom plate units 1004. The longitudinal bars and hook bars at the connection positions between the units are reserved when the units are manufactured but not installed. When the steel bar component 10 is assembled, the longitudinal bars and hook bars at the connection positions between the units are installed. With this solution, the individual units can be decomposed and processed in the factory, that is, the sheets are first processed, then welded into units, and then the individual units are assembled into the steel bar component 10. The assembly of the steel bar component 10 can be completed in the steel bar factory where the box girder 9 has been cast, or it can be completed step by step in the formwork after the formwork is erected according to the construction progress.

[0148] The preferred solution is shown in Figures 6 and 8. The intelligent integrated beam-building machine assists in lifting and assembles the units except the top plate unit 1001 into the steel bar component 10 on the steel bar frame 12, and then lifts the entire unit into the outer formwork 701 for assembly.

[0149] The preferred solution is shown in Figures 5 and 6. The intelligent integrated beam-building machine includes a main beam 1 and a crane 5 arranged along the longitudinal direction of the bridge. There are multiple cranes 5, which are arranged on the top of the main beam 1. The multiple cranes 5 move along the main beam 1. Front legs 2, middle legs 3 and rear legs 4 are provided at the bottom of the main beam 1. The bottoms of the front legs 2, middle legs 3 and rear legs 4 are all provided with running wheels. The front legs 2 are of a structure that can be raised and lowered and folded or detached. The middle legs 3 are of a detachable structure. The rear legs 4 are of a structure that can be raised and lowered.

[0150] As shown in Figures 5 to 17, the steps for the production scheduling center to control the intelligent integrated beam-building machine include:

[0151] S101: The main beam 1 is moved above the steel bar component factory. The overhead crane 5 is moved to the lifting point to take the steel bar component 10. The steel bar component 10 is hung below the overhead crane 5. The front legs 2 are swung and folded to the sides.

[0152] S102, the main beam 1 moves toward the span to be cast 8. When the front leg 2 passes over the rear hanger 6 of the mobile formwork, the front leg 2 is retracted, and the front leg wheel assembly 202 of the front leg 2 falls on the track at the top of the flange of the mobile formwork 7. The middle leg connecting pin 301 is removed, and the connection between the middle leg 3 and the triangular truss 102 is released.

[0153] S103, the middle leg 3 is turned as a whole in the original position to leave space for the rear leg 4 to pass through;

[0154] S104. The main beam 1 continues to move forward, supported by the front legs 2 and the rear legs 4, until it reaches the top of the span 8 to be poured. The overhead crane 5 hoists the steel bar component 10 to the top of the span 8 to be poured, and lowers the steel bar component 10 to the designed position.

[0155] S105. After the steel bar components are installed, the folding roof is opened to create factory-like working conditions. The overhead crane 5 assists in the lifting, laying and vibrating processes until the box girder is poured.

[0156] S106: The main beam 1 retreats under the support of the front legs 2 and the rear legs 4. When the installation position of the middle legs exceeds the rear hanger 6 of the movable formwork, the middle leg connecting pin 301 is reinstalled to connect the middle legs 3 with the triangular truss 102 and bear the force. At the same time, the front legs 2 are swung and folded to the sides.

[0157] S107. The main beam 1 is returned to the top of the steel bar component factory under the support of the front support legs 2 and the rear support legs 4.

[0158] As shown in FIG5 , a preferred solution includes first obstacle sensors 11 at both ends of the front leg 2, second obstacle sensors 25 at both ends of the middle leg 3, and a third obstacle sensor 26 at the rear leg 4 close to the span 8 to be cast. The obstacle sensors are preferably optical sensors, cameras, or ultrasonic radar sensors.

[0159] The main control center receives the approach signal from the first obstacle sensor 11 and first determines the direction of travel of the intelligent integrated beam-building machine. If it is determined that the machine is moving toward the span to be poured 8, it sends a control signal to swing and fold the front legs 2 to both sides.

[0160] The intelligent integrated beam-building machine continues to move forward. When it receives the approach signal from the second obstacle sensor 25, the main control center first sends a control signal for the front leg 2 to reset. After completion, it then sends a control signal for the middle leg 3 to separate from the triangular truss 102 and rotate.

[0161] The intelligent integrated beam-building machine continues to move forward until it receives a signal from the third obstacle sensor 26, and then stops moving;

[0162] When it is necessary to return, the intelligent integrated beam-building machine moves in the reverse direction until it receives a signal from the second obstacle sensor 25 on the front leg 2 near one end of the cast box beam 9. The main control center sends a control signal for the middle leg 3 to connect with the triangular truss 102 and rotate and reset. After completion, the main control center sends a control signal for the front leg 2 to swing and fold to both sides.

[0163] The above steps realize the automated operation of the automatic straddle mobile die frame rear hanger 6. By the above operation, the mistakes of human operation are avoided.

[0164] The preferred solution is shown in FIG8 , where the template accuracy is detected by using a combination of one or more of a total station, a detection video or a laser scanner to detect the shape and position accuracy of the template;

[0165] The main control center provides correction parameters based on the detection parameters, and the operating mold frame is adjusted according to the correction parameters. Adjustable struts are installed between the template and the mold frame. The data obtained by the sensor is used to obtain the three-dimensional coordinates of multiple key positions of the template. After converting the measured three-dimensional coordinates into design coordinates, these coordinates are compared with the coordinates in the design plan to determine the parameter differences at each key position. The parameter differences are fitted with the adjustment position of the template to determine the adjustment parameters of each adjustment position, that is, the adjustment parameters of the adjustable struts. Based on the given adjustment parameters, the template can be adjusted.

[0166] In the preferred solution, before the steel bar component 10 is hoisted, an image of the measured box girder longitudinal reinforcement 19 of the cast box girder 9 is obtained; that is, an end face image of the longitudinal reinforcement 19, and the collected end face image of the longitudinal reinforcement 19 is used to obtain the end face position coordinates of each longitudinal reinforcement 19 through artificial intelligence recognition.

[0167] The main control center compares the image of the measured box girder longitudinal reinforcement 19 with the position of the designed box girder longitudinal reinforcement 20, finds the error value, and provides a longitudinal reinforcement correction plan;

[0168] The longitudinal reinforcement correction scheme includes correction of the longitudinal reinforcement of the cast box beam 9 and correction of the reinforcement component 10 in production;

[0169] In the longitudinal reinforcement correction scheme, correction is first performed within the correction range of the longitudinal reinforcement of the cast box girder;

[0170] If there are longitudinal bars that exceed the correction range of the cast box girder longitudinal reinforcement, the longitudinal bars of the assembled steel bar component 10 are corrected in the design plan. This solution avoids the need to process longitudinal bars with large errors in a single box girder. The longitudinal bar positions are gradually corrected through multiple box girders.

[0171] The preferred solution, shown in Figure 19, involves assembling steel bar components 10 according to the design. First, the longitudinal bars at the non-connected locations between the top plate elements 1001, web elements 1002, oblique hook bar elements 1003, and web elements 1004 are connected to the longitudinal bars of the cast box girder. The longitudinal bars at the connecting portions 1005 between the individual steel bar components are then installed and connected to the longitudinal bars of the cast box girder. This structure maximizes the use of factory-based production methods for steel bar components, thereby improving the construction efficiency of cast-in-place box girders.

[0172] In a preferred embodiment, the connection method of the longitudinal reinforcement includes threaded sleeve connection, welding connection or additive melting connection;

[0173] The threaded sleeve connection is a connection in which the end of the steel bar is connected by a threaded sleeve; the tool for the threaded sleeve connection is shown in Figure 29. The threaded sleeve is quickly tightened with a friction belt 282 through a sleeve tightening tool 28, greatly improving the connection operation efficiency of the steel bar end.

[0174] Welding connection is to weld the longitudinal reinforcement whose end faces are in contact with each other;

[0175] Additive fusion joining involves filling metal powder between longitudinal bars spaced at a distance from each other. A circumferentially segmented sleeve is positioned at the joint between the bars. Heat, preferably electromagnetic heating, is used to fuse the bar ends, the sleeve, and the metal powder together. As shown in Figures 27 and 28, a fusion joining device 27 is used to fuse the bar ends.

[0176] The preferred solution, as shown in Figure 20, is to install a transparent formwork 7011 at a location where formwork ventilation is unfavorable. Opposite to the transparent formwork 7011 is a formwork camera 7012 for capturing images of the concrete. The images captured by the formwork camera 7012 are transmitted to the main control center, which, after identification, sends control instructions to the vibrator to vibrate, eliminating bubbles and compacting the concrete. In this example, the locations where formwork ventilation is unfavorable primarily refer to the formwork on the outside of the box girder that is arranged horizontally and difficult to vibrate, such as the bottom of the bottom plate, the outside of the web, and the bottom of the top plate flange.

[0177] A preferred solution, as shown in Figure 21, comprises vibrators 18 arranged in an array on the outer wall of the formwork. These vibrators 18 vibrate as a whole according to control instructions, causing each vibrator 18 in the array to vibrate at different phases, forming an overall vibration waveform based on the outer wall of the formwork. This vibration propagates as a wave across the surface of each formwork unit, assisting in exhaust based on the collected concrete image. This solution allows each vibrator 18 to improve the exhaust performance of the formwork through overall vibration.

[0178] The preferred solution is shown in Figures 8, 23 and 24, in which the template is set on a movable formwork 7, and a steam curing machine 14 and a vacuum machine 15 are provided at the position of the movable formwork 7. A template sealing layer 17 is coated on the outer formwork 701, a top plate sealing layer 16 is provided at the top open position, and an end surface sealing layer 22 is provided on the end surface to construct a sealed concrete curing space. The steam curing machine 14 and the vacuum machine 15 are connected to the concrete curing space through valves and pipelines.

[0179] In the preferred solution, the main control center generates a maintenance plan based on the collected ambient temperature and humidity. The maintenance plan includes the time when the steam curing machine 14 provides steam exceeding normal pressure and the time when the vacuum machine 15 evacuates the concrete curing space to a pressure below normal pressure. Through time-based automatic control, intelligent maintenance of the concrete box girder is achieved.

[0180] Example 2:

[0181] As shown in FIG2 , a system for the above-mentioned integrated intelligent construction method of cast-in-situ box girders includes a main control center, which is equipped with a production scheduling center and a quality control center;

[0182] The production scheduling center is used to generate design and control plans for controlling the steel component factory, intelligent integrated beam building machine, formwork, concrete distribution device, intelligent vibrating device and intelligent maintenance device;

[0183] The quality control center is used to test the production accuracy of steel components, the accuracy of formwork setting, the accuracy of steel component assembly, the smoothness of prestressed pipes, the quality of concrete vibration, concrete strength, elastic modulus and curing quality, and to modify the design and control plan of the production scheduling center based on the feedback of quality parameters.

[0184] The preferred solution is shown in FIG5 , in which the steel bar parts factory is set on the ground and / or on the cast box beam 9, and is equipped with one or more of an automatic reinforcement arranging machine, an automatic welding machine, an automatic single reinforcement bending machine, an automatic mesh bending machine, and an automatic assembly welding machine;

[0185] The automatic reinforcement spreading and arranging machine is used to spread out the steel bars and arrange them at preset spacings, and the robot arranges the transverse bars on the longitudinal bars;

[0186] Automatic welding machine is used to weld steel bar nodes;

[0187] Automatic mesh bending machine is used to bend steel mesh;

[0188] Automatic single bar bending machine is used to produce stirrups;

[0189] An automatic welding machine is used to weld stirrups and longitudinal bars together. Depending on the rebar preparation method, the equipment used varies. For example, an automatic mesh bending machine is not required for a sheet-to-block solution.

[0190] In a preferred solution, a laser scanner or a video acquisition device is further provided to locate the position of the steel bars, locate the position of the steel bar nodes and detect the shape and position accuracy of the finished product.

[0191] The preferred solution is shown in Figures 5 to 17. The intelligent integrated beam-building machine includes a main beam 1 and a lifting trolley 5 arranged along the longitudinal direction of the bridge. There are multiple lifting trolleys 5, which are arranged on the top of the main beam 1. The multiple lifting trolleys 5 move along the main beam 1. Front support legs 2, middle support legs 3 and rear support legs 4 are provided at the bottom of the main beam 1. The bottoms of the front support legs 2, middle support legs 3 and rear support legs 4 are all provided with walking wheels. The front support legs 2 are a liftable and foldable or detachable structure, the middle support legs 3 are a detachable structure, and the rear support legs 4 are a liftable structure.

[0192] The preferred solution is shown in Figures 6, 9, 16-17. The main beam 1 includes triangular trusses 102 on both sides. Main beam transverse connecting beams 103 are provided at both ends of the main beam 1 to connect the triangular trusses 102 into a whole.

[0193] The bottom of the triangular truss 102 is a side and the top is a corner. A main beam track 101 for the crane 5 to travel is provided on the top of the triangular truss 102.

[0194] The front support leg 2 and the rear support leg 4 are located near the two ends of the main beam 1, and the middle support leg 3 is located between the front support leg 2 and the rear support leg 4 and near the front support leg 2;

[0195] The front legs 2 are foldable and can be evaded.

[0196] In the preferred embodiment shown in Figures 10 to 12 , the structure of the front leg 2 is as follows: the front leg wheel assembly seat 207 is connected to the bottom of the lifting column 200, the top of the lifting column is hinged to the triangular truss 102 via the front leg articulated seat 206, the front leg articulated seat 206 swings in a lateral direction, one end of the front leg transverse support 209 is connected to the triangular truss 102, and the other end is connected to the bottom of the lifting column 200, one end of the front leg folding cylinder 208 is connected to the triangular truss 102, and the other end is connected to the front leg transverse support 209, and the front leg folding cylinder 208 is used to drive the front leg 2 to fold to avoid obstacles;

[0197] The front legs 2 fall on the flanges on both sides of the movable formwork 7;

[0198] A hinged portion is provided in the middle of the front leg transverse support 209 to form a foldable structure. The front leg transverse support 209, the lifting column 200 and the bottom of the triangular truss 102 form a triangular structure. The front leg folding cylinder 208 is connected to the upper half of the front leg transverse support 209. The front leg folding cylinder 208 pushes the front leg 2 to fold.

[0199] In the lifting column 200, the front leg upper column 205 is connected to the front leg articulated seat 206, the front leg upper column 205 is connected to the front leg lower column 203 through the front leg telescopic cylinder 204, and the front leg lower column 203 is connected to the front leg wheel assembly seat 207;

[0200] A front leg longitudinal strut 201 is also provided, one end of the front leg longitudinal strut 201 is connected to the triangular truss 102 , and the other end is connected to the front leg wheel assembly seat 207 .

[0201] The preferred solution is shown in Figures 5, 16~17, in which the structure of the middle leg 3 is as follows: the bottom of the middle leg cross beam 303 is connected to the middle leg wheel seat 304, and the top of the middle leg cross beam 303 is connected to the middle leg swing seat 302 through the middle leg connecting pin 301. The middle leg 3 can be disassembled by removing the middle leg connecting pin 301.

[0202] The preferred solution is shown in Figures 5, 14~15, in which the structure of the rear support leg 4 is as follows: a vertical rear support leg sleeve 401 is provided on the triangular truss 102, a rear support leg sliding column 403 is slidingly connected to the rear support leg sleeve 401, a rear support leg telescopic cylinder 402 is provided between the rear support leg sleeve 401 and the rear support leg sliding column 403, a rear support leg inner folding seat 408 is provided at the bottom of the rear support leg sliding column 403, the bottom of the rear support leg inner folding seat 408 is connected to the rear support leg wheel seat 405 through the rear support leg shaking seat 404, and the rear support leg inner folding seat 408 has an inward bending structure so that when the rear support leg 4 moves longitudinally, the walking wheels of the rear support leg wheel seat 405 fall on the root of the flange of the cast box girder 9.

[0203] As shown in FIG14 and FIG15 , a preferred solution is provided with a plurality of running wheels 305 and 409 at the bottom of the rear leg wheel seat 405 and the middle leg wheel seat 304 , and the running wheels are connected to the wheel seat through a rotating seat so that the running wheels can rotate in different directions.

[0204] As shown in FIG5 , a preferred solution is provided with first obstacle sensors 11 at both ends of the front leg 2, second obstacle sensors 25 at both ends of the middle leg 3, and a third obstacle sensor 26 at the rear leg 4 close to the span to be cast 8;

[0205] The first obstacle sensor 11 , the second obstacle sensor 25 and the third obstacle sensor 26 are laser radars or ultrasonic sensors.

[0206] The preferred solution is shown in Figures 6 and 7. The formwork is a mobile formwork 7. The structure of the mobile formwork 7 is as follows: a formwork base 707 is fixed on the pier 13, and sliding formworks 704 are provided on both sides of the pier 13. The sliding formwork 704 slides along the formwork base 707 through a formwork traction device 706 to realize the opening and closing of the formwork.

[0207] The sliding mold frame 704 is connected to the first template unit 7021, the second template unit 7022 and the third template unit 7023 respectively through multiple adjustable support rods 703. The adjustable support rods 703 are used to adjust the positions of the first template unit 7021, the second template unit 7022 and the third template unit 7023;

[0208] The first template unit 7021 , the second template unit 7022 and the third template unit 7023 are hingedly connected.

[0209] In a preferred solution, a plurality of reflective targets are provided on the first template unit 7021, the second template unit 7022 and the third template unit 7023. A laser rangefinder or video acquisition device is set at a preset position to collect the coordinate data of the reflective targets and send it to the main control center. The main control center converts the coordinate system and compares it with the preset design coordinates, and returns the correction parameters to adjust the corresponding positions of the template units until they meet the preset design requirements.

[0210] As shown in FIG29 , a preferred solution further includes a sleeve fastening tool 28 for fastening the threaded sleeve connected to the end of the longitudinal reinforcement;

[0211] The sleeve tightening tool 28 is provided with a movable handle 283 that can be opened and closed. The movable handle 283 is hingedly connected to a tightening handle 285. A plurality of guide wheels 281 are provided on the movable handle 283 and the tightening handle 285. A friction belt 282 passes around the plurality of guide wheels 281, one of which is connected to a tightening motor 284. The friction belt 282 passes through an opening between the movable handle 283 and the tightening handle 285 to drive the threaded sleeve to rotate through friction. The movable handle 283 is in an open state by default under the action of a spring, and the friction belt 282 is also in an open state at the end of the tightening handle 285. When tightening is required, the ends of the movable handle 283 and the tightening handle 285 are brought close to the threaded sleeve, and the friction belt 282 wraps around the threaded sleeve. The rotation of the tightening motor 284 drives the friction belt 282 to move, and drives the threaded sleeve to rotate, thereby quickly tightening the threaded sleeve. The adoption of this solution significantly improves the connection efficiency of the steel bar end. And compared with end welding, it has higher strength.

[0212] The preferred solution is shown in Figures 27 and 28, and a fusion joint device 27 is further provided. The end of the handle 271 is provided with a fixed clamp 276, and the position of the handle 271 near the end is also pivotally connected to the movable clamp 273;

[0213] The shapes of the fixed clamp 276 and the movable clamp 273 are adapted to the shapes of the steel bar ends and extend to both sides to cover the cast steel bar ends 171 and the uncast steel bar ends 172. The fixed clamp 276 and the movable clamp 273 are provided with electromagnetic coils 275;

[0214] The extended end of the movable chuck 273 is hinged to one end of the chuck cylinder 272, and the other end of the chuck cylinder 272 is hinged to the handle 271. This solution is typically used in working conditions where the ends of the rebar are a certain distance apart, or in locations where the threaded sleeve is inconvenient to operate. During use, the half sleeve 274 is placed over the ends of the longitudinal bars, and a compacted metal powder cake is filled between the ends. The movable chuck 273 and the fixed chuck 276 are then placed over the ends of the longitudinal bars. Electric heating is applied to melt the half sleeve 274, the compacted metal powder cake, and the ends of the longitudinal bars together. This solution allows for faster construction and a higher connection strength.

[0215] In the preferred solutions 7, 8, 23 and 24, a template truss 702 is provided on the back of the first template unit 7021, the second template unit 7022 and the third template unit 7023, and a template sealing layer 17 is coated outside the template truss 702;

[0216] A top plate sealing layer 16 is provided at the top open position of the template, and an end surface sealing layer 22 is provided at the end surface position of the template to form a closed curing space;

[0217] There are also steam curing machine 14 and vacuum machine 15, which are connected to the closed curing space through management. This structure realizes the curing with mold, improves the surface hydration degree, and prevents the further growth of micro cracks.

[0218] In a preferred solution, temperature and humidity sensors are provided outside the curing space, and pressure, temperature and humidity sensors are provided inside the curing space;

[0219] Based on the collected ambient temperature and humidity data, the main control center generates a curing plan, controls the steam curing machine 14 to provide steam above atmospheric pressure to the curing space, and switches to the vacuum machine 15 to evacuate the concrete curing space to below atmospheric pressure within a preset period of time, thus achieving intelligent curing of the concrete box girder. This solution allows moisture to fully enter the cracks, promoting hydration at the cracks and preventing further crack growth.

[0220] The preferred solution is shown in Figure 5, in which an automatic feeding device 24 is also provided on the intelligent integrated beam-building machine, and a video acquisition device facing the span 8 to be poured is also provided. The image collected by the video acquisition device is sent to the main control center, and the automatic feeding device 24 first executes the automatic feeding instruction, and the main control center gives a corrected automatic feeding instruction based on the image.

[0221] In the preferred solution, a prestressed pipe rope threading robot is also provided. The prestressed pipe rope threading robot is provided with a moving device and a shifting mechanism along the X-axis and the Z-axis. A rope threading manipulator that moves back and forth along the rope threading direction is provided on the shifting mechanism.

[0222] In the preferred solution, there is also an in-warehouse vibrating device that moves along the length direction of the mold frame. The walking device of the in-warehouse vibrating device is provided with a stroke sensor, the vibrating device is provided with a lifting device, and the lifting device is provided with a lifting sensor. The in-warehouse vibrating device performs in-warehouse vibrating according to preset vibration instructions, and the quality control center monitors the quality of the vibration based on the data of the stroke sensor and the lifting sensor.

[0223] Concrete surface defects include honeycombs and rough surfaces, some of which are caused by poor ventilation, while others are caused by cavities formed by the arching of aggregates. A preferred embodiment, as shown in FIG30 , further comprises an arch-eliminating vibrating device 30. The arch-eliminating vibrating device 30 comprises an arch-eliminating head 308 fixed to the end of a vibrating rod 303. The arch-eliminating head 308 includes an arch-eliminating side slider 309 and an arch-eliminating head slider 312. The arch-eliminating head 308 includes a capsule 310 connected to the pressure interface seat 304 of the vibrating rod 303 via a pressure interface 305. The capsule 310 is deformed by inputting a pressure medium, causing the arch-eliminating side slider 309 and the arch-eliminating head slider 312 to extend beyond the outer wall of the arch-eliminating head 308, thereby eliminating the arched cavities in the concrete through volume changes. By repeatedly extending and retracting the arch-eliminating side slider 309 and the arch-eliminating head slider 312, the local volume and pressure change, which makes it easier to squeeze the air in the direction of lower pressure. Moreover, the pressure change can easily destroy the stability of the arch, causing the arch structure to disappear, thereby effectively overcoming the problems of honeycomb and rough surface.

[0224] As shown in FIG20 , a preferred solution is provided with transparent templates 7011 at exhaust-unfavorable positions of the first template unit 7021, the second template unit 7022, and the third template unit 7023. A template camera 7012 is provided at a position facing the transparent template 7011. A camera guide rail 7013 is also provided, and the template camera 7012 slides along the camera guide rail 7013.

[0225] The template camera 7012 collects the image of the concrete surface behind the transparent template 7011, performs artificial intelligence recognition on the bubbles in the image, and sends the recognition results to the quality control center to monitor the quality of concrete vibration.

[0226] The preferred solution is shown in Figure 21, in which an array of attached vibrators 18 are provided on the outer wall of each formwork unit. The main control center controls the overall vibration of the attached vibrators 18 based on the collected concrete surface image, so that the attached vibrators 18 vibrate at different phases, causing the vibration to propagate in the form of waves on the surface of each formwork unit. By adjusting the parameters of the wave, the exhaust effect is improved. This structure enables the attached vibrators 18 to form a combined force, which can better assist in exhaust. Generally, for bubbles with larger diameters, the vibration amplitude transmitted to the formwork by the array of vibrators 18 as a whole is larger and the frequency is lower. For bubbles with smaller diameters, the vibration amplitude transmitted to the formwork by the array of vibrators 18 as a whole is smaller and the frequency is higher.

[0227] In a preferred embodiment, a venting layer is installed on the inner surface of each formwork unit at locations where air is not easily exhausted, and vent holes are provided in the formwork steel plate to assist in degassing the concrete. Preferably, the venting layer is a vertical groove on the inner surface of the formwork, or a flexible polyurethane foam layer. This structure creates a channel that facilitates airflow and facilitates the discharge of bubbles. Furthermore, the flexible polyurethane foam layer helps absorb water seepage from vibration, thereby improving the water-cement ratio. Industrial Applicability

[0228] The present invention provides an integrated intelligent construction method and system for cast-in-situ box girders. By adopting the above scheme, it is possible to improve the mechanization, automation and intelligence level of cast-in-situ box girder construction, greatly improve construction efficiency, reduce labor intensity, improve on-site management level, and ensure safe construction and construction quality.

Claims

1. A cast-in-place box girder integrated intelligent construction method, characterized in that The following steps are involved: S1. Design scheme based on BIM; S2, forming and transportation of steel bar parts; S3, box girder formwork set up; S4, template accuracy detection; S5. Assemble steel bar components in the formwork; S6. Quality inspection of steel bar components; S7. Prestressed pipe construction and linear detection; S8, concrete pouring; S9, concrete quality inspection; S10, concrete curing; S11. Maintenance quality control; S12, prestressing tension and grouting testing; The above steps can realize intelligent integrated box girder construction.

2. The method for integrated intelligent construction of cast-in-place box beams according to claim 1 is characterized in that: A main control center is also provided, and the main control center has a production scheduling center and a quality control center. The production scheduling center is used to control the intelligent integrated beam building machine, the steel bar component forming factory, the formwork, the automatic material distribution device (24), the vibrator (18), the prestressed construction and detection device and the concrete curing device according to the design plan and the data collected by the sensor; The quality control center is used to collect stress, shape and position parameters of the steel bar component (10); it is also used to collect template positioning parameters; it is also used to collect concrete distribution parameters, concrete pouring quality parameters, prestressed pipe shape and position accuracy, tension force, grouting density, and concrete curing parameters, and feeds back the collected parameters to the main control center, which then sends the control data to the production scheduling center.

3. The method for integrated intelligent construction of cast-in-place box beams according to claim 2 is characterized in that: According to the data collected and analyzed by the main control center, the box girder finite element simulation model is automatically updated to grasp the real-time stress and linear state, and determine the optimal timing of formwork demoulding, prestressing and formwork spanning; Based on the time when the relevant equipment of each process is put into use, the actual time consumption and man-machine input of each process are determined. The main control center conducts data mining and statistical analysis, and establishes a mathematical model of man-machine, material-machine and construction time consumption at the process level. Based on construction needs, the process-level construction optimization plan and resource allocation plan are determined to guide construction.

4. The method for integrated intelligent construction of cast-in-place box beams according to claim 2 is characterized in that: The main control center is also connected to the interactive digital twin system, which builds an interactive digital twin system of the box girder construction progress based on the data provided by the main control center; The interactive digital twin system is equipped with an expert system, which provides suggestions based on the construction rule library and warning library, and sends the suggestions to the main control center in a loosely coupled manner; The expert database system includes expert members and artificial intelligence models, identifies technical problems based on large-scale artificial intelligence semantic recognition, analyzes and decomposes technical problems, and provides solutions based on the listing of constraints. The solution includes one or more optional solutions, which are sent to the main control center in a non-mandatory manner. After selection and decision-making, the main control center sends the final execution plan with constraints to the interactive digital twin system to iterate the expert library system.

5. The method for integrated intelligent construction of cast-in-place box beams according to claim 1 is characterized by: In step S2, BIM has multiple design schemes for steel bar components, which are compared and determined according to different box girder types and size parameters; The design schemes of multiple reinforcement components include one of a core box scheme, a sheet-block scheme, and a mesh-block scheme; The core box solution is a design solution that prepares the center box first and then inserts the steel reinforcement components of the flange structure; The sheet-block solution is to first weld the transverse reinforcement into a steel sheet, then insert the main reinforcement into a steel block, and then assemble it into a steel component design. The mesh-block solution is a design solution in which the transverse and longitudinal bars are first welded into a steel mesh, the steel mesh is then bent or welded into a steel block, and then assembled into a steel component.

6. The method for integrated intelligent construction of cast-in-place box beams according to claim 5 is characterized by: The sheet-block solution of the BIM design solution is to decompose the steel bar component (10) into a plurality of top plate units (1001), a plurality of web plate units (1002), a plurality of oblique hook bar units (1003) and a bottom plate unit (1004). When the units are manufactured, the longitudinal bars and hook bars at the connection positions between the units are reserved but not installed. When the steel bar component (10) is assembled, the longitudinal bars and hook bars at the connection positions between the units are installed. The intelligent integrated beam-building machine assists in lifting and assembling the units except the top plate unit (1001) on the steel bar frame (12) into a steel bar component (10), and then hoists the entire component into the outer formwork template (701) for assembly.

7. The method for integrated intelligent construction of cast-in-place box beams according to claim 6 is characterized by: The intelligent integrated beam-building machine comprises a main beam (1) and a crane (5) arranged along the longitudinal direction of the bridge. The cranes (5) are multiple and arranged on the top of the main beam (1). The multiple cranes (5) travel along the main beam (1). A front support leg (2), a middle support leg (3) and a rear support leg (4) are arranged at the bottom of the main beam (1). The bottoms of the front support leg (2), the middle support leg (3) and the rear support leg (4) are all provided with running wheels. The front support leg (2) is a structure that can be raised and lowered and is foldable or detachable. The middle support leg (3) is a detachable structure. The rear support leg (4) is a structure that can be raised and lowered. The steps for the production dispatch center to control the intelligent integrated beam building machine include: S101, the main beam (1) is moved to the top of the steel bar component factory, the crane (5) is moved to the lifting point to take the steel bar component (10), the steel bar component (10) is suspended under the crane (5), and the front legs (2) are swung to both sides and folded; S102, the main beam (1) moves toward the span to be cast (8), and when the front leg (2) passes over the rear hanger (6) of the mobile formwork, the front leg (2) is retracted, and the front leg wheel group (202) of the front leg (2) falls on the track at the top of the flange of the mobile formwork (7), and the middle leg connecting pin (301) is removed to release the connection between the middle leg (3) and the triangular truss (102); S103, the middle leg (3) is turned as a whole in the original position to leave space for the rear leg (4) to pass through; S104, the main beam (1) continues to move forward under the support of the front legs (2) and the rear legs (4) until it reaches the top of the span to be poured (8), the crane (5) hoists the steel bar component (10) to the top of the span to be poured (8), and lowers the steel bar component (10) to the designed position; S105. After the steel bar parts are installed, the folding roof is opened to form factory-like working conditions. The crane (5) assists in the lifting, material distribution and vibration processes until the box beam is cast. S106, the main beam (1) is retreated under the support of the front legs (2) and the rear legs (4), and when the installation position of the middle legs exceeds the rear hanger (6) of the movable formwork, the middle leg connecting pin (301) is reinstalled, so that the middle legs (3) are connected to the triangular truss (102) and subjected to force, and at the same time, the front legs (2) are swung to both sides and folded; S107. The main beam (1) is returned to the top of the steel bar component factory under the support of the front support legs (2) and the rear support legs (4).

8. The method for integrated intelligent construction of cast-in-place box beams according to claim 7 is characterized by: A first obstacle sensor (11) is provided at both ends of the front supporting leg (2), a second obstacle sensor (25) is provided at both ends of the middle supporting leg (3), and a third obstacle sensor (26) is provided at the rear supporting leg (4) in a direction close to the span to be cast (8); The main control center receives the approach signal from the first obstacle sensor (11), first determines the moving direction of the intelligent integrated beam-building machine, and when it is determined that it is moving towards the span to be cast (8), sends a control signal for the front legs (2) to swing and fold to both sides; The intelligent integrated beam-building machine continues to move forward, and when receiving the approach signal from the second obstacle sensor (25), the main control center first sends a control signal for the front support leg (2) to reset, and after completion, sends a control signal for the middle support leg (3) to separate from the triangular truss (102) and rotate; The intelligent integrated beam-building machine continues to move forward until it receives a signal from the third obstacle sensor (26), and then stops moving; When it is necessary to return, the intelligent integrated beam-building machine moves in the reverse direction until it receives a signal from the second obstacle sensor (25) on the front leg (2) close to one end of the cast box beam (9), and the main control center sends a control signal for the middle leg (3) to connect with the triangular truss (102) and rotate and reset. After completion, the main control center sends a control signal for the front leg (2) to swing and fold to both sides. The above steps realize the automated operation of the rear hanger (6) of the automated crossing mobile mold frame.

9. The method for integrated intelligent construction of cast-in-place box beams according to claim 1 is characterized in that: Before the steel bar component (10) is hoisted, an image of the measured box girder longitudinal reinforcement (19) of the cast box girder (9) is obtained; The main control center compares the image of the measured box girder longitudinal reinforcement (19) with the position of the designed box girder longitudinal reinforcement (20), finds the error value, and provides a longitudinal reinforcement correction plan; The longitudinal reinforcement correction scheme includes correcting the longitudinal reinforcement of the cast box beam (9) and correcting the reinforcement components (10) in production; In the longitudinal reinforcement correction scheme, correction is first performed within the correction range of the longitudinal reinforcement of the cast box girder; If there are longitudinal reinforcements that exceed the correction range of the cast box girder longitudinal reinforcements, the longitudinal reinforcements of the assembled steel bar component (10) are corrected in the design plan.

10. The method for integrated intelligent construction of cast-in-place box beams according to claim 9, characterized in that: Assemble the steel bar components (10) according to the design plan, first connect the longitudinal bars at the non-connected positions between the steel bar units in the top plate unit (1001), the web unit (1002), the oblique hook bar unit (1003) and the web unit (1004) with the longitudinal bars of the cast box girder, and then install the longitudinal bars at the connection parts (1005) between the steel bar units and connect them with the longitudinal bars of the cast box girder.

11. The method for integrated intelligent construction of cast-in-place box beams according to claim 1 is characterized in that: A transparent template (7011) is provided at a position where the template exhaust is unfavorable, and a template camera (7012) for collecting concrete images is provided at a position facing the transparent template (7011). The image collected by the template camera (7012) is sent to the main control center, and after identification, the main control center sends a control instruction to the vibrator to vibrate, so as to eliminate bubbles and make the concrete dense. The vibrator comprises an attached vibrator (18), which is arranged in an array on the outer wall of the template and forms an overall vibration according to a control instruction, so that the array attached vibrators (18) vibrate at different phases respectively, forming an overall vibration waveform based on the outer wall of the template, so that the vibration propagates in the form of waves on the surface of each template unit, so as to assist exhaust according to the collected concrete image.

12. The method for integrated intelligent construction of cast-in-place box beams according to claim 1, characterized in that: The template is arranged on a movable template (7), a steam curing machine (14) and a vacuum machine (15) are arranged at the position of the movable template (7), a template sealing layer (17) is coated on the outside of the outer template (701), a top plate sealing layer (16) is arranged at the top open position, and an end surface sealing layer (22) is arranged on the end surface, so as to construct a sealed concrete curing space, and the steam curing machine (14) and the vacuum machine (15) are connected to the concrete curing space via valves and pipelines; The main control center generates a maintenance plan based on the collected ambient temperature and humidity. The maintenance plan includes the time for the steam curing machine (14) to provide steam exceeding normal pressure, and the time for the vacuum machine (15) to evacuate the concrete curing space to a pressure lower than normal pressure. Intelligent maintenance of the concrete box girder is achieved through time-based automatic control.

13. A system for the integrated intelligent construction method of cast-in-situ box beams according to any one of claims 1 to 12, characterized in that: It includes the main control center, which has a production scheduling center and a quality control center; The production dispatch center is used to generate design and control solutions for controlling the steel bar component factory, intelligent integrated beam building machine, formwork, concrete distribution device, intelligent vibrating device and intelligent maintenance device; The quality control center is used to detect the production accuracy of steel bar components, the accuracy of formwork setting, the assembly accuracy of steel bar components, the smoothness of prestressed pipes, the quality of concrete vibration, concrete strength, elastic mold and maintenance quality, and to correct the design and control plan of the production scheduling center based on the feedback quality parameters.

14. The system for the integrated intelligent construction method of cast-in-situ box beams according to claim 13 is characterized in that: The steel bar component factory is arranged on the ground and / or on the cast box beam (9), and is provided with one or more of an automatic reinforcement arranging machine, an automatic welding machine, an automatic single reinforcement bending machine, an automatic mesh bending machine and an automatic assembly welding machine; The automatic reinforcement spreading and arranging machine is used to spread out the steel bars and arrange them at preset spacings, and the robot arranges the transverse bars on the longitudinal bars; Automatic welding machines are used to weld steel bar nodes; Automatic mesh bending machine is used to bend steel mesh; Automatic single bar bending machine is used to produce stirrups; The automatic welding machine is used to weld stirrups and longitudinal reinforcements; A laser scanner or video acquisition device is also provided to locate the position of the steel bars, locate the position of the steel bar nodes and detect the shape and position accuracy of the finished product.

15. The system for the integrated intelligent construction method of cast-in-situ box beams according to claim 13, characterized in that: The intelligent integrated beam-building machine comprises a main beam (1) and a crane (5) arranged along the longitudinal direction of the bridge. The cranes (5) are multiple and arranged on the top of the main beam (1). The multiple cranes (5) travel along the main beam (1). A front support leg (2), a middle support leg (3) and a rear support leg (4) are arranged at the bottom of the main beam (1). The bottoms of the front support leg (2), the middle support leg (3) and the rear support leg (4) are all provided with running wheels. The front support leg (2) is a structure that can be raised and lowered and is foldable or detachable. The middle support leg (3) is a detachable structure. The rear support leg (4) is a structure that can be raised and lowered. The main beam (1) comprises triangular trusses (102) located on both sides, and main beam transverse connecting beams (103) are provided at both ends of the main beam (1) to connect the triangular trusses (102) into a whole; The bottom of the triangular truss (102) is a side and the top is an angle. A main beam track (101) for the crane (5) to travel is provided on the top of the triangular truss (102); The front supporting legs (2) and the rear supporting legs (4) are located near the two ends of the main beam (1), and the middle supporting legs (3) are located between the front supporting legs (2) and the rear supporting legs (4) and near the front supporting legs (2); The structure of the front leg (2) is as follows: the front leg wheel assembly seat (207) is connected to the bottom of the lifting column (200); the top of the lifting column is hinged to the triangular truss (102) via the front leg hinge seat (206); the swing direction of the front leg hinge seat (206) is lateral swing; one end of the front leg lateral support (209) is connected to the triangular truss (102) and the other end is connected to the bottom of the lifting column (200); one end of the front leg folding cylinder (208) is connected to the triangular truss (102) and the other end is connected to the front leg lateral support (209); the front leg folding cylinder (208) is used to drive the front leg (2) to fold to avoid obstacles; The front legs (2) fall on the flanges on both sides of the movable mold frame (7); A hinged portion is provided in the middle of the front leg transverse support (209) to form a foldable structure; the front leg transverse support (209), the lifting column (200) and the bottom of the triangular truss (102) form a triangular structure; the front leg folding cylinder (208) is connected to the upper half of the front leg transverse support (209); the front leg folding cylinder (208) folds the front leg (2) in a pushing manner; In the lifting column (200), the front leg upper column (205) is connected to the front leg articulated seat (206), the front leg upper column (205) is connected to the front leg lower column (203) via the front leg telescopic cylinder (204), and the front leg lower column (203) is connected to the front leg wheel assembly seat (207); A front leg longitudinal support rod (201) is also provided, one end of the front leg longitudinal support rod (201) is connected to the triangular truss (102), and the other end is connected to the front leg wheel assembly seat (207).

16. The system for the integrated intelligent construction method of cast-in-situ box beam according to claim 15 is characterized in that: The structure of the supporting leg (3) is as follows: the bottom of the middle supporting leg cross beam (303) is connected to the middle supporting leg wheel seat (304), and the top of the middle supporting leg cross beam (303) is connected to the middle supporting leg swing seat (302) via the middle supporting leg connecting pin (301). The middle supporting leg (3) can be disassembled by removing the middle supporting leg connecting pin (301); The structure of the rear leg (4) is as follows: a vertical rear leg sleeve (401) is provided on the triangular truss (102); a rear leg sliding column (403) is slidably connected to the rear leg sleeve (401); a rear leg telescopic cylinder (402) is provided between the rear leg sleeve (401) and the rear leg sliding column (403); a rear leg inner folding seat (408) is provided at the bottom of the rear leg sliding column (403); the bottom of the rear leg inner folding seat (408) is connected to the rear leg wheel seat (405) via a rear leg shaking seat (404); the rear leg inner folding seat (408) has an inwardly bent structure, so that when the rear leg (4) moves longitudinally, the running wheels of the rear leg wheel seat (405) fall on the root of the flange of the cast box beam (9); A plurality of running wheels (305, 409) are provided at the bottom of the rear leg wheel seat (405) and the middle leg wheel seat (304), and the running wheels are connected to the wheel seats via rotating seats so that the running wheels can rotate in different directions.

17. The system for the integrated intelligent construction method of cast-in-situ box beam according to claim 15, characterized in that: A first obstacle sensor (11) is provided at both ends of the front supporting leg (2), a second obstacle sensor (25) is provided at both ends of the middle supporting leg (3), and a third obstacle sensor (26) is provided at the rear supporting leg (4) in a direction close to the span to be cast (8); The first obstacle sensor (11), the second obstacle sensor (25) and the third obstacle sensor (26) are laser radars or ultrasonic sensors.

18. The system for the integrated intelligent construction method of cast-in-situ box beams according to claim 13, characterized in that: A fusion joint device (27) is also provided, and a fixed clamp (276) is provided at the end of the handle (271), and a position of the handle (271) near the end is also pivotally connected to a movable clamp (273); The shapes of the fixed clamp (276) and the movable clamp (273) are adapted to the shapes of the steel bar ends, and extend to both sides to cover the cast steel bar ends (171) and the uncast steel bar ends (172). The fixed clamp (276) and the movable clamp (273) are provided with electromagnetic coils (275); An extended end of the movable chuck (273) is hinged to one end of the chuck cylinder (272), and the other end of the chuck cylinder (272) is hinged to the handle (271).

19. The system for the integrated intelligent construction method of cast-in-situ box beams according to claim 13, characterized in that: A de-arching vibration device (30) is also provided. The de-arching vibration device (30) comprises a de-arching head (308) fixedly mounted on the end of a vibration rod (303). A de-arching side slider (309) and a de-arching head slider (312) are provided in the de-arching head (308). A capsule (310) is provided in the de-arching head (308). The capsule (310) is connected to a pressure interface seat (304) of the vibration rod (303) via a pressure interface (305). The capsule (310) is deformed by inputting a pressure medium, thereby causing the de-arching side slider (309) and the de-arching head slider (312) to extend out of the outer wall of the de-arching head (308), thereby eliminating the arching cavity of the concrete by volume change.

20. The system for integrated intelligent construction of cast-in-situ box beams according to claim 13, characterized in that: An exhaust layer is provided on the inner surface of the formwork at the exhaust-unfavorable position of each formwork unit, and exhaust holes are provided on the formwork steel plate to assist the exhaust of concrete.

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